Manual de Taller GM Chevrolet Luv 1997-2005 Isuzu

WORKSHOP MANUAL
TFR / TFS SERIES
PubNo. TF97_03-01-E.S
TF SERIES Workshop Manual
Section
Applicable Component Publication No, MY Remarks
No.
0 General Information TFGEN-WE-981 97-99
0 General Information TFGEN-WE-0005AAR 00 Australia(Draft)
0 General Information TFGEN-WE-0001A 00-03
0 General Information TFGEN-WE-0325AR 03 AR
1 Heating and Airconditioning TFHAC-WE-761 97-98 Exp/EU/AR/South Africa
1 Heating and Airconditioning TFHAC-WE-981 99-03 Exp/EU/HEC/South Africa
2 Frame and Cab TFFAB-WE-761 97-98 Exp/EU/AR/South Africa
2 Frame and Cab TFFAB-WE-981 99-00
2 Frame and Cab TFFAB-WE-0101 01-03
3 Steering,Suspension Wheels and Tires TFSSW-WE-0001A 97-00
3 Steering,Suspension Wheels and Tires TFSSW-WE-0101 01-03
4 Axle TFAXL-WE-981 98-03 HEC
4 Axle TFAXL-WE-9711 97-03
4C2 Shift on the Fly System TFSOF-WE-0091 00-03
5 Brakes TFBRK-WE-981 97-03
6-1 Gasoline Engine(4Z Series) TF4ZE-WE-761 97-03 Exp/EU/South Africa
6-2 Gasoline Engine(6VD1) TF6VD-WE-881 98-03 Exp/EU/AR/South Africa
6-3 Diesel Engine(4J Series) TF4JE-WE-9712 97-03 Exp/EU/AR/South Africa
6 Gasoline Engine(HEC:C24SEC22NE,22LE and 20LE) TFHEC-WE-9821 99-03 Exp/HEC/AR/South Africa
Engine Driveability and Emissions(TF 4JA1-TC/TF 4JH1-TC ENGINE With
6E 4JEED-WE-0221T 02-03 Exp/EU/AR/South Africa
Bosch VP44)
6E Engine Driveability and Emissions(ENGINE C24 on TF) HECED-WE-0321 03 Exp/HEC/AR/South Africa
Engine Driveability and Emissions(TF 4JH1-TC Engine with Bosch VP44
6E 4JHED-WE-0321 03
System)
7A Automatic Transmission TF4L3-WE-889AR 98-03 AR(Draft)
7A Automatic Transmission TF40L-WE-989IR 98-03 IR
7A-1 Automatic Transmission（sime Control Type） RVAW3-WE-0211S 02-03 Exp/EU/AR/South Africa
7A-1 Automatic Transmission（Full Control Type） RVAW3-WE-0211F 02-03 Exp/EU/AR/South Africa
7A Automatic Transmission TFJR4-WE-0325AR 03 AR
7B Transmission(MSG Type) TFMSG-WE-981 97-03
7B-1 Transmission(MUA Type) TFMUA-WE-9711 97-03
7B-1 Transmission(MUA Type) TFMUA-WE-0325AR 03 AR
7C Clutch TFCLU-WE-0005AAR 00 AR(Draft)
7C Clutch TFCLU-WE-9711 97-03
7D Transfer Case TFTRN-WE-989IR 98-03 IR
8 Electrical-Body and Chassis TFELC-WE-781 97-98 Exp/EU/AR/South Africa
8 Electrical-Body and Chassis TFELC-WE-981 99-03 Exp/HEC/AR/South Africa
8 Electrical-Body and Chassis TFELC-WE-9991AR 00 AR(Draft)
8 Electrical-Body and Chassis TFELC-WE-0101 01-03 Exp/EU/AR/South Africa
8 Electrical-Body and Chassis TFELC-WE-0111 00-02 AR/South Africa
8 Electrical-Body and Chassis TFELC-WE-989IR 98-03 IR
9 Accessories TFACC-WE-981 97-03
9 Accessories TFRET-WE-9995EU 00-03 EU
10 Cab TFCAB-WE-981 97-99
10 Cab TFCAB-WE-9991 00
10 Cab TFCAB-WE-0101 01-03
Immobilizer System IMM-WE-0101 01-02
Immobilizer System IMM-WE-0121 01-03 EU/AR
Immobilizer System IMM-WS-0101 01 Spanish
WORKSHOP MANUAL
TF SERIES
ENGINE DRIVEABILITY AND EMISSIONS

4JA1-TC/4JH1-TC ENGINE WITH BOSCH VP44 SYSTEM
SECTION 6E
NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section - 0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model : TFR/S 54/77
This manual is applicable to 2002 year model and later vehicles.

4JA1-TC/4JH1-TC ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 PSG CONNECTOR PIN ASSIGNMENT &

ECM CIRCUIT DIAGRAM OUTPUT SIGNAL (4JH1-TC) .................. 6E-45
(4JA1-TC LHD) (1/2) ............................... 6E-13 GENERAL DESCRIPTION FOR ECM AND
ECM CIRCUIT DIAGRAM SENSORS ............................................... 6E-46
(4JA1-TC LHD) (2/2) ............................... 6E-14 Engine Control Module (ECM) ................... 6E-46
ECM CIRCUIT DIAGRAM Pump Control Unit (PSG) & Data Exchange
(4JA1-TC RHD) (1/2) ............................... 6E-15 Between Control Module ......................... 6E-46
ECM CIRCUIT DIAGRAM Mass Air Flow (MAF) Sensor & Intake Air
(4JA1-TC RHD) (2/2) ............................... 6E-16 Temperature (IAT) Sensor ....................... 6E-47
ECM CIRCUIT DIAGRAM Pedal/Throttle Position Sensor (TPS) ........ 6E-47
(4JH1-TC RHD M/T) (1/2) ....................... 6E-17 Crankshaft Position (CKP) Sensor ............ 6E-48
ECM CIRCUIT DIAGRAM Engine Coolant Temperature (ECT)
(4JH1-TC RHD M/T) (2/2) ....................... 6E-18 Sensor ..................................................... 6E-48
ECM CIRCUIT DIAGRAM Vehicle Speed Sensor (VSS) ..................... 6E-49
(4JH1-TC RHD A/T) (1/2) ........................ 6E-19 EGR EVRV (4JA1-TC Only) ...................... 6E-49
ECM CIRCUIT DIAGRAM GENERAL DESCRIPTION FOR INJECTION
(4JH1-TC RHD A/T) (2/2) ........................ 6E-20 PUMP ...................................................... 6E-50
GROUND LOCATION ............................... 6E-21 Outline ....................................................... 6E-50
CABLE HARNESS & CONNECTOR Characteristic of VP44 Injection System .... 6E-50
LOCATION (4JA1-TC LHD) .................... 6E-22 Cross-section View .................................... 6E-51
CABLE HARNESS & CONNECTOR Low Pressure Fuel Circuit .......................... 6E-52
LOCATION (4JA1-TC RHD) .................... 6E-23
High Pressure Fuel Circuit ......................... 6E-52
CABLE HARNESS & CONNECTOR
Timing Control ........................................... 6E-53
LOCATION (4JH1-TC RHD) .................... 6E-24
Start of Injection ......................................... 6E-53
CONNECTOR LIST ................................... 6E-25
ISUZU Strategy Based Diagnostics .............. 6E-54
RELAY AND FUSE .................................... 6E-28
Overview .................................................... 6E-54
RELAY AND FUSE BOX LOCATION (LHD) 6E-28
STRATEGY BASED DIAGNOSTICS
RELAY AND FUSE BOX LOCATION (RHD) 6E-28
CHART .................................................... 6E-54
RELAY & FUSE LOCATION ..................... 6E-29
Diagnostic Thought Process ...................... 6E-55
RELAY & FUSE LOCATION ..................... 6E-30
1. Verify the Complaint .............................. 6E-55
ECM WIRING DIAGRAM (1/7) .................. 6E-31
2. Perform Preliminary Checks .................. 6E-55
3. Check Bulletins and Troubleshooting
ECM WIRING DIAGRAM (3/7) .................. 6E-33 Hints ........................................................ 6E-56
ECM WIRING DIAGRAM (4/7) .................. 6E-34 4. Perform Service Manual Diagnostic
ECM WIRING DIAGRAM (5/7) .................. 6E-35 Checks ..................................................... 6E-56
ECM WIRING DIAGRAM (6/7) .................. 6E-36 5a and 5b. Perform Service Manual
ECM WIRING DIAGRAM (7/7) .................. 6E-37 Diagnostic Procedures ............................. 6E-56
ECM CONNECTOR PIN ASSIGNMENT & 5c. Technician Self Diagnoses .................. 6E-56
OUTPUT SIGNAL (4JA1-TC) .................. 6E-38 5d. Intermittent Diagnosis .......................... 6E-57
PSG CONNECTOR PIN ASSIGNMENT & 5e. Vehicle Operates as Designed ............ 6E-58
OUTPUT SIGNAL (4JA1-TC) .................. 6E-41 6. Re-examine the complaint ..................... 6E-59
ECM CONNECTOR PIN ASSIGNMENT & 7. Repair and Verify Fix ............................. 6E-59
OUTPUT SIGNAL (4JH1-TC) .................. 6E-42
6E–2 4JA1-TC/4JH1-TC ENGINE DRIVEABILITY AND EMISSIONS
GENERAL SERVICE INFORMATION ....... 6E-60 Supply Circuit High Input ......................... 6E-105
ON-BOARD DIAGNOSTIC (OBD) ............. 6E-60 Diagnostic Trouble Code (DTC) P0100
TECH 2 OPERATING FLOW CART (Symptom Code 9) (Flash Code 65)
(START UP) ............................................ 6E-64 Mass Air Flow (MAF) Sensor Voltage
TYPICAL SCAN DATA & DEFINITIONS Supply Circuit Low Input .......................... 6E-108
4JA1-TC (ENGINE DATA) .................... 6E-66 Diagnostic Trouble Code (DTC) P0100
TYPICAL SCAN DATA & DEFINITIONS (Symptom Code B) (Flash Code 65)
4JH1-TC (ENGINE DATA) ................... 6E-68 Mass Air Flow (MAF) Sensor Output
MISCELLANEOUS TEST .......................... 6E-70 Circuit Low Input ...................................... 6E-110
Plotting Snapshot Graph ........................... 6E-71 Diagnostic Trouble Code (DTC) P0100
(Symptom Code C) (Flash Code 65)
Plotting Graph Flow Chart (Plotting graph
Mass Air Flow (MAF) Sensor Output
after obtaining vehicle information) .......... 6E-72
Circuit High Input ..................................... 6E-113
Flow Chart for Snapshot Replay
DIAGNOSTIC TROUBLE CODE (DTC) P0110
(Plotting Graph) ....................................... 6E-73
(SYMPTOM CODE 1) (FLASH CODE 23)
SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-74
INTAKE AIR TEMPERATURE (IAT)
ON-BOARD DIAGNOSTIC (OBD) SYSTEM SENSOR CIRCUIT HIGH INPUT ............ 6E-116
CHECK .................................................... 6E-83
Circuit Description ..................................... 6E-83 (SYMPTOM CODE 2) (FLASH CODE 23)
Diagnostic Aids .......................................... 6E-83 INTAKE AIR TEMPERATURE (IAT) SENSOR
Test Description ......................................... 6E-83 CIRCUIT LOW INPUT ............................. 6E-116
On-Board Diagnostic (OBD) System Check 6E-84 Circuit Description ...................................... 6E-116
NO CHECK ENGINE LAMP (MIL) ............. 6E-87 Diagnostic Aids .......................................... 6E-117
Circuit Description ..................................... 6E-87 Diagnostic Trouble Code (DTC) P0110
Diagnostic Aids .......................................... 6E-87 (Symptom Code 1) (Flash Code 23)
No Check Engine Lamp (MIL) ................... 6E-88 Intake Air Temperature (IAT) Sensor
CHECK ENGINE LAMP (MIL) “ON” Circuit High Input ..................................... 6E-117
STEADY .................................................. 6E-90 Diagnostic Trouble Code (DTC) P0110
Circuit description ...................................... 6E-90 (Symptom Code 2) (Flash Code 23)
Intake Air Temperature (IAT) Sensor
Diagnostic Aids .......................................... 6E-90
Circuit Low Input ...................................... 6E-121
Check Engine Lamp (MIL) On Steady ....... 6E-91
ECM Diagnostic Trouble Codes ................ 6E-93
ENGINE COOLANT TEMPERATURE
(SYMPTOM CODE 7) (FLASH CODE 65) SENSOR CIRCUIT HIGH INPUT ............ 6E-124
MASS AIR FLOW (MAF) SENSOR VOLTAGE
SUPPLY CIRCUIT HIGH INPUT ............. 6E-104
DIAGNOSTIC TROUBLE CODE (DTC) P0100 ENGINE COOLANT TEMPERATURE
(SYMPTOM CODE 9) (FLASH CODE 65) SENSOR CIRCUIT LOW INPUT ............. 6E-124
Circuit Description ...................................... 6E-124
SUPPLY CIRCUIT LOW INPUT .............. 6E-104
Diagnostic Trouble Code (DTC) P0115
(SYMPTOM CODE B) (FLASH CODE 65)
(Symptom Code 1) (Flash Code 14)
MASS AIR FLOW (MAF) SENSOR OUTPUT
Engine Coolant Temperature Sensor
CIRCUIT LOW INPUT ............................. 6E-104
Circuit High Input ..................................... 6E-125
(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
Engine Coolant Temperature Sensor
CIRCUIT HIGH INPUT ............................ 6E-104
Circuit Low Input ...................................... 6E-129
Circuit Description ..................................... 6E-105
Diagnostic Trouble Code (DTC) P0100 FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE ....................... 6E-132
Mass Air Flow (MAF) Sensor Voltage
Circuit Description ..................................... 6E-132 Injection Timing Control Circuit Malfunction
Diagnostic Aids .......................................... 6E-132 (Timer Fluctuation) ................................... 6E-144
Diagnostic Trouble Code (DTC) P0180 DIAGNOSTIC TROUBLE CODE (DTC) P0251
(Symptom Code B) (Flash Code 15) (SYMPTOM CODE 6) (FLASH CODE 53)
Fuel Temperature Sensor Circuit Range/ INJECTION PUMP MALFUNCTION ....... 6E-146
Performance ............................................ 6E-133 DIAGNOSTIC TROUBLE CODE (DTC) P0251
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE 7) (FLASH CODE 53)
(SYMPTOM CODE A) (FLASH CODE 52) INJECTION PUMP MALFUNCTION ....... 6E-146
FUEL CUTOFF SOLENOID VALVE DIAGNOSTIC TROUBLE CODE (DTC) P0251
MALFUNCTION ....................................... 6E-134 (SYMPTOM CODE 9) (FLASH CODE 53)
DIAGNOSTIC TROUBLE CODE (DTC) P0215 INJECTION PUMP MALFUNCTION ....... 6E-146
(SYMPTOM CODE B) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0251
FUEL CUTOFF SOLENOID VALVE CIRCUIT (SYMPTOM CODE A) (FLASH CODE 53)
HIGH INPUT ............................................ 6E-134 INJECTION PUMP MALFUNCTION ....... 6E-146
DIAGNOSTIC TROUBLE CODE (DTC) P0215 DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE C) (FLASH CODE 52) (SYMPTOM CODE B) (FLASH CODE 53)
FUEL CUTOFF SOLENOID VALVE ALWAYS INJECTION PUMP MALFUNCTION ....... 6E-146
ACTIVE .................................................... 6E-134 DIAGNOSTIC TROUBLE CODE (DTC) P0251
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D) (FLASH CODE 53)
(SYMPTOM CODE D) (FLASH CODE 52) INJECTION PUMP MALFUNCTION ....... 6E-146
FUEL CUTOFF SOLENOID VALVE DIAGNOSTIC TROUBLE CODE (DTC) P0251
MALFUNCTION ....................................... 6E-134 (SYMPTOM CODE E) (FLASH CODE 53)
Circuit Description ..................................... 6E-135 INJECTION PUMP MALFUNCTION ....... 6E-146
Diagnostic Aids .......................................... 6E-135 Circuit Description ...................................... 6E-147
Diagnostic Trouble Code (DTC) P0215 Diagnostic Aids .......................................... 6E-147
(Symptom Code A) (Flash Code 52) Diagnostic Trouble Code (DTC) P0251
Fuel Cutoff Solenoid Valve Malfunction ... 6E-135 (Symptom Code 6) (Flash Code 53)
Diagnostic Trouble Code (DTC) P0215 Injection Pump Malfunction ...................... 6E-147
(Symptom Code B) (Flash Code 52) Diagnostic Trouble Code (DTC) P0251
Fuel Cutoff Solenoid Valve Circuit (Symptom Code 7) (Flash Code 53)
High Input ................................................ 6E-137 Injection Pump Malfunction ...................... 6E-149
Diagnostic Trouble Code (DTC) P0215 Diagnostic Trouble Code (DTC) P0251
(Symptom Code C) (Flash Code 52) (Symptom Code 9) (Flash Code 53)
Fuel Cutoff Solenoid Valve Always Active 6E-139 Injection Pump Malfunction ...................... 6E-153
(Symptom Code D) (Flash Code 52) (Symptom Code A) (Flash Code 53)
Fuel Cutoff Solenoid Valve Malfunction ... 6E-141 Injection Pump Malfunction ...................... 6E-154
DIAGNOSTIC TROUBLE CODE (DTC) P0216 Diagnostic Trouble Code (DTC) P0251
(SYMPTOM CODE A) (FLASH CODE 54) (Symptom Code B) (Flash Code 53)
INJECTION TIMING CONTROL CIRCUIT Injection Pump Malfunction ...................... 6E-155
MALFUNCTION (TIMER DEVIATION) .... 6E-142 Diagnostic Trouble Code (DTC) P0251
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (Symptom Code D) (Flash Code 53)
(SYMPTOM CODE B) (FLASH CODE 54) Injection Pump Malfunction ...................... 6E-156
INJECTION TIMING CONTROL CIRCUIT Diagnostic Trouble Code (DTC) P0251
MALFUNCTION (TIMER FLUCTUATION) 6E-142 (Symptom Code E) (Flash Code 53)
Circuit Description ..................................... 6E-143 Injection Pump Malfunction ...................... 6E-157
Diagnostic Aids .......................................... 6E-143 DIAGNOSTIC TROUBLE CODE (DTC) P0335
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE
(Symptom Code A) (Flash Code 54) 43)CRANKSHAFT POSITION SENSOR
Injection Timing Control Circuit Malfunction CIRCUIT MALFUNCTION ....................... 6E-158
(Timer Deviation) ..................................... 6E-143 DIAGNOSTIC TROUBLE CODE (DTC) P0335
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE D) (FLASH CODE 43)
(Symptom Code B) (Flash Code 54) CRANKSHAFT POSITION SENSOR
MALFUNCTION ....................................... 6E-158 SHORT TO GROUND OR OPEN CIRCUIT 6E-177
(SYMPTOM CODE E) (FLASH CODE 43) (SYMPTOM CODE 5) (FLASH CODE 32)
ENGINE SPEED INPUT CIRCUIT RANGE/ EXHAUST GAS RECIRCULATION FLOW
PERFORMANCE ..................................... 6E-158 INSUFFICIENT DETECTED .................... 6E-177
Circuit Description ..................................... 6E-159 DIAGNOSTIC TROUBLE CODE (DTC) P0400
Diagnostic Aids .......................................... 6E-159 (SYMPTOM CODE 8) (FLASH CODE 32)
Diagnostic Trouble Code (DTC) P0335 EXHAUST GAS RECIRCULATION CIRCUIT
(Symptom Code B) (Flash Code 43) Crankshaft SHORT TO BATTERY ............................. 6E-177
Position Sensor Circuit Malfunction ......... 6E-159 Circuit Description ...................................... 6E-178
(Symptom Code D) (Flash Code 43) Crankshaft Diagnostic Trouble Code (DTC) P0400
Position Sensor Malfunction .................... 6E-159 (Symptom Code 3) (Flash Code 32)
Diagnostic Trouble Code (DTC) P0335 Exhaust Gas Recirculation Flow Excessive
(Symptom Code E) (Flash Code 43) Engine Detected .................................................. 6E-178
Speed Input Circuit Range/Performance . 6E-164 Diagnostic Trouble Code (DTC) P0400
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (Symptom Code 4) (Flash Code 32)
(SYMPTOM CODE 4) (FLASH CODE 66) Exhaust Gas Recirculation Circuit Short to
GLOW RELAY CIRCUIT VOLTAGE LOW 6E-167 Ground or Open Circuit ............................ 6E-181
(SYMPTOM CODE 8) (FLASH CODE 66) (Symptom Code 5) (Flash Code 32)
GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-167 Exhaust Gas Recirculation Flow Insufficient
Circuit Description ..................................... 6E-167 Detected .................................................. 6E-184
Diagnostic Aids .......................................... 6E-168 Diagnostic Trouble Code (DTC) P0400
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 32)
(Symptom Code 4) (Flash Code 66) Exhaust Gas Recirculation Circuit Short to
Glow Relay Circuit Voltage Low .............. 6E-168 Battery ..................................................... 6E-187
(Symptom Code 8) (Flash Code 66) (SYMPTOM CODE 1) (FLASH CODE 24)
Glow Relay Circuit Voltage High ............. 6E-171 VEHICLE SPEED SENSOR CIRCUIT
HIGH INPUT ............................................ 6E-189
(SUB CODE 4) (FLASH CODE 67) DIAGNOSTIC TROUBLE CODE (DTC) P0500
GLOW PLUG INDICATOR CIRCUIT (SYMPTOM CODE A) (FLASH CODE 24)
VOLTAGE LOW ...................................... 6E-172 VEHICLE SPEED SENSOR INPUT SIGNAL
FREQUENCY TOO HIGH ....................... 6E-189
(SUB CODE 8) (FLASH CODE 67) DIAGNOSTIC TROUBLE CODE (DTC) P0500
GLOW PLUG INDICATOR CIRCUIT (SYMPTOM CODE B) (FLASH CODE 24)
VOLTAGE HIGH ...................................... 6E-172 VEHICLE SPEED SENSOR INCORRECT
SIGNAL ................................................... 6E-189
(Symptom Code 4) (Flash Code 67) Diagnostic Trouble Code (DTC) P0500
Glow Plug Indicator Circuit Voltage Low . 6E-173 (Symptom Code 1) (Flash Code 24)
Vehicle Speed Sensor Circuit High Input . 6E-190
Glow Plug Indicator Circuit Voltage High . 6E-176 (Symptom Code A) (Flash Code 24)
Vehicle Speed Sensor Input Signal
Frequency Too High ................................ 6E-195
EXHAUST GAS RECIRCULATION FLOW Diagnostic Trouble Code (DTC) P0500
EXCESSIVE DETECTED ........................ 6E-177 (Symptom Code B) (Flash Code 24)
Vehicle Speed Sensor Incorrect Signal ... 6E-198
(SYMPTOM CODE 4) (FLASH CODE 32) DIAGNOSTIC TROUBLE CODE (DTC) P0560
EXHAUST GAS RECIRCULATION CIRCUIT (SYMPTOM CODE 1) (FLASH CODE 35)
SYSTEM VOLTAGE TOO HIGH ............. 6E-202 DIAGNOSTIC TROUBLE CODE (DTC) P0645
(SYMPTOM CODE 2) (FLASH CODE 35) A/C COMPRESSOR RELAY CIRCUIT
SYSTEM VOLTAGE TOO LOW .............. 6E-202 VOLTAGE LOW ...................................... 6E-217
(SYMPTOM CODE A) (FLASH CODE 35) (SYMPTOM CODE 8) (FLASH CODE 46)
SYSTEM VOLTAGE MALFUNCTION A/C COMPRESSOR RELAY CIRCUIT
(PSG) ....................................................... 6E-202 VOLTAGE HIGH ...................................... 6E-217
Circuit Description ..................................... 6E-202 Circuit Description ...................................... 6E-217
Diagnostic Aids .......................................... 6E-203 Diagnostic Aids .......................................... 6E-218
(Symptom Code 1) (Flash Code 35) (Symptom Code 4) (Flash Code 46) A/C
System Voltage Too High ........................ 6E-203 Compressor Relay Circuit Voltage Low ... 6E-218
(Symptom Code 2) (Flash Code 35) (Symptom Code 8) (Flash Code 46) A/C
System Voltage Too Low ......................... 6E-205 Compressor Relay Circuit Voltage High .. 6E-222
(Symptom Code A) (Flash Code 35) (SYMPTOM CODE A) (FLASH CODE 25)
System Voltage Malfunction (PSG) ......... 6E-207 BRAKE SWITCH INCORRECT SIGNAL (1) 6E-223
(SYMPTOM CODE A) (FLASH CODE 18) (SYMPTOM CODE B) (FLASH CODE 25)
IGNITION SWITCH CIRCUIT BRAKE SWITCH INCORRECT SIGNAL (2) 6E-223
MALFUNCTION ....................................... 6E-209 Circuit Description ...................................... 6E-224
DIAGNOSTIC TROUBLE CODE (DTC) P0561 Diagnostic Aids .......................................... 6E-224
(SYMPTOM CODE B) (FLASH CODE 18) Diagnostic Trouble Code (DTC) P0703
IGNITION SWITCH CIRCUIT (Symptom Code A) (Flash Code 25)
MALFUNCTION ....................................... 6E-209 Brake Switch Malfunction ........................ 6E-224
Diagnostic Aids .......................................... 6E-209 (Symptom Code B) (Flash Code 25)
Diagnostic Trouble Code (DTC) P0561 Brake Switch Malfunction ........................ 6E-228
(Symptom Code A) (Flash Code 18) DIAGNOSTIC TROUBLE CODE (DTC) P0704
Ignition Switch Circuit Malfunction ........... 6E-210 (SYMPTOM CODE 6) (FLASH CODE 57)
Diagnostic Trouble Code (DTC) P0561 CLUTCH SWITCH CIRCUIT
(Symptom Code B) (Flash Code 18) MALFUNCTION ....................................... 6E-232
Ignition Switch Circuit Malfunction ........... 6E-210 Circuit Description ...................................... 6E-232
ECU PROGRAMMING ERROR .............. 6E-213 Diagnostic Trouble Code (DTC) P0704
Circuit Description & Diagnostic Aids ........ 6E-213 (Symptom Code 6) (Flash Code 57)
Diagnostic Trouble Code (DTC) P0602 ECU Clutch Switch Circuit Malfunction ............ 6E-233
Programming Error .................................. 6E-213 DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE A) (FLASH CODE 28) BAROMETRIC PRESSURE SENSOR
ECU MALFUNCTION .............................. 6E-214 CIRCUIT HIGH INPUT ............................ 6E-237
(SYMPTOM CODE B) (FLASH CODE 28) (SYMPTOM CODE 2) (FLASH CODE 86)
ECU MALFUNCTION .............................. 6E-214 BAROMETRIC PRESSURE SENSOR
Circuit Description & Diagnostic Aids ........ 6E-214 CIRCUIT LOW INPUT ............................. 6E-237
Diagnostic Trouble Code (DTC) P0606 Circuit Description ...................................... 6E-237
(Symptom Code A) (Flash Code 28) Diagnostic Aids .......................................... 6E-237
ECU Malfunction ...................................... 6E-214 Diagnostic Trouble Code (DTC) P1105
Diagnostic Trouble Code (DTC) P0606 (Symptom Code 1) (Flash Code 86) Barometric
(Symptom Code B) (Flash Code 28) Pressure Sensor Circuit High Input ......... 6E-237
(Symptom Code 2) (Flash Code 86) Barometric (SYMPTOM CODE A) (FLASH CODE 22)
Pressure Sensor Circuit Low Input .......... 6E-237 FUEL REDUCTION CAUSED BY LOW
DIAGNOSTIC TROUBLE CODE (DTC) P1120 TEMPERATURE ...................................... 6E-255
(SYMPTOM CODE 1) (FLASH CODE 21) Circuit Description ...................................... 6E-255
PEDAL/THROTTLE POSITION SENSOR Diagnostic Aids .......................................... 6E-255
CIRCUIT HIGH INPUT ............................ 6E-239 Diagnostic Trouble Code (DTC) P1173
(SYMPTOM CODE 7) (FLASH CODE 21) Fuel Reduction Caused By High Coolant
PEDAL/THROTTLE POSITION SENSOR Temperature ............................................ 6E-255
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-239 Diagnostic Trouble Code (DTC) P1173
(SYMPTOM CODE 9) (FLASH CODE 21) Fuel Reduction Caused By High Fuel
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-239 Diagnostic Trouble Code (DTC) P1173
DIAGNOSTIC TROUBLE CODE (DTC) P1120 (Symptom Code A) (Flash Code 22)
(SYMPTOM CODE D) (FLASH CODE 21) Fuel Reduction Caused By Low
BRAKE SWITCH ERROR ....................... 6E-239 DIAGNOSTIC TROUBLE CODE (DTC) P1335
DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE A) (FLASH CODE 43)
(SYMPTOM CODE E) (FLASH CODE 21) ENGINE SPEED OUTPUT CIRCUIT
PEDAL/THROTTLE POSITION SENSOR MALFUNCTION ....................................... 6E-259
IDLE POSITION SWITCH ERROR ......... 6E-239 Circuit Description ...................................... 6E-259
Circuit Description ..................................... 6E-240 Diagnostic Aids .......................................... 6E-259
Diagnostic Trouble Code (DTC) P1120 (Symptom Code A) (Flash Code 43)
(Symptom Code 1) (Flash Code 21) Engine Speed Output Circuit Malfunction 6E-260
Pedal/Throttle Position Sensor Circuit DIAGNOSTIC TROUBLE CODE (DTC) P1345
High Input ................................................ 6E-240 (SYMPTOM CODE A) (FLASH CODE 45)
Diagnostic Trouble Code (DTC) P1120 CAMSHAFT SPEED MALFUNCTION ..... 6E-264
(Symptom Code 7) (Flash Code 21) Circuit Description ...................................... 6E-264
Pedal/Throttle Position Sensor Voltage Diagnostic Aids .......................................... 6E-264
Supply Circuit High Input ......................... 6E-246
(Symptom Code 9) (Flash Code 21) Camshaft Speed Malfunction ................... 6E-265
Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input .......................... 6E-248
(SYMPTOM CODE A) (FLASH CODE 47)
Diagnostic Trouble Code (DTC) P1120 NEUTRAL SWITCH ON ERROR ............ 6E-266
(Symptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake
Switch Error ............................................. 6E-251
NEUTRAL SWITCH OFF ERROR ........... 6E-266
(Symptom Code E) (Flash Code 21)
Pedal/Throttle Position Sensor Idle
Position Switch Error ............................... 6E-253 Diagnostic Trouble Code (DTC) P1520
(Symptom Code A) (Flash Code 47)
Neutral Switch ON Error .......................... 6E-267
FUEL REDUCTION CAUSED BY HIGH Diagnostic Trouble Code (DTC) P1520
COOLANT TEMPERATURE ................... 6E-255 (Symptom Code B) (Flash Code 47)
Neutral Switch OFF Error ........................ 6E-267
FUEL REDUCTION CAUSED BY HIGH FUEL (SYMPTOM CODE 4) (FLASH CODE 71)
TEMPERATURE ..................................... 6E-255 EXHAUST THROTTLE VSV 1 CIRCUIT
VOLTAGE LOW ...................................... 6E-272
EXHAUST THROTTLE VSV 1 CIRCUIT Diagnostic Aids .......................................... 6E-290
VOLTAGE HIGH ...................................... 6E-272 Diagnostic Trouble Code (DTC) P1611
Circuit Description ..................................... 6E-272 (Symptom Code A) (Flash Code 56)
Diagnostic Aids .......................................... 6E-273 Wrong Security Code Entered ................. 6E-291
(Symptom Code 4) (Flash Code 71) Exhaust (SYMPTOM CODE A) (FLASH CODE 56)
Throttle VSV 1 Circuit Voltage Low ......... 6E-273 IMMOBILISER NO OR WRONG SIGNAL 6E-292
(Symptom Code 8) (Flash Code 71) Exhaust Diagnostic Aids .......................................... 6E-292
Throttle VSV 1 Circuit Voltage High ........ 6E-277 Diagnostic Trouble Code (DTC) P1612
(SYMPTOM CODE 4) (FLASH CODE 71) Immobiliser No or Wrong Signal .............. 6E-293
EXHAUST THROTTLE VSV 2 CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P1613
VOLTAGE LOW ...................................... 6E-279 (SYMPTOM CODE A) (FLASH CODE 56)
DIAGNOSTIC TROUBLE CODE (DTC) P1577 IMMOBILISER NO OR WRONG SIGNAL 6E-298
EXHAUST THROTTLE VSV 2 CIRCUIT Diagnostic Aids .......................................... 6E-298
VOLTAGE HIGH ...................................... 6E-279
Circuit Description ..................................... 6E-279 (Symptom Code A) (Flash Code 56)
Diagnostic Aids .......................................... 6E-280 Immobiliser No or Wrong Signal .............. 6E-299
(Symptom Code 4) (Flash Code 71) Exhaust (SYMPTOM CODE A) (FLASH CODE 56)
Throttle VSV 2 Circuit Voltage Low ......... 6E-280 WRONG TRANSPONDER KEY .............. 6E-303
(Symptom Code 8) (Flash Code 71) Exhaust Diagnostic Aids .......................................... 6E-303
Throttle VSV 2 Circuit Voltage High ........ 6E-284
(SYMPTOM CODE D) (FLASH CODE 55) Wrong Transponder Key .......................... 6E-304
EEPROM DEFECT .................................. 6E-286
(SYMPTOM CODE E) (FLASH CODE 55) ECM MAIN RELAY SWITCHED OFF TOO
EEPROM DEFECT .................................. 6E-286 EARLY ..................................................... 6E-305
Circuit Description & Diagnostic Aids ........ 6E-286 DIAGNOSTIC TROUBLE CODE (DTC) P1625
Diagnostic Trouble Code (DTC) P1605 (SYMPTOM CODE B) (FLASH CODE 76)
(Symptom Code D) (Flash Code 55) ECM MAIN RELAY SWITCHED OFF TOO
EEPROM Defect ...................................... 6E-286 LATE ........................................................ 6E-305
(Symptom Code E) (Flash Code 55) Diagnostic Aids .......................................... 6E-305
EEPROM Defect ...................................... 6E-286
DIAGNOSTIC TROUBLE CODE (DTC) P1610 (Symptom Code A) (Flash Code 76) ECM
(SYMPTOM CODE A) (FLASH CODE 56) Main Relay Switched Off Too Early ......... 6E-306
SECURITY KEY AND SECURITY CODE
NOT PROGRAMMED ............................. 6E-288
(Symptom Code B) (Flash Code 76) ECM
Circuit Description ..................................... 6E-288 Main Relay Switched Off Too Late .......... 6E-307
Diagnostic Trouble Code (DTC) P1610 (SYMPTOM CODE A) (FLASH CODE 51)
(Symptom Code A) (Flash Code 56) FUEL INJECTION QUANTITY CIRCUIT
Security Key and Security Code Not MALFUNCTION ....................................... 6E-308
Programmed ............................................ 6E-289 DIAGNOSTIC TROUBLE CODE (DTC) P1630
DIAGNOSTIC TROUBLE CODE (DTC) P1611 (SYMPTOM CODE B) (FLASH CODE 51)
(SYMPTOM CODE A) (FLASH CODE 56) FUEL INJECTION QUANTITY CIRCUIT
WRONG SECURITY CODE ENTERED .. 6E-290 MALFUNCTION ....................................... 6E-308
Circuit Description ..................................... 6E-308 PRELIMINARY CHECKS .......................... 6E-330
Diagnostic Aids .......................................... 6E-309 VISUAL/PHYSICAL CHECK ...................... 6E-330
Diagnostic Trouble Code (DTC) P1630 INTERMITTENT ........................................ 6E-330
(Symptom Code A) (Flash Code 51) Fuel ENGINE CRANKS BUT WILL NOT RUN .. 6E-331
Injection Quantity Circuit Malfunction ...... 6E-309 HARD START SYMPTOM ......................... 6E-335
Diagnostic Trouble Code (DTC) P1630 ROUGH, UNSTABLE, OR INCORRECT IDLE,
(Symptom Code B) (Flash Code 51) Fuel STALLING SYMPTOM ............................ 6E-339
Injection Quantity Circuit Malfunction ...... 6E-309 SURGES AND/OR CHUGS SYMPTOM ... 6E-346
DIAGNOSTIC TROUBLE CODE (DTC) P1650 HESITATION, SAG, STUMBLE SYMPTOM 6E-351
CUTS OUT, MISSES SYMPTOM .............. 6E-357
CAN DEVICE OFFLINE .......................... 6E-310
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM .............................................. 6E-363
POOR FUEL ECONOMY SYMPTOM ....... 6E-369
CAN DEVICE HANG-UP ......................... 6E-310
EXCESSIVE WHITE SMOKE .................... 6E-374
EXCESSIVE BLACK SMOKE .................... 6E-379
ON-VEHICLE SERVICE PROCEDURE .... 6E-384
(Symptom Code A) (Flash Code 44) CAN ENGINE CONTROL MODULE (ECM) ....... 6E-384
Device Offline .......................................... 6E-311 CRANKSHAFT POSITION (CKP) SENSOR 6E-384
Diagnostic Trouble Code (DTC) P1650 ENGINE COOLANT TEMPERATURE (ECT)
(Symptom Code B) (Flash Code 44) CAN SENSOR ................................................. 6E-385
Device Hang-up ....................................... 6E-316 MASS AIR FLOW (MAF) & INTAKE AIR
DIAGNOSTIC TROUBLE CODE (DTC) P1651 TEMPERATURE (IAT) SENSOR ............ 6E-385
(SYMPTOM CODE A) (FLASH CODE 45) PEDAL/THROTTLE POSITION SENSOR
CAN MALFUNCTION (PSG) ................... 6E-317 (TPS) ....................................................... 6E-386
DIAGNOSTIC TROUBLE CODE (DTC) P1651 EGR EVRV (Electrical Vacuum Regulating
(SYMPTOM CODE B) (FLASH CODE 45) Valve) ...................................................... 6E-386
CAN RECEIVES ERROR ........................ 6E-317
(Symptom Code A) (Flash Code 45) CAN
Malfunction (PSG) ................................... 6E-318
(Symptom Code B) (Flash Code 45) CAN
Receives Error ......................................... 6E-319
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE LOW ...................................... 6E-324
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE HIGH ...................................... 6E-324
(Symptom Code 4) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage Low .. 6E-325
(Symptom Code 8) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage High . 6E-329
SYMPTOM DIAGNOSIS ........................... 6E-330
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
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
Engine Component Locator Table
5 6 4 1 2 3
4JA1-TC
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) Option Box
(3) Air Cleaner Case
2 1 3
1
4JA1-TC 4JA1-TC
(1) Throttle Position Sensor (TPS) (1) Throttle Position Sensor (TPS)
(2) To Vacuum Pump
(3) To EGR Valve
4 3 1 2
4JH1-TC
3 2
4JH1-TC
(1) Pedal/Throttle Position Sensor (TPS)
(2) Accelerator Pedal
(3) Brake Pedal
1 2 2 1
(1) Engine Control Module (ECM) (1) Engine Coolant Temperature (ECT) Sensor
(2) SRS Control Module (2) Thermo Unit for Water Temperature Gauge
1 2 1
(1) Vehicle Speed Sensor (VSS) (1) Crankshaft Position (CKP) Sensor
(2) Clutch Housing
ECM CIRCUIT DIAGRAM (4JA1-TC LHD) (1/2)
ECM CIRCUIT DIAGRAM (4JA1-TC LHD) (2/2)
ECM CIRCUIT DIAGRAM (4JA1-TC RHD) (1/2)
ECM CIRCUIT DIAGRAM (4JA1-TC RHD) (2/2)
ECM CIRCUIT DIAGRAM (4JH1-TC RHD M/T) (1/2)
ECM CIRCUIT DIAGRAM (4JH1-TC RHD M/T) (2/2)
ECM CIRCUIT DIAGRAM (4JH1-TC RHD A/T) (1/2)
ECM CIRCUIT DIAGRAM (4JH1-TC RHD A/T) (2/2)
GROUND LOCATION
C2 C36
E10
CABLE HARNESS & CONNECTOR LOCATION (4JA1-TC LHD)
CABLE HARNESS & CONNECTOR LOCATION (4JA1-TC RHD)
CABLE HARNESS & CONNECTOR LOCATION (4JH1-TC RHD)
CONNECTOR LIST
No. Connector face No. Connector face
B-23 C-41
B-24 C-44
B-25 C-49
B-68 C-51
Immobiliser
C-2 C-52
EVRV
C-13 C-53
C-14 C-55
C-23 C-56
C-24 C-57
C-36 C-58

C-92 E-12
C-93 E-41
TPS 1 main
C-96 E-44
E-3 E-49
E-6 E-51
E-7 H-4
TPS 1 main
E-8 H-5
Idle SW
E-9 H-6
E-10 H-7
(LHD)
E-11 H-7
(RHD)

H-8 X-4
(LHD) ECM
Main
H-8 X-5
(RHD) A/C
Com-
pressor
(4JA1)
H-18 X-8
A/C
Thermo
H-22 X-10
(4JH1- A/C
MT) Com-
pressor
(4JH1)
H-22 X-12
(4JH1- Glow
A/T) (4JH1)
H-23
P-2
P-5
P-6
P-10
RELAY AND FUSE
RELAY AND FUSE BOX LOCATION (LHD)
(Engine Room) (Cabin)
OPTION BOX (Engine Room)
RELAY AND FUSE BOX LOCATION (RHD)
(Engine Room) (Cabin)
OPTION BOX (Engine Room) (4JA1-TC Only)

RELAY & FUSE LOCATION
RELAY
4JA1-TC 4JH1-TC
X-1 RELAY; HEATER RELAY; HEATER
X-2 RELAY; ST CUT RELAY; ST CUT
X-3 RELAY; HONE RELAY; HONE
X-4 RELAY; ECM MAIN RELAY; ECM MAIN
X-5 RELAY; A/C COMP. RELAY; HATCH GATE
X-6 RELAY; TAIL LIGHT RELAY; TAIL LIGHT
X-7 RELAY; IMMOBILISER RELAY; IMMOBILISER
X-8 RELAY; A/C THERMO RELAY; A/C THERMO
X-9 RELAY; HEAD LIGHT RELAY; HEAD LIGHT
X-10 — RELAY; A/C COMP.
X-11 RELAY; RR FOG —
X-12 RELAY; DIMMER RELAY; GLOW
X-13 RELAY; STARTER RELAY; STARTER
C-49 RELAY; GLOW —
C-49
FUSE
4JA1-TC 4JH1-TC
EB-1 15A HAZARD 15A HAZARD
EB-2 10A HORN 10A HORN
EB-3 10A STOP LIGHT (LHD) 20A BLOWER
— (RHD)
EB-4 20A BLOWER 10A A/C
EB-5 10A A/C —
EB-6 10A RR FOG LIGHT (LHD) —
— (RHD)
EB-7 10A CHARGE 10A CHARGE
EB-8 10A H/LIGHT-RH (HI) (LHD) 10A H/LIGHT-LH
10A H/LIGHT-LH (RHD)
EB-9 10A H/LIGHT-LH (HI) (LHD) 10A H/LIGHT-RH
10A H/LIGHT-RH (RHD)
EB-10 10A H/LIGHT-RH (LO) (LHD) 10A STOP LIGHT
— (RHD)
EB-11 10A H/LIGHT-LH (LO) (LHD) 10A TAIL LIGHT
10A STOP LIGHT (RHD)
EB-12 10A ECM (LHD) 10A TCM
10A TAIL LIGHT (RHD)
EB-13 10A TAIL LIGHT RH (LHD) —
10A RR FOG LIGHT (RHD)
EB-14 10A TAIL LIGHT LH (LHD) 10A ECM
10A ECM (RHD)
EB-15 30A ECM 30A ECM
EB-16 100A MAIN 100A MAIN
EB-17 40A IGN-B2 40A IGN-B2
EB-18 30A HEAD LIGHT WASHER (LHD) —
— (RHD)
EB-19 50A GLOW 50A GLOW
EB-20 40A IGN-B1 40A IGN-B1
RELAY & FUSE LOCATION
FUSE
(LHD) LHD RHD
CB-1 10A STARTER 10A STARTER
CB-2 — — — —
CB-3 15A ENGINE-1 15A ENGINE-1
CB-4 10A ENGINE-2 10A ENGINE-2
CB-5 — — 15A METER
CB-6 — — 20A FRONT WIPER
CB-7 15A METER — —
CB-8 20A FRONT WIPER — —
CB-9 — — — —
CB-10 — — — —
CB-11 15A BACK UP, TURN 15A BACK UP, TURN
CB-12 10A (SEAT HEATER) — —
(RHD)
CB-13 15A (RR DEFOG.) 15A (RR DEFOG.)
CB-14 10A DOME LIGHT 10A DOME LIGHT
CB-15 20A (DOOR LOCK) 20A (DOOR LOCK)
CB-16 — — — —
CB-17 — — — —
CB-18 — — — —
CB-19 15A AUDIO 15A AUDIO
CB-20 15A CIGAR 15A CIGAR
CB-21 10A (SRS-2) 20A (POWER WINDOW)
CB-22 10A (SRS-1) 20A (POWER WINDOW)
CB-23 20A (POWER WINDOW) 10A (SRS-2)
CB-24 20A (POWER WINDOW) 10A (SRS-1)
( )······IF EQUIPPED
ECM WIRING DIAGRAM (1/7)
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
PSG(Pump Control Unit)
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLU/ BLU/ WHT RED ORG PNK 0.5
BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T
Engine
Tacho
Speed
Check
Meter
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

RED/ ORG/ BRN/ BLK/ BLU/ WHT
WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Engine
Light Turn
15A 15A
10A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
BLU/ GRN BLU/ BLU/ WHT
RED RED RED
Brake Clutch Neutral Inhibitor
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Injection Resister RED GRN
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
BLU/ BLU/ WHT/ BLU/ 0.5 0.5 BLU/
BLK RED BLK 0.85 YEL RED/ YEL
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
ECM Battery Heater

Main Relay Voltage Relay
Glow A/C Blower

80A 10A 20A
Pressure
SW
0.5 5.0 0.5 0.5
BLU/ RED/ BLU/ BRN
RED WHT RED
Glow A/C A/C

Relay Compressor Thermo
Relay Relay
5.0 0.5 0.5

BLK/ GRN GRN
RED 0.5
0.5 GRY/
GRY YEL
Resister
Glow A/C
Plug Compressor 0.5 Electronic
BLK Thermostat
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
BLU/ BLU/ BLU/ GRN/ BLU/
RED RED RED RED RED
IAT
Sensor MAF &
Exhaust Exhaust Thermo EGR- IAT
Throttle Throttle SW EVRV Sensor
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

WHT/ WHT/ BRN/ BLK/ WHT/ GRN/ BLK/ BLK/
BLK BLU RED URG RED RED RED BLU
40 61 46 97 83 88 92 84
Engine
Control
Module
(ECM) Batt Batt Batt
IC
IC CPU IC
µP µP µP
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
GRN/ RED/ GRN/ BLK/ BLK BLK BLK/ GRY WHT GRN/
BLK GRN ORG GRN PNK RED
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Butery
Voltage
Ignition
SW
Stop
Light
10A
Meter
15A
0.5
RED/
YEL
Check
Engine Imnobiliser 16 15 14 13 12 11 10 9
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL (4JA1-TC)
View Looking Into ECM Case
Signal or Continuity Tester Position

Pin B/Box Wire ECM
Pin Function Key SW Engine Engine
No. No. Color Key SW Off Connection Range (+) (-)
On Idle 2000rpm
1 1 ECM Ground BLK Continuity - - - Disconnect Ω 1 GND
with ground
with ground
3 3 Battery Power Supply BLU/RED Less than 1V Battery voltage Connect DC V 3 GND
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output BLU/RED - - Approx. Approx. Connect AC V 27 GND
(To Tacho Meter) 23Hz by 68Hz by
wave form wave form
or approx. or approx.
7.2V 7.5V
28 28 No Connection - - - - - - - - -
29 29 No Connection - - - - - - - - -
30 30 Brake Switch 1 Signal RED Less than 1V Battery voltage when pedal is Connect DC V 30 GND
stepped on
31 31 Clutch Switch Signal YEL Less than 1V Battery voltage when pedal is not Connect DC V 31 GND
stepped on
32 32 No Connection - - - - - - - - -
33 33 A/C Thermo Relay GRN Less than 1V Battery voltage when A/C request Connect DC V 33 GND
switch is turned on
34 34 No Connection - - - - - - - - -
35 35 Immobiliser Control RED/BLU - Wave form - - - -
Unit (ICU B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position GRN/ Less than 1V Less than 1V Approx. 1V Connect DC V 38 49
Sensor (TPS) Output ORG
Signal
39 39 Key Switch Input Signal BLU/YEL Less than 1V Battery voltage Connect DC V 39 GND
Via Engine Fuse
40 40 Exhaust Throttle VSV 1 WHT/BLK Less than 1V Battery voltage when QWS is not Connect DC V 40 GND
activated
41 41 A/C Compressor Relay BRN/RED Less than 1V Battery Battery voltage when A/ Connect DC V 41 GND
voltage C compressor is not
activated
42 42 Check Engine Lamp RED/YEL Less than 1V Battery voltage when lamp is turned Connect DC V 42 GND
off
43 43 Glow Lamp ORG/BLU Less than 1V Battery voltage when lamp is turned Connect DC V 43 GND
off
44 44 No Connection - - - - - - - - -
Pin B/Box Wire ECM
On Idle 2000rpm
45 45 Data Link Connector BLU Less than 1V Battery voltage Connect DC V 45 GND
(No. 6)
46 46 QWS Switch BRN/RED Less than 1V Battery voltage when thermo switch Connect DC V 46 GND
is closed
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position RED/GRN Idle: Approx. - - - Disconnect Ω 38 49
Sensor (TPS) Ground 0.4kΩ/
WOT: Approx.
3.8kΩ
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 BLK/GRN Less than 1V Approx. 5V Connect DC V 57 49
Sensor (TPS) Power
Supply
58 58 ECM Main Relay BLU/BLK Battery Less than 1V Connect DC V 58 GND
voltage
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply BLU/RED Less than 1V Battery voltage Connect DC V 63 GND
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/BLK Less than 1V Battery voltage when pedal is not Connect DC V 65 GND
stepped on
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sensor BLU/WHT - Approx. 15Hz by wave form or Connect AC V 68 GND
(VSS) Via Speed Meter approx. 5.8V at vehicle speed
20km/h
69 69 Idle Switch GRN/BLK Less than 1V Approx. 5V when pedal is stepped on Connect DC V 69 GND
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 - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/RED Less than 1V Approx. 5V Connect DC V 83 92
Sensor Power Supply
Pin B/Box Wire ECM
On Idle 2000rpm
84 84 Intake Air Temperature BLK/BLU Less than 1V Approx. 2.5V at IAT 25°C Connect DC V 84 92
(IAT) Sensor Signal
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/WHT Less than 1V Battery voltage at other than neutral Connect DC V 87 GND
88 88 Mass Air Flow (MAF) GRN/RED Less than 1V Approx. 1V Approx. 2V Approx. 3V Connect DC V 88 92
Sensor Signal
89 89 Engine Coolant GRY Less than 1V Approx. 1.3V at ECT 80°C Connect DC V 89 93
Temperature (ECT)
Sensor Signal
90 90 TDC Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 133Hz by
wave form wave form
0.7V at 1.0V
700rpm
91 91 TDC Sensor Output To PNK - - Approx. Approx. - - - -
Pump Control Unit 47Hz by 133Hz by
(PSG) No.8 wave form wave form
92 92 Mass Air Flow (MAF) BLK/RED Continuity - - - Connect Ω 92 GND
Sensor Ground with ground
93 93 Engine Coolant BLK/PNK Continuity - - - Connect Ω 93 GND
Temperature (ECT) with ground
Sensor Ground
94 94 Glow Relay BLK/BLU Less than 1V Battery voltage when glow system is Connect DC V 94 GND
not activated
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ORG - Approx. 140Hz by wave - - - -
form when EVRV is
activated
98 98 TDC Sensor Ground WHT Continuity - - - Connect Ω 98 GND
with ground
99 99 CAN (Controller Area RED - - - - - - - -
Network) to PSG No.1
100 100 CAN (Controller Area WHT - - - - - - - -
101 101 TDC Sensor Shield - Continuity - - - Connect Ω 101 GND
Line with ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Fuel Cutoff Solenoid ORG - Wave form - - - -
Valve (MAB) Output
Signal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL (4JA1-TC)
View Looking Into PSG Case

Pin B/Box Wire PSG
On Idle 2000rpm
1 99 CAN (Controller Area RED Continuity - - - Disconnect Ω 1 99
Network) to ECM between ECM
No.99 & PSG
2 100 CAN (Controller Area WHT Continuity - - - Disconnect Ω 2 100
Network) to ECM between ECM
No.100 & PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut ORG Continuity - - - Disconnect Ω 5 105
Off (MAB) Output between ECM
Signal to ECM No.105 & PSG
6 - Ground BLK Continuity - - - Disconnect Ω 6 GND
with ground
7 3 Battery Power Supply BLU/RED Continuity - - - Disconnect Ω 7 3
between ECM
& PSG
8 91 TDC Sensor Output PNK Continuity - - - Disconnect Ω 8 91
ECM No.91 To Pump between ECM
Control Unit (PSG) & PSG
9 - No Connection - - - - - - - - -
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL (4JH1-TC)

Pin B/Box Wire ECM
On Idle 2000rpm
with ground
with ground
3 3 Battery Power Supply BLU/RED Less than 1V Battery voltage Connect DC V 3 GND
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
wave form wave form
7.2V 7.5V
28 28 No Connection - - - - - - - - -
29 29 Throttle Position Signal BLK/RED - Approx. 140Hz by wave form (Idle: - - - -
(AT Only) Off duty 10% WOT: Off duty 90%)
30 30 Brake Switch 1 Signal RED Less than 1V Battery voltage when pedal is Connect DC V 30 GND
stepped on
31 31 Clutch Switch Signal YEL Less than 1V Battery voltage when pedal is not Connect DC V 31 GND
(MT Only) stepped on
32 32 No Connection - - - - - - - - -
33 33 A/C Thermo Relay GRN Less than 1V Battery voltage when A/C request Connect DC V 33 GND
switch is turned on
34 34 No Connection - - - - - - - - -
35 35 Immobiliser Control RED/BLU - Wave form - - - -
Unit (ICU B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position GRN/ Less than 1V Less than 1V Approx. 1V Connect DC V 38 49
Sensor (TPS) Output ORG
Signal
39 39 Key Switch Input Signal BLU/YEL Less than 1V Battery voltage Connect DC V 39 GND
Via Engine Fuse
40 40 No Connection WHT/BLK - - - - - - - -
41 41 A/C Compressor Relay BRN/RED Less than 1V Battery Battery voltage when A/ Connect DC V 41 GND
voltage C compressor is not
activated
42 42 Check Engine Lamp RED/YEL Less than 1V Battery voltage when lamp is turned Connect DC V 42 GND
off
43 43 Glow Lamp ORG/BLU Less than 1V Battery voltage when lamp is turned Connect DC V 43 GND
off
44 44 No Connection - - - - - - - - -
Pin B/Box Wire ECM
On Idle 2000rpm
45 45 Data Link Connector BLU Less than 1V Battery voltage Connect DC V 45 GND
(No. 6)
46 46 No Connection BRN/RED - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position RED/GRN Idle: Approx. - - - Disconnect Ω 38 49
Sensor (TPS) Ground 0.4kΩ/
WOT: Approx.
3.8kΩ
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 BLK/GRN Less than 1V Approx. 5V Connect DC V 57 49
Sensor (TPS) Power
Supply
voltage
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply BLU/RED Less than 1V Battery voltage Connect DC V 63 GND
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/BLK Less than 1V Battery voltage when pedal is not Connect DC V 65 GND
stepped on
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
(VSS) Via Speed Meter approx. 6.4V at vehicle speed 20km/
h
69 69 Idle Switch GRN/BLK Less than 1V Approx. 5V when pedal is stepped on Connect DC V 69 GND
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 - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/RED Less than 1V Approx. 5V Connect DC V 83 92
Sensor Power Supply
84 84 Intake Air Temperature BLK/BLU Less than 1V Approx. 2.5V at IAT 25°C Connect DC V 84 92
(IAT) Sensor Signal
Pin B/Box Wire ECM
On Idle 2000rpm
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/WHT Less than 1V Battery voltage at other than neutral Connect DC V 87 GND
(MT) / Battery voltage in P or N (AT)
88 88 Mass Air Flow (MAF) GRN/RED Less than 1V Approx. 1V Approx. 2V Approx. 3V Connect DC V 88 92
Sensor Signal
89 89 Engine Coolant GRY Less than 1V Approx. 1.3V at ECT 80°C Connect DC V 89 93
Temperature (ECT)
Sensor Signal
90 90 TDC Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 133Hz by
wave form wave form
0.7V at 1.0V
700rpm
91 91 TDC Sensor Output To PNK - - Approx. Approx. - - - -
Sensor Ground with ground
Temperature (ECT) with ground
Sensor Ground
94 94 Glow Relay BLK/BLU Less than 1V Battery voltage when glow system is Connect DC V 94 GND
not activated
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ORG - Approx. 140Hz by wave - - - -
form when EVRV is
activated
98 98 TDC Sensor Ground WHT Continuity - - - Connect Ω 98 GND
with ground
101 101 TDC Sensor Shield - Continuity - - - Connect Ω 101 GND
Line with ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - Wave form - - - -
Off (MAB) Output
Signal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL (4JH1-TC)

Pin B/Box Wire PSG
On Idle 2000rpm
Network) to ECM between
No.99 ECM & PSG
No.100 ECM & PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
Off (MAB) Output between
Signal to ECM No.105 ECM & PSG
6 - Ground BLK Continuity - - - Disconnect Ω 6 GN
with ground D
between
ECM & PSG
8 91 TDC Sensor Output PNK Continuity - - - Disconnect Ω 8 91
ECM No.91 To Pump between
Control Unit (PSG) ECM & PSG
9 - No Connection - - - - - - - - -
GENERAL DESCRIPTION FOR ECM AND management system.
SENSORS • Engine Control Module (ECM)
• Pump Control Unit (PSG) = Pumpen Steuer Great
Engine Control Module (ECM) (German)
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
The engine control module (ECM) is located on the module (ECM) and the pump control unit (PSG) is
transmission tunnel. perfumed via a CAN-bus system. The abbreviation CAN
The fuel quantity and injection timing related functions stands for Controller Area Network. By having two
are controlled by the pump control unit (PSG). separate control modules, the high pressure solenoid
The engine control module (ECM) performs the valve. This prevents the discharge of any disturbing
following functions. signals.
• Control of the exhaust gas re-circulation (EGR)
The following signals are exchanged via the CAN-bus:
• Control of the quick on start (QOS) glow control From ECM to PSG
system
• Desired injection quantity
• Control of the A/C compressor
• Desired injection timing
• Execution of the immobiliser function
• Engine speed
Pump Control Unit (PSG) & Data Exchange
Between Control Module From PSG to ECM
• Fuel temperature
• Pump speed
• Cylinder identifier
• Control pulse (actual injection quantity + actual
Self Diagnosis / Interface / Signal injection timing)
To High Pressure Solenoid
• PSG status
Cam Ring Rotational Angle
Engine Speed Fuel Temperature
Engine
Control Injection Timing
Module
Accelerator Pedal (ECM High Pressure
Injection Quantity Solenoid Valve
Pump
Intake Air Temperature Control Fuel Injection
Unit (Mechanical)
Response Signal
(PSG
Mass Air Flow
Additional Signal
Others Timing Device
Additional Operations To Timing Control Valve (TCV)
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
Mass Air Flow (MAF) Sensor & Intake Air The ECM supplies 5 volts signal to the IAT sensor
Temperature (IAT) Sensor through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is hot.
Pedal/Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor is part of the intake air
system. 1 2
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine. (1) Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor uses a hot film element (2) Idle Switch
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.
Characteristic of IAT Sensor

+5V Output Ground Ground +5V
Resistance ( )
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Temperature (oC)
The IAT sensor is a thermistor. A temperature changes

the resistance value. And it changes voltage. In other
words it measures a temperature value. Low air
temperature produces a high resistance.
Engine Coolant Temperature (ECT) Sensor
Characteristic of TPS
Output Voltage (V)
Throttle Angle (%)
2 1
The TPS is a potentiometer connected to throttle shaft
on the throttle body. It is installed to the main TPS and (1) Engine Coolant Temperature (ECT) Sensor
idle switch. (2) Thermo Unit for Water Temperature Gauge
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
Characteristic of ECT Sensor
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
Resistance ( )
delivery based on throttle valve angle.
Crankshaft Position (CKP) Sensor
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Temperature (deg. C)
The ECT sensor is a thermistor. A temperature changes

words it measures a temperature value. It is installed on
the coolant stream. Low coolant temperature produces
a high resistance.
The ECM supplies 5 volts signal to the ECT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.
The CKP sensor is located on top of the flywheel
housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
and engine cylinder top dead center (TDC).
Vehicle Speed Sensor (VSS) EGR EVRV (4JA1-TC Only)
2 1 3
(1) EGR EVRV

The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall element. It interacts with the (2) Connecting to Vacuum Pump
magnetic field treated by the rotating magnet. It outputs (3) Connecting to EGR Valve
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle 7.1ms
Voltage
speed by VSS.
Time
0.7ms
Off duty 10% =EGR Pulse Ratio 10%
7.1ms
Voltage
Time
6.4ms
The EGR system on this engine is largely responsible

for a reduction of the NOx exhaust emission.
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
GENERAL DESCRIPTION FOR INJECTION dispersion and distribution (mixing with air is improved)
PUMP and results in better combustion. This contributes to
cleaner emissions.
Outline
3. Optimum Fuel Injection
High speed control of fuel injection quantity and fuel
injection timing, is performed by the control unit,
enabling lower fuel cost and high output.
4. Improved Durability
The components used in the pump are very resistant to
high pressure, ensuring improved durability.
5. Improved Engine Matching

As fuel injection is controlled by cylinder selective
adaptation, smooth running is improved.
6. Improved Reliability
As a control unit system with both an engine control
module (ECM) and a pump control unit (PSG) is used,
the control system is extremely reliable.
7. Improved Power Performance

(1) Drive Shaft As the control unit controls the optimum fuel injection
(2) Feed Pump quantify corresponding to accelerator position,
(3) Pump Camshaft Speed Sensor increased torque in low accelerator pedal positions is
(4) Pump Control Unit (PSG) possible, enabling improved power performance.
(5) Distributor Head
8. Decreased Smoke at Acceleration
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve When the amount of injected fuel is increased, to
increase engine power at acceleration, the excess fuel
(8) Constant Pressure Valve (CPV)
usually generates smoke. The VP44 fuel injection pump,
(9) Timing Control Valve (TCV)
accurately controls fuel injection quantity even in this
(10) Timer range to prevent the generation of smoke without
(11) Radial Plunger High Pressure Pump adversely affecting acceleration.
Instead of the previous face cam type, the radial plunger 9. Additional Devices are Unnecessary
distributor type injection pump utilizes a cam ring to
Such additional devices as the boost compensator and
enable fuel injection at high-pressures, marking it
the aneroid compensator are unnecessary, as the
suitable for small, high-speed direct injection diesel
control unit compensates, based on signals from each
engines. This pump was developed to provide the most
sensor. This results in less “clutter” injection pump.
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
10. Self Diagnosis Function
smoke, low noise, high output and clear exhaust
emissions. The system includes a self-diagnosis function, which
displays error codes to facilitate the diagnosis of
Characteristic of VP44 Injection System malfunctions.
1. High Pressure Injection

The radial plunger distributor type injection pump is
capable of generating pressure of 100 Mpa
(approximately 1000 Bar) demanded by small, high
speed direct injection diesel engines.
2. High Pressure Atomization of Fuel Injected from

the Nozzle
Through high pressure fuel injection, the fuel is
atomized at high pressure with a high penetrating force
(the fuel droplets penetrate further) and with greater
Cross-section View
(1) Rotor Shaft

(1) Drive Shaft (2) Radial Plunger
(2) Feed Pump (3) High Pressure Passage
(3) Pump Camshaft Speed Sensor (4) Low Pressure Inlet
(4) Pump Control Unit (PSG) (5) Distributor Slit
(5) Distributor Head (6) Valve Needle
(6) Constant Pressure Valve (CPV) Holder (7) Barrel
(7) High Pressure Solenoid Valve (8) Annular Passage
(8) Constant Pressure Valve (CPV) (9) Fuel Return
(9) Timing Control Valve (TCV) (10) High Pressure Solenoid Valve
(10) Timer (11) High Pressure Outlet
(11) Radial Plunger High Pressure Pump (12) Diaphram Chamber
(13) Accumulator Diaphram
Low Pressure Fuel Circuit High Pressure Fuel Circuit
(1) Fuel Suction (1) Pump Control Unit (PSG)

(2) Regulating Valve (2) Distributor Head
(3) Overflow Valve (3) High Pressure Solenoid Valve
(4) Feed Pump (4) Constant Pressure Valve (CPV)
(5) To Fuel Tank (5) Radial Plunger High Pressure Pump
The low pressure fuel circuit must supply sufficient fuel In addition high pressure generating device, the high
to the high pressure fuel circuit. The main components pressure circuit also consists of fuel piping, and devices
are the feed pump, the regulating valve and the overflow to set the beginning of injection and fuel injection
valve. quantity.
The main components are as follows.

• High pressure generation: Radial Plunger High
Pressure Pump
• Fuel distribution: Distributor Head
• Beginning of injection timing: Timing Device
• Prevention of secondary injection: Constant Pressure
Valve (CPV)
Timing Control Start of Injection
Engine Load
Engine Pump Timing
Engine Speed Control Control Control
Module Unit Valve
Engine Coolant
(ECM) (PSG) (TCV)
Temperature
Pump
Camshaft
Speed Sensor
(1) Cam Ring

The engine control module (ECM) contains
(2) Servo Valve characteristic maps of the beginning of injection,
(3) Timer Piston corresponding to engine operating conditions (engine
(4) Outlet load, engine speed and engine coolant temperature).
(5) Feed Pump The pump control unit (PSG) is constantly comparing
(6) Inlet the set beginning of injection timing and the actual
(7) Fuel Suction beginning of injection timing.
(8) Ball Pin If there is a difference, the timing control valve (TCV) is
(9) Annular Chamber controlled by the duty ratio. (The actual beginning of
(10) Hydraulic Stopper injection timing is determined from the pump camshaft
speed sensor.)
(11) Return Passage
The timing device determines the optimum injection

timing against variations in engine speed.
The pressure of the fuel fed from the feed pump is
adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
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.
The main components are timing plunger, the timing
control valve (TCV) and pump camshaft speed sensor.
ISUZU Strategy Based Diagnostics
Overview You have maximum efficiency in diagnosis when you

have an effective, organized plan for your work. Strategy
As a retail service technician, you are part of the ISUZU Based Diagnostics (refer to Figure 1) provides you with
service team. The team goal is FIX IT RIGHT THE guidance as you create and follow a plan of action for
FIRST TIME for the satisfaction of every customer. You each specific diagnostic situation.
are a very important member of the team as you
diagnose and repair customer vehicles.
STRATEGY BASED DIAGNOSTICS CHART
Diagnostic Thought Process • Circuit testing tools
• Vehicle road tests
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use • Complaint check sheet
the diagnostic thought process. This method of thinking • Contact with the customer
optimizes your diagnosis in the following ways:
• Improves your understanding and definition of the 2. Perform Preliminary Checks
customer complaint
NOTE: An estimated 10 percent of successful vehicle
• Saves time by avoiding testing and/or replacing good repairs are diagnosed with this step!
parts
• Allows you to look at the problem from different What you should do
perspectives
You perform preliminary checks for several reasons:
• Guides you to determine what level of understanding
about system operation is needed: • To detect if the cause of the complaint is VISUALLY
OBVIOUS
– Owner’s manual level
• To identify parts of the system that work correctly
– Service manual level
• To accumulate enough data to correctly and
– In-depth (engineering) level
accurately search for a ISUZU Service Bulletin on
– Owner’s manual level ISUZU Web site.
– Service manual level The initial checks may vary depending on the
– In-depth (engineering) level complexity of the system and may include the following
actions:
• Operate the suspect system
1. Verify the Complaint
• Make a visual inspection of harness routing and
What you should do accessible/visible power and ground circuits
• Check for blown fuses
To verify the customer complaint, you need to know the
• Make a visual inspection for separated connectors
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the • Make a visual inspection of connectors (includes
system. checking terminals for damage and tightness)
The following information will help you verify the • Check for any DTCs stored by the on-board
complaint: computers
• WHAT the vehicle model/options are • Sense unusual noises, smells, vibrations or
• WHAT aftermarket and dealer-installed accessories movements
exist • Investigate the vehicle service history (call other
• WHAT related system(s) operate properly dealerships, if appropriate)
• WHEN the problem occurs
What resources you should use
• WHERE the problem occurs
• HOW the problem occurs Whenever appropriate, you should use the following
resources for assistance in performing preliminary
• HOW LONG the condition has existed (and if the
checks:
system ever worked correctly)
• Tech II or other technical equipment for viewing DTCs
• HOW OFTEN the problem occurs
• Service manual information:
• Whether the severity of the problem has increased,
decreased or stayed the same – Component locations
– Harness routing
What resources you should use – Wiring schematics
Whenever possible, you should use the following – Procedures for viewing DTCs
resources to assist you in verifying the complaint: • Dealership service history file
• Service manual Theory or Circuit Description • Vehicle road test
sections • Identical vehicle or system for comparison
• Service manual “System Performance Check”
• Owner manual operational description
• Technician experience
• Identical vehicle for comparison
3. Check Bulletins and steps of diagnostic procedures to locate the fault related
to the customer complaint.
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle What resources you should use
repairs are diagnosed with this step! Whenever appropriate, you should use the following
resources to perform service manual diagnostic
What you should do procedures:
You should have enough information gained from • Service manual
preliminary checks to accurately search for a bulletin • Technical equipment (for analyzing diagnostic data)
and other related service information. Some service • Digital multimeter and circuit testing tools
manual sections provide troubleshooting hints that
match symptoms with specific complaints. • Essential and special tools
What resources you should use 5c. Technician Self Diagnoses

You should use the following resources for assistance in When there is no DTC stored and no matching
checking for bulletins and troubleshooting hints: symptom for the condition identified in the service
• Printed bulletins manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
• Access ISUZU Bulletin Web site, https://www.einet.isuzu.
service manual combined with you experience and a
co.jp//
good process of elimination will result in accurate
• Videotapes diagnosis of the condition.
• Service manual
What you should do
4. Perform Service Manual
Step 1: Identify and understand the suspect
Diagnostic Checks circuit(s)
Having completed steps 1 through 4 of the Strategy
What you should do Based Diagnostics chart, you should have enough
The “System Checks” in most service manual sections information to identify the system(s) or sub-system(s)
and in most cells of section 8A (electrical) provide you involved. Using the service manual, you should
with: determine and investigate the following circuit
• A systematic approach to narrowing down the characteristics:
possible causes of a system fault • Electrical:
• Direction to specific diagnostic procedures in the – How is the circuit powered (power distribution
service manual charts and/or fuse block details)?
• Assistance to identify what systems work correctly – How is the circuit grounded (ground distribution
charts)?
What resources you should use – How is the circuit controlled or sensed (theory of
Whenever possible, you should use the following operation):
resources to perform service manual checks: – If it is a switched circuit, is it normally open or
• Service manual normally closed?
• Technical equipment (for viewing DTCs and analyzing – Is the power switched or is the ground
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
temperatures? • If only one component fails to operate, begin testing
– 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
• Experience
drivetrain or suspension components without
causing and immediate problem)? • Technical Assistance
– Does the vehicle have aftermarket or dealer- • Circuit testing tools
installed equipment (radios, telephone, etc.)
5d. Intermittent Diagnosis
Step 2: Isolate the problem
At this point, you should have a good idea of what could By definition, an intermittent problem is one that does
cause the present condition, as well as could not cause not occur continuously and will occur when certain
the condition. Actions to take include the following: conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
• Divide (and separate, where possible) the system or intermittents are caused by:
circuit into smaller sections
• Faulty electrical connections and wiring
• Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing • Malfunctioning components (such as sticking relays,
panels and trim as necessary in order to eliminate solenoids, etc.)
large vehicle sections from further investigation) • EMI/RFI (Electromagnetic/radio frequency
• For two or more circuits that do not share a common interference)
power or ground, concentrate on areas where • Aftermarket equipment
harnesses are routed together or connectors are Intermittent diagnosis requires careful analysis of
shared (refer to the following hints) suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
Hints interpret customer complaints and simulating all
Though the symptoms may vary, basic electrical failures external and internal system conditions to duplicate the
are generally caused by: problem.
• Loose connections:
What you should do
– Open/high resistance in terminals, splices,
connectors or grounds Step 1: Acquire information
• Incorrect connector/harness routing (usually in new A thorough and comprehensive customer check sheet is
vehicles or after a repair has been made): critical to intermittent problem diagnosis. You should
– Open/high resistance in terminals, splices, require this, since it will dictate the diagnostic starting
connectors of grounds point. The vehicle service history file is another
• Corrosion and wire damage: source for accumulating information about the
complaint.
connectors of grounds
Step 2: Analyze the intermittent problem
• Component failure:
Analyze the customer check sheet and service history
– Opens/short and high resistance in relays, file to determine conditions relevant to the suspect
modules, switches or loads system(s).
• Aftermarket equipment affecting normal operation of Using service manual information, you must identify,
other systems trace and locate all electrical circuits related to the
You may isolate circuits by: malfunctioning system(s). If there is more than one
• Unplugging connectors or removing a fuse to system failure, you should identify, trace and locate
separate one part of the circuit from another part areas of commonality shared by the suspect circuits.
• Operating shared circuits and eliminating those that
function normally from the suspect circuit
Step 3: Simulate the symptom and isolate the For parts and sensors, apply slight vibration to the part
problem with a light tap of the finger while monitoring the system
Simulate the symptom and isolate the system by for a malfunction.
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/ 2. Heat
systems to isolate the problem symptom. Begin with the This method is important when the complaint suggests
most logical circuit/component. that the problem occurs in a heated environment. Apply
Isolate the circuit by dividing the suspect system into moderate heat to the component with a hair drier or
simpler circuits. Next, confine the problem into a smaller similar tool while monitoring the system for a
area of the system. Begin at the most logical point (or malfunction.
point of easiest access) and thoroughly check the CAUTION: Care must be take to avoid overheating
isolated circuit for the fault, using basic circuit tests. the component.
Hints 3. Water and Moisture

You can isolate a circuit by: This method may be used when the complaint suggests
• Unplugging connectors or removing a fuse to that the malfunction occurs on a rainy day or under
separate one part of the circuit from another conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
• If only component fails to operate, begin testing the
CAUTION: Care must be take to avoid directly
component
exposing electrical connections to water.
• If a number of components do not operate, begin test
at areas of commonality (such as power sources, 4. Electrical loads
ground circuits, switches, main connectors or major
This method involves turning systems ON (such as the
components)
blower, lights or rear window defogger) to create a load
• Substitute a known good part from the parts on the vehicle electrical system at the same time you
department or the vehicle system are monitoring the suspect circuit/component.
• Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for 5e. Vehicle Operates as Designed
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent This condition refers to instances where a system
diagnosis. Follow procedures for basic circuit testing in operating as designed is perceived to be unsatisfactory
service manual section 8A. or undesirable. In general, this is due to:
• A lack of understanding by the customer
What resources you should use • A conflict between customer expectations and vehicle
Whenever appropriate, you should use the following design intent
resources to assist in the diagnostic process: • A system performance that is unacceptable to the
• Service manual customer
• Bulletins
What you should do
• Digital multimeter (with a MIN/MAX feature)
• Tech II and Tech II upload function You can verify that a system is operating as designed
by:
• Circuit testing tools (including connector kits/
harnesses and jumper wires) • Reviewing service manual functional/diagnostic
checks
• Experience
• Examining bulletins and other service information for
• Intermittent problem solving simulation methods
supplementary information
• Customer complaint check sheet
• Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
Symptom Simulation Tests or a conflict between customer expectation and system
operation, you should explain the system operation to
1. Vibration the customer.
This method is useful when the customer complaint If the complaint is due to a case of unsatisfactory
analysis indicates that the problem occurs when the system performance, you should contact Technical
vehicle/system undergoes some form of vibration. Assistance for the latest information.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint What resources you should use
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful. Whenever possible, you should use the following
resources to facilitate the diagnostic process:
• Vehicle service information (service manual, etc.)
• ISUZU field support
• Experience
• Identical vehicle or system for comparison
6. Re-examine the complaint

When you do not successfully find/isolate the problem
after executing a diagnostic path, you should re-
examine the complaint.
What you should do

In this case, you will need to backtrack and review
information accumulated from step 1 through 4 of
Strategy Based Diagnostics. You also should repeat any
procedures that require additional attention.
A previous path may be eliminated from consideration
only if you are certain that all steps were executed as
directed. You must then select another diagnostic path
(step 5a, 5b, 5c or 5d). If all possible options have been
explored, you may call or seek ISUZU field support.

Whenever possible, you should use the following
• Service manual
• Accumulated information form a previous diagnostic
path
• Service information and publications
7. Repair and Verify Fix

What you should do
After you have located the cause of the problem, you
must execute a repair by following recommended
service manual procedures.
When the repair is completed, you should verify the fix
by performing the system checks under the conditions
listed in the customer complaint.
If applicable, you should carry out preventive measures
to avoid a repeat complaint.

resources to facilitate the repair process:
• Electrical repair procedures
• Service manual information and publications
GENERAL SERVICE INFORMATION ON-BOARD DIAGNOSTIC (OBD)
Serviceability Issues On-Board Diagnostic (Self Diagnosis
System) Tests
Non-OEM Parts
A diagnostic test is a series of steps, the result of which
All of the OBD diagnostics have been calibrated to run
is a pass or fail reported to the diagnostic executive.
with OEM parts. Accordingly, if commercially sold
When a diagnostic test reports a pass result, the
sensor or switch is installed, it makes a wrong diagnosis
diagnostic executive records the following data:
and turns on the check engine lamp.
Aftermarket electronics, such as cellular phones, • The diagnostic test has been completed since the
stereos, and anti-theft devices, may radiate EMI into the last ignition cycle.
control system if they are improperly installed. This may • The diagnostic test has passed during the current
cause a false sensor reading and turn on the check ignition cycle.
engine lamp. • The fault identified by the diagnostic test is not
currently active.
Poor Vehicle Maintenance When a diagnostic test reports a fail result, the
The sensitivity of OBD diagnostics will cause the check diagnostic executive records the following data:
engine lamp to turn on if the vehicle is not maintained • The diagnostic test has been completed since the
properly. Restricted oil filters, fuel filters, and crankcase last ignition cycle.
deposits due to lack of oil changes or improper oil
• The fault identified by the diagnostic test is currently
viscosity can trigger actual vehicle faults that were not
active.
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle • The fault has been active during this ignition cycle.
fault”, but with the sensitivity of OBD diagnostics, • The operating conditions at the time of the failure.
vehicle maintenance schedules must be more closely
followed. The Diagnostic Executive
The Diagnostic Executive is a unique segment of
Related System Faults
software which is designed to coordinate and prioritize
Many of the OBD system diagnostics will not run if the the diagnostic procedures as well as define the protocol
ECM detects a fault on a related system or component. for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
Visual/Physical Engine Compartment follows:
Inspection • Commanding the check engine lamp on and off
Perform a careful visual and physical engine • DTC logging and clearing
compartment inspection when performing any • Current status information on each diagnostic
diagnostic procedure or diagnosing the cause of an
emission test failure. This can often lead to repairing a Diagnostic Information
problem without further steps. Use the following
The diagnostic charts and functional checks are
guidelines when performing a visual/physical inspection:
designed to locate a faulty circuit or component through
• Inspect all vacuum hoses for punches, cuts, a process of logical decisions. The charts are prepared
disconnects, and correct routing. with the requirement that the vehicle functioned
• Inspect hoses that are difficult to see behind other correctly at the time of assembly and that there are not
components. multiple faults present.
• Inspect all wires in the engine compartment for There is a continuous self-diagnosis on certain control
proper connections, burned or chafed spots, pinched functions. This diagnostic capability is complemented
wires, contact with sharp edges or contact with hot by the diagnostic procedures contained in this manual.
exhaust manifolds or pipes. The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
Basic Knowledge of Tools Required When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
NOTE: Lack of basic knowledge of this powertrain lamp is illuminated.
when performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain Check Engine Lamp
components. Do not attempt to diagnose a powertrain The check engine lamp looks the same as the check
problem without this basic knowledge. engine lamp you are already familiar with, the “Check
A basic understanding of hand tools is necessary to Engine” lamp.
effectively use this section of the Service Manual. Basically, the check engine lamp is turned on when the
ECM detects a DTC that will impact the vehicle Reading Flash Diagnostic Trouble Codes
emissions.
The provision for communicating with the Engine
• When the check engine lamp remains “ON” while the Control Module (ECM) is the Data Link Connector
engine is running, or when a malfunction is (DLC). The DLC is located in the front console box. It is
suspected due to a driveability or emissions problem, used in the assembly plant to receive information in
a Powertrain On-Board Diagnostic (OBD) System checking that the engine is operating properly before it
Check must be performed. The procedures for these leaves the plant.
checks are given in On-Board Diagnostic (OBD) The diagnostic trouble code(s) (DTCs) stored in the
System Check. These checks will expose faults which ECM’s memory can be read either through a hand-held
may not be detected if other diagnostics are diagnostic scanner plugged into the DLC or by counting
performed first. the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
Data Link Connector (DLC)
DLC terminal “6” (diagnostic request) is pulled “Low”
The provision for communication with the contorl (grounded) by jumping to DLC terminal “4 or 5”, which is
module is the Data Link Connector (DLC). It is located a ground wire.
behind the lower front instrument panel. The DLC is This will signal the ECM that you want to “flash” DTC(s),
used to connect to a Tech2. Some common uses of the if any are present. Once terminals “4 or 5” and “6” have
Tech2 are listed below: been connected, the ignition switch must be moved to
• Identifying stored Diagnostic Trouble Codes (DTCs). the “ON” position, with the engine not running.
• Clearing DTCs. The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
• Reading serial data.
stored in the ECM’s memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a

Tech 2
The procedure for reading diagnostic trouble code(s) is
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes

To clear Diagnostic Trouble Codes (DTCs), use the
Tech2 “clear DTCs” or “clear information” function.
When clearing DTCs follow instructions supplied by the
Tech2 manufacturer.
Verifying Vehicle Repair History DTC

Verification of vehicle repair will be more comprehensive History DTC can be candeled after 40 cycle driving with
for vehicles with OBD system diagnostic. Following a no defect. Or history code can be deleted by Tech 2
repair, the technician should perform the following “Clear DTCs” function.
steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the
Fail Records.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps is very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
DIAGNOSIS WITH Tech 2 cable (4).
If no codes are set: • Connect the DLC cable (4) to the Tech 2 (5).
• Refer to F1: Data Display and identify the electrical • Connect the SAE 16/19 adapter (3) to the data
faults that are not indicated by trouble code. link connector of the vehicle.
• Refer to “SYMPTOM DIAGNOSIS”.
If codes are set:

1. Record all trouble codes displayed by Tech 2 and
check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty
status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is
intermittent. In this case, refer to “DIAGNOSIS
AIDS”.
6. If a code is present, refer to DTC Chart for
diagnosis.
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.
Tech 2 scan tool is used to electrically diagnose the

automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Tech 2.
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).
• Connect the SAE 16/19 adapter (3) to the DLC
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
Press “ENTER” key. Select “(TF/UC)”.

Main Menu System Selection Menu
F0: Diagnostic F0: Powertrain
F1: Service Programming System (SPS) F1: Chassis
F2: View Capture Data F3: Body
F3: Tool Option
F4: Download/ Upload Help
Select “F0: Diagnostic”. Select “F0: Powertrain”.

Vehicle Identification Vehicle Identification
(3) 2003 4JH1-TC Bosch
(2) 2002 4JA1-TC Bosch
(1) 2001 4JH1-T Denso
(Y) 2000 3.5L V6 6VE1 Hitachi
(X) 1999 AW30-40LE
(W) 1998 AT JR405E
Select “(2) 2002”or later. Select “4JH1-TC Bosch”.

or “4JH1-TC Bosch”.
Select “4JA1-TC Bosch” or “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.
F0: Diagnostic Trouble Codes F1: Data Display

The purpose of the “Data Display” mode is to
F0: Read DTC Infor As Stored By ECU
continuously monitor data parameters.
F1: Clear DTC Information The current actual values of all important sensors and
F1: Data Display signals in the system are display through F1 mode.
See the “Typical Scan Data” section.
F2: Snapshot F2: Snapshot

“Snapshot” allows you to focus on making the condition
occur, rather than trying to view all of the data in
F3: Miscellaneous Test
anticipation of the fault.
F0: Lamps The snapshot will collect parameter information around
F0: Check Light a trigger point that you select.
F1: Glow Time Telltale Test
F3: Miscellaneous Test:
F1: Relays The purpose of “Miscellaneous Test” mode is to check
F0: Glow Time Relay Test for correct operation of electronic system actuators.
F2: Engine Speed (RPM) Control
F4: Programming (Factory Use Only)
The purpose of “Programming” is to program VIN in the
F4: Programming ECM and lock the programmed data.
F0: Program VIN
F1: Lock ECU
F0: Diagnostic Trouble Code

The purpose of the “Diagnostic Trouble Codes” mode is
to display stored trouble code in the ECM.
When “Clear DTC Information” is selected, a “Clear
DTC Information”, warning screen appears.
This screen informs you that by cleaning DTC's “all
stored DTC information in the ECM will be erased”.
After clearing codes, confirm system operation by test
driving the vehicle.
Read DTC Infor As Stored By ECU
P0100 Present
(7) Mass Air Flow (MAF) Sensor
DTC No. Voltage Supply Circuit High Input
Symptom Code
Symptom Code:
This number or alphabet means identification of the
malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
TYPICAL SCAN DATA & DEFINITIONS 4JA1-TC (ENGINE DATA)
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 diagnostics are functioning properly. Tech 2 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.)
Tech 2/TIS 2000

Units Idle 1500rpm 2000rpm Description
Parameter
1 Engine Speed rpm 705 - 755 1475 - 1525 1975 - 2025 The engine speed is measured by ECM from the CKP
sensor.
2 Vehicle Speed km/h 0 0 0 This displays vehicle speed. The vehicle speed is
measured by ECM from the vehicle speed sensor.
3 Pump Speed rpm 353 - 375 725 - 775 975 - 1025 This displays injection pump speed. The injection speed
is measured by ECM from the pump cam sensor.
4 Accelerator % 0 5-7 7-9 Throttle position operating angle is measured by the
Position Signal ECM from throttle position output voltage. This should
display 0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Inactive Active Active Inactive This displays operating status of the idle switch. This
should display “Active” when the idle condition.
6 Mass Air Flow mg/strk 380 - 430 360 - 390 360 - 390 This displays intake air amount. The mass air flow is
Sensor measured by ECM from the MAF sensor output voltage.
7 Barometric hpa 990 - 1015 990 - 1015 990 - 1015 The barometric pressure is measured by ECM from the
Pressure sensor in the ECM. This data is changing by altitude.
8 Desired Injection mg/stk 8 - 10 8 - 11 8 - 11 This displays commanded value from the ECM. The ECM
Quantity compensates for fuel rate to basic rate.
9 Injection Quantity mg/stk 8 - 10 8 - 11 8 - 11 This displays actual fuel quantity. The PSG controls high
pressure solenoid valve to meet commanded value from
the ECM.
10 Desired Fuel °CA 2-3 3-4 3-4 This displays commanded value from the ECM. The ECM
Injection Start compensates for fuel injection timing by throttle position
and various sensor signal.
11 Actual Injection °CA 2-3 3-4 3-4 This displays actual injection timing value controlled by
Start the TCV. The TCV controls duty ratio to meet
commanded value from the PSG.
12 Coolant °C 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
Temperature voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg.
13 Fuel Temperature °C 25 - 50 25 - 50 25 - 50 The FT is measured by PSG from FT sensor. This data is
changing by fuel temperature.
14 Intake Air °C 25 - 50 25 - 50 25 - 50 The IAT is measured by ECM from IAT sensor output
Temperature voltage. This data is changing by intake air temperature.
15 Ignition Status On12V/ Off0V On 12V On 12V On 12V This displays the key switch status indicated by the ECM
with key switch signal. This should display “Off 0V” at key
OFF and “On12V” at key ON.
16 Brake Switch 1 Active/ Inactive Inactive Inactive Inactive This displays operating status of the brake switch. This
should display “Active” when the brake pedal is stepped
on.
17 Brake Switch 2 Active/ Inactive Inactive Inactive Inactive This displays operating status of the brake switch. This
on.
18 Clutch Switch Active/ Inactive Inactive Inactive Inactive This displays operating status of the clutch switch. This
should display “Active” when the clutch pedal is stepped
on.
19 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.
20 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.
Tech 2/TIS 2000
Units Idle 1500rpm 2000rpm Description
Parameter
21 Diagnostic Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Request Inactive 12V 12V 12V 12V display “Inactive 12V” when the Tech 2 is connected.
22 System Voltage V 11 - 14 11 - 14 11 - 14 This displays the system voltage measured by the ECM
at ignition feed.
23 Main Relay Active/ Inactive Active Active Active This displays operating status for the ECM main relay.
This should display “On” when the key switch is turned on
and while engine is running.
24 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.
25 Check Engine On/Off Off Off Off This displays operating status for the Check Engine
Lamp Lamp. This should display “On” when the Check Engine
Lamp is turned on.
26 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.
27 EGR Pulse Ratio % 70 60 - 70 60 - 70 This displays the duty signal from the ECM to control the
EGR flow amount.
28 EGR Command mg/strk 340 - 360 350 - 370 350 - 370 This displays EGR amount commanded value from the
ECM This data is changing with EVRV operation.
29 Intake Manifold Active/ Inactive Inactive Inactive Inactive This displays operating status of the intake throttle. This
Valve should display “Active” when the intake throttle VSV is
operated. (Not Used for TF*)
30 Exhaust Brake Active/ Inactive Inactive Inactive Inactive This displays operating status of the exhaust throttle. This
Valve 1 should display “Active” when the exhaust throttle VSV 1 is
operated.
31 Exhaust Brake Active/ Inactive Inactive Inactive Inactive This displays operating status of the exhaust throttle. This
Valve 2 should display “Active” when the exhaust throttle VSV 2 is
operated.
32 Desired Engine rpm 730 730 730 The desired engine idle speed that the ECM
Idle Speed commanding. The ECM compensates for various engine
loads based on engine coolant temperature.
33 Start of Delivery °CA 18 - 22 22 - 24 22 - 24 This displays commanded value from the ECM when
engine start.
34 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor.
Inactive 12V 12V 12V 12V This should display “Active 0V” when the compressor
relay is operated.
35 Immobiliser Active/ Inactive Inactive Inactive Inactive This should display “Inactive” when the immobiliser is
normal.
36 Immobiliser Signal Received/ Not Not Not This should display “Not Received” when the immobiliser
Not Received Received Received Received is not activated.
37 Immobiliser Yes/No Yes Yes Yes This should display “Yes” when the immobiliser is
Function programmed.
Programmed
TYPICAL SCAN DATA & DEFINITIONS 4JH1-TC (ENGINE DATA)
80 deg.)
Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

sensor.
Position Signal (0) (4 - 7) (8 - 11) ECM from throttle position output voltage. This should
Value of ( ) shows display 0% at idle and 99 - 100% at full throttle.
AT model
Sensor (730 - 785) (700 - 780) (780 - 830) measured by ECM from the MAF sensor output voltage.
Value of ( ) shows
AT model
8 Desired Injection mg/stk 5-8 5-9 6 - 10 This displays commanded value from the ECM. The ECM
Quantity (10 - 16) (8 - 12) (9 - 13) compensates for fuel rate to basic rate.
Value of ( ) shows
AT model
9 InjectionQuantity mg/stk 6-8 6-9 7 - 10 This displays actual fuel quantity. The PSG controls high
Value of ( ) shows (10 - 16) (8 - 12) (9 - 13) pressure solenoid valve to meet commanded value from
AT model the ECM.
16 Brake Switch 1 Active/ Inactive Inactive Inactive Inactive This displays operating status of the brake switch 1. This
on.
on.
Value of ( ) shows (-) (-) (-) should display “Active” when the clutch pedal is stepped
AT model on.
22 System Voltage V 10 -14 10 -14 10 -14 This displays the system voltage measured by the ECM
at ignition feed.
This should display “Inactive” at key OFF and “Active” at
key ON.
upped.
Lamp is turned on.
on.
engine start.
relay is operated.
normal.
31 Immobiliser Signal Received/ Not Not Not This should display “Not Received” when the immobiliser
Not Received Received Received Received is not activated.
Programmed
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC cannot
be detected, a faulty circuit can be diagnosed by testing
each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
mechanical trouble and an electrical trouble.
Connect Tech 2 and select “Powertrain”, “4JH1-TC
Bosch” & “Miscellaneous Test”.
F0: Lamps
F0: Check Light
When the Tech 2 is operated, “Malfunction Indicator
Lamp (Check Engine Lamp)” is turned on or off.
The circuit is normal if the “Malfunction Indicator Lamp
(Check Engine Lamp)” in the instrument panel is turned
on or off in accordance with this operation.

When the Tech 2 is operated, “Glow Indicator Lamp” is
turned on or off.
The circuit is normal if the “Glow Indicator Lamp” 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 signal turns ON
or OFF.
The circuit is normal if glow system is activated/
deactivated in accordance with this operation when key
switch is turned ON.

When the Tech 2 is operated, “Desired Idle Speed”
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is normal if engine speed is changed in
accordance with this operation.
Engine Speed (RPM) Control

Engine Speed 850 RPM
Desired Idle Speed 850 RPM
Injection Quantity 7.5mg/strk
• Press “Increase” key.

Then, Desired Idle speed increases 50rpm-by-50rpm
up to 1200rpm. Engine speed is also changed by this
operation.
• Press “Quit” Key.
Plotting Snapshot Graph
This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)
SNAPSHOT DISPLAY WITH TIS2000
Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]
function is described below.
Snapshot data can be displayed with [Snapshot Upload]
function included in TIS2000.
By analyzing these data in various methods, trouble
conditions can be checked.
Snapshot data is displayed by executing the three steps
below shown:
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.

After recording the snapshot in Tech2, transfer the data
from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen.
3. Snapshot data is displayed with TIS2000

[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
screen.
3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
5. Open the snapshot, to display the data parameter
list on the screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter] 6. Graph display can be moved with the navigation
window opens. icon.
2. Click the first graph icon of the window upper part, 7. For displaying another parameter by graph, click the
and select one parameter from the list of the window parameter of the list, drug the mouse to the display
lower part. Selected parameter is displayed nest to screen while pressing the mouse button and release
the graph icon. Graph division can be selected in the mouse button. New parameter is displayed at
the field on the parameter right side. the position of the previous parameter. For
3. Repeat the same procedures with the 2nd and 3rd displaying the graph display screen in full size, move
icons. the cursor upward on the screen. When the cursor
is changed to the magnifying glass form, click the
4. After selecting all parameters to be displayed (Max.
screen. Graph screen is displayed on the whole
3 parameters), click [OK] button.
screen.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window 4. Click the [OK] button to display.
opens. 5. In this case, parameters are displayed only in graph
2. Click the graph icon, select the parameter to be form. All parameters are displayed in one graph.
displayed from the list and change divisions 6. The graph display screen can be moved with the
according to necessity. navigation icon.
3. Repeat the same procedures with the graph icons,
from the 2nd to 6th.
SERVICE PROGRAMMING SYSTEM (SPS)
latest software release.
The procedure to program the control unit by using the
Service Programming System (SPS) software • The latest release of TIS2000 is loaded on the PC.
contained in TIS2000 is explained below.
• The vehicle battery is fully charged.
NOTE: • The control unit to be programmed is connected to
• If the Engine Control Module (ECM) was the vehicle.
programmed, the Immobiliser System must be linked
to the ECM: Refer to section 11 “Immobiliser System- 1. Preparations of TIS 2000
ECM replacement” for the ECM/Immobiliser linking 1. Connect Tech 2 to P/C.
procedure.
2. Check to see if Hardware Key is plugged into Port.
Important: Perform the following checks before 3. Activate TIS 2000 by P/C.
attempting to program the control unit: 4. On the activating screen of TIS2000, choose
• The Tech2 PCMCIA card is programmed with The “Service Programming System”
5. On the screen of “Diagnostic Tester and Processing

Program Selection”, choose the one that will comply
with the following.
• Diagnostic tester in use
• New programming by the existing module or new
programming by the replaced/new module.
• Fixing position of the control unit.
6. Upon completion of the selection, push the button of
“Continue”.
2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by
turning on the power of Tech-2, push the “Enter”
switch.
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. Where vehicle data has been already saved in Tech
2, the existing data come on display. In this instance,
as Tech-2 starts asking whether to keep the data or
to continue obtaining anew data from the control
unit, choose either of them.
6. If you select “continue”, you have to select “Model 3. Data Exchange

Year”, “Vehicle Type”, “Controller Type (Engine)”. 1. Connect Tech-2 to P/C, turn on the power and click
7. After that. then push button and turn Ignition switch the “Next” button of P/C.
tuned on, off, on following Tech-2 display. Tech-2 will 2. Check VIN of the vehicle and choose “Next”.
read information from controller after this procedure.
3. When a lack of data is asked from among the
8. During obtaining information, Tech-2 is receiving following menu, enter accordingly.
information from the control unit chosen. In Select following Menu
replacing the control unit, please be sure to
• Model Year
undertake “Obtaining Information” from the new
unit. With VIN not being programmed into the new • Model
control unit at the time of shipment, “obtaining • Engine type
information” is not complete (because the vehicle • Transmission type
model, engine model and model year are specified
• Destination code (vehicles for general export)*1
from VIN). For the procedure get additional
information on vehicles, instruction will be provided • Immobiliser
in dialog form, when TIS2000 is in operation. * 1: How to read the destination code
Destination code can be read from ID Plate affixed on
9. Following instructions by Tech-2, push the “Exit”
vehicles, while on VIN plate the destination code is
switch of Tech-2, turn off the ignition of the vehicle
described at the right-hand edge of Body Type line. In
and turn off the power of Tech-2, thereby removing
Fig.-3, the destination code can be read as “EK4
from the vehicle.
(Europe)”.
4. After choosing the data, click the “Next” button. the “Program” switch and then download the new
5. When all the necessary information is entered, the software onto Tech-2.
“details” of software within the database that match 6. “Data Transfer” comes on display. The progress of
the entered data will appear for confirmation. Click downloading will be displayed on the screen in the
form of bar graph.
7. Upon finishing the data transfer, turn off the power
of Tech-2, removing from P/C.
4. Programming of ECM
1. Check to see if batteries are fully charged, while
ABS connectors shall be removed from the vehicle.
2. Connect Tech-2 to Vehicle Diagnostic Connectors.
3. Turn on the power of Tech-2 and the title screen
comes on display.
4. Turn on the ignition (without allowing the engine to
start)
5. On the title screen of Tech-2, push the “Enter”
button.
6. Choose “F: Service Programming System” on the
main screen and then choose “Fl: Programming”.
7. While data is being transferred, “Downloading” will
be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
“Reprogramming 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.
HOW TO USE BREAKER BOX
3 1
(1) Engine Control Module (ECM) (3) Breaker Box

(2) Harness Adapter
The engine control module (ECM) and other connectors

have water proof connector and special terminal. Water
proof terminal does not allow to use back prove. In
addition, the engine control module (ECM) special
terminal can not let regular digital voltage meter prove to
access, because terminal shape is very fin pin type.
In order to prevent damage of female terminal and
connector itself, the breaker box and adapter is the most
suitable special tool.
Breaker Box Connection Type A
4 3 5 2
(1) Engine Control Module (ECM) (4) Digital Voltage Meter

(2) Harness Adapter (5) ECM - Harness Adapter Disconnection
(3) Breaker Box
Breaker box connection type A, check for “open circuit”

and “short to ground circuit”.
Breaker Box Connection Type B
4 3 5 2

(2) Harness Adapter (5) ECM - Harness Adapter Connection
(3) Breaker Box
Breaker box connection type B, check for “short to

power supply circuit” and “power, signal voltage check”
between the engine control module (ECM) and
electrical components.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Butery
Voltage
Ignition
SW
Stop
Light
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
Circuit Description connection, and damaged harness.

The on-board diagnostic system check is the starting
Test Description
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical Number(s) below refer the step number(s) on the
check of the ECM and engine grounds for cleanliness Diagnostic Chart:
and tightness. 1. The Check Engine Lamp (MIL) should be ON steady
The on-board diagnostic system check is an organized with the ignition “On”, engine “Off”. If not, “No Check
approach to identifying a problem created by an Engine Lamp (MIL)” chart should be used to isolate the
electronic engine control system malfunction. malfunction.
2. Checks the Class 2 data circuit and ensures that the
Diagnostic Aids ECM is able to transmit serial data.
An intermittent may be caused by a poor connection, 3. This test ensures that the ECM is capable of
rubbed-through wire insulation or a wire broken inside controlling the Check Engine Lamp (MIL) and the Check
the insulation. Check for poor connections or a Engine Lamp (MIL) driver circuit is not shorted to
damaged harness. Inspect the ECM harness and ground circuit.
connector for improper mating, broken locks, improperly 4. If the engine will not start, “Engine Cranks But Will
formed or damaged terminals, poor terminal-to-wire Not Run” chart should be used to diagnose the fault.
6. The Tech2 parameters which is not within the typical 12. This vehicle is equipped with ECM which utilizes an
range may help to isolate the area which is causing the electrically erasable programmable read only memory
problem. (EEPROM).
On-Board Diagnostic (OBD) System Check

Step Action Value(s) Yes No
1 1. Ignition “On”, engine “Off”. Go to No
2. Check the “CHECK ENGINE” lamp (MIL). CHECK
Does the “CHECK ENGINE” lamp turn “On”? — Go to Step 2 ENGINE Lamp
2 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Attempt to display “Data Display” with the Tech 2.
Does the Tech 2 display engine data? — Go to Step 3 Go to Step 7
2. Select the “Miscellaneous Test” and perform the
“Check Light” in “Lamps”.
3. Operate the Tech 2 in accordance with the Tech 2 Go to CHECK
instructions. ENGINE LAMP
Does the “CHECK ENGINE” lamp turn “Off”? — Go to Step 4 On Steady
4 Attempt to start the engine. Go to Engine
Does the engine start and continue to “Run”? Cranks But Will
— Go to Step 5 Not Run
2. Select the “Read DTC Infor As Stored By ECU” in
“Diagnostic Trouble Code”. Go to DTC
3. Are any DTCs stored? — Chart Go to Step 6
6 Compare typical scan data values displayed on the Refer to Refer to
Tech 2 “Data Display”. SYMPTOM TYPICAL
Are the displayed values within the range? — DIAGNOSIS SCAN DATA
7 Using the DVM and check the data link connector
power supply circuit.
1. Ignition “Off”, engine “Off”.
2. Check the circuit for open circuit.
Was the problem found?
C-96
16
Repair faulty
V harness and
— verify repair Go to Step 8

ground circuit.
C-96
4 5
Repair faulty
harness and
ground circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
C-96
4 5
Repair faulty
V V
harness and
Less than 1V Go to Step 10 verify repair
communication circuit.
Was the DVM indicated battery voltage?
C-96
6
Repair faulty
V
harness and

2. Disconnect the ECM connector.
3. Check the circuit for open or short to ground
circuit.
C-56
45
C-96
6 Repair faulty
harness and
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 “Immobiliser System-ECM replacement” for
the ECM/Immobiliser linking procedure. — Verify repair —
NO CHECK ENGINE LAMP (MIL)
Butery
Voltage
Ignition
SW
Stop
Light
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
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
The Engine Control Module (ECM) turns the check connection, 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
No Check Engine Lamp (MIL)
1 Check the meter fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 2
2 Using the DVM and check the “CHECK ENGINE”
lamp circuit.
3. Ignition “On”.
C-56
42
V
Battery
voltage Go to Step 5 Go to Step 3
3 Check the “CHECK ENGINE” lamp bulb.
If the bulb is burnt out, repair as necessary.

lamp circuit.
2. Disconnect the meter connector and ECM
connector.
4JA1-TC
C-56
42
B-23
2
4JH1-TC
C-56
42
B-23
6
— Verify repair Go to Step 5

release?
6 Replace the ECM.
CHECK ENGINE LAMP (MIL) “ON” STEADY
Butery
Voltage
Ignition
SW
Stop
Light
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
Circuit description Diagnostic Aids

The check engine lamp should always be illuminated An intermittent may be caused by a poor connection,
and steady for about five seconds with ignition “ON” and rubbed-through wire insulation, or a wire broken inside
the engine stopped. Ignition feed voltage is supplied the insulation. Check for the following items:
directly to the check engine lamp indicator. The Engine • Poor connection or damaged harness – Inspect the
Control Module (ECM) turns the check engine lamp ECM harness and connectors for improper mating,
“ON” by grounding the check engine lamp driver circuit. broken locks, improperly formed or damaged
The check engine lamp should not remain “ON” with the terminals, poor terminal-to-wire connection, and
engine running and no DTC(s) set. A steady check damaged harness.
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Check Engine Lamp (MIL) On Steady
1 1. Ignition “Off”, engine “Off”.
Was the “CHECK ENGINE” lamp turned on? — Go to Step 2 Go to Step 4
lamp circuit.
connector.
3. Check the circuit for short to ground circuit.
C-56
42
4JA1-TC
B-23
4JH1-TC
6 B-23

3 Replace the meter assembly.
Is the action complete? — Verify repair —
release?

5 Replace the ECM.
ECM Diagnostic Trouble Codes
Related Related 4JA1 4JH1 4JH1

Flash Symptom
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple -TC -TC -TC
Code Code
No. DTC (MT) (MT) (AT)
65 P0100 7 ON Mass Air Flow (MAF) Sensor Volt- MAF sensor power supply ECM uses mass air flow MAF sensor power supply voltage 1. Sensor power supply circuit 83 -
age Supply Circuit High Input voltage is more than 5.2V. 1600mg/strk & EGR 10% is below 5.2V. short to battery voltage circuit.
(4JA1-TC only) condition(s) 2. MAF sensor malfunction.
as substitute. 3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor Volt- MAF sensor power supply MAF sensor power supply voltage 1. Sensor power supply circuit 83 -
age Supply Circuit Low Input voltage is below 4.6V. is more than 4.6V. short to ground circuit.
2. MAF sensor malfunction.
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor Out- 1. Engine speed is between MAF sensor output is more than - 1. Sensor power supply circuit 83/88 P0110(1)
put Circuit Low Input 600rpm and 5000rpm. 27.4mg/strk. open circuit.
2. MAF sensor output is below 2. Sensor signal circuit open or
-33.7mg/strk. short to ground circuit.
3. Sensor heater harness open
circuit.
4. Poor connector connection.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor Out- 1. Engine speed is between MAF sensor output is below 1. Sensor signal circuit short to 88/ 92 P0110(1)
put Circuit High Input 600rpm and 5000rpm. 1784mg/strk. voltage circuit.
2. MAF sensor output is more 2. Sensor ground circuit open or
than 1784mg/strk. short to voltage circuit.
4. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) Sen- IAT sensor output voltage is ECM use 0°C conditions as IAT sensor output voltage is below 1. Sensor signal circuit open or 84/92 P0100(B)/
sor Circuit High Input more than 4.7V. substitute. 4.7V. short to voltage circuit. P0100(C)
2. Sensor ground circuit open or
short to voltage circuit.
3. Poor connector connection
4. IAT sensor malfunction.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) Sen- IAT sensor output voltage is IAT sensor output voltage is more 1. Sensor signal circuit short to 84 -
sor Circuit Low Input below 0.3V. than 0.3V. ground circuit.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel tempera- ECT sensor output voltage is below 1. Sensor signal circuit open or 89/93 -
(ECT) Sensor Circuit High Input more than 4.7V. ture as substitute. 4.7V. short to voltage circuit.
2. ECM uses 60°C condition 2. Sensor ground circuit open or
for injection timing control. short to voltage circuit.
3. ECM uses -15°C condition 3. Poor connector connection
for glow time control. 4. ECT sensor malfunction.
5. ECM malfunction.
2 ON Engine Coolant Temperature ECT sensor output voltage is ECT sensor output voltage is more 1. Sensor signal circuit short to 89 -
(ECT) Sensor Circuit Low Input below 0.3V. than 0.3V. ground circuit.
2. ECT sensor malfunction.
3. ECM malfunction.

Flash Symptom
Code Code
15 P0180 B ON Fuel Temperature Sensor Circuit FT sensor output is high tem- The ECM use 75°C condi- FT sensor output is correct temper- 1. ECM malfunction. - -
Range/Performance perature (more than 150°C) or tions as substitute. ature range between 150°C and - 2. PSG (pump control unit) mal-
low temperature (below - 40°C. function.
40°C).
52 P0215 A ON at Fuel Cutoff Solenoid Valve Mal- 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in 1. PSG (pump control unit) mal- - -
next function 2. Engine speed is below valve) is operated. the next ignition key cycle. function.
igni- 1500rpm. 2. Desired injection quantity 2. MAB (fuel cutoff solenoid
tion 3. Vehicle speed is below becomes 0mg/strk. valve) malfunction.
cycle 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 Circuit ECM does not command MAB Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid 105 -
High Input (fuel cutoff solenoid valve) sig- valve) signal circuit short to volt-
nal to the PSG (pump control age circuit.
unit), but PSG detected MAB 2. PSG (pump control unit) mal-
signal line circuit is high level. function.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in 1. MAB (fuel cutoff solenoid 105 -
Always Active 2. Engine speed is below valve) is operated. the next ignition key cycle. valve) signal circuit open or short
1500rpm. 2. Desired injection quantity to ground circuit.
3. Vehicle speed is below becomes 0mg/strk. 2. PSG (pump control unit) mal-
1.5km/h. function.
does not recognize MAB (fuel
cutoff solenoid valve) signal
from the ECM.
D ON Fuel Cutoff Solenoid Valve Mal- 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction. - -
function 2. CAN controller does not 2. PSG (pump control unit) mal-
operate Bus-off. function.
54 P0216 A ON Injection Timing Control Circuit 1. Engine speed is more than Fuel injection quantity is Deviation of actual injection timing 1. Timing control valve malfunc- - -
Malfunction (Timer Deviation) 700rpm. reduced. and desired injection timing is tion.
2. Fuel injection quantity is below +3°CA or -6°CA for 8 sec- 2. Timer piston sticking.
more than 4mg/stk. onds. 3. Pump camshaft speed sensor
3. Deviation of actual injection malfunction.
timing and desired injection
timing is more than +3°CA or
-6°CA for 8 seconds.
B ON Injection Timing Control Circuit 1. Engine speed is more than 1. Engine speed is more than 1. Insufficient air bleeding of fuel - -
Malfunction (Timer Fluctuation) 2014rpm. 2014rpm. line.
2. Fluctuation of actual injec- 2. Fluctuation of actual injection tim- 2. Fuel filter clogging.
tion timing is more than ing is below ±5.2°CA. 3. Timing control valve malfunc-
±5.2°CA. tion.
4. Pump camshaft speed sensor
malfunction.

Flash Symptom
Code Code
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed 1. MAB (fuel cutoff solenoid No recovery until condition match in 1. PSG (pump control unit) mal- - -
sensor error. valve) is operated. the next ignition key cycle. function.
2. High pressure solenoid 2. Desired injection quantity 2. Pump camshaft speed sensor
valve control pulse width does becomes 0mg/strk. malfunction.
not match with desired fuel
injection quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed 1. No pump camshaft speed sensor 1. Missing CKP sensor pulses. 91 -
sensor error. error. 2. Electrical interference.
2. No CKP sensor error. 2. No CKP sensor error. 3. Magnetic interference.
3. Difference of engine speed 3. Difference of engine speed and 4. PSG (pump control unit) mal-
and doubled pump camshaft doubled pump camshaft speed is function.
speed is more than 720rpm below 720rpm (4JA1-TC) or
(4JA1-TC) or 690rpm (4JH1- 690rpm (4JH1-TC).
TC). No recovery until in the next ignition
key cycle.
9 ON Injection Pump Malfunction No pump map programmed in No recovery until condition match in PSG (pump control unit) malfunc- - -
the PSG (pump control unit) or the next ignition key cycle. tion.
PSG malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is EEPROM or A/D converter no mal- PSG (pump control unit) malfunc- - -
malfunction in the PSG (pump reduced. function in the PSG (pump control tion.
control unit). unit).
No recovery until in the next ignition
key cycle.
B ON Injection Pump Malfunction PSG (pump control unit) rec- No fail-safe function. No recovery until condition match in PSG (pump control unit) malfunc- - -
ognized high pressure sole- the next ignition key cycle. tion.
noid valve drive circuit error.
D ON Injection Pump Malfunction PSG (pump control unit) could PSG (pump control unit) malfunc- - -
not measure the high pressure tion.
solenoid valve drive voltage.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump control 1. CAN high circuit open, short to 99/100 P1650(A)/
(pump control unit) message. valve) is operated. unit) message. ground or short to voltage circuit. P1651(B)
2. Desired injection quantity 2. CAN low circuit open, short to
becomes 0mg/strk. ground or short to voltage circuit.
3. ECM malfunction.
4. PSG (pump control unit) mal-
function.

Flash Symptom
Code Code
43 P0335 B ON Crankshaft Position Sensor Cir- 1. Engine speed is more than When pump camshaft speed ECM detects correct CKP pulse During engine run: 90/ 98/ P1335 (A)
cuit Malfunction 665rpm. sensor is OK: width. 1. CKP sensor harness open cir- 101
2. CKP sensor pulse width ECM uses doubled pump cuit, short to ground or short to
error. camshaft speed as substitute voltage circuit.
engine speed. 2. Poor connector connection.
When pump camshaft speed 3. CKP sensor malfunction.
sensor is not OK: 4. Pulse sensing gap incorrect.
1. MAB (fuel cutoff solenoid 5. Pulser malfunction.
valve) is operated. 6. Electrical interference.
2. Desired injection quantity 7. Magnetic interference.
becomes 0mg/strk. 8. ECM malfunction.
D ON Crankshaft Position Sensor Cir- 1. No pump camshaft speed When pump camshaft speed 1. Engine speed is more than 0rpm. During engine crank: 90/ 98/ P1135 (A)
cuit Malfunction sensor error. sensor is OK: 2. Doubled pump camshaft speed is 1. CKP sensor harness open cir- 101
2. “Crankshaft Position Sensor ECM uses doubled pump below 100rpm. cuit, short to ground or short to
Circuit Malfunction (Symptom camshaft speed as substitute voltage circuit.
Code B)” is not stored. engine speed. 2. Poor connector connection.
3. Engine speed is 0rpm. Other than pump camshaft 3. CKP sensor malfunction.
4. Doubled pump camshaft speed sensor is OK: 4. Pulse sensing gap incorrect.
speed is more than 50rpm. Fuel injection quantity is 5. Pulser malfunction.
reduced. 6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent malfunc- Engine speed is below 5700rpm. 1. Engine over-running. 90/ 98/ -
Range/Performance 5700rpm. tion: 2. CKP sensor malfunction. 101
valve) is operated. 4. ECM malfunction.
2. Desired injection quantity
becomes 0mg/strk.
When preliminary malfunc-
tion:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
66 P0380 4 ON Glow Relay Circuit Voltage Low Glow relay circuit open or No fail-safe function. Glow relay circuit is correct condi- 1. Glow relay circuit open or short 94 -
short to ground circuit. tion. to ground circuit.
2. Glow relay malfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage High Glow relay circuit short to volt- ECM malfunction. - -
age circuit.
67 P0381 4 ON Glow Plug Indicator Circuit Volt- Glow plug indicator circuit No fail-safe function. Glow plug indicator circuit is correct 1. Glow plug indicator circuit 43 -
age Low open or short to ground circuit. condition. open or short to ground circuit.
2. Glow plug indicator lamp mal-
function.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Volt- Glow plug indicator circuit ECM malfunction. - -
age High short to voltage circuit.

Flash Symptom
Code Code
32 P0400 3 ON Exhaust Gas Recirculation Flow 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at open 88/97 - - -
Excessive Detected between 15°C and 100°C. reduced. 1500rpm and 3100rpm. position.
2. Engine coolant tempera- 2. Injection quantity is between 2. EGR EVRV malfunction.
ture is between 55°C and 8mg/strk and 32mg/strk. 3. Air intake is obstructed.
100°C. 3. Correct amount of mass air flow. 4. Air intake is leaking.
3. Barometric pressure is 5. MAF sensor malfunction.
between 850hpa and 6. ECM malfunction.
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 Circuit EGR EVRV circuit open or Fuel injection quantity is EGR EVRV circuit is correct condi- 1. EGR EVRV circuit open or 97 - - -
Short to Ground or Open Circuit short to ground circuit. reduced and EGR EVRV tion. short to ground circuit.
10% conditions as substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation Flow 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at close 88/97 - - -
Insufficient Detected between 15°C and 100°C. reduced. 1500rpm and 3100rpm. position.
2. Engine coolant tempera- 2. Injection quantity is between 2. EGR valve operating vacuum
ture is between 55°C and 8mg/strk and 32mg/strk. hose is clogged or disconnected.
100°C. 3. Correct amount of mass air flow. 3. EGR EVRV malfunction.
3. Barometric pressure is 4. MAF sensor signal circuit short
between 850hpa and to voltage circuit.
1100hpa. 5. MAF sensor malfunction.
4. Large mount of mass air 6. ECM malfunction.
flow. (Desired mass air flow -
mass air flow is below 150 mg/
strk)
8 ON Exhaust Gas Recirculation Circuit EGR EVRV circuit short to Fuel injection quantity is EGR EVRV circuit is correct condi- 1. EGR EVRV circuit short to volt- 97 - - -
Short to Battery voltage circuit. reduced & EGR EVRV 10% tion. age circuit.
conditions as substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
24 P0500 1 ON at Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed Vehicle speed is below 200km/h. 1. VSS signal circuit open, short 68 -
next High Input 200km/h. 5km/h condition as substi- to ground or short to voltage cir-
igni- tute. cuit.
tion 2. VSS malfunction.
cycle 3. Speed meter malfunction.
4. ECM malfunction.
A ON at Vehicle Speed Sensor Input Sig- Input signal frequency is too ECM uses vehicle speed Correct vehicle speed signal fre- 1. VSS malfunction. 68 -
next nal Frequency Too High high. 5km/h condition as substi- quency. 2. Speed meter malfunction.
igni- tute. 3. Electrical interference.
tion 4. Magnetic interference.
cycle 5. ECM malfunction.
B ON at Vehicle Speed Sensor Incorrect 1. Engine speed is more than Fuel injection quantity is Vehicle speed is more than 1.5km/ 1. VSS open circuit, short to 68 - -
next Signal 3600rpm. reduced. h. ground or short to voltage.
igni- 2. Fuel injection quantity is 2. Poor connector connection.
tion more than 41mg/stk. 3. VSS malfunction.
cycle 3. Vehicle speed is below 4. Speed meter malfunction.
1.5km/h. 5. ECM malfunction.

Flash Symptom
Code Code
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 malfunction. 3/39 -
20V. substitute. 2. Battery jump start cable mis-
connect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 7V. 1. Battery power feed harness 3/39 -
open circuit or short to ground
circuit.
2. ECM ground harness open or
poor connection.
4. Battery malfunction.
5. Charge system malfunction.
6. ECM malfunction.
A OFF System Voltage Malfunction System voltage of PSG (pump PSG uses default voltage as System voltage of PSG is between 1. Battery power feed harness - -
(PSG) control unit) is below 4.5V or substitute. 4.5V and 27V. open circuit or short to ground
more than 27V. circuit.
ground harness open or poor
connection.
6. Battery jump start cable mis-
connect.
function.
18 P0561 A OFF System Voltage Circuit Malfunc- The ECM recognized ignition ECM stops engine. No recovery until condition match in 1. Ignition switch circuit open or 39 -
tion switch turn off signal during the next ignition key cycle. short to ground circuit.
ECM is activated. 2. Poor connector connection.
3. Ignition switch malfunction.
4. ECM malfunction.
B ON System Voltage Circuit Malfunc- Ignition switch circuit is mal- 1. Ignition switch circuit open or 39 -
tion function. short to ground circuit.
4. ECM malfunction.
- P0602 - ECU Programming Error ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed. - -
28 P0606 A ON ECU Malfunction Gate Array communication 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction. - -
error. valve) is operated.
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below MAB (fuel cutoff solenoid Desired injection quantity is below 1. ECM malfunction. - -
1%. valve) is operated. 0mg/strk. 2. PSG (pump control unit) mal-
2. Desired injection quantity is function.
more than 0mg/strk.
3. Engine speed is more than
2000rpm.

Flash Symptom
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function. A/C compressor relay circuit is cor- 1. A/C compressor relay circuit 41 -
Voltage Low open or short to ground circuit. rect condition. open or short to ground circuit.
3. A/C compressor relay malfunc-
tion.
4. ECM malfunction.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit ECM malfunction. - -
Voltage High short to voltage circuit.
25 P0703 A ON Brake Switch Malfunction 1. Throttle position is more No fail-safe function. Brake switch 1 signal and brake 1. Brake switch 1 circuit open, 30 -
than 0%. switch 2 signal are correctly input- short to ground or short to volt-
2. Engine speed is more than ted to the ECM. age circuit.
693rpm (4JA1-TC) or 665rpm 2. Poor connector connection.
(4JH1-TC). 3. Brake switch 1 malfunction.
3. Vehicle speed is more than 4. ECM malfunction.
0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are dif-
ferently inputted to the ECM
since the ignition switch was
turned on.
B ON Brake Switch Malfunction 1. Throttle position is more 1. Brake switch 2 circuit open or 65 -
than 0%. short to ground circuit.
2. Engine speed is more than 2. Poor connector connection.
693rpm (4JA1-TC) or 665rpm 3. Brake switch 2 malfunction.
(4JH1-TC). 4. ECM malfunction.
3. Vehicle speed is more than
0km/h.
brake switch 2 signal are dif-
ferently inputted to the ECM.
57 P0704 6 ON Clutch Switch Input Circuit Mal- Clutch signal does not change No fail-safe function. Clutch signal correctly changes. 1. Clutch switch circuit open, 31 - -
function between vehicle speed 1.5km/ short to ground or short to volt-
h and 80km/h since ignition age circuit.
switch was tuned on. 2. Poor connector connection.
3. Clutch switch malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Cir- Barometric pressure sensor ECM uses 1013hpa condition Barometric pressure sensor output ECM malfunction. - -
cuit High Input output voltage is more than as substitute. voltage is below 4.4V.
4.4V.
2 ON Barometric Pressure Sensor Cir- Barometric pressure sensor Barometric pressure sensor output ECM malfunction. - -
cuit Low Input output voltage is below 1.5V. voltage is more than 1.5V.

Flash Symptom
Code Code
21 P1120 1 ON Pedal/Throttle Position Sensor Throttle position sensor out- ECM increases idle speed up Throttle position sensor output volt- 1. Sensor power supply circuit 38/ 49/ 57 -
Circuit High Input put voltage is more than 4.5V. to 1400rpm. age is below 4.5V. short to voltage circuit.
2. Sensor signal circuit short to
voltage circuit.
3. Sensor ground circuit open or
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Sensor Throttle position sensor power Throttle position sensor power sup- 1. Sensor power supply circuit 57 -
Voltage Supply Circuit High Input supply voltage is more than ply voltage is below 5.2V. short to battery voltage circuit.
5.2V. 2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Sensor Throttle position sensor power Throttle position sensor power sup- 1. Sensor power supply circuit 57 -
Voltage Supply Circuit Low Input supply voltage is below 4.6V. ply voltage is more than 4.6V. short to ground circuit.
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position Sensor 1. Engine speed is more than Throttle position is more than 20% 1. Throttle sticking. 30/ 38/ 65 -
Brake Switch Error 1700rpm. or brake pedal is released (switch is 2. TPS incorrect adjusting.
2. Throttle position sensor is inactive). 3. TPS malfunction.
more than 8.7%. 4. Brake switch malfunction.
3. When brake pedal is 5. ECM malfunction.
depressed during accelerator
pedal is depressing.
E ON Pedal/Throttle Position Sensor 1. When idle switch is turned 1. When throttle position sensor is 1. TPS malfunction. 38/ 69 -
Idle Position Switch Error off, throttle position sensor 100%, idle switch turns off. 2. Idle switch malfunction.
was below 0.35%. 2. When throttle position sensor is 3. ECM malfunction.
or 0%, idle switch turns on.
2. When idle switch is tuned
on, throttle position sensor
was more than 7.8%.
22 P1173 3 OFF Fuel Reduction Caused By High Excessive high engine cool- No fail-safe function. Engine coolant temperature is nor- 1. Engine overheat. 89 -
Coolant Temperature ant temperature is detected. mal range. 2. ECT sensor malfunction.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By High Fuel temperature is more than PSG (pump control unit) con- Fuel temperature is below 100°C. 1. ECM malfunction. - -
Fuel Temperature 100°C. trols fuel injection quantity 2. PSG (pump control unit) mal-
based on engine speed and function.
fuel temperature.
A OFF Fuel Reduction Caused By Low Excessive low fuel tempera- No fail-safe function. Fuel temperature is normal range. 1. ECM malfunction. - -
Fuel Temperature ture is detected. 2. PSG (pump control unit) mal-
function.

Flash Symptom
Code Code
43 P1335 A ON Engine Speed Output Circuit Mal- The PSG (pump control unit) Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness open cir- 90/91/98/ P0335(B)/
function is recognized defective engine reduced. cuit, short to ground or short to 101 P0335(D)
speed signal form the ECM. voltage.
2. CKP sensor output harness
open circuit, short to ground or
short to voltage.
4. CKP sensor malfunction.
5. Pulse sensing gap incorrect.
6. Pulser malfunction.
7. Electrical interference.
9. ECM malfunction.
function.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed sensor - -
is recognized incorrect cam- malfunction.
shaft speed signal. 2. Pulse sensing gap incorrect.
5. ECM malfunction.
function.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function. Correct neutral switch signal is 1. Neutral switch circuit short to 87 - - -
ted “On” three times consecu- inputted two times consecutively voltage circuit.
tively under driving conditions. under driving conditions. 2. Neutral switch malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is input- 1. Neutral switch circuit open, 87 - - -
ted “Off” three times consecu- short to ground circuit.
tively under driving conditions. 2. Poor connector connection.
3. Neutral switch malfunction.
4. ECM malfunction.
71 P1576 4 ON Exhaust Throttle VSV 1 Circuit Exhaust throttle VSV 1 circuit No fail-safe function. Exhaust throttle VSV 1 circuit is cor- 1. Exhaust throttle VSV 1 circuit 40 - - -
3. Exhaust throttle VSV 1 mal-
function.
4. ECM malfunction.
8 ON Exhaust Throttle VSV 1 Circuit Exhaust throttle VSV 1 circuit ECM malfunction. - - - -
71 P1577 4 ON Exhaust Throttle VSV 2 Circuit Exhaust throttle VSV 2 circuit No fail-safe function. Exhaust throttle VSV 2 circuit is cor- 1. Exhaust throttle VSV 2 circuit 61 - - -
3. Exhaust throttle VSV 2 mal-
function.
4. ECM malfunction.
8 ON Exhaust Throttle VSV 2 Circuit Exhaust throttle VSV 2 circuit ECM malfunction. - - - -

Flash Symptom
Code Code
55 P1605 D ON EEPROM Defect Write and read from the ECM uses default values Write and read from the EEPROM ECM malfunction. - -
EEPROM are failed during ini- from the EPROM. are correct during initialization of
tialization of the ECM. the ECM.
E ON EEPROM Defect EEPROM checksum does not EEPROM checksum match with the ECM malfunction. - -
match with the read check read check sum during initialization
sum during initialization of the of the ECM.
ECM.
56 P1610 A - Security Key and Security Code Immobiliser functions are not 1. Engine does not start. No recovery. ECM malfunction. - B****
not Programmed programmed in the ECM. 2. Check engine lamp flash.
56 P1611 A - Wrong Security Code Entered Received security code is not 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
correct. 2. Check engine lamp flash. 2. Immobiliser control unit mal-
function.
3. Transponder key malfunction.
56 P1612 A - Immobiliser No or Wrong Signal Received challenge signal is 1. Engine does not start. No recovery. 1. ECM and immobiliser control 27/35 B****
not correct or not received. 2. Check engine lamp flash. unit communication circuit open
circuit, short to ground circuit or
2. ECM malfunction.
3. Immobiliser control unit mal-
function.
56 P1613 A - Immobiliser No or Wrong Signal Received response signal is 1. Engine does not start. No recovery. 1. ECM and immobiliser control 27/35 B****
not correct or not received. 2. Check engine lamp flash. unit communication circuit open
circuit, short to ground circuit or
2. ECM malfunction.
3. Immobiliser control unit mal-
function.
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
not correct from the transpon- 2. Check engine lamp flash. 2. Immobiliser control unit mal-
der key. function.
76 P1625 A OFF ECM Main Relay Switched Off When ignition switch was No fail-safe function. No recovery. ECM malfunction. 3/58 -
Too Early turned off, timing of the ECM
main relay turning off is too
early.
B OFF ECM Main Relay Switched Off When ignition switch was No recovery. 1. ECM main relay malfunction. 3/58 -
Too Late turned off, timing of the ECM 2. ECM malfunction.
late or does not off.
51 P1630 A ON Fuel Injection Quantity Circuit The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) PSG (pump control unit) malfunc- - -
Malfunction detects high pressure solenoid reduced. detects correct high pressure sole- tion.
valve control circuit malfunc- noid valve control circuit.
tion due to high current.
B ON Fuel Injection Quantity Circuit The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit) malfunc- - -
Malfunction detects high pressure solenoid valve) is operated. tion.
valve control circuit malfunc- 2. Desired injection quantity
tion due to continuous current. becomes 0mg/strk.

Flash Symptom
Code Code
44 P1650 A ON CAN Device Offline CAN controller detects Bus-off MAB (fuel cutoff solenoid CAN controller detects correct Bus 1. CAN high circuit open, short to 99/100 P1651(B)
or canceling. valve) is operated. signal. ground or short to voltage circuit.
2. CAN low circuit open, short to
ground or short to voltage circuit.
5. ECM malfunction.
function.
B ON CAN Device Hang-up CAN controller does not react CAN controller reacts correctly 1. ECM malfunction. - -
under engine running. under engine running. 2. PSG (pump control unit) mal-
function.
45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit) 1. MAB (fuel cutoff solenoid The PSG (pump control unit) recog- 1. ECM malfunction. - -
does not recognize CAN sig- valve) is operated. nizes CAN signal from the CAN 2. PSG (pump control unit) mal-
nal from the CAN controller. 2. Desired injection quantity controller. function.
becomes 0mg/strk.
B ON CAN Receives Error The ECM does not read CAN The ECM reads CAN signal from 1. CAN high circuit open, short to 99/100 P1650(A)
signal from the PSG (pump the PSG (pump control unit). ground or short to voltage circuit.
control unit). 2. CAN low circuit open, short to
5. ECM malfunction.
function.
77 P1690 4 OFF Check Engine Lamp (MIL) Circuit Check engine lamp circuit No fail-safe function. Check engine lamp circuit is correct 1. Check engine lamp circuit 42 B****
Voltage Low open or short to ground circuit. condition. open or short to ground circuit.
2. Check engine lamp malfunc-
tion.
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Circuit Check engine lamp circuit ECM malfunction. - -
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT

CIRCUIT LOW INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE B)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW
INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE C)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
RED RED RED RED RED
IAT
Sensor MAF &
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

40 61 46 97 83 88 92 84
Engine
Control
Module
IC
IC CPU IC
µP µP µP
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
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 1784mg/strk.
Circuit Description Diagnostic Aids

The mass air flow (MAF) sensor is part of the intake air An intermittent may be caused by the following:
system. It is fitted between the air cleaner and • Poor connections.
turbocharger and measure the mass air flowing into the
• Misrouted harness.
engine.
The mass air flow (MAF) sensor element measures the • Rubbed through wire insulation.
partial air mass through a measurement duct on the • Broken wire inside the insulation.
sensor housing. Check for the following conditions:
The ECM monitors the MAF sensor supply voltage and • Poor connection at ECM-Inspect harness connectors
MAF sensor output voltage. The supply voltage is out of for backed out terminals, improper mating, broken
range, DTC P0100 (Symptom Code 7) or P0100 locks, improperly formed or damaged terminals, and
(Symptom Code 9) will be stored. The output voltage poor terminal to wire connection.
excessively high or low, DTC P0100 (Symptom Code B)
• Damaged harness-Inspect the wiring harness for
or P0100 (Symptom Code C) will be stored.
damage. If the harness appears to be OK, observe
the “Mass Air Flow” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
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

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 7) 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.
C-57(B) 92 C-51
2 3 4
5
88 83 — Verify repair Go to Step 5

5 Visually check the MAF sensor.
Was the problem found? — Go to Step 11 Go to Step 6
6 Using the DVM and check the MAF sensor power
supply circuit.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for short to battery voltage
circuit.
C-51
4
Less than 1V:

Go to Step 7
More than
V
Approximately specified value:
5.0V Go to Step 11 Go to Step 8
7 Repair the open circuit between the ECM and MAF
sensor.
Was the problem solved?
C-57(B) C-51
4
83 — Verify repair Go to Step 8

supply circuit.
2. Disconnect the MAF & IAT sensor connector and
ECM connector.
3. Check the circuit for short to MAF sensor heater
circuit.
C-51
2 4
No continuity Go to Step 10 Go to Step 9

9 Repair the circuit for short to MAF sensor heater
circuit.
10 Repair the short to battery voltage circuit between the
ECM and MAF sensor.
C-57(B) C-51
4
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.
release?
14 Replace the ECM.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
(OBD) System
C-57(B) 92 C-51
2 3 4
5

supply circuit.
C-51
4
V Approximately

supply circuit.
ECM connector.
3. Check the circuit for short to MAF sensor ground
circuit.
C-51
3 4

8 Repair the circuit for short to MAF sensor ground.
9 Repair the short to ground circuit between the ECM
and MAF sensor.
C-57(B) C-51
4
and recheck.
release?
13 Replace the ECM.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
(OBD) System
Is the DTC P0100 (Symptom Code B) stored as and Go to Step
Was the DTC P0100 (Symptom Code B) stored in this and Go to Step
C-57(B) 92 C-51
2 3 4
5


6 Using the DVM and check the MAF sensor signal
circuit.
Breaker box is available:
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-81
4. Check the circuit for open, short to sensor ground
or short to ground circuit.
C-51
88
Breaker box is not available:

ECM connector.
C-57(B) C-51
88 5
Repair faulty
harness and
supply circuit.
C-51
4
V Approximately

sensor.
C-57(B) C-51
4
9 Using the DVM and check the MAF sensor heater
circuit.
C-51
2
V Battery
10 Repair the open circuit between the ECM main relay
and MAF sensor.
and recheck.
release?
14 Replace the ECM.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
(OBD) System
Is the DTC P0100 (Symptom Code C) stored as and Go to Step
Was the DTC P0100 (Symptom Code C) stored in this and Go to Step
C-57(B) 92 C-51
2 3 4
5


6 Using the DVM and check the MAF sensor ground
circuit.
3. Disconnect the MAF sensor connector.
C-51
92

2. Disconnect the MAF sensor connector and ECM
connector.
C-57 C-51
3 Repair faulty
92 harness and
circuit.
2. Disconnect the MAF sensor connector .
C-51
3
Repair faulty
V harness and

circuit.
C-51
5
Repair faulty
V harness and
and recheck.
release?
12 Replace the ECM.
(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
RED RED RED RED RED
IAT
Sensor MAF &
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

40 61 46 97 83 88 92 84
Engine
Control
Module
IC
IC CPU IC
µP µP µP
Code Code
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0°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.
Circuit Description the resistance value. And it changes voltage. In other

The IAT sensor is a thermistor. A temperature changes temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor • Rubbed through wire insulation.
through resisters in the ECM and measures the voltage. • Broken wire inside the insulation.
The signal voltage will be high when the air temperature Check for the following conditions:
• Poor connection at ECM-Inspect harness connectors
The output voltage excessively high or low, DTC P0110
for backed out terminals, improper mating, broken
(Symptom Code 1) or P0110 (Symptom Code 2) will be
locks, improperly formed or damaged terminals, and
stored.
poor terminal to wire connection.
Diagnostic Aids • Damaged harness-Inspect the wiring harness for
An intermittent may be caused by the following: the “Intake Air Temperature” display on the Tech2
• Poor connections. while moving connectors and wiring harness related
• Misrouted harness. to the sensor.
Intake Air Temperature (IAT) Sensor Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the IAT sensor or
C-57(B) C-51
92
84 1 3 — Verify repair Go to Step 5

5 Visually check the IAT sensor.

6 Using the DVM and check the IAT sensor.
2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.
Does the tester indicate standard resistance as shown
in the following table?
Temperature (°C) Resistance (Ω) (Approximately)

-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
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.
C-51
Less than 1V:

Go to Step 8
1
More than
V Approximately specified value:
8 Repair the open circuit between the ECM and IAT
sensor.
C-57(B) C-51
84 1

9 Repair the short to voltage circuit between the ECM
and IAT sensor.
C-57(B) C-51
84 1
10 Using the DVM and check the IAT sensor ground
circuit.
C-51
3
Repair faulty
V harness and

circuit.
C-51
92

ECM connector.
C-57(B) C-51
3 Repair faulty
92
harness and
and recheck.
release?
15 Replace the ECM.
Intake Air Temperature (IAT) Sensor Circuit Low Input
(OBD) System
C-57(B) C-51
92

5 Remove the MAF & IAT sensor assembly and visually
check.


-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
IAT Sensor
5 4 3 2 1
Standard
3 1

circuit.
4. Check the circuit for short to sensor ground or
ground circuit.
84 92

ECM connector.
ground circuit.
C-57(B)
92
84
Repair faulty
harness and
and recheck.
release?
11 Replace the ECM.
(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
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°C condition for
injection timing control.
2 ON Engine Coolant Temperature ECT sensor output voltage is
(ECT) Sensor Circuit Low below 0.3V. 3. ECM uses -15°C condition
Input for glow time control.
Circuit Description the coolant stream. Low coolant temperature produces

a high resistance.
The ECT sensor is a thermistor. A temperature changes The ECM supplies 5 volts signal to the ECT sensor
the resistance value. And it changes voltage. In other through resisters in the ECM and measures the voltage.
words it measures a temperature value. It is installed on The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine • Broken wire inside the insulation.
temperature is hot. Check for the following conditions:
The output voltage excessively high or low, DTC P0115 • Poor connection at ECM-Inspect harness connectors
(Symptom Code 1) or P0115 (Symptom Code 2) will be for backed out terminals, improper mating, broken
stored. locks, improperly formed or damaged terminals, and
An intermittent may be caused by the following: damage. If the harness appears to be OK, observe
• Poor connections. the “Coolant Temperature” display on the Tech2 while
• Misrouted harness. sensor.
• Rubbed through wire insulation.
Engine Coolant Temperature Sensor Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the ECT sensor or
C-57(B) E-41
93 1 2

5 Visually check the ECT sensor.

6 Using the DVM and check the ECT sensor.
2. Disconnect ECT sensor connector.
3. Measure the resistance of ECT sensor.

-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
7 Using the DVM and check the ECT sensor signal
circuit.
2. Disconnect the ECT sensor connector.
E-41
Less than 1V:

1 Go to Step 8
More than
V
8 Repair the open circuit between the ECM and ECT
sensor.
C-57(B) E-41
89 1

and ECT sensor.
C-57(B) E-41

10 Using the DVM and check the ECT sensor ground
circuit.
E-41
2
Repair faulty
V harness and
circuit.
E-41
93

2. Disconnect the ECT sensor connector ECM
connector.
C-57 E-41
Repair faulty
2 harness and
93 — verify repair Go to Step 14

12 Substitute a known good ECT sensor assembly and
recheck.
13 Replace the ECT sensor.
release?
15 Replace the ECM.
Engine Coolant Temperature Sensor Circuit Low Input
(OBD) System
C-57(B) E-41
93 1 2



-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard

circuit.
ground circuit.
89 93

2. Disconnect the ECT sensor connector and ECM
connector.
ground circuit.
C-57(B)
93
89
Repair faulty
harness and
recheck.
release?
11 Replace the ECM.
(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
15 P0180 B ON Fuel Temperature Sensor Cir- FT sensor output is high tem- The ECM use 75°C conditions
cuit Range/Performance perature (more than 150°C) as substitute.
or low temperature (below -
40°C).
Circuit Description • Misrouted harness.

The fuel temperature sensor is assembled inside of the • Rubbed through wire insulation.
pump control unit (PSG). The signal of fuel temperature • Broken wire inside the insulation.
is sent via the CAN-bus from the PSG to ECM. Check for the following conditions:
If the fuel temperature is excessively high or low • Poor connection at ECM and PSG-Inspect harness
condition, DTC P0180 will be stored. connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
Diagnostic Aids terminals, and poor terminal to wire connection.
An intermittent may be caused by the following: • Damaged harness-Inspect the wiring harness for
• Poor connections.
the “Fuel Temperature” display on the Tech2 while
sensor.
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
(OBD) System
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
release?
5 Substitute a known good ECM and recheck.
the ECM/Immobiliser linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
7 Replace the injection pump assembly.
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A)
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D)

Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
52 P0215 A ON at Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
next Malfunction 2. Engine speed is below valve) is operated.
igni- 1500rpm. 2. Desired injection quantity
tion 3. Vehicle speed is below becomes 0mg/strk.
cycle 1.5km/h.
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.
Circuit High Input MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line cir-
cuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated.
1500rpm. 2. Desired injection quantity
3. Vehicle speed is below becomes 0mg/strk.
1.5km/h.
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.
Malfunction 2. CAN controller does not
operate Bus-off.

When the ignition switch is turned “Off”, the fuel An intermittent may be caused by the following:
solenoid valve (MAB) signal is supplied from the ECM to • Poor connections.
the PSG. This signal is the command for the PSG to
turn “Off” the engine.
If the MAB signal circuit is short to voltage circuit or • Rubbed through wire insulation.
short to ground circuit, DTC P0215 (Symptom Code B) • Broken wire inside the insulation.
or P0215 (Symptom Code C) will be stored. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
(OBD) System
Is the DTC P0215 (Symptom Code A) stored as and Go to Step

Was the DTC P0215 (Symptom Code A) stored in this Refer to
Cutoff Solenoid Valve Circuit High Input
(OBD) System
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.
105 C-57 E-6

5

5 Visually check the PSG (pump control unit).

6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) circuit.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-81
3. Check the circuit for short to voltage circuit.
105

C-57
105
V
Less than 1V Go to Step 8 Go to Step 7
and PSG (pump control unit).
C-57 E-6
5
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
(OBD) System
105 C-57 E-6

5


3. Disconnect the PSG (pump control unit)
connector.
circuit.
E-6
105

connector.
circuit.
C-57 E-6
105
5
Repair faulty
harness and
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
(OBD) System
Is the DTC P0215 (Symptom Code D) stored as and Go to Step
Was the DTC P0215 (Symptom Code D) stored in this Refer to
release?
6 Replace the ECM.
(FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
(TIMER DEVIATION)

(TIMER FLUCTUATION)
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
54 P0216 A ON Injection Timing Control Cir- 1. Engine speed is more than Fuel injection quantity is
cuit Malfunction (Timer Devia- 700rpm. reduced.
tion) 2. Fuel injection quantity is
more than 4mg/stk.
3. Deviation of actual injection
timing and desired injec-
tion timing is more than
+3°CA or -6°CA for 8 sec-
onds.
B ON Injection Timing Control Cir- 1. Engine speed is more than
cuit Malfunction (Timer Fluc- 2014rpm.
tuation) 2. Fluctuation of actual injec-
±5.2°CA.
The ECM is calculates an injection quantity and an An intermittent may be caused by the following:
injection timing using the various sensors (crankshaft • Poor connections.
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing • Rubbed through wire insulation.
decision. • Broken wire inside the insulation.
The TCV performs as a variable throttle, using the rapid • Insufficient air bleeding of fuel line.
opening and closing cycle of the valve needle in the Check for the following conditions:
TCV.
• Insufficient air bleeding of fuel line inside, clogged
The TCV is assembled in the injection pump. The signal
fuel filter or pinched fuel pipe/hose may cause the
of desired injection timing and actual injection timing are
DTC store or improper engine performance.
exchanged via the CAN-bus between the PSG and
ECM. • Poor connection at ECM and PSG-Inspect harness
If the timer position is out of tolerance (deviation or connectors for backed out terminals, improper
fluctuation), DTC P0216 will be stored. mating, broken locks, improperly formed or damaged
the “Actual Injection Start” display on the Tech2 while
sensor.
Injection Timing Control Circuit Malfunction (Timer Deviation)
(OBD) System
Injection Timing Control Circuit Malfunction (Timer Fluctuation)
(OBD) System
4 Perform the air bleeding in the fuel line sufficiently.
1. Using the Tech 2, ignition “On” and engine “Off”.
Was the DTC P0216 (Symptom Code B) restored in
this ignition cycle? — Go to Step 5 Verify repair
5 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 6
6 Replace the fuel filter.

7 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
• Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.
Replace the eye

bolt with gauze
filter and verify
— repair Go to Step 8
(FLASH CODE 53) INJECTION PUMP MALFUNCTION





DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E)

Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed 1. MAB (fuel cutoff solenoid
sensor error. valve) is operated.
2. High pressure solenoid 2. Desired injection quantity
valve control pulse width becomes 0mg/strk.
does not match with
desired fuel injection quan-
tity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed
sensor error.
2. No CKP sensor error.
3. Difference of engine speed
and doubled pump cam-
shaft speed is more than
720rpm (4JA1-TC) or
690rpm (4JH1-TC).
9 ON Injection Pump Malfunction No pump map programmed in
the PSG (pump control unit)
or PSG malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is
malfunction in the PSG (pump reduced.
control unit).
B ON Injection Pump Malfunction PSG (pump control unit) rec- No fail-safe function.
ognized high pressure sole-
D ON Injection Pump Malfunction PSG (pump control unit) could
not measure the high pres-
sure solenoid valve drive volt-
age.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid
(pump control unit) message. valve) is operated.
becomes 0mg/strk.

injection timing using the various sensors. And the PSG • Poor connections.
controls the high pressure solenoid valve depending on
programmed pump map data.
The signal of desired injection quantity and actual injec-
tion quantify are exchanged via the CAN-bus between • Broken wire inside the insulation.
Check for the following conditions:
the PSG and ECM.
If the relation of engine speed signal and doubled pump • Poor connection at ECM and PSG-Inspect harness
camshaft speed signal excessively large, DTC P0251 connectors for backed out terminals, improper
(Symptom Code 7) will be stored. mating, broken locks, improperly formed or damaged
If the CAN high or low circuit is defected, DTC P0251 terminals, and poor terminal to wire connection.
(Symptom Code E) will be stored. • Damaged harness-Inspect the wiring harness for
the “Injection Quantity” display on the Tech2 while
sensor.
Injection Pump Malfunction
(OBD) System

Was the DTC P0251 (Symptom Code 6) stored in this Refer to
(OBD) System
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
connection is found, repair the faulty terminal.
C-57(B) 91 E-6


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
CKP Sensor Output Reference Wave Form
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Terminal: 91 (+) 1 (-) to Step 7
Measurement Scale: 5.0V/div 2.0ms/div
Measurement Condition: Engine speed at 2000rpm
Fixed at High:
— Go to Step 13 Go to Step 8

7 Using the DVM and check the CKP sensor output
circuit.
connector.
circuit.
E-6
91

connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

9 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 10
release?
12 Replace the ECM.
(OBD) System
(OBD) System
(OBD) System
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53)
(OBD) System
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
(OBD) System
Is the DTC P0251 (Symptom Code E) stored as and Go to Step
Was the DTC P0251 (Symptom Code E) stored in this Refer to
4 Was the DTC P1650 (Symptom Code A) or P1651 Go to DTC
(Symptom Code B) stored at the same time? Chart P1650
(Symptom
release?
7 Replace the ECM.
(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION

(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more than When pump camshaft speed
Circuit Malfunction 665rpm. sensor is OK:
2. CKP sensor pulse width ECM uses doubled pump cam-
error. shaft speed as substitute
engine speed.
When pump camshaft speed
sensor is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
D ON Crankshaft Position Sensor 1. No pump camshaft speed When pump camshaft speed
Circuit Malfunction sensor error. sensor is OK:
2. “Crankshaft Position Sen- ECM uses doubled pump cam-
sor Circuit Malfunction shaft speed as substitute
(Symptom Code B)” is not engine speed.
stored. Other than pump camshaft
3. Engine speed is 0rpm. speed sensor is OK:
4. Doubled pump camshaft Fuel injection quantity is
speed is more than 50rpm. reduced.
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.
becomes 0mg/strk.
When preliminary malfunction:
ECM uses doubled pump cam-
shaft speed as substitute
engine speed.

The CKP sensor is located on top of the flywheel An intermittent may be caused by the following:
housing of the flywheel and fixed with a bolt. The CKP • Poor connections.
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine • Rubbed through wire insulation.
cylinder top dead center. • Broken wire inside the insulation.
If the CKP sensor harness or sensor malfunction is Check for the following conditions:
detected during engine run, DTC P0335 (Symptom • Poor connection at ECM-Inspect harness connectors
Code B) is stored. for backed out terminals, improper mating, broken
If the CKP sensor harness or sensor malfunction is locks, improperly formed or damaged terminals, and
detected during engine cranking, DTC P0335 poor terminal to wire connection.
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
the “Engine Speed” display on the Tech2 while
is stored.
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
(OBD) System

Is the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the CKP sensor or
repair the faulty terminal.
C-57(B) 101 E-9
1 2 3
98
90

5 Visually check the CKP sensor. If a faulty installation is
found, repair as necessary.
6 Using the DVM and check the CKP sensor circuit.
3. Check the resistance of the CKP sensor.
90 98

C-57(B) 98
Approximately
90 0.9kΩ at 20°C Go to Step 10 Go to Step 7

2. Disconnect the CKP sensor connector.
E-9
1
2 Approximately
0.9kΩ at 20°C Go to Step 8 Go to Step 14
4. Check the circuit for open, short to sensor wire or
short to ground circuit.
90 98 101
E-9
90 98 101
1 2

98
C-57(B) E-9
1 2
101 Repair faulty
90 harness and

If the DVM indicated out of specified value, repair
faulty harness and verify repair.
E-9
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?
Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Approximately 1.0 V at
At ECM C57 connector 90 & 98 2000rpm
If a oscilloscope is available, monitor the CKP sensor

signal. Does the oscilloscope indicate correct wave
form?
CKP Sensor Reference Wave Form
0V→
Measurement Terminal: 90 (+) 98(-)

Measurement Scale: 20V/div 2.0ms/div
Go to Step 13 Go to Step 11
11 Remove the CKP sensor from the flywheel housing
and visually check.
Check for the following conditions.
• Objects sticking the CKP sensor.
• Objects sticking the CKP sensor pulser.
12 Check the CKP sensor shield wire for open or short Repair faulty
circuit. harness and
Was the problem found? — verify repair Go to Step 13

14 Substitute a known good CKP sensor and recheck.
15 Replace the CKP sensor.
release?
17 Replace the ECM.
Engine Speed Input Circuit Range/Performance
(OBD) System
Was the DTC P0335 (Symptom Code E) stored in this and Go to Step
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
C-57(B) 101 E-9

1 2 3
98
90


and ECM.


form?
0V→

and visually check.
release?

13 Replace the ECM.
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

Glow A/C Blower

80A 10A 20A
Pressure
SW
0.5 5.0 0.5 0.5
BLU/ RED/ BLU/ BRN
RED WHT RED
Glow A/C A/C

Relay Relay
5.0 0.5 0.5

BLK/ GRN GRN
RED 0.5
0.5 GRY/
GRY YEL
Resister
Glow A/C
BLK Thermostat
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
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.
Circuit Description In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
The voltage on the coil of the relay glow plug is supplied depending on engine coolant temperature.
by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
Diagnostic Aids • Poor connection at ECM-Inspect harness connectors
An intermittent may be caused by the following: locks, improperly formed or damaged terminals, and
• Poor connections. poor terminal to wire connection.
• Misrouted harness. • Damaged harness-Inspect the wiring harness for
• Rubbed through wire insulation. damage. If the harness appears to be OK, observe
• Broken wire inside the insulation. the DTC P0380 display on the Tech2 while moving
Check for the following conditions: connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Glow Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the glow relay or
4JA1-TC 4JH1-TC
C-57 C-49 X-12
1 3
2
4


5 Using the DVM and check the glow relay.
2. Remove the glow relay from the relay box.
3. Check the relay coil.
Glow Relay
3 2
Replace glow
relay and verify
Continuity Go to Step 6 repair
6 Using the DVM and check the glow relay power supply
circuit.
circuit.
4JA1-TC 4JH1-TC
C-49 X-12
V
Battery
7 Repair the open or short to ground circuit between the
ECM main relay and glow relay.
4JA1-TC 4JH1-TC
X-4 C-49 X-12
2
1
— Verify repair —

8 Using the DVM and check the glow relay ground
circuit.
circuit.
4JA1-TC 4JH1-TC
C-49 X-12
3
94

circuit.
4JA1-TC 4JH1-TC
C-57 C-49 X-12
3
94
Repair faulty
harness and
release?
10 Replace the ECM.
Glow Relay Circuit Voltage High
(OBD) System
release?
the ECM/Immobiliser linking procedure. — Go to Step 6 —
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T
Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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
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
• 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.
Glow Plug Indicator Circuit Voltage Low
(OBD) System
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
Does the lamp turn “Off”? — Go to Step 9 Go to Step 7
6 Check the glow plug indicator lamp bulb.

7 Check for poor/faulty connection at the meter
connector and ECM connector. If a poor/faulty
C-56 43
B-24
2

8 Using the DVM and check the glow time telltale circuit.
3. Remove the meter connector.
circuit.
B-24
43

circuit.
C-56
43
8 B-24
Repair faulty
harness and

release?
10 Replace the ECM.
Glow Plug Indicator Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
GROUND OR OPEN CIRCUIT

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED

BATTERY
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
RED RED RED RED RED
IAT
Sensor MAF &
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

40 61 46 97 83 88 92 84
Engine
Control
Module
IC
IC CPU IC
µP µP µP
Code Code
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Excessive Detected between 15°C and 100°C. reduced.
2. Engine coolant temperature
is between 55°C and
100°C.
3. Barometric pressure is
between 850hpa and
1100hpa.
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
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV 10%
Open Circuit conditions as substitute.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Insufficient Detected between 15°C and 100°C. reduced.
100°C.
between 850hpa and
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
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10%
conditions as substitute.

The amount of EGR is controlled by EVRV (electrical An intermittent may be caused by the following:
vacuum regulating valve) via the engine control module • Poor connections.
temperature. • Rubbed through wire insulation.
The EVRV is shaped to control vacuum applied to the • Broken wire inside the insulation.
diaphragm chamber of the EGR valve based on duty • EGR valve sticking.
• Faulty intake air duct connection.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored. • Poor connection at ECM-Inspect harness connectors
If the EGR EVRV circuit is open or short ground circuit, for backed out terminals, improper mating, broken
DTC P0400 (Symptom Code 4) is stored. locks, improperly formed or damaged terminals, and
If the EGR EVRV circuit is short to voltage circuit, DTC poor terminal to wire connection.
P0400 (Symptom Code 8) is stored. • Damaged harness-Inspect the wiring harness for
the DTC P0400 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
Exhaust Gas Recirculation Flow Excessive Detected
(OBD) System

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.
check.
and recheck.
8 Using the DVM and check the EGR EVRV.
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
14Ω at 20°C Go to Step 11 Go to Step 9
9 Substitute a known good EGR EVRV and recheck.
10 Replace the EGR EVRV.

11 Using the vacuum pump and check the EGR valve
operation for the following condition through the small
window.
• Restrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Was a problem found?
Small Window
Verify repair or
Vacuum Pump — Go to Step 13 Go to Step 12
12 Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is
stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat. Verify repair or
13 Replace the EGR valve.
release?
15 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
(OBD) System
4 Check for poor/faulty connection at the EGR EVRV or
C-57 C-52
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV power
supply circuit.
2. Remove the EGR EVRV connector.
C-52
V
Battery
and EGR EVRV.
X-4 C-52
1
1

8 Using the DVM and check the EGR EVRV circuit.
circuit.
C-52
2
97

circuit.
C-57 C-52
97
Repair faulty
harness and
release?
12 Replace the ECM.
Exhaust Gas Recirculation Flow Insufficient Detected
(OBD) System
4 Visually check the EGR control vacuum hose.
If the hose is clogged or disconnected, repair as
necessary.
coil.
EGR EVRV
2 1
2 1
Approximately

window.
deposit.
Small Window
Verify repair or
stuck or damaged.
Is the action complete? — Verify repair -
C-57(B) 92 C-51
2 3 4
5


circuit.
C-51
5
Repair faulty
V
harness and
and recheck.
release?
17 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Battery
(OBD) System
C-57 C-52
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

2. Remove the EGR EVRV connector and ECM
connector.
3. 3. Check the circuit for short to voltage circuit.
C-52
1 2

7 Repair the short to voltage circuit.
release?
11 Replace the ECM.
(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY
TOO HIGH

(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T
Engine
Tacho
Speed
Check
Meter
Meter
Glow
Imnobiliser
TCM VSS Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed 5km/
at High Input 200km/h. h condition as substitute.
next
igni-
tion
cycle
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed 5km/
at Signal Frequency Too High high. h condition as substitute.
next
igni-
tion
cycle
B ON Vehicle Speed Sensor Incor- 1. Engine speed is more than Fuel injection quantity is
at rect Signal 3600rpm. reduced.
next 2. Fuel injection quantity is
igni- more than 41mg/stk.
tion 3. Vehicle speed is below
cycle 1.5km/h.

The VSS is a magnet rotated by the transmission output • Rubbed through wire insulation.
shaft. The VSS uses a hall element. It interacts with the • Broken wire inside the insulation.
magnetic field treated by the rotating magnet. It outputs Check for the following conditions:
pulse signal. The 12 volts operating supply from the • Poor connection at ECM-Inspect harness connectors
meter fuse. for backed out terminals, improper mating, broken
The engine control module (ECM) calculates the vehicle locks, improperly formed or damaged terminals, and
speed by VSS. poor terminal to wire connection.
Diagnostic Aids damage. If the harness appears to be OK, observe
An intermittent may be caused by the following: the DTC P0500 display on the Tech2 while moving
Vehicle Speed Sensor Circuit High Input
(OBD) System

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 14 Go to Step 7
6 Remove the VSS from the housing case and visually
check.
7 Using the DVM and check the VSS signal.
1. Ignition “On”, vehicle “Run (lift up)”.
2. Measure the VSS output voltage at sensor, meter
and ECM.
Does the tester indicate specified value?
Measurement Position Voltage (V) If No
(AC Range) Good
VSS terminal 3 & GND Approximately 6.5 Go to
V at 20km/h Step 8
Meter B23 connector 9 & Go to
GND Step 9
GND Step 11
ECM C56 connector 68 & Go to
GND Step 12
If a oscilloscope is available, monitor the VSS signal at

each connector connection. Does the oscilloscope
indicate correct wave form?
Vehicle Speed Sensor Reference Wave Form
0V→
Refer to
Measurement Scale: 10V/div 50ms/div Diagnostic Aids
Measurement Condition: Vehicle Speed 20km/h and Go to Step
Measurement Terminal: At Engine Control Module
14 Refer the table

8 Replace the VSS.
Is the action complete? — Verify repair
9 Using the DVM and check the VSS signal circuit.
2. Disconnect the meter connector.
B-23
9
V Repair faulty
harness and
2. Disconnect the VSS connector and meter
connector.
circuit.
If a open or short to ground circuit is found, repair the
B-23 E-44
11 Replace the speed meter.

connector.
B-23
8
V Repair faulty
harness and

4. Check the circuit for open or shot to ground circuit.
B-23
68

connector.
circuit.
C-56
68
B-23
Repair faulty
harness and
release?
15 Replace the ECM.
Vehicle Speed Sensor Input Signal Frequency Too High
(OBD) System
Was the DTC P0500 (Symptom Code A) stored in this and Go to Step
check.

and ECM.
(AC Range) Good
V at 20km/h Step 8
GND Step 9
GND Step 10
GND Step 9

0V→
Refer to
9 Refer the table
8 Replace the VSS.
release?

12 Replace the ECM.
Vehicle Speed Sensor Incorrect Signal
(OBD) System
6 Check for poor/faulty connection at the VSS and meter
connectors. If a poor/faulty connection is found, repair
the faulty terminal.
E-44
1 3
2
B-23


7 Check for poor/faulty connection at the ECM and other
C-56

check.
and ECM.
(AC Range) Good
V at 20km/h Step 10
GND Step 11
GND Step 13
GND Step 14

0V→
Refer to
16 Refer the table
10 Replace the VSS.

B-23
9
V Repair faulty
harness and
connector.
circuit.
B-23 E-44
connector.
B-23
8
Repair faulty
V
harness and

B-23
68

connector.
circuit.
C-56
68
B-23
Repair faulty
harness and
release?
17 Replace the ECM.
(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION (PSG)
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Engine
Light Turn
15A
10A 15A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
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
(PSG) (pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
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
or low, DTC P0560 (Symptom Code A) will be stored. • Poor connection at ECM and PSG-Inspect harness
Diagnostic Aids mating, broken locks, improperly formed or damaged
An intermittent may be caused by the following:
• 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.
System Voltage Too High
(OBD) System
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 - 14V Go to Step 6 system
release?

7 Replace the ECM.
System Voltage Too Low
(OBD) System
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14V 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 - 14V 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.
C-56
3


7 Using the DVM and check the ECM main relay.
2. Remove the ECM main relay from the relay box.
ECM Main Relay
5 3
Replace ECM
main relay and
Continuity Go to Step 8 verify repair
8 Check for poor/faulty connection of the ECM ground at
the fender panel. If a poor/faulty connection is found,
C-36

release?
10 Replace the ECM.
System Voltage Malfunction (PSG)
(OBD) System
4 Check for poor/faulty connection at the PSG (pump
control unit) connector. If a poor/faulty connection is
E-6
6

5 Using the DVM and check the PSG (pump control
unit) power supply circuit.
connector.
3. Check the PSG (pump control unit) power supply
circuit.
6 E-6
7 10 - 14V Go to Step 7 Go to Step 6


6 Check for poor/faulty connection of the PSG (pump
control unit) ground at the cylinder body. If a poor/
faulty connection is found, repair as necessary.
E-10

(FLASH CODE 18) SYSTEM VOLTAGE CIRCUIT MALFUNCTION

(FLASH CODE 18) SYSTEM VOLTAGE CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Turn Engine
Light
15A
10A 15A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
18 P0561 A OFF System Voltage Circuit Mal- The ECM recognized ignition ECM stops engine.
function switch turn off signal during
ECM is activated.
B ON System Voltage Circuit Mal- Ignition switch circuit is mal-
function function.
Circuit Description P0561 (Symptom Code B) will be stored.

The ECM monitors the ignition switch signal on the feed
Diagnostic Aids
terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC An intermittent may be caused by the following:
• Poor connections. locks, improperly formed or damaged terminals, and
• Misrouted harness. poor terminal to wire connection.
• Rubbed through wire insulation. • Damaged harness-Inspect the wiring harness for
• Broken wire inside the insulation.
the “Ignition Status” display on the Tech2 while
• Poor connection at ECM-Inspect harness connectors sensor.
System Voltage Circuit Malfunction
System Voltage Circuit Malfunction
(OBD) System
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
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-2” fuse (10A).

5 Using the DVM and check the ignition power feed
circuit.
disconnected)
circuit.
C-41
39

circuit.
C-56
39
C-41
Repair faulty
harness and
6 Check the ignition switch.
If a poor/faulty connection is found, repair as
necessary.
release?

8 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR
Code Code
- P0602 - - Programming Error ECM memory area error. Engine control disabled.
Circuit Description & Diagnostic Aids ECM does not programmed.

When the service ECM is used without SPS, DTC
The replacement ECM must be programmed by Service P0602 will appear.
Programming System (SPS). Because, the service
Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

(OBD) System
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”. Refer to
Is the DTC P0602 stored as “Present Failure”? — Go to Step 3 Diagnostic Aids
3 Download the latest software to the ECM using the
“SPS (Service Programming System)”.
(FLASH CODE 28) ECU MALFUNCTION

Code Code
28 P0606 A ON ECM Malfunction (1) Gate Array communication 1. MAB (fuel cutoff solenoid
error. valve cutoff) is operated.
becomes 0mg/strk.
B ON ECM Malfunction (2) 1. Throttle position is below MAB (fuel cutoff solenoid valve
1%. cutoff) is operated.
2. Desired injection quantity is
more than 0mg/strk.
2000rpm.
Circuit Description & Diagnostic Aids

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
(OBD) System
release?

5 Replace the ECM.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
(OBD) System
release?
6 Replace the ECM.
(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

Glow A/C Blower

80A 10A 20A
Pressure
SW
0.5 5.0 0.5 0.5
BLU/ RED/ BLU/ BRN
RED WHT RED
Glow A/C A/C

Relay Relay
5.0 0.5 0.5

BLK/ GRN GRN
RED 0.5
0.5 GRY/
GRY YEL
Resister
Glow A/C
BLK Thermostat
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function.
cuit.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit
Circuit Description on the A/C request signal and certain setting conditions.
The voltage on the coil of the A/C compressor is
supplied by the ECM main relay. The ECM switches A/C
compressor relay to operate A/C compressor depends
Diagnostic Aids Check for the following conditions:
An intermittent may be caused by the following: • Poor connection at ECM-Inspect harness connectors
• Broken wire inside the insulation. damage. If the harness appears to be OK, observe
connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
C-56
41
4JA1-TC 4JH1-TC
X-5 X-10
1
2
3 5

5 Using the DVM and check the A/C compressor relay.
2. Remove the A/C compressor relay from the relay
box.
A/C Compressor Relay
5 3
Replace A/C
compressor
relay and verify
6 Using the DVM and check the A/C compressor relay
box.
circuit.
4JA1-TC 4JH1-TC
X-5 X-10
V
Battery
ECM main relay and A/C compressor relay.
4JA1-TC 4JH1-TC
X-4 X-5 X-10

ground circuit.
disconnected)
box.
circuit.
4JA1-TC 4JH1-TC
X-5 X-10
41
3

box.
circuit.
C-56
41
4JA1-TC 4JH1-TC
X-5 X-10
3
Repair faulty
harness and
release?

10 Replace the ECM.
Compressor Relay Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
(FLASH CODE 25) BRAKE SWITCH MALFUNCTION

(FLASH CODE 25) BRAKE SWITCH MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Turn Engine
Light
15A 15A
10A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
25 P0703 A ON Brake Switch Malfunction 1. Throttle position is more No fail-safe function.
than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
0km/h.
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.
B ON Brake Switch Malfunction 1. Throttle position is more
than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
0km/h.
ECM.
Circuit Description • Rubbed through wire insulation.

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
Diagnostic Aids poor terminal to wire connection.
• 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.
Brake Switch Malfunction
(OBD) System

4 Check the “Stop Light fuse (10A)”.
5 Check for poor/faulty connection at the brake switch or
C-56 C-44
1
4
6 Using the DVM and check the brake switch 1.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 1.
Brake Switch
1
4 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.
2. Remove the brake switch connector from the
brake switch.
C-44
V
Battery

8 Repair the open circuit between the “Stop Light fuse
(10A)” and brake switch 1.
9 Using the DVM and check the brake switch 1 circuit.
4. Check the circuit for open or short to voltage
circuit.
30

2. Back probe the DVM to the brake switch 1 and
check the circuit for open or short to voltage
circuit.
C-44
Pedal is not Fixed at battery

stepped on: voltage: Go to
4
Less than 1V Step 10
Pedal stepped Fixed at less
V
on: Battery than 1V: Go to
voltage Go to Step 12 Step 11
10 Repair the short to voltage circuit between the brake
switch 1 connector and ECM.
C-56 C-44
4
30
11 Repair the open circuit between the brake switch 1
connector and ECM.
C-56 C-44
4
30

release?
13 Replace the ECM.
(OBD) System
C-56 C-44
2
3
pedal.
Brake Switch
2
3
Pedal is not
stepped on:
No continuity Replace pedal
Pedal stepped switch and
on: Continuity Go to Step 6 verify repair

supply circuit.
brake switch.
C-44
V
Battery
7 Repair the open circuit between the “ECM Main
Relay” and brake switch 2.
X-4 C-44
2
1

connected)
circuit.
65

circuit.
C-44
Pedal is not
stepped on: Fixed at battery
3 Battery voltage: Go to
voltage Step 9
V
on: Less than than 1V: Go to
1V Go to Step 11 Step 10
C-56 C-44
65 3
connector and ECM.
C-56 C-44
65 3

release?
12 Replace the ECM.
(FLASH CODE 57) CLUTCH SWITCH CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Engine
Light Turn
15A 15A
10A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
57 P0704 6 ON Clutch Switch Circuit Malfunc- Clutch signal does not change No fail-safe function.
tion between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.

The ECM monitors the clutch switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If clutch switch circuit with Check for the following conditions:
malfunction, DTC P0704 (Symptom Code 6) will be • Poor connection at ECM-Inspect harness connectors
stored. for backed out terminals, improper mating, broken
• Poor connections. the “Clutch Switch” display on the Tech2 while moving
• Misrouted harness. connectors and wiring harness related to the sensor.
Clutch Switch Circuit Malfunction
(OBD) System
4 Check for poor/faulty connection at the clutch switch
or ECM connector. If a poor/faulty connection is found,
31 C-56 C-53
1
2

5 Using the DVM and check the clutch switch.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch
Pedal is not
1
stepped on:
2 Continuity
on: No switch and

6 Using the DVM and check the clutch switch power
supply circuit.
2. Remove the clutch switch connector from the
clutch switch.
C-53
V
Battery
7 Repair the open circuit between the “ECM Main
Relay” and clutch switch.
X-4 C-53
1
1

8 Using the DVM and check the clutch switch circuit.
circuit.
31

2. Back probe the DVM to the clutch switch and
circuit.
C-53
Pedal is not
voltage Step 9
V Pedal stepped Fixed at less
9 Repair the short to voltage circuit between the clutch
switch connector and ECM.
C-56 C-53
2
31 — Verify repair —
10 Repair the open circuit between the clutch switch
connector and ECM.
C-56 C-53
2

release?
12 Replace the ECM.
(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Code Code
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa condition
Circuit High Input output voltage is more than as substitute.
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor
Circuit Low Input output voltage is below 1.5V.

The ECM monitors the barometric pressure signal at If the DTC P1105 is stored, sensor or circuit of ECM
inside of the ECM. If the sensor with malfunction, DTC inside is failed.
P1105 (Symptom Code 1) or P1105 (Symptom Code 2)
will be stored.
Barometric Pressure Sensor Circuit High Input
Barometric Pressure Sensor Circuit Low Input
(OBD) System
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
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
release?

5 Replace the ECM.
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT

CIRCUIT LOW INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH
ERROR

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
21 P1120 1 ON Pedal/Throttle Position Sen- Throttle position sensor out- ECM increases idle speed up
sor Circuit High Input put voltage is more than 4.5V. to 1400rpm.
7 ON Pedal/Throttle Position Sen- Throttle position sensor power
sor Voltage Supply Circuit supply voltage is more than
High Input 5.2V.
sor Voltage Supply Circuit supply voltage is below 4.6V.
Low Input
D ON Pedal/Throttle Position Sen- 1. Engine speed is more than
sor Brake Switch Error 1700rpm.
2. Throttle position sensor is
more than 8.7%.
3. When brake pedal is
depressed during accelera-
tor pedal is depressing.
E ON Pedal/Throttle Position Sen- 1. When idle switch is turned
sor Idle Position Switch Error off, throttle position sensor
was below 0.35%.
or
was more than 7.8%.

The TPS is a potentiometer connected to throttle shaft An intermittent may be caused by the following:
on the throttle body. It is installed to the main TPS and • Poor connections.
idle switch.
on the signal line and calculates throttle position. As the • Rubbed through wire insulation.
throttle valve angle is changed when accelerator pedal • Broken wire inside the insulation.
moved. The TPS signal also changed at a moved Check for the following conditions:
throttle valve. As the throttle valve opens, the output • Poor connection at ECM-Inspect harness connectors
increases so that the output voltage should be high. for backed out terminals, improper mating, broken
The ECM monitors the TPS supply voltage and TPS locks, improperly formed or damaged terminals, and
output voltage. The supply voltage is out of range, DTC poor terminal to wire connection.
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
the “Throttle Position”, “Idle Switch”, “Brake Switch 1”
If the brake pedal is depressed during accelerator pedal
and “Brake Switch 2” display on the Tech2 while
is depressing, DTC P1120 (Symptom Code D) will be
stored.
sensor.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.
Pedal/Throttle Position Sensor Circuit High Input
(OBD) System

4 Check for poor/faulty connection at the TPS or ECM
as necessary.
49 C-56 39
57
4JA1-TC 4JH1-TC
E-7 C-93
1 2 3

5 Visually check the TPS.

6 Using the DVM and check the TPS.
2. Disconnect TPS connector.
3. Measure the resistance of TPS.
Measurement Resistance (Ω)

Terminal
Approximately 0.5kΩ at idle position
1-2
Approximately 4.0kΩ at WOT
2-3
1-3 Approximately 4.6kΩ at idle position & WOT
TPS
3 2 1
3 2 1
Standard
7 Using the DVM and check the TPS power supply
circuit.
2. Disconnect the TPS connector.
4JA1-TC 4JH1-TC
E-7 C-93
3
V
Approximately
and TPS.
C-56
57
4JA1-TC 4JH1-TC
E-7 C-93


9 Using the DVM and check the TPS signal circuit.
4JA1-TC 4JH1-TC
E-7 C-93
2
Repair faulty
V harness and
10 Using the DVM and check the TPS ground circuit.
2. Disconnect the TPS connector .
4JA1-TC 4JH1-TC
E-7 C-93
1
Repair faulty
V
harness and

4JA1-TC 4JH1-TC
E-7 C-93
49

2. Disconnect the TPS connector and ECM
connector.
C-56
49
4JA1-TC 4JH1-TC
E-7 C-93
Repair faulty
harness and
12 Substitute a known good TPS and recheck.
13 Replace the TPS.
release?

15 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
(OBD) System
as necessary.
49 C-56 39
57
4JA1-TC 4JH1-TC
E-7 C-93
1 2 3


circuit.
4JA1-TC 4JH1-TC
E-7 C-93
3
V
Approximately
ECM and TPS.
C-56
57
4JA1-TC 4JH1-TC
E-7 C-93

9 Replace the TPS.
release?
11 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
(OBD) System
as necessary.
49 C-56 39
57
4JA1-TC 4JH1-TC
E-7 C-93
1 2 3


circuit.
circuit.
4JA1-TC 4JH1-TC
E-7 C-93
3
V
Approximately
circuit.
connector.
3. Check the circuit for short to TPS ground circuit.
4JA1-TC 4JH1-TC
E-7 C-93
1 3

8 Repair the circuit for short to TPS ground circuit.
and TPS.
C-56
57
4JA1-TC 4JH1-TC
E-7 C-93


11 Replace the TPS.
release?
13 Replace the ECM. Is the action complete?
Pedal/Throttle Position Sensor Brake Switch Error
(OBD) System
Was the DTC P1120 (Symptom Code D) stored in this and Go to Step
• Accelerator pedal sticking.
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
3. Adjust the TPS within 0% to 100%.
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.
9 Substitute a known good brake switch and recheck.
10 Replace the brake switch.
12 Replace the TPS.

release?
14 Replace the ECM.
Pedal/Throttle Position Sensor Idle Position Switch Error
(OBD) System
from 0% to 100% depending on accelerator pedal Go to Step 6Go
operation? — Go to Step 7 to Step 6
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
9 Replace the TPS.
release?

11 Replace the ECM.
(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE

(FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW TEMPERATURE
Code Code
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine cool- No fail-safe function.
High Coolant Temperature ant temperature is detected.
7 OFF Fuel Reduction Caused By Fuel temperature is more than PSG (pump control unit) con-
High Fuel Temperature 100°C. trols fuel injection quantity
based on engine speed and
fuel temperature.
A OFF Fuel Reduction Caused By Excessive low fuel tempera- No fail-safe function.
Low Fuel Temperature ture is detected.

The engine coolant temperature (ECT) sensor is An intermittent may be caused by the following:
installed on the coolant stream. High coolant • Poor connections.
temperature produces a low resistance. The ECM
supplies 5 volts signal to the ECT sensor through
resisters in the ECM and measures the voltage. The • Rubbed through wire insulation.
signal voltage will be low when the engine temperature • Broken wire inside the insulation.
is hot. Check for the following conditions:
The fuel temperature sensor is assembled inside of the • Poor connection at ECM and PSG-Inspect harness
pump control unit (PSG). The signal of fuel temperature connectors for backed out terminals, improper
is sent via the CAN-bus from the PSG to ECM. mating, broken locks, improperly formed or damaged
If the engine coolant temperature is excessively high terminals, and poor terminal to wire connection.
condition, DTC P1173 (Symptom Code 3) will be stored.
If the fuel temperature is excessively high or low
condition, DTC P1173 (Symptom Code 7) or P1173
the “Coolant Temperature” or “Fuel Temperature”
(Symptom Code A) will be stored.
display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
(OBD) System

4 Check the engine overheat condition. Repair the
Was the problem found? cause of
overheat and
2. Monitor the “Coolant Temperature” in the data
display.
Does the Tech 2 indicate correct “Coolant
Temperature” depending on warm up time? — Go to Step 9 Go to Step 6

-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
recheck.
release?

10 Replace the ECM.
Reduction Caused By High Fuel Temperature
Reduction Caused By Low Temperature
(OBD) System
(Symptom Code A) stored as “Present Failure”? — Go to Step 3 3
(Symptom Code A) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
6 Replace the ECM.
(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The ECM converts sine wave signal to square wave Check for the following conditions:
signal. And this signal is provided from the ECM to • Poor connection at ECM-Inspect harness connectors
pump control unit (PSG). for backed out terminals, improper mating, broken
• Damaged harness-Inspect the wiring harness for moving connectors and wiring harness related to the
damage. If the harness appears to be OK, observe sensor.
Engine Speed Output Circuit Malfunction
(OBD) System
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
C-57(B) 91 E-6


wave form?
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Scale: 5.0V/div 2.0ms/div Fixed at High:

circuit.
connector.
circuit.
E-6
91

connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

release?
12 Replace the ECM.
(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The pump camshaft sensor is a magnet with a coil. It • Broken wire inside the insulation.
uses to combine with the pulser. The pulser is attached Check for the following conditions:
main shaft in the pump. It likes a gear shape. • Poor connection at ECM and PSG-Inspect harness
The pump camshaft sensor is attached to the pump connectors for backed out terminals, improper
control unit (PSG). The signal of pump camshaft speed mating, broken locks, improperly formed or damaged
is sent via the CAN-bus from the PSG to ECM. terminals, and poor terminal to wire connection.
the “Pump Speed” display on the Tech2 while moving
• Poor connections. display will indicate the location of the fault.
Camshaft Speed Malfunction
(OBD) System
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
release?
8 Replace the ECM.
(FLASH CODE 47) NEUTRAL SWITCH ON ERROR

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
Stop Back,
Turn Engine
Light
15A 15A
10A
M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED WHT/ RED/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
BLK
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
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-

The ECM monitors the neutral switch (A/T: N or P An intermittent may be caused by the following:
position switch in inhibitor switch) signal on the feed • Poor connections.
terminal to the ECM. If the neutral switch with
malfunction, DTC P1520 (Symptom Code A) or P1520
(Symptom Code B) will be stored. • Rubbed through wire insulation.
Check for the following conditions: • Damaged harness-Inspect the wiring harness for
• Poor connection at ECM-Inspect harness connectors damage. If the harness appears to be OK, observe
for backed out terminals, improper mating, broken the “Neutral Switch” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harness related to the
poor terminal to wire connection. sensor.
Neutral Switch ON Error
Neutral Switch OFF Error
(OBD) System
(Symptom Code B) stored in this ignition cycle? — Go to Step 4 4

4 Check for poor/faulty connection at the neutral switch
(inhibitor switch) or ECM connector. If a poor/faulty
C-57
87
M/T
E-11 E-12
A/T
E-51

5 Using the DVM and check the neutral switch (inhibitor
switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range N range
switch).
M/T
E-11 E-12
A/T
3
Neutral (P or
4 3 2 1 N): Continuity
10 9 8 7 6 5
Other than Replace neutral
neutral (P or switch (inhibitor
N): No switch) and
6 5 continuity Go to Step 6 verify repair

switch) power supply circuit.
2. Remove the neutral switch (inhibitor switch)
connector from the switch.
M/T A/T
E-11 E-51
V
3
V
Battery
7 Repair the open circuit between the ECM Main Relay
and neutral switch (between the “Back, Turn fuse
(15A)” and inhibitor switch).

switch) circuit.
circuit.
87

2. Back probe the DVM to the neutral switch (inhibitor
switch) and check the circuit for open or short to
voltage circuit.
M/T A/T
E-12 E-51
Neutral (P or
N): Battery Fixed at battery
voltage voltage: Go to
V 5 6 Other than Step 9
V V neutral (P or Fixed at less
N): Less than than 1V: Go to
9 Repair the short to voltage circuit between the neutral
switch connector (inhibitor switch connector) and
ECM.
M/T
C-57 E-12
87
A/T
C-57 E-51
87 5 6

10 Repair the open circuit between the neutral switch
connector (inhibitor switch connector) and ECM.
M/T
C-57 E-12
87
A/T
C-57 E-51
87 5 6 — Verify repair —
release?
12 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P1576 (SYMPTOM CODE 4) (FLASH
CODE 71) EXHAUST THROTTLE VSV 1 CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P1576 (SYMPTOM CODE 8) (FLASH

CODE 71) EXHAUST THROTTLE VSV 1 CIRCUIT VOLTAGE HIGH
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
RED RED RED RED RED
IAT
Sensor MAF &
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

40 61 46 97 83 88 92 84
Engine
Control
Module
IC
IC CPU IC
µP µP µP
Code Code
71 P1576 4 ON Exhaust Throttle VSV 1 Cir- Exhaust throttle VSV 1 circuit No fail-safe function.
cuit Voltage Low open or short to ground cir-
cuit.
8 ON Exhaust Throttle VSV 1 Cir- Exhaust throttle VSV 1 circuit
cuit Voltage High short to voltage circuit.
Circuit Description If the exhaust throttle VSV 1 circuit is open or short

ground circuit, DTC P1576 (Symptom Code 4) is stored.
The switch engine warming signals the engine control If the exhaust throttle VSV 1 circuit is short to voltage
module (ECM) to activate the quick warm-up system circuit, DTC P1576 (Symptom Code 8) is stored.
(QWS).
Switch only provides the request and that the ECM
decides when to activated when certain conditions are
met.
Check for the following conditions: connectors and wiring harnesses.
Exhaust Throttle VSV 1 Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the exhaust
throttle VSV 1 or ECM connector. If a poor/faulty
C-56 40
C-13


5 Using the DVM and check the exhaust throttle VSV 1.
2. Disconnect the exhaust throttle VSV 1 connector.
3. Measure the resistance of exhaust throttle VSV 1
solenoid coil.
VSV-1
2 1
2 1
Approximately
6 Using the DVM and check the exhaust throttle VSV 1
2. Remove the exhaust throttle VSV 1 connector.
C-13
1
V
Battery
and exhaust throttle VSV 1.
X-4 C-13

circuit.
circuit.
C-13
40

circuit.
C-56
40
C-13
Repair faulty
harness and
9 Substitute a known good exhaust throttle VSV 1 and
recheck.
10 Replace the exhaust throttle VSV 1.
release?

12 Replace the ECM.
Exhaust Throttle VSV 1 Circuit Voltage High
(OBD) System
C-56 40
C-13

coil.
VSV-1
2 1
2 1
Approximately

circuit.
2. Remove the exhaust throttle VSV 1 connector and
ECM connector.
C-13
1 2

recheck.
release?
11 Replace the ECM.
(FLASH CODE 71) EXHAUST THROTTLE VSV 2 CIRCUIT VOLTAGE LOW

(FLASH CODE 71) EXHAUST THROTTLE VSV 2 CIRCUIT VOLTAGE HIGH
ECM Battery
Main Relay Voltage
Rr Fog
Light
10A
0.5
4JA1-TC BLU/
2 RED
0.5 0.5 0.5 0.5 0.5
RED RED RED RED RED
IAT
Sensor MAF &
VSV1 VSV2
0.5
GRY/
YEL
Engine 4 5 3 1
Warming Up
SW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

40 61 46 97 83 88 92 84
Engine
Control
Module
IC
IC CPU IC
µP µP µP
Code Code
71 P1577 4 ON Exhaust Throttle VSV 2 Cir- Exhaust throttle VSV 2 circuit No fail-safe function.
cuit Voltage Low open or short to ground cir-
cuit.
8 ON Exhaust Throttle VSV 2 Cir- Exhaust throttle VSV 2 circuit
cuit Voltage High short to voltage circuit.
Circuit Description If the exhaust throttle VSV 2 circuit is open or short

ground circuit, DTC P1577 (Symptom Code 4) is stored.
The switch engine warming signals the engine control If the exhaust throttle VSV 2 circuit is short to voltage
module (ECM) to activate the quick warm-up system circuit, DTC P1577 (Symptom Code 8) is stored.
(QWS).
Switch only provides the request and that the ECM
decides when to activated when certain conditions are
met.
Check for the following conditions: connectors and wiring harnesses.
Exhaust Throttle VSV 2 Circuit Voltage Low
(OBD) System
C-56 61
C-14
1 2


3. Measure the resistance of exhaust throttle VSV 2
solenoid coil.
VSV-2
2 1
2 1
Approximately
C-14
1
V
Battery
and exhaust throttle VSV 2.
X-4 C-14

circuit.
circuit.
C-14
61

circuit.
C-56
61
C-14
Repair faulty
harness and
recheck.
release?

12 Replace the ECM.
Exhaust Throttle VSV 2 Circuit Voltage High
(OBD) System
C-56 61
C-14
1 2

coil.
VSV-2
2 1
2 1
Approximately

circuit.
2. Remove the exhaust throttle VSV 2 connector and
ECM connector.
C-14
1 2

recheck.
release?
11 Replace the ECM.
(FLASH CODE 55) EEPROM DEFECT

Code Code
55 P1605 D ON EEPROM Defect Write and read from the ECM uses default values from
EEPROM are failed during ini- the EPROM.
tialization of the ECM.
E ON EEPROM Defect EEPROM checksum does not
match with the read check
sum during initialization of the
ECM.
Circuit Description & Diagnostic Aids diagnostics operation.

The ECM used in this vehicle utilizes an electrically P1605 (Symptom Code C), P1605 (Symptom Code D)
erasable & programmable read only memory or P1605 (Symptom Code E) will be stored.
(EEPROM). The EEPROM contains program
information and the calibrations required for engine and
EEPROM Defect
EEPROM Defect
(OBD) System
Is the DTC P1605 (Symptom Code D) or P1605 and Go to Step
(Symptom Code E) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1605 (Symptom Code D) or P1605 Refer to
(Symptom Code E) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?

5 Replace the ECM.
(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1610 A - Security Key and Security Immobiliser functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.

The ECM decides whether that is an abnormality in the Check for the following conditions:
immobiliser control system. DTC P1610 (Symptom • Poor connection at ECM and immobiliser control unit-
Code A) is recorded when immobiliser function was not Inspect harness connectors for backed out terminals,
programmed in the ECM. improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Security Key and Security Code Not Programmed
(OBD) System
Refer to
2. Select “Immobiliser” in the system selection menu “Immobiliser
“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
release?
6 Replace the ECM.
(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

Code A) is recorded when received immobiliser security Inspect harness connectors for backed out terminals,
code was not correct. improper mating, broken locks, improperly formed or
connection.
Wrong Security Code Entered
(OBD) System
Refer to
release?
6 Replace the ECM.
(FLASH CODE 56) IMMOBILISER NO OR WRONG SIGNAL
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1612 A - Immobiliser No or Wrong Sig- Received challenge signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

Code A) is recorded when received immobiliser Inspect harness connectors for backed out terminals,
challenge signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobiliser No or Wrong Signal
(OBD) System
Refer to
“Diagnositic Trouble Code”. to DTC Chart
5 Check for poor/faulty connection at the immobiliser
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68
8

lamp circuit.
2. Disconnect the meter connector and immobiliser
control unit connector.
Was DVM indicated specified value?
B-68
7
Repair faulty
V
harness and

lamp circuit.
3. Disconnect the immobiliser control unit connector.
circuit.
B-68
42

2. Disconnect the the immobiliser control unit
connector and ECM connector.
circuit.
C-56
42
B-68
Repair faulty
harness and

8 Using the DVM and check the ECM and immobiliser
control unit communication circuit.
B-68
8
V Repair faulty
harness and
circuit.
B-68
35

circuit.
C-56
B-68 35
Repair faulty
harness and

release?
11 Replace the ECM.
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1613 A - Immobiliser No or Wrong Sig- Received response signal is 1. Engine does not start.

response signal was not correct. improper mating, broken locks, improperly formed or
connection.
(OBD) System
Refer to
C-56 42
35
B-68
8

lamp circuit.
B-68
7
V Repair faulty
harness and

lamp circuit.
circuit.
B-68
42

circuit.
C-56
42
B-68
Repair faulty
harness and
B-68
8
Repair faulty
V
harness and

circuit.
B-68
35

circuit.
C-56
B-68 35
Repair faulty
harness and
release?
11 Replace the ECM.
(FLASH CODE 56) WRONG TRANSPONDER KEY
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

response signal was not correct from the transponder improper mating, broken locks, improperly formed or
key. damaged terminals, and poor terminal to wire
connection.
Wrong Transponder Key
(OBD) System
Refer to
release?
6 Replace the ECM.
IMPORTANT: The replacement ECM must e
(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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
early.
B OFF ECM Main Relay Switched When ignition switch was
Off Too Late turned off, timing of the ECM

The ECM switches ECM main relay to operate ECM and An intermittent may be caused by the following:
other sensors or controller. • Poor connections.
• Poor connection at ECM-Inspect harness connectors the “Main Relay” display on the Tech2 while moving
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early
(OBD) System
release?
5 Replace the ECM.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late
(OBD) System
3. Check the relay switch.
ECM
Main Relay
1
Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
release?
6 Replace the ECM.
(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION

Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.
Circuit Description programmed pump map data.

The ECM is calculates an injection quantity and an
injection timing using the various sensors. And the PSG
Diagnostic Aids • Broken wire inside the insulation.
• Poor connections. connectors for backed out terminals, improper
• Misrouted harness. mating, broken locks, improperly formed or damaged
• Rubbed through wire insulation. terminals, and poor terminal to wire connection.
Injection Quantity Circuit Malfunction
(OBD) System
(symptom Code B) stored as “Present Failure”? — Go to Step 3 3
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
(FLASH CODE 44) CAN DEVICE OFFLINE

(FLASH CODE 44) CAN DEVICE HANG-UP
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The interchange of data between the engine control An intermittent may be caused by the following:
module (ECM) and the pump control unit (PSG) is • Poor connections.
performed via a CAN-bus system. The individual CAN-
bus systems are connected via two interfaces and can
exchange information and data. This allows control • Rubbed through wire insulation.
modules that are connected to different CAN-bus • Broken wire inside the insulation.
systems to communicate. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness • Damaged harness-Inspect the wiring harness for
connectors for backed out terminals, improper damage. If the harness appears to be OK, observe
mating, broken locks, improperly formed or damaged the DTC P1650 display on the Tech2 while moving
terminals, and poor terminal to wire connection. connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN
Device Offline
(OBD) System
C-57 E-6 2
1
6 Using the DVM and check the CAN high circuit.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 7 verify repair

connector.
circuit.
E-6
100

connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

8 Using the DVM and check the CAN low circuit.
connector.
circuit.
E-6
99

connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
99 1 — Verify repair —
unit) ground circuit.
connector.
E-6
6
Repair faulty
harness and

interference. accessory parts
release?
17 Replace the ECM.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN
Device Hang-up
(OBD) System
release?
6 Replace the ECM.
(FLASH CODE 45) CAN MALFUNCTION (PSG)

(FLASH CODE 45) CAN RECEIVES ERROR
Battery
Voltage Battery
Voltage
ECM Stop
Main Relay Light
10A
0.5
RED/
2.0 YEL
BLU/
RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
45 P1651 A ON CAN Malfunction (PSG) 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 Receives Error The ECM does not read CAN
signal from the PSG (pump
control unit).
Circuit Description systems to communicate.

Diagnostic Aids
module (ECM) and the pump control unit (PSG) is
performed via a CAN-bus system. The individual CAN- An intermittent may be caused by the following:
bus systems are connected via two interfaces and can • Poor connections.
exchange information and data. This allows control
modules that are connected to different CAN-bus
• Poor connection at ECM and PSG-Inspect harness the DTC P1651 display on the Tech2 while moving
connectors for backed out terminals, improper connectors and wiring harnesses.
Malfunction (PSG)
(OBD) System
release?
6 Replace the ECM.
Receives Error
(OBD) System
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
C-57 E-6 2
1
E-6
2
Repair faulty
harness and

connector.
circuit.
E-6
100

connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

connector.
circuit.
E-6
99

connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
connector.
E-6
6
Repair faulty
harness and

release?
18 Replace the ECM.
(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Ignition
SW
Meter
15A
0.85 0.85
0.5 BLU/BLK YEL
YEL
A/T
Engine
Tacho
Speed
Check
Meter
Meter
Glow
VSS Imnobiliser
TCM Control Unit
6 15 7 7 8
2.0
BLK
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

The Check Engine Lamp (Malfunction Indicator Lamp An intermittent may be caused by the following:
=MIL) should always be illuminated and steady with • Poor connections.
ignition “On”. Ignition feed voltage is supplied to the
Check Engine Lamp bulb through the meter fuse. The
ECM turns the Check Engine Lamp “On” by grounding • Rubbed through wire insulation.
the check engine lamp driver circuit for a certain time. • Broken wire inside the insulation.
for backed out terminals, improper mating, broken the “Check Engine Lamp” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harnesses. A change
poor terminal to wire connection. in the display will indicate the location of the fault.
Check Engine Lamp (MIL) Circuit Voltage Low
(OBD) System
2. Check the “Check Engine” lamp.
6 Check the “Check Engine” lamp bulb.

C-56 42
4JA1-TC
B-23
2
4JH1-TC
B-23
6


8 Using the DVM and check the “Check Engine” lamp
circuit.
circuit.
4JA1-TC B-23
42
4JH1-TC B-23
42

circuit.
4JA1-TC
C-56
42
B-23
4JH1-TC
C-56
42
B-23
Repair faulty
harness and

release?
10 Replace the ECM.
Check Engine Lamp (MIL) Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
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 located
lamp (MIL=malfunction indicator lamp are operating an intermittent condition. Use the following features to
correctly. 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, disconnect
Typical Scan Data Values. the MAF sensor and idle the engine until the check
engine lamp (MIL=malfunction indicator lamp) comes
• Verify the customer complaint and locate the correct on. Diagnostic Trouble Code P0100 should be stored
symptom in the table of contents. Perform the and kept in memory when the ignition is turned OFF.
procedure included in the symptom chart. If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
VISUAL/PHYSICAL CHECK P0100 from memory.
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a An intermittent check engine lamp (MIL=malfunction
problem without further checks and can save valuable indicator lamp) with no stored Diagnostic Trouble Code
time. This check should include the following items: may be caused by the following:
• ECM grounds for cleanliness, tightness and proper • Check engine lamp (MIL=malfunction indicator lamp)
location. wire to ECM short to ground.
• Vacuum hoses for splits, kinks, and proper • Poor ECM grounds. Refer to the ECM wiring
connection. Check thoroughly for any type of leak or diagrams.
restriction.
• Air intake ducts for collapsed or damaged areas. Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
• Air leaks at throttle body mounting area, mass air flow to the ignition control module for poor connections.
(MAF) sensor and intake manifold sealing surfaces. Check for an open diode across the A/C compressor
• Wiring for proper connections, pinches and cuts. clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
INTERMITTENT
If problem has not been found, refer to ECM connector
Important: An intermittent problem may or may not turn
symptom tables.
on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use • Check the “Broadcast Code” of the ECM, and
the Diagnostic Trouble Code (DTC) charts for compare it with the latest Isuzu service bulletins and/
intermittent problems. or Isuzu EEPROM reprogramming equipment to
The fault must be present to locate the problem. determine if an update to the ECM's reprogrammable
Most intermittent problems are cased by faulty electrical memory has been released.
connections or wiring. Perform a careful visual/physical
check for the following conditions. This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
• Poor mating of the connector halves or a terminal not
If the “Broadcast Code” is not the most current available,
fully seated in the connector (backed out).
it is advisable to reprogram the ECM's EEPROM
• Improperly formed or damaged terminal. memory, which may either help identify a hard-to find
• All connector terminals in the problem circuit should problem or may fix the problem.
be carefully checked for proper contact tension. The Service Programming System (SPS) will not allow
• Poor terminal-to-wire connection. This requires incorrect software programming or incorrect calibration
removing the terminal form the connector body to changes.
check.
• Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
• Poor ECM grounds. Refer to the ECM wiring
diagrams.
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobiliser system, this system may be activated. Check the immobiliser system diagnosis.

(OBD) System
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visually/physical check performed? Go to Visual /
— Go to Step 4 physical Check
4 Is the fuel amount enough?
Add fuel to the

— Go to Step 5 tank
5 Is the customer using the incorrect fuel type? Diesel fuel Replace with
only diesel fuel Go to Step 6
6 Check the “Engine-1” fuse (15A) and “Engine-2” fuse
(10A).
• Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
• Check for objects blocking or excessive deposits in
the throttle bore and on the throttle plate
• Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
• Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
8 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?

and check for the following conditions.
11 Check the CKP 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.
14 Using the vacuum pump and check the exhaust
throttle valve (if equipped) operation for the following
condition.
deposit.

15 Check the exhaust system for a possible restriction.
• Damaged or collapsed pipes or catalytic converter.
• Internal muffler failure.
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
19 Check the engine compression pressure for each
cylinders.
More than 30
Mpa (31.0 kg/
cm2) Verify repair Go to Step 20
20 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
Repair as
— Go to Step 21 necessary

21 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
release?
24 Replace the ECM.
HARD START SYMPTOM
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.

(OBD) System
intake system
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
8 1. Using the Tech 2, display the FT sensor value.
9 1. Using the Tech 2, ignition “On”.
2. Monitor the “Glow Time Relay” in the data display.
Does the Tech 2 indicate correct “Glow Time Relay”
status depending on the time from ignition switch
“On”?

2. Monitor the “Glow Time Relay” in the data display
and then, does the supply voltage correctly supply
to the glow plug?
Repair voltage
supply circuit
— Go to Step 11 and verify repair
11 Check the glow plugs for continuity.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
16 Remove the injection nozzles from the engine and
check for the following conditions.
• Improper splay condition.
• Operating pressure is incorrect.
1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2) Replace the
4JH1-TC 20.0 - 21.0 Mpa 34.3 - 35.8 Mpa injection nozzle
(204 -214 kg/cm2) (350 - 365 kg/cm2)
— and verify repair Go to Step 17
cylinders.
More than 30
Mpa (31.0 kg/

18 Check the inlet/exhaust valve clearance for each
valves.
Are the valve clearances within the specified value?
0.4mm at cold Adjust and

(In/Ex) Go to Step 19 verify repair
following:
• Tech 2 data
and/or system
release?
22 Replace the ECM.
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM
DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed may
vary in RPM. Either condition may be severe enough to
rpm
stall the engine.
X
Rough Idle
Stall
time

(OBD) System
5 1. Check for incorrect idle speed. Ensure that the
following conditions are present.
• Engine fully warm.
• Accessories are “OFF”. Desired
2. Using a Tech 2, monitor “Desired Engine Idle Engine Idle
Speed” and “Engine Speed”. Speed ± 25
Is the “Engine Speed” within the specified values? rpm Go to Step 7 Go to Step 6
intake system

9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “A/C Information Switch” in the data
display.
Does the Tech 2 indicate correct “A/C Information
Switch” status depending on A/C switch position?
sensor value.
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
• Objects blocking at the MAF sensor element.
13 Check the MAF sensor harness for the following
conditions.
and recheck.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation? — Go to Step 21 Go to Step 17

3. Adjust the accelerator cable or TPS within 0% to
100%.
18 Check the TPS harness for the following conditions.
20 Replace the TPS.
conditions.

25 1. Using the Tech 2 and ignition “On” and engine
“Run”.
2. Monitor the following parameters in the data
display.
• “Desired Injection Quantity” & “Injection Quantity”
• “Desired Injection Start” & “Actual Injection Start”
Are the large gap or unstable parameter displayed
between “Desired” and “Actual”?
When idling or part-throttle
Desired
High
Actual
Low
Time
26 Using the vacuum pump and check the EGR valve (if
equipped) operation for the following condition through
the small window.
deposit.
Small Window
Vacuum Pump

condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2)
Replace the
(204 -214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
38 Replace the ECM.
SURGES AND/OR CHUGS SYMPTOM
DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time

(OBD) System
intake system
display.

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
When idling or part-throttle When accelerated
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window
Vacuum Pump — Verify repair Go to Step 25


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?

31 Replace the ECM.
HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to Stumble
rpm
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Sug
Hesitation
time

(OBD) System
5 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
intake system

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?
33 Replace the ECM.

CUTS OUT, MISSES SYMPTOM
DEFINITIONS: Steady pulsation or jerking that follows
engine speed; usually more pronounced as engine load
increases.
rpm
time

(OBD) System
intake system
compressor
wheel or turbine shaft sticking.

7 1. Using the Tech 2, perform test drive.
2. Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct “Vehicle Speed”
depending on driving speed?
When constant vehicle speed

Correct Speed
High
Unstable Data
Low
Time
8 Check the VSS harness for the following conditions.
9 Substitute a known good VSS and recheck.
10 Replace the VSS assembly.
conditions.
and recheck.

100%.
20 Replace the TPS.
conditions.

“Run”.
display.

Desired
High
Actual
Low
Time
the small window.
deposit.
Small Window

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?
33 Replace the ECM.

LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM
DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.

(OBD) System
intake system
sensor value.

conditions.
and recheck.
100%.
18 Replace the TPS.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window

condition.
deposit.


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify

1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2)
Replace the
(204 -214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system

release?
32 Replace the ECM.
POOR FUEL ECONOMY SYMPTOM
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)

(OBD) System
— Go to Step 4 physical Check.
4 Check owner's driving habits.
• Is the A/C “On” full time?
• Are tires at the correct pressure?
• Are excessively heavy loads being carried?
• Is acceleration too much, too often? — Go to Step 5 Go to Step 6
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete? — System OK —
6 Check for low engine coolant level.
7 Check for incorrect or faulty engine thermostat. Refer
to Engine Cooling.
8 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2? — Go to Step 10 Go to Step 9
9 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis. — Verify repair —
10 Check for proper calibration of the fuel gauge.
as necessary.

display.
intake system
sensor value.
conditions.

and recheck.
100%.
26 Replace the TPS.
1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2)
Replace the
(204 -214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

33 Replace the ECM.
EXCESSIVE WHITE SMOKE

(OBD) System
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or exhaust through the
gasket.
sensor value.
conditions.

and recheck.
status depending on the time from engine “Run”?
to the glow plug?
Repair voltage
supply circuit

conditions.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2)
Replace the
(204 -214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
32 Replace the ECM.
EXCESSIVE BLACK SMOKE

(OBD) System
intake system
sensor value.

conditions.
and recheck.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

1st Stage 2nd Stage

4JA1-TC 19.5 - 20.5 Mpa 34.0 - 35.5 Mpa
(199 -209 kg/cm2) (347 - 362 kg/cm2)
Replace the
(204 -214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

24 Replace the ECM.
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE (ECM) CRANKSHAFT POSITION (CKP)

Location SENSOR
Upper the transmission tunnel. Location
Installed to the clutch housing.
Removal Procedure
1. Disconnect the negative battery cable. Removal Procedure
2. Remove the ECM cover. 1. Disconnect the negative battery cable.
3. Disconnect the two connectors from the ECM. 2. Disconnect connector from the CKP sensor.
4. Remove four screws from the ECM braket. 3. Loosen a bolt and remove the CKP sensor from the
clutch housing.
Installation Procedure
1. Put on the ECM to the braket and tighten by four Installation Procedure
screws. 1. Install the CKP sensor to the clutch housing.
2. Connect the two connectors to the ECM. 2. Tighten CKP sensor by a bolt with specified
3. Refit the ECM cover by four screws. tightening torque.
4. Connect the negative battery cable. Tightening Torque
• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
NOTE: The replacement ECM must be programmed. 3. Connect a CKP sensor connector to the CKP
Refer to section of the Service Programming System sensor.
(SPS) in this manual. 4. Connect the negative battery cable.
Following ECM programming, the immobiliser system (if
equipped) must be linked to the ECM. Refer to section NOTE: Verify any DTCs (diagnosis Trouble Code) are
11 “Immobiliser System-ECM replacement” for the not stored after replacement.
ECM/Immobiliser linking procedure.
ENGINE COOLANT TEMPERATURE MASS AIR FLOW (MAF) & INTAKE
(ECT) SENSOR AIR TEMPERATURE (IAT) SENSOR
Location Location
Installed to the thermostat housing. Installed to the intake duct housing.
Removal Procedure Removal Procedure

1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Drain enough engine coolant so that the coolant 2. Disconnect a MAF & IAT sensor connector from the
level will be below the ECT sensor. MAF & IAT sensor assembly.
3. Disconnect connector from the ECT sensor. 3. Loosen the clips and remove the MAF & IAT sensor
4. Loosen and remove the ECT sensor from the assembly from the intake duct housing.
thermostat housing.
NOTE: Cool down the engine before above procedures

are carried out.
1. Install the MAF & IAT sensor assembly into intake
air duct.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF
1. Apply sealer to threads of screw at the ECT sensor. & IAT sensor assembly.
2. Tighten the ECT sensor with specified tightening 4. Connect the negative battery cable.
torque.
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.
NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.
Verify no engine coolant leaking from the sensor
threads after replacement.
PEDAL/THROTTLE POSITION position.
SENSOR (TPS) 7. Tighten two screws.
Location NOTE: Verify any DTCs (diagnosis Trouble Code) are

Installed on the throttle body. not stored after replacement.
Removal Procedure
EGR EVRV (Electrical Vacuum
1. Disconnect the negative battery cable.
Regulating Valve)
3. Loosen two screws and remove TPS from the Location
throttle body. Back of the air cleaner case.
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.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.

Verify proper connection of two hoses.
1. Temporary tighten the TPS by two screws.
2. Connect a TPS connectors to the TPS.
3. Connect the Tech2 to the vehicle.
5. Select “Data Display” with the Tech2.
6. Check the throttle position data and adjust the TPS
SPECIAL SERVICE TOOLS
ILLUSTRATION TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
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
4JEED-WE-0221T
You are requested to order this manual using the

manual number that is shown above.
All rights reserved, This manual may not be reproduced

in whole or in part, without the permission in writing of
ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
No.4JEED-TC-WE-0221T PRINTED IN JAPAN
WORKSHOP MANUAL
TF SERIES

4JH1-TC ENGINE WITH BOSCH VP44 SYSTEM
SECTION 6E
NOTICE

notice.
Applicable Model : TFR/S 77

4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 High Pressure Fuel Circuit ......................... 6E-46
ECM CIRCUIT DIAGRAM ......................... 6E-13 Timing Control ........................................... 6E-47
GROUND POINT CHART (1/4) ................. 6E-14 Start of Injection ......................................... 6E-47
LOCATION ................................................ 6E-18 ISUZU Strategy Based Diagnostics .............. 6E-48
ENGINE CONTROL MODULE (ECM) ....... 6E-20 Overview .................................................... 6E-48
PARTS LOCATION ................................... 6E-20 STRATEGY BASED DIAGNOSTICS
................................................................... 6E-21 CHART .................................................... 6E-48
PARTS LOCATION ................................... 6E-22 Diagnostic Thought Process ...................... 6E-49
CONNECTOR LIST ................................... 6E-23 1. Verify the Complaint .............................. 6E-49
RELAY AND FUSE .................................... 6E-26 2. Perform Preliminary Checks .................. 6E-49
RELAY AND FUSE BOX LOCATION ........ 6E-26 3. Check Bulletins and Troubleshooting
RELAY AND FUSE BOX LOCATION ........ 6E-27 Hints ........................................................ 6E-50
FUSE AND RELAY LOCATION ................ 6E-28 4. Perform Service Manual Diagnostic
ECM WIRING DIAGRAM (1/7) .................. 6E-29 Checks ..................................................... 6E-50
ECM WIRING DIAGRAM (2/7) .................. 6E-30 5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-50
5c. Technician Self Diagnoses .................. 6E-50
5d. Intermittent Diagnosis .......................... 6E-51
5e. Vehicle Operates as Designed ............ 6E-52
6. Re-examine the complaint ..................... 6E-53
7. Repair and Verify Fix ............................. 6E-53
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-36 GENERAL SERVICE INFORMATION ....... 6E-54
PSG CONNECTOR PIN ASSIGNMENT & ON-BOARD DIAGNOSTIC (OBD) ............. 6E-54
OUTPUT SIGNAL .................................... 6E-39 TECH 2 OPERATING FLOW CART
GENERAL DESCRIPTION FOR ECM AND (START UP) ............................................. 6E-58
SENSORS ............................................... 6E-40 TYPICAL SCAN DATA & DEFINITIONS
Engine Control Module (ECM) ................... 6E-40 (ENGINE DATA) ................................... 6E-60
Pump Control Unit (PSG) & Data Exchange MISCELLANEOUS TEST .......................... 6E-62
Between Control Module ......................... 6E-40 Plotting Snapshot Graph ............................ 6E-63
Mass Air Flow (MAF) Sensor & Intake Air Plotting Graph Flow Chart (Plotting graph
Temperature (IAT) Sensor ....................... 6E-41 after obtaining vehicle information) .......... 6E-64
Throttle Position Sensor (TPS) .................. 6E-41 Flow Chart for Snapshot Replay
Crankshaft Position (CKP) Sensor ............ 6E-42 (Plotting Graph) ....................................... 6E-65
Engine Coolant Temperature (ECT) Sensor 6E-42 SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-66
Vehicle Speed Sensor (VSS) .................... 6E-43 ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK .................................................... 6E-75
EGR EVRV ................................................ 6E-43
GENERAL DESCRIPTION FOR INJECTION
PUMP ...................................................... 6E-44 Diagnostic Aids .......................................... 6E-75
Outline ....................................................... 6E-44 Test Description ......................................... 6E-75
Characteristic of VP44 Injection System ... 6E-44 On-Board Diagnostic (OBD) System Check 6E-76
Cross-section View .................................... 6E-45 NO CHECK ENGINE LAMP (MIL) ............. 6E-79
Low Pressure Fuel Circuit ......................... 6E-46 Circuit Description ...................................... 6E-79
6E–2 4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Aids .......................................... 6E-79 (Symptom Code 1) (Flash Code 23) Intake Air
No Check Engine Lamp (MIL) ................... 6E-80 Temperature (IAT) Sensor Circuit
CHECK ENGINE LAMP (MIL) “ON” High Input ................................................ 6E-108
STEADY .................................................. 6E-82 Diagnostic Trouble Code (DTC) P0110
Circuit description ...................................... 6E-82 (Symptom Code 2) (Flash Code 23) Intake Air
Diagnostic Aids .......................................... 6E-82 Temperature (IAT) Sensor Circuit
Low Input ................................................. 6E-112
Check Engine Lamp (MIL) On Steady ....... 6E-83
ECM Diagnostic Trouble Codes ................ 6E-84
SENSOR CIRCUIT HIGH INPUT ............ 6E-115
SUPPLY CIRCUIT HIGH INPUT ............. 6E-95
SENSOR CIRCUIT LOW INPUT ............. 6E-115
SUPPLY CIRCUIT LOW INPUT .............. 6E-95
(SYMPTOM CODE B) (FLASH CODE 65) Diagnostic Trouble Code (DTC) P0115 (Symptom
MASS AIR FLOW (MAF) SENSOR OUTPUT Code 1) (Flash Code 14) Engine Coolant
CIRCUIT LOW INPUT ............................. 6E-95 Temperature Sensor Circuit High Input ... 6E-116
DIAGNOSTIC TROUBLE CODE (DTC) P0100 Diagnostic Trouble Code (DTC) P0115 (Symptom
(SYMPTOM CODE C) (FLASH CODE 65) Code 2) (Flash Code 14) Engine Coolant
MASS AIR FLOW (MAF) SENSOR OUTPUT Temperature Sensor Circuit Low Input .... 6E-120
CIRCUIT HIGH INPUT ............................ 6E-95 DIAGNOSTIC TROUBLE CODE (DTC) P0180
Circuit Description ..................................... 6E-96 (SYMPTOM CODE B) (FLASH CODE 15)
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE ....................... 6E-123
(Symptom Code 7) (Flash Code 65) Mass Air
Flow (MAF) Sensor Voltage Supply Circuit Diagnostic Aids .......................................... 6E-123
High Input ................................................ 6E-96 Diagnostic Trouble Code (DTC) P0180
(Symptom Code 9) (Flash Code 65) Mass Air Temperature Sensor Circuit Range/
Flow (MAF) Sensor Voltage Supply Circuit Performance ............................................ 6E-124
Low Input ................................................. 6E-99 DIAGNOSTIC TROUBLE CODE (DTC) P0215
(Symptom Code B) (Flash Code 65) Mass Air FUEL CUTOFF SOLENOID VALVE
Flow (MAF) Sensor Output Circuit MALFUNCTION ....................................... 6E-125
Low Input ................................................. 6E-101 DIAGNOSTIC TROUBLE CODE (DTC) P0215
Diagnostic Trouble Code (DTC) P0100 (SYMPTOM CODE B) (FLASH CODE 52)
(Symptom Code C) (Flash Code 65) Mass Air FUEL CUTOFF SOLENOID VALVE
Flow (MAF) Sensor Output Circuit CIRCUIT HIGH INPUT ............................ 6E-125
High Input ................................................ 6E-104 DIAGNOSTIC TROUBLE CODE (DTC) P0215
DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE C) (FLASH CODE 52)
(SYMPTOM CODE 1) (FLASH CODE 23) FUEL CUTOFF SOLENOID VALVE ALWAYS
INTAKE AIR TEMPERATURE (IAT) SENSOR ACTIVE .................................................... 6E-125
CIRCUIT HIGH INPUT ............................ 6E-107 DIAGNOSTIC TROUBLE CODE (DTC) P0215
(SYMPTOM CODE 2) (FLASH CODE 23) FUEL CUTOFF SOLENOID VALVE
INTAKE AIR TEMPERATURE (IAT) SENSOR MALFUNCTION ....................................... 6E-125
CIRCUIT LOW INPUT ............................. 6E-107 Circuit Description ...................................... 6E-126
Fuel Cutoff Solenoid Valve Malfunction ... 6E-126 (Symptom Code 6) (Flash Code 53)
Diagnostic Trouble Code (DTC) P0215 Injection Pump Malfunction ...................... 6E-138
(Symptom Code B) (Flash Code 52) Diagnostic Trouble Code (DTC) P0251
Fuel Cutoff Solenoid Valve Circuit (Symptom Code 7) (Flash Code 53)
High Input ................................................ 6E-128 Injection Pump Malfunction ...................... 6E-140
(Symptom Code C) (Flash Code 52) (Symptom Code 9) (Flash Code 53)
Fuel Cutoff Solenoid Valve Always Active 6E-130 Injection Pump Malfunction ...................... 6E-144
(Symptom Code D) (Flash Code 52) (Symptom Code A) (Flash Code 53)
Fuel Cutoff Solenoid Valve Malfunction ... 6E-132 Injection Pump Malfunction ...................... 6E-145
(SYMPTOM CODE A) (FLASH CODE 54) (Symptom Code B) (Flash Code 53)
INJECTION TIMING CONTROL CIRCUIT Injection Pump Malfunction ...................... 6E-146
MALFUNCTION (TIMER DEVIATION) .... 6E-133 Diagnostic Trouble Code (DTC) P0251
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (Symptom Code D) (Flash Code 53)
(SYMPTOM CODE B) (FLASH CODE 54) Injection Pump Malfunction ...................... 6E-147
INJECTION TIMING CONTROL CIRCUIT Diagnostic Trouble Code (DTC) P0251
MALFUNCTION (TIMER FLUCTUATION) 6E-133 (Symptom Code E) (Flash Code 53)
Circuit Description ..................................... 6E-134 Injection Pump Malfunction ...................... 6E-148
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE
(Symptom Code A) (Flash Code 54) 43)CRANKSHAFT POSITION SENSOR
Injection Timing Control Circuit CIRCUIT MALFUNCTION ....................... 6E-149
Malfunction (Timer Deviation) .................. 6E-134 DIAGNOSTIC TROUBLE CODE (DTC) P0335
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE D) (FLASH CODE 43)
(Symptom Code B) (Flash Code 54) CRANKSHAFT POSITION SENSOR
Injection Timing Control Circuit MALFUNCTION ....................................... 6E-149
Malfunction (Timer Fluctuation) ............... 6E-135 DIAGNOSTIC TROUBLE CODE (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E) (FLASH CODE 43)
(SYMPTOM CODE 6) (FLASH CODE 53) ENGINE SPEED INPUT CIRCUIT RANGE/
INJECTION PUMP MALFUNCTION ....... 6E-137 PERFORMANCE ..................................... 6E-149
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Circuit Description ...................................... 6E-150
(SYMPTOM CODE 7) (FLASH CODE 53) Diagnostic Aids .......................................... 6E-150
INJECTION PUMP MALFUNCTION ....... 6E-137 Diagnostic Trouble Code (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (Symptom Code B) (Flash Code 43)
(SYMPTOM CODE 9) (FLASH CODE 53) Crankshaft Position Sensor Circuit
INJECTION PUMP MALFUNCTION ....... 6E-137 Malfunction .............................................. 6E-150
(SYMPTOM CODE A) (FLASH CODE 53) (Symptom Code D) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-137 Crankshaft Position Sensor Malfunction .. 6E-150
(SYMPTOM CODE B) (FLASH CODE 53) (Symptom Code E) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-137 Engine Speed Input Circuit Range/
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Performance ............................................ 6E-155
(SYMPTOM CODE D) (FLASH CODE 53) DIAGNOSTIC TROUBLE CODE (DTC) P0380
INJECTION PUMP MALFUNCTION ....... 6E-137 (SYMPTOM CODE 4) (FLASH CODE 66)
DIAGNOSTIC TROUBLE CODE (DTC) P0251 GLOW RELAY CIRCUIT VOLTAGE LOW 6E-158
(SYMPTOM CODE E) (FLASH CODE 53) DIAGNOSTIC TROUBLE CODE (DTC) P0380
INJECTION PUMP MALFUNCTION ....... 6E-137 (SYMPTOM CODE 8) (FLASH CODE 66)
Circuit Description ..................................... 6E-138 GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-158
(Symptom Code 4) (Flash Code 66) Exhaust Gas Recirculation Circuit Short to
Glow Relay Circuit Voltage Low .............. 6E-159 Battery ..................................................... 6E-178
Glow Relay Circuit Voltage High ............. 6E-162 VEHICLE SPEED SENSOR CIRCUIT
DIAGNOSTIC TROUBLE CODE (DTC) P0381 HIGH INPUT ............................................ 6E-180
(SUB CODE 4) (FLASH CODE 67) GLOW DIAGNOSTIC TROUBLE CODE (DTC) P0500
PLUG INDICATOR CIRCUIT VOLTAGE (SYMPTOM CODE A) (FLASH CODE 24)
LOW ........................................................ 6E-163 VEHICLE SPEED SENSOR INPUT SIGNAL
DIAGNOSTIC TROUBLE CODE (DTC) P0381 FREQUENCY TOO HIGH ....................... 6E-180
(SUB CODE 8) (FLASH CODE 67) GLOW DIAGNOSTIC TROUBLE CODE (DTC) P0500
PLUG INDICATOR CIRCUIT VOLTAGE (SYMPTOM CODE B) (FLASH CODE 24)
HIGH ........................................................ 6E-163 VEHICLE SPEED SENSOR INCORRECT
Circuit Description ..................................... 6E-163 SIGNAL ................................................... 6E-180
Glow Plug Indicator Circuit Voltage Low . 6E-164 (Symptom Code 1) (Flash Code 24) Vehicle
Diagnostic Trouble Code (DTC) P0381 Speed Sensor Circuit High Input ............. 6E-181
Glow Plug Indicator Circuit Voltage High . 6E-167 (Symptom Code A) (Flash Code 24) Vehicle
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Speed Sensor Input Signal Frequency
(SYMPTOM CODE 3) (FLASH CODE 32) Too High .................................................. 6E-186
EXHAUST GAS RECIRCULATION FLOW Diagnostic Trouble Code (DTC) P0500
EXCESSIVE DETECTED ........................ 6E-168 (Symptom Code B) (Flash Code 24) Vehicle
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Speed Sensor Incorrect Signal ................ 6E-189
EXHAUST GAS RECIRCULATION CIRCUIT (SYMPTOM CODE 1) (FLASH CODE 35)
SHORT TO GROUND OR OPEN CIRCUIT 6E-168 SYSTEM VOLTAGE TOO HIGH ............. 6E-194
(SYMPTOM CODE 5) (FLASH CODE 32) (SYMPTOM CODE 2) (FLASH CODE 35)
EXHAUST GAS RECIRCULATION FLOW SYSTEM VOLTAGE TOO LOW .............. 6E-194
INSUFFICIENT DETECTED ................... 6E-168 DIAGNOSTIC TROUBLE CODE (DTC) P0560
(SYMPTOM CODE 8) (FLASH CODE 32) SYSTEM VOLTAGE MALFUNCTION
EXHAUST GAS RECIRCULATION CIRCUIT (PSG) ....................................................... 6E-194
SHORT TO BATTERY ............................ 6E-168 Circuit Description ...................................... 6E-194
(Symptom Code 3) (Flash Code 32) System Voltage Too High ........................ 6E-195
Exhaust Gas Recirculation Flow Excessive Diagnostic Trouble Code (DTC) P0560
Detected .................................................. 6E-169 (Symptom Code 2) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Too Low ......................... 6E-197
Exhaust Gas Recirculation Circuit Short to (Symptom Code A) (Flash Code 35)
Ground or Open Circuit ........................... 6E-172 System Voltage Malfunction (PSG) ......... 6E-199
(Symptom Code 5) (Flash Code 32) (SYMPTOM CODE A) (FLASH CODE 18)
Exhaust Gas Recirculation Flow Insufficient IGNITION SWITCH CIRCUIT
Detected .................................................. 6E-175 MALFUNCTION ....................................... 6E-201
IGNITION SWITCH CIRCUIT (Symptom Code A) (Flash Code 25)
MALFUNCTION ....................................... 6E-201 Brake Switch Malfunction ........................ 6E-215
Diagnostic Aids .......................................... 6E-201 (Symptom Code B) (Flash Code 25)
Diagnostic Trouble Code (DTC) P0561 Brake Switch Malfunction ........................ 6E-219
(Symptom Code A) (Flash Code 18) DIAGNOSTIC TROUBLE CODE (DTC) P0704
Ignition Switch Circuit Malfunction ........... 6E-202 (SYMPTOM CODE 6) (FLASH CODE 57)
Diagnostic Trouble Code (DTC) P0561 CLUTCH SWITCH CIRCUIT
(Symptom Code B) (Flash Code 18) MALFUNCTION ....................................... 6E-222
Ignition Switch Circuit Malfunction ........... 6E-202 Circuit Description ...................................... 6E-222
ECU PROGRAMMING ERROR .............. 6E-205 Diagnostic Trouble Code (DTC) P0704
Circuit Description & Diagnostic Aids ........ 6E-205 (Symptom Code 6) (Flash Code 57)
Diagnostic Trouble Code (DTC) P0602 Clutch Switch Circuit Malfunction ............ 6E-223
ECU Programming Error ......................... 6E-205 DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE A) BAROMETRIC PRESSURE SENSOR
(FLASH CODE 28) ECU MALFUNCTION 6E-206 CIRCUIT HIGH INPUT ............................ 6E-226
(SYMPTOM CODE B) (SYMPTOM CODE 2) (FLASH CODE 86)
(FLASH CODE 28) ECU MALFUNCTION 6E-206 BAROMETRIC PRESSURE SENSOR
Circuit Description & Diagnostic Aids ........ 6E-206 CIRCUIT LOW INPUT ............................. 6E-226
(Symptom Code A) (Flash Code 28) Diagnostic Aids .......................................... 6E-226
Diagnostic Trouble Code (DTC) P0606 (Symptom Code 1) (Flash Code 86) Barometric
(Symptom Code B) (Flash Code 28) Pressure Sensor Circuit High Input ......... 6E-226
DIAGNOSTIC TROUBLE CODE (DTC) P0645 (Symptom Code 2) (Flash Code 86) Barometric
(SYMPTOM CODE 4) (FLASH CODE 46) Pressure Sensor Circuit Low Input .......... 6E-226
A/C COMPRESSOR RELAY CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P1120
VOLTAGE LOW ...................................... 6E-209 (SYMPTOM CODE 1) (FLASH CODE 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0645 PEDAL/THROTTLE POSITION SENSOR
(SYMPTOM CODE 8) (FLASH CODE 46) CIRCUIT HIGH INPUT ............................ 6E-228
A/C COMPRESSOR RELAY CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P1120
VOLTAGE HIGH ...................................... 6E-209 (SYMPTOM CODE 7) (FLASH CODE 21)
Circuit Description ..................................... 6E-209 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Aids .......................................... 6E-209 VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-228
A/C Compressor Relay Circuit Voltage Low 6E-210 PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-228
(Symptom Code 8) (Flash Code 46) DIAGNOSTIC TROUBLE CODE (DTC) P1120
A/C Compressor Relay Circuit Voltage High 6E-213 (SYMPTOM CODE D) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH ERROR ....................... 6E-228
BRAKE SWITCH INCORRECT SIGNAL (1) 6E-214 DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE E) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
IDLE POSITION SWITCH ERROR ......... 6E-228
BRAKE SWITCH INCORRECT SIGNAL (2) 6E-214
(Symptom Code 1) (Flash Code 21) Camshaft Speed Malfunction ................... 6E-253
Pedal/Throttle Position Sensor Circuit DIAGNOSTIC TROUBLE CODE (DTC) P1520
High Input ................................................ 6E-229 (SYMPTOM CODE A) (FLASH CODE 47)
Diagnostic Trouble Code (DTC) P1120 NEUTRAL SWITCH ON ERROR ............ 6E-254
(Symptom Code 7) (Flash Code 21) DIAGNOSTIC TROUBLE CODE (DTC) P1520
Pedal/Throttle Position Sensor Voltage (SYMPTOM CODE B) (FLASH CODE 47)
Supply Circuit High Input ......................... 6E-234 NEUTRAL SWITCH OFF ERROR ........... 6E-254
(Symptom Code 9) (Flash Code 21) Diagnostic Aids .......................................... 6E-254
Pedal/Throttle Position Sensor Voltage Diagnostic Trouble Code (DTC) P1520
Supply Circuit Low Input .......................... 6E-236 (Symptom Code A) (Flash Code 47)
Diagnostic Trouble Code (DTC) P1120 Neutral Switch ON Error .......................... 6E-255
(Symptom Code D) (Flash Code 21) Diagnostic Trouble Code (DTC) P1520
Pedal/Throttle Position Sensor Brake (Symptom Code B) (Flash Code 47)
Switch Error ............................................. 6E-239 Neutral Switch OFF Error ........................ 6E-255
(Symptom Code E) (Flash Code 21) (SYMPTOM CODE C) (FLASH CODE 55)
Pedal/Throttle Position Sensor Idle SEED AND KEY FILE DESTROYED ...... 6E-259
Position Switch Error ............................... 6E-241
(SYMPTOM CODE 3) (FLASH CODE 22) EEPROM DEFECT .................................. 6E-259
FUEL REDUCTION CAUSED BY HIGH
COOLANT TEMPERATURE ................... 6E-243
(SYMPTOM CODE E) (FLASH CODE 55)
DIAGNOSTIC TROUBLE CODE (DTC) P1173 EEPROM DEFECT .................................. 6E-259
Circuit Description & Diagnostic Aids ........ 6E-259
FUEL REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ..................................... 6E-243
(Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed .................. 6E-259
(Symptom Code 3) (Flash Code 22) EEPROM Defect ...................................... 6E-259
Fuel Reduction Caused By High Coolant
Temperature ............................................ 6E-243
(Symptom Code E) (Flash Code 55)
Diagnostic Trouble Code (DTC) P1173 EEPROM Defect ...................................... 6E-259
Fuel Reduction Caused By High Fuel
Temperature ............................................ 6E-246
SECURITY KEY AND SECURITY CODE
DIAGNOSTIC TROUBLE CODE (DTC) P1335 NOT PROGRAMMED .............................. 6E-261
ENGINE SPEED OUTPUT CIRCUIT
MALFUNCTION ....................................... 6E-247
(Symptom Code A) (Flash Code 56) Security
Key and Security Code Not Programmed 6E-262
Engine Speed Output Circuit Malfunction 6E-248
WRONG SECURITY CODE ENTERED .. 6E-263
CAMSHAFT SPEED MALFUNCTION ..... 6E-252
Wrong Security Code Entered ................. 6E-264
(SYMPTOM CODE A) (FLASH CODE 56) Diagnostic Trouble Code (DTC) P1630
IMMOBILISER NO OR WRONG SIGNAL 6E-265 (Symptom Code B) (Flash Code 51) Fuel
Circuit Description ..................................... 6E-265 Injection Quantity Circuit Malfunction ...... 6E-282
(Symptom Code A) (Flash Code 56) CAN DEVICE OFFLINE ........................... 6E-283
Immobiliser No or Wrong Signal .............. 6E-266 DIAGNOSTIC TROUBLE CODE (DTC) P1650
DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE B) (FLASH CODE 44)
(SYMPTOM CODE A) (FLASH CODE 56) CAN DEVICE HANG-UP ......................... 6E-283
IMMOBILISER NO OR WRONG SIGNAL 6E-271 Circuit Description ...................................... 6E-283
(Symptom Code A) (Flash Code 56) CAN Device Offline .................................. 6E-284
Immobiliser No or Wrong Signal .............. 6E-272 Diagnostic Trouble Code (DTC) P1650
DIAGNOSTIC TROUBLE CODE (DTC) P1614 (Symptom Code B) (Flash Code 44)
(SYMPTOM CODE A) (FLASH CODE 56) CAN Device Hang-up .............................. 6E-289
WRONG TRANSPONDER KEY .............. 6E-276 DIAGNOSTIC TROUBLE CODE (DTC) P1651
Circuit Description ..................................... 6E-276 (SYMPTOM CODE A) (FLASH CODE 45)
Diagnostic Aids .......................................... 6E-276 CAN MALFUNCTION (PSG) ................... 6E-290
(Symptom Code A) (Flash Code 56) (SYMPTOM CODE B) (FLASH CODE 45)
Wrong Transponder Key ......................... 6E-277 CAN RECEIVES ERROR ........................ 6E-290
(SYMPTOM CODE A) (FLASH CODE 76) Diagnostic Aids .......................................... 6E-290
ECM MAIN RELAY SWITCHED OFF Diagnostic Trouble Code (DTC) P1651
TOO EARLY ............................................ 6E-278 (Symptom Code A) (Flash Code 45)
DIAGNOSTIC TROUBLE CODE (DTC) P1625 CAN Malfunction (PSG) ........................... 6E-291
ECM MAIN RELAY SWITCHED OFF (Symptom Code B) (Flash Code 45)
TOO LATE ............................................... 6E-278 CAN Receives Error ................................ 6E-292
Diagnostic Aids .......................................... 6E-278 (SYMPTOM CODE 4) (FLASH CODE 77)
Diagnostic Trouble Code (DTC) P1625 CHECK ENGINE LAMP (MIL) CIRCUIT
(Symptom Code A) (Flash Code 76) ECM VOLTAGE LOW ...................................... 6E-297
Main Relay Switched Off Too Early ......... 6E-279 DIAGNOSTIC TROUBLE CODE (DTC) P1690
Diagnostic Trouble Code (DTC) P1625 (SYMPTOM CODE 8) (FLASH CODE 77)
(Symptom Code B) (Flash Code 76) ECM CHECK ENGINE LAMP (MIL) CIRCUIT
Main Relay Switched Off Too Late .......... 6E-280 VOLTAGE HIGH ...................................... 6E-297
(SYMPTOM CODE A) (FLASH CODE 51) Diagnostic Aids .......................................... 6E-297
FUEL INJECTION QUANTITY CIRCUIT Diagnostic Trouble Code (DTC) P1690
MALFUNCTION ....................................... 6E-281 (Symptom Code 4) (Flash Code 77) Check
DIAGNOSTIC TROUBLE CODE (DTC) P1630 Engine Lamp (MIL) Circuit Voltage Low .. 6E-298
FUEL INJECTION QUANTITY CIRCUIT (Symptom Code 8) (Flash Code 77) Check
MALFUNCTION ....................................... 6E-281 Engine Lamp (MIL) Circuit Voltage High . 6E-301
Circuit Description ..................................... 6E-281 SYMPTOM DIAGNOSIS ............................ 6E-302
Diagnostic Aids .......................................... 6E-282 PRELIMINARY CHECKS .......................... 6E-302
Diagnostic Trouble Code (DTC) P1630 VISUAL/PHYSICAL CHECK ...................... 6E-302
(Symptom Code A) (Flash Code 51) Fuel INTERMITTENT ........................................ 6E-302
Injection Quantity Circuit Malfunction ...... 6E-282 ENGINE CRANKS BUT WILL NOT RUN .. 6E-303
HARD START SYMPTOM ........................ 6E-307
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM .................. 6E-311
SURGES AND/OR CHUGS SYMPTOM ... 6E-318
HESITATION, SAG, STUMBLE
SYMPTOM .............................................. 6E-323
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM .............................................. 6E-335
EXCESSIVE WHITE SMOKE .................... 6E-346
EXCESSIVE BLACK SMOKE ................... 6E-351
ENGINE CONTROL MODULE (ECM) ... 6E-355
CRANKSHAFT POSITION (CKP) SENSOR 6E-356
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ................................................. 6E-356
MASS AIR FLOW (MAF) & INTAKE AIR
TEMPERATURE (IAT) SENSOR ............ 6E-357
THROTTLE POSITION SENSOR (TPS) ... 6E-357
Regulating Valve) .................................... 6E-358
ABBREVIATION CHARTS
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
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
Engine Component Locator Table
3 1 2 6 4 5
(2) Throttle Cable (6) EGR Pipe
3 2 4
(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

(2) Pump Control Unit (PSG) (4) Fuel Filter
2 3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (3) Air Cleaner Case
(IAT) Sensor Assembly
(2) EGR EVRV
3 2 1
(1) Engine Control Module (ECM) (1) EGR EVRV

(2) To Vacuum Pump
(3) To EGR Valve
2 1
(1) Engine Coolant Temperature (ECT) Sensor 2 1

(2) Thermo Unit for Water Temperature Gauge
(1) Crankshaft Position (CKP) Sensor
(2) Clutch Housing
(1) Vehicle Speed Sensor (VSS)

ECM CIRCUIT DIAGRAM
GROUND POINT CHART (1/4)
LOCATION
ENGINE CONTROL MODULE (ECM)
PARTS LOCATION
PARTS LOCATION
CONNECTOR LIST
B-24 C-56
Green Meter-B ECM-A

B-54 C-57
White J/B I2 ECM-B

B-56 C-77
White J/B I4 Clutch switch

B-58 C-94
Black Check connector White TCM

B-62 C-95
White Ignition switch (IGSUB : G1) White TCM

B-63 C-107
White Ignition switch (IGSUB : G2) White J/B E2

B-68 C-108
Immobiliser White J/B E1

C-2 C-109
Silver Engine room-RH ground Silver Body-LH ; ground

C-36 C-115
Silver Engine room-LH ; Ground Brown EVRV

C-44 C-116
White Stop lamp switch


C-118 E-44
A/C Resister & Neutral switch Gray Vehicle speed sensor

E-3 E-49
Black Magnetic clutch AC COMP Gray Glow plug

E-6 E-51
Black Inhibiter switch

E-9 H-4
White Engine room ~ Mission

E-10 H-6
Silver Engine ground White Engine room ~ INST

E-11 H-7
Natural
green Neutral switch White Engine room ~ INST
E-12 H-18
Natural
green Neutral switch White Engine room ~ INST
E-22 H-22
Brown TPS 1 main White Engine ~ Engine room C

E-23 H-33
Gray Idle SW Engine ~ Engine room

E-41 P-1
Black Coolant temp sensor Silver Battery (+)


P-2
Silver Relay & Fuse box

P-5
Silver Battery (-)

P-6
Silver Body earth (Ground)

P-10
Silver Engine ground

X-5
Black Relay ; Glow

X-13
Black Relay ; ECM MAIN

X-14
Black Relay; A/C Compressor

X-15
Black Relay; Thermo

X-16
Black DIODE
X-17
Black DIODE
RELAY AND FUSE
RELAY AND FUSE BOX LOCATION
RELAY & FUSE BOX

RELAY
No. RELAY (4JH1-TC)
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; GLOW
X-6 —
X-7 RELAY; COND, FAN
X-8 RELAY; —
X-9 —
X-10 —
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; —
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
ENGINE MODEL
FUSE NO. 4JH1-TC
EB-1 10A ECM
EB-2 —
EB-3 15A FRT FOG
EB-4 10A ACG (S)
EB-5 10A ILLUMI
EB-6 10A TAIL
EB-7 10A H/LIGHT-RH
EB-8 10A H/LIGHT-LH
EB-9 —
EB-10 —
EB-11 —
EB-12 —
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD
SLOW BLOW FUSE

ENGINE MODEL
FUSE NO. 4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2
FUSE AND RELAY LOCATION
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
22 20A RR DEF
23 30A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
4JH1-TC REAR POWER ACC
DEFOGGER WINDOW SOCKET
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 Engine 4P out
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
ECM Stop Back up Engine

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Injection Resister BLK VIO
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
BLK RED BLK 0.85 YEL BLK/ YEL
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
ECM Battery Heater

ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
Plug Compressor 0.5 Pressure
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

BLK/ WHT/ GRN/ BLK/ BLK/
URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
GRN/ RED WHT BLK BLK BLK BLK/ GRY WHT RED
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

Pin B/Box Wire ECM
Pin Function Key SW Key SW Engine Engine
No. No. Color Connection Range (+) (-)
Off On Idle 2000rpm
with
ground
with
ground
3 3 Battery Power Supply BLU/RED Less than Battery voltage Connect DC V 3 GND
1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
wave form wave form
7.2V 7.5V
28 28 No Connection - - - - - - - - -
29 29 Throttle Position RED/ - Approx. 140Hz by wave form (Idle: - - - -
Signal (To TCM A16) WHT Off duty 10% WOT: Off duty 90%)
(A/T Only)
30 30 Brake Switch 1 Signal RED Less than Battery voltage when pedal is Connect DC V 30 GND
1V stepped on
31 31 Clutch Switch Signal YEL Less than Battery voltage when pedal is not Connect DC V 31 GND
(M/T Only) 1V stepped on
32 32 No Connection - - - - - - - - -
33 33 A/C Thermo Relay GRN Less than Battery voltage when A/C request Connect DC V 33 GND
1V switch is turned on
34 34 No Connection - - - - - - - - -
35 35 Immobiliser Control WHT - Wave form - - - -
Unit (ICU B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position WHT Less than Less than 1V Approx. Connect DC V 38 49
Sensor (TPS) Output 1V 1V
Signal
39 39 Key Switch Input BLU/YEL Less than Battery voltage Connect DC V 39 GND
Signal Via Engine 1V
Fuse
40 40 No Connection - - - - - - - - -
41 41 A/C Compressor BRN/RED Less than Battery Battery voltage when Connect DC V 41 GND
Relay 1V voltage A/C compressor is not
activated

Pin B/Box Wire ECM
Off On Idle 2000rpm
42 42 Check Engine Lamp RED/YEL Less than Battery voltage when lamp is turned Connect DC V 42 GND
1V off
43 43 Glow Lamp ORG/BLU Less than Battery voltage when lamp is turned Connect DC V 43 GND
1V off
44 44 No Connection - - - - - - - - -
45 45 Data Link Connector BLU Less than Battery voltage Connect DC V 45 GND
(No. 6) 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position RED/ Idle: - - - Disconnect Ω 38 49
Sensor (TPS) Ground GRN Approx.
0.4kΩ/
WOT:
Approx.
3.8kΩ
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 BLK/GRN Less than Approx. 5V Connect DC V 57 49
Sensor (TPS) Power 1V
Supply
voltage
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply BLU/RED Less than Battery voltage Connect DC V 63 GND
1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/BLK Less than Battery voltage when pedal is not Connect DC V 65 GND
1V stepped on
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
(VSS) Via Speed approx. 6.4V at vehicle speed
Meter 20km/h
69 69 Idle Switch GRN/BLK Less than Approx. 5V when pedal is stepped Connect DC V 69 GND
1V on
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 - - - - - - - - -

Pin B/Box Wire ECM
Off On Idle 2000rpm
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 Temperature BLK/BLU Less than Approx. 2.5V at IAT 25°C Connect DC V 84 92
(IAT) Sensor Signal 1V
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/WHT Less than Battery voltage at other than neutral Connect DC V 87 GND
1V (M/T) / Battery voltage in
P or N (A/T)
88 88 Mass Air Flow (MAF) GRN/ Less than Approx. Approx. Approx. Connect DC V 88 92
Sensor Signal RED 1V 1V 2V 3V
89 89 Engine Coolant GRY Less than Approx. 1.3V at ECT 80°C Connect DC V 89 93
Temperature (ECT) 1V
Sensor Signal
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 133Hz by
wave form wave form
0.7V at 1.0V
700rpm
91 91 CKP Sensor Output To PNK - - Approx. Approx. - - - -
Sensor Ground with
ground
Temperature (ECT) with
Sensor Ground ground
94 94 Glow Relay BLK/BLU Less than Battery voltage when glow system Connect DC V 94 GND
1V is not activated
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ORG - Approx. 140Hz by wave form when - - - -
EVRV is activated
98 98 CKP Sensor Ground WHT Continuity - - - Connect Ω 98 GND
with
ground
101 101 CKP Sensor Shield - Continuity - - - Connect Ω 101 GND
Line with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - Wave form - - - -
Off (MAB) Output
Signal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

Pin B/Box Wire PSG
Off On Idle 2000rpm
No.99 ECM &
PSG
No.100 ECM &
PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
Off (MAB) Output between
Signal to ECM No.105 ECM &
PSG
6 - Ground BLK Continuity - - - Disconnect Ω 6 GND
with
ground
between
ECM &
PSG
8 91 CKP Sensor Output PNK Continuity - - - Disconnect Ω 8 91
ECM No.91 To Pump between
Control Unit (PSG) ECM &
PSG
9 - No Connection - - - - - - - - -
GENERAL DESCRIPTION FOR ECM AND management system.
SENSORS • Engine Control Module (ECM)
• Pump Control Unit (PSG) = Pumpen Steuer Great
Engine Control Module (ECM) (German)
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The engine control module (ECM) is located flower module (ECM) and the pump control unit (PSG) is
panel just under the passenger's seat. perfumed via a CAN-bus system. The abbreviation CAN
The fuel quantity and injection timing related functions stands for Controller Area Network. By having two
are controlled by the pump control unit (PSG). separate control modules, the high pressure solenoid
The engine control module (ECM) performs the valve. This prevents the discharge of any disturbing
following functions. signals.
• Control of the exhaust gas re-circulation (EGR)
The following signals are exchanged via the CAN-bus:
• Control of the quick on start (QOS) glow control From ECM to PSG
system
• Desired injection quantity
• Control of the A/C compressor
• Desired injection timing
• Execution of the immobiliser function
• Engine speed
Pump Control Unit (PSG) & Data Exchange
Between Control Module From PSG to ECM
• Fuel temperature
• Pump speed
• Cylinder identifier
• Control pulse (actual injection quantity + actual
Self Diagnosis / Interface / Signal injection timing)
To High Pressure Solenoid
• PSG status
Cam Ring Rotational Angle
Engine Speed Fuel Temperature
Engine
Control Injection Timing
Module
Accelerator Pedal (ECM High Pressure
Injection Quantity Solenoid Valve
Pump
Intake Air Temperature Control Fuel Injection
Unit (Mechanical)
Response Signal
(PSG
Mass Air Flow
Additional Signal
Others Timing Device
Additional Operations To Timing Control Valve (TCV)
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
Mass Air Flow (MAF) Sensor & Intake Air The ECM supplies 5 volts signal to the IAT sensor
Temperature (IAT) Sensor through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor is part of the intake air
system. 1 2
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine. (1) Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor uses a hot film element (2) Idle Switch
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.
Characteristic of IAT Sensor

+5V Output Ground Ground +5V
Resistance ( )
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Temperature (oC)
The IAT sensor is a thermistor. A temperature changes

temperature produces a high resistance.
Engine Coolant Temperature (ECT) Sensor
Characteristic of TPS
Output Voltage (V)
Throttle Angle (%)

2 1

on the throttle body. It is installed to the main TPS and (1) Engine Coolant Temperature (ECT) Sensor
idle switch. (2) Thermo Unit for Water Temperature Gauge
Characteristic of ECT Sensor
The engine control module (ECM) calculates fuel
Resistance ( )
delivery based on throttle valve angle.
Crankshaft Position (CKP) Sensor
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Temperature (deg. C)
The ECT sensor is a thermistor. A temperature changes

a high resistance.
temperature is hot.
The CKP sensor is located on top of the flywheel
housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
and engine cylinder top dead center (TDC).
Vehicle Speed Sensor (VSS) EGR EVRV
3 2 1
M/T & A/T 4WD

(1) EGR EVRV
(2) Connecting to Vacuum Pump
(3) Connecting to EGR Valve
7.1ms
Voltage
Time
0.7ms
7.1ms
Voltage
A/T 2WD
Time
The VSS is a magnet rotated by the transmission output 6.4ms
shaft. The VSS uses a hall element. It interacts with the Off duty 70% =EGR Pulse Ratio 70%
magnetic field treated by the rotating magnet. It outputs
meter fuse. The EGR system on this engine is largely responsible
The engine control module (ECM) calculates the vehicle for a reduction of the NOx exhaust emission.
speed by VSS. The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
GENERAL DESCRIPTION FOR INJECTION dispersion and distribution (mixing with air is improved)
PUMP and results in better combustion. This contributes to
cleaner emissions.
Outline
3. Optimum Fuel Injection
High speed control of fuel injection quantity and fuel
injection timing, is performed by the control unit,
enabling lower fuel cost and high output.
4. Improved Durability
The components used in the pump are very resistant to
high pressure, ensuring improved durability.
5. Improved Engine Matching

As fuel injection is controlled by cylinder selective
adaptation, smooth running is improved.
6. Improved Reliability
As a control unit system with both an engine control
module (ECM) and a pump control unit (PSG) is used,
the control system is extremely reliable.
7. Improved Power Performance

(1) Drive Shaft As the control unit controls the optimum fuel injection
(2) Feed Pump quantify corresponding to accelerator position,
(3) Pump Camshaft Speed Sensor increased torque in low accelerator pedal positions is
(4) Pump Control Unit (PSG) possible, enabling improved power performance.
(5) Distributor Head
8. Decreased Smoke at Acceleration
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve When the amount of injected fuel is increased, to
increase engine power at acceleration, the excess fuel
(8) Constant Pressure Valve (CPV)
usually generates smoke. The VP44 fuel injection pump,
accurately controls fuel injection quantity even in this
(10) Timer range to prevent the generation of smoke without
(11) Radial Plunger High Pressure Pump adversely affecting acceleration.
Instead of the previous face cam type, the radial plunger 9. Additional Devices are Unnecessary
distributor type injection pump utilizes a cam ring to
Such additional devices as the boost compensator and
enable fuel injection at high-pressures, marking it
the aneroid compensator are unnecessary, as the
suitable for small, high-speed direct injection diesel
control unit compensates, based on signals from each
engines. This pump was developed to provide the most
sensor. This results in less “clutter” injection pump.
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
10. Self Diagnosis Function
smoke, low noise, high output and clear exhaust
emissions. The system includes a self-diagnosis function, which
displays error codes to facilitate the diagnosis of
Characteristic of VP44 Injection System malfunctions.
1. High Pressure Injection

The radial plunger distributor type injection pump is
capable of generating pressure of 100 Mpa
(approximately 1000 Bar) demanded by small, high
speed direct injection diesel engines.
2. High Pressure Atomization of Fuel Injected from

the Nozzle
Through high pressure fuel injection, the fuel is
atomized at high pressure with a high penetrating force
(the fuel droplets penetrate further) and with greater
Cross-section View
(1) Rotor Shaft

(1) Drive Shaft (2) Radial Plunger
(2) Feed Pump (3) High Pressure Passage
(3) Pump Camshaft Speed Sensor (4) Low Pressure Inlet
(4) Pump Control Unit (PSG) (5) Distributor Slit
(5) Distributor Head (6) Valve Needle
(6) Constant Pressure Valve (CPV) Holder (7) Barrel
(7) High Pressure Solenoid Valve (8) Annular Passage
(8) Constant Pressure Valve (CPV) (9) Fuel Return
(9) Timing Control Valve (TCV) (10) High Pressure Solenoid Valve
(10) Timer (11) High Pressure Outlet
(11) Radial Plunger High Pressure Pump (12) Diaphram Chamber
(13) Accumulator Diaphram
Low Pressure Fuel Circuit High Pressure Fuel Circuit
(1) Fuel Suction (1) Pump Control Unit (PSG)

(2) Regulating Valve (2) Distributor Head
(3) Overflow Valve (3) High Pressure Solenoid Valve
(4) Feed Pump (4) Constant Pressure Valve (CPV)
(5) To Fuel Tank (5) Radial Plunger High Pressure Pump
The low pressure fuel circuit must supply sufficient fuel In addition high pressure generating device, the high
to the high pressure fuel circuit. The main components pressure circuit also consists of fuel piping, and devices
are the feed pump, the regulating valve and the overflow to set the beginning of injection and fuel injection
valve. quantity.
The main components are as follows.

• High pressure generation: Radial Plunger High
Pressure Pump
• Fuel distribution: Distributor Head
• Beginning of injection timing: Timing Device
• Prevention of secondary injection: Constant Pressure
Valve (CPV)
Timing Control Start of Injection
Engine Load
Engine Pump Timing
Engine Speed Control Control Control
Module Unit Valve
Engine Coolant
(ECM) (PSG) (TCV)
Temperature
Pump
Camshaft
Speed Sensor
(1) Cam Ring The engine control module (ECM) contains

(2) Servo Valve characteristic maps of the beginning of injection,
(3) Timer Piston corresponding to engine operating conditions (engine
(4) Outlet load, engine speed and engine coolant temperature).
(5) Feed Pump The pump control unit (PSG) is constantly comparing
(6) Inlet the set beginning of injection timing and the actual
(7) Fuel Suction beginning of injection timing.
(8) Ball Pin If there is a difference, the timing control valve (TCV) is
(9) Annular Chamber controlled by the duty ratio. (The actual beginning of
(10) Hydraulic Stopper injection timing is determined from the pump camshaft
speed sensor.)
(11) Return Passage
The timing device determines the optimum injection

timing against variations in engine speed.
The pressure of the fuel fed from the feed pump is
adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
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.
The main components are timing plunger, the timing
control valve (TCV) and pump camshaft speed sensor.
ISUZU Strategy Based Diagnostics


• Complaint check sheet
Strategy Based Diagnostics chart requires you to use
customer complaint
parts
perspectives
OBVIOUS
actions:
• Make a visual inspection for separated connectors
correct (normal) operating behavior of the system and
checks:
– Harness routing

co.jp//
• Service manual
What you should do
charts)?
data) switched?
VSS, for example)?
drivetrain or suspension components without • Experience
What you should do
complaint.

component
components)
blower, lights or rear window defogger) to create a load
• Bulletins
What you should do
by:
checks
• Experience
• Experience

What you should do


• Service manual
path

What you should do

GENERAL SERVICE INFORMATION ON-BOARD DIAGNOSTIC (OBD)

Serviceability Issues On-Board Diagnostic (Self Diagnosis
System) Tests
Non-OEM Parts
A diagnostic test is a series of steps, the result of which
is a pass or fail reported to the diagnostic executive.
with OEM parts. Accordingly, if commercially sold
When a diagnostic test reports a pass result, the
sensor or switch is installed, it makes a wrong diagnosis
Aftermarket electronics, such as cellular phones, • The diagnostic test has been completed since the
stereos, and anti-theft devices, may radiate EMI into the last ignition cycle.
control system if they are improperly installed. This may • The diagnostic test has passed during the current
cause a false sensor reading and turn on the check ignition cycle.
engine lamp. • The fault identified by the diagnostic test is not
currently active.
Poor Vehicle Maintenance When a diagnostic test reports a fail result, the
The sensitivity of OBD diagnostics will cause the check diagnostic executive records the following data:
engine lamp to turn on if the vehicle is not maintained • The diagnostic test has been completed since the
properly. Restricted oil filters, fuel filters, and crankcase last ignition cycle.
deposits due to lack of oil changes or improper oil
viscosity can trigger actual vehicle faults that were not
active.
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle • The fault has been active during this ignition cycle.
fault”, but with the sensitivity of OBD diagnostics, • The operating conditions at the time of the failure.
vehicle maintenance schedules must be more closely
followed. The Diagnostic Executive
Related System Faults
Many of the OBD system diagnostics will not run if the the diagnostic procedures as well as define the protocol
ECM detects a fault on a related system or component. for recording and displaying their results. The main
Visual/Physical Engine Compartment follows:
Inspection • Commanding the check engine lamp on and off
Perform a careful visual and physical engine • DTC logging and clearing
compartment inspection when performing any • Current status information on each diagnostic
emission test failure. This can often lead to repairing a Diagnostic Information
• Inspect all vacuum hoses for punches, cuts, a process of logical decisions. The charts are prepared
disconnects, and correct routing. with the requirement that the vehicle functioned
• Inspect hoses that are difficult to see behind other correctly at the time of assembly and that there are not
components. multiple faults present.
• Inspect all wires in the engine compartment for There is a continuous self-diagnosis on certain control
proper connections, burned or chafed spots, pinched functions. This diagnostic capability is complemented
wires, contact with sharp edges or contact with hot by the diagnostic procedures contained in this manual.
exhaust manifolds or pipes. The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
Basic Knowledge of Tools Required When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
NOTE: Lack of basic knowledge of this powertrain lamp is illuminated.
when performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain Check Engine Lamp
components. Do not attempt to diagnose a powertrain The check engine lamp looks the same as the check
problem without this basic knowledge. engine lamp you are already familiar with, the “Check
A basic understanding of hand tools is necessary to Engine” lamp.
effectively use this section of the Service Manual. Basically, the check engine lamp is turned on when the
ECM detects a DTC that will impact the vehicle Reading Flash Diagnostic Trouble Codes
emissions.
The provision for communicating with the Engine
• When the check engine lamp remains “ON” while the Control Module (ECM) is the Data Link Connector
engine is running, or when a malfunction is (DLC). The DLC is located in the front console box. It is
suspected due to a driveability or emissions problem, used in the assembly plant to receive information in
a Powertrain On-Board Diagnostic (OBD) System checking that the engine is operating properly before it
Check must be performed. The procedures for these leaves the plant.
checks are given in On-Board Diagnostic (OBD) The diagnostic trouble code(s) (DTCs) stored in the
System Check. These checks will expose faults which ECM’s memory can be read either through a hand-held
may not be detected if other diagnostics are diagnostic scanner plugged into the DLC or by counting
performed first. the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
Data Link Connector (DLC)
DLC terminal “6” (diagnostic request) is pulled “Low”
The provision for communication with the contorl (grounded) by jumping to DLC terminal “4 or 5”, which is
module is the Data Link Connector (DLC). It is located a ground wire.
behind the lower front instrument panel. The DLC is This will signal the ECM that you want to “flash” DTC(s),
used to connect to a Tech2. Some common uses of the if any are present. Once terminals “4 or 5” and “6” have
Tech2 are listed below: been connected, the ignition switch must be moved to
• Identifying stored Diagnostic Trouble Codes (DTCs). the “ON” position, with the engine not running.
• Clearing DTCs. The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
• Reading serial data.
stored in the ECM’s memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a

Tech 2
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes

To clear Diagnostic Trouble Codes (DTCs), use the
Tech2 “clear DTCs” or “clear information” function.
Tech2 manufacturer.
Verifying Vehicle Repair History DTC

Verification of vehicle repair will be more comprehensive History DTC can be candeled after 40 cycle driving with
for vehicles with OBD system diagnostic. Following a no defect. Or history code can be deleted by Tech 2
repair, the technician should perform the following “Clear DTCs” function.
steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the
Fail Records.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
DIAGNOSIS WITH Tech 2 cable (4).
If no codes are set: • Connect the DLC cable (4) to the Tech 2 (5).
• Refer to F1: Data Display and identify the electrical • Connect the SAE 16/19 adapter (3) to the data
faults that are not indicated by trouble code. link connector of the vehicle.
If codes are set:

2. Clear the codes.
status.
AIDS”.
diagnosis.
Tech 2 CONNECTION • Turn the key switch of the vehicle ON and press
the “PWR” key of the Tech 2.
card.

Tech 2.
1. Configuration of Tech 2
• Tech 2 scan tool kit (No. 7000086), Tech 2 scan
• SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
2. Tech 2 Connection
• Check the key switch is turn OFF.
• Insert the PCMCIA card (1) into the Tech 2 (5).
TECH 2 OPERATING FLOW CART (START UP)
(TBR)
(N*) ELF, NPR, NQR

F3: Tool Option

(2) 2002 4JA1-TC Bosch
(1) 2001 4JH1-T Denso
(X) 1999 AW30-40LE
(W) 1998 A/T JR405E
Select “(3) 2003”or later. Select “4JH1-TC Bosch”.

Select “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the Tech 2 screen.
F0: Diagnostic Trouble Codes F1: Data Display

F0: Read DTC Infor As Stored By ECU
F1: Clear DTC Information The current actual values of all important sensors and
F1: Data Display signals in the system are display through F1 mode.
See the “Typical Scan Data” section.
F2: Snapshot F2: Snapshot

“Snapshot” allows you to focus on making the condition
occur, rather than trying to view all of the data in
F3: Miscellaneous Test
F0: Lamps The snapshot will collect parameter information around
F0: Check Light a trigger point that you select.
F3: Miscellaneous Test:
F1: Relays The purpose of “Miscellaneous Test” mode is to check
F0: Glow Time Relay Test for correct operation of electronic system actuators.
F4: Programming (Factory Use Only)
The purpose of “Programming” is to program VIN in the
F4: Programming ECM and lock the programmed data.
F0: Program VIN
F1: Lock ECU
F0: Diagnostic Trouble Code

The purpose of the “Diagnostic Trouble Codes” mode is
When “Clear DTC Information” is selected, a “Clear
DTC Information”, warning screen appears.
This screen informs you that by cleaning DTC's “all
driving the vehicle.
Read DTC Infor As Stored By ECU
P0100 Present
(7) Mass Air Flow (MAF) Sensor
DTC No. Voltage Supply Circuit High Input
Symptom Code
Symptom Code:
This number or alphabet means identification of the
malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
80 deg.)

sensor.
Position Signal (0) (4 - 7) (8 - 11) ECM from throttle position output voltage. This should
Value of ( ) shows display 0% at idle and 99 - 100% at full throttle.
A/T model
Sensor (730 - 785) (700 - 780) (780 - 830) measured by ECM from the MAF sensor output voltage.
Value of ( ) shows
A/T model
8 Desired Injection mg/stk 5-8 5-9 6 - 10 This displays commanded value from the ECM. The ECM
Quantity (10 - 16) (8 - 12) (9 - 13) compensates for fuel rate to basic rate.
Value of ( ) shows
A/T model
9 Injection Quantity mg/stk 6-8 6-9 7 - 10 This displays actual fuel quantity. The PSG controls high
Value of ( ) shows (10 - 16) (8 - 12) (9 - 13) pressure solenoid valve to meet commanded value from
A/T model the ECM.
on.
on.
Value of ( ) shows (-) (-) (-) should display “Active” when the clutch pedal is stepped
A/T model on.

22 System Voltage V 10 -14 10 -14 10 -14 This displays the system voltage measured by the ECM
at ignition feed.
This should display “Inactive” at key OFF and “Active” at
key ON.
upped.
Lamp is turned on.
on.
engine start.
relay is operated.
normal.
31 Immobiliser Signal Received/ Not Not Not Not This should display “Not Received” when the immobiliser
Received Received Received Received is not activated.
Programmed
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC cannot
be detected, a faulty circuit can be diagnosed by testing
each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
Connect Tech 2 and select “Powertrain”, “4JH1-TC
Bosch” & “Miscellaneous Test”.
F0: Lamps
F0: Check Light
When the Tech 2 is operated, “Malfunction Indicator
Lamp (Check Engine Lamp)” is turned on or off.
on or off in accordance with this operation.

When the Tech 2 is operated, “Glow Indicator Lamp” is
turned on or off.
The circuit is normal if the “Glow Indicator Lamp” 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 signal turns ON
or OFF.
The circuit is normal if glow system is activated/
deactivated in accordance with this operation when key
switch is turned ON.

When the Tech 2 is operated, “Desired Idle Speed”
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is normal if engine speed is changed in
accordance with this operation.
Engine Speed (RPM) Control

Injection Quantity 7.5mg/strk
• Press “Increase” key.

Then, Desired Idle speed increases 50rpm-by-50rpm
up to 1200rpm. Engine speed is also changed by this
operation.
• Press “Quit” Key.
Plotting Snapshot Graph


is not available.

below shown:

1. Start TIS2000.
screen.
information.

procedures.
1. Start TIS2000.
screen.
list on the screen.
window opens. icon.
screen.
The procedure to program the control unit by using the latest software release.
procedure.

with the following.
“Continue”.
2. Demand of Data
switch.
engine)

• Model Year
switch of Tech-2, turn off the ignition of the vehicle
described at the right-hand edge of Body Type line. In
and turn off the power of Tech-2, thereby removing
Fig.-3, the destination code can be read as “EK4
from the vehicle.
(Europe)”.
form of bar graph.
comes on display.
start)
button.
3 1

(2) Harness Adapter

3 4 2 5 1

(3) Breaker Box

3 4 2 5 1

(3) Breaker Box

Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
Circuit Description connection, and damaged harness.

The on-board diagnostic system check is the starting
Test Description
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical Number(s) below refer the step number(s) on the
check of the ECM and engine grounds for cleanliness Diagnostic Chart:
and tightness. 1. The Check Engine Lamp (MIL) should be ON steady
The on-board diagnostic system check is an organized with the ignition “On”, engine “Off”. If not, “No Check
approach to identifying a problem created by an Engine Lamp (MIL)” chart should be used to isolate the
electronic engine control system malfunction. malfunction.
2. Checks the Class 2 data circuit and ensures that the
Diagnostic Aids ECM is able to transmit serial data.
An intermittent may be caused by a poor connection, 3. This test ensures that the ECM is capable of
rubbed-through wire insulation or a wire broken inside controlling the Check Engine Lamp (MIL) and the Check
the insulation. Check for poor connections or a Engine Lamp (MIL) driver circuit is not shorted to
damaged harness. Inspect the ECM harness and ground circuit.
connector for improper mating, broken locks, improperly 4. If the engine will not start, “Engine Cranks But Will
formed or damaged terminals, poor terminal-to-wire Not Run” chart should be used to diagnose the fault.
6. The Tech2 parameters which is not within the typical 12. This vehicle is equipped with ECM which utilizes an
range may help to isolate the area which is causing the electrically erasable programmable read only memory
problem. (EEPROM).
On-Board Diagnostic (OBD) System Check

2. Attempt to display “Data Display” with the Tech 2.
Does the Tech 2 display engine data? — Go to Step 3 Go to Step 7
“Check Light” in “Lamps”.
2. Select the “Read DTC Infor As Stored By ECU” in
Tech 2 “Data Display”. SYMPTOM TYPICAL
B-58
16
Repair faulty
V harness and

ground circuit.
B-58
4 5
Repair faulty
harness and
ground circuit.
B-58
4 5
Repair faulty
V V
harness and
B-58
6
Repair faulty
V harness and

circuit.
C-56
45
B-58
6 Repair faulty
harness and
release?
13 Replace the ECM.
Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
following items:
engine ground.

1 Check the meter fuse (15A).
lamp circuit.
C-56
42
V
Battery
lamp circuit.
connector.
C-56
42
B-24

release?

6 Replace the ECM.
12Volt
METER (C10)
METER (C19)
10A
RED/
YEL
0.5
BLK
BLK/
GRN

directly to the check engine lamp indicator. The Engine • Poor connection or damaged harness – Inspect the
driver circuit.
Check Engine Lamp (MIL) On Steady

lamp circuit.
connector.
C-56
42
B-24
17

release?
5 Replace the ECM.
ECM Diagnostic Trouble Codes
Related Related
Flash Symptom
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code
No. DTC
65 P0100 7 ON Mass Air Flow (MAF) Sensor Voltage MAF sensor power supply voltage ECM uses mass air flow MAF sensor power supply voltage is 1. Sensor power supply circuit short 83 -
Supply Circuit High Input is more than 5.2V. 1600mg/strk & EGR 10% condi- below 5.2V. to battery voltage circuit.
tions as substitute. 2. MAF sensor malfunction.
3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor Voltage MAF sensor power supply voltage MAF sensor power supply voltage is 1. Sensor power supply circuit short 83 -
Supply Circuit Low Input is below 4.6V. more than 4.6V. to ground circuit.
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor Output 1. Engine speed is between MAF sensor output is more than - 1. Sensor power supply circuit open 83/88 P0110(1)
Circuit Low Input 600rpm and 5000rpm. 27.4mg/strk. circuit.
2. MAF sensor output is below - 2. Sensor signal circuit open or short
33.7mg/strk. to ground circuit.
3. Sensor heater harness open cir-
cuit.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor Output 1. Engine speed is between MAF sensor output is below 1784mg/ 1. Sensor signal circuit short to volt- 88/ 92 P0110(1)
Circuit High Input 600rpm and 5000rpm. strk. age circuit.
2. MAF sensor output is more than 2. Sensor ground circuit open or short
1784mg/strk. to voltage circuit.
4. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) Sensor IAT sensor output voltage is more ECM use 0°C conditions as sub- IAT sensor output voltage is below 4.7V. 1. Sensor signal circuit open or short 84/92 P0100(B)/
Circuit High Input than 4.7V. stitute. to voltage circuit. P0100(C)
2. Sensor ground circuit open or short
to voltage circuit.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) Sensor IAT sensor output voltage is below IAT sensor output voltage is more than 1. Sensor signal circuit short to 84 -
Circuit Low Input 0.3V. 0.3V. ground circuit.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature (ECT) ECT sensor output voltage is more 1. ECM uses fuel temperature as ECT sensor output voltage is below 1. Sensor signal circuit open or short 89/93 -
Sensor Circuit High Input than 4.7V. substitute. 4.7V. to voltage circuit.
2. ECM uses 60°C condition for 2. Sensor ground circuit open or short
injection timing control. to voltage circuit.
3. ECM uses -15°C condition for 3. Poor connector connection
glow time control. 4. ECT sensor malfunction.
5. ECM malfunction.
2 ON Engine Coolant Temperature (ECT) ECT sensor output voltage is ECT sensor output voltage is more than 1. Sensor signal circuit short to 89 -
Sensor Circuit Low Input below 0.3V. 0.3V. ground circuit.
3. ECM malfunction.
Related Related
Flash Symptom
Code Code
No. DTC
15 P0180 B ON Fuel Temperature Sensor Circuit FT sensor output is high tempera- The ECM use 75°C conditions as FT sensor output is correct temperature 1. ECM malfunction. - -
Range/Performance ture (more than 150°C) or low tem- substitute. range between 150°C and -40°C. 2. PSG (pump control unit) malfunc-
perature (below -40°C). tion.
52 P0215 A ON at Fuel Cutoff Solenoid Valve Malfunc- 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. PSG (pump control unit) malfunc- - -
next tion 2. Engine speed is below valve) is operated. next ignition key cycle. tion.
igni- 1500rpm. 2. Desired injection quantity 2. MAB (fuel cutoff solenoid valve)
tion 3. Vehicle speed is below 1.5km/h. becomes 0mg/strk. malfunction.
cycle 4. PSG (pump control unit) recog-
nizes MAB (fuel cutoff solenoid
valve) signal from the ECM, but
the MAB could not operate.
B ON Fuel Cutoff Solenoid Valve Circuit ECM does not command MAB Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid valve) 105 -
High Input (fuel cutoff solenoid valve) signal signal circuit short to voltage circuit.
to the PSG (pump control unit), but 2. PSG (pump control unit) malfunc-
PSG detected MAB signal line cir- tion.
cuit is high level.
C ON Fuel Cutoff Solenoid Valve Always 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. MAB (fuel cutoff solenoid valve) 105 -
Active 2. Engine speed is below valve) is operated. next ignition key cycle. signal circuit open or short to ground
1500rpm. 2. Desired injection quantity circuit.
3. Vehicle speed is below 1.5km/h. becomes 0mg/strk. 2. PSG (pump control unit) malfunc-
4. PSG (pump control unit) does tion.
not recognize MAB (fuel cutoff
solenoid valve) signal from the
ECM.
D ON Fuel Cutoff Solenoid Valve Malfunc- 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction. - -
tion 2. CAN controller does not operate 2. PSG (pump control unit) malfunc-
Bus-off. tion.
54 P0216 A ON Injection Timing Control Circuit Mal- 1. Engine speed is more than Fuel injection quantity is Deviation of actual injection timing and 1. Timing control valve malfunction. - -
function (Timer Deviation) 700rpm. reduced. desired injection timing is below +3°CA 2. Timer piston sticking.
2. Fuel injection quantity is more or -6°CA for 8 seconds. 3. Pump camshaft speed sensor mal-
than 4mg/stk. function.
3. Deviation of actual injection tim-
ing and desired injection timing is
more than +3°CA or -6°CA for 8
seconds.
B ON Injection Timing Control Circuit Mal- 1. Engine speed is more than 1. Engine speed is more than 2014rpm. 1. Insufficient air bleeding of fuel line. - -
function (Timer Fluctuation) 2014rpm. 2. Fluctuation of actual injection timing is 2. Fuel filter clogging.
2. Fluctuation of actual injection below ±5.2°CA. 3. Timing control valve malfunction.
timing is more than ±5.2°CA. 4. Pump camshaft speed sensor mal-
function.
Related Related
Flash Symptom
Code Code
No. DTC
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed sen- 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. PSG (pump control unit) malfunc- - -
sor error. valve) is operated. next ignition key cycle. tion.
2. High pressure solenoid valve 2. Desired injection quantity 2. Pump camshaft speed sensor mal-
control pulse width does not match becomes 0mg/strk. function.
with desired fuel injection quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed sen- 1. No pump camshaft speed sensor 1. Missing CKP sensor pulses. 91 -
sor error. error. 2. Electrical interference.
2. No CKP sensor error. 2. No CKP sensor error. 3. Magnetic interference.
3. Difference of engine speed and 3. Difference of engine speed and dou- 4. PSG (pump control unit) malfunc-
doubled pump camshaft speed is bled pump camshaft speed is below tion.
more than 690rpm. 690rpm.
No recovery until in the next ignition key
cycle.
9 ON Injection Pump Malfunction No pump map programmed in the No recovery until condition match in the PSG (pump control unit) malfunction. - -
PSG (pump control unit) or PSG next ignition key cycle.
malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter mal- Fuel injection quantity is EEPROM or A/D converter no malfunc- PSG (pump control unit) malfunction. - -
function in the PSG (pump control reduced. tion in the PSG (pump control unit).
unit). No recovery until in the next ignition key
cycle.
B ON Injection Pump Malfunction PSG (pump control unit) recog- No fail-safe function. No recovery until condition match in the PSG (pump control unit) malfunction. - -
nized high pressure solenoid valve next ignition key cycle.
drive circuit error.
D ON Injection Pump Malfunction PSG (pump control unit) could not PSG (pump control unit) malfunction. - -
measure the high pressure sole-
noid valve drive voltage.
E ON Injection Pump Malfunction ECM could not accept PSG (pump 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump control unit) 1. CAN high circuit open, short to 99/100 P1650(A)/
control unit) message. valve) is operated. message. ground or short to voltage circuit. P1651(B)
2. Desired injection quantity 2. CAN low circuit open, short to
becomes 0mg/strk. ground or short to voltage circuit.
3. ECM malfunction.
4. PSG (pump control unit) malfunc-
tion.
Related Related
Flash Symptom
Code Code
No. DTC
43 P0335 B ON Crankshaft Position Sensor Circuit 1. Engine speed is more than When pump camshaft speed ECM detects correct CKP pulse width. During engine run: 90/ 98/ P1335 (A)
Malfunction 665rpm. sensor is OK: 1. CKP sensor harness open circuit, 101
2. CKP sensor pulse width error. ECM uses doubled pump cam- short to ground or short to voltage cir-
shaft speed as substitute engine cuit.
speed. 2. Poor connector connection.
When pump camshaft speed 3. CKP sensor malfunction.
sensor is not OK: 4. Pulse sensing gap incorrect.
valve) is operated. 6. Electrical interference.
2. Desired injection quantity 7. Magnetic interference.
becomes 0mg/strk. 8. ECM malfunction.
D ON Crankshaft Position Sensor Circuit 1. No pump camshaft speed sen- When pump camshaft speed 1. Engine speed is more than 0rpm. During engine crank: 90/ 98/ P1135 (A)
Malfunction sor error. sensor is OK: 2. Doubled pump camshaft speed is 1. CKP sensor harness open circuit, 101
2. “Crankshaft Position Sensor Cir- ECM uses doubled pump cam- below 100rpm. short to ground or short to voltage cir-
cuit Malfunction (Symptom Code shaft speed as substitute engine cuit.
B)” is not stored. speed. 2. Poor connector connection.
3. Engine speed is 0rpm. Other than pump camshaft 3. CKP sensor malfunction.
4. Doubled pump camshaft speed speed sensor is OK: 4. Pulse sensing gap incorrect.
is more than 50rpm. Fuel injection quantity is 5. Pulser malfunction.
reduced. 6. Electrical interference.
8. ECM malfunction.
E ON Engine Speed Input Circuit Range/ Engine speed is more than When intermittent malfunction: Engine speed is below 5700rpm. 1. Engine over-running. 90/ 98/ -
Performance 5700rpm. 1. MAB (fuel cutoff solenoid 2. CKP sensor malfunction. 101
valve) is operated. 3. Pulser malfunction.
2. Desired injection quantity 4. ECM malfunction.
becomes 0mg/strk.
shaft speed as substitute engine
speed.
66 P0380 4 ON Glow Relay Circuit Voltage Low Glow relay circuit open or short to No fail-safe function. Glow relay circuit is correct condition. 1. Glow relay circuit open or short to 94 -
ground circuit. ground circuit.
2. Glow relay malfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage High Glow relay circuit short to voltage ECM malfunction. - -
circuit.
67 P0381 4 ON Glow Plug Indicator Circuit Voltage Glow plug indicator circuit open or No fail-safe function. Glow plug indicator circuit is correct con- 1. Glow plug indicator circuit open or 43 -
Low short to ground circuit. dition. short to ground circuit.
2. Glow plug indicator lamp malfunc-
tion.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Voltage Glow plug indicator circuit short to ECM malfunction. - -
High voltage circuit.
Related Related
Flash Symptom
Code Code
No. DTC
32 P0400 3 ON Exhaust Gas Recirculation Flow 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1500rpm 1. EGR valve is stuck at open posi- 88/97 -
Excessive Detected between 15°C and 100°C. reduced. and 3200rpm. tion.
2. Engine coolant temperature is 2. Injection quantity is below 40mg/stk. 2. EGR EVRV malfunction.
between 35°C and 100°C. 3. Correct amount of mass air flow. 3. Air intake is obstructed.
3. Barometric pressure is between 4. Air intake is leaking.
850hpa and 1100hpa. 5. MAF sensor malfunction.
4. Small amount of mass air flow. 6. ECM malfunction.
(Desired mass air flow - mass air
flow is more than 150mg/strk)
4 ON Exhaust Gas Recirculation Circuit EGR EVRV circuit open or short to Fuel injection quantity is reduced EGR EVRV circuit is correct condition. 1. EGR EVRV circuit open or short to 97 -
Short to Ground or Open Circuit ground circuit. and EGR EVRV 10% conditions ground circuit.
as substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation Flow Insuf- 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1500rpm 1. EGR valve is stuck at close posi- 88/97 -
ficient Detected between 15°C and 100°C. reduced. and 3200rpm. tion.
2. Engine coolant temperature is 2. Injection quantity is below 40mg/stk. 2. EGR valve operating vacuum hose
between 35°C and 100°C. 3. Correct amount of mass air flow. is clogged or disconnected.
3. Barometric pressure is between 3. EGR EVRV malfunction.
850hpa and 1100hpa. 4. MAF sensor signal circuit short to
4. Large mount of mass air flow. voltage circuit.
(Desired mass air flow - mass air 5. MAF sensor malfunction.
flow is below 150 mg/strk) 6. ECM malfunction.
8 ON Exhaust Gas Recirculation Circuit EGR EVRV circuit short to voltage Fuel injection quantity is reduced EGR EVRV circuit is correct condition. 1. EGR EVRV circuit short to voltage 97 -
Short to Battery circuit. & EGR EVRV 10% conditions as circuit.
substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
24 P0500 1 ON at Vehicle Speed Sensor Circuit High Vehicle speed is more than ECM uses vehicle speed 5km/h Vehicle speed is below 200km/h. 1. VSS signal circuit open, short to 68 -
next Input 200km/h. condition as substitute. ground or short to voltage circuit.
igni- 2. VSS malfunction.
tion 3. Speed meter malfunction.
cycle 4. TCM malfunction (A/T 2WD).
5. ECM malfunction.
A ON at Vehicle Speed Sensor Input Signal Input signal frequency is too high. ECM uses vehicle speed 5km/h Correct vehicle speed signal frequency. 1. VSS malfunction. 68 -
next Frequency Too High condition as substitute. 2. Speed meter malfunction.
igni- 3. Electrical interference.
tion 4. Magnetic interference.
cycle 5. ECM malfunction.
B ON at Vehicle Speed Sensor Incorrect Sig- 1. Engine speed is more than Fuel injection quantity is Vehicle speed is more than 1.5km/h. 1. VSS open circuit, short to ground 68 -
next nal 3600rpm. reduced. or short to voltage.
igni- 2. Fuel injection quantity is more 2. Poor connector connection.
tion than 41mg/stk. 3. VSS malfunction.
cycle 3. Vehicle speed is below 1.5km/h. 4. Speed meter malfunction.
5. ECM malfunction.
Related Related
Flash Symptom
Code Code
No. DTC
35 P0560 1 OFF System Voltage Too High System voltage is more than 20V. ECM uses 9V conditions as sub- System voltage is below 20V. 1. Charge system malfunction. 3/39 -
stitute. 2. Battery jump start cable miscon-
nect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 7V. 1. Battery power feed harness open 3/39 -
circuit or short to ground circuit.
2. ECM ground harness open or poor
connection.
6. ECM malfunction.
A OFF System Voltage Malfunction (PSG) System voltage of PSG (pump PSG uses default voltage as sub- System voltage of PSG is between 4.5V 1. Battery power feed harness open - -
control unit) is below 4.5V or more stitute. and 27V. circuit or short to ground circuit.
than 27V. 2. PSG (pump control unit) ground
harness open or poor connection.
6. Battery jump start cable miscon-
nect.
tion.
18 P0561 A OFF Ignition Switch Circuit Malfunction The ECM recognized ignition ECM stops engine. No recovery until condition match in the 1. Ignition switch circuit open or short 39 -
switch turn off signal during ECM next ignition key cycle. to ground circuit.
is activated. 2. Poor connector connection.
4. ECM malfunction.
B ON Ignition Switch Circuit Malfunction Ignition switch circuit is malfunc- 1. Ignition switch circuit open or short 39 -
tion. to ground circuit.
4. ECM malfunction.
- P0602 - ECU Programming Error ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed. - -
28 P0606 A ON ECU Malfunction Gate Array communication error. 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction. - -
valve) is operated.
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below 1%. MAB (fuel cutoff solenoid valve) Desired injection quantity is below 0mg/ 1. ECM malfunction. - -
2. Desired injection quantity is is operated. strk. 2. PSG (pump control unit) malfunc-
more than 0mg/strk. tion.
2000rpm.
Related Related
Flash Symptom
Code Code
No. DTC
46 P0645 4 ON A/C Compressor Relay Circuit Voltage A/C compressor relay circuit open No fail-safe function. A/C compressor relay circuit is correct 1. A/C compressor relay circuit open 41 -
Low or short to ground circuit. condition. or short to ground circuit.
3. A/C compressor relay malfunction.
4. ECM malfunction.
8 ON A/C Compressor Relay Circuit Voltage A/C compressor relay circuit short ECM malfunction. - -
High to voltage circuit.
25 P0703 A ON Brake Switch Malfunction 1. Throttle position is more than No fail-safe function. Brake switch 1 signal and brake switch 2 1. Brake switch 1 circuit open, short to 30 -
0%. signal are correctly inputted to the ECM. ground or short to voltage circuit.
665rpm. 3. Brake switch 1 malfunction.
0km/h.
4. Brake switch 1 signal and brake
switch 2 signal are differently
inputted to the ECM since the igni-
tion switch was turned on.
B ON Brake Switch Malfunction 1. Throttle position is more than 1. Brake switch 2 circuit open or short 65 -
0%. to ground circuit.
665rpm. 3. Brake switch 2 malfunction.
0km/h.
4. Brake switch 1 signal and brake
switch 2 signal are differently
inputted to the ECM.
57 P0704 6 ON Clutch Switch Input Circuit Malfunc- Clutch signal does not change No fail-safe function. Clutch signal correctly changes. 1. Clutch switch circuit open, short to 31 -
tion between vehicle speed 1.5km/h ground or short to voltage circuit.
and 80km/h since ignition switch 2. Poor connector connection.
was tuned on. 3. Clutch switch malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Circuit Barometric pressure sensor output ECM uses 1013hpa condition as Barometric pressure sensor output volt- ECM malfunction. - -
High Input voltage is more than 4.4V. substitute. age is below 4.4V.
2 ON Barometric Pressure Sensor Circuit Barometric pressure sensor output Barometric pressure sensor output volt- ECM malfunction. - -
Low Input voltage is below 1.5V. age is more than 1.5V.
Related Related
Flash Symptom
Code Code
No. DTC
21 P1120 1 ON Pedal/Throttle Position Sensor Circuit Throttle position sensor output ECM increases idle speed up to Throttle position sensor output voltage is 1. Sensor power supply circuit short 38/ 49/ 57 -
High Input voltage is more than 4.5V. 1400rpm. below 4.5V. to voltage circuit.
2. Sensor signal circuit short to volt-
age circuit.
3. Sensor ground circuit open or short
to voltage circuit.
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Sensor Volt- Throttle position sensor power Throttle position sensor power supply 1. Sensor power supply circuit short 57 -
age Supply Circuit High Input supply voltage is more than 5.2V. voltage is below 5.2V. to battery voltage circuit.
2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Sensor Volt- Throttle position sensor power Throttle position sensor power supply 1. Sensor power supply circuit short 57 -
age Supply Circuit Low Input supply voltage is below 4.6V. voltage is more than 4.6V. to ground circuit.
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position Sensor Brake 1. Engine speed is more than Throttle position is more than 20% or 1. Throttle sticking. 30/ 38/ 65 -
Switch Error 1700rpm. brake pedal is released (switch is inac- 2. TPS incorrect adjusting.
2. Vehicle speed is more than tive). 3. TPS malfunction.
1.5km/h. 4. Brake switch malfunction.
3. When brake pedal is depressed 5. ECM malfunction.
during accelerator pedal is
depressing.
E ON Pedal/Throttle Position Sensor Idle 1. When idle switch is turned off, 1. When throttle position sensor is 1. TPS malfunction. 38/ 69 -
Position Switch Error throttle position sensor was below 100%, idle switch turns off. 4. Idle switch malfunction.
0.35%. 2. When throttle position sensor is 0%, 5. ECM malfunction.
or idle switch turns on.
2. When idle switch is tuned on,
throttle position sensor was more
than 7.8%.
22 P1173 3 OFF Fuel Reduction Caused By High Cool- Excessive high engine coolant No fail-safe function. Engine coolant temperature is normal 1. Engine overheat. 89 -
ant Temperature temperature is detected. range. 2. ECT sensor malfunction.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By High Fuel Fuel temperature is more than PSG (pump control unit) controls Fuel temperature is below 100°C. 1. ECM malfunction. - -
Temperature 100°C. fuel injection quantity based on 2. PSG (pump control unit) malfunc-
engine speed and fuel tempera- tion.
ture.
Related Related
Flash Symptom
Code Code
No. DTC
43 P1335 A ON Engine Speed Output Circuit Malfunc- The PSG (pump control unit) is Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness open circuit, 90/91/98/ P0335(B)/
tion recognized defective engine speed reduced. short to ground or short to voltage. 101 P0335(D)
signal form the ECM. 2. CKP sensor output harness open
circuit, short to ground or short to volt-
age.
9. ECM malfunction.
tion.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) is No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed sensor mal- - -
recognized incorrect camshaft function.
speed signal. 2. Pulse sensing gap incorrect.
5. ECM malfunction.
tion.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is inputted No fail-safe function. Correct neutral switch signal is inputted 1. Neutral switch circuit short to volt- 87 -
“On” three times consecutively two times consecutively under driving age circuit.
under driving conditions. conditions. 2. Neutral switch malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is inputted 1. Neutral switch circuit open, short to 87 -
“Off” three times consecutively ground circuit.
under driving conditions. 2. Poor connector connection.
3. Neutral switch malfunction.
4. ECM malfunction.
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM is No fail-safe function. No recovery. ECM malfunction. - -
destroyed.
D ON EEPROM Defect Write and read from the EEPROM ECM uses default values from Write and read from the EEPROM are ECM malfunction. - -
are failed during initialization of the the EPROM. correct during initialization of the ECM.
ECM.
E ON EEPROM Defect EEPROM checksum does not EEPROM checksum match with the ECM malfunction. - -
match with the read check sum read check sum during initialization of
during initialization of the ECM. the ECM.
56 P1610 A - Security Key and Security Code not Immobiliser functions are not pro- 1. Engine does not start. No recovery. ECM malfunction. - B****
Programmed grammed in the ECM. 2. Check engine lamp flash.
56 P1611 A - Wrong Security Code Entered Received security code is not cor- 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
rect. 2. Check engine lamp flash. 2. Immobiliser control unit malfunc-
tion.
Related Related
Flash Symptom
Code Code
No. DTC
56 P1612 A - Immobiliser No or Wrong Signal Received challenge signal is not 1. Engine does not start. No recovery. 1. ECM and immobiliser control unit 27/35 B****
correct or not received. 2. Check engine lamp flash. communication circuit open circuit,
short to ground circuit or short to volt-
age circuit.
2. ECM malfunction.
3. Immobiliser control unit malfunc-
tion.
56 P1613 A - Immobiliser No or Wrong Signal Received response signal is not 1. Engine does not start. No recovery. 1. ECM and immobiliser control unit 27/35 B****
correct or not received. 2. Check engine lamp flash. communication circuit open circuit,
short to ground circuit or short to volt-
age circuit.
2. ECM malfunction.
3. Immobiliser control unit malfunc-
tion.
56 P1614 A - Wrong Transponder Key Received response signal is not 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
correct from the transponder key. 2. Check engine lamp flash. 2. Immobiliser control unit malfunc-
tion.
76 P1625 A OFF ECM Main Relay Switched Off Too When ignition switch was turned No fail-safe function. No recovery. ECM malfunction. 3/58 -
Early off, timing of the ECM main relay
turning off is too early.
B OFF ECM Main Relay Switched Off Too When ignition switch was turned No recovery. 1. ECM main relay malfunction. 3/58 -
Late off, timing of the ECM main relay 2. ECM malfunction.
turning off is too late or does not
off.
51 P1630 A ON Fuel Injection Quantity Circuit Mal- The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) detects PSG (pump control unit) malfunction. - -
function detects high pressure solenoid reduced. correct high pressure solenoid valve
valve control circuit malfunction control circuit.
due to high current.
B ON Fuel Injection Quantity Circuit Mal- The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit) malfunction. - -
function detects high pressure solenoid valve) is operated.
valve control circuit malfunction 2. Desired injection quantity
due to continuous current. becomes 0mg/strk.
44 P1650 A ON CAN Device Offline CAN controller detects Bus-off or MAB (fuel cutoff solenoid valve) CAN controller detects correct Bus sig- 1. CAN high circuit open, short to 99/100 P1651(B)
canceling. is operated. nal. ground or short to voltage circuit.
2. CAN low circuit open, short to
5. ECM malfunction.
tion.
B ON CAN Device Hang-up CAN controller does not react CAN controller reacts correctly under 1. ECM malfunction. - -
under engine running. engine running. 2. PSG (pump control unit) malfunc-
tion.
Related Related
Flash Symptom
Code Code
No. DTC
45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit) does 1. MAB (fuel cutoff solenoid The PSG (pump control unit) recognizes 1. ECM malfunction. - -
not recognize CAN signal from the valve) is operated. CAN signal from the CAN controller. 2. PSG (pump control unit) malfunc-
CAN controller. 2. Desired injection quantity tion.
becomes 0mg/strk.
B ON CAN Receives Error The ECM does not read CAN sig- The ECM reads CAN signal from the 1. CAN high circuit open, short to 99/100 P1650(A)
nal from the PSG (pump control PSG (pump control unit). ground or short to voltage circuit.
unit). 2. CAN low circuit open, short to
5. ECM malfunction.
tion.
77 P1690 4 OFF Check Engine Lamp (MIL) Circuit Volt- Check engine lamp circuit open or No fail-safe function. Check engine lamp circuit is correct con- 1. Check engine lamp circuit open or 42 B****
age Low short to ground circuit. dition. short to ground circuit.
2. Check engine lamp malfunction.
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Circuit Volt- Check engine lamp circuit short to ECM malfunction. - -
age High voltage circuit.

CIRCUIT HIGH INPUT

CIRCUIT LOW INPUT

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW
INPUT

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Code Code
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 1784mg/strk.

The mass air flow (MAF) sensor is part of the intake air An intermittent may be caused by the following:
system. It is fitted between the air cleaner and • Poor connections.
turbocharger and measure the mass air flowing into the
engine.
The mass air flow (MAF) sensor element measures the • Rubbed through wire insulation.
partial air mass through a measurement duct on the • Broken wire inside the insulation.
sensor housing. Check for the following conditions:
The ECM monitors the MAF sensor supply voltage and • Poor connection at ECM-Inspect harness connectors
MAF sensor output voltage. The supply voltage is out of for backed out terminals, improper mating, broken
range, DTC P0100 (Symptom Code 7) or P0100 locks, improperly formed or damaged terminals, and
(Symptom Code 9) will be stored. The output voltage poor terminal to wire connection.
excessively high or low, DTC P0100 (Symptom Code B)
or P0100 (Symptom Code C) will be stored.
the “Mass Air Flow” display on the Tech2 while
sensor.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
(OBD) System

C-57(B) 92 C-116
2 3 4
5

supply circuit.
circuit.
C-116
4
Less than 1V:

Go to Step 7
More than
V
sensor.
C-57(B) C-116
4

supply circuit.
ECM connector.
3. Check the circuit for short to MAF sensor heater
circuit.
C-116
2 4

9 Repair the circuit for short to MAF sensor heater
circuit.
ECM and MAF sensor.
C-57(B) C-116
4
and recheck.
release?
14 Replace the ECM.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
(OBD) System
C-57(B) 92 C-116
2 3 4
5

supply circuit.
C-116
4
V Approximately

supply circuit.
ECM connector.
3. Check the circuit for short to MAF sensor ground
circuit.
C-116
3 4

8 Repair the circuit for short to MAF sensor ground.
and MAF sensor.
C-57(B) C-116
4
and recheck.
release?
13 Replace the ECM.
Mass Air Flow (MAF) Sensor Output Circuit Low Input
(OBD) System
C-57(B) 92 C-116
2 3 4
5


circuit.
C-116
88

ECM connector.
C-57(B) C-116
88 5
Repair faulty
harness and
supply circuit.
C-116
4
V Approximately

sensor.
C-57(B) C-116
4
9 Using the DVM and check the MAF sensor heater
circuit.
C-116
2
V Battery
and MAF sensor.
and recheck.
release?
14 Replace the ECM.
Mass Air Flow (MAF) Sensor Output Circuit High Input
(OBD) System
C-57(B) 92 C-116
2 3 4
5


circuit.
C-116
92

2. Disconnect the MAF sensor connector and ECM
connector.
C-57 C-116
3 Repair faulty
92 harness and
circuit.
2. Disconnect the MAF sensor connector .
C-116
3
Repair faulty
V harness and

circuit.
C-116
5
Repair faulty
V harness and
and recheck.
release?
12 Replace the ECM.

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Code Code
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0°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.
Circuit Description the resistance value. And it changes voltage. In other

The IAT sensor is a thermistor. A temperature changes temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor • Rubbed through wire insulation.
through resisters in the ECM and measures the voltage. • Broken wire inside the insulation.
The signal voltage will be high when the air temperature Check for the following conditions:
• Poor connection at ECM-Inspect harness connectors
The output voltage excessively high or low, DTC P0110
stored.
An intermittent may be caused by the following: the “Intake Air Temperature” display on the Tech2
• Poor connections. while moving connectors and wiring harness related
• Misrouted harness. to the sensor.
Intake Air Temperature (IAT) Sensor Circuit High Input
(OBD) System
C-57(B) C-116
92



-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
IAT Sensor
5 4 3 2 1
Standard
3 1
circuit.
C-116
Less than 1V:

Go to Step 8
1
More than
V Approximately specified value:
sensor.
C-57(B) C-116
84 1

and IAT sensor.
C-57(B) C-116
84 1
circuit.
C-116
3
Repair faulty
V harness and

circuit.
C-116
92

ECM connector.
C-57(B) C-116
3 Repair faulty
92
harness and
and recheck.
release?
15 Replace the ECM.
Intake Air Temperature (IAT) Sensor Circuit Low Input
(OBD) System
C-57(B) C-116
92

check.


-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
IAT Sensor
5 4 3 2 1
Standard
3 1

circuit.
ground circuit.
84 92

ECM connector.
ground circuit.
C-57(B)
92
84
Repair faulty
harness and
and recheck.
release?
11 Replace the ECM.

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
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°C condition for
injection timing control.
2 ON Engine Coolant Temperature ECT sensor output voltage is
(ECT) Sensor Circuit Low below 0.3V. 3. ECM uses -15°C condition
Input for glow time control.
Circuit Description the coolant stream. Low coolant temperature produces

a high resistance.
The ECT sensor is a thermistor. A temperature changes The ECM supplies 5 volts signal to the ECT sensor
the resistance value. And it changes voltage. In other through resisters in the ECM and measures the voltage.
words it measures a temperature value. It is installed on The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine • Broken wire inside the insulation.
temperature is hot. Check for the following conditions:
The output voltage excessively high or low, DTC P0115 • Poor connection at ECM-Inspect harness connectors
(Symptom Code 1) or P0115 (Symptom Code 2) will be for backed out terminals, improper mating, broken
stored. locks, improperly formed or damaged terminals, and
An intermittent may be caused by the following: damage. If the harness appears to be OK, observe
• Poor connections. the “Coolant Temperature” display on the Tech2 while
• Misrouted harness. sensor.
Engine Coolant Temperature Sensor Circuit High Input
(OBD) System
C-57(B) E-41
93 1 2



-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
circuit.
E-41
Less than 1V:

1 Go to Step 8
More than
V
sensor.
C-57(B) E-41
89 1

and ECT sensor.
C-57(B) E-41

circuit.
E-41
2
Repair faulty
V harness and
circuit.
E-41
93

2. Disconnect the ECT sensor connector ECM
connector.
C-57 E-41
Repair faulty
2 harness and

recheck.
release?
15 Replace the ECM.
Engine Coolant Temperature Sensor Circuit Low Input
(OBD) System
C-57(B) E-41
93 1 2



-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard

circuit.
ground circuit.
89 93

2. Disconnect the ECT sensor connector and ECM
connector.
ground circuit.
C-57(B)
93
89
Repair faulty
harness and
recheck.
release?
11 Replace the ECM.

(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
15 P0180 B ON Fuel Temperature Sensor Cir- FT sensor output is high tem- The ECM use 75°C conditions
cuit Range/Performance perature (more than 150°C) as substitute.
or low temperature (below -
40°C).

The fuel temperature sensor is assembled inside of the • Rubbed through wire insulation.
pump control unit (PSG). The signal of fuel temperature • Broken wire inside the insulation.
is sent via the CAN-bus from the PSG to ECM. Check for the following conditions:
If the fuel temperature is excessively high or low • Poor connection at ECM and PSG-Inspect harness
condition, DTC P0180 will be stored. connectors for backed out terminals, improper
Diagnostic Aids terminals, and poor terminal to wire connection.
An intermittent may be caused by the following: • Damaged harness-Inspect the wiring harness for
the “Fuel Temperature” display on the Tech2 while
sensor.
Temperature Sensor Circuit Range/Performance
(OBD) System
release?
6 Replace the ECM.


(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE

Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
52 P0215 A ON at Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
next Malfunction 2. Engine speed is below valve) is operated.
igni- 1500rpm. 2. Desired injection quantity
tion 3. Vehicle speed is below becomes 0mg/strk.
cycle 1.5km/h.
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.
Circuit High Input MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line cir-
cuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated.
1500rpm. 2. Desired injection quantity
3. Vehicle speed is below becomes 0mg/strk.
1.5km/h.
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.
Malfunction 2. CAN controller does not
operate Bus-off.

When the ignition switch is turned “Off”, the fuel An intermittent may be caused by the following:
solenoid valve (MAB) signal is supplied from the ECM to • Poor connections.
the PSG. This signal is the command for the PSG to
turn “Off” the engine.
If the MAB signal circuit is short to voltage circuit or • Rubbed through wire insulation.
short to ground circuit, DTC P0215 (Symptom Code B) • Broken wire inside the insulation.
or P0215 (Symptom Code C) will be stored. Check for the following conditions:
(OBD) System

Cutoff Solenoid Valve Circuit High Input
(OBD) System
105 C-57 E-6

5


105

C-57
105
V
Less than 1V Go to Step 8 Go to Step 7
C-57 E-6
5
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
(OBD) System
105 C-57 E-6

5


connector.
circuit.
E-6
105

connector.
circuit.
C-57 E-6
105
5
Repair faulty
harness and
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
(OBD) System
release?
6 Replace the ECM.

(TIMER DEVIATION)

(TIMER FLUCTUATION)
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
54 P0216 A ON Injection Timing Control Cir- 1. Engine speed is more than Fuel injection quantity is
cuit Malfunction (Timer Devia- 700rpm. reduced.
tion) 2. Fuel injection quantity is
more than 4mg/stk.
3. Deviation of actual injection
timing and desired injec-
+3°CA or -6°CA for 8 sec-
onds.
B ON Injection Timing Control Cir- 1. Engine speed is more than
cuit Malfunction (Timer Fluc- 2014rpm.
tuation) 2. Fluctuation of actual injec-
±5.2°CA.
injection timing using the various sensors (crankshaft • Poor connections.
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing • Rubbed through wire insulation.
decision. • Broken wire inside the insulation.
The TCV performs as a variable throttle, using the rapid • Insufficient air bleeding of fuel line.
opening and closing cycle of the valve needle in the Check for the following conditions:
TCV.
• Insufficient air bleeding of fuel line inside, clogged
The TCV is assembled in the injection pump. The signal
fuel filter or pinched fuel pipe/hose may cause the
of desired injection timing and actual injection timing are
DTC store or improper engine performance.
exchanged via the CAN-bus between the PSG and
ECM. • Poor connection at ECM and PSG-Inspect harness
If the timer position is out of tolerance (deviation or connectors for backed out terminals, improper
fluctuation), DTC P0216 will be stored. mating, broken locks, improperly formed or damaged
the “Actual Injection Start” display on the Tech2 while
sensor.
Injection Timing Control Circuit Malfunction (Timer Deviation)
(OBD) System
Injection Timing Control Circuit Malfunction (Timer Fluctuation)
(OBD) System
4 Perform the air bleeding in the fuel line sufficiently.
1. Using the Tech 2, ignition “On” and engine “Off”.
Was the DTC P0216 (Symptom Code B) restored in
this ignition cycle? — Go to Step 5 Verify repair
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify







Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed 1. MAB (fuel cutoff solenoid
sensor error. valve) is operated.
2. High pressure solenoid 2. Desired injection quantity
valve control pulse width becomes 0mg/strk.
does not match with
desired fuel injection quan-
tity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed
sensor error.
2. No CKP sensor error.
3. Difference of engine speed
and doubled pump cam-
shaft speed is more than
690rpm.
9 ON Injection Pump Malfunction No pump map programmed in
the PSG (pump control unit)
or PSG malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is
malfunction in the PSG (pump reduced.
control unit).
B ON Injection Pump Malfunction PSG (pump control unit) rec- No fail-safe function.
ognized high pressure sole-
D ON Injection Pump Malfunction PSG (pump control unit) could
not measure the high pres-
sure solenoid valve drive volt-
age.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid
(pump control unit) message. valve) is operated.
becomes 0mg/strk.

injection timing using the various sensors. And the PSG • Poor connections.
programmed pump map data.
The signal of desired injection quantity and actual injec-
tion quantify are exchanged via the CAN-bus between • Broken wire inside the insulation.
the PSG and ECM.
If the relation of engine speed signal and doubled pump • Poor connection at ECM and PSG-Inspect harness
camshaft speed signal excessively large, DTC P0251 connectors for backed out terminals, improper
(Symptom Code 7) will be stored. mating, broken locks, improperly formed or damaged
If the CAN high or low circuit is defected, DTC P0251 terminals, and poor terminal to wire connection.
(Symptom Code E) will be stored. • Damaged harness-Inspect the wiring harness for
the “Injection Quantity” display on the Tech2 while
sensor.
(OBD) System

(OBD) System
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
C-57(B) 91 E-6


wave form?
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Scale: 5.0V/div 2.0ms/div
Fixed at High:

circuit.
connector.
circuit.
E-6
91

connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

release?
12 Replace the ECM.
(OBD) System
(OBD) System
(OBD) System
(OBD) System
(OBD) System
Was the DTC P0251 (Symptom Code E) stored in this Refer to
4 Was the DTC P1650 (Symptom Code A) or P1651 Go to DTC
(Symptom Code B) stored at the same time? Chart P1650
(Symptom
release?
7 Replace the ECM.

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION

(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more than When pump camshaft speed
Circuit Malfunction 665rpm. sensor is OK:
2. CKP sensor pulse width ECM uses doubled pump cam-
error. shaft speed as substitute
engine speed.
When pump camshaft speed
sensor is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
D ON Crankshaft Position Sensor 1. No pump camshaft speed When pump camshaft speed
Circuit Malfunction sensor error. sensor is OK:
2. “Crankshaft Position Sen- ECM uses doubled pump cam-
sor Circuit Malfunction shaft speed as substitute
(Symptom Code B)” is not engine speed.
stored. Other than pump camshaft
3. Engine speed is 0rpm. speed sensor is OK:
4. Doubled pump camshaft Fuel injection quantity is
speed is more than 50rpm. reduced.
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.
becomes 0mg/strk.
shaft speed as substitute
engine speed.

If the CKP sensor harness or sensor malfunction is Check for the following conditions:
detected during engine run, DTC P0335 (Symptom • Poor connection at ECM-Inspect harness connectors
Code B) is stored. for backed out terminals, improper mating, broken
If the CKP sensor harness or sensor malfunction is locks, improperly formed or damaged terminals, and
detected during engine cranking, DTC P0335 poor terminal to wire connection.
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
is stored.
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
(OBD) System

Is the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored in this ignition cycle? — Go to Step 4 4
C-57(B) 101 E-9
1 2 3
98
90

90 98

C-57(B) 98
Approximately
90 0.9kΩ at 20°C Go to Step 10 Go to Step 7

E-9
1
2 Approximately
0.9kΩ at 20°C Go to Step 8 Go to Step 14
90 98 101
E-9
90 98 101
1 2

98
C-57(B) E-9
1 2
101 Repair faulty
90 harness and

E-9
1
2
V V
and ECM.


form?
0V→

and visually check.

release?
17 Replace the ECM.
Engine Speed Input Circuit Range/Performance
(OBD) System
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
C-57(B) 101 E-9

1 2 3
98
90


and ECM.


form?
0V→

and visually check.
release?

13 Replace the ECM.

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
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.

The voltage on the coil of the relay glow plug is supplied An intermittent may be caused by the following:
by the relay engine control module (ECM) main. The • Poor connections.
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but • Rubbed through wire insulation.
the glow plugs remain active for a certain period • Broken wire inside the insulation.
depending on engine coolant temperature. Check for the following conditions:
• Poor connection at ECM-Inspect harness connectors • Damaged harness-Inspect the wiring harness for
for backed out terminals, improper mating, broken damage. If the harness appears to be OK, observe
locks, improperly formed or damaged terminals, and the DTC P0380 display on the Tech2 while moving
poor terminal to wire connection. connectors and wiring harnesses. A change in the
Glow Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the glow relay or
C-57 X-5 3
1
2
4

5 Using the DVM and check the glow relay.
Glow Relay
3 2
Replace glow
relay and verify

6 Using the DVM and check the glow relay power supply
circuit.
circuit.
X-5
V
Battery
ECM main relay and glow relay.
8 Using the DVM and check the glow relay ground
circuit.
circuit.
X-5
3
94

circuit.
C-57 X-5
3
94
Repair faulty
harness and

release?
10 Replace the ECM.
Glow Relay Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function.
cuit.
8 ON Glow Plug Indicator Circuit Glow plug indicator 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
• Rubbed through wire insulation. poor terminal to wire connection.
• Poor connection at ECM-Inspect harness connectors the DTC P0381 display on the Tech2 while moving
Glow Plug Indicator Circuit Voltage Low
(OBD) System
6 Check the glow plug indicator lamp bulb.

C-56 43
6 B-24

8 Using the DVM and check the glow time telltale circuit.
circuit.
B-24
43

circuit.
C-56
43
6 B-24
Repair faulty
harness and

release?
10 Replace the ECM.
Glow Plug Indicator Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

GROUND OR OPEN CIRCUIT

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED

BATTERY
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Code Code
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Excessive Detected between 15°C and 100°C. reduced.
100°C.
between 850hpa and
1100hpa.
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
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV 10%
Open Circuit conditions as substitute.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Insufficient Detected between 15°C and 100°C. reduced.
100°C.
between 850hpa and
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
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10%
conditions as substitute.

The amount of EGR is controlled by EVRV (electrical An intermittent may be caused by the following:
vacuum regulating valve) via the engine control module • Poor connections.
temperature. • Rubbed through wire insulation.
The EVRV is shaped to control vacuum applied to the • Broken wire inside the insulation.
diaphragm chamber of the EGR valve based on duty • EGR valve sticking.
• Faulty intake air duct connection.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored. • Poor connection at ECM-Inspect harness connectors
If the EGR EVRV circuit is open or short ground circuit, for backed out terminals, improper mating, broken
DTC P0400 (Symptom Code 4) is stored. locks, improperly formed or damaged terminals, and
If the EGR EVRV circuit is short to voltage circuit, DTC poor terminal to wire connection.
P0400 (Symptom Code 8) is stored. • Damaged harness-Inspect the wiring harness for
Exhaust Gas Recirculation Flow Excessive Detected
(OBD) System

• Objects blocking the MAF sensor.
• Objects blocking the turbocharger.
check.
and recheck.
coil.
EGR EVRV
2 1
2 1
Approximately

window.
deposit.
Small Window
Verify repair or
stuck or damaged.
release?
15 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
(OBD) System
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV power
supply circuit.
C-115
V
Battery
and EGR EVRV.
circuit.
C-115
2
97

circuit.
C-57 C-115
97
Repair faulty
harness and

release?
12 Replace the ECM.
Exhaust Gas Recirculation Flow Insufficient Detected
(OBD) System
4 Visually check the EGR control vacuum hose.
If the hose is clogged or disconnected, repair as
necessary.
coil.
EGR EVRV
2 1
2 1
Approximately

window.
deposit.
Small Window
Verify repair or
stuck or damaged.
C-57(B) 92 C-116
2 3 4
5


circuit.
C-116
5
Repair faulty
V
harness and
and recheck.
release?
17 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Battery
(OBD) System
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

2. Remove the EGR EVRV connector and ECM
connector.
3. 3. Check the circuit for short to voltage circuit.
C-115
1 2

release?
11 Replace the ECM.

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY
TOO HIGH

(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed 5km/
at High Input 200km/h. h condition as substitute.
next
igni-
tion
cycle
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed 5km/
at Signal Frequency Too High high. h condition as substitute.
next
igni-
tion
cycle
B ON Vehicle Speed Sensor Incor- 1. Engine speed is more than Fuel injection quantity is
at rect Signal 3600rpm. reduced.
next 2. Fuel injection quantity is
igni- more than 41mg/stk.
tion 3. Vehicle speed is below
cycle 1.5km/h.

The VSS is a magnet rotated by the transmission output • Rubbed through wire insulation.
shaft. The VSS uses a hall element. It interacts with the • Broken wire inside the insulation.
magnetic field treated by the rotating magnet. It outputs Check for the following conditions:
pulse signal. The 12 volts operating supply from the • Poor connection at ECM-Inspect harness connectors
meter fuse. for backed out terminals, improper mating, broken
The engine control module (ECM) calculates the vehicle locks, improperly formed or damaged terminals, and
speed by VSS. poor terminal to wire connection.
An intermittent may be caused by the following: the DTC P0500 display on the Tech2 while moving
Vehicle Speed Sensor Circuit High Input
(OBD) System

check.

2. Measure the VSS output voltage at sensor, TCM
(A/T 2WD), meter and ECM.
(AC Range) Good
V at 20km/h Step 8
TCM C94 connector 10 & Go to
GND (A/T 2WD) Step 9
GND Step 10
GND Step 12
GND Step 13

0V→
Refer to
15 Refer the table
8 Replace the VSS.
9 Replace the TCM.
IMPORTANT: The replacement TCM must be
programmed. “SPS (Service Programming System)
is necessary.” — Verify repair —

B-24
9
Repair faulty
V
harness and
connector.
circuit.
B-24 E-44
connector.
B-24
10
Repair faulty
V
harness and

B-24
68
10

connector.
circuit.
C-56
68
B-24 10
Repair faulty
harness and
release?
16 Replace the ECM.
Vehicle Speed Sensor Input Signal Frequency Too High
(OBD) System
check.

(AC Range) Good
V at 20km/h Step 8
TCM terminal A10 & B5 Go to
(A/T 2WD) Step 9
GND Step 10
GND Step 11
GND Step 10

0V→
Refer to
10 Refer the table
8 Replace the VSS.
9 Replace the TCM.
release?

13 Replace the ECM.
Vehicle Speed Sensor Incorrect Signal
(OBD) System
6 Check for poor/faulty connection at the VSS, TCM (A/
T 2WD) and meter connectors. If a poor/faulty
E-44
1 3
2
B-24 9 10
C-94(10)


7 Check for poor/faulty connection at the ECM and other
C-56

check.
(AC Range) Good
V at 20km/h Step 10
TCM C94 connector 10 & Go to
GND (A/T 2WD) Step 11
GND Step 12
GND Step 14
GND Step 15

0V→
Refer to
17 Refer the table
10 Replace the VSS.

11 Replace the TCM.
B-24
9
Repair faulty
V
harness and
connector.
circuit.
B-24 E-44

connector.
B-24
10
Repair faulty
V harness and
B-24
68
10

connector.
circuit.
C-56
68
B-24 10
Repair faulty
harness and

release?
18 Replace the ECM.

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION (PSG)
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
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
(PSG) (pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
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
or low, DTC P0560 (Symptom Code A) will be stored. • Poor connection at ECM and PSG-Inspect harness
Diagnostic Aids mating, broken locks, improperly formed or damaged
• 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.
System Voltage Too High
(OBD) System
4 Was the battery jump start cable incorrectly Verify
connecting? — procedure Go to Step 5
3. Load the electrical system by turning on the Check the
headlights, etc.. charging
Does the Tech 2 indicate correct ignition voltage? 10 - 14V Go to Step 6 system
release?

7 Replace the ECM.
System Voltage Too Low
(OBD) System
headlights, etc..
or replace the
as necessary.
C-56
3


ECM Main Relay
4 3
Replace ECM
main relay and
the body. If a poor/faulty connection is found, repair as
necessary.
C-109

release?
10 Replace the ECM.
System Voltage Malfunction (PSG)
(OBD) System
4 Check for poor/faulty connection at the PSG (pump
control unit) connector. If a poor/faulty connection is
E-6
6

unit) power supply circuit.
connector.
3. Check the PSG (pump control unit) power supply
circuit.
6 E-6
7 10 - 14V Go to Step 7 Go to Step 6


6 Check for poor/faulty connection of the PSG (pump
control unit) ground at the cylinder body. If a poor/
E-10


(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
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 ON Ignition Switch Circuit Mal- Ignition switch circuit is mal-
function function.
Circuit Description P0561 (Symptom Code B) will be stored.

The ECM monitors the ignition switch signal on the feed
Diagnostic Aids
terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC An intermittent may be caused by the following:
the “Ignition Status” display on the Tech2 while
• Poor connection at ECM-Inspect harness connectors sensor.
Ignition Switch Circuit Malfunction
Ignition Switch Circuit Malfunction
(OBD) System
(Symptom Code B)stored in this ignition cycle? — Go to Step 4 4
4 Check the “Engine fuse (10A)”.

5 Using the DVM and check the ignition power feed
circuit.
disconnected)
circuit.
C-107
39

circuit.
C-56
39
C-107
Repair faulty
harness and
6 Check the ignition switch.
If a poor/faulty connection is found, repair as
necessary.
release?

8 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR

Code Code
- P0602 - - Programming Error ECM memory area error. Engine control disabled.
Circuit Description & Diagnostic Aids ECM does not programmed.

When the service ECM is used without SPS, DTC
The replacement ECM must be programmed by Service P0602 will appear.
Programming System (SPS). Because, the service
Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

(OBD) System


Code Code
28 P0606 A ON ECM Malfunction (1) Gate Array communication 1. MAB (fuel cutoff solenoid
error. valve cutoff) is operated.
becomes 0mg/strk.
B ON ECM Malfunction (2) 1. Throttle position is below MAB (fuel cutoff solenoid valve
1%. cutoff) is operated.
2. Desired injection quantity is
more than 0mg/strk.
2000rpm.
Circuit Description & Diagnostic Aids

P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
(OBD) System
release?

5 Replace the ECM.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function.
cuit.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit

The voltage on the coil of the A/C compressor is An intermittent may be caused by the following:
supplied by the ECM main relay. The ECM switches A/C • Poor connections.
compressor relay to operate A/C compressor depends
on the A/C request signal and certain setting conditions.
for backed out terminals, improper mating, broken the DTC P0645 display on the Tech2 while moving
locks, improperly formed or damaged terminals, and connectors and wiring harnesses.
Compressor Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
C-56 1 X-14
2
3

5 Using the DVM and check the A/C compressor relay.
box.
A/C Compressor Relay
X-14
3 4
Replace A/C
compressor
relay and verify

box.
circuit.
X-14
V
Battery
ECM main relay and A/C compressor relay.

ground circuit.
disconnected)
box.
circuit.
X-14
33

box.
circuit.
C-56 X-14
33 4
Repair faulty
harness and
release?
10 Replace the ECM.
Compressor Relay Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 25) BRAKE SWITCH INCORRECT SIGNAL (1)

(FLASH CODE 25) BRAKE SWITCH INCORRECT SIGNAL (2)
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
25 P0703 A ON Brake Switch Incorrect Signal 1. Throttle position is more No fail-safe function.
(1) than 0%.
665rpm.
0km/h.
ECM since the ignition
switch was turned on.
B ON Brake Switch Incorrect Signal 1. Throttle position is more
(2) than 0%.
665rpm.
0km/h.
ECM.

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
• 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.
(OBD) System

4 Check the “Stop Lamp fuse (15A)”.
C-56 C-44
1 2

pedal.
Brake Switch
4 3 Pedal is not
stepped on:
Continuity
on: No switch and
supply circuit.
brake switch.
C-44
V
Battery

8 Repair the open circuit between the “Stop Lamp fuse
(15A)” and brake switch 1.
circuit.
30

circuit.
C-44
2 Pedal is not Fixed at battery

stepped on: voltage: Go to
Less than 1V Step 10
V
on: Battery than 1V: Go to
voltage Go to Step 12 Step 11
C-56 C-44
30 2
connector and ECM.
C-56 C-44
30 2

release?
13 Replace the ECM.
(OBD) System
C-56 C-44
3 4
pedal.
Brake Switch
4 3
Pedal is not
stepped on:
No continuity Replace pedal
Pedal stepped switch and
on: Continuity Go to Step 6 verify repair

supply circuit.
brake switch.
C-44
V Battery
7 Repair the open circuit between the “ECM fuse (10A)”
and brake switch 2.
connected)
circuit.
65

circuit.
C-44
Pedal is not
voltage Step 9
V

C-56 C-44
65 4
connector and ECM.
C-56 C-44
65 4
release?
12 Replace the ECM.

(FLASH CODE 57) CLUTCH SWITCH CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
57 P0704 6 ON Clutch Switch Circuit Malfunc- Clutch signal does not change No fail-safe function.
tion between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.

The ECM monitors the clutch switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If clutch switch circuit with Check for the following conditions:
malfunction, DTC P0704 (Symptom Code 6) will be • Poor connection at ECM-Inspect harness connectors
stored. for backed out terminals, improper mating, broken
• Poor connections. the “Clutch Switch” display on the Tech2 while moving
• Misrouted harness. connectors and wiring harness related to the sensor.
Clutch Switch Circuit Malfunction
(OBD) System
4 Check for poor/faulty connection at the clutch switch
31 C-56 C-77
1
2

5 Using the DVM and check the clutch switch.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch
Pedal is not
1
stepped on:
2 Continuity
on: No switch and

6 Using the DVM and check the clutch switch power
supply circuit.
2. Remove the clutch switch connector from the
clutch switch.
C-77
V
Battery
and clutch switch.
8 Using the DVM and check the clutch switch circuit.
circuit.
31

2. Back probe the DVM to the clutch switch and
circuit.
C-77
Pedal is not
voltage Step 9
V Pedal stepped Fixed at less

9 Repair the short to voltage circuit between the clutch
switch connector and ECM.
C-56 C-77
2
10 Repair the open circuit between the clutch switch
connector and ECM.
C-56 C-77
2
release?
12 Replace the ECM.

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Code Code
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa condition
Circuit High Input output voltage is more than as substitute.
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor
Circuit Low Input output voltage is below 1.5V.

The ECM monitors the barometric pressure signal at If the DTC P1105 is stored, sensor or circuit of ECM
inside of the ECM. If the sensor with malfunction, DTC inside is failed.
will be stored.
Barometric Pressure Sensor Circuit High Input
Barometric Pressure Sensor Circuit Low Input
(OBD) System
(Symptom Code 2) stored as “Present Failure”? — Go to Step 3 3
(Symptom Code 2) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?

5 Replace the ECM.

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH
INPUT

CIRCUIT HIGH INPUT

CIRCUIT LOW INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH
ERROR

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
21 P1120 1 ON Pedal/Throttle Position Sen- Throttle position sensor out- ECM increases idle speed up
sor Circuit High Input put voltage is more than 4.5V. to 1400rpm.
sor Voltage Supply Circuit supply voltage is more than
High Input 5.2V.
sor Voltage Supply Circuit supply voltage is below 4.6V.
Low Input
D ON Pedal/Throttle Position Sen- 1. Engine speed is more than
sor Brake Switch Error 1700rpm.
1.5km/h.
3. When brake pedal is
depressed during accelera-
tor pedal is depressing.
E ON Pedal/Throttle Position Sen- 1. When idle switch is turned
sor Idle Position Switch Error off, throttle position sensor
was below 0.35%.
or
was more than 7.8%.

The TPS is a potentiometer connected to throttle shaft An intermittent may be caused by the following:
on the throttle body. It is installed to the main TPS and • Poor connections.
idle switch.
on the signal line and calculates throttle position. As the • Rubbed through wire insulation.
throttle valve angle is changed when accelerator pedal • Broken wire inside the insulation.
moved. The TPS signal also changed at a moved Check for the following conditions:
throttle valve. As the throttle valve opens, the output • Poor connection at ECM-Inspect harness connectors
increases so that the output voltage should be high. for backed out terminals, improper mating, broken
The ECM monitors the TPS supply voltage and TPS locks, improperly formed or damaged terminals, and
output voltage. The supply voltage is out of range, DTC poor terminal to wire connection.
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
the “Throttle Position”, “Idle Switch”, “Brake Switch 1”
If the brake pedal is depressed during accelerator pedal
and “Brake Switch 2” display on the Tech2 while
is depressing, DTC P1120 (Symptom Code D) will be
stored.
sensor.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.
Pedal/Throttle Position Sensor Circuit High Input
(OBD) System

as necessary.
49 C-56 39
57
E-22
1 2 3



Terminal
1-2
2-3
TPS
3 2 1
3 2 1
Standard
circuit.
E-22
3
V
Approximately
and TPS.
C-56
57
E-22


E-22
2
Repair faulty
V
harness and
E-22
1
Repair faulty
V
harness and

E-22
49

connector.
C-56
49
E-22
Repair faulty
harness and
13 Replace the TPS.
release?
15 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
(OBD) System
as necessary.
49 C-56 39
57
E-22
1 2 3


circuit.
E-22
3
V Approximately
ECM and TPS.
C-56
57
E-22

9 Replace the TPS.
release?
11 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
(OBD) System
as necessary.
49 C-56 39
57
E-22
1 2 3


circuit.
circuit.
E-22
3
V
Approximately
circuit.
connector.
3. Check the circuit for short to TPS ground circuit.
E-22
1 3

8 Repair the circuit for short to TPS ground circuit.
and TPS.
C-56
57
E-22

11 Replace the TPS.

release?
13 Replace the ECM. Is the action complete?
Pedal/Throttle Position Sensor Brake Switch Error
(OBD) System
Was the DTC P1120 (Symptom Code D) stored in this and Go to Step
• Accelerator pedal sticking.
from 0% to 100% depending on accelerator pedal
operation? — Go to Step 7 Go to Step 6
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.
9 Substitute a known good brake switch and recheck.
10 Replace the brake switch.
12 Replace the TPS.

release?
14 Replace the ECM.
Pedal/Throttle Position Sensor Idle Position Switch Error
(OBD) System
from 0% to 100% depending on accelerator pedal Go to Step 6Go
operation? — Go to Step 7 to Step 6
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
9 Replace the TPS.
release?

11 Replace the ECM.

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE
Code Code
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine cool- No fail-safe function.
High Coolant Temperature ant temperature is detected.
7 OFF Fuel Reduction Caused By Fuel temperature is more than PSG (pump control unit) con-
High Fuel Temperature 100Åé. trols fuel injection quantity
based on engine speed and
fuel temperature.
Circuit Description An intermittent may be caused by the following:

The engine coolant temperature (ECT) sensor is • Poor connections.
installed on the coolant stream. High coolant • Misrouted harness.
temperature produces a low resistance. The ECM • Rubbed through wire insulation.
supplies 5 volts signal to the ECT sensor through • Broken wire inside the insulation.
resisters in the ECM and measures the voltage. The Check for the following conditions:
signal voltage will be low when the engine temperature
is hot.
The fuel temperature sensor is assembled inside of the
pump control unit (PSG). The signal of fuel temperature
is sent via the CAN-bus from the PSG to ECM.
If the engine coolant temperature is excessively high • Damaged harness-Inspect the wiring harness for
condition, DTC P1173 (Symptom Code 3) will be stored. damage. If the harness appears to be OK, observe
If the fuel temperature is excessively high condition, the “Coolant Temperature” or “Fuel Temperature”
DTC P1173 (Symptom Code 7) will be stored. display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Aids
Reduction Caused By High Coolant Temperature
(OBD) System

4 Check the engine overheat condition. Repair the
Was the problem found? cause of
overheat and
2. Monitor the “Coolant Temperature” in the data
display.
Does the Tech 2 indicate correct “Coolant
Temperature” depending on warm up time? — Go to Step 9 Go to Step 6

-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
recheck.
release?

10 Replace the ECM.
Reduction Caused By High Fuel Temperature
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The ECM converts sine wave signal to square wave Check for the following conditions:
signal. And this signal is provided from the ECM to • Poor connection at ECM-Inspect harness connectors
pump control unit (PSG). for backed out terminals, improper mating, broken
• Damaged harness-Inspect the wiring harness for moving connectors and wiring harness related to the
damage. If the harness appears to be OK, observe sensor.
Engine Speed Output Circuit Malfunction
(OBD) System
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
C-57(B) 91 E-6


wave form?
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Scale: 5.0V/div 2.0ms/div Fixed at High:

circuit.
connector.
circuit.
E-6
91

connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

release?
12 Replace the ECM.

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The pump camshaft sensor is a magnet with a coil. It • Broken wire inside the insulation.
uses to combine with the pulser. The pulser is attached Check for the following conditions:
main shaft in the pump. It likes a gear shape. • Poor connection at ECM and PSG-Inspect harness
The pump camshaft sensor is attached to the pump connectors for backed out terminals, improper
control unit (PSG). The signal of pump camshaft speed mating, broken locks, improperly formed or damaged
is sent via the CAN-bus from the PSG to ECM. terminals, and poor terminal to wire connection.
the “Pump Speed” display on the Tech2 while moving
• Poor connections. display will indicate the location of the fault.
Camshaft Speed Malfunction
(OBD) System
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
release?
8 Replace the ECM.

(FLASH CODE 47) NEUTRAL SWITCH ON ERROR

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function.
ted “On” three times consecu-
B ON Neutral Switch OFF Error Neutral switch signal is input-
ted “Off” three times consecu-

The ECM monitors the neutral switch (A/T: N or P An intermittent may be caused by the following:
position switch in inhibitor switch) signal on the feed • Poor connections.
terminal to the ECM. If the neutral switch with
malfunction, DTC P1520 (Symptom Code A) or P1520
(Symptom Code B) will be stored. • Rubbed through wire insulation.
for backed out terminals, improper mating, broken the “Neutral Switch” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harness related to the
poor terminal to wire connection. sensor.
Neutral Switch ON Error
Neutral Switch OFF Error
(OBD) System
(Symptom Code B) stored in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the neutral switch
(inhibitor switch) or ECM connector. If a poor/faulty
C-57
87
M/T
E-11 E-12
A/T
E-51
2 3


switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range N range
switch).
M/T
E-11 E-12
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
switch) power supply circuit.
2. Remove the neutral switch (inhibitor switch)
connector from the switch.
M/T A/T
E-12 E-51
V 3
V
Battery
and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).

switch) circuit.
circuit.
87

2. Back probe the DVM to the neutral switch (inhibitor
switch) and check the circuit for open or short to
voltage circuit.
M/T A/T
E-11 E-51
Neutral (P or
N): Battery Fixed at battery
voltage voltage: Go to
2 8 Other than Step 9
V neutral (P or Fixed at less
V V N): Less than than 1V: Go to
9 Repair the short to voltage circuit between the neutral
switch connector (inhibitor switch connector) and
ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8

10 Repair the open circuit between the neutral switch
connector (inhibitor switch connector) and ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8
release?
12 Replace the ECM.

(FLASH CODE 55) SEED AND KEY FILE DESTROYED


Code Code
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM No fail-safe function.
is destroyed.
D ON EEPROM Defect Write and read from the ECM uses default values from
EEPROM are failed during ini- the EPROM.
tialization of the ECM.
E ON EEPROM Defect EEPROM checksum does not
match with the read check
sum during initialization of the
ECM.
Circuit Description & Diagnostic Aids diagnostics operation.

The ECM used in this vehicle utilizes an electrically P1605 (Symptom Code C), P1605 (Symptom Code D)
erasable & programmable read only memory or P1605 (Symptom Code E) will be stored.
(EEPROM). The EEPROM contains program
information and the calibrations required for engine and
Seed and Key File Destroyed
EEPROM Defect
EEPROM Defect
(OBD) System
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

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E) Refer to
stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
5 Replace the ECM.

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1610 A - Security Key and Security Immobiliser functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.

Code A) is recorded when immobiliser function was not Inspect harness connectors for backed out terminals,
programmed in the ECM. improper mating, broken locks, improperly formed or
connection.
Security Key and Security Code Not Programmed
(OBD) System
Refer to
release?
6 Replace the ECM.

(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

Code A) is recorded when received immobiliser security Inspect harness connectors for backed out terminals,
code was not correct. improper mating, broken locks, improperly formed or
connection.
Wrong Security Code Entered
(OBD) System
Refer to
release?
6 Replace the ECM.

Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1612 A - Immobiliser No or Wrong Sig- Received challenge signal is 1. Engine does not start.

challenge signal was not correct. improper mating, broken locks, improperly formed or
connection.
(OBD) System
Refer to
C-56 42
35
B-68
8

lamp circuit.
B-68
7
Repair faulty
V
harness and

lamp circuit.
circuit.
B-68
42

circuit.
C-56
42
B-68
Repair faulty
harness and

B-68
8
V Repair faulty
harness and
circuit.
B-68
35

circuit.
C-56
B-68 35
Repair faulty
harness and

release?
11 Replace the ECM.

Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1613 A - Immobiliser No or Wrong Sig- Received response signal is 1. Engine does not start.

response signal was not correct. improper mating, broken locks, improperly formed or
connection.
(OBD) System
Refer to
C-56 42
35
B-68
8

lamp circuit.
B-68
7
V Repair faulty
harness and

lamp circuit.
circuit.
B-68
42

circuit.
C-56
42
B-68
Repair faulty
harness and
B-68
8
Repair faulty
V
harness and

circuit.
B-68
35

circuit.
C-56
B-68 35
Repair faulty
harness and
release?
11 Replace the ECM.

(FLASH CODE 56) WRONG TRANSPONDER KEY
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

response signal was not correct from the transponder improper mating, broken locks, improperly formed or
key. damaged terminals, and poor terminal to wire
connection.
Wrong Transponder Key
(OBD) System
Refer to
release?
6 Replace the ECM.
IMPORTANT: The replacement ECM must e

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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
early.
B OFF ECM Main Relay Switched When ignition switch was
Off Too Late turned off, timing of the ECM

The ECM switches ECM main relay to operate ECM and An intermittent may be caused by the following:
other sensors or controller. • Poor connections.
• Poor connection at ECM-Inspect harness connectors the “Main Relay” display on the Tech2 while moving
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early
(OBD) System
release?
5 Replace the ECM.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late
(OBD) System
3. Check the relay switch.
ECM
Main Relay
1
Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
release?
6 Replace the ECM.


Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.
Circuit Description programmed pump map data.

The ECM is calculates an injection quantity and an
injection timing using the various sensors. And the PSG
Diagnostic Aids • Broken wire inside the insulation.
• Poor connections. connectors for backed out terminals, improper
• Misrouted harness. mating, broken locks, improperly formed or damaged
(OBD) System
(symptom Code B) stored as “Present Failure”? — Go to Step 3 3
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

(FLASH CODE 44) CAN DEVICE OFFLINE

(FLASH CODE 44) CAN DEVICE HANG-UP
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
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.

The interchange of data between the engine control An intermittent may be caused by the following:
module (ECM) and the pump control unit (PSG) is • Poor connections.
performed via a CAN-bus system. The individual CAN-
bus systems are connected via two interfaces and can
exchange information and data. This allows control • Rubbed through wire insulation.
modules that are connected to different CAN-bus • Broken wire inside the insulation.
systems to communicate. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness • Damaged harness-Inspect the wiring harness for
connectors for backed out terminals, improper damage. If the harness appears to be OK, observe
mating, broken locks, improperly formed or damaged the DTC P1650 display on the Tech2 while moving
terminals, and poor terminal to wire connection. connectors and wiring harnesses.
Device Offline
(OBD) System
C-57 E-6 2
1
E-6
2
Repair faulty
harness and

connector.
circuit.
E-6
100

connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

connector.
circuit.
E-6
99

connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
connector.
E-6
6
Repair faulty
harness and

release?
17 Replace the ECM.
Device Hang-up
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 45) CAN MALFUNCTION (PSG)

(FLASH CODE 45) CAN RECEIVES ERROR
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
45 P1651 A ON CAN Malfunction (PSG) 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 Receives Error The ECM does not read CAN
signal from the PSG (pump
control unit).
Circuit Description systems to communicate.

The interchange of data between the engine control Diagnostic Aids
module (ECM) and the pump control unit (PSG) is
performed via a CAN-bus system. The individual CAN- An intermittent may be caused by the following:
bus systems are connected via two interfaces and can • Poor connections.
exchange information and data. This allows control
modules that are connected to different CAN-bus
• Poor connection at ECM and PSG-Inspect harness the DTC P1651 display on the Tech2 while moving
connectors for backed out terminals, improper connectors and wiring harnesses.
Malfunction (PSG)
(OBD) System
release?
6 Replace the ECM.
Receives Error
(OBD) System
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
C-57 E-6 2
1
E-6
2
Repair faulty
harness and

connector.
circuit.
E-6
100

connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

connector.
circuit.
E-6
99

connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
connector.
E-6
6
Repair faulty
harness and

release?
18 Replace the ECM.

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
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.

The Check Engine Lamp (Malfunction Indicator Lamp An intermittent may be caused by the following:
=MIL) should always be illuminated and steady with • Poor connections.
ignition “On”. Ignition feed voltage is supplied to the
Check Engine Lamp bulb through the meter fuse. The
ECM turns the Check Engine Lamp “On” by grounding • Rubbed through wire insulation.
the check engine lamp driver circuit for a certain time. • Broken wire inside the insulation.
for backed out terminals, improper mating, broken the “Check Engine Lamp” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harnesses. A change
poor terminal to wire connection. in the display will indicate the location of the fault.
Check Engine Lamp (MIL) Circuit Voltage Low
(OBD) System
C-56 42
17 B-24


circuit.
circuit.
B-24
42
17

circuit.
C-56
42
B-24
Repair faulty
harness and
release?

10 Replace the ECM.
Check Engine Lamp (MIL) Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
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 located
lamp (MIL=malfunction indicator lamp are operating an intermittent condition. Use the following features to
correctly. 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, disconnect
Typical Scan Data Values. the MAF sensor and idle the engine until the check
engine lamp (MIL=malfunction indicator lamp) comes
• Verify the customer complaint and locate the correct
on. Diagnostic Trouble Code P0100 should be stored
symptom in the table of contents. Perform the
and kept in memory when the ignition is turned OFF.
procedure included in the symptom chart.
If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
VISUAL/PHYSICAL CHECK P0100 from memory.
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a An intermittent check engine lamp (MIL=malfunction
problem without further checks and can save valuable indicator lamp) with no stored Diagnostic Trouble Code
time. This check should include the following items: may be caused by the following:
• ECM grounds for cleanliness, tightness and proper • Check engine lamp (MIL=malfunction indicator lamp)
location. wire to ECM short to ground.
• Vacuum hoses for splits, kinks, and proper • Poor ECM grounds. Refer to the ECM wiring
connection. Check thoroughly for any type of leak or diagrams.
restriction.
• Air intake ducts for collapsed or damaged areas. Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
• Air leaks at throttle body mounting area, mass air flow to the ignition control module for poor connections.
(MAF) sensor and intake manifold sealing surfaces. Check for an open diode across the A/C compressor
• Wiring for proper connections, pinches and cuts. clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
INTERMITTENT
If problem has not been found, refer to ECM connector
Important: An intermittent problem may or may not turn
symptom tables.
on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use • Check the “Broadcast Code” of the ECM, and
the Diagnostic Trouble Code (DTC) charts for compare it with the latest Isuzu service bulletins and/
intermittent problems. or Isuzu EEPROM reprogramming equipment to
The fault must be present to locate the problem. determine if an update to the ECM's reprogrammable
Most intermittent problems are cased by faulty electrical memory has been released.
connections or wiring. Perform a careful visual/physical
check for the following conditions. This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
• Poor mating of the connector halves or a terminal not
If the “Broadcast Code” is not the most current available,
fully seated in the connector (backed out).
it is advisable to reprogram the ECM's EEPROM
• Improperly formed or damaged terminal. memory, which may either help identify a hard-to find
• All connector terminals in the problem circuit should problem or may fix the problem.
be carefully checked for proper contact tension. The Service Programming System (SPS) will not allow
• Poor terminal-to-wire connection. This requires incorrect software programming or incorrect calibration
removing the terminal form the connector body to changes.
check.
• Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
• Poor ECM grounds. Refer to the ECM wiring
diagrams.

NOTE: The vehicle with immobiliser system, this system may be activated. Check the immobiliser system diagnosis.

(OBD) System
4 Is the fuel amount enough?
Add fuel to the

— Go to Step 5 tank
6 Check the “ECM” fuse (10A) and “Engine” fuse (15A).
intake system

conditions.
condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
cylinders.
More than 30
Mpa (31.0 kg/
20 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
Repair as
— Go to Step 21 necessary

following:
• Tech 2 data
and/or system
release?
24 Replace the ECM.
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.

(OBD) System
intake system
sensor value.
status depending on the time from ignition switch
“On”?

to the glow plug?
Repair voltage
supply circuit

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

Replace the
20.0 - 21.0 Mpa 34.3 - 35.8 Mpa injection nozzle
(204 - 214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
22 Replace the ECM.

rpm
stall the engine.
X
Rough Idle
Stall
time

(OBD) System
• Engine fully warm.
• Accessories are “OFF”. Desired
2. Using a Tech 2, monitor “Desired Engine Idle Engine Idle
Speed” and “Engine Speed”. Speed ± 25
Is the “Engine Speed” within the specified values? rpm Go to Step 7 Go to Step 6
intake system

display.
sensor value.
conditions.
and recheck.

100%.
20 Replace the TPS.
conditions.

“Run”.
display.
Desired
High
Actual
Low
Time
the small window.
deposit.
Small Window
Vacuum Pump

condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage Replace the

(204 - 214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
38 Replace the ECM.

DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time

(OBD) System
intake system
display.

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?

31 Replace the ECM.

speed. Usually most pronounced when first trying to Stumble
rpm
Sug
Hesitation
time

(OBD) System
as necessary.
intake system

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?
33 Replace the ECM.


increases.
rpm
time

(OBD) System
intake system
compressor
wheel or turbine shaft sticking.

7 1. Using the Tech 2, perform test drive.
2. Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct “Vehicle Speed”
depending on driving speed?
When constant vehicle speed

Correct Speed
High
Unstable Data
Low
Time
8 Check the VSS harness for the following conditions.
10 Replace the VSS assembly.
conditions.
and recheck.

100%.
20 Replace the TPS.
conditions.

“Run”.
display.

Desired
High
Actual
Low
Time
the small window.
deposit.
Small Window

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?
33 Replace the ECM.



(OBD) System
intake system
sensor value.

conditions.
and recheck.
100%.
18 Replace the TPS.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window

condition.
deposit.


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

Replace the
(204 - 214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

32 Replace the ECM.

is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)

(OBD) System
4 Check owner's driving habits.
• Is the A/C “On” full time?
to Engine Cooling.
Sensor in Electrical Diagnosis. — Verify repair —
as necessary.

display.
intake system
sensor value.
conditions.

and recheck.
100%.
26 Replace the TPS.
1st Stage 2nd Stage

Replace the
(204 - 214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

33 Replace the ECM.
EXCESSIVE WHITE SMOKE

(OBD) System
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or exhaust through the
gasket.
sensor value.
conditions.

and recheck.
status depending on the time from engine “Run”?
to the glow plug?
Repair voltage
supply circuit

conditions.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

Replace the
20.0 - 21.0 Mpa 34.3 - 35.8 Mpa
(204 - 214 kg/cm2) (350 - 365 kg/cm2)
injection nozzle
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
32 Replace the ECM.
EXCESSIVE BLACK SMOKE

(OBD) System
intake system
sensor value.

conditions.
and recheck.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

1st Stage 2nd Stage Replace the

(204 - 214 kg/cm2) (350 - 365 kg/cm2) — and verify repair Go to Step 19
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
24 Replace the ECM.
ENGINE CONTROL MODULE tightening torque.

Tightening torque
(ECM)
• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
Location 4. Lay the floor carpet exactly.
Under the left-hand side seat.
5. Put on the seat to the floor panel and tighten with
specified tightening torque.
Removal Procedure
Tightening torque
• Bolts: 40.0 N·m (4.1 kgf·m)
2. Remove the seat left-hand side.
3. Roll up the floor carpet.
4. Remove four bolts from the ECM cover. NOTE: The replacement ECM must be programmed.
5. Disconnect the two connectors from the ECM. 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 “Immobiliser System-ECM replacement” for the
ECM/Immobiliser linking 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
CRANKSHAFT POSITION (CKP) ENGINE COOLANT TEMPERATURE

SENSOR (ECT) SENSOR
Location Location
Installed to the clutch housing. Installed to the thermostat housing.

2. Disconnect connector from the CKP sensor. 2. Drain enough engine coolant so that the coolant
3. Loosen a bolt and remove the CKP sensor from the level will be below the ECT sensor.
clutch housing. 3. Disconnect connector from the ECT sensor.
4. Loosen and remove the ECT sensor from the
thermostat housing.

are carried out.
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
• 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.
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.

MASS AIR FLOW (MAF) & INTAKE THROTTLE POSITION SENSOR (TPS)
AIR TEMPERATURE (IAT) SENSOR Location
Location Installed on the throttle body.
Installed to the intake duct housing.
Removal Procedure
Removal Procedure 1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable. 2. Disconnect the TPS connector.
2. Disconnect a MAF & IAT sensor connector from the 3. Loosen two screws and remove TPS from the
MAF & IAT sensor assembly. throttle body.
3. Loosen the clips and remove the MAF & IAT sensor
assembly from the intake duct housing.
Installation Procedure 2. Connect a TPS connectors to the TPS.
1. Install the MAF & IAT sensor assembly into intake 3. Connect the Tech2 to the vehicle.
air duct. 4. Connect the negative battery cable.
2. Tighten the clips. 5. Select “Data Display” with the Tech2.
3. Connect a MAF & IAT sensor connector to the MAF 6. Check the throttle position data and adjust the TPS
& IAT sensor assembly. position.
4. Connect the negative battery cable. 7. Tighten two screws.
NOTE: Verify any DTCs (diagnosis Trouble Code) are NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement. not stored after replacement.

Regulating Valve)
Location
Back of the air cleaner case.
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.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.

Verify proper connection of two hoses.

TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
4JHED-WE-0321


Issued by
Tokyo, Japan
No.4JHED-WE-0321 PRINTED IN JAPAN
WORKSHOP MANUAL

ENGINE C24SE on TF
SECTION 6E
NOTICE

notice.
Applicable Model : TFR/TFS

ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
C24SE ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATIONS CHARTS ...................... 6E-6 Starting Mode ............................................ 6E-44

ECM CIRCUIT DIAGRAM ......................... 6E-12 Run Mode .................................................. 6E-44
GROUND POINT CHART (1/4) ................. 6E-13 Fuel Metering System Components .......... 6E-45
LOCATION ................................................ 6E-17 Fuel Injector ............................................... 6E-45
CABLE HARNESS & CONNECTOR Fuel Pressure Regulator ............................ 6E-45
LOCATION .............................................. 6E-19 Fuel Rail ..................................................... 6E-45
CONNECTOR LIST ................................... 6E-22 Fuel Pump Electrical Circuit ....................... 6E-45
RELAY AND FUSE .................................... 6E-24 Thottle Body Unit ....................................... 6E-45
RELAY AND FUSE BOX LOCATION ........ 6E-24 GENERAL DESCRIPTION FOR ELECTRIC
RELAY AND FUSE BOX LOCATION ........ 6E-25 IGNITION SYSTEM ................................. 6E-46
FUSE AND RELAY LOCATION ................ 6E-26 Spark Plug ................................................. 6E-46
ECM WIRING DIAGRAM (1/9) .................. 6E-27 GENERAL DESCRIPTION FOR EVAPORATIVE
ECM WIRING DIAGRAM (2/9) .................. 6E-28 EMISSION SYSTEM ............................... 6E-49
ECM WIRING DIAGRAM (3/9) .................. 6E-29 EVAP Emission Control System Purpose .. 6E-49
ECM WIRING DIAGRAM (4/9) .................. 6E-30 EVAP Emission Control System Operation 6E-49
ECM WIRING DIAGRAM (5/9) .................. 6E-31 System Fault Detection .............................. 6E-49
ECM WIRING DIAGRAM (6/9) .................. 6E-32 POSITIVE CRANKCASE VENTILATION (PCV)
ECM WIRING DIAGRAM (7/9) .................. 6E-33 SYSTEM .................................................. 6E-51
ECM WIRING DIAGRAM (8/9) .................. 6E-34 Crankcase Ventilation System Purpose .... 6E-51
ECM WIRING DIAGRAM (9/9) .................. 6E-35 A/C CLUTCH DIAGNOSIS ........................ 6E-52
ECM CONNECTOR PIN ASSIGNMENT & A/C Clutch Circuit Operation ...................... 6E-52
OUTPUT SIGNAL .................................... 6E-36 A/C Clutch Circuit Purpose ........................ 6E-52
GENERAL DESCRIPTION FOR ECM AND A/C Request Signal ................................... 6E-52
SENSORS ............................................... 6E-40 ISUZU STRATEGY BASED DIAGNOSTICS 6E-53
Engine Control Module (ECM) ................... 6E-40 Overview .................................................... 6E-53
Manifold Absolute Pressure (MAP) Sensor 6E-40 STRATEGY BASED DIAGNOSTICS CHART 6E-53
Throttle Position Sensor (TPS) .................. 6E-41 Diagnostic Thought Process ...................... 6E-54
Idle Air Control (IAC) Valve ....................... 6E-41 1. Verify the Complaint .............................. 6E-54
Crankshaft Position (CKP) Sensor ............ 6E-42 2. Perform Preliminary Checks .................. 6E-54
Engine Coolant Temperature (ECT) Sensor 6E-42 3. Check Bulletins and Troubleshooting
Intake Air Temperature (IAT) Sensor ........ 6E-43 Hints ........................................................ 6E-55
Vehicle Speed Sensor (VSS) .................... 6E-43 4. Perform Service Manual Diagnostic
Heated Oxygen (O2) Sensor ..................... 6E-43 Checks ..................................................... 6E-55
GENERAL DESCRIPTION FOR FUEL 5a and 5b. Perform Service Manual Diagnostic
METERING .............................................. 6E-44 Procedures .............................................. 6E-55
Battery Voltage Correction Mode .............. 6E-44 5c. Technician Self Diagnoses .................. 6E-55
Clear Flood Mode ...................................... 6E-44 5d. Intermittent Diagnosis .......................... 6E-56
Deceleration Fuel Cutoff (DFCO) Mode .... 6E-44 5e. Vehicle Operates as Designed ............ 6E-57
Engine Speed/ Vehicle Speed/ Fuel Disable 6. Re-examine the complaint ..................... 6E-58
Mode ........................................................ 6E-44 7. Repair and Verify Fix ............................. 6E-58
Acceleration Mode ..................................... 6E-44 GENERAL SERVICE INFORMATION ....... 6E-59
Fuel Cutoff Mode ....................................... 6E-44 On-Board Diagnostic (OBD) ...................... 6E-60
6E–2 ENGINE DRIVEABILITY AND EMISSIONS
On-Board Diagnostic Tests ....................... 6E-60 Test Description ......................................... 6E-100
The Diagnostic Executive .......................... 6E-60 Fuel Pressure Relief Procedure ................. 6E-101
Diagnostic Information ............................... 6E-60 Fuel Pressure Gauge Installation .............. 6E-101
Check Engine Lamp .................................. 6E-60 Fuel System Diagnosis .............................. 6E-102
Data Link Connector (DLC) ....................... 6E-60 ECM DIAGNOSTIC TROUBLE CODES
Tech 2 Operating Flow Cart (Start Up) ...... 6E-62 (DTC) ....................................................... 6E-105
TYPICAL SCAN DATA & DEFINITIONS DIAGNOSTIC TROUBLE CODE (DTC) P0107
(ENGINE DATA) ................................... 6E-64 MANIFOLD ABSOLUTE PRESSURE
TYPICAL SCAN DATA & DEFINITIONS CIRCUIT LOW INPUT ............................. 6E-111
(O2 SENSOR DATA) ............................ 6E-66 Circuit Description ...................................... 6E-111
MISCELLANEOUS TEST .......................... 6E-68 Diagnostic Aids .......................................... 6E-111
PLOTTING SNAPSHOT GRAPH .............. 6E-70 Diagnostic Trouble Code (DTC) P0107
Plotting Graph Flow Chart (Plotting graph after Manifold Absolute Pressure Circuit Low
obtaining vehicle information) .................. 6E-71 Input ......................................................... 6E-112
Flow Chart for Snapshot Replay DIAGNOSTIC TROUBLE CODE (DTC) P0108
(Plotting Graph) ....................................... 6E-72 MANIFOLD ABSOLUTE PRESSURE CIRCUIT
ON-BOARD DIAGNOSTIC (OBD) SYSTEM HIGH INPUT ............................................ 6E-115
CHECK .................................................... 6E-82 Circuit Description ...................................... 6E-115
Test Description ......................................... 6E-82 Manifold Absolute Pressure Circuit High
Input ......................................................... 6E-116
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK .................................................... 6E-83 DIAGNOSTIC TROUBLE CODE (DTC) P0112
INTAKE AIR TEMPERATURE SENSOR LOW
NO CHECK ENGINE LAMP (MIL) ............. 6E-86
INPUT ...................................................... 6E-119
No Check Engine Lamp (MIL) ................... 6E-86
CHECK ENGINE LAMP (MIL) “ON”
Intake Air Temperature Sensor Low
STEADY .................................................. 6E-88
Input ......................................................... 6E-120
Circuit description ...................................... 6E-88
Diagnostic Aids .......................................... 6E-88 INTAKE AIR TEMPERATURE SENSOR
Check Engine Lamp (MIL) “ON” Steady .... 6E-88 HIGH INPUT ............................................ 6E-123
FUEL METERING SYSTEM CHECK ........ 6E-90 Circuit Description ...................................... 6E-123
FUEL INJECTOR COIL TEST PROCEDURE Diagnostic Aids .......................................... 6E-123
AND FUEL INJECTOR BALANCE TEST Diagnostic Trouble Code (DTC) P0113
PROCEDURE .......................................... 6E-90 Intake Air Temperature Sensor High Input 6E-124
Test Description ......................................... 6E-90 DIAGNOSTIC TROUBLE CODE (DTC) P0117
Injector Coil Test Procedure (Steps 1-6) ENGINE COOLANT TEMPERATURE
and Injector Balance Test Procedure SENSOR LOW INPUT ............................. 6E-128
(Steps 7-11) ............................................. 6E-91 Circuit Description ...................................... 6E-128
Injector Coil Test Procedure (Steps 1-6) Diagnostic Aids .......................................... 6E-128
and Injector Balance Test Procedure
(Steps 7-11) ............................................. 6E-92
Engine Coolant Temperature Sensor Low
FUEL SYSTEM ELECTRICAL TEST ........ 6E-95 Input ......................................................... 6E-129
Diagnostic Aids .......................................... 6E-95 ENGINE COOLANT TEMPERATURE
Fuel Pressure Relief Procedure ................ 6E-96 SENSOR HIGH INPUT ............................ 6E-131
Fuel Pressure Gauge Installation .............. 6E-96 Circuit Description ...................................... 6E-131
Fuel System Electrical Test ....................... 6E-96 Diagnostic Aids .......................................... 6E-131
FUEL SYSTEM DIAGNOSIS ..................... 6E-100 Diagnostic Trouble Code (DTC) P0118
Circuit Description ..................................... 6E-100 Engine Coolant Temperature Sensor High
Input ......................................................... 6E-132 INJECTOR 3 CONTROL CIRCUIT .......... 6E-159
THROTTLE POSITION SENSOR LOW INJECTOR 4 CONTROL CIRCUIT .......... 6E-159
INPUT ...................................................... 6E-135 Circuit Description ...................................... 6E-159
Diagnostic Trouble Code (DTC) P0122 Injector 1 Control Circuit .......................... 6E-160
Throttle Position Sensor Low Input .......... 6E-136 Diagnostic Trouble Code (DTC) P0202
DIAGNOSTIC TROUBLE CODE (DTC) P0123 Injector 2 Control Circuit .......................... 6E-160
THROTTLE POSITION SENSOR HIGH Diagnostic Trouble Code (DTC) P0203
INPUT ...................................................... 6E-139 Injector 3 Control Circuit .......................... 6E-160
Diagnostic Aids .......................................... 6E-139 Injector 4 Control Circuit .......................... 6E-160
Throttle Position Sensor High Input ......... 6E-140 KNOCK SENSOR (KS) CIRCUIT
DIAGNOSTIC TROUBLE CODE (DTC) P0131 MALFUNCTION ....................................... 6E-166
O2 SENSOR CIRCUIT LOW VOLTAGE Circuit Description ...................................... 6E-166
(BANK 1 SENSOR 1) .............................. 6E-143 Diagnostic Aids .......................................... 6E-166
Diagnostic Aids .......................................... 6E-143 Knock Sensor Module Circuit .................. 6E-166
O2 Sensor Circuit Low Voltage KNOCK SENSOR (KS) CIRCUIT LOW
(Bank 1 Sensor 1)..................................... 6E-144 INPUT ...................................................... 6E-169
O2 SENSOR CIRCUIT HIGH VOLTAGE Diagnostic Aids .......................................... 6E-169
(BANK 1 SENSOR 1) .............................. 6E-147 Diagnostic Trouble Code (DTC) P0327
Circuit Description ..................................... 6E-147 Knock Sensor Circuit ............................... 6E-170
Diagnostic Trouble Code (DTC) P0132 CRANKSHAFT POSITION (CKP) SENSOR
O2 Sensor Circuit High Voltage CIRCUIT RANGE/PERFORMANCE (58X) 6E-172
(Bank 1 Sensor 1) .................................... 6E-148 DIAGNOSTIC TROUBLE CODE (DTC) P0337
DIAGNOSTIC TROUBLE CODE (DTC) P0134 CRANKSHAFT POSITION (CKP) SENSOR
O2 SENSOR NO ACTIVITY DEFECTED CIRCUIT LOW INPUT (58X) ................... 6E-172
CIRCUIT (BANK 1 SENSOR 1) ............... 6E-151 Circuit Description ...................................... 6E-172
Diagnostic Trouble Code (DTC) P0134 Crankshaft Position Sensor Circuit Range/
O2 Sensor Circuit No Activity Detected performance (58x) ................................... 6E-173
(Bank 1 Sensor 1) .................................... 6E-152 Diagnostic Trouble Code (DTC) P0337
DIAGNOSTIC TROUBLE CODE (DTC) P0135 Crankshaft Position Sensor Circuit Low
O2 SENSOR HEATER CIRCUIT Input (58x) ............................................... 6E-173
(BANK 1 SENSOR 1) .............................. 6E-155 DIAGNOSTIC TROUBLE CODE (DTC) P0351
Circuit Description ..................................... 6E-155 IGNITION 1 CONTROL CIRCUIT ............ 6E-178
Diagnostic Trouble Code (DTC) P0135 IGNITION 2 CONTROL CIRCUIT ............ 6E-178
O2 Sensor Heater Circuit Circuit Description ...................................... 6E-178
(Bank 1 Sensor 1) .................................... 6E-156 Diagnostic Aids .......................................... 6E-178
INJECTOR 1 CONTROL CIRCUIT ......... 6E-159 Ignition 1 Control Circuit .......................... 6E-179
INJECTOR 2 CONTROL CIRCUIT ......... 6E-159 Ignition 2 Control Circuit .......................... 6E-179
EVAPORATIVE EMISSION (EVAP) CONTROL Diagnostic Trouble Code (DTC) P1167
SYSTEM PURGE CONTROL VALVE CIRCUIT Fuel Supply System Rich During Deceleration
MALFUNCTION ....................................... 6E-183 Fuel Cutoff ............................................... 6E-204
Diagnostic Aids .......................................... 6E-183 FUEL SUPPLY SYSTEM LEAN DURING
Diagnostic Trouble Code (DTC) P0443 POWER ENRICHMENT .......................... 6E-206
Evap Emission Control System Purge Control Circuit Description ...................................... 6E-206
Circuit ...................................................... 6E-184 Diagnostic Aids .......................................... 6E-207
VEHICLE SPEED SENSOR (VSS) CIRCUIT Fuel Supply System Lean During Power
LOW INPUT ............................................. 6E-187 Enrichment .............................................. 6E-207
Diagnostic Aids .......................................... 6E-187 ECM SYSTEM RESET ............................ 6E-209
Diagnostic Trouble Code (DTC) P0502 Vehicle Circuit Description ...................................... 6E-209
Speed Sensor Circuit Low Input .............. 6E-188 Diagnostic Aids .......................................... 6E-209
SYSTEM VOLTAGE LOW ....................... 6E-194 ECM System Reset ................................. 6E-209
Diagnostic Aids .......................................... 6E-194 IMMOBILISER NO SIGNAL ..................... 6E-210
System Voltage Low ................................ 6E-194 Diagnostic Aids .......................................... 6E-210
SYSTEM VOLTAGE HIGH ...................... 6E-196 Immobiliser No Signal .............................. 6E-211
Diagnostic Aids .......................................... 6E-196 IMMOBILISER WRONG SIGNAL ............ 6E-214
System Voltage High ............................... 6E-196 Diagnostic Aids .......................................... 6E-214
ECM MEMORY CHECKSUM .................. 6E-198 Immobiliser Wrong Signal ........................ 6E-215
Diagnostic Aids .......................................... 6E-198 WRONG SECURITY CODE ENTERED .. 6E-216
ECM Memory Checksum ......................... 6E-198 Diagnostic Aids .......................................... 6E-216
PROGRAMMING ERROR ....................... 6E-199 Wrong Security Code Entered ................. 6E-217
Diagnostic Aids .......................................... 6E-199 IMMOBILISER FUNCTION NOT
Diagnostic Trouble Code (DTC) P0602 PROGRAMMED ...................................... 6E-218
Programming Error .................................. 6E-199 Circuit Description ...................................... 6E-218
DTC P0650 MALFUNCTION INDICATOR Diagnostic Aids .......................................... 6E-218
LAMP (MIL) CONTOROL CIRCUIT Diagnostic Trouble Code (DTC) P1649
MALFUNCTION ....................................... 6E-200 Immobiliser Function Not Programmed ... 6E-219
Diagnostic Aids .......................................... 6E-200 TACHOMETER OUTPUT LOW VOLTAGE 6E-220
Malfunction Indicator Lamp (MIL) Control Diagnostic Aids .......................................... 6E-220
Circuit Malfunction ................................... 6E-201 Diagnostic Trouble Code (DTC) P1693
DIAGNOSTIC TROUBLE CODE (DTC) P1167 Tachometer Output Low Voltage ............. 6E-221
FUEL SUPPLY SYSTEM RICH DURING SYMPTOM DIAGNOSIS ............................ 6E-224
DECELERATION FUEL CUT OFF .......... 6E-203 PRELIMINARY CHECKS .......................... 6E-224
Circuit Description ..................................... 6E-203 VISUAL/PHYSICAL CHECK ...................... 6E-224
INTERMITTENT ........................................ 6E-224
ENGINE CRANKS BUT WILL NOT RUN .. 6E-225
HARD START SYMPTOM ........................ 6E-228
ROUGH, UNSTABLE, OR INCORRECT IDLE,
STALLING SYMPTOM ............................ 6E-231
SURGES AND/OR CHUGS SYMPTOM ... 6E-234
HESITATION, SAG, STUMBLE SYMPTOM 6E-237
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM .............................. 6E-243
DETONATION/SPARK KNOCK SYMPTOM 6E-246
EXCESSIVE EXHAUST EMISSIONS OR
ODORS SYMPTOM ................................ 6E-251
DIESELING, RUN-ON SYMPTOM ............ 6E-254
BACKFIRE SYMPTOM ............................. 6E-255
ENGINE CONTROL MODULE (ECM) ....... 6E-257
CRANKSHAFT POSITION (CKP)
SENSOR ................................................. 6E-257
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ................................................. 6E-258
INTAKE AIR TEMPERATURE (IAT)
SENSOR ................................................. 6E-258
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR ................................................. 6E-259
THROTTLE POSITION SENSOR (TPS) ... 6E-259
IDLE AIR CONTROL (IAC) VALVE ........... 6E-260
KNOCK SENSOR .................................. 6E-261
POWER STEERING PRESSURE (PSP)
SWITCH .................................................. 6E-261
HEATED OXYGEN SENSOR (HO2S) ...... 6E-262
EVAP CANISTER PURGE VALVE
SOLENOID .............................................. 6E-262
FUEL PRESSURE RELIEF ....................... 6E-263
FUEL RAIL ASSEMBLY ............................ 6E-263
FUEL INJECTOR ...................................... 6E-265
FUEL PRESSURE REGULATOR ............. 6E-266
IGNITION COIL ......................................... 6E-268
SPARK PLUGS ......................................... 6E-269
SPARK PLUG CABLES ............................ 6E-270
ABBREVIATIONS CHARTS
A/C Air Conditioner
A/T Automatic Transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CEL Check Engine Lamp
CKP Crankshaft Position
DLC Data Link Connector
DTC Diagnostic Trouble Code
DVM Digital Volt Meter
ECM Engine Control Module
ECT Engine Coolant Temperature
EEPROM Electrically Erasable & Programmable Read Only Memory
EVAP Evaporative Emission
EVRV Electric Vacuum Regulating Valve
EXH Exhaust
FT Fuel Temperature
GND Ground
GRY Gray
HOS2 Heated Oxygen Sensor
IAC Idel Air Control
IAT Intake Air Temperature
IG Ignition
ITP Intake Throttle Position
KS Knock Sensor
M/T Manual Transmission
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
OBD On-Board Diagnostic
ORN Orange
OT Oil Temperature
PNK Pink
RED Red
SW Switch
TB Throttle Body
TEMP Temperature
TP Throttle Position
VSS Vehicle Speed Sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
2
1
Legend
(1) Engine Coolant Temperature (ECT) Sensor
(2) Crankshaft Position (CKP) Sensor
EndOFCallout
Legend (3) Knock Sensor (KS)

(1) Idle Air Control (IAC) Valve (4) Manifold Absolute Pressure (MAP) Sensor
(2) Throttle Position Sensor (TPS)
EndOFCallout
2 4
(1) Air Cleaner (3) Engine Coolant Temperature (ECT) Sensor

(2) Idle Air Control (IAC) Valve (4) Engine Control Module (ECM)
3 2 1
(1) Intake Air Temperature (IAT) Sensor

(2) Idle Air Control (IAC) Valve
(3) Throttle Position Sensor (TPS)
1 2 3 4
(1) Injector #1 Cylinder (3) Injector #3 Cylinder

(2) Injector #2 Cylinder (4) Injector #4 Cylinder (Under the ECM)
(1) Ignition Coil Module Assembly (1) Heated Oxygen Sensor

(1) Crankshaft Position (CKP) Sensor (1) Knock Sensor (KS)
2 1
(1) Engine Coolant Temperature (ECT) Sensor (1) Manifold Absolute Pressure (MAP) Sensor
(2) Thermo Meter Sensor
(1) Throttle Position Sensor (1) EVAP Purge Solenoid

(2) Idle Air Control (IAC) Valve
1 2
(1) Canister (1) Fuel Tank

(2) Fuel Pump
1 2 1 2
(1) Vehicle Speed Sensor (VSS) (1) Power Steering Pressure Switch
(2) Transmission Assembly (2) Power Steering Oil Pump Assembly
ECM CIRCUIT DIAGRAM
LOCATION
CABLE HARNESS & CONNECTOR LOCATION
CONNECTOR LIST
B-24 E-6
Green Meter-B Injector pump

B-58 E-7
Black Check connector Fuel injector

B-62 E-8
White Ignition switch (IGSUB : G1) Fuel injector

B-63 E-9
White Ignition switch (IGSUB : G2) Fuel injector

B-68 E-18
Immobiliser Ignition coil

C-2 E-60
Silver Engine room-RH ground ECM

C-56 E-72
ECM Engine earth-A

C-107 E-74
White J/B E2 Engine earth-B

C-108 E-77
White J/B E1 O2 sensor

C-121 E-84
IAT sensor Knock sensor


E-85 P-2
MAP sensor Silver Relay & Fuse box

F-2 P-5
White Fuel pump & sensor Silver Battery (-)

H-4 P-6
White Engine room ~ Mission Silver Body earth (Ground)

H-6 P-10
White Engine room ~ INST Silver Engine ground

H-7 X-2
White Engine room ~ INST Black Relay; Fuel pomp

H-9 X-11
Blue Engine room ~ Chassis Black Relay; Heater

H-18 X-14
White Engine room ~ INST Black Relay; A/C Compressor

H-31 X-15
Engine room ~ Mission Black Relay; Thermo

H-34
Engine ~ Engine room

P-1
Silver Battery (+)

RELAY AND FUSE
RELAY & FUSE BOX

RELAY
No. RELAY (C24SE)
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 —
X-6 RELAY; STARTER
X-7 RELAY; COND, FAN
X-8 RELAY; —
X-9 —
X-10 —
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 —
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
ENGINE MODEL
FUSE NO. C24SE
EB-1 15A ECM
EB-2 —
EB-3 —
EB-4 15A ACG (S)
EB-5 10A ILLUMI
EB-6 10A TAIL
EB-7 10A H/LIGHT-RH
EB-8 10A H/LIGHT-LH
EB-9 20A FUEL PUMP
EB-10 10A O2 SENSOR
EB-11 —
EB-12 —
EB-13 10A A/C
EB-14 —
EB-15 10A HORN
EB-16 10A HAZARD
SLOW BLOW FUSE

ENGINE MODEL
FUSE NO. C24SE
SBF-1 100A MAIN
SBF-2 —
SBF-3 —
SBF-4 20A COND, FAN
SBF-5 40A IG 1
SBF-6 —
SBF-7 —
SBF-8 30A BLOWER
SBF-9 50A IG 2
FUSE AND RELAY LOCATION
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
22 20A RR DEF
23 20A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
C24SE REAR DEFOGGER POWER WINDOW ACC SOCKET
Buttery
Voltage
Ignition
SW
METER
10A
METER
15A
0.5
RED/
YEL
Diagnostic
16 15 14 13 12 11 10 9 Comectar
8 7 6 5 4 3 2 1
Check
Engine
Lamp
0.85 BLK
Imnobiliser
Control
Unit Engine
Room-RH
7
0.5 0.5
0.5 BLU GRN
BRN/
YEL
J2-32 J2-4 J2-30

Engine
Control Diag Class 2
Module SW Serial
(ECM) Data
µP
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
Battery Voltage
IGN
Switch
IGN
Fuse
15A
COIL
MODULE
Injector Injector Injector Injector
#1 #2 #3 #4
Cylinder Cylinder Cylinder Cylinder
PNK/ BLU/ BLU/ BLU/ 0.85 0.85

BLU BLK WHT YEL GRN BLU
J1-9 J1-22 J1-8 J1-11 J1-19 J1-18

Engine
Control
Module
(ECM)
µP
Idle
Air
Control(IAC) Valve
HI LO
A B
LO HI
0.5 0.5 0.5 0.5

YEL/ YEL/ BLU/ YEL/
BLU GRN RED BLK
J1-28 J1-30 J1-13 J1-29

Engine
Control
Module
(ECM)
Battery Voltage
Intake Ignition
Air SW
Temperature(IAT)
Sensor
Engine
15A
0.5
BLU/
YEL
Evaporativ
Power Emission(EVAP)
Steering Canistor
Pressure Purge
SW Valve
Solenoid
0.5 0.5 0.5 0.5 0.5

GRN YEL/ GRN/ BLU/ GRN/
GRN YEL YEL WHT
J2-1 J2-22 J2-20 J2-3 J1-5

Engine
Control
Module +5V
(ECM)
µP
µP
Crankshaft
Position(CKP)
Manifold Sensor
Absolute
Pressure(MAP) Sensor
INLET
MANIFOLD
0.5
BLK/
WHT
0.5 0.5
BLK WHT
0.5 0.5 0.5
GRY/ GRY/ YEL/
BLU RED RED
0.5 0.5
BLK/ BLK/
WHT WHT
J1-16 J1-24 J1-31 J1-1 J1-2 J1-17 J1-6 J1-21

Engine
Control
Module
(ECM)
5 Volts
Reference
µP
Engine
Throttle Coolant
Position Sensor Temperature(ECT)
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
Battery
Voltage
A/C
10A
COMPRESSOR THERMO
RELAY RELAY
0.5
BRN/
YEL
MAGNETIC
CLUTCH
A/C PRESSURE S/W
0.5 0.5
GRY/ GRN/
RED BLK
J2-13 J2-26
Engine
Control
Module
(ECM)
µP µP
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
Connector J1 Port: View Looking Into ECM Case
PIN1 PIN16
1 16
17 32
PIN32
PIN17

Pin B/Box Wire ECM
Off On Idle 2000rpm
J1-1 1 Ground BLK/WHT Continuity - - - Disconnect Ω 1 GND
with
ground
J1-2 2 Ground BLK/WHT Continuity - - - Disconnect Ω 2 GND
with
ground
J1-3 3 Knock Sensor Signal YEL - - - - - - - -
J1-4 4 No Connection - - - - - - - - -
J1-5 5 Canister Purge GRN/ Less than Battery Wave form/ battery Connect DC V 5 GND
Solenoid Valve WHT 1V voltage voltage while solenoid
is not activated
J1-6 6 Crankshaft Position BLK Continuity - - - Connect Ω 6 GND
(CKP) Sensor with
(Ground) ground
J1-7 7 Throttle Position WHT/BLU Approx. 6.0kΩ at idle / - - Disconnect Ω 7 15 /
Sensor (TPS) Output Approx. 1.7kΩ at WOT 32
Signal Approx. 2.3kΩ at idle /
Approx. 6.6kΩ at WOT
J1-8 8 No. 3 Injector BLU/WHT Less than Battery Wave form Connect DC V 8 GND
1V voltage
J1-9 9 No. 1 Injector PNK/BLU Less than Battery Wave form Connect DC V 9 GND
1V voltage
J1-10 10 No Connection - - - - - - - - -
J1-11 11 No. 4 Injector BLU/YEL Less than Battery Wave form Connect DC V 11 GND
1V voltage
J1-12 12 No Connection - - - - - - - - -
J1-13 13 Idle Air Control Valve YEL/BLU Less than Less than 1V / Battery voltage Connect DC V 13 GND
(IACV) Coil B High 1V
J1-14 14 No Connection - - - - - - - - -
J1-15 15 Throttle Position BLK/YEL Less than Approx. 5V Connect DC V 15 32
Sensor (TPS) Power 1V
Supply
J1-16 16 MAP Sensor Ground GRY/BLU Continuity - - - Connect Ω 16 GND
with
ground
J1-17 17 Ground BLK/WHT Continuity - - - Connect Ω 17 GND
with
ground
J1-18 18 Coil Module No. 1 & BLU Less than Battery Wave form Connect DC V 18 GND
No.4 1V voltage
J1-19 19 Coil Module No. 2 & GRN Less than Battery Wave form Connect DC V 19 GND
No. 3 1V voltage

Pin B/Box Wire ECM
Off On Idle 2000rpm
J1-20 20 No Connection - - - - - - - - -
J1-21 21 Crankshaft Position WHT - - Wave Wave Connect AC V 21 6
(CKP) Sensor Signal form or form or
approx. approx.
3.7V 7.7V
J1-22 22 No.2 Injector BLU/BLK Less than Battery Wave form Connect DC V 22 GND
1V voltage
J1-23 23 No Connection - - - - - - - - -
J1-24 24 MAP Sensor Signal GRY/RED Less than Approx. Approx. Approx. Connect DC V 24 16
1V 4.8V 1.3V 0.9V
J1-25 25 No Connection - - - - - - - - -
J1-26 26 No Connection - - - - - - - - -
J1-27 27 Engine Coolant Temp. GRY Less than Approx. 2.5V at ECT 80°C Connect DC V 27 32
(ECT) Sensor Signal 1V
J1-28 28 Idle Air Control Valve YEL/BLK Less than Less than 1V / Battery voltage Connect DC V 28 GND
(IACV) Coil A High 1V
J1-29 29 Idle Air Control Valve YEL/GRN Less than Less than 1V / Battery voltage Connect DC V 29 GND
(IACV) Coil B Low 1V
J1-30 30 Idle Air Control Valve BLU/WHT Less than Less than 1V / Battery voltage Connect DC V 30 GND
(IACV) Coil A Low 1V
J1-31 31 MAP Sensor Power YEL/RED Less than Approx.. 5V Connect DC V 31 16
Supply 1V
J1-32 32 ECT Sensor, Knock BLU/PNK Continuity - - - Connect Ω 32 GND
Sensor, Throttle with
Position Sensor ground
Ground
Connector J2 Port: View Looking Into ECM Case
PIN32 PIN17
32 17
16 1
PIN16 PIN1

Pin B/Box Wire ECM
Off On Idle 2000rpm
J2-1 33 Intake Air Temp. (IAT) GRN Continuity - - - Disconnect Ω 33 GND
Sensor Ground with
ground
J2-2 34 Battery Power Supply RED/ Battery voltage Connect DC V 34 GND
WHT
J2-3 35 Ignition Power Supply BLU/YEL Less than Battery voltage Connect DC V 35 GND
1V
J2-4 36 To Data Link BLU Less than Approx. 5V Connect DC V 36 GND
Connector No. 6 1V
J2-5 37 No Connection - - - - - - - - -
J2-6 38 Oxygen Sensor PNK Continuity - - - Connect Ω 38 GND
(Ground) with
ground
J2-7 39 No Connection - - - - - - - - -
J2-8 40 No Connection - - - - - - - - -
J2-9 41 No Connection - - - - - - - - -
J2-10 42 No Connection - - - - - - - - -
J2-11 43 Fuel Pump Relay GRN/ Less than Less than Battery voltage Connect DC V 43 GND
WHT 1V 1V /
Battery
voltage
while fuel
pump is
activated
J2-12 44 No Connection - - - - - - - - -
J2-13 45 A/C Compressor GRY/RED Less than Battery Less than 1V Connect DC V 45 GND
Relay 1V voltage
J2-14 46 No Connection - - - - - - - - -
J2-15 47 No Connection - - - - - - - - -
J2-16 48 No Connection - - - - - - - - -
J2-17 49 No Connection - - - - - - - - -
J2-18 50 Battery Power Supply RED/ Battery voltage Connect DC V 50 GND
WHT
J2-19 51 No Connection - - - - - - - - -
J2-20 52 Power Steering GRN/YEL Less than Less than 1V when switch is turned Connect DC V 52 GND
Pressure Switch 1V on / Battery voltage when switch is
turned off
J2-21 53 Oxygen Sensor BLU Less than Approx. 0.1 - 0.9V Connect DC V 53 38
1V 0.4V
J2-22 54 Intake Air Temp. (IAT) YEL/GRN Less than Approx. 1.8V at IAT 30°C Connect DC V 54 33
Sensor (Signal) 1V

Pin B/Box Wire ECM
Off On Idle 2000rpm
J2-23 55 Vehicle Speed Signal WHT - - Approx. 16Hz by wave Connect AC V 55 GND
(Immobiliser Control form or approx. 4.8V at
Unit Terminal B8) 20km/h
J2-24 56 No Connection - - - - - - - - -
J2-25 57 Tachometer Output BLK/RED - Wave form - - - -
Signal
J2-26 58 Thermo Relay GRN/BLK Less than Battery voltage when A/C request is Connect DC V 58 GND
1V activated
J2-27 59 No Connection - - - - - - - - -
J2-28 60 No Connection - - - - - - - - -
J2-29 61 No Connection - - - - - - - - -
J2-30 62 To Data Link GRN - - - - - - - -
Connector No. 2
J2-31 63 Oxygen Sensor Heater BLU/WHT Continuity - - - Connect Ω 63 GND
with
ground
J2-32 64 Check Engine Lamp BRN/YEL Less than Less than Battery voltage while Connect DC V 64 GND
(Immobiliser Control 1V 1V lamp is turned off
Unit Terminal B7)
GENERAL DESCRIPTION FOR ECM AND • Knock signal
SENSORS • Throttle position
• Vehicle speed
Engine Control Module (ECM) • Power steering pressure
• Air conditioning request on or off
Outputs (Systems controlled):

• Ignition control
• Fuel control
• Idle air control
• Fuel pump
• EVAP canister purge
• Air conditioning
• Diagnostics functions
Manifold Absolute Pressure (MAP) Sensor
1 2
(1) J1 Port
(2) J2 Port
The engine control module (ECM) is located on the

intake manifold. The ECM controls the following.
• Fuel metering system
• Ignition timing
• On-board diagnostics for electrical functions.
The ECM constantly observes the information from vari-

ous sensors. The ECM controls the systems that affect
vehicle performance. And it performs the diagnostic
function of the system.
The function can recognize operational problems, and
Characteristic of MAP Sensor (Reference)
warn to the driver through the check engine lamp, and 5
4.5
store diagnostic trouble code (DTC). DTCs identify the
4
problem areas to aid the technician in marking repairs.
3.5
Output Voltage (V)
3
The input / output devices in the ECM include analog to 2.5
digital converts, signal buffers, counters and drivers. 2

1.5
The ECM controls most components with electronic
1
switches which complete a ground circuit when turned
0.5
on. 0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pressure (KPa)
Inputs (Operating condition read):
• Battery voltage The MAP sensor is a strain gage. A pressure strains the
• Electrical ignition resistance on the silicon base. At that time the
• Exhaust oxygen content resistance value changes. And it changes voltage. In
other words it measures a pressure value. It is installed
• Intake manifold pressure to the intake manifold. Output voltage of the MAP
• Intake air temperature sensor is low as pressure is low.
• Engine coolant temperature
• Crankshaft position
Throttle Position Sensor (TPS) controlled steps by the engine control module (ECM),
the IAC valve's pintle is moved to adjust idle speed,
raising it for fast idle when cold or there is extra load
from the air conditioning or power steering.
By moving the pintle in (to decrease air flow) or out (to
increase air flow), a controlled amount of the air can
move around the throttle plate. If the engine speed is too
low, the engine control module (ECM) will retract the
IAC pintle, resulting in more air moving past the throttle
plate to increase the engine speed.
If the engine speed is too high, the engine control
2 module (ECM) will extend the IAC pintle, allowing less
air to move past the throttle plate, decreasing the engine
speed.
The IAC pintle valve moves in small step called counts.

During idle, the proper position of the IAC pintle is
calculated by the engine control module (ECM) based
on battery voltage, coolant temperature, engine load,
1 and engine speed.
If the engine speed drops below a specified value, and
(1) Throttle Position Sensor the throttle plate is closed, the engine control module
(2) Idle Air Control (IAC) Valve (ECM) senses a near-stall condition. The engine control
module (ECM) will then calculate a new IAC pintle valve
Characteristic of TPS (Reference) position to prevent stalls.
5
4.5
If the IAC valve is disconnected and reconnected with
4 the engine running, the idle speed will be wrong. In this
Output Voltage (V)
3.5 case, the IAC must be reset. The IAC resets when the
3
2.5
key is cycled “On” then “Off”. When servicing the IAC, it
2 should only be disconnected or connected with the
1.5 ignition “Off”.
1
0.5
The position of the IAC pintle valve affects engine start-
0 up and the idle characteristic of the vehicle.
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Throttle Angle (%) If the IAC pintle is fully open, too much air will be
allowed into the manifold. This results in high idle
speed, along with possible hard starting and lean air/
fuel ratio.
on the throttle body.
Idle Air Control (IAC) Valve
Step A B C D
Coil
Coil A High On On
(ECM J1-28)
Coil A Low On On
(ECM J1-30)
Coil B High On On
(ECM J1-13)
Coil B Low On On
(ECM J1-29)
(IAC Valve Close Direction)
(IAC Valve O pen Direction)
The idle air control valve (IAC) valve is two directional

and gives 2-way control. With power supply to the coils
Crankshaft Position (CKP) Sensor Engine Coolant Temperature (ECT) Sensor
The crankshaft position (CKP) sensor, which sends a

signal necessary for deciding on injection timing to the
ECM, is mounted on the left-hand side of the cylinder
block just back of the A/C compressor.
Resistance ( )
The crankshaft has a 58 teeth press-fit timing disc, from

which the CKP sensor reads the position of the
crankshaft at all the times. It converts this to an
electrical signal, which it sends to the ECM.
Using the 58 X signals per rotation and the timing-mark
signal sent by the CKP sensor, the ECM is able to
accurately calculate engine speed and crank position. -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
The ECM converts the 58 X signals into square signals. Temperature (ºC)
This converted signal is sent from the ECM terminal J2-
25 to the tachometer. The ECT sensor is a thermistor. A temperature changes
a high resistance.
temperature is hot.
Intake Air Temperature (IAT) Sensor Heated Oxygen (O2) Sensor
The heated oxygen sensor consists of a 4-wire low

temperature activated zirconia oxygen analyzer element
with heater for operating temperature of 315°C, and
The IAT sensor is a thermistor. A temperature changes there is one mounted on each exhaust pipe.
the resistance value. And it changes voltage. In other A constant 450millivolt is supplied by the ECM between
words it measures a temperature value. Low air the two supply terminals, and oxygen concentration in
temperature produces a high resistance. the exhaust gas is reported to the ECM as returned
The ECM supplies 5 volts signal to the IAT sensor signal voltage.
through resisters in the ECM and measures the voltage. The oxygen present in the exhaust gas reacts with the
The signal voltage will be high when the air temperature sensor to produce a voltage output. This voltage should
is cold, and it will be low when the air temperature is hot. constantly fluctuate from approximately 100mV to
The ECM uses to this value 1000mV and the ECM calculates the pulse width
commanded for the injectors to produce the proper
Vehicle Speed Sensor (VSS) combustion chamber mixture.
Low oxygen sensor output voltage is a lean mixture
which will result in a rich commanded to compensate.
High oxygen sensor output voltage is a rich mixture
which result in a lean commanded to compensate.
When the engine is first started the system is in “Open
Loop” operation. In “Open Loop”, the ECM ignores the
signal from the oxygen sensors. When various
conditions (ECT, time from start, engine speed &
oxygen sensor output) are met, the system enters
“Closed Loop” operation. In “Closed Loop”, the ECM
calculates the air fuel ratio based on the signal from the
oxygen sensors.
The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
meter fuse.
GENERAL DESCRIPTION FOR FUEL Engine Speed/ Vehicle Speed/ Fuel Disable
METERING Mode
The ECM monitors engine speed. It turns off the fuel
The fuel metering system starts with the fuel in the fuel injectors when the engine speed increases above 6000
tank. An electric fuel pump, located in the fuel tank, RPM. The fuel injectors are turned back on when
pumps fuel to the fuel rail through an in-line fuel filter. engine speed decreases below 3500 RPM.
The pump is designed to provide fuel at a pressure
above the pressure needed by the injectors. Acceleration Mode
A fuel pressure regulator in the fuel rail keeps fuel The ECM provides extra fuel when it detects a rapid
available to the fuel injectors at a constant pressure. increase in the throttle position and the air flow.
A return line delivers unused fuel back to the fuel tank.
The basic function of the air/fuel metering system is to Fuel Cutoff Mode
control the air/fuel delivery to the engine. Fuel is No fuel is delivered by the fuel injectors when the
delivered to the engine by individual fuel injectors ignition is OFF. This prevents engine run-on. In addition,
mounted in the intake manifold. the ECM suspends fuel delivery if no reference pulses
The main control sensor is the heated oxygen sensor are detected (engine not running) to prevent engine
located in the exhaust system. The heated oxygen flooding.
sensor reports to the ECM how much oxygen is in the
exhaust gas. The ECM changes the air/fuel ratio to the
Starting Mode
When the ignition is first turned ON, the ECM energizes
engine by controlling the amount of time that fuel
the fuel pump relay for two seconds to allow the fuel
injector is “On”.
pump to build up pressure. The ECM then checks the
The best mixture to minimize exhaust emissions is 14.7
engine coolant temperature (ECT) sensor and the
parts of air to 1 part of gasoline by weight, which allows
throttle position sensor to determine the proper air/fuel
the catalytic converter to operate most efficiently.
ratio for starting.
Because of the constant measuring and adjusting of the
The ECM controls the amount of fuel delivered in the
air/fuel ratio, the fuel injection system is called a “closed
starting mode by adjusting how long the fuel injectors
loop” system.
are energized by pulsing the injectors for very short
The ECM monitors signals from several sensors in order
times.
to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called “mode”. Run Mode
All modes are controlled by the ECM. The run mode has the following two conditions:
Battery Voltage Correction Mode • Open loop
When battery voltage is low, the ECM will compensate • Closed loop
for the weak spark by increasing the following: When the engine is first started, the system is in “open
• The amount of fuel delivered. loop” operation. In “Open Loop,” the ECM ignores the
signal from the heated oxygen sensor (HO2S). It
• The idle RPM.
calculates the air/fuel ratio based on inputs from the TP,
Clear Flood Mode ECT, and MAP sensors.
Clear a flooded engine by pushing the accelerator pedal The system remains in “Open Loop” until the following
down all the way. The ECM then de-energizes the fuel conditions are met:
injectors. The ECM holds the fuel injectors de-energized • The HO2S has a varying voltage output showing that
as long as the throttle remains above 75% and the it is hot enough to operate properly (this depends on
engine speed is below 800 RPM. If the throttle position temperature).
becomes less than 75%, the ECM again begins to pulse • The ECT has reached a specified temperature.
the injectors ON and OFF, allowing fuel into the • A specific amount of time has elapsed since starting
cylinders.
the engine.
Deceleration Fuel Cutoff (DFCO) Mode • Engine speed has been greater than a specified RPM
The ECM reduces the amount of fuel injected when it since start-up.
detects a decrease in the throttle position and the air The specific values for the above conditions vary with
flow. When deceleration is very fast, the ECM may cut different engines and are stored in the programmable
off fuel completely. Until enable conditions meet the read only memory (PROM). When these conditions are
engine revolution less 1000 rpm or manifold absolute met, the system enters “closed loop” operation. In
pressure less than 10 kpa. “closed loop,” the ECM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.
Fuel Metering System Components pressure will result in poor performance.
The fuel metering system is made up of the following
parts. Thottle Body Unit
The throttle body has a throttle plate to control the
• Fuel injector
amount of air delivered to the engine. The Thottle
• Throttle body position sensor and IAC valve are also mounted on the
• Fuel rail throttle body.
• Fuel pressure regulator Vacuum ports located behind the throttle plate provide
the vacuum signals needed by various components.
• ECM
Engine coolant is directed through a coolant cavity in
• Crankshaft position (CKP) sensor the throttle body to warm the throttle valve and to
• Idle air control (IAC) valve prevent icing.
• Fuel pump
Fuel Injector
The group fuel injection fuel injector is a solenoid
operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel
not used by the injectors passes through the fuel
pressure regulator before being returned to the fuel
tank.
Fuel Pressure Regulator

The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the
other side. The fuel pressure regulator maintains the
fuel pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separately.
If the pressure is too low or poor performance, DTC
P0131 or P1171 will be the result. If the pressure is too
high, DTC P0132 or P1167 will be the result. Refer to
Fuel System Diagnosis for information on diagnosing
fuel pressure conditions.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator
maintains a constant fuel pressure at the injectors.
Remaining fuel is then returned to the fuel tank.
Fuel Pump Electrical Circuit

When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits
until the engine is cranked. When the engine is cranked
and the 58X crankshaft position signal has been
detected by the ECM, the ECM supplies 12 volts to the
fuel pump relay to energize the electric in-tank fuel
pump.
An inoperative fuel pump will cause a “no-start”
condition. A fuel pump which does not provide enough
GENERAL DESCRIPTION FOR gap, or a cracked or broken insulator. If misfiring occurs

before the recommended replacement interval, locate
ELECTRIC IGNITION SYSTEM and correct the cause.
The engine use two ignition coils, one per two cylinders. Carbon fouling of the spark plug is indicated by dry,
A two wire connector provides a battery voltage primary black carbon (soot) deposits on the portion of the spark
supply through the ignition fuse. plug in the cylinder. Excessive idling and slow speeds
The ignition control spark timing is the ECM’s method of under light engine loads can keep the spark plug
controlling the spark advance and the ignition dwell. temperatures so low that these deposits are not burned
The ignition control spark advance and the ignition dwell off. Very rich fuel mixtures or poor ignition system output
are calculated by the ECM using the following inputs. may also be the cause. Refer to DTC P1167.
• Engine speed Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
• Crankshaft position (CKP) sensor usually with little electrode wear. This may be caused by
• Engine coolant temperature (ECT) sensor oil during break-in of new or newly overhauled engines.
• Throttle position sensor Deposit fouling of the spark plug occurs when the
• Vehicle speed sensor normal red-brown, yellow or white deposits of
combustion by-products become sufficient to cause
• ECM and ignition system supply voltage
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the center
Ignition coil works to generate only the secondary
electrode. If the fouling is found in only one or two
voltage be receiving the primary voltage from ECM.
cylinders, valve stem clearances or intake valve seals
The primary voltage is generated at the coil driver
may be allowing excess lubricating oil to enter the
located in the ECM. The coil driver generate the primary
cylinder, particularly if the deposits are heavier on the
voltage based on the crankshaft position signal. In
side of the spark plug facing the intake valve.
accordance with the crankshaft position signal, ignition
coil driver determines the adequate ignition timing and
also cylinder number to ignite.
Ignition timing is determined the coolant temperature,
intake air temperature, engine speed, engine load,
knock sensor signal, etc.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequently fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels Excessive gap means that the air space between the
and lubricating oils with additives. Some electrode wear center and the side electrodes at the bottom of the
will also occur. Engines which are not running properly spark plug is too wide for consistent firing. This may be
are often referred to as “misfiring.” This means the due to improper gap adjustment or to excessive wear of
ignition spark is not igniting the air/fuel mixture at the the electrode during use. A check of the gap size and
proper time. While other ignition and fuel system causes comparison to the gap specified for the vehicle in
must also be considered, possible causes include Maintenance and Lubrication will tell if the gap is too
ignition system conditions which allow the spark voltage wide. A spark plug gap that is too small may cause an
to reach ground in some other manner than by jumping unstable idle condition. Excessive gap wear can be an
across the air gap at the tip of the spark plug, leaving indication of continuous operation at high speeds or with
the air/fuel mixture unburned. Misfiring may also occur engine loads, causing the spark to run too hot. Another
when the tip of the spark plug becomes overheated and possible cause is an excessively lean fuel mixture.
ignites the mixture before the spark jumps. This is
referred to as “pre-ignition.”
Spark plugs may also misfire due to fouling, excessive
Low or high spark plug installation torque or improper A broken or cracked lower insulator tip (around the
seating can result in the spark plug running too hot and center electrode) may result from damage during re-
can cause excessive center electrode wear. The plug gapping or from “heat shock” (spark plug suddenly
and the cylinder head seats must be in good contact for operating too hot).
proper heat transfer and spark plug cooling. Dirty or • Damage during re-gapping can happen if the gapping
damaged threads in the head or on the spark plug can tool is pushed against the center electrode or the
keep it from seating even though the proper torque is insulator around it, causing the insulator to crack.
applied. Once spark plugs are properly seated, tighten When re-gapping a spark plug, make the adjustment
them to the torque shown in the Specifications Table. by bending only the ground side terminal, keeping the
Low torque may result in poor contact of the seats due tool clear of other parts.
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poor
contact between the seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug re-
gapping, or heat shock to the insulator material. Upper
insulators can be broken when a poorly fitting tool is
used during installation or removal, when the spark plug
is hit from the outside, or is dropped on a hard surface.
Cracks in the upper insulator may be inside the shell
and not visible. Also, the breakage may not cause
problems until oil or moisture penetrates the crack later.
• “Heat shock” breakage in the lower insulator tip

generally occurs during several engine operating
conditions (high speeds or heavy loading) and may
be caused by over-advanced timing or low grade
fuels. Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped, then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.
GENERAL DESCRIPTION FOR EVAP Emission Control System Operation
EVAPORATIVE EMISSION SYSTEM The EVAP canister purge is controlled by a solenoid
valve that allows the manifold vacuum to purge the
canister. The engine control module (ECM) supplies a
ground to energize the solenoid valve (purge on). The
EVAP purge solenoid control is pulse-width modulated
(PWM) (turned on and off several times a second). The
duty cycle (pulse width) is determined by engine
operating conditions including load, throttle position,
coolant temperature and ambient temperature. The duty
cycle is calculated by the ECM. the output is
commanded when the appropriate conditions have
been met. These conditions are:
• The engine is fully warmed up.
• The engine has been running for a specified time.
• The IAT reading is above 10°C (50°F).
• Purge/Vacuum Hoses. Made of rubber compounds,
1 3 2 these hoses route the gasoline fumes from their
sources to the canister and from the canister to the
(1) Purge Solenoid Valve intake air flow.
(2) From Canistor to Purge Solenoid • EVAP Canister. Mounted on a bracket ahead of the
(3) From Purge Solenoid to Intake fuel tank, the canister stores fuel vapors until the
ECM determined that engine conditions are right for
them to be removed and burned.
Poor idle, stalling and Poor driveability can be caused
by:
• A malfunctioning purge solenoid.
• A damaged canister.
• Hoses that are split, cracked, or not connected
properly.
System Fault Detection

The EVAP leak detection strategy is based on applying
vacuum to the EVAP system and monitoring vacuum
1 2 decay. At an appropriate time, the EVAP purge solenoid
is turned “ON,” allowing the engine vacuum to draw a
(1) Canistor small vacuum on the entire evaporative emission
(2) Air Separator system.
After the desired vacuum level has been achieved, the
EVAP Emission Control System Purpose EVAP purge solenoid is turned “OFF,” sealing the
The basic evaporative emission control system used on system. A leak is detected by monitoring for a decrease
the charcoal canister storage method. The method in vacuum level over a given time period, all other
transfers fuel vapor from the fuel tank to an activated variables remaining constant.
carbon (charcoal) storage devise to hold the vapors If the desired vacuum level cannot be achieved in the
when the vehicle is not operating. test described above, a large leak or a faulty EVAP
The canister is located on the rear axle housing by the purge control solenoid valve is indicated.
frame cross-member. Leaks can be caused by the following conditions:
When the engine is running, the fuel vapor is purged • Missing or faulty fuel cap
from the carbon element by intake air flow and • Disconnected, damaged, pinched, or blocked EVAP
consumed in the normal combustion process. purge line
• Disconnected, damaged, pinched, or blocked fuel
tank vapor line
• Disconnected or faulty EVAP purge control solenoid
valve
• Open ignition feed circuit to the purge solenoid
• Damaged EVAP canister
• Leaking fuel sender assembly O-ring
• Leaking fuel tank or fuel filler neck
The ECM supplies a ground to energize the purge
control solenoid valve (purge “ON” ). The EVAP purge
control is turned “ON” and “OFF,” several times a
second. The duty cycle (pulse width) is determined by
engine operating conditions including load, throttle
position, coolant temperature and ambient temperature.
The duty cycle is calculated by the ECM and the output
is commanded when the appropriate conditions have
been met.
The system checks for conditions that cause the EVAP
system to purge continuously by commanding the EVAP
purge solenoid “OFF”, EVAP purge solenoid duty ratio
“0%”. If fuel tank vacuum level increases during the test,
a continuous purge flow condition is indicated. This can
be caused by the following conditions:
• EVAP purge solenoid leaking
• EVAP purge and engine vacuum lines switched at the
EVAP purge control solenoid valve
• EVAP purge control solenoid valve driver circuit
grounded
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
Crankcase Ventilation System Purpose
The crankcase ventilation system is used to consume
crankcase vapors in the combustion process instead of
venting them to the atmosphere. Fresh air from the
throttle body is supplied to the crankcase and mixed
with blow-by gases. This mixture is then passed through
the positive crankcase ventilation (PCV) port into the
intake manifold.
While the engine is running, exhaust gases and small
amounts of the fuel/air mixture escape past the piston
rings and enter the crankcase. these gases are mixed
with clean air entering through a tube from the air intake
duct.
During normal, part-throttle operation, the system is

designed to allow crankcase gases to flow through the
PCV hose into the intake manifold to be consumed by
normal combustion.
A plugged positive crankcase ventilation port or PCV
hose may cause the following conditions:
• Rough idle.
• Stalling or slow idle speed.
• Oil leaks.
• Sludge in the engine.
A leaking PCV hose would cause:
• Rough idle.
• Stalling.
• High idle speed.
A/C CLUTCH DIAGNOSIS

A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of
the ECM when the A/C is selected through the A/C
control switch.
The A/C compressor clutch relay is controlled through
the ECM. This allows the ECM to modify the idle air
control position prior to the A/C clutch engagement for
better idle quality. If the engine operating conditions are
within their specified calibrated acceptable ranges, the
ECM will enable the A/C compressor relay. This is done
by providing a ground path for the A/C relay coil within
the ECM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor relay is
enabled, battery voltage is supplied to the compressor
clutch coil.
The ECM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The ECM will not enable the A/C
compressor clutch if any of the following conditions are
met:
• The engine speed is greater than 6000 RPM.
• The ECT is greater than 122°C (251°F).
• The throttle is more than 95% open.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the
engine control module (ECM) for the following reasons:
• It improves idle quality during compressor clutch
engagement.
• It improves wide open throttle (WOT) performance.
• It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
• The A/C control switch.
• The A/C refrigerant pressure switches.
• The A/C compressor clutch.
• The A/C compressor clutch relay.
• The ECM.
A/C Request Signal

This signal tells the ECM when the A/C mode is
selected at the A/C control switch. The ECM uses this
input to adjust the idle speed before turning on the A/C
clutch. The A/C compressor will be inoperative if this
signal is not available to the ECM.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for the A/C electrical system.
ISUZU STRATEGY BASED DIAGNOSTICS


Strategy Based Diagnostics chart requires you to use • Complaint check sheet
customer complaint
parts
perspectives
OBVIOUS
actions:
correct (normal) operating behavior of the system and • Make a visual inspection for separated connectors
checks:
– Harness routing

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• Service manual
What you should do
charts)?
data) switched?
VSS, for example)?
drivetrain or suspension components without • Experience
What you should do
complaint.

component
components) blower, lights or rear window defogger) to create a load
• Bulletins
What you should do
by:
checks
• Experience
• Experience

What you should do


• Service manual
path

What you should do

GENERAL SERVICE INFORMATION Non-OEM Parts

Aftermarket Electrical and Vacuum with OEM parts. Accordingly, if commercially sold
Equipment sensor or switch is installed, it makes a wrong diagnosis
Aftermarket (add-on) electrical and vacuum equipment Aftermarket electronics, such as cellular phones,
is defined as any equipment which connects to the stereos, and anti-theft devices, may radiate EMI into the
vehicle's electrical or vacuum systems that is installed control system if they are improperly installed. This may
on a vehicle after it leaves the factory. No allowances cause a false sensor reading and turn on the check
have been made in the vehicle design for this type of engine lamp.
equipment.
NOTE: No add-on vacuum equipment should be added Poor Vehicle Maintenance
to this vehicle. The sensitivity of OBD diagnostics will cause the check
NOTE: Add-on electrical equipment must only be engine lamp to turn on if the vehicle is not maintained
connected to the vehicle's electrical system at the properly. Restricted oil filters, fuel filters, and crankcase
battery (power and ground). deposits due to lack of oil changes or improper oil
Add-on electrical equipment, even when installed to viscosity can trigger actual vehicle faults that were not
these guidelines, may still cause the electric system to previously monitored prior to OBD. Poor vehicle
malfunction. This may also include equipment not maintenance can not be classified as a “non-vehicle
connected to the vehicle electrical system such as fault”, but with the sensitivity of OBD diagnostics,
portable telephones and radios. Therefore, the first step vehicle maintenance schedules must be more closely
in diagnosing any electric problem is to eliminate all followed.
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be Related System Faults
diagnosed in the normal manner.
Many of the OBD system diagnostics will not run if the
ECM detects a fault on a related system or component.
Electrostatic Discharge Damage
Visual/Physical Engine Compartment
Inspection
Perform a careful visual and physical engine
compartment inspection when performing any
emission test failure. This can often lead to repairing a
• Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Electronic components used in the ECM are often • Inspect hoses that are difficult to see behind other
designed to carry very low voltage. Electronic components.
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static • Inspect all wires in the engine compartment for
electricity can cause damage to some electronic proper connections, burned or chafed spots, pinched
components. By comparison, it takes as much as 4000 wires, contact with sharp edges or contact with hot
volts for a person to feel even the zap of a static exhaust manifolds or pipes.
discharge.
There are several ways for a person to become statically Basic Knowledge of Tools Required
charged. The most common methods of charging are by NOTE: Lack of basic knowledge of this powertrain
friction and induction. when performing diagnostic procedures could result in
• An example of charging by friction is a person sliding an incorrect diagnosis or damage to powertrain
across a vehicle seat. components. Do not attempt to diagnose a powertrain
• Charge by induction occurs when a person with well- problem without this basic knowledge.
insulated shoes stands near a highly charged object A basic understanding of hand tools is necessary to
and momentarily touches ground. Charges of the effectively use this section of the Service Manual.
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
to use care when handling and testing electronic
components.
On-Board Diagnostic (OBD) suspected due to a driveability or emissions problem,

a Powertrain On-Board Diagnostic (OBD) System
On-Board Diagnostic Tests Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
A diagnostic test is a series of steps, the result of which System Check. These checks will expose faults which
is a pass or fail reported to the diagnostic executive. may not be detected if other diagnostics are
When a diagnostic test reports a pass result, the performed first.
• The diagnostic test has been completed since the Data Link Connector (DLC)
last ignition cycle. The provision for communication with the contorl
• The diagnostic test has passed during the current module is the Data Link Connector (DLC). It is located
ignition cycle. behind the lower front instrument panel. The DLC is
• The fault identified by the diagnostic test is not used to connect to a Tech2. Some common uses of the
currently active. Tech2 are listed below:
When a diagnostic test reports a fail result, the • Identifying stored Diagnostic Trouble Codes (DTCs).
• Clearing DTCs.
• The diagnostic test has been completed since the • Reading serial data.
last ignition cycle.
active.
• The fault has been active during this ignition cycle.
• The operating conditions at the time of the failure.
The Diagnostic Executive

the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
follows:
• Commanding the check engine lamp on and off
• DTC logging and clearing
• Current status information on each diagnostic
Diagnostic Information
a process of logical decisions. The charts are prepared Verifying Vehicle Repair
with the requirement that the vehicle functioned Verification of vehicle repair will be more comprehensive
correctly at the time of assembly and that there are not for vehicles with OBD system diagnostic. Following a
multiple faults present. repair, the technician should perform the following
There is a continuous self-diagnosis on certain control steps:
functions. This diagnostic capability is complemented
by the diagnostic procedures contained in this manual. 1. Review and record the Fail Records for the DTC
The language of communicating the source of the which has been diagnosed.
malfunction is a system of diagnostic trouble codes. 2. Clear DTC(s).
When a malfunction is detected by the control module, a 3. Operate the vehicle within conditions noted in the
diagnostic trouble code is set and the check engine Fail Records.
lamp is illuminated. 4. Monitor the DTC status information for the specific
Check Engine Lamp DTC which has been diagnosed until the diagnostic
The check engine lamp looks the same as the check
engine lamp you are already familiar with, the “Check
Engine” lamp.
Basically, the check engine lamp is turned on when the
ECM detects a DTC that will impact the vehicle
emissions.
• When the check engine lamp remains “ON” while the
engine is running, or when a malfunction is
Reading Diagnostic Trouble Codes Using a 1. Configuration of Tech 2
Tech 2 • Tech 2 scan tool kit (No. 7000086), Tech 2 scan
to used a diagnostic Tech2. When reading DTC(s), • SAE 16/19 adapter (No. 3000098) (3), RS232
follow instructions supplied by Tech2 manufacturer. loop back connector (No. 3000112) (2) and
Clearing Diagnostic Trouble Codes 2. Tech 2 Connection
To clear Diagnostic Trouble Codes (DTCs), use the • Check the key switch is turn OFF.
Tech2 “clear DTCs” or “clear information” function. • Insert the PCMCIA card (1) into the Tech 2 (5).
Tech2 manufacturer.
cable (4).
Diagnosis With Tech 2 • Connect the DLC cable (4) to the Tech 2 (5).
• Connect the SAE 16/19 adapter (3) to the data
If no codes are set: link connector of the vehicle.
• Refer to F1: Data Display and identify the electrical
faults that are not indicated by trouble code.
If codes are set:

2. Clear the codes.
status.
AIDS”.
diagnosis.
• Turn the key switch of the vehicle ON and press
Tech 2 CONNECTION the “PWR” key of the Tech 2.
card.

Tech 2.
Tech 2 Operating Flow Cart (Start Up)
(TBR)
(N*) ELF, NPR, NQR

F3: Tool Option

(2) 2002 4JH1-T Denso
(1) 2001 2.XL L4 HV240
(X) 1999 AW30-40LE
(W) 1998 AT JR405E
Select “(3) 2003” or later. Select “2.XL L4 HV240”.

Select “2.XL L4 HV240” in Vehicle Identification menu and the following table is shown in the Tech 2 screen.
History
F0: Diagnostic Trouble Code This selection will display only DTCs that are stored in
F0: Read DTC Infor By Priority the ECM's history memory. It will not display Type B
DTCs that have not requested the MIL (“Check Engine
F1: Clear DTC Information
Lamp”). It will display all type A and B DTCs that
F2: DTC Information requested the MIL and have failed within the last 40
warm-up cycles. In addition, it will display all type C and
F0: History
D DTCs that have failed within the last 40 warm-up
F1: MIL SVS or Message Requested cycles.
F2: Last Test Failed
MIL SVC or Message Request
F3: Test Failed Since Code Cleared This selection will display only DTCs that are requesting
the MIL. Type C and Type D DTCs cannot be displayed
F4: Not Run Since Code Cleared
using the MIL. Type C and D DTCs cannot be displayed
F5: Failed This Ignition using this option.
This selection will report type B DTCs only after the MIL
has been requested.
F1: Data Display
F0: Engine Data Last Test Failed
This selection will display only DTCs that have failed the
F1: O2 Sensor Data last time the test run. The last test may have run during
a previous ignition cycle of a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
F2: Snapshot must have occurred during the current ignition cycle to
appear as last test fail.
F3: Miscellaneous Test Test Failed Since Code Cleared

F0: Lamps The selection will display all active and history DTCs
that have reported a test failure since the last time DTCs
F0: Malfunction Indicator Lamps
were cleared. DTCs that last failed more that 40 warm-
F1: Relays up cycles before this option is selected will not be
displayed.
F0: Fuel Pump Relay
F1: A/C Clutch Relay Failed This Ignition
This selection will display all DTCs that have failed
F2: EVAP
during the present ignition cycle.
F0: Purge Solenoid
F1: Data Display
F3: IAC System
F0: IAC Control continuously monitor data parameters.
The current actual values of all important sensors and
F1: IAC Reset
signals in the system are display through F1 mode.
F4: Injector Balance Test See the “Typical Scan Data” section.
F2: Snapshot
F4: Programming “Snapshot” allows you to focus on making the condition
F0: Program VIN occur, rather than trying to view all of the data in
F0: Diagnostic Trouble Code The snapshot will collect parameter information around
The purpose of the “Diagnostic Trouble Codes” mode is a trigger point that you select.
When “Clear DTC Information” is selected, a “Clear F3: Miscellaneous Test:
DTC Information”, warning screen appears. The purpose of “Miscellaneous Test” mode is to check
This screen informs you that by cleaning DTC's “all for correct operation of electronic system actuators.
After clearing codes, confirm system operation by test F4: Programming (Factory Use Only)
driving the vehicle. The purpose of “Programming” is to program VIN in the
Use the “DTC Information” mode to search for a specific ECM and lock the programmed data.
type of stored DTC information.
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
80 deg.)
Tech 2 Parameter Units Idle 2000rpm Description

1 Engine Speed rpm 775 - 875 1950 - 2050 The actual engine speed is measured by ECM from the
CKP sensor 58X signal.
2 Desired Idle Speed rpm 825 800 - 850 The desired engine idle speed that the ECM
commanding. The ECM compensates for various engine
loads.
3 Engine Coolant °C or °F 80 - 90 80 - 90 The ECT is measured by ECM from ECT sensor output
Temperature voltage. When the engine is normally warm upped, this
data displays approximately 80 °C or more.
4 Start Up ECT (Engine °C or °F Depends on engine Depends on engine Start-up ECT is measured by ECM from ECT sensor
Coolant Temperature) coolant temp. at coolant temp. at output voltage when engine is started.
time of start-up time of start-up
5 Intake Air °C or °F Depends on Depends on The IAT is measured by ECM from IAT sensor output
Temperature ambient temp. ambient temp. voltage. This data is changing by intake air temperature.
6 Start Up IAT (Intake °C or °F Depends on Depends on Start-up IAT is measured by ECM from IAT sensor output
Air Temperature) ambient temp. at ambient temp. at voltage when engine is started.
start-up start-up
7 Manifold Absolute Kpa 33 - 38 26 - 30 The MAP (Kpa) is measured by ECM from MAP output
Pressure voltage. This data is changing by inlet manifold pressure.
8 Throttle Position % 0 2-5 Throttle position operating angle is measured by the
ECM from throttle position output voltage. This should
9 Barometric Pressure Kpa Depends on Depends on The barometric pressure is measured by ECM from the
altitude altitude MAP sensor output voltage monitored during key up and
wide open throttle. This data is changing by altitude.
10 Calculated Air Flow g/s 4.0 - 5.0 8.0 - 10.0
11 Air Fuel Ratio 14.6:1 14.6:1 This displays the ECM commanded value. In closed loop,
this should normally be displayed around 14.2:1 - 14.7:1.
12 Spark Advance °CA 10 - 15 25 - 32 This displays the amount of spark advance being
commanded by the ECM.
13 Engine Load % 2-5 5 - 10 This displays is calculated by the ECM form engine
speed and MAF sensor reading. Engine load should
increase with an increase in engine speed or air flow
amount.
14 Injection Pulse Width ms 3.0 - 4.5 3.0 - 4.0 This displays the amount of time the ECM is
commanding each injector On during each engine cycle.
A longer injector pulse width will cause more fuel to be
delivered. Injector pulse width should increase with
increased engine load.
15 Fuel System Status Open Loop/ Close Loop Close Loop When the engine is first started the system is in “Open
Close Loop Loop” operation. In “Open Loop”, the ECM ignores the
signal from the oxygen sensors. When various conditions
(ECT, time from start, engine speed & oxygen sensor
output) are met, the system enters “Closed Loop”
operation. In “Closed Loop”, the ECM calculates the air
fuel ratio based on the signal from the oxygen sensors.
16 Knock Present Yes/No No No
17 Knock Counter - -
18 Knock Retard °CA 0 0 This displays the commanded ignition spark timing retard
timing based on the signal from the knock sensor.
19 A/C Clutch Relay On/Off Off Off This displays whether the ECM has commanded the A/C
compressor clutch “On” or “Off”.

20 A/C Request Yes/No Off Off This displays the air conditioner request signal. This
should display “On” when the air conditioner switch is
switched on.
21 EVAP Purge Solenoid % 0 - 10 0 - 10 This displays the duty signal from the ECM to control the
(Evaporative canister purge solenoid valve.
Emission)
22 Deceleration Fuel Active/ Inactive Inactive The ECM reduces the amount of fuel injected when it
Cutoff Inactive detects a decrease in the throttle position and the air flow.
When deceleration is very fast, the ECM may cut off fuel
completely. Until enable conditions meet the engine
revolution less than 1000rpm or MAP less than 10KPa.
23 Fuel Pump On/Off On On This displays operating status for the fuel pump main
relay. This should display “On” when the key switch is
turned on and while engine is running.
24 Idle Air Control Steps 20 - 30 65 - 75 This displays the ECM commanded position of the idle air
control valve pintle. A larger number means that more air
is being commanded through the idle air passage.
25 Idle Speed Variation rpm -25 - 0 1125 - 1225
26 Vehicle Speed km/h or 0 0 This displays vehicle speed. The vehicle speed is
mph measured by ECM from the vehicle speed sensor.
27 Ignition Voltage V 11.0 - 14.5 11.0 - 14.5 This displays the system voltage measured by the ECM
at ignition feed.
28 Reference Voltage V 5.00 5.00
29 Malfunction Indicator On/Off Off Off This displays operating status for the Check Engine
Lamp is turned on.
30 Time From Start - - This displays the engine time elapsed since the engine
was started. If the engine is stopped, engine run time will
be reset to 00:00:00
TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA)
80 deg.)

1 Engine Speed rpm 710 - 860 1950 - 2050 The actual engine speed is measured by ECM from the
CKP sensor 58X signal.
2 Desired Idle Speed rpm 800 - 850 800 - 850 The desired engine idle speed that the ECM
commanding. The ECM compensates for various engine
loads.
3 Engine Coolant °C or °F 80 - 90 80 - 90 The ECT is measured by ECM from ECT sensor output
Temperature voltage. When the engine is normally warm upped, this
data displays approximately 80 °C or more.
4 Start Up ECT (Engine °C or °F Depends on engine Depends on engine Start-up ECT is measured by ECM from ECT sensor
Coolant Temperature) coolant temp. at coolant temp. at output voltage when engine is started.
time of start-up time of start-up
5 Intake Air °C or °F Depends on Depends on The IAT is measured by ECM from IAT sensor output
Temperature ambient temp. ambient temp. voltage. This data is changing by intake air temperature.
6 Start Up IAT (Intake °C or °F Depends on Depends on Start-up IAT is measured by ECM from IAT sensor output
Air Temperature) ambient temp. at ambient temp. at voltage when engine is started.
start-up start-up
7 Manifold Absolute Kpa 33 - 38 26 - 30 The MAP (Kpa) is measured by ECM from MAP output
Pressure voltage. This data is changing by inlet manifold pressure.
8 Barometric Pressure Kpa Depends on Depends on The barometric pressure is measured by ECM from the
altitude altitude MAP sensor output voltage monitored during key up and
wide open throttle. This data is changing by altitude.
9 Throttle Position % 0 2-5 Throttle position operating angle is measured by the
ECM from throttle position output voltage. This should
10 Calculated Air Flow g/s 4.0 - 5.0 8.0 - 10.0 This displays intake air amount. The mass air flow is
measured by ECM from the MAF sensor output voltage.
11 Air Fuel Ratio 14.6:1 14.6:1 This displays the ECM commanded value. In closed loop,
this should normally be displayed around 14.2:1 - 14.7:1.
12 Fuel System Status Open Loop/ Close Loop Close Loop When the engine is first started the system is in “Open
Close Loop Loop” operation. In “Open Loop”, the ECM ignores the
signal from the oxygen sensors. When various conditions
(ECT, time from start, engine speed & oxygen sensor
output) are met, the system enters “Closed Loop”
operation. In “Closed Loop”, the ECM calculates the air
fuel ratio based on the signal from the oxygen sensors.
13 Engine Load % 2-5 5 - 10 This displays is calculated by the ECM form engine
speed and MAF sensor reading. Engine load should
increase with an increase in engine speed or air flow
amount.
14 B1 O2 Sensor Ready Yes/No Yes Yes This displays the status of the exhaust oxygen sensor.
(Bank 1) This display will indicate “Yes” when the ECM detects a
fluctuating oxygen sensor output voltage sufficient to
allow closed loop operation. This will not occur unless the
oxygen sensor is warmed up.
15 B1S1 Status Rich / Lean Rich / Lean Rich / Lean This displays dependent on the exhaust oxygen sensor
(Bank 1 Sensor 1) output voltage. Should fluctuate constantly “Rich” and
“Lean” in closed loop.
16 Fuel Trim Learned Yes/No Yes Yes When conditions are appropriate for enabling long term
fuel trim corrections, fuel trim learn will display “Yes”. This
indicates that the long term fuel trim is responding to the
short term fuel trim. If the fuel trim lean displays “No”,
then long term fuel trim will not respond to changes in
short term fuel trim.

17 Fuel Trim Cell 15 - 20 1 This displays dependent on engine speed and calculated
intake air flow reading. A plot of engine speed versus
intake air flow amount is divided into the cells. Fuel trim
cell indicates which cell is currently active.
18 B1S1 O2 Sensor mV 50 - 950 50 -950 This displays the exhaust oxygen sensor output voltage.
(Bank1 Sensor 1) Should fluctuate constantly within a range between 10mV
(lean exhaust) and 1000mV (rich exhaust) while
operating in closed loop.
19 B1 Short Term Fuel % -3 - 0 -10 - 14 The short term fuel trim to a bank represents a short term
Trim (Bank 1) correction to the bank fuel delivery by the ECM in
response to the amount of time the bank fuel control
oxygen sensor voltage spends above or below the
450mV threshold. If the oxygen sensor voltage has
mainly remained less than 450mV, indicating a lean air/
fuel, short term fuel trim will increase into the positive
range above 0% and the ECM will pass fuel. If the
oxygen sensor voltage stays mainly above the threshold,
short term fuel trim will decrease below 0% into the
negative range while the ECM reduces fuel delivery to
compensate for the indicated rich condition. Under
certain conditions such as extended idle and high
ambient temperatures, canister purge may cause short
term fuel trim to read in the negative range during normal
operation. Fuel trim values at maximum authority may
indicate an excessively rich or lean system.
20 B1 Long Term Fuel % -10 - 0 0 The long term fuel trim is delivered from the short term
Trim (Bank 1) fuel term values and represents a long term correction of
fuel delivery for bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
the ECM commanded air fuel ratio. A negative value
indicates that the fuel system is rich and fuel delivery is
being reduced (decreased injector pulse width). A
positive value indicates that a lean condition exists and
the ECM is compensating by add fuel (increased injector
pulse width). Because long term fuel trim tends to follow
short term fuel trim, a value in the negative range due to
canister purge at idle should not be considered unusual.
Fuel trim values at maximum authority may indicate an
excessively rich or lean system.
21 Power Enrichment Yes/No No No The ECM provides the extra amount of fuel when it
detects a rapid increase in the throttle position and air
flow (Power Enrichment). Under this condition the ECM
should detect a “rich condition (high oxygen sensor
voltage).
22 Time From Start - - This displays the engine time elapsed since the engine
was started. If the engine is stopped, engine run time will
be reset to 00:00:00
MISCELLANEOUS TEST F3: IAC System
F0: IAC Control
The state of each circuit can be tested by using When the Tech 2 is operated, “Idle Air Control”
miscellaneous test menus. Especially when DTC cannot increases or decreases 5steps-by-5steps up to
be detected, a faulty circuit can be diagnosed by testing 150steps.
each circuit by means of these menus. The circuit is normal if idle engine speed is changed in
Even DTC has been detected, the circuit tests using accordance with this operation.
IAC Control
Connect Tech 2 and select “Powertrain”, “2.XL L4
HV240” & “Miscellaneous Test”. Engine Speed 800 RPM
F0: Lamps
Engine Coolant Temperature 80 °C
F0: Malfunction Indicator Lamp
When the Tech 2 is operated, “Malfunction Indicator Start Up ECT 50 °C
Lamp (Check Engine Lamp)” is turned on or off. Intake Air Temperature 30 °C
Start Up IAT 25 °C
on or off in accordance with this operation. Manifold Absolute Pressure 35KPa
Idle Air Control 30 Steps
F1: Relays
F0: Fuel Pump Relay – Press “Increase” key.
When the Tech 2 is operated, fuel pump relay signal Then, Idle Air Control is increases 1osteps-by-
turns ON or OFF. 10steps up to 160steps. Engine speed is also
The circuit is normal if fuel pump sound is generated in changed by this operation.
accordance with this operation when key switch is – Press “Quit” Key.
turned ON.
F1: IAC Reset
F1: A/C Clutch Relay When the Tech 2 is operated, “Idle Air Control” resets.
When the Tech 2 is operated, A/C clutch relay signal The circuit is normal if idle engine speed is droped in
turns ON or OFF. accordance with this operation.
The circuit is normal if A/C compressor clutch is
energized in accordance with this operation when the IAC Reset
engine is running. 800 RPM
Engine Speed
F2: EVAP Desired Idle Speed 762 RPM
F0: Purge Solenoid 80 °C
Engine Coolant Temperature
When the Tech 2 is operated, duty ratio of EVAP purge
solenoid is changed 10%-by-10%. Start Up ECT 50 °C
Intake Air Temperature 30 °C
Purge Solenoid Start Up IAT 25 °C
Engine Speed 800 RPM 35KPa
Manifold Absolute Pressure
Desired Idle Speed 762 RPM 30 Steps
Idle Air Control
Engine Coolant Temperature 80 °C
– Press “Increase” key.
Start Up ECT 50 °C
Then, Desired Idle speed is increases 50rpm-by-
Intake Air Temperature 30 °C 50rpm up to 1550rpm. Engine speed is also changed
Start Up IAT 25 °C by this operation.
– Press “Quit” Key.
Manifold Absolute Pressure 35KPa
EVAP Purge Solenoid 30 %
– Press “Increase” key.

Then, EVAP Purge Solenoid is increases 10%-by-
10%.
F4: Injector Balance Test
When the Tech 2 is operated, selected injector turns ON
or OFF.
The circuit is normal if engine vibration is changed at
selected cylinder in accordance with this operation
when engine is idling.
Injector Balance Test

Engine Coolant Temperature 80
Start Up ECT 50
Intake Air Temperature 30
Start Up IAT 25
Manifold Absolute Pressure 35KPa
Injector 1 On
– Press “Injector Off” key.

Then, engine speed drops and vibration occurs when
a cylinder is selected.
PLOTTING SNAPSHOT GRAPH

060RX037

is not available.
D06RY00167
060RX0-40

below shown:

1. Start TIS2000.
screen.
information.

procedures.
1. Start TIS2000.
screen.
list on the screen.
window opens. icon.
screen.
The procedure to program the control unit by using the latest software release.
procedure.

with the following.
“Continue”.
2. Demand of Data
switch.
engine)

• Model Year
switch of Tech-2, turn off the ignition of the vehicle described at the right-hand edge of Body Type line. In
and turn off the power of Tech-2, thereby removing Fig.-3, the destination code can be read as “EK4
from the vehicle.
(Europe)”.
form of bar graph.
comes on display.
start)
button.
3 1

(2) Harness Adapter

4 3 1 5 2

(3) Breaker Box

4 3 1 5 2

(3) Breaker Box

Buttery
Voltage
Ignition
SW
METER
10A
METER
15A
0.5
RED/
YEL
Diagnostic
16 15 14 13 12 11 10 9 Comectar
8 7 6 5 4 3 2 1
Check
Engine
Lamp
0.85 BLK
Imnobiliser
Control
Unit Engine
Room-RH
7
0.5 0.5
0.5 BLU GRN
BRN/
YEL
J2-32 J2-4 J2-30

Engine
Module SW Serial
(ECM) Data
µP
Circuit Description Test Description

The on-board diagnostic system check is the starting Number(s) below refer the step number(s) on the
point for any driveability complaint diagnosis. Before Diagnostic Chart:
using this procedure, perform a careful visual/physical 1. The Check Engine Lamp (MIL) should be ON steady
check of the ECM and engine grounds for cleanliness with the ignition “On”, engine “Off”. If not, “No Check
and tightness. Engine Lamp (MIL)” chart should be used to isolate the
The on-board diagnostic system check is an organized malfunction.
approach to identifying a problem created by an 2. Checks the Class 2 data circuit and ensures that the
electronic engine control system malfunction. ECM is able to transmit serial data.
3. This test ensures that the ECM is capable of
Diagnostic Aids controlling the Check Engine Lamp (MIL) and the Check
Engine Lamp (MIL) driver circuit is not shorted to
An intermittent may be caused by a poor connection,
ground circuit.
rubbed-through wire insulation or a wire broken inside 4. If the engine will not start, “Engine Cranks But Will
the insulation. Check for poor connections or a Not Run” chart should be used to diagnose the fault.
damaged harness. Inspect the ECM harness and
6. The Tech2 parameters which is not within the typical
connector for improper mating, broken locks, improperly range may help to isolate the area which is causing the
formed or damaged terminals, poor terminal-to-wire problem.
connection, and damaged harness.
12. This vehicle is equipped with ECM which utilizes an
electrically erasable programmable read only memory
(EEPROM).

2. Attempt to display “Engine Data” with the Tech 2.
Does the Tech 2 display “Engine Data” and “O2
Sensor Data”? — Go to Step 3 Go to Step 7
“Malfunction Indicator Lamp” in “Lamps”.
2. Select the “Read DTC Infor By Priority” in
Tech 2 “Engine Data” and “O2 Sensor Data”. SYMPTOM TYPICAL
B58
16
V Repair faulty
harness and
ground circuit.
4 5
B58
Repair faulty
harness and

ground circuit.
4 5
B58
V V Repair faulty
harness and
2 6
B58
V V Repair faulty
harness and
circuit.
30 C56(J2) 4 2 B58 6
Repair faulty
harness and
release?

13 Replace the ECM.
Buttery
Voltage
Ignition
SW
METER
10A
METER
15A
0.5
RED/
YEL
Diagnostic
16 15 14 13 12 11 10 9 Comectar
8 7 6 5 4 3 2 1
Check
Engine
Lamp
0.85 BLK
Imnobiliser
Control
Unit Engine
Room-RH
7
0.5 0.5
0.5 BLU GRN
BRN/
YEL
J2-32 J2-4 J2-30

Engine
Module SW Serial
(ECM) Data
µP
following items:
engine ground.

1 Check the “Meter” fuse (15A).

lamp circuit.
32
C56(J2)
V Battery
lamp circuit.
connector.
32 17
C56(J2) B24

release?
6 Replace the ECM.
Buttery
Voltage
Ignition
SW
METER
10A
METER
15A
0.5
RED/
YEL
Diagnostic
16 15 14 13 12 11 10 9 Comectar
8 7 6 5 4 3 2 1
Check
Engine
Lamp
0.85 BLK
Imnobiliser
Control
Unit Engine
Room-RH
7
0.5 0.5
0.5 BLU GRN
BRN/
YEL
J2-32 J2-4 J2-30

Engine
Module SW Serial
(ECM) Data
µP

directly to the check engine lamp indicator. The Engine • Poor connection or damaged harness - Inspect the
driver circuit.
Check Engine Lamp (MIL) “ON” Steady


lamp circuit.
connector.
32
C56(J2)

release?
5 Replace the ECM.
FUEL METERING SYSTEM CHECK FUEL INJECTOR COIL TEST PROCEDURE
Some failures of the fuel metering system will result in AND FUEL INJECTOR BALANCE TEST
an “Engine Cranks But Will Not Run” symptom. If this PROCEDURE
condition exists, refer to the Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the ECM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump.
Followings are applicable to the vehicles with
closed Loop System:
If a malfunction occurs in the fuel metering system, it
usually results in either a rich HO2S signal or a lean
HO2S signal. This condition is indicated by the HO2S
voltage, which causes the ECM to change the fuel
calculation (fuel injector pulse width) based on the
HO2S reading. Changes made to the fuel calculation
will be indicated by a change in the long term fuel trim
values which can be monitored with a Scan Tool. Ideal
long term fuel trim values are around 0%; for a lean
HO2S signal, the ECM will add fuel, resulting in a fuel
Test Description
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the Number(s) below refer to the step number(s) on the
same. If the evaporative emission canister purge is 02 Diagnostic Chart:
status may be rich condition. 02 status indicates the 2. Relieve the fuel pressure by connecting 5-8840-
lean condition, refer to DTC P1171 for items which can 0378-0 T-Joint to the fuel pressure connection on the
cause a lean HO2S signal. fuel rail.
Caution: In order to reduce the risk of fire and

personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge is
complete.
Place the fuel pressure gauge bleed hose in an
approved gasoline container.
With the ignition switch OFF open the valve on the
fuel pressure gauge.
3. Record the lowest voltage displayed by the DVM

after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
Voltage Specification at
Resistance Ohms
10°C-35°C (50°F-95°F)
11.8-12.6 5.7-6.6
• The voltage displayed by the DVM should be

within the specified range.
• The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector
windings changes.
• An erratic voltage reading (large fluctuations in 7. The Fuel Injector Balance Test portion of this chart
voltage that do not stabilize) indicates an (Step 7 through Step 11) checks the mechanical
intermittent connection within the fuel injector. (fuel delivery) portion of the fuel injector. An engine
5. Injector Specifications: cooldown period of 10 minutes is necessary in order
to avoid irregular fuel pressure readings due to “Hot
Highest Acceptable Voltage Soak” fuel boiling.
Acceptable
Reading Above/Below
Subtracted Value
35°C/10°C (95°F/50°F)
9.5Volts 0.6Volt
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
CYLINDER
1 2 3 4
1st Reading (1) 296kPa 296kPa 296kPa 296kPa
(43psi) (43psi) (43psi) (43psi)
2nd Reading (2) 205kPa 205kPa 196kPa 274kPa
(29psi) (29psi) (28psi) (39psi)
Amount of Drop 91kPa 91kPa 100kPa 22kPa
(1st Reading-2nd Reading) (14psi) (14psi) (15psi) (4psi)
Av. Drop = 166kPa/24psi Faulty, Lean Faulty, Lean Faulty, Lean Faulty, Lean
±10kPa/1.5psi (Too Little Fuel (Too Little Fuel (Too Little Fuel (Too Little Fuel
= 156 - 176kPa or Drop) Drop) Drop) Drop)
22.5 - 25.5psi
NOTE: These figures are examples only.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? — Go to Step 2 System Check
2 1. Turn the engine OFF.
NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Test
Description Number 2.
3. Connect the 5-8840-2618-0 Fuel Injector Tester to
B+ and ground, and to the 5-8840-2589-0 Injector
Adapter Cable.
4. Remove the harness connector of the Fuel
Injector and connect the 5-8840-2589-0 Injector
Adapter Cable for F/I check.
5. Set the amperage supply selector switch on the
fuel injector tester to the “Coil Test” 0.5 amp
position.
6. Connect the leads from the 5-8840-2392-0 Digital
Voltmeter (DVM) to the fuel injector tester. Refer to
the illustrations associated with the test
description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature. 10°C (50°F)
Is the engine coolant temperature within the specified to
values? 35°C (95°F) Go to Step 3 Go to Step 5
3 1. Set the injector adapter cable to injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector adapter cable to the next injector
and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values? 5.7-6.6V Go to Step 4 Go to Step 7
4 Replace the faulty fuel injector(S). Refer to Fuel
Injector.
Is the action complete? — Go to Step 7 —

5 1. Set the Injector Adapter Cable to injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the Injector Adapter Cable to the next injector
and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value? 9.5V Go to Step 4 Go to Step 6
6 1. Identify the highest voltage reading recorded
(other than those above 9.5V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted value in step 2
greater than the specified value? 0.6V Go to Step 4 Go to Step 7
7 Caution: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any
fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the Towel in an
approved container when the connection of the
fuel pressure gauge is complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the Scan Tool.
3. Place the bleed hose of the fuel pressure gauge
into an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading 296kPa- Go to Fuel
on the fuel pressure gauge. 376kPa System
Is the fuel pressure within the specified values? (43-55psi) Go to Step 8 Diagnosis
8 Turn the fuel pump OFF. Go to Fuel
Does the fuel pressure remain constant? System
— Go to Step 9 Diagnosis

9 1. Connect the 5-8840-0378-0 Fuel Injector Tester
and 5-8840-2589-0 Injector Adapter Cable to the
fuel injector harness connector.
2. Set the amperage supply selector switch on the
fuel injector tester to the “Balance Test” 0.5-2.5
amp position.
3. Using the Scan Tool turn the fuel pump ON then
OFF in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push
to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the
first pressure reading for one fuel injector. The
result is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values.
This is the total pressure drop.
11. Divide the total pressure drop by the number of
fuel injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or
lower than the average pressure drop by the specified 10kPa Go to OBD
value? (1.5psi) Go to Step 10 System Check
10 Re-test any fuel injector that does not meet the
specification. Refer to the procedure in Step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified 10kPa Go to
value? (1.5psi) Go to Step 11 Symptoms
11 1. Replace the faulty fuel injector(s). Refer to Fuel
Injector.
2. Disconnect the 5-8840-2589-0 Injector Adapter
Cable for F/I check and re-connect the original F/I
check connector.
FUEL SYSTEM ELECTRICAL TEST
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter

When the ignition switch is first turned ON, the engine An intermittent may be caused by a poor connection,
control module (ECM) energizes the fuel pump relay rubbed-through wire insulation, or a wire broken inside
which applies power to the in-tank fuel pump. The fuel the insulation. Check for the following items:
pump relay will remain ON as long as the engine is • Poor connection or damaged harness - Inspect the
running or cranking and the ECM is receiving 58X ECM harness and connectors for improper mating,
crankshaft position pulses. If no 58X crankshaft position broken locks, improperly formed or damaged
pulses are present, the ECM de-energizes the fuel terminals, poor terminal-to-wire connection, and
pump relay within 2 seconds after the ignition is turned damaged harness.
ON or the engine is stopped. Caution: To reduce the risk of fire and personal
The fuel pump delivers fuel to the fuel rail and injectors, injury:
then to the fuel pressure regulator. The fuel pressure • It is necessary to relieve fuel system pressure
regulator controls fuel pressure by allowing excess fuel before connecting a fuel pressure gauge.
to be returned to the fuel tank. With the engine stopped Refer to Fuel Pressure Relief Procedure,
and ignition ON, the fuel pump can be turned ON by below.
using a command by the scan tool.
• A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
Fuel Pressure Relief Procedure Fuel Pressure Gauge Installation
1. Remove the fuel cap. 1. Remove the fuel pressure fitting cap.
2. Remove the fuel pump relay from the underhood 2. Install fuel pressure gauge 5-8840-0378-0 to the
relay center. fuel feed line located in front of and above the right
3. Start the engine and alow it to stall. side valve cover.
4. Crank the engine for an additional 3 seconds. 3. Reinstall the fuel pump relay.
Fuel System Electrical Test

(OBD) System
“Fuel Pump Relay” in the “Relays”.
3. Operate the Tech 2 in accordance with procedure. Go to Fuel
Was the fuel pump operated, when the Tech 2 is System
operated? — Diagnosis Go to Step 3
3 Check the “Fuel Pump” fuse (20A).
4 Check for poor/faulty connection at the fuel pump, fuel
pump relay or ECM connector. If a poor/faulty
11
C56(J2)
X2 F2

5 Using the DVM and check the fuel pump relay.
2. Remove the fuel pump relay from the relay box.
Fuel Pump Relay
4 3
Replace fuel
pump relay and

6 Using the DVM and check the fuel pump relay power
supply circuit.
circuit.
X2
3
V
Battery
“ECM” fuse (15A) and fuel pump relay.
8 Using the DVM and check the fuel pump relay ground
circuit.
circuit.
11 C56(J2) X2
Repair faulty
harness and
9 Using the DVM and check the fuel pump relay power
supply circuit.
1 X2
V
Battery

10 Repair the open circuit between the fuel pump relay
and battery.
11 Using the DVM and check the fuel pump power supply
circuit.
2. Disconnect the fuel pump connector.
circuit.
F2
1
V Battery
fuel pump relay and fuel pump.
13 Using the DVM and check the fuel pump ground
circuit.
2. Disconnect the fuel pump connector.
F2
4
V
Continuity Go to Step 15 Go to Step 14
14 Repair the open circuit between the fuel pump and
body ground.
15 Replace the fuel pump.
release?

17 Replace the ECM.
FUEL SYSTEM DIAGNOSIS
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
Circuit Description Test Description

When the ignition switch is turned ON, the engine Number(s) below refer to the step number(s) on the
control module (ECM) will turn ON the in-tank fuel Diagnostic Chart.
pump. The in-tank fuel pump will remain ON as long as 2. Connect the fuel pressure gauge to the fuel feed line
the engine is cranking or running and the ECM is as shown in the fuel system illustration. Wrap a shop
receiving 58X crankshaft position pulses. If there are no towel around the fuel pressure connection in order to
58X crankshaft position pulses, the ECM will turn the in- absorb any duel leakage that may occur when
tank fuel pump OFF 2 seconds after the ignition switch installing the fuel pressure gauge. With the ignition
is turned ON or 2 seconds after the engine stops switch ON and the fuel pump running, the fuel
running. pressure indicated by the fuel pressure gauge
The in-tank fuel pump is an electric pump within an should be 283-376 kPa (41-55 psi). This pressure is
integral reservoir. The in-tank fuel pump supplies fuel controlled by the amount of pressure the spring
through an in-line fuel filter to the fuel rail assembly. The inside the fuel pressure regulator can provide.
fuel pump is designed to provide fuel at a pressure 3. A fuel system that cannot maintain a constant fuel
above the pressure needed by the fuel injectors. A fuel pressure has a leak in one or more of the following
pressure regulator, attached to the fuel rail, keeps the areas:
fuel available to the fuel injectors at a regulated • The fuel pump check valve.
pressure. Unused fuel is returned to the fuel tank by a
• The fuel pump flex line.
separate fuel return line.
• The valve or valve seat within the fuel pressure
regulator.
• The fuel injector(s). with rich conditions can include hard starting
4. Fuel pressure that drops off during acceleration, (followed by black smoke) and a strong sulfur smell
cruise, or hard cornering may case a lean condition. in the exhaust.
A lean condition can cause a loss of power, surging, 20.This test determines if the high fuel pressure is due
or misfire. A lean condition can be diagnosed using a to a restricted fuel return line or if the high fuel
Tech 2 Scan Tool. pressure is due to a faulty fuel pressure regulator.
Following are applicable to the vehicle with 21.A lean condition may result from fuel pressure below
closed Loop System: 333 kPa (48 psi). A lean condition may cause a 44 to
If an extremely lean condition occurs, the oxygen set. Driveability conditions associated with lean
sensor(s) will stop toggling. The oxygen sensor conditions can include hard starting (when the
output voltage(s) will drop below 500 mV. Also, the engine is cold), hesitation, poor driveability, lack of
fuel injector pulse width will increase. power, surging, and misfiring.
Important: Make sure the fuel system is not 22.Restricting the fuel return line causes the fuel
operating in the “Fuel Cut-Off Mode.” pressure to rise above the regulated fuel pressure.
When the engine is at idle, the manifold pressure is Command the fuel pump ON with the scan tool. The
low (high vacuum). This low pressure (high vacuum) fuel pressure should rise above 376 kPa (55 psi) as
is applied to the fuel pressure regulator diaphragm. the fuel return line becomes partially closed.
The low pressure (high vacuum) will offset the
NOTE: Do not allow the fuel pressure to exceed 414
pressure being applied to the fuel pressure regulator
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel psi) may damage the fuel pressure regulator.
pressure. The fuel pressure at idle will vary slightly Caution: To reduce the risk of fire and personal
as the barometric pressure changes, but the fuel injury:
pressure at idle should always be less than the fuel • It is necessary to relieve fuel system pressure
pressure noted in step 2 with the engine OFF. before connecting a fuel pressure gauge.
16.Check the spark plug associated with a particular Refer to Fuel Pressure Relief Procedure,
fuel injector for fouling or saturation in order to below.
determine if that particular fuel injector is leaking. If
• A small amount of fuel may be released when
checking the spark plug associated with a particular
disconnecting the fuel lines. Cover fuel line
fuel injector for fouling or saturation does not
fittings with a shop towel before
determine that a particular fuel injector is leaking,
disconnecting, to catch any fuel that may leak
use the following procedure:
out. Place the towel in an approved container
• Remove the fuel rail, but leave the fuel lines and when the disconnect is completed.
injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service. Fuel Pressure Relief Procedure
• Lift the fuel rail just enough to leave the fuel
1. Remove the fuel cap.
injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and 2. Located on the intake manifold which is at the top
personal injury that may result from fuel right part of the engine.
spraying on the engine, verify that the fuel rail is 3. Start the engine and allow it to stall.
positioned over the fuel injector ports and verify
4. Crank the engine for an additional 3 seconds.
that the fuel injector retaining clips are intact.
• Pressurize the fuel system by connecting a 20 Fuel Pressure Gauge Installation
amp fused jumper between B+ and the fuel
pump relay connector. 1. Remove the fuel pressure fitting cap.
• Visually and physically inspect the fuel 2. Install fuel pressure gauge 5-8840-0378-0 to the
injector nozzles for leaks. fuel feed line located on the upper right side of the
17.A rich condition may result from the fuel pressure engine.
being above 376 kPa (55 psi). A rich condition may 3. Reinstall the fuel pump relay.
cause a 45 to set. Driveability conditions associated
Fuel System Diagnosis

2 1. Turn the ignition OFF.
2. Turn the air conditioning system OFF.
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition ON.
NOTE: The fuel pump will run for approximately 2
seconds. Use the Scan Tool to command the fuel
pump ON.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 283-376 kPa
Is the fuel pressure within the specified limits? (41-55 psi) Go to Step 3 Go to Step 17
3 Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
NOTE: The fuel pressure will drop when the fuel
pump stops running, then it should stabilize and
remain constant. — Go to Step 4 Go to Step 12
4 1. When the vehicle is at normal operating
temperature, turn the ignition ON to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Did the reading drop by the amount specified after the 21-105 kPa
engine was started? (3-15 psi) Go to Step 5 Go to Step 9
5 Is fuel pressure dropping off during acceleration, Check for
cruise, or hard cornering? — Go to Step 6 improper fuel
6 Visually and physically inspect the following items for
a restriction:
• The in-line fuel filter.
• The fuel feed line.
Was a restriction found? — Verify repair Go to Step 7
7 Remove the fuel tank and visually and physically
inspect the following items:
• The fuel pump strainer for a restriction.
• The fuel line for a leak.
• Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas? — Verify repair Go to Step 8
8 Replace the fuel pump.
9 1. Disconnect the vacuum hose from the fuel
pressure regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure 21-105 kPa
gauge drop by the amount specified? (3-15 psi) Go to Step 10 Go to Step 11

10 Locate and repair the loss of vacuum to the fuel
pressure regulator.
11 Replace the fuel pressure regulator.
12 1. Run the fuel pump with the Scan Tool.
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant? — Go to Step 13 Go to Step 15
13 Visually inspect the fuel supply line and repair any
leaks.
14 Remove the fuel tank and inspect for leaky hose or in-
tank fuel line.
15 1. If the pliers are still clamped to the fuel supply
hose, remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
3. Run the fuel pump with the Scan Tool.
4. After pressure has built up, remove power to the
pump.
gauge remain constant? — Go to Step 11 Go to Step 16
16 Locate and replace any leaking fuel injector(s).
17 Is the fuel pressure indicated by the fuel pressure 376 kPa
gauge above the specified limit? (55 psi) Go to Step 18 Go to Step 21
18 1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with the Scan Tool.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 290-376 kPa
Is the fuel pressure within the specified limits? (42-55 psi) Go to Step 19 Go to Step 20
19 Locate and correct the restriction in the fuel return
line.
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found? — Verify repair Go to Step 11
21 Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22 Go to Step 23

22 1. Command the fuel pump ON with the Scan Tool.
2. Using suitable pliers which will not damage the
fuel hose, gradually apply pressure with the pliers 376 kPa
to pinch the flexible fuel return hose closed. (55 psi)
gauge rise above the first specified value?
Caution: Do not let the fuel pressure exceed the 414 kPa
second specified value. (60 psi) Go to Step 11 Go to Step 7
23 1. Command the fuel pump ON with the Scan Tool.
2. Remove the fuel filler cap and listen for the sound Go to Fuel
of the fuel pump running. System
3. Turn the pump off. Electrical Test
Was the fuel pump running? — Go to Step 7 Chart
ECM DIAGNOSTIC TROUBLE CODES (DTC)
Type A
• Emission related.
• Requests illumination of the MIL (Malfunction Indicator Lamp = Check Engine Lamp) of the first trip with a fail.
• Stores a history DTC on the first trip.
• Stores a freeze frame (If empty).
• Stores a fail record.
• Updates the fail record each time the diagnostic test fails.
Type B
• Emission related.
• “Armed” after one trip with fail.
• “Disarmed” after one trip with a pass.
• Requests illumination of the MIL on the second consecutive trip with a fail.
• Store a history DTC on the second consecutive trip with a fail. (The DTC will be armed after the first fail.)
• Stores a freeze frame on the second consecutive trip with a fail (If empty).
• Stores a fail record when the first test fails (not dependent on consecutive trip).
Type D
• Non emission related.
• Does not request illumination of any lamp.
• Stores a history DTC on the first trip.
• Does not store a freeze frame.
• Stores fail record when test fails.
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related ECM
Pin No.
P0107 A Manifold Absolute Pressure Circuit Low 1. No DTC relating to TPS. The ECM uses default manifold MAP sensor output is more than 12KPa. 1. Sensor power supply circuit open or J1-24/
Input 2. Throttle position is more than 0% if absolute pressure value based on short to ground circuit. J1-31
engine speed is below 1000rpm, or engine speed and throttle position. 2. Sensor signal circuit open or short to
throttle position more than 5% if engine ground circuit.
speed is more than 1000rpm. 3. Poor connector connection.
3. MAP sensor output is below 12KPa. 4. MAP sensor malfunction.
5. ECM malfunction.
P0108 A Manifold Absolute Pressure Circuit High 1. No DTC relating to TPS. MAP sensor output is below 103KPa. 1. Sensor power supply circuit short to J1-16/
Input 2. Throttle position is below 15% if engine voltage circuit. J1-24/
speed is below 2500rpm, or throttle 2. Sensor signal circuit short to voltage J1-31
position is below 35% if engine speed circuit.
is more than 2500rpm. 3. Sensor ground circuit open or short to
3. Engine run time is longer than 10 voltage circuit.
seconds. 4. Poor connector connection.
4. MAP sensor output is more than 5. MAP sensor malfunction.
103KPa.
6. ECM malfunction.
P0112 A Intake Air Temperature Sensor Low Input 1. No DTC relating to VSS. The ECM uses 20°C condition as IAT sensor output is below 149°C 1. Sensor signal circuit short to ground J2-22
2. Vehicle speed is more than 25km/h. substitute. circuit.
3. Engine run time is longer than 120 2. IAT sensor malfunction.
seconds. 3. ECM malfunction.
4. IAT sensor output is more than 149°C.
P0113 A Intake Air Temperature Sensor High Input 1. No DTC relating to VSS & ECT sensor. IAT sensor output is more than -38°C. 1. Sensor signal circuit open or short to J2-1/
2. Vehicle speed is below 70km/h. voltage circuit. J2-22
3. 3Engine coolant temperature is more 2. Sensor ground circuit open or short to
than -8°C. voltage circuit.
4. Engine run time is longer than 120 3. Poor connector connection
seconds. 4. IAT sensor malfunction.
5. Mass air flow is below 30g/s. 5. ECM malfunction.
6. IAT sensor output is below -38°C.
P0117 A Engine Coolant Temperature Sensor Low 1. Engine run time is longer than 120 The ECM uses default engine ECT sensor output is below 149°C. 1. Sensor signal circuit short to ground J1-27
Input seconds. coolant temperature value based circuit.
2. ECT sensor output is more than 149°C. on intake air temperature and 2. ECT sensor malfunction.
engine run time.
3. ECM malfunction.
P0118 A Engine Coolant Temperature Sensor High 1. Engine run time is longer than 120 ECT sensor output is more than -38°C. 1. Sensor signal circuit open or short to J1-27/
Input seconds. voltage circuit. J1-32
2. ECT sensor output is below -38°C. 2. Sensor ground circuit open or short to
voltage circuit.
5. ECM malfunction.
Pin No.
P0122 A Throttle Position Sensor Low Input TPS output voltage is below 0.14V. The ECM uses 0% condition as TPS output voltage is more than 0.14V. 1. Sensor power supply circuit open or J1-7/
substitute. short to ground circuit. J1-15/
2. Sensor signal circuit open or short to
ground circuit.
4. TPS malfunction.
5. ECM malfunction.
P0123 A Throttle Position Sensor High Input TPS output voltage is more than 4.9V. TPS output voltage is below 4.9V. 1. Sensor power supply circuit short to J1-7/
voltage circuit. J1-15/
2. Sensor signal circuit short to voltage J1-32
circuit.
3. Sensor ground circuit open or short to
voltage circuit.
5. TPS malfunction.
6. ECM malfunction.
P0131 A O2 Sensor Circuit Low Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control. O2 sensor bank 1 output voltage is more 1. Sensor harness short to ground circuit. J2-6/
Sensor 1) EVAP purge, ECT sensor, CKP sensor, than 50mV. 2. O2 sensor malfunction. J2-21
VSS, injector control circuit and ignition
3. ECM malfunction.
control circuit.
2. Engine coolant temperature is more
than 60°C.
3. O2 sensor bank 1 output voltage is
below 50mV in “Closed Loop”
condition.
P0132 A O2 Sensor Circuit High Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control. O2 sensor bank 1 output voltage is below 1. Sensor harness short to voltage circuit. J2-6/
Sensor 1) EVAP purge, ECT sensor, CKP sensor, 952mV. 2. O2 sensor malfunction. J2-21
3. MAF sensor output is incorrect.
control circuit.
4. Air intake line malfunction.
than 60°C. 5. IAC valve malfunction.
3. O2 sensor bank 1 output voltage is 6. Incorrect fuel pressure.
more than 952mV in “Closed Loop” 7. Injector malfunction.
condition. 8. ECM malfunction.
P0134 A O2 Sensor Circuit No Activity Detected 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control. O2 sensor bank 1 output voltage is below 1. Sensor harness open circuit. J2-6/
(Bank 1 Sensor 1) EVAP purge, ECT sensor, CKP sensor, 300mV consecutively. 2. O2 sensor malfunction. J2-21
VSS, injector control circuit and ignition OR
control circuit. O2 sensor bank 1 output voltage is more
than 600mV consecutively. 4. Air intake line malfunction.
than 60°C. 5. IAC valve malfunction.
3. Engine run time is longer than 40 6. Incorrect fuel pressure.
seconds. 7. Injector malfunction.
4. Mass air flow is more than 7g/s. 8. ECM malfunction.
between 300mV and 600mV.
Pin No.
P0135 A O2 Sensor Heater Circuit (Bank 1 Sensor 1. No DTC relating to MAP sensor and No fail-safe function. O2 sensor bank 1 heater circuit is correct 1. Heater harness open, short to ground or J2-31
1) ECT sensor. condition. short to voltage circuit.
2. Engine coolant temperature is more 2. O2 sensor heater malfunction.
than 60°C. 3. ECM malfunction.
3. Engine run time is longer than 20
seconds.
4. MAP sensor output is more than
70KPa.
5. O2 sensor bank 1 heater current more
than 10mA.
P0201 A Injector 1 Control Circuit 1. Engine is running. No fail-safe function. Injector circuit is correct condition. 1. Injector harness open circuit, short to J1-9
2. Engine speed is more than 1000rpm. ground or short to voltage circuit.
P0202 A Injector 2 Control Circuit J1-22
3. Injector voltage does not meet to the 2. Injector malfunction.
P0203 A Injector 3 Control Circuit battery voltage when the injector is 3. ECM malfunction. J1-8
commanded Off or does not meet to
P0204 A Injector 4 Control Circuit J1-11
the 0V when the injector is
commanded On.
P0325 B Knock Sensor Module Circuit 1. No DTC relating to MAP sensor. ECM retards ignition timing 4°C. Knock sensor is correct condition. 1. KS harness open circuit. J1-3/
2. Engine coolant temperature is more 2. Poor connector connection. J1-32
than 50°C. 3. KS sensor malfunction.
3. Engine speed is more than 1600rpm. 4. ECM malfunction.
4. Knock sensor filter module integrated
circuit malfunction.
P0327 A Knock Sensor Circuit 1. No DTC relating to MAP sensor. 1. KS harness short to ground or short to J1-3/
2. Engine coolant temperature is more voltage circuit. J1-32
than 50°C. 2. Poor connector connection.
3. Engine speed is more than 1600rpm. 3. KS sensor malfunction.
4. Knock sensor harness short to ground 4. ECM malfunction.
or short to voltage circuit.
P0336 B Crankshaft Position Sensor Circuit Range/ 1. Engine is running. No fail-safe function. Correct pulse is detected consecutively. 1. CKP sensor harness open circuit, short J1-6/
Performance (58X) 2. Extra or missing pulse is detected to ground or short to voltage circuit. J1-21
consecutively. 2. Poor connector connection.
5. Pluser malfunction.
8. ECM malfunction.
P0337 B Crankshaft Position Sensor Circuit Low No pulse is detected during engine 1. CKP sensor harness open circuit, short J1-6/
Input (58X) cranking. to ground or short to voltage. J1-21
5. Pluser malfunction.
8. ECM malfunction.
Pin No.
P0351 A Ignition 1 Control Circuit #2 or #3cylinder ignition signals are not No fail-safe function. Consecutive ignition signals are detected. 1. Ignition coil module 1 harness open J1-19
detected consecutively. circuit, short to ground or short to
voltage circuit.
2. Ignition coil module malfunction.
3. ECM malfunction.
P0352 A Ignition 2 Control Circuit #1 or #4 cylinder ignition signals are not 1. Ignition coil module 2 harness open J1-18
detected consecutively. circuit, short to ground or short to
voltage circuit.
2. Ignition coil module malfunction.
3. ECM malfunction.
P0443 B EVAP Emission Control System Purge EVAP purge solenoid circuit open, short to No fail-safe function. EVAP purge solenoid circuit is correct 1. Solenoid harness open circuit, short to J1-5
Control Circuit ground or short to voltage circuit. condition. ground or short to voltage circuit.
2. Solenoid malfunction.
3. ECM malfunction.
P0502 B Vehicle Speed Sensor Circuit Low Input 1. No DTC relating to MAP sensor, TPS, ECM uses 0km/h condition as VSS circuit correct condition. 1. Sensor harness open circuit, short to J2-23
ECT sensor, injector control circuit and substitute. ground circuit or short to voltage circuit.
ignition control circuit. 2. Poor connector connection.
2. Engine is running. 3. VSS malfunction.
3. Vehicle speed is below 3km/h in power 4. ECM malfunction.
condition or 2km/h in deceleration
condition.
P0562 D System Voltage Low Battery voltage is below 11V. No fail-safe function. Battery voltage is between 11V and 16V. 1. Battery power feed harness open circuit -
2. ECM ground harness open or poor
connection.
6. ECM malfunction.
P0563 A System Voltage High Battery voltage is above 16V. 1. Charge system malfunction. -
2. Battery jump start cable misconnect.
3. ECM malfunction.
P0601 A ECM Memory Checksum ECM memory area error. Engine control disabled. Memory are is OK. ECM malfunction. -
P0602 - Programming Error ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed. -
P0650 A Malfunction Indicator Lamp (MIL) Control Check engine lamp circuit open, short to No fail-safe function. Check engine lamp circuit is correct 1. Solenoid harness open circuit, short to J2-32
Circuit Malfunction ground or short to voltage circuit. condition. ground or short to voltage circuit.
2. Solenoid malfunction.
3. ECM malfunction.
Pin No.
P1167 D Fuel Supply System Rich During 1. No DTC relating to MAP sensor, TPS, No fail-safe function. O2 sensor output voltage is below 550mV. 1. Sensor harness open or short to ground J2-6/
Deceleration Fuel Cutoff EVAP purge, ECT sensor, CKP sensor, circuit. J2-21
VSS, injector control circuit and ignition 2. O2 sensor malfunction.
control circuit.
more than 550mV in deceleration fuel
cutoff mode. 5. IAC valve malfunction.
6. Low fuel pressure.
7. Injector malfunction.
8. EVAP purge solenoid valve malfunction.
9. Ignition system malfunction.
10. Spark plug malfunction.
11. ECM malfunction.
P1171 D Fuel Supply System Lean During Power 1. No DTC relating to MAP sensor, TPS, No fail-safe function. O2 sensor output voltage is more than 1. Sensor harness open or short to ground J2-6/
Enrichment EVAP purge, ECT sensor, CKP sensor, 350mV. circuit. J2-21
VSS, injector control circuit and ignition 2. O2 sensor malfunction.
control circuit.
than 60°C.
5. IAC valve malfunction.
3. Mass air flow is below 13.5m/s.
6. Low fuel pressure.
below 350mV in power enrichment 7. Injector malfunction.
mode. 8. ECM malfunction.
P1625 B ECM System Reset ECM reset has occurred other than “On”. Engine control disabled. Memory are is OK. 1. Electrical interference. -
3. ECM malfunction.
P1626 - Immobiliser No Signal No response from immobiliser control unit. 1. Engine does not start. No recovery. 1. ECM and immobiliser control unit J2-23/
2. Check engine lamp flash. communication circuit open circuit, short J2-32
to ground circuit or short to voltage
circuit.
2. ECM malfunction.
3. Immobiliser control unit malfunction.
P1631 - Immobiliser Wrong Signal Received response is not correct. 1. ECM malfunction. -
P1648 - Wrong Security Code Entered Received incorrect security code. 1. ECM malfunction. -
P1649 - Immobiliser Function Not Programmed Immobiliser function is not programmed in ECM malfunction. -
the ECM.
P1693 B Tachometer Output Low Voltage Tacho output circuit short to ground circuit. No fail-safe function. Tacho output circuit is correct condition. 1. Tacho output circuit short to ground J2-25
circuit.
3. ECM malfunction.
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE

PRESSURE CIRCUIT LOW INPUT
Crankshaft
Position(CKP)
Manifold Sensor
Absolute
INLET
MANIFOLD
0.5
BLK/
WHT
0.5 0.5
BLK WHT
0.5 0.5 0.5
GRY/ GRY/ YEL/
BLU RED RED
0.5 0.5
BLK/ BLK/
WHT WHT
J1-16 J1-24 J1-31 J1-1 J1-2 J1-17 J1-6 J1-21

Engine
Control
Module
(ECM)
5 Volts
Reference
µP
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P0107 A Manifold Absolute Pressure Circuit Low 1. No DTC relating to TPS. The ECM uses default manifold absolute
Input 2. Throttle position is more than 0% if engine pressure value based on engine speed
speed is below 1000rpm, or throttle posi- and throttle position.
tion more than 5% if engine speed is more
than 1000rpm.
3. MAP sensor output is below 12KPa.
Circuit Description Air Temperature (IAT) sensor. The MAP sensor is the
main sensor used in this calculation, and measuring
The manifold absolute pressure (MAP) sensor responds engine load is its main function.
to changes in intake manifold pressure. The MAP The ECM monitors the MAP signals for voltages outside
sensor signal voltage to the engine control module the normal range (10-104 kpa) of the MAP sensor. If the
(ECM) varies from below 2 volts at idle (low manifold ECM detects a MAP signal voltage that is excessively
pressure) to above 4 volts with the ignition ON, engine low, Diagnostic Trouble Code P0107 will be set.
not running or at wide-open throttle (high manifold
pressure).
Diagnostic Aids
A “speed density” method of determining engine load is
used on the 2.4L engine. This is calculated using inputs Check for the following conditions:
from the MAP sensor, the CKP Sensor, and the Intake • Poor connection at ECM - Inspect harness
connectors for backed-out terminals, improper damage, short to ground, short to battery positive,
mating, broken locks, improperly formed or damaged and open circuit. If the harness appears to be OK,
terminals, and poor terminal-to-wire connection. observe the MAP display on the Tech 2 while moving
• If these codes are also set, it could indicate a connectors and wiring harnesses related to the
problem with the 5 Volt reference circuit. sensor. A change in the display will indicate the
location of the fault.
• Damaged harness - Inspect the wiring harness for

Manifold Absolute Pressure Circuit Low Input
(OBD) System
2. Review and record the failure information. Refer to
3. Select “F0: Read DTC Infor By Priority” in “F0: Diagnostic Aids
Diagnostic Trouble Code”. and Go to Step
Is the DTC P0107 stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech2, ignition “On” and engine “Off”.
2. Select “Clear DTC Information” with the Tech2 and
clear the DTC information. Refer to
3. Operate the vehicle and monitor the “F5: Failed Diagnostic Aids
This Ignition” in “F2: DTC Information”. and Go to Step
Was the DTC P0107 stored in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the MAP sensor or
16
E60(J1) E85

5 Visually check the MAP.
6 Using the DVM and check the MAP sensor power
supply circuit.
2. Disconnect the MAP sensor connector.
circuit.
E85
3
V
Approximately

ECM and MAP sensor
31 E60(J1) E85
3

8 Using the DVM and check the MAP sensor signal
circuit.
disconnected) Ref. 6E-80.
3. Disconnect MAP sensor connector.
E85
2
16 24

2. Disconnect the MAP sensor connector and ECM
connector.
16 E60(J1) 24 E85
2
Repair faulty
harness and
9 Substitute a known good MAP sensor and recheck.
10 Replace the MAP sensor.
release?

12 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE

PRESSURE CIRCUIT HIGH INPUT
Crankshaft
Position(CKP)
Manifold Sensor
Absolute
INLET
MANIFOLD
0.5
BLK/
WHT
0.5 0.5
BLK WHT
0.5 0.5 0.5
GRY/ GRY/ YEL/
BLU RED RED
0.5 0.5
BLK/ BLK/
WHT WHT
J1-16 J1-24 J1-31 J1-1 J1-2 J1-17 J1-6 J1-21

Engine
Control
Module
(ECM)
5 Volts
Reference
µP
P0108 A Manifold Absolute Pressure Circuit 1. No DTC relating to TPS. The ECM uses default manifold absolute
High Input 2. Throttle position is below 15% if engine pressure value based on engine speed
speed is below 2500rpm, or throttle posi- and throttle position.
tion is below 35% if engine speed is more
than 2500rpm.
3. Engine run time is longer than 10 seconds.
4. MAP sensor output is more than 103KPa.
Circuit Description from the MAP sensor, RPM, CKP Sensor, and the
Intake Air Temperature (IAT) sensor. The MAP sensor is
The manifold absolute pressure (MAP) sensor responds the main sensor used in this calculation, and measuring
to changes in intake manifold pressure. The MAP engine load is its main function.
sensor signal voltage to the engine control module The ECM monitors the MAP signals for voltages outside
(ECM) varies from below 2 volts at idle (low manifold the normal range (10-104 kpa) of the MAP sensor. If the
pressure) to above 4 volts with the ignition ON, engine ECM detects a MAP signal voltage that is excessively
not running or at wide-open throttle (high manifold high, Diagnostic Trouble Code P0108 will be set.
pressure).
A “speed density” method of determining engine load is
used on the 2.4L engine. This is calculated using inputs
Diagnostic Aids problem with the 5 Volt reference circuit.
Check for the following conditions: • Damaged harness - Inspect the wiring harness for
damage; an open circuit, a short to ground, or a short
• Poor connection at ECM - Inspect harness to voltage. If the harness appears to be OK, observe
connectors for backed-out terminals, improper the MAP display on the Tech 2 while moving
mating, broken locks, improperly formed or damaged connectors and wiring harnesses related to the
terminals, and poor terminal-to-wire connection. sensor. A change in the display will indicate the
• If these codes are also set, it could indicate a location of the fault.

Manifold Absolute Pressure Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the MAP sensor or
16
E60(J1) E85

5 Visually check the MAP sensor.

6 Using the DVM and check the MAP sensor power
supply circuit.
E85
3
V
Approximately
and MAP sensor.
31 E60(J1) E85
3

8 Using the DVM and check the MAP sensor signal
circuit.
E85
2
Repair faulty
V
harness and
9 Using the DVM and check the MAP sensor ground
circuit.
2. Disconnect the MAP sensor connector .
E85
1
Repair faulty
V harness and

10 Using the DVM and check the MAP sensor ground
circuit.
E85
1
16

2. Disconnect the MAP sensor connector and ECM
connector.
E60(J1) E85
16
1
Repair faulty
harness and
11 Substitute a known good MAP sensor and recheck.
release?
14 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE

SENSOR LOW INPUT
Battery Voltage
Intake Ignition
Air SW
Temperature(IAT)
Sensor
Engine
15A
0.5
BLU/
YEL
Evaporativ
Steering Canistor
Pressure Purge
SW Valve
Solenoid
0.5 0.5 0.5 0.5 0.5

GRN YEL YEL WHT
J2-1 J2-22 J2-20 J2-3 J1-5

Engine
Control
Module +5V
(ECM)
µP
µP
P0112 A Intake Air Temperature Sensor Low 1. No DTC relating to VSS. The ECM uses 20°C condition as substi-
Input 2. Vehicle speed is more than 25km/h. tute.
3. Engine run time is longer than 120 sec-
onds.
4. IAT sensor output is more than 149°C.
Circuit Description (short to ground) on the intake air temperature sensor

signal circuit.
The intake air temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering the Diagnostic Aids
engine. The engine control module (ECM) applies 5
volts through a pull-up resistor to the IAT sensor. When Check for the following conditions:
the intake air is cold, the sensor resistance is high and • Poor connection at ECM - Inspect harness
the ECM will monitor a high signal voltage on the IAT connectors for backed-out terminals, improper
signal circuit. If the intake air is warm, the sensor mating, broken locks, improperly formed or damaged
resistance is lower, causing the ECM to monitor a lower terminals, and poor terminal-to-wire connection.
voltage. Diagnostic Trouble Code P0112 will set when
the ECM detects an excessively low signal voltage
damage, short to ground, short to battery and open
circuit. If the harness appears to be OK, observe the change in the IAT display will indicate the location of
IAT display on the Tech 2 while moving connectors the fault.
and wiring harnesses related to the IAT sensor. A

Intake Air Temperature Sensor Low Input
(OBD) System
C56(J2) 1 C121

5 Remove the IAT sensor and visually check.

2. Disconnect IAT sensor connector.

-20 32040
0 9788
20 3516
40 1439
60 656
80 327
100 175
IAT Sensor
2 1
2 1
Standard
circuit.
3. Disconnect the IAT sensor connector.
ground circuit.
33 54

ground circuit.
C56(J2) 22 1
Repair faulty
harness and

8 Substitute a known good IAT sensor assembly and
recheck.
9 Replace the IAT sensor assembly.
release?
11 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE

SENSOR HIGH INPUT
Battery Voltage
Intake Ignition
Air SW
Temperature(IAT)
Sensor
Engine
15A
0.5
BLU/
YEL
Evaporativ
Steering Canistor
Pressure Purge
SW Valve
Solenoid
0.5 0.5 0.5 0.5 0.5

GRN YEL YEL WHT
J2-1 J2-22 J2-20 J2-3 J1-5

Engine
Control
Module +5V
(ECM)
µP
µP
P0113 A Intake Air Temperature Sensor High 1. No DTC relating to VSS & ECT sensor. The ECM uses 20°C condition as substi-
Input 2. Vehicle speed is below 70km/h. tute.
3. 3Engine coolant temperature is more than -
8°C.
4. Engine run time is longer than 120 sec-
onds.
5. Mass air flow is below 30g/s.
6. IAT sensor output is below -38°C.
Circuit Description voltage. Diagnostic Trouble Code P0113 will set when
the ECM detects an excessively high signal voltage on
The intake air temperature (IAT) sensor is a thermistor the intake air temperature sensor signal circuit.
which measures the temperature of the air entering the
engine. The engine control module (ECM) applies 5
Diagnostic Aids
volts through a pull-up resistor to the IAT sensor. When
the intake air is cold, the sensor resistance is high and Check for the following conditions:
the ECM will monitor a high signal voltage on the IAT • Poor connection at ECM - Inspect harness
signal circuit. If the intake air is warm, the sensor connectors for backed-out terminals, improper
resistance is lower causing the ECM to monitor a lower mating, broken locks, improperly formed or damaged
terminals, and poor terminal-to-wire connection. observe the IAT display on the Tech 2 while moving
• Damaged harness - Inspect the wiring harness for connectors and wiring harnesses related to the IAT
damage, short to ground, short to battery positive, sensor. A change in the IAT display will indicate the
and open circuit. If the harness appears to be OK, location of the fault.

Intake Air Temperature Sensor High Input
(OBD) System
C56(J2) 1 C121


2. Disconnect IAT sensor connector.

-20 32040
0 9788
20 3516
40 1439
60 656
80 327
100 175
IAT Sensor
2 1
2 1
Standard
circuit.
1 C121
Less than 1V:

Go to Step 8
More than
V
sensor.
C56(J2) 22 1 C121

and IAT sensor.
C56(J2) 22 1 C121


circuit.
C121 2
V Repair faulty
harness and
circuit.
C121 2
33

C56(J2) 1 C121 2
Repair faulty
harness and
12 Substitute a known good IAT sensor assembly and
recheck.
13 Replace the IAT sensor assembly.
release?

15 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT

TEMPERATURE SENSOR LOW INPUT
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0117 A Engine Coolant Temperature Sensor 1. Engine run time is longer than 120 sec- The ECM uses default engine coolant
Low Input onds. temperature value based on intake air
2. ECT sensor output is more than 149°C. temperature and engine run time.

The engine coolant temperature (ECT) sensor is a Check for the following conditions:
thermistor mounted in the engine coolant stream. The • Poor connection at ECM - Inspect harness
engine control module (ECM) applies a voltage (about 5 connectors for backed-out terminals, improper
volts) through a pull-up resistor to the ECT signal circuit. mating, broken locks, improperly formed or damaged
When the engine coolant is cold, the sensor (thermistor) terminals, and poor terminal-to-wire connection.
resistance is high, therefore the ECM will measure a
high signal voltage. As the engine coolant warms, the
damage, short to ground, short to battery positive,
sensor resistance becomes lower, and the ECT signal
and open circuit. If the harness appears to be OK,
voltage measured at the ECM drops. Diagnostic Trouble
observe the ECT display on the Tech 2 while moving
code P0117 set when the ECM detects an excessively
connectors and wiring harnesses related to the ECT
low signal voltage on the engine coolant temperature
sensor. A change in the ECT display will indicate the
sensor signal circuit.

Engine Coolant Temperature Sensor Low Input
(OBD) System
E60(J1) E69


-20 32040
0 9788
20 3516
40 1439
60 656
80 327
100 175
120 100
ECT Sensor
2 1
2 1
Standard

circuit.
ground circuit.
27 32

ground circuit.
32 27 E60(J1)
Repair faulty
harness and
recheck.
release?
11 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT

TEMPERATURE SENSOR HIGH INPUT
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0118 A Engine Coolant Temperature Sensor 1. Engine run time is longer than 120 sec- The ECM uses default engine coolant
High Input onds. temperature value based on intake air
2. ECT sensor output is below -38°C. temperature and engine run time.

The engine coolant temperature (ECT) sensor is a Check for the following conditions:
thermistor mounted in the engine coolant stream. The • Poor connection at ECM - Inspect harness
engine control module (ECM) applies a voltage (about 5 connectors for backed-out terminals, improper
volts) through a pull-up resistor to the ECT signal circuit. mating, broken locks, improperly formed or damaged
When the engine coolant is cold, the sensor (thermistor) terminals, and poor terminal-to-wire connection.
resistance is high, therefore the ECM will measure a
high signal voltage. As the engine coolant warms, the
damage, short to ground, short to battery positive,
sensor resistance becomes less, and the ECT signal
and open circuit. If the harness appears to be OK,
voltage measured at the ECM drops. Diagnostic Trouble
observe the ECT display on the Tech 2 while moving
code P0118 set when the ECM detects an excessively
connectors and wiring harnesses related to the ECT
high signal voltage on the engine coolant temperature
sensor. A change in the ECT display will indicate the
sensor signal circuit.

Engine Coolant Temperature Sensor High Input
(OBD) System
E60(J1) E69


-20 32040
0 9788
20 3516
40 1439
60 656
80 327
100 175
120 100
ECT Sensor
2 1
2 1
Standard

circuit.
E69
1
Less than 1V:

Go to Step 8
V More than
sensor.
27 E60(J1) E69
1

and ECT sensor.
27 E60(J1) E69
1

circuit.
E69
2
Repair faulty
V
harness and

circuit.
E69
2
32

32 E60(J1) E69
2
Repair faulty
harness and
recheck.
release?
15 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION SENSOR

LOW INPUT
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0122 A Throttle Position Sensor Low Input TPS output voltage is below 0.14V. The ECM uses 0% condition as substitute.

The throttle position sensor circuit provides a signal • Poor connection at ECM - Inspect harness
voltage that changes relative to throttle blade angle. The connectors for backed-out terminals, improper
signal voltage will vary from below 1 volt at closed mating, broken locks, improperly formed or damaged
throttle to about 4 volts at wide open throttle (WOT). terminals, and poor terminal-to-wire connection.
The TPS signal is used by the engine control module • Damaged harness - Inspect the wiring harness for
(ECM) for fuel control and most of the ECM-controlled damage, short to ground, short to battery positive,
outputs. If the ECM detect a continuous short to ground and open circuit. If the harness appears to be OK,
in the TPS or circuit, then a code P0122 will set. observe the throttle position display on the Tech 2
while moving connectors and wiring harnesses
related to the TPS. A change in the display will
indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0122 Throttle Position Sensor Low Input
(OBD) System
as necessary.
E60(J1) E68


Terminal
2-3 Approximately 6.0kΩ at idle position
TPS
2 1
Standard
3 resistance Go to Step 7 Go to Step 10

circuit.
circuit.
E68
2
V
Approximately
ECM and TPS.
15 E60(J1) E68
2


E68
3
7 32

connector.
32 E60(J1) 7 E68
3
Repair faulty
harness and
11 Replace the TPS.
release?
13 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION SENSOR

HIGH INPUT
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0123 A Throttle Position Sensor High Input TPS output voltage is more than 4.9V. The ECM uses 0% condition as substitute.
Circuit Description connectors for backed-out terminals, improper

The throttle position sensor circuit provides a voltage terminals, and poor terminal-to-wire connection.
signal that changes relative to throttle blade angle. The
signal voltage will vary from below 1 volt at closed • If these codes are also set, it could indicate a
throttle to about 4 volts at wide open throttle (WOT). problem with the 5 Volt reference circuit or
The TPS is used by the engine control module (ECM) components itself.
for fuel control and most of the ECM-controlled outputs. • Damaged harness - Inspect the wiring harness for
If the ECM detect a continuous short voltage in the TPS damage, short to ground, short to battery positive
or circuit, then a code P0123 will set. and open circuit. If the harness appears to be OK,
observe the Throttle Position sensor display on the
Diagnostic Aids Tech 2 while moving connectors and wiring
harnesses related to the TP sensor. A change in the
Check for the following conditions: display will indicate the location of the fault.
• Poor connection at ECM - Inspect harness
Diagnostic Trouble Code (DTC) P0123 Throttle Position Sensor High Input
(OBD) System
as necessary.
E60(J1) E68


Terminal
2-3 Approximately 6.0kΩ at idle position
TPS
2 1
Standard
3

circuit.
E68
2
V
Approximately
and TPS.
15 E60(J1) E68
2

E68
3
Repair faulty
V harness and
E68
1
Repair faulty
V
harness and

E68
1
32

connector.
32 E60(J1) E68
1
Repair faulty
harness and
13 Replace the TPS.
release?
15 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW

VOLTAGE (BANK 1 SENSOR 1)
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0131 A O2 SensorCircuit Low Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control.
Sensor 1) EVAP purge, ECT sensor, CKP sensor,
control circuit.
2. Engine coolant temperature is more than
60°C.
3. O2 sensor bank 1 output voltage is below
50mV in “Closed Loop” condition.
Circuit Description Bank 1 HO2S 1 voltage remains excessively low for an

extended period of time, Diagnostic Trouble Code
The engine control module (ECM) supplies a bias P0131 will be set.
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal and low circuits. The oxygen
Diagnostic Aids
sensor varies the voltage within a range of about 1000
mV when the exhaust is rich, down through about 10 Check for the following conditions:
mV when exhaust is lean. The ECM constantly monitors • Heated oxygen sensor wiring - The sensor pigtail
the HO2S signal during “Closed Loop” operation and may be routed incorrectly and/or contacting the
compensates for a rich or lean condition by decreasing exhaust system. Also, check for shorts to ground,
or increasing injector pulse width as necessary. If the shorts to battery positive and open circuits.
• Poor ECM to engine block grounds. • Exhaust leaks - An exhaust leak may cause outside
• Fuel pressure - The system will go lean if pressure is air to be pulled into the exhaust gas stream past the
too low. The ECM can compensate for some HO2S, causing the system to appear lean. Check for
decrease. However, if fuel pressure is too low, a exhaust leaks that may cause a false lean condition
Diagnostic Trouble Code P0131 may be set. Refer to to be indicated.
Fuel System Diagnosis. • Fuel contamination - Water, even in small amounts,
• Lean injector(s) - Perform “Injector Balance Test.” can be delivered to the fuel injectors. The water can
cause a lean exhaust to be indicated. Excessive
• Vacuum leaks - Check for disconnected or damaged
alcohol in the fuel can also cause this condition. For
vacuum hoses and for vacuum leaks at the intake
the procedure to check for fuel contamination, Refer
manifold, throttle body, EGR system, and PCV
to Fuel System Diagnosis.
system.

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
(OBD) System
4 Check for poor/faulty connection at the O2 sensor or
C56(J2) 6 E77

5 Using the DVM and check the O2 sensor circuit.
2. Disconnect the O2 sensor connector.
3. Check the circuit for short to heater ground or
ground circuit.
E77
1 2
Approximatly
V 450mV Go to Step 7 Go to Step 6

3. Disconnect the O2 sensor.
38 53 63

2. Disconnect the O2 sensor connector and ECM
connector.
C56(J2) C56(J2)
6 21 6
31 31
21
Repair faulty
harness and
2. Disconnect the the O2 sensor connector.
3. Check the circuit for short to heater ground circuit.
O2 Sensor
4 2 1
4 3 2 1

8 Repair the short to heater ground circuit.

2. Monitor the “Manifold Absolute Pressure” in the
data display.
Does the Tech 2 indicate correct “Manifold Absolute
Pressure” in accordance with engine speed or
acceleration? — Go to Step 11 Go to Step 10
10 Remove the MAP sensor and check for the following
conditions.
• Objects blocking the MAP sensor.
• Objects blocking the throttle valve.
• Vacuum leaking at throttle body.
“IAC Control” in the “IAC System”.
3. Operate the Tech 2 in accordance with procedure.
Was the engine speed changed, when the IAC valve is
operating step by step? — Go to Step 13 Go to Step 12
12 Check for the following conditions.
• Objects blocking the IAC valve.
13 Check for injector for the affected bank. Refer to Injector
Refer to “Injector Coil Test & Injector Balance Test Coil Test &
Procedure”. Injector
Was the injector operation correct? Balance Test
— Go to Step 14 Procedure
14 Check for fuel pressure. Refer to Fuel
Refer to “Fuel System Diagnosis”. System
Was the fuel pressure correct? — Go to Step 15 Diagnosis
15 Replace the O2 sensor.
release?
17 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH

VOLTAGE (BANK 1 SENSOR 1)
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0132 A O2 Sensor Circuit High Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control.
Sensor 1) EVAP purge, ECT sensor, CKP sensor,
control circuit.
60°C.
3. O2 sensor bank 1 output voltage is more
than 952mV in “Closed Loop” condition.
Circuit Description Bank 1 HO2S 1 voltage remains excessively high for an

extended period of time, Diagnostic Trouble Code
The engine control module (ECM) supplies a bias P0132 will be set.
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal and low circuits. The oxygen
Diagnostic Aids
sensor varies the voltage within a range of about 1000
mV when the exhaust is rich, down through about 10 Check the following items:
mV when exhaust is lean. The ECM constantly monitors • Fuel pressure - The system will go rich if pressure is
the HO2S signal during “Closed Loop” operation and too high. The ECM can compensate for some
compensates for a rich or lean condition by decreasing increase. However, if fuel pressure is too high, a
or increasing injector pulse width as necessary. If the Diagnostic Trouble Code P0132 may be set. Refer to
Fuel System Diagnosis. • An intermittent TPS output will cause the system to
• Perform “Injector Balance Test” - Refer to Fuel go rich due to a false indication of the engine
System Diagnosis. accelerating.
• Check the EVAP canister for fuel saturation - If full of • Silicon contamination of the HO2S can also cause a
fuel, check canister control and hoses. Refer to high HO2S voltage to be indicated. This condition is
Evaporative (EVAP) Emission Control System. indicated by a powdery white deposit on the portion
of the HO2S exposed to the exhaust stream. If
• Check for a leak in the fuel pressure regulator
contamination is noticed, replace the affected HO2S.
diaphragm by checking the vacuum line to the
regulator for the presence of fuel.

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Step Action Value(S) Yes No
(OBD) System
C56(J2) 6 E77

E77
1 2
Approximatly

Was the DVM indicated specifed value?
E77
1 2
Repair faulty
V V
harness and
3. Check the circuit for short to heater power supply
circuit.
O2 Sensor
4 2 1
4 3 2 1

8 Repair the short to heater power supply circuit.
data display.
conditions.

release?
17 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR NO ACTIVITY

DEFECTED CIRCUIT (BANK 1 SENSOR 1)
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0134 A O2 Sensor Circuit No Activity Detected 1. No DTC relating to MAP sensor, TPS, “Open Loop” fuel control.
(Bank 1 Sensor 1) EVAP purge, ECT sensor, CKP sensor,
control circuit.
60°C.
4. Mass air flow is more than 7g/s.
between 300mV and 600mV.
Circuit Description compensates for a rich or lean condition by decreasing

or increasing injector pulse width as necessary. If the
The engine control module (ECM) supplies a bias Bank 1 HO2S 1 voltage remains at or near the 450 mV
voltage of about 450 mV between the heated oxygen bias for an extended period of time, Diagnostic Trouble
sensor (HO2S) high and low circuits. The oxygen Code P0134 will be set, indicating an open sensor
sensor varies the voltage within a range of about 1000 signal or sensor low circuit.
mV when the exhaust is rich, down through about 10
mV when exhaust is lean. The ECM constantly monitors
the HO2S signal during “Closed Loop” operation and
Diagnostic Aids harness connectors for backed-out terminals,
improper mating, broken locks, improperly formed or
Check for the following conditions: damaged terminals, poor terminal-to-wire
• Poor connection or damaged harness - Inspect the connection, and damaged harness.

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
(OBD) System
C56(J2) 6 E77

E77
1 2
Approximatly

3. Disconnect the O2 sensor.
E77
1 2
38 53

connector.
6 C56(J2) 1 E77
Repair faulty
harness and
21 2 — verify repair Go to Step 13
data display.
conditions.

release?
15 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT

(BANK 1 SENSOR 1)
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0135 A O2 SensorHeater Circuit (Bank 1 Sen- 1. No DTC relating to MAP sensor and ECT No fail-safe function.
sor 1) sensor.
60°C.
4. MAP sensor output is more than 70KPa.
5. O2 sensor bank 1 heater current more than
10mA.
Circuit Description engine.

The engine control module (ECM) will run the heater
Heated oxygen sensors are used to minimize the test only after a cold start (determined by engine
amount of time required for “Closed Loop” fuel control coolant and intake air temperature at the time of start-
operation and to allow accurate catalyst monitoring. The up) and only once during an ignition cycle. When the
oxygen sensor heater greatly decreases the amount of engine is started the ECM will monitor the HO2S
time required for fuel control sensors Bank 1 HO2S 1 1 voltage. When the HO2S voltage indicates a sufficiently
to become active. Oxygen sensor heaters are required active sensor, the ECM looks at how much time has
by catalyst monitor sensors Bank 1 HO2S 2 to maintain elapsed since start-up. If the ECM determines that too
a sufficiently high temperature which allows accurate much time was required for the Bank 1 HO2S 1 to
exhaust oxygen content readings further from the
become active, a Diagnostic Trouble Code P0135 will connectors for backed-out terminals, improper
set. mating, broken locks, improperly formed or damaged
terminals, and poor terminal-to-wire connection.
Diagnostic Aids • Damaged harness - Inspect the wiring harness for
Check for the following conditions: damage; shorts to ground, shorts to battery positive
and open circuits.
• Poor connection at ECM - Inspect harness

O2 Sensor Heater Circuit (Bank 1 Sensor 1)
(OBD) System
C56(J2) E77
31
5 Visually check the O2 sensor.
6 Using the DVM and check the O2 sensor.
2. Disconnect O2 sensor connector
3. Measure the resistance of heater.
Was the tester indicated specified value?
O2 Sensor
4 3
4 3 2 1
Approximately
12.5Ω at 20°C Go to Step 7 Go to Step 11

7 Using the DVM and check the heater power supply
circuit for the affected cylinder.
E77
4
V Battery
“O2 Sensor” fuse (10A) and O2 sensor.
9 Using the DVM and check the heater ground circuit.
circuit.
E77
3
63

connector.
circuit.
31 E56(J2) E77
3
Repair faulty
harness and

10 Using the DVM and check the heater ground circuit.
circuit.
Was the DVM indicated voltage?
E77
3
Repair faulty
V harness and
release?
13 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR 1 CONTROL CIRCUIT
Battery Voltage
IGN
Switch
IGN
Fuse
15A
COIL
MODULE
#1 #2 #3 #4

J1-9 J1-22 J1-8 J1-11 J1-19 J1-18

Engine
Control
Module
(ECM)
µP
P0201 A Injector 1 Control Circuit 1. Engine is running. No fail-safe function.

2. Engine speed is more than 1000rpm.
P0202 A Injector 2 Control Circuit 3. Injector voltage does not meet to the bat-
tery voltage when the injector is com-
P0203 A Injector 3 Control Circuit manded Off or does not meet to the 0V
when the injector is commanded On.
P0204 A Injector 4 Control Circuit
Circuit Description activated. The ECM monitors the current in each driver
circuit. The ECM measures a voltage drop through a
The engine control module (ECM) has four individual fixed resistor and controls it. The voltage on each driver
injector driver circuits. Each controls an injector. When a is monitored to detect a fault. If the voltage is not what
driver circuit is grounded by the ECM, the injector is the ECM expects to monitor on the circuit, a Diagnostic
Trouble Code is set. This Diagnostic Trouble Code is injector. A misfire Diagnostic Trouble Code will also be
also set if an injector driver is shorted to voltage. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Diagnostic Aids high or low are a good indication that an injector is
faulty.
An injector driver circuit that is open or shorted to
Use Fuel Injector Coil Test Procedure to check for faulty
voltage will cause a Diagnostic Trouble Code P0201 to injectors.
set. It will also cause a misfire due to an inoperative
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit

(OBD) System
3. Select “F0: Read DTC Infor By Priority” in “F0: Refer to
Diagnostic Trouble Code”. Diagnostic Aids
Is the DTC P0201, P0202, P0203 or P0204 stored as and Go to Step
3. Operate the vehicle and monitor the “F5: Failed Refer to
This Ignition” in “F2: DTC Information”. Diagnostic Aids
Was the DTC P0201, P0202, P0203 or P0204 stored and Go to Step
in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the injector or
11 98
E-60(J1)
22
E-6/E-7/E-8/E-9

5 Visually check the injector for the affected cylinder.

6 Using the DVM and check the injector coil for the
affected cylinder.
2. Disconnect injector connector for the affected
cylinder.
3. Measure the resistance of injector coil.
Was the tester indicated specified value?
Injector
2 1
2 1
Approximately
12.5Ω at 20°C Go to Step 7 Go to Step 11

7 Using the DVM and check the injector power supply
circuit for the affected cylinder.
2. Disconnect the injector connector for the affected
cylinder.
No.1 Cylinder E-6
1
No.2 Cylinder E-7

1
No.3 Cylinder E-8

1
No.4 Cylinder E-9

1
V
Battery
“IGN” fuse (15A) and injector for the affected cylinder.

9 Using the DVM and check the injector signal circuit for
the affected cylinder.
cylinder.
circuit.
No.1 Cylinder
E-6
2
9
No.2 Cylinder
E-7
2
22
No.3 Cylinder
E-8
2
8
No.4 Cylinder
E-9
2
11
Repair faulty
harness and

9 Breaker box is not available:
cylinder and ECM connector.
circuit.
No.1 Cylinder
E-60(J1)
E-6
2
No.2 Cylinder
E-60(J1)
E-7
2
22
No.3 Cylinder
E-60(J1)
E-8
2
No.4 Cylinder
E-60(J1)
E-9
2
11
Repair faulty
harness and

10 Using the DVM and check the injector signal circuit.
cylinder.
circuit.
No.1 Cylinder E-6

2
No.2 Cylinder E-7

2
No.3 Cylinder E-8

2
No.4 Cylinder E-9

2
V Repair faulty
harness and
11 Replace the injector for the affected cylinder.
release?
13 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT

MALFUNCTION
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0325 B Knock Sensor Module Circuit 1. No DTC relating to MAP sensor. ECM retards ignition timing 4°C.
50°C.
4. Knock sensor filter module integrated cir-
cuit malfunction.
Circuit Description signals from the Knock Sensor.

The knock sensor (KS) system is used to detect engine
Diagnostic Aids
detonation. The knock sensor produced an AC voltage
signal. The knock sensor sends this signal to the ECM. Correct any abnormal engine noise before using the
The amplitude and the frequency of the AC voltage diagnostic table.
signal depends upon the knock level being detected. Check for an open circuit.
The ECM will then retard the spark timing based on the
Diagnostic Trouble Code (DTC) P0325 Knock Sensor Module Circuit

(OBD) System

4 Check for poor/faulty connection at the knock sensor
E-60(J1) E-84
3

5 Visually check the knock sensor.
6 Listen to the engine noise while raising and lowering
the engine speed.
Is a knock or audible noise present? — Go to Step 7 Go to Step 8
7 Repair the mechanical engine problem or a loose
bracket or component.

8 Using the DVM and check the knock sensor circuit.
3. Disconnect the knock sensor.
E-84
1 2
3 32

2. Disconnect the knock sensor connector and ECM
connector.
E-60(J1) 3 E-84
1 2
32
Repair faulty
harness and
9 Substitute a known good knock sensor and recheck.
10 Replace the knock sensor.
release?
12 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT

LOW INPUT
Engine
Throttle Coolant
Sensor
Knock
Sensor
0.5
YEL
0.5
GRY
0.5 0.5 0.5

BLU/ WHT/ BLK/
PNK BLU YEL
J1-3 J1-32 J1-7 J1-15 J1-27

Engine
Control
Module
(ECM) +5V
5Volts
Reference
µP µP
Knock Filter
Module
µP
P0327 A Knock Sensor Circuit 1. No DTC relating to MAP sensor. ECM retards ignition timing 4°C.
50°C.
4. Knock sensor harness short to ground or

The ECM uses the Knock Sensor (KS) in order to detect Check for the following conditions:
engine detonation. This allows the ECM to retard the A poor connection at the ECM. Inspect the knock
Ignition Control (IC) spark timing based on the KS signal sensor and the ECM connectors for: , broken locks,
the ECM receives. The knock sensors produce an AC improperly formed or damaged terminals.
signal that rides on the 1.3 volts DC. The signal’s • Backed out terminals
amplitude and frequency are dependent upon the
• Broken locks
amount of the knock being experienced.
The ECM determines whether the knock is occurring by • Improperly formed or damaged terminals
comparing the signal level on the KS circuit with a Also, check the wiring harness for: shorts to ground,
voltage level on the noise channel. The normal engine shorts to battery positive, and open circuits.
noise varies depending on the engine speed and load. • A misrouted harness. Inspect the knock sensor
Then the ECM determines that an abnormally high harness in order to ensure that it is not routed too
noise channel voltage level is being experienced, a close to high voltage wires such as spark plug leads.
Diagnostic Trouble Code P0327 sets.
Diagnostic Trouble Code (DTC) P0327 Knock Sensor Circuit

(OBD) System
4 Check for poor/faulty connection at the knock sensor
E-60(J1) E-84
3

5 Visually check the knock sensor.
2. Disconnect the knock sensor connector and ECM
connector.
ground circuit.
E-84
1 2
Repair faulty
harness and

2. Disconnect the knock sensor connector.
circuit.
E-84
1 2
Repair faulty
V V harness and
8 Substitute a known good knock sensor and recheck.
9 Replace the knock sensor.
release?
11 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP)

SENSOR CIRCUIT RANGE/PERFORMANCE (58X)
DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP)

SENSOR CIRCUIT LOW INPUT (58X)
Crankshaft
Position(CKP)
Manifold Sensor
Absolute
INLET
MANIFOLD
0.5
BLK/
WHT
0.5 0.5
BLK WHT
0.5 0.5 0.5
GRY/ GRY/ YEL/
BLU RED RED
0.5 0.5
BLK/ BLK/
WHT WHT
J1-16 J1-24 J1-31 J1-1 J1-2 J1-17 J1-6 J1-21

Engine
Control
Module
(ECM)
5 Volts
Reference
µP
P0336 B Crankshaft Position Sensor Circuit 1. Engine is running. No fail-safe function.

Range/Performance (58X) 2. Extra or missing pulse is detected consecu-
tively.
P0337 B Crankshaft Position Sensor Circuit Low No pulse is detected during engine cranking.
Input (58X)
Circuit Description 58X reference circuit. If the ECM receives an incorrect

number of pulses on the 58X reference circuit,
The 58X reference signal is produced by the crankshaft Diagnostic Trouble Code P0336 will set. If the ECM
position (CKP) sensor. During one crankshaft revolution, does not receive pluses on the 58X reference circuit,
58 crankshaft pulses will be produced. The engine Diagnostic Trouble Code P0337 will set.
control module (ECM) uses the 58X reference signal to
calculate engine RPM and crankshaft position. The
ECM constantly monitors the number of pulses on the
Diagnostic Aids • Damaged harness - Inspect the wiring harness for
damage; shorts to ground, shorts to battery positive
An intermittent may be caused by a poor connection, and open circuits. If the harness appears to be OK,
rubbed-through wire insulation or a wire broken inside disconnect the ECM, turn the ignition on and observe
the insulation. Check for: a voltmeter connected to the 58X reference circuit at
• Poor connection - Inspect the ECM harness and the ECM harness connector while moving connectors
connectors for improper mating, broken locks, and wiring harnesses related to the ECM. A change
improperly formed or damaged terminals, and poor in voltage will indicate the location of the fault.
terminal-to-wire connection.

Crankshaft Position Sensor Circuit Range/performance (58x)
Crankshaft Position Sensor Circuit Low Input (58x)
(OBD) System
Is the DTC P0336 or P0337 stored as “Present and Go to Step
Failure”? — Go to Step 3 3
Was the DTC P0336 or P0337 stored in this ignition and Go to Step
cycle? — Go to Step 4 4
E-60(J1) 6 1 E-59


6 21

3. 3. Check the resistance of the CKP sensor.
6 E-60(J1)
21 Approximately
0.55kΩ at
20°C Go to Step 10 Go to Step 7
CKP Sensor
2 1
3 2 1
Approximately
0.55kΩ at

E-59
1 2
6 21

6 E-60(J1)
21
E-60(J1) E-59
6 1 2
Repair faulty
21 harness and

E-59
1 2
V V
and ECM.

At CKP sensor terminal 1 & 2 Approx. 3.7V in engine idle
At ECM E60 (J1) connector 21 & 6 Approx. 7.7V at 2000rpm

form?
CKP Sensor Signal Reference Wave Form
0V→
Measurement Terminal: J1-21 (+) J1-6 (-)

and visually check.

release?
17 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION 1 CONTROL CIRCUIT
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION 2 CONTROL CIRCUIT
Battery Voltage
IGN
Switch
IGN
Fuse
15A
COIL
MODULE
#1 #2 #3 #4

J1-9 J1-22 J1-8 J1-11 J1-19 J1-18

Engine
Control
Module
(ECM)
µP
P0351 A Ignition 1 Control Circuit #2 or #3cylinder ignition signals are not No fail-safe function.
detected consecutively.
P0352 A Ignition 2 Control Circuit #1 or #4 cylinder ignition signals are not

detected consecutively.
Circuit Description The circuit between the ECM and the ignition control
module is monitored for an open circuit, short to voltage,
The ignition control circuit provides a zero volt or a 5 volt and short to ground. When the ECM detects a problem
signal to the ignition control module. The normal circuit in the ignition control circuit, it will set DTC P0351 or
voltage is zero volts. When the module receives the 5 P0352.
volt signal from the ECM, it provides a ground path for
the B+ voltage supplied to the ignition primary coil. Diagnostic Aids
When the ECM turns off the 5 volts to the module, the
module will remove the ground path of the ignition Check for the following conditions:
primary coils; causing the magnetic field produces a • Poor connection at the ECM - Inspect the harness
voltage in the secondary coils which fires the spark connectors for backed-out terminals, improper
plug.
mating, broken locks, improperly formed or damaged the Tech 2 display related to DTC P0351 or P0352
terminals, and poor terminal-to-wire connections. while moving the connector and wiring related to the
• Damaged harness - Inspect the wiring harness for ignition system. A change in the display will indicate
damage; Open circuits, shorts to ground, or shorts to the location of the fault.
Voltage. If the harness appears to be OK, observe
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit

Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit
(OBD) System
Is the DTC P0351 or P0352 stored as “Present and Go to Step
Failure”? — Go to Step 3 3
Was the DTC P0351 or P0352 stored in this ignition and Go to Step
cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ignition coil
module or ECM connector. If a poor/faulty connection
is found, repair as necessary.
E-60(J1) E-18

5 Visually check the ignition coil module.

6 Using the DVM and check the ignition coil module
signal circuit for the affected coil.
2. Disconnect the ignition coil module connector.
3. Check the circuit for short to battery voltage circuit
for the affected coil.
Coil 1 Coil 2
E-18 E-18
1 3
Repair faulty
V V harness and

7 Using the DVM and check the ignition coil signal
circuit for the affected coil.
4. Check the circuit for open or short to ground circuit
Coil 1 E-18
1
18
Coil 2 E-18
3
19

2. Disconnect the ignition coil module connector and
ECM connector.
3. Check the circuit for open or short to ground circuit
Coil 1
E-60(J1) E-18
2
18
Coil 2
E-60(J1) E-18
19 3
Repair faulty
harness and

8 Using the DVM and check the ignition coil module
E-18
2
V Battery
“IGN. Coil” fuse (15A) and ignition coil module.
10 Replace the ignition coil module.
release?
12 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP)

CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION
Battery Voltage
Intake Ignition
Air SW
Temperature(IAT)
Sensor
Engine
15A
0.5
BLU/
YEL
Evaporativ
Steering Canistor
Pressure Purge
SW Valve
Solenoid
0.5 0.5 0.5 0.5 0.5

GRN YEL YEL WHT
J2-1 J2-22 J2-20 J2-3 J1-5

Engine
Control
Module +5V
(ECM)
µP
µP
P0443 B EVAP Emission Control System Purge EVAP purge solenoid circuit open, short to No fail-safe function.
Control Circuit ground or short to voltage circuit.

The Engine Control Module (ECM) controls the • Poor connections, or a damaged harness - Inspect
Evaporative Emission (EVAP) Canister Purge Solenoid the harness connectors for: backed-out terminals,
Valve through the use of a control (ground) circuit. If the improper mating or damaged terminals. Also check
ECM commands the Purge solenoid to maximum duty for open circuits, shorts to ground, and shorts to
cycle (100%) but the voltage remains High (12 Volts); or, voltage.
if the ECM commands the Purge solenoid to minimum
duty cycle (0%) but the voltage remains Low (0 volts),
then DTC P0443 will set.

Evap Emission Control System Purge Control Circuit
(OBD) System
4 Check for poor/faulty connection at the purge solenoid
valve or ECM connector. If a poor/faulty connection is
E-60(J1) 5 E-66

5 Using the DVM and check the purge solenoid valve.
2. Disconnect purge solenoid valve connector.
3. Measure the resistance of purge solenoid valve
coil.
EVAP Purge Solenoid
2 1
2 1
25 - 30Ω at

6 Using the DVM and check the purge solenoid valve
2. Disconnect the purge solenoid valve connector.
E-66
2
V
Battery
“Engine” fuse (15A) and purge solenoid valve.
solenoid signal circuit.
circuit.
E-66
1
5

2. Disconnect the purge solenoid valve connector
and ECM connector.
circuit.
E-60(J1) E-66
1
5
Repair faulty
harness and

signal circuit.
circuit.
E-66
1
Repair faulty
V harness and
10 Substitute a known good purge solenoid valve and
recheck.
11 Replace the purge solenoid valve.
release?
13 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS)

CIRCUIT LOW INPUT
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P0502 B Vehicle Speed Sensor Circuit Low 1. No DTC relating to MAP sensor, TPS, ECT ECM uses 0km/h condition as substitute.
Input sensor, injector control circuit and ignition
control circuit.
2. Engine is running.
3. Vehicle speed is below 3km/h in power con-
dition or 2km/h in deceleration condition.

The vehicle speed sensor has a magnet rotated by the • Poor connection at ECM: Inspect harness connectors
transmission output shaft. Attached to the sensor is a for backed out terminals, improper mating, broken
hall effect circuit that interacts with the magnetic field locks, improperly formed or damaged terminals, and
created by the rotating magnet. A 12-volt operating poor terminal to wire connection.
supply for the speed sensor hall circuit is supplied from
the meter fuse.
Diagnostic Trouble Code (DTC) P0502 Vehicle Speed Sensor Circuit Low Input
(OBD) System
4 Check for poor/faulty connection at the VSS, meter,
immobiliser control unit (if equipped), ECM and other
C-56(J2)
23
B-68
8
6
B-24 9 10
27
E-44

check.

2. Measure the VSS output voltage at sensor, meter,
immobiliser control unit (if equipped) and ECM.
(AC Range) Good
VSS terminal 3 & GND Approximately Go to
7.0 V at 20km/h Step 7
GND Step 11
GND Step 13
Immobiliser control unit B68 Go to
connector 6 & GND Step 14
Immobiliser control unit B68 Approximately Go to
connector 8 & GND 4.8 V at 20km/h Step 16
ECM C56 (J2) connector 23 & Go to
GND Step 17
If a oscilloscope is available, monitor the VSS signal.

Does the oscilloscope indicate correct wave form?
0V→
Measurement Scale: 10V/div 50ms/div

Measurement Condition: Vehicle speed 20km/h
Measurement Terminal: At Vehicle Speed Sensor
0V→
Refer to
Measurement Condition: Vehicle speed 20km/h and Go to Step
21 Refer the table

7 Using the DVM and check the VSS power supply
circuit.
2. Disconnect the VSS connector.
circuit.
1 E-44
V Battery
8 Repair the open circuit between the VSS and meter
fuse.
9 Using the DVM and check the VSS ground circuit.
E-44
2
Repair faulty
V harness and
10 Using the DVM and check the VSS ground circuit.
E-44
2
Repair faulty
harness and

connector.
B-24
9
Repair faulty
V
harness and
connector.
circuit.
B-24 E-44
3
9
control unit connector (if equipped).
B-68
6
Repair faulty
V
harness and

control unit connector (if equipped).
circuit.
B-24 B-68
10
16 Replace the immobiliser control unit (if equipped).
2. Disconnect the immobiliser control unit connector
(if equipped) and ECM connector.
C-56(J2)
23
V Repair faulty
harness and

(if equipped).
B-68
8
55

(if equipped) and ECM connector.
circuit.
C-56(J2) B-68
23
8
Repair faulty
harness and
20 Replace the VSS.
release?
22 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0562 D System Voltage Low Battery voltage is below 11V. No fail-safe function.

The engine control module (ECM) monitors the system • If the Diagnostic Trouble Code sets when an
voltage on the ignition feed terminal to the ECM. A accessory is operated, check for a poor connection or
system voltage Diagnostic Trouble Code will set excessive current draw.
whenever the voltage is below a calibrated value. • Check for open circuits or shorts to ground on the
ECM’s battery or ignition inputs.
Diagnostic Trouble Code (DTC) P0562 System Voltage Low

(OBD) System

2. Monitor the “Ignition Voltage” in the data display.
headlights, etc..
or replace the
as necessary.
C-56(J2) 2 E-60(J1) 2 1

the inlet manifold. If a poor/faulty connection is found,
E-72

release?
9 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P0563 A System Voltage High Battery voltage is above 16V. No fail-safe function.
Circuit Description whenever the voltage is above a calibrated value.

The engine control module (ECM) monitors the system
Diagnostic Aids
voltage on the ignition feed terminals to the ECM. A
system voltage Diagnostic Trouble Code will set Check for a faulty charging system components.
Diagnostic Trouble Code (DTC) P0563 System Voltage High

(OBD) System

2. Monitor the “Ignition Voltage” in the data display. Check the
3. Load the electrical system by turning on the charging
headlights, etc.. system and Go
Does the Tech 2 indicate correct ignition voltage? 10 - 14V Go to Step 5 to Step 5
5 Is the battery jamp start cable incorrectly connecting? Verify
— procedure Go to Step 6
release?
7 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0601 ECM MEMORY CHECKSUM

P0601 A ECM Memory Checksum ECM memory area error. Engine control disabled.
Circuit Description programmed using a Tech 2.

The engine control module (ECM) used in this vehicle
Diagnostic Aids
utilizes an electrically erasable programmable read-only
memory (EEPROM). The EEPROM contains program • Diagnostic Trouble Code P0601 indicates that the
information and the calibrations required for engine, contents of the EEPROM have changed since the
transmission, and powertrain diagnostics operation. ECM was programmed. The only possible repair is
Unlike the PROM used in past applications, the ECM reprogramming or replacement. Check service
EEPROM is not replaceable. When the ECM is replaced bulletins to program the replacement ECM with the
or a calibration update is required, the ECM must be correct software and calibration for the vehicle.
Diagnostic Trouble Code (DTC) P0601 ECM Memory Checksum

(OBD) System
3. Operate the vehicle and monitor the “F5: Failed
This Ignition” in “F2: DTC Information”. Refer to
Was the DTC P0601 stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
5 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0602 PROGRAMMING ERROR

P0602 - Programming Error ECM memory area error. Engine control disabled.
Circuit Description or a calibration update is required, the ECM must be

programmed using a Tech 2.
The engine control module (ECM) used in this vehicle
utilizes an electrically erasable programmable read-only
Diagnostic Aids
memory (EEPROM). The EEPROM contains program
information and the calibrations required for engine, • Diagnostic Trouble Code P0602 indicates when non
transmission, and powertrain diagnostics operation. programmed ECM is used without service
Unlike the PROM used in past applications, the programming system (SPS). The replacement ECM
EEPROM is not replaceable. When the ECM is replaced must be programmed.
Diagnostic Trouble Code (DTC) P0602 Programming Error

(OBD) System
3. Select “F0: Read DTC Infor By Priority” in “F0:
Diagnostic Trouble Code”. Refer to
DTC P0650 MALFUNCTION INDICATOR LAMP (MIL) CONTOROL CIRCUIT

MALFUNCTION
Buttery
Voltage
Ignition
SW
METER
10A
METER
15A
0.5
RED/
YEL
Diagnostic
16 15 14 13 12 11 10 9 Comectar
8 7 6 5 4 3 2 1
Check
Engine
Lamp
0.85 BLK
Imnobiliser
Control
Unit Engine
Room-RH
7
0.5 0.5
0.5 BLU GRN
BRN/
YEL
J2-32 J2-4 J2-30

Engine
Module SW Serial
(ECM) Data
µP
P0650 A Malfunction Indicator Lamp (MIL) Con- Check engine lamp circuit open, short to No fail-safe function.
trol Circuit Malfunction ground or short to voltage circuit.

and steady with ignition “ON” and the engine stopped. rubbed-through wire insulation, or a wire broken inside
Ignition feed voltage is supplied directly to the check the insulation. Check for the following items:
engine lamp indicator. The Engine Control Module • Poor connection or damaged harness - Inspect the
(ECM) turns the check engine lamp “ON” by grounding ECM harness and connectors for improper mating,
the check engine lamp driver circuit. The check engine broken locks, improperly formed or damaged
lamp should not remain “ON” with the engine running terminals, poor terminal-to-wire connection, and
and no DTC(s) set. A steady check engine lamp with the damaged harness.
engine running and no DTC(s) suggests a short to
ground in the check engine lamp driver circuit.

Malfunction Indicator Lamp (MIL) Control Circuit Malfunction
(OBD) System
C-56(J2) B-24


circuit.
circuit.
B-24
64
17

circuit.
32 C-56(J2) 17 B-24
Repair faulty
harness and
release?
10 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P1167 FUEL SUPPLY SYSTEM RICH

DURING DECELERATION FUEL CUT OFF
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P1167 D Fuel Supply System Rich During 1. No DTC relating to MAP sensor, TPS, No fail-safe function.
Deceleration Fuel Cutoff EVAP purge, ECT sensor, CKP sensor,
control circuit.
2. O2 sensor bank 1 output voltage is more
than 550mV in deceleration fuel cutoff
mode.
Circuit Description “lean” exhaust is not detected at this time, a Diagnostic

Trouble Code P1167 will set.
The engine control module (ECM) internal circuitry can
identify if the vehicle fuel system is capable of supplying Diagnostic Aids
adequate amounts of fuel during deceleration (fuel cut
off). The ECM monitors the voltage of the oxygen Check the following items:
sensor during fuel cut off. When a fuel cut off mode of • Fuel pressure - The system will go rich if pressure is
operation is requested during “Closed Loop” operation too high. The ECM can compensate for some
(by deceleration), the ECM will provide more fuel to the increase. However, if fuel pressure is too high, a
engine. Under these conditions the ECM should detect Diagnostic Trouble Code P1167 may be set. Refer to
a “lean” condition (low oxygen sensor voltage). If this Fuel System Diagnosis.
• Perform “Injector Balance Test” - Refer to Fuel • An intermittent TP sensor output will cause the
System Diagnosis. system to go rich due to a false indication of the
• Check the EVAP canister for fuel saturation - If full of engine accelerating.
fuel, check canister control and hoses. Refer to • Silicon contamination of the HO2S can also cause a
Evaporative (EVAP) Emission Control System. high HO2S voltage to be indicated. This condition is
• Check for a leak in the fuel pressure regulator indicated by a powdery white deposit on the portion
diaphragm by checking the vacuum line to toe of the HO2S exposed to the exhaust stream. If
regulator for the presence of fuel. contamination is noticed, replace the affected HO2S.

Fuel Supply System Rich During Deceleration Fuel Cutoff
(OBD) System
Does the Tech 2 indicate correct “Throttle Position” in
accordance with accelerator pedal operation? — Go to Step 6 Go to Step 5
• Incorrectly installed.
data display.
conditions.

12 Replace the TPS.
14 Replace the IAC valve.
release?
17 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SUPPLY SYSTEM LEAN

DURING POWER ENRICHMENT
Battery Battery
Voltage Voltage
2.0 ECM
WHT 10A
Fuel
Pump
Relay
O2
FUEL SENSOR
PUMP 0.85
10A RED/
20A
2.0 WHT
BLK/
BLU 0.5 PNK
Heated 0.5
- GRN/
Fuel O2
M + WHT
Pump Sensor
Crankshaft
Position
Sensor 2.0 0.5 0.5
BLK BLU RED/
0.5 WHT
BLU/
WHT
TIMING
J1-1 J1-2 J1-17 J2-6 J2-21 COVER J2-31 J2-11 J2-2 J2-18
Engine
Control
Module 450
(ECM) mV VIgn
Vcc - +
+5V
µP
A/D Converter
P1171 D Fuel Supply System Lean During 1. No DTC relating to MAP sensor, TPS, No fail-safe function.
Power Enrichment EVAP purge, ECT sensor, CKP sensor,
control circuit.
60°C.
3. Mass air flow is below 13.5m/s.
4. O2 sensor bank 1 output voltage is below
350mV in power enrichment mode.
Circuit Description the ECM will provide more fuel to the engine. Under
these conditions the ECM should detect a “rich”
The engine control module (ECM) internal circuitry can condition (high oxygen sensor voltage). If this “rich”
identify if the vehicle fuel system is capable of supplying exhaust is not detected at this time, a Diagnostic Trouble
adequate amounts of fuel during heavy acceleration Code P1171 will set. A plugged fuel filter or restricted
(power enrichment). The ECM monitors the voltage of fuel line can prevent adequate amounts of fuel from
the oxygen sensor during power enrichment. When a being supplied during power enrichment mode.
power enrichment mode of operation is requested
during “Closed Loop” operation (by heavy acceleration),
Diagnostic Aids • Vacuum leaks - Check for disconnected or damaged
vacuum hoses and for vacuum leaks at the intake
Check for the following conditions: manifold, throttle body, and PCV system.
• Heated oxygen sensor wiring - The sensor pigtail • Exhaust leaks - An exhaust leak may cause outside
may be routed incorrectly and contacting the exhaust air to be pulled into the exhaust gas stream past the
system. HO2S, causing the system to appear lean. Check for
• Poor ECM to engine block ground. exhaust leaks that may cause a false lean condition
• Fuel pressure - The system will go lean if pressure is to be indicated.
too low. The ECM can compensate for some • Fuel contamination - Water, even in small amounts,
decrease. However, if fuel pressure is too low, a can be delivered to the fuel injectors. The water can
diagnostic Trouble Code P1171 may be set. Refer to cause a lean exhaust to be indicated, Excessive
Fuel System Diagnosis. alcohol in the fuel can also cause this condition.
• Lean injector(s) - Perform “Injector Balance Test.” Refer to Fuel System Diagnosis for the procedure to
check for fuel contamination.

Fuel Supply System Lean During Power Enrichment
(OBD) System
Does the Tech 2 indicate correct “Throttle Position” in
accordance with accelerator pedal operation? — Go to Step 6 Go to Step 5
• Incorrectly installed.
data display.

conditions.
12 Replace the TPS.
14 Replace the IAC valve.
release?
17 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM SYSTEM RESET

P1625 B ECM ECM reset has occurred other than “On”. Engine control disabled.
System Reset

The powertrain control module (ECM) monitors Check for the follwing conditions:
unexpected ECM reset. This will not turn on MIL light • P1625 alone stored does not need diagnosis. Clear
on, only records code DTC P1625. DTC code.
NOTE: DTC P1625 is a DTC to record a ECM reset
history. If DTC P1625 is not reset and no engine
abnormality occurs after learing the DTC, no farther
diagnostic procedures are required.
Diagnostic Trouble Code (DTC) P1625 ECM System Reset

(OBD) System
release?
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILISER NO SIGNAL
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P1626 - Immobiliser No Signal No response from immobiliser control unit. 1. Engine does not start.
2. Check engine lamp flash.
Circuit Description damaged terminals, and poor terminal to wire

connection.
The ECM decides whether that is an abnomality in the
immobiliser control system. DTC P1626 is recorded by • Damaged harness Inspect the wiring harness for
the ECM when no response from immobiliser. damage, If the harness appears to be OK, disconnect
the ECM and Immobiliser, turn the ignition “ON” and
observe a voltmeter connected to the suspect driver
Diagnostic Aids
circuit at the ECM and Immobiliser harnass
Check for the following conditions: connector while moving connectors and wiring
• Poor connection at ECM and Immobiliser-Inspect harnesses relates to the MIL. A change in voltage will
harness connectors for backed out terminals, indicate the location of the fault.
Diagnostic Trouble Code (DTC) P1626 Immobiliser No Signal

(OBD) System
Refer to
C-56(J2) B-68
32 23 7 8 — Verify repair Go to Step 6

lamp circuit.
B-68 B-24
17
7
Repair faulty
V V harness and

lamp circuit.
circuit.
B-68
7
64

circuit.
32 C-56(J2) B-68
7
Repair faulty
harness and
and ECM connector.
C-56(J2) B-68
7
23
Repair faulty
V V harness and

4. Check thecircuit for openorshottogroundcircuit.
B-68
8
55

and ECM connector.
circuit.
C-56(J2) 23 B-68
8
Repair faulty
harness and
— verify repair Go to Srtep 10
release?
11 Replace the ECM.

IMMOBILISER WRONG SIGNAL
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P1631 - Immobiliser Wrong Signal Received response is not correct. 1. Engine does not start.

connection.
immobiliser control system. DTC P1631 is recorded by • Damaged harness-Inspect the wiring harness for
the ECM when received response was not correct. damage, If the harness appears to be OK, disconnect
Diagnostic Aids
Diagnostic Trouble Code (DTC) P1631 Immobiliser Wrong Signal

(OBD) System
Refer to
release?
6 Replace the ECM.

WRONG SECURITY CODE ENTERED
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P1648 - Wrong Security Code Entered Received incorrect security code. 1. Engine does not start.

connection.
immobiliser control system. DTC P1648 is recorded by • Damaged harness Inspect the wiring harness for
the ECM when received incorrect security code. damage, If the harness appears to be OK, disconnect
Diagnostic Aids
Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered

(OBD) System
Refer to
release?
6 Replace the ECM.

IMMOBILISER FUNCTION NOT PROGRAMMED
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P1649 - Immobiliser Function Not Programmed Immobiliser function is not programmed in the 1. Engine does not start.
ECM. 2. Check engine lamp flash.
Circuit Description improper mating, broken locks, improperly formed or

The ECM decides whether that is an abnomality in the connection.
immobiliser control system. DTC P1649 is recorded by
the ECM when security code & secret key not • Damaged harness Inspect the wiring harness for
programmed. damage, If the harness appears to be OK, disconnect
Diagnostic Aids
Diagnostic Trouble Code (DTC) P1649 Immobiliser Function Not Programmed

(OBD) System
Refer to
release?
6 Replace the ECM.

TACHOMETER OUTPUT LOW VOLTAGE
Ignition
SW
Meter
15A
0.8 YEL/GRN
0.85
YEL
Sped Tacho Check

Meter Meter Engine
Imnobiliser
Vehicle Control
Speed Unit
Sensor
CPU
6 7 8
(–) (+)
0.5 BRN/YEL
0.5 0.5
BRN/ WHT
YEL
J2-25 J2-32 J2-23

Engine
Control
Module VIgn
(ECM)
VIgn
µP µP µP
P1693 B Tachometer Output Low Voltage Tacho output circuit short to ground circuit. No fail-safe function.
Circuit Description ground or open contact on the Tacho output, the

Diagnostic Trouble Code P1693 will be set.
Based on the information from the Crank Position
Sensor (CKP), X58 reference signal is generated at Diagnostic Aids
each rotation of the crankshaft.
Engine Control Module (ECM) converts X58 reference • Poor connections or a damaged harness - Inspect the
signal into the square wave signal which is used to drive harness connections for: backed out terminals,
the pulse generator of the tachometer. imprope, mating or damaged terminals. Also check
When the wave length of the output signal is long, the for open circuit, short to ground, and short to voltage.
tacho meter indicates the engine speed is low, and vise • This malfunction detects a low impedance short to
versa. ground or open contact on the ECM out put circuit.
This malfunction detects a low impedance short to
Diagnostic Trouble Code (DTC) P1693 Tachometer Output Low Voltage

(OBD) System
4 Check for poor/faulty connection at the ECM or meter
C-56(J2) B-24 11

5 If a oscilloscope is available, monitor the Tachometer
wave form?
Tachometer Output Signal Reference Wave Form
0V→
Not available:
Go to Step 6
Fixed at low: Go
Measurement Terminal: J2-25 (+) J1-1 (-) to Step 6
Measurement Condition: Engine Speed at 2000rpm
Fixed at High:

6 Using the DVM and check the Tacho output circuit.
circuit.
B-24
11
57

circuit.
C-56(J2) B-24 11
25
Repair faulty
harness and
7 Using the DVM and check the Tacho output circuit.
B-24
11
Repair faulty
V harness and

9 Replace the Tacho meter.
release?
11 Replace the ECM.
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS • MIL (Check Engine Lamp) wire to ECM shorted to
ground.
Before using this section, perform the “On-Board
Diagnostic (OBD) System Check” and verify all of the • Poor ECM grounds. Refer to the ECM wiring
following items: diagrams.
• The engine control module (ECM) and malfunction Road test the vehicle with a Digital Multimeter
indicator lamp (MIL = Check Engine Lamp) are connected to a suspected circuit. An abnormal voltage
operating correctly. when the malfunction occurs is a good indication that
• There are no Diagnostic Trouble Code(s) stored. there is a fault in the circuit being monitored.
• Tech 2 data is within normal operating range. Refer to Using Tech 2 to help detect intermittent conditions. The
Typical Scan Data Values. Tech 2 has several features that can be used to located
• Verify the customer complaint and locate the correct an intermittent condition.
symptom in the table of contents. Perform the
procedure included in the symptom chart. An intermittent MIL (Check Engine Lamp) with no stored
Diagnostic Trouble Code may be caused by the
VISUAL/PHYSICAL CHECK following:
• Ignition coil shorted to ground and arcing at ignition
Several of the symptom procedures call for a careful wires or plugs.
visual/physical check. This can lead to correcting a
• MIL (Check Engine Lamp) wire to ECM short to
problem without further checks and can save valuable
ground.
time. This check should include the following items:
• Poor ECM grounds. Refer to the ECM wiring diagrams.
• ECM grounds for cleanliness, tightness and proper
location.
Check for improper installation of electrical options such
• Vacuum hoses for splits, kinks, and proper as light, cellular phones, etc. Check all wires from ECM
connection, shown on the “Emission Control System to the ignition control module for poor connections.
Schematics”. Check thoroughly for any type of leak or Check for an open diode across the A/C compressor
restriction. clutch and check for other open diodes (refer to wiring
• Air intake ducts for collapsed or damaged areas. diagrams in Electrical Diagnosis).
• Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold If problem has not been found, refer to ECM connector
sealing surfaces. symptom tables.
• Ignition wires for cracking, harness, and carbon • Check the “Broadcast Code” of the ECM, and
tracking. compare it with the latest Isuzu service bulletins and/
• Wiring for proper connections, pinches and cuts. or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECM’s reprogrammable
memory has been released.
INTERMITTENT
To check the “Broadcast Code”, connect the Tech 2,
Important: An intermittent problem may or may not turn then look for “ID info.” then select “Broadcast Code”.
on the malfunction indicator lamp (MIL) or store a This should display a 4 character code, such as “XBYA”
Diagnostic Trouble Code. Do NOT use the Diagnostic (example only).
Trouble Code (DTC) charts for intermittent problems. This identifies the contents of the reprogrammable
The fault must be present to locate the problem. software and calibration contained in the ECM.
Most intermittent problems are cased by faulty electrical If the “Broadcast Code” is not the most current available,
connections or wiring. Perform a careful visual/physical it is advisable to reprogram the ECM’s EEPROM
check for the following conditions. memory, which may either help identify a hard-to find
• Poor mating of the connector halves or a terminal not problem or may fix the problem.
fully seated in the connector (backed out). The Service Programming System (SPS) will not allow
incorrect software programming or incorrect calibration
• Improperly formed or damaged terminal.
changes.
• All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
• Poor terminal-to-wire connection. This requires
removing the terminal form the connector body to
check.
• Ignition coils shorted to ground and arcing at ignition
wires or plugs.

NOTE: 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 “Immobiliser System-ECM replacement” for the ECM/Immobiliser linking procedure.
NOTE: The vehicle with immobiliser system, this system may be activated. Check the immobiliser system diagosis.

4 Check the “Ignition coil” fuse (15A) and “ECM” fuse
(15A).
Was a fuse blown? — Verify repair Go to Step 5
5 1. Ignition ON
2. Use a DVM to verify that battery voltage at the
ignition coil fuse, and the ECM fuse.
Was battery voltage presented at the fuses? — Go to Step 6 Verify & repair
6 1. Visually/physically inspect for the following
conditions:
• Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
• Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
• Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
7 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
8 1. Using a Tech 2, display the MAP sensor value.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
9 If oscilloscope is available, check the wave form of the
CKP signal.
Was the correct wave form found? — Go to Step 12 Go to Step 10
10 Check the CKP sensor wire for open or short circuit.
11 Replace CKP sensor. Replace pulsar
Is there still problem? — ring. Verify repair

12 Visually/physically inspect the secondary ignition
wires. Check for the following conditions:
• Verify that all ignition wire resistance are less than
the specified value.
• Verify that ignition wires are correctly routed to
eliminate cross-fitting.
• Verify that ignition wires are not arcing to ground.
Spraying the secondary ignition wires with a light #1 cyl. 4.4kΩ
mist of water may help locate an intermittent #2 cyl. 3.6kΩ
problem. #3 cyl. 3.1kΩ
Was a problem found? #4 cyl. 2.8kΩ Verify repair Go to Step 13
13 1. Disconnect the spark plug high tension cable from
No.1 spark plug.
2. Install a spark tester at the end of the
disconnected ignition coil.
3. Clip the spark tester to a good ground.
4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same
as “No Spark”.) — Go to Step 21 Go to Step 14
14 1. Disconnect the ignition coil harness connector.
2. Check for an open or short circuit between the
ignition coil and the ECM.
15 1. Ignition “On”.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition coil harness connector. Battery
Was the voltage equal to the specified value? voltage Go to Step 16 Verify repair
16 1. Ignition “Off”.
2. With DVM, check for an open in the ground wire at
the ignition coil harness connector.
Was the ground wire OK? — Go to Step 17 Verify repair
17 Replace the ignition coil, verify the repair.
Attempt to start the engine.
Is there still a problem? — Go to Step 18 Verify repair
18 Use an ohmmeter to check the ignition coil primary
winding resistance.
Was the primary winding resistance approximately
equal to the specified value? 0.8-18kΩ Go to Step 19 Go to Step 20
19 Use an ohmmeter to check the ignition coil secondary
winding resistance.
Was the primary winding resistance hear around the
to the specified value? 2.5kΩ Go to Step 21 Go to Step 20
20 Replace the ignition coil. — Verify repair —
21 1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators. Correct the
Did your inspection reveal any spark plugs exhibiting fouling
excessive fouling? — condition Go to Step 22

22 Perform the procedure in Fuel System Pressure Test
to determine if there is a problem with fuel delivery.
23 Refer to Fuel System Diagnosis to determine if there
is a problem with fuel delivery.
24 Check for the following engine mechanical problems
(refer to Engine Mechanical):
• Low compression
• Leaking cylinder head gaskets
• Worn camshaft
• Camshaft drive belt slipped or stripped
following:
• Tech 2 data
• All electrical connections within a suspected
circuit and/or system
release?
27 Replace the ECM.
the ECM/Immobiliser linking procedure. — Verify Repair —
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, of may start and then
immediately stall.

conditions:
blocking the air intake system
bore and on the throttle plate
hose.
5 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
6 Check engine coolant temperature (ECT) sensor for
shift in value.
1. After 8 hours with hood up and the engine not
running, connect the Tech 2.
2. Ignition On, engine not running.
3. Using Tech 2, compare Engine Coolant
Temperature to Intake Air Temperature.
Are ECT and IAT within the specified value of each
other? ±5°C Go to Step 8 Go to Step 7

7 1. Using a Tech 2, display the engine coolant
temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?

-20 32040
0 9788
20 3516
40 1439
60 656
80 327 Replace the
100 175 ECT sensor.
120 100 — Go to Step 8 Verify repair
8 1. Using a Tech 2, display the MAP sensor value in
comparison with atmosphere temperature.
MAP sensor.
9 Visually/physically inspect all spark plug high-tension
cables. Check for the following conditions:
• Verify that the resistance of all spark plug high-
tension cables are less than the specified value.
• Verify that the all spark plug high-tension cables are
correctly fitted to eliminate cross-fitting.
not arcing to ground.
Spraying the spark plug high-tension cables with a #1 cyl. 4.4kΩ
light mist of water may help locate an intermittent #2 cyl. 3.6kΩ
10 Check for proper ignition voltage output with a spark
tester.
11 1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
12 Check for a loose ignition control module ground.
13 1. Check the ignition coil secondary resistance.
2. Replace the coil if it is greater than the specified
resistance.
Did the coil require replacement? 2.5kΩ Verify repair Go to Step 14

14 Drain sample fuel, visual inspection.
Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspicion of alcohol contamination, completely
drain the fuel, replace by fuel from known vehicle
source. — Verify repair Go to Step 15
16 1. Check the injector connectors.
2. If any of the connectors are connected at an
improper cylinder, connect as necessary.
• Low compression
• Worn camshaft
following:
• Tech 2 data
release?
20 Replace the ECM.

stall the engine.

3 Was a visual/physical check performed? Go to Visual /
4 1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
• Engine fully warm
• Accessories are “Off”
2. Using a Tech 2, monitor IAC position.
Is the IAC position within the specified values? 20-30 Steps Go to Step 7 Go to Step 6
conditions:
• Restriction of the air intake system. Check for a
hose.

7 1. Using a Tech 2, display the engine coolant
temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?

-20 32040
0 9788
20 3516
40 1439
60 656
80 327 Replace the
100 175 ECT sensor.
120 100 — Go to Step 8 Verify repair
MAP sensor.
9 Using Tech 2, monitor throttle position with the engine Refer to
idling. Diagnostic
Is the throttle position at the specified value and Trouble Code
steady? P0123 for
further
0% Go to Step 10 diagnosis
10 Check for proper ignition voltage output with the spark
tester.
range.
13 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
14 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
15 Check the injector connectors, if any of the injectors
are connected any incorrect cylinder, correct as
necessary.
16 1. Check for faulty engine mounts.
2. If a problem is found, repair as necessary.

• Low compression
• Worn camshaft
• Sticking or leaking valves
• Valve timing
• Broken valve springs
following:
• Tech 2 data
release?
21 Replace the ECM.

DEFINITIONS: See the illustration below. Feels like the
vehicle speeds up and slows down with no charge in the
accelerator pedal.

4 Be sure that the driver understands A/C compressor
operation as explained in the owner’s manual. Inform
the customer how the A/C clutch operate.
Is the customer experiencing a normal condition? — System OK Go to Step 5
MAP sensor.
6 Observe the throttle position display on the Tech 2 Refer to
while slowly increasing throttle pedal. Diagnostic
Is the throttle position at the specified value and Trouble Code
steady in any position? P0123 for
further
— Go to Step 7 diagnosis
7 Check the knock sensor wire, shield wire, or
installation condition.
8 Run Engine.
Check the fuel control Heated Oxygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn’t check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may have
a white powdery coating. Silicon contamination sends
a rich exhaust signal which causes the ECM to
command an excessively lean air/fuel mixture.

9 Check the fuel pressure. Refer to Fuel System
Diagnosis.
10 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition? — Verify repair Go to Step 11
tester.
resistance.
range.
18 1. Check the injector connectors.
2. If any of the connectors are connected at an
improper cylinder, connect as necessary.
19 Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
20 Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.

21 Check the exhaust system for a possible restriction:
• Damaged or collapsed pipes
• Internal muffler failure
following:
• Tech 2 data
release?
24 Replace the ECM.

speed. Usually most pronounced when first trying to

4 Check the fuel quality.
Is the customer using improper fuel or degraded fuel? — Replace fuel Go to Step 5
MAP sensor.
Does the throttle position increase steady with Trouble Code
increasing smoothly? P0123 for
further
8 Run Engine.
command and excessively lean air/fuel mixture.
Diagnosis.

2.
condition? — Go to Step 11 Go to Step 12
tester.
resistance.
range.
19 Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.

following:
• Tech 2 data
release?
22 Replace the ECM.

increases.

and tight. Refer to the ECM wiring diagrams in
Electrical Diagnosis.
5 Check for a loose or short circuit of ignition coil
module voltage feed.
6 Check for a loose or short circuit of ignition coil
module ground.
8 Check the CKP sensor wire, shield wire, or installation
condition.
2.

2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the lean
conditions:
hose.
are connected an incorrect cylinder, correct as
necessary.
15 Perform the Injector Coil/Balance Test.
Was a problem found. — Verify repair Go to Step 16
16 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure
regulator assembly.
tester.
range.

• Low compression
• Worn camshaft
• Valve timing
20 1. Check for faulty engine mounts.
following:
• Tech 2 data
release?
23 Replace the ECM.


4 1. Remove and check the air filter element for dirt or
restrictions.
2. Replace the air filter element if necessary.
Was a repair required? — Verify repair Go to Step 5
MAP sensor.
7 1. Using a Tech 2, display the ECT sensor and IAT
sensor value and warm up condition compared
with the typical data.
2. Check the specified value or wire.
further
10 Run Engine.
Diagnosis.

2.
15 Check for proper ignition voltage output with a spark
tester.
range.
17 Drain sample fuel, visual inspection.
Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspencion of alcohol contamination,
completely drain the fuel, replace by fuel from known
vehicle source. — Verify repair Go to Step 18
• Internal muffler failure
• Low compression
• Worn camshaft
• Loose timing belt
following:
• Tech 2 data

release?
22 Replace the ECM.
DETONATION/SPARK KNOCK SYMPTOM

DEFINITIONS: A mild to severe ping, usually worse under acceleration. The engine makes a sharp metallic knocking
sound that changes with throttle opening. Prolonged detonation may lead to complete engine tailure.

4 1. If Tech 2 readings are normal (refer to Typical
Scan Data Values) and there are no engine
mechanical faults, fill the fuel tank with a known
quality gasoline.
2. Re-evaluate the vehicle performance.
Is detonation present? — Go to Step 5 Verify repair
5 1. Check for obvious overheating problems:
• Low engine coolant
• Restricted air flow to radiator
• Incorrect coolant solution
Diagnosis.
MAP sensor.
further

12 Check spark plugs for proper heat range.
Were incorrect spark plugs installed? — Verify repair Go to Step 13
13 1. Remove excessive carbon buildup with a top
engine cleaner.
2. Re-evaluate vehicle performance.
Is detonation still present? — Verify repair Go to Step 14
14 Check for an engine mechanical problem. Perform a
cylinder compression check. Refer to Engine
Mechanical.
following:
• Tech 2 data
release?
17 Replace the ECM.

is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.

4 Check owner’s driving habits.
• Is the A/C On full time (defroster mode On)?
6 Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
shown on the “Emission Control System Schematics”.
to Engine Cooling.
9 Remove and check the air filter element for dirt or for
restrictions.
MAP sensor.
Diagnosis.

2.
range.
17B Check the vehicle speed on accurate chassisi dynamo
on check number of pulse fun speed sensor. See
typical data below.
Sensor in Electrical Diagnosis. — Verify Repair —
• Low compression
• Worn camshaft
• Valve timing
following:
• Tech 2 data
release?

23 Replace the ECM.
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITIONS: Vehicle fails an emission test. There is excessive “rotten egg” smell. (Excessive odors do not
necessarily indicate excessive emissions.)

4 Does the customer continual accelerate On/Off during
cold condition? — System OK Go to Step 5
5 Is the customer using the incorrect fuel type? Replace with
— unleaded fuel Go to Step 6
6 Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found? — Go to Step 17 Go to Step 7
7 1. Check fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was a problem found? — Go to Step 17 Go to Step 8
Pressure Test.
9 1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
are connected to an incorrect cylinder, correct as
necessary.
11 Perform the Injector Coil/Balance Test.
Was a problem found. — Go to Step 17 Go to Step 12
12 Check for a problem with the engine cooling system.
13 Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
14 Check the EVAP purge solenoid valve operation. Verify repair &
Is the valve operated normally? — Go to Step 17 Go to Step 15
• Internal catalytic converter failure Verify repair &

16 1. Remove excessive carbon buildup with a top
engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 18
17 Perform the exhaust emission test.
18 Run Engine.
2.
20 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P1167 “Fuel
Supply System Rich During Deceleration Fuel Cut
Off”. Make any necessary repairs.
21 1. Check items that can cause the engine to run
lean. Refer to Diagnostic Aids in DTC P1171 “Fuel
Supply System Lean During Power Enrichment”.
Make any necessary repairs.
• Low compression
• Worn camshaft
• Valve timing
following:
• Tech 2 data

release?
25 Replace the ECM.
DIESELING, RUN-ON SYMPTOM

DEFINITIONS: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check
the ignition switch and adjustment.

4 Check for a short between battery voltage and the
ignition feed circuit.
5 Check the fuel leaking from injector. Refer to Fuel
System Diagnostic.
following:
• Tech 2 data
release?
8 Replace the ECM.
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.

tester.
range.
Pressure Test.
8 Check for an intermittent ignition system malfunction:
• Intermittent CKP 58X signal
• Intermittent ignition feed circuit or sensor ground
circuit to the crankshaft position sensor.
9 Refer to Fuel System Diagnosis to determine if there
is a problem with fuel delivery.

• Low compression
• Worn camshaft
• Valve timing
11 Check leakage at exhaust system.
Check the intake and exhaust manifold for casting
flash. Refer to Engine Mechanical.
following:
• Tech 2 data
release?
14 Replace the ECM.
ENGINE CONTROL MODULE (ECM) CRANKSHAFT POSITION (CKP)

Location SENSOR
On the intake manifold. Location
Left-hand side of the cylinder block. (Back of the A/C
Removal Procedure compressor)
2. Disconnect the two connectors from the ECM. Removal Procedure
3. Remove four bolts. 1. Disconnect the negative battery cable.
4. Remove the ECM from bracket. 2. Remove the drive belt. Refer to Engine Mechanical
Section.
3. Remove the A/C compressor from engine. Refer to
Engine Mechanical Section.
4. Disconnect connector from the CKP sensor.
5. Loosen a bolt and remove the CKP sensor from the
cylinder block.
NOTE: Use caution to avoid any hot oil that might drip
out.
1. Put on the ECM to the bracket.
2. Tighten the ECM by four bolts with specified
tightening torque.
Tightening torque
• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
3. Connect the two connectors to the ECM.
not stored after replacement. 1. Install the CKP sensor to the cylinder block.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
• Bolt: 6N·m (0.6kgf·m)
3. Reinstall the A/C compressor to the engine.
4. Reinstall the accessory drive belt.

ENGINE COOLANT TEMPERATURE INTAKE AIR TEMPERATURE (IAT)

(ECT) SENSOR SENSOR
Location Location
Installed to the thermostat housing. Installed to the intake duct housing.

2. Drain enough engine coolant so that the coolant 2. Disconnect a IAT sensor connector from the IAT
level will be below the ECT sensor. sensor.
3. Disconnect connector from the ECT sensor. 3. Remove the IAT sensor from the intake duct.
4. Loosen and remove the ECT sensor from the
thermostat housing.

are carried out.
1. Install the IAT sensor into intake air duct.
2. Connect a IAT sensor connector to the IAT sensor.
1. Apply sealer to threads of screw at the ECT sensor. not stored after replacement.
2. Tighten the ECT sensor with specified tightening
torque.
Tightening Torque
3. Connect a ECT sensor connector to the ECT
sensor.

MANIFOLD ABSOLUTE PRESSURE THROTTLE POSITION SENSOR (TPS)

(MAP) SENSOR Location
Location Installed on the throttle body.
Installed on the intake manifold.
Removal Procedure
Removal Procedure 1. Disconnect the negative battery cable.
1. Disconenct the negative battery cable. 2. Disconnect the TPS connector.
2. Disconnect a MAP sensor connector from the MAP 3. Loosen two screws and remove TPS from the
sensor. throttle body.
3. Loosen a bolt and remove the MAP sensor from the
intake manifold.
4. Remove the MAP sensor from the bracket.
2. Connect a TPS connectors to the TPS.
Installation Procedure 3. Connect the Tech2 to the vehicle.
1. Tighten the MAP sensor by a bolt with specified 4. Connect the negative battery cable.
tightening torque. 5. Select "Data Display" with the Tech2.
Tightening Torque
6. Check the throttle position data and adjust the TPS
• Bolt: 8N·m (0.8kgf·m) position.
2. Connect a MAP sensor connector to the MAP 7. Tighten two screws.
sensor.
3. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are
IDLE AIR CONTROL (IAC) VALVE

Location
Installed on the throttle body.
Removal Procedure
2. Disconnect the IAC valve connector.
3. Loosen two screws and remove IAC valve from the
throttle body.
1. Tighten the IAC valve by two screws.
2. Connect a IAC valve connector to the MAP sensor.

Cleaning and Inspection

1. Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
2. Use carburetor cleaner and a parts cleaning brush
to remove carbon deposit.
Do not use a cleaner that contain methyl ethyl
ketone. This is an extremely strong solvent and not
necessary for this type of deposit.
3. Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
4. Inspect the IAC valve O-ring for cuts, cracks or
distortion.
Measurement
• Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
• Use carburetor cleaner and a parts cleaning brush to
remove carbon deposit. Do not use a cleaner that
contain methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
• Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
• Inspect the IAC valve O-ring for cuts, cracks or
distortion. Replace the O-ring if damaged.
KNOCK SENSOR POWER STEERING PRESSURE

Location (PSP) SWITCH
Right-hand side of the cylinder block. Location
Installed on the power steering pump assembly.
Removal Procedure
2. Disconnect the knock sensor connector. 1. Disconnect the negative battery cable.
3. Loosen a bolt and remove knock sensor from the 2. Disconnect the power steering pressure switch
cylinder block. connector.
3. Loosen and remove the power steering pressure
switch from the power steering pump.
1. Tighten the knock sensor by a bolt with specified
tightening torque. Installation Procedure
Tightening Torque 1. Install the power steering pressure switch to the
• Bolt: 20N·m (2.0kgf·m) power steering pump.
2. Connect a knock sensor connector to the knock 2. Tighten the power steering pressure switch.
sensor. 3. Connect a connector to the power steering pressure
3. Connect the negative battery cable. switch.
not stored after replacement. NOTE: Verify any DTCs (diagnosis Trouble Code) are
Verify no power steering fluid leaking from the sensor
HEATED OXYGEN SENSOR (HO2S) EVAP CANISTER PURGE VALVE

Location SOLENOID
Installed on the exhaust pipe. Location
On the intake manifold.
Removal Procedure
2. Disconnect the O2 sensor connector. 1. Disconenct the negative battery cable.
3. Loosen and remove the O2 sensor from the exhaust 2. Disconnect a purge solenoid connector from the
pipe. purge solenoid.
3. Disconnect two hoses from the purge solenoid
valve.
4. Slide from the bracket and remove the purge
solenoid.
Inspection
Inspect the louvered end of the sensor for grease, dirt,
excessive carbon build up or other contamination.
1. Install the O2 sensor to the exhaust pipe. Installation Procedure
2. Tighten the O2 sensor with specified tightening 1. Insert EVAP purge solenoid valve onto the bracket.
torque.
2. Connect two hoses to the purge solenoid valve.
Tightening Torque
3. Connect a purge solenoid connector to the purge
solenoid.
3. Connect a O2 sensor connector to the O2 sensor.
NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
not stored after replacement. Verify proper connection of two hoses.
Verify no exhaust gas leaking from the sensor threads
after replacement.
FUEL PRESSURE RELIEF FUEL RAIL ASSEMBLY

Caution: To reduce the risk of fire and personal Removal Procedure
injury, it is necessary to relieve the fuel system NOTE:
pressure before servicing the fuel system • Use care when removing the fuel rail assembly in
components. order to prevent damage to the injector al connector
Caution: After relieving the fuel system pressure, a terminal and the injector spray tips.
small amount of fuel may be released when
• Fitting should be capped and holes plugged during
servicing fuel lines or connections. Reduce the
servicing to prevent dirt and other contaminants from
chance of personal injury by covering the fuel line
entering open lines and passage.
fitting with a short towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
Important: An eight-digit identification number is
out. When the disconnect is completed, place the
stamped on side of the fuel injector. Refer to this
towel in an approved container.
number when you service the fuel rail or when a
1. Remove the fuel filler cap. replacement part is required.
2. Remove the fuel pump relay from the underhood 1. Disconnect 4 injector connectors.
relay box.
2. Lift side-clip up on the fuel rail.
3. Start the engine and allow it to stall.
3. Disconnect fuel pressure regulator hose.
4. Crank the engine for about 30 seconds.
4. Disconnect wiring harness from the bands on the
5. Disconnect the negative battery cable. fuel rail.
5. Remove the intake pipe.
6. Loosen flare nut.
A. Lift up the injectors carefully to separate them
from intake manifold.
B. Lift up the fuel rail with injectors as assembly. Do
not separate the fuel injectors from fuel rail.
C. If an injector become separated from fuel rail,
injector backup O-ring and injector retainer clip
must be replaced.
D. Drain residual fuel from fuel rail into an
approved container.
7. If removal of fuel pressure regulator is necessary,

Refer to Fuel Pressure Regulator Removal
Procedure.
8. If removal of fuel injector is necessary, Refer to Fuel
Injectors Removal Procedure.
10. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel system. Check for leak. If fuel leak is observed,
stop engine immediately. Before correcting fuel
leak, be sure to depressurize system again.
1. Install the fuel injectors if necessary. Refer to Fuel
Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer
to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold
and insert the injectors into each port by pushing
fuel rail.
4. Install two fuel rail retaining bolts. Tighten fuel rail

retaining bolt to 19 N·m (1.9kgf·m)
5. Place wiring harness in its place and secure it with
two nuts.
6. Connect all connector to each fuel injector.
7. Connect the fuel supply line securely. Do not over
tighten.
8. Connect the fuel return line securely. Do not over
tighten.
FUEL INJECTOR
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil for signs of
contamination and change the oil and filter if necessary.
NOTE: Use care in removing the fuel injector in order to

prevent damage to the fuel injector al connector pins or
fuel injector nozzles. The fuel injector is an al
component and should not be immersed in any type of
cleaner as this may damage the fuel injector.
Inspection
1. Inspect O-ring for crack, damage or leaks.
2. Replace worn or damaged O-ring.
3. Lubricate the new O-rings with engine oil before
installation.
1. Lubricate the new O-ring with engine oil.
2. Install the O-ring backup on the fuel injector.
3. Install new O-ring on the fuel injector.
4. Install all four injector on the fuel rail.
Important: Fuel injectors are serviced as complete 5. Use new injector retainer clip to retain the injetor to
assembly only. the fuel rail.
1. Disconnect the negative battery cable. 6. Coat the end of the fuel injector with engine oil.
2. Disconnect al connector from fuel injector.
3. Remove the fuel rail. Refer to Fuel Rail Removal
Procedure.
4. Remove the fuel injector retainer clip.
5. Remove the fuel injector assembly from fuel rail.
6. Remove O-ring from the fuel injector.
7. Remove O-ring backup from fuel injector.
7. Install fuel rail assembly. Tighten the nuts to 19 N·m FUEL PRESSURE REGULATOR
(1.9 kgf·m). Refer to Fuel Rail Installation
Procedure. Removal Procedure
Tighten the flare nut to 27 - 33 N·m (2.8 - 3.4 kgf·m). Caution: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
Caution: After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fitting with a shop towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
out. When the disconnect is completed, place the
towel in an approved container.
NOTE: Compressed air must never be used to test or

clean a fuel pressure regulator, as damage to the fuel
pressure regulator may occur.
NOTE: To prevent damage to the fuel pressure

regulator, do not immerse the pressure regulator in
solvent.
Removal Procedure
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure.
3. Remove the fuel pump relay.
4. Disconnect the vacuum line form fuel pressure
regulator.
5. Remove the fuel pressure regulator retaining screw. 2. Install the fuel pressure regulator retaining bracket
6. Remove the fuel pressure regulator from fuel rail. and tighten with a screw.
3. Connect vacuum line onto the fuel pressure
regulator.
1. Insert the fuel pressure regulator into the fuel rail.
4. Install the fuel pump relay.
6. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel line.
7. Tighten the flare nut to 27 - 33 N·m (2.8 - 3.4 kgf·m).
IGNITION COIL
Location
Back of the engine right-hand side.
Removal Procedure
2. Disconnect the ignition coil connector.
3. Disconnect four spark plug cables from the ignition
coil.
4. Loosen three bolts and remove ignition coil from the
bracket.
1. Tighten the ignition coil by three bolts.
2. Connect four spark plug cables to the ignition coil.
3. Connect a ignition coil connector to the ignition coil.

Verify proper connection of spark plug cables for each
cylinders.
SPARK PLUGS • Oil in the combustion chamber.

• The spark plug gap is not set correctly.
Location
If spark plug fouling is excessive, check the fuel and al
Installed on the left-hand side of cylinder head.
system for possible causes of trouble. If fuel and al
system are normal, install spark plugs of a higher heat
Removal Procedure
range which have the same physical dimensions as the
1. Disconnect the negative battery cable original equipment spark plugs.
2. Remove the spark plug cable. The following symptoms are characteristics of spark
3. Remove the spark plug. plugs that are running too hot:
• Fuel mixture is too lean.
• Heat range is incorrect.
Inspection
1. Check the insulator for cracks. Replace the spark
plug if cracks are present. If vehicle usage does not conform to normal driving
2. Check the electrode condition and replace the spark conditions, a more suitable spark plug may be
plug if necessary. substituted.
If fuel and al system are normal, in most cases of this
sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as
the original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.0
to 1.1mm (0.039 to 0.043").
5. Adjust the spark gap by bending the grounded
electrode.
If the spark plug electrodes and insulators are fouled

with carbon or oil, the engine will not operate efficiently.
There are a number of possible causes:
• Fuel mixture is too rich.
SPARK PLUG CABLES

The cable contains a synthetic conductor which is easily
damaged. Never stretch or kink the cable. Disconnect
the cable from spark plug and the ignition coil.
The original equipment cables and the ignition coil are
marked to show correct location of the cables. If spark
plug cables or the ignition coil are replaced previously,
before cables are removed from the ignition coil, mark
the cables and the coil so they can be reconnected in
the same position.
Inspection
NOTE: Never puncture the spark plug cable’s insulation
with a needle or the pointed end of a probe into the
cable. An increase in resistance would be created which
would cause the cable to become defective.
1. If the cable has broken or cracked insulation, it must
be replaced.
2. If the terminals are corroded or loose, the cable
Installation must be replaced.
1. Tighten the spark plug to the 25N·m (2.5kgf·m). 3. Check that the cable resistance does not exceed
2. Push the spark plug cable in until it snaps in. specified value.
#1 cylinder: 3.50kΩ - 5.24kΩ
1. Install the spark plug to the cylinder head.
2. Tighten the spark plug with specified tightening
torque.
Tightening Torque
3. Connect the spark plug cable to the spark plug.

Verify proper connection of spark plug cables for each
cylinders.

TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
5-8840-0378-0
(J34730-E)
Port Fuel Injection
Diagnostic Kit
Breaker Box
5-8840-2589-0
Injector Adapter Cable
HECED-WE-0321


Issued by
Tokyo, Japan
First edition Oct., 2002

No.HECED-WE-0321 PRINTED IN JAPAN
WORKSHOP MANUAL
TF SERIES
Isuzu TFR/S Immobilizer

System
Service management procedure
and workshop manual
1
CONTENTS
Page
Isuzu TFR/S Immobilizer System lntroduction........................................................................ 3
What your organization should provide for your customer .............................................. 3
System outline ........................................................................................................................... 4
While the system is On......................................................................................................... 4
What happens without proper transponder operation?.................................................... 4
No proper transponder is available, what should be done for the system? ................... 4
Caution to the operation ...................................................................................................... 4
Summary of operation.......................................................................................................... 4
Illustration of lnstrument panel ........................................................................................... 5
Immobilizer system Gas Engine (6VD1 3.2L/C22NE 2.2L/22LE 2.2L/2.0LE 2.0L)................. 6
Immobilizer system Diesel Engine (4JG2 3.1L/4JB1 2.8L/4JA1 2.5L) ................................... 7
Electrical Equipment Instruments ........................................................................................... 8
Location of Components...................................................................................................... 8
Electrical Equipment – Instruments ........................................................................................ 9
Terminal Assignment of wiring Harness Connector, Immobilizer Controller ................. 9
Electrical Equipment – Instruments ...................................................................................... 10
Function (Continued).......................................................................................................... 10
Car Pass Card................................................................................................................. 10
Checking Component Required ........................................................................................ 11
Tech 2 illustration ............................................................................................................... 11
Important information on Programming................................................................................ 12
Security code ...................................................................................................................... 12
1. Entering a code.............................................................................................................. 12
2. Getting started ............................................................................................................... 13
3. Transponder................................................................................................................... 14
Transponder program.................................................................................................... 14
Erase transponder key................................................................................................... 15
4. Reset Immobilizer ICU (Immobilizer Control Unit) (Gas Engine Model).................... 16
5. Programming ICU, ECM ................................................................................................ 17
Important ............................................................................................................................. 23
2
Page
Loss of car pass ................................................................................................................. 24
Diagnostic procedure.............................................................................................................. 26
Diagnostic procedure.............................................................................................................. 27
1. 12V power is not supplied to lCU. ................................................................................ 27
2. Engine does not start after steering assembly is repaired. ....................................... 27
3. If engine does not start after ICU replacement, check part number (01MY)............. 27
4. Electrical wiring ............................................................................................................. 32
3
Isuzu TFR/S Immobilizer System Introduction

This manual is an introduction of immobilizer system for service readiness view.
An electrical immobilizer is available as of Model Year 2001 TFR/S to prevent unauthorized persons from starting
the engine. To support customers, there are some important items your organization needs to provide. If fails, your
organization and lsuzu Motors may face severe customer complains.
What your organization should provide for your customer

• Car Pass
For a new owner, your dealership must hand Car Pass card, which has identification numbers of new owner's
vehicle immobilizer system. This information is very important in case of repair or lost of transponder.
The followings are necessary items provided by your responsibility.
1) Car Pass with identification for a new owner
2) Blank Car Pass Card when it is for reissue
3) Instruction to dealers how to use Car Pass Card
• Security code management
Your organization must keep security codes for all vehicles as confidential data. Once the security codes are
lost, anybody who have the security code can access the immobilizer system. Your organization has
responsibility of any missing vehicles caused by stolen security code.
• Customer support
Lost Car Pass may happen when customer needs security code. Your organization sets up release security
code process with verification procedure.
Sometimes customer needs security code in urgent manner. Therefore Isuzu recommends your organization
organizes 24 hours support.
• Essential tool
Your dealership must have Tech 2, and Tech 2 updated software for immobilizer system.
• Dealer training
Dealer technician must be trained how to diagnose, program, reprogram the immobilizer system. Even though
no problem happens, customer may request additional transponders when releases new vehicle to customer, or
even afterward.
Before sales start, dealer training must be done.
4
System outline
The immobilizer system consists of the four major components, which are DDS-1, Engine Control Module (ECM),
Immobilizer Control Unit (lCU), and transponder.
See page 6 for Gas engine, page 7 for Diesel Engine.
This system can be activated by a correctly programmed transponder and starter switch is set to OFF. This system
can be deactivated by a correctly programmed Transponder Key connected with a correctly programmed ECM and
a correctly programmed immobilizer lCU.
While the system is On

ln case of Gas engine;
The starter cut off relay deactivates function of starter, and the fuel injector power source is deactivated also.
ln case of Diesel engine;
The starter cut off relay deactivates function of starter, and the pump is deactivated also.
What happens without proper transponder operation?

One of the function of transponder is to deactivate or activate starter function. lf the proper transponder is not used,
starter cannot be operated. Because starter cut off relay stays On, cranking engine is not possible.
After the starter cut off relay is deactivated, transponder signal triggers to let immobilizer lCU calculate by
transponder address signal and immobilizer algorithm.
When the result matches with necessary condition, it makes injector power source be activated.
If transponder does not send correct signal, immobilizer lCU and ECM do not activate injector system On. Therefore
the vehicle cannot be operated.
No proper transponder is available, what should be done for the system?

When any proper transponder is not available, a new transponder should be programmed. Up to 5 transponders
can be provided with Tech 2 and by proper procedure. See pages 14-15.
In addition to the absence of proper transponder, it may happen particular secret code to the particular vehicle is
missing. ln this case, the secret code must be provided by your organization (refer to “loss of car pass” on pages
24, 25). Otherwise transponder cannot be programmed in any way.
lf the essential tool Tech 2 for programming and proper software for Tech 2 are not available, there is no permanent
way to fix system. Temporary replace with new ECM, new ECU and new transponder without any secret code can
make the system be deactivated, but it does not last long. Such a replacement does not solve any condition. Even
after replacement, the system is activated automatically in short time and then no operation of the vehicle can be
made in any way.
Tech 2 should be provided in your organization. See page 12.
Caution to the operation

lf an attempt is made to start the engine while the immobilizer system is activated, the CHECK ENGINE indicator
flashes and the engine will not start. See the illustration at the bottom of this page.
Summary of operation
Switch On: Set the ignition and starter switch to OFF.
(Activate)
Switch Off: Set the ignition and starter switch to ON by using the transponder key.
(Deactivate)
5
Illustration of Instrument panel

6
Immobilizer system Gas Engine

(6VD1 3.2L/C22NE 2.2L/22LE 2.2L/20LE 2.0L)
7
Immobilizer system Diesel Engine

(4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
8
Electrical Equipment – Instruments

Location of Components
2
1
1 Control unit; electronic immobilizer

(located at the under cross Beam)
2 Antenna coil
3 DLC
9

Terminal Assignment of wiring Harness Connector, Immobilizer Controller
1 Back up voltage supply 8 Communication: carry on line from

2 Voltage from ignition switch ON immobilizer to ECM (Gas Engine)
3 Communication: carry on line from ECM Communication: carry on line from
to immobilizer (Gas Engine) immobilizer to DDS-1 (Diesel Engine)
Check Engine Lamp (Diesel Engine) 9 To Tech 2
4 DWA (South Africa model only) 10 Speed sensor voltage (Gas Engine)
5 N.C. 11 N.C.
6 Antenna coil positive 12 N.C.
7 Ground 13 Antenna coil negative
14 Starter relay
10

Function (Continued)
Car pass Card
Each vehicle has a car pass, which is issued to the customer on delivery of the vehicle along with the other papers.
For this, a card is used, similar to the conventional radio passes.
Note:
This car pass is an important document and must be treated with the same care as the vehicle papers. It
must not be kept in the vehicle. The customer must present the car pass for operations involving the
immobilizer or the engine control unit.
11
Checking Component Required

Tech 2
Tech 2 software 01MY TFR/S immobilizer system
DLC kit for 16 pin diagnostic plug
Key cutter
Tech 2 illustration
12
lmportant information on Programming

Security code
If the immobilizer and engine control unit are replaced at the same time, the immobilizer control unit must be
programmed first before the “IMMOBILIZER” function in the engine control unit can be activated.
The security code protects the immobilizer control unit against unauthorized programming and data access from
Tech 2. The security code consists of a 4 digit code number and is programmed into the immobilizer control unit
and ECM (Engine Control Module; Gas Engine only).
New control units are not programmed with a security code. If the control units are replaced, the security code
entered in the car pass, transponder lD, etc. must be programmed into the new control unit with Tech 2.
The security code can only be programmed with Tech 2 once and must therefore be performed with great care.
Once programmed, the security code cannot be overwritten.
An already used immobilizer can be reused in a different car by initializing the immobilizer.
After that you can program the security code again. For initializing command you need the current security code.
If the immobilizer control unit is returned (e.g. warranty cases), always enclose the security code that is allocated to
that control unit. If this is not done, we can not process the case and the warranty will not be recognized.
1. Entering a code
If the Tech 2 display requests the
• security code
• mechanical key number
• Vehicle Identification No.
to be entered, process as follows;
To input a digit you need to use the up and down buttons of the Tech 2. By using the numeric buttons, the
according digit will be displayed at the current position and the cursor will move to the next position.
For letters you need to use the up and down buttons of the Tech 2. The up and down key might be used for
digits as well. By using the up and down buttons, the displayed digit or letter will be increased or decreased. To
move to the next position you need to use the move-to-right-button.
With the two buttons, move-to-right and move-to-left you can select the position of number you want to change.
This will allow you to correct a wrong number.
After the number is completed you need to press the Enter button to accept the number.
Correction is now no longer possible.
Use the OKAY soft key to program the number and the NOT OKAY soft key to abort the programming.
13
2. Getting started
Operate Tech 2 to get the following screen as start.
• Select “Body” in System Selection Menu.

• The following table shows.
F0: Diagnostic Trouble Codes

F0: Read DTC Info Ordered By Priority
F1: Read DTC Info As Stored By ECU
F1: Data Display
F2: Snapshot
F3: Actuator Test
F0: Immobilizer Relay Output Test
F4: Additional Functions
F0: Read ECU Identification
F1: Reset Immobilizer
F2: Erase Transponder - Keys
F5: Programming
F0: Program Immobilizer Function
F1: Program Transponder - Keys
F2: Program Mechanical Key Number
F3: Program Diesel Cutoff Solenoid
Note:
Before going to programming process, Tech 2 indicates instruction as follows.
See Checking Procedure Before

Programming!
Confirm
14
3. Transponder
If a transponder key is lost;
All transponder keys in the immobilizer control system must be erased. Transponder keys can be ordered via
the "Your proper organization name such as Parts and accessory department" as previously by providing the
mechanical key number.
The mechanical key number is provided on the car pass.
Thereafter, existing and new transponder keys are programmed consecutively using Tech 2. The vehicle can
then no longer be started using lost key.
5 transponder keys can be provided:

Each transponder has different Identifications. If a customer wants more than 2 transponder keys, maximum to
5 transponder keys can be provided by additional programming by Tech 2.
lf a new ignition key with different mechanical key number needs to be installed;
If installation of an ignition lock with a different mechanism key number is necessary (an ignition lock which
belongs to the mechanical key number has to be ordered first), all transponder keys must first be erased and
the two transponder keys which belong to the ignition lock that is now installed must be programmed.
The new mechanical key number must be programmed now into the immobilizer. The mechanical key number
in the car pass is to be changed as well.
Transponder program
1. Connect Tech 2, select "Body" and "Immobilizer".
2. Select program TP-Key mode.
3. See immobilizer status on Tech 2 screen, and enter security code. If the status does not allow the
programming, only immobilizer status is displayed.
4. Insert Non-programmed Transponder-key and press soft key of "Confirm".
Insert Non-programmed Transponder - Key!
Confirm
5. "Turn On ignition key", is displayed if the ignition is Off.

6. The transponder status is displayed if the status does not allow the programming.
7. When programming starts "Programming Transponder - Key!" is displayed.
8. Turn Off Ignition key.
9. Turn On Ignition.
10. If the programming was not successful, the transponder status is only displayed.
15
11. To program more illustration press soft key.
Program more Keys!
YES NO
12. See programming result.
Erase transponder key

1. Select Erase TP-Key mode.
2. See immobilizer status on Tech 2 screen and type security code. If the status does not allow the
programming, only immobilizer status is displayed.
3. See illustration of caution.
CAUTION Erase
CAUTION: All Transponder-Keys Will Be Erased! Erasing Transponder-Keys
Confirm
4. See programming result on display.

16
4. Reset Immobilizer ICU (Immobilizer Control Unit) (Gas Engine Model)

CAUTION:
Do not reset immobilizer ICU for diesel engine models.
1. Select “Body” and “Immobilizer”.

2. Select “Additional Function” and “Reset Immobilizer”.
3. Enter the security code and press Confirm.
4. Reset Immobilizer screen shows up with warning. See the following screen.
Reset Immobilizer
Warning: Engine will not start after reset!
Do this only before replace the immobilizer ECU
Confirm
5. When reset is completed, the following screen shows up.
Program completed
Confirm
17
5. Programming ICU, ECM

Program immobilizer ICU (Gas Engine Model)
2. See immobilizer status on the display of Tech 2.
3. Select engine type.
4. Enter the security code.
5. See ECM status.
6. Input a program option by moving the cursor on the selection, then press Enter.
7. Select “Immobilizer installed”.
Input Program Option
Immobilizer installed
Engine Control Module installed
Immobilizer And ECM installed
Confirm
8. Input the security code, then press the soft key of “Okay” or “Not Okay”.
CAUTION
Security Code
0000
Press ENTER Key to continue
Not
Okay
Okay
9. Enter VIN.
Enter VIN Input Screen
Vehicle Identification Number:

00000000000000000
Not
Okay
Okay
18
10. Enter Mechanical key number.
Enter Key No. Input Screen
Mechanical Key Number:

-------
Not
Okay
Okay
11. Turn ON ignition.
Turn On Ignition
Ignition Status Off 0V
Turn Ignition On!
12. See the programming result.

Tech 2 displays the result of programming as the following.
Follow those instructions.
Selected Programming is not possible due to wrong System Status!

Immobilizer Not Programmed!
Immobilizer Already Programmed!
ECM Not Programmed!
ECM Already Programmed!
13. Transponder key must be reprogrammed, because all transponder information is erased
when ICU is programmed. See Transponder programming.
19
Program immobilizer ICU (Diesel Engine Model)

2. See immobilizer status on the display of Tech 2.
5. See ECM status.
CAUTION
Security Code
0000
Not
Okay
Okay
7. Enter VIN.
Enter VIN Input Screen
Vehicle Identification Number:

00000000000000000
Not
Okay
Okay
Enter Key No. Input Screen
Mechanical Key Number:

-------
Not
Okay
Okay
20
Turn On Ignition
Ignition Status Off 0V
Turn Ignition On!

Tech 2 displays the result of programming as the following.

ECM Not Programmed!
11. Transponder key must be reprogrammed, because all transponder information is erased
Program ECM
1. Procedure is the same as Program Immobilizer ICU procedure steps 1 through 5.
3. Select an Engine system.
4. See the display of programming result.
Program ECM / Immobilizer ICU

Caution:
1) Do not replace ICU and ECM at the same time.
2) Change ICU at first or ECM and other one change follows.
Follow Program Immobilizer ICU steps 1 through 6, procedure is the same as program
Immobilizer ICU procedure steps 1 through 6.
1. Input the security code.
2. Enter VIN.
3. Enter Key No.
4. Select an engine system.
See programming result display and follow instructions of the display.
5. Transponder key must be reprogrammed, because all transponder information on ICU is Erased when
ICU is programmed. See Transponder programming.
6. Follow program ECM steps 1 through 8.
21
Program Diesel Cutoff Solenoid

NOTE:
Perform this function only when the Immobilizer C/U is replaced.
1. Select "Body" and "Immobilizer".

3. See Immobilizer status on the display of Tech 2.
5. See ECM or PCM status.
6. Select "F3: Program Diesel Cutoff Solenoid".
Programming
F0: Program Immobilizer Function

F1: Program Transponder-Keys
F2: Program Mechanical Key Number
F3: Program Diesel Cutoff Solenoid
7. Confirm the following screen shows up.

(1) 2001 (TF) LUV
Electronic System: Immobilizer
See Checking Procedure Before

Programming!
Confirm

(1) 2001 (TF) LUV
If Battery Voltage Is Low Disconnect

Fuse For Glow Plugs!
Confirm
22
9. Turn the ignition switch OFF/ON following the screen.

10. The following screen shows up.

(1) 2001 (TF) LUV
0 % 100
11. Follow the screen procedure.

12. Confirm that there is frequent rattling every 10 seconds.

(1) 2001 (TF) LUV
Frequent Rattling Every 10 Seconds?
NO YES

(1) 2001 (TF) LUV
Reconnect Fuse Glow Plugs!
Confirm
23
14. Confirm that the engine starts.

NOTE:
The engine will only start at the second trial.

(1) 2001 (TF) LUV
Start Engine! Does The Engine Run?
NO YES
15. Program is completed.

(1) 2001 (TF) LUV

Programming Completed!
Confirm
Important
After successful programming, the engine control can only be used for vehicles with immobilizer and transponder.
Faults that occur in connection with the immobilizer control unit are recognized by the engine control unit and as
long as “IMMOBILIZER” is not programmed, are indicated by a flashing of the engine check light.
The DDS-1 unit can be reprogrammed and takes around 10 minutes for Tech 2 to complete.
24
Loss of car pass

If the car pass is lost, the data can be requested from your proper organization name. This request will only be
processed if accompanied by the enclosed form and proof of ownership.
Once the data is received, it can be entered in a blank car pass and given to the customer. The unused car pass
should be destroyed.
• Instructions on Filling Out the form "Data request, car pass"

To be provided by the dealership
The data requested under items 1-10 must be provided completely, including the authorized
dealership number, the vehicle identification, number(VIN) and engine type/number (Engine type/No.)
Mark missing data / desired data with a cross:
19. Security code (for diagnosis and programming with Tech 2)

20. Mechanical Key Number
Complete the form by entering the data and signature/authorized dealership stamp and send it along with
proof of ownership (Vehicle lD or invoice) to address provided in the form. The requested data will be sent
by Fax to the dealership that made the request after your organization has confirmed that the info is
corrected.
Important Instructions:
Only data corresponding to the delivery status of the vehicle can be issued. Car pass data requests will only
be processed if the first column is filled out completely, signed and sent to your organization along with
proof of ownership.
Information via telephone is only possible in exceptional circumstances via your service organization.
As for the delivery of new vehicles, the customer must be informed about all features of the car pass that are
relevant to vehicle security, for example, that the car pass should be kept in a safe place (not in the vehicle) and
should be presented when an authorized your organization name workshop is visited. The exact phrasing can
be found in the relevant Owner's Manual.
25
Data Request Your organization name

Car Pass
To be filled out by authorized dealership: Comment, plant security
---------------------------------------------------------
1. Dealership name --------------------------------------------------- ---------------------------------------------------------
2. Name of contact partner ------------------------------------------ ---------------------------------------------------------
3. Dealership number------------------------------------------------- ---------------------------------------------------------
4. Address --------------------------------------------------------------- ---------------------------------------------------------
-------------------------------------------------------------------------- ---------------------------------------------------------
5. Tel: ------------------------------- Fax -------------------------------- ---------------------------------------------------------
6. Name of registered keeper
7. Reason for request (please mark with cross)
- Loss by customer
- Loss by dealership
- New delivery Car Pass
- Theft
8. Vehicle type---------------------------------------------------------- ---------------------------------------------------------
9. VIN --------------------------------------------------------------------- ---------------------------------------------------------
10. Engine type / No ---------------------------------------------------- ---------------------------------------------------------
Requested data (please mark with cross)

11. Security Code : ---------------------------------------------------------
12. Key No. : ---------------------------------------------------------
13. Radio code (if lost, please supply radio unit number) ---------------------------------------------------------
14. CD-changer code (if lost, please supply CD-changer unit
number) ---------------------------------------------------------
Only data corresponding to the delivery status of the vehicle Ex works can be Issued.
Car pass requests will only be processed if they are filled out completely, signed and sent to
your organization along with proof of ownership (enclosure).
Comments form Plant Security
No signature Data / proof of ownership incomplete,
please resend
Data / proof of ownership missing, Illegible due to poor fax communication,
Please complete Please supply
Data, signature / stamp Data, signature
(Dealership) (Plant Security)
Enclosure : Proof of ownership
26
Diagnostic procedure
System guidance
• Engine does not run when any Diagnostic Trouble Code (DTC) is flagged, starting from 01MY TFR/S.
• Once the cause of DTC is repaired or gone, engine can be operated normally, and present DTC becomes
history code.
• History code is canceled by no repeat failure on 25 consequence ignition key On afterward.
• History code cannot be canceled by battery connector disconnected, starting from 01MY
Diagnostic Trouble Code (DTC) list

Code
Item Detecting Condition
(BCD)
B0011 TRANSPONDER Transponder code unsuccessfully read 5 consecutive time.
KEY PROBLEM (Not completely read in 500ms transponder code)
B0012 WRONG Transponder code read from the ignition key does not match the
TRANSPONDER transponder code stored in the control unit.
KEY
B0013 IMMOBILIZER NOT Immobilizer program no executed.
PROGRAMMED
B0014 NO TRANSPONDER Processing to save the transponder key in the control unit not
KEY PROGRAMMED executed.
B0015 VEHICLE SPEED Lo level (2.5v or less) input during the Hi level was being output
SIGNAL Lo (Gas) in the immobilizer signal. (Gas)
FREQUENCY Lo level (2.5v or less) input during the Hi level was being output to the
SIGNAL Lo (Diesel) communication line. (Diesel)
B0016 VEHICLE SPEED Hi level (more than 2.5v) input during the Lo level was being output in
SIGNAL Hi (Gas) the immobilizer signal. (Gas)
FREQUENCY Hi level (more than 2.5v) input during the Lo level was being output to
SIGNAL Hi (Diesel) the communication line. (Diesel)
B0017 NO ENGINE No request signal received from the engine control unit in a second
REQUEST after the ignition key has been placed at ON.
RECEIVED (Gas engine only)
B0023 ANTENNA COIL Antenna coil not connected.
OPEN
B0024 WRONG Transponder response signal with the challenge is wrong.
TRANSPONDER
RESPONSE
B0025 WRONG ENGINE The challenge signal from the engine control unit is invalid.
REQUEST (Gas engine only)
B0055 EEPROM ERROR Write and read cannot be correctly made to and from the EEPROM in
the control unit.
27
No DTC indicates
Engine does not start to run even though all engine and electrical system are OK, and no DTC appears.
1. 12V power is not supplied to ICU.
Check engine light No ECM or electrical

Is blinking at 2Hz. unit wiring check
Yes
Starter is not rotated No

Check DTC with Tech 2
By correct key at all.
Yes
12V power is not ICU power supply turns off when both +B line
supplied to ICU
Repair 12V circuit and ignition switch line turn off.
No.1 Pin
+B
ICU Check both wiring systems for continuity.
No.2 Pin
Ignition SW
2. Engine does not start after steering assembly is repaired.

Check if connector for Antenna coil circuit at steering shaft is correct, or missing connection.
If not correct, replace the steering assy with corrector.
3. If engine does not start after ICU replacement, check part number (01MY).
Proper parts Numbers are following.
Gas Engine 897228-184X
Suffix number
Diesel Engine 897228-183X
Suffix number
28
DTC appears
B0011 TRANSPONDER KEY PROBLEM
Transponder key code read error
Is key correct?
OK With other keys,

Rewrite transponder key. check for proper
operation
Please refer to “transponder programming”
on page 14. NG
OK
Rewrite all key Reregistration
NG
No
Does B0023 appear?
Yes
Check antenna wiring
No
OK ICU replacement Correction check OK
Transponder replacement
Note: B0011 means Body category Number 0011 Diagnostic Trouble Code.
29
B0012 WRONG TRANSPONDER KEY
Is key correct?
OK
Rewrite transponder key. Check other keys
NG
OK Reregister
Rewrite all key transponder key
NG
ICU replacement
B0013 IMMOBILIZER NOT PROGRAMMED

Replace ICU.
B0014 NO TRANSPONDER KEY PROGRAMMED

Replace ICU.
B0055 EEPROM ERROR

Replace ICU.
B0015 VEHICLE SPEED SIGNAL Lo (Gas Engine)

FREQUENCY SIGNAL Lo (Diesel ENGINE)
*Speed sensor signal voltage lower than 2.5v. (Gas)
*Frequency signal voltage lower than 2.5v (Diesel)
Check path and

NG between ICU pin 8, ECM
pin (Gas), or DDS-1 (Diesel)
for continuity
Disconnect both
connectors and check OK
path between ICU
and body earth for
continuity
Wiring repair
30
B0016 VEHICLE SPEED SIGNAL Hi (Gas Engine)

FREQUENCY SIGNAL Hi (Diesel ENGINE)
Disconnect both No
connectors and check Clear DTC
voltage on ICU side.
voltage ≥ 2.5v
Yes
Wiring repair
B0017 NO ENGINE REQUEST RECEIVED (Gas Engine)
Check path ICU

NG
pin 3 and ECM pin B-18(V6) Wiring repair
J2-B4(L4) for continuity
OK
Replace ECM, because ECM internal circuit fails.
B0023 ANTENNA COIL OPEN

Antenna coil open
Check path between

ICU pin 6 and pin 13 Clear DTC
for continuity
NG
NG
NG Check path between
Correction ICU pin 6 and connector A pin
for continuity
OK
NG A connector 2 pin
NG Check path between 6
for continuity ICU
13 Antenna coil
OK
Replace steering lock Assy

31
B0024 WRONG TRANSPONDER RESPONSE

Wrong Transponder code
Rewrite transponder
Reregistration
NG
ICU replacement
32
4. Electrical wiring
Immobilizer system Electrical wiring for Gas Engine
(6VD1 3.2L)
33
Immobilizer system Electrical wiring for Gas Engine

(C22NE 2.2L/22LE 2.2L/20LE 2.0L)
34
RELAY ;
STARTER
3B 3B/W
STARTER
SW ; STARTER LA04 LA25 RELAY ;
(STEERING LOCK) STARTER IMMOBILIZER
10A
OFF 0.5B/W 0.5L/W 0.5B
MAIN BUSBAR ACC LA06 LA27 LX21
100A
8B/R 3W/B (4) B2 0.85W/G
PA01 PA03 IG2
MB08
ST ENGINE
40A 15A
3W/B (2) B1 IG1 (7) 3B/Y 0.85W/G
PA02 PA05 HB12
BATT IGN-B1
40A METER
10A
0.5Y
IGN-B2
MA01 (B-14)
(4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
STOP
METER
10A
CHECK ENG
STOP LAMP SW
HORN (B-12)
10A 0.5G/R 0.5R/W
DA01 MB07
HB09
0.85W/G
MB03
0.5O
MA42
MB01
MB02
MB03
0.5O/L
DDS-1 ; IMMOBILIZER
0.5BR/Y
0.85W/G
(1) (2) (ENGINE)
1 3 14 2 8
HORN
IMMOBILIZER CONT
IB20
0.5G
9 6 13 7
(3)
Immobilizer system Electrical wiring for Diesel Engine
0.5L
0.5Y
0.5B
MB04
MB05
MB06
MY01
0.5O/B
0.5B
MY02
(INJ PUMP)
FUEL CUT VALVE
( ) ( )
ANT.COIL
: Special connector of DDS-1

(STRG LOCK)
0.5B ZZ07
0.5B ZZ06
WORKSHOP MANUAL
TF-SERIES

System
and workshop manual
No.TF IMM-WE-0121 PRINTED IN JAPAN

NOTICE

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
CONTENTS
Immobilizer System lntroduction

System Description
While the System is on
Illustration of lnstrument panel
Immobilizer System for Gasoline Engine (6VD1 3.2L/C22NE 2.2L/22LE 2.2L/2.0LE 2.0L)
Immobilizer System for Mechanical Control Diesel Engine (4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
Immobilizer System for Electrical Control Diesel Engine (4JA1-TC 2.5L/4JH1-TC 3.0L)
Electrical Equipment Instruments

Electrical Equipment Instruments

Immobilizer Control Unit (ICU) : Connector Pin Assignment
6VD1 3.2L/C22NE 2.2L/22LE 2.2L/20LE 2.0L/4JG2 3.1L/4JB1 2.8L/4JA1 2.5L
4JA1-TC 2.5L/4JH1-TC 3.0L
Car Pass Card
Tech-2 illustration
Important information on Programming

Security code
1. Entering a code
2. Getting started (Tech-2 Operation)
3. Transponder
Transponder program
4. Reset ICU (Immobilizer Control Unit )
5. Reset Function
Important
Loss of car pass
(6VD1 3.2L/C22NE 2.2L/22LE 2.2L/20LE 2.0L/4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
System guidance
No DTC indicates
1.12V power is not supplied to ICU
2.Engine does not start after steering assembly is repaired
3.If engine does not start after ICU replacement, check part number (01MY)
DTC appears
B8013 IMMOBILIZER NOT PROGRAMED
B8014 NO TRANSPONDER KEY PROGRAMED
B8055 EEPROM ERROR
B8015 VEHICLE SPEED SIGNAL Lo (Gasoline Engine)
FREQUENCY SIGNAL Lo (Diesel Engine)
B8016 VEHICLE SPEED SIGNAL Hi (Gasoline Engine)
FREQUENCY SIGNAL Hi (Diesel Engine)
B8017 NO ENGINE REQUEST RECEIVED (Gasoline Engine)
Diagnostic procedure (4JA1-TC 2.5L/4JH1-TC 3.0L)
System guidance
No DTC indicates
1.12V power is not supplied to ICU
2.Engine does not start after steering assembly is repaired
3.If engine does not start after ICU replacement, check part number (02MY)
DTC appears
B8001 REPLACE ELECTRONIC CONTROL UNIT (ECU) (IMMOBILIZER FAULT)
B8004 IMMOBILIZER COIL CIRCUIT (ANTENNA COIL FAULT)
B8005 COMMUNICATION LINE W VOLTAGE Low
B8006 COMMUNICATION LINE W VOLTAGE High
B8007 NO ENGINE REQUEST RECEIVED
B8010 UNKNOWN TRANSPONDER KEY
Immobilizer system electrical wiring

Gasoline Engine (6VD1 3.2L)
Gasoline Engine (C22NE 2.2L/22LE 2.2L/20LE 2.0L)
Diesel Engine (Mechanical Control , 4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
Diesel Engine (Electrical Control , 4JA1-TC 2.5L/4JH1-TC 3.0L)
Immobilizer System Introduction
This manual is an introduction of immobilizer system for service readiness view.
An electrical immobilizer is available as of Model Year 2002 TFR/S to prevent unauthorized

persons from starting the engine. To support customers. there are some important items your
organization needs to provide. If fails, your organization and lsuzu Motors may face severe
customer complains.
l Car Pass For a new owner, your dealership must hand Car Pass card, which has
identification numbers of new owner's vehicle immobilizer system. This information is very
important in case of repair or lost of transponder.
The followings are necessary items provided by your responsibility.
1) Car Pass with Identification for a new owner
2) Blank Car Pass Card when it is for reissue
3) Instruction to dealers how to use Car Pass Card
l Security code management Your organization must keep security codes for all vehicles
as confidential data. Once the security codes are lost, anybody who have the security code
can access immobilizer system. Your organization has responsibility of any missing vehicles
caused by stolen security code.
l Customer Support Lost Car Pass may happen when customer needs security code. Your
organization sets up release security code process with verification procedure.
Sometimes customer needs security code in urgent manner. Therefore Isuzu recommends
your organization organizes 24 hours support.
l Essential tool Your dealership must have Tech-2, and Tech-2 updated software for
immobilizer system.
l Dealer training Dealer technician must be trained how to diagnose, program, reprogram
immobilizer system. Even though no problem happens, customer may request additional
transponders when releases new vehicle to customer, or even afterward.
Before Sales start, dealer training must be done.
System description
The immobilizer system consists of the four major components. which are Engine Control
Module (ECM), Immobilizer Control Unit (lCU), transponder, DDS-1 and scan tool (Tech-2).
See page 4 for Gasoline engine, page 5 for Mechanical Control Diesel Engine, page 6 for
Electrical Control Diesel Engine.
This system can be activated by a correctly programmed transponder and starter switch is set to
OFF. This system can be deactivated by a correctly programmed Transponder Key connected with
a correctly programmed ECM and a correctly programmed lCU.
While the system is on

ln case of Gasoline engine and Electrical Control Diesel engine;
The starter cut off relay deactivates function of starter, and the fuel injector power source is
deactivated also.
ln case of Mechanical Control Diesel engine;
The starter cut off relay deactivates function of starter, and the pump is deactivated also.
One of the function of transponder is to deactivate or activate starter function. lf the proper
transponder is not used, starter cannot be operated. Because starter cut off relay stays on,
cranking engine is not possible.
After the starter cut off relay is deactivated, transponder signal triggers to let lCU calculate
by transponder address signal and immobilizer algorithm.
When the result matches with necessary condition, it makes injector power source be activated.
If transponder does not send correct signal, lCU and ECM do not activate injector system on.
Therefore the vehicle cannot be operated.

When any proper transponder is not available, a new transponder should be programmed. Up to
5 transponders can be provided with Tech-2 and by proper procedure. See pages 12 to13.
In addition to the absence of proper transponder, it may happen particular secret code to the
particular vehicle is missing. ln this case, the secret code must be provided by your organization
(refer to 'loss of car pass' on pages 23,24). Otherwise transponder cannot be programmed in any
Way.
lf the essential tool Tech-2 for programming and proper software for Tech-2 are not available,
there is no permanent way to fix system. Temporary replace with new ECM, new ECM and new
transponder without any secret code can make the system be deactivated, but it does not last
long. Such a replacement does not solve any condition. Even after replacement, the system is
activated automatically in short time and then no operation of the vehicle can be made in any
Way.
Tech-2 should be provided in your organization. Refer to page 10.
lf an attempt is made to start the engine while the immobilizer system is activated, the CHECK
ENGINE Lamp flashes and the engine will not start. See the illustration at the bottom of this
Page.
Switch on: Set the ignition and starter Switch to OFF.
(Activate)
Switch off: Set the ignition and starter switch to ON by using the transponder key.
(Deactivate)
Illustration of Instrument panel

Immobilizer system for Gasoline Engine
(6VD1 3.2L/C22NE 2.2L/22LE 2.2L/20LE 2.0L)
Immobilizer system for Mechanical Control Diesel Engine
(4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
Immobilizer system for Electrical Control Diesel Engine
(4JA1-TC 2.5L/4JH1-TC 3.0L)
1 Control unit; electronic immobilizer (located at the under cross Beam)

2 Antenna coil

1 Back up Voltage supply

2 Voltage from ignition switch ON
3 Communication: carry on line from ECM to immobilizer (Gasoline Engine)
Check Engine Lamp (Diesel Engine)
4 N.C
5 N.C
6 Antenna coil positive
7 Ground
8 Communication: carry on line from immobilizer to ECM (Gasoline Engine)
Communication: carry on line from immobilizer to DDS-I (Diesel Engine)
9 To Tech-2
10 Speed sensor voltage (Gasoline Engine)
11 N.C
12 N.C
13 Antenna coil negative
14 Starter relay
(4JA1-TC 2.5L/4JH1-TC 3.0L)
B3 B2 B1
B8 B7 B6 B5 B4 A3 A2 A1
A-1 Antenna coil positive

A-2 N.C
A-3 Antenna coil negative
B-1 Starter relay

B-2 Ground
B-3 Voltage from ignition switch ON
B-4 Back up Voltage supply
B-5 To Tech-2
B-6 N.C
B-7 Communication: carry on line from ECM to immobilizer (Check Engine Lamp)
B-8 Communication: carry on line from immobilizer to ECM
Car pass Card
Each vehicle has a car pass, which is issued to the customer on delivery of the vehicle along
with the other papers. For this, a card is used, similar to the conventional radio passes.
Notes:
This car pass is an important document and must be treated with the same care as the vehicle
papers. It must not be kept in the vehicle. The customer must present the car pass for operations
involving the immobilizer or the engine control unit.
Tech-2
Tech-2 software TFR/S immobilizer system
DLC kit for 16 pin diagnostic plug
Key cutter
Tech-2 illustration
lmportant information on Programming
Security code
The security code protects the immobilizer control unit against unauthorized programming and
data access from Tech-2. The security code consists of a 4 digit code number and is programmed
into the immobilizer control unit and Engine Control Module (ECM). (ECM : Gasoline Engine only)
New ECM is not programmed with a security code. If the control units are replaced, the
security code entered in the car pass, transponder lD, etc. must be programmed into the new
ECM with Tech-2.
The security code can only be programmed with Tech-2 once and must therefore be performed
with great care. Once programmed, the security code cannot be overwritten.
An already used immobilizer can be reused in a different car by initializing the immobilizer.
After that you can program the security code again. For initializing command you need the
current security code.
If the immobilizer control unit is returned (e.g. warranty cases), always enclosed the security code
that is allocated to that control unit. If this is not done, we can not process the case and the
warranty will not be recognized.
1. Entering a code
If the Tech-2 display requests that the

l security code
l mechanical key number
l Vehicle Identification No.
be entered, process as follows;
To input a digit you need to use the up and down buttons of the Tech-2. By using the numeric
buttons the according digit will be displayed at the current position and the cursor will move to
the next position.
For letters you need to use the up and down buttons of the Tech-2. The up and down key might
be used for digits as well. By using the up and down buttons the displayed digit or letter will be
increased or decreased. To move to the next position you need to use the
move-to-right-button.
With the two buttons, move-to-right and move-to-left you can select the position of number you
want to change. This will allow you to correct a wrong number.
After the number is completed you need to press the Enter button to accept the number.
Correction is now no longer possible.
Use the OKAY soft key to program the number and the NOT OKAY soft key to abort the
programming.
2. Getting started (Tech-2 Operation)
Operate Tech-2 to get the following screen as start.
l Select “Body” in System Selection Menu.

l The following table shows.
Notes:
Before going to programming process, Tech-2 indicates instruction as follows.

3. Transponder
If a transponder key is lost;

If a transponder key is lost, all transponder keys in the immobilizer control system must be
erased. Transponder keys can be ordered via the "Your proper organization name such as Parts
and accessory department" as previously by providing the mechanical key number.
The mechanical key number is provided on the car pass.
Thereafter, existing and new transponder keys are programmed consecutively using Tech-2. The
vehicle can then no longer be started using lost key.
5 transponder keys can be provided:

Each transponder has different Identifications. If a customer wants more than 2 transponder
keys, maximum 5 transponder keys can be provided by additional programming by Tech-2.
lf a new ignition key with different mechanical key number needs to be installed; If installation of
an ignition lock with a different mechanism key number is necessary (an ignition lock which
belongs to the mechanical key number has to be ordered first), all transponder keys must first be
erased and the two transponder keys which belong to the ignition lock that is now installed must
be programmed.
The new mechanical key number must be programmed now into the immobilizer. The mechanical
key number in the car pass is to be changed as well.
Transponder program
1. Connect Tech-2, select "Body" and "Immobilizer".

2. Select program Transponder (TP) - Key mode.
3. See immobilizer status on Tech-2 screen, and enter security code. If the status does not
allow the programming, only immobilizer status is displayed.
4. Insert Non-programmed Transponder-key and press soft key of "Confirm".
5. "Turn On ignition key", is displayed if the ignition is off.

6. The transponder status is displayed if the status does not allow the programming.
7. When programming starts "Programming Transponder - key!" is displayed.
8. Turn off Ignition key.
10. If the programming was not successful, the transponder status is only displayed.
11. To program more illustration press soft key
12. See programming result.
1. Select Erase Transponder (TP) - Key mode.

2. See immobilizer status on Tech-2 screen and type security code. If the status dose not
allow the programming, only immobilizer status is displayed.
3. See illustration of caution.
CAUTION Erase

4. See programming result on display.
4. Reset Immobilizer ICU (Immobilizer Control Unit)

2. Select “Additional Function” and “Reset Immobilizer”.
3. Enter the security code and press Confirm.
4. Reset Immobilizer screen shows up with warning. See the following screen.
5. When reset is completed, the following screen shows up.

5. Reset Function
1. Select “Body” and F4 “Additional Functions”.

2. Select “Reset Engine Control Module”

5. Input the security code, then press the soft key of “Not Okay” or “Okay”.
7. Programming is completed.
8. When the procedure is completed waits 10 seconds and then turn the Key on.
The fail lamp begins to flash.
9. Turn the ignition on, then engine dose not run.
10. Reset is completed.
l Program ICU
1. Select “Body” and “immobilizer”.
2. See immobilizer status on the display of Tech-2.
4. See ECM status.
5. Input a program option, by moving the cursor on the selection, then press “Enter”.
7. Enter VIN.

Tech-2 displays the result of programming as the following.


ECM Not Programmed!
12. Transponder key must be reprogrammed, because all transponder information is erased.
l Program ECM
1. Procedure is the same as program ICU procedure steps 1 through 5.
6. Turn on the Ignition.
7. Select an Engine system.
8. See the display of programming result.
l Program ICU / ECM

Caution 1) Do not replace ICU and ECM at the same time
2)Change ICU at first or ECM and other one change follows.
Follow Program ICU steps 1 through 6, procedure is the same as program ECM procedure
steps 1 through 6.
7. Input the security code.
8. Enter VIN
9. Enter Key No.
See programming result display and follow instructions of the display.
11. Transponder key must be reprogrammed, because all transponder information on ICU is
Erased when ICU is programmed. See Transponder programming.
12. Follow program ECM steps 1 through 8.
Important
After successful programming, the engine control can only be used for vehicles with immobilizer
and transponder. Faults that occur in connection with the immobilizer control unit are recognized
by the engine control unit and as long as “IMMOBILOZER” is not programmed, are indicated by a
flashing of the engine check lamp.
If the immobilizer and engine control unit are replaced at the same time, the immobilizer control
unit must be programmed first before the “IMMOBILIZER” function in the engine control unit can be
activated.
Loss of car pass
If the car pass is lost, the data can be requested from your proper organization name. This
request will only be processed if accompanied by the enclosed form and proof of ownership.
Once the data is received, it can be entered in a blank car pass and given to the customer. The
unused car pass should be destroyed.
l Instructions on Filling Out the form "Data request, car pass"

To be provided by the dealership
The data requested under items 1-10 must be provided completely, including the authorized
dealership number, the vehicle Identification number(VIN) and engine type/number (Engine type/No)
Mark missing data / desired data with a cross:
19. Security code (for diagnosis and programming with Tech-2)

20. Mechanical key Number
Complete the form by entering the data and signature/authorized dealership stamp and
send it along with proof of ownership(Vehicle lD or invoice) to address provided in the
form. The requested data will be sent by Fax to the dealership that made the request
after your organization has confirmed that the info is corrected.
Only data corresponding to the delivery status of the vehicle can be issued. Car pass
data requests will only be processed if the first column is filled out completely. signed
and sent to your organization along with proof of ownership.
Information via telephone is only possible in exceptional circumstances via your service
organization.
As for the delivery of new vehicles, the customer must be informed about all features of the
car pass that are relevant to vehicle security, for example, that the car pass should be kept
in a safe place(not in the vehicle) and should be presented when an authorized your
organization name workshop is visited, The exact phrasing can be found in the relevant
Owner's Manual.
Data Request
Car Pass Your organization name
To be filled out by authorized dealership: Comment, plant security
1. Dealership name
2. Name of contact partner
3. Dealership number
4. Address
5. Tel: Fax
6. Name of registered keeper
7. Reason for request (please mark with cross)
- Loss by customer
- Loss by dealership
- New delivery Car Pass
- Theft
8. Vehicle type
9. VIN
10. Engine type / No
Requested data (please mark with cross)

11. Security Code :
12. Key No. :
13. Radio code (if lost, please supply
radio unit number)
14. CD-changer code (if lost, please
supply CD-changer unit number)
Only data corresponding to the delivery status of the vehicle Ex works can be Issued.
Car pass requests will only be processed if they are filled out completely, signed and sent to
your organization along with proof of ownership (enclosure).
Comments form Plant Security
No signature Data / proof of ownership incomplete,
Please complete
Data / proof of ownership missing, Illegible due to poor fax communication,
Please supply please resend
Data, signature / stamp Data, signature
(Dealership) (Plant Security)
Enclosure : Proof of ownership
System guidance
Note:
Immobilizer may detect a history DTC by the timing of ON-OFF of a ignition switch.
Don't remove the ECM and ICU recklessly.
l Engine dose not run when any Diagnostic Trouble Code (DTC) is flagged, starting from 01MY
TFR/S.
l Once the cause of DTC is repaired or gone, engine can be operated normally, and present
DTC becomes history code.
l History code is canceled by no repeat failure on 25 consequence ignition key on afterward.
l History code cannot be canceled by battery connector disconnected, starting from 01MY.
Code
Item Detecting Condition
(BCD)
B8011 TRANSPONDER Transponder code unsuccessfully read 5 consecutive time.
KEY PROBLEM (Not completely read in 500ms transponder code)
B8012 WRONG Transponder code read from the ignition key does not match the
TRANSPONDER transponder code stored in the control unit.
KEY
B8013 IMMOBILIZER NOT Immobilizer program no executed.
PROGRAMMED
B8014 NO TRANSPONDER Processing to save the transponder key in the control unit not
KEY PROGRAMMED Executed.
B8015 VEHICLE SPEED Lo level (2.5v or less) input during the Hi level was being output
SIGNAL Lo (Gasoline) In the immobilizer Signal. (Gasoline Engine)
FREQUENCY Lo level (2.5v or less) input during the Hi level was being output
SIGNAL Lo (Diesel) to the communication line. (Diesel Engine)
B8016 VEHICLE SPEED Hi level (more than 2.5v) input during the Lo level was being
SIGNAL Hi (Gasoline) output in the immobilizer Signal. (Gasoline Engine)
FREQUENCY Hi level (more than 2.5v) input during the Lo level was being
SIGNAL Hi (Diesel) output to the communication line. (Diesel Engine)
B8017 NO ENGINE No request signal received from the engine control unit in a
REQUEST second after the ignition key has been placed at ON.
RECEIVED (Gasoline engine only)
B8023 ANTENNA COIL Antenna coil not connected.
OPEN
B8024 WRONG Transponder response signal with the challenge is wrong.
TRANSPONDER
RESPONSE
B8025 WRONG ENGINE The challenge signal from the engine control unit is invalid.
REQUEST (Gasoline engine only)
B8055 EEPROM ERROR Write and read cannot be correctly made to and from the
EEPROM in the control unit.
No DTC indicates
Engine does not start to run even though all engine and electrical system are OK, and no DTC
appears.
Check engine light No

ECM or electrical
Yes
Starter is not rotated

Check DTC with Tech-2
Yes
supplied to ICU and ignition switch line turn off.
Repair 12V circuit
No.1 Pin
+B
No.2 Pin
Ignition SW

Gasoline Engine 897228-184X
Suffix number
Diesel Engine 897228-183X
Suffix number
DTC appears
Is key correct?
OK With other keys,

operation
on page 14. NG
OK
NG
No
Does B0023 appear?
Yes
NG
Note : B0011 means Body category Number 0011 Diagnostic Trouble Code.
Is key correct?
OK Check other keys

Rewrite transponder key.
NG
OK Reregister
NG
ICU replacement
B8013 IMMOBILIZER NOT PROGRAMED

Replace ICU
B8014 NO TRANSPONDER KEY PROGRAMED

Replace ICU
B8055 EEPROM ERROR

Replace ICU
B8015 VEHICLE SPEED SIGNAL Lo (Gasoline Engine)

FREQUENCY SIGNAL Lo (Diesel Engine)
*Speed sensor signal voltage lower than 2.5v. (Gasoline Engine)

*Frequency signal voltage lower than 2.5v (Diesel Engine)
Check path
NG between ICU pin 8,ECM
pin for continuity
Disconnect both
path between ICU
and body earth for
continuity
Wiring repair
B8016 VEHICLE SPEED SIGNAL Hi (Gasoline Engine)
FREQUENCY SIGNAL Hi (Diesel Engine)
Disconnect both
connectors and check No
Clear DTC
voltage Ǩ 2.5v
Yes
Wiring repair
B8017 NO ENGINE REQUEST RECEIVED (Gasoline Engine)
Check path ICU NG

pin 3 and ECM pin B-8(V6) Wiring repair
J2-B4(L4) for continuity
OK

Antenna coil open
Check path between

ICU pin 6 and pin 13 Clear DTC
for continuity
NG
A connector 2 pin
NG Check path between 6
NG
for continuity
ICU
13
OK Antenna coil
NG Check path between

NG ICU pin 13 and connector A pin
Correction for continuity
OK
Need following repair

1. Key replacement
2. Rewrite transponder
3. Replace door key cylinder
Wrong Transponder code
Rewrite transponder
Reregistration
NG
ICU replacement
(4JA1-TC 2.5L/4JH1-TC 3.0L)
System guidance
Note:
Immobilizer may detect a history DTC by the timing of ON-OFF of a ignition switch.
Don't remove the ECM and ICU recklessly.
l Engine dose not run when any Diagnostic Trouble Code (DTC) is flagged, starting from 02MY
TFR/S.
l Once the cause of DTC is repaired or gone, engine can be operated normally, and present
DTC becomes history code.
l History code is canceled by no repeat failure on 25 consequence ignition key on afterward.
l History code cannot be canceled by battery connector disconnected, starting from 01MY.
Code
No Detecting Condition
(BCD)
Replace Electronic Control Unit(ECU)
1 B8001 This error code appears if a RAM /ROM Error was detected or the EEPROM
Is defect.
2 B8002 Immobiliser Not Programmed
Transponder Key Problem

B8003 Reading of Transponder information failed with ignition on transponder has
3
a fault.
Hardware fault in reading circuit.
4 B8004 Immobiliser Coil Circuit
5 B8005 Communication Line W Voltage Low
6 B8006 Communication Line W Voltage High
7 B8007 No Engine Request Received (Check Engine Lamp disconnected?)
8 B8008 Wrong Transponder Key
9 B8009 No Transponder Key Programmed
10 B8010 Unknown Transponder Key

No DTC indicates
Engine does not start to run even though all engine and electrical system are OK, and no DTC
appears.
Check engine light No

ECM or electrical
Yes
Starter is not rotated

Check DTC with Tech-2
Yes
supplied to ICU and ignition switch line turn off.
Repair 12V circuit
B-4 Pin
+B
B-3 Pin
Ignition SW
Electrical Die Engine 897234-671X

Suffix number
DTC appears
B8001 REPLACE ELECTRONIC CONTROL UNIT (ECU) (IMMOBILIZER FAULT)
Replace ICU
Programming Immobilizer Function.
Is key correct?
OK With other keys,

operation
on page 14. NG
OK
NG
No
Does B8003 appear?
Yes
NG
B8004 IMMOBILIZER COIL CIRCUIT (ANTENNA COIL FAULT)
Check path between

ICU pin A-1 and pin A-3 Clear DTC
for continuity
NG
Connector 2 pin
NG Check for A1
NG
Correction Ext Harness; Antenna
ICU
A3
OK Antenna coil
Need following repair

1. Key replacement
2. Rewrite transponder
3. Replace door key cylinder
B8005 COMMUNICATION LINE W VOLTAGE Low
Check path
NG between ICU pin B-8,ECM
pin for continuity
Disconnect both
path between ICU
and body earth for
continuity
Wiring repair
B8006 COMMUNICATION LINE W VOLTAGE High
Disconnect both
connectors and check No
Clear DTC
voltage Ǩ 2.5v
Yes
Wiring repair
B8007 NO ENGINE REQUEST RECEIVED
Check path ICU NG

pin B-7 and ECM pin A-39 Wiring repair
for continuity
OK
Rewrite transponder
Reregistration
NG
ICU replacement

B8010 UNKNOWN TRANSPONDER KEY
Is key correct?
OK Check other keys

Rewrite transponder key.
NG
OK Reregister
NG
ICU replacement
Immobilizer system Electrical wiring
Gasoline Engine (6VD1 3.2L)

Gasoline Engine (C22NE 2.2L/22LE 2.2L/20LE 2.0L)

Diesel Engine (Mechanical Control , 4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)

Diesel Engine (Electrical Control , 4JA1-TC 2.5L/4JH1-TC 3.0L)

IMM-WE-0121

This manual is applicable for vehicles in Europe

except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
First edition April., 2002

WORKSHOP MANUAL
TF-SERIES

System
and workshop manual
No.TF IMM-WE-0121 PRINTED IN JAPAN

MANUAL DE SERVICIO
SERIE TF
Sistema inmovilizador
Isuzu TFR/S
Procedimiento de administración de servicio
y Manual de servicio
International Service & Parts

Tokyo, Japan
INDEX
1
CONTENIDO
Página
Introducción al sistema inmovilizador Isuzu para TFR/S ........................................... 3
Qué debe suministrar su organización a sus clientes ........................................... 3
Descripción del sistema ................................................................................................ 4
Mientras el sistema está encendido ........................................................................ 4
¿Qué sucede si la operación del transponder no es apropiada? ............................ 4
¿No hay un transponder apropiado disponible, qué se debe hacer por el sistema? 4
Precaución para la operación ................................................................................... 4
Resumen de la operación ......................................................................................... 5
Ilustración del panel de instrumentos ........................................................................ 5
Sistema inmovilizador Motor gasolina (6VD1 3.2L/C22NE 2.2L/22LE 2.2L/2.0LE 2.0L) 6
Sistema inmovilizador Motor diesel (4JG2 3.1L/4JB1 2.8L/4JA1 2.5L) ................... 7
Equipo eléctrico - Instrumentos ................................................................................... 8
Ubicación de componentes ...................................................................................... 8
Equipo eléctrico - Instrumentos ................................................................................... 9
Asignación de terminales de conectores de alambrados,
controlador del inmovilizador .................................................................................. 9
Equipo eléctrico – Instrumentos.................................................................................... 10
Función (Continuación) ............................................................................................ 10
Tarjeta de identificación del automóvil (Car Pass Card) .................................... 10
Componentes de comprobación requeridos .......................................................... 11
Ilustración del Tech 2 ............................................................................................... . 11
Información importante sobre programación ............................................................. 12
Código de seguridad ................................................................................................. 12
1. Entrando un código ............................................................................................... 12
2. Iniciando ................................................................................................................. 13
3. Transponder ............................................................................................................ 14
Programación del transponder ........................................................................... 14
Borrado de la llave del transponder .................................................................... 15
4. Recalibración del ICU del inmovilizador (Unidad de control del inmovilizador)
(Motor modelo a Gas)................................................................................................. 16
5. Programación del ICU, ECM ...................................................................................... 17
2
Importante ........................................................................................................................ 23
Pérdida del código de identificación del automóvil ............................................... 24
Procedimiento de diagnóstico ...................................................................................... 26
Procedimiento de diagnóstico ...................................................................................... 27
1. La alimentación de 12 V no es suministrada al ICU ............................................ 27
2. El motor no arranca después de que el conjunto de
dirección se ha reparado....................................................................................... 27
3. Si el motor no arranca después del reemplazo del ICU,
verifique el número de parte (01MY) ................................................................... 27
4. Diagrama eléctrico ................................................................................................ 32
3
Introducción al sistema de inmovilizador Isuzu para TFR/S
Este manual es una introducción al sistema inmovilizador desde el punto de vista de aprestamiento de
servicio.
Un inmovilizador eléctrico está disponible en el vehículo TFR/S a partir del modelo del año 2001 para
impedir que personas no autorizadas pongan el motor en funcionamiento. Para dar soporte a los clientes
hay algunos elementos importantes que su organización necesita proporcionar. Si falla, su organización e
Isuzu Motors pueden encarar severas quejas de los clientes.
Qué debe suministrar su organización a sus clientes
• Identificación del automóvil

Para un nuevo propietario, su distribuidor debe suministrar la tarjeta de identificación del automóvil,
que contiene los números de identificación del nuevo propietario del sistema inmovilizador del
vehículo. Esa información es muy importante en caso de reparación o perdida del transponder.
Los siguientes elementos necesarios son suministrados bajo su responsabilidad.
1) Identificación del automóvil con la identificación del nuevo propietario.
2) Tarjeta de identificación del automóvil en blanco para una reentrega.
3) Instrucción a los concesionarios sobre cómo usar la tarjeta de identificación del automóvil.
• Administración del código de seguridad
Su organización debe mantener los códigos de seguridad para todos los vehículos como información
confidencial. Una vez que los códigos de seguridad se pierden, cualquiera que tenga el código de
seguridad puede acceder al sistema inmovilizador. Su organización tiene la responsabilidad de cual-
quier pérdida de vehículos ocasionada por el hurto del código de seguridad.
• Soporte al cliente
La pérdida de la identificación del automóvil puede suceder cuando el cliente necesita el código de
seguridad. Su organización debe establecer un proceso de entrega de los códigos de seguridad con
un procedimiento de comprobación.
Algunas veces el cliente necesita el código de seguridad de manera urgente. Por lo tanto Isuzu
recomienda que su organización suministre soporte durante las 24 horas.
• Herramientas esenciales
Su distribuidor debe tener un Tech 2 y el software actualizado para el sistema inmovilizador en el Tech
2.
• Entrenamiento para el concesionario
El técnico del concesionario debe ser entrenado en la forma cómo diagnosticar, programar y reprogra-
mar el sistema inmovilizador. Aunque no ocurra ningún problema, el cliente puede requerir transpon-
ders adicionales cuando se le entrega un vehículo nuevo o aún después.
Antes de iniciar las ventas debe hacerse el entrenamiento de los concesionarios.
4
Descripción del sistema

El sistema inmovilizador consiste de cuatro componentes principales que son el DDS-1, el Módulo de
Control del Motor (ECM), la Unidad de Control del Inmobilizador (ICU) y el transponder.
Vea la página 6 para el motor a gasolina y la página 7 para el motor a diesel.
Este sistema puede activarse mediante un transponder correctamente programado y con el interruptor de
arranque apagado (OFF). Este sistema puede desactivarse con una Llave del Transponder correctamente
programada conectada con un ECM y un inmobilizador ICU programados correctamente.
Mientras el sistema está encendido

En el caso del motor a gasolina;
El relé de corte del arranque desactiva la función del arranque y la fuente de potencia del inyector de com-
bustible también se desactiva.
En el caso del motor diesel;
El relé de corte del arranque desactiva la función del arranque y también se desactiva la bomba.
¿Qué sucede si la operación del transponder no es apropiada?

Una de las funciones del transponder es desactivar o activar la función del arranque. Si no se usa el trans-
ponder apropiado, el arranque no puede operarse. Ya que el relé de corte del arranque permanece encen-
dido, el arranque del motor no es posible.
Después de que el relé de corte del arranque está desactivado, la señal del transponder se dispara para per-
mitir al ICU del inmovilizador calcular la señal de dirección del transponder y el algoritmo del inmovilizador.
Cuando el resultado coincide con la condición necesaria, hace que la alimentación de potencia del inyec-
tor sea activada.
Si el transponder no envía la señal correcta, el ICU del inmovilizador y el ECM no activan el sistema inyec-
tor. Por lo tanto el vehículo no puede ser operado.
¿No hay un transponder apropiado disponible, qué se debe hacer por el sistema ?
Cuando no está disponible un transponder apropiado, un nuevo transponder debe programarse. Hasta 5
transponders pueden ser suministrados con el Tech 2 y con el procedimiento apropiado. Vea las páginas
14 y 15.
Adicionalmente a que no haya un transponder apropiado, puede suceder que el código secreto particular
del vehículo esté perdido. En este caso, el código secreto debe suministrado por su organización
(refiérase a “Pérdida de la identificación del automóvil”, páginas 24, 25). De otra forma, el transponder no
puede programarse de ninguna manera.
Si la herramienta Tech 2, esencial para programar y el software apropiado para el Tech 2 no están disponi-
bles, no hay una forma permanente para arreglar el sistema. El reemplazo provisional con un nuevo ECM,
un nuevo ICU y un nuevo transponder sin el código secreto pueden desactivar el sistema, pero esto no
dura mucho. Este reemplazo no resuelve ninguna condición. Aun después del reemplazo, el sistema se
activa automáticamente en un corto tiempo y entonces ninguna operación del vehículo puede hacerse de
ninguna manera.
El Tech 2 debe suministrarse dentro de su organización. Vea la página 12.
Precaución para la operació n

Si se hace un intento para poner el motor en funcionamiento mientras el sistema inmovilizador se encuen-
tra activo, el indicador de CHECK ENGINE (LUZ DE COMPROBACIÓN DEL MOTOR) destella y el motor
no arranca. Vea la ilustración en la siguiente página.
5
Resumen de la operación
Interruptor en On: Coloque el encendido y el interruptor del motor de arranque en ON.
(Activado)
Interruptor en Off: Coloque el encendido y el interruptor del motor de arranque en ON (ENCENDIDO)

usando la llave del transponder.
(Desactivado)
Ilustración del panel de instrumento s

6
Sistema inmovilizador motor gasolina

(6VD1 3.2L/C22NE 2.2L/22LE 2.2L/2.0LE 2.0L)
7
Sistema inmovilizador motor diesel

(4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
8
Equipo eléctrico - Instrumentos
Ubicación de componentes
1 Unidad de control, inmovilizador electrónico

(ubicado en el tirante inferior del tablero de instrumentos)
2 Bobina de la antena
3 DLC
9
Asignación de terminales de conectores de alambrados, controlador del inmovilizador
1 Suminstro de voltaje de respaldo 8 Línea de comunicación desde el

2 Voltaje desde el interruptor de inmovilizador al ECM (Motor a
encendido en ON (ENCENDIDO) Gasolina)
3 Comunicación: Línea portadora Línea de comunicación desde el
desde el ECM hasta el inmobiliza- inmovilizador al DDS-1(Motor Die-
dor (motor a gasolina) sel)
Lámpara de inspección del motor 9 Al Tech-2
(motor diesel) 10 Voltaje del sensor de velocidad
4 DWA (Solo para modelo de Sur (Motor a Gasolina)
Africa) 11 SIN CONECTAR
5 SIN CONECTAR 12 SIN CONECTAR
6 Positivo de la bobina de la antena 13 Negativo de la bobina de la
7 Tierra antena
14 Relé de arranque
10

Función (Continuación)
Tarjeta de identificación del automóvil
Cada vehículo tiene una tarjeta de identificación del automóvil, que se suministra al cliente durante la
entrega del vehículo junto con los otros papeles del vehículo. Para esto se usa una tarjeta parecida a los
permisos de radio corrientes.
CAR PASS
1 VIN XXXXXXXXXXXXXXXX VIN
2 Código de seguridad XXXXX Código de seguridad
3 Tipo de motor No. XX-XXXXX Tipo de motor No.
4 Llave No. XXXXXX Llave No.
VIN : (NUMERO DE IDENTIFICACION DEL VEHÍCULO)
Nota:
Esta identificación del automóvil es un documento importante y debe tratarse con el
mismo cuidado que los papeles del vehículo. No debe guardarse dentro del vehículo. El
cliente debe presentar la identificación del automóvil para operaciones que involucran al
inmovilizador o al módulo de control del motor.
11
Componentes de comprobación requeridos

Tech 2
Software para el Tech 2 del sistema inmovilizador de la TFR/S AÑO MODELO 01
El kit del DLC para el conector de diagnóstico de 16 terminales
Cortador de la llave
Ilustración del Tech 2

Acerca del Tech 2 (Suministro de potencia)
12
Información importante sobre la programación

Código de seguridad
Si se reemplazan el inmovilizador y la unidad de control del motor al mismo tiempo, la unidad de control
del inmovilizador 24debe programarse primero con el "INMOVILIZADOR", puede activarse con la función
de la unidad de control de motor.
El código de seguridad protege a la unidad de control del inmovilizador contra programación y acceso no
autorizado desde el Tech 2. El código de seguridad consiste de un número de código de 4 dígitos y se pro-
grama en la unidad de control del inmovilizador y en el ECM (módulo de control del motor; sólamente
motor a gasolina).
Las unidades de control nuevas no están programadas con un código de seguridad. Si las unidades de
control son reemplazadas, el código de seguridad colocado en la tarjeta de identificación del automóvil, la
identificación del transponder etc., deben programarse en la nueva unidad de control con el Tech 2.
El código de seguridad puede programarse con el Tech 2 únicamente una vez, por lo tanto la progra-
mación debe realizarse con gran cuidado. Un código de seguridad programado una vez no puede ser
sobre escrito.
Un inmovilizador ya usado puede reutilizarse en un automóvil diferente inicializando el inmovilizador.
Después de eso usted puede programar el código de seguridad nuevamente. Para el comando de iniciali-
zación usted necesita el código de seguridad previo.
Si la unidad de control del inmovilizador es devuelta (p.ej. casos de garantía), guarde siempre el código de
seguridad que ha sido asignado a esa unidad de control. Si esto no se hace, nosotros no podemos proce-
sar el caso y la garantía no será reconocida.
1. Entrando un código
Si el Tech 2 muestra que requiere que el;
• Código de seguridad
• Número de la llave mecánica
• Número de identificación del vehículo (VIN)
sean suministrados, proceda como se indica a continuación;
Para entrar un dígito necesita usar los botones de flecha arriba y abajo del Tech 2. Usando los
botones numéricos el dígito, correspondiente se mostrará en la posición actual y el cursor se mov-
erá a la posición siguiente.
Para las letras necesita usar los botones de flecha arriba y abajo del Tech 2. Los mismos que se
pueden usar para los dígitos. Usando las teclas arriba y abajo la letra o el dígito mostrado aumen-
tará o se reducirá.
Para moverse a la siguiente posición necesita usar la tecla de movimiento a la derecha.
Con las dos teclas, de movimiento a la derecha y de movimiento a la izquierda puede seleccionar
la posición del número que quiere cambiar. Esto le permitirá corregir un número equivocado.
Después de que se haya completado el número necesita oprimir la tecla de entrada (ENTER) para
aceptar el número.
Ahora no es posible una corrección.
Use la tecla blanda OKAY (DE ACUERDO) para programar el número y la tecla blanda NO OKAY
(EN DESACUERDO) para abortar la programación.
13
2. Iniciando
Opere el Tech 2 para obtener el siguiente menú en la pantalla para comenzar.
• Seleccione “Body” (Carrocería) en el menú de selección del sistema.

• Se mostrará la siguiente tabla
F0 : Códigos de diagnóstico de falla

F0 : Lea la información de DTC ordenados por prioridad
F1 : Lea la información de DTC tal como fueron guardados en la ECU
F2 : Borre la información de DTCs
F1 : Mostrar datos
F2 : Fotografía instantánea (Snap shot)
F3 : Prueba de actuadores
F0 : Prueba de salida del relé del inmovilizador
F4 : Funciones adicionales
F0 : Leer la identificación del ECU
F1 : Reajustar el inmovilizador
F2 : Borrado de Transponder - llaves
F5 : Programación
F0 : Función de programación del inmovilizador
F1 : Programación de Transponder – llaves
F2 : Programación del número de la llave mecánica
F3 : Programación del solenoide de corte Diesel
Nota:
Antes de iniciar el proceso de programación, el Tech 2 indica instrucciones como las siguientes:
Introduzca la llave no programada

del transponder
Confirme
14
3. Transponder
Si se pierde una llave del transponder;
Todas las claves del transponder del sistema de control del inmovilizador deben borrarse. Las llaves
del transponder pueden pedirse mediante "El nombre apro-piado en su organización, tal como medi-
ante el departamento de partes y accesorios" como anteriormente, suministrando el número de la
llave mecánica.
El número de la llave mecánica se suministra en la identificación del automóvil.
De ahí en adelante, las llaves del transponder existentes y las nuevas se programan consecutivamente
usando el Tech 2. El vehículo no puede entonces ser encendido usando la llave perdida.
Pueden suministrarse 5 llaves del transponder;

Cada transponder tiene identificaciones diferentes. Si un cliente quiere más de 2 llaves de transponder,
máximo 5 llaves de transponder pueden suministrarse mediante programación adicional en el Tech 2.
Si se necesita instalar una nueva llave de encendido con un número de llave mecánica diferente; o si
es necesaria la instalación de un seguro de encendido con un número de llave mecánica diferente (un
seguro de encendido que pertenece al número de la llave mecánica que fue ordenado primero), todas
las llaves de transponder deben primero ser borradas y las dos llaves de transponder que pertenecen
al seguro de encendido que se está instalando deben programarse.
El nuevo número de llave mecánica debe programarse en el inmovilizador ahora. El número de la llave
mecánica en la identificación del automóvil también será cambiado.
Programación del transponder

1. Conecte elTech 2, seleccione "Body” (Carrocería) e "Inmovilizador ".
2. Seleccione el programa en modo TP – Key (Llave de transponder).
3. Vea la condición del inmovilizador en la pantalla del Tech 2 e ingrese el código de seguridad. Si la
condición no permite la programación, solo se muestra la condición del inmovilizador.
4. Introduzca la llave del transponder no programada y presione la tecla blanda "Confirm" (Con-
firme).
Inserte la llave de Transponder

no programada
Confirme
5. “Encienda la llave de encendido”, se mostrará si el encendido está en apagado.

6. Se muestra la condición del transponder si la condición no permite la programación.
7. Cuando empieza la programación se muestra "ProgramingTransponder – Key!” (Programando la
llave del transponder).
8. Apague la llave de encendido.
9. Encienda el encendido.
10. Si la programación no fue exitosa, se muestra solamente la condición del tran sponder.
15
11. Para programar más llaves, presione la tecla blanda.
Programe más llaves!
SI NO
12. Vea el resultado de la programación.
Borrado de la llave del transponder

1. Seleccione el modo de “Erase the TP Key” (Borrado de la llave del transponder).
2. Vea la condición del inmovilizador en la pantalla del Tech 2 y escriba el código de seguridad. Si la
condición no permite la programación, se muestra solamente la condición del inmovilizador.
3. Vea la ilustración de precaución.
PRECAUCIÓN Borrado
PRECAUCION: Borrando las llaves del Transponder

!Todas las llaves del Transponder serán borra-
das!
Confirme
4. Vea el resultado de la programación en la pantalla.

16
4. Reajuste del ICU del inmobilizador (Unidad de Control del inmobilizador)(Modelos de

motor a gasolina)
PRECAUCIÓN
No reajuste el ICU del inmobilizador para modelos con motor diesel
1. Seleccione "Body” (Carrocería) e "inmovilizer” (Inmovilizador)
2. Seleccione "Funciones adicionales" y "Recalibración del inmovilizador".
3. Entre el código de seguridad y presione “Confirm” (Confirme).
4. La pantalla de recalibración del inmovilizador muestra una advertencia. Vea la siguiente pantalla.
Recalibración del inmovilizador

Advertencia: El motor no arrancará
después de la recalibración!
Haga esto únicamente antes de

reemplazar el ECU del inmovilizador
Confirme
5. Cuando la recalibración está completa, se muestra la siguiente pantalla.
Programa completo
Confirme
17
5. Programación del ICU, E CM

Programación del ICU del inmovilizador
1. Seleccione "Body" (Carrocería) e "immobilizer " (inmovilizador).
2. Vea la condición del inmovilizador en la pantalla del Tech 2.
3. Seleccione el tipo de motor
4. Ingrese el código de seguridad.
5. Vea la condición del ECM.
6. Ingrese a la opción de programa moviendo el cursor a la selección, entonces oprima
Enter.
7. Seleccione "Inmobilizador instalado”
Opciones del programa de entrada
Inmovilizador instalado
Módulo de control del motor instalado
Inmovilizador y ECM instalados
Confirme
8. Ingrese el código de seguridad y oprima las teclas blandas "Okay" o "No Okay".
PRECAUCIÓN
0000
Presione la tecla ENTER para continuar
No Okay
Okay
9. Ingrese el VIN.
Entre en la pantalla de ingreso del VIN
Número de identificación del vehículo:

00000000000000000
No Okay
Okay
18
10. Ingrese el número de la llave mecánica.
Entre el número de la llave en la pantalla de ingreso
Número de la llave mecánica:

-------------
No Okay
Okay
11. Accione la llave de encendido.
Accione la llave de encendido
Condición de encendido Apagado OV
Accione la llave de encendido!
12. Vea el resultado de la programación.

El Tech 2 muestra el resultado de la programación de la siguiente forma.
Siga estas instrucciones.
La programación seleccionada no es posible debido a una condición
equivocada del sistema!
Inmovilizador no programado!
Inmovilizador ya programado!
ECM no programado!
ECM ya programado!
13. La llave del transponder debe programarse de nuevo porque toda la información del transponder
es borrada cuando se programa el ICU. Vea programación del transponder.
19
Programa del ICU del inmobilizador (Modelo de motor diesel)

1. Seleccione "Carrocería" y "Inmobilizador"
2. Vea Condición del inmobilizador en la pantalla delTech 2
4. Ingrese el código de seguridad
5. Vea el estado del ECM
6. Ingrese el código de seguridad, presione luego la tecla blanda de "OK" o "NO OK"
PRECAUCIÓN
0000
No Okay
Okay
7. Ingrese el VIN
Pantalla de ingreso del VIN
Número de identificación del vehículo:

00000000000000000
No Okay
Okay
8. Ingrese el número de la llave mecánica
Entre en la pantalla de ingreso del número de la llave
Número de la llave mecánica:

------
No Okay
Okay
20
9. Accione la llave de encendido
Accione la llave de encendido
Condición de encendido Apagado OV
Accione la llave de encendido!
10. Mire el resultado de la programación.

El Tech 2 muestra el resultado de la programación como se indica.
Siga esas instrucciones.
La programación seleccionada no es posible debido a un estado equivocado

del sistema
Inmobilizador no programado !
Inmobilizador ya programado!
ECM no programado !
ECM ya programado!
11. La llave del transponder debe ser reprogramada, porque toda la información del transponder es
borrada cuando se programa el ECU. Vea Programación del transponder
Programación del ECM

1. El procedimiento es el mismo que el de programación del ICU del inmobilizador, pasos 1 a 5.
2. Abra el interruptor de encendido.
3. Seleccione un sistema de motor
4. Vea la pantalla de resultado de la programación.
Programación del ECM / ICU del inmobilizador

Precaución:
1) No reemplace el ICU y el ECM al mismo tiempo.
2) Cambie el ICU o el ECM primero y el otro despu és.
Siga los pasos 1 hasta 6 de programación del ICU del inmobilizador, el procedimiento es el mismo
que el de programación del ICU del inmobilizador.
1. Ingrese el código de seguridad
2. Ingrese el VIN
3. Ingrese el número de la llave
4. Seleccione un sistema de motor.
Mire la pantalla de resultado de la programación y siga las instrucciones en la pantalla.
5. La llave del transponder debe ser programada, porque toda la información del transponder en el
ECU se borra cuando el ECU se reprograma. Vea Programación del transponder.
6. Siga los pasos de programación del ECM desde el 1 hasta el 8.
21
Programe el solenoide de corte de diesel

Nota:
Realice esta función solamente cuando se reemplace la Unidad de control del inmobilizador.
1. Seleccione "CarrocerÌa" e "Inmobilizador"

3. Vea el estado del inmobilizador en la pantalla del Tech 2.
4. Ingrese el código de seguridad.
5. Vea el estado del ECM o el PCM.
6. Seleccione "F3: Programa del solenoide de corte de diesel"
Programación
F0 : Función de programación del inmovilizador

F1 : Programación del transponder – llaves
F2 : Programación del número de la llave
mecánica
F3: Programación solenoide de corte de diesel
7. Confirme lo que muestra la siguiente pantalla.
Programación solenoide de corte de diesel

(1) 2001 (TF) LUV
Sistema electrónico: Inmovilizador
Verifique el procedimiento
antes de programar!
Confirme

(1) 2001 (TF) LUV
Si el voltaje de la batería es bajo,

desconecte el fusible de la
bujía de precalentamiento!
Confirme
22
9. Gire el interruptor de encendido OFF/ON, siguiendo la pantalla.

10. Se muestra la siguiente pantalla.

(1) 2001 (TF) LUV
0 % 100
11. Siga el procedimiento de la pantalla.

12. Confirme que hay un traqueteo frecuente cada 10 segundos.

(1) 2001 (TF) LUV
Traqueteo frecuente cada 10 segundos?
NO SI

(1) 2001 (TF) LUV
Reconecte el fusible de la bujía

de precalentamiento
Confirme
23
14. Confirme que el motor arranca.

Nota:
El motor solo arrancará en el segundo intento.

(1) 2001 (TF) LUV
Encienda el motor!
Arranca el motor?
NO SI
15. La programación está completa.

(1) 2001 (TF) LUV

Programación completa!
Confirme
Importante
Después de la programación exitosa, el control del motor puede solamente ser usado para vehículos con
inmovilizador y transponder. Las fallas que ocurren relacionadas con la unidad de control del inmovilizador
son reconocidas por el módulo de control del motor y mientras el "INMOVILIZADOR " no esté programado
será indicado por un titileo de la luz de verificación del motor.
La unidad del DDS-1 puede ser reprogramada y toma alrededor de 10 minutos para que el Tech 2 la com-
plete.
24
Pérdida de la identificación del automóvil
Si se pierde la identificación del automóvil, la información puede ser solicitada a nombre de su organiza-
ción. Este pedido solamente será procesado si está acompañado por el formato y la prueba de
propiedad.
Una vez que la información sea recibida, puede ser introducida en una tarjeta de identificación del
automóvil vacía y puede ser entregada al cliente. La tarjeta del automóvil inutilizada debe destruirse.
• Instrucciones sobre cómo llenar la forma "Solicitud de información, identificación del automóvil"
Para ser suministrada por el distribuidor
Los datos pedidos bajo los ítems 1-10 deben suministrarse completos, incluyendo el número autoriza-
do del distribuidor, el número de identificación del vehículo (VIN) y el tipo y número del motor (Tipo/No.
del motor)
Marque la información perdida o deseado con una cruz:
19. Código de seguridad (para el diagnóstico y la programación conel Tech 2).

20. Número de la llave mecánica.
Complete la forma ingresando la información y coloque la firma y el sello autorizado del distri-
buidor y envíela conjuntamente con la demostración de propiedad (Identificación del vehículo o
factura), a la dirección suministrada en la forma. Los datos solicitados serán enviados por fax al
distribuidor que hizo la solicitud después de que su organización haya confirmado que la infor-
mación es correcta.
Instrucciones importantes:
Unicamente pueden ser suministrados los datos que corresponden a la condición de entrega del
vehículo. Los pedidos de datos de identificación del automóvil únicamente se procesarán si la pri-
mera columna se llena completamente, está firmada, y es enviada a su organización conjunta-
mente con la demostración de propiedad.
La Información por vía telefónica es únicamente posible en circunstancias excepcionales a través de

su organización de servicio.
En lo que concierne a la entrega de vehículos nuevos, el cliente debe ser informado de todos los
aspectos sobre la identificación del automóvil que sean relevantes para la seguridad del vehículo; por
ejemplo, que la identificación del automóvil debe guardarse en un lugar seguro (no en el vehículo) y
debe presentarse cuando visite un taller autorizado de su organización. La redacción exacta puede
encontrarse en el Manual de Propietario pertinente.
25
Solicitud de información,
Nombre de su organización
Identificación del automóvil
Para ser llenado por el distribuidor autorizado: Comentario, seguridad de planta
1. Nombre del distribuidor ..................................................... .............................................

2. Nombre del contacto ......................................................... .............................................
3. Número del distribuidor ..................................................... .............................................
4. Dirección: .......................................................................... .............................................
........................................................................................... .............................................
5. Tel: ..................................... Fax:.......................................
.............................................
6. Nombre del poseedor registrado .......................................
7. Razón para el pedido (por favor marque con una cruz)....
- Perdida por el cliente
- Perdida por el distribuidor
- Entrega de identificación del automóvil nuevo
- Robo
8. Tipo de vehículo: .............................................................. ...............................................
9. VIN: ................................................................................... ...............................................
10. Tipo de motor /No.: ......................................................... ...............................................
Información solicitada (por favor marque con una cruz)

11. Código de seguridad:
12. Llave No.: ...............................................
13. Código del radio (si se perdió, por favor suministre ...............................................
el número de unidad del radio) ...............................................
14. Código del cambiador de CD (si se perdió, por favor ...............................................
suministre el número de unidad)
Instrucciones importantes:
Unicamente puede ser suministrada la información correspondiente a la condición de entrega del
vehículo en condición de trabajo. Los datos de identificación del automóvil solicitados, única-
mente se procesarán si están diligenciados completamente, firmados y enviados a su organiza-
ción conjuntamente con la demostración de propiedad (guardada).
La Información vía teléfono es únicamente posible en circunstancias excepcionales por medio de
su organización de servicio.
Comentarios de Seguridad de Planta:

No viene firmado Información/demostración de propiedad
incompleta, por favor complétela
Información/demostración de propiedad Ilegible debido a mala comunicación a través
perdida, por favor suminístrela del fax, por favor envíela nuevamente
Fecha, firma/sello Fecha, firma
(Distribuidor) (Seguridad de Planta)
Anexo: Demostración de propiedad
26
Procedimiento de diagnóstico
Guía del sistema
• El motor no funciona cuando se despliega algún Código de Diagnóstico de Falla (DTC), comenzando
en el modelo TFR/S del año 2001.
• Una vez que se repara o desaparece la causa del DTC, el motor puede operarse normalmente, y el
DTC actual se convierte en un código histórico.
• El código histórico es anulado después de no repetirse ninguna falla durante 25 accionamientos de la
llave de encendido.
• El código histórico no puede ser anulado mediante la desconexión del conector de la batería, desde el
modelo del año 2001 (01MY).
Lista de Códigos de Diagnóstico de Falla (DTC)
COD.
Elemento Condición de detección
(DTC)
B0011 PROBLEMA DE LA LLAVE DEL Código del transponder leído sin éxito 5 veces con-
TRANSPONDER secutivas (No completamente leído en el código de
500 ms. del transponder).
B0012 LLAVE DEL TRANSPONDER El código del transponder leído de la llave de encen-
EQUIVOCADA dido no concuerda con el código del transponder
almacenado en la unidad de control.
B0013 INMOVILIZADOR NO PROGRA- Programa del inmovilizador no ejecutado
MADO
B0014 LLAVE DEL TRANSPONDER NO Proceso para almacenar la llave del transponder en
PROGRAMADA la unidad de control no ejecutado.
SEÑAL DE VELOCIDAD DEL Bajo nivel de entrada (2.5V o menos) siendo alta la
VEHÍCULO BAJA (Gasolina) señal de salida en el inmovilizador. (Gasolina)
B0015
SEÑAL DE FRECUENCIA BAJA Bajo nivel de entrada (2.5V o menos) siendo alta la
(Diesel) salida en la línea de comunicación. (Diesel)
SEÑAL DE VELOCIDAD DEL Alto nivel de entrada (2.5V o más) siendo baja la
VEHÍCULO ALTA (Gasolina) señal de salida en el inmovilizador (Gasolina)
B0016
SEÑAL DE FRECUENCIA ALTA Alto nivel de entrada (2.5V o más) siendo baja la
(Diesel) salida en la línea de comunicación (Diesel)
B0017 NO SE RECIBE SEÑAL DE SOLICI- No se recibe señal de solicitud de la unidad de con-
TUD DEL MOTOR trol del motor en el siguiente segundo después de
que la llave de encendido ha sido puesta en ON.
(Sólamente motor a gasolina)
B0023 BOBINA DE LA ANTENA ABIERTA Bobina de la antena desconectada
B0024 RESPUESTA EQUIVOCADA DEL La señal de respuesta del transponder con el
TRANSPONDER desafío está equivocada.
B0025 SOLICITUD DEL MOTOR EQUIVO- La señal de desafío desde la unidad de control del
CADA motor es invalida. (Sólamente motor a gasolina)
B0055 ERROR DEL EEPROM La escritura y la lectura no pueden ser realizadas
correctamente desde el EEPROM en la unidad de
control.
27
Procedimiento de diagnóstico
No hay ningún DTC indicad o

El motor no arranca ni funciona aunque todos los sistema del motor y los sistemas eléctricos están bien, y
no aparece ningún DTC.
1. Alimentación de energía de 12 V no es suministrada al ICU.
La luz de
NO Inspeccione el
verificación
alambrado del ECM o de
del motor parpadea
la unidad eléctrica
a 2 Hz.
SI
El arranque no NO
es girado por la llave Inspeccione DTC con
correcta de ninguna el Tech 2
manera.
SI
La potencia
de 12V no es
El suministro de energía al ICU se apaga cuando ambas
suministrada al ICU. Repare
líneas, +B y del interruptor de encendido se apagan
el circuito de 12V
}
Terminal No. 1
+B
ICU Terminal No. 2

Inspeccione los alambrados de
ambos sistemas por continuidad.
Interruptor de
encendido
2. El motor no arranca después de la reparación del conjunto de la dirección .
Verifique si el conector para el circuito de la bobina de la antena en la columna de dirección está correcto
o mal conectado. Si no está correcto, reemplace el conjunto de dirección con el conector.
3. Si el motor no arranca después del reemplazo del ICU, verifique el número de parte
Los números de par te apropiados son los siguientes.
Motor a gasolina 897228-184X
Número de sufijo
Motor diesel 897228-183X
Número de sufijo
28
Aparecen DTCs
B0011 PROBLEMA EN LA LLAVE DEL TRANSPONDER
El código de la llave del transponder lee error
Está la llave correcta?
BIEN Con otras llaves,

Reescriba la llave del transponder verifique la operación
apropiada
Por favor refiérase a “Programación del transponder”
en la página 14. MAL
BIEN
Reescriba todas las llaves
Registro
MAL
NO
Aparece el código B0023?
SI
Inspeccione el cableado de la antena
MAL
BIEN Reemplace el ICU Verifique la corrección OK
Reemplace el transponder
Nota : B0011 significa Código de Diagnóstico de Falla del Número de categoría de carrocería 0011.
29
B0012 LLAVE DE TRANSPONDER EQUIVOCADA
¿Está correcta la llave?
BIEN
Reescriba la llave del transponder Revise otras llaves
MAL
BIEN
Reescriba todas las llaves Registre nuevamente la
llave del transponder
MAL
Reemplace el ICU
B0013 INMOVILIZADOR NO PROGRAMAD O

Reemplace el ICU
B0014 NO HAY UNA LLAVE DE TRANSPONDER PROGRAMADA

Reemplace el ICU
B0055 ERROR DEL EEPRO M
Reemplace el ICU
B0015 SEÑAL DE VELOCIDAD DEL VEHÍCULO Baja (Motor a Gasolina)

SEÑAL DE FRECUENCIA Baja (Motor diesel )
*Señal de voltaje del sensor de velocidad por debajo de 2.5v. (Gasolina)
*Voltaje de señal de frecuencia por debajo de 2.5v. (Diesel)
Inspeccione la
MAL
ruta entre el terminal 8 del ICU y el
terminal del ECM (Gasolina) o por continuidad
en DDS-1 (Diesel)
Desconecte ambos BIEN

conectores y verifique continuidad en la ruta
entre el ICU y la tierra de la
carrocería
Repare el alambrado
B0016 SEÑAL DE VELOCIDAD DEL VEHÍCULO Alta (Motor a Gasolina )

30
SEÑAL DE FRECUENCIA Alta (Motor diesel)
Desconecte ambos NO
conectores y verifique voltaje del lado del Borre DTC
ICU. Voltaje > = 2.5 V
SI
Repare el alambrado
B0017 NO SE RECIBE NINGUNA SOLICITUD DEL MOTOR (Motor a Gasolina )
Verifique la trayectoria
MAL Repare el alambrado
entre el terminal 3 del ICU y
el B-18(V6), J2-B4(L4) del ECM
por continuidad
SI
Reemplace el ECM, porque hay falla en el circuito interno del ECM
B0023 BOBINA DE LA ANTENA ABIERTA

Bobina de la antena abierta
Verifique continuidad
entre los terminales 6 y 13del ICU Borre el DTC
MAL
MAL Verifique continuidad

MAL entre el terminal 6 del ICU y el
Corregir terminal del conector (A)*
BIEN
MAL Verifique continuidad

MAL
entre el terminal 13 del ICU y el
Corregir terminal del conector (A)*
BIEN
Reemplace el conjunto del seguro de dirección

31
B8024 RESPUESTA EQUIVOCADA DEL TRANSPONDER
Código equivocado del transponder
Reescriba el transponder
Vuelva a registrar
MAL
Reemplace el ICU
32
4. Diagramas eléctricos
Alambrado del sistema Eléctrico del Inmovilizador para Motor Gasolina
(6VD1 3.2L)
33
Alambrado para el sistema Eléctrico del Inmovilizador para Motor Gasolina

(C22NE 2.2L/22LE 2.2L/20LE 2.0L)
34
Alambrado para el sistema Eléctrico del Inmovilizador para Motor Diesel

(4JG2 3.1L/4JB1 2.8L/4JA1 2.5L)
35
IMM-WS-0101
Usted debe ordenar este manual usando el

número del manual que aparece arriba.
Este manual es aplicable para vehículos en todos

los países excepto EE.UU. y el Canadá, Europa y
Tailandia.
Todo los derechos están reservados. Este manual

no puede ser reproducido total ni parcialmente sin
el permiso escrito de ISUZU MOTORS LIMITED.
Emitido por
INTERNATIONAL SERVICE DEPARTAMENT
Tokyo, Japón
Primera edición. Enero, 2001

Primera edición en español Febrero, 2001
Traducido por:
Compañía de Entrenamiento Técnico Automotriz
CETa Ltda.
Bogotá, Colombia
e-mail: rienzi_rodriguez@yahoo.es
36
IMM-WS-0101 IMPRESO EN COLOMBI A

WORKSHOP MANUAL
UBS AND TF SERIES
TRANSMISSION
AW30-40LE MODEL
(FULLY-AUTOMATIC ELECTRONICALLY CONTROLLED)
SECTION 7
NOTICE
MANUAL”.

notice.
Applicable Model : ‘02UBS 73 (For General Export)

‘02TFS 77 (For Australia)
‘02TFR 77 (For Australia and South Africa)
‘01TFR 77 (For Thailand)
This manual is applicable to 2001 year model vehicle.

INDEX
AUTOMATIC TRANSMISSION (AW30-40LE) 7A-1
SECTION 7A
AUTOMATIC TRANSMISSION (AW30-40LE)
TABLE OF CONTENTS
PAGE
General Description.........................................................................................................7A- 5
Construction................................................................................................................7A- 5
Electronic Control Components ................................................................................7A- 7
Transmission Control Module (TCM) ........................................................................7A- 9
Control System Diagram ............................................................................................7A- 11
Control and Functions ................................................................................................7A- 13
Major Input/Output Components ...............................................................................7A- 15
Location of Clutch, Brake, One-way Clutch and Solenoid ......................................7A- 16
Operation of Clutch, Brake and One-Way Clutch.....................................................7A- 18
Speed Change and Lock-up Pattern..........................................................................7A- 18
Overdrive and Lock-up Operating Conditions..........................................................7A- 19
Diagnosis..........................................................................................................................7A- 20
Basic Troubleshooting ...............................................................................................7A- 20
Self Diagnosis .............................................................................................................7A- 21
Diagnosis with Tech 2 ................................................................................................7A- 25
Tech 2 Connection ......................................................................................................7A- 26
Tech 2 Operating Flow Chart (Start up) ....................................................................7A- 28
Transmission Data ......................................................................................................7A- 30
TCC Data ......................................................................................................................7A- 31
Intermittent Conditions...............................................................................................7A- 32
Identification of Transmission Control Module (TCM).............................................7A- 33
Diagnostic Trouble Codes (DTC) Check ...................................................................7A- 34
DTC P0120 (Flashing Code 21) Analog Throttle Signal Failure (VTH) (For UBS) ..7A- 35
DTC P0502 (Flashing Code 24) Speed Meter Sensor Failure (SP1) ........................7A- 38
DTC P0705 (Flashing Code 17) Gear Selector Failure (PRND2L)............................7A- 41
DTC P0710 (Flashing Code 16) Oil Temperature Sensor Failure (OT2)..................7A- 45
DTC P0717 (Flashing Code 14) Input Revolution Sensor Failure (NC0).................7A- 48
DTC P0722 (Flashing Code 11) Output Revolution Sensor Failure (SP2) ..............7A- 52
7A-2 AUTOMATIC TRANSMISSION (AW30-40LE)
DTC P0727 (Flashing Code 13) Engine Revolution Signal Failure (NE) .................7A- 55
DTC P0743 (Flashing Code 33) Torque Converter Clutch Control Lock-up (ON/OFF)
Solenoid Failure (SL) ...........................................................................................7A- 58
DTC P0748 (Flashing Code 35) Pressure Control Solenoid Failure (STH).............7A- 62
DTC P0753 (Flashing Code 31) Solenoid 1 Failure (S1)...........................................7A- 66
DTC P0758 (Flashing Code 32) Solenoid 2 Failure (S2)...........................................7A- 71
DTC P1120 (Flashing Code 22) PWM Throttle Signal Failure (TH) (For TFR/S) .....7A- 75
DTC P1121 (Flashing Code 23) Analog Throttle Signal Failure (VREF, VGND)
(ForUBS) ..............................................................................................................7A- 79
Wiring Diagram............................................................................................................7A- 81
Connector List.............................................................................................................7A- 87
Troubleshooting Chart ...............................................................................................7A- 93
Manual Shifting Test ...................................................................................................7A- 99
Stall Test ......................................................................................................................7A-100
Time Lag Test ..............................................................................................................7A-101
Hydraulic Test .............................................................................................................7A-102
Road Test.....................................................................................................................7A-103
Shift Point Chart and Lock-Up Point Chart ...............................................................7A-107
TCM Voltage Check.....................................................................................................7A-113
TCM Standard Voltage ................................................................................................7A-114
On-Vehicle Service ..........................................................................................................7A-116
Transmission Fluid Level and Condition ..................................................................7A-116
ATF Replacement........................................................................................................7A-116
Neutral Start Switch Inspection .................................................................................7A-117
Brake Signal Inspection .............................................................................................7A-118
Vehicle Speed Sensor Inspection..............................................................................7A-118
Input and Output Revolution Sensor Inspection......................................................7A-118
Pattern Select Switch Inspection...............................................................................7A-119
Overdrive Switch Inspection......................................................................................7A-119
Solenoid Inspection ....................................................................................................7A-120
ATF Temperature Sensor Inspection ........................................................................7A-120
Throttle Position Sensor Inspection (UBS and TFR/S) ............................................7A-121
Throttle Position Sensor Inspection (’01 TFR) .........................................................7A-122
Selector Lever .............................................................................................................7A-122
Transmission Control Module (TCM) ........................................................................7A-125
Shift Solenoid and Lock-Up Solenoid .......................................................................7A-126

Valve Body Assembly and Pressure Control Solenoid............................................7A-127
Rear Oil Seal (Adapter Housing, 4×
×4) ......................................................................7A-129
Rear Oil Seal (Extension Housing, 4×
×2) ..................................................................7A-129
Transmission Removal and Installation (UBS).........................................................7A-130
Transmission Removal and Installation (TFR/S)......................................................7A-136
Unit Repair........................................................................................................................7A-143
Major Components......................................................................................................7A-143
Disassembly of Major Components (1) .....................................................................7A-145
Reassembly of Major Components (1) ......................................................................7A-147
Disassembly, Inspection and Reassembly of Minor Components .........................7A-183
Oil Pump ......................................................................................................................7A-184
OD Planetary Gear and OD Direct Clutch Assembly (C-0).......................................7A-189
OD Support Assembly ................................................................................................7A-199
Direct Clutch Assembly (C-2) .....................................................................................7A-204
Forward Clutch Assembly (C-1).................................................................................7A-211
Front Planetary Gear...................................................................................................7A-220
Planetary Sun Gear and No.1 One-Way Clutch ........................................................7A-224
Second Brake Assembly (B-2) ...................................................................................7A-229
Rear Planetary Gear Assembly and Output Shaft ....................................................7A-233
First and Reverse Brake Assembly (B-3) ..................................................................7A-240
Transmission Valve Body Assembly.........................................................................7A-246
Lower Valve Body .......................................................................................................7A-251
Upper Valve Body........................................................................................................7A-267
Transmission Case .....................................................................................................7A-281
Torque Converter ........................................................................................................7A-285
Adapter Housing (4×
×4) ..............................................................................................7A-286
Extension Housing (4×
×2)...........................................................................................7A-288
Main Data and Specifications .........................................................................................7A-290
General Specifications ...............................................................................................7A-290
Torque Specifications.................................................................................................7A-291
Special Tool......................................................................................................................7A-295
CAUTION:
When fasteners are removed, always reinstall them Fasteners that are not reused, and those requiring
at a the same location from which they were thread locking compound, will be called out. The
removed. If a fastener needs to be replaced, use correct torque values must be used when installing
the correct part number fastener for that fasteners that require torque. If the above
application. If the correct part number fastener is conditions are not followed, parts or system
not available, a fastener of equal size and strength damage could result.
(or stronger) may be used.
GENERAL DESCRIPTION
CONSTRUCTION
A07RY00001&A07L200001
CONSTRUCTION (Cont’d)
’01 TFR (4×2, For Thailand)
A07L100001
ELECTRONIC CONTROL COMPONENTS

UBS
C07R200024
ELECTRONIC CONTROL COMPONENTS (Cont’d)

TFR/S
C07L200001
TRANSMISSION CONTROL MODULE (TCM)

UBS
C07R200025
TRANSMISSION CONTROL MODULE (TCM) (Cont’d)

TFR/S
C07L200002
CONTROL SYSTEM DIAGRAM

UBS
C07R200021
CONTROL SYSTEM DIAGRAM (Cont’d)

TFR/S
C07L200003
CONTROL AND FUNCTIONS

Item Description
Shift and lock-up control • In D range, speed change point and Lock-up point can be
changed by setting pattern selection switch to "POWER",
"NORMAL" or "WINTER (UBS)" mode.
• Gear shift position in the conditions made up of transmission shift
positions (D.2.L) combined with pattern selection switch
(POWER, NORMAL, and WINTER) can be controlled in
accordance with vehicle speed and the opening of throttle valve.
Overdrive cut control • If O/D switch is set on in D range (O/D OFF lamp ON), gear shift
to O/ D is not effected.
• Overdrive is released at O/D switch on and high transmission oil
temperature (More than 130°C).
However, to prevent engine over revolution
• 4→3 shifting at vehicle speed is less than 118 km/h (UBS) or
117 km/h (TF).
• 3→4 shifting at vehicle speed is more than 131 km/h (UBS) or
125 km/h (TF) or 120 km/h (‘01TFR for Thailand).
Lock-up cut control • In D range, 2nd (TF), 3rd or O/D lock-up is conducted in
"POWER" or "NORMAL" mode.
• In 2, L range, lock-up is off in the whole area.
• Lock-up is released at brake on or high transmission oil
temperature
(More than 130°C  UBS and 01’TFR for thailand) .
(More than 140°C  TF).
• Lock-up is prohibited while driving in coasting condition.
Driving mode select control • The TCM selects a suitable driving mode from the nine kinds for
the variety driving condition.
i) Economy mode ii)Power mode iii)Winter mode(UBS) iv)HOT1
mode v)HOT2 mode vi)L4 mode(4×4) vii)Slope mode(UBS)
(Up slope 1, Up slope 2 and Down slope mode)
• The priority of driving mode:
Economy < Power < Slope(UBS) < L4(4×4) < Winter(UBS) <
HOT1 < HOT2
Squat control • When the TCM detects D signal on, the TCM controls 1–3–1 shift
by setting a timer, in order to improve the shift feel at N→D.
Line pressure control • The TCM output current which corresponds to throttle oil
pressure to pressure control solenoid based on throttle opening.
Indicate oil temperature warning function • If the transmission oil temperature sensor senses that
transmission oil temperature is greater than 146°C, the TCM turn
on A/T OIL TEMP warning lamp. (The warning lamp is turned off,
if oil temperature is less than 126°C.)
L4 mode control (4×4) • The TCM judges whether the transfer is engaged in high or low
based on the ratio rpm data from output speed sensor in the
transmission and the rpm data from speed meter sensor to select
the shift map.
Up and down hill control (UBS) • The TCM judges up and down hill, and change shift pattern
based on throttle opening and acceleration.
CONTROL AND FUNCTIONS (Cont’d)

Item Description
Correct oil temperature control • If the temperature exceeds a predetermined value, the TCM
selects the high oil temperature shift point for downshifting, thus
preventing the oil temperature from rising. (More than 130°C, D
range – UBS and ’01 TFR for Thailand) (More than 140°C, D
range – ’02 TF)
Winter mode control (UBS) • The TCM controls the vehicle start smoothly on low frictional road
like snow road by executing this control.
Activate condition:
When all following conditions are satisfied and winter mode switch
ON, winter mode is activated on “D” range. (Winter mode ON is
judged at the time of switch release after switch ON condition is 200
ms continuously or more.)
1. Excluding "2", "L" range
2. Vehicle speed is less than 11 km/h
3. Transmission oil temperature is less than 115°C
4. Throttle opening is less than 8%
5. Excluding winter mode
Cancel condition:
When at least one among the following five conditions is satisfied,
the winter mode is canceled.
1. When winter mode switch is pushed again
2. When either "2" or "L" is detected
3. Ignition switch "OFF"
4. Vehicle speed is more than 34 km/h for 1 second or mode
continuously
5. Transmission oil temperature is more than 130°C
Fail-safe function • When trouble occurs to vehicle sensor and each solenoid, TCM
automatically exerts fail-safe control not to spoil driveability.
• This control is exerted when sensor or actuator is in trouble, while
TCM works normally.
Diagnosis function • If there is an abnormality in vehicle sensors, each solenoid (S1-
S3, STH), or throttle position sensor, "CHECK TRANS" lamp is
actuated to warn the drive. But when the abnormality items have
been restored to normal, the light does not blink.
• Faulty parts are memorized in TCM. If self-diagnosis start signal
is inputted, "CHECK TRANS" lamp is blinked and results of
diagnosis are indicated. A history of faults remains recorded even
when IGN switch is off.
TECH 2 • Output of control data in the TCM
• Actuator (Solenoid) operation check
• Erasure of trouble code
MAJOR INPUT/OUTPUT COMPONENTS
Component Function
Vehicle speed sensor (Speedometer) Detects the vehicle speed (Back-up sensor of output revolution
sensor).
Output revolution sensor (Transmission) Detects the vehicle speed
Input revolution sensor (Transmission) Detects the input revolution (O/D direct clutch drum revolution).
Engine revolution sensor Detects the engine revolution.
Throttle position sensor Detects the throttle opening rate.
Input
Neutral start switch Detects the select lever position.

Pattern select switch Detects whether the driver has selected "NORMAL",
"POWER", or "WINTER" (UBS) mode.
Overdrive switch Detects whether the driver has selected O/D.
Brake lamp switch Detects whether the driver has pressed the brake pedal or not.
Oil temperature sensor Detects the oil temperature.
Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.
Data link connector When connected with Tech2 or tester, can communicate the
Output
Input/
data for function check, etc.
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle
running condition on the basis of TCM output.
Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running
condition on the basis of TCM output.
Pressure control solenoid STH Adjusts throttle pressure by energizing current of linear
pressure control solenoid to prevent the shift shock and to
Output
obtain shift smoothly.

"CHECK TRANS" lamp When trouble has occurred to throttle position sensor, vehicle
speed sensor, or solenoid, "CHECK TRANS" lamp is blinked to
warn the driver. If also displays the trouble code.
A/T OIL TEMP warning lamp Lights when ATF oil temperature rises. (Turned on at greater
than 146°C. Turned off at less than 126°C.)
Power mode lamp Informs the driver whether the vehicle is in power mode or not.
Winter mode lamp (UBS) Informs the driver whether the vehicle is in winter mode or not.
Transmission Control Module (TCM) Based on the signals from each switch and sensor, judges
Computer
necessary shift point and lock-up operation, and send signal to

each solenoid.
LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID

UBS AND TFR/S
C07R200022
‘01TFR For Thailand
C07R200023
Legend
1. Overdrive direct clutch (C-0) 9. Shift solenoid (S-1)
2. Overdrive brake (B-0) 10. Shift solenoid (S-2)
3. Direct clutch (C-2) 11. One-way clutch (No.1) (F-1)
4. Second coast brake (B-1) 12. Pressure control solenoid (STH)
5. Forward clutch (C-1) 13. Lock-up solenoid (SL)
6. Second brake (B-2) 14. Overdrive one-way clutch (F-0)
7. First and reverse brake (B-3)
8. One-way clutch (No.2) (F-2)
OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH

: Operating : Free at coast down : Operating at lock-up
Shift lever
Gear position C-0 C-1 C-2 B-0 B-1 B-2 B-3 F-0 F-1 F-2 S-1 S-2 S-3
position
P Parking
R Reverse
N Neutral
1st
2nd
D
3rd
O/D
1st
2 2nd
3rd
1st ○
L (1*) 2nd
(2*) 3rd
(1*) Down-shift only in the L range and 2nd gear – no up-shift
(2*) Down-shift only in the L range and 3rd gear – no up-shift
SPEED CHANGE AND LOCK-UP PATTERN

If you select a speed range and a lock-up pattern as shown below by specifying respective positions of
transmission shift lever, transfer shift lever and pattern select switch, the transmission control computer controls
speed change and lock-up operations based on the specified pattern in accordance with the degree of throttle
opening and vehicle speed.
Transmission shift position

Pattern select sw. D
position Overdrive switch Overdrive switch 2 L
ON OFF
NORMAL, POWER 1st⇔[2nd]*⇔[3rd]⇔ 1st⇔[2nd]*⇔[3rd]← 1st⇔2nd⇔(3rd) 1st←(2nd)←(3rd)
[O/D] [O/D]
WINTER (UBS) 3rd fixing  
[ ]: The lock-up operation is available.
( ): Transmission is shifted at high speed to prevent overrun.
*: TF model
OVERDRIVE AND LOCK-UP OPERATING CONDITIONS

The overdrive and lock-up clutch operate if the following conditions are satisfied.
Overdrive Lock-up clutch

Transmission shift position D range ← (1*)
O/D switch position ON (O/D OFF lamp OFF) ―
Brake lamp switch ― OFF
Throttle opening ― Except fully closed
(UBS)
3rd: About 50 km/h or more
O/D: About 65 km/h or more
(UBS)
(TFR/S)
About 49 km/h or more
2nd: About 35 km/h or more
(TFR/S)
Vehicle speed 3rd: About 49 km/h or more
(’01 TFR)
(’01 TFR)
2nd: About 31 km/h or more
(1*): If transmission oil temperature is more than 130°C (UBS and ‘01TFR) or 140°C (TFR/S), lock-up is
inhibit.
DIAGNOSIS
BASIC TROUBLESHOOTING
AW30-40LE transmission, called Electronic Controlled Transmission (ECT), differs from the Mechanical - Hydraulic
control type transmissions. Accordingly, its troubleshooting procedure differs also.
Before troubleshooting an ECT, first determine whether the problem is electrical or mechanical. To do this, just
refer to the basic troubleshooting flowchart provided below.
If the cause is already known, using the basic troubleshooting chart below along with the troubleshooting chart
should speed the procedure.
F07R200005
UBS SELF DIAGNOSIS

Warning to the driver
・ When trouble has occurred to throttle position sensor,
vehicle speed sensor, or solenoid, “CHECK TRANS” lamp
is blinked (1.25 Hz) even during driving to warn the driver.
・ The trouble is recorded by trouble code is TCM.
・ When temporary trouble has been shooted, the “CHECK
TRANS” lamp stops blinking. This blinking can be stopped
by setting the ignition key off. But the trouble code
825R200084 remains memorized in TCM.
TFR/S
825R200085
F07LV002
UBS (RHD) Self-diagnosis code display

・ For quick search for faulty parts, 11 (TF) or 12 (UBS)
different items of trouble code are indicated by “CHECK
TRANS” lamp blinking.
・ The storaged trouble codes can be identified by shorting
the terminals No.11 and No.4 or 5 (ground) of diagnosis
connector with a lead wire.
740RY00013
UBS (LHD)
740RY00014
TFR/S (RHD)
826LV002
Indication Method:
(1) Terminals No.11 and No.4 or 5 (ground) of diagnosis
connector are short circuited.
(2) Turn the ignition key to the ON position.
(3) In case there no trouble, normal code is indicated.
(4) In case a plurality of trouble codes have occurred at a
time, each code is indicated three times in numerical
order.
NOTE:
Power line runs through diagnosis connector.
Be careful shorting with a lead wire, etc.
(The vehicle side of control module may be damaged.)
For identification of trouble code, connect Tech 2 to
diagnosis connector.
F07LV001
Clear of trouble code memory

1. Clear the trouble code memory using F1: Clear DTC
Information for Tech 2.
2. After more than 1 second has elapsed after the ignition
key has been turned ON, short between NO.11 and No.4
or 5 (ground) of data link connector. Then, after 1 second,
but within 6 seconds, discontinue shorting.
After erasing trouble code, check to see if the normal code is
outputted through running test.
Flashing code
Trouble Code
Mode Diagnostic area and Failure
(P-Code)
11
Output revolution sensor failure (SP2)
(P0722)
13
Engine revolution signal failure (NE)
(P0727)
14
Input revolution sensor failure (NC0)
(P0717)
16
Oil temperature sensor failure (OT2)
(P0710)
17
Gear selector failure (PRND2L)
(P0705)
21 Analog throttle signal failure (VTH)

(P0120) (For UBS)
22 PWM throttle signal failure (TH)

(P1120) (For TFR/S)
23 Analog throttle signal failure (VREF, VGND)

(P1121) (For UBS)
24
Speed meter sensor failure (SP1)
(P0502)
31
Solenoid 1 failure (S1)
(P0753)
32
Solenoid 2 failure (S2)
(P0758)
33 Torque converter clutch control lock-up

(P0743) (ON/OFF) solenoid failure (SL)
35
Pressure control solenoid failure (STH)
(P0748)
F07R200014
DIAGNOSIS WITH TECH 2

In this AW30-40LE transmission, troubleshooting can be
performed for electrical faults using the Tech 2 scan tool.
If the CHECK TRANS lamp blinks, or if an electrical fault in
the transmission may probably exist, check trouble codes
using the Tech 2 scan tool.
In the diagnostic procedures described in this manual, first
repair the faulty positions indicated by trouble code in the
order of numbers and then perform troubleshooting for the
faulty positions that are not indicated by trouble code. For
correct troubleshooting, it is necessary to first repair the
trouble codes of lower-order numbers, then to repair the
trouble codes of higher-order numbers in sequence.
How to Use This Manual:

Check trouble codes using the Tech 2 scan tool.
If no codes are set:

・ Refer to Data List and identify the electrical faults that are
not indicated by trouble code.
If codes are set:
・ Record all the codes displayed by the Tech 2 and check if
the codes are intermittent (intermittent faults).
・ Clear the codes.
・ Drive the vehicle for a test to reproduce the faulty status.
・ Check trouble codes again using the Tech 2.
・ If no code is displayed by test driving, the fault is
intermittent. In this case, refer to the cautions on
intermittent conditions.
・ If a code is present, refer to “DIAGNOSTIC TROUBLE
CODES (DTC) CHECK” for diagnosis.
・ Because a code of high-order number may be set for the
reason that a code of low-order number has been set after
occurrence of a fault, perform repair work starting with a
lower-order number is ascending order.
TECH2 CONNECTION
The Tech2 scan tool is used to electrically diagnose the
automatic transmission system and to check the system. The
Tech2 enhances the diagnosis efficiency though all the
troubleshooting can be done without the Tech2.
The Tech2 is a portable, compact, and light tester. When it is
connected to the diagnosis connector of the vehicle, you can
perform a variety of diagnoses and tests by communicating
with the Transmission Control Module (TCM) of the vehicle.
1. Configuration of Tech2
901RW176 1. Tech2 scan tool kit (No. 7000086), Tech2 scan tool (No.
7000057) and DLC cable (No. 3000095)
2. SAE16/19 adapter (No. 3000098) (1), RS232 loop back
connector (No. 3000112) (2), and PCMCIA card (No.
3000117) (3)
F07RW033
UBS (RHD) 2. Tech2 Connection

・ Observe the Tech 2 User Guide.
1. Check the ignition is OFF.
2. Insert the ISUZU (model year) system PCMCIA card (1)
into the Tech2 (4).
3. Connect the SAE16/19 adapter (2) to the DLC cable (3).
4. Connect the DLC cable (3) to the Tech2 (4).
5. Connect the SAE16/19 adapter (2) to the diagnosis
connector of the vehicle.
740RY00013
6. Turn the ignition of the vehicle ON and press the "PWR"
UBS (LHD) key of the Tech2.
・ Check the display of the Tech 2.
NOTE:
Be sure to check that the power is not supplied to the
Tech2 when attaching or removing the PCMCIA card.
740RY00014
TFR/S (RHD)
826LV002
901RY00014
TECH2 OPERATING FLOW CHART (START UP)
060R20266
Once the test vehicle has been identified an DTC Information

“Application (Powertrain) Menu" screen appears. When “DTC Information" is selected, an “Application
Please select the appropriate application. Menu" appears with a list of DTC information function
The following table shows, which functions are used keys addressing DTC specifics and their origins.
for the available equipment versions. Function key selections may vary for particular vehicle
F0: Diagnostic Trouble Codes and/or system.
F0: Read DTC Info By Priority Data Display
The purpose of the “Data Display" mode is to
F2: DTC Information
The current actual values of all important sensors and
F0: History signals in the system are display through F1 mode.
F1: Last Test Failed When “Data Display" is selected an “Application Menu"
F1: Data Display appears.
F0: Transmission Data See “TRANSMISSION DATA" and “TCC DATA” on
F1: TCC Data next page.
F2: Snapshot Snapshot
F0: Transmission Data When “Snapshot" is selected an “Application Menu"
appears.
F1: TCC Data
When “Transmission Snapshot" application is selected
F3: Miscellaneous Tests
from the “Application Menu", a “Snapshot Menu"
F0: Lamps appears, displaying several options. “Snapshot"
F0: Check Light Test options may vary from one system to another.
F1: Power Lamp Test (For UB) / F1: AT Oil “Snapshot" allows a recording of all vehicle
Temperature Lamp Test (For TF) parameters. There parameters may then be replayed
F2: Winter Lamp Test (For UB) at a future point in time.
F1: Solenoids This action allows you to focus on making the condition
F0: Solenoid 1-2/3-4 Test occur, rather than trying to view all of the data in
anticipation of the fault. The snapshot will collect
F1: Solenoid 2-3 Test parameter information around a trigger point that you
F2: TCC Solenoid Test select.
F3: Pressure Control Solenoid (PCS) When a snapshot is taken. It is recorded onto the
Diagnostic Trouble Codes PCMCIA memory card. When the Tech2 is powered
The purpose of the “Diagnostic Trouble Codes" mode down. Snapshots are not lost.
is to display stored TCM trouble codes. Miscellaneous Tests
When “Diagnostic Trouble Codes" is selected an The purpose of “Miscellaneous Tests" mode is to
“Application Menu" screen appears. check for correct operation of electronic system
actuators.
Clear DTC Information
The purpose of the “Clear DTC Information" mode is to Lamps
command the clearing of stored TCM trouble codes. You can operate the lamps by pressing the ON and
OFF buttons.
When “Clear DTC Information" is selected, a “Clear
DTC Information", warning screen appears. This Preconditions: P or N position
screen informs you that by cleaning DTC's, “all stored Solenoid
DTC information in controller will be erased". Solenoid S1(1-2/3-4), S2(2-3) and TCC Solenoid
Do you want to clear DTC's (Yes/No). (Torque Converter Clutch)
Press either the Yes or No key when answering. You can operate the solenoids by pressing the ON and
OFF buttons.
driving the vehicle. Preconditions: P or N position, no vehicle speed, no
engine speed
Allow the vehicle to shift through all four forward gears
in a manner which attempts to repeat the failure Pressure Control Solenoid (PCS)
condition. You can operate the PC Solenoid by pressing the ON
and OFF buttons. ON will command a maximum
NOTE: When the trouble has not been repaired and
current of 1000 mA and OFF a minimum of 200 mA.
the trouble code cannot be erased, check the vehicle
again. Preconditions: P or N position, no vehicle speed,
engine running
TRANSMISSION DATA
Item Unit Engine running at idle
Current Gear 1
Lock Up L - Up
Selector Position Park
AT Output Speed (Automatic Transmission) RPM 0 RPM
Output Speed (Meter Signal Side) RPM 0 RPM
AT Input Speed (Automatic Transmission) RPM 0 RPM
Engine Speed RPM 695 ~ 745 RPM (UBS)
Vehicle Speed (Output Side) km/h 0 km/h
Throttle Position % 0%
Throttle Position Sensor (For UB) V 0.25 ~ 0.45V
AT Oil Temperature (Automatic Transmission) °C, °F 70 ~ 80°C (158 ~ 176°F)
Shift Pattern None
Desired PCS Pressure (Pressure Control
Solenoid) kPa
PCS Desired Current (Pressure Control Solenoid) A
PCS Actual Current (Pressure Control Solenoid) A
Overdrive Off Switch Off, On
Brake Switch Open 0V, Closed 12V Closed 12V
Winter Switch (For UB) Open, Closed 0V Open
Power Switch Open, Closed 0V Open
Diagnostic Request Open, Closed Open
Winter Lamp (For UB) Inactive 12V, Active 0V Inactive 12V
Power Lamp (For UB) Inactive 12V, Active 0V Inactive 12V
Check Light Inactive 12V, Active 0V Inactive 12V
AT Oil Temperature Lamp (Automatic
Transmission) Inactive 12V, Active 0V Inactive 12V
Solenoid 2-3 Inactive 0V, Active 12V Inactive 0V
Solenoid 1-2/3-4 Inactive 0V, Active 12V Active 12V
TCC Solenoid (Torque Converter Clutch) Inactive 0V, Active 12V Inactive 0V
Driving Mode Economy
TCC DATA
Item Unit Engine running at idle
Current Gear 1
Lock Up L - Up
AT Output Speed (Automatic Transmission) RPM 0 RPM
Output Speed (Meter Signal Side) RPM 0 RPM
AT Input Speed (Automatic Transmission) RPM 0 RPM
Engine Speed RPM 695 ~ 745 RPM (UBS)
Vehicle Speed (Output Side) km/h 0 km/h
Throttle Position % 0%
Gear Ratio :1 2.804
AT Oil Temperature (Automatic Transmission) °C, °F 70 ~ 80°C (158 ~ 176°F)
TCC Slip Speed RPM 695 ~ 745 RPM
TCC Solenoid Pressure Desired kPa 0 kPa
Desired TCC Solenoid Current A 0A
Actual TCC Solenoid Current A 0A
INTERMITTENT CONDITIONS
If the Tech2 displays a code as intermittent, or if after a test
drive a code does not reappear, the problem is most likely a
faulty electrical connection or loose wiring.
Terminals should always be the prime suspect.
Intermittent rarely occur in sophisticated electronic
components such as the Transmission Control Module (TCM).
When an intermittent problem is encountered, check suspect
circuits for:
・Poor terminal to wire connection.
・Terminals not fully seated in the connector body (backed
out).
・Improperly formed or damaged terminals.
・Loose, dirty, or corroded ground connections.
HINT: Any time you have an intermittent in more than one
circuit, check whether the circuits share a common
ground connection.
・Pinched or damaged wires.
・Electro-Magnetic Interference (EMI)
HINT: Check that all wires are properly routed away from
coil, and generator. Also check for improperly
installed electrical options, such as lights, 2-way
radios, etc.
Use the F2: SNAPSHOT mode of the Tech2 to help isolate
the cause of an intermittent fault. The snapshot mode will
record information before and after the problem occurs. Set
the snapshot to "trigger" on the suspect code (or codes) or, if
you notice the reported symptom during test drive, trigger the
snapshot manually.
After the snapshot has been triggered, command the Tech2 to
play back the flow of data recorded from each of the various
sensors. Signs of an intermittent fault in a sensor circuit are a
sudden unexplainable jump in data values out of the normal
range.
IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)
826R200032
Legend
1. ISUZU Parts No.:
‘02UBS ― 8-97230-821-0 (For General Export)
‘02TFS ― 8-97303-885-0 (For Australia)
‘02TFR ― 8-97303-884-0 (For Australia and South Africa)
‘01TFR ― 8-97254-431-0 (For Thailand)
2. Calibration Code
3. Production Date:
4. Software Version No.:
5. Model Year, Vehicle Model, Engine Type

6. Serial No.
DIAGNOSTIC TROUBLE CODES (DTC) CHECK

DTC FLASHING
DESCRIPTION
NUMBER CODE
P0120 21 ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)
P0502 24 SPEED METER SENSOR FAILURE (SP1)
P0705 17 GEAR SELECTOR FAILURE (PRND2L)
P0710 16 OIL TEMPERATURE SENSOR FAILURE (OT2)
P0717 14 INPUT REVOLUTION SENSOR FAILURE (NC0)
P0722 11 OUTPUT REVOLUTION SENSOR FAILURE (SP2)
P0727 13 ENGINE REVOLUTION SIGNAL FAILURE (NE)
P0743 33 TORQUE CONVERTER CLUTCH CONTROL LOCK-UP (ON/OFF) SOLENOID
FAILURE (SL)
P0748 35 PRESSURE CONTROL SOLENOID FAILURE (STH)
P0753 31 SOLENOID 1 FAILURE (S1)
P0758 32 SOLENOID 2 FAILURE (S2)
P1120 22 PWM THROTTLE SIGNAL FAILURE(TH) (FOR TFR/S)
P1121 23 ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND) (FOR UBS)
DTC P0120 (FLASHING CODE 21)

ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)
D07R200063
Circuit Description: Conditions of turning "CHECK TRANS" lamp

When the signal of the engine throttle position sensor off:
located on the accelerator pedal is supplied to the Turns “CHECK TRANS” lamp off when judged 0km/h
TCM, the TCM judges the opening condition of the by output revolution sensor after throttle signal input
throttle. voltage is detected more than 0.112V and less than
The shift point of the transmission is determined by this 4.717V.
opening condition of the throttle. (however, uses 0 km/h judgment by back-up vehicle
speed at output revolution failure)
Fail-safe control:
The TCM controls fail-safe by detecting analog throttle Reversion conditions from fail-safe:
signal (VTH) failure. At failure detection
Failure detection: Immediately recovers when the throttle input
voltage is detected more than 0.112V and less than
• When the throttle input voltage is detected less 4.717V.
than 0.112V or more than 4.417V for 2.0 seconds.
At failure decision
Contents of control: Recovers at the same time as the conditions of
At failure detection turning “CHECK TRANS” lamp off are satisfied.
• Throttle opening for line pressure control ... Throttle Test description:
opening 100%
The following numbers correspond to the step numbers
• Throttle opening for shift control ... Throttle opening on the diagnostic chart.
0%
1. Check that the throttle input voltage is 0.25 to
• Lock-up control inhibit 0.45V.
• Up hill and down hill control inhibit 2. At this test, check that as the throttle opens, the
• Squat control inhibit voltage goes up and that the voltage reaches 3.74
At failure decision to 4.56V at the full open status.
Executes following items in addition to above 6. Check the power supply voltage (4.75 – 5.25V) of
control items at failure detection. the throttle position sensor.
• Blinks "CHECK TRANS" lamp
• Stores the failure information in failure-memory
Diagnostic aids:
rubbed through wire insulation or a wire broken inside
the insulation. Inspect related harness connector for
backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.
.

ANALOG THROTTLE SIGNAL FAILURE (VTH) (FOR UBS)
1. With the engine “OFF”, turn the ignition “ON”. 0.25−0.45 V Go to Step 2 Go to Step 3
2. Connect a voltmeter between the TCM 28
1 pin connector terminal (6) and ground
terminal (28).
Is the voltage within the specified valve?
Open the throttle fully. 3.74−4.56 V The problem is Go to Step 3
Is the voltage within the specified value? intermittent.
2 Refer to
“Diagnostic
aids”.
Connect a voltmeter between the ECM 32 pin 0.25−0.45 V Go to Step 4 Go to Step 6
3 connector terminal (E1-6) and (E2-22).
Is the voltage within the specified value?
Open the throttle fully. 3.74−4.56 V Go to Step 5 Go to Step 6
4
1. Check the wiring harness between the TCM − Go to Step 9 −
28 pin connector terminal (6) and ECM 32
5 pin connector terminal (E1-6).
2. Or TCM is faulty.
Was a problem found and corrected?
1. Disconnect the TPS 3 pin connecter. 4.75−5.25 V Go to Step 7 Go to Step 8
2. Connect a voltmeter between the TPS 3 pin
6
connector terminal (3) and (1).
Check the TPS connector. If OK, replace the − Go to Step 9 −
7 TPS.
Is the replacement complete?
Check the wiring harness between the TPS and − Go to Step 9 −
8 ECM. If OK, replace the ECM.
1. After the repair is complete, use the scan tool − Begin the System OK
to select “DTC”, then “clear Info” function. diagnosis
again.
2. Make a road running test for the vehicle.
9 Go to Step 1
3. Review the scan tool “DTC Info”.
Has the last test failed or is the current DTC
displayed?

SPEED METER SENSOR FAILURE (SP1)
UBS (For General Export)
D07R200056
TFR/S (For Australia) and TFR (For South Africa)
D07L200001
’01 TFR (For Thailand)
D07L100004
• The failure detection of oil temperature sensor

Circuit description:
inhibit
Speed information is provided by the speed meter
At failure decision
sensor to the meter.
Executes following items in adition to above control
In the meter, the pulses of the speed meter sensor are
items at failure detection.
converted to speed signals (pulses), and these signals
are output to the TCM and ECM(TF). The TCM
converts these pulse voltages to km/h signals. Conditions of turning "CHECK TRANS" lamp
Fail-safe control: off:
The TCM controls fail-safe by detecting speed meter Turns "CHECK TRANS" lamp off when judged 0km/h
signal failure. by speed meter sensor after more than 1 pulse are
input in the speed meter signal during the time 27
Failure detection: pulses are input in the output revolution sensor.
• When the speed meter signal is not detected from Reversion conditions from fail-safe:
right after ignition turned ON:
At failure detection and decision
When not even 1 pulse is input in the speed meter
signal during the time 100 pulses are input in the Recovers at the same time as the conditions of turning
output revolution sensor signal. “CHECK TRANS” lamp off are satisfied.
• When the speed meter signal is not detected, after Test description:
the speed meter signal is detected more than 1
pulse after ignition turned ON:
on the diagnostic chart.
When not even 1 pulse is input in the speed meter
2. The cause of DTC P0502 setting is due to the
signal during the time 27 pulses are input in the
operation fault of the speed meter.
output revolution sensor signal.
3. Speed signals are output from the meter. The
Contents of control: sensor power supply is given from the TCM.
At failure detection Diagnostic aids:
• Keeps the condition of transfer (High/Low An intermittent may be caused by a poor connection,
judgment) just before detection until vehicle speed rubbed through wire insulation or a wire broken inside
is 0km/h, and changes shift map to L4 map (3→4 the insulation. Inspect related harness connector for
UP None) at vehicle speed is 0km/h. (For UBS) backed out terminals, improper mating, broken locks,
• Uses high oil temperature map according to shift improperly formed or damaged terminals, poor terminal
map priority at correct oil temperature control. to wire connection and damaged harness.
• Up hill and down hill control inhibit. (For UBS)
• Stores the failure information in failure -memory.

SPEED METER SENSOR FAILURE (SP1)
1. Lift the driving wheels. 0 km/h Go to Step 2 DTC P0502 is
2. With the engine idling in gear D range. intermittent.
Is the Tech 2 displayed speed the specified If other DTCs
value? are not stored
1
in memory.
Refer to
“Diagnostic
aids”.
2 Does the speed meter operate? − Go to Step 3 Go to Step 4
1. Open the throttle and increase the revolution Less than 1.4 V ⇔ Go to Step 5 Go to Step 6
speed of the driving wheels Greater than 9 V
2. Measure the voltage between the TCM 28 (Pulse check)
(Vehicle speed 1∼
3 pin connector terminal (7) and TCM 20 pin
2 km/h)
connector ground terminal (15 or 19) with a
voltmeter.
Does the voltage vary intermittently in the
specified value?
The speed meter or speed meter sensor is − Go to Step 7 −
4 faulty.
The TCM connect is faulty or the TCM is faulty. − Go to Step 7 −
5
The wiring harness between the speed meter − Go to Step 7 −
and TCM is open or the speed meter sensor is
6
faulty.
to select “DTC”, then “Clear Info” function. diagnosis
again.
7 2. Make the road running test for the vehicle.
Go to Step 1
displayed?

GEAR SELECTOR FAILURE (PRND2L)
D07R200057
D07L200002
‘01TFR (For Thailand)
D07L200011
• Winter mode inhibit (For UBS)

At failure decision
The neutral start switch gives the signals related to the
selector lever position (PRND2L) to the Transmission Excutes following items in addition to above control
Control Module (TCM). The neutral start switch turns items at failure detection.
on when the select lever is shifted to the P, R, N, D, 2 • Blinks "CHECK TRANS" lamp
or L range. The neutral start switch, which is connected • Stores the failure information in failure-memory
to the starter switch circuit, is available only when the • Reverse lockout control inhibit
select lever is in the P or N range
The neutral start switch is connected to the
Conditions of turning “CHECK TRANS” off:
transmission manual shaft and installed in the Turns “CHECK TRANS” lamp off when only one of all
transmission case. switches is ON.
Fail-safe condition: Reversion conditions from fail-safe:

The TCM controls fail-safe by detecting selector Turns “CHECK TRANS” lamp off when only one of all
position switch failure. switches is ON.
Failure detection: Test description:

(1) OPEN: The following numbers correspond to the step numbers
• When all switches are OFF on the diagnostic chart.
• When the failure criteria continues for 30 seconds if 1. It is judged whether the input signal received from
the vehicle speed which is calculated by output the neutral start switch by the TCM is proper or not.
revolution sensor is more than 30 km/h and the 5. The power status of the neutral start switch is
engine revolution is more than 1500 rpm. checked.
(2) SHORT: 6. The continuity between neutral start switch
• When more than two switches are ON at the same terminals and the continuity of the wire connected
time. to the neutral start switch are checked.
• When the failure criteria condition for 10 seconds. Diagnostic aids:
Contents of control: An intermittent may be caused by a poor connection,
At failure detection
(1) OPEN: D range judgment backed out terminals, improper mating, broken locks,
(2) SHORT: Judged by priority D>2>L>R>N>P improperly formed or damaged terminals, poor terminal
• Up hill and down hill control inhibit (For UBS) to wire connection and damaged harness.

GEAR SELECTOR FAILURE (PRND2L)
1. With the engine "OFF", turn the ignition See table 1 Go to Step 2 Go to Step 3
"ON".
2. Connect a voltmeter to the each terminals of
the TCM 28 pin connector and TCM 20 pin
1 connector ground terminal (15 or 19).
3. Measure the voltage shifting the selector
lever to very position.
(Comparison with table 1)
Is the displayed voltage at every position
normal?
1. Clear the TCM memory. − Go to Step 4 The continuity
2. Make a running test. (Greater than 30 of wiring is
temporarily
seconds).
2 faulty.
Is DTC P0705 displayed by self-diagnosis?
Refer to
“Diagnostic
aids”.
Is the displayed voltage at every position − Go to Step 5 Go to Step 6
3
abnormal?
The TCM is faulty or the continuity of wiring is − Go to Step 9 −
temporarily faulty.
4
Refer to "Diagnostic aids".
1. Check if there is any breaking in the fuse and − Go to Step 9 −
wire connected to the 10 pin connector
terminal (3) of the neutral start switch.
2. Check the adjusted condition of the neutral
5
start switch.
3. If no fault is found, replace the neutral start
switch.
1. Disconnect the 10 pin connector of the See table 2 Go to Step 7 Go to Step 8
neutral start switch.
2. Make a continuity check between each
6
terminals of the neutral start switch with an
ohmmeter.
Is the continuity at every position normal?
The wiring harness between the TCM and − Go to Step 9 −
7 neutral start switch is open or shorted.
Replace the neutral start switch. − Go to Step 9 −
8
to select "DTC", then "Clear Info" function. diagnosis
again.
9 2. Make a road running test for the vehicle.
Go to Step 1
3. Review the scan tool "DTC Info".
displayed?
(Table 1)
TCM 20 pin TCM 28 pin
Voltage (V)
terminal (-) terminal (+)
8-16: P range
2
1 or less: Other than P range
8-16: R range
1
1 or less: Other than R range
8-16: N range
9
1 or less: Other than N range
15 or 19
8-16: D range
8
1 or less: Other than D range
8-16: 2 range
21
1 or less: Other than 2 range
8-16: L range
20
1 or less: Other than L range
(Table 2)
Terminal Neutral start switch 10 pin connector
Range 1 4 3 5 2 6 8 7 9
Continuity

OIL TEMPERATURE SENSOR FAILURE (OT2)
D07R200058
D07L200003
D07L100006

Circuit Description:
The oil temperature sensor is a thermistor sensor that
is installed in the transmission case and converts At failure decision
temperature changes into continuous electric signals, • Same as failure detection.
then outputs them to the Transmission Control Module Conditions of turning "CHECK TRANS" off:
(TCM). When the ATF temperature is low, the
resistance of the sensor (thermistor) goes up, so that Turns "CHECK TRANS" lamp off when judged 0km/h
the voltage of the TCM signal becomes high. by output revolution sensor after the normal area of oil
temperature 40°C – 150°C is detected for 10 sec
As the ATF is gradually warmed, the resistance of the
continuously.
sensor goes down and the voltage becomes low. At the
normal operating ATF temperature (80°C/176°F) of the Reversion conditions from fail-safe:
transmission, the voltage of the TCM is about 3.7V.
Recovers at the same time as the conditions of turning
Fail-safe condition: “CHECK TRANS” lamp off are satisfied.
The TCM controls fail-safe by detecting oil temperature Test description:
sensor failure.
Failure detection: on the diagnostic chart.
Short detection 1. Check that the voltage of the oil temperature
sensor varies with ATF temperatures.
• When the A/D value is detected less than 10
(220°C) for 5 minutes continuously while normal 3. Check that the resistance of the oil temperature
judgment is not satisfied from ignition on. sensor varies with ATF temperatures.
Open detection Diagnostic aids:
• After 15 minites passed when the engine revolution An intermittent may be caused by a poor connection,
is more than 400 rpm and the selector position rubbed through wire insulation or a wire broken inside
switch is selected on R, D, 2, L range. the insulation. Inspect related harness connector for
• When the change of the A/D value from engine backed out terminals, improper mating, broken locks,
start is less than 15 and the minnum A/D value is improperly formed or damaged terminals, poor terminal
more than 1000 (-10°C) from engine start. to wire connection and damaged harness.
Contents of control:
• Changes shift map to HOT2 map
• Controls as A/T oil temperature 200°C
• Lock-up control inhibit
• Up hill and down hill control inhibit (For UBS)

OIL TEMPERATURE SENSOR FAILURE (OT2)
1. With the engine "OFF", turn the ignition See table Go to Step 2 Go to Step 3
"ON".
1 2. Connect a voltmeter between the TCM 28
pin connector terminal (18) and (27).
Is the voltage as shown in the table?
1. Replace the TCM with a new one. − Go to Step 4 The TCM is
2. Make a running test. faulty.
2 Is DTC P0710 displayed by self-diagnosis? (TCM before
replacement)
Go to Step 9
1. Disconnect the TCM 28 pin connector. See table Go to Step 5 Go to Step 6
2. Measure the resistance between the TCM 28
3
pin connecter terminal (18) and (27).
Is the resistance as shown in the table?
Check the wiring harness or connector − Go to Step 9 −
connection between the TCM and oil
4 temperature sensor.
temporarily faulty.
5 Refer to "Diagnostic aids".
1. Disconnect the A/T 2 pin connector. See table Go to Step 7 Go to Step 8
2. Measure the resistance between the A/T 2
6
Is the resistance as shown in the table?
The wiring harness between the TCM and oil − Go to Step 9 −
7 temperature sensor connector is ground-shorted.
Replace the oil temperature sensor. − Go to Step 9 −
8
the select "DTC", then "Clear Info" function. diagnosis
again.
9 Go to Step 1
displayed?
(Table)
ATF temperature (°C/°F) Voltage (V) Resistance (kΩ)
20/68 Approx. 4.7
0.5 − 30
80/176 Approx. 3.7

INPUT REVOLUTION SENSOR FAILURE (NC0)
D07R200059
D07L200004
D07L100007
Timer starts when D, 2 or L range are detected (fixation

signal).
Input revolution information is provided to TCM by the
input revolution sensor. This sensor is located in the Contents of control:
transmission case. At failure detection
The input revolution sensor is an electromagnetic pulse • Lock-up control inhibit
pickup type that generates a speed signal according to • Up hill and down hill control inhibit (For UBS)
the revolution of the transmission OD direct clutch
At failure decision
drum.
Executes following items in addition to above
As a result, the sensor sends a sine wave signal (AC)
control items at failure detection.
to the TCM, which converts this sine wave signal (pulse
voltage) to a RPM signal. • Blinks "CHECK TRANS" lamp
Fail-safe control:
The TCM controls fail-safe by detecting input revolution
Conditions of turning "CHECK TRANS" off:
sensor failure. At D, 2 or L range and not shifting, turns "CHECK
TRANS" lamp off when judged 0km/h by output
Failure detection: revolution sensor after more than 1 pulse input in the
• When not even 1 pulse is input in the input input revolution sensor and finished vehicle speed
revolution sensor during the time 4 pulses are input calculation during the time 4 pulse are input in the
in the output revolution sensor. output revolution sensor.
• When the failure criteria is continuously 1000 times Reversion conditions from fail-safe:
from the time ignition is turned ON until it is turned
OFF. Recovers at the same time as the conditions of turning
“CHECK TRANS” lamp off are satisfied.
Prohibits failure detection when at least one among the
following conditions is satisfied. Test description:
• When D, 2 and L range signal is not fixed. The following numbers correspond to the step numbers
• When output revolution is less than 775 rpm. on the diagnostic chart.
• When the failure detection timer T1 (*1) is less than 1. When the engine is running, a revolution signal is
25 seconds. input from the input revolution sensor to the TCM.
• Solenoid S1, S2, and selector position switch is on 2. At this test, the continuity of circuit wiring and the
failure detection or decision. input revolution sensor is checked.
• At 4th gear. 4. At this test, the continuity of the input revolution
• When passed less than 10 seconds after shift sensor is checked.
command output.
*1: Failure detection inhibit timer T1
Diagnostic aids:

INPUT REVOLUTION SENSOR FAILURE (NC0)
1. Turn the ignition "ON" and the engine "ON". 0-3 V (AC) DTC P0707 is Go to Step 2
2. With the engine edling, connect a voltmeter or more intermittent.
If other codes
between the TCM 28 pin connector terminal
are not stored,
1 (5) and ground terminal (17). refer to
Does the voltage rary in the specified value? “Diagnostic
(The voltage increases in proportion to the aids”.
speed.)
1. Turn the ignition "OFF". 560-680 Ω Go to Step 3 Go to Step 4
2. Disconnect the TCM 28 pin connector. (at 20°C, 4×4)
2 387-473 Ω
3. Connect an ohmmeter between the TCM 28
(at 20°C, 4×2)
Is the resistance within the specified value?
1. Replace the TCM with a new one.  Go to Step 5 Go to Step 7
Is DTC P0717 displayed?
1. Disconnect the 2 pin connector of the input 560-680 Ω Go to Step 6 Go to Step 5
revolution sensor. (at 20°C, 4×4)
387-473 Ω
2. Measure the resistance between each
4 (at 20°C, 4×2)
terminals of the input revolution sensor 2 pin
connector with an ohmmeter.
Replace the input revolution sensor.  Go to Step 7 
5
Check the wiring harness between the TCM and  Go to Step 7 
6 input revolution sensor for an open or shorted.
1. After the repair is complete, use the scan tool  Begin the System OK
again.
7 Go to Step 1
3. Reviews the scan tool "DTC Info".
Has the last test failed or is the current
DTC displayed?

OUTPUT REVOLUTION SENSOR FAILURE (SP2)
D07R200060
D07L200005
‘01TFR/S (For Thailand)
D07L100008
• Squat control inhibit

Vehicle speed information is provided to the TCM by
• Reverse lockout control inhibit
the output revolution sensor. This sensor is located in
the transmission adapter housing (4×4) or extension • Stores the failure information in failure-memory
housing (4×2). The output revolution sensor is an At failure decision
electromagnetic pulse pickup type that generates a Executes following items in addition to above
speed signal according to the revolution of the control items at failure detection.
transmission output shaft. As a result, the sensor • Blinks "CHECK TRANS" lamp
sends a sine wave signal (AC) to the TCM, which
converts this sine wave signal (pulse voltage) to a km/h Conditions of turning "CHECK TRANS" off:
signal. Turns "CHECK TRANS" lamp off when judged 0km/h
by speed meter sensor after more than 1 pulse input in
Fail-safe control:
the output revolution sensor and finished vehicle speed
The TCM controls fail-safe by detecting output calculation during the time 4 pulse are input in the
revolution sensor failure. speed meter sensor.
Failure detection: Reversion conditions from fail-safe:
• When not even 1 pulse is input in the output Recovers at the same time as the conditions of turning
revolution sensor during the time 4 pulses are input “CHECK TRANS” lamp off are satisfied.
in the speed meter sensor.
• When the failure criteria is continuously 500 times Test description:
from the time ignition is turned ON until it is turned The following numbers correspond to the step numbers
OFF. on the diagnostic chart.
• Detection inhibit condition: 1. When the vehicle is running, a speed signal is input
When speed meter sensor revolution is less than from the output revolution sensor to the TCM.
80 rpm. 2. At this test, the continuity of circuit wiring and the
output revolution sensor is checked.
4. At this test, the continuity of the output revolution
sensor is checked.
• Uses the vehicle speed calculated by speed meter
sensor for shift control Diagnostic aids:
• Keeps the condition of transfer (High/Low An intermittent may be caused by a poor connection,
judgment) just before detection until vehicle speed rubbed through wire insulation or a wire broken inside
is 0km/h, and changes shift map to L4 map the insulation. Inspect related harness connector for
(3→4UP None) at vehicle speed 0km/h. (For UBS) backed out terminals, improper mating, broken locks,
• Use high oil temperature map according to shift improperly formed or damaged terminals, poor terminal
map priority at correct oil temperature control. to wire connection and damaged harness.

OUTPUT REVOLUTION SENSOR FAILURE (SP2)
1. Lift the driving wheels. 0-3 V or more DTC P0722 is Go to Step 2
2. With the engine idling in gear, connect a intermittent. If
other codes
voltmeter between the TCM 28 pin connector
are not stored,
1 terminal (4) and ground terminal (16). refer to
Does the voltage vary in the specified value? "Diagnostic
(The voltage increase in proportion to the aids".
speed.)
1. Turn the ignition "OFF". 560-680Ω Go to Step 3 Go to Step 4
2. Disconnect the TCM 28 pin connector. (at 20℃)
2 3. Connect an ohmmeter between the TCM 28
1. Replace the TCM with a new one.  Go to Step 5 The TCM is
2. Make a road running test for the vehicle. faulty.
3 Is DTC P0722 displayed? (TCM before
replacement)
Go to Step 7
1. Disconnect the 2 pin connector of the output 560-680Ω Go to Step 6 Go to Step 5
revolution sensor. (at 20℃)
2. Measure the resistance between each
4
terminals of the 2 pin connector with an
ohmmeter.
Replace the output revolution sensor.  Go to Step 7 
5
6 output revolution sensor for an open or shorted.
again.
7 Go to Step 1
displayed?

ENGINE REVOLUTION SIGNAL FAILURE (NE)
D07R200061
D07L200006
D07L100009
Circuit description: Conditions of turning "CHECK TRANS" lamp

Engine revolution (rpm) signals are sent from Engine off:
Control Module (ECM) to the Transmission Control Turns "CHECK TRANS" lamp off when judged 0km/h
Module (TCM). by speed meter sensor after the engine revolution
The engine speed sensor is an electromagnetic pulse signal pulses are input 250 pulses normally.
pickup type that generates signals when the flywheel (however, uses 0 km/h judgment by back-up vehicle
gear revolves (2 pulses at a single revolution of the speed at output revolution failure)
flywheel gear).
The TCM converts these sine wave signals into engine
Reversion conditions from fail-safe:
revolution (RPM) signals. Recovers at the same time as the conditions of turning
“CHECK TRANS” lamp off are satisfied.
Fail-safe control:
The TCM controls fail-safe by detecting engine
Test description:
revolution sensor failure. The following numbers correspond to the step numbers
Failure detection: 2. Engine revolution signals are input from the ECM
• When input revolution is more than 2000 rpm into the TCM.
• When not even 1 pulse is input in the engine 3. When the engine idling, voltage fluctuates with (AC
revolution signal during 5 seconds intermittent) range of less than 1.4V ⇔ 9 ∼ 16V.
• Detection inhibit condition: At 4th gear
Diagnostic aids:
Contents of control: An intermittent may be caused by a poor connection,
At failure detection rubbed through wire insulation or a wire broken inside
• Up hill and down hill control inhibit (For UBS) the insulation. Inspect related harness connector for
• Oil temperature sensor failure detection inhibit
• Blinks "CHECK TRANS" lamp to wire connection and damaged harness.
• Stores the failure information in failure memory.
At failure decision
Same as failure detection

ENGINE REVOLUTION SIGNAL FAILURE (NE)
1. Clear the TCM memory.  Go to Step 2 DTC P0727
2. Turn the ignition "ON" and start the engine. was
temporarily
3. With the engine "OFF", turn the ignition
stored into
1 "ON". TCM memory.
Is DTC P0727 displayed by self-diagnosis? Refer to
"Diagnostic
aids".
1. With the engine "OFF", turn the ignition 9-16V Go to Step 3 Go to Step 4
"ON".
2. Connect a voltmeter to the TCM 28 pin
2
connector terminal (15) and TCM 20 pin
connector ground terminal (15 or 19).
1. With the ignition "ON" and the engine "ON". Less than Go to Step 5 Go to Step 6
2. Connect a voltmeter between the TCM 28 1.4-9∼16 V
pin connector terminal (15) and TCM 20 pin (AC intermittently)
3
connector ground terminal (15 or 19).
Does the voltage vary in the specified value at
the engine idling?
4 ECM for breaking or voltage shorted.
Check the TCM connection. If OK, replace the  Go to Step 7 
5 TCM.
ECM for ground shorted. If OK, the ECM or the
6 engine revolution sensor is faulty.
again.
2. Make a road running, test for the vehicle.
7 Go to Step 1
displayed?
DTC P0743 (FLASHING CODE 33) TORQUE CONVERTER CLUTCH

CONTROL LOCK-UP (ON/OFF) SOLENOID FAILURE (SL)
D07R200062
D07L200007
D07L200010
Circuit description: Conditions of turning “CHECK TRANS” lamp

The lock-up solenoid SL of the torque converter clutch off:
(TCC) controls the lock-up clutch by a signal according None
to the lock-up range judgement of the TCM when the
vehicle runs. Reversion conditions from fail-safe:
This function can improve the fuel consumption to When a normal condition is judged by rechecking on
almost the same extent as the manual transmission. the state of lock-up ON/OFF
The lock-up solenoid SL is put into B+ by the TCM, so
Test description:
that the solenoid is actuated with the result of lock-up.
Fail-safe control: on the diagnostic chart.
The TCM controls fail-safe by detecting SL solenoid 1. When the key is ON, the voltage between the TCM
failure. 20 pin connector terminals (12) and (15 or 19) is
1.0 V or less.
Failure detection:
2. When the gear is of the 2nd speed in the D range
GND SHORT detection and the throttle opening is about 50% at a higher
• When SHORT detection continues for 0.3 sec. speed than about 40km/h, the TCM supplies 8 to
• When SHORT failure detection continues 8 times. 16 V, so that the solenoid is actuated with the result
Open detection of lock-up.
• When OPEN detection continues for 0.5 sec. 3.5.7.8. The resistance range of the solenoid is 11 to
15Ω (at 20°C).
• When OPEN failure detection continues 8 times.
Contents of control: Diagnostic aids:
In case of faulty connection, open or shorted circuit. to
the TCM 20 pin connector terminal (12), DTC P0743 is
• Lock-up control inhibit displayed. A intermittent failure may be caused by a
• If + B short failure is detected, keeps 1st gear when poor connection, rubbed through wire insulation or a
the vehicle speed calculated by output revolution wire broke inside the insulation.
sensor is less than 10km/h to prevent stall.
(Canceled at more than 15km/h)
At failure decision
• Executes following items in addition to above
• Stores the failure information in failure-memory.

CONTROL LOCK-UP (ON/OFF) SOLENOID FAILURE (SL)
1. With the engine "OFF", turn the ignition "ON" 1V Go to Step 2 Go to Step 3
after warming up.
1
pin connector terminal (12) and ground
terminal (15 or 19).
Is the voltage less than the specified value?
1. Lift the driving sheels and support them. 8-16V Go to Step 4 Go to Step 5
2. At the D range and 2nd speed gear.
3. Make a test at a speed of about 40 km/h or
2 more with 50% or more opening of the
throttle.
Is the voltage between the TCM 20 pin connector
terminal (12) and ground terminal (15 or 19)
within the specified value?
1. Turn the ignition "OFF". 11-15Ω Go to Step 6 Go to Step 7
3 3. Measure the resistance between the terminal
(12) and ground.
1. Clear the TCM memory.  Go to Step 6 The continuity
2. Make a running test. of wiring is
Is DTC P0743 displayed by self-diagnosis? intermittent.
4
Refer to
"Diagnostic
aids".
1. Turn the ignition "OFF". 11-15Ω Go to Step 6 Go to Step 8
5 3. Measure the TCM 20 pin connector terminal
(12) and ground.
The TCM is faulty or the continuity of wiring  Go to Step 12 
6 harness is intermittent.
Disconnect the A/T 8 pin connector. 11-15Ω Go to Step 9 Go to Step 10
Is the resistance between the lock-up solenoid (at 20℃)
7
connector terminal (7) and ground within the
specified value?
Disconnect the A/T 8 pin connector. 11-15Ω Go to Step 11 Go to Step 10
Is the resistance between the lock-up solenoid (at 20℃)
8
specified value?
Check the wiring harness between the TCM 20  Go to Step 12 
pin connector terminal (12) and A/T 8 pin
9 connector terminal (7) for open.

CONTROL LOCK-UP (ON/OFF) SOLENOID FAILURE (SL) (Cont’d)
Replace the lock-up solenoid (SL).  Go to Step 12 
10
11 connector terminal (7) for ground shorted.
again.
12 Go to Step 1
Has the last failed or is the current DTC
displayed?

PRESSURE CONTROL SOLENOID FAILURE (STH)
D07R200062
D07L200007
D07L100010

The pressure control solenoid is a PWM duty control • Turns Solenoid power supply OFF
solenoid located in the valve body.
The pressure control solenoid is a TCM-controled
device used to regulate transmission throttle pressure • Stores the failure information in failure memory
by energizing current from the TCM. *Prohibits failure detection of S1, S2, SL, STH, selector
position switch, and oil temperature sensor.
Fail-safe control:
The TCM controls fail-safe by detecting pressure
control solenoid failure. Turns "CHECK TRANS" lamp off after ignition is turned
ON→ OFF→ ON.
Failure detection:
IG short failure
• When the feedback A/D value is more than 1020 At failure detection
for 500 milli-second continuously. When IG short failure···The feedback A/D value is
• Detection inhibit condition: Prohibition during 1 less than 1020 for 1 second continuously.
second after reversion from open failure, because When open failure···Detection criteria is not
the possibility of the mis-detection is high. satisfied or the feedback A/D value is more than 15
Open failure (Including GND Short) for 1 second continuously.
• When the feedback A/D value is less than 15 for At failure decision
more than 70 milli-second continuously, judges as Recovers at the same time as the conditions of
faliure, and turns the current of target output off, turning “CHECK TRANS” lamp off are satisfied.
after 1.5 second passed turns the current of target Test description:
value to normal. The A/D value is checked, and this
operation is repeated during 70 milli-second again. The following numbers correspond to the step numbers
• When it continues for 12.5 second in total.
1. The solenoid resistance is within the range of 5 to
Contents of control: 5.6Ω. (at 20°C)
At failure detection 2. This test checks for shorted circuit at the TCM.
At failure decision
Diagnostic aids:

PRESSURE CONTROL SOLENOID FAILURE (STH)
1. Turn the ignition "OFF". 5-5.6Ω (at 20°C) Go to Step 2 Go to Step 3
2. Disconnect the TCM 20 pin connector.
1 3. Connect an ohmmeter between the TCM 20
1. Connect an ohmmeter between the TCM 20  Go to Step 4 The problem is
pin connector terminal (11) and ground intermittent.
Refer to
"Diagnostic
2. Then, connect between the TCM 20 pin aids".
connector terminal (11) and ignition terminal
2 (20).
3. Then, connect TCM 20 pin connector
terminal (8) and ground terminal (15 or 19),
then between TCM 20 pin connector
terminal (8) and ignition terminal (20).
Does display a short circuit?
1. Disconnect the A/T 8 pin connector. 5-5.6Ω (at 20°C) Go to Step 5 Go to Step 6
2. Connect an ohmmeter between the A/T 8 pin
3
connector terminal (2) and (6).
Repair the short circuit.  Go to Step 7 
4
Is the repair complete?
Repair the wiring harness for open between TCM  Go to Step 7 
5 20 pin connector and A/T 8 pin connector.
Is the repair complete?
1. Check the wiring harness for open between  Go to Step 7 
A/T 8 pin connector and pressure control
6 solenoid.
2. If OK, replace pressure control solenoid
(valve body assembly).
to select "DTC", then "Clear Info" function diagnosis
again.
7 Go to Step 1
displayed?
DTC P0753 (FLASHING CODE 31) SOLENOID 1 FAILURE (S1)

D07R200062
D07L200007
D07L100010
The shift solenoid S1 changes the hydraulic route with
the signals from the TCM according to the vehicle
speed and the throttle opening to control shifting. When
the solenoid S1 or S2 fails, the hydraulic circuit is
mechanically operated as a backup.
Fail-safe control:
The TCM controls fail-safe by detecting S1, S2 shift
solenoid failure.
Failure detection:
GND SHORT detection
• When SHORT detection continues for 0.3 sec.
• When SHORT failure detection continues 8 times.
Open detection
• When OPEN detection continues for 0.5 sec.
• When OPEN failure detection continues 8 times.
• Changes solenoid output pattern as following figure
The shift theory at shift solenoid failure

Shift Normal S1 failure S2 filure S1 and S2 failure
lever Gear S1 S2 Gear S1 S2 Gear S1 S2 Gear S1 S2
Position
1 × 1
2 3
D O/D
3 × O/D ×
O/D × × O/D × ×
1 × 1
2 2 3 3
O/D
3 × ×
1 × 1
L 3 3
2 O/D
At failure decision Diagnostic aids:

Executes following items in addition to above control In case of faulty connection, open or shorted circuit to
items at failure detection. the TCM 20 pin connector terminal (4), DTC P0753 is
• Turns Solenoid power supply OFF displayed. A intermittent failure may be caused by a
• Blinks "CHECK TRANS" lamp poor connection, rubbed through wire insulation or a
wire broke inside the insulation.
*Prohibits failure detection of S1, S2, SL, STH,
Selector position switch, and Oil temp. sensor.
Turns "CHECK TRANS" lamp off after ignition is turned
ON→ OFF→ ON.
When a normal judgment is obtained by rechecking
during shifting.
At failure decision
Recovers at the same time as the conditions of
turning “CHECK TRANS” lamp off are satisfied.
Test description:
1. With the key "ON", the voltage between the TCM
20 pin connector terminals (4) and (15 or 19) is 8 to
16V.
4. When the driving wheels revolve with the 3rd speed
gear, the voltage is 1 V or less.
3.6.8.11. The solenoid resistance is within the range of
11 to 15Ω (at 20°C).

1. With the engine "OFF", turn the ignition 8-16 V Go to Step 2 Go to Step 3
"ON".
1
1. Lift the driving wheels and support them.  Go to Step 4 Go to Step 8
2. Turn the ignition "ON", and the engine "ON".
2 Can the speed be changed normally by
acceleration is the "NORMAL" mode and the D
range?
1. Turn the ignition "OFF". 11-15Ω (at 20°C) Go to Step 5 Go to Step 6
3 3. Measure the resistance between the TCM 20
pin connector terminal (4) and ground.
At the 3rd speed gear. 1V Go to Step 7 Go to Step 8
4
terminal (4) and ground terminal (15 or 19) less
than the specified value?
Disconnect the A/T 8 pin connector. 11-15Ω (at 20°C) Go to Step 9 Go to Step 10
Is the resistance between the solenoid S1
6
specified value?
7
Refer to
"Diagnostic
aids".
Replace the solenoid S1.  Go to Step 13 
10
1. Disconnect the A/T 8 pin connector. 11-15Ω (at 20°C) Go to Step 12 Go to Step 10
11
DTC P0753 (FLASHING CODE 31) SOLENOID 1 FAILURE (S1) (Cont’d)

again.
13 Go to Step 1
displayed?

D07R200062
D07L200007
D07L100010

*Prohibits failure detection of S1, S2, SL, STH,
The solenoid S2 changes the hydraulic route with the Selector position switch, and Oil temperature
signals from the TCM according to the vehicle speed sensor.
and the throttle opening to control shifting. When the
solenoid S1 or S2 fails, the hydraulic circuit is Conditions of turning "CHECK TRANS" off:
mechanically operated as a backup. Turns "CHECK TRANS" lamp off after ignition is turned
ON→ OFF→ ON.
Fail-safe control:
The TCM controls fail-safe by detecting S1, S2 shift Reversion conditions from fail-safe:
solenoid failure. At failure detection
Failure detection: When a normal judgment is obtained by rechecking
during shifting.
GND SHORT detection
At failure decision
• When SHORT detection continues for 0.3 sec.
Recovers at the same time as the conditions of
• When SHORT failure detection continues 8 times.
Open detection
• When OPEN detection continues for 0.5 sec. Test description:
• When OPEN failure detection continues 8 times. The following numbers correspond to the step numbers
Contents of control: 1. With the key "ON", the voltage between the TCM
At failure detection 20 pin connector terminals (3) or (15 or 19) is 1V or
• Lock-up control inhibit less.
• Up hill and down hill control inhibit (For UBS) 4. When the driving wheels revolve with the 2nd
• Squat control inhibit speed gear, the voltage is 8 to 16V.
• Changes solenoid output pattern as "The shift 3.6.8.11. The resistance of the solenoid is in the range
theory at shift solenoid failure". (See DTC P0753) of 11 to 15Ω (at 20).
At failure decision Diagnostic aids:
• Executes following items in addition to above In case of faulty connection, open or shorted circuit to
control items at failure detection. the TCM 20 pin connector terminal (3), DTC P0758 is
• Turns Solenoid power supply OFF displayed. A intermittent failure may be caused by a
• Blinks "CHECK TRANS" lamp poor connection, rubbed through wire insulation or a
wire broken inside the insulation.

1. With the engine "OFF", turn the ignition 1V Go to Step 2 Go to Step 3
"ON".
1
1. Lift the driving wheels and support them.  Go to Step 4 Go to Step 8
2. Turn the ignition "ON", and the engine "ON".
acceleration is the "NORMAL" mode and the D
range?
At the 2nd speed gear. 8-16 V Go to Step 7 Go to Step 8
4
terminal (3) and ground terminal (15 or 19) within
the specified value?
Disconnect the A/T 8 pin connector. 11-15Ω (at 20°C) Go to Step 9 Go to Step 10
Is the resistance between the solenoid S2
6
specified value?
7
Refer to
"Diagnostic
aids".
Replace the solenoid S2.  Go to Step 13 
10
1. Disconnect the A/T 8 pin connector. 11-15Ω (at 20°C) Go to Step 12 Go to Step 10
11
DTC P0758 (FLASHING CODE 32) SOLENOID 2 FAILURE (S2) (Cont’d)

again.
13 Go to Step 1
displayed?

PWM THROTTLE SIGNAL FAILURE (TH) (For TFR/S)
D07L200008
D07L100003
• When the throttle input duty ratio is detected less

than 1% or more than 99% for 2.0 seconds.
When the PWM signal of the engine throttle position
sensor located on the engine manifold (‘01TFR, For Contents of control:
Thailand) or accelerator pedal assembly (TFR/S) is At failure detection
supplied to the TCM via the ECM, the TCM judges the
• Throttle opening for line pressure control …
opening condition of the throttle
The shift point of th transmission is determined by this Throttle opening 100%
PWM throttle signal. • Throttle opening for shift control … Throttle
opening 0%
Fail-safe control:
The TCM controls fail-safe by detecting PWM throttle
signal (TH) failue.
Failure detection:

control items at faulure datection.
• Blinks “CHECK TRANS” lamp
Conditions of turning “CHECK TRANS” lamp
off:
Trurns “CHECK TRANS” lamp off when judged 0km/h
by output revolution sensor after throttle signal input
duty ration is detected more than 1% and less than
99%.
(however, uses 0km/h judgment by back-up vehicle
apeed at output rebolution gailure)
Reversion conditions from hail-safe:
At filure detection
• Immediately recovers when the throttle input duty
ratio is detected more than 1% and less than 99%.
At filure detection
• Recovers at the same time as the conditions of
Test description:
1. Check that the throttle input voltage is 4.4 to 4.6V.
2. At this test, check that as the throttle opens, the
voltage goes up and that the voltage reached 0.4 to
0.6V at the full open status.
6. Check the power supplu voltage (4.99-5.01V) of the
each throttle position sensors.
Diagnostic aids:

PWM THROTTLE SIGNAL FAILURE (TH) (For TFR/S)
1. Connect a analog voltmeter between the 4.4-4.6 V Go to Step 2 Go to Step 3
TCM 28 pin connector terminal (6) and TCM *
1 20 pin connector terminal (15 or 19).
2. Turn the ignition "ON".
Open the throttle fully. 0.4-0.6 V The problem is Go to Step 3
Is the voltage within the specified value? * intermittent.
2 Refer to
"Diagnostic
aids".
1. Turn the ignition "ON". 4.4-4.6 V Go to Step 4 Go to Step 6
2. Measure the voltage between the ECM 81 *
3 terminal (47) (TFR/S), or ECM 32 pin
connector terminal (14) and ground terminal
(33 or 49) ('01 TFR, for Thailand).
Open the throttle fully. 0.4-0.6 V Go to Step 5 Go to Step 6
4
Is the voltage within the specified value? *
pin connector terminal (6) and ECM 81 pin
connector terminal (26) (TFR/S), or ECM 32 pin
5 connector terminal (14) ('01 TFR, for Thailand).
Or TCM is faulty.
1. Disconnect the TPS connector. 4.99-5.01 V Go to Step 7 Go to Step 8
2. Connect a voltmeter between the TPS
connector terminal (C93-3) and (C93-1)
6 (TFR/S), or TPS connector terminal (B17-2)
and (B17-1), or (B18-3) and (B18-2) ('01
TFR, for Thailand).
Check the TPS connectors. If OK, replace the  Go to Step 9 
7 TPS.
Check the wiring harness between the TPS and  Go to Step 9 
ECM.
8 If OK, replace the ECM.

PWM THROTTLE SIGNAL FAILURE (TH) (For TFR/S) (Cont’d)
again.
9 Go to Step 1
displayed?
*Reference (Oscilloscope waveform)

(TFR/S)
('01 TFR, for Thailand)


ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND)(For UBS)
D07R200063
Circuit description: Reversion conditions from fail-safe:

When the signal of the engine throttle position sensor At failure detection
located on the accelerator pedal is supplied to the When the Vref input voltage is detected less than 5.55
transmission TCM, the TCM judges the opening V and more than 4.45 V.
condition of the throttle. When the Vgnd input voltage is detected less than 0.40
The shift point of the transmission is determined by this V and more than -0.40 V.
opening condition of the throttle.
At failure decision
Fail-safe control: • Recovers when judged 0km/h by output revolution
The TCM controls fail-safe by detecting analog throttle sensor after the Vref input voltage is detected less
signal (VREF, VGND) failure. than 5.55V and more than 4.45V.
(however, uses 0 km/h judgment by back-up
Failure detection: vehicle speed at output revolution failure)
• When the Vref input voltage is detected more than • Recovers when judged 0km/h by output revolution
5.55V or less than 4.45V. sensor after the Vgnd input voltage is detected less
• When the Vgnd input voltage is detected more than than 0.40V and more than -0.40V.
0.40V or less than -0.40V. (however, uses 0 km/h judgment by back-up
• When the failure criteria is continuously for 1.0 sec. vehicle speed at output revolution failure)
Contents of control: Test description:

At failure detection The following numbers correspond to the step numbers
• Judges throttle opening of linear sensor (Vth) as on the diagnostic chart.
Vref:5V, Vgnd:0V 1. Check the power supply voltage (4.75-5.25V) of
• Throttle learning control inhibit throttle position sensor.
• Up hill and down hill control inhibit Diagnostic aids:
At failure decision An intermittent may be caused by a poor connection,
Executes following items in addition to above rubbed through wire insulation or a wire broken inside
control items at failure detection. the insulation. Inspect related harness connector for
• Stores the failure information in failure-memory backed out terminals, improper mating, broken locks,
Conditions of turning “CHECK TRANS” lamp to wire connection and damaged harness.
off:
None

ANALOG THROTTLE SIGNAL FAILURE (VREF, VGND)(For UBS)
1. With the engine "OFF", turn the ignition 4.75-5.25 V The problem is Go to Step 2
"ON". intermittent.
Refer to
1 2. Connect a voltmeter between the TCM 28
"Diagnostic
pin connector terminal (19) and (28). aids".
Connect a voltmeter between the ECM 32 pin 4.75-5.25 V Go to Step 3 Go to Step 4
2 connector terminal (E1-4) and (E2-22).
3 ECM.
Check the ECM 32 pin connectors. If OK,  Go to Step 5 
4 replace the ECM.
1. After the repair is complete, use the scan tool  Begin in the System OK
again. Go to
5 Step 1
displayed?
WIRING DIAGRAM
D07R200064
WIRING DIAGRAM (Cont’d)

D07R200065

D07L200009

D07L200010

D07L200012

D07L200013
CONNECTOR LIST
B-11 E-29
(WHITE)
B-14 E-30
(BLACK)
B-17 E-31
B-30 E-32
(WHITE)
B-35 E-49
(WHITE)
C-63 H-4
(BLACK)
C-78 H-5
(GREEN)
C-79 H-7
(RHD)
E-1 H-7
(LHD)
E-2 H-8
(RHD)
CONNECTOR LIST (Cont’d)

H-8 H-42
(LHD)
(BLACK)
H-9 I-9
(RHD)
H-9 I-10
(LHD)
H-12
(RHD)
H-24
(RHD)
H-24
(LHD)
H-25
(LHD)
H-26
(RHD)
H-30
(NATURAL)
H-32
(BLACK)

B-23 C-92
B-24 C-93
B-39 C-96
C-41 E-51
C-44 E-52
C-56 E-53
C-57 E-54
C-58 E-55
C-78 H-4
(BLACK)
C-79 H-5
(BLACK)

H-6
(WHITE)
H-8
H-22
(GRAY)

B-14 E-20
B-17 E-29
B-18 E-30
B-30 E-31
B-35 E-32
C-63 E-49
C-78 H-5
(GRAY)
C-79 H-6
(BLUE)
E-1 H-7
E-2 H-9

H-10
H-30
(BLACK)
I-9
I-10
I-11
TROUBLESHOOTING CHART
Number are arranged in order of probability.
Parform inspections starting with number one and working up.
MANUAL SHIFTING TEST

NOTE:
With this test, it can be determined whether the trouble
lies within the electrical circuit or is a mechanical
problem in the transmission.
1. Disconnect TCM connector
With the engine OFF, disconnect the TCM connector.
2. Inspect manual driving operation
Check that the shift and gear positions correspond with
the table.
If the “L”, “2” and “D” range gear positions are difficult to
distinguish, do perform the following road test.
While driving, shift through the “L”, “2” and “D” renges.
Check that the gear change corresponds to the gear
position.
If any abnormality is found in the above test, do perform
the stall, time lag or gear change tests.
F07RY00024
3. Connect TCM connector

With the engine off, connect the TCM connector.
STALL TEST
The object of this test is to check the overall performance
of the transmission and engine by measuring the maximum
engine speeds at the “D” and “R” ranges.
NOTE:
(1) Perform the test at normal operation fluid
temperature (50 – 80º
ºC or 122-176 ºF).
(2) Do not continuously run this test longer than 5
seconds.
MEASURE STALL SPEED

1. Chock the four wheels.
2. Mount an engine tachometer.
3. Fully apply the parking brake.
4. Step down strongly on the brake pedal with your left
foot.
5. Start the engine.
6. Turn off the A/C.
7. Shift into the “D” range. Step all the way down on the
accelerator pedal with your right foot. Quickly read the
highest engine rpm.
Stall speed: 2450±
±150 rpm (UBS)
: 2270±
±150 rpm (TFR/S)
: 2415±
±150 rpm (’01 TFR)
8. Perform the same test in the “R” range.
EVALUATION
1. If the engine speed is the same for both ranges but
lower than the specified value:
・Engine output is insufficient.
・Stator one-way clutch is not operating properly.
NOTE:
If more than 600 rpm below the specified value, the
torque converter could be faulty.
2. If the stall speed is “D” range is higher than specified:
・Line pressure too low
・Forward clutch slipping
・No.2 one-way clutch not operating properly
3. If the stall speed in “R” range is higher than specified:
・Direct clutch slipping
・No.3 brake slipping
4. If the stall speed in the “R” and “D” ranges are higher
than specified:
F07RY00002
・Improper fluid level
TIME LAG TEST

If the shift lever is shifted while the engine is idling, there
will be a certain time elapse or lag before the shock can be
felt. This is used for checking the condition of the forward
clutch, direct clutch, No.3 brake, and No.2 one-way clutch.
NOTE:
temperature (50 – 80º
ºC or 122 – 176º
ºF)
(2) Be sure to allow one minute interval between
tests.
(3) Make three measurements and take the average
value.
MEASURE TIME LAG

Check idling speed (A/C OFF).
3. Shift the shift lever from “N” to “D” range. Using a stop
watch, measure the time it takes from sihfting the lever
until the shock is felt.
Time lag: Less than 0.7 seconds
4. In same manner, measure the time lag for “N” → “R”.
EVALUATION
1. If “N” → “D” time lag is longer than specified:
・Forward clutch malfunction
2. If “N” → “R” time lag is longer than specified:
・Direct clutch malfunction
・No.3 brake malfunction
3. If both time lag is longer than specified:
F07RY00003
HYDRAULIC TEST
PREPARATION
1. Warm up the transmission fluid.
2. Remove the transmission case test plug and mount the
hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE:
Perform the test at normal operation fluid temperature
(50 – 80º
ºC or 122 – 176º
ºF).
MEASURE LINE PRESSURE

1. Fully apply the parking brake and chock the four
wheels.
2. Start the engine and check idling rpm.
3. Shift into “D” range, step down strongly on the brake
pedal with your left foot and, while manipulating the
accelerator pedal with the right foot, measure the line
pressures at the engine speeds specified in the table.
4. In the same manner, perform the test in “R” range.
2
Engine Line pressure kPa (kg/cm /psi)
speed “D” range “R” range
358 – 417 588 – 686
Idling (3.6 – 4.3/ (6.0 – 7.0/
51 – 61) 85 – 100)
1,176 – 1,323 1,607 – 1,940
Stall (12.0 – 13.5/ (16.4 – 19.8/
171 – 192) 233 – 282)
EVALUATION
1. If the measured values at all ranges are higher than
specified:
・Pressure control solenoid defective
・Primary regulator valve defective
2. If the measured values at all ranges are lower than
specified:
・Oil pump defective
・Pressure control solenoid defective
3. If pressure is low in “D” range only:
・“D” range circuit fluid leakage
4. If pressure is low in “R” range only:
・“R” range circuit fluid leakage
F07RY00004
ROAD TEST
NOTE:
(50 – 80º
ºC or 122 – 176º
ºF).
“D” RANGE TEST IN “NORMAL”, AND “POWER”

PATTERN RANGES
Shift into the “D” range and hold the accelerator pedal
255RT004 constant at the 50% and 100% throttle valve opening
positions.
Push in one of the pattern selector buttons and check the
following:
1. 1-2, 2-3, 3-OD and lock-up, up-shifts should take place,
and shift points should conform to those shown in the
automatic shift diagram.
NOTE:
Drive the vehicle on level ground.
EVALUATION
(1) If there is no 1→2 up-shift:
・Solenoid S2 is stuck
・1-2 shift valve is stuck
(3) If there is no 3→OD up-shift (throttle valve opening
1/2):
・3-OD shift valve is stuck
(4) If the shift point is defective:
Refer to “TROUBLESHOOTING CHART” in this
section.
(5) If the lock-up is defective:
section.
2. In the same manner, check the shock and slip at the 1
F07R200019 →2, 2→3 and 3→OD up-shifts.
EVALUATION
If the shock is excessive:
section.
F07RY00006
3. Run at “D” range lock-up or OD gear and check for

abnormal noise and vibration.
NOTE:
The check for the cause of abnormal noise and
vibration must be made with extreme care as it could
also be due to loss of balance in the propeller shaft,
differential, the torque converter, etc. or insufficient
bending, rigidity, etc. in the power train.
F07RY00007
4. While running in “D” range, 2nd, 3rd gears and OD,

check to see that the possible kick-down vehicle speed
limits for 2→1, 3→1, 3→2, OD→3 and OD→2 kick-
downs conform to those indicated on the automatic shift
diagram.
5. Check for abnormal shock and slip at kick-down.
6. While running in “D” range, OD gear or “lock-up”, shift
to “2” and “L” ranges and check the engine braking
effect at each of these ranges.
7. Also check to see that downshift is made from 3→2 or
from OD to 3 and then to 2 immediately and that 2→1
downshift point is within the limits shown in the diagram
when tested by releasing the accelerator pedal and
shifting into position of “L” while driving in the third gear
or in overdrive.
F07R200020
EVALUATION
(1) If there is no engine braking effect in the “2” range:
・Second coast (No.1) brake is defective.
(2) If there is no engine braking effect in the “L” range:
・First and reverse (No.3) brake is defective.
F07RY00009
(3) Also check to see that downshift is made from 3→2 or

from OD to 3 and then to 2 immediately and that 2→1
downshift point is within the limits shown in the
diagram when tested by releasing the accelerator
pedal and shifting into “L” position while driving in the
third gear or in overdrive.
F07RY00010
“2” RANGE TEST

Shift into “2” range and, while driving with the accelerator
pedal held constantly at the specified point (throttle valve
opening 50% and 100%), push in one of the pattern
selectors (only for 4×4) and check on the following points.
1. At each of the above throttle openings, check to see
that the 1→ 2 up-shift takes place and that the shift
points conform to those shown on the automatic shift
diagram.
NOTE:
There is no OD and no lock-up in the “2” range.
2. While running in the “2” range and 2nd gear, release
the accelerator pedal and check the engine’s braking
effect.
3. Check for 2 → 1 down-shift and abnormal noise at
acceleration and deceleration, and for shock at upshift
and down-shift.
F07R200021
F07RY00012
“L” RANGE TEST

1. While running above 80 km/h (50 mph) in the “D” range,
release your foot from the accelerator pedal and shift
into the “L” range.
Then check to see that the 2→1 down-shift occurs at
the specified point shown on the automatic shift
diagram.
F07R200018
2. While running in the “L” range, check to see that there

is no up-shift to 2nd gear.
3. While running in the “L” range, release the accelerator
pedal and check the engine braking effect.
4. Check for abnormal noise during acceleration and
deceleration.
F07RY00014
“R” RANGE TEST

Shift into the “R” range and, while starting at full throttle,
check for slipping.
“P” RANGE TEST

Stop the vehicle on a grade (more than 9%) and after
shifting into the “P” range, release the parking brake.
Then check to see that the parking lock pawl holds the
F07RY00015 vehicle in place.
SHIFT POINT CHART AND LOCK-UP POINT CHART

SHIFT POINT CHART (UBS)
(H2, H4)
(REAR AXLE RATIO: 4.300)
(RADIUS OF TIRE: 0.363m)
“NORMAL” mode
Up shift km/h
Range Throttle Opening 1→2 2→3 3→4
Fully opened 39 – 45 78 – 84 128 – 134
D
Half throttle 22 – 28 48 – 54 89 – 95
Fully opened 39 – 45 89 – 95 ―
2
Half throttle 22 – 28 89 – 95 ―
Down shift km/h

Range Throttle Opening 1←2 2←3 3←4
Fully opened 30 – 36 65 – 71 115 – 121
D Half throttle 9 – 15 27 – 33 64 – 70
Fully closed 9 – 15 22 – 28 37 – 43
Fully opened 30 – 36 85 – 91 ―
2 Half throttle 9 – 15 85 – 91 ―
Fully closed 9 – 15 85 – 91 ―
Fully opened 43 – 49 85 – 91 ―
L Half throttle 43 – 49 85 – 91 ―
Fully closed 43 – 49 85 – 91 ―
“POWER” mode
Up shift km/h
Fully opened 39 – 45 78 – 84 128 – 134
D
Half throttle 29 – 35 58 – 64 89 – 95
Fully opened 39 – 45 89 – 95 ―
2
Half throttle 22 – 28 89 – 95 ―
Down shift km/h

Fully opened 30 – 36 65 – 71 115 – 121
D Half throttle 11 – 17 45 – 51 74 – 80
Fully closed 9 – 15 22 – 28 37 – 43
Fully opened 30 – 36 85 – 91 ―
2 Half throttle 9 – 15 85 – 91 ―
Fully closed 9 – 15 85 – 91 ―
Fully opened 43 – 49 85 – 91 ―
L Half throttle 43 – 49 85 – 91 ―
Fully closed 43 – 49 85 – 91 ―
LOCK-UP POINT CHART (UBS)

(H2, H4)
km/h
Throttle Opening: 20 %
Range A/T Mode Lock-up ON Lock-up OFF
3rd 4th 3rd 4th
NORMAL 47 – 53 62 – 68 45 – 51 62 – 68
D
POWER 47 – 53 66 – 72 45 – 51 62 – 68
SHIFT POINT CHART AND LOCK-UP POINT CHART (Cont’d)

SHIFT POINT CHART (TFR/S)
(H2, H4)
“NORMAL” mode
Up shift km/h
Fully opened 34 – 40 71 – 77 112 – 118
D
Half throttle 24 – 30 44 – 50 75 – 81
Fully opened 34 – 40 76 – 82 ―
2
Half throttle 28 – 34 76 – 82 ―
Down shift km/h

Fully opened 26 – 32 57 – 63 97 – 103
D Half throttle 9 – 15 27 – 33 49 – 55
Fully closed 5 – 11 13 – 19 26 – 32
Fully opened 26 – 32 74 – 80 ―
2 Half throttle 17 – 23 74 – 80 ―
Fully closed 5 – 11 74 – 80 ―
Fully opened 38 – 44 74 – 80 ―
L Half throttle 38 – 44 74 – 80 ―
Fully closed 38 – 44 74 – 80 ―
“POWER” mode
Up shift km/h
Fully opened 34 – 40 71 – 77 112 – 118
D
Half throttle 28 – 34 52 – 58 79 – 85
Fully opened 34 – 40 76 – 82 ―
2
Half throttle 28 – 34 76 – 82 ―
Down shift km/h

Fully opened 26 – 32 57 – 63 97 – 103
D Half throttle 17 – 23 42 – 48 66 – 72
Fully closed 5 – 11 13 – 19 26 – 32
Fully opened 26 – 32 74 – 80 ―
2 Half throttle 17 – 23 74 – 80 ―
Fully closed 5 – 11 74 – 80 ―
Fully opened 38 – 44 74 – 80 ―
L Half throttle 38 – 44 74 – 80 ―
Fully closed 38 – 44 74 – 80 ―
LOCK-UP POINT CHART (TFR/S)

(H2, H4)
km/h
2nd 3rd 4th 2nd 3rd 4th
NORMAL 32 – 38 46 – 52 56 – 62 26 – 32 42 – 48 54 – 60
D
POWER 32 – 38 46 – 52 56 – 62 26 – 32 42 – 48 54 – 60
SHIFT POINT CHART AND LOCK-UP POINT CHART (Cont’d)

SHIFT POINT CHART (’01 TFR For Thailand)
“NORMAL” mode
Up shift km/h
Fully opened 30 – 36 67 – 73 105 – 111
D
Half throttle 15 – 21 45 – 51 70 – 76
Fully opened 30 – 36 76 – 82 ―
2
Half throttle 22 – 28 76 – 82 ―
Down shift km/h

Fully opened 23 – 29 45 – 51 90 – 96
D Half throttle 9 – 15 31 – 37 47 – 53
Fully closed 6 – 12 13 – 19 27 – 33
Fully opened 24 – 30 73 – 79 ―
2 Half throttle 13 – 19 73 – 79 ―
Fully closed 6 – 12 73 – 79 ―
Fully opened 47 – 53 73 – 79 ―
L Half throttle 47 – 53 73 – 79 ―
Fully closed 47 – 53 73 – 79 ―
“POWER” mode
Up shift km/h
Fully opened 30 – 36 67 – 73 105 – 111
D
Half throttle 22 – 28 51 – 57 80 – 86
Fully opened 30 – 36 76 – 82 ―
2
Half throttle 22 – 28 76 – 82 ―
Down shift km/h

Fully opened 24 – 30 49 – 55 93 – 99
D Half throttle 13 – 19 39 – 45 67 – 73
Fully closed 6 – 12 13 – 19 27 – 33
Fully opened 24 – 30 73 – 79 ―
2 Half throttle 13 – 19 73 – 79 ―
Fully closed 6 – 12 73 – 79 ―
Fully opened 47 – 53 73 – 79 ―
L Half throttle 47 – 53 73 – 79 ―
Fully closed 47 – 53 73 – 79 ―
LOCK-UP POINT CHART (’01 TFR For Thailand)

km/h
nd rd th nd rd th
2 3 4 2 3 4
NORMAL 28 – 34 43 – 49 58 – 64 25 – 31 40 – 46 55 – 61
D
POWER 28 – 34 43 – 49 56 – 64 25 – 31 40 – 46 55 – 61
TCM VOLTAGE CHECK

TCM voltage check is done to check for transmission and
transmission control module (TCM) problems which cannot
be detected by self-diagnosis.
Additionally, it serves as a back-up check for self-
diagnosis.
Measure the voltage drop and make a continuity test for
each of the sensors, solenoids, and switches.
If the voltage is within the specified range and continuity
exists, that particular area of the TCM and automatic
transmission assembly is normal.
If voltage deviation or lack of continuity is discovered,
disconnect the applicable parts and check each of them
individually.
This will allow you to determine the trouble location (TCM,
automatic transmission unit, or another area of the
vehicle).
Inspection Tool
Use a circuit tester to measure voltage and circuit
continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.
NOTE:
TCM is located in the behind instrument panel of the
driver’s compartment.
826RY00017 TCM Voltage Check Procedure
1. Remove the TCM.
2. Turn the ignition switch on. Do not start the engine.
3. Measure the voltage at the terminal.
Refer the following table for the specified voltage
ranges.
TCM STANDARD VOLTAGE
Terminal
Check circuit Measuring condition Voltage (V)
+ –
Throttle fully closed (Idling) 0.25 ∼ 0.45
Throttle position sensor C79-6 C79-28
(UBS) Throttle fully opened (WOT) 3.47 ∼ 4.56
C79-19 C79-28 Key switch ON 4.75 ∼ 5.25
Throttle position sensor C78-15 Throttle fully closed (Idling) (*1) 4.4 ∼ 4.6
C79-6
(TFR/S) or –19 Throttle fully opened (WOT) (*1) 0.4 ∼ 0.6
Output revolution sensor C79-4 C79-16 Engine idling in gear 0∼3
Input revolution sensor C79-5 C79-17 Engine idling 0∼3
C78-15 Vehicle speed 1 ∼ 2 km/h (Pulse Less than 1.4
Speed meter sensor C79-7
or –19 check) ⇔ Greater than 9
C78-15 Depress brake 7 ∼ 16
Brake switch C78-18
or –19 Release brake Less than 1
O/D switch position ON
Less than 1
C78-15 (O/D OFF lamp OFF)
O/D switch C79-3
or –19
O/D switch position OFF
7 ∼ 16
(O/D OFF lamp ON)
Neutral start switch C78-15 Selector “P” range 7 ∼ 16
C79-2
(P) or –19
Selector all ranges except “P” Less than 1
Neutral start switch C78-15 Selector “R” range 7 ∼ 16
C79-1
® or –19
Selector all ranges except “R” Less than 1
Neutral start switch C78-15 Selector “N” range 7 ∼ 16
C79-9
(N) or –19
Selector all ranges except “N” Less than 1
Neutral start switch C78-15 Selector “D” range 7 ∼ 16
C79-8
(D) or –19
Selector all ranges except “D” Less than 1
Neutral start switch C78-15 Selector “2” range 7 ∼ 16
C79-21
(2) or –19
Selector all ranges except “2” Less than 1
Neutral start switch C78-15 Selector “L” range 7 ∼ 16
C79-20
(L) or -19
Selector all ranges except “L” Less than 1
C78-15 Engine idling
Engine revolution signal C79-15 Less than 1.4 ⇔ 9 ∼ 16
or -19
C78-15 Self-diagnosis ON
Diagnosis terminal C79-24 0 ∼ 1.5
or -19
C78-15 Power pattern switch OFF (NORMAL) 8 ∼ 16
Power pattern switch C79-23
or -19
Power pattern switch ON (POWER) Less than 1.4
C78-15 Switch OFF 8 ∼ 16
Winter select switch C79-13
or -19
Switch ON Less than 1.4
C78-15 ―
Electrical source (Battery) C78-13 9 ∼ 16
or -19
TCM STANDARD VOLTAGE (Cont’d)
Terminal
+ –
C78-15 Key switch ON
Electrical source (Ignition) C78-20 9 ∼ 16
or -19
Oil temperature warning C78-15 Oil temperature warning lamp ON Less than 1
C79-11
lamp or -19 Oil temperature warning lamp OFF 8 ∼ 16
C78-15 “CHECK TRANS” lamp ON Less than 1
“CHECK TRANS lamp” C79-10
or -19 “CHECK TRANS” lamp OFF 8 ∼ 16
C78-15 Power lamp ON Less than 1
Power lamp (UBS) C79-22
or -19 Power lamp OFF 8 ∼ 16
C78-15 Winter lamp ON Less than 1
Winter lamp (UBS) C79-12
or -19 Winter lamp OFF 8 ∼ 16
C78-15 OFF (3rd or O/D) Less than 1
Solenoid S1 C78-4
or -19 ON (1st or 2nd) 8 ∼ 16
C78-15 OFF (1st or O/D) Less than 1
Solenoid S2 C78-3
or -19 ON (2nd or 3rd) 8 ∼ 16
C78-15 OFF (Lock up OFF) Less than 1
Lock up solenoid SL C78-12
or -19 ON (Lock up ON) 8 ∼ 16
At throttle pressure changing Less than
Pressure control solenoid C78-11 C78-8
1 ⇔ 8-16
ATF temperature 20° 4.70
Oil temperature sensor C79-18 C79-27
ATF temperature 80°C 3.65
Tech 2 diagnosis terminal C78-15 On diagnosis communication 0-1.5 ⇔
C78-6
(J1850) or -19 6.25-8.0
Throttle position sensor C78-15 Key switch ON
C79-19 -0.1 ∼ 0.1
(ground) (UBS) or -19
*1: Reference (Oscilloscope waveform)
(TFR/S) (’01 TFR for Thailand)

ON-VEHICLE SERVICE
UBS TRANSIMISSION FLUID LEVEL AND
CONDITION
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from "P" to "L", then return to position "P".
Check to see If the level of fluid comes to "HOT" range of
about 80°C (176°F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in "HOT" range.
Inspection of fluid condition
If the ATF is black or smells burnt, replace it.
242R200004
TF ATF REPLACEMENT
NOTE:
Do not overfill.
1. Remove the drain plug from oil pan and drain the fluid.
2. Reinstall the drain plug securely.
Torque: 19 N･
･m (1.9 kg･
･m/14 Ib･
･ft)
3. With the engine OFF, add new fluid through the filler
tube.
5.2 liter (UBS and TFR/S)
242R200005 Drain and refill
4.5 liter (’01 TFR)
8.7 liter (UBS and TFR/S)
Dry fill
8 liter (’01 TFR)
Fluid BESCO ATF Ⅲ
4. Start the engine and shift the selector into all position
from "P" through "L", and then shift into "P".
5. With the engine idling, check the fluid level. Add fluid
up to the "COLD" level on the dipstick.
6. The ATF level must be checked again for correct level
with the "HOT" level.
NOTE:
To prevent fluid leaks, the drain plug gasket must be
replaced each time this plug is removed.
NEUTRAL START SWITCH INSPECTION

Inspection
With a circuit tester, make a continuity test on the neutral
start switch with the moving piece set in each position.
Terminal
1 4 3 5 2 6 8 7 9
Position
P ○ ○ ○ ○
R ○ ○
249RY00010 N ○ ○ ○ ○
D ○ ○
2 ○ ○
L ○ ○
○ ○ Continuity
Removal
Preparation:
Disconnect negative (-) battery cable.
1. Remove rear sound cover (UBS).
2. Remove the rear side ATF cooler pipe from the
transmission elbow.
3. Disconnect neutral start switch connector.
4. Unstake the lock washer, and then remove the shaft
nut.
5. Remove the neutral start switch.
Installation
To install, follow the removal steps in the reverse order,
noting the following points;
Torque:
Nut – 7 N･
･m (0.7 kg･
･m/61 Ib･
･in)
Bolt – 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
Adjustment
1. Loosen the neutral start switch bolt and set the shift
selector to the “N” range.
2. Align the groove and neutral basic line.
3. Hold in position and tighten the bolt.
Torque: 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
249RY00008
BRAKE SIGNAL INSPECTION

Check that the brake light comes on when the brake pedal
is depressed.
310RW020
VEHICLE SPEED SENSOR INSPECTION

1. Connect the vehicle speed sensor connector terminal
(1) to the battery ( +) terminal and terminal (2) to the
battery (-) terminal.
2. Connect a resistance of 1.3k ohm to 5k ohm (1.4W or
more) between terminals (1) and (3).
NOTE:
Be extremely careful not to connect the battery (+)
F07RY00017
terminal to the terminal (3).
This may damage the vehicle speed sensor.
3. Rotate the shaft of the vehicle speed sensor slowly and
measure the voltage at both ends with a digital tester.
The voltage, with one rotation of shaft, fluctuates four
times in the following range: 10 to 14V ⇔ 2V or less.
Replace the sensor when the result of inspection is
found abnormal.
INPUT AND OUTPUT REVOLUTION

SENSOR INSPECTION
1. Disconnect the input and output revolution sensor
connector.
2. Use an ohmmeter to measure the resistance between
terminals 1 and 2.
Standard resistance
Input revolution sensor: 387 – 473 Ω (at 20℃
℃, 4×
×2)
F07RY00018 560 – 680 Ω (at 20℃
℃, 4×
×4)
Output revolution sensor: 560 – 680 Ω (at 20℃
℃)
UBS PATTERN SELECT SWITCH INSPECTION

Inspect that there is continuity between each terminals.
F07RY00019
TF
F07L100005
UBS OVERDRIVE SWITCH INSPECTION

225R200003
TF
225L200001
SOLENOID INSPECTION
1. Resistance check
・ Using an ohmmeter, check the resistance between
each terminals (S1/S2/SL) and body.
Solenoid S1, S2 and lock-up solenoid resistance:
11 – 15 Ω (at 20℃
℃)
(Reference) 12 – 16 Ω (at 40℃
℃)
220L100001 each terminals (STH) and (STHG).
Pressure control solenoid resistance:
5 – 5.6 Ω (at 20℃
℃)
(Reference) 5.4 – 6.1 Ω (at 40℃
℃)
NOTE:
If the pressure control solenoid resistance is not
within specification, replace the valve body
assembly.
2. Operation check
Check the solenoid operation by blowing into an oil
hole as shown in the figure.
Solenoid S1 and S2 (Normal close type)
When battery terminal is
No air leaks
disconnected
Air passes through
connected
244RX00001
Lock-up solenoid S3 (Normal open type)

Air passes through
disconnected
No air leaks
connected
244RY00005
ATF TEMPERATURE SENSOR

INSPECTION
1. Disconnect the front side ATF cooler pipe from the
elbow and remove the elbow.
2. Remove the ATF temperature sensor from the
transmission case.
3. Place the ATF temperature sensor in a container of
ATF.
249L100001
4. Measure the resistance between each terminals.

Resistance: 0.5 – 30 kΩ
Ω (at 0℃
℃ - 120℃
℃)
5. If either of the measured values exceeds the specified,
replace the ATF temperature sensor.
Torque: 15 N･
･m (1.5 kg･
･m/11 Ib･
･ft)
242RW013
(LHD) THROTTLE POSITION SENSOR

INSPECTION (UBS and TFR/S)
1. Turn the starter switch to the “ON” position.
2. Measure the voltage between throttle position sensor
connector terminals 2 (output) and 1 (ground).
NOTE:
・ Do not remove the sensor connector.
・ Make sure that power source (4.75 – 5.25V) is
measured between terminals 1 and 3 before
measurement at step 2.
101R200007 Standard voltage:
(RHD) Idling − 0.25 – 0.45V
WOT − 3.74 – 4.56V
101L200001
THROTTLE POSITION SENSOR

INSPECTION (’01 TFR)
2. Measure the voltage between TPS1 connector
terminals (A) (output) and (C) (ground), and TPS2
connector terminals (D) (output) and (E) (ground).
NOTE:
・ Make sure that power source (5.0± ±0.01V) is
measured between TPS1 connector terminals (B)
and (C), and TPS2 connector terminals (F) and (E)
before measurement at step 2.
Standard voltage:
TPS1 TPS2
Idling 0.55−0.65 V 0.2−0.4 V
WOT 3.1−3.3 V 1.5−1.6 V

035L100001
SELECTOR LEVER
Inspection
1. Make sure that when the selector lever is shifted from
"P" to "L", a "clicking" can be felt at each shift position.
Make sure that the gear corresponds to that of the
position plate indicator.
2. Check to see if the selector lever can be shifted as
shown.
256RY00001
REMOVAL
Preparation:
1. Transfer Control Lever Knob (4×4)
2. Front Console
Disconnect wiring harness connectors.
UBS 3. Selector Lever Assembly
1. Disconnect shift lock cable from the selector lever
assembly side (UBS).
2. Disconnect wiring harness connectors.
256RW012
3. Disconnect shift control rod from the selector lever

assembly side.
256RW013
’01 TFR
220L200001
INSTALLATION
Adjustment of select lever and control rod
1. Place the vehicle on a level surface.
NOTE:
If the vehicle is not on a level surface, the shift
select cable set position will vary with the
256RW014 movement of the engine. To prevent possible
’01 TFR misadjustment of the cable, the vehicle must be
placed on a level surface.
2. Install the shift control rod (1) to the transfmission
select lever (2), and then place the lever in the "N"
position.
3. Set select lever in the "N" position.
4. Push selector lever forward and secure it (using a
rubber band (3), etc.) so that pin comes into contact
with the wall of detent plate.
256L200001
5. Install the shift control rod (1) to the selector lever arm
(4).
Nut torque: 27 N･
･m (2.8 kg･
･m/20 Ib･
･ft)
NOTE:
Do not apply oil to threaded portions.
6. (’01 TFR)
a. Turn nut (5) until it butts against boss (6).
b. Tighten nut (7) to lock boss while keeping nut (5)
stationary with a tool.
Nut torque: 27 N･
･m (2.8 kg･
･m/20 Ib･
･ft)
c. Attach clip (8) and fix it with nut (9).
Nut torque: 7 N･
･m (70 kg･
･cm/61 Ib･
･in)
7. After adjustment, operate select lever on a trial basis to
makes sure of its smooth operation and no abnormal
indication in each position.
Adjustment of shift lock cable (UBS)

1. Set ignition key in "LOCK" position and selector lever in
"P" position.
2. Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 1-2mm between rod
on steering lock side and stopper
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to put off slack of
256RW015
inner cable.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5mm (0.2in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Lock nut torque: 3.7 N･
･m (38 kg･
･cm/33 Ib･
･in)
NOTE:
Clean the rod threads and do not apply oil to the
threaded portions.
3. Make sure of proper operation of shift lock through
checks as follows:
a. Selector lever shall not be moved out of "P" position
with ingition key in "Lock" position.
b. Selector lever can be moved out of "P" position with
ignition key in "ON" position only when brake pedal is
depressed.
c. Ignition key can be turned to "LOCK" position only
when selector lever is in "P" position (key can be
pulled out).
If (a) and (c) fail, readjust cable. If (b) fails, readjust
connector wiring and brake pedal switch.
UBS (RHD) TRANSMISSION CONTROL MODULE

(TCM)
REMOVAL
Preparation:
1. Disconnect the TCM harness connectors.
2. Remove fixing nuts (3 pieces) and TCM from the
bracket.
NOTE:
The TCM is fitted under instrument panel of the
driver’s compartment by means of two stud bolts.
INSTALLATION
To install, follow the removal steps in reverse order.
826R200033
TF
826L100002
SHIFT SOLENOID AND LOCK-UP

SOLENOID
REMOVAL
Preparation:
・ Disconnect negative (-) battery cable.
・ Remove the rear sound cover. (UBS)
・ Drain the fluid.
249RY00011
Refer to "ATF REPLACEMENT" in this section.
1. Remove the nineteen bolts and oil pan.
2. Remove the oil strainer assembly.
3. Disconnect the solenoid wiring connectors from the
shift solenoid S1(1), S2(2) and lock-up solenoid (3).
4. Remove each retaining bolts and solenoids.
INSTALLATION
To install, follow the removal steps in reverse order noting
249RY00012
the following point;
Torque:
Solenoid S1, S2 bolt − 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
Lock-up solenoid bolt − 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID
244RY00009
REMOVAL
Preparation:
・ Remove the rear sound cover. (UBS)
・ Drain the fluid.
Refer to "ATF REPLACEMENT" in this section.
2. Remove the oil strainer assembly.
solenoids.
4. Remove the twenty bolts from the valve body.
5. Remove the valve body assembly and pressure control
solenoid.
・ When removing valve body assembly from the
transmission case, loosen the solenoid clamp bolt
244RY00003
and remove the pressure control solenoid from the
upper valve body assembly.
Also disconnect the harness connector from the
pressure control solenoid.
NOTE:
1. Two or more persons are required for removal
and installation of the valve body assembly and
pressure control solenoid.
2. The check valve assembly (1) and the C0
accumulator piston springs (2) will fall from the
transmission case during removal of valve body
assembly.
Protect these parts from damage.
The B0 (3), C2 (4), and B2 (5) accumulator piston
and springs may also fall free and must be
244RY00018
protected.
244RY00006
INSTALLATION
1. Reinstall the parts removed with the valve body
assembly to their assigned positions in the
transmission case (check valve assembly, C0
accumulator pistons, etc). Install the valve body
assembly to the transmission case.
Refer to “REASSEMBLY OF MAJOR COMPONENTS
(2).”
2. Solenoid clamp bolt
Torque : 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
3. Valve body fixing bolts
Each bolt location and length (mm) is indicated in the
figure.
Torque : 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
4. Oil strainer fixing bolts
Torque : 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200078
5. Oil pan fixing bolts
Torque : 7.4 N･
･m (0.75 kg･
･m/65 Ib･
･in)
REAR OIL SEAL (ADAPTER HOUSING, 4

×4)
REMOVAL
1. Remove the front and rear propeller shaft assembly
form the transfer case.
2. Remove the transfer case assembly from the
transmission case.
Refer to Section 4 “DRIVELINE/AXLE”.
3. Using a screwdriver, remove the rear oil seal.
INSTALLATION
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the
adapter housing.
Oil seal installer : 5-8840-2282-0
3. Install the transfer case assembly.
4. Install the front and rear propeller shaft assembly.
Torque:
240RY00003
Flange bolt : 63 N･
･m (6.4 kg･
･m/46 Ib･
･ft)
Center bearing retainer bolt
: 69 N･
･m (7.0 kg･
･m/51 Ib･
･ft)
REAR OIL SEAL (EXTENSION HOUSING,

4×
×2)
REMOVAL
1. Remove the rear propeller shaft assembly.
INSTALLATION
extension housing.
3. Install the rear propeller shaft.
Torque:
･m (6.4 kg･
･m/46 Ib･
･in)
249L100005
: 69 N･
･m (7.0 kg･
･m/51 Ib･
･ft)
TRANSMISSION REMOVAL AND INSTALLATION (UBS)
240R200031
Removal Steps
1. Transfer protector 11. Under cover and flex plate-torque
2. Rear sound cover converter bolt
3. Front sound cover 12. Rear mounting nut
4. Rear propeller shaft 13. 3rd crossmember
5. Front propeller shaft 14. Oil level gauge and tube
6. Exhaust pipe 15. Starter
7. Harness connector 16. Breather hose
8. Front console, selector lever assembly, 17. Engine-transmission bolt
and transfer control lever 18. Transmission assembly
9. Transfer case assembly
Installation Steps
10. ATF cooler pipe and clamp
To install, follow the removal steps in reverse
order.
REMOVAL
Preparation:
・ Remove engine hood.
1. Transfer protector
2. Rear sound cover
3. Front sound cover
4. Rear propeller shaft
5. Front propeller shaft
NOTE:
Apply alignment marks on the flange at both front
and rear sides.
6. Exhaust pipe
・ Remove the 2nd front exhaust pipe from the 1st front
exhaust pipe and exhaust silencer.
7. Harness connector
・ Disconnect the engine harness connectors from the
transmission side.
8. Front console, selector lever assembly, and
transfer control lever
・ Disconnect the transfer control lever knob.
・ Remove the front console.
・ Disconnect the harness connector.
・ Remove the transfer control lever.
・ Remove the selector lever assembly.
・ Disconnect the shift control rod from the selector
lever assembly.
9. Transfer case assembly

・ Disconnect the breather hose from the transfer case.
・ Remove the transfer case assembly from the
transmission.
・ Disconnect two ATF cooler pipes from A/T side.
・ Remove oil pipe clamp from torque converter housing
side.
・ Loosen oil pipe clamp bolt at engine mount side.
253RY00001
11. Under cover and flex plate-torque converter bolt

・ Remove the under cover.
・ Turn the crankshaft to gain access to each bolt.
Remove the six torque coverter fixing bolts.
NOTE:
New fixing bolts should be replaced for
reassembly.
240RY00026
12. Rear mounting nut

・ Support transmission with a jack.
・ Remove two rear mounting nuts from the 3rd
crossmember.
13. 3rd crossmember
022RY00001
14. Oil level gauge and tube

15. Starter
・ Remove the mounting bolts, and pull the starter
toward the front of the vehicle.
Lay the starter alongside the engine.
16. Breather hose
17. Engine-transmission bolt
・ Remove engine-transmission fixing bolts.
・ Disconnect the breather hose from the breather hose
2 way.
18. Transmission assembly

NOTE:
Keep the oil pan positioned down.
Be careful not to let the torque converter slide out.
INSTALLATION
To install, follow the removal steps in reverse order, noting
1. Torque
Rear mounting to 3rd
50 N･m (5.1 kg･m/37 Ib･ft)
crossmember
Torque converter bolt 29 N･m (3.0 kg･m/22 Ib･ft)
ATF cooler pipe to
44 N･m (4.5 kg･m/33 Ib･ft)
transmission
Exhaust pipe flange to
43 N･m (4.4 kg･m/32 Ib･ft)
flange
3rd crossmember to flame 76 N･m (7.8 kg･m/56 Ib･ft)
Front propeller shaft bolt 63 N･m (6.4 kg･m/46 Ib･ft)
Rear propeller shaft bolt 63 N･m (6.4 kg･m/46 Ib･ft)
Under cover bolt 6 N･m (0.6 kg･m/52 Ib･in)
Transfer protector 37 N･m (3.8 kg･m/27 Ib･ft)
Engine-Transmission Bolt Torque (UBS)
225R200006
Transmission-Transfer Case Bolt Torque (Reference)
260RY00001
TRANSMISSION REMOVAL AND INSTALLATION (TFR/S)
240L200001
Removal Steps
1. Center console, rear console, select 9. Rear mounting nut
lever assembly, and transfer control 10. 3rd crossmember
lever (4×4) 11. Oil level gauge and tube
2. Transfer protector (4×4) 12. Starter
3. Rear propeller shaft 13. Breather hose
4. Front propeller shaft (4×4) 14. Engine – transmission bolt
5. Exhaust pipe 15. Transmission assembly
Installaiton Steps
To install, follow the removal steps in reverse
8. Under cover and flex plate-torque
order.
converter bolt
REMOVAL
Preparation:
・ Remove engine hood.
1. Center console, rear console, select lever
assembly, and transfer control lever (4×
×4)
・ Disconnect the control rod from the select lever
assembly.
2. Transfer protector (4×
×4)
Disconnect the center bearing bracket, and remove
rear propeller shaft.
4. Front propeller shaft (4×
×4)
5. Exhaust pipe
Disconnect the engine harness connectors from the
transmission side.
・ Remove oil pipe clamp from the under cover and
torque converter housing side.
253LV001
8. Under cover and flex plate-torque converter bolt

・ Remove the under cover.
Remove the six torque converter fixing bolts.
NOTE:
reassembly.
9. Rear mounting nut
240RW037 ・ Support transmission with a jack.
crossmember.
・ If necessary, remove the rear mounting from the
transmission.
10. 3rd crossmember
12. Starter
13. Breather hose
・ If necessary, remove the transfer case from the
transmission assembly. (4×4)
Refer to Section 4 “DRIVE LINE/AXLE” for removal
and installation.
NOTE:
Keep the oil pan positioned down.
INSTALLATION
1. Torque
Rear mounting to
41 N･m (4.2 kg･m/30 Ib･ft)
crossmember
Rear mounting to
41 N･m (4.2 kg･m/30 Ib･ft)
transmission
Torque converter bolt 29 N･m (3.0 kg･m/22 Ib･ft)
ATF cooler pipe to
44 N･m (4.5 kg･m/33 Ib･ft)
elbow
Exhaust pipe flange to
43 N･m (4.4 kg･m/32 Ib･ft)
flange
Exhaust pipe to exhaust
67 N･m (6.8 kg･m/4.9 Ib･ft)
manifold
Rear propeller shaft bolt 63 N･m (6.4 kg･m/46 Ib･ft)
Center bearing retainer
69 N･m (7.0 kg･m/51 Ib･ft)
bolt
Front propeller shaft bolt 63 N･m (6.4 kg･m/46 Ib･ft)
3rd crossmember bolt 76 N･m (7.8 kg･m/56 Ib･ft)
Under cover bolt 6 N･m (0.6 kg･m/52 Ib･in)
Engine – Transmission Bolt Torque (’02 TFR/S)
E07R200019
Engine – Transmission Bolt Torque (’01 TFR)
E07L200003
260RY00001
UNIT REPAIR
MAJOR COMPONENTS
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all component
groups are assembled correctly.
If something wrong is found in a certain component group
during assembly, inspect and repair this group
immediately.
GENERAL ASSEMBLY NOTES:

1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful inspection
before assembly because even a small nick could cause
fluid leakage or affect performance.
2. Before assembling new clutch discs and brake bands,
soak them in automatic transmission fluid for at least thirty
minutes.
3. Apply automatic transmission fluid on the sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their palces.
5. Do not use adhesive cements on gaskets and similar
parts.
6. When assembling the transmission, be sure to use new
gaskets and O-rings.
7. Dry all parts with compressed air – never use shop rags.
8. Be sure to install the thrust bearings and races in the
correct direction and position.
240RY00022
DISASSEMBLY OF MAJOR
COMPONENTS (1)
240R200036
Disassembly steps
1. Torque converter 8. Input revolution sensor
2. Transmission control rod and select 9. Output revolution sensor (4×4)
lever (UBS and TFR/S) 10. Output revolution sensor (4×2)
3. Transmission control rod and select 11. Speedometer sensor, speedometer
lever (’01 TFR) driven gear and plate (4 × 2)
4. Neutral start switch 12. Extension housing (4 × 2)
5. Elbow 13. Adapter housing (4 × 4)
6. Oil temperature sensor 14. Transmission assembly
7. Breather hose
Disassembly steps
1. Torque converter
2. Transmission control rod and select lever (UBS and
TFR/S)
3. Transmission control rod and select lever (’01 TFR)
4. Neutral start switch
Unstake the lock washer.
Remove the nut and bolts, and then remove the neutral
start switch.
Remove the lock washer and grommet.
249RW003
5. Elbow
Remove two elbows from transmission case.
6. Oil temperature sensor
7. Breather hose
8. Input revolution sensor
9. Output revolution sensor (4××4)
10. Output revolution sensor (4×
×2)
11. Speedometer sensor, speedometer driven gear and
plate (4 × 2)
240RY00001
12. Extension housing (4 × 2)
13. Adapter housing (4 × 4)

Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (J-37227)
Holding fixture base: 5-8840-0003-0 (J-3289-20)
240R200021
REASSEMBLY OF MAJOR
COMPONENTS (1)
240R200035
Reassembly steps
1. Transmission assembly 8. Transmission control rod and select
2. Extension housing (4×2) lever (UBS and TFR/S)
3. Speedometer driven gear, plate, and 9. Transmission control rod and select
speedometer sensor (4×2) lever (’01 TFR)
4. Adapter housing (4×4) 10. Output revolution sensor (4×2)
5. Neutral start switch 11. Output revolution sensor (4×4)
6. Oil temperature sensor 12. Input revolution sensor
7. Elbow 13. Breather hose
14. Torque converter
Reassembly steps
2. Extension housing (4×
×2)
Install a new gasket and the extension housing to the
transmission case.
Torque: 36 N･
･m (3.7 kg･
･m/27 Ib･
･ft)
3. Speedometer driven gear, plate, and speedometer

sensor (4×
×2)
Torque:
Plate bolt – 15 N･
･m (1.5 kg･
･m/11 Ib･
･ft)
Speedometer sensor – 25 N･
･m (2.5 kg･
･m/18 Ib･
･ft)
4. Adapter housing (4×

×4)
Remove any gasket material on the contacting surfaces
of the adapter housing and transmission case.
Apply liquid gasket (TB1281-B or its equivalent) (1) and
install the apply gaskets (2) to the adapter housing as
shown in the figure.
Install the adapter housing to the transmission case.
Torque: 34 N･
･m (3.5 kg･
･m/25 Ib･
･ft)
241RY00020

Using the transmission select lever, fully turn the
manual valve lever shaft back and return two notches.
It is now in neutral.
Insert the neutral start switch onto the manual valve
lever shaft and temporarily tighten the adjusting bolt.
Install the lock washer and nut.
Torque: 7 N･
･m (0.7 kg･
･m/61 Ib･
･in)
249L100003 Align the neutral standard line and the switch groove
and tighten the adjusting bolt.
Torque: 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
Bend the tabs of the lock washer.
NOTE:
Bend at least two of the lock washer tabs.
Install the oil temperature sensor to the transmission
case.
Torque: 15 N･
･m (1.5 kg･
･m/11 Ib･
･ft)
249L100001
UBS 7. Elbow
Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29 N･
･m (3.0 kg･
･m/22 Ib･
･ft)
8. Transmission control rod and select lever (UBS and
TFR/S)
9. Transmission control rod and select lever (’01 TFR)
Torque: 29 N･
･m (3.0 kg･
･m/22 Ib･
･ft)
249RW003
TF
249R200009

×2)
×4)
12. Input revolution sensor
13. Breather hose

Using calipers and a straight edge, measure from the
installed surface of the transmission housing.
Correct distance: 67 mm (2.64 in) or more
240RY00005
COMPONENTS (2)
242R200006
Disassembly steps
1. Converter housing 10. Accumulator piston (C-0)
2. Oil pan 11. Second brake drum gasket
3. Oil strainer assembly 12. Solenoid wiring
4. Valve body 13. Snap ring, rotor, key (4×4)
5. Check valve, spring 14. Snap ring, speedometer sensor drive
6. Spring gear, ball (4×2)
7. Accumulator piston (B-2) 15. Spacer, rotor, key, snap ring (4×2)
8. Accumulator piston (C-2)
9. Accumulator piston (B-0)
Disassembly steps
1. Converter housing
Remove the six bolts.
Remove the converter housing.
240R200022
2. Oil pan
NOTE:
Do not turn over the transmission as this will
contaminate the valve body with foreign materials
in the bottom of the oil pan.
Remove the nineteen bolts.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: 5-8840-2153-0 (J-37228)
240RY00007
Examine particles in oil pan

Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil pan
and on the magnet to anticipate what type of wear you
will find in the transmission:
Steel (magnetic) …… bearing, gear and clutch plate
wear
240RY00008
Brass (non-magnetic)… bushing wear
3. Oil strainer assembly
Remove four bolts holding the oil strainer (UBS and
TFR/S).
244RY00003
Remove three bolts holding the oil strainer (’01 TFR).

NOTE:
When reassembling components, install a new oil
strainer assembly.
244L100001
4. Valve body
Disconnect the connectors from the solenoid S1 (1), S2
(2), lock-up solenoid (3) and pressure control solenoid
(4).
249RY00011
249RY00012
Remove the twenty bolts from valve body.
244R200078
5. Check valve, spring

6. Spring
Remove the check valve and spring.
Remove two springs from C-0 accumulator piston.
240RY00028

Remove accumulator pistons and springs from
transmission case.
240RY00010

Applying compressed air to the oil hole, remove the B-0
accumulator piston and spring.
240RY00011

Remove the C-0 accumulator piston.
11. Second brake drum gasket
12. Solenoid wiring
Turn over transmission, remove the solenoid wiring
stopper plate from the case.
Pull the wiring out of the transmission case.
240RY00012
13. Snap ring, rotor, key (4×

×4)
Remove the snap ring from the output shaft.
Remove the rotor and key.
247R200002
14. Snap ring, speedometer sensor drive gear, ball

(4×
×2)
Remove the speedometer sensor drive gear, and ball.
15. Spacer, rotor, key, snap ring (4×
×2)
Remove the spacer, rotor and key.
247L100001
REASSEMBLY OF MAJOR
COMPONENTS (2)
242R200007
Reassembly steps
1. Converter housing 7. Check valve, spring
2. Snap ring, key, rotor (4×2) 8. Valve body
3. Spacer, ball, speedometer sensor drive 9. Solenoid wiring
gear, snap ring (4×2) 10. Oil strainer assembly
4. Key, rotor, snap ring (4×4) 11. Oil pan
6. Accumulator piston
Reassembly steps
Torque:
M10 - 34 N･
･m (3.5 kg･
･m/25 Ib･
･ft)
M12 - 57 N･
･m (5.8 kg･
･m/42 Ib･
･ft)
240R200022
2. Snap ring, key, rotor (4×

×2)
Install the snap ring to the output shaft.
Install the key and rotor.
3. Spacer, ball, speedometer sensor drive gear, snap
ring (4×
×2)
Install the spacer, ball and speedometer sensor drive
gear.
247L100001
4. Key, rotor, snap ring (4×

×4)
247R200002

Install a new second brake drum gasket to the
transmission case.
240RY00013
Individual piston operation inspection

Check for the sound of operation while injecting
compressed air into the oil hole indicated in the figure.
1: OD direct clutch 5: Second coast brake

2: Direct clutch 6: Second brake
3: Forward clutch 7: First and reverse brake
4: OD brake A: C-0 Accumulator piston
240RY00014 hole
NOTE:
When inspecting the direct clutch, check with the
C-0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the
parts.
Coat the O-ring with ATF and install it to the piston.
Install the three springs and four accumulator pistons to
the bore as shown in th figure.
240RY00027
Piston Outer diameter Height

B-2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C-2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B-0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C-0 29.8 mm (1.173 in) 44.0 mm (1.732 in)
UBS
Spring Free length Outer diameter
240RY00029
B-2 75.8 mm (2.984 in) 20.1 mm (0.791 in)
C-2 (Outer) 64.0 mm (2.520 in) 20.2 mm (0.795 in)
C-2 (Inner) 42.1 mm (1.658 in) 14.7 mm (0.579 in)
B-0 63.6 mm (2.504 in) 16.0 mm (0.630 in)
C-0 (Outer) 74.6 mm (2.937 in) 20.9 mm (0.823 in)
C-0 (Inner) 46.0 mm (1.811 in) 14.0 mm (0.551 in)
TFR/S
B-2 73.4 mm (2.890 in) 19.9 mm (0.783 in)
240RY00010
C-2 (Outer) 70.3 mm (2.768 in) 20.2 mm (0.795 in)
C-2 (Inner) 42.1 mm (1.658 in) 14.7 mm (0.579 in)
B-0 62.0 mm (2.441 in) 16.0 mm (0.630 in)
C-0 (Outer) 74.6 mm (2.937 in) 20.9 mm (0.823 in)
C-0 (Inner) 46.0 mm (1.811 in) 14.0 mm (0.551 in)

Install new check valve and spring.
240RY00016
8. Valve body
Align the groove of the manual valve to the pin of the
lever.
240RY00017
Install the twenty bolts.

NOTE:
Each bolt length (mm) is indicated in the figure.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200078
9. Solenoid wiring
Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2 (2),
lock-up solenoid (3), and pressure control solenoid (4).
249RY00011
249RY00012
UBS and TFR/S 10. Oil strainer assembly

Install a new oil strainer assembly with gaskets.
244RY00002
UBS and TFR/S Install the oil strainer with the gaskets to the valve
body. Tighten the four (UBS and TFR/S) or three (’01
TFR) bolts.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244RY00003
’01 TFR
244L100001
11. Oil pan

Install two magnets in oil pan.
Remove any gasket material and be careful not to drop
oil on the contacting surfaces of the transmission case
and oil pan.
Apply liquid gasket (TB1281 or its equivalent) to the oil
pan as shown in the figure.
NOTE:
240RY00019 Install the oil pan as soon as the seal gasket is
applied.
Install and tighten the nineteen bolts.

Torque: 7.4 N･
･m (0.75 kg･
･m/65 Ib･
･in)
240RY00020
COMPONENTS (3)
248L100001
Disassembly steps
1. Oil pump 15. E-ring and pin
2. Race 16. Second coast brake band
3. OD planetary gear and OD direct 17. Front planetary ring gear
clutch 18. Bearing and race
4. Race 19. Race
5. OD planetary ring gear 20. Snap ring
6. Snap ring 21. Front planetary gear
7. Flange, plate and disc (B-0) 22. Drum and one-way clutch
8. Bearing and race 23. Snap ring
9. Snap ring 24. Flange, plate and disc (B-2)
10. OD support 25. Snap ring
11. Race 26. Rear planetary gear, second brake
12. Snap ring drum and output shaft
13. Second coast brake piston assembly 27. Bearing
14. Direct clutch and forward clutch
Disassembly steps
1. Oil pump
Remove seven bolts fixing the oil pump to the
transmission case.
Remove the oil pump.
241RY00003
2. Race
Remove race from oil pump.
241RY00002
3. OD planetary gear and OD direct clutch

Remove the overdrive planetary gear and overdrive
direct clutch with thrust needle bearing from the
transmission case.
252L100001
4. Race
Remove the race from OD planetary gear.
252L100017
5. OD planetary ring gear

Remove the overdrive planetary ring gear from the
transmission case.
252RY00002
Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake piston as
252RY00003
Measure the stroke applying and releasing the

compressed air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 –
114 psi) as shown in the figure.
Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)
If the values are nonstandard, select another flange.
Available flange sizes

3.3 mm (0.130 in) 3.8 mm (0.150 in)
244RY00001 3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)
6. Snap ring
Remove the snap ring.
246RY00001
7. Flange, plate and disc (B-0)

Remove two flange, three plates and four discs.
246RY00026
8. Bearing and race

Remove the thrust bearing and two races.
247RY00003
9. Snap ring
Using snap ring pliers, remove the snap ring.
246RY00002
10. OD support
Remove two bolts fixing the overdrive support
252RY00004
Install two removed bolts to the OD support, and pull

out the OD support assembly.
252RY00005
11. Race
Remove the race from OD support.
252RY00006
Check piston stroke of second coast brake (B-1)

Place a mark on the second coast brake piston rod as
Using feeler gauge, measure the stroke applying the
248RY00004
If the values are nonstandard, replace piston rod and

recheck piston stroke.
If piston stroke is nonstandard, replace brake band.
There are two piston rods.
Rod length 71.4 mm (2.811 in)
72.9 mm (2.870 in)
248RY00005
12. Snap ring

248RY00006
13. Second coast brake piston assembly

Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
248RY00007

Remove the direct clutch and forward clutch from the
transmission case.
248RY00008
15. E-ring and pin

Remove the E-ring from the pin.
Remove the pin from the brake band.
248RY00009
16. Second coast brake band

Remove the second coast brake band from the
transmission case.
248RY00010
17. Front planetary ring gear

Remove the front planetary ring gear from the
transmission case.
247RY00004
18. Bearing and race

Remove the bearing and race.
247RY00005
19. Race
Remove the race.
247RY00006
20. Snap ring

NOTE:
Hold the output shaft to prevent it from falling.
The output shaft falls when the snap ring is
removed.
248RY00011
21. Front planetary gear

Remove the front planetary gear from the transmission
case.
247RY00007
22. Drum and one-way clutch

Remove sun gear input drum and one-way clutch.
248RY00012
23. Snap ring

Using two screwdrivers, remove the snap ring.
248RY00014

Remove the flange, five discs and five plates.
248RY00015
Check pack clearance of first and reverse brake (B-3)

Using a feeler gauge, measure the clearance between
the plate and second brake drum as shown in the
figure.
Clearance: 0.7 – 1.22 mm (0.0276 – 0.0480 in) (UBS)
: 0.6 – 1.12 mm (0.0236 – 0.0441 in)
(TFR/S)
If the values are nonstandard, replace the discs.
248RY00016

4.0 mm (0.158 in) 4.8 mm (0.189 in)
4.2 mm (0.165 in) 5.0 mm (0.197 in)
4.4 mm (0.173 in) 5.2 mm (0.205 in)
4.6 mm (0.181 in) 5.4 mm (0.213 in)
25. Snap ring

248RY00017
26. Rear planetary gear, second brake drum and output

shaft
Remove the rear planetary gear, second brake drum
and output shaft as an assembly.
247R200001
27. Bearing
Remove the assembled thrust bearing and race from
the transmission case.
248RY00018
REASSEMBLY OF MAJOR
COMPONENTS (3)
248L100002
Reassembly steps
1. Bearing 17. Bearing and race
2. Rear planetary gear, second brake 18. Direct clutch and forward clutch
drum and output shaft 19. Second coast brake piston assembly
3. Snap ring 20. Snap ring
4. Second brake piston sleeve 21. Race
5. One-way clutch 22. OD support
6. Flange, plate and disc (B-2) 23. Snap ring
7. Snap ring 24. Flange, plate and disc (B-0)
8. Drum 25. Snap ring
9. Front planetary gear and bearing 26. Bearing and race
10. Snap ring 27. OD planetary ring gear
11. Race 28. Bearing and race
12. Second coast brake band 29. Race
13. E-ring and pin 30. OD planetary gear and OD direct
14. Bearing and race clutch
15. Race 31. Bearing
16. Front planetary ring gear 32. Race
33. Oil pump
Reassembly steps
1. Bearing
Coast the assembled bearing and race with petroleum
jelly and install it onto the transmission case.
Assembled bearing and race

(Reference)
Bearing and race Diameter
247RY00008
Inside 39.38 mm (1.550 in)
Outside 58.15 mm (2.289 in)

shaft.
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
247RY00009
Align the splines of the transmission case and the

assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure.
247RY00010
3. Snap ring
Using snap ring pliers, install the snap ring.
246RY00003
Check pack clearance of first and reverse brake

Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown in
the figure.
Clearance: 0.7 – 1.22 mm (0.0276 – 0.0480 in) (UBS)
0.6 – 1.12 mm (0.0236 – 0.0441 in)
(TFR/S)
If the values are nonstandard, check for an improper
248RY00016
installation.
4. Second brake piston sleeve
Install second brake piston sleeve.
246RY00004
5. One-way clutch
Install one-way clutch.
247RY00011

Install flange, discs and plates.
Install the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and five plates (Disc first)
Install the flange with the rounded edge of the flange
facing the disc.
246RY00005
7. Snap ring
Install the snap ring.
248RY00014
8. Drum
While turning the sun gear input drum clockwise.
Install it into the one-way clutch.
NOTE:
Confirm the thrust washers are installed correctly.
248RY00020
9. Front planetary gear and bearing

Install the front planetary gear to the sun gear.
NOTE:
Confirm the bearing and race is installed correctly.
247RY00012
With wooden blocks under the output shaft, stand the

transmission on the output shaft.
247RY00013
10. Snap ring

248RY00011
11. Race
Coat the bearing race with petroleum jelly and install it
onto the front planetary gear.
Bearing race diameter (Reference)

Bearing race Diameter
Inside 34.3 mm (1.350 in)
247RY00014

Insert the second coast brake band to the transmission
case.
248RY00010
13. E-ring and pin

Install the pin through the brake band.
248RY00021
Install the E-ring to the pin.
248RY00022

Coat the bearing and race with petroleum jelly and
install them onto the forward clutch.
Bearing and race diameter (Reference)

Inside Outside
Bearing 26.0 mm (1.024 in) 46.7 mm (1.839 in)
248RY00023 Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)
15. Race
Coat the race with petroleum jelly and install it onto the
front planetary ring gear.
Race diameter (Reference)

Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)
247RY00015
Align the flukes of the discs in the forward clutch.
247RY00016

Align the spline of the front planetary gear with the
flukes of the discs and install the front planetary gear to
the forward clutch.
247RY00017

install them onto the ring gear.

Inside Outside
Race 30.6 mm (1.205 in) 53.6 mm (2.110 in)
247RY00019

Install the assembled direct clutch, forward clutch and
front planetary ring gear into the transmission case.
247RY00018
Using vernier calipers, measure the distance between

the sun gear input drum and direct clutch drum as
Height: 9.8 – 11.8 mm (0.386 – 0.465 in)
installation.
248RY00024
Coat the assembled bearing and race with petroleum

jelly and install it onto the forward clutch.
Assembled bearing and race diameter

(Reference)
Inside Outside
Bearing
29.1 mm (1.146 in) 50.2 mm (1.976 in)
and race
248RY00025

Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E-ring.
①: Second coast brake piston
②: Oil seal
③: Piston rod
248RY00026
20. Snap ring

Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly
and piston cover to the transmission case.
248RY00027
Check piston stroke of second coast brake

248RY00005
Using wire gauge, measure the stroke by applying the

installation.
248RY00004
21. Race
overdrive support assembly.

Inside Outside
Race 28.45 mm (1.120 in) 47.3 mm (1.862 in)
252RY00007
22. OD support
Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the bolt
hole of the transmission case and insert.
252RY00005
23. Snap ring

Using snap ring pliers, install the snap ring as shown in
the figure.
252RY00008
Install and tighten the two bolts.

Torque: 25 N･
･m (2.6 kg･
･m/19 Ib･
･ft)
252RY00004
Check end of output shaft

Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)
247RY00020

Install the (flat ring) 4.0 mm (0.157 in) thick flange with
the rounded edge side of the flange facing the disc.
Alternately install four discs and three plates. (Disc first)
252RY00009
25. Snap ring

Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Snap ring (Reference)

Inside diameter 167.9 mm (6.61 in)
246RY00001

252RY00003
Measure the stroke by applying and releasing the

installation.
Available flange size

244RY00001 3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)
246RY00001
Remove two flanges, three plates and four discs.
246RY00026

Coat the bearing and races with petroleum jelly and
install them onto the overdrive support.
Bearing and races diameter (Reference)

Inside Outside
Race (Front) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
Bearing and
33.7 mm (1.327 in) 50.1 mm (1.972 in)
252RY00010 race (Rear)

Install the overdrive planetary ring gear.
252RY00002

install them onto the planetary ring gear.

Inside Outside
Bearing
24.2 mm (0.953 in) 47.8 mm (1.882 in)
and race
252RY00011
29. Race
planetary gear.

Inside Outside
Race 24.7 mm (0.972 in) 41.8 mm (1.646 in)
252RY00001

Install the overdrive planetary gear and direct clutch.
252L100001
31. Bearing
jelly and install it onto the direct clutch.

Inside Outside
Bearing
28.9 mm (1.138 in) 50.2 mm (1.976 in)
and race
252L100018
Alternately install four discs and three plates. (Disc first)
252RY00009
246RY00001
32. Race
oil pump.

Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)
252RY00014
33. Oil pump

Coat the O-ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the transmission
case.
Hold the input shaft, and lightly press the oil pump body
to slide the oil seal rings on the stator shaft through the
direct clutch drum.
241RY00003
CAUTION:
Do not push on the oil pump strongly or the oil seal
ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N･
･m (2.2 kg･
･m/16 Ib･
･ft)
Check input shaft rotation
Make sure the input shaft rotates smoothly.
DISASSEMBLY, INSPECTION AND

REASSEMBLY OF MINOR COMPONENTS
NOTE:
The instructions here are organized so that you work on
only one component group at a time.
This will help avoid confusion from similar-looking parts of
different subassemblies being on your workbench at the
same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair and
reassembly before proceeding to the next component
group. If a component group cannot be reassembled
because parts are being ordered, be sure to keep all parts
of that group in separate container while proceeding with
disassembly, inspection, repair and reassembly of other
component groups.
Recommended ATF type BESCO ATF Ⅲ.
GENERAL CLEANING NOTES:

1. All disassembled parts should be washed clean and any
fluid passages and holes blown through with compressed
air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid should be
used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper
order to allow performing inspection, repairs, and
reassembly with efficiency.
2. When disassembling a valve body, be sure to keep each
valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid for at
least thirty minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts,
and sliding surfaces should be coated with transmission
fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not aligned
with one of the cutouts and are installed in the groove
correctly.
4. If a worn bushing is to be replaced, the subassembly
containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage.
Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in place.
OIL PUMP
DISASSEMBLY
241R200003
Disassembly steps
1. Oil seal ring 4. Oil pump drive gear
2. O-ring 5. Oil pump driven gear
3. Stator shaft 6. Oil pump body
Disassembly steps
1. Oil seal ring
Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
2. O-ring
Remove O-ring.
241RY00005
3. Stator shaft
4. Oil pump drive gear
5. Oil pump driven gear
6. Oil pump body
Remove 13 bolts, and then remove the stator shaft
from oil pump body.
Then remove drive and driven gear.
241RY00006
INSPECTION AND REPAIR

Make necessary correction or parts replacement if
wear, damage or any abnormal conditions are found
through inspection.
Check oil pump body bushing

Using a dial indicator, measure the inside diameter of
the oil pump body bushing.
Maximum inside diameter: 38.19 mm (1.5035 in)
If the inside diameter is greater than the maximum,
replace the oil pump body.
241RY00007
Check stator shaft bushing

the stator shaft bushing.
Maximum inside diameter:
Front side: 21.58 mm (0.8496 in)
Rear side: 27.08 mm (1.0661 in)
replace the stator shaft.
241RY00008
Check tip clearance of both gears

Measure between the gear teeth and the cresent-
shaped part of the pump body.
Standard tip clearance: 0.11 – 0.14 mm
(0.0043 – 0.0055 in)
Maximum tip clearance: 0.19 mm (0.0075 in)
If the tip clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.
241RY00009
Check body clearance of driven gear

Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
Standard body clearance: 0.07 – 0.15 mm
(0.0028 – 0.0059 in)
Maximum body clearance: 0.2 mm (0.0079 in)
If the body clearance is greater than the maximum,
241RY00010
Check side clearance of both gears

Using a steel straightedge and a feeler gauge, measure
the side clearance of both gears.
Standard side clearance: 0.02 – 0.05 mm
(0.0008 – 0.0020 in)
Maximum side clearance: 0.1 mm (0.004 in)
If the side clearance is greater than the maximum,
241RY00011
Check oil seal

Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
241RY00012
Using special tool, install a new oil seal.

The oil seal end should be flush with the outer edge of
the pump body.
Oil seal installer : 5-8840-2256-0 (J-9617)
Coat the oil seal lip with multi purpose grease.
241RY00013
REASSEMBLY
241R200004
Reassembly steps
1. Oil pump body 4. Stator shaft
2. Oil pump driven gear 5. Oil seal ring
3. Oil pump drive gear 6. O-ring
Reassembly steps
1. Oil pump body
Place the oil pump body on the torque converter.
Coat the driven gear and drive gear with ATF.
Install the driven gear and drive gear.
241RY00014
4. Stator shaft
Align the stator shaft with the bolt holes.
Tighten the thirteen bolts.
Torque: 11 N･
･m (1.1 kg･
･m/95 Ib･
･in)
241RY00006
5. Oil seal ring

Coat the oil seal rings with ATF.
Contract the oil seal rings as shown, and install them
onto the stator shaft.
NOTE:
Do not spread the ring ends too much.
241RY00015
6. O-ring
Coat a new O-ring with ATF and install it to the oil
pump body.
O-ring size (Reference)

Thickness 3.5 mm (0.138 in)
241RY00016
Check oil pump drive gear rotation

Make sure the drive gear rotates smoothly when
installed to the torque converter.
241RY00017
OD PLANETARY GEAR AND OD

DIRECT CLUTCH ASSEMBLY (C-0)
DISASSEMBLY
252R200007
Disassembly steps
1. OD direct clutch assembly 10. Thrust bearing
2. OD planetary gear assembly 11. Snap ring
3. Thrust bearing 12. Ring gear flange
5. Flange, disk and plate 14. Race
7. Piston return spring 16. Retaining plate
8. OD direct clutch piston with O-ring 17. OD one-way clutch
9. O-ring 18. Thrust washer
Disassembly steps
Check operation of one-way clutch
Hold the OD direct clutch drum and turn the input shaft.
The input shaft should turn freely clockwise and should
lock counterclockwise.
1 : Free
○
2 : Lock
○
252L100003
1. OD direct clutch assembly

2. OD planetary gear assembly
Remove OD direct clutch assembly from OD planetary
gear assembly.
3. Thrust bearing
Then remove thrust bearing with the race from OD
direct clutch drum.
252L100004
Check piston stroke of OD direct clutch (C-0)

Place the oil pump onto the torque converter, and then
place the OD direct clutch assembly onto the oil pump.
252L100005
Use a dial indicator, measure the OD direct clutch

piston stroke applying and releasing the compressed air
(390 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as
shown.
252L100016
4. Snap ring
Remove snap ring from clutch drum.
5. Flange, disc and plate
Remove flange, two discs and two plates.
252L100006
6. Snap ring
Place special tool on the spring retainer and compress
the return spring.
Spring compressor : 5-8840-0195-0 (J-23327-1)
7. Piston return spring
Remove piston return spring
252L100007
8. OD direct clutch piston with O-ring.

Place the oil pump onto the torque converter and then
place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand, apply
compressed air to the oil pump to remove the OD direct
clutch piston.
Remove the OD direct clutch piston.
9. O-ring
252L100008 Remove two O-rings from piston.
10. Thrust bearing
Remove bearing and race from OD planetary ring gear.
252RY00021
11. Snap ring

Remove snap ring.
252RY00022
12. Ring gear flange

Remove ring gear flange from OD planetary ring gear.
252RY00023
14. Race
15. Snap ring
Remove snap ring, using screwdriver.
252RY00024
16. Retaining plate

Remove retaining plate from OD planetary gear.
252RY00025
17. OD one-way clutch

Remove OD one-way clutch with outer race.
18. Thrust washer
252RY00026

Check discs
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace the
disc.
252RY00027
Check piston return spring

Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
252RY00028
Check OD direct clutch piston

Check that the check ball is free by shaking the piston.
Check that the valve does not leak by applying low-
pressure compressed air.
252RY00029
Check OD direct clutch drum bushings

the OD direct clutch drum bushings.
replace the OD direct clutch drum.
252L100009
Check OD planetary gear bushing

replace the OD planetary gear bushing.
replace the OD planetary gear.
252RY00031
REASSEMBLY
252R200008
Reassembly steps
1. OD planetary gear assembly 10. Thrust bearing
2. Thrust washer 11. O-ring
3. OD one-way clutch 12. OD direct clutch piston with O-ring
4. Retaining plate 13. Piston return spring
6. Race 15. Flange, disc and plate
8. Ring gear flange 17. Thrust bearing
9. Snap ring 18. OD direct clutch assembly
Reassembly steps
2. Thrust washer
Install the thrust washer to the OD planetary gear,
facing the grooved side upward.
252RY00032
Install the one-way clutch into the outer race, with the
flanged side of the one-way clutch facing upward.
252RY00033
Install OD one-way clutch with outer race to overdrive

planetary gear.
252RY00026
4. Retaining plate
5. Snap ring
Install retaining plate, then install snap ring, using a
screwdriver.
252RY00024
6. Race
Coat the race with petroleum jelly and install it to the
planetary gear.

Outside diameter 41.8 mm (1.646 in)
252RY00034

8. Ring gear flange
Install ring gear flange to OD planetary ring gear.
252RY00023
9. Snap ring
Install snap ring, using a screwdriver.
252RY00022
10. Thrust bearing

Coat the race and bearing with petroleum jelly and
install them onto the OD planetary ring gear.
Race and bearing diameter (Reference)

Inside Outside
Bearing
24.2 mm (0.953 in) 47.8 mm (1.882 in)
and race
252RY00035
11. O-ring
Coat new O-rings with ATF and install them on the OD
direct clutch piston.
12. OD direct clutch piston with O-ring
Being careful not to damage the O-rings, press in the
OD direct clutch piston into the clutch drum, using both
hands.
252L100011

Install piston return spring.
252L100012
14. Snap ring

Place special tool on the spring retainer, and compress
the return spring.
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
252L100007

Install two plates and tow discs then install the flange,
with the flat side facing downward.
252L100013
16. Snap ring

Install snap ring.
252L100014

252L100005
Using a dial indicator, measure the OD direct clutch

piston stroke by applying and releasing the compressed
air (390 – 780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as
shown.
If the piston stroke is not within specification, replace
the disc and recheck the piston stroke.
If the piston stroke is non standard, select another
flange.
252L100016
Flange sizes
Flange thickness Flange thickness
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)
17. Thrust bearing

jelly and install it with the race side facing downward.
Bearing and race (Reference)

252L100015

Align the flukes of discs in the direct clutch.
Install the OD direct clutch assembly onto the OD
planetary gear.
252L100004

1 : Free
○
2 : Lock
○
252L100003
OD SUPPORT ASSEMBLY
DISASSEMBLY
252R200003
Disassembly steps
1. Thrust bearing 6. OD brake piston
2. Race 7. O-ring
3. Thrust washer (plastic) 8. Oil seal ring
4. Snap ring 9. OD support
Disassembly steps
Check OD brake piston movement
Place the OD support assembly onto the direct clutch
assembly.
252RY00042
Apply compressed air into the oil passage as shown,

and be sure that the OD brake piston moves smoothly.
252RY00043
1. Thrust bearing
2. Race
3. Thrust washer (plastic)
4. Snap ring
the return spring with a shop press.
Spring compressor : 5-8840-2170-0 (J-37233)
Remove the snap ring with a screwdriver.
252RY00044
6. OD brake piston
Place the OD support onto the direct clutch assembly.
Hold the OD brake piston so it is not slanted and apply
compressed air into the passage to remove the OD
brake piston.
Remove the OD brake piston.
7. O-ring
8. Oil seal ring
252RY00045 9. OD support

through inspection.

spring.
252RY00046
REASSEMBLY
252R200004
Reassembly steps
2. Oil seal ring 7. Thrust washer (Plastic)
3. O-ring 8. Race
4. OD brake piston 9. Thrust bearing
Reassembly steps
1. OD support
2. Oil seal ring
Coat the two oil seal rings with ATF.
Contract the oil seals as shown, and install them onto
the OD support.
NOTE :
Do not spread the ring ends more than necessary.
252RY00047
3. O-ring
Coat two new O-rings with ATF and install them on the
OD brake piston.
4. OD brake piston
brake piston into the OD support, using both hands.
252RY00048

252RY00049
6. Snap ring
Install the snap ring with a screwdriver.
cutout portion of the OD support.
252RY00050

Coat the thrust washer with petroleum jelly and install it
onto the OD support.
NOTE :
Make sure that the lug fits into the hole on the OD
support.
252RY00051
8. Race
Coat the race with petroleum jelly, and install it onto the
OD support.

252RY00052
9. Thrust bearing
Turn over OD support.
Coat the two races with petroleum jelly, and install them

Inside Outside
Race (A) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
252RY00069
Bearing and
33.7 mm (1.327 in) 50.1 mm (1.972 in)
race (B)

assembly.
252RY00042

252RY00043

DISASSEMBLY
248R200001
Disassembly steps
1. Clutch drum thrust washer (Plastic) 5. Snap ring
2. Snap ring 6. Piston return spring
3. Flange 7. Direct clutch drum
4. Plate and disc 8. Direct clutch piston
Five plates and five discs (UBS) 9. O-ring
Four plates and four discs (TFR/S)
Disassembly steps
Remove direct clutch drum assembly from forward
clutch assembly.
248RY00028
Check piston stroke of direct clutch (C-2)

Place the direct clutch assembly onto the OD support
assembly.
248RY00029
Using a dial indicator, measure the direct clutch piston

stroke by applying and releasing compressed air (390 –
780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as shown.
(UBS)
Pack clearance: 0.4 – 0.7 mm (0.0157 – 0.0276 in)
(TFR/S)
248RY00061
1. Clutch drum thrust washer (Plastic)

2. Snap ring
3. Flange
4. Plate and disc
5. Snap ring
the return spring.
248RY00002
7. Direct clutch drum

8. Direct clutch piston
9. O-ring
Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the direct
clutch piston.
Remove the direct clutch piston.
248RY00030 Remove two O-rings from piston.
INSPECTON AND REPAIR

spring.
247RY00034
Check discs
Using micrometer, measure the thickness of the discs.
Minimum thickness: 2.04 mm (0.0803 in)
disc.
252RY00027
Check direct clutch piston

Check that check ball is free by shaking the piston.
248RY00031
Check direct clutch drum bushing

the clutch drum bushing.
If the inside diamater is greater than the maximum,
replace the clutch drum.
248RY00032
REASSEMBLY
248R200002
Reassembly steps
1. O-ring 6. Disc and plate
2. Direct clutch piston Five discs and five plates (UBS)
3. Direct clutch drum Four discs and four plates (TFR/S)
4. Piston return spring 7. Flange
Reassembly steps
1. O-ring
Coat new O-rings with ATF and install them on the
Install direct clutch piston to direct clutch drum.
248RY00033 direct clutch piston into the clutch drum, using both
hands.

248RY00034
5. Snap ring
Compress piston return spring and install snap ring in
groove.
the return spring.
248RY00002 Spring compressor: 5-8840-0254-0 (J-25048)
6. Disc and plate
Install plates and discs.
Install in order : P-D-P-D-P-D-P-D-P-D (UBS)
: P-D-P-D-P-D-P-D (TFR/S)
P : Plate, D : Disc
248RY00062
7. Flange
Install the flange, with the flat side facing downward.
248RY0035
8. Snap ring
the cutout portion of the direct clutch drum.
248RY00036

assembly.
248RY00029

780 kPa, 4 – 8 kg/cm2 or 57 – 114 psi) as shown.
(UBS)
(TFR/S)
the discs and recheck the piston stroke.
248RY00061

flange.
Flange sizes
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.4 mm (0.134 in) 3.9 mm (0.154 in)
3.5 mm (0.138 in) 4.0 mm (0.157 in)
3.6 mm (0.142 in) 4.1 mm (0.161 in)
3.7 mm (0.146 in) 4.2 mm (0.165 in)
9. Clutch drum thrust washer (plastic)

onto the direct clutch.
NOTE :
Make sure that the lugs fit into the cutout portions
on the direct clutch.
248RY00037

Install the direct clutch assembly onto the forward
clutch assembly.
Check that the distance from the direct clutch end to
the forward clutch end is 71.2 mm (2.803 in).
248RY00038
FORWARD CLUTCH ASSEMBLY

(C-1)
DISASSEMBLY
248R200003
Disassembly steps
1. Thrust bearing 8. Piston return spring
2. Race 9. Piston
3. Snap ring 10. O-ring
4. Flange 11. O-ring
5. Disc and plate 12. Oil seal ring
Six discs and six plates (UBS) 13. Thrust bearing
Five discs and five plates (TFR/S) 14. Forward clutch drum
6. Cushion plate
7. Snap ring
Disassembly steps
Remove forward clutch assembly from direct clutch
assembly.
248RY00039
1. Thrust bearing
2. Race
Place wooden blocks, etc. to prevent forward clutch
shaft from touching the work stand, and place the OD
support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.
248RY00048
Check piston stroke of forward clutch (C-1)

Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing compressed air
2
(390 – 780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as
shown.
(UBS)
: 0.5 – 0.9 mm (0.0197 – 0.0354 in)
(TFR/S)
248R200008
3. Snap ring
4. Flange
5. Disc and plate
6. Cushion plate
248RY00041
7. Snap ring
Place special tool on the sparing retainer and compress
the return spring.
248RY00003
9. Piston
Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
248RY00042
10. O-ring
11. O-ring
12. Oil seal ring
13. Thrust bearing
14. Forward clutch drum

Check forward clutch piston
248RY00031
Check forward clutch drum bushing

the forward clutch drum bushing.
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
248RY00043
Check disc, plate and flange

Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
・ If the lining of the disc is peeling off or discolored, or
even if parts of the printed numbers are defaced,
replace all discs.
・ Before assembling new discs, soak them in ATF for
at least fifteen minutes.
248RY00045

spring.
247RY00034
REASSEMBLY
248R200004
Reassembly steps
1. Forward clutch drum 8. Snap ring
2. Thrust bearing 9. Cushion plate
3. Oil seal ring 10. Disc and plate
4. O-ring Six discs and six plates (UBS)
5. O-ring Five discs and five plates (TFR/S)
6. Forward clutch piston 11. Flange
7. Piston return spring 12. Snap ring
13. Race
14. Thrust bearing
Reassembly steps
2. Thrust bearing
jelly and install it onto the forward clutch drum, with the
race side facing downward.

248RY00044
3. Oil seal ring

Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil
seal rings onto the forward clutch drum.
NOTE:
248RY00046
4. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
5. O-ring
Coat new O-rings with ATF and install two O-rings on
the forward clutch piston.
248RY00047
6. Forward clutch piston

Being careful not to damage the O-rings, press the
forward clutch piston into the forward clutch drum.
248RY00049

248RY00065
8. Snap ring
the return spring.
Spring compressor: 5-8840-0254-0 (J-25048)
248RY00003
9. Cushion plate
Install cushion plate rounded side down as shown.
248RY00069
10. Disc and plate

Install discs and plates.
Install in order: P-D-P-D-P-D-P-D-P-D-P-D (UBS)
: P-D-P-D-P-D-P-D-P-D (TFR/S)
11. Flange
And then install the flange, with the rounded edge
facing downward.
248RY00070
12. Snap ring

the cutout portion of the forward clutch drum.
248RY00041

2
air (380 – 780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as
shown.
(UBS)
: 0.5 – 0.9 mm (0.0197 – 0.0354 in)
(TFR/S)
248R200008

the discs, and recheck the piston stroke.

3.0 mm (0.118 in) 3.4 mm (0.134 in)
4.2 mm (0.165 in) 3.6 mm (0.142 in)
4.4 mm (0.173 in) 3.8 mm (0.150 in)
3.2 mm (0.126 in) 4.0 mm (0.158 in)
13. Race
14. Thrust bearing
Coat the race and bearing with petroleum jelly, and
install them onto the forward clutch drum.

Inside Outside
Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)
248RY00048

Install the direct clutch assembly onto the forward
clutch assembly.
248RY00039
Check that the distance from the direct clutch end to

the forward clutch end is 71.2 mm (2.803 in).
248RY00038
FRONT PLANETARY GEAR

DISASSEMBLY
247R200003
Disassembly steps
1. Race 5. Race (Metal)
2. Thrust bearing 6. Thrust bearing
3. Race 7. Race
4. Front planetary gear 8. Front planetary ring gear
Disassembly steps
1. Race
2. Thrust bearing
3. Race
5. Race (Metal)
6. Thrust bearing
7. Race

Check front planetary ring gear bushing
the front planetary ring gear bushing.
replace the front planetary ring gear.
247RY00021
REASSEMBLY
247R200004
Reassembly steps
2. Race 6. Race
4. Race (Metal) 8. Race
Reassembly steps
2. Race
3. Thrust bearing
Coat the race and bearing with petroleum jelly.
Install the race and bearing to the rear side of the front
planetary gear.
247RY00023
Inside Outside
Race 33.7 mm (1.327 in) 47.6 mm (1.874 in)
4. Race (Metal)
Turn over the planetary gear and install the race.
Make sure that the lugs fit into the holes on the front
planetary gear.

Inside Outside
Race 34.3 mm (1.350 in) 47.8 mm (1.882 in)
247RY00024

6. Race
7. Thrust bearing
Install the race and bearing onto the rear side of the

247RY00025
Inside Outside
Race 30.6 mm (1.205 in) 53.6 mm (2.110 in)
8. Race
Turn over the planetary ring gear and install the race
onto the front side of the front planetary ring gear.

Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)
247RY00026
PLANETARY SUN GEAR AND NO.1

ONE-WAY CLUTCH
DISASSEMBLY
248R200005
Disassembly steps
1. One-way clutch and second brake hub 5. Sun gear input drum
2. Thrust washer (plastic) 6. Snap ring
3. Oil seal ring (Metal) 7. Planetary sun gear
4. Snap ring
Disassembly steps
Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second brake
hub.
The second brake hub should turn freely clockwise and
should lock counterclockwise.
①: Free
②: Lock
248RY00051
1. One-way clutch and second brake hub

3. Oil seal ring (Metal)
Remove two oil seal rings.
248RY00052
4. Snap ring
Remove the snap ring with snap ring pliers.
5. Sun gear input drum
6. Snap ring
7. Planetary sun gear
248RY00053

Check planetary sun gear bushing
the planetary sun gear bushing.
replace the planetary sun gear.
248RY00054
REASSEMBLY
248R200006
Reassembly steps
1. Planetary sun gear 5. Oil seal ring (Metal)
2. Snap ring 6. Thrust washer (Plastic)
3. Sun gear input drum 7. One-way clutch and second brake hub
4. Snap ring
Reassembly steps
2. Snap ring
Install snap ring to planetary sun gear.
248RY00055

Place a wooden block, etc. as a work stand and place
the planetary sun gear onto it.
Install the sun gear input drum onto the planetary sun
gear.
248RY0056
4. Snap ring
Install snap ring with snap ring pliers.
248RY00053

Install the two oil seal rings onto the planetary sun gear.
NOTE:
248RY00052
6. Thrust washer (Plastic)

Install thrust washer.
NOTE:
Make sure that the lugs fit into the holes on the sun
gear input drum.
248RY00057

Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
248RY00058

hub.
①: Free
②: Lock
248RY00051
SECOND BRAKE ASSEMBLY (B-2)

DISASSEMBLY
246R200001
Disassembly steps
1. Second brake assembly 6. Piston sleeve
2. Thrust washer (Plastic) 7. Second brake piston
4. Spring retainer 9. Second brake drum
Disassembly steps
1. Second brake assembly
Remove second brake assembly from output shaft.
246RY00007

3. Snap ring
the return spring.
4. Spring retainer
247RY00001
6. Piston sleeve
7. Second brake piston
Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston.
8. O-ring
9. Second brake drum
246RY00008

spring.
247RY00034
REASSEMBLY
246R200002
Reassembly steps
1. O-ring 6. Spring retainer
2. Second brake piston 7. Snap ring
3. Second brake drum 8. Thrust washer (Plastic)
4. Piston sleeve 9. Second brake assembly
Reassembly steps
1. O-ring
second brake piston.
second brake piston into the second brake drum.
246RY00009 4. Piston sleeve
Install piston sleeve.

6. Spring retainer
Install spring retainer.
246RY00010
7. Snap ring
the return spring.
247RY00001
Check second brake piston movement

Make sure the second brake piston moves smoothly
when applying and releasing the low compressed air to
the second brake drum.
246RY00011

to the second brake piston, with the grooved side
facing upward.
NOTE:
Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
246RY00012

Install second brake assembly to output shaft.
246RY00014
REAR PLANETARY GEAR

ASSEMBLY AND OUTPUT SHAFT
DISASSEMBLY
247R200005
Disassembly steps
1. Second brake assembly 9. Thrust washer (Plastic)
2. Output shaft 10. Thrust washer (Plastic)
3. Oil seal ring 11. Rear planetary gear
4. Disc, plate and flange (B-3) 12. Thrust bearing and race
Seven discs and seven plates (UBS) 13. Snap ring
Six discs and six plates (TFR/S) 14. Ring gear flange
5. Rear planetary gear assembly 15. Rear planetary ring gear
6. One-way clutch inner race
7. Snap ring
8. One-way clutch
Disassembly steps
2. Output shaft
246RY00014
3. Oil seal ring

Remove oil seal ring from output shaft.
4. Disc, plate and flange (B-3)
Seven discs and seven plates (UBS)
Six discs and six plates (TFR/S)
247RY00028
5. Rear planetary gear assembly

Remove rear planetary gear from rear planetary ring
gear.
247RY00029

Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
①: Lock
②: Free
247RY00030

Remove the one-way clutch inner race from the rear
planetary gear.
247RY00031
7. Snap ring
247RY00032
8. One-way clutch
Remove the one-way clutch with retainers from the
planetary gear.
11. Rear planetary gear
12. Thrust bearing and race
13. Snap ring
247RY00033
15. Rear planetary ring gear
replace all discs.
248RY00045
REASSEMBLY
247R200006
Reassembly steps
1. Rear planetary ring gear 9. Snap ring
2. Ring gear flange 10. One-way clutch inner race
3. Snap ring 11. Rear planetary gear assembly
4. Thrust bearing and race 12. Disc, plate and flange (B-3)
5. Rear planetary gear Seven discs and seven plates (UBS)
6. Thrust washer (Plastic) Six discs and six plates (TFR/S)
7. Thrust washer (Plastic) 13. Oil seal ring
8. One-way clutch 14. Output shaft
Reassembly steps
2. Ring gear flange
Install ring gear flange to the rear planetary ring gear.
3. Snap ring
Install snap ring to the rear planetary ring gear.
247RY00035

Coat the races and bearing with petroleum jelly, and
install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)

Inside Outside
Race (A) 28.5 mm (1.122 in) 44.2 mm (1.740 in)
Bearing
247RY00036 and race 27.7 mm (1.091 in) 44.2 mm (1.740 in)
(B)

Coat the thrust washers with petroleum jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE:
247RY00037 on the rear planetary gear.
8. One-way clutch
Install the one-way clutch with the flanged side facing
upward onto the rear planetary gear.
247RY00038
9. Snap ring
Install snap ring.
247RY00039

While turning counterclockwise, install one-way clutch
inner race to rear planetary gear.
247RY00040

inner race.
①: Lock
②: Free
247RY00041

Install rear planetary gear onto rear planetary ring gear.
247RY00029
12. Disc, plate and flange (B-3)

Install a brake flange onto the rear planetary gear
assembly.
Install a clutch plate onto the rear planetary gear
assembly.
NOTE:
The claw interval of the plate should be as shown in
the figure when viewing the clutch plate from the
246RY00013
arrow direction.
Install seven clutch discs and seven brake plates (UBS)

or six clutch discs and six brake plates (TFR/S)
alternately, starting with clutch disc, onto the rear
planetary gear assembly.
247RY00047
13. Oil seal ring

output shaft.
NOTE:
247RY00028
14. Output shaft

Install output shaft into rear planetary gear assembly.
247RY00042

246RY00014
FIRST AND REVERSE BRAKE (B-3)

DISASSEMBLY
246RY00024
Disassembly steps
1. Thrust bearing and race 6. Reaction sleeve
3. Piston return spring 8. First and reverse brake piston No.1
4. First and reverse brake piston No.2 9. O-ring
5. O-ring
Disassembly steps
Remove assembled bearing and race from
transmission case.
247RY00043
Check first and reverse brake piston movement

Make sure that first and reverse brake piston moves
smoothly when applying and releasing the compressed
air into the transmission case.
246RY00016
2. Snap ring
Set special tool on the spring retainer, and compress
the return spring.
247RY00002
4. First and reverse brake piston No.2

Holding the first and reverse brake piston No.2 by
hand, apply compressed air to the transmission case to
remove the first and reverse brake piston No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air, lift
the piston out with needle-nose pliers.
5. O-ring
246RY00016
6. Reaction sleeve
Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: 5-8840-2173-0 (J-37236)
7. O-ring
246RY00017

Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the transmission
case.
Piston puller: 5-8840-2174-0 (J-37237)
9. O-ring
247RY00044
REASSEMBLY
246RY00025
Reassembly steps
1. O-ring 6. First and reverse brake piston No.2
2. O-ring 7. Return spring
3. First and reverse brake piston No.1 8. Snap ring
4. O-ring 9. Thrust bearing and race
5. Reaction sleeve
Reassembly steps
1. O-ring
Coat three new O-rings with ATF.
Install the two O-rings on the No.1 piston.
2. O-ring
Install the O-ring on the reaction sleeve.
Install the first and reverse brake piston No.1 to the
246RY00018
reaction sleeve.
4. O-ring
Coat a new O-ring with ATF and install it on the first
and reverse brake piston No.2.
5. Reaction sleeve
Install the first and reverse brake piston No.1 with
reaction sleeve onto the first and reverse brake piston
No.2.
246RY00019

Align the teeth of the first and reverse brake piston
No.2 into the proper grooves.
first and reverse brake piston No.2 with No.1 into the
transmission case.
246RY00020
7. Return spring
Place piston return spring onto first and reverse brake
piston No.2.
246RY00021
8. Snap ring
Set special tool as shown, and compress the return
spring with special tool.
247RY00002

Make sure the first and reverse brake piston moves
246RY00022

jelly.
Install the assembled bearing and race facing the
bearing side upward.

247RY00043 Outside diameter 58.15 mm (2.289 in)
TRANSMISSION VALVE BODY

ASSEMBLY
DISASSEMBLY
240R200039
Disassembly steps
1. Detent spring 6. Clamp
2. Manual shift valve 7. Pressure control solenoid
3. Upper valve body 8. No.2 gasket (Lower valve body side)
4. No.1 gasket (Upper valve body side) 9. Lower valve body
5. Valve body plate
Disassembly steps
1. Detent spring
Remove detent spring from valve body.
2. Manual shift valve
Remove manual shift valve.
240R200040
3. Upper valve body

4. No.1 gasket (Upper valve body side)
5. Valve body plate
Turn over assembly and remove thirty bolts.
6. Clamp
7. Pressure control solenoid
244R200049
Hold the valve body plate to the upper valve body.

Lift off upper valve body and plate as a single unit.
NOTE:
Be careful that the check balls and strainers do not
fall out.
8. No.2 gasket (Lower valve body side)
9. Lower valve body
244R200061
REASSEMBLY
240R200041
Reassembly steps
1. No.1 gasket (Upper valve body side) 6. Pressure control solenoid
2. Valve body plate 7. Clamp
3. No.2 gasket (Lower valve body side) 8. Manual shift valve
4. Upper valve body 9. Detent spring
5. Lower valve body
Reassembly steps
Position a new No.1 gasket (1) on upper valve body.
Align the No.1 gasket at each bolt hole.
2. Valve body plate
Position valve body plate (2) on No.1 gasket (1).
Align the plate at each bolt hole.
244R200073
Position a new No.2 gasket (3) on valve body plate (2).
Align the No.2 gasket at each bolt hole.
4. Upper valve body
5. Lower valve body
Place upper valve body with plate and gaskets on top
lower valve body.
Align each bolt hole and gasket in the valve body.
6. Pressure control solenoid
7. Clamp
244R200074
Install thirty bolts to upper valve body.

Each bolt is indicated in the figure.
Length (mm) Quantity
A 20 7
B 28 12
C 40 11
Torque: 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
244R200050

Install manual shift valve.
9. Detent spring
Install detent spring.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
240R200040
LOWER VALVE BODY

DISASSEMBLY
244R200046
244R200075
Disassembly steps
1. By-pass valve 19. Retainer
2. Spring 20. Plug
3. Strainer 21. Spring
4. Shift solenoid S1 22. Accumulator control valve
5. Shift solenoid S2 23. Retainer
6. Lock-up solenoid SL 24. Spring
7. Clamp 25. Coast modulator valve
8. Accumulator sub-assembly 26. Retainer
9. Retainer 27. Plug
10. Spring 28. Spring
11. Ball 29. Cut back valve
12. Retainer 30. Retainer
13. Plug 31. Sleeve
14. Spring 32. Plunger
15. 1-2 shift valve 33. Plunger
16. Retainer 34. Spring
17. Spring 35. Washer
18. Low coast modulator valve 36. Primary regulator valve
37. Lower valve body
Disassembly steps
1. By-pass valve
2. Spring
Remove by-pass valve and spring.
244R200063
3. Strainer
Remove three strainers.
244R200064
NOTE:
Confirm six retainers are installed correctly.
244R200066
4. Shift solenoid S1
Remove the fixing bolt.
Remove the shift solenoid S1 (2) and S2 (1) from each
bore.
Remove the O-rings from each solenoid.
6. Lock-up solenoid SL
Remove the lock-up solenoid SL (3) from the bore.
Remove the O-ring from solenoid.
7. Clamp
8. Accumulator sub-assembly
Remove the clamp.
Remove the accumulator sub-assembly (4) from the
bore.
9. Retainer
10. Spring
11. Ball
Remove the retainer (5).
Remove the spring and ball from the valve body.
244R200052
240R200042
12. Retainer
Remove the retainer with a magnetic finger by pushing
in the plug.
13. Plug
14. Spring
15. 1-2 shift valve
Remove the plug, spring and 1-2 shift valve.
244R200067
244R200054
16. Retainer
Remove the retainer by pushing in the spring with a
screwdriver.
17. Spring
18. Low coast modulator valve
Remove the spring and low coast modulator valve.
244R200068
244R200056
19. Retainer
in the plug.
20. Plug
21. Spring
22. Accumulator control valve
Remove the plug, spring and accumulator control valve.
244R200069
244R200057
23. Retainer
Remove the retainer by pushing in the spring with a
screwdriver.
24. Spring
25. Coast modulator valve
Remove the spring and coast modulator valve.
244R200070
244R200058
26. Retainer
in the plug.
27. Plug
28. Spring
29. Cut back valve
Remove the plug, spring and cut back valve.
244R200071
244R200065
30. Retainer
Place a mark on the bevel when the retainer is
positioned.
NOTE:
When reassembling, position the retainer in the
same position.
in the sleeve.
244R200072 31. Sleeve
32. Plunger
33. Plunger
34. Spring
35. Washer
36. Primary regulator valve
Remove the sleeve with the plungers, spring and
washer.
Remove the two plungers from the sleeve.
244R200059
Remove the primary regulator valve from the valve

body.
37. Lower valve body
244R200060

Inspect strainer
Inspect strainer for residual adhesive and damage, and
clean and replace as necessary.
244R200051
Inspect valve springs

Check for damage, squareness, rust and distorted
coils.
Measure the spring free height and replace if less than
shown below.
Spring Free length

(1) By-pass valve 21.3 mm (0.839 in)
(2) Steel ball 20.5 mm (0.807 in)
(3) 1-2 shift valve 30.8 mm (1.213 in)
(4) Low coast modulator valve 30.4 mm (1.197 in)
(5) Accumulator control valve 33.8 mm (1.331 in)
(6) Coast modulator valve 26.6 mm (1.047 in)
(7) Cut back valve 34.0 mm (1.339 in)
(8) Primary regulator valve 41.6 mm (1.638 in)
244R200077
REASSEMBLY
244R200046
244R200076
Reassembly steps
1. Lower valve body 19. Retainer
2. Washer 20. Low coast modulator valve
3. Primary regulator valve 21. Spring
4. Plunger 22. Retainer
5. Plunger 23. 1-2 shift valve
7. Sleeve 25. Plug
8. Retainer 26. Retainer
9. Cut back valve 27. Ball
11. Plug 29. Retainer
12. Retainer 30. Accumulator sub-assembly
13. Coast modulator valve 31. Clamp
14. Spring 32. Lock-up solenoid SL
15. Retainer 33. Shift solenoid S2
16. Accumulator control valve 34. Shift solenoid S1
17. Spring 35. Strainer
18. Plug 36. Spring
37. By-pass valve
Reassembly steps
1. Lower valve body
2. Washer
Install the washer onto the primary regulator valve.
Install the primary regulator valve with the washer into
the bore.
4. Plunger
244R200060
5. Plunger
Install the two plungers into the sleeve.
6. Spring
7. Sleeve
Install the sleeve with the two plungers and spring into
the bore.
8. Retainer
Install the retainer to the bevel by pushing in the
sleeve.
NOTE:
Install the retainer to the same position on the
sleeve, as when disassembling.
244R200072
244R200059
9. Cut back valve

10. Spring
11. Plug
Install the cut back valve, spring and plug into the bore.
12. Retainer
Install the retainer by pushing in the plug.
244R200065
244R200071
13. Coast modulator valve

14. Spring
15. Retainer
244R200058
244R200070

17. Spring
18. Plug
Install the accumulator control valve, spring and plug
into the bore.
19. Retainer
244R200057
244R200069

21. Spring
Install the low coast modulator valve and spring into the
bore.
22. Retainer
Install the retainer by pushing in the spring.
244R200056
244R200068
23. 1-2 shift valve

24. Spring
25. Plug
Install the 1-2 shift valve, spring and plug into the bore.
26. Retainer
244R200054
244R200067
27. Ball
28. spring
29. Retainer
Install the ball, spring and retainer (5) to the valve body.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
30. Accumulator sub-assembly
31. Clamp
Install the accumulator sub-assembly (4) and clamp to
244R200052
the valve body.
Torque: 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
32. Lock-up solenoid SL
Install a new O-ring to the solenoid (3).
Install the solenoid to the valve body.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
Install a new O-ring to the solenoids (1) and (2).
Install the solenoids to the valve body.
Torque: 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
240R200042
NOTE:
Make sure six retainers are installed correctly.
244R200066
35. Strainer
Install the three strainers to the valve body as shown.
244R200064
36. Spring
37. By-pass valve
Install the spring and by-pass valve to the valve body
as shown.
244R200063
UPPER VALVE BODY

DISASSEMBLY
243R200052
243R200074
Disassembly steps
1. Check ball 18. Retainer
3. Check valve NO.2 20. Spring
4. Ball 21. Reverse control valve
5. Check valve NO.1 22. Retainer
7. Check valve NO.2 24. Second coast modulator valve
8. Ball 25. Spring
9. Check valve NO.1 26. Retainer
11. Plug 28. 3-4 shift valve
12. Secondary regulator valve 29. Spring
13. Spring 30. Retainer
14. Retainer 31. Sleeve
15. Plug 32. Plunger
17. 2-3 shift valve 34. Lock-up relay valve
35. Upper valve body
UBS Disassembly steps

1. Check ball
Remove the two types of check balls from the valve
body.
Number of check ball : UBS − 11
TFR/S − 10
243R200053
TFR/S
243L200001
NOTE:
Confirm eight retainers are installed correctly.
243R200054
2. Retainer
3. Check valve NO.2
4. Ball
5. Check valve NO.1
Remove the check valve NO.2 ball and check valve
NO.1 from the valve body.
243R200066
243R200062
6. Retainer
7. Check valve NO.2
8. Ball
9. Check valve NO.1
Remove the check valve NO.2, ball and check valve
NO.1 from the valve body.
243R200067
243R200062
10. Retainer
in the plug.
11. Plug
12. Secondary regulator valve
13. Spring
Remove the plug, secondary regulator valve and
spring.
243R200070
243R200056
14. Retainer
Remove the trainer with a magnetic finger by pushing in
the plug.
15. Plug
16. Spring
17. 2-3 shift valve
243R200069
243R200058
18. Retainer
in the plug.
19. Plug
20. Spring
21. Reverse control valve
Remove the plug, spring and reverse control valve.
243R200068
243R200060
22. Retainer
in the plug.
23. Plug
24. Second coast modulator valve
25. Spring
Remove the plug, second coast modulator valve and
spring.
243R200073
243R200063
26. Retainer
in the plug.
27. Plug
28. 3-4 shift valve
29. Spring
Remove the plug, 3-4 shift valve and spring.
243R200072
243R200064
30. Retainer
in the sleeve.
31. Sleeve
32. Plunger
33. Spring
34. Lock-up relay valve
Remove the sleeve with the plunger, spring and lock-up
243R200071 relay valve.
Remove the lock-up relay valve, spring and plunger
from the sleeve.
35. Upper valve body
243R200065

Check for damage, squareness, rust and distorted
coils.
that down below.
Spring Free length

(1) secondary regulator valve 32.9 mm (1.295 in)
(2) 2-3 shift valve 30.8 mm (1.213 in)
(3) Reverse control valve 25.6 mm (1.008 in)
(4) Second coast modulator
30.9 mm (1.217 in)
valve
(5) 3-4 shift valve 30.8 mm (1.213 in)
(6) Lock-up relay valve 23.4 mm (0.912 in)
243R200076
REASSEMBLY
243R200052
243R200075
Reassembly steps
1. Upper valve body 19. 2-3 shift valve
2. Plunger 20. Spring
3. Spring 21. Plug
4. Lock-up relay valve 22. Retainer
5. Sleeve 23. Spring
6. Retainer 24. Secondary regulator valve
7. Spring 25. Plug
8. 3-4 shift valve 26. Retainer
9. Plug 27. Check valve NO.1
10. Retainer 28. Ball
11. Spring 29. Check valve NO.2
12. Second coast modulator valve 30. Retainer
13. Plug 31. Check valve NO.1
14. Retainer 32. Ball
15. Reverse control valve 33. Check valve NO.2
17. Plug 35. Check ball
18. Retainer
Reassembly steps
1. Upper valve body
2. Plunger
3. Spring
5. Sleeve
Install the plunger and spring into the sleeve.
Install the lock-up relay valve into the sleeve.
243R200065
Install the sleeve with the plunger, spring and lock-up
relay valve into the bore.
6. Retainer
Install the retainer.
243R200071
7. Spring
8. 3-4 shift valve
9. Plug
Install the spring, 3-4 shift valve and plug into the bore.
10. Retainer
243R200064
243R200072
11. Spring
13. Plug
Install the spring, second coast modulator valve and
plug into the bore.
14. Retainer
243R200063
243R200073
15. Reverse control valve

16. Spring
17. Plug
Install the reverse control valve, spring and plug into
the bore.
18. Retainer
243R200060
243R200068
19. 2-3 shift valve

20. Spring
21. Plug
Install the 2-3 valve, spring and plug into the bore.
22. Retainer
243R200058
243R200069
23. Spring
25. Plug
Install the spring, secondary regulator valve and plug
into the bore.
26. Retainer
243R200056
243R200070
27. Check valve NO.1

28. Ball
Install the check valve NO.1, ball and check valve NO.2
to valve body.
30. Retainer
243R200062
243R200067

32. Ball
Install the check valve NO.1, ball and check valve NO.2
to the valve body.
34. Retainer
243R200062
243R200066
NOTE:
Make sure eight retainers are installed correctly
243R200054
UBS 35. Check ball

Install the two types of check balls to the valve body.
Number of check ball : UBS – 11
TFR/S – 10
Check ball Diameter
(A) Rubber ball 5.535 mm (0.2179 in)
(B) Rubber ball 6.35 mm (0.2500 in)
243R200053
TFR/S
243L200001
TRANSMISSION CASE
DISASSEMBLY
249RY00001
Disassembly steps
1. Spacer 4. Manual valve lever
2. Pin 5. Oil seal
3. Manual valve lever shaft 6. Oil seal
Disassembly steps
1. Spacer
Using a chisel, cut off the spacer and remove it from
the shaft.
249RY00002
2. Pin
Using a punch, drive out the pin.
3. Manual valve lever shaft
4. Manual valve lever
Pull the manual valve lever shaft out through the case
by the threads.
249RY00003
5. Oil seal
6. Oil seal
Using a screwdriver, remove the oil seal.
249RY00004
REASSEMBLY
249RX00001
Reassembly steps
1. Oil seal 4. Manual valve lever
2. Oil seal 5. Manual valve lever shaft
3. Spacer 6. Pin
Reassembly steps
1. Oil seal
2. Oil seal
Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : 5-8840-2169-0 (J-37232-2)
240RY00021
3. Spacer
Assemble a new spacer to the manual valve lever.
Install the manual valve lever shaft to the transmission
case through the manual valve lever by the threads.
249RY00005
6. Pin
Drive in the pin with the slot at a right angle to the
shaft.
249RY00006
Match the spacer hole to the lever staking hollow and

stake the spacer to the lever.
Make sure the manual valve lever shaft turns smoothly.
249RY00003
TORQUE CONVERTER
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : 5-8840-2168-0
(J-35467)
Insert the stopper so that it fits in the notch of the
241RY00018
converter hub and outer race of the one-way clutch.
One-way clutch test
The clutch should lock when turned counterclockwise,
and rotate freely and smoothly clockwise. Less than 25
kg･cm (22 Ib･in) of torque should be required to rotate
the clutch clockwise. If necessary, clean the converter
and retest the clutch. Replace the converter if the
clutch still fails the test.
ADAPTER HOUSING (4×

×4)
DISASSEMBLY
241R200005
Disassembly steps
1. Oil seal
2. Adapter housing
Disassembly steps
1. Oil seal
2. Adapter housing
REASSEMBLY
241R200006
Reassembly steps
1. Adapter housing
2. Oil seal
Reassembly steps
1. Adapter housing
2. Oil seal
Using oil seal installer, install the new oil seal to the
adapter housing.
240RY00003
EXTENSION HOUSING (4×

×2)
DISASSEMBLY
241R200007
Disassembly steps
1. Gasket 4. Oil seal
2. Tube 5. Dust deflector
3. Tube packing 6. Extension housing
Disassembly steps
1. Gasket
2. Tube
3. Tube packing
4. Oil seal
NOTE:
The oil seal can be removed without removing the
dust deflector.
5. Dust deflector
6. Extension housing
REASSEMBLY
241R200008
Reassembly steps
1. Extension housing 4. Tube packing
2. Oil seal 5. Dust deflector
3. Tube 6. Gasket
Reassembly steps
2. Oil seal
extension housing.
NOTE:
The oil seal can be installed without removing the
249L100005 dust deflector.
3. Tube
4. Tube packing
5. Dust deflector
6. Gasket
MAIN DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
Remaks
Model AW30-40LE
’02 UBS − 4JX1-TC
Engine ’02 TFR/S − 4JH1-TC
’01 TFR − 4JH1-T
Electronic control planetary gear type
Type 3-element 1-stage 2-phase type
(with lock-up mechanism)
1st 2.804
2nd 1.532
Gear ratio 3rd 1.000
4th (O/D) 0.705
Reverse 2.394
Name BESCO ATF Ⅲ
Oil used UBS and TFR/S − 8.7
Q’ty (l)
‘01 TFR − 8
UBS 2450±150
Torque converter TFR/S 2270±150 Stall speed (rpm)
’01 TFR 2415±150
Forward clutch C-1 UBS − 6, TFR/S − 5
Direct clutch C-2 UBS − 5, TFR/S − 4 Number of discs
Friction element
OD direct clutch C-0 2

Band width or
Second coast brake B-1 40 mm
Number of discs
Second brake B-2 5
First and reverse brake B-3 UBS − 7, TFR/S − 6 Number of discs
Overdrive brake B-0 4
One-way clutch No.1 F-1 22
Clutch
One-way clutch No.2 F-2 28 Number of sprage

OD one-way clutch F-0 24
Sun gear 42
Front planetary Pinion gear 19
Ring gear 79
Planetary gear
Sun gear 33
Rear planetary Pinion gear 23 Number of teeth
Ring gear 79
Sun gear 33
O/D planetary Pinion gear 23
Ring gear 79
TORQUE SPECIFICATIONS
UBS N･
･m (kg･
･m/Ib･
･ft)
E07R200015
TORQUE SPECIFICATIONS (Cont’d)

TFR/S N･
･m (kg･
･m/Ib･
･ft)
E07L200005

N･
･m (kg･
･m/Ib･
･ft)
E07R200018

N･
･m (kg･
･m/Ib･
･ft)
E07R200020
SPECIAL TOOLS
ILLUSTRATION PART NO. PART NAME
Tech 2 scan tool
5-8840-0093-0 Oil pressure gauge
5884000930
5-8840-2152-0
Holding fixture
(J-37227)
901RY00018
5-8840-0003-0
Holding fixture base
(J-3289-20)
901RT096
5-8840-2153-0
Oil pan seal cutter
(J-37228)
901RY00019
5-8840-0195-0
Spring compressor
(J-23327-1)
901RY00028
5-8840-2256-0
Oil seal installer; oil pump
(J-9617)
901RY00020
5-8840-2170-0
Spring compressor; OD brake piston
(J-37233)
901RY00021
5-8840-0254-0
Spring compressor
(J-25048)
901RY00022
5-8840-2173-0
Reaction sleeve puller; first and reverse brake
(J-37236)
901RY00023
5-8840-2174-0
Piston puller; first and reverse brake
(J-37237)
901RY00024
5-8840-2169-0 Oil seal installer; manual valve shaft seal installer &
(J-37232-2) remover
901RY00025
5-8840-2168-0
One-way clutch testing tool; torque converter
(J-35467)
901RY00026
Oil seal installer;

5-8840-2282-0
adapter housing (4×4)
901RY00027
Oil seal installer;

5-8840-2702-0
extension housing (4×2)
5884027020
RVAW3-WE-0211F

This manual is applicable for vehicles in all countries


reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
First edition Nov, 2001

NO.RVAW3-WE-0211F
WORKSHOP MANUAL
UBS AND TF SERIES
TRANSMISSION
AW30-40LE MODEL
(SEMI-AUTOMATIC ELECTRONICALLY CONTROLLED)
SECTION 7
NOTICE
MANUAL”.

notice.
Applicable Model : UBS 69 (For General Export)

TFS 69 (For Israel)
TFR 69 (For Israel)
This manual is applicable to 2002 year model vehicle.

INDEX
SECTION 7A
AUTOMATIC TRANSMISSION (AW30-40LE)
TABLE OF CONTENTS
PAGE
General Description.........................................................................................................7A- 4
Construction................................................................................................................7A- 4
Electronic Control Components ................................................................................7A- 5
Transmission Control Module (TCM) ........................................................................7A- 6
Control System Diagram ............................................................................................7A- 7
Control and Functions ................................................................................................7A- 8
Major Input/Output Components ...............................................................................7A- 11
Location of Clutch, Brake, One-way Clutch and Solenoid ......................................7A- 12
Operation of Clutch, Brake and One-Way Clutch.....................................................7A- 14
Speed Change and Lock-up Pattern..........................................................................7A- 14
Overdrive and Lock-up Operating Conditions..........................................................7A- 15
Diagnosis..........................................................................................................................7A- 16
Basic Troubleshooting ...............................................................................................7A- 16
Self Diagnosis .............................................................................................................7A- 17
Diagnosis with Tech 2 ................................................................................................7A- 20
Tech 2 Connection ......................................................................................................7A- 21
Tech 2 Operating Flow Chart (Start up) ....................................................................7A- 23
Intermittent Conditions...............................................................................................7A- 24
Data List.......................................................................................................................7A- 25
Identification of Transmission Control Module (TCM).............................................7A- 26
Diagnostic Trouble Codes (DTC) Check ...................................................................7A- 27
Wiring Diagram............................................................................................................7A- 43
Connector List.............................................................................................................7A- 47
Troubleshooting Chart ...............................................................................................7A- 51
Manual Shifting Test ...................................................................................................7A- 56
Stall Test ......................................................................................................................7A- 57
Time Lag Test ..............................................................................................................7A- 58
Hydraulic Test .............................................................................................................7A- 59
Road Test.....................................................................................................................7A- 61
Shift Point Chart and Lock-Up Point Chart ...............................................................7A- 64
TCM Voltage Check.....................................................................................................7A- 68
On-Vehicle Service ..........................................................................................................7A- 70
Transmission Fluid Level and Condition ..................................................................7A- 70
ATF Replacement........................................................................................................7A- 70
Throttle Cable Adjustment .........................................................................................7A- 71
Neutral Start Switch Inspection .................................................................................7A- 72
Brake Signal Inspection .............................................................................................7A- 73
Vehicle Speed Sensor 1 Inspection...........................................................................7A- 73
Vehicle Speed Sensor 2 Inspection...........................................................................7A- 73
Pattern Select Switch Inspection...............................................................................7A- 74
Overdrive Switch Inspection......................................................................................7A- 74
Solenoid Inspection ....................................................................................................7A- 75
ATF Temperature Sensor Inspection ........................................................................7A- 75
Throttle Position Sensor Inspection..........................................................................7A- 76
Selector Lever .............................................................................................................7A- 76
Shift Solenoid and Lock-Up Solenoid .......................................................................7A- 78
Valve Body Assembly .................................................................................................7A- 79
Rear Oil Seal (Adapter Housing, 4×
×4) ......................................................................7A- 82
Rear Oil Seal (Extension Housing, 4×
×2) ..................................................................7A- 82
Transmission Removal and Installation....................................................................7A- 83
Unit Repair........................................................................................................................7A- 90
Disassembly of Major Components (1) .....................................................................7A- 92
Reassembly of Major Components (1) ......................................................................7A- 94
Disassembly of Major Components (2) .....................................................................7A- 97
Disassembly, Inspection and Reassembly of Minor Components .........................7A-130
Oil Pump ......................................................................................................................7A-131
OD Planetary Gear and OD Direct Clutch Assembly (C-0).......................................7A-136
OD Support Assembly ................................................................................................7A-146
Direct Clutch Assembly (C-2) .....................................................................................7A-151
Forward Clutch Assembly (C-1).................................................................................7A-157
Front Planetary Gear...................................................................................................7A-165

Planetary Sun Gear and No.1 One-Way Clutch ........................................................7A-169
Second Brake Assembly (B-2) ...................................................................................7A-174
Rear Planetary Gear Assembly and Output Shaft ....................................................7A-178
First and Reverse Brake Assembly (B-3) ..................................................................7A-185
Transmission Valve Body Assembly.........................................................................7A-191
Lower Valve Body .......................................................................................................7A-195
Upper Valve Body........................................................................................................7A-207
Transmission Case .....................................................................................................7A-223
Torque Converter ........................................................................................................7A-227
Adapter Housing (4×
×4) ..............................................................................................7A-228
Extension Housing (4×
×2)...........................................................................................7A-230
Main Data and Specifications .........................................................................................7A-232
General Specifications ...............................................................................................7A-232
Torque Specifications.................................................................................................7A-233
Special Tool......................................................................................................................7A-236
CAUTION:
When fasteners are removed, always reinstall them Fasteners that are not reused, and those requiring
at a the same location from which they were thread locking compound, will be called out. The
removed. If a fastener needs to be replaced, use correct torque values must be used when installing
the correct part number fastener for that fasteners that require torque. If the above
application. If the correct part number fastener is conditions are not followed, parts or system
not available, a fastener of equal size and strength damage could result.
(or stronger) may be used.
GENERAL DESCRIPTION
CONSTRUCTION
A07R200001
ELECTRONIC CONTROL COMPONENTS
C07R200008
C07R200009
C07R200010
CONTROL AND FUNCTIONS
Item Description
Pattern selection control ・ In D range, speed change point and Lock-up point can be
changed by setting pattern selection switch to “POWER” or
“NORMAL”, or “WINTER” (UBS) mode.
Gear shift control ・ Gear shift position in the conditions made up of transmission shift
(Speed change point positions (D.2.L) combined with pattern selection switch
Speed change timing) (POWER, NORMAL, and WINTER) can be controlled in
accordance with vehicle speed and the opening of throttle valve.
Lock-up control ・ In D range, 2nd, 3rd, or O/D lock-up is conducted in “POWER” or
“NORMAL” mode.
・ In 2, L range, lock-up is off in the whole area.
・ Lock-up timing is controlled to reduce gear shift shock using kind
of gear shift (shift up, etc.) lock-up status at the time of gear shift
judgement, gear step and throttle opening after gear shift.
・ When the brake is switched on, lock-up is discontinued.
・ Lock-up is prohibited when idling is defected by throttle position
sensor.
Overdrive gear shift control ・ If O/D switch is set on in D range (O/D OFF lamp ON), gear shift
to O/D is not effected.
However, to prevent engine over revolution.
・ 4→3 shifting at vehicle speed is less than 126 km/h (TF), 124
km/h (UBS).
・ 3→4 shifting at vehicle speed is more than 128 km/h (TF), 126
km/h (UBS).
Throttle leaning control ・ Variation in throttle position sensor voltage is corrected in TCM
thereby to ensure a constant gear shift control.
Fail-safe function ・ When trouble occurs to vehicle sensor and each solenoid, TCM
automatically exerts fail-safe control not to spoil driveability.
・ This control is exerted when sensor or actuator is in trouble,
while TCM works normally.
Self-diagnosis function ・ If there is an abnormality in vehicle sensors, each solenoid (S1-
S3), or throttle position sensor, “CHECK TRANS” lamp is
actuated to warn the driver. But when the abnormality items have
been restored to normal, the light does not blink.
・ Faulty parts are memorized in TCM. If self-diagnosis start signal
is inputted, “CHECK TRANS” lamp is blinked and results of
diagnosis are indicated. A history of faults remains recorded even
when IGN switch is off.
Tech 2 ・ Output of control data in the TCM
・ Actuator (Solenoid) operation check
・ Erasure of trouble code
Driving mode select control ・ The TCM selects a suitable driving mode at high A/T oil
temperature (D range).
i)Economy mode ii)Power mode iii)Winter mode (UBS)
iv)HOT1 mode (more than 160℃ TF) v)HOT2 mode (more
than 140℃) vi)L4 mode
・ The priority of driving mode:
Economy < Power < L4 < Winter < HOT1 < HOT2
Oil temperature warning function ・ If the transmission oil temperature sensor senses that
transmission oil temperature is greater than 146℃, the TCM turn
on A/T OIL TEMP warning lamp. (The warning lamp is turned off,
if oil temperature is less than 126℃.)
L4 mode control (4×4) ・ The TCM judges whether the transfer is engaged in high or low
based on the ratio rpm data from output speed sensor in the
transmission and the rpm data form speed meter sensor to
select the shift map.
Winter mode control (UBS) ・ The TCM controls the vehicle start smoothly on low frictional road
like snow road by executing this control.
Active condition:
1. Excluding “2”, “L” range
2. Vehicle speed is less than 11 km/h
3. Transmission oil temperature is less than 115℃
4. Throttle opening is less than 8%
5. Excluding winter mode
Cancel condition:
1. When winter mode switch is pushed again
2. When either “2” or “L” is detected
3. Ignition switch “OFF”
4. Vehicle speed is more than 34 km/h for 1 second or mode
continuously
5. Transmission oil temperature is more than 130℃
FAIL-SAFE FUNCITON
Vehicle speed sensor 1, 2 The vehicle speed is detected by two systems, one from a sensor
fitted to the transmission (output shaft revolution sensor) and another
from the speedometer.
In case of malfunction in one of two, the speed signal from the other
is used for control.
Neutral start switch In case “2” and “L” range signals are on, priority is given “L”.
Shift solenoid S1 and S2 If there is an abnormality is one or both of solenoids, TCM
automatically exerts fail-safe control, thereby maintaining driveability.
Lock-up control solenoid S3 This keeps lock-up control solenoid S3 off.
SHIFT SOLENOID S1, S2 (FAIL-SAFE FUNCTION)
SOLENOID S1 SOLENOID S2 BOTH SOLENOIDS

NORMAL
MALFUNCTIONING MALFUNCTIONING MALFUNCTIONING
Solenoid Gear Solenoid Gear Solenoid Gear Solenoid Gear
Range
S1 S2 position S1 S2 position S1 S2 position S1 S2 position
ON←
ON OFF 1st × 3rd ON × 1st × × OD
(OFF)
OFF←
ON ON 2nd × ON 3rd × OD × × OD
(ON)
“D” range
OFF ON 3rd × ON 3rd OFF × OD × × OD
OFF OFF OD × OFF OD OFF × OD × × OD
ON←
ON OFF 1st × 3rd ON × 1st × × 3rd
(OFF)
OFF←
“2” range ON ON 2nd × ON 3rd × 3rd × × 3rd
(ON)
OFF ON 3rd × ON 3rd OFF × 3rd × × 3rd
ON OFF 1st × OFF 3rd ON × 1st × × 3rd

“L” range
OFF←
ON ON 2nd × 3rd ON × 1st × × 3rd
(ON)
( ): Fail-safe function X: Malfunctions
MAJOR INPUT/OUTPUT COMPONENTS
Component Function
Vehicle speed sensor 1 (Speedometer) Detects the vehicle speed
Vehicle speed sensor 2 (Transmission) Detects the vehicle speed
Throttle position sensor Detects the injection pump lever opening rate
Neutral start switch Detects the select lever position
Pattern select switch Detects whether the driver has select “NORMAL” or
Input
“POWER”, or “WINTER” (UBS) mode

A/T Fluid temperature sensor Detects the A/T Fluid temperature
Overdrive switch Detects whether the driver has selected O/D
Brake lamp switch Detects whether the driver has pressed the brake pedal or not
Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any
Diagnosis connector When connected with Tech 2 or tester, can communicate the
Output
Input/
data for function check, etc.
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle
running condition on the basis of TCM output.
Lock-up control solenoid S3 Control the lock-up clutch suited to the vehicle running
condition on the basis of TCM output.
“CHECK TRANS” lamp When trouble has occurred to throttle position sensor, vehicle
Output
speed sensor, or solenoid, “CHECK TRANS” lamp is blinked

to warn the driver. If also displays the trouble code.
“AT OIL TEMP” lamp When A/T Fluid temperature is high, “AT OIL TEMP” lamp is
on to be warm the driver. (Turned on at greater than 146℃.
Turned off at less than 126℃.)
Power mode lamp Informs the driver whether the vehicle is in power mode or not.
Winter mode lamp (UBS) Informs the driver whether the vehicle is in winter mode or not.
Transmission Control Module (TCM) Based on the signal from each switch and sensors, judges
Computer
necessary shift point and lock-up operation, and send signal to

each solenoid.
LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID
C07R200007
Legend
1. Overdrive direct clutch (C-0) 7. First and reverse brake (B-3)
2. Overdrive brake (B-0) 8. One-way clutch (No.2) (F-2)
3. Direct clutch (C-2) 9. One-way clutch (No.1) (F-1)
4. Second coast brake (B-1) 10. Shift solenoid (S-1), Shift solenoid
5. Forward clutch (C-1) (S-2), and Lock-up solenoid (S-3)
6. Second brake (B-2) 11. Overdrive one-way clutch (F-0)
OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH

○: Operating ◎: Operating at lock-up
Shift lever
Gear position C-0 C-1 C-2 B-0 B-1 B-2 B-3 F-0 F-1 F-2 S-3
position
P Parking ○
R Reverse ○ ○ ○ ○
N Neutral ○
1st ○ ○ ○ ○
2nd ○ ○ ○ ○ ○ ◎
D
3rd ○ ○ ○ ○ ○ ◎
O/D ○ ○ ○ ○ ◎
1st ○ ○ ○ ○
2 2nd ○ ○ ○ ○ ○ ○
3rd ○ ○ ○ ○ ○
1st ○ ○ ○ ○ ○
L (1*) 2nd ○ ○ ○ ○ ○ ○
(2*) 3rd ○ ○ ○ ○ ○
(1*) Down-shift only in the L range and 2nd gear – no up-shift
(2*) Down-shift only in the L range and 3rd gear – no up-shift
SPEED CHANGE AND LOCK-UP PATTERN

If you select a speed range and a lock-up pattern as shown below by specifying respective positions of
transmission shift lever, transfer shift lever and pattern select switch, the transmission control computer controls
speed change and lock-up operations based on the specified pattern in accordance with the degree of throttle
opening and vehicle speed.
Transmission shift position

Pattern select sw.
D
position 2 L
Overdrive switch ON Overdrive switch OFF
NORMAL, POWER 1st⇔[2nd]⇔[3rd]⇔[O/D] 1st⇔[2nd]⇔[3rd]←[O/D] 1st⇔2nd⇔(3rd) 1st←(2nd)←(3rd)
[ ]: The lock-up operation is available.
( ): Transmission is shifted at high speed to prevent overrun.
OVERDRIVE AND LOCK-UP OPERATING CONDITIONS

The overdrive and lock-up clutch operate if the following conditions are satisfied.
Overdrive Lock-up clutch

Transmission shift position D range ←
Transmission O/D switch ON (O/D OFF lamp OFF) ―
Brake lamp switch ― OFF
Throttle opening ― Except fully closed
(TF) 2nd: About 30 km/h or more
About 46 km/h or more (TF) O/D: About 80 km/h or more
Vehicle speed
About 42 km/h or more (UBS) (UBS) 2nd: About 57 km/h or more
DIAGNOSIS
BASIC TROUBLESHOOTING
AW30-40LE transmission, called Electronic Controlled Transmission (ECT), differs from oil pressure control type
transmissions in that it is controlled by a microcomputer. Accordingly, its troubleshooting procedure differs also.
Before troubleshooting an ECT, first determine whether the problem is electrical or mechanical. To do this, just refer
to the basic troubleshooting flowchart provided below.
If the cause is already known, using the basic troubleshooting chart below along with the troubleshooting chart
should speed the procedure.
F07R200005
UBS SELF DIAGNOSIS

Warning to the driver
・ When trouble has occurred to throttle position sensor,
vehicle speed sensor, or solenoid, “CHECK TRANS” lamp
is blinked (1.25 Hz) even during driving to warn the driver.
・ The trouble is recorded by trouble code is TCM.
・ When temporary trouble has been shooted, the “CHECK
TRANS” lamp stops blinking. This blinking can be stopped
by setting the ignition key off. But the trouble code remains
825R200084 memorized in TCM.
TFR/S
825R200085
F07LV002
UBS (RHD) Self-diagnosis code display

・ For quick search for faulty parts, 6 different items of
trouble code are indicated by “CHECK TRANS” lamp
blinking.
・ The storaged trouble codes can be identified by shorting
the terminals No.11 and No.4 or 5 (ground) of diagnosis
connector with a lead wire.
740RY00013
UBS (LHD)
740RY00014
TFR/S
740R200046
Indication Method:
(1) Terminals No.11 and No.4 or 5 (ground) of diagnosis
connector are short circuited.
(2) Turn the ignition key to the ON position.
(3) In case there no trouble, normal code is indicated.
(4) In case a plurality of trouble codes have occurred at a
time, each code is indicated three times in numerical
order.
NOTE:
Power line runs through diagnosis connector.
Be careful shorting with a lead wire, etc.
(The vehicle side of control module may be damaged.)
For identification of trouble code, connect Tech 2 to
diagnosis connector.
F07LV001
Clear of trouble code memory

1. Clear the trouble code memory using F1: Clear DTC
Information for Tech 2.
2. Shorting terminals for 3-4 second between No.11 and
No.4 or 5 (ground) of diagnosis connectors after the
ignition key tuned to the on position for 1 second of longer.
・ After erasing trouble code, check to see if the normal code
is outputted through running test.
Trouble code
Trouble
Mode Diagnostic area and Failure
Code
11 Vehicle speed sensor 2 (Transmission mounting)
Open or shorted circuit
21 Throttle position sensor input

24 Vehicle speed sensor 1 (In speedometer)

31 Shift solenoid S1
32 Shift solenoid S2
33 Lock-up solenoid S3
F07L100030
DIAGNOSIS WITH TECH 2

In this AW30-40LE transmission, troubleshooting can be
performed for electrical faults using the Tech 2 scan tool.
If the CHECK TRANS lamp blinks, or if an electrical fault in the
transmission may probably exist, check trouble codes using
the Tech 2 scan tool.
In the diagnostic procedures described in this manual, first
repair the faulty positions indicated by trouble code in the order
of numbers and then perform troubleshooting for the faulty
positions that are not indicated by trouble code. For correct
troubleshooting, it is necessary to first repair the trouble codes
of lower-order numbers, then to repair the trouble codes of
higher-order numbers in sequence.
How to Use This Manual:

Check trouble codes using the Tech 2 scan tool.
If no codes are set:

・ Refer to Data List and identify the electrical faults that are
not indicated by trouble code.
If codes are set:
・ Record all the codes displayed by the Tech 2 and check if
the codes are intermittent (intermittent faults).
・ Clear the codes.
・ Drive the vehicle for a test to reproduce the faulty status.
・ Check trouble codes again using the Tech 2.
・ If no code is displayed by test driving, the fault is
intermittent. In this case, refer to the cautions on
intermittent conditions.
・ If a code is present, refer to “DIAGNOSTIC TROUBLE
CODES (DTC) CHECK” for diagnosis.
・ Because a code of high-order number may be set for the
reason that a code of low-order number has been set after
occurrence of a fault, perform repair work starting with a
lower-order number is ascending order.
TECH2 CONNECTION
The Tech2 scan tool is used to electrically diagnose the
automatic transmission system and to check the system. The
Tech2 enhances the diagnosis efficiency though all the
troubleshooting can be done without the Tech2.
The Tech2 is a portable, compact, and light tester. When it is
connected to the diagnosis connector of the vehicle, you can
perform a variety of diagnoses and tests by communicating
with the Transmission Control Module (TCM) of the vehicle.
1. Configuration of Tech2
901RW176 1. Tech2 scan tool kit (No. 7000086), Tech2 scan tool (No.
7000057) and DLC cable (No. 3000095)
2. SAE16/19 adapter (No. 3000098) (1), RS232 loop back
connector (No. 3000112) (2), and PCMCIA card (No.
3000117) (3)
F07RW033
UBS (RHD) 2. Tech2 Connection

・ Observe the Tech 2 User Guide.
1. Check the ignition is OFF.
2. Insert the ISUZU (model year) system PCMCIA card (1)
into the Tech2 (4).
3. Connect the SAE16/19 adapter (2) to the DLC cable (3).
4. Connect the DLC cable (3) to the Tech2 (4).
5. Connect the SAE16/19 adapter (2) to the diagnosis
connector of the vehicle.
740RY00013
6. Turn the ignition of the vehicle ON and press the "PWR"
UBS (LHD) key of the Tech2.
・ Check the display of the Tech 2.
NOTE:
Be sure to check that the power is not supplied to the
Tech2 when attaching or removing the PCMCIA card.
740RY00014
TF
740R200046
901RY00014
TECH2 OPERATING FLOW CHART (START UP)
060R200181
If the Tech2 displays a code as intermittent, or if after a test
drive a code does not reappear, the problem is most likely a
faulty electrical connection or loose wiring.
Terminals should always be the prime suspect.
Intermittent rarely occur in sophisticated electronic
components such as the Transmission Control Module (TCM).
When an intermittent problem is encountered, check suspect
circuits for:
・Poor terminal to wire connection.
・Terminals not fully seated in the connector body (backed
out).
・Improperly formed or damaged terminals.
・Loose, dirty, or corroded ground connections.
HINT: Any time you have an intermittent in more than one
circuit, check whether the circuits share a common
ground connection.
・Pinched or damaged wires.
・Electro-Magnetic Interference (EMI)
HINT: Check that all wires are properly routed away from
radios, etc.
Use the F2: SNAPSHOT mode of the Tech2 to help isolate
the cause of an intermittent fault. The snapshot mode will
record information before and after the problem occurs. Set
the snapshot to "trigger" on the suspect code (or codes) or, if
you notice the reported symptom during test drive, trigger the
snapshot manually.
After the snapshot has been triggered, command the Tech2 to
play back the flow of data recorded from each of the various
sensors. Signs of an intermittent fault in a sensor circuit are a
sudden unexplainable jump in data values out of the normal
range.
DATA LIST
Item Status and reference value

ON/CLOSED 12V
BRAKE SWITCH
OFF/OPEN 0V
ON/CLOSED 0V
COOLANT TEMP. SW
OFF/OPEN 12V
ACTIVE 12V
SOLENOID S1
INACTIVE 0V
ACTIVE 12V
SOLENOID S2
INACTIVE 0V
TCC SOLENOID ACTIVE 12V
(SOLENOID S3) INACTIVE 0V
0 – 254 KPH (km/h)
SPEED SENSOR 1
0 – 11430 p/min
0 – 254 KPH (km/h)
SPEED SENSOR 2
0 – 48006 p/min
TIME FROM START 0:00 – 4:15 (hr:min:sec)
–40℃ – +199℃
TRANSM. OIL TEMP.
4.96V – 0.00V
ON 0V
OIL LAMP
OFF 12V
LOW
OIL TEMPERATURE
HIGH
ACTIVE 0V (POWER mode)
PROGRAM SWITCH
INACTIVE 12V (NORMAL mode)
ON 0V
OVERDRIVE SWITCH
OFF 12V
SELECTOR POS. - P/R/D - or - 1 - or - 2 - or - N - FAULT -
ACTIVE 12V
SELECTOR POS.2
INACTIVE 0V
ACTIVE 12V
SELECTOR POS.L
INACTIVE 0V
0.00 - 9.99V
TPS SIGNAL
0 - 99%, 00 – 07
ACTUAL GEAR - 1 -, - 2 -, - 2L/U -, - 3 -, - 3L/U -, - 4 -, -4L/U -
ACTIVE 12V
SELECTOR POS.N
INACTIVE 0V
ACTIVE 0V
WINTER SWITCH
INACTIVE 12V
IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)
826R200028
ISUZU Parts No:

UBS ― 8-97302-387-0
TFS ― 8-97257-060-0
TFR ― 8-97257-061-0
DIAGNOSTIC TROUBLE CODES (DTC) CHECK

CODE 11 VEHICLE SPEED SENSOR 2 (OPEN/SHORTED CIRCUIT)
UBS
D07R200023
TF
D07R200015
1. When the vehicle is running, a speed signal is input

from the vehicle speed sensor 2 to the TCM.
Vehicle speed information is provided to the TCM by
2. At this test, the continuity of circuit wiring and the
the vehicle speed sensor 2. This sensor is located in
vehicle speed sensor 2 is checked.
the transmission extension housing (4×2) or adapter
housing (4×4). 4. At this test, the continuity of the vehicle speed
sensor 2 is checked.
The speed sensor is an electromagnetic pulse pickup
type that generates a speed signal according to the
revolution of the transmission output shaft. Diagnostic Aids:
As a result, the sensor sends a sine wave signal (AC)
to the TCM, which converts this sine wave signal (pulse
voltage) to a km/h signal.
Test Description: improperly formed or damaged terminals, poor terminal

1. Lift the driving wheels. 0−About 3 V Code 11 is Go to Step 2
2. With engine idling in gear, connect a (Vehicle speed 10 intermittent. If
voltmeter between the TCM 26 pin connector −20 km/h) other codes
1 terminal (22) and ground terminal (23). are not stored,
Does the voltage vary in the specified value? refer to
(The voltage increases in proportion to the “Diagnostic
speed.) Aids”.
1. Turn the ignition “OFF”. 560−680 Ω Go to Step 3 Go to Step 4
2. Disconnect the TCM 26 pin connector. (20 ℃)
2 3. Connect an ohmmeter between the TCM 610−740 Ω
terminal (22) and (23). (40℃)
1. Replace the TCM with a new one. − Go to Step 5 Go to Step 7
Is code 11 displayed?
1. Disconnect the connector of the vehicle 560−680 Ω Go to Step 6 Go to Step 5
speed sensor 2 on the transmission side. (20 ℃)
2. Measure the resistance between the 610−740 Ω
4
connector on the vehicle speed sensor 2 side (40℃)
with an ohmmeter.
Replace the vehicle speed sensor 2. − Go to Step 7 −
5
Check the wiring harness between TCM and − Go to Step 7 −
6 vehicle speed sensor 2 for an open or short.
1. After the repair is complete, use the scan − Begin the System OK
tool to select “DTC”, then “Clear Info” diagnosis
function. again
7 2. Make a road running test for the vehicle. Go to Step 1
displayed?
CODE 21 THROTTLE POSITION SENSOR (TPS) SIGNAL (OPEN/SHORTED

CIRCUIT)
UBS
D07R200024
TF
D07R200016
2. At this test, check that as the throttle opens, the

voltage goes up and that the voltage reaches 5.30
When the signal of the engine throttle position sensor to 7.50 V at the full open status.
is located on the injection pump is supplied to the
6. Check the power supply voltage (7.0 – 8.0 V) of the
transmission TCM, the TCM judges the opening
throttle position sensor.
condition of the throttle.
The shift point of the transmission is determined by this
opening condition of the throttle. Diagnostic Aids:
Test Description: rubbed through wire insulation or a wire broken inside
The following numbers correspond to the step numbers backed out terminals, improper mating, broken locks,
on the diagnostic chart. improperly formed or damaged terminals, poor terminal
1. Check that the throttle input voltage is 0.24 to 1.30 to wire connection and damaged harness.
V.
CODE 21 THROTTLE POSITION SENSOR (TPS) SIGNAL (OPEN/SHORTED
CIRCUIT)
1. With the engine “off”, turn the ignition “on”. 0.24−1.30 V Go to Step 2 Go to Step 3
1 pin connector terminal (18) and ground
terminal (24).
5.30−7.50 V The problem is Go to Step 3
intermittent.
Open the throttle fully.
2 Refer to
“Diagnostic
Aids” .
Measure the voltage between TPS 3 pin 0.24−1.30 V Go to Step 4 Go to Step 6
3 connector terminal (2) and (3).
Open the throttle fully. 5.30−7.50 V Go to Step 5 Go to Step 6
4
1. Check the wiring harness between the TCM − Go to Step 9 −
connector terminal (18) and TPS connector
terminal (2) or grow control unit 20 pin
5
connector terminal (1).
2. Or TCM is faulty.
1. Disconnect the TPS wiring harness 7.25−7.55V Go to Step 7 Go to Step 8
connector (H-4).
2. Connect a voltmeter between the connector
6
terminal (H4-1) and (H4-5)(UBS), or terminal
(H4-9) and (H4-8)(TF).
Check the TPS connector. If OK, replace TPS. − Go to Step 9 −
7
Check the wiring harness between the TPS and − Go to Step 9 −
grow control unit. If OK, replace the grow control
8
unit.
function. again
displayed?

UBS
D07R200025
TF
D07R200017
3. Speed signals are output from the meter. The

sensor power supply is given from the TCM.
Speed information is provided by the vehicle speed
sensor 1 to the meter.
In the meter, the pulses of the speed sensor are Diagnostic Aids:
converted to speed signals (pulses), and these signals An intermittent may be caused by a poor connection,
are output to the TCM. The TCM converts these pulse rubbed through wire insulation or a wire broken inside
voltages to km/h signals. the insulation. Inspect related harness connector for
Test Description:
2. The cause of code 24 setting is due to the
operation fault of the speedometer.

0 km/h Go to Step 2 Code 24 is
intermittent.
1. Lift the driving wheels.
If other codes
2. With engine idling in gear and D range.
1 are not stored,
Is the Tech 2 displayed speed the specified
refer to
value?
“Diagnostic
Aids”.
2 Does the speedometer operate? − Go to Step 3 Go to Step 4
1. Open the throttle and increase the revolution Less than 1.4− Go to Step 5 Go to Step 6
speed of the driving wheels. About 5 V
2. Measure the voltage between the TCM 26 (Vehicle speed 10
3 pin connector terminal (6) and ground −20 km/h)
terminal (24) with a voltmeter.
Does the voltage vary intermittently in the
specified value?
The vehicle speed sensor 1 or the speed meter − Go to Step 7 −
4 is faulty.
The TCM connection is faulty or the TCM is − Go to Step 7 −
5 faulty.
The wiring harness between the speed meter − Go to Step 7 −
and TCM is open or the vehicle speed sensor 1
6
is faulty.
function. again
displayed?
CODE 31 SHIFT SOLENOID S1 (OPEN/SHORTED CIRCUIT)

UBS
D07R200026
TF
D07R200018
4. When the driving wheels revolve with the 3rd

speed gear, the voltage is 1 V or less.
The shift solenoid S1 changes the hydraulic route with
3. 6. 8. 11. The solenoid resistance is within the range
the signals from the TCM according to the vehicle
of 11 to 15 Ω (20 ℃).
speed and the throttle opening to control shifting. When
the solenoid S1 or S2 fails, the hydraulic circuit is
mechanically operated as a backup. Diagnostic Aids:
In case of faulty connection , open or shorted circuit to
Test Description: the TCM terminal (13), code 31 is displayed.
The following numbers correspond to the step numbers A intermittent failure may be caused by a poor
on the diagnostic chart. connection, rubbed through wire insulation or a wire
1. With the key “ON”, the voltage between the TCM broken inside the insulation.
terminal (13) and ground terminal (24) is 8 to 16 V.

1. With the engine “OFF”, turn the ignition 8−16 V Go to Step 2 Go to Step 3
“ON”.
1
terminal (24).
1. Lift the driving wheels. − Go to Step 4 Go to Step 8
2. Turn the ignition “ON”, engine “ON”.
acceleration in the “NORMAL” mode and the D
range?
1. Turn the ignition “OFF”. 11−15 Ω (20 ℃) Go to Step 5 Go to Step 6
2. Disconnect the TCM 26 pin connector. 12−16 Ω (40 ℃)
(13) and ground.
At the 3rd speed. 1V Go to Step 7 Go to Step 8
4
terminal (13) and ground terminal (24) less than
the specified value?
5 intermittent. Refer to “Diagnostic Aids”.
Disconnect the A/T 12 pin connector. 11−15 Ω (20 ℃) Go to Step 9 Go to Step 10
Is the resistance between the solenoid S1 12−16 Ω (40 ℃)
6
terminal (1) and ground within the specified
value.
− Go to Step 5 The continuity
of wiring is
1. Clear the TCM memory.
intermittent.
7 2. Make a running test.
Refer to
Is code 31 displayed by self-diagnosis?
“Diagnostic
Aids”.
(13) and ground.
Check the wiring harness between the TCM 26 − Go to Step 13 −
9
connector terminal (1) for ground shorted.
Replace the shift solenoid S1. − Go to Step 13 −
10
1. Disconnect the A/T 12 pin connector. 11−15 Ω (20 ℃) Go to Step 12 Go to Step 10
2. Measure the resistance between the terminal 12−16 Ω (40 ℃)
11
(1) and ground.
12
connector terminal (1).
CODE 31 SHIFT SOLENOID S1 (OPEN/SHORTED CIRCUIT) (Cont’d)

function. again
displayed?

UBS
D07R200026
TF
D07R200018
5. When the driving wheels revolve with the 2nd

speed gear, the voltage is 8 to 16 V.
The solenoid S2 changes the hydraulic route with the
3. 6. 8. 11. The solenoid resistance is within the range
signals from the TCM according to the vehicle speed
of 11 to 15 Ω (20 ℃).
and the throttle opening to control shifting. When the
solenoid S1 or S2 fails, the hydraulic circuit is
mechanically operated as a backup. Diagnostic Aids:
Test Description: the TCM terminal (12), code 32 is displayed.
The following numbers correspond to the step numbers A intermittent failure may be caused by a poor
on the diagnostic chart. connection, rubbed through wire insulation or a wire
2. With the key “ON”, the voltage between the TCM broken inside the insulation.
terminal (12) and ground terminal (24) is 1 V or
less.

1. With the engine “OFF”, turn the ignition 1V Go to Step 2 Go to Step 3
“ON”.
1
terminal (24).
1. Lift the driving wheels. − Go to Step 4 Go to Step 8
2. Turn the ignition “ON”, engine “ON”.
acceleration in the “NORMAL” mode and the D
range?
(12) and ground.
At the 2nd speed. 8−16 V Go to Step 7 Go to Step 8
4
terminal (12) and ground terminal (24) within the
specified value?
6
value.
of wiring is
intermittent.
Refer to
“Diagnostic
Aids”.
2. Disconnect the TCM 26 pin connect. 12−16 Ω (40 ℃)
(12) and ground.
9
Replace the shift solenoid S2. − Go to Step 13 −
10
1. Disconnect the A/T 12 pin connector. 11−15 Ω (20 ℃) Go to Step 12 Go to Step 10
2. Measure the resistance between A/T 12 pin 12−16 Ω (40 ℃)
11
connector terminal (9) and ground.
Check the wiring harness between the TCM − Go to Step 13 −
connector terminal (12) and A/T 12 pin connector
12
terminal (9).
CODE 32 SHIFT SOLENOID S2 (OPEN/SHORTED CIRCUIT) (Cont’d)

function. again
displayed?
CODE 33 LOCK-UP SOLENOID S3 (OPEN/SHORTED CIRCUIT)

UBS
D07R200026
TF
D07R200018
2. When the gear is of the 2nd speed in the D range

and the throttle opening is about 15% or more at a
The lock-up duty solenoid S3 of the torque converter higher speed than about 54 km/h (UBS), 27 km/h
clutch (TCC) controls the lock-up clutch by a signal (TF), the TCM supplies 8 to 16 V, so that the
according to the lock-up range judgement of the TCM solenoid is actuated with the result of lock-up.
when the vehicle runs.
3. 5. 7. 8. The resistance range of the solenoid is 11 to
This function can improve the fuel consumption to 15 Ω (20 ℃).
almost the same extent as the manual transmission.
The lock-up solenoid S3 is put into B+ by the TCM, so
that the solenoid is actuated with the result of lock-up. Diagnostic Aids:
the TCM terminal (11), code 33 is displayed.
Test Description:
A intermittent failure may be caused by a poor
The following numbers correspond to the step numbers connection, rubbed through wire insulation or a wire
on the diagnostic chart. broken inside the insulation.
1. When the key is ON, the voltage between the TCM
connector terminal (11) and ground terminal (24) is
1 V or less.
CODE 33 LOCK-UP SOLENOID S3 (OPEN/SHORTED CIRCUIT)

1. With the engine “OFF”, turn the ignition “ON” 1V Go to Step 2 Go to Step 3
after warming up.
1
terminal (24).
1. Lift the driving wheels and support them. 8−16 V Go to Step 4 Go to Step 5
2. D range, 2nd speed gear.
3. Make a test at a speed of about 54 km/h
(UBS), 27 km/h (TF) or more with 15% or
2 more opening of the throttle.
4. Measure the voltage between the TCM 26
terminal (24).
(11) and ground.
of wiring is
intermittent.
Refer to
“Diagnostic
Aids”.
(11) and ground.
7
value?
8
value?
9
connector terminal (12) for open.
Replace the lock-up solenoid S3. − Go to Step 12 −
10
11
CODE 33 LOCK-UP SOLENOID S3 (OPEN/SHORTED CIRCUIT) (Cont’d)

function. again
displayed?
WIRING DIAGRAM
UBS
D07R200021
WIRING DIAGRAM
UBS
D07R200022
WIRING DIAGRAM
TF
D07R200019
WIRING DIAGRAM
TF
D07R200020
CONNECTOR LIST
(UBS)
B-11 H-4
B-14 H-7
B-30 H-8
(RHD)
B-35 H-8
(LHD)
C-12 H-9
(RHD)
C-46 H-9
(LHD)
C-63 H-11
C-66 H-12
(RHD)
C-78 H-24
(RHD)
E-5 H-24
(LHD)
CONNECTOR LIST
(UBS)
H-25
H-27
(RHD)
H-42
E-9
I-10
CONNECTOR LIST
(TF)
B-23 C-57
B-24 C-58
B-39 C-97
C-41 E-5
C-44 E-45
C-46 E-46
C-53 H-4
C-54 H-6
C-55 H-7
C-56 H-8
CONNECTOR LIST
(TF)
H-18
TROUBLESHOOTING CHART
Number are arranged in order of probability.
Parform inspections starting with number one and working up.
MANUAL SHIFTING TEST

NOTE:
With this test, it can be determined whether the trouble
lies within the electrical circuit or is a mechanical
problem in the transmission.
1. Disconnect TCM connector
With the engine OFF, disconnect the TCM connector.
2. Inspect manual driving operation
Check that the shift and gear positions correspond with
the table.
If the “L”, “2” and “D” range gear positions are difficult to
distinguish, do perform the following road test.
While driving, shift through the “L”, “2” and “D” renges.
Check that the gear change corresponds to the gear
position.
If any abnormality is found in the above test, do perform
the stall, time lag or gear change tests.
F07RY00024
3. Connect TCM connector

With the engine off, connect the TCM connector.
STALL TEST
The object of this test is to check the overall performance
of the transmission and engine by measuring the maximum
engine speeds at the “D” and “R” ranges.
NOTE:
temperature (50 – 80°
°C or 122-176°
°F).
(2) Do not continuously run this test longer than 5
seconds.
MEASURE STALL SPEED

1. Chock the four wheels.
2. Mount an engine tachometer.
4. Step down strongly on the brake pedal with your left
foot.
6. Shift into the “D” range. Step all the way down on the
accelerator pedal with your right foot. Quickly read the
highest engine rpm.
Stall speed: 2400±
±150 rpm
7. Perform the same test in the “R” range.
EVALUATION
1. If the engine speed is the same for both ranges but
lower than the specified value:
・Engine output is insufficient.
・Stator one-way clutch is not operating properly.
NOTE:
If more than 600 rpm below the specified value, the
torque converter could be faulty.
2. If the stall speed is “D” range is higher than specified:
・Forward clutch slipping
・OD one-way clutch not operating properly
3. If the stall speed in “R” range is higher than specified:
・Direct clutch slipping
・No.3 brake slipping
4. If the stall speed in the “R” and “D” ranges are higher
than specified:
・Improper fluid level
F07RY00002
TIME LAG TEST

If the shift lever is shifted while the engine is idling, there
will be a certain time elapse or lag before the shock can be
felt. This is used for checking the condition of the forward
clutch, direct clutch, No.3 brake, and No.2 one-way clutch.
NOTE:
temperature (50 – 80°
°C or 122 – 176°
°F)
(2) Be sure to allow one minute interval between
tests.
(3) Make three measurements and take the average
value.
MEASURE TIME LAG

Check idling speed (A/C OFF)
“N” range: 855 – 905 rpm (UBS)
: 825 – 875 rpm (TF)
3. Shift the shift lever from “N” to “D” range. Using a stop
watch, measure the time it takes from sihfting the lever
until the shock is felt.
4. In same manner, measure the time lag for “N” → “R”.
EVALUATION
1. If “N” → “D” time lag is longer than specified:
・Forward clutch malfunction
2. If “N” → “R” time lag is longer than specified:
・Direct clutch malfunction
・No.3 brake malfunction
3. If both time lag is longer than specified:
F07RY00003
HYDRAULIC TEST
PREPARATION
1. Warm up the transmission fluid.
2. Remove the transmission case test plug and mount the
hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE:
(50 – 80°
°C or 122 – 176°
°F).
MEASURE LINE PRESSURE

1. Fully apply the parking brake and chock the four
wheels.
2. Start the engine and check idling rpm.
3. Shift into “D” range, step down strongly on the brake
pedal with your left foot and, while manipulating the
accelerator pedal with the right foot, measure the line
pressures at the engine speeds specified in the table.
4. In the same manner, perform the test in “R” range.
2
Engine Line pressure kPa (kg/cm /psi)
speed “D” range “R” range
422 – 481 510 – 608
Idling (4.3 – 4.9/ (5.2 – 6.2/
61 – 70) 74 – 88)
1117 – 1362 1373 – 1715
Stall (11.4 – 13.9/ (14 – 17.5/
162 – 198) 199 – 249)
5. If the measured pressures are not up to specified
values, recheck the throttle cable adjustment and
perform a retest.
EVALUATION
1. If the measured values at all ranges are higher than
specified:
・Throttle cable out of adjustment
・Throttle valve defective
2. If the measured values at all ranges are lower than
specified:
・Throttle cable out of adjustment
・Throttle valve defective
・Oil pump defective
3. If pressure is low in “D” range only:
・“D” range circuit fluid leakage
F07RY00004
4. If pressure is low in “R” range only:

・“R” range circuit fluid leakage
ROAD TEST
NOTE:
(50 – 80°
°C or 122 – 176°
°F).
“D” RANGE TEST IN “NORMAL”, AND “POWER”

PATTERN RANGES
Shift into the “D” range and hold the accelerator pedal
255RT004 constant at the 50% and 100% throttle valve opening
positions.
Push in one of the pattern selector buttons and check the
following:
1. 1-2, 2-3, 3-OD and lock-up, up-shifts should take place,
and shift points should conform to those shown in the
automatic shift diagram.
NOTE:
Drive the vehicle on level ground.
EVALUATION
(3) If there is no 3→OD up-shift (throttle valve opening
1/2):
・3-OD shift valve is stuck
(4) If the shift point is defective:
section.
(5) If the lock-up is defective:
section.
2. In the same manner, check the shock and slip at the 1
F07RY00005 →2, 2→3 and 3→OD up-shifts.
EVALUATION
If the shock is excessive:
section.
F07RY00006
3. Run at “D” range lock-up or OD gear and check for

abnormal noise and vibration.
NOTE:
The check for the cause of abnormal noise and
vibration must be made with extreme care as it could
also be due to loss of balance in the propeller shaft,
differential, the torque converter, etc. or insufficient
bending, rigidity, etc. in the power train.
F07RY00007
4. While running in “D” range, 2nd, 3rd gears and OD,

check to see that the possible kick-down vehicle speed
limits for 2→1, 3→1, 3→2, OD→3 and OD→2 kick-
downs conform to those indicated on the automatic shift
diagram.
5. Check for abnormal shock and slip at kick-down.
6. While running in “D” range, OD gear or “lock-up”, shift
to “2” and “L” ranges and check the engine braking
effect at each of these ranges.
F07RY00008
7. Also check to see that downshift is made from 3→2 or
from O.D. to 3 and then to 2 immediately and that 2→1
downshift point is within the limits shown in the diagram
when tested by releasing the accelerator pedal and
shifting into position of “L” while driving in the third gear
or in overdrive.
EVALUATION
(1) If there is no engine braking effect in the “2” range:
・Second coast (No.1) brake is defective.
(2) If there is no engine braking effect in the “L” range:
・First and reverse (No.3) brake is defective.
F07RY00009
(3) Also check to see that downshift is made from 3→2 or

from O.D. to 3 and then to 2 immediately and that 2→
1 downshift point is within the limits shown in the
diagram when tested by releasing the accelerator
pedal and shifting into “L” position while driving in the
third gear or in overdrive.
F07RY00010
“2” RANGE TEST

Shift into “2” range and, while driving with the accelerator
pedal held constantly at the specified point (throttle valve
opening 50% and 100%), push in one of the pattern
selectors (only for 4×4) and check on the following points.
1. At each of the above throttle openings, check to see
that the 1→ 2 up-shift takes place and that the shift
points conform to those shown on the automatic shift
diagram.
F07RY00011
NOTE:
There is no OD and no lock-up in the “2” range.
2. While running in the “2” range and 2nd gear, release
the accelerator pedal and check the engine’s braking
effect.
3. Check for 2 → 1 down-shift and abnormal noise at
acceleration and deceleration, and for shock at upshift
and down-shift.
F07RY00012
“L” RANGE TEST

1. While running above 80 km/h (50 mph) in the “D” range,
release your foot from the accelerator pedal and shift
into the “L” range.
Then check to see that the 2→1 down-shift occurs at
the specified point shown on the automatic shift
diagram.
F07RY00020
2. While running in the “L” range, check to see that there

is no up-shift to 2nd gear.
3. While running in the “L” range, release the accelerator
pedal and check the engine braking effect.
4. Check for abnormal noise during acceleration and
deceleration.
F07RY00014
“R” RANGE TEST

Shift into the “R” range and, while starting at full throttle,
check for slipping.
“P” RANGE TEST

Stop the vehicle on a grade (more than 9%) and after
shifting into the “P” range, release the parking brake.
Then check to see that the parking lock pawl holds the
F07RY00015 vehicle in place.

SHIFT POINT CHART (UBS)
(H2, H4)
“NORMAL” mode
Up shift km/h
Fully opened 34 – 40 76 – 82 113 – 119
D
Half throttle 10 – 16 22 – 28 42 – 48
Fully opened 34 – 40 92 – 98 ―
2
Half throttle 10 – 16 92 – 98 ―
Down shift km/h

Fully opened 23 – 29 62 – 68 93 – 99
D Half throttle 8 – 14 14 – 20 35 – 41
Fully closed 8 – 14 14 – 20 27 - 33
Fully opened 23 – 29 89 – 95 ―
2 Half throttle 8 – 14 89 – 95 ―
Fully closed 8 – 14 89 – 95 ―
Fully opened 45 – 51 89 – 95 ―
L Half throttle 45 – 51 89 – 95 ―
Fully closed 45 – 51 89 – 95 ―
“POWER” mode
Up shift km/h
Fully opened 34 – 40 76 – 82 113 – 119
D
Half throttle 17 – 23 38 – 44 57 – 63
Fully opened 34 – 40 92 – 98 ―
2
Half throttle 10 – 16 92 – 98 ―
Down shift km/h

Fully opened 29 – 35 71 – 77 105 – 111
D Half throttle 11 – 17 26 – 32 42 – 48
Fully closed 8 – 14 14 – 20 27 - 33
Fully opened 23 – 29 89 – 95 ―
2 Half throttle 8 – 14 89 – 95 ―
Fully closed 8 – 14 89 – 95 ―
Fully opened 45 – 51 89 – 95 ―
L Half throttle 45 – 51 89 – 95 ―
Fully closed 45 – 51 89 – 95 ―
LOCK-UP POINT CHART (UBS)

(H2, H4)
km/h
Throttle Opening: 15∼25 %
NORMAL 54 – 60 56 – 62 56 – 62 51 – 57 53 – 59 53 – 59
D
POWER 54 – 60 60 – 66 72 – 78 51 – 57 57 – 63 69 – 75

SHIFT POINT CHART (TF)
(H2, H4)
“NORMAL” mode
Up shift km/h
Fully opened 28 – 34 69 – 75 111 – 117
D
Half throttle 10 – 16 31 – 37 43 – 49
Fully opened 28 – 34 81 – 87 ―
2
Half throttle 10 – 16 81 – 87 ―
Down shift km/h

Fully opened 20 – 26 63 – 69 107 – 113
D Half throttle 7 – 13 23 – 29 35 – 41
Fully closed 7 – 13 15 – 21 31 – 37
Fully opened 20 – 26 79 – 85 ―
2 Half throttle 7 – 13 79 – 85 ―
Fully closed 7 – 13 79 – 85 ―
Fully opened 40 – 46 79 – 85 ―
L Half throttle 40 – 46 79 – 85 ―
Fully closed 40 – 46 79 – 85 ―
“POWER” mode
Up shift km/h
Fully opened 28 – 34 69 – 75 111 – 117
D
Half throttle 13 – 19 40 – 46 53 – 59
Fully opened 28 – 34 81 – 87 ―
2
Half throttle 10 – 16 81 – 87 ―
Down shift km/h

Fully opened 20 – 26 63 – 69 107 – 113
D Half throttle 7 – 13 29 – 35 44 – 50
Fully closed 7 – 13 15 – 21 31 – 37
Fully opened 20 – 26 79 – 85 ―
2 Half throttle 7 – 13 79 – 85 ―
Fully closed 7 – 13 79 – 85 ―
Fully opened 40 – 46 79 – 85 ―
L Half throttle 40 – 46 79 – 85 ―
Fully closed 40 – 46 79 – 85 ―
LOCK-UP POINT CHART (TF)

(H2, H4)
km/h
Throttle Opening: 10∼25 %
NORMAL 27 – 33 47 – 53 57 – 63 22 – 28 37 – 43 55 – 61
D
POWER 27 – 33 47 – 53 57 – 63 22 – 28 42 – 48 55 – 61
TCM VOLTAGE CHECK

TCM voltage check is done to check for transmission and
transmission control module (TCM) problems which cannot
be detected by self-diagnosis.
Additionally, it serves as a back-up check for self-
diagnosis.
Measure the voltage drop and make a continuity test for
each of the sensors, solenoids, and switches.
If the voltage is within the specified range and continuity
exists, that particular area of the TCM and automatic
transmission assembly is normal.
If voltage deviation or lack of continuity is discovered,
disconnect the applicable parts and check each of them
individually.
This will allow you to determine the trouble location (TCM,
automatic transmission unit, or another area of the
vehicle).
Inspection Tool
Use a circuit tester to measure voltage and circuit
continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.
NOTE:
TCM is located in the behind instrument panel of the
driver’s compartment.
826L100005 TCM Voltage Check Procedure
1. Remove the TCM.
2. Turn the ignition switch on. Do not start the engine.
3. Measure the voltage at the terminal.
Refer the following table for the specified voltage
ranges.
TCM STANDARD VOLTAGE

[26 PIN CONNECTOR]
Terminal
+ –
Throttle fully opened 5.3 – 7.5
Throttle position sensor 18 24
Throttle fully closed (idling) 0.24 – 1.3
Vehicle speed sensor 1 6 24 Vehicle speed 10 – 20 km/h Less than 1.4 ⇔ About 5
Vehicle speed sensor 2 22 23 Vehicle speed 10 – 20 km/h 0 ⇔ About 3
Selector “2” range 7 – 16
2 range switch 2 24
Selector all ranges except “2” Less than 1
Selector “L” range 7 – 16
L range switch 1 24
Selector all ranges except “L” Less than 1
Pattern select switch OFF (NORMAL) 8 – 16
Pattern select switch 16 24
Pattern select switch ON (POWER) Less than 1
Depress brake 7 – 16
Brake switch 14 24
Release brake Less than 1
O/D switch position OFF
7 – 16
(O/D OFF lamp ON)
O/D switch 15 24
O/D switch position ON
Less than 1
(O/D OFF lamp OFF)
OFF (3rd or O/D) Less than 1
Shift solenoid S1 13 24
ON (1st or 2nd) 8 – 16
OFF (1st or O/D) Less than 1
Shift solenoid S2 12 24
ON (2nd or 3rd) 8 – 16
OFF (Lock-up OFF) Less than 1
Lock-up control solenoid S3 11 24
ON (Lock-up ON) 8 – 16
Diagnosis terminal 21 24 Self-diagnosis ON 0 – 1.5
Electrical source (Battery) 25 24 ― 9 – 16
Electrical source (Ignition) 26 24 Key switch ON 9 – 16
Selector “N” range 7 – 16
N range switch 3 24
Selector all ranges except “N” Less than 1
ATF fluid temperature ATF temperature 20℃ 4.70
20 8
sensor ATF temperature 80℃ 3.65
OFF 8 – 16
Winter select switch (UBS) 4 24
ON Less than 1
ON Less than 1
Power lamp 5 24
OFF 8 – 16
ON Less than 1
Winter lamp (UBS) 7 24
OFF 8 – 16
ON Less than 1
CHECK TRANS lamp 19 24
OFF 8 – 16
Tech 2 diagnosis terminal
10 24 On diagnosis communication 0 – 1.5 ⇔ 6.25 – 8.0
(DG)
ON-VEHICLE SERVICE
TRANSIMISSION FLUID LEVEL AND
CONDITION
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from "P" to "L", then return to position "P".
Check to see If the level of fluid comes to "HOT" range of
about 80°C (176°F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in "HOT" range.
Inspection of fluid condition
242RX00001
If the ATF is black or smells burnt, replace it.
ATF REPLACEMENT
NOTE:
Do not overfill.
1. Remove the drain plug from oil pan and drain the fluid.
2. Reinstall the drain plug securely.
Torque: 19 N･
･m (1.9 kg･
･m/14 Ib･
･ft)
3. With the engine OFF, add new fluid through the filler
tube.
Drain and refill 4.5 liter
Dry fill 8 liter
Fluid BESCO ATF Ⅲ
4. Start the engine and shift the selector into all position
from "P" through "L", and then shift into "P".
5. With the engine idling, check the fluid level. Add fluid up
to the "COLD" level on the dipstick.
6. The ATF level must be checked again for correct level
with the "HOT" level.
NOTE:
To prevent fluid leaks, the drain plug gasket must be
replaced each time this plug is removed.
THROTTLE CABLE ADJUSTMENT

1. Check that the idling set bolt comes into contact with
control lever.
2. Measure the distance (C) between the end of the boot
and stopper on the cable (1).
Standard distance (C): 0.5 – 1.5 m (0.03 – 0.06 in)
If the distance is not within the standard, adjust the
cable by the adjust nuts.
101R200001 3. Fully depress the accelerator, check that the control
lever comes into contact with the full stopper.
4. Measure the control lever stroke (S).
Standard stroke (S): 32.9 +1 mm (1.30 +0.04 in)

0 0
If the stroke is not within the standard, adjust the
turning radius of control lever (3) by bolt (2).
S < 32.9 → Turning radius is enlarged.
S > 33.9 → Turning radius is made small.
5. Recheck the adjustments.
NEUTRAL START SWITCH INSPECTION

Inspection
With a circuit tester, make a continuity test on the neutral
start switch with the moveing piece set in each position.
Terminal
1 5 4 11 3 12 2 6 7
Position
P ○ ○ ○ ○
R ○ ○
240R200027 N ○ ○ ○ ○
D ○ ○
2 ○ ○
L ○ ○
○ ○ Continuity
Removal
Preparation:
1. Remove the rear side ATF cooler pipe from the
transmission elbow.
2. Disconnect neutral start switch connector.
3. Unstake the lock washer, and then remove the shaft
nut (3).
4. Remove the neutral start switch.
240R200018
Installation
Torque:
Nut – 7 N･
･m (0.7 kg･
･m/61 Ib･
･in)
Bolt – 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
Adjustment
1. Loosen the neutral start switch bolt and set the shift
selector to the “N” range.
2. Align the groove and neutral basic line (1).
3. Hold in position and tighten the bolt (2).
Torque: 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
BRAKE SIGNAL INSPECTION

Check that the brake light comes on when the brake pedal
is depressed.
310RW020
VEHICLE SPEED SENSOR 1 INSPECTION

1. Connect the Vehicle speed sensor connector terminal
(1) to the battery ( +) terminal and terminal (2) to the
battery (-) terminal.
2. Connect a resistance of 1.3k ohm to 5k ohm (1.4W or
more) between terminals (1) and (3).
NOTE:
Be extremely careful not to connect the battery (+)
F07RY00017
terminal to the terminal (3).
This may damage the vehicle speed sensor.
3. Rotate the shaft of the vehicle speed sensor slowly and
measure the voltage at both ends with a digital tester.
The voltage, with one rotation of shaft, fluctuates four
times in the following range: 10 to 14V ⇔ 2V or less.
Replace the sensor when the result of inspection is
found abnormal.
VEHICLE SPEED SENSOR 2 INSPECTION

1. Disconnect the vehicle speed sensor 2 connector.
2. Use an ohmmeter to measure the resistance between
terminals 5 (SP2+) and 6 (SP2-).
Standard resistance: 560 – 680 Ω (20℃
℃)
: 610 – 740 Ω (40℃
℃)
F07RT004
UBS PATTERN SELECT SWITCH INSPECTION

F07RY00019
TF
F07LV004
UBS OVERDRIVE SWITCH INSPECTION

225R200003
TF
225R200004
SOLENOID INSPECTION
1. Resistance check
each terminals (S1/S2/S3) and body.
Standard resistance: 11 – 15 Ω (20℃
℃)
12 – 16 Ω (40℃
℃)
244R200042
2. Operation check
Check the solenoid operation by blowing into an oil hole
as shown in the figure.
Solenoid S1 and S2 (Normal close type)
No air leaks
disconnected
Air passes through
connected
244RX00001
Lock-up solenoid S3 (Normal open type)

Air passes through
disconnected
No air leaks
connected
244RY00005
ATF TEMPERATURE SENSOR

INSPECTION
1. Disconnect the front side ATF cooler pipe from the
elbow and remove the elbow.
2. Remove the ATF temperature sensor from the
transmission case.
3. Place the ATF temperature sensor in a container of
ATF.
240R200026
4. Measure the resistance between each terminals.

Resistance: 0.5 – 30 kΩ
Ω (0℃
℃ - 120℃
℃)
5. If either of the measured values exceeds the specified,
replace the ATF temperature sensor.
Torque: 15 N･
･m (1.5 kg･
･m/11 Ib･
･ft)
242RW013
THROTTLE POSITION SENSOR

INSPECTION
2. Measure the voltage between throttle position sensor
connector terminals 2 (output) and 3 (ground).
NOTE:
・ Make sure that power source (7 – 8V) is measured
between terminals 1 and 3 before measurement at
101R200003 step 2.
Standard voltage:
Idling − 0.24 – 1.30V
WOT − 5.30 – 7.50V
SELECTOR LEVER
Inspection
1. Make sure that when the selector lever is shifted from
"P" to "L", a "clicking" can be felt at each shift position.
Make sure that the gear corresponds to that of the
position plate indicator.
2. Check to see if the selector lever can be shifted as
shown.
256RY00001
REMOVAL
Preparation:
1. Transfer Control Lever Knob (4×4)
2. Front Console
(4×
×4) 3. Selector Lever Assembly
1. Disconnect shift lock cable from the selector lever
assembly side.
2. Disconnect wiring harness connectors.
256RW012
3. Disconnect shift control rod from the selector lever

assembly side.
256RW013
INSTALLATION
1. Place the vehicle on a level surface.
NOTE:
If the vehicle is not on a level surface, the shift
select cable set position will vary with the
movement of the engine. To prevent possible
misadjustment of the cable, the vehicle must be
placed on a level surface.
256RW014
2. Install the shift control rod (1) to the transfmission
select lever (2), and then place the lever in the "N"
position.
3. Set select lever in the "N" position.
4. Push selector lever forward and secure it (using a
5. Install the shift control rod (1) to the selector lever arm
(4).
Nut torque: 27 N･
･m (2.8 kg･
･m/20 Ib･
･ft)
NOTE:
Do not apply oil to threaded portions.
6. After adjustment, operate select lever on a trial basis to
makes sure of its smooth operation and no abnormal
indication in each position.
Adjustment of shift lock cable

1. Set ignition key in "LOCK" position and selector lever in
"P" position.
2. Adjust cable screw cap on selector lever side to provide
a gap (slack for cable) of 1-2mm between rod on
steering lock side and stopper
a. Pull screw cap (1) in arrow direction to put off slack of
256RW015
inner cable.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5mm (0.2in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Lock nut torque: 3.7 N･
･m (38 kg･
･cm/33 Ib･
･in)
NOTE:
Clean the rod threads and do not apply oil to the
threaded portions.
3. Make sure of proper operation of shift lock through
checks as follows:
a. Selector lever shall not be moved out of "P" position
with ingition key in "Lock" position.
b. Selector lever can be moved out of "P" position with
ignition key in "ON" position only when brake pedal is
depressed.
c. Ignition key can be turned to "LOCK" position only
when selector lever is in "P" position (key can be
pulled out).
If (a) and (c) fail, readjust cable. If (b) fails, readjust
SHIFT SOLENOID AND LOCK-UP

SOLENOID
REMOVAL
Preparation:
・ Drain the fluid
Seal cutter: 5-8840-2153-0
240RY00007
Examine particles in pan

chips. Look carefully at the chips and particles in the
pan and on the magnet to anticipate what type of wear
you will find in the transmission:
Steel (magnetic).....bearing, gear and clutch plate wear
Brass (non-magnetic)...bushing wear
240RY00008

shift solenoid S1, S2 and lock-up solenoid S3.
3. Remove each retaining bolts and solenoids.
INSTALLATION
the following point.
1. Solenoid retaining bolt
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
2. Oil pan bolts
Torque: 8 N･
･m (0.8 kg･
･m/69 Ib･
･in)
VALVE BODY ASSEMBLY

REMOVAL
Preparation:
・ Drain the fluid
Seal cutter: 5-8840-2153-0
・ Examine particles in pan.
Refer to “SHIFT SOLENOID AND LOCK-UP
SOLENOID”.
2. Remove four retaining bolts and oil strainer.
244R200001
3. Pry up both oil tube ends with a large screwdriver and

remove the two oil tubes.
244R200002

shift solenoid S1, S2 and lock-up solenoid S3.
249R200001
5. Disconnect the throttle cable from the cam.
249R200003
6. Remove the seventeen bolts from the valve body.

Remove the valve body from the transmission case.
249R200007
NOTE:
The check valve assembly (1) and the C-0
accumulator piston springs (2) will fall from the
transmission case during removal of valve body
assembly.
Protect these parts from damage.
The B-0 (3), C-2 (4), and B-2 (5) accumulator piston
and springs may also fall free and must be
protected.
244RY00018
INSTALLATION
the following points;
1. Reinstall the parts removed with the valve body
assembly to their assigned positions in the
transmission case (check valve assembly, C-0
accumulator pistons, etc). Install the valve body
Refer to “REASSEMBLY OF MAJOR COMPONENTS
(2).”
2. Solenoid retaining bolt

Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
3. Valve body fixing bolts
Each bolt location and length (mm) is indicated in the
figure.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
249R200008
4. Oil strainer fixing bolts

Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
5. Oil pan fixing bolts
Torque: 8 N･
･m (0.8 kg･
･m/69 Ib･
･in)
REAR OIL SEAL (ADAPTER HOUSING, 4

×4)
REMOVAL
1. Remove the front and rear propeller shaft assembly
form the transfer case.
2. Remove the transfer case assembly from the
transmission case.
Refer to Section 4 “DRIVELINE/AXLE”.
INSTALLATION
adapter housing.
3. Install the transfer case assembly.
4. Install the front and rear propeller shaft assembly.
Torque:
240RY00003
･m (6.4 kg･
･m/46 Ib･
･ft)
: 69 N･
･m (7.0 kg･
･m/51 Ib･
･ft)
REAR OIL SEAL (EXTENSION HOUSING,

4×
×2)
REMOVAL
1. Remove the rear propeller shaft assembly.
INSTALLATION
extension housing.
3. Install the rear propeller shaft.
Torque:
･m (6.4 kg･
･m/46 Ib･
･in)
249L100005
: 69 N･
･m (7.0 kg･
･m/51 Ib･
･ft)
TRANSMISSION REMOVAL AND INSTALLATION
220R200002
Legend
1. Throttle cable 10. Torque converter bolt
2. Transfer protector (UBS) 11. Transmission harness connector
3. Rear propeller shaft 12. Rear mounting
4. Front propeller shaft (4×4) 13. 3rd crossmember
5. Exhaust pipe 14. Oil level gauge and tube
6. Control rod 15. Starter
7. Transfer control lever (4×4) 16. Engine – transmission bolt
8. ATF cooler pipe 17. Transmission assembly
9. Under cover
REMOVAL
Preparation:
・ Remove engine hood
1. Throttle cable
Loosen the adjusting nuts, and disconnect the cable
housing from the injection pump side bracket.
2. Transfer protector (4×
×4)
Disconnect the center bearing bracket, and remove
rear propeller shaft.
4. Front propeller shaft (4×
×4)
5. Exhaust pipe
6. Control rod
Disconnect the control rod from the selector lever
assembly.
7. Transfer control lever (4×
×4)
Remove the transfer control lever fixing bolts and push
up transfer control lever.
262RW015
8. ATF cooler pipe

・ Remove oil pipe clamp from the under cover and
torque converter housing side.
9. Under cover
253LV001
10. Torque converter bolt

Remove the six torque converter fixing bolts.
NOTE:
reassembly.
11. Transmission harness connector
・ Disconnect the transmission harness connectors from
240RW037 the engine room harness connectors.
・ Disconnect the breather hose clip from the engine
harness.
12. Rear mounting
・ Support transmission with a jack.
crossmember.
・ Remove the rear mounting from the transmission.
13. 3rd crossmember
15. Starter
・ Hoist engine with a chain block.
・ If necessary, remove the transfer case from the
transmission assembly.
Refer to Section 4 “DRIVE LINE/AXLE” for removal
and installation.
NOTE:
Do not let the throttle cable or neutral start switch
cable catch on anything. Keep the oil pan
positioned down.
INSTALLATION
1. Torque
N･m (kg･m/Ib･ft)
Rear mounting to crossmember 41 (4.2/30)
Rear mounting to transmission 41 (4.2/30)
Torque converter bolt 29 (3.0/22)
ATF cooler pipe to transmission 44 (4.5/33)
Exh. pipe flange to flange 43 (4.4/32)
Exh. pipe to exh. manifold 67 (6.8/4.9)
Rear propeller shaft bolt 63 (6.4/46)
Center bearing retainer bolt 69 (7.0/51)
Front propeller shaft bolt 63 (6.4/46)
3rd crossmember bolt 76 (7.8/56)
Under cover bolt 6 (0.6/52 Ib･in)
Engine to transmission See next page
Engine – Transmission Bolt Torque
225R200005
260RY00001
UNIT REPAIR
MAJOR COMPONENTS
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all component
groups are assembled correctly.
If something wrong is found in a certain component group
during assembly, inspect and repair this group
immediately.
GENERAL ASSEMBLY NOTES:

1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful inspection
before assembly because even a small nick could cause
fluid leakage or affect performance.
2. Before assembling new clutch discs and brake bands,
soak them in automatic transmission fluid for at least thirty
minutes.
3. Apply automatic transmission fluid on the sliding or rotating
surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their palces.
5. Do not use adhesive cements on gaskets and similar
parts.
6. When assembling the transmission, be sure to use new
gaskets and O-rings.
7. Dry all parts with compressed air – never use shop rags.
8. Be sure to install the thrust bearings and races in the
correct direction and position.
240RY00022
COMPONENTS (1)
240R200015
Disassembly steps
1. Torque converter 6. Transmission select lever
2. Neutral start switch 7. Adapter housing (4 × 4)
3. Oil temperature sensor 8. Speedometer sensor, speedometer
4. Elbow driven gear and plate (4 × 2)
5. Breather hose 9. Extension housing (4 × 2)
Disassembly steps
1. Torque converter
Unstake the lock washer.
Remove the nut and bolts, and then remove the neutral
start switch.
Remove the lock washer and grommet.
240R200016
4. Elbow
Remove two elbows from transmission case.
5. Breather hose
6. Transmission select lever
Remove the transmission select lever.
7. Adapter housing (4 × 4)
8. Speedometer sensor, speedometer driven gear and
plate (4 × 2)
9. Extension housing (4 × 2)
240RY00001

Install special tool to the transmission unit.
Holding fixture: 5-8840-2152-0 (J-37227)
Fixture base: 5-8840-0003-0 (J-3289-20)
240R200021
REASSEMBLY OF MAJOR
COMPONENTS (1)
240R200020
Reassembly steps
1. Transmission assembly 6. Breather hose
2. Extension housing (4×2) 7. Elbow
3. Speedometer driven gear, plate, and 8. Oil temperature sensor
speedometer sensor (4×2) 9. Neutral start switch
4. Adapter housing (4×4) 10. Torque converter
Reassembly steps
2. Extension housing (4×
×2)
Install a new gasket and the extension housing to the
transmission case.
Torque: 36 N･
･m (3.7 kg･
･m/27 Ib･
･ft)
3. Speedometer driven gear, plate, and speedometer

sensor (4×
×2)
Torque:
Plate bolt – 15 N･
･m (1.5 kg･
･m/11 Ib･
･ft)
Speedometer sensor – 25 N･
･m (2.5 kg･
･m/18 Ib･
･ft)
4. Adapter housing (4×

×4)
Remove any gasket material on the contacting surfaces
of the adapter housing and transmission case.
Apply liquid gasket (TB1281-B or its equivalent) (1) and
install the apply gaskets (2) to the adapter housing as
Install the adapter housing to the transmission case.
Torque: 34 N･
･m (3.5 kg･
･m/25 Ib･
･ft)
241RY00020

Install transmission select lever.
Torque: 16 N･
･m (1.6 kg･
･m/12 Ib･
･ft)
6. Breather hose.
7. Elbow
Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29 N･
･m (3.0 kg･
･m/22 Ib･
･ft)
240R200017

Install the oil temperature sensor to the transmission
case.
Torque: 30 N･
･m (3.1 kg･
･m/22 Ib･
･ft)
240R200026

Using the transmission select lever, fully turn the
manual valve lever shaft back and return two notches.
It is now in neutral.
Insert the neutral start switch onto the manual valve
lever shaft and temporarily tighten the adjusting bolt (2).
Install the lock washer and nut (3).
Torque: 7 N･
･m (0.7 kg･
･m/61 Ib･
･in)
240R200018 Align the neutral standard line (1) and the switch groove
and tighten the adjusting bolt (2).
Torque: 13 N･
･m (1.3 kg･
･m/113 Ib･
･in)
Bend the tabs of the lock washer.
NOTE:
Bend at least two of the lock washer tabs.
Using calipers and a straight edge, measure from the
installed surface of the transmission housing.
Correct distance: 67 mm (2.64 in) or more
240RY00005
COMPONENTS (2)
242R200002
Disassembly steps
1. Converter housing 9. Spring
2. Oil pan 10. Accumulator piston (B-2)
3. Oil strainer assembly 11. Accumulator piston (C-2)
4. Oil tube 12. Accumulator piston (B-0)
5. Solenoid wiring 13. Accumulator piston (C-0)
6. Throttle cable 14. Second brake drum gasket
7. Valve body 15. Snap ring, rotor, key (4×4)
8. Check valve, spring 16. Snap ring, speedometer sensor drive
gear, ball (4×2)
17. Spacer, rotor, key, snap ring (4×2)
Disassembly steps
Remove the six bolts.
Remove the converter housing.
240R200022
2. Oil pan
NOTE:
Do not turn over the transmission as this will
contaminate the valve body with foreign materials
in the bottom of the oil pan.
Remove the nineteen bolts.
Remove oil pan by lifting the transmission case.
Seal cutter: 5-8840-2153-0 (J-37228)
240RY00007
Examine particles in oil pan

chips.
Look carefully at the chips and particles in the oil pan
and on the magnet to anticipate what type of wear you
will find in the transmission:
Steel (magnetic) …… bearing, gear and clutch plate
wear
240RY00008
Brass (non-magnetic)… bushing wear
Remove four bolts holding the oil strainer.
244R200001
4. Oil tube
Pry up both tube ends with a large screwdriver and
remove the two tubes.
244R200002
5. Solenoid wiring
Disconnect the connectors from the solenoid S1, S2
and S3.
249R200001
Turn over transmission, remove the solenoid wiring

stopper plate from the case.
Pull the wiring out of the transmission case.
249R200002
6. Throttle cable
Remove throttle cable from transmission case.
249R200004
7. Valve body
Turn over transmission and remove the seventeen bolts
from valve body.
249R200007
Disconnect the throttle cable from the cam.

Remove the valve body from transmission case.
249R200003

9. Spring
Remove the check valve and spring.
Remove two springs from C-0 accumulator piston.
240RY00028

Remove accumulator pistons and springs from
transmission case.
240RY00010

Applying compressed air to the oil hole, remove the B-0
accumulator piston and spring.
240RY00011

Remove the C-0 accumulator piston.
240RY00012
15. Snap ring, rotor, key (4×

×4)
Remove the rotor and key.
247R200002
16. Snap ring, speedometer sensor drive gear, ball

(4×
×2)
Remove the speed meter sensor drive gear, and ball.
17. Spacer, rotor, key, snap ring (4×
×2)
Remove the spacer, rotor and key.
247L100001
REASSEMBLY OF MAJOR
COMPONENTS (2)
242R200003
Reassembly steps
1. Converter housing 8. Check valve, spring
2. Snap ring, key, rotor (4×2) 9. Valve body
3. Spacer, ball, speedometer sensor drive 10. Solenoid wiring
gear, snap ring (4×2) 11. Oil tube
4. Key, rotor, snap ring (4×4) 12. Oil strainer assembly
5. Throttle cable 13. Oil pan
Reassembly steps
Torque:
M10 - 34 N･
･m (3.5 kg･
･m/25 Ib･
･ft)
M12 - 57 N･
･m (5.8 kg･
･m/42 Ib･
･ft)
240R200022
2. Snap ring, key, rotor (4×

×2)
3. Spacer, ball, speedometer sensor drive gear, snap
ring (4×
×2)
Install the spacer, ball and speedometer sensor drive
gear.
247L100001
4. Key, rotor, snap ring (4×

×4)
247R200002
5. Throttle cable
Coat a new O-ring with the ATF and install it to the
throttle cable.
Install the throttle cable to the transmission case.
249R200004

Install a new second brake drum gasket to the
transmission case.
240RY00013
Individual piston operation inspection

Check for the sound of operation while injecting
compressed air into the oil hole indicated in the figure.
1: OD direct clutch 5: Second coast brake

2: Direct clutch 6: Second brake
3: Forward clutch 7: First and reverse brake
4: OD brake A: C-0 Accumulator piston
240RY00014 hole
NOTE:
When inspecting the direct clutch, check with the
C-0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the
parts.
Coat the O-ring with ATF and install it to the piston.
Install the three springs and four accumulator pistons to
the bore as shown in th figure.
240RY00027
Piston Outer diameter Height

B-2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C-2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B-0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C-0 29.8 mm (1.173 in) 44.0 mm (1.732 in)

240RY00029
B-2 70.5 mm (2.276 in) 19.7 mm (0.776 in)
C-2 (Outer) 68.5 mm (2.697 in) 20.2 mm (0.795 in)
12.06 mm
C-2 (Inner) 20.0 mm (0.787 in)
(0.4748 in)
B-0 62.0 mm (2.441 in) 16.0 mm (0.630 in)
C-0 (Outer) 74.6 mm (2.937 in) 20.9 mm (0.823 in)
C-0 (Inner)) 46.0 mm (1.811 in) 14.0 mm (0.551 in)
240RY00010

Install new check valve and spring.
240RY00016
9. Valve body
Align the groove of the manual valve to the pin of the
lever.
240RY00017
Connect the throttle cable to the cam.

Confirm the springs into the accumulator piston are
installed correctly.
249R200003
Install the seventeen bolts.

NOTE:
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
249R200008
10. Solenoid wiring

Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the transmission case and
install the stopper plate.
249R200002
Connect the connectors to the solenoid S1, S2 and S3.
249R200001
11. Oil tube

Using a plastic hammer, install the two tubes into the
positions shown in the figure.
CAUTION:
Be careful not to bend or damage the tubes.
249R200005

Install two new gaskets to the oil strainer.
244R200037
Install the oil strainer with the gaskets to the valve body.
Tighten the four bolts.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200001
13. Oil pan

Install two magnets in oil pan.
NOTE:
Make sure that the magnet does not interfere with
the oil tubes.
Remove any gasket material and be careful not to drop
oil on the contacting surfaces of the transmission case
and oil pan.
240RY00019 Apply liquid gasket (TB1281 or its equivalent) to the oil
pan as shown in the figure.
NOTE:
Install the oil pan as soon as the seal gasket is
applied.
Install and tighten the nineteen bolts.
Torque: 8 N･
･m (0.8 kg･
･m/69 Ib･
･in)
240RY00020
COMPONENTS (3)
248RY00067
Disassembly steps
1. Oil pump 15. E-ring and pin
2. Race 16. Second coast brake band
3. OD planetary gear and OD direct clutch 17. Front planetary ring gear
5. OD planetary ring gear 19. Race
7. Flange, plate and disc (B-0) 21. Front planetary gear
8. Bearing and race 22. Drum and one-way clutch
10. OD support 24. Flange, plate and disc
11. Race 25. Snap ring
12. Snap ring 26. Rear planetary gear, second brake
13. Second coast brake piston assembly drum and output shaft
14. Direct clutch and forward clutch 27. Bearing
Disassembly steps
1. Oil pump
Remove seven bolts fixing the oil pump to the
transmission case.
Remove the oil pump.
241RY00003
2. Race
Remove race from oil pump.
241RY00002

Remove the overdrive planetary gear and overdrive
direct clutch with thrust needle bearing from the
transmission case.
252RY00012
4. Race
Remove the race from OD planetary gear.
252RY00001

Remove the overdrive planetary ring gear from the
transmission case.
252RY00002

252RY00003
Measure the stroke applying and releasing the

2
compressed air (390 – 780 kPa, 4 – 8 kg/cm or 57 –
If the values are nonstandard, select another flange.

3.3 mm (0.130 in) 3.8 mm (0.150 in)
244RY00001 3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)
6. Snap ring
246RY00001

Remove one flange, four plates and four discs.
246RY00026
8. Bearing and race

Remove the thrust bearing and two races.
247RY00003
9. Snap ring
246RY00002
10. OD support
Remove two bolts fixing the overdrive support assembly
to the transmission case.
252RY00004
Install two removed bolts to the OD support, and pull

out the OD support assembly.
252RY00005
11. Race
Remove the race from OD support.
252RY00006
Check piston stroke of second coast brake (B-1)

Using feeler gauge, measure the stroke applying the
2
248RY00004
If the values are nonstandard, replace piston rod and

recheck piston stroke.
If piston stroke is nonstandard, replace brake band.
There are two piston rods.
Rod length 71.4 mm (2.811 in)
72.9 mm (2.870 in)
248RY00005
12. Snap ring

248RY00006

Applying compressed air to the oil hole, remove the
second coast brake piston assembly.
248RY00007

Remove the direct clutch and forward clutch from the
transmission case.
248RY00008
15. E-ring and pin

Remove the E-ring from the pin.
Remove the pin from the brake band.
248RY00009

Remove the second coast brake band from the
transmission case.
248RY00010

Remove the front planetary ring gear from the
transmission case.
247RY00004

Remove the bearing and race.
247RY00005
19. Race
Remove the race.
247RY00006
20. Snap ring

NOTE:
Hold the output shaft to prevent it from falling.
The output shaft falls when the snap ring is
removed.
248RY00011

Remove the front planetary gear from the transmission
case.
247RY00007
22. Drum and one-way clutch

Remove sun gear input drum and one-way clutch.
248RY00012
23. Snap ring

Using two screwdrivers, remove the snap ring.
248RY00014
24. Flange, plate and disc

Remove the flange, five discs and five plates.
248RY00015
Check pack clearance of first and reverse brake (B-3)

Using a feeler gauge, measure the clearance between
the plate and second brake drum as shown in the
figure.
Clearance: 0.6 – 1.12 mm (0.0236 – 0.0441 in)
If the values are nonstandard, replace the discs.
248RY00016
25. Snap ring

248RY00017

shaft
Remove the rear planetary gear, second brake drum
and output shaft as an assembly.
247R200001
27. Bearing
Remove the assembled thrust bearing and race from
248RY00018
REASSEMBLY OF MAJOR
COMPONENTS (3)
248RY00068
Reassembly steps
1. Bearing 17. Bearing and race
2. Rear planetary gear, second brake 18. Direct clutch and forward clutch
drum and output shaft 19. Second coast brake piston assembly
4. Second brake piston sleeve 21. Race
5. One-way clutch 22. OD support
6. Flange plate and disc 23. Snap ring
7. Snap ring 24. Flange, plate and disc
8. Drum 25. Snap ring
9. Front planetary gear and bearing 26. Bearing and race
12. Second coast brake band 29. Race
13. E-ring and pin 30. OD planetary gear and OD direct clutch
14. Bearing and race 31. Bearing
15. Race 32. Race
16. Front planetary ring gear 33. Oil pump
Reassembly steps
1. Bearing
Coast the assembled bearing and race with petroleum
jelly and install it onto the transmission case.
Assembled bearing and race

(Reference)
Bearing and race Diameter
247RY00008
Inside 39.38 mm (1.5504 in)

shaft.
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
247RY00009
Align the splines of the transmission case and the

assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure.
247RY00010
3. Snap ring
246RY00003
Check pack clearance of first and reverse brake

Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown in
the figure.
Clearance: 0.6 – 1.12 mm (0.0236 – 0.0441 in)
installation.
248RY00016
4. Second brake piston sleeve

Install second brake piston sleeve.
246RY00004
5. One-way clutch
Install one-way clutch.
247RY00011
6. Flange plate and disc

Install flange, discs and plates.
Install the 2.5 mm (0.098 in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install four discs and three plates (Disc first)
Install the flange with the rounded edge of the flange
facing the disc.
246RY00005
7. Snap ring
248RY00014
8. Drum
While turning the sun gear input drum clockwise.
Install it into the one-way clutch.
NOTE:
Confirm the thrust washers are installed correctly.
248RY00020
9. Front planetary gear and bearing

Install the front planetary gear to the sun gear.
NOTE:
Confirm the bearing and race is installed correctly.
247RY00012
With wooden blocks under the output shaft, stand the

transmission on the output shaft.
247RY00013
10. Snap ring

248RY00011
11. Race
Coat the bearing race with petroleum jelly and install it
onto the front planetary gear.
Bearing race diameter (Reference)

Bearing race Diameter
Inside 34.3 mm (1.350 in)
247RY00014

Insert the second coast brake band to the transmission
case.
248RY00010
13. E-ring and pin

Install the pin through the brake band.
248RY00021
Install the E-ring to the pin.
248RY00022

install them onto the forward clutch.

Inside Outside
248RY00023 Race 30.6 mm (1.205 in) 53.6 mm (2.110 in)
15. Race

Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)
247RY00015
Align the flukes of the discs in the forward clutch.
247RY00016

Align the spline of the front planetary gear with the
flukes of the discs and install the front planetary gear to
the forward clutch.
247RY00017

install them onto the ring gear.

Inside Outside
Race 25.98 mm (1.0238 in) 48.87 mm (1.9240 in)
247RY00019

Install the assembled direct clutch, forward clutch and
front planetary ring gear into the transmission case.
247RY00018
Using vernier calipers, measure the distance between

the sun gear input drum and direct clutch drum as
Height: 9.8 – 11.8 mm (0.386 – 0.465 in)
installation.
248RY00024

jelly and install it onto the forward clutch.
Assembled bearing and race diameter

(Reference)
Inside Outside
Bearing
33.7 mm (1.327 in) 47.8 mm (1.882 in)
and race
248RY00025

second coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E-ring.
①: Second coast brake piston
②: Oil seal
③: Piston rod
248RY00026
20. Snap ring

Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly
and piston cover to the transmission case.
248RY00027
Check piston stroke of second coast brake

248RY00005
Using wire gauge, measure the stroke by applying the

2
installation.
248RY00004
21. Race
overdrive support assembly.

Inside Outside
Race 36.8 mm (1.449 in) 50.9 mm (2.004 in)
252RY00007
22. OD support
Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the bolt
hole of the transmission case and insert.
252RY00005
23. Snap ring

Using snap ring pliers, install the snap ring as shown in
the figure.
252RY00008
Install and tighten the two bolts.

Torque: 25 N･
･m (2.6 kg･
･m/19 Ib･
･ft)
252RY00004
Check end of output shaft

Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in)
247RY00020
24. Flange, plate and disc

Alternately install three discs and two plates. (Disc first)
252RY00009
25. Snap ring

Snap ring (Reference)

246RY00001

252RY00003
Measure the stroke by applying and releasing the

2
installation.
244RY00001
246RY00001
Remove two flanges, four plates and four discs.
246RY00026

Coat the bearing and races with petroleum jelly and
install them onto the overdrive support.
Bearing and races diameter (Reference)

Inside Outside
Race (Front) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
252RY00010
Race (Rear) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

Install the overdrive planetary ring gear.
252RY00002

install them onto the planetary ring gear.

Inside Outside
Race 24.2 mm (0.953 in) 47.8 mm (1.882 in)
252RY00011
29. Race
planetary gear.

Inside Outside
Race 27.3 mm (1.075 in) 41.8 mm (1.646 in)
252RY00001

Install the overdrive planetary gear and direct clutch.
252RY00012
31. Bearing
jelly and install it onto the direct clutch.

Inside Outside
Bearing
28.9 mm (1.138 in) 50.2 mm (1.976 in)
and race
252RY00013
Alternately install three discs and two plates. (Disc first)
252RY00009
246RY00001
32. Race
oil pump.

Inside Outside
Race 28.8 mm (1.134 in) 46.4 mm (1.827 in)
252RY00014
33. Oil pump

Coat the O-ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body
to slide the oil seal rings on the stator shaft through the
direct clutch drum.
241RY00003
CAUTION:
Do not push on the oil pump strongly or the oil seal
ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N･
･m (2.2 kg･
･m/16 Ib･
･ft)
Check input shaft rotation
Make sure the input shaft rotates smoothly.
DISASSEMBLY, INSPECTION AND

REASSEMBLY OF MINOR COMPONENTS
NOTE:
The instructions here are organized so that you work on
only one component group at a time.
This will help avoid confusion from similar-looking parts of
different subassemblies being on your workbench at the
same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair and
reassembly before proceeding to the next component
group. If a component group cannot be reassembled
because parts are being ordered, be sure to keep all parts
of that group in separate container while proceeding with
disassembly, inspection, repair and reassembly of other
component groups.
Recommended ATF type BESCO ATF Ⅲ.
GENERAL CLEANING NOTES:

1. All disassembled parts should be washed clean and any
fluid passages and holes blown through with compressed
air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid should be
used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper
order to allow performing inspection, repairs, and
reassembly with efficiency.
2. When disassembling a valve body, be sure to keep each
valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid for at
least thirty minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts,
and sliding surfaces should be coated with transmission
fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not aligned
with one of the cutouts and are installed in the groove
correctly.
4. If a worn bushing is to be replaced, the subassembly
containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage.
Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in place.
OIL PUMP
DISASSEMBLY
241R200003
Disassembly steps
1. Oil seal ring 4. Oil pump drive gear
2. O-ring 5. Oil pump driven gear
3. Stator shaft 6. Oil pump body
Disassembly steps
1. Oil seal ring
Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
2. O-ring
Remove O-ring.
241RY00005
3. Stator shaft
6. Oil pump body
Remove 13 bolts, and then remove the stator shaft from
oil pump body.
Then remove drive and driven gear.
241RY00006

through inspection.
Check oil pump body bushing

the oil pump body bushing.
replace the oil pump body.
241RY00007
Check stator shaft bushing

the stator shaft bushing.
Maximum inside diameter:
Front side: 21.58 mm (0.8496 in)
Rear side: 27.08 mm (1.0661 in)
replace the stator shaft.
241RY00008
Check tip clearance of both gears

Measure between the gear teeth and the cresentshaped
part of the pump body.
Standard tip clearance: 0.11 – 0.14 mm
(0.0043 – 0.0055 in)
Maximum tip clearance: 0.3 mm (0.012 in)
If the tip clearance is greater than the maximum,
241RY00009
Check body clearance of driven gear

Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
Standard body clearance: 0.07 – 0.15 mm
(0.0028 – 0.0059 in)
Maximum body clearance: 0.3 mm (0.012 in)
If the body clearance is greater than the maximum,
241RY00010
Check side clearance of both gears

Using a steel straightedge and a feeler gauge, measure
the side clearance of both gears.
Standard side clearance: 0.02 – 0.05 mm
(0.0008 – 0.0020 in)
Maximum side clearance: 0.1 mm (0.004 in)
If the side clearance is greater than the maximum,
241RY00011
Check oil seal

Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
241RY00012
Using special tool, install a new oil seal.

The oil seal end should be flush with the outer edge of
the pump body.
Oil seal installer : 5-8840-2256-0 (J-9617)
Coat the oil seal lip with multi purpose grease.
241RY00013
REASSEMBLY
241R200004
Reassembly steps
1. Oil pump body 4. Stator shaft
2. Oil pump driven gear 5. Oil seal ring
3. Oil pump drive gear 6. O-ring
Reassembly steps
1. Oil pump body
Place the oil pump body on the torque converter.
Coat the driven gear and drive gear with ATF.
Install the driven gear and drive gear.
241RY00014
4. Stator shaft
Align the stator shaft with the bolt holes.
Tighten the thirteen bolts.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
241RY00006
5. Oil seal ring

Coat the oil seal rings with ATF.
Contract the oil seal rings as shown, and install them
onto the stator shaft.
NOTE:
241RY00015
6. O-ring
Coat a new O-ring with ATF and install it to the oil pump
body.
O-ring size (Reference)

Thickness 3.5 mm (0.138 in)
241RY00016
Check oil pump drive gear rotation

Make sure the drive gear rotates smoothly when
installed to the torque converter.
241RY00017
OD PLANETARY GEAR AND OD

DISASSEMBLY
252R200005
Disassembly steps
1. OD direct clutch assembly 10. Thrust bearing
2. OD planetary gear assembly 11. Snap ring
3. Thrust bearing 12. Ring gear flange
5. Flange, disk and plate 14. Race
7. Piston return spring 16. Retaining plate
8. OD direct clutch piston with O-ring 17. OD one-way clutch
9. O-ring 18. Thrust washer
Disassembly steps
1 : Free
○
2 : Lock
○
252RY0015

Remove OD direct clutch assembly from OD planetary
gear assembly.
3. Thrust bearing
Then remove thrust bearing with the race from OD
direct clutch drum.
252RY00016

252RY00017
Use a dial indicator, measure the OD direct clutch

piston stroke applying and releasing the compressed air
2
(390 – 780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as
shown.
252RY00018
4. Snap ring
Remove flange, two discs and two plates.
252RY00019
6. Snap ring
the return spring.
Remove piston return spring
248RY00001
8. OD direct clutch piston with O-ring.

Place the oil pump onto the torque converter and then
place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand, apply
compressed air to the oil pump to remove the OD direct
clutch piston.
Remove the OD direct clutch piston.
9. O-ring
10. Thrust bearing
Remove bearing and race from OD planetary ring gear.
252RY00021
11. Snap ring

Remove snap ring.
252RY00022

Remove ring gear flange from OD planetary ring gear.
252RY00023
14. Race
15. Snap ring
Remove snap ring, using screwdriver.
252RY00024
16. Retaining plate

Remove retaining plate from OD planetary gear.
252RY00025

Remove OD one-way clutch with outer race.
18. Thrust washer
252RY00026

Check discs
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04±
±0.05 mm
(0.0803±
±0.0020 in)
disc.
252RY00027

spring.
252RY00028
Check OD direct clutch piston

Check that the check ball is free by shaking the piston.
252RY00029
Check OD direct clutch drum bushings

the OD direct clutch drum bushings.
replace the OD direct clutch drum.
252RY00030
Check OD planetary gear bushing

replace the OD planetary gear bushing.
replace the OD planetary gear.
252RY00031
REASSEMBLY
252R200006
Reassembly steps
1. OD planetary gear assembly 10. Thrust bearing
2. Thrust washer 11. O-ring
3. OD one-way clutch 12. OD direct clutch piston with O-ring
4. Retaining plate 13. Piston return spring
6. Race 15. Flange, disc and plate
8. Ring gear flange 17. Thrust bearing
9. Snap ring 18. OD direct clutch assembly
Reassembly steps
2. Thrust washer
Install the thrust washer to the OD planetary gear,
facing the grooved side upward.
252RY00032
Install the one-way clutch into the outer race, with the
flanged side of the one-way clutch facing upward.
252RY00033
Install OD one-way clutch with outer race to overdrive

planetary gear.
252RY00026
4. Retaining plate
5. Snap ring
Install retaining plate, then install snap ring, using a
screwdriver.
252RY00024
6. Race
Coat the race with petroleum jelly and install it to the
planetary gear.

252RY00034

8. Ring gear flange
Install ring gear flange to OD planetary ring gear.
252RY00023
9. Snap ring
Install snap ring, using a screwdriver.
252RY00022
10. Thrust bearing

Coat the race and bearing with petroleum jelly and
install them onto the OD planetary ring gear.

Inside Outside
Race 24.2 mm (0.953 in) 47.8 mm (1.882 in)
252RY00035
11. O-ring
Coat new O-rings with ATF and install them on the OD
12. OD direct clutch piston with O-ring
OD direct clutch piston into the clutch drum, using both
hands.
252RY00036

252RY00037
14. Snap ring

the return spring.
248RY00001

Install two plates and tow discs then install the flange,
with the flat side facing downward.
252RY00038
16. Snap ring

Install snap ring.
252RY00039

252RY00017
Using a dial indicator, measure the OD direct clutch

2
shown.
the disc and recheck the piston stroke.
flange.
252RY00018
Flange sizes
3.8 mm (0.150 in) 3.4 mm (0.134 in)
3.7 mm (0.146 in) 3.3 mm (0.130 in)
3.6 mm (0.142 in) 3.2 mm (0.126 in)
3.5 mm (0.138 in) 3.1 mm (0.122 in)
17. Thrust bearing

jelly and install it with the race side facing downward.

252RY00040

Install the OD direct clutch assembly onto the OD
planetary gear.
252RY00016

1 : Free
○
2 : Lock
○
252RY00015
OD SUPPORT ASSEMBLY
DISASSEMBLY
252R200003
Disassembly steps
1. Thrust bearing 6. OD brake piston
2. Race 7. O-ring
3. Thrust washer (plastic) 8. Oil seal ring
4. Snap ring 9. OD support
Disassembly steps
assembly.
252RY00042

252RY00043
1. Thrust bearing
2. Race
4. Snap ring
252RY00044
6. OD brake piston
Place the OD support onto the direct clutch assembly.
Hold the OD brake piston so it is not slanted and apply
compressed air into the passage to remove the OD
brake piston.
Remove the OD brake piston.
7. O-ring
8. OD seal ring
252RY00045 9. OD support

through inspection.

spring.
252RY00046
REASSEMBLY
252R200004
Reassembly steps
2. Oil seal ring 7. Thrust washer (Plastic)
3. O-ring 8. Race
4. OD brake piston 9. Thrust bearing
Reassembly steps
1. OD support
2. Oil seal ring
Contract the oil seals as shown, and install them onto
the OD support.
NOTE :
252RY00047
3. O-ring
Coat two new O-rings with ATF and install them on the
OD brake piston.
4. OD brake piston
brake piston into the OD support, using both hands.
252RY00048

252RY00049
6. Snap ring
cutout portion of the OD support.
252RY00050

NOTE :
Make sure that the lug fits into the hole on the OD
support.
252RY00051
8. Race
Coat the race with petroleum jelly, and install it onto the
OD support.

252RY00052
9. Thrust bearing
Turn over OD support.
Coat the two races with petroleum jelly, and install them

Inside Outside
Race (A) 37.2 mm (1.465 in) 58.8 mm (2.315 in)
252RY00069
Race (B) 33.7 mm (1.327 in) 50.1 mm (1.972 in)

assembly.
252RY00042

252RY00043

DISASSEMBLY
248R200001
Disassembly steps
1. Clutch drum thrust washer (Plastic) 6. Piston return spring
2. Snap ring 7. Direct clutch drum
3. Flange 8. Direct clutch piston
4. Plate and disc 9. O-ring
5. Snap ring
Disassembly steps
Remove direct clutch drum assembly from forward
clutch assembly.
248RY00028

assembly.
248RY00029

2
780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as shown.
248RY00061

2. Snap ring
3. Flange
4. Plate and disc
5. Snap ring
the return spring.
248RY00002

9. O-ring
Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the direct
clutch piston.
Remove the direct clutch piston.
INSPECTON AND REPAIR

spring.
247RY00034
Check discs
Using micrometer, measure the thickness of the discs.
Minimum thickness: 2.04±
±0.05 mm
(0.0803±
±0.0020 in)
disc.
252RY00027
Check direct clutch piston

248RY00031
Check direct clutch drum bushing

the clutch drum bushing.
If the inside diamater is greater than the maximum,
replace the clutch drum.
248RY00032
REASSEMBLY
248R200002
Reassembly steps
1. O-ring 6. Disc and plate
2. Direct clutch piston 7. Flange
3. Direct clutch drum 8. Snap ring
4. Piston return spring 9. Clutch drum thrust washer (Plastic)
5. Snap ring
Reassembly steps
1. O-ring
Install direct clutch piston to direct clutch drum.
248RY00033 direct clutch piston into the clutch drum, using both
hands.

248RY00034
5. Snap ring
Compress piston return spring and install snap ring in
groove.
the return spring.
248RY00002 Spring compressor: 5-8840-0254-0 (J-25048)
6. Disc and plate
Install plates and discs.
Install in order : P-D-P-D-P-D-P-D-P-D
P : Plate, D : Disc
248RY00062
7. Flange
Install the flange, with the flat side facing downward.
248RY0035
8. Snap ring
the cutout portion of the direct clutch drum.
248RY00036

assembly.
248RY00029

2
780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as shown.
the discs and recheck the piston stroke.
flange.
248RY00061
Flange sizes
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.4 mm (0.134 in) 3.9 mm (0.154 in)
3.5 mm (0.138 in) 4.0 mm (0.157 in)
3.6 mm (0.142 in) 4.1 mm (0.161 in)
3.7 mm (0.146 in) 4.2 mm (0.165 in)
9. Clutch drum thrust washer (plastic)

onto the direct clutch.
NOTE :
on the direct clutch.
248RY00037

Install the direct clutch assembly onto the forward clutch
assembly.
Check that the distance from the direct clutch end to the
forward clutch end is 71.2 mm (2.803 in).
248RY00038
FORWARD CLUTCH ASSEMBLY

(C-1)
DISASSEMBLY
248R200003
Disassembly steps
1. Thrust bearing 8. Piston return spring
2. Race 9. Piston
4. Flange 11. O-ring
5. Disc and plate 12. Oil seal ring
6. Cushion plate 13. Thrust bearing
7. Snap ring 14. Forward clutch drum
Disassembly steps
Remove forward clutch assembly from direct clutch
assembly.
248RY00039
1. Thrust bearing
2. Race
Place wooden blocks, etc. to prevent forward clutch
shaft from touching the work stand, and place the OD
support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.
248RY00048

piston stroke by applying and releasing compressed air
2
(390 – 780 kPa, 4 – 8 kg/cm or 57 – 114 psi) as
shown.
248R200008
3. Snap ring
4. Flange
5. Disc and plate
6. Cushion plate
248RY00041
7. Snap ring
Place special tool on the sparing retainer and compress
the return spring.
248RY00003
9. Piston
Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
248RY00042
10. O-ring
11. O-ring
12. Oil seal ring
13. Thrust bearing

Check forward clutch piston
248RY00031
Check forward clutch drum bushing

the forward clutch drum bushing.
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
248RY00043

replace all discs.
248RY00045

spring.
247RY00034
REASSEMBLY
248R200004
Reassembly steps
1. Forward clutch drum 8. Snap ring
2. Thrust bearing 9. Cushion plate
3. Oil seal ring 10. Disc and plate
4. O-ring 11. Flange
5. O-ring 12. Snap ring
6. Forward clutch piston 13. Race
7. Piston return spring 14. Thrust bearing
Reassembly steps
2. Thrust bearing
jelly and install it onto the forward clutch drum, with the
race side facing downward.

248RY00044
3. Oil seal ring

Coat the three oil rings with ATF.
Contract the oil seal rings as shown, and install three oil
seal rings onto the forward clutch drum.
NOTE:
248RY00046
4. O-ring
Coat a new O-ring with ATF and install O-ring on the
forward clutch drum.
5. O-ring
Coat new O-rings with ATF and install two O-rings on
the forward clutch piston.
248RY00047
6. Forward clutch piston

Being careful not to damage the O-rings, press the
forward clutch piston into the forward clutch drum.
248RY00049

248RY00065
8. Snap ring
the return spring.
248RY00003
9. Cushion plate
Install cushion plate rounded side down as shown.
248RY00069
10. Disc and plate

Install discs and plates.
Install in order: P-D-P-D-P-D-P-D-P-D
11. Flange
And then install the flange, with the rounded edge
facing downward.
248R200007
12. Snap ring

the cutout portion of the forward clutch drum.
248RY00041

2
shown.
the discs, and recheck the piston stroke.
248R200008
13. Race
14. Thrust bearing
Coat the race and bearing with petroleum jelly, and
install them onto the forward clutch drum.

Inside Outside
Race 32.6 mm (1.283 in) 47.7 mm (1.878 in)
248RY00048

Install the direct clutch assembly onto the forward clutch
assembly.
248RY00039
Check that the distance from the direct clutch end to the
forward clutch end is 71.2 mm (2.803 in).
248RY00038
FRONT PLANETARY GEAR

DISASSEMBLY
247R200003
Disassembly steps
1. Race 5. Race (Metal)
3. Race 7. Race
Disassembly steps
1. Race
2. Thrust bearing
3. Race
5. Race (Metal)
6. Thrust bearing
7. Race

Check front planetary ring gear bushing
the front planetary ring gear bushing.
replace the front planetary ring gear.
247RY00021
REASSEMBLY
247R200004
Reassembly steps
2. Race 6. Race
4. Race (Metal) 8. Race
Reassembly steps
2. Race
3. Thrust bearing
Install the race and bearing to the rear side of the front
planetary gear.
247RY00023
Inside Outside
Race 33.7 mm (1.327 in) 47.6 mm (1.874 in)
4. Race (Metal)
Turn over the planetary gear and install the race.
Make sure that the lugs fit into the holes on the front
planetary gear.

Inside Outside
Race 34.3 mm (1.350 in) 47.8 mm (1.882 in)
247RY00024

6. Race
7. Thrust bearing
Install the race and bearing onto the rear side of the

247RY00025
Inside Outside
Race 25.98 mm (1.0228 in) 48.87 mm (1.9240 in)
8. Race
Turn over the planetary ring gear and install the race
onto the front side of the front planetary ring gear.

Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)
247RY00026
PLANETARY SUN GEAR AND NO.1

ONE-WAY CLUTCH
DISASSEMBLY
248R200005
Disassembly steps
1. One-way clutch and second brake hub 5. Sun gear input drum
2. Thrust washer (plastic) 6. Snap ring
3. Oil seal ring (Metal) 7. Planetary sun gear
4. Snap ring
Disassembly steps
hub.
①: Free
②: Lock
248RY00051

Remove two oil seal rings.
248RY00052
4. Snap ring
6. Snap ring
248RY00053

Check planetary sun gear bushing
the planetary sun gear bushing.
replace the planetary sun gear.
248RY00054
REASSEMBLY
248R200006
Reassembly steps
1. Planetary sun gear 5. Oil seal ring (Metal)
2. Snap ring 6. Thrust washer (Plastic)
3. Sun gear input drum 7. One-way clutch and second brake hub
4. Snap ring
Reassembly steps
2. Snap ring
Install snap ring to planetary sun gear.
248RY00055

Place a wooden block, etc. as a work stand and place
the planetary sun gear onto it.
Install the sun gear input drum onto the planetary sun
gear.
248RY0056
4. Snap ring
Install snap ring with snap ring pliers.
248RY00053

Install the two oil seal rings onto the planetary sun gear.
NOTE:
248RY00052

Install thrust washer.
NOTE:
Make sure that the lugs fit into the holes on the sun
gear input drum.
248RY00057

Install assembled No.1 one-way clutch and second
brake hub onto planetary sun gear as shown.
248RY00058

hub.
①: Free
②: Lock
248RY00051
SECOND BRAKE ASSEMBLY (B-2)

DISASSEMBLY
246R200001
Disassembly steps
1. Second brake assembly 6. Piston sleeve
2. Thrust washer (Plastic) 7. Second brake piston
4. Spring retainer 9. Second brake drum
Disassembly steps
246RY00007

3. Snap ring
the return spring.
4. Spring retainer
247RY00001
6. Piston sleeve
Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston.
8. O-ring
246RY00008

spring.
247RY00034
REASSEMBLY
246R200002
Reassembly steps
1. O-ring 6. Spring retainer
2. Second brake piston 7. Snap ring
3. Second brake drum 8. Thrust washer (Plastic)
4. Piston sleeve 9. Second brake assembly
Reassembly steps
1. O-ring
second brake piston.
second brake piston into the second brake drum.
246RY00009 4. Piston sleeve
Install piston sleeve.

6. Spring retainer
Install spring retainer.
246RY00010
7. Snap ring
the return spring.
247RY00001
Check second brake piston movement

Make sure the second brake piston moves smoothly
when applying and releasing the low compressed air to
the second brake drum.
246RY00011

to the second brake piston, with the grooved side facing
upward.
NOTE:
Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
246RY00012

246RY00014
REAR PLANETARY GEAR

ASSEMBLY AND OUTPUT SHAFT
DISASSEMBLY
247R200005
Disassembly steps
1. Second brake assembly 9. Thrust washer (Plastic)
2. Output shaft 10. Thrust washer (Plastic)
3. Oil seal ring 11. Rear planetary gear
4. Disc, plate and flange 12. Thrust bearing and race
5. Rear planetary gear assembly 13. Snap ring
6. One-way clutch inner race 14. Ring gear flange
7. Snap ring 15. Rear planetary ring gear
8. One-way clutch
Disassembly steps
2. Output shaft
246RY00014
3. Oil seal ring

Remove oil seal ring from output shaft.
4. Disc, plate and flange
247RY00028

Remove rear planetary gear from rear planetary ring
gear.
247RY00029

inner race.
①: Lock
②: Free
247RY00030

Remove the one-way clutch inner race from the rear
planetary gear.
247RY00031
7. Snap ring
247RY00032
8. One-way clutch
Remove the one-way clutch with retainers from the
planetary gear.
13. Snap ring
247RY00033
replace all discs.
248RY00045
REASSEMBLY
247R200006
Reassembly steps
1. Rear planetary ring gear 9. Snap ring
2. Ring gear flange 10. One-way clutch inner race
3. Snap ring 11. Rear planetary gear assembly
4. Thrust bearing and race 12. Disc, plate, flange and cushion plate
5. Rear planetary gear 13. Oil seal ring
6. Thrust washer (Plastic) 14. Output shaft
7. Thrust washer (Plastic) 15. Second brake assembly
8. One-way clutch
Reassembly steps
2. Ring gear flange
Install ring gear flange to the rear planetary ring gear.
3. Snap ring
Install snap ring to the rear planetary ring gear.
247RY00035

Coat the races and bearing with petroleum jelly, and
install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)

Inside Outside
Race (A) 28.8 mm (1.134 in) 44.8 mm (1.764 in)
247RY00036
Race (B) 27.8 mm (1.094 in) 44.8 mm (1.764 in)

Coat the thrust washers with petroleum jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE:
247RY00037 on the rear planetary gear.
8. One-way clutch
Install the one-way clutch with the flanged side facing
upward onto the rear planetary gear.
247RY00038
9. Snap ring
Install snap ring.
247RY00039

While turning counterclockwise, install one-way clutch
inner race to rear planetary gear.
247RY00040

inner race.
①: Lock
②: Free
247RY00041

Install rear planetary gear onto rear planetary ring gear.
247RY00029
12. Disc, plate, flange and cushion plate

Install a clutch plate onto the rear planetary gear
assembly.
NOTE:
The claw interval of the plate should be as shown in
the figure when viewing the clutch plate from the
arrow direction.
246RY00013
Install a brake flange onto the rear planetary gear

assembly.
Install six clutch discs and six brake plates alternately,
starting with clutch disc, onto the rear planetary gear
assembly.
247RY00047
13. Oil seal ring

Coat the oil seal ring with ATF and install it to the output
shaft.
NOTE:
247RY00028
14. Output shaft

Install output shaft into rear planetary gear assembly.
247RY00042

246RY00014
FIRST AND REVERSE BRAKE (B-3)

DISASSEMBLY
246R200003
Disassembly steps
1. Thrust bearing and race 6. Reaction sleeve
3. Piston return spring 8. First and reverse brake piston No.1
4. First and reverse brake piston No.2 9. O-ring
5. O-ring
Disassembly steps
Remove assembled bearing and race from
transmission case.
247RY00043

Make sure that first and reverse brake piston moves
246RY00016
2. Snap ring
Set special tool on the spring retainer, and compress
the return spring.
247RY00002

Holding the first and reverse brake piston No.2 by hand,
apply compressed air to the transmission case to
remove the first and reverse brake piston No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air, lift
the piston out with needle-nose pliers.
5. O-ring
246RY00016
6. Reaction sleeve
Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: 5-8840-2173-0 (J-37236)
7. O-ring
246RY00017

Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the transmission
case.
Piston puller: 5-8840-2174-0 (J-37237)
9. O-ring
247RY00044
REASSEMBLY
246R200004
Reassembly steps
1. O-ring 6. First and reverse brake piston No.2
2. O-ring 7. Return spring
3. First and reverse brake piston No.1 8. Snap ring
4. O-ring 9. Thrust bearing and race
5. Reaction sleeve
Reassembly steps
1. O-ring
Coat three new O-rings with ATF.
Install the two O-rings on the No.1 piston.
2. O-ring
Install the O-ring on the reaction sleeve.
Install the first and reverse brake piston No.1 to the
246RY00018
reaction sleeve.
4. O-ring
Coat a new O-ring with ATF and install it on the first and
reverse brake piston No.2.
5. Reaction sleeve
Install the first and reverse brake piston No.1 with
reaction sleeve onto the first and reverse brake piston
No.2.
246RY00019

Align the teeth of the first and reverse brake piston No.2
into the proper grooves.
first and reverse brake piston No.2 with No.1 into the
transmission case.
246RY00020
7. Return spring
Place piston return spring onto first and reverse brake
piston No.2.
246RY00021
8. Snap ring
Set special tool as shown, and compress the return
spring with special tool.
247RY00002

Make sure the first and reverse brake piston moves
246RY00022

jelly.
Install the assembled bearing and race facing the
bearing side upward.

247RY00043 Outside diameter 58.1 mm (2.287 in)
TRANSMISSION VALVE BODY

ASSEMBLY
DISASSEMBLY
240R200019
Disassembly steps
1. Detent spring 4. No.1 gasket (Upper valve body side)
2. Manual shift valve 5. Valve body plate
3. Upper valve body 6. No.2 gasket (Lower valve body side)
7. Lower valve body
Disassembly steps
1. Detent spring
Remove detent spring from valve body.
244R200004

Remove manual shift valve.
244R200005
3. Upper valve body

5. Valve body plate
Turn over assembly and remove twenty five bolts.
244R200006
Hold the valve body plate to the upper valve body.

Lift off upper valve body and plate as a single unit.
NOTE:
Be careful that the check balls and strainer do not
fall out.
7. Lower valve body
244R200007
REASSEMBLY
240R200023
Reassembly steps
1. No.1 gasket (Upper valve body side) 5. Lower valve body
2. Valve body plate 6. Manual shift valve
3. No.2 gasket (Lower valve body side) 7. Detent spring
4. Upper valve body
Reassembly steps
Position new No.1 gasket ① on upper valve body.
Align a new No.1 gasket at each bolt hole.
244R200034
2. Valve body plate

Position valve body plate ② on No.1 gasket.
Align the plate at each bolt hole.
Position new No.2 gasket on valve body plate.
Align a new No.2 gasket at each bolt hole.
244R200035
4. Upper valve body

5. Lower valve body
Place upper valve body with plate and gaskets on top
lower valve body.
Align each bolt hole and gasket in the valve body.
244R200007
Install twenty-five bolts to upper valve body.

NOTE:
Torque: 6.4 N･
･m (0.65 kg･
･m/57 Ib･
･in)
244R200043

Install manual shift valve.
7. Detent spring
Install detent spring..
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200004
LOWER VALVE BODY

DISASSEMBLY
244R200008
242R200009
Disassembly steps
1. Check valve 9. Retainer
2. Pressure relief valve 10. Sleeve with plunger, spring and washer
3. Strainer 11. Primary regulator valve
4. Solenoid S1 12. Clip
5. Solenoid S2 13. Pressure regulator plug
6. Solenoid S3 14. Retainer
7. Retainer 15. Sleeve with accumulator control valve
8. Plug, spring and 1-2 shift valve and spring
16. Pin
17. Plug
Disassembly steps
1. Check valve
2. Pressure relief valve
Remove check valve, pressure relief valve and springs.
244R200010
3. Strainer
Remove three strainers.
244R200011
NOTE:
Confirm clip, pin and three retainers are installed
correctly.
244R200012
4. Solenoid S1
5. Solenoid S2
Remove each fixing bolt.
Remove the solenoid S1 and S2 from each bore.
Remove the O-rings form solenoid.
244R200013
6. Solenoid S3
Remove the solenoid S3 from the bore.
Remove the O-ring.
244R200014
7. Retainer
in the sleeve.
244R200015
8. Plug, spring and 1-2 shift valve

244R200016
9. Retainer
Place a mark on the bevel when the retainer is
positioned.
NOTE:
When reassembling, position the retainer in the
same position.
244R200017

in the sleeve.
WARNING:
There is a highly compressed spring inside-keep
away from your face.
244R200018
10. Sleeve with plunger, spring and washer

Remove the sleeve with the plunger, spring and
washer.
244R200019
Remove the plunger from the sleeve.
244R200020

Remove the primary regulator valve from the valve
body.
244R200021
12. Clip
Using a screwdriver, remove the clip.
NOTE:
Tape the end of the screwdriver to prevent
scratching the valve body.
244R200022
13. Pressure regulator plug

Remove the pressure regulator plug.
244R200023
14. Retainer
in the sleeve.
244R200024
15. Sleeve with accumulator control valve and spring

Remove the sleeve with the accumulator control valve
and spring.
244R200025
Remove the accumulator control valve and spring from

the sleeve.
16. Pin
Remove the pin with a magnetic finger.
17. Plug
Remove the plug.
244R200026

Inspect strainer
244R200027

Check for damage, squareness, rust and distorted coils.
shown below.
Spring Free length

(1) Check valve 20.2 mm (0.795 in)
(2) Pressure relief valve 11.2 mm (0.441 in)
(3) 1-2 shift valve 30.8 mm (1.213 in)
(4) Primary regulator valve 62.3 mm (2.453 in)
(5) Accumulator control valve 33.9 mm (1.335 in)
244R200028
REASSEMBLY
244R200008
244R200038
Reassembly steps
2. Pin 15. 1-2 shift valve
3. Accumulator control valve 16. Spring
4. Spring 17. Plug
5. Sleeve with accumulator control valve 18. Retainer
6. Retainer 19. Solenoid S3
7. Pressure regulator plug 20. Solenoid S1
8. Clip 21. Solenoid S2
9. Washer 22. Strainer
10. Primary regulator valve 23. Check valve and spring
11. Plunger 24. Pressure relief valve
12. Spring
13. Sleeve
Reassembly steps
1. Plug
Install the plug.
2. Pin
Install the pin.
4. Spring
Install the accumulator control valve and spring into the
244R200026
sleeve.
5. Sleeve with accumulator control valve
Install the sleeve with the accumulator control valve and
spring into the bore.
244R200025
6. Retainer
Install the retainer by pushing in the sleeve.
244R200029
7. Pressure regulator plug

Install the accumulator reducing plug into the bore.
244R200023
8. Clip
Install the clip into the groove of the pressure regulator
plug.
244R200030
9. Washer
Install the washer onto the primary regulator valve.
244R200031

Install the primary regulator valve with the washer into
the bore.
244R200021
11. Plunger
Install the plunger into the sleeve.
244R200039
12. Spring
13. Sleeve
Install the sleeve with the plunger and spring into the
bore.
244R200040
14. Retainer
Install the retainer to the bevel by pushing in the sleeve.
NOTE:
Install the retainer to the same position on the
sleeve, as when disassembling.
244R200041
15. 1-2 shift valve

16. Spring
17. Plug
Install the 1-2 shift valve, spring and plug into the bore.
244R200016
18. Retainer
244R200032
19. Solenoid S3
Install a new O-ring to the solenoid.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200014
20. Solenoid S1
21. Solenoid S2
Install a new O-ring to the solenoid.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
244R200013
NOTE:
Make sure clip, pin and three retainers are installed
correctly.
244R200012
22. Strainer
Install the three strainers to the valve body as shown.
Strainer Height Diameter (a)

Solenoid
(A) 12.3 mm (0.484 in) 10.3 mm (0.406 in)
oil strainer
Throttle oil
(B) 19.5 mm (0.768 in) 10.3 mm (0.406 in)
strainer
244R200033
23. Check valve and spring

24. Pressure relief valve
Install check valve, pressure relief valve and springs.
244R200010
UPPER VALVE BODY

DISASSEMBLY
243R200001
243R200002
Disassembly steps
1. Strainer 19. Sleeve with plunger, spring and lock-up
2. Check ball relay valve
3. Valve stopper 20. Retainer
4. Throttle valve cam 21. Plug
5. Pin 22. Secondary regulator valve
6. Down-shift plug 23. Spring
8. Throttle valve 25. Plug
9. Spring and adjusting ring 26. Cut-back valve
10. Retainer 27. Spring
12. 3-4 shift valve 29. Plug
14. Retainer 31. 2-3 shift valve
16. Second coast modulator valve 33. Plug
18. Retainer 35. Low coast modulator valve
Disassembly steps
Remove valve body plate and gaskets.
243R200003
1. Strainer
Remove strainer.
243R200004
2. Check ball
Remove nine check balls.
243R200051
NOTE:
Confirm pin, seven retainers and valve stopper are
installed correctly.
243R200006
3. Valve stopper
Remove valve stopper.
243R200007
4. Throttle valve cam

Remove throttle valve cam.
243R200008
5. Pin
Remove the pin with a magnetic finger by pushing in the
down-shift plug.
243R200009
6. Down-shift plug
7. Spring
8. Throttle valve
Remove the down-shift plug, spring and throttle valve.
243R200010
9. Spring and adjusting ring

Turn over assembly, and remove the spring and
adjusting rings.
NOTE:
Note the number of adjusting rings installed.
(Sometimes adjusting rings will not be used.)
243R200011
10. Retainer
in the plug.
243R200012
11. Plug
12. 3-4 shift valve
13. Spring
Remove the plug, 3-4 shift valve and spring.
243R200013
14. Retainer
Remove the retainer.
243R200014
15. Plug
17. Spring
Remove the plug, second coast modulator valve and
spring.
243R200015
18. Retainer
Remove the retainer with the magnetic finger.
243R200016
19. Sleeve with plunger, spring and lock-up relay valve

Remove the sleeve with the plunger, spring and lock-up
relay valve.
243R200017
Remove the lock-up relay valve, spring and plunger

from the sleeve.
243R200018
20. Retainer
in the plug.
243R200019
21. Plug
23. Spring
Remove the plug, secondary regulator valve and spring.
243R200020
24. Retainer
in the plug.
243R200021
25. Plug
26. Cut-back valve
27. Spring
Remove the plug, cut-back valve and spring.
243R200022
28. Retainer
in the plug.
243R200023
29. Plug
30. Spring
31. 2-3 shift valve
243R200024
32. Retainer
in the plug.
243R200025
33. Plug
34. Spring
Remove the plug, spring and low coast modulator valve.
243R200026

Inspect strainer
243R200027

Check for damage, squareness, rust and distorted coils.
that down below.
Spring Free length

(1) Down-shift plug 27.3 mm (1.075 in)
20.6 mm (0.811 in)
(2) Throttle valve
or 23.3 mm (0.917 in)
(3) 3 – 4 shift valve 30.8 mm (1.213 in)
(4) second coast modulator
30.9 mm (1.217 in)
valve
(5) Lock-up relay valve 21.4 mm (0.843 in)
(6) Secondary regulator valve 30.9 mm (1.217 in)
(7) Cut-back valve 21.8 mm (0.858 in)
(8) 2 – 3 shift valve 30.8 mm (1.213 in)
(9) Low coast modulator valve 30.4 mm (1.197 in)
243R200028
REASSEMBLY
243R200049
243R200002
Reassembly steps
1. Low coast modulator valve 21. Retainer
3. Plug 23. Second coast modulator valve
5. 2-3 shift valve 25. Retainer
7. Plug 27. 3-4 shift valve
10. Cut-back valve 30. Throttle valve
11. Plug 31. Valve stopper
12. Retainer 32. Adjusting ring
14. Secondary regulator valve 34. Spring
15. Plug 35. Down-shift plug
16. Retainer 36. Pin
17. Plunger 37. Sleeve
19. Lock-up relay valve 39. Throttle cam assembly
20. Sleeve with plunger, spring and lock-up 40. Check ball
relay valve 41. Strainer
Reassembly steps
2. Spring
3. Plug
Install the low coast modulator valve, spring and plug
into the bore.
243R200026
4. Retainer
243R200029
5. 2-3 shift valve

6. Spring
7. Plug
Install the 2-3 valve, spring and plug into the bore.
243R200024
8. Retainer
243R200030
9. Spring
10. Cut-back valve
11. Plug
Install the spring, cut-back valve and plug into the bore.
243R200002
12. Retainer
243R200031
13. Spring
15. Plug
Install the spring, secondary regulator valve and plug
into the bore.
243R200020
16. Retainer
243R200032
17. Plunger
18. Spring
Install the plunger and spring into the sleeve.
243R200033

Install the lock-up relay valve into the sleeve.
243R200034
20. Sleeve with plunger, spring and lock-up relay valve

Install the sleeve with the plunger, spring and lock-up
relay valve into the bore.
243R200017
21. Retainer
Install the retainer.
243R200035
22. Spring
24. Plug
Install the spring, second coast modulator valve and
plug into the bore.
243R200015
25. Retainer
243R200036
26. Spring
27. 3-4 shift valve
28. Plug
Install the spring, 3-4 shift valve and plug into the bore.
243R200013
29. Retainer
243R200037
30. Throttle valve

Inset the throttle valve into the bore.
NOTE:
Check that the valve is fully inserted into the bore.
243R200038
31. Valve stopper

Install the valve stopper as shown.
243R200039
32. Adjusting ring

Turn over valve body, and install the same number of
adjusting rings as were removed during disassembly.
243R200040
33. Spring
Install the spring onto the end of the valve shaft.
243R200041
34. Spring
35. Down-shift plug
Install the spring and down-shift plug into the bore.
243R200042
36. Pin
Install the pin by pushing in the plug.
243R200043
37. Sleeve
Insert the sleeve through one side of the cam.
243R200044
38. Spring
Install the spring with the hook through the hole in the
cam.
243R200045
39. Throttle cam assembly

Check that position of the spring end is positioned as
Tighten bolt.
Torque: 10 N･
･m (1.0 kg･
･m/87 Ib･
･in)
243R200046
NOTE:
Make sure pin, seven retainers and valve stopper are
installed correctly
243R200006
40. Check ball

Install the two types of check balls (total 9 pcs.) to the
valve body.
Check ball Diameter

(A) Rubber ball 6.35 mm (0.2500 in)
(B) Rubber ball 5.56 mm (0.2189 in)
243R200050
41. Strainer
Install strainer.
243R200048
TRANSMISSION CASE
DISASSEMBLY
249RY00001
Disassembly steps
1. Spacer 4. Manual valve lever
2. Pin 5. Oil seal
3. Manual valve lever shaft 6. Oil seal
Disassembly steps
1. Spacer
Using a chisel, cut off the spacer and remove it from the
shaft.
249RY00002
2. Pin
Using a punch, drive out the pin.
Pull the manual valve lever shaft out through the case
by the threads.
249RY00003
5. Oil seal
6. Oil seal
249RY00004
REASSEMBLY
249RX00001
Reassembly steps
1. Oil seal 4. Manual valve lever
2. Oil seal 5. Manual valve lever shaft
3. Spacer 6. Pin
Reassembly steps
1. Oil seal
2. Oil seal
Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : 5-8840-2169-0 (J-37232-2)
240RY00021
3. Spacer
Assemble a new spacer to the manual valve lever.
Install the manual valve lever shaft to the transmission
case through the manual valve lever by the threads.
249RY00005
6. Pin
Drive in the pin with the slot at a right angle to the shaft.
249RY00006
Match the spacer hole to the lever staking hollow and

stake the spacer to the lever.
Make sure the manual valve lever shaft turns smoothly.
249RY00003
TORQUE CONVERTER
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : 5-8840-2168-0
(J-35467)
Insert the stopper so that it fits in the notch of the
241RY00018
converter hub and outer race of the one-way clutch.
One-way clutch test
The clutch should lock when turned counterclockwise,
and rotate freely and smoothly clockwise. Less than 25
kg･cm (22 Ib･in) of torque should be required to rotate
the clutch clockwise. If necessary, clean the converter
and retest the clutch. Replace the converter if the clutch
still fails the test.
ADAPTER HOUSING (4×

×4)
DISASSEMBLY
241R200005
Disassembly steps
1. Oil seal
2. Adapter housing
Disassembly steps
1. Oil seal
2. Adapter housing
REASSEMBLY
241R200006
Reassembly steps
1. Adapter housing
2. Oil seal
Reassembly steps
1. Adapter housing
2. Oil seal
adapter housing.
240RY00003
EXTENSION HOUSING (4×

×2)
DISASSEMBLY
241R200007
Disassembly steps
1. Gasket 4. Oil seal
2. Tube 5. Dust deflector
3. Tube packing 6. Extension housing
Disassembly steps
1. Gasket
2. Tube
3. Tube packing
4. Oil seal
NOTE:
The oil seal can be removed without removing the
dust deflector.
5. Dust deflector
REASSEMBLY
241R200008
Reassembly steps
1. Extension housing 4. Tube packing
2. Oil seal 5. Dust deflector
3. Tube 6. Gasket
Reassembly steps
2. Oil seal
extension housing.
NOTE:
The oil seal can be installed without removing the
249L100005 dust deflector.
3. Tube
4. Tube packing
5. Dust deflector
6. Gasket

GENERAL SPECIFICATIONS
Remaks
Model AW30-40LE
Engine 4JG2-T
Electronic control planetary gear type
Type 3-element 1-stage 2-phase type
(with lock-up mechanism)
1st 2.804
2nd 1.532
4th (O/D) 0.705
Reverse 2.394
Name BESCO ATF Ⅲ
Oil used
Q’ty (l) 8
Torque converter 2400±150 Stall speed (rpm)
Forward clutch C-1 5
Direct clutch C-2 4 Number of discs
Friction element
OD direct clutch C-0 2

Band width or
Second coast brake B-1 40 mm
Number of discs
Second brake B-2 5
First and reverse brake B-3 6 Number of discs
Overdrive brake B-0 4
One-way clutch No.1 F-1 22
Clutch
One-way clutch No.2 F-2 28 Number of sprage

OD one-way clutch F-0 24
Sun gear 42
Front planetary Pinion gear 19
Ring gear 79
Planetary gear
Sun gear 33
Rear planetary Pinion gear 23 Number of teeth
Ring gear 79
Sun gear 33
O/D planetary Pinion gear 23
Ring gear 79
N･
･m (kg･
･m/Ib･
･ft)
E07R20006
N･
･m (kg･
･m/Ib･
･ft)
E07R200014
N･
･m (kg･
･m/Ib･
･ft)
E07R200005
SPECIAL TOOLS
Tech 2 scan tool
5-8840-0093-0 Oil pressure gauge
5884000930
5-8840-2152-0
Holding fixture
(J-37227)
901RY00018
5-8840-0003-0
(J-2389-20)
901RT096
5-8840-2153-0
Oil pan seal cutter
(J-37228)
901RY00019
5-8840-0195-0
Spring compressor
(J-23327-1)
901RY00028
5-8840-2256-0
Oil seal installer; oil pump
(J-9617)
901RY00020
5-8840-2170-0
OD brake piston spring compressor
(J-37233)
901RY00021
5-8840-0254-0
Spring compressor (snap ring)
(J-25048)
901RY00022
5-8840-2173-0
1st/reverse brake puller
(J-37236)
901RY00023
5-8840-2174-0
1st/reverse brake puller
(J-37237)
901RY00024
5-8840-2169-0
Manual valve shaft seal installer & remover
(J-37232-2)
901RY00025
5-8840-2168-0 One-way clutch testing tool;

(J-35467) torque converter
901RY00026
Oil seal installer;

5-8840-2282-0
adapter housing (4×4)
901RY00027
Oil seal installer;

5-8840-2702-0
extension housing (4×2)
5884027020
RVAW3-WE-0211S



Issued by
Tokyo, Japan
First edition July, 2001

NO.RVAW3-WE-0211S
WORKSHOP MANUAL
TFR-TFS
ENGINE
4J SERIES
SECTION 6
NOTICE

information contained in Section - 0A under the headings
MANUAL”.

notice.
Applicable Model : TFR/S 54, TFR/S 55, TFR/S 69, TFR/S 77

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION NO. CONTENTS
6 Troubleshooting
6A Engine Mechanical
6B Engine Cooling
6C Fuel System
6D Engine Electrical
6E Exhaust Gas Recirculation (EGR) System
6F Exhaust System
INDEX
TROUBLESHOOTING 6 – 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE
Hard Starting ..................................................................................................................... 6 - 3
Starter Motor Inoperative ............................................................................................. 6 - 3
Starter Motor Operates But Engine Does Not Turn Over .......................................... 6 - 4
Engine Turns Over But Does Not Start....................................................................... 6 - 5
Unstable Idling .................................................................................................................. 6 - 8
Insufficient Power............................................................................................................. 6 - 11
Excessive Fuel Consumption .......................................................................................... 6 - 15
Excessive Oil Consumption............................................................................................. 6 - 17
Overheating....................................................................................................................... 6 - 18
White Exhaust Smoke ...................................................................................................... 6 - 20
Dark Exhaust Smoke ........................................................................................................ 6 - 21
Oil Pressure Does Not Rise ............................................................................................. 6 - 22
Abnormal Engine Noise ................................................................................................... 6 - 24
Turbocharger .................................................................................................................... 6 - 27
6 – 2 TROUBLESHOOTING
Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems.
1. This Section is divided into ten Sub-Sections.
Refer to the Table of Contents.
2. Each troubleshooting chart has three headings arranged from left to right.
Example:
1503
3.INSUFFICIENT POWER
Checkpoint Trouble Cause Countermeasure
NG Fuel filter cartridge

Fuel line Replace the fuel flter
clogged or fouled
NG Fuel line clogged Clean the fuel line
OK
Fuel pump NG Defective fuel pump Replace the fuel pump
3. Easily checked areas are presented at the beginning of the troubleshooting chart. Procedures become more
complex as the chart progresses.
4. It is suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle.
5. It is possible that a seemingly apparent engine problem is not related to the engine.
For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a
slipping clutch instead of an engine malfunction.
Refer to the other troubleshooting charts if required.
6. Optional equipment and variations are included in the troubleshooting charts.
If the vehicle you are servicing is not equipped with a particular option or variation noted in the “Checkpoint”
frame, disregard the frame and move on to the next one.
HARD STARTING
1. STARTER INOPERATIVE
NG Loose battery cable terminals Clean and/or retighten the

Battery
Poor connections due to rusting battery cable terminals
NG
Battery discharged or weak Recharge or replace the battery
NG
Fan belt loose or broken Adjust or replace the fan belt
OK
NG
Main fuse Main fuse shorted Replace the main fuse
OK
NG
Starter switch Defective starter switch or Replace the starter switch or
starter relay the starter relay
OK
NG Defective magnetic switch or Repair or replace the magnetic

Starter motor
starter relay switch
NG Repair or replace the starter

Defective starter motor
motor
150102
2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER
NG Loose battey cable terminals

Battery Clean and/or retighten the
Poor connections due to rusting battery cable terminals
NG
Battery discharged or weak Recharge or replace the battery
NG
Fan belt loose or broken Adjust or replace the fan belt
OK
NG
Starter motor Defective pinion gear Replace the pinion gear
NG
Defective magnetic switch Repair or replace the magnetic
switch
NG Brush wear Replace the brush and/or the

Weak brush spring brush spring
OK
NG Piston, crank bearing seizure, Repair or replace the related

Engine
or other damage parts
3. ENGINE TURNS OVER BUT DOES NOT START
NG Defective fuel cut solenoid Replace the fuel cut solenoid

Engine stop mechanism
value valve
1500010301
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
NG
Fuel Fuel tank is empty Fill the fuel tank
OK
NG Repair or replace the fuel lines

Fuel piping Clogged or damaged fuel lines
Retighten the fuel line
Loose fuel line connections
connections
OK
NG
Fuel filter Fuel filter overflow valve does Repair or replace the fuel filter
not close overflow valve
NG
Clogged fuel filter element Replace the fuel filter element
or the fuel filter cartridge
OK
NG Bleed the air from the fuel

Fuel system Air in the fuel system
system
OK
NG Repair or replace the feed

Fuel feed pump Defective feed pump
pump
1500010302
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
NG
Fuel Use of the wrong fuel Use the correct fuel
NG
Water particles in the fuel Change the fuel
OK
NG Bleed the air from the fuel

Fuel system Air in the injection pump
system
OK
NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle
NG Injection nozzle injection

Adjust or replace the injection
starting pressure too low
nozzle
Improper spray condition
OK
NG Defective fuel injection nozzle

Injection pump resulting in fuel drippage after Replace the delivery valve
fuel injection
NG Injection pump plunger worn or Replace the injection pump

stuck plunger assembly
Continued on the next page

Continued from the previous page
NG Injection pump drive shaft Replace the injection pump

Injection pump
seizure or other damage drive shaft
NG Injection pump governor spring Replace the injection pump

seizure governor spring
UNSTABLE IDLING
NG
Idling system Idling improperly adjusted Adjust the idling
OK
Fast idling speed control device NG Defective fast idling speed Repair or replace the fast idling
control device speed control device
OK
NG Accelerator control system Adjust the accelerator control

Accelerator control system
improperly adjusted system
OK
NG
Fuel system Fuel system leakage or Repair or replace the fuel
blockage system
NG
Air in the fuel system Bleed the air from the fuel
system
NG Water particles in the fuel Change the fuel

system
OK
NG Replace the fuel filter cartridge

Fuel filter Clogged fuel filter element
the fuel filter cartridge

OK
NG
Fuel feed pump Defective fuel feed pump Replace the fuel feed pump
OK
NG

Improper spray condition nozzle
OK
NG Defective delivery valve

fuel injection
NG
Injection timing improperly Adjust the injection timing
adjusted
NG
Insufficient injection volume Adjust the injection volume
NG
Defective idle spring Replace the idle spring

NG Defective governor lever Repair or replace the governor

Injection pump
operation lever
NG Regulator valve improperly Adjust or replace the regulator

adjusted valve
NG
Broken plunger spring Replace the plunger spring
NG
Worn plunger Replace the plunger assembly
NG
Worn cam disc Replace the cam disc
OK
NG Valve clearance improperly

Valve clearance Adjust the valve clearance
adjusted
OK
Blown out cylinder head gasket
NG Worn cylinder liner
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
1503
INSUFFICIENT POWER
NG Clean or replace the air cleaner

Air cleaner Clogged air cleaner element
element
OK
NG
Fuel Water particles in the fuel Replace the fuel
OK
NG Replace the fuel filter element

Fuel filter Clogged fuel filter element
or the fuel filter cartridge
OK
NG
Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed
pump
OK
NG

OK
NG Fuel injection pipes damaged or

Fuel injection pipes Replace the fuel injection pipes
obstructed

OK
NG Repair or replace the regulating

Injection pump Defective regulating valve
valve
NG
Defective delivery valve Replace the delivery valve
NG
Defective timer Repair or replace the timer
NG
Worn cam disk Replace the cam disk
NG
Improper control lever operation Adjust or replace the control
lever
NG Adjust the injection timing

Defective injection timing Repair or replace the injection
pump timer
NG
Weak governor spring Replace the governor spring

NG
Injection pump Worn plunger Replace the plunger assembly
NG
Worn cam disc Replace the cam disc
OK
NG Booster compensator pipe Replace the booster

Turbocharger
broken or cracked compensator pipe
Exhaust gas leakage from the

NG
exhaust system Repair or replace the related
Air leakage from the intake parts
system
NG
Defective waste gate Repair or replace the waste
gate
NG Defective turbocharger Replace the turbocharger

assembly assembly
OK

OK

adjusted
OK
NG
Valve spring Valve spring weak or broken Replace the valve spring
OK
NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
OK
NG
Full load adjusting screw seal Open and improperly set Adjust and reseal the adjusting
adjusting screw seal screw
1504
EXCESSIVE FUEL CONSUMPTION
NG Repair or replace the fuel

Fuel system Fuel leakage
system related parts
OK

element
OK
NG
Idling speed Poorly adjusted idling speed Adjust the idling speed
OK

Injection nozzle Adjust or replace the injection
OK
NG
Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing
adjusted
OK

fuel injection
OK
NG Air leakage from the Repair the turbocharger intake

Turbocharger
turbocharger intake side side

NG Defective turbocharger
Turbocharger Replace the turbocharger
assembly assembly
OK

adjusted
OK
OK
NG
Valve spring Valve spring weak or broken Replace the valve spring
1505
EXCESSIVE OIL CONSUMPTION
NG Engine oil unsuitable Replace the engine oil

Engine oil
Too much engine oil Correct the engine oil volume
OK
NG Replace the oil seal and/or the

Oil seal and gasket Oil leakage from the oil seal
and/or the gasket gasket
OK
NG
Air breather Clogged air breather Clean the air breather
OK
NG
Intake and exhaust valves Worn valve stems and valve Replace the intake and exhaust
guides valves and the valve guides
1506
OVERHEATING
NG
Cooling water Insufficient cooling water Replenish the cooling water
OK
NG Oil leakage from the fan Replace the fan coupling

Fan coupling (if so equipped)
coupling
OK
NG Fan belt loose or cracked

Fan belt Replace the fan belt
causing slippage
OK
NG
Radiator Defective radiator cap or Replace the radiator cap or
clogged radiator core clean the radiator core
OK
NG
Water pump Defective water pump Repair or replace the water
pump
OK
Cylinder head and cylinder body NG Defective sealing cap resulting Replace the sealing cap
sealing cap in water leakage
OK
NG
Thermostat Defective thermostat Replace the thermostat

OK
NG Cooling system clogged by Clean the foreign material from

Cooling system
foreign material the cooling system
OK
NG Fuel injection timing improperly

Fuel injection timing Adjust the fuel injection timing
adjusted
1507
WHITE EXHAUST SMOKE
NG
Fuel Water particles in the fuel Replace the fuel
OK
NG
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing
OK
OK
NG
Turbocharger Defective turbocharger Replace the turbocharger
OK
NG Defective valve seals

Inlet and exhaust valves Replace the valve seals, the
Worn valve stems and valve
Valve seals valve, and the valve guides
guides
1508
DARK EXHAUST SMOKE

element
OK

OK

adjusted
OK

fuel injection
NG
Excessive injection volume Adjust the injection volume
1509
OIL PRESSURE DOES NOT RISE
NG Improper viscosity engine oil Replace the engine oil

Engine oil
Insufficient engine oil Correct the engine oil volume
OK
NG Defective oil pressure gauge or Repair or replace the oil

Oil pressure gauge or unit
unit pressure gauge or unit
Oil pressure indicator light Defective indicator light Replace the indicator light
OK
NG Replace the oil filter element or

Oil filter Clogged oil filter element
the oil filter cartridge
OK
NG
Relief valve and bypass valve Relief valve sticking and/or Replace the relief valve and/or
weak bypass valve spring the bypass valve spring
OK
NG
Oil pump Clogged oil pump strainer Clean the oil pump strainer
NG Replace the oil pump related

Worn oil pump related parts
parts
OK
NG Replace the rocker arm

Rocker arm shaft Worn rocker arm bushing
bushing

OK
NG Worn camshaft and camshaft Replace the camshaft and the

Camshaft
bearing camshaft bearings
OK
NG Replace the crankshaft and/or

Crankshaft and bearings Worn crankshaft and bearings
the bearings
1510
ABNORMAL ENGINE NOISE

1. Engine knocking
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
NG
Fuel Fuel unsuitable Replace the fuel
OK

adjusted
OK
NG Improper injection nozzle

starting pressure and spray
nozzle
condition
OK
NG
Compression pressure Blown out head gasket Replace the head gasket or the
Broken piston ring piston ring
2. Gas Leakage Noise
NG Loosely connected exhaust Tighten the exhaust pipe

Exhaust pipes pipes connections
Broken exhaust pipes Replace the exhaust pipes
OK
NG Replace the washers

Injection nozzles and/or glow Loose injection nozzles and/or
Tighten the injection nozzles
plugs glow plugs
and/or the glow plugs

OK
NG Loosely connected exhaust Tighten the exhaust manifold

Exhaust manifold
manifold and/or glow plugs connections
OK
NG Replace the cylinder head

Cylinder head gasket Damaged cylinder head gasket
gasket
3. Continuous Noise
NG
Fan belt Loose fan belt Readjust the fan belt tension
OK
NG
Cooling fan Loose cooling fan Retighten the cooling fan
OK
NG Worn or damaged water pump Replace the water pump

Water pump bearing
bearing bearing
OK
NG
Generator or vacuum pump Defective generator or vacuum Repair or replace the generator
pump or the vacuum pump
OK
NG
Valve clearance Valve clearance improperly Adjust the valve clearance
adjusted
4. Slapping Noise

adjusted
OK
NG
Rocker arm Damaged rocker arm Replace the rocker arm
OK
NG
Flywheel Loose flywheel bolts Retighten the flywheel bolts
OK
NG
Crankshaft and thrust bearings Worn or damaged crankshaft Replace the crankshaft and/or
and/or thrust bearings the thrust bearings
OK
NG
Crankshaft and connecting rod Worn or damaged crankshaft Replace the crankshaft and/or
bearings and/or connecting rod bearings the connecting rod bearings
OK
Connecting rod bushing and NG Worn or damaged connecting Replace the connecting rod
piston pin rod bushing and piston pin bushing and/or the piston pin
OK
NG Worn or damaged piston and

Piston and cylinder liner Replace the piston and the
cylinder liner
cylinder liner
Foreign material in the cylinder
TURBOCHARGER
1) ENGINE HAS LESS THAN NORMAL POWER
NG
Air cleaner Restricted Clean or replace
OK
NG
Intake pipe and hose Restricted Clean or replace
OK
NG
Compressor/intake manifold Loose (Leaking) Repair
OK
NG
Exhaust manifold/turbine inlet Loose (Leaking) Repair
OK
NG
Exhaust piping and silencers Restricted Clean or replace
OK
NG
Air breather Restricted Clean or replace
OK
Boost compensator NG
Defective Repair or replace
(Injection pump)

OK
NG
Compressor wheel Impact damage Replace
OK
NG
Turbine wheel Impact damage Replace
NG
Carbon build-up Replace
OK
NG
Rotating assembly Dragging or seized Replace
2) BLUE OR BLACK SMOKE
NG
Air cleaner or intercooler Restricted Clean, repair, or replace
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Repair or replace
OK
NG
PCV system Defective Repair or replace
OK
NG
Crankcase Excessive pressure Repair
OK
NG
Compressor wheel Impact damage Replace
OK
NG
Turbine wheel Impact damage Replace

OK
Center housing oil drain NG

Restricted Clean or replace
passage
3) EXCESSIVE OIL CONSUMPTION
NG
P.C.V system Defective Repair or replace
OK
NG
Crankcase Excessive pressure Repair
OK
NG
Turbocharger oil seal Leakage Replace
OK
NG
Turbocharger oil drain pipe Restricted Clean or replace
OK
NG
Turbine wheel Impact damaged Replace the turbine housing
OK
NG Replace the compressor

Compressor wheel Impact damage
housing and rotating assembly
OK
NG
Oil Pressure Excessive Repair

OK
Center housing oil drain NG

Restricted Clean or replace
passage
4) EXCESSIVE TURBOCHARGER NOISE
NG
Intake and exhaust system Loose Repair
joints
OK
Intake and exhaust system NG

Damaged Repair
gaskets
OK
NG
Turbocharger rotating parts Rough rotation Replace
OK
NG
Compressor wheel Rubbing against housing Repair or replace
NG
Damaged Replace
OK
NG
Turbine wheel Rubbing against housing Repair or replace
NG
Damaged Replace

NG
Carbon deposits Clean or replace
OK
NG
Oil Level Too low Correct
NG
Contaminated Replace oil
OK
NG
Turbocharger oil feed pipe Restricted Repair or replace
OK
NG
Turbine housing Carbon deposits Clean
OK
NG
Compressor housing Dirty Clean
OK
NG
Turbine shaft bearings Worn Replace
5) EXCESSIVE ROTATING PART WEAR
NG
Engine oil Contaminated Change
NG
Wrong grade or type Change
OK
NG
Turbocharger oil feed pipe Restricted Clean or replace
OK
NG
Turbocharger oil seal Defective Replace
OK
NG
Center housing oil drain Restricted Clean or replace
passage
OK
NG
Turbine shaft Oil sludge and coking Replace
OK
NG
Engine lubrication system Inadequate oil supply Correct
MEMO
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INDEX
ENGINE MECHANICAL 6A – 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 2
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Flare Nuts ................................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
General Description....................................................................................................... 6A - 38
Removal and Installation............................................................................................... 6A - 41
Engine Repair Kit........................................................................................................... 6A - 54
Engine Overhaul ............................................................................................................ 6A - 55
Removal...................................................................................................................... 6A - 55
Inspection and Repair ............................................................................................... 6A - 75
Reassembly................................................................................................................ 6A -112
Lubricating System........................................................................................................ 6A -151
Main Data and Specifications ................................................................................... 6A -151
General Description .................................................................................................. 6A -152
Oil Pump..................................................................................................................... 6A -155
Oil Filter and Oil Cooler ............................................................................................ 6A -158
Special Tools.................................................................................................................. 6A -165
6A – 2 ENGINE MECHANICAL

Engine model
4JA1 4JB1T
Item
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type Dry type, chrome plated, stainless steel tube
Timing gear train system Gear drive
No. of cylinders-bore × stroke mm (in) 4 – 93 × 92 (3.66 × 3.62) 4 – 93 × 102 (3.66 × 4.02)
No. of piston rings Compression ring: 2 / Oil ring: 1
3 3
Total piston displacement cm (in ) 2,499 (152.4) 2,771 (169.0)
Compression ratio (to 1) 18.5 18.1
2
Compression pressure kg/cm (psi/MPa) 31 (441/3.0) – 200 rpm
Engine weight kg (lb) Approximately 226 (498) Approximately 250 (550)
Fuel injection order 1–3–4-2
Fuel injection timing BTDC deg 12 11
Specified fuel type SAE No. 2 diesel fuel
Idling speed rpm 750
Valve clearances (At cold): Intake mm (in) 0.4 (0.016)
Exhaust mm (in) 0.4 (0.016)
Intake valves Open at (BTDC) deg 24.5
Close at (ABDC) deg 55.5
Exhaust valves Open at (BBDC) deg 54.0
Close at (ATDC) deg 26.0
Fuel system
Injection pump type BOSCH distributor VE type
Governor type Mechanical (Variable speed) Mechanical (Limit speed)
Injection nozzle type Hole with 5 orifices
Injection nozzle opening pressure
2
(Design value) kg/cm (psi/MPa) 185 (2,631/18.1)
Single spring type
Main fuel filter type Cartridge paper element and water separator
Lubricating system
Lubricating method Pressure circulation
Specified engine oil (API grade) CC or CD CD
Oil pump type Gear
Oil filter type Cartridge paper element
Oil capacity lit(US/UK gal) 6.5 (1.7/1.43)
Oil cooler type Water cooled
4JB1T : 4JB1 Engine with turbocharger.

Engine model
4JA1 4JB1T
Item
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element
Battery type/voltage × No. of units 95D31R-12 × 1
Generator capacity V-A (kw) 12 – 40 (480) 12 – 50 (600)
Starter motor output V-kw 12 – 2.0 or 12 – 2.8
Turbocharger model *IHI RHF4H
Turbine type Radial-inflow
Compressor type Radial-outflow
*IHI : Ishikawajima-Harima Heavy Industries., Ltd.


Engine model
4JA1T (L) 4JG2T
Item
Combustion chamber type Direct injection In Direct injection
Timing gear train system Belt drive
No. of cylinders-bore × stroke mm (in) 4 – 93 × 92 (3.66 × 3.62) 4 – 95.4 × 107 (3.76 × 4.21)
3 3
2
Compression pressure kg/cm (psi/MPa) 31 (441/3.0) – 200 rpm
Engine weight kg (lb) Approximately 226 (498) Approximately 267 (588.7)
Fuel injection timing BTDC deg 12 0
Specified fuel type EC diesel fuel
Idling speed rpm 770 720
Fuel system
Injection pump type BOSCH distributor VE type
Governor type Mechanical (HALF variable speed)
Injection nozzle type Hole with 5 orifices Throttle
2
(Design value) kg/cm (psi/MPa) 185 (2,631/18.1) 150 (2,133/14.7)
Single spring type
Lubricating system
Specified engine oil (API grade) CD
Oil pump type Gear
Oil capacity lit (US/UK gal) 6.5 (1.7/1.4) 6.5 (1.7/1.4) For 4 × 2
7.3 (1.9/1.6) For 4 × 4
4JG2T : 4JG2 Engine with turbocharger. 4JA1T : 4JA1 Engine with turbocharger.
Engine model
4JA1T (L) 4JG2T
Item
Cooling system
Air cleaner type Wet paper element
Generator capacity V-A (kw) 12 – 50 (600)
Starter motor output V-kw 12 – 2.3 12 – 2.8
Turbocharger model IHI RHF 4H IHI RHB52W (manual T/M)
IHI RHF5 (automatic T/M)


Engine model
4JA1TC 4JH1TC
Item
Combustion chamber type Direct injection
Timing gear train system Gear drive
No. of cylinders-bore × stroke mm (in) 4 – 93 × 92 (3.66 × 3.62) 4 – 95.4 × 104.9 (3.76 × 4.13)
3 3
2
Compression pressure kg/cm (psi/MPa) 31 (441/3.0) – 200 rpm 28 (398/2.8) – 200 rpm
Engine weight kg (lb) Approximately 274 (604.2)
Fuel injection timing BTDC deg Not Adjustment
Specified fuel type EC diesel fuel
Idling speed rpm 730±25 700±25
Fuel system
Injection pump type BOSCH VP44
(electronic controlled fuel injection pump)
Injection nozzle type Double spring type (Hole type)
2
(Design value) kg/cm (psi/MPa) 1st: 199(2,830/19.5) 1st: 198(2,816/19.4)
2nd: 347(4,934/33,500) 2nd: 344(4,906/33,800)
Number of injection nozzle orifices 5
Lubricating system
Specified engine oil (API grade) CD
Oil pump type Gear
Oil capacity lit (US/UK gal) 6.5 (1.7/1.4) For 4 × 2
7.3 (1.9/1.6) For 4 × 4
4JA1TC, 4JH1TC : 4JA1, 4JH1 Engine with turbocharger and inter cooler
Engine model
4JA1TC 4JH1TC
Item
Cooling system
Air cleaner type Wet paper element
Generator capacity V-A (kw) 12 – 60 (720)
Starter motor output V-kw 12 – 2.3
Turbocharger model *IHI RHF4H *IHI RHF5H

STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
kg·m (lb·ft/N·m)
Strength 8.8
Class 4.8 (4T) (7T) 9.8 (9T)
Refined Non-Refined
Bolt
Identification
Bolt
Diameter ×
Pitch (mm)
M 6 × 1.0 0.60 ± 0.20 0.75 ± 0.25 -
(4.33 ± 1.44/5.88 ± 1.96) (5.43 ± 1.80/7.35 ± 2.45)
M 8 × 1.25 1.30 ± 0.50 1.75 ± 0.55 2.40 ± 0.70
(9.40 ± 3.62/12.74 ± 4.90) (12.66 ± 4.00/17.15 ± 5.39) (17.36 ± 5.06/23.52 ± 6.86)
M 10 × 1.25 2.80 ± 0.70 3.75 ± 0.95 5.10 ± 1.30
(20.25 ± 5.06/27.44 ± 6.86) (27.12 ± 6.87/36.75 ± 9.31) (36.89 ± 9.40/49.98 ± 12.74)
M 12 × 1.25 6.25 ± 1.25 7.75 ± 1.55 9.65 ± 1.95
(45.21 ± 9.04/61.25 ± 12.25) (56.06 ± 11.21/75.95 ± 15.19) (69.80 ± 14.10/94.57 ± 19.11)
M 14 × 1.5 9.75 ± 1.95 11.85 ± 2.35 14.50 ± 2.90
(70.52 ± 14.10/95.55 ± 19.11) (85.71 ± 17.00/116.13 ± 23.03) (104.88 ± 21.00/142.10 ± 28.42)
M 16 × 1.5 13.30 ± 2.70 17.30 ± 3.50 20.40 ± 4.10
(96.20 ± 19.53/130.34 ± 26.46) (125.13 ± 25.32/169.54 ± 34.30) (147.55 ± 29.66/199.92 ± 40.18)
M 18 × 1.5 19.20 ± 3.80 24.90 ± 5.00 29.30 ± 5.90
(138.87 ± 27.49/188.16 ± 37.24) (180.10 ± 36.17/244.02 ± 49.00) (211.93 ± 42.67/287.14 ± 57.82)
M 20 × 1.5 26.30 ± 5.30 34.40 ± 6.90 40.40 ± 8.10
(190.23 ± 38.33/257.74 ± 51.94) (248.82 ± 49.41/337.12 ± 67.62) (292.21 ± 58.59/395.92 ± 79.38)
M 22 × 1.5 33.90 ± 8.30 46.25 ± 9.25 54.10 ± 10.80
(245.20 ± 60.03/332.22 ± 81.34) (334.53 ± 66.91/453.25 ± 90.65) (391.30 ± 78.12/530.18 ± 105.84)
M 24 × 2.0 45.80 ± 9.20 58.20 ± 14.30 70.60 ± 14.10
(331.27 ± 66.54/448.84 ± 90.16) (420.96 ± 103.43/570.36 ± 140.14) (510.65 ± 101.99/691.88 ± 138.18)
* M 10 × 1.5 2.70 ± 0.70 3.70 ± 0.90 4.90 ± 1.20
(19.53 ± 5.06/26.46 ± 6.86) (26.76 ± 6.50/36.26 ± 8.82) (35.44 ± 8.68/48.02 ± 11.76)
* M 12 × 1.5 5.80 ± 1.20 7.20 ± 1.40 9.10 ± 1.80
(41.95 ± 8.68/56.84 ± 11.76) (52.08 ± 10.13/70.56 ± 13.72) (65.82 ± 13.02/89.18 ± 17.64)
* M 14 × 2.0 9.10 ± 1.80 11.20 ± 2.20 13.60 ± 2.70
(65.82 ± 13.02/89.18 ± 17.64) (81.01 ± 15.91/109.76 ± 21.56) (98.37 ± 19.53/133.28 ± 26.46)
* M 16 × 2.0 12.70 ± 2.50 16.50 ± 3.30 19.50 ± 3.90
(91.86 ± 18.08/124.46 ± 24.50) (119.34 ± 23.87/161.70 ± 32.34) (141.04 ± 28.21/191.10 ± 38.22)
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 kg·m (lb·ft/N·m)
Pipe diameter mm Pipe diameter mm

Torque Torque
(in) (in)
4.76 (0.187) 1.55 ± 0.25 (11.2 ± 1.8/15.2 ± 2.45) 10.00 (0.394) 5.50 ± 0.5 (39.7 ± 3.6/53.95 ± 4.90)
6.35 (0.250) 2.70 ± 0.30 (19.5 ± 2.1/26.48 ± 2.94) 12.00 (0.472) 9.00 ± 1.0 (65.0 ± 7.2/88.29 ± 9.80)
8.00 (0.315) 4.50 ± 0.50 (32.5 ± 3.6/44.14 ± 4.90) 15.00 (0.591) 10.75 ± 1.25 (77.7 ± 9.0/105.45 ± 12.26)
SPECIAL PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
kg·m (lb·ft/N·m)
Crankshaft Bearing Cap, Connecting Rod Bearing Cap,

Crankshaft Damper Pulley, Flywheel, and Oil Pan kg·m (lb·ft/N·m)
, 4JA1T
4JB1T, 4JG2T, 4JA1TC, 4JH1TC
17±
±1
(123.0±
±7.2/166.7±
±9.8)
Timing Pulley, and Camshaft

kg·m (lb·ft/N·m)
0.8 ± 0.2
(5.8 ± 1.4/7.84 ± 1.96)
Timing Gear Case, Pulley Housing, Timing Gear,

and Camshaft kg·m (lb·ft/N·m)
2.4±
±0.4
(13.7±
±2.9/18.6±
±3.9)
4JA1TC, 4JH1TC
(scissor gear)
3.0±
±0.5
(21.7±
±3.6/30±
±5.0)
7.7±
±1
(55.7±
±7.2/74±
±9.8)
7.7±
±1
(55.7±
±7.2/74±
±9.8)
Cooling and Lubricating System

kg·m (lb·ft/N·m)
3.0 ± 0.5
(21.7 ± 3.6/29.4 ± 4.9)
1.9 ± 0.5
(13.7 ± 3.6/18.6 ± 4.9)
Intake and Exhaust Manifold

kg·m (lb·ft/N·m)
Intake Manifold, Exhaust Manifold, and Turbocharger

kg·m (lb·ft/N·m)
4JB1T, 4JA1T, 4JG2T ENGINE Model

Intake Manifold, Exhaust Manifold, and Turbocharger

kg·m (lb·ft/N·m)
4JA1TC, 4JH1TC ENGINE Model

Inter Cooler, EGR Cooler

kg·m (lb·ft/N·m)
4JA1TC, 4JH1TC
ENGINE Model
4JA1TC Only
4JA1TC Only
5)
4JA1TC Only
5)
Engine Electricals
kg·m (lb·ft/N·m)
Fuel Injection System

kg·m (lb·ft/N·m)
4JA1, 4JA1T, 4JB1T, 4JG2T ENGINE Model
3.8 ± 0.6
(27.5 ± 4.3/37.2 ± 5.9)
Fuel Injection System

kg·m (lb·ft/N·m)
4JA1TC, 4JH1TC ENGINE Model
1.7 ± 0.5
(12.0 ± 3.6/17.0 ± 4.9)
3.8 ± 0.6
(27.5 ± 4.3/37.2 ± 5.9)
3.0 ± 0.5
(21.7 ± 3.6/29.4 ± 4.9)
1.9 ± 0.5
(13.7 ± 3.6/18.6 ± 4.9)
2.4 ± 0.4 2.4(17/24)

(13.7 ± 2.9/18.6 ± 3.9)
1.9 ± 0.5
(13.7 ± 3.6/18.6 ± 4.9)
4.1 ± 0.6
(29.6 ± 4.3/40.2 ± 5.9)
Engine Mounting Bracket

kg·m (lb·ft/N·m)
4.2±
±0.5
(30.4±
±3.6/41.2±
±4.9)
4.2±
±0.5
(30.4±
±3.6/41.2±
±4.9)
12.9 ± 2.3
(93.3 ± 16.6/126.5 ± 22.6)
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacturer Remarks
RTV* ThreeBond 1207B Three Bond
Silicon Base ThreeBond 1207C Three Bond
Water Base ThreeBond 1141E Three Bond
Solvent ThreeBond 1104 Three Bond
BelcoBond 4 Isuzu
BelcoBond 401 Isuzu
BelcoBond 402 Isuzu
Anaerobic LOCTITE 515 Loctite Recommended for
LOCTITE 518 Loctite transaxle repairs
* RTV : Room Temperature Vulcanizer
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.
LOCTITE APPLICATION PROCEDURE

LOCTITE Type LOCTITE Color Application Steps
1. Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
LOCTITE 242 Blue The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
LOCTITE 262 Red
LOCTITE 270 Green 3. Tighten the bolts to the specified torque.

4. Wait at least one hour before continuing the installation procedure.
LOCTITE 271 Red
1. Completely remove lubricant and moisture from the connecting

surfaces.
The surfaces must be perfectly dry.
2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting
surfaces.
There must be no gaps in the bead.
LOCTITE 515 Violet
3. Tighten the bolts to the specified torque.

4. Let the joined parts set for at least thirty minutes.
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 front left hand side
of the cylinder body.
A06RY00006
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
Oil Wetted (Viscous Type) Paper Element

The air cleaner has an oil wetted paper element. No
servicing is required until the replacement interval is
reached. Never attempt to clean the element, no matter
how dirty may appear. The element is designed to provide
normal filtering efficiency until it becomes due for
replacement. Refer to the Item “Service and Maintenance”
in the Owner’s and Driver’s Manual for general service
information.
Dust Fouled Element

Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
2
Compressed air pressure must not exceed 7 kg/cm (100
psi/690 kPa).
Carbon and Dust Fouled Element

1. Prepare a cleaning solution of Isuzu Genuine Element
Cleaner (Donaldson D1400) diluted with water.
2. Submerge the element in the solution for twenty
minutes.
3. Remove the element from the solution and rinse it well

with running water.
2
Water pressure must not exceed 2.8 kg/cm (40
psi/270 kPa).
4. Dry the element in a well ventilated area.

An electric fan will hasten drying.
Note:
Do not use compressed air or an open flame to dry the
element quickly. Damage to the element will result.
It will usually take two or three days for the element to
dry completely. Therefore, it is a good idea to have a
spare on hand to use in the interim.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
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 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 1
and 1/8 turns.
Filter Wrench: 5-8840-0200-0 (4JB1T, 4JG2T, 4JA1T,
4JA1TC, 4JH1TC)
: 5-8840-0201-0 (4JA1)
8. Check the engine oil level and replenish to the

specified level if required.
Replenished Engine Oil lit (US/UK gal)
4JA1, 4JA1T 4×2
6.5 (1.7/1.4)
4JB1T 4×4
4JG2T, 4JA1-TC 4×2 6.5 (1.7/1.4)
4JH1TC 4×4 7.3 (1.9/1.6)
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel Filter
Replacement Procedure
1. Place the end of the vinyl hose (beneath the drain
plug) in a container.
2. Open the drain plug.
3. Operate the priming pump several times to drain water
from the fuel filter.
4. Close the drain plug.
5. Operate the priming pump and check for fuel leakage.
6. Check that the water level warning light is off.
Fuel Filter Replacement Procedure

1. Remove the fuel filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
2. Remove the level sensor from the filter by turning it
counterclockwise with a wrench.
3. Install the level sensor to the water separator body

with wrench.
Level Sensor Torque kg·m (lb.in/N·m)
1.3 (113/13)
4. Clean the water separator cover fitting faces.

This will allow the new fuel filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.

6. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
7. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench : 5-8840-0253-0 (J-22700)
8. Loosen the bleeder plug Q on the priming pump body.

9. Operate the priming pump until fuel begins to flow
from the fuel filter.
10. Retighten the bleeder plug Q.
11. Operate the priming pump several times and check for
fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.
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 with the following procedure.
1. Place the end of the vinyl hose (beneath the drain

plug) in a container.
2. Loosen the drain plug Q.
3. Operate the priming pump R several times to drain
the water.
4. After draining the water, tighten the drain plug Q .
fuel leakage.
6. Check the water separator indicator light. It should be
off.
Air Bleeding
1. Loosen the bleeder screw on the injection pump
overflow valve.
2. Operate the priming pump until fuel mixed with foam
flows from the bleeder screw.
3. Tighten the bleeder screw.
fuel leakage.
Injection Pump Air Bleeding (4JA1TC, 4JH1TC)

Injection pump air bleeding is required to start the engine
when −
• The fuel supply has been exhausted (running out of
gas).
• The fuel filter has been replaced.
• The injection pump has been replaced.
CAUTION:
If the injection pump has been replaced, the air
bleeding procedure will require more time and effort
(this is because there is no fuel in the pump).
1. Loosen the air bleed nut on the priming pump plunger
(at the top of the fuel filter).
2. Move the priming pump plunger up-and-down until
strong resistance is felt (about 15 cycles).
3. Stop pumping and tighten the air bleed nut.
4. Wait for 1 minute.
again.
strong resistance if felt (about 10 cycles).
8. Wait for 1 minute.
again.
strong resistance is felt (about 5 cycles).
12. Press the accelerator and clutch pedals all the way to
the floor and hold them down. Turn the ignition switch
to the ON position. Wait until the glow indicator lamp
turns on and off.
CAUTION:
If the engine is cold, the glow indicator light will stay
on for 4∼ ∼7 seconds before turning off.
However, if the engine is hot, the lamp will not turn
on.
13. Turn the ignition switch to the START position and
crank the engine until it starts (do not crank the engine
for more than 10 seconds).
If the engine does not start, repeat Steps 9∼13.
14. Allow the engine to idle for 5 minutes.
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.
Engine coolant Filling up procedure

1. Make sure that the engine is cool
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.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. 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.
5. 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 intoheater water system.
6. Chech to see the thermometer, continuously idling 5
minutes and stop the engine.
7. 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 hosefor leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.
Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage. The testing pressure must not exceed the
specified pressure.
2
Testing Pressure kg/cm (psi/kPa)
2 (28/200)
Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant
2
pressure in the cooling system at 1.05 kg/cm (15 psi/103
kPa).
Check the radiator filler cap with a radiator filler cap tester.
The radiator filler cap must be replaced if it fails to hold the
specified pressure during the test procedure.
Radiator Filler Cap Pressure
2
Pressure Valve kg/cm (psi/kPa)
0.9 – 1.2 (13 – 17/90 – 120)
2
Negative Valve (Reference) kg/cm (psi/kPa)
0.01 – 0.04 (0.14 – 0.57/0.98 – 3.92)
Thermostat Operating Test

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C (°F)
82 (180)
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)
95 (203)
Valve Lift at Fully Open position mm (in)

9.5 (0.37)
Q Thermometer
R Agitating rod
S Wooden piece
Drive Belt Adjustment

Depress the drive belt mid-portion with a 10 kg (22 lb/98N)
force.
Drive Belt Deflection mm (in)
10 (0.39)
Check the drive belt for cracking and other damage.
Q Crankshaft damper pulley
R Generator pulley
S Cooling fan pulley
T Oil pump pulley or idler pulley
U Compressor pulley or idler pulley
Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 10 kg (22 lb/98N)
force.
Drive Belt Deflection mm (in)
10 (0.39)
R Generator pulley
S Cooling fan pulley
Compressor Pulley Drive Belt

Move the idler pulley as required to adjust the compressor
drive belt tension.
If the vehicle is equipped with power steering, move the oil
pump as required
Depress the drive belt mid-portion with a 10 kg (22 lb/98
N) force.
Belt Deflection mm (in)
12 – 15 (0.47 – 0.59)
R Oil pump pulley or idler pulley
Power Steering Oil Pump Pulley Drive Belt

Move the oil pump as required to adjust the oil pump drive
belt tension.
On air conditioner equipped models, both drive belts pulley
must always be replaced as a set.
Depress the drive belt mid-portion with a 10 kg (22 lb/98
N) force.
Belt Deflection mm (in)
14 - 17 (0.55 – 0.67)
R Oil pump pulley
S Compressor pulley or idler pulley
ENGINE CONTROL
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80°C (158 - 176°F).
4. Disconnect the engine control cable from the control

lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed rpm
4JA1, 4JB1 750 ± 50
4JA1T 770 ± 50
4JG2T 720 ± 50
4JA1TC 730 ± 25
4JH1TC 700 ± 25
Idling Speed Adjustment

(Except 4JA1TC, 4JH1TC)
1. Loosen the idling set screw lock nut Q on the injection

pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt R.
3. Lock the engine set nut Q with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.
Fast Idling Speed Inspection

1. Set tachometer to the engine.
2. Disconnect the vacuum hose Q from the fast idle
actuator U on the injection pump.
3. Disconnect the other vacuum hose R from the
vacuum switching valve S and connect it to the fast
idle actuator U.
The vacuum line will now be connected directly from
the vacuum pump T to the fast idle actuator.
4. Check the engine fast idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Fast Idling Speed rpm
850 - 950
Fast Idling Speed Adjustment

1. Loosen the fast idle actuator bracket bolts.
1. Adjust the fast idling speed by moving the actuator

bracket, so that the clearance “S” can be 1 ~ 2 mm
(0.04 ~ 0.08 in.).
2. Tighten the bracket bolts.
Accelerator Control
Accelerator Control Cable Adjustment
1. Loosen the accelerator cable clamp bolt Q.
2. Check that the idling control knob is in the engine
idling position.
3. Hold the accelerator lever R in the fully closed
position and stretch the control cable S in the
direction indicated by the arrow to remove any slack.
101RY00014
VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No. 4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.
2. Check the rocker arm shaft bracket nuts for

looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.
Rocker Arm Shaft Bracket Nut Torque kg·m (lb·ft/N·m)
5.5 ± 0.5 (39.8 ± 3.6/53.9 ± 4.9)
3. Check for play in the No. 1 intake and exhaust valve

push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.
Adjust the No.1 or the No. 4 cylinder valve clearances

while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)
4. Loosen each valve clearance adjusting screw as

shown in the illustration.
5. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
6. Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.
7. Tighten the lock nut securely.
8. Rotate the crankshaft 360°.
9. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
10 Adjust the clearances for the remaining valves as
INJECTION TIMING ADJUSTMENT

(Except 4JA1TC, 4JH1TC)
1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.
2. Bring the piston in the No. 1 cylinder to TDC Q on the

compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark R.
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
rods have play, the No. 1 piston is at TDC on the
compression stroke.
3. Disconnect the injection pipe from the injection pump

4. Remove one bolt from the distributor head.
5. Insert a screwdriver into a hole in the fast idle lever
and turn the lever to release the W-C.S.D. function. (if
so equipped)
6. Install the static timing gauge S.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)
7. Rotate the crankshaft to bring the piston in the No. 1

cylinder to a point 30 - 40° BTDC.
8. Set the timing gauge needle to zero.
9. Move the crankshaft pulley slightly in both directions to
check that the gauge indication is stable.
10. Turn the crankshaft clockwise and read the gauge

indication when the crankshaft pulley timing mark (12°
(4JA1, 4JA1T) 11° (4JB1T) 0° (4JG2T) on pulley) is
aligned with the pointer.
4JA1 4JA1T 4JB1T 4JG2T
BTDC BTDC BTDC TDC
12 ± 2° 12 ± 2° 11 ± 2° 0 ± 2°
Standard Reading mm (in)

0.5 (0.02)
If the injection timing is outside the specified range,

continue with the following steps.
11. Loosen the injection pump fixing nuts and bracket

bolts.
12. Adjust the injection pump setting angle.
When large than When smaller than
standard value standard value
Gear drive R A
A: Move the injection pump toward the engine.

R: Move the injection pump away from the engine.
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.
• Glow plugs
• Fuel cut solenoid connector
3. Set the adapter and compression gauge to the No. 1
cylinder glow plug hole.
Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
2
Compression Pressure kg/cm (psi/MPa) at 200 rpm
Standard Limit
4JH1TC 28 (398/2.8) 20 (284/2.0)
Others 31 (441/3.0) 22 (313/2.2)
5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
PRE-HEATING SYSTEM
System Inspection Procedure
1. Disconnect the thermo-switch on the thermostat outlet
pipe.

If the Pre-heating System is operating properly, the
glow relay will make a clicking sound about seven
seconds after the starter switch is turned on.
3. Measure the glow plug terminal voltage with a circuit

tester immediately after turning the starter switch to
the “ON” position.
Glow Plug Terminal Voltage V
Approx. 11
GENERAL DESCRIPTION
4JB1T
4JA1TC
4JH1TC
F06L200022
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.
The model 4JG2 diesel engine has swirl type combustion chambers.
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 4JA1, 4JB1T, 4JA1T and 4JG2T engines are equipped with the VE-Type distributor injection pump.
The 4JA1TC, 4JH1TC are equipped with the electronic controlled fuel injection pump. The type of this pump is
VP44 in the product made from BOSCH
The 4JG2T, 4JB1T, 4JA1TC, 4JH1TC and 4JA1T engines are equipped with turbocharger.
The 4JA1TC engine is equipped with intercooler and EGR cooler.
The 4JH1TC engine is equipped with intercooler.
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

1. Carefully remove the piping, hoses, wiring harness
connectors, engine control cables, and control rods
from the engine.
2. Remove the clutch slave cylinder, the back up light
switch connector, and the speedometer cable from the
transmission.
Battery
1. Disconnect the battery cable Q and the grounding
cable R from the battery terminals.
2. Remove the battery clamp S.
Take care not to accidentally short the battery with the
spanner 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.
Engine Hood
Apply setting marks to the engine hood Q and the engine
hood hinges R before removing the engine hood.
This will facilitate reinstallation of the engine hood to its
original position.
Fuel Filter and Water Separator

1. Pull the fuel hose from the fuel filter Q and the water
separator R.
2. Plug the fuel hose to prevent fuel leakage.
3. Remove the fuel filter and the water separator.
Air Cleaner
Remove the air cleaner duct from the engine.
Coolant
Remove the coolant drain plug (at the lower left of the
engine) and the radiator drain plug.
Allow the engine coolant to drain completely.
012RY00020
Gear Shift Lever

1. Place the gear shift lever in the neutral position.
2. Remove the front console from the floor panel.
3. Pull the gear shift lever grommet Q and the dust
cover R to the top of the gear shift lever.
4. Remove the gear shift lever cover bolt S.
5. Remove the gear shift lever T.
6. Remove the gear shift lever hole cover U or the

center console from the floor.
7. Remove the quadrant box V from the transmission

rear cover.
Note:
Cover the quadrant box hole to prevent the entry of
foreign material into the transmission.
Transfer Change Lever (For 4 × 4)

Perform this procedure after removing the gear shift lever.
1. Place the transfer change lever in the “H” position.
2. Pull the transfer change lever grommet Q and the
dust cover R to the top of the transfer change lever.
3. Remove the retainer bolts S.
4. Remove the transfer change lever T along with the
retainer and the ball seat cover.
5. Remove the change lever hole cover U or the center
console from the floor.
6. Remove the quadrant box V from the transfer case
adapter.
Note:
Cover the quadrant box hole and the change lever
hole to prevent the entry of foreign material into the
transmission.
Radiator
1. Remove the cooling fan Q, the pulley R, and the belt
S.
2. Disconnect the radiator upper hose T and the radiator
lower hose U from the engine.
3. Remove the radiator shroud V.
4. Remove the radiator grille from the deflector panel.
5. Remove the radiator W.
Take care not to damage the radiator core.
6. Remove the radiator undercover from the chassis
frome.
Supporting the Vehicle

1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.
3. Remove the wheels from the vehicle.
Engine Oil Draining

Remove the oil pan drain plug to drain the engine oil.
Do this while the engine is hot.
Do not forget to reinstall the drain plug after draining the
engine oil.
Transfer Case Protector (4 × 4 model)

Remove the transfer case protector Q from the
transmission mounting member R and the side menber
S.
Transmission Oil Draining

1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.
Control Cables or Rods

1. Disconnect the clutch control cable or the hydraulic
cylinder from the transmission.
2. Disconnect the parking brake control cable from the
rear wheel brake back plate.
3. Disconnect the speedometer drive cable from the
transmission.
Exhaust Pipe
1. Disconnect the exhaust pipe from the exhaust
manifold.
Without turbocharger
With turbocharger
037RY00002
Rear Propeller Shaft

1. Remove the propeller shaft flange yoke at the drive
② pinion Q.
2. Remove the 2nd propeller shaft flange yoke bolts R at
the center bearing.
3. Remove the center bearing retainer bolts S.
4. Remove the 1st propeller shaft T together with the
center bearing from the transmission mainshaft spline.
Front Propeller Shaft (For 4 × 4)

Remove the splined yoke flange bolt at the transfer output
shaft.
Do not allow the splined yoke to fall away from the front
propeller shaft.
If the splined yoke should fall away from the front propeller
shaft, align the setting marks S on the splined yoke Q
and the propeller shaft R to reassemble the two parts.
The setting marks are puncked circles approximately S
mm (0.12 in) in diameter.
Transmission
1. Check that the lifting wires Q are securely attached.
2. Operate the hoist to slightly raise the engine.
Warning:
Take care not to lift the chassis from the chassis
stands.
If you do accidentally raise the chassis from the
chassis stands, make absolutely certain that the
chassis stands are correctly positioned before
lowering the chassis.
3. Place the jack R beneath the transmission case.

4. Operate the jack to slightly raise the transmission.
5. Remove the transmission member lower mounting

bolts S fixing the transmission member to the chassis
frame rail.
6. Loosen the engine mounting nuts T at the rubber

mountings.
7. Use the jack to slightly lower the transmission.
8. Remove the remaining transmission coupling bolts.
9. Separate the transmission from the engine.
Take care not to damage the transmission, the
engine, and their related parts.
10. Use the jack to lower the transmission together with

the mounting member to the floor.
11. Remove the engine mounting bolts U from the

chassis frame.
12. Use the hoist to lift the engine from the engine
compartment.
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.
Engine
1. Attach a lifting wire to the engine lifting hanger.
2. Operate the hoist to position the engine above the
engine compertment.
Hold the front of the engine slightly higher than the
rear.
3. Slowly lower the engine into the engine compartment.
Be careful not to damage the brake pipes, the fuel
pipes, and other exposed parts.
4. Support the oil pan with a jack.
5. Temporarily tighten the engine front mounting rubber

nuts.
Transmission
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Place the transmission with the mounting rubbers on a
transmission jack.
3. Carefully move the transmission jack and
transmission into position behind the cab.
4. Slowly raise the transmission jack until the front of the

transmission is aligned with the engine flywheel.
The slope of the engine and the transmission must be
the same.
5. Align the top gear shaft spline with the clutch driven
plate internal spline.
6. Install the transmission to the engine.
Tighten the transmission coupling nuts and bolts to
the specified torque.
Transmission Coupling Nut and Bolt
Torque kg·m (lb.ft/N·m)
3.8 ± 0.8 (27.5 ± 5.8/37.2 ± 7.8)
7. Install the mounting member Q to the mounting

rubber R.
8. Tighten the mounting member nuts S to the specified
torque.
Mounting Rubber Nut Torque kg·m (lb.ft/N·m)
4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 4.9)
9. Install the mounting member T to the sidemembers

U.
10. Tighten the mounting member bolts to the specified
torque.
Mounting Member Bolt Torque kg·m (lb.ft/N·m)
7.8 ± 1.6 (56.1 ± 11.2/76.0 ± 15.2)
11. Tighten the engine mounting rubber nuts to the

specified torque.
Engine Mounting Rubber Nut Torque kg·m (lb.ft/N·m)
4.2 ± 0.5 (30.4 ± 3.6/41.2 ± 4.9)
Exhaust Pipe
Connect the exhaust pipe to the exhaust manifold.
6.8 ± 0.5 (49 ± 3.6/67 ± 5)
Front Propeller Shaft (For 4 × 4)

1. Connect the propeller shaft flange yoke to the
matching flange.
2. Tighten the propeller shaft flange yoke bolt to the
specified torque.
Propeller Shaft Flange Yoke Bolt
3.6 ± 0.3 (26.0 ± 2.2/35.3 ± 2.9)
Note:
If the splined yoke and the front propeller shaft have
accidentally separated, align their setting marks and
recouple them.
Refer to “FRONT PROPELLER SHAFT REMOVAL.”
Rear Propeller Shaft

1. Place the center bearing and retainer Q together with
the 1st propeller shaft R on the No. 4 crossmember
S.
2. Insert the splined yoke T into the transmission main
shaft spline U.
3. Tighten the center bearing retainer bolts V to the
specified torque.
Center Bearing Retainer Bolt Torque kg·m (lb.ft/N·m)
6.2 ± 0.2 (44.8 ± 1.5/60.8 ± 2.0)
4. Connect the 2nd propeller shaft W center coupling

side X and drive pinion side Y.
Propeller Shaft Flange Yoke Bolt
3.6 ± 0.3 (26.0 ± 2.2/35.3 ± 2.9)
Transfer Case Protector (For 4 × 4)

1. Install the transfer case protector Q to the mounting
member R and the sidemembers S.
2. Tighten the transfer case protector bolts to the
specified torque.
Transfer Case Protector Bolt Torque kg·m (lb.ft/N·m)
3.7 ± 1.0 (26.8 ± 7.2/36.3 ± 9.8)
Gear Shift Lever

1. Replenish the transmission case and the transfer case
with the specified engine oil.
Transmission and Transfer Case Oil lit (US/UK gal)
4×2 4×4
MSG 1.55 (0.41/0.34) 4.40 (1.16/0.97)
2.95 (T/M)
MUA 2.95 (0.65/0.54)
1.45 (Transter)
2. Install the quadrant box to the transmission rear cover.

3. Install the gear shift lever Q to the transmission case.

4. Tighten the gear shift lever cover R bolts to the
specified torque.
Shift Lever Cover Bolt Torque kg·m (lb.ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 2.0)
5. Install the dust cover S and the grommet T.
Transfer Change Lever (For 4 × 4)

1. Insert the transfer change lever Q into the transfer
side case.
2. Install the ball seat cover along with the change lever
retainer R.
3. Tighten the change lever retainer bolts to the specified
torque.
Change Lever Retainer Bolt Torque kg·m (lb.ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 2.0)
4. Install the dust cover S and the grommet T.
Radiator
1. Install the radiator Q.
Be careful not to damage the radiator core.
2. Install the cooling fan R and the fan shroud S.
3. Connect the radiator upper and lower hoses.
4. Install the radiator undercover to the chassis frame.
5. Install the radiator grill to the deflector panel.
Lowering the Vehicle

1. Install the wheels to the vehicle.
2. Place a jack beneath the vehicle.
3. Raise the jack to remove the chassis stands.
4. Lower the vehicle to the ground.
Coolant Replenishment
Replenish the cooling system with coolant.
When radiator is emptied (for coolant change, etc.):
After filling with coolant up to the inlet port level, put the
radiator cap on and idle the engine for 5 to 6 consecutive
minute. Then remove the radiator cap and check and see
the coolant level. If the coolant is short, add to the radiator
as well as to the reserve tank.
If the reserve tank coolant level is lower than MIN,
replenish coolant to the reserve tank only.
In case there is no coolant in the reserve tank, make sure
of a drop in coolant temperature and add coolant through
the radiator inlet port. Then remove the cap and check the
coolant level after idling the engine for 5 to 6 consecutive
minutes.
Then add coolant into reserve tank fill up to full level.
Coolant Capacity lit (US/UK gal)
4JA1, 4JA1T 7.0 (1.8/1.5)
4JB1 with turbo engine 9.5 (2.5/2.1)
4JG2T 8.6 (2.3/1.9)
4JA1-TC, 4JH1TC 8.4 (2.2/1.8)
Engine Oil Replenishment

1. Fill the engine through the filler port with new engine
oil of the specified grade.
Engine Oil Capacity and Grade lit (US/UK gal)
4×2
4JA1, 4JA1T, 4JB1T 6.5 (1.7/1.4)
4×4
Capacity
4JG2T, 4JA1TC, 4×2 6.5 (1.7/1.4)
4JH1TC 4×4 7.3 (1.9/1.6)
For 4JA1 CC or CD
Grade For 4JB1T, 4JG2T, 4JA1T,
CD
4JA1TC, 4JH1TC
2. Start the engine and allow it to idle for several

minutes.
3. Stop the engine and wait five minutes for the oil to
settle.
4. Recheck the oil level and replenish if necessary.
Engine Hood
Align the setting marks (applied at removal) on the engine
hood Q and the engine hood hinges R to install the
engine hood.
Battery
1. Check the battery fluid level and the specific gravity.
2. Secure the battery with the battery clamp.
Do not overtighten the battery clamp.
3. Connect the battery cable R and the ground cable S
to the battery.
4. Connect the battery cable to the starter motor and the
ground cable to the cylinder body.
5. Apply grease to the battery terminals.
6. Install the battery clamp Q.
Take care not to accidentally short the battery with the
spanner or some other tool.
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
Refer to “SERVICING” for the idle speed adjustment
procedure.
2. Engine noise level.
3. Engine lubricating system and cooling system
Carefully check for oil and coolant leakage.
4. Engine control cable operation
5. Clutch engagement
6. Indicator warning light operation
ENGINE REPAIR KIT

All of the numbered parts listed below are included in the Engine Repair Kit.
The gaskets marked with an asterisk (*) are also included in the Top Overhaul Kit.
* 1. Cylinder head gasket 12. Water pump O-ring

* 2. Head cover gasket * 13. Water outlet pipe gasket
* 3. Head cover cap nut gasket * 14. Intake pipe gasket
4. Drain cock gasket 15. Thermostat housing gasket
5. Crankshaft rear oil seal * 16. Intake manifold gasket
6. Gear case gasket * 17. Exhaust manifold gasket
7. Oil pan drain plug gasket * 18. Nozzle holder O-ring
8. Oil pan gasket * 19. Nozzle holder gasket
9. Oil filter gasket 20. Crankshaft front oil seal
EGR Cooler gasket (4JA1TC
10. Joint bolt gasket 21.
only)
Inter cooler outlet pipe gasket
11. Vacuum pump gasket 22.
(4JA1TC, 4JH1TC only)
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
These removal steps are based on the 4JB1T engine.
The triangle (J) mark indicates the important operations.
Removal Steps
1. Cooling fan drive belt 16. Turbocharger heat protector
2. Cooling fan pulley 17. Exhaust adaptor
3. Heater pipe (rear side) 18. Turbocharger oil return pipe
4. Oil level gauge and guide tube 19. Turbocharger oil feed pipe
5. Starter motor J 20. Turbocharger
6. Water drain cock 21. Exhaust manifold heat protector
7. Oil pressure warning switch and 22. Oil cooler with Oil filter
nipple 23. Exhaust manifold
8. Engine mounting bracket 24. Compressor bracket
J 9. Intake manifold 25. Generator bracket
J 10. Fuel injection pipe with clip 26. Power steering oil pump
11. Fuel leak off pipe 27. Vacuum pipe
12. Injection pump
13. Compressor
14. Generator and adjusting plate
15. Water inlet pipe
Important Operations
9. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Disconnect the intake duct and intake rubber hose
from the turbocharger.
3) Remove the upper intake manifold the lower intake
manifold with intake duct, and the PCV hose.
10. Fuel Injection Pipe with Clip

1) Loosen the injection pipe sleeve nuts at the delivery
valve side Q and injection nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips R.
3) Remove the injection pipes S.
Note:
Plug the delivery holder ports with the shipping caps
to prevent the entry of foreign material.
20. Turbocharger
Plug the turbocharger body oil ports after removing the
turbocharger assembly to prevent the entry of foreign
material.
INTERNAL PARTS
MAJOR COMPONENTS
025L200001
Disassembly Steps-1
1. Water bypass pipe 5. Glow plug and glow plug
2. Thermostat housing with thermo connector
switch J 6. Rocker arm shaft and rocker
3. Cylinder head cover arm
J 4. Injection nozzle and Injection 7. Push rod
nozzle holder J 8. Cylinder head
4a. Injection nozzle (4JG2T) 9. Cylinder head gasket
4b. Injection nozzle and Injection
Nozzle holder (4JA1TC, 4JH1TC)
Disassembly Steps-2 (Belt Drive Model)

10. Crankshaft damper pulley 15. Timing belt tension adjusting
11. Timing pulley housing upper Lever
cover 16. Timing belt tensioner
12. Timing pulley housing lower 17. Timing belt
Cover 18. Tension idler
13. Water pump J 19. Crankshaft timing pulley center
14. Camshaft timing pulley flange J 20. Crankshaft timing pulley
J 21. Injection pump timing pulley
J 22. Injection pump
014RY00045
Disassembly Steps-3 (Belt Drive Model)

J 23. Flywheel J 33. Piston and connecting road with
24. Oil pan upper bearing
25. Oil pump with oil pipe J 34. Crankshaft bearing cap with
26. Camshaft timing pulley lower bearing
J 27. Piston cooling oil pipe 35. Crankshaft thrust bearing
28. Cylinder body rear plate 36. Crankshaft
29. Oil seal retainer J 37. Crankshaft upper bearing
J 30. Camshaft J 38. Tappet
31. Timing pulley housing J 39. Crankshaft rear oil seal
J 32. Connecting rod bearing cap with 40. Cylinder body
lower bearing
4. Injection Nozzle Holder
1. Remove the nozzle holder bracket nuts.
2. Use the nozzle holder remover and the sliding hammer

to remove the nozzle holder together with the holder
bracket.
Nozzle Holder Remover: 5-8840-2034-0
Sliding Hammer: 5-8840-0019-0
6. Rocker Arm Shaft and Rocker Arm

Loosen the rocker arm shaft bracket bolts in numerical
order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bots in
numerical order a little at a time will adversely affect
the rocker arm shaft.
8. 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.
19. Crankshaft Timing Pulley Center

1. Use the fixing wrench to prevent the cranksahft from
turning.
Fixing Wrench: 5-8840-0161-0
2. Remove the timing pulley center from the crankshaft.
20. Camshaft Timing Pulley

1. Install the stopper bolt Q to the timing pulley to
prevent it from turning.
21. Injection Pump Timing Pulley

1. Install the stopper bolt Q to the timing pulley to
2. Use the timing pulley remover R to remove the

injection pump timing pulley.
Timing Pulley Puller: 5-8840-0086-0
3. Remove the stopper bolt.
22. Injection Pump

1. Remove the three injection pump bracket nuts Q at
the rear of the timing pulley housing.
2. Remove the injection pump rear bracket bolts R from

the injection pump bracket S.
3. Remove the injection pump rear bracket bolts T and
the bracket U from the cylinder body.
4. Pull the injection pump free toward the rear of the
engine.
Note:
Plug the injection pump delivery holder ports with the
shipping caps (or the equivalent) to prevent the entry
of foreign material.
23. Flywheel
Block the crankshaft with a piece of hard wood to prevent
the flywheel from turning.
Loosen the flywheel bolts in numerical order a little at a
time.
27. Piston Cooling Oil Pipe

The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.
30. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.
32. Connecting Rod Bearing Cap with Lower Bearing

If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
33. Piston and Connecting Rod with Upper Bearing

1) Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
2) Move the piston to the top of the cylinder and tap it
with a hammer grip or a similar object from the
connecting rod lower side to drive it out.
If the connecting rod upper bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with the
015R100020
34. Crankshaft Bearing Cap with Lower Bearing

1) Measure the crankshaft end play at the center journal
of the crankshaft.
Do this before removing the crankshaft bearing caps.
If the measured value exceeds the specified limit, the
crankshaft thrust bearing must be replaced.
Crankshaft End Play mm (in)
Standard Limit
0.10 (0.004) 0.30 (0.012)
2) Loosen the crankshaft bearing cap bolts in numerical

order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
37. Crankshaft Upper Bearing

If the crankshaft upper bearings are to be reinstalled, mark
38. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.
39. Crankshaft Rear Oil Seal

• With the oil seal pushed in deep, install the special tool
as shown in the illustration and remove the oil seal.
Oil Seal Remover: 5-8840-2362-0
6a
Disassembly Steps-2 (Gear Drive Model)

J 1. Crankshaft damper pulley
2. Gear case upper cover and
lower cover
3. Space rubber
J 4. Timing gear case cover
5. Timing gear oil pipe (Except
4JA1TC, 4JH1TC)
6. Idler gear “B” and shaft
J 6a. Idler gear “B” and shaft (scissor
gear) (4JA1TC, 4JH1TC only)
J 7. Idler gear “A”
8. Idler gear shaft
9. Crankshaft timing gear
J 10. Injection pump
014RY00046
Disassembly Steps-3 (Gear Drive Model)

J 11. Camshaft timing gear
12. Camshaft thrust plate
13. Timing gear case
1. Crankshaft Damper Pulley

Use the remover to remove the damper pulley
NOTE:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when removing the
crankshaft pulley.
4. Timing Gear Case Cover

The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.
6a. Idle Gear B (4JA1TC, 4JH1TC only)

Install lock bolts to the holes marked with an arrow in the
illustration to hold the gear in place. Remove the gear.
7. Idler Gear “A”

1. Measure the camshaft timing gear backlash and the
crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the
idler gear.
Note:
Refer to the following items for details on the
backlash and end play measurement procedures.
Timing Gear Backlash Measurement

1) Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjusting
gear stationary.
2) Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
timing gear must be replaced.
Timing Gear Backlash mm (in)
Standard Limit
0.10 – 0.17 (0.0039 – 0.0067) 0.30 (0.012)
Idler Gear “A” End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
thrust collar must be replaced.
Idler Gear End Play mm (in)
Standard Limit
0.07 (0.0028) 0.2 (0.0079)
10. Injection Pump

1 Remove the injection pump rear bracket bolts R from
the injection pump bracket S.
2 Remove the injection pump rear bracket bolts T and
the bracket U from the cylinder body.
3. Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
4JA1TC, 4JH1TC
1 Remove the injection pump upper bracket from the
injection pump.
080L200005
2 Remove the injection pump bottom bracket from the

injection pump.
3 Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
Note:
080L200006
11. Camshaft Timing Gear

1. Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
Camshaft End Play mm (in)
Standard Limit
0.050 – 0.114 0.20
(0.002 – 0.0044) (0.008)
2. Remove the camshaft timing gear bolt from the

camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Use the universal puller Q to pull out the camshaft
timing gear R.
Universal Puller: 5-8521-0002-0
4. Remove the thrust plate S.
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
Disassembly Steps
J 1. Rocker arm shaft snap ring 5. Rocker arm shaft spring

J 2. Rocker arm 6. Rocker arm shaft snap ring
J 3. Rocker arm shaft bracket 7. Rocker arm shaft
4. Rocker arm
1. Rocker Arm Shaft Snap Ring

2. Rocker Arm
3. Rocker Arm Shaft Bracket
1) Use a pair of pliers to remove the snap rings.
2) Remove the rocker arms.
3) Remove the rocker arm shaft brackets.
If the rocker arms and rocker arm shaft brackets are
to be reinstalled, mark their installation positions by
tagging each rocker arm and rocker arm shaft bracket
with the cylinder number from which it was removed.
CYLINDER HEAD
Disassembly Steps
1. Intake manifold J 6. Intake and exhaust valve
2. Intake manifold gasket 7. Valve stem oil seal
J 3. Split collar 8. Valve spring lower seat
4. Valve spring upper seat 9. Cylinder head
5. Valve spring
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 (J-29760)
6. Intake and Exhaust Valve

If the intake and exhaust valves are to be reinstalled, mark
their installation positions by tagging each valve with the
If the intake and exhaust valves are to be replaced, the
valve guides must also be replaced.
PISTON AND CONNECTING ROD
For 4JA1/4JA1T/4JA1TC
/4JH1TC only
015L200002
Disassembly Steps
J 1. Connecting rod bearing J 4. Piston pin

J 2. Piston ring 5. Connecting rod
J 3. Piston pin snap ring J 6. Piston
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
015R100020
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.
3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.
4. Piston Pin
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.
015R100015

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
FACE WARPAGE
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.
If the measured values exceed the limit, the cylinder head

must be replaced.
Cylinder Head Lower Face Warpage mm (in)
Standard Limit
0.05 0.20
(0.002) or less (0.008)
Note:
The cylinder head lower face cannot be reground.
Cylinder Head Height H (Reference) mm (in)

Standard
91.95 – 92.05
(3.620 – 3.624)
Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but
less than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
Manifold Fitting Face Warpage mm (in)
Maximum Grinding
Standard Limit
Allowance
0.05 0.20 0.40
(0.002) or less (0.008) (0.016)
Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the
manifold must be replaced.
Exhaust Manifold Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)
HOT PLUG (4JG2T ENGINE ONLY)

Hot Plug Depression
1. Clean the cylinder head lower face, taking care not to
damage the hot plug surfaces.
2. Use a straight edge and a feeler gauge to measure
hot plug depression in a straight line from the No. 1
hot plug to the No. 4 hot plug.
hot plugs must be replaced.
Hot Plug Depression mm (in)
Limit
0.02 (0.0008)
Combustion Chamber Inspection

1. Remove the carbon adhering to the inside of the
combustion chamber. Take care not to damage the
hot plug fitting positions.
2. Inspect the inside of the combustion chamber, the hot
plug hole, and the hot plug machined faces for
cracking and other damage.
If cracking or damage is present, the cylinder head
must be replaced.
Note:
Be absolutely certain that there are no scratches or
protuberances on the combustion chamber surfaces
which will be in contact with the hot plug after it is
installed. These flaws will prevent the hot plug from
seating correctly.
Hot Plug Replacement

Hot Plug Removal
1. Insert a 3 – 5 mm (0.12 – 0.20 in) diameter brass bar
into the nozzle holder fitting hole until it makes contact
with the hot plug.
2. Lightly tap the bar with a hammer to drive the hot plug
free.
Hot Plug Inspection

Inspect the hot plugs for excessive wear and other
damage. Replace the hot plugs if either of these
conditions are discovered.
Refer to “Hot Plug Installation”.
Hot Plug Installation

1. Align the hot plug knock ball Q with the cylinder head
groove R and tap it temporarily into position with a
plastic hammer.
2. Place a metal plate S approximately 25 mm (1 in)

thick over the hot plug upper surface T.
3. Use a bench press U to exert a pressure of 4,500 –
5,500 kg (9,923 – 12,128 lb/44,100 – 53,900 N) on the
metal plate covering the hot plug upper surface.
This will drive the hot plug into position.
4. Lightly tap the hot plug head to make sure that it is
firmly seated.
5. Repeat the procedure (Steps 1 – 4) for the remaining
hot plugs.
Note:
Do not apply pressure greater than that specified.
Damage to the cylinder head will result.
6. Use a surface grinder to grind off any hot plug surface
protuberances.
The hot plug surfaces must be perfectly flush with the
cylinder head lower face.
7. After grinding, make sure that the hot plug surfaces

are completely free of protuberances.
The hot plug surfaces must also be free of
depressions.
Once again, lightly tap the hot plug heads to make
sure that they are firmly seated.
Heat Shield Replacement

Heat Shield Removal
After removing the hot plugs, use a hammer Q and a
brass bar R to lightly tap the lower side of the heat shield
S and drive it free.
Heat Shield Installation

Install the heat shield to the cylinder head from the nozzle
holder installation hole side. Lightly tap the heat shield
flange into place with a hammer and a brass bar.
The heat shield flange side must be facing up.
Note:
Always install a new heat shield. Never reuse the old
heat shield.
VALVE GUIDE
Valve Stem and Valve Guide Clearance
Measuring Method-I
1. With the valve stem inserted in the valve guide, set
the dial indicator needle to “0”.
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Clearance mm (in)
Standard Limit
0.039 – 0.069 0.200
Intake Valve
(0.0015 – 0.0027) (0.008)
0.064 – 0.093 0.250
Exhaust Valve
(0.0025 – 0.0037) (0.0098)
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.
Valve Guide Replacement

Valve Guide Removal
Use a hammer and the valve guide replacer to drive out
the valve guide from the cylinder head lower face.
Valve Guide Replacer: 9-8523-1212-0
Valve Guide Installation

1. Apply engine oil to the valve guide outer
circumference.
2. Attach the valve guide installer to the valve guide.
3. Use a hammer to drive the valve guide into position
from the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0
4. Measure the height of the valve guide upper end from

the upper face of the cylinder head.
Valve Guide Upper End Height H (Reference) mm (in)
13 (0.51)
Note:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
VALVE AND VALVE SEAT INSERT

Valve Stem Outside Diameter
Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
Valve Stem Outside Diameter mm (in)
Standard Limit
7.946 – 7.961 7.880
Intake Valve
(0.3128 – 0.3134) (0.3102)
7.921 – 7.936 7.850
Exhaust Valve
(0.3119 – 0.3124) (0.3090)
Valve Thickness
Measure the valve thickness.
Intake and Exhaust Valve Thickness mm (in)
Standard Limit
4JA1T, 4JA1, 4JB1T,
1.8 (0.07) 1.5 (0.06)
4JA1TC Engine
Inlet 1.34 (0.0528)
4JG2T Engine 1.1 (0.043)
Exhaust 1.38 (0.0544)
Inlet 1.41 (0.0555)
4JH1TC 1.1 (0.043)
Exhaust 1.38 (0.0543)
Valve Depression
1. Install the valve Q to the cylinder head R.
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head
lower surface.
valve seat insert must be replaced.
Valve Depression mm (in)
Standard Limit
4JA1T, 4JA1, Intake 0.73 (0.029) 1.28 (0.050)
4JB1T, 4JA1TC
Engine Exhaust 0.70 (0.028) 1.20 (0.047)
4JG2T, 4JH1TC Engine 1.1 (0.043) 1.6 (0.063)
3. Check that the rocker arm oil port is free of

obstructions.
If necessary, use compressed air to clean the rocker
arm oil port.
Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for
step wear Q and scoring R.
If the contact surfaces have light step wear or scoring,
they may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must
be replaced.
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to “Cylinder Liner Replacement”.
3. Use a straight edge Q and a feeler gauge R to

measure the four sides and the two diagonals of the
cylinder body upper face.
If the measured values exceeds the limit, the cylinder
body must be replaced.
Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)
Cylinder Body Height H (Reference) mm (in)

Standard
4JA1, 4JA1T, 244.945 – 245.055 (9.6430 – 9.6478)
4JA1TC
4JB1T, 4JG2T, 269.945 – 270.055 (10.6277 – 10.6320)
4JH1TC
5. Reinstall the cylinder liner.
Refer to “Cylinder Liner Replacement”.
6. Reinstall the cylinder body dowel.
ROCKER ARM SHAFT AND ROCKER

ARM
Rocker Arm Shaft Run-Out
1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm must
be at cold condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.
Rocker Arm Shaft Run-Out mm (in)
Limit
0.3 (0.012)
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
rocker arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter mm (in)
Standard Limit
18.98 – 19.00 (0.747 – 0.748) 18.90 (0.744)
Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier caliper or a dial indicator to
measure the rocker arm inside diameter.
Rocker Arm Inside Diameter mm (in)
Standard Limit
19.010 – 19.030
19.100 (0.752)
(0.748 – 0.749)
2. Measure the rocker arm shaft outside diameter.

If the measured value exceeds the specified limit,
replace either the rocker arm or the rocker arm shaft.
Rocker Arm Shaft and Rocker Arm
Clearance mm (in)
Standard Limit
0.01 – 0.05
0.20 (0.008)
(0.0004 – 0.0020)
VALVE SPRING
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
valve spring must be replaced.
Inner and Outer Spring Free Height mm (in)
Standard Limit
4JA1, 4JA1T, Inner spring 45.3 (1.78) 44.4 (1.75)

4JA1TC Outer spring 49.7 (1.96) 48.2 (1.90)
4JB1T, 4JG2T,
Single spring 48.0 (1.89) 47.1 (1.85)
4JH1TC
Valve Spring Squareness

Use a surface plate and a square to measure the valve
spring squareness.
Inner and Outer Spring Squareness mm (in)
Limit
4JA1, 4JA1T, Inner Spring 3.0 (0.120)

4JA1TC Outer Spring 3.2 (0.126)
4JB1T, 4JG2T,
Single Spring 1.7 (0.07)
4JH1TC
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
Valve Spring Tension kg (lb/N)
Compressed
Standard Limit
Height
Inner 37.0 mm 5.9 5.0
4JA1, Spring (1.46 in) (13.0/57.9) (11.0/49.0)
4JA1T,
4JA1TC Outer 39.0 mm 20.9 18.1
Spring (1.54 in) (46.0/205.0) (39.8/177.4)
4JB1T,
Single 38.9 mm 30.2 26.3
4JG2T,
Spring (1.53 in) (66.4/296.0) (57.9/257.7)
4JH1TC
Valve Seat Insert Installation

1. Carefully place the attachment Q (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert R.
Note:
The smooth side of the attachment must contact the
valve seat insert.
2. Use a bench press S 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.
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve Seat Angle degree

45
Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width.
valve seat insert must be replaced.
Valve Contact Width mm (in)
Standard Limit
Intake 1.7 (0.067) 2.2 (0.087)
Exhaust 2.0 (0.079) 2.5 (0.078)
Valve Seat Insert Replacement

Valve Seat Insert Removal
1. Arc weld the entire inside circumference Q of the
valve seat insert R.
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
3. Use a screwdriver S to pry the valve seat insert free.
Take care not to damage the cylinder head T.
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.
Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore at
measuring point Q, R in the thrust a-a and axial b-b
directions of the crankshaft.
cylinder liner must be replaced.
012L200001
Measuring Points Q 20 mm (0.8 in) for 4JA1, 4JA1TC
and 4JB1T, 4JG2T,
4JH1TC
R140 mm(5.5 in) for 4JA1, 4JA1TC
R160 mm(6.3 in) for 4JB1T, 4JG2T,
4JH1TC
Cylinder Liner Bore (Service Part) mm (in)
Grade 4JA1, 4JA1T, 4JB1T 4JG2T, 4JH1TC
93.035 – 93.050 95.435 – 95.450
AX
(3.6628 – 3.6634) (3.7573 – 3.7579)
93.051 – 93.066 95.451 – 95.466
CX
(3.6634 – 3.6640) (3.7579 – 3.7585)
Grade 4JA1TC
93.021 – 93.040
AX
(3.6622 – 3.6630)
93.041 – 93.060
CX
(3.6630 – 3.6638)
Note:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection

1. Hold a straight edge Q along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge R to measure each cylinder liner
projection.
Cylinder Liner Projection mm (in)
Standard
0 – 0.1 (0 – 0.004)
The difference in the cylinder liner projection height

between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
Cylinder Liner Replacement

Cylinder Liner Removal
1. Insert the cylinder liner remover Q into the cylinder
body (from the lower side of the cylinder body) until it
makes firm contact with the cylinder liner.
Cylinder Liner Remover:
5-8840-2039-0
5-8840-2304-0: 4JG2T, 4JH1TC
Engine
2. Use a bench press R to slowly force the cylinder liner
from the cylinder body.
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”.
Cylinder Liner Grade Selection

Subtract the average cylinder body bore from the average
cylinder liner outside diameter to obtain the fitting
interference.
Fitting Interference mm (in)
Standard
– 0.0010* – 0.019 (– 0.00004* – 0.0007)
* A minus (–) value indicates that the cylinder body bore

is smaller than the liner outside diameter.
Cylinder Body Bore Measurement

1. Take measurements at measuring point Q across
positions Q-Q, R-R, S-S, and T-T.
Measuring Point Q 98 mm (3.86 in)
2. Calculate the average value of the four measurements
to determine the correct cylinder grade.
3. Consult the following table with the resultant diameter
for the correct liner application.
Cylinder Liner Grade Selection and Standard

Fitting Interference
Accurately measured fitting interference and proper
cylinder liner grade selection are extremely important.
If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will be
difficult to insert the cylinder liner into the cylinder body.
A mark was stamped on the upper of the cylinder block

during production to indicate the correct liner.
The liner grade (i.e.1.2.3.4) is indicated in metal stamp.
012RY00022
Cylinder Liner Grade

4JA1, 4JA1T, 4JB1T, 4JA1TC mm (in)
Liner Liner
Cylinder Body Liner Outside
Outside Bore Service Liner Bore Measurement
Bore Diameter Diameter
Grade Grade
95.001 – 95.010 95.011 – 95.020 AX 93.035 – 93.050 (3.6628 – 3.6634)

1
(3.7402 – 3.7405) (3.7406 – 3.7409) CX 93.051 – 93.066 (3.6634 – 3.6640)
95.011 – 95.020 95.021 – 95.030 AX 93.035 – 93.050 (3.6628 – 3.6634)
2
(3.7406 – 3.7409) (3.7410 – 3.7413) CX 93.051 – 93.066 (3.6634 – 3.6640)
95.021 – 95.030 95.031 – 95.040 AX 93.035 – 93.050 (3.6628 – 3.6634)
3
(3.7410 – 3.7413) (3.7414 – 3.7417) CX 93.051 – 93.066 (3.6634 – 3.6640)
95.031 – 95.040 95.041 – 95.050 AX 93.035 – 93.050 (3.6628 – 3.6634)
4
(3.7414 – 3.7417) (3.7418 – 3.7421) CX 93.051 – 93.066 (3.6634 – 3.6640)
4JG2T, 4JH1TC mm (in)

Liner Liner
Cylinder Body Liner Outside
Outside Bore 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)
Cylinder Liner Installation

1. Cylinder Liner Installation Using The Special Tool
1) Use new kerosene or diesel oil to thoroughly clean
the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder liner
and bore surfaces.
Note:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3) Insert the cylinder liner Q into the cylinder body R
from the top of the cylinder body.
4) Set the cylinder liner installer S to the top of the

cylinder liner.
Cylinder Liner Installer: 5-8840-2040-0
5-8840-2313-0 (4JG2T,
4JH1TC)
5) S is directly beneath the bench press shaft center
T.
Note:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
6) Use the bench press to apply a seating force of
500 kg (1,100 lb/4,900 N) to the cylinder liner.
7) Apply a force of 2,500 kg (5,500 lb/24,500 N) to
fully seat the cylinder liner.
8) After installing the cylinder liner, measure the
cylinder liner projection.
Refer to “Cylinder Liner Projection Inspection”.
2. Cylinder Liner Installation Using Dry Ice
Cylinder liner is a chrome plated dry type, it is
advisable to use dry ice during the installation
procedure.
Cooling the cylinder liner with dry ice will cause the
cylinder liner to contract, thus making installation
easier.
Note:
It is important that the cylinder liner be inserted to the
cylinder body immediately after it has been cooled.
Warning:
Dry ice must be used with great care. Careless
handling of dry ice can result in severe frostbite.
Piston Grade Selectin

Measure the cylinder liner bore after installing the cylinder
liner. Then select the appropriate piston grade for the
installed cylinder liner.
1. Measure the cylinder liner bore.
Refer to “Cylinder Liner Bore Measurement”
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.
2. Measure the piston diameter.

Piston Measuring Point mm (in)
4JA1 70 (2.76)
4JA1T 78 (3.07)
4JB1T 74 (2.91)
4JG2T, 4JH1TC 71 (2.79)
4JA1TC 68.1 (2.68)
Grade 4JA1T/4JA1 4JB1T 4JG2T

92.979 – 92.994 92.974 – 92.989 95.369 – 95.384
AX
(3.6606 – 3.6612) (3.6604 – 3.6610) (3.7547 –3.7553)
92.995 – 93.010 92.990 – 93.005 95.385 – 95.400
CX
(3.6612 – 3.6618) (3.6610 – 3.6616) (3.7553 – 3.7559)
Grade 4JA1TC 4JH1TC

92.945 – 92.964 95.359 – 95.374
AX
(3.6592 – 3.6600) (3.7543 – 3.7549)
92.965 – 92.984 95.375 – 95.390
CX
(3.6600 – 3.6607) (3.7549 – 3.7555)
Cylinder Liner and Piston Clearance mm (in)

4JA1T/4JA1 0.041 – 0.071 (0.0016 – 0.0027)
4JB1T 0.046 – 0.076 (0.0018 – 0.0030)
4JG2T 0.051 – 0.081 (0.0020 – 0.0032)
4JA1TC 0.057 – 0.095 (0.0022 – 0.0029)
4JH1TC 0.061 – 0.091 (0.0024 – 0.0036)
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.
TAPPET AND PUSH ROD

Visually inspect the tappet contact surfaces for pitting,
cracking, and other abnormal conditions. The tappet must
be replaced if any of these conditions are present.
Refer to the illustration at the left.
Q Normal contact
R Cracking
S Pitting
T Irregular contact Uneven contact
U Irregular contact One-sided contact
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.
Tappet Outside Diameter

Measure the tappet outside diameter with a micrometer.
tappet must be replaced.
Tappet Outside Diameter mm (in)
Standard Limit
12.97 – 12.99
12.95 (0.510)
(0.510 – 0.511)
Tappet and Cylinder Body Clearance mm (in)

Standard Limit
0.01 – 0.046
0.10 (0.004)
(0.0004 – 0.0018)
Push Rod Curvature

1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and measure
the push rod curvature with a thickness gauge.
push rod must be replaced.
Pushrod Curvature mm (in)
Limit
0.3 (0.012)
3. Visually inspect both ends of the push rod for

excessive wear and damage. The push rod must be
replaced if these conditions are discovered during
inspection.
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.
Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal
diameter in two directions (Q and R). If the measured
value is less than the specified limit, the camshaft must be
replaced.
Camshaft Journal Diameter mm (in)
Standard Limit
49.945 – 49.975
49.60 (1.953)
(1.9663 – 1.9675)
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.
Cam Height H mm (in)
Standard Limit
42.08 (1.657) 41.65 (1.640)
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
camshaft must be replaced.
Camshaft Run-Out mm (in)
Standard Limit
0.02 (0.0008) 0.10 (0.004)
Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft
bearing inside diameter.
Crankshaft Bearing Inside Diameter mm (in)
Standard Limit
50.00 – 50.03
50.08 (1.972)
(1.968 – 1.970)
If the clearance between the camshaft bearing inside

diameter and the journal exceeds the specified limit, the
camshaft bearing must be replaced.
Camshaft Bearing Clearance mm (in)
Standard Limit
0.05 (0.002) 0.12 (0.005)
Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft
bearing.
Bearing Replacer: 5-8840-2038-0
Camshaft Bearing Installation

1. Align the bearing oil holes with the cylinder body oil
holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and
crankpins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and
damage.
Inspect the oil ports for obstructions.
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 Tufftriding Inspection

1. Use an organic cleaner to thoroughly clean the
crankshaft. There must be no traces of oil on the
surfaces to be inspected.
2. Prepare a 5 – 10% solution of ammonium cuprous
chloride (dissolved in distilled water).
3. Use a syringe to apply the solution to the surface to be
inspected.
Hold the surface to be inspected perfectly horizontal to
prevent the solution from running.
Note:
Do not allow the solution to come in contact with the
oil ports and their surrounding area.
Judgment
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty seconds,
the crankshaft is usable.
If discoloration appears (the surface being tested will
become the color of copper), the crankshaft must be
replaced.
2. Steam clean the crankshaft surface immediately after
completing the test.
Note:
The ammonium cuprous chloride solution is highly
corrosive. Because of this, it is imperative that the
surfaces being tested be cleaned immediately after
completing the test.
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.
crankshaft must be replaced.
Crankshaft Run-Out mm (in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)
Bearing Spread
Use a vernier caliper to measure the bearing spread.
bearing must be replaced.
Bearing Spread mm (in)
Limit
4JA1, 4JA1T,
64.5 (2.54)
4JA1TC
Crankshaft Bearing
4JB1T, 4JG2T,
74.5 (2.93)
4JH1TC
Connecting Rod Bearing 56.5 (2.22)
Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal
diameter across points Q - Q and R - R.
2. Use the micrometer to measure the crankshaft journal
diameter at the two points (S and T).
3. Repeat Steps Q and R to measure the crankpin
diameter.
If the measured values are less than the specified
limit, the crankshaft must be replaced.
Crankshaft Journal Diameter mm (in)

Standard Limit
4JA1T, 4JA1, 59.92 – 59.93
59.91 (2.3586)
4JA1TC (2.3591 – 2.3594)
4JG2T, 4JB1T, 69.92 – 69.93
69.91 (2.7524)
4JH1TC (2.7527 – 2.7531)
Crankpin Diameter mm (in)

Standard Limit
52.92 – 52.93
52.90 (2.083)
(2.0833 – 2.0839)
Crankshaft Journal and Crankpin

Uneven Wear mm (in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)
Crankshaft Journal and Bearing Clearance

If the clearance between the measured bearing inside
diameter and the crankshaft journal diameter exceeds the
specified limit, the bearing and/or the crankshaft must be
replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.031 – 0.064
0.110 (0.0043)
(0.0012 – 0.0025)
Connecting Rod Bearing Inside Diameter

1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the specified torque.
Connecting Rod Bearing Cap Bolt
4JA1 / 4JA1T engine 8.5 ± 0.5(61.4 ± 3.6 / 83.3 ± 4.9)
4JB1T / 4JG2T / 1st step ; 3.0 ± 0.5(21.7 ± 3.6 /
4JA1TC / 4JH1TC 29 ± 5)
engine 2nd step ; 45° ~ 75°
3. Use an inside dial indicator to measure the connecting

rod bearing inside diameter.
Crankpin and Bearing Clearance

If the clearance between the measured bearing inside
diameter and the crankpin exceeds the specified limit, the
bearing and/or the crankshaft must be replaced.
Crankpin and Bearing Clearance mm (in)
Standard Limit
0.029 – 0.066
0.100 (0.0039)
(0.0011 – 0.0026)
Clearance Measurements (With Plastigage)

Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting
surface, the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30° to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft
journal across the full width of the bearing.
6. Install the bearing caps with the bearing.
7. Tighten the bearing caps to the specified torque.

Crankshaft Bearing Cap Bolt Torque kg·m (lb.ft/N·m)
17 ± 1 (123.0 ± 7.2/166.7 ± 9.8)
Do not allow the crankshaft to turn during bearing cap

installation and tightening.
8. Remove the bearing cap.
9. Compare the width of the Plastigage attached to either

the crankshaft or the bearing against the scale printed
on the Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1) Use a micrometer to measure the crankshaft
outside diameter.
2) Use an inside dial indicator to measure the
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the
bearing must be replaced.
Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.031 – 0.064
0.110 (0.0043)
(0.0012 – 0.0025)
Crankpin and Bearing Clearance

1. Clean the crankshaft, the connecting rod, the bearing
cap, and the bearings.
2. Install the bearing to the connecting rod and the
bearing cap.
Do not allow the crankshaft to move when installing
the bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from
falling.
5. Install the bearing cap and tighten it to the specified
torque.
Do not allow the connecting rod to move when
installing and tightening the bearing cap.
4JA1 / 4JA1T engine 8.5 ± 0.5(61.4 ± 3.6 / 83.3 ± 4.9)
4JB1T / 4JG2T / 1st step ; 3.0 ± 0.5(21.7 ± 3.6 /
4JA1TC / 4JH1TC 29 ± 5)
6. Remove the bearing cap.

7. Compare the width of the Plastigage attached to either
the crankshaft or the bearing against the scale printed
on the Plastigage container.
If the measured value exceeds the specified limit,
perform the following additional steps.
1) Use a micrometer to measure the crankpin
outside diameter.
2) Use an inside dial indicator to measure the
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing
must be replaced.
Crankpin and Bearing Clearance mm (in)
Standard Limit
0.029 – 0.066
0.100 (0.0039)
(0.0011 – 0.0026)
CRANKSHAFT BEARING SELECTION

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing
inserts.
Match the crankshaft bearing housing grade marks and
the crankshaft journal grade marks in the table below to
determine the correct crankshaft bearing size.
Crankshaft Bearing Housing Grade Mark

Position
Crankshaft bearing housing grade marks 1 or 2 are
stamped on the rear right hand side of the cylinder body.
Example:
1 2 1 1 2
No. 1 Bearing No. 2 Bearing No. 3 Bearing No. 4 Bearing No. 5 Bearing
Housing Housing Housing Housing Housing
Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or -) are stamped
on each crankshaft journal web.
The crankshaft journal and bearing clearance must be the
same for each position after installation of the crankshaft
and the crankshaft bearings.
Note:
The crankshaft journal mark No. 4 is stamped on
crankshaft No. 4 journal web front side or rear side.
REFERENCE
4JA1, 4JA1T, 4JA1TC ENGINE mm (in)
Crankshaft BearingQ Crankshaft Journal R Crankshaft
Bearing
Grade Grade Size Color
Diameter Diameter
Mark Mark Code S
1 or 59.927 – 59.932
Black
- (2.3593 – 2.3595)
63.987 –
64.000 2 or 59.922 – 59.927
1
(2.5191 – -- (2.3591 – 2.3593)
2.6196) Blue
3 or 59.917 – 59.922
--- (2.3589 – 2.3591)
1 or 59.927 – 59.932
- (2.3593 – 2.3595)
63.975 – Green
63.987 2 or 59.922 – 59.927
2
(2.5186 – -- (2.3591 – 2.3593)
2.5191)
3 or 59.917 – 59.922
Black
--- (2.3589 – 2.3591)
4JB1T, 4JG2T, 4JH1TC ENGINE mm (in)

Crankshaft BearingQ Crankshaft Journal R Crankshaft
Bearing
Grade Grade Size Color
Diameter Diameter
Mark Mark Code S
1 or 69.927 – 69.932
Black
- (2.7530 – 2.7532)
73.987 –
74.000 2 or 69.922 – 69.927
1
(2.9129 – -- (2.7528 – 2.7530)
2.9134) Blue
3 or 69.917 – 69.922
--- (2.7556 – 2.7528)
1 or 69.927 – 69.932
- (2.7530 – 2.7532)
73.975 – Green
73.987 2 or 69.922 – 69.927
2
(2.9124 – -- (2.7528 – 2.7530)
2.9129)
3 or 69.917 – 69.922
Black
--- (2.7556 – 2.7528)
CRANKSHAFT PILOT BEARING

Check the crankshaft pilot bearing for excessive wear and
damage and replace it if necessary.
Crankshaft Pilot Bearing Replacement

Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the crankshaft
pilot bearing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0 (J-23907)
Crankshaft Pilot Bearing Installation

1. Place the crankshaft pilot bearing right angle across
the crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing
outer races with a brass hammer to drive the bearing
into the crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0
Note:
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.
FLYWHEEL AND RING GEAR

Flywheel
1. Inspect the flywheel friction surface for excessive wear
and heat cracks.
2. Measure the flywheel friction surface depth.
If the measured value is within the specified limit, the
flywheel may be reground.
flywheel must be replaced.
Flywheel Friction Surface Depth Q mm (in)
Standard Limit
4JA1, 4JA1T,
20 (0.787) 21 (0.827)
4JA1TC
4JB1T 14 (0.551) 15 (0.591)
4JG2T,
18 (0.708) 19 (0.748)
4JH1TC
Flywheel Friction Surface Roughness mm (in)

Less than 0.006 (0.00024)
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
Ring Gear Replacement

Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.
Ring Gear Installation

1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer
facing the clutch.
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.
PISTON RING
Piston Ring Gap
1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the piston) into the
cylinder liner.
2. Push the piston ring into the cylinder bore until it

reaches the measuring point Q or R 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 Q 10 mm (0.4 in)
or
Measuring Point R 120 mm (4.7 in)
3. Use a feeler gauge to measure the piston ring gap.

piston ring must be replaced.
Piston Ring Gap mm (in)
Standard Limit
1st Compression Ring 0.2 – 0.4
2nd Compression Ring (0.008 – 0.016) 1.5
(0.059)
0.1 – 0.3
Oil Ring
(0.004 – 0.012)
4JG2 mm (in)
Standard Limit
1st 0.20 – 0.35

Compression (0.0079 – 0.0138)
ring 0.37 – 0.52 1.5
2nd
(0.0146 – 0.0205) (0.059)
Oil ring 0.20 – 0.40

(0.0079 – 0.0157)
4JH1TC mm (in)
Standard Limit
1st 0.30 – 0.50

Compression (0.0118 – 0.0197)
ring 0.30 – 0.50 0.15
2nd
(0.0118 – 0.0197) (0.0059)
Oil ring 0.25 – 0.45

(0.0098 – 0.0117)
Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between the
piston ring and the piston ring groove at several points
around the piston.
If the clearance between the piston ring and the piston ring
groove exceeds the specified limit, the piston ring must be
replaced.
Piston Ring and Piston Ring Groove
Clearance
015RY00029 4JA1, 4JB1T, 4JA1T, 4JA1TC mm (in)
Standard Limit
0.09 – 0.125
1st Compression Ring
(0.0035 – 0.0049)
0.05 – 0.085 0.15
2nd Compression Ring
(0.002 – 0.0033) (0.0059)
0.03 – 0.070
Oil Ring
(0.0012 – 0.0028)
4JG2, 4JH1TC mm (in)

Standard Limit
1st 0.09 – 0.13

Compression (0.0035 – 0.0051)
ring 0.05 – 0.09 0.15
2nd
(0.0020 – 0.0035) (0.0059)
Oil ring 0.03 – 0.07

(0.0012 – 0.0028)
4. Visually inspect the piston rings.

If a piston ring groove is damaged or distorted, the
piston must be replaced.
PISTON PIN
Piston Pin Diameter
Use a micrometer to measure the piston pin diameter at
several points.
piston pin must be replaced.
Piston Pin Diameter mm (in)
Standard Limit
4JA1
4JA1T 30.995 – 31.000 30.97 (1.219)
4JA1TC (1.2202 – 1.2204)
4JH1TC
4JB1T 33.994 – 34.000 33.97 (1.337)
4JG2T (1.3383 – 1.3386)
Piston Pin and Piston Clearance

Use and inside dial indicator to measure the piston pin
hole (in the piston).
Piston Pin Hold mm (in)
Standard
4JA1, 4JA1T 31.002 – 31.010 (1.2206 – 1.2208)
4JB1T 34.002 – 34.010 (1.3387 – 1.3390)
4JG2T (1.3383 – 1.3386)
015RY00030
4JA1TC
31.005 – 31.013 (1.2207 – 1.2210)
4JH1TC
Piston Pin and Piston Pin Hole Clearance mm (in)

0.002 – 0.015 (0.00008 – 0.0006)
4JA1TC, 4JH1TC
0.005 – 0.018 (0.00019 – 0.0007)
CYLINDER HEAD GASKET SELECTION

Cylinder head gasket is determined by the piston head
projection from the cylinder body upper surface, in order to
improve engine performance.
Three types of gasket are provided by the difference of
thickness. Select the adequet one out of three grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
head and cylinder body surface and also clean the place
where a gasket was installed.
Piston Head Projection Measuring Point

1. Use a dial indicator to measure the piston projection
amount.
2. Refer to the illustration for the piston head projection
measuring positions.
All measuring positions should be as close as possible
to the cylinder liner.
3. Measure the points Q R S T and obtain two

differences Q–R and S–T on each cylinder.
Calculate the average value of the piston head
projection on each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum
value described above in accordance with the following
table.
For 4JA1/4JA1T/4JB1T/4JA1TC/4JH1TC
Cylinder Head Gasket Combination mm (in)
Gasket Grade Piston Projection Gasket
Mark 4JA1, 4JA1TC 4JB1T Thickness
(Reference)
0.718 – 0.773 0.758 – 0.813 1.6

A
(0.0283 – 0.0304) (0.0298 – 0.0320) (0.0630)
0.773 – 0.819 0.813 – 0.859 1.65
B
(0.0304 – 0.0322) (0.0320 – 0.0338) (0.0650)
0.819 – 0.874 0.859 – 0.914 1.70
C
(0.0322 – 0.0344) (0.0338 – 0.0360) (0.0669)
4JH1TC Cylinder Head Gasket Thickness mm (in)

Gasket Grade Gasket Thickness
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)
For 4JG2T 4JG2T Cylinder Head Gasket Combination mm (in)

Gasket Grade Gasket Thickness
Piston Projection
Mark (Reference)
A 0.658 – 0.712 1.6

(0.0259 – 0.0281) (0.0630)
B 0.713 – 0.758 1.65
(0.0281 – 0.0299) (0.0650)
C 0.759 – 0.813 1.70
011RY00031 (0.0299 – 0.0320) (0.0669)
Note:
Difference of the each piston projection and must be
equal or within 0.1 mm (0.004 in).
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.
Connecting Rod Alignment
Per Length of 100 mm (3.94 in) mm (in)
Standard Limit
Distortion 0.08 or Less (0.003) 0.20 (0.008)
Parallelism 0.05 or Less (0.002) 0.15 (0.006)
Connecting Rod Side Face Clearance

1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance between
the connecting rod big end side face and the crankpin
side face.
connecting rod must be replaced.
Connecting Rod Big End and Crankpin Side
Face Clearance mm (in)
Standard Limit
0.23 (0.009) 0.35 (0.014)
Piston Pin and Connecting Rod Small End

Bushing Clearance
Use a caliper calibrator and a dial indicator to measure the
piston pin and connecting rod small end bushing
clearance.
If the clearance between the piston pin and the connecting
rod small end bushing exceeds the specified limit, replace
the piston pin and/or the connecting rod bushing.
Piston Pin and Connecting Rod Small End
Bushing Clearance mm (in)
Standard Limit
0.008 – 0.020
0.050 (0.002)
(0.0003 – 0.0008)
Connecting Rod Bushing Replacement

Connecting Rod Bushing Removal
1. Set the connecting rod small end to the bench press
V-block Q.
2. Use the bench press R and the bar S to slowly force
the bushing from the connecting rod T.
Note:
Take care not to damage the connecting rod with the
bar when removing the bushing.
Connecting Rod Bushing Installation

1. Set the connecting rod small end Q to the bench
press V-block.
The connecting rod must be perfectly horizontal.
2. Use the bench press R and the bar S to slowly force
the bushing with oil hole into position.
3. Use a pin hole grinder T fitted with a reamer U to

ream the piston pin hole.
TIMING PULLEY HOUSING

Replace the crankshaft front oil seal if it is worn or
damaged.
Take care not to damage the oil seal fitting surfaces.
Crankshaft Front Oil Seal Replacement

Oil Seal Removal
With the oil seal pushed in deep, install the special tool as
shown in the illustration and remove the oil seal.
Oil Seal Remover: 5-8840-2362-0
Note:
Take care not to damage sealing surface of front plate
and crankshaft when removing oil seal.
Oil Seal Installation

Use the special tool to install the oil seal.
1. With the oil seal attached to the sleeve, insert it into
the front end section of the crankshaft.
2. With the oil seal end section attached securely to the
crankshaft, tighten up the center bolt until the sleeve
hits the front end reference plane of the crankshaft
securely.
3. Remove the sleeve.
4. With the seal pressed in, check the dimension of the
oil seal section.
Standard Dimension = 0.9 ± 0.3 mm
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.
Front Oil Seal Installer: 5-8840-2361-0
IDLER GEAR SHAFT AND IDLER GEAR

(GEAR Drive Model)
Idler Gear “A” Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside
diameter.
idler gear shaft must be replaced.
Idler Gear “A” Shaft Outside Diameter mm (in)
Standard Limit
44.945 – 44.975
44.845 (1.766)
(1.769 – 1.770)
Idler Gear “A” Shaft inside Diameter

1. Use an inside dial indicator or an inside micrometer to
measure the idler gear inside diameter.
Idler Gear Inside Diameter mm (in)
Standard Limit
45.0 – 45.03
45.10 (1.7756)
(1.7717 – 1.7718)
If the clearance between the idler gear shaft outside

diameter and the idler gear inside diameter exceeds the
limit, the idler gear must be replaced.
Idler Gear Shaft and Idler Gear Clearance mm (in)
Standard Limit
0.025 – 0.085
0.200 (0.008)
(0.0010 – 0.0033)
Idler Gear “B”

Bearing Replacement
Bearing Removal
Use a bench press or a hammer and a bar to remove the
bearing from the idler gear.
Bearing Installation
Use a bench press and bar to install the bearing into the
idler gear.
Bearing Projection and Height mm (in)
Projection Q 0.4 – 0.6 (0.016 – 0.024)
Height R 23.7 – 24.0 (0.933 – 0.945)
Note:
The bench press and bar should make contact only
with the bearing outer races. Do not allow them to
make contact with the bearing inner races.
Bearing damage and reduced bearing service life will
result.
TIMING GEAR CASE COVER

Replace the crankshaft front oil seal if it is excessively
worn or damaged.
Crankshaft Front Oil Seal Replacement

Oil Seal Removal
Use a plastic hammer and a screwdriver to tap around the
oil seal to free it from the gear case cover.
Take care not to damage the oil seal lip surfaces.
Oil Seal Installation

Use the installer to install the front oil seal Q to the gear
case cover R.
Oil Seal Installer: 5-8840-2061-0
Note the oil seal installation depth S shown in the
illustration.
Depth S = 1 mm (0.039 in.)
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
Reassembly Steps
t 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
1. Rocker Arm Shaft
1) Position the rocker arm shaft with the large oil hole
(4φ) 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.
CYLINDER HEAD
Reassembly Steps
1. Cylinder head 6. Valve spring upper seat
7.
2. Valve spring lower seat t Split collar
t 3. Valve stem oil seal t 8. Intake manifold gasket
t 4. Intake and exhaust valve t 9. Intake manifold
t 5. Valve spring
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.
4. Intake and Exhaust Valve

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.
7. Split Collar
1) Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0 (J-29760)
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.
8. Intake Manifold Gasket

9. Intake Manifold
1) Install the manifold gasket with the end having the
sharp corners facing the front of the engine.
2) Install the intake manifold to the cylinder head.
3) Tighten the manifold bolts to the specified torque.
Manifold Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
PISTON AND CONNECTING ROD
For 4JA1/4JA1T/4JA1TC
/4JH1TC only
015L200003
Reassembly Steps
t 1. Piston t 5. Piston pin snap ring

t 2. Piston pin snap ring t 6. Piston ring
t 3. Connecting rod t 7. Connecting rod bearing
t 4. Piston pin
1. Piston
3. 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.
Install the piston to the connecting rod so that the piston

head front mark c and the connecting rod “ISUZU”
casting mark d are facing in the same direction.
015R100022
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.
015R100018

3) Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
4) Check that the connecting rod moves smoothly on the
piston pin.
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.
c Oil ring
d 2nd compression ring
e 1st compression ring
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.
2) Apply engine oil to the piston ring surfaces.
3) Check that the piston rings rotate smoothly in the
piston ring grooves.
7. Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
INTERNAL PARTS
MAJOR COMPONENTS
Belt Drive Model
014RY00047
Reassembly Steps-1 (Belt Drive Model)

t 1. Cylinder body t 11. Camshaft timing pulley
t 2. Tappet t 12. Piston and connecting rod with
t 3. Crankshaft upper bearing upper bearing
t 4. Crankshaft t 13. Connecting rod bearing cap with
t 5. Crankshaft thrust bearing lower bearing
t 6. Crankshaft bearing cap with t 14. Piston cooling oil pipe
lower bearing t 15. Oil pump with oil pipe
t 7. Crankshaft rear oil seal t 16. Oil pan
t 8. Camshaft t 17. Cylinder body rear plate
t 9. Timing pulley housing t 18. Flywheel
t 10. Oil seal retainer
Reassembly Steps-2 (Belt Drive Model)

t 19. Crankshaft timing pulley t 26. Timing belt tension adjusting
t 20. Crankshaft timing pulley center lever
t 21. Injection pump t 27. Camshaft timing pulley flange
t 22. Injection pump timing pulley t 28. Water pump
t 23. Tension idler t 29. Timing pulley housing lower
t 24. Timing belt cover
t 25. Timing belt tensioner t 30. Timing pulley housing upper
cover
31. Crankshaft damper pulley
Reassembly Steps-3
t 32. Cylinder head gasket 37. Water by-pass hose
t 33. Cylinder head
t 38. Glow plug and glow plug
34. Push rod connector
t 35. Rocker arm shaft and rocker
t 39. Injection nozzle and Injection
arm nozzle holder
t 36. Thermostat housing with thermo t 39a. Injection nozzle (4JG2T engine)
switch 39b. Injection nozzle and injection
nozzle holder (4JA1TC, 4JH1TC)
t 40. Cylinder head cover
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.
2. Tappet
1) Apply a coat of engine oil to the tappet c and the
cylinder body tappet insert holes d.
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.
3. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and an oil
groove. The lower bearings do not.
1) Carefully wipe any foreign material from the upper
bearing.
Note:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
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.
5. Crankshaft Thrust Bearing

Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
6. Crankshaft Bearing Cap With Lower Bearing

Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1) Apply the recommended liquid gasket or its equivalent
to the No. 5 crankshaft bearing cap c as shown in the
illustration.
2) Install the arch gasket d to the No. 5 bearing cap.
Use your fingers to push the arch gasket into the
bearing cap groove.
Take care not to scratch the arch gasket outer
surface.
to the No. 5 crankshaft bearing cap cylinder body
fitting surfaces at the points (f) shown in the
illustration.
Note:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.
4) Install the bearing caps with the bearing cap head

arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.
5) Apply engine oil to the crankshaft bearing cap bolts.
6) Temporarily tighten the bearing cap bolts.
The bolts will be tightened to the specified torque after
the crankshaft rear oil seal is installed.
7. Crankshaft Rear Oil Seal

1) Tighten the adapter to the crankshaft rear end section
with 2 bolts.
2) Insert the oil seal into the peripheral section of the
adapter.
3) Insert the sleeve into the adapter section, and 1)
tighten it with a bolt (M12 × 1.75L = 70) until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of the
oil seal section.
Standard Dimension = 12.5 ± 0.3 mm
8. Camshaft
1) Apply a coat of engine oil to the camshaft and the
camshaft bearings.
Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
9. Timing Pulley Housing (For Belt Drive)

1) Install the timing pulley housing to the cylinder body.
Take care not to twist the front oil seal.
2) Tighten the timing pulley housing together with the
timing pulley housing gasket to the specified torque.
Timing Pulley Housing Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.62 ± 490)
3) Cut away the flash from the gasket.
10. Oil Seal Retainer

1) Apply engine oil to the oil seal lip of the oil seal
retainer.
c to the reatiner d at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
3) Install the oil seal retainer d.
4) Tighten the reatiner bolts to the specified torque.
Oil Seal Retainer Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.62 ± 4.90)
11. Camshaft Timing Pulley

1) Align the timing pulley center c with the camshaft
key.
2) Tighten the timing pulley center bolts to the specified
torque.
Prevent the camshaft from turning when tightening the
timing center.
Timing Center Bolt Torque kg·m (lb.ft/N·m)
6.5 ± 0.5 (47.0 ± 3.6/63.70 ± 4.90)
3) Align the timing pulley with the timing center knock pin
d and then install the timing pulley e to the center.
Install the stopper bolt to the camshaft timing pulley to
4) Tighten the timing pulley bolts to the specified torque.
Timing Pulley Bolt Torque kg·m (lb.ft/N·m)
0.8 ± 0.2 (5.8 ± 1.4/7.84 ± 1.96)
12. Piston and Connecting Rod with Upper Bearing

13. Connecting Rod Bearing Cap with Lower Bearing
1) Apply a coat of engine oil to the circumference of each
piston ring and piston.
2) Position the piston ring gaps as shown in the
illustration.
c Oil ring
d 2nd compression ring
e 1st compression ring
015RY00033
3) Apply a coat of molybdenum disulfide grease to the

two piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4) Apply a coat of engine oil to the upper bearing
surfaces.
5) Apply a coat of engine oil to the cylinder wall.
6) Position the piston head front mark so that it is facing

the front of the engine.
7) Use the piston ring compressor to compress the
piston rings.
Piston Ring Compressor: 5-8840-9018-0 (J-8037)
8) Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
9) Align the bearing cap cylinder number marks and the

connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.
10) Apply a coat of engine oil to the threads and setting

faces of each connecting rod cap bolt.
11) Tighten the connecting rod caps to the specified
torque.
4JA1 / 4JA1T engine 8.5 ± 0.5(61.4 ± 3.6 / 83.3 ± 4.9)
4JB1T / 4JG2T / 1st step ; 3.0 ± 0.5(21.7 ± 3.6 / 29
4JA1TC / 4JH1TC ± 5)
14. Piston Cooling Oil Pipe

1) Install the piston cooling oil pipe to the cylinder body.
2) Tighten the oil pipe bolts and relief valve to the
specified torque.
Oil Pipe Bolt Torque kg·m (lb.ft/N·m)
c M8 × 1.25 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
d M6 × 1.00 0.8 ± 0.2 (5.8 ± 1.5/7.8 ± 2.0)
Relief valve Torque kg·m (lb.ft/N·m)

e M16 × 1.5 3.0 ± 0.5 (21.7 ± 3.6/29.4 ± 4.9)
Note:
Check that there is no interference between the piston
and the oiling jet pipe f by slowly rotating the
crankshaft.
15. Oil Pump with Oil Pipe

Install the oil pump with the oil pipe and tighten the bolts to
Oil Pump Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
Note:
Take care not to damage the O-rings when tightening
the oil pipe bolts.
16. Oil Pan

1) Apply the recommended liquid gasket (three bond
TB1207 & TB1207C) or its equivalent to arch gasket
fitting surface as shown in the illustration.
2) Install the crank case front gasket 1 to the timing gear
case arches.
The gasket projection 2 must be facing forward.
3) Install the rear arch gasket 2 to the No. 5 bearing cap.

Use your fingers to push the arch gasket into the
bearing cap groove.
Take care not to scratch the arch gasket outer
surface.
Also apply the recommended liquid gasket (TB1207B
& TB1207C) or its equivalent to arch gasket fitting
area as indicated in the illustration.

to groove of the crank case fitting surface as shown in
the illustration.
Note:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.
5) Install the crank case to the cylinder body.

6) Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.
Crank Case Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
17. Cylinder Body Rear Plate

1) Align the rear plate with the cylinder body knock pins.
2) Tighten the rear plate to the specified torque.
Rear Plate Torque kg·m (lb.ft/N·m)
8.4 ± 0.8 (60.8 ± 5.8/83.3 ± 7.8)
18. Flywheel
1) Block the crankshaft with a piece of hard wood to
prevent the flywheel from turning.
2) Apply a coat of engine oil to the threads of the flywheel
bolts.
3) Align the flywheel with the crankshaft dowel pin.
4) Tighten the flywheel bolts to the specified torque in the
numerical order shown in the illustration.
Flywheel Bolt Torque kg·m (lb.ft/N·m)
12.0 ± 0.5 (86.8 ± 3.6/117.6 ± 4.9)
19. Crankshaft Timing Pulley

1) Install the timing pulley to the crankshaft.
2) Use the crankshaft timing pulley installer to install the
timing pulley.
The timing pulley flange must be facing the cylinder
body.
20. Crankshaft Timing Pulley Center

1) Install the crankshaft timing pulley center.
2) Use the fixing wrench to prevent the crankshaft from
turning.
Fixing Wrench: 5-8840-0161-0
3) Tighten the crankshaft pulley center bolt to the
specified torque.
Crankshaft Pulley Center Bolt Torque kg·m (lb.ft/N·m)
4JA1T 19.0 ± 2 (137.4 ± 14.5/186.20 ± 19.60)
4JG2T 28.0 ± 4.5 (202.5 ± 32.5/274.4 ± 44.1)
21. Injection Pump

1) Install the injection pump c to the timing pulley
housing d.
2) Temporarily tighten the three injection pump nuts e.
The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.
3) Install the injection pump rear bracket f and the rear

bracket bolts g to the cylinder body.
4) Install the rear bracket bolts h to the injection pump
bracket.
Do not tighten the bolts.
The rear bracket bolts g and h will be finally tighten
tened to the specified torque after the injection pump
nuts.
5) Tighten the injection pump nuts to the specified
torque.
Injection Pump Nut and Bracket Bolt
g, h 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

1) Align the timing pulley with the pump shaft key.
2) Install the stopper bolt c to the timing pulley.
This will prevent the timing pulley from turning.
3) Tighten the timing pulley nut to the specified torque.
Injection Pump Timing Pulley Nut Torque kg·m (lb.ft/N·m)
6.5 ± 0.5 (47.0 ± 3.6/63.7 ± 4.9)
23. Tension Idler

1) Install the tensioner idler to the timing pulley housing.
2) Tighten the tensioner idler to the specified torque.
Tensioner Idler Bolt Torque kg·m (lb.ft/N·m)
7.7 ± 1.0 (55.7 ± 3.6/75.5 ± 9.8)
24. Timing Belt

25. Timing Belt Tensioner
26. Timing Belt Tension Adjusting Lever
1) Check that the stopper bolts are properly installed to
the camshaft timing pulley c and the injection pump
timing pulley d.
2) Check that the timing pulley housing mark e and the

crankshaft timing pulley mark f are aligned.
3) Install the timing belt to the crankshaft timing pulley

g, the camshaft timing pulley h, the tensioner idler
i, and the injection timing pulley j.
Follow the numerical order.
4) Install the timing belt tensioner k to the timing pulley
housing.
5) Temporarily tighten the tnesioner bolt.
The tensioner should move freely.
Note:
The timing belt is easily damaged. Be careful.
6) Set the tensioner adjusting lever l to the timing

pulley housing.
7) Remove the stopper bolts from the camshaft timing
pulley c and the injection pump timing pulley d.
8) Attach the spring balancer 11 .
9) Adjust timing belt tension by pulling straight down on

the spring balancer with the specified force.
Tension Adjusting Lever Force kg (lb/N)
10 - 12 (22.1 – 26.5/98.1 – 117.7)
Note:
Timing belt tension must be adjusted.
Failure to adjust the timing belt tension will result in
timing belt damage.
10) Tighten the tension bolt.
11) Rotate the crankshaft 45 degrees counterclockwise.
Note:
Never rotate crankshaft clockwise when adjusting the
timing belt.
12) Readjust the timing belt tension.

Refer to Step 9
This will remove any remaining timing belt slack.
13) Tighten the tensioner bolt to the specified torque.
Tensioner Bolt Torque kg·m (lb.ft/N·m)
7.7 ± 1.0 (55.7 ± 3.6/75.5 ± 9.8)
14)Tighten the tension adjusting lever nut 13 and bolt 14 .

Note:
If on-vehicle timing belt replacement is performed, the
crankshaft must not be allowed to turn.
If the crankshaft is allowed to turn, piston and valve
damage will result.
27. Camshaft Timing Pulley Flange

Tighten the timing pulley flange bolts to the specified
torque.
Timing Puley Flange Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
28. Water Pump

to the water pump at the position shown in the
illustration.
2) Tighten the water pump bolts to the specified torque.
Water Pump Bolt Torque kg·m (lb.ft/N·m)
2.0 ± 0.5 (14.5 ± 3.6/19.6 ± 4.9)
29. Timing Pulley Housing Lower Cover

30. Timing Pulley Housing Upper Cover
to the timing pulley lower cover.
2) Install the lower cover c to the timing pulley housing
d.
Use the lower cover guide bolts e to prevent the
liquid gasket from running.
3) Install the upper cover f to the lower cover and pulley
housing.
4) Tighten the timing cover bolts to the specified torque a
little at a time in the sequence shown in the illustration.
Timing Pulley Cover Bolt Torque kg·m (lb.ft/N·m)
0.8 ± 0.2 (5.8 ± 1.4/7.8 ± 2.0)
5) Remove the lower cover guide pin.

32. Cylinder Head Gasket

The cylinder head gasket “TOP” mark must be facing up.
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”.
015RY00031
33. 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.
3) Tighten the cylinder head bolts in two steps.

Follow the numerical sequence shown in the
illustration.
Cylinder Head Bolt Torque kg·m (lb.ft/N·m)
1st Step 2nd Step 3rd Step
5.0 ± 0.5
60° ~ 75° 60° ~ 75°
(36.2 ± 3.6/49.00 ± 4.90)
Cylinder Head Bolt Torque kg·m (lb.ft/N·m)

1st Step 2nd Step
5.0 ± 0.5 8.7 ± 0.5
New
4JB1 (36.2 ± 3.6/ (62.9 ± 3.6/
bolt
For 83.3 ± 4.9) 85.26 ± 4.90)
CHINA 8.5 ± 0.5 10.5 ± 0.5
only Reuse
(61.4 ± 3.6/ (75.9 ± 3.6/
bolt
83.3 ± 4.9) 102.90 ± 4.90)
v
35. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.
Rocker Arm Shaft Bracket Bolt Torque kg·m (lb.ft/N·m)
5.5 ± 0.5 (39.8 ± 3.6/53.9 ± 4.9)
36. Thermostat Housing

1) Install the thermostat housing.
2) Tighten the thermostat housing bolts to the specified
torque.
Thermostat Housing Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
38. Glow Plug and Glow Plug Connector

1) Install the glow plugs to the cylinder head.
2) Tighten the glow plugs to the specified torque.
Glow Plug Torque kg·m (lb.ft/N·m)
2.25 ± 0.25 (16.3 ± 1.8/22.1 ± 2.5)
3) Install the glow plug connector.
39. Injection Nozzle Holder

1) Install the injection nozzle gasket c and the O-ring d
to the injection nozzle holder e.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2) Install the nozzle holder toghther with the nozzle holder
bracket f to the cylinder head.
Nozzle Holder Bracket Bolt Torque kg·m (lb.ft/N·m)

3.8 ± 0.6 (27.5 ± 4.3/37.2 ± 5.9)
3) Tighten the holder nut with washer g to the specified

torque.
Injection Nozzle Holder Nut Torque kg·m (lb.ft/N·m)
3.8 ± 0.6 (26.0 ± 4.3/37.2 ± 5.9)
39a.Nozzle Holder Assembly (4JG2T Engine)
Install the parts in sequence of corrugated washer, nozzle
gasket and nozzle holder.
Do not reuse the corrugated washer and nozzle gasket.
Use the new one.
The corrugated washer should be installed with blue color
painted side turned to the nozzle.
Tighten the nozzle holder.

Nozzle Holder Torque kg·m (lb.ft/N·m)
6.5 ± 0.5 (47.0 ± 3.6/63.7 ± 4.9)
Install the leak-off pipe via the copper gasket.

Leak Off Pipe Torque kg·m (lb.ft/N·m)
3.5 – 4.7 (25.3 – 34.0/34.3 – 46.1)
Note on Valve Clearance Adjustment

Valve clearances must be adjusted before the cylinder
head cover is reinstalled.
Refer to “Valve Clearance Adjustment” in the “Servicing”
Section of this Manual.
40. Cylinder Head Cover

1) Apply engine oil to the rocker arm and the valve
spring.
2) Install the cylinder head cover gasket to the head
cover.
Check to see that the head cover gasket has no loose
areas.
3) Tighten the cylinder head cover nuts in the numerical
order shown in the illustration.
Cylinder Head Cover Bolt Torque kg·m (lb.ft/N·m)
1.3 ± 0.5 (9.4 ± 3.6/12.7 ± 4.9)
4) Connect the PCV hose to the cylinder head cover.

INTERNAL PARTS
MAJOR COMPONENTS
014RY00048
Reassembly Steps-1 (Gear Drive Model)

J 1. Timing gear case
J 2. Camshaft thrust plate
J 3. Camshaft timing gear
7a
Reassembly Steps-2 (Gear Drive Model)

J 4. Crankshaft timing gear J 9. Injection pump
J 5. Idler gear shaft J 10. Timing gear case cover
J 6. Idler gear “A” 11. Space rubber
J 7. Idler gear “B” and shaft 12. Gear case cover upper cover
J 7a. Idler gear “B” and shaft (Scissor and lower cover
gear
J 8. Timing gear oil pipe (Except 13.
J Crankshaft damper pulley
4JA1TC, 4JH1TC)
1. Timing Gear Case

1) Tighten the timing gear case with timing gear case
gasket to the specified torque.
Timing Gear Case Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
2. Camshaft Thrust Plate

Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.
Thrust Plate Bolt Torque kg·m (lb.ft/N·m)
1.8 ± 0.5 (13.0 ± 3.6/17.6 ± 4.9)
3. Camshaft Timing Gear

1) Install the camshaft timing gear to the camshaft.
The timing gear mark (“Y – Y” or “：”) must be facing
outward.
2) Tighten the timing gear to the specified torque.
Timing Gear Bolt Torque kg·m (lb.ft/N·m)
11.0 ± 1 (79.6 ± 7.2/107.8 ± 9.8)
4. Crankshaft Timing Gear

Use the crankshaft timing gear installer to install the
crankshaft timing gear .
The crankshaft timing gear setting mark (“X – X” or “・”)
must be facing outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0
5. Idler Gear Shaft

6. Idler Gear “A”
1) Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole A must be facing up.
2) Position the idler gear setting marks “X” or “・”, “Y” or
“：” and “Z” or “∴” so that they are facing the front of
the engine.
3) Align the idler gear “X” or “：” setting mark with the
crankshaft timing gear “X – X” or “：” setting mark.
4) Align the idler gear “Y” or “・” setting mark with the
camshaft timing gear “Y – Y” or “・” setting mark.
5) Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
6) Tighten the idler gear bolt to the specified torque.
Idler Gear “A” Bolt Torque kg·m (lb.ft/N·m)
3.0 ± 0.5 (21.7 ± 3.6/30 ± 5.0)
7. 7a. Idler Gear “B” and Shaft

1) Apply engine oil to the idler gear and the idler gear
shaft.
2) Align the idler gear “B” “Z” or “∴” setting mark with
the idler gear “A” “Z – Z” or “∴” setting mark.
3) Tighten the idler gear bolt to the specified torque.
Idler Gear “B” Bolt Torque kg·m (lb.ft/N·m)
7.7 ± 1.0 (55.7 ± 7.2/74 ± 9.8)
7a. If the idle gear “B” is disassemble, reassemble in the
following procedure.
Idle Gear B (scissor gear) Reassembly Steps (4JA1TC,

4JH1TC only)
1) Drive pins into the main gear, the front gear, and the
rear gear.
020L200019
2) Apply pressure to the main gear bearing from the front

side of the main gear (the side with the groove).
020L200007
3) Place the special tool in a vise so that the main gear is

pushed up toward the rear side.
Scissor gear setting tool

Base 5-8673-9149-0
020L200008
4) Set the spring as shown in the illumination.
020L200009
5) Position the rear gear so that it pin is aligned with the

receiving end of the spring.
020L200010
6) Install the snap ring to the main gear groove.
020L200011
7) Set the rear gear setting hole to the pin of the special
tool.
8) Place the special tool in a vise so that the main gear is
pushed up toward the front side.
9) Repeat Steps 3, 4, and 5.
020L200013
10) Use the special tool to mesh the teeth of the front
gear, the main gear, and the rear gear.

Lever 5-8673-9150-0
020L200014
11) Insert a lock bolt (M6×1 L=30) into the scissor gear
fixing hole to prevent the scissor gear from turning.
020L200012
8. Timing Gear Oil Pipe (Except 4JA1TC, 4JH1TC)

1) Install the oil pipe to the timing gear case and idler
gear “A”.
2) Tighten the oil pipe eye bolt and bolt to the
specified torque.
Eye Joint and Bolt Torque kg·m (lb.ft/N·m)
1.25 ± 0.25 (9.0 ± 1.8/12.3 ± 2.5)
9. Injection Pump
1) Install the O-ring to the injection pump flange .
2) Install the injection pump to the timing gear case.
Align the idler gear “B” “V – V” or “‥” mark with the
injection pump timing gear “V” or “‥” mark.
3) Install the injection pump rear bracket and the rear

bracket bolts to the cylinder body.
4) Install the rear bracket bolts to the injection pump
bracket .
5) Tighten the injection pump bracket bolts to the

specified torque.
Injection Pump Bracket Bolt Torque kg·m (lb.ft/N·m)
, 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
4.1 ± 0.6 (29.6 ± 4.3/40.2 ± 5.9)
4JA1TC, 4JH1TC
1) Install the O-ring to the injection pump flange .
2) Install the injection pump to the timing gear case.
Align the idler gear “B” “‥” mark with the injection
pump timing gear “‥” mark.
020L200021
3) Install the injection pump bracket.

4) Tighten the injection pump bracket bolts to the
specified torque.
Injection Pump Bracket Bolt Torque kg·m (lb.ft/N·m)
4.1 ± 0.6 (29.6 ± 4.3/40.2 ± 5.9)
080L200006
5) Remove the scissor gear set bolt.

10. Timing Gear Case Cover

6) Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.
7) Tighten the gear case cover bolts to the specified
torque.
Gear Case cover Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)

Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley.
Crankshaft Damper Pulley Bolt Torque kg·m (lb.ft/N·m)
21.0 ± 2.0 (151.9 ± 14.5/206.0 ± 19.6)
Take care not to damage the crankshaft damper pulley

boss.
INSTALLATION
EXTERNAL PARTS
These installation steps are based on the 4JB1T engine.
Installation Steps
J 1. Generator bracket J 16. Intake manifold

J 2. Water inlet pipe J 17. Compressor bracket
J 3. Heater pipe (Rear side) J 18. Compressor
J 4. Generator and adjusting plate J 19. Starter motor
J 5. Engine mounting bracket J 20. Power steering oil pump bracket
J 6. Exhaust manifold J 21. Power steering oil pump
7. Exhaust manifold heat protector 22. Water drain cock
J 8. Turbocharger 23. Oil pressure warning switch and
J 9. Turbocharger oil return pipe nipple
J 10. Turbocharger oil feed pipe 24. Oil level gauge guide tube
J 11. Oil cooler with Oil filter J 25. Cooling fan pulley
12. Turbocharger heat protector J 26. Cooling fan drive belt
13. Injection pump 27. Vacuum pipe
J 14. Fuel injection pipe with clip
15. Fuel leak off pipe
1. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque kg·m (lb.ft/N·m)
4.1 ± 0.6 (29.7 ± 4.3/40.2 ± 5.9)
2. Water Inlet Pipe

1) Tighten the water inlet pipe bolts to the specified
torque.
Suction Pipe Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
3. Heater Pipe (Rear Side)

1) Install the heater pipe to the cylinder head.
2) Connect the oil cooler return hose and feed hose to
the oil cooler.
3) Connect the water rubber hose to the heater pipe.
4. Generator and Adjusting Plate

1) Install the generator to the bracket .
2) Temporarily tighten the generator bolt and
adjusting plate bolts .
The bolts will be finally tightened after installation of
the cooling fan drive belt.
3) Connect the vacuum pump rubber hose to the

vacuum pump , and the oil pan .
4) Connect the vacuum oil pipe to the vacuum pump,
and the cylinder body.
5. Engine Mounting Bracket

Install the engine mounting bracket to the cylinder body
and tighten the bracket bolts to the specified torque.
Mounting Bracket Bolt Torque kg·m (lb.ft/N·m)
Right Side M10 × 1.25 (9T) 5.6 (40.5/54.9)
M10 × 1.25 (7T) 4.1 (30/40)
Left Side
M14 × 1.50 (7T) 12 (86.7/118)
6. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head
with the manifold gasket .
2) Tighten the exhaust manifold bolts to the specified
torque a little at a time.
Exhaust Manifold Bolt Torque kg·m (lb.ft/N·m)
2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)
3) Install the exhaust manifold bracket to the manifold

and the cylinder body.
Manifold Bracket Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
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.
3) Install the exhaust adapter with gasket and tighten the

adapter nut to the specified torque.
Adapter Nut Torque kg·m (lb.ft/N·m)
2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)
9. Turbocharger Oil Return Pipe

1) Install the oil return pipe with gasket to the
turbocharger.
2) Tighten the turbocharger oil return pipe to the
specified torque.
Turbocharger Oil Reutrn Pipe Torque kg·m (lb.ft/N·m)
0.8 ± 0.2 (5.8 ± 1.4/7.8 ± 2.0)
10. Turbocharger Oil Feed Pipe

1) Before installing the oil feed pipe, supply 10 – 20 cc of
clean engine oil to the turbocharger center housing
through the oil feed opening.
2) Turn the rotating assembly with your hand to
thoroughly lubricate the internal parts.
3) Tighten the oil feed pipe to the specified torque.
Turbocharger Oil Feed Pipe Joint
Bolt Torque kg·m (lb.ft/N·m)
M10 × 1.5 2.25 ± 0.25 (16.3 ± 1.8/22.1 ± 2.5)
M14 × 1.5 5.5 ± 0.25 (39.8 ± 1.8/53.9 ± 2.5)
4) Tighten the turbocharger nut to the specified torque.

Turbocharger Nut Torque kg·m (lb.ft/N·m)
2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)
v
11. Oil Cooler with Oil Filter

1) Install the O-ring to the oil filter flange groove.
2) Tighten the oil filter and oil cooler to the specified
torque.
Oil Filter Flange Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
3) Lightly oil the O-ring of oil filter cartridge.

4) Turn in the new oil filter cartridge by hand until the
sealing face is fitted again the O-ring.
5) Use the filter wrench to turn in the oil filter and
additional one and 1·1/8 turns.
6) Start the engine and check for oil leakage from oil
filter.

1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Injection Pipe Sleeve Nut Torque kg·m (lb.ft/N·m)
3 ± 1 (21.7 ± 7.2/29.4 ± 9.8)
16. Intake Manifold

1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts
to the specified torque.
Intake Manifold Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
Intake Manifold Flange Nut Torque kg·m (lb.ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
4) Connect the PCV hose to the cylinder head cover.

17. Compressor Bracket

1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque kg·m (lb.ft/N·m)
M 8 × 1.25 1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
M10 × 1.25 4.1 ± 0.6 (30 ± 7.2/40 ± 6)
18. Compressor
1) Install the compressor to the compressor bracket.
2) Tighten the compressor bolts to the specified torque.
Compressor Bolt Torque kg·m (lb.ft/N·m)
3.8 ± 1.0 (27.5 ± 7.2/37.2 ± 9.8)
19. Starter Motor

Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque kg·m (lb.ft/N·m)
7.0 ± 1.0 (50.6 ± 7.2/68.6 ± 9.8)
20. Power Steering Oil Pump Bracket

21. Power Steering Oil Pump
1) Install the oil pump bracket to the cylinder head.
2) Tighten the pump bracket nut and bolts to the
specified torque.
Oil Pump Bracket Nut and Bolt
3.75 ± 0.95
M10 × 1.25 (7T)
(27.1 ± 6.9/36.75 ± 9.31)
1.75 ± 0.55
M 8 × 1.25 (7T)
(12.7 ± 4.0/17.75 ± 5.39)
1.30 ± 0.50
M 8 × 1.25 (4T)
(9.4 ± 3.6/12.74 ± 4.90)
3) Install the oil pump to the bracket.

4) Temporarily tighten the oil pump nut and bolts .
The nut and bolts will be finally tightened after
installation of the drive belt.
25. Cooling Fan Pulley

1) Install the cooling fan pulley to the water pump with
spacer.
2) Tighten the cooling fan pulley bolts to the specified
torque.
Cooling Fan Pulley Bolt Torque kg·m (lb.ft/N·m)
0.8 ± 0.2 (5.8 ± 1.4/7.8 ± 2.0)
26. Cooling Fan Drive Belt

Install the fan drive belt and adjust the belt tension
referring SERVICING of this section.
EGR Pipe (If equipped)

Install EGR pipe and tighten fixing bolt and nuts to the
specified torque.
Bolt kg·m (lb.ft/N·m)
2.7 ± 0.5 (19.5 ± 3.6/26.5 ± 4.9)
Nuts kg·m (lb.ft/N·m)

2.4 ± 0.5 (17.4 ± 3.6/23.5 ± 4.9)
027RY00007
LUBRICATING SYSTEM
Engine Model 4JA1, 4JA1T 4JB1T, 4JG2T, 4JA1TC,
4JH1TC
Oil pump type Gear
Oil pressure switch operating pressure 0.2 – 0.5 (2.8 – 7.1/19.6 – 49.0)
2
kg/cm (psi/kPa)
Oil filter type Full flow with cartridge paper element
2
Relief valve opening pressure kg/cm (psi/kPa) 4.3 – 4.7 5.7 – 6.3
(61.1 – 66.8/421.4 – 460.6) (82.5 – 89.5/558.6 – 617.4)
2
Safety valve opening pressure kg/cm (psi/kPa) 0.8 – 1.2 (11.38 – 17.07/78.9 – 117.6)
Oil cooler type Water-cooled
2
Safety valve opening pressure kg/cm (psi/kPa) 2.3 – 2.7 (32.7 – 38.4/225.4 – 264.6)
GENERAL DESCRIPTION
LUBRICATING OIL FLOW
Except
4JA1
4JA1TC,
4JH1TC
Oil filter safety valve opening pressure : 0.8 – 1.2 (11.4 – 17.1/78.9 – 117.6)
Oil cooler safety valve opening pressure : 2.3 – 2.7 (32.7 – 38.4/225.4 – 264.6)
Oil filter relief valve opening pressure : 5.7 – 6.3 (82.5 – 89.5/558.6 – 617.4)
Oil pressure switch opening pressure : 0.2 – 0.5 (2.8 – 7.1/19.6 – 49.0)
Engine regulating valve : 2.3 – 2.7 (32.7 – 38.4/225.4 – 264.6)
Oil pump relief valve opening pressure : 6.7 – 7.8 (95.3 – 110.9/657.0 – 764.9)
C06L200010
The 4J series engine has a full flow type lubricating system.

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.
OIL PUMP AND OIL FILTER
For 4JA1 Except 4JA1
The 4J series engine is equipped with a gear type oil pump.

The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.
OIL PUMP
DISASSEMBLY
051L200001
Disassembly Steps
1. Oil pipe 4. Driven gear with bush
2. Strainer 5. Relief valve asm.
3. Pump cover 6. Oil pump body

inspection.
Gear Teeth and Body Inner Wall Clearance
gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, either the gear or the body
must be replaced.
Gear Teeth and Body Inner Wall Clearance mm (in)
Standard Limit
0.14 (0.0055) 0.20 (0.0079)
Gear and Body Clearance

body and the gear.
If the clearance between the gear and the body exceeds
the specified limit, the body must be replaced.
Gear and Body Clearance mm (in)
Standard Limit
0.06 (0.024) 0.15 (0.0059)
REASSEMBLY
051L200002
Reassembly Steps
1. Oil pump body 4. Strainer
2. Driven gear with bush 5. Relief valve asm.
3. Pump cover 6. Oil pipe
OIL FILTER AND OIL COOLER

DISASSEMBLY
Disassembly Steps
1. Drain plug 5. Safety valve
2. Cartridge oil filter 6. Relief valve
3. Oil cooler 7. Oil filter body
4. O-ring
DISASSEMBLY
Except 4JA1
Disassembly Steps
1. Oil filter cartridge 5. Gasket
2. Bolt 6. Body
3. Gasket 7. Relief valve
4. Oil cooler

inspection.
Relief Valve
1. Attach an oil pressure gauge to the oil gallery near the
oil filter.
2. Start the engine to check the relief valve opening
pressure.
2
Relief Valve Opening Pressure kg/cm (psi/kPa)
4JA1, 4JA1T 4.3 – 4.7 (61.1 – 66.8/421.4 – 460.6)
4JB1T, 4JG2T, 5.7 – 6.3 (82.5 – 89.5/558.6 – 617.4)
4JA1TC,
4JH1TC
Oil Cooler
Water Leakage at Water Passage
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
2
3. Apply compressed air (2 kg/cm (28 psi/200 kPa)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water leakage.
REASSEMBLY
Reassembly Steps
1. Oil filter body J 5. Oil cooler
J 2. Relief valve J 6. Oil filter cartridge
3. Safety valve J 7. Drain plug
4. O-ring
2. Relief Valve
Tighten the relief valve to the specified torque.
Relief Valve Torque kg·m (lb.ft/N·m)
3.0 ± 0.5 (21.7 ± 3.6/29.4 ± 4.9)
5. Oil Cooler
1) Align the oil filter holes with the body knock pins at
installation.
2) Tighten the oil cooler nut to the specified torque.
Oil Cooler Nut Torque kg·m (lb.ft/N·m)
3.0 ± 0.5 (21.7 ± 3.6/29.4 ± 4.9)
6. Oil Filter Cartridge

1) Apply engine oil to the O-ring.
2) Turn in the cartridge oil filter until the filter sealing face
makes contact with the O-ring.
3) Turn in the cartridge oil filter an additional one and 1/8
of a turn.
7. Drain Plug
Tighten the drain plug to the specified torque.
Drain Plug Torque kg·m (lb.ft/N·m)
2.5 ± 0.5 (18.1 ± 3.6/24.5 ± 4.9)
REASSEMBLY
Except 4JA1
Reassembly Steps
1. Body 5. Gasket
J 2. Relief valve J 6. Bolt
3. Gasket J 7. Oil filter cartridge
J 4. Oil cooler
2. Relief Valve
Tighten the safety valve to the specified torque.
Safety Valve Torque kg·m (lb.ft/N·m)
0.3 ± 00.5 (4.3 ± 0.7/29.4 ± 4.9)
4. Oil Cooler
6. Bolt
Tighten Bolt with gaskets and oil cooler to the specified
torque.
Bolt Torque kg·m (lb.ft/N·m)
3.0 ± 0.5 (21.7 ± 3.6/29.4 ± 4.9)
7. Oil Filter Cartridge

1) Lightly oil the O-ring of oil filter cartridge.
2) Turn in the new oil filter cartridge by hand until the
sealing face is fitted again the O-ring.
3) Use the filter wrench to turn in the oil filter and
additional one and 1·1/8 turns.
4) Start the engine and check for oil leakage from oil
filter.
SPECIAL TOOLS
Illustration Tool Number Tool Name
5-8840-0200-0 (4JG2T,
4JB1T, 4JA1T, 4JA1TC,
4JH1TC) Filter Wrench
5-8840-0201-0 (4JA1)
5-8840-0253-0
Filter Wrench
(J-22700)
5-8840-0145-0
Static Timing Gauge
(J-28827)
5-8840-2675-0 Compression Gauge
5-8531-7001-0 Adapter; Compression Gauge
5-8840-2034-0 Nozzle Holder Remover
5-8840-0019-0
Sliding Hammer
(J-23907)
5-8840-0161-0 Fixing Wrench
5-8840-0086-0 Timing Pulley Puller
5-8521-0002-0 Universal Puller
5-8840-2362-0 Oil Seal Remover

9-8523-1423-0
Spring Compressor
(J-29760)
9-8523-1212-0 Valve Guide Replacer
5-8840-2039-0
Cylinder Liner Remover
5-8840-2304-0
(4JG2T, 4JH1TC)
5-8840-2040-0
5-8840-2313-0 Cylinder Liner Installer
(4JG2T, 4JH1TC)
5-8840-2038-0 Bearing Replacer; Camshaft
5-8840-2000-0 Pilot Bearing Remover
5-8522-0024-0 Pilot Bearing Installer
5-8840-2361-0 Front Oil Seal Installer
5-8840-2033-0 Oil Seal Installer
5-8840-9018-0
Piston Ring Compressor
(J-8037)
5-8840-2359-0 Oil Seal Installer
9-8522-0020-0 Crankshaft Timing Gear Installer
5-8840-0266-0 Angle Gauge
Base
5-8673-9149-0
Lever
5-8673-9150-0
INDEX
ENGINE COOLING 6B – 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B - 2
General Description....................................................................................................... 6B - 3
Water Pump.................................................................................................................... 6B - 7
Removal and Installation .......................................................................................... 6B - 7
Thermostat ..................................................................................................................... 6B - 9
Removal and Installation .......................................................................................... 6B - 9
Inspection and Repair ............................................................................................... 6B - 10
Fan Clutch with Cooling Fan ........................................................................................ 6B - 11
Inspection and Repair ............................................................................................... 6B - 11
6B – 2 ENGINE COOLING

Item Description
Pump to crankshaft speed ratio (To 1) 1.1
Delivery volume lit (US/UK gal)/min 100 (26.3/22.2)
Pump speed at 3000 rpm
Water temperature at 30°C (86°F)
Pump bearing type Double row shaft

Valve initial opening temperature °C (°F) 82 (180)
Valve full opening temperature °C (°F) 95 (203)
Valve lift at fully open position mm (in) 9.5 (0.37)
GENERAL DESCRIPTION
COOLANT FLOW
4JA1TC
4JH1TC
C06L200009
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.
WATER PUMP
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.
THERMOSTAT
A wax pellet type thermostat is used.

The jiggle valve accelerates engine warm-up.
WATER PUMP
begin.
Important Operations - Removal
Radiator Upper Hose

1. Disconnect the wiring harness Q.
2. Partially drain the engine coolant.
3. Remove the radiator upper hose S.
Fan and Fan Clutch

1. Loosen the fan clutch nuts T.
2. Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
Water Pump
1. Remove the water pump bolts.
2. Remove the water pump.

Water Pump
to the water pump at the position shown in the
illustration.
2) Tighten the water pump bolts to the specified torque.
Water Pump Bolt Torque kg·m (lb.ft/N·m)
2.0 ± 0.5 (14.5 ± 3.6/19.6 ± 4.9)
Cooling Fan Drive Belt

1. Install the cooling fan drive belt.
2. Apply tension to the cooling fan drive belt by moving
the generator .
3. Apply a force of 10 kg (22 lb/98 N) to the drive belt
mid-portion to check the drive belt deflection.
Cooling Fan Drive Belt Deflection mm (in)
10 (0.4)

R Generator pulley
SCooling fan drive pulley
4. Tighten the remaining water pump bolt to the specified
torque.
Radiator Upper Hose

Heater Hose
1. Connect the radiator upper hose to the water outlet
pipe.
2. Replenish the engine coolant.
3. Make sure the wiring harness is properly connected.
4. Start the engine and allow it to warm up.
5. Check the temperature gauge operation.
THERMOSTAT
begin.
Important Operations – Removal

Radiator Upper Hose
1. Disconnect the wiring harness Q.
2. Partially drain the engine coolant.
3. Disconnect the radiator upper hose R.
Water Outlet Pipe

Thermostat
1. Loosen the water outlet pipe bolt Q.
2. Remove the water outlet pipe R.
3. Remove the thermostat S from the thermostat
housing.
Take care not to damage the thermostat.

Thermostat
Water Outlet Pipe
1. Install the thermostat to the thermostat housing.
2. Install the water outlet pipe with the gasket to the
thermostat housing.
3. Tighten the outlet pipe to the specified torque.
Outlet Pipe Bolt Torque kg·m (lb.ft/N·m)
1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
Radiator Upper Hose

1. Connect the radiator upper hose to the water outlet
pipe.
2. Replenish the engine coolant.
3. Make sure the wiring harness is properly connected.
4. Start the engine and allow it to warm up.
5. Check the temperature gauge operation.

inspection.
Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C (°F)
82 (180)
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature °C (°F)
95 (203)
Valve Lift At Fully Open Position mm (in)

9.5 (0.37)
Q Thermometer
R Agitating rod
S Wooden piece
FAN CLUTCH WITH COOLING FAN

Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found
through inspection.
Visually inspect for damage, leak (sillicon grease) or other

abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at
the fan clutch portion gets to around 80°C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.
2. Inspection (in unit)

Warm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80°C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.
MEMO
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INDEX
FUEL SYSTEM 6C – 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 2
General Description....................................................................................................... 6C - 4
Injection Pump ............................................................................................................... 6C - 13
Removal and Installation .......................................................................................... 6C - 13
Belt Drive Model (4JA1T, 4JG2T) ......................................................................... 6C - 13
Gear Drive Model (4JA1, 4JB1T) .......................................................................... 6C - 18
Gear Drive Model (4JA1TC, 4JH1TC) ................................................................... 6C - 20
Injection Pump Calibration Data................................................................................... 6C - 23
Injection Nozzle.............................................................................................................. 6C - 31
Disassembly............................................................................................................... 6C - 31
Inspection and Repair ............................................................................................... 6C - 32
Reassembly................................................................................................................ 6C - 33
Injection Nozzle (For 4JG2T Engine)............................................................................ 6C - 35
Disassembly............................................................................................................... 6C - 35
Inspection and Repair ............................................................................................... 6C - 37
Reassembly................................................................................................................ 6C - 38
Inspection and Adjustment....................................................................................... 6C - 39
Injection Nozzle (For 4JA1TC, 4JH1TC Engine) .......................................................... 6C - 40
Disassembly............................................................................................................... 6C - 40
Reassembly................................................................................................................ 6C - 41
Injection Nozzle Adjustment ..................................................................................... 6C - 43
Adjustment Procedure For Potentiometer................................................................... 6C - 51
6C – 2 FUEL SYSTEM

Description
Item
4JA1 4JB1T
Injection pump type Bosch Distributor
Plunger outside diameter mm (in) 11 (0.43)
Plunger prestroke mm (in) 0.45 (0.0177)
Governor type Mechanical variable all speed Mechanical limit speed
Timer type Oil pressure
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Injection nozzle orifices mm (in) 0.21 (0.0083) 0.27 (0.0106)
Inside diameter
2
Injection nozzle opening kg/cm (psi/MPa) 185 (2,631/18.1)
Main fuel filter type Disposable cartridge paper element and water separator
Item 4JA1T 4JG2T

Injection pump type Bosch Distributor
Plunger outside diameter mm (in) 11 (0.43)
Plunger prestroke mm (in) 0.45 (0.0177) -
Governor type Mechanical variable (Variable half speed)
Timer type Oil pressure
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type Throttle type
Number of injection nozzle orifices 5 1
Injection nozzle orifices mm (in) 0.21 (0.0083) 1 (0.04)
Inside diameter
2
Injection nozzle opening kg/cm (psi/MPa) 185 (2,631/18.1) 150 (2,133/14.7)
Item 4JA1TC 4JH1TC

Injection pump type BOSCH VP44
(electronic controlled fuel injection pump)
Injection nozzle type Hole type (Double spring type)

Injection nozzle orifices mm (in) 0.17 (0.0067) 0.21 (0.0083)
Inside diameter
2
Injection nozzle opening kg/cm (psi/MPa) 1st: 199 (2,830/19.5) 1st: 198 (2,816/19.4)
2nd: 347 (4,934/34,000) 2nd: 344 (4,906/33,800)
GENERAL DESCRIPTION
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 where 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 repairs.
FUEL FLOW
Except 4JA1TC, 4JH1TC Engine
The fuel system consists of the fuel tank, the water separator, the fuel filter, 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.
For 4JA1TC, 4JH1TC Engine
・ The 4JA1TC, 4JH1TC engine are equipped with the electronically controlled fuel injection system. For
information on fuel injection pump maintenance and/or part replacement, contact the Bosch Automotive
Systems Corporation.
・ Contact the Bosch Automotive Systems Corporation for information on 4JA1TC, 4JH1TC engine fuel injection
nozzle maintenance.
INJECTION PUMP
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.
An aneroid compensator is available as an option for vehicles to be operated at high altitudes. It adjusts the fuel and
air mixing ratio.
A boost compensator is installed on turbocharger equipped vehicles.
ANEROID COMPENSATOR
The aneroid compensator consists of the compensator housing, the bellows, the adjusting pin, the aneroid
compensator lever pin, and the aneroid compensator lever.
Atmospheric pressure decreases as altitude increases. The decreased atmospheric pressure causes the bellows to
expand and push the adjusting pin down.
The adjusting pin pushes the aneroid compensator lever pin and the aneroid compensator lever to the left.
The aneroid compensator lever pushes the tension lever to the right.
The tension lever actuates the control sleeve to decrease the fuel flow.
BOOST COMPENSATOR
The boost compensator consists of the compensator housing, the diaphragm, the adjusting pin, the boost
compensator lever pin, and the boost compensator lever.
The increase boost pressure cause the diaphragm to lower and push the adjusting pin down.
The adjusting pin pushes the boost compensator lever pin and the boost compensator lever to the left.
The boost compensator lever pushes the tension lever to the right.
The tension lever actuates the control sleeve to increase the fuel flow.
FAST IDLE ACTUATOR
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.
WAX TYPE COLD START DEVICE (W–CSD) (If so equipped)
Because engine starting in cold conditions is very difficult, the W-C.S.D. (wax type cold start device) has been
developed to provide the optimum fuel injection timing for engine starting by responding to temperature changes.
The thermo-wax piston contains a wax that changes its volume according to the temperature changes of the engine
coolant which flows through the unit at all times.
The engine coolant temperature above A °C the wax expands in proportion to the coolant temperature, below A °C
it contracts.
The coolant temperature A is classified as –20, -10 and 0°C.
FUEL FILTER WITH BUILT-IN WATER SEPARATOR
Level Sensor
A fuel filter with a built-in water separator is used along with the VE type injection pump.
As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the water separator. It is used during the water draining
and the air bleeding procedures.
INJECTION NOZZLE
A hole (with 5 orifices) type injection nozzle is used for 4JA1T, 4JA1, 4JB1T Engine and a throttle type injection is
used for 4JG2T Engine. 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.
INJECTION PUMP
begin.
BELT DRIVE MODEL (4JA1T, 4JG2T)

Removal Steps
1. Cooling Fan
Drain the engine coolant.
The following parts must be removed before the cooling
fan can be removed.
Battery, Air cleaner duct, Radiator
Additionally, all piping, wiring, and hoses which will
interfere with the removal of the cooling fan must be
disconnected.
Refer to Section 6A, “REMOVAL AND INSTALLATON” of
this Manual for detailed information on part removal.

Turn the crankshaft to align the damper pulley mark with
the timing pointer.
This will bring the No. 1 piston to TDC on the compression
stroke.

1. Loosen the injection pipe sleeve nuts at the delivery
valve side .
Do not apply excessive force to the injection pipes.
2. Loosen the injection pipe clips .
3. Remove the injection pipes .
Note:
Plug the delivery holder ports with the shipping caps
to prevent the entry of foreign material.
4. Timing Case Cover Upper

5. Timing Case Cover Lower
6. Timing Belt
1. Loosen the timing belt tensioner bolt and remove the
timing belt.

1. Install the stopper bolt to the timing pulley to
2. Use the timing pulley remover to remove the

injection pump timing pulley.
Timing Pulley Puller: 5-8840-0086-0
3. Remove the stopper bolt.
8. Injection Pump
1. Remove the three injection pump bracket nuts at
the rear of the timing pulley housing.
2. Remove the injection pump rear bracket bolts from

the injection pump bracket .
3. Remove the injection pump rear bracket bolts and
the bracket from the cylinder body.
4. Pull the injection pump free toward the rear of the
engine.
Note:
Installation Steps
To install, follow the removal procedure in reverse order
and note the following point.
1. Injection Pump
1) Install the injection pump to the timing pulley
housing .
2) Temporarily tighten the three injection pump nuts .
The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.
3) Install the injection pump rear bracket and the rear
bracket bolts to the cylinder body.
4) Install the rear bracket bolts to the injection pump
bracket.
Do not tighten the bolts.
The rear bracket bolts and will be finally tighten
tened to the specified torque after the injection pump
nuts.
5) Tighten the injection pump nuts to the specified
torque.
Injection Pump Nut and Bracket Bolt
1.5 ± 0.5 (10.8 ± 3.6/14.7 ± 4.9)

1) Align the timing pulley with the pump shaft key.
2) Install the stopper bolt to the timing pulley.
This will prevent the timing pulley from turning.
3) Tighten the timing pulley nut to the specified torque.
Injection Pump Timing Pulley Nut Torque kg·m (lb.ft/N·m)
6.5 ± 0.5 (47.0 ± 3.6/63.7 ± 4.9)
3. Timing Belt
4. Timing Belt Tensioner
5. Timing Belt Tension Adjusting Lever
1) Check that the stopper bolts are properly installed to
the camshaft timing pulley and the injection pump
timing pulley .
2) Check that the timing pulley housing mark and the

crankshaft timing pulley mark are aligned.
3) Install the timing belt to the crankshaft timing pulley

, the camshaft timing pulley , the tensioner idler
, and the injection timing pulley .
Follow the numerical order.
4) Install the timing belt tensioner to the timing pulley
housing.
5) Temporarily tighten the tnesioner bolt.
The tensioner should move freely.
Note:
The timing belt is easily damaged. Be careful.
6) Set the tensioner adjusting lever to the timing pulley
housing.
7) Remove the stopper bolts from the camshaft timing
pulley and the injection pump timing pulley .
8) Attach the spring balancer 11 .
9) Adjust timing belt tension by pulling straight down on

the spring balancer with the specified force.
Tension Adjusting Lever Force kg (lb/N)
10 - 12 (22.1 – 26.5/98.1 – 117.7)
Note:
Timing belt tension must be adjusted.
Failure to adjust the timing belt tension will result in
timing belt damage.
10) Tighten the tension bolt.
11) Rotate the crankshaft 45 degrees counterclockwise.

Note:
Never rotate crankshaft clockwise when adjusting the
timing belt.
12) Readjust the timing belt tension.

Refer to Step 9
This will remove any remaining timing belt slack.
13) Tighten the tensioner bolt to the specified torque.
Tensioner Bolt Torque kg·m (lb.ft/N·m)
7.7 ± 1.0 (55.7 ± 3.6/75.5 ± 9.8)
14) Tighten the tension adjusting lever nut 13 and bolt 14 .

Note:
If on-vehicle timing belt replacement is performed, the
crankshaft must not be allowed to turn.
If the crankshaft is allowed to turn, piston and valve
damage will result.
GEAR DRIVE MODEL (4JA1, 4JB1T)

Removal Steps
1. Disconnect the battery ground cable.
2. Disconnect the air cleaner duct.
3. Disconnect the PCV hose.
4. Remove the head cover.
5. Remove the power steering V belt. (if so equipped)
6. Disconnect the accelerator cable and harness from
injection pump.
7. Remove the fuel pipes and injection pipes.
8. Remove the cover of timing gear case cover. (injection
pump side only)
9. Remove the timing hole cover.
10. For ease in reinstalling the injection pump, align the
timing “O” mark on the pump gear with the allow mark
on the timing gear case cover using the crank shaft
turning wrench.
11. Remove the six injection pump mounting bolts from

the timing gear case cover.
12. Remove the rear bracket bolts from the injection pump
bracket.
13. Pull the injection pump together with pump gear free
toward the rear of the engine.
Installation Steps
To install, follow the removal procedure in reverse order
and note the following point.
• Recheck the crankshaft to align the timing mark on the
crank pulley with the TDC mark.
• Install injection pump so that the timing “O” mark on

the pump gear the arrow mark on the timing gear case
cover.
GEAR DRIVE MODEL (4JA1TC, 4JH1TC)

Removal Steps
1. Disconnect the battery ground cable.
2. Remove the intercooler.
3. Separate the air cleaner duct from the air cleaner.
4. Disconnect the radiator upper hose.
5. Remove the air conditioner V-belt.
6. Remove the power steering V-belt.
7. Remove the power steering oil tank. Place the tank in
a safe place.
8. Remove the fuel filter and its bracket.
9. Disconnect the accelerator cable and connector at the
intake duct.
10. Remove the intake duct.
11. Remove the accelerator control lever.
12. Remove the check hole cover from the timing gear
case.
13. Rotate the crank pulley until the scissor gear fixing
hole becomes visible through the check hole (2).
020L200016
14. Insert a lock bolt (M6×1 L=30) into the scissor gear
fixing hole to prevent the scissor gear from turning.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.
020L200018
15. Rotate the crank pulley to align the crank pulley TDC
mark and the timing gear case TDC mark.
16. Look through check hole (1) to confirm that the
injection pump alignment mark is visible. If it is not
visible, turn the crank pulley an additional full turn.
015L200004
020L200017
17. Remove the fuel piping and the injection pipes.

18. Remove the connector from the injection pump.
19. Remove the injection pump mounting bolts (6 bolts)

from the timing gear case.
20. Remove the injection pump bracket.

21. Remove the injection pump and pump gear by pulling
it toward the rear of the engine.
080L200006
Installation Steps
Follow the removal procedure in reverse order.
Pay close attention to the following.
• Be sure to align the crank pulley TDC mark and the
timing gear case TDC mark.
015L200004
• Install the injection pump and pump gear so that the

timing mark (dot) on the pump gear is aligned with the
arrow on the timing gear case cover.
020L200017
Note:
• Do not forget to remove the lock bolt from the
scissor gear. (if you have forgotten to remove the
bolt, the bolt will strike the check hole guides and
the crank pulley will not turn)
• Injection pump Air bleeding is required to start
the engine when the injection pump has been
replaced.
Refer to Injection Pump Air Bleeding (Section 00).
020L200018
INJECTION PUMP CALIBRATION DATA

INJECTION VOLUME ADJUSTMENT
TEST CONDITIONS
Item Condition
Injection nozzle ZEXEL Part No.: 105780-0060
Bosch Type No.: DNOSD1510
Injection nozzle holder ZEXEL Part No.: 105780-2150
2
kg/cm (psi/kPa) 133 (1,891/13,000)
Injection line dimensions mm (in)
Inside diameter 2 (0.079)
Outside diameter 6 (0.236)
Length 450 (17.7)
2
Fuel delivery pressure kg/cm (psi/kPa) 0.2 (2.84/19.6)
Test fuel Bosch Diesel Fuel OL61V11
SAE Standard Test Diesel Fuel (SAE967D)
Test fuel temperature °C (°F) 45 – 50 (113 – 122)
Identification numbers 104746-6192
104746-6162
IDENTIFICATION PLATE AND NUMBER

Use the data following the injection pump identification
number to adjust the injection volume.
INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Engine: 4JB1T
Identification Numbers: 104746-6152 (ISUZU Part Number 8-97132-678-2)
Test Fuel: Standard Diesel Fuel SAE J967D (or ISO 4113)
Governor Adjustment
Timer and Pump Case Pressure

Pump speed Timer piston Pump case pressure Boost pressure
Reference
rpm stroke mm kpa (kg/cm2) kpa (kg/cm2)
750 Below 0.5 73.3 (0.75)
1600 (2.2 ± 0.4) 73.3 (0.75)
1900 4.5 ± 0.2 618 ± 20 (6.3 ± 0.2) 73.3 (0.75) Base
2300 7.0+0.4
-0.3 73.3 (0.75)
Timer Performance Diagram


Engine: 4JA1T
Identification Numbers: 104746-6501 (ISUZU Part Number 8971884490)
Governor Adjustment
Cold Advancer Performance Diagram


Engine: 4JA1
Identification Numbers: 104746-6192
Governor Adjustment


Engine: 4JA1L For SOUTH AFRICA only
Governor Adjustment
080RY00004
080RY00005

Engine: 4JA1L For ARGENTINA only
Governor Adjustment
080RY00006
080RY00007

Engine: 4JG2T
Identification Numbers: 104741-5862
Governor Adjustment

Vacuum Fast Idle Control Device (V-FICD) Adjustment

1. Set the bracket clearance “S” to 1.5 ± 0.5 mm (0.06 ± 0.02 in).
2. Apply 400 mmHg negative pressure to the inside of the actuator.
Check that the actuator shaft moves one complete stroke.
INJECTION NOZZLE
DISASSEMBLY
Disassembly Steps
1. Retaining nut 5. Spring
J 2. Injection nozzle 6. Adjusting shim
3. Spacer 7. Nozzle holder
4. Spring seat
2. Injection nozzle
1) Remove the nozzle assemblies from the nozzle
holders.
Tag the nozzle assemblies and the nozzle holders to
ensure that they are reinstalled in their original
positions.
The nozzle assembly and nozzle holder combinations
must not be interchanged.
2) Immerse the injection nozzles in a tool tray filled with
clean diesel oil to protect them from dust.

inspection.
Injection Nozzle Needle Inspection

1. Remove the nozzle needle from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle body
in clean diesel fuel.
3. Check that the nozzle needle moves smoothly inside
the injection nozzle body.
If the nozzle needle does not move smoothly, it must
be replaced.
Nozzle Body and Needle Valve Inspection

Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if either
of these two conditions are discovered during inspection.
Injection Nozzle Inspection

Use a nozzle tester to check the injection nozzle opening
pressure and the spray condition.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or adjusted.
2
Injection Nozzle Opening Pressure kg/cm (psi/kPa)
4JA1T, 4JA1, 4JB1T 185 (2,631/18,1)
4JB1T
For ARGENTINA and 220 (3,128/21,575)
MALAYSIA only.
If the spray condition is bad, the injection nozzle must be

replaced or repaired.
Spray Condition
Correct
Incorrect (Restrictions in orifice)
Incorrect (Dripping)
REASSEMBLY
Reassembly Steps
1. Nozzle holder 5. Spacer
2. Adjusting shim 6. Injection nozzle
3. Spring J 7. Retaining nut
4. Spring seat
7. Retaining Nut
Tighten the retaining nut to the specified torque.
Retaining Nut Torque kg·m (lb.ft/N·m)
3.5 ± 0.5 (25.3 ± 3.6/34.3 ± 4.9)
Injection Nozzle Adjustment

The fuel injection starting pressure adjustment of this
injection nozzle is done by rereplacing or decreasing or
increasing the number of shims installed.
1) Attach the injection nozzle holder to the injection
nozzle tester.
2) Apply pressure to the nozzle tester to check that the
injection nozzle opens at the specified pressure.
If the injection nozzle does not open at the specified
pressure, install or remove the appropriate number of
ajusting shims to adjust it.
2
Nozzle Opening Pressure kg/cm (psi/MPa)
185 (2,631/18.1)
Adjusting Shim Availability rnm(in)

Range 0.50 – 1.50 (0.02 – 0.06)
Increment 0.025 (0.001)
Total No. of Shims 41
Removing or installing one shim will increase or decrease

3
the nozzle opening pressure approximately 3.77 kg/cm
(53.6 psi/369.46 kPa).
WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PERSON’S SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE
TESTER AT ALL TIMES.
INJECTION NOZZLE
(For 4JG2T Engine)
DISASSEMBLY
Disassembly Steps
J 1. Nozzle holder body 5. Distance piece

2. Adjusting shim J 6. Nozzle assembly
3. Spring 7. Retained nut
4. Push rod
1. Nozzle holder body
Clamp the nozzle holder in a vise and remove the
retaining nut.
6. Nozzle assembly
Keep nozzle assembly removed from the holder body
separated to maintain proper needle valve and body
combinations.

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Injection nozzle needle seizure inspection

1) Remove the injection nozzle needle from the injection
nozzle body.
2) Carefully wash the injection nozzle needle and the
injection nozzle body in clean diesel fuel.
3) Check that the injection needle valve moves smoothly
inside the injection nozzle body.
If the injection needle valve does not move smoothly, it
must be replaced.
Injection nozzle body and injection needle

inspection
Check the injection nozzle body and the injection needle
valve for damage and deformation.
The injection nozzle assembly must be replaced if either of
these two conditions are discovered during inspection.
Injection Nozzle Inspection

Use a nozzle tester to check the injection nozzle opening
pressure and the spray condition.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or adjusted.
2
Injection Nozzle Opening Pressure kg/cm (psi/MPa)
4JG2T 150 (2,133/14.7)
If the spray condition is bad, the injection nozzle must be

replaced or repaired.
Spray Condition
Correct
Incorrect (Restrictions in orifice)
Incorrect (Dripping)
REASSEMBLY
Reassembly Steps
1. Retaining nut 5. Spring
2. Nozzle 6. Adjusting shim
3. Distance piece J 7. Nozzle holder body
4. Push rod
7. Nozzle holder body
Torque 3.0 – 5.0
kg·m (lb.ft/N·m) (21.7 – 36.2/29.4 – 49.0)
INSPECTION AND ADJUSTMENT (AFTER

DISASSEMBLY)
Adjustment of nozzle opening pressure, inspection for
leakage and spray condition should be explained.
Adjustment of nozzle opening pressure

Install injection nozzle and nozzle holder assembly to
nozzle tester.
Adjust the nozzle opening pressure by setting pressure
adjusting shim until desired pressure is obtained.
Check nozzle openinig pressure by pumping tester lever
once per second.
Nozzle opening pressure can be changed by:
1. Change of adjusting shim thickness at the rate of 4.8
kg/cm2 (68.3 psi/470.9 kpa) every thickness change
of adjusting shim by 0.04 mm (0.0016 in.).
2
2. Adding one 0.05 mm shim to increase 6 kg/cm (85.3
psi/588.6 kpa).
Nozzle opening pressure of injection nozzles:
2
150 kg/cm (2,133 psi/14.7 MPa)
Adjusting shims used for injection nozzle assembly.
Adjusting Shim Available mm (in)

IDENTIFICATION
SHIM THICKNESS
MARK ON SHIM
0.50 (0.0197) 50
0.54 (0.0213) 54
↓ ↓
0.94 (0.0370) 94
0.98 (0.0386) 98
1.00 (0.0394) 00
0.05 (0.0020) NONE
INJECTION NOZZLE
(For 4JA1TC, 4JH1TC Engine)
DISASSEMBLY
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
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel enigne 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.
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)
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.
REASSEMBLY AND ADJUSTMENT PROCEDURE
1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2 Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the
closed method.
3 Pre-lift confirmation Confirm pre-lift in accordance with the closed method.
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
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.
First nozzle opening pressure adjustment
Nozzle needle valve full-lift 0.25 mm (0.0098 in)

2
Nozzle needle valve pre-lift 0.04 mm(0.0016 in) at 204 kg/cm (2901 psi, 20,000 kpa)
2
Nozzle pressure 1st Stage 4JA1TC : 199−209 kg/cm (2830−2972 psi, 19.5−20.5 Mpa)
2
4JH1TC : 204−214 kg/cm (2901−3043 psi, 20.0−21.0 Mpa)
2
2nd Stage 4JA1TC : 347−362 kg/cm (4934−5148 psi, 34.0−35.5 Mpa)
2
4JH1TC : 350−365 kg/cm (4977−5190 psi, 34.3−35.8 Mpa)
at lift 0.09 mm (0.0035 in)
= (pre lift + 0.05 mm (0.0020 in))
Injection Nozzle Adjustment

First nozzle opening pressure adjustment
1.Claim the nozzle holder in a vise.
040MV015.tif
2. Install the shim, first spring and spring seat in the

nozzle holder.
040MV016.tif
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017.tif
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018.tif
5. Install the pins in the spacer.

6. Install the nozzle on the spacer.
040MV019.tif
7. Hand-tighten the adjustment retaining nut together

with the gasket to the nozzle holder.
Retaining nut: 157892-3200 (Bosch AS)
Gasket: 157892-5100 (Bosch AS)
(Bosch AS = Bosch Automotive Systems Corporation)
040MV010.tif
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 5.1 kg·m (36.9 Ib·ft/50 N·m)
040MV014-1.tif
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
• Use a micrometer to measure shim thickness.
• Use some combination of 3 adjusting shims to
040MV030.tif adjust the pressure.
• 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
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket: 026508-1140 (Bosch AS)
894227-6020 (ISUZU)
Plug: 157892-1600 (Bosch AS)
040MV013.tif
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (Bosch AS)
040MV012.tif
3. Install the nut on the dial gauge holder.

Nut: 157892-1000 (Bosch AS)
040MV011.tif
4. Install the pin to the dial gauge.
Note:
The lengths of the pins do not include the
threaded portions.
Pin (liter=100 mm): 157892-5200 (Bosch AS)
Dial gauge: 157954-3800 (Bosch AS)
185317-0150 (ISUZU)
040MV029.tif
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
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
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030.tif
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 ± 0.02 (0.0098 ± 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
040M100004
2. Read the needle valve lift ‘liter’ from the dial gauge
indication (once the needle valve has descended when
the second spring has stopped operating). Refer to the
pre-lift measuring point for ‘liter’.
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
2
1 MPa (10 kg/cm ).
Pre-lift mm
2
Pressure kg/cm Lift mm (in)
(psi/kpa)
040H100007
204 (2,901/20,000) 0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.
3. Confirm that pre-lift ‘liter’ is as specified.
040MV005.tif
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit
105017-2990 (Bosch AS)
897302-3070 (ISUZU)
040MV031.tif
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzle’s needle valve moves
through its full lift.
040MV030.tif
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
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift liter + 0.05 mm).
Second Nozzle Opening Pressure
2
Lift mm (in) Pressure kg/cm (psi/Mpa)
347 – 362
4JA1TC
(4934−5148/34.0−35.5)
0.09 (0.0035)
350 – 365
040M100006 4JH1TC
(4977−5190/34.3−35.8)
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.
• Second nozzle opening pressure adjusting shims

Part No. Thickness Part No. Thickness
(ISUZU) (mm) (ISUZU) (mm)
897116-0290 0.10 897116-0380 0.53
897116-0320 0.20 897116-0390 0.54
897116-0330 0.30 897116-0400 0.55
897116-0340 0.40 897116-0410 0.56
897116-0350 0.50 897116-0420 0.57
897116-0360 0.51 897116-0430 0.58
897116-0370 0.52 897116-0440 0.59
040LX009.tif
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 7.0 kg·m (50.6 Ib·ft/69 N·m)
040MV014-1.tif
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
ADJUSTMENT PROCEDURE FOR POTENTIOMETER

Development view of Potentiometer
1. Advance Assembly (CSD)

Remove the advance assembly from the injection pump
assembly.
2. Digital Volt Meter and DC Constant Voltage Power

Supply.
1) Connect digital volt meter to B and C connector on
wire harness from potentiometer.
2) Connect DC constant voltage power supply to A (for
positive electricity) and C (for negative electricity)
connector on wire harness from potentiometer.
3) Supply DC 10V to between A and C connector.
4) Measure the output voltage from potentiometer at
idling position on the fuel control lever.
Idling Position Output Voltage Volt
Until 99 Model From 00 Model
4JA1T 1.62 ± 0.45 2.12 ± 0.45
4JG2T 1.41 ± 0.45 1.41 ± 0.45
5) Measure the output voltage from potentiometer at full

load position on the fuel control lever.
Full Load Position Output Voltage Volt
Until 99 Model From 00 Model
4JA1T 7.7 ± 0.45 4.1 ± 0.03
4JG2T - 3.65 ± 0.03
3. Adjustment of Output Voltage from Potentiometer

If the Measuring value is without standard above, readjust
setting position of the potentiometer as below.
1) Loose the potentiometer fixing bolts.
2) Keep fuel control lever on idling position then move
the potentiometer until reading the output voltage
within standard.
3) Same time read the output voltage with full load
position on the control lever.
4) Make sure that fuel control lever return to idling
position by return spring.
5) Fix the advance assembly to the injection pump

assembly.
Note:
If can not be readjusted potentiometer output voltage,
recommend to contact Zexel or Bosch argent near
your garage.
INDEX
ENGINE ELECTRICAL 6D – 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description......................................................................................................... 6D - 3
Wire Coding...................................................................................................................... 6D - 5
Symbols and Abbreviations............................................................................................ 6D - 7
Torque Specifications ..................................................................................................... 6D - 9
Generator.......................................................................................................................... 6D - 10
Removal and Installation ............................................................................................ 6D - 10
Disassembly................................................................................................................. 6D - 12
Inspection and Repair ................................................................................................. 6D - 15
Reassembly.................................................................................................................. 6D - 22
Starter Motor .................................................................................................................... 6D - 26
Removal and Installation ............................................................................................ 6D - 26
Disassembly................................................................................................................. 6D - 27
Reassembly.................................................................................................................. 6D - 35
Pre-heating System ......................................................................................................... 6D - 38
Troubleshooting .............................................................................................................. 6D - 41
QOSll Preheating System................................................................................................ 6D - 51
QOSll System Troubleshooting...................................................................................... 6D - 54
6D – 2 ENGINE ELECTRICAL

Description
Item 4JA1TC, 4JH1TC 4JA1, 4JA1T (L), 4JB1T 4JG2T
General Option General Option General
Generator
Type AC brush with IC regulator and vacuum pump
Voltage V 12
Drive and rotation V-belt, clockwise viewed from the drive pulley
Ground polarity Negative
Maximum output A 60 80 40 50 80 60
at 5,000 rpm at 5,000 rpm at 5,000 at 5,000 at 5,000 at 6,000 rpm
rpm rpm rpm
Engine speed ratio to 1 1.77 1.85 1.77
Maximum speed rpm 11,000 11,000 11,000 9,500 11,000
Starter Motor
Type Solenoid controlled
Rated voltage V 12
Rated output kW 2.3 2.8
Load characteristics
Terminal voltage V 8.76
Load current A 300
Vacuum Pump
3
Delivery volume cm /rev 30 50
500 mmHg build up time 35 seconds or less at 1,000 rpm 21 seconds or
less at
1,000 rpm
7~10 seconds or less at 5,000 rpm
Maximum vacuum 680 mmHg or more at 5,000 650 mmHg or more at 5,000 rpm
rpm
Weight kg(lb) 0.65 (1.43) 0.9 (1.99) 1.2 (2.6)
GENERAL DESCRIPTION
GENERATOR STARTER MOTOR
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, starter switch with safety
lock, etc. The starter motor circuit utilizes negative ground polarity.
CHARGING CIRCUIT DIAGRAM
STARTING CIRCUIT DIAGRAM

WIRE CODING
DESCRIPTION
Codes used in the circuit diagram represent wire size and
color .
Example: 0.5 R
Wire color (Red)

2
Wire size (0.5 mm )
WIRE SIZE
Wire size is specified with the metric gauge system.
The metric gauge system gives the wire size in cross-
sectional area measured in square millimeters.
WIRE SIZE SPECIFICATIONS
Wire size Number of wires/ Resistance at normal room Maximum allowable

2
Wire diameter temperature of 20°C (68°F) current
mm AWG mm (in.) Ω/m (Ω/ft.) A
0.5 20 7/0.32 (0.013) 0.03250 (0.00991) 11.3
0.85 18 11/0.32 (0.013) 0.02050 (0.00625) 14.8
1.25 16 16/0.32 (0.013) 0.01410 (0.00430) 18.8
2 14 26/0.32 (0.013) 0.00867 (0.00264) 25.4
3 12 41/0.32 (0.013) 0.00550 (0.00168) 34.2
5 10 65/0.32 (0.013) 0.00347 (0.00106) 45.9
8 8 50/0.45 (0.018) 0.00228 (0.00070) 59.8
15 6 84/0.45 (0.018) 0.00136 (0.00042) 82.8
20 4 41/0.80 (0.031) 0.00087 (0.00027) 110.9
30 2 70/0.80 (0.031) 0.00051 (0.00016) 147.0
WIRE COLOR
All wires have color-coded insulation.
Wires belonging to a system’s main harness will have a
single color .
Wires belonging to a system’s sub-circuits will have a
colored stripe .
Striped wires use the following code to show wire size and
colors.
Example: 0.5 G R
2
Wire size (0.5 mm )
Green (Base color)
Red (Stripe color)
Abbreviations are used to indicate wire color within a

circuit diagram.
Refer to the following table.
WIRE COLOR-CODING
Color-coding Meaning Circuits

B Black Starter circuit and grounding circuit
W White Charging circuit
R Red Lighting circuit
G Green Signal circuit
Y Yellow Instrument circuit
L Blue Wiper circuit
O Orange
Br Brown
Lg Light green
Gy Grey Other circuits
P Pink
Sb Sky blue
V Violet
SYMBOLS AND ABBREVIATIONS

DESCRIPTION
The symbols and abbreviations used in the circuit diagram
make the diagram easier to read and understand.
SYMBOLS
The illustration at the left shows a typical symbol used
in circuit diagrams.
SYMBOL AND MEANING
Symbol Meaning Symbol Meaning
Fuse Single filament bulb
Main fuse Double filament bulb
Fusible link wire Motor
Switch Variable resistor
Switch Coil (Inductor)

Symbol Meaning Symbol Meaning

Relay
Contact wiring Note:
Relay contact shown in the
wiring diagram indicates
condition before actuation.
Battery
Diode Connector
Electronic part Light emitting diode
Resistor Reed switch
Speaker Condenser
ABBREVIATIONS
The illustration at the left shows a typical abbreviation
used in circuit diagrams.
These same abbreviations may also appear in the next.
ABBREVIATION AND MEANING
Abbreviation Meaning Abbreviation Meaning

RH Right-hand side STD Standard equipment
LH Left-hand side OPT Optional equipment
SW Switch W/ With
M/T Manual transmission WO/ Without
A/T Automatic transmission OD Overdrive
FT Front ACC Accessories
RR Rear A/C Air conditioner
FLW Fusible link wire ATF Automatic transmission fluid
TEMP Temperature VSV Vacuum switching valve
ECM Electronic control module
GENERATOR kg m(ft. lbs/N m)
0.65 ± 0.5(4.7 ± 3.6/6.3 ± 4.9)
STARTER MOTOR kg m(ft. lbs/N m)

GENERATOR
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
Remove the generator bolt and the generator from the
bracket.
Important Operations-Installation
Generator
1) Install the generator to the bracket.
2) Tighten the generator bolt to the specified torque.
Generator Bolt Torque kg·m (lb·ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.6 ± 4.9)
4.1 ± 0.6 (29.6 ± 4.3/40.2 ± 5.9)
066L200001
Cooling Fan Belt

1) Hold the generator toward the engine.
2) Install the fan belt to the three pulleys.
(1) Crankshaft pulley
(2) Water pump pulley
(3) Generator pulley
3) Adjust the fan belt tension

(1) Use a bar to pull the generator away from the
engine as far as possible.
(2) Use your hand to apply a pressure of 10 kg (22
lb/98N) to the area of the fan belt indicated by the
arrow in the illustration.
There should be from 8 – 12 mm (0.3 – 0.5 in) of
belt deflection.
4) Tighten the adjusting plate bolts to the specified

torque.
Pulley Nut Torque kg·m (lb·ft/N·m)

1.9 ± 0.5 (13.7 ± 3.6/18.3 ± 4.9)
5) Reconnect the battery cable to the battery.

DISASSEMBLY
Disassembly Steps
J 1. Vacuum pump 14. Front cover

J 2. Cover 15. Ball bearing
J 3. Brush 16. Bearing retainer
J 4. Through bolt 17. Screw
J 5. Pulley assembly J 18. Terminal bolt and nut
6. Pulley nut 19. Condenser
7. Pulley J 20. Rear cover
8. Fan J 21. Stator
J 9. Rotor assembly J 22. Diode
10. Spacer 23. Holder plate
11. Ball bearing 24. Brush holder
12. Rotor J 25. IC regulator assembly
J 13. Front cover assembly 26. Lead wire
1. Vacuum Pump
1) Loosen the vacuum pump fixing bolts.
2) Support the vacuum pump center plate.
3) Carefully remove the vacuum pump.
2. Cover
3. Brush
1) Remove the cover.
2) Remove the brush fixing bolts.
3) Remove the brushes from the brush holder.
4. Through Bolt
9. Rotor Assembly
1) Loosen the through bolts.
2) Remove the rotor and front cover assembly from the
stator and rear cover assembly.
Do not allow the stator to separate from the rear
cover.
Take care not to damage the oil seal.
3) Tape the rotor splines to protect them from damage.
5. Pulley Assembly
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.
13. Front Cover Assembly

1. Remove the front cover bearing retainer screws.
2. Remove the bearing.
18. Terminal Nut and Bolt

20. Rear Cover
21. Stator
22. Diode
1) Loosen the terminal nuts and bolts.
2) Remove the insulators and the washers.
3) Remove the stator together with the diodes.
4) Disconnect the stator coil leads between each diode
and the N-terminal by melting the solder connection.
Hold the lead wire between the solder and the diode
with a pair of long nose pliers.
This will prevent heat transfer and resultant damage to
the diode.
25. IC Regulator Assembly

1) Melt away the solder from the IC regulator holder plate
terminal.
2) Remove the IC regulator assembly.
Remove the center plate, rotor and vane in the vacuum

pump.

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.
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)
If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.
3. Measure the rotor coil resistance.

Rotor Coil Resistance at 20°C (68°F) ohms
Standard 4.2
4. Check for continuity between the slip rings and the

rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.
STATOR COIL ASSEMBLY

1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal “N” and the Coil Ends
(Reference) ohms
Standard 0.1
2. Check for continuity between each stator coils and the

stator core.
If there is continuity, the stator coils must be replaced.
BRUSH
Each brush has a line to indicate whether or not the brush
is serviceable.
If the line is not visible, the brush must be replaced.
Brush Length (Reference) mm (in)
Standard Limit
20 (0.8) 6 (0.2)
DIODE
1. Check for continuity between the battery and each of
the three stator coil lead terminals.
If there is continuity, the diode is normal.
If there is no continuity, the diode must be replaced.
2. Reverse the polarity of the test probes.
If there is no continuity, the diode is normal.
If there is continuity, the diode must be replaced.
IC REGULATOR
The IC regulator may be tested with either a circuit tester
or a pair of standard voltmeters.
Refer to the illustration.
(1) Circuit tester (or voltmeter) range is from 0 to 50 volts
in 0.5 volt increments.
(2) Two 12-volt batteries are required.
(3) Note the variable resistor.
(4) This resistor is rated at 100 watts or 3 ohms.
Testing the IC Regulator
Refer to the wiring diagram in the illustration when testing
the IC regulator.
1. Connect the batteries in series.

2. Measure the battery power (Voltage).
Battery Power V
20 – 26
3. Connect the circuit tester (or voltmeter V2) as shown

in the illustration.
4. Set the variable resistor (3) to zero.
5. Slowly increase the resistance of the variable resistor
toward the build-up point.
Measure the voltage between E and F.
As long as the resistance is below the build-up point,
the voltage reading should be stable and less than two
volts.
When the resistance exceeds the build-up point, the
voltage reading should be two volts or greater.
If the voltage does not exceed two volts after reaching
the build-up point, the IC regulator must be replaced.
6. Return the variable resistor to zero.
7. Connect the circuit tester (or voltmeter V1) as shown
in the illustration.
8. Measure the voltage at terminals S, L, and E.
9. Slowly increase the resistance of the variable resistor.
Note the point at which the voltage quickly builds up to
between 2 and 6 volts.
This will indicate the point at which the voltage
regulator begins to function.
If the measured voltage is outside the specified range,
the voltage regulator must be replaced.
10. Repeat Steps 3 through 5 to measure the voltage

between terminals B, L, and E.
Refer to the illustration.
The regulator voltage should be between 0.5 and 3
volts higher than the measured voltage.
If the regulator voltage is outside this range, the
voltage regulator must be replaced.
Oil Seal
Check the rear cover oil seal bore for oil leakage.
Oil Seal Replacement

1. Use a screwdriver to remove the oil seal from the rear
cover side.
Take care not to damage the oil seal bore.
2. Discard the used oil seal.
3. Use the oil seal installer to install the new oil seal.
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.
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 kg/cm (psi/kPa)
1-5 (14 – 71/98 - 490)
Check for air leakage from the check valve.

If there is air leakage, the valve must be replaced.
Vacuum Pump Reassembly

1. Install the vanes to the rotor slits.
The rounded side of the vanes must be facing the
rotor housing.
2. Install the rotor with the concave side facing the center
plate.
3. Install the center plate to the rotor housing.

Be sure to use a new O-ring.
REASSEMBLY
Reassembly Steps
1. Rear cover 14. Bearing retainer
J 2. Lead wire J 15. Rotor assembly
J 3. IC regulator assembly 16. Ball bearing
4. Brush holder 17. Rotor
5. Holder plate 18. Spacer
J 6. Diode J 19. Pulley assembly
J 7. Stator 20. Fan
8. Screw 21. Pulley
9. Condenser 22. Nut and washer
10. Terminal bolt and nut J 23. Through bolt
11. Front cover assembly J 24. Brush
12. Front cover J 25. Cover
13. Ball bearing J 26. Vacuum pump
2. Lead Wire
3. IC Regulator
Solder the IC regulator lead wires.
6. Diode
7. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the diode leads.
Finish the work as quickly as possible to prevent the diode
from heat transferred by the soldering.
15. Rotor Assembly

19. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque kg⋅m(lb⋅ft)
5.0 ± 1.0 (36.2 ± 7.2/49.0 ± 9.8)
Remove the tape from the splines.
23. 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 kg⋅m(lb⋅ft)
0.65 ± 0.5 (4.7 ± 3.6/6.3 ± 4.9)
24. Brush
Install the brush into the brush holders.
25. Cover
Install the brush cover and tighten the cover bolts to the
specified torque.
Brush Cover Bolt Torque kg⋅m(lb⋅ft)
0.35 ± 0.5 (2.5 ± 3.6/3.4 ± 5.0)
26. Vaccum Pump

Position the rotor, with the serrated boss turned up, on the
center plate and housing.
Align the holes in the center plate and the rotor.
Install vanes into slits in rotor.

The vanes should be installed with the chamfered side
facing outward.
Install the vacuum pump housing.

Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.
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 kg⋅m(lb⋅ft)
0.65 ± 0.5 (4.7 ± 3.6/6.3 ± 4.9)
STARTER MOTOR
begin.
Important Operations - Removal

Starter Motor
1) Disconnect the battery cable and the ground cable at
the battery terminals.
2) Disconnect the magnetic switch cable at the terminal
bolts.
3) Disconnect the battery cable at the starter motor and
4) Remove the starter motor from the engine.

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 kg⋅m(lb⋅ft/N⋅m)
7 ± 1 (50.6 ± 7.2/68.7 ± 9.8)
3) Reconnect the battery cable at the starter motor and

4) Reconnect the battery cable and the ground cable at
the battery terminals.
DISASSEMBLY
Disassembly Steps
J 1. Lead wire J 14. Armature

2. Bolt 15. Screw
J 3. Magnetic switch assembly J 16. Bearing retainer
4. Torsion spring J 17. Pinion assembly
5. Plunger 18. Pinion stopper clip
6. Adjusting shims 19. Pinion stopper
7. Magnetic switch 20. Return spring
J 8. Screw 21. Pinion shaft
J 9. Through bolt 22. Clutch
J 10. Rear cover J 23. Dust cover
J 11. Motor assembly J 24. Shift lever
J 12. Brush holder J 25. Gear case
J 13. Yoke
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
3. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove the
switch from the shift lever.
Remove the torsion spring from the magnetic switch.
8. Screw
9. Through Bolt
10. Rear Cover
Remove the through bolts, then remove the rear cover.
11. Motor Assembly

Remove the four brushes from the brush holders.
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.
12. Brush Holder

13. Yoke
14. Armature
Remove the brush holder and pull out the armature
assembly free from the yoke.
16. Bearing Retainer

17. Pinion Assembly
23. Dust Cover
24. Shift Lever
25. Gear Case
1. Remove the bearing retainer.
2. Remove the pinion from the gear case.
3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.

inspection.
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
0.02 (0.001) 0.05 (0.002)
2. Check the commutator mica segments for excessive

wear.
3. Measure the mica segment depth.
Mica Segment Depth mm (in)
Standard Limit
0.7 – 0.9 (0.028 – 0.035) 0.2 (0.01)
If the mica segment depth is less than the standard but

more than the limit, the commutator may be reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
4. Measure the commutator outside diameter.

Commutator Outside Diameter mm (in)
Standard Limit
35 (1.4) 34 (1.3)
If the measured outside diameter is less than the specified

limit, the commutator must be replaced.
5. Test the armature for short circuiting.

a. Place the armature in a growler tester.
b. Hold a hacksaw blade against the armature core.
If the armature has a short circuit, the hacksaw blade
will vibrate.
Replace the armature if there is a short circuit.
6. 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.
7. Use the circuit tester to check the armature for

continuity.
1) Hold the circuit tester probes against two armature
core segments.
2) Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the armature core.
If there is not, the armature must be replaced.
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.
2. Use the circuit tester to check the field winding

continuity.
1) Hold one circuit tester probe against the “C”
terminal lead wire.
2) Hold the other circuit tester probe against the field
winding brush.
There should be continuity.
If there is no continuity, the yoke must be replaced.
BRUSH AND BRUSH HOLDER

1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
14.5 (0.57) 9.5 (0.37)
2. Use a circuit tester to check the brush holder

insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.
3. Inspect the brushes for excessive wear.

If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, only the
brushes must be replaced.
1) Use a pair of side cutters to cut the lead wire from

the brush.
2) File away any foreign material clinging to the edge
of the lead wire.
3) Remove the brushes from the brush holder.
4) Install the new brushes.
5) Straighten the bent portion of the clip.

6) File away any foreign material clinging to the clip
surface.
7) Place the lead wire in the clip.

8) Bend the clip shut.
9) Solder the brush lead.
10) Repeat the procedure for each of the brushes.
OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “C”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
Temporarily connect the solenoid switch between the

clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the C terminal. When current is applied to
the 50 terminal from the battery positive terminal, the
pinion should flutter.
2. Hold-in Maintenance Test

Disconnect the lead at the C terminal. The pinion should
continue to flutter.
3. Return Test
Connect the battery negative leads to the starter body and
the 50 terminal.
Connect the battery positive lead at the C terminal.
The pinion should return to its home position.
REASSEMBLY
Reassembly Steps
J 1. Magnetic switch assembly 14. Pinion stopper

2. Magnetic switch 15. Pinion stopper clip
3. Adjusting shims 16. Bearing retainer
4. Plunger 17. Screw
5. Torsion spring 18. Motor assembly
6. Shift lever 19. Armature
J 7. Gear case 20. Yoke
J 8. Dust cover J 21. Brush holder
9. Bolt 22. Rear cover
J 10. Pinion assembly 23. Screw
11. Clutch J 24. Through bolt
12. Pinion shaft J 25. Lead wire
13. Rerurn spring
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.
7. Gear Case
8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
Dust Cover Bolt Torque kg⋅m(lb⋅ft/N⋅m)

0.75 ± 0.5 (5.4 ± 3.6/7.4 ± 5)
10. Pinion Assembly

Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
21. Brush Holders

1. Install the brushes into the brush holder with raising
the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of

the yoke and the brush holder.
24. Through Bolt

Install the through bolts in the rear cover and tighten them
Through Bolt Torque kg⋅m(lb⋅ft/N⋅m)
0.6 ± 0.1 (4.3 ± 0.7/5.9 ± 1.0)
25. Lead Wire

Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque kg⋅m(lb⋅ft)
0.8 ± 0.1 (5.8 ± 0.7/7.8 ± 1.0)
Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.3 - 1.5 (0.01 – 0.06)
In a case where the pinion gap outside the

specified value;
Make an adjustment using a shim(s).
Adjusting shims are available in 0.5 mm and 0.8 mm (0.02 and
0.03 in.) sizes.
PRE-HEATING SYSTEM
inspection.
SYSTEM CIRCUIT
Visual Check
Check the main fuses and the glow indicator for damage.
Replace the part(s) if required.
GLOW TIMER
The glow timer is initially activated by the starter switch.
Thereafter, signals from the thermoswitch reach the glow
timer to control the glow plug relay operation time.
The thermoswitch and timer unit also act to protect the
battery in the event the starter key is engaged for an
excessively long time.
Glow Timer Operation

1. Disconnect the lead wires at the thermoswitch.
2. Connect a voltmeter between the glow plug and
ground.
3. Turn the starter switch from “OFF” to “ON”.
The engine must be stopped.
4. Note the time the glow indicator remains on.

If the glow indicator remains on for approximately 1~6
seconds (4JG2T Engine model) or 3.5 seconds (4JA1,
4JB1T Engine model), the glow timer “ON” time is
normal.
If the glow indicator does not remain on for
approximately 1~6 seconds or 3.5 seconds, trouble in
the glow timer or, the glow relay, is indicated.
5. Return the starter switch to “OFF”.
GLOW RELAY
The glow relay is located near the fuse box in the engine
compartment.
Use an ohmmeter to measure the resistance between

terminals No. 3 and No. 4.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistnace Ohms
10 - 15
THERMO SWITCH/THERMO SENSOR

The thermo switch or thermo sensor are located on the
water outlet pipe.
Use a circuit tester to check the thermo switch for

continuity.
• Thermo switch (4JA1, 4JB1T engine)
OFF → ON : 7 - 13°C (44.6 – 55.4°F)
ON → OFF : Below 3°C (37.4°F)
• Thermo sensor (4JG2T engine)

Thermo Sensor Resistance K-Ohm
Temperature Temperature
Resistance Resistance
°C (°F) °C (°F)
-15 (5) 12.00 40 (104) 1.10
0 (32) 6.00 60 (140) 0.60
10 (50) 3.60 80 (176) 0.30
20 (68) 2.45
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Check each of the glow plugs for continuity.
TROUBLESHOOTING (For Charging and Starting system)

Refer to this Section to quickly diagnose and repair electrical problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into two Sub-Sections:
I. Battery Charging and Noise Problems
1. No Charging
2. Overcharging
3. Undercharging
4. Unstable Charging Current
5. Noise
II. Hard Starting
1. Pinion Does Not Engage The Ring Gear When The Starter Switch Is Turned On
2. Pinion Engages The Ring Gear But The Engine Does Not Turn Over
3. Incorrect Pinion And Ring Gear Engagement
4. Starter Continues To Run After The Starter Switch Is Turned Off
5. Excessive Commutator Sparking
I. BATTERY CHARGING AND NOISE PROBLEMS

1. NO CHARGING
NG
Terminals and connectors Broken or defective Repair the push rod play
OK
NG
Ground connections Poorly grounded Correct
OK
NG
Brush with slip ring Poor contact Repair or replace
OK
NG
Generator stator coil Open or scorched Replace
OK
NG
Generator rotor coil Open or scorched Replace
OK
NG
Generator diode Defective Replace
OK
NG
IC regulator Defective Replace
2. OVERCHARGING
NG
B and F terminal circuit Shorted Repair
OK
NG
IC regulator Excessive voltage Replace
3. UNDERCHARGING
NG
Battery terminals Loosely connected Retighten
OK
NG
Drive belt Slippage Adjust or replace
OK
NG Replace or repair the brush

Brush and slip ring contact Intermittent
holder assembly
OK
NG
Generator rotor coil Short circuit Repair or replace
OK
NG
Generator stator coil Short or open circuit Repair or replace
OK
NG
Generator diode Defective Replace
OK
NG
IC regulator Insufficient voltage Replace
OK
NG Use a higher capacity alternator

Electrical load Excessive or reduce the accessory load
4. UNSTABLE CHARGING CURRENT
NG
Terminals and connectors Broken or defective Repair the push rod play
OK
NG
Drive belt Loose Tighten (Readjust)
OK
NG
Brush with slip ring Poor contact Repair or replace
OK
NG
Generator rotor coil Open or short circuit Repair or replace
OK
NG
Generator stator coil Open or short circuit Repair or replace
OK
Stator coil and diode NG

Loose Repair
connections
OK
NG
IC regulator Defective Replace
5. NOISE
NG
Part mounting fasteners Loose Tighten
OK
NG
Drive belt Defective Replace
OK
NG
Bearing Defective Replace
OK
NG
Diode Defective Replace
OK
NG
Stator coil Short circuited Repair or replace
II. HARD STARTING

1. PINION DOES NOT ENGAGE THE RING GEAR WHEN THE STARTER SWITCH IS
TURNED ON
NG
Battery Discharged Recharge
OK
NG
Starter circuit Open or intermittent Clean and reconnect
OK
NG
Magnetic solenoid switch Contact points defective Replace
OK
NG
Magnetic solenoid coil Open or scorched Replace
OK
NG
Plunger shaft Bent or scorched Bent or scorched
2. PINION ENGAGES THE RING GEAR BUT THE ENGINE DOES NOT TURN OVER
NG
Battery Weak Recharge
OK
Brush and commutator face NG

Intermittent Repair or replace
contact
NG
Face dirty Clean
OK
NG
Pinion clutch Slippage Replace
OK
NG
Armature field coil Open or short circuit Repair of replace
3. INCORRECT PINION AND RING GEAR ENGAGEMENT
NG
Battery Discharged Recharge
OK
NG
Pinion and ring gear teeth Worn or broken Replace
OK
NG
Pinion gear return movement Incorrect Adjust
4. STARTER CONTINUES TO RUN AFTER THE STARTER SWITCH IS TURNED OFF
Magnetic solenoid switch NG

Seized Repair or replace
contact points
OK
NG
Starter switch Defective Replace
5. EXCESSIVE COMMUTATOR SPARKING
Brush and commutator face NG

Intermittent Repair or replace
contact
NG
Slag accumulation on the face Clean or replace
OK
NG
Commutator Excessive wear or pitting Repair or replace
NG
Loose solder Clean and repair
OK
NG
Armature shaft Run-out due to worn bearing Repair
OK
NG
Brush holder Loose in mount Repair
QOS II PREHEATING SYSTEM

GENERAL DESCRIPTION
QOS II preheating system features a quick-on glow With the employment of the thermoswitch, the glow
plug with thermometer control of the glowing time and time changes according to the engine coolant
the afterglow time function. temperature, thus allowing optimum starting conditions
to be obtained.
The system consists of a controller, indicator lamp,
thermoswitch, relay, and glow plug (4pcs).
SYSTEM DIAGRAM
QOS II Timing Chart

Inspection on QOS II System Operation

THERMO SWITCH
The thermo switch is located on the water outlet pipe.
Use a circuit tester to check the thermo switch for

continuity.
Thermo sensor (4JA1, 4JA1T, 4JG2T engine)
OFF → ON : 7 - 13°C (44.6 – 55.4°F)
ON → OFF : Below 3°C (37.4°F)
10°C ON
OFF
3°C
Thermo sensor (4JG2T engine)

Thermo Sensor Resistance K-Ohm
Temperature Temperature
Resistance Resistance
°C (°F) °C (°F)
-15 (5) 12.00 40 (104) 1.10
0 (32) 6.00 60 (140) 0.60
10 (50) 3.60 80 (176) 0.30
20 (68) 2.45
GLOW PLUG
Use a circuit tester to test the glow glugs for continuity.
Glow plug Resistance (Reference) Ohms
Quick on start model Approximately 0.9
QOS II SYSTEM TROUBLESHOOTING
1) Problems when the water temperature of the engine is 0°C or below.
Condition Cause Circuit

Glow plug relay will Bad connection of FLW between battery and starter. 3
not be lit.
Bad connection or disconnection of starter SW circuit
Bad connection or disconnection Malfunction of other
of Fuse No . 8 circuits occurred 2
simultaneously.
Bad starter switch.
Bad connection of glow plug relay terminal. 1
Disconnection of glow plug relay excitation coil.
Disconnection of circuit between glow plug relay and timer. 6
Bad glow relay. (The main contact does not pass electricity.)
Bad connection of timer.
Bad timer.
Bad earth circuit of timer. 7
Bad thermoswitch. (It remains ON even in water temperature below 0°C.)
Earth short-circuiting of thermo SW. 7

Through glow plug Bad connection of FLW between battery and glow relay. 1
relay turns ON,
Bad connection or disconnection in preheating circuit of glow relay main contact
preheating is not
terminal connector.
done.
Bad connection between plug connector and preheating circuit 9
Glow plug relay Bad timer.
turns ON, but does
Bad timer. Short circuiting in circuit or earth between 5 terminal and glow relay. 6
not go OFF.
Bad glow relay.
Indication lamp is Bad timer.
not lit.
Burning-out of light bulb. 8
Note: Circuit No. in rectangle is shown in the previous pre-heating chart.
2) Problems when the time water temperature of the engine is 0°C or above.
Indicator lamp is Bad timer
not lit
Burning-out of bulb. 8
Turn glow relay Bad thermoswitch or disconnection of thermo SW circuit. 4
ON. (Indicator will light up for 3.5 seconds.)
Bad timer.
Bad timer. Short-circuiting in circuit or earth between terminal 5 and glow relay.
Note: Circuit No. in rectangle is shown in the previous pre-heating chart.
3) Burning-out of glow plug

When only one line is burned out, it has no effect on the start up of the engine. Even if one line is burned out,
judging from the characteristics of the glow plug, the impressed voltage will change only slightly. Therefore, no
judgment can be made by normal testing while the glow plug is installed. In order to check for disconnections
and burn-outs, the glow plugs will have to be removed from the connectors and checked one by one for
continuity.
ENGINE WARMING-UP SYSTEM

GENERAL DESCRIPTION
The engine warm-up system is a device which changes the openning of the throttle valve for intake in accordance
with the engine rpm, controls the amount of the intake air, and changes the air ratio which is supplied to the cylinder.
The device is also provided with such functions as to measure the amount of heat capacity, to close the exhaust
throttle valve to raise the exhaust pressure, and to accelerate the rise in compression and temperature, and the
increase of fuel.
Operation of each device when warming-up switch is ON position.

Temp. sw. Vacuum switching valve
Accel EXH. Intake
Ambient sw. FICD
sw. 1 2 FICD. valve valve
Half sw. (only 4JA1)
NOT
One of above sw. OFF - OFF OFF OFF Open Open
Working
OFF ON OFF ON Full Close Close Working
All of above sw. ON
ON ON ON ON Half Close Close Working
ENGINE WARMING-UP SYSTEM CIRCUIT

Type A
Type B
TROUBLE SHOOTING
QUICK CHART FOR CHECK POINT
ENGINE WARMING-UP
When this system is out of order, checking as follows.
Checking parts Switch VSV Throttle
ENG. Warming Cable
Engine Ambient Half Accel FICD
Thermo Accel up Indicator 1 2 INT EXH harness
Trouble mode warming up temperature (only 4JA1)
The indicator light does not
light when switch is ON ¡ ¡ ¡ ¡
position.
The system does not operate ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡
Abbreviation
V.S.V. ; Vacuum switching valve
FICD ; Fast idle control device
INT ; Intake
EX ; Exhaust

Make necessary correction or parts replacement if wear,
damage or any other abnormal conditions are found
through inspection.
Engine Warming Up Switch

1. Inspect the switch continuity by following table.
Terminal

SW position
ON ¡ ¡ ¡
OFF ¡ ¡
2. Make sure the indicator light turns on, when the engine
warming up switch is “ON” with engine running.
Thermo Switch/Ambient Temp. Switch

1. Submerge end of switch in water.
2. Connect circuit tester to the connector terminals.
3. Use a burner to heat the water.
4. Check the continuity test across.
Operating temperature
Thermo Ambient temp.
OFF → ON 73°C or less 8°C or less
ON → OFF About 80°C About 15°C
Accel Switch
Half accel switch (only 4JA1T)
1. Connect a circuit tester to the connector terminals.
2. Check the Continuity test across.
Operating
Position
Free Push
Accel switch Continuity Not continuity
Half accel switch Not continuity Continuity
Vacuum switch valve (VSV)

Use a circuit tester to measure the V.S.V. resistance.
V.S.V. Resistance at 20°C
Approx. 40Ω
If the resistance is not within specification replace it.
Vacuum Control Valve

Check the control valve operating pressure.
1. Make sure that port (X) is open to the atmosphere (no
obstructions).
2. Apply a constant pressure of − 500 mmHg to port (Z).
3. Apply a pressure of − 155 mmHg to port (S).
Measure the valve operating pressure at port (Y).
Valve Operating Pressure mmHg
Standard reading 0 to − 100
4. Apply a pressure of − 75 mmHg to port (S).

Measure the valve operating pressure at port (Y).
Valve Operating Pressure mmHg
Standard reading − 400 to − 500
Vacuum Regulator Valve

Check the vacuum regulator valve operating pressure.
1. Apply a pressure of − 450 mmHg (− 17.7 Hg) to port
(S).
Measure the regulator pressure at port (Z).
Regulator Operating Pressure mmHg (Hg)

Standard reading − 235 to − 265 (− 9.3 to − 10.4)
Half Accel. Switch Adjustment (only 4JA1T)

1. Insert a feeler gauge of 6 mm thickness between the
idle adjust screw end and control lever (A).
2. Loosen each bolts ( & ).
3. Set the circuit tester to micro-switch harness.
4. Find out the just continuity from OFF to ON position
with moving the micro-switch in the direction of the
arrow.
5. Tigten each bolts ( & ).
Half Accel. Switch (on the vehicle)

Inspection
1. Connect a circuit tester to the half accel. switch
connector terminals.
2. Operate control lever slowly to a point where continuity
is switched over from “ON” to “OFF”. Then measure
the clearance between the idle stopper bolt (A) and
control lever (B).
Standard clearance mm (in) 5.0 - 7.8 (0.2 - 0.3)
If the clearance is out of the range, the switch must be

adjusted.
Adjustment
1. Insert a feeler gauge of specified thickness between
the idle stopper bolt (A) and control lever (B).
Adjustment clearance mm (in) 5.0 (0.2)
2. Loosen two switch bolts.

3. Connect a circuit tester to the switch connector
terminals.
4. Moving the switch in directions indicated by arrows.

Check to make sure of the point where continuity is
cut.
5. Tighten the two bolts & .
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INDEX
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 6E– 1
SECTION 6E
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
TABLE OF CONTENTS
PAGE
General Description........................................................................................................... 6E -2
EGR System Diagram ........................................................................................................ 6E -4
EGR System Operation ..................................................................................................... 6E -4
Inspection........................................................................................................................... 6E -5
EGR Cooler......................................................................................................................... 6E -6
6E – 2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL DESCRIPTION
Except 4JA1TC Engine

4JA1TC
C06H200001
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake maniflld.
The two EGR values are controlled by tow VSV controlled by EGR controller according to signals from various
snsors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator. Also, EGR may
fail to operate at some water temperature ranges of the engine.
The 4JA1TC engines is intercooler and EGR cooler equipped.
EGR SYSTEM DIAGRAM (Except 4JA1TC Engine)
EGR SYSTEM OPERATION

Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
• Inspection point (Engine RPM)
RPM Idling 2000 2750 3250
Engine Front Side VSV-1 ON ON ON OFF
Engine Rear Side VSV-2 ON ON OFF OFF
ON means VSV should receive signal to move EGR valve.

OFF means VSV shouldn’t receive signal to move EGR valve.
INSPECTION
Thermo Switch
1. Submerge end of switch in water.
2. Connect circuit tester to the connector terminals.
3. Use a burner to heat the water.
4. Check the continuity test across.
Operating temperature
Thermo sw. No.2 Thermo sw. No.1
OFF → ON Over 73°C Over 30°C
ON → OFF 76°C ~ 84°C 36°C ~ 44°C
If there is no continuity, replace the switch.
Vacuum switch valve (VSV)

Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance Ω at 20°C
35 ~ 45
If the resistance is not within specification, replace it.
EGR Valve
Apply Vacuum to the EGR Valve, check to see the Valve
Apply Vacuum
Less then 120 mmHg Not operation
More than 180 mmHg Operation
EGR COOLER (For 4JA1TC Engine)
057L200024
Removal Steps Installation Steps

Preparation: To install, follow the removal procedure in
･ Disconnect battery ground cable reverse order.
･ Drain coolant J 5. EGR pipe
･ Remove the intercooler J 4. EGR valve
1. Water hose J 3. EGR cooler ASM
2. EGR cooler bracket J 2. EGR cooler bracket
3. EGR cooler ASM J 1. Water hose
4. EGR valve
5. EGR pipe
Installation Steps
5. EGR Pipe
Install the EGR pipe to the Exhaust manifold and tighten
the EGR pipe bolt with EGR pipe gasket to the specified
torque.
EGR Pipe Bolt Torque kg·m (lb·ft/N·m)
2.4 ± 0.5 (17.4 ± 3.6/23.5 ± 5)
057L200022
4. EGR Valve
Install the EGR valve to the intake manifold and tighten the
EGR valve nut with EGR valve gasket to the specified
torque.
EGR Valve Nut Torque kg·m (lb·ft/N·m)
2.4 ± 0.5 (17.4 ± 3.6/23.5 ± 5)
057L200021
3. EGR Cooler ASM

Temporarily install the EGR cooler assembly.
2. EGR Cooler Bracket

1) Temporarily install the EGR cooler bracket Hand-
tighten each of the bolts.
2) Fintal tighten the bolts in the order shown in the
illustration (QRST).
QR Torque kg·m (lb·ft/N·m)
2.4 ± 0.5 (17.4 ± 3.6/23.5 ± 5)
ST Torque kg·m (lb·ft/N·m)

057L200023
1.9 ± 0.5 (14 ± 3.6/19 ± 5)
1. Water Hose
Connect the water hose to the EGR cooler ASM.
Note:
• Take care not to scratch the installation surfaces.
• Do not allow dirt to adhere to the installation
surfaces.
INDEX
EXHAUST SYSTEM 6F – 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
General Description........................................................................................................... 6F - 2
Removal and Installation................................................................................................... 6F - 6
Inspection and Repair ....................................................................................................... 6F -11
Turbocharger ..................................................................................................................... 6F -12
Main Data and Specifications ....................................................................................... 6F -12
General Description........................................................................................................... 6F -13
Inspection and Repair ....................................................................................................... 6F -15
Special Tools...................................................................................................................... 6F -17
IHI Service Network ........................................................................................................... 6F -18
6F – 2 EXHAUST SYSTEM
GENERAL DESCRIPTION
4JA1TC
150L200004
4JH1TC
150L200007
The exhaust system consists of a front exhaust pipe, a catalytic converter, a silencer and a tail pipe.
When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points
on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment
insulation and trim materials.
Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes
to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an
indication of a problem in one of these areas. Any faulty areas should be corrected immediately.
OXIDIZING CATALYTIC CONVERTER

The oxidizing catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.
Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust
system.
A dual bed monolith catalytic converter is used in
combination with oxidizing catalytic converter.
150L200005.tif
GASKET
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.

1. Rear hanger clamp 10. Exhaust pipe gasket
2. Silencer rear clamp 9. Front exhaust pipe
3. Rear exhaust pipe J 8. Exhaust pipe nut and washer
4. Silencer front clamp 7. Exhaust front bracket
4a. Silencer front clamp 6. Front hanger clamp
(For long wheel base) J 5. Exhaust silencer
5. Exhaust silencer 4. Silencer front clamp
6. Front hanger clamp 4a. Silencer front clamp
7. Exhaust front bracket (For long wheel base)
8. Exhaust pipe nut and washer 3. Rear exhaust pipe
9. Front exhaust pipe 2. Silencer rear clamp
10. Exhaust pipe gasket 1. Rear hanger clamp

8. Exhaust Pipe Nut and Washer

Connect the exhaust pipe to the exhaust manifold.
Torque kg·m (lb·ft/N·m)
6.8 ± 0.5 (49 ± 3.6/67 ± 5)
5. Exhaust Silencer
Apply muffler sealer to the joining portion of the pipes.
4JA1TC
150L200006

1. Tail pipe hanger clamp and J 8. Front pipe with gasket
nuts
2. Tail pipe with gasket 7. Front pipe hanger clamp and nuts
3. Silencer with gasket J 6. Front pipe BRKT
4. Oxidizing Catalytic converter J 5. Oxidizing Catalytic converter with
hanger clamp and bolts gasket
5. Oxidizing Catalytic converter 4. Oxidizing Catalytic converter hanger
with gasket clamp and bolts
6. Front pipe BRKT J 3. Silencer with gasket
7. Front pipe hanger clamp and J 2. Tail pipe with gasket
nuts
8. Front pipe with gasket 1. Tail pipe hanger clamp and nuts
4JH1TC
150L200008

1. Tail pipe hanger clamp and J 8. Front pipe with gasket
nuts
2. Tail pipe with gasket 7. Front pipe hanger clamp and nuts
3. Silencer with gasket and nuts J 6. Front pipe BRKT
4. Center pipe hanger clamp and J 5. Center pipe with gasket
nuts
5. Center pipe with gasket 4. Center pipe hanger clamp and nuts
6. Front pipe BRKT J 3. Silencer with gasket
7. Front pipe hanger clamp and J 2. Tail pipe with gasket
nuts
8. Front pipe with gasket 1. Tail pipe hanger clamp and nuts

8. Front Pipe With Gasket

Connect the front pipe to the exhaust manifold.
Torque kg⋅m(lb⋅ft/N⋅m)
6.8 ± 0.5 (49 ± 3.6/67 ± 5)
6. Front Pipe BRKT

Tighten the fixing bolt to the specified torque.
Front pipe side 2.4 ± 0.5 (17 ± 3.6/23 ± 5)
Transmission side 4.1 ± 1.0 (30 ± 7/40 ± 1)
5. Oxidizing Catalytic Converter With Gasket (4JA1TC)

Center Pipe With Gasket (4JH1TC)
Tighten the fixing nuts to the specified torque.
4.4 ± 1.3 (32 ± 9.4/43 ± 13)
3. Silencer With Gasket

4.4 ± 1.3 (32 ± 9.4/43 ± 13)
2. Tail Pipe With Gasket

4.4 ± 1.3 (32 ± 9.4/43 ± 13)
• Connect battery ground cable.
• After assembling each part, start the engine to check
for any leakage of gas at each connection.

inspection.
Front Exhaust Pipe

Rear Exhaust Pipe
Exhaust Silencer
Check the pipes for corrosion, cracking, damage or
misalignment and repair as required.
Check the rubber rings for deterioration or damage and repair
as required.
TURBOCHARGER
4JA1T, 4JB1T,
Engine model 4JG2T 4JH1TC
4JA1TC
IHI RHB 52W or
Turbocharger model IHI RHF 4H RHF5H
RHF5H
Turbine type Radial inflow
Compressor type Radial outflow
Maximum permissible speed rpm 180,000 172,000 180,000
Wastegate opening pressure mmHg (inHg) 189 – 887
Safety valve opening pressure mmHg (inHg) 850 - 910
Weight kg (lb) 4.2 (9.3) 4.6 (10.1)
IHI : Ishikawajima Harima Heavy Industries., Ltd.

GENERAL DESCRIPTION
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial brarings.
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.
IDENTIFICATION OF UNIT
The turbocharger nameplate gives the date of manufacture
and other important information required to identify the unit
when service inquiries are made.
The turbocharger nameplate has the following information

stamped on it.
QTurbo Specification Number, Production Year and
Month
RProduction Date, Daily Serial Number
SISUZU Parts Number

inspection.
Turbocharger pressure check

(1) Remove the pressure switch connecting hose from
intake duct.
(2) Connect the pressure gauge.
(3) Start the engine and gradually increase the engine
speed (the vehicle must be stationary with no load
applied to the engine).
(4) Check to see that turbocharger pressure rises to
approximately 300 mmHg.
Pressure Gauge : 5-8840-0075-0
Waste gate operation check

(1) Remove the hose between the waste gate and the
intake pipe.
(2) Connect the pressure gauge.
(3) Check to see that the rod begins to move when a
pressure of approximately 665 mmHg is applied to the
waste gate.
Note:
2
Do not apply a pressure greater than 1 kg/cm to the
wastegate during this check.
Unit Inspection (Remove Turbo. from engine)

Check to see the pressure required to move the control
rod Q 2 mm is within the limits shown below.
Control Rod Q Operating Pressure Approx. 860 mmHg
Safety valve check

Operate the valve with your hand to check its operation.
Check the valve seal are for excessive wear or damage.
Contact the “ISUZU MOTORS LIMITED” Dealer service

department or “IHI SERVICE FACILITY” for major repairs
and maintenance.
Important wheel shaft end play and bearing clearance
standards and limits are included below for your reference.
Wheel Shaft End Play

Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the
compressor wheel end and the turbine wheel end.
Wheel Shaft End Play mm (in)
Standard Limit
0.03 - 0.06
0.09 (0.004)
(0.001 - 0.002)
Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and
bearing clearance.
Wheel Shaft and Bearing Clearance mm (in)
Standard Limit
0.056 - 0.127
0.127 (0.0050)
(0.0022 - 0.0050)
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-0070-0 Pressure Gauge

IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.
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
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TF4JE-WE-9712


All rights reserved, This manual may not be

Issued by
Tokyo, Japan
First edition July, 2001

No. TF4JE-WE-9712
W/M CoverBasexp3.3J 2001.1.24 16:00PM ページ 1
WORKSHOP MANUAL
TF SERIES
AUTOMATIC TRANSMISSION
4L30-E
SECTION 7A1
No.TF4L3-WE-889AR PRINTED IN JAPAN

NOTICE

“GENERAL INFORMATION”.

All rights are reserved to make changes at any time without
prior notice.
THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION CONTENTS
00 Service Information
7A1 Automatic Transmission (4L30-E)
INDEX
SERVICE INFORMATION 00 – 1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Main Data and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 2
Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 3
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 4
Fixing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00– 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11
00 – 2 SERVICE INFORMATION

Remarks
Model 4L30-E
Engine V6 3.2L 6VD1 DOHC
Automatic four speed
overdrive in 4th gear
Type
lock-up clutch torque
converter
Shift control Hydraulic
Shift pattern Electronic
Control systems
Shift quality Electronic
Lock-up clutch Electronic
1st 2.856
2nd 1.618
4th (O/D) 0.723
Reverse 2.000
Gear set Noiseless, high torque capability
Name ATF DEXRON-III
Oil used
Q’ty lit (Imp qt / US qt) 8.6 (7.6 / 9.1)
Torque converter 2200 ± 150 Stall speed (rpm)
Reverse clutch RC 4
Second clutch C2 6 Number of discs
Third clutch C3 6
Brake band Double wrap
Fourth clutch C4 2
Number of discs
Overrun clutch OC 1
Overdrive OFW 10 Number of rollers
Principal PFW 26 Number of sprags
Input sun gear 30
Pinion gear 19
Long pinion 23
Ravigneaux
Ring gear 90
Long pinion 19 Number of teeth
Output sun gear 46
Sun gear 31
Overdrive Pinion gear 24
Ring gear 81
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
PLANETARY CARRIER
Planetary Carrier Pinion End Play mm (in) 0.13 – 0.89 (0.005 – 0.035) –
SECOND CLUTCH
Second Clutch End Play mm (in) 0.36 – 0.79 (0.014 – 0.031) –
OVERDRIVE CLUTCH
Overdrive Clutch End Play mm (in) 0.1 – 0.8 (0.004 – 0.031) –
MAIN CASE
Main Case End Play mm (in) 0.36 – 0.80 (0.014 – 0.031) –
OVERDRIVE CARRIER
Overdrive Carrier Pinion End Play mm (in) 0.24 – 0.64 (0.0094 – 0.025) –
SERVICING
CHECKING TRANSMISSION FLUID LEVEL AND
CONDITION
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis
information about the transmission. This information
may be used to correct a condition that, if not
detected early, could result in major transmission
repairs.
IMPORTANT:
When new, automatic transmission fluid is red in
color. As the vehicle is driven, the transmission fluid
will begin to look darker in color. The color may
eventually appear light brown.
A DARK brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for
fluid change.
FLUID LEVEL
When adding or changing fluid, use only DEXRON®-
III.
Refer to the Maintenance and Lubrication (Section 0)
for maintenance information and servicing interval.
CAUTION: Do not overfill.

Overfilling will cause foaming, loss of fluid, abnormal
shifting and possible damage to the transmission.
CAUTION:
DO NOT CHECK FLUID LEVEL UNDER THESE
CONDITIONS:
• Immediately after driving at sustained highway
speeds.
• In heavy city traffic during hot weather.
– If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to “cool” for
thirty (30) minutes. After the cool-down period, restart the
vehicle and continue from step 2 above.
1. Parking the vehicle on level ground and apply the

parking brake firmly.
Overfill screw
2. Check fluid level with engine running at idle.
NOTE:
Drain screw
Be sure that transmission fluid temperature is below 30°C
(86°F).
3. Move through all gear ranges the selector lever.
4. Move the selector lever to “Park”.
5. Let engine idle for 3 minutes and open the overfill
242RT001
screw.
6. Let engine idle until a fluid temperature between 32°C
(90°F) and 57°C (135°F) is reached.
7. Add transmission fluid until it flows out over the
overfill screw-opening, then close the overfill screw.
Overfill Screw Torque N·m(kg·m/lb·ft)
38 (3.9 / 28)
NOTE:
Transmission fluid temperature to be check with
service tool.
Minimum fluid level → 57°C (135°F)
Maximum fluid level → 32°C (90°F)
CAUTION:
Do not open overfill screw with engine stopped.
FLUID CONDITION
FLUID CONDITION
NORMAL* CONTAMINATED
RED NON-TRANSPARENT
COLOR BROWN BROWN
OR LIGHT BROWN /PINK
DRAIN
NO YES YES YES
REQUIRED?
CONTAMI- NONE Very small amount Contamination by Large pieces of
NATION of foreign material coolant or other metal or other
in bottom of pan source foreign material in
bottom of pan
1. LOW LEVEL:
A. Add fluid to – Remove both pans – Repair/replace
obtain proper radiator cooler
level & check – Change filter – Transmission – Transmission
CORRECT for external overhaul required overhaul required
LEVEL leaks. – Flush cooler – Check for:
& B. Correct cause • Damaged plates – Flush cooler and
CONDITION of leak. – Add new fluid and seals cooler lines
2. HIGH LEVEL: • Contaminated – Add new fluid
– Remove excess – Check level solenoids
fluid – Flush cooler – Check level
– Add new fluid
– Check level
* Fluid should be changed according to maintenance schedule.
CHANGING TRANSMISSION FLUID

There is no need to change the transmission fluid unless
the transmission is used under one or more of the
following heavy duty conditions.
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Towing a trailer
If the vehicle is used under these conditions, change the
fluid every 27,000 miles (45,000 km.)
1. Place a large drain pan under the oil pan.

2. Remove the transmission oil drain screw and drain
Overfill screw
fluid.
3. Tighten drain screw.
Drain screw
Drain Screw Torque N·m(kg·m/lb·ft)
38 (3.9 / 28)
4. Remove the transmission overfill screw and fill
transmission through overfill screw opening, using
DEXRON®-III ATF.
242RT001 5. Let engine idle until a fluid temperature between 32°C
(90°F) and 57°C (135°F) is reached, then close the
overfill screw.
Overfill Screw Torque N·m(kg·m/lb·ft)
38 (3.9 / 28)
6. Add transmission fluid until it flows out over the
overfill screw opening.
NOTE:
Transmission fluid temperature to be check with
service tool.
FIXING TORQUE
AUTOMATIC TRANSMISSION N·m (kg·m / lb·ft)
63(6.4/40)
54(5.5/40)
See page 7A1-153
41(4.2/30)
★ 55(5.6/41)
8(80kg•cm/69 lb in)
50(5.1/37)
6(60kg･cm/52 lb in)
40(4.1/30)
67(6.8/49)
43(4.4/32)
★ Non-reusable part
E07LW003
FIXING TORQUE (CONT.)

13(130kg·cm/113 lb.in)
23(2.3/17)
13(130kg·cm/113 lb.in)
25(2.5/18)
20(2.0/15)
20(2.0/15)
11(110kg·cm/96 lb.in)
20(2.0/15) 11(110kg·cm/96 lb.in)
38(3.9/28) 作業番号 10012

発注者鈴木発注日 '97/ 11/ 28
受注番号希望納期修
E07LW001
FIXING TORQUE (CONT.)

25 (2.5/18)
20 (2.0/15)
3 (30kg·cm/26 Ib·in)
39 (4.0/29)
10 (100kg·cm/87 Ib·in)
22 (2.2/16)
9 (90kg·cm/78 Ib·in)
10 (100kg·cm/87 Ib·in)
103 (10.5/76 )
32 (3.3/24 )
E07LW002
SPECIAL TOOLS
ILLUSTRATION PARTS NO. PARTS NAME
5-8840-0501-0
Spring compressor (For servo piston)
(J-23075)
5-8840-2258-0
Third clutch retaining ring compressor
(J-38450)
5-8840-2259-0 Third clutch spring compressor adapter

(J-23075-12) (Use with 5-8840-0501-0 (J-23075))
5-8840-2260-0
Third clutch piston installer
(J-23084)
5-8840-0195-0
Spring compressor
(J-23327)
5-8840-2261-0
Second clutch piston installer
(J-23080-A)
5-8840-2262-0
Selective washer gaging tool
(J-23085-A)
5-8840-2263-0 Fourth clutch spring compressor

(J-23327-90) (Use with 5-8840-0195-0 (J-23327))
5-8840-2264-0
3/4 Accumulator piston fitter
(J-38553)
5-8840-2265-0 (’94) Cover remover

(J-38552) (Use with 5-8840-2266-0 (J-38584))
5-8840-2403-0 (’96) Cover remover

(J-41096) (Use with 5-8840-2266-0 (J-38584))
SPECIAL TOOLS (CONT.)

5-8840-2266-0 Slide hammer adapter

(J-38584) (Use with 5-8840-0019-0 (J-23907))
5-8840-2267-0
Fourth clutch piston fitter
(J-38554)
5-8840-2268-0
Guide pins: adapter case to main case
(J-38588)
5-8840-2269-0
Overrun clutch piston seal installer set
(J-38555)
5-8840-2270-0 Guide pins: gasket and transfer plate to valve

(J-3387-2) body
5-8840-2271-0 Turbine shaft puller

(J-25022) (Use with 5-8840-0618-0 (J-24773-1))
5-8840-0196-0 Oil seal remover (Use with 5-8840-0019-0

(J-23129) (J-23907) and 5-8840-2266-0 (J-38584))
5-8840-2272-0
Oil pump centering tool
(J-38557)
5-8840-2273-0
Oil pump rotation tool
(J-23082-01)
5-8840-0022-0
Guide pins: valve body to main case
(J-25025-B)
5-8840-0019-0 &
5-8840-2000-0 Slide hammer
(J-23907)
SPECIAL TOOLS (CONT.)

5-8840-2274-0
Servo piston fitter
(J-38428)
5-8840-2275-0
Overrun clutch spring compressor
(J-23327-91)
5-8840-2277-1
3/4 Accumulator piston cover compressor
(J-38559-A)
5-8840-2278-0
Holding fixture
(J-8763-02)
5-8840-2282-0
A/T extension housing oil seal installer (Inside)
(J-36797)
5-8840-0003-0
(J-3289-20)
5-8840-0004-0
Pressure gauge
(J-21867)
5-8840-0618-0 End play fixture

(J-24773-1) (Use with 5-8840-2271-0(J-25022))
MEMO
INDEX
AUTOMATIC TRANSMISSION (4L30-E) 7A1–1
SECTION 7A1
AUTOMATIC TRANSMISSION (4L30-E)
CAUTION
When fasteners are removed, always reinstall Fasteners that are not reused, and those
them at the same location from which they requiring thread locking compound, will be
were removed. If a fastener needs to be called out. The correct torque values must be
replaced, use the correct part number fastener used when installing fasteners that require
for that application. If the correct part number torque. If the above conditions are not
fastener is not available, a fastener of equal followed, parts or system damage could
size and strength (or stronger) may be used. result.
CONTENTS
PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 4
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 5
Electronic Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 6
Transmission Control Module (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 7
Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 8
Functions of Input/Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–13
Range Reference Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–14
Normal Operation of 4L30-E Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–17
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–17
Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–18
General Diagnosis Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–20
Preliminary Inspection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–21
Checking Transmission Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . . . . . 7A1–22
Test Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–23
Mechanical/Hydraulic Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–25
Check Trans Indicator Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–25
Mechanical/Hydraulic Diagnosis Symptoms Index. . . . . . . . . . . . . . . . . . . . . . . . 7A1–26
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–43
Line Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–43
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–45
7A1–2 AUTOMATIC TRANSMISSION (4L30-E)
Lock-up Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 46

Electronic Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 47
Check Trans Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 48
Diagnostic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 49
”Check Trans“ Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 50
Flashing Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 52
TECH2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 54
Clear DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 57
DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 58
F0 : Data List Quick Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 59
Chart 1 : Diagnosis Connector and Voltage Supply Test . . . . . . . . . . . . . . . . . . 7A1– 61
Chart 2 : Diagnostic Trouble Code (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 63
Chart 3 : Transmission and TCM Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 64
Chart 5 : F5 : Actuator Test Quick Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1– 65
Without DTC Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–132
TCM Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–135
Intermittent Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–136
TCM MEM-CAL Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–137
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–140
Connector Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–142
Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–143
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–145
Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–145
Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–147
Transmission (With Transfer Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–149
Solenoid Valve (Main Case Valve Body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–155
Solenoid Valve (Adapter Case Valve Body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–157
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–159
Transmission (4L30-E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–159
Converter Housing and Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–180
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–182
Main Case Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–184
Adapter Case Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–187
Third Clutch and Sprag Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–189
Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–191
Sprag Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–193

Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–194
3-4 Accumulator Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–196
Reverse Clutch Piston and Center Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–198
Overrun Clutch and Turbine Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–201
4L30-E Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–205
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End of This Manual
GENERAL DESCRIPTION
The 4L30-E is a 4-speed fully-automatic transmission.
It uses a microcomputer as a control unit to judge
running conditions including throttle opening rate
and vehicle speed, then it sets the shifting point in
the optimum timing so that best driving perform-
ance can be achieved.
In addition, the built-in shift mode select function
can select two shift modes according to the driver’s
preference.
• Normal mode –Normal shift pattern.
• Power mode has a delayed upshift for when
more powerful acceleration is required.
Also, the built-in fail-safe function (”backup mode“)
assures driving performance even if the vehicle
speed sensor, throttle signal or any solenoid fails.
Further, the self-diagnostic function conducts
diagnosis in a short time when the control system
fails, thus improving serviceability.
The major features of 4L30-E are as follows:
• A compact structure consisting of 2 sets of
planetary gears and flat torque converter.
• Electronic control selects the optimum shift
mode according to the driving conditions.
• Electronic control maintains the optimum
hydraulic pressure for clutch, band brake as
well as transmission so that shift feeling is
improved.
• Two sets of planetary gears reduce friction of
power train.
Also, a lock-up mechanism in the torque
converter reduces fuel consumption.
• Wide gear ratio and high torque rate of torque
converter provide excellent starting perform-
ance.
CROSS SECTION
CONSTRUCTION
1 10 2 3 4 5 6 7 11 8 9
1. TORQUE CONVERTER-CLUTCH (TCC) 5. REVERSE CLUTCH (RC) 9. BRAKE BAND (B)

2. FOURTH CLUTCH (C4) 6. SECOND CLUTCH (C2) 10. OVERDRIVE FREE WHEEL
3. OVERRUN CLUTCH (OC) 7. THIRD CLUTCH (C3) (ONE WAY CLUTCH) (OFW)
4. OVERDRIVE UNIT 8. RAVIGNEAUX PLANETARY GEARSET 11. SPRAG FREE WHEEL
(ONE WAY CLUTCH) (PFW)
A07LW004
DRIVER'S INPUT
COMPENSATION FOR ENGINE LOAD
DASH BOARD DISPLAY MANUAL SELECTOR
AIR CONDITIONING SWITCH

CHECK TRANS LAMP
KICKDOWN SWITCH
POWER DRIVE MODE
LAMP
BRAKE SWITCH
SHIFT INDICATOR LAMP PUSH BUTTON FOR

A/T SHIFT INDICATOR NORMAL/POWER
(CONTROL UNIT ( DRIVE MODE
ELECTRONIC CONTROL DIAGRAM
ON-BOARD DIAGNOSTIC
TRANSMISSION
ENGINE CONTROL CONTROL

MODULE(ECM) MODULE
(TCM)
THROTTLE POSITION
SENSOR VEHICLE SPEED
SENSOR
CRANK ANGLE SENSOR
5 SOLENOID ATF TEMPERATURE
VALVES SENSOR
ENGINE COOLANT PRND32L MODE SWITCH

TEMPERATURE SENSOR BATTERY
+12
IGNITION
C07LW003
IGN BATT GND
ENGINE A7 A8 A4 C1 D1
ENGINE
CRANK ECM SPEED
ANGLE D12
SENSOR ENGINE
VEHICLE
COOLANT IGN
TEMP SW
D14 BRAKE SW
D9
A/C REQUEST
SERIAL DATA D8
C8 POWER SW
TORQUE B8
MANAGEMENT
TPS +
OUT
C5
KICKDOWN SW
C6 B5
–
4L30-E
Xa MODE SW A IGN
D7
Xb MODE SW B
D6
Xc MODE SW C CHECK TRANS LAMP
D5 C10
IGN Xg MODE SW G TCM POWER LAMP
D4 B9
Ac OIL TEMP
B3
Ad DIAG SW
C14 D16
X2 OUTPUT SPEED HI
A12
X1 OUTPUT SPEED LO
B12
B11
Aa TCC HI
C7
Mc SHIFT SOL. HI
C12
Md SHIFT SOL. A
A2
Ma SHIFT SOL. B
A3
Mb BAND APPLY SOL.
A9
Ab FORCE MOTOR HI
C15
Ac FORCE MOTOR LO
C16
ECM: Engine Control Module

TPS: Throttle Position Sensor
TCC: Torque Converter Clutch
C07LW002
AUTOMATIC TRANSMISSION ASSEMBLY
FINAL DRIVE GEAR

MULTIPLATE CLUTCH
LOCKUP PISTON
OUTPUT SHAFT
MULTIPLATE BRAKE
INPUT SHAFT
DRIVE SHAFT
ONE WAY CLUTCH
CONVERTER
PLANETARY GEAR
TORQUE
ENGINE
TIRE
BRAKE BAND
OIL PUMP SERVO MECHANISM
CONTROL VALVE
POWER
:
OIL TEMP.
TRANSMIT
VEHICLE SPEED
SENSOR
SENSOR
TORQUE CONVERTER
OIL PRESSURE
CLUTCH SOLENOID
SHIFT SOLENOID A
SHIFT SOLENOID B
:
MANUAL VALVE
CONTROL
FORCE MOTOR
BAND APPLY
SOLENOID
MECHANICAL
:
SIGNAL
SWITCH
MODE
ELECTRONIC
:
SIGNAL
SHIFT INDICATOR LAMP
(A/T SHIFT INDICATOR

CONTROL UNIT (
CRANK ANGLE SENSOR ECM TRANSMISSION CONTROL

MODULE (TCM)
KICKDOWN SWITCH
ENGINE COOLANT
TEMPERATURE SENSOR BRAKE SWITCH
• SHIFT CONTROL
THROTTLE POSITION POWER MODE SWITCH
• BAND APPLY CONTROL
SENSOR
• TORQUE CONVERTER CLUTCH
CONTROL
• LINE PRESSURE CONTROL
CHECK TRANS LAMP • SAFETY MODE
• ON-BOARD DIAGNOSTIC
POWER LAMP SYSTEM AIR CONDITIONING
SWITCH
• TORQUE MANAGEMENT
C07LW001
1. SHIFT CONTROL
The transmission gear is shifted according to the
shift pattern selected by the driver.
In shifting gears, the gear ratio is controlled by the
ON/OFF signal using the shift solenoid A and the
shift solenoid B.
2. BAND APPLY CONTROL

The band apply is controlled when in the 3-2
downshift (engine overrun prevention) and the
garage shift (shock control).
The band apply solenoid is controlled by the signal
from the Pulse Width Modulation (PWM) to regulate
the flow of the oil.
3. TORQUE CONVERTER CLUTCH CONTROL

The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch (TCC) solenoid using the ON/OFF
signal.
4. LINE PRESSURE CONTROL

The throttle signal allows the current signal to be
sent to the force motor. After receiving the current
signal, the force motor activates the pressure
regulator valve to regulate the line pressure.
5. ON-BOARD DIAGNOSTIC SYSTEM

Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and
read out of it afterward.
The serial data lines, which are required for the
testing of the final assembly and the coupling to
other electronic modules, can be regulated by this
function.
6. FAIL-SAFE MECHANISM
If there is a problem in the transmission system, the
TCM will go into a “backup” mode. The vehicle can
still be driven, but the drive must use the gear lever
to shift gears.
7. TORQUE MANAGEMENT CONTROL

The TCM sends the absolute spark advance signal
to the Engine Control Module (ECM) while the
transmission is being shifted, to control the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the
change of speed.
SHIFT MODE CONTROL
1 Mode type
Mode type Select lever position

Normal drive mode (NOR) Entire range (excluding “R”)
Power drive mode (PWR) Entire range (excluding “R”)
2 Mode selection
SWITCH (SW) LAMP

Mode type PWR/NOR. SW POWER DRIVE LAMP
Normal drive mode (NOR) OFF OFF
Power drive mode (PWR) ON ON
3 Comparison of mode
(1) The normal drive mode is set at the normal shift points.
(2) The shift points of the power drive mode are shifted to the higher speed side, compared to the
normal drive mode.
Shift diagram
N: Normal drive mode
P: Power drive mode
N P N P
2 3
2 3
N P
1 2
Amount of
1 2
throttle
opening
3 4
3 4
Speed mph(km/h)
GEAR SHIFT CONTROL
1 Shift pattern
SELECT LEVER RANGE SHIFT PATTERN

D (Drive) 1 ← 2TCC →
→ ← 3TCC →
← 4TCC
3 (Third) → →
1 ← 2TCC ← 3TCC ← 4TCC
2 (Second) 1 →
← 2TCC ← 3TCC
L (First) 1 ←2
TCC = Torque Converter Clutch
2 Gear position
The gear is selected by ON/OFF of two solenoids.
SOL ● = ON
GEAR A B
✕ = OFF
4 (Fourth) ✕ ✕
SOLENOID A ON → PRESSURE TO
3 (Third) ● ✕ (Normally closed) SHIFT VALVE
2 (Second) ● ● SOLENOID B OFF → PRESSURE TO
1 (First) ✕ ● (Normally open) SHIFT VALVE
P (Park)
R (Reverse) ✕ ●
N (Neutral)
3 Selecting gear position
Seven types of positions can be selected according to 5 signals from the mode switch as shown
below.
MODE SW TERMINALS
SELECT LEVER RANGE 5(D) 8(A) 7(B) 6(C) 3(G)
P (Park) • • •
R (Reverse) • • •
N (Neutral) • • •
D (Drive) • • •
3 (Third) • • • • •
2 (Second) • • •
L (First) • • •
• = Continuity
BACKUP MODE
If a major system failure occurs which could affect safety or damage the transmission under normal
vehicle operation, the diagnostic system detects the fault and overrides the TCM.
The “CHECK TRANS” light flashes to alert the driver, and the transmission must be manually shifted
as follows:
Select lever position Gear Ratio Selected

D 4 (Fourth)
Manual 3 4 (Fourth)
Manual 2 3 (Third)
Manual L 1 (First)
R Reverse
Shifts are firmer to prevent clutch slip and consequent wear. The fault should be corrected as soon as
possible.
FUNCTIONS OF INPUT/OUTPUT COMPONENTS

Components Function
Speed sensor Senses rotation of output shaft and feeds the data to Transmission
(fixed to transmission T/M) Control Module (TCM)
Throttle Senses the extent of throttle valve opening and the speed of the throttle
position sensor (TPS) valve lever motion to open the valve and feeds the data to TCM (fed to
(fixed to engine) Engine Control Module (ECM) also)
Brake Switch (SW) Senses whether the driver has pressed the brake pedal or not and feeds
I (fixed to brake pedal) the information to TCM
N
Kick-down SW (fixed to Senses whether the driver has pushed the accelerator pedal fully or not
P
accelerator pedal) and feeds the information to TCM
U
T Mode SW (fixed to T/M) Senses the select lever position and feeds the information to TCM
Power drive SW Senses whether the driver has selected the power mode and feeds the
S (fixed to front console) information to TCM
I
T/M oil temp. sensor Senses the T/M oil temperature and feeds the data to TCM
G
N Engine coolant Senses the engine cooling water temperature and feeds the data to TCM
A temperature SW (feeds the signal from ECM)
L Engine speed signal Feeds the signals monitoring engine speed to TCM from crank angle sensor
(feeds the signal from ECM)
Air conditioning Senses whether the air conditioner has been switched on or not and
information feeds the information to TCM
On-board diagnostic input By monitoring the Ground (GND), the location of failure is shown on the
T/M monitor lamp (“CHECK TRANS”) by flashing the diagnostic trouble
code
Shift solenoid A, B Selects shift point and gear position suited to the vehicle running con-
S dition on the basis of TCM output
O Band apply solenoid Controls oil flow suited to the vehicle running condition on the basis of
O L TCM output
U E
N Torque Converter Controls clutch engagement/disengagement suited to the vehicle
T
O Clutch solenoid running condition on the basis of TCM output
P
U I Force motor Adjusts the oil pump delivery pressure to line pressure suited to the
T D (Pressure regulator vehicle running condition on the basis TCM output
valve)
S Power drive mode lamp Informs the driver whether the vehicle is in power mode or not
I
T/M monitor lamp Informs the driver of failure in the system. It also displays the self diag-
G
(“CHECK TRANS”) nosis code.
N
A Data Link Connector (DLC) When connected with TECH2 or tester, can communicate the data for
L function check, etc. (fed to ECM also). When TECH2 is not connected,
can communicate the signal for torque management with ECM.
When short-circuited with the bipolar connector, the T/M monitor lamp
displays a failure by code.
RANGE REFERENCE CHART
O/DRIVE PRINCIPLE
1-2/3-4 2-3 OVERRUN FOURTH THIRD REVERSE SECOND BAND
ROLLER SPRAG ENGINE
RANGE GEAR SOL SOL CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH ASSEMBLY
CLUTCH ASSEMBLY BRAKING
N.C. N.O. (OC) (C4) (C3) (RC) (C2) (B)
(OFW) (PFW)
P-N OFF ON APPLIED NO
R REVERSE OFF ON LD APPLIED APPLIED LD NO
1ST OFF ON LD APPLIED LD APPLIED NO
2ND ON ON LD APPLIED APPLIED FW APPLIED YES

D
3RD ON OFF LD APPLIED APPLIED APPLIED NE YES
4TH OFF OFF FW APPLIED APPLIED APPLIED NE YES
1ST OFF ON LD APPLIED LD APPLIED NO
3 2ND ON ON LD APPLIED APPLIED FW APPLIED YES
3RD ON OFF LD APPLIED APPLIED APPLIED NE YES
1ST OFF ON LD APPLIED APPLIED LD APPLIED YES

2
2ND ON ON LD APPLIED APPLIED FW APPLIED YES
L 1ST OFF ON LD APPLIED APPLIED LD APPLIED YES
LD : LOCKED IN DRIVE FW : FREEWHEELING NE : NOT EFFECTIVE
C07RT010
NORMAL OPERATION OF 4L30-E

TRANSMISSION
1. TORQUE CONVERTER CLUTCH (TCC) 2. SPECIAL SHIFT PATTERN WHEN THE
APPLICATION CONDITIONS: ENGINE IS COLD:
The TCC is normally applied in 2nd, 3rd and 4th A special shift pattern is activated when the engine
gears only when all of the following conditions coolant temperature is below 70°C (158°F). (3-4
exist: shifts for example are delayed for small throttle
– The engine coolant temperature is above 70°C openings and will occur a few MPH higher)
(158°F).
– The brake pedal is released.
– The shift pattern requests TCC apply.
Moreover, TCC is always applied in 2nd, 3rd and
4th gears when the transmission oil temperature is
above 135°C (275°F).
This mode should be canceled at 125°C (257°F).
MEMO
DIAGNOSIS
INTRODUCTION
The systematic trouble shooting information covered by this Section offers a practical and systematic
approach to diagnosing 4L30-E transmission, using information that can be obtained from road tests,
electrical diagnosis, oil pressure checks or noise evaluation.
The key to correcting a complaint is to make use of all of the available symptoms and logically letting them
direct you to the cause.
When dealing with automatic transmission complaints, it is best to gather as many symptoms as possible
before making the decision to remove the transmission from the vehicle.
Frequently, the correction of the cause of the complaint does not require removal of the transmission from
the vehicle.
DRIVER INFORMATION
To analyze the problem fill a complete description of the owner’s complaint.
Please draw a circle around the right information and complete the following form. (Find next page an
example of form completed). You can draw a circle around many numbers if you are not sure.
Example of form completed.

GENERAL DIAGNOSIS PROCEDURE
Complaint
Follow
Perform repair
PRELIMINARY
per
INSPECTION
SYMPTOMS CHART
CHART
Can
fault
NO be corrected YES
by on-car
component
replacement?
Remove trans-
Replace
mission assembly
component
and repair/replace
as required
Flush cooler lines
Reinstall
transmission TEST DRIVING
assembly
NO Problem YES
fixed? END
PRELIMINARY INSPECTION CHART
Complaint TCM: Transmission Control Module
Does Hydraulic
symptom reflect system appears
NORMAL YES OK! NO
OPERATIONS Are any DTC’s
OF 4L30-E stored in
TRANSMISSION? TCM?
(See page 7A1-15)
System
OK
NO YES
Check CHART3: TRANSMISSION AND Note

TCM IDENTIFICATION on page 7A1-64. codes
Check TRANSMISSION FLUID LEVEL

and CONDITION. See page 00-4.
Refer to SELECTOR LEVER in this manual.

Check manual linkage. See page 7A1-145.
Verify engine performance. Refer to Engine Section
Road test vehicle to verify concern. See page 7A1-23 for TEST DRIVING
“CHECK TRANS” YES

See CHECK TRANS INDICATOR
flashing CHART on page 7A1-25.
NO
Any
Trouble Codes YES See ELECTRONIC DIAGNOSIS
stored by Section of this manual on page 7A1-47.
TCM?
NO
See MECHANICAL/HYDRAULIC
DIAGNOSIS Section on page 7A1-26.
CHECKING TRANSMISSION FLUID LEVEL

AND CONDITION
Refer to “SERVICING” of the SERVICE INFORMATION
(Section 00).
TEST DRIVING 2. Drive the vehicle. During the test drive be sure
that the transmission achieves normal
Some 4L30-E automatic transmission complaints
operating temperature (approx. 20 minutes).
vehicles will require a test drive as a part of the
Allow the transmission to go through all of its
diagnostic procedure. Some codes will not set
gear ranges, checking shift timing and
unless the vehicle is moving. The purpose of the
firmness. Duplicate the owner’s complaint
test drive is to duplicate the customer’s complaint
condition as closely as possible during the test
condition and set a current Transmission Control
drive.
Module (TCM) trouble code. Perform this procedure
3. If, during the test drive, the “CHECK TRANS”
before each 4L30-E automatic transmission repair,
lamp comes on, use the scan tool to check for
and again after repairs are made.
trouble codes.
4. If, during the test drive, a problem is felt, but
IMPORTANT:
the “CHECK TRANS” lamp does not come on
• Duplicate the condition under which the
and no trouble codes are present, drive the
customer’s complaint was observed.
vehicle with the TCM disconnected (manually
• Depending on the complaint, line pressure
shifting the vehicle).
gauge and the scan tool may be required
• In Manual L, the vehicle operates in first
during the test drive.
gear.
• During the test drive, it is important to record
• In Manual 2, the vehicle operates in third
all necessary data from the areas being
gear.
monitored, for use in diagnosis. Also listen for
• In Manual 3 or “D”, the vehicle operates in
and note any unusual noises.
fourth gear.
The following procedure should be used to test If the problem still exists with the TCM
drive 4L30-E automatic transmission complaint disconnected, refer to the MECHANICAL/
vehicles: HYDRAULIC DIAGNOSIS in this Section.
1. Turn the ignition ON without starting the 5. If no problem has been found at this point,
engine. Check that the “CHECK TRANS” lamp check all underhood connections that supply
comes on for approximately 2 to 3 seconds power to the TCM and ignition fuses.
and then goes out and remains out. Physically and visually inspect all the TCM
• If the lamp is flashing, GOTO CHECK TRANS harness connectors for loose or corroded
INDICATOR. terminals. Inspect the TCM ground points.
• If no serial data is present, see Chart 1:
DIAGNOSTIC CONNECTOR AND VOLTAGE
SUPPLY TEST.
• If the lamp stays ON or stays OFF, GOTO
“CHECK TRANS” CHECK.
MEMO
MECHANICAL/HYDRAULIC DIAGNOSIS
CHECK TRANS INDICATOR CHART
PERFORM PRELIMINARY INSPECTION FIRST!
When the “CHECK TRANS” indicator is flashing, it If the initial problem is intermittent or seldom,
indicates that a problem related to the trans- switching OFF/ON the engine might allow normal
mission, the Transmission Control Module (TCM), operation again until the problem re-occurs.
or the vehicle harness has occurred:
The system is now operating in a “BACKUP MODE”

where the risk of further damaging the transmission
has been reduced. The vehicle may be shifted
manually.
“CHECK TRANS” indicator flashing
Read and record the Diagnostic

Trouble Codes (DTC) stored by TCM.
WARNING:
Disconnecting battery or TCM will
result in loss of stored trouble code(s).
NO DTC ANY DTC
Use “CHECK TRANS” CHECK in Refer to appropriate DTC chart in

Electronic Diagnosis section in this Electronic Diagnosis section in this
manual manual.
SHIFT LEVER GEAR

BACKUP MODE PATTERN: POSITION SELECTED
P P
- No automatic shifting R R
- Manual shifting only N N
- “CHECK TRANS” Flashing D 4
3 4
2 3
L 1
MECHANICAL/HYDRAULIC DIAGNOSIS SYMPTOMS INDEX
CHART SYMPTOMS PAGE
1 NO ENGINE START IN NEUTRAL OR PARK 7A1-27
2 NO FORWARD GEARS IN ANY RANGE/NO REVERSE 7A1-28
3 NO ENGINE BRAKE IN ANY RANGE 7A1-29
4 POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT) 7A1-30
5a DELAYS IN DRIVE AND REVERSE

7A1-31
5b DELAYS IN REVERSE ONLY
6 DIAGNOSTIC TROUBLE CODE (DTC) 61 7A1-32
7 HARSH 1-2 SHIFT

7A1-33
8 HARSH 3-4 SHIFT
9a 3-2 DOWNSHIFT COMPLAINT
HARSH SHIFT WHEN SHIFTING INTO “D” OR ACCELERATING

9b 7A1-34
FROM STOP
9c COASTDOWN HARSH SHIFT OR CLUNK AT 3-2 DOWNSHIFT
10 INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED 7A1-35
11 ENGINE FLARE AT SHIFTING DURING TURNING ONLY

7A1-36
12 ENGINE FLARE DURING 1-2 OR 2-3 SHIFT
13 SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING 7A1-37
14 POSSIBLE CAUSES OF TRANSMISSION NOISE 7A1-38
15a POSSIBLE CAUSES OF LOW LINE PRESSURE 7A1-39
15b POSSIBLE CAUSES OF HIGH LINE PRESSURE 7A1-40
16 POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS 7A1-41
NOTE:
Numbers with parenthesis on the following charts refer to Parts List at end of this Section.
CHART 1: NO ENGINE START IN NEUTRAL OR PARK
NO ENGINE START IN NEUTRAL NO START IN P

When shift lever moved from drive to (Any condition)
neutral mostly in hot condition
Does Check
engine also not mode switch
start in neutral when YES YES
(63) setting. Readjust END
shift lever moved from if necessary.
park to neutral? Problems
fixed?
NO NO
Open
in neutral YES
start circuit of mode END
switch (63)
NO
Replace mode switch (63)
( ) Refer to Parts List at the end of this Section.

CHART 2: NO FORWARD GEARS IN ANY RANGE/NO REVERSE
Check
Normal line pressure line pressure Low line pressure
( Refer to Line Pressure chart

in this Section. )
Check internal linkage:

– Manual linkage (58) not moving
manual valve (326)
Check for internal mechanical Use CHART 15a: POSSIBLE CAUSES

damage: OF LOW LINE PRESSURE on page
– Turbine shaft (506) broken loose 7A1-39
– Overrun roller clutch (516) broken
loose
– Etc.

CHART 3: NO ENGINE BRAKE IN ANY RANGE
Check
line pressure

in this Section. )
Normal line pressure Low line pressure
Check for overrun clutch leaks caused

by:
– Damaged piston lip (513)
– Check ball defective (504)
Check for overrun lockout valve (705)

stuck by foreign material
Check for leaks at turbine shaft (506) Use CHART 15a: POSSIBLE CAUSES
Caused by: OF LOW LINE PRESSURE on page
– Teflon seal rings damaged (508) 7A1-39
– Excessive wear of turbine shaft
bearing surfaces

CHART 4: POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)

in this Section. )
Check
line pressure
Low line pressure High line pressure
Check for these conditions which

could affect clutch apply time:
Use CHART 15a: POSSIBLE CAUSES • Defective band apply solenoid Use CHART 15b: POSSIBLE CAUSES
OF LOW LINE PRESSURE on page (323) OF HIGH LINE PRESSURE on page
7A1-39 7A1-40
• Defective servo or/and
accumulator piston
• Excessive clutch piston travel
Check of possible causes of internal

leaks:
– Cut or damaged sealing ring(s)
– Damaged sealing gasket (s)
– Check ball missing or out of
location in 2nd and 3rd clutch
pistons
Check for causes of burned clutch

plates or band

CHART 5a: DELAYS IN DRIVE AND REVERSE

NOTE: A short delay (less than 3
seconds) when first engaging drive or
reverse after allowing vehicle to sit
overnight is normal.

in this Section. )
Check
line pressure
More than 3 second delay in drive and Use CHART 15a: POSSIBLE CAUSES
reverse with engine off 1 hour or less OF LOW LINE PRESSURE on page
7A1-39
Teflon seals (508) on turbine shaft

damaged
CHART 5b: DELAYS IN REVERSE ONLY

in this Section. )
Check
line pressure
Main case to valve body gasket (88) Use CHART 15a: POSSIBLE CAUSES
damaged OF LOW LINE PRESSURE on page
7A1-39
Reverse check ball (85) in valve body Check for restrictions at valve body
(84) missing or out of location transfer plate orifice

CHART 6: DIAGNOSTIC TROUBLE CODE (DTC) 61

in this Section. )
DTC 61 sets.
Check line Low line pressure
pressure
Use CHART 15a: POSSIBLE CAUSES

OF LOW LINE PRESSURE on page
7A1-39
Normal line pressure
1st and 2nd gear missing 1st and 4th gear missing DTC 61 is set in “D” range DTC 61 is set in “D” range
or 3rd and 4th gear or 2nd and 3rd gear 1st gear above 3500 rpm 3rd gear between 55-80
missing missing mph *
Check appropriate shift

Check
valve
YES 3rd gear in “D”
If OK replace solenoid Shift solenoid A stuck. in winter mode.
Replace shift solenoid A. Does vehicle
move?
No engine brake in any

range NO
(All ranges in Drive &
Reverse are OK)
Check for suspected conditions Check for suspected conditions
modifying delays to clutch apply: modifying delays to clutch apply:
– 2nd clutch seal damaged – 4th clutch seal damaged
Check for suspected conditions
modifying delays to clutch apply: – Excessive 2nd clutch piston travel – Excessive 4th clutch piston travel
– Overrun clutch seal damaged – Defective accumulator piston – Defective 3-4 accumulator piston
– Excessive overrun clutch piston – Causes of internal leaks – Causes of internal leaks
travel – Check ball missing or out of – Causes of burned clutch plates
– Defective 3-4 accumulator piston location in 2nd clutch
– Causes of internal leaks – Seals cut, damaged or missing
– Causes of burned clutch plates – Gaskets defective
– Causes of burned clutch plates
* Perform this test within safe and legal limits.

CHART 7: HARSH 1-2 SHIFT

in this Section. )
Check
line pressure
Normal line pressure High line pressure
Check for 1-2 accumulator valve (320) Use CHART 15b: POSSIBLE CAUSES
stuck by foreign material in main case OF HIGH LINE PRESSURE on page
valve body 7A1-40
CHART 8: HARSH 3-4 SHIFT

in this Section. )
Check
line pressure
Check for 3-4 accumulator valve (407) Use CHART 15b: POSSIBLE CAUSES
stuck in adapter case valve body (401) OF HIGH LINE PRESSURE on page
7A1-40
Check for 3-4 accumulator piston (18)

stuck in adapter case (20)

CHART 9a: 3-2 DOWNSHIFT COMPLAINT

in this Section. )
Check
line pressure
Replace band apply solenoid (PWM) Use CHART 15a: POSSIBLE CAUSES OF
(323) LOW LINE PRESSURE on page 7A1-39
CHART 9b: HARSH SHIFT WHEN SHIFTING INTO "D" OR ACCELERATING FROM STOP

in this Section. )
Check
line pressure
Replace band apply solenoid (PWM) Use CHART 15b: POSSIBLE CAUSES OF
(323) HIGH LINE PRESSURE on page 7A1-40
CHART 9c: COASTDOWN HARSH SHIFT OR CLUNK AT 3-2 DOWNSHIFT

in this Section. )
Check
line pressure
Replace band apply solenoid (PWM) Use CHART 15b: POSSIBLE CAUSES OF
(323) HIGH LINE PRESSURE on page 7A1-40

CHART 10: INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED
Check for
consistent speed
sensor reading NOT OK Check for wiring harness damage
with TECH2 or short to ground
OK
Check transmission speed sensor

connections
OK OK
Replace transmission speed

sensor
Replace mode switch for intermittent
contact
CHART 11: ENGINE FLARE AT SHIFTING DURING TURNING ONLY

(USUALLY WITH WARM ENGINE)
Leak at transmission oil filter, gasket,

or wrong filter type
Replace transmission oil filter and

gasket
CHART 12: ENGINE FLARE DURING 1-2 OR 2-3 SHIFT

in this Section. )
Check
line pressure
Check for 1-2 accumulator valve (320) Use CHART 15a: POSSIBLE CAUSES OF
stuck LOW LINE PRESSURE on page 7A1-39
Check for servo piston (106) leaks
Check for band apply solenoid (323)

stuck

CHART 13: SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING
TCC shudder is one of the most commonly misdiagnosed conditions in

an automatic transmission. The key to diagnosing TCC shudder is to
note when it happens and under what conditions. Once the TCC has
been fully applied, it is nearly impossible to make it shudder. TCC
shudder (short burst of noise normally less than 1 second) will only
occur during clutch applying. It is not a steady state condition.
Drive until whole drivetrain is at normal operating temperature.

– Shudder is a SHORT BURST OF NOISE NORMALLY LESS THAN 1
SECOND IN DURATION, and can be induced by the following
maneuver:
From coast condition at 50 mph in “D” range (Normal mode), depress

the throttle to 1/4-1/3 throttle. NO Perform mechanical inspection of
If present, shudder (short burst of noise normally less than 1 sec.) will
other drivetrain components.
occur within 5 seconds together with TCC applying.
(TECH2 may be used to determine the exact time of TCC applying)
YES
Replace transmission fluid and filter (remove both pans) and flush
cooler lines.
Replace converter assembly and O-ring on turbine shaft.
CHART 14: POSSIBLE CAUSES OF TRANSMISSION NOISE
CAUTION:
Before checking transmission for what is believed to be transmission noise,
ensure presence and positioning of insulating plugs, pads etc. Also make
sure that noise does not come from other drivetrain components.
1. WHINE OR BUZZ:
– Oil level low
– Plugged or restricted oil filter
– Damaged oil filter gasket
2. KNOCKING NOISE FROM FRONT OF TRANSMISSION:

– Loose bolts (Converter to flex plate)
– Cracked or broken flex plate
– Converter damaged
3. KNOCKING NOISE WHILE DRIVING - MOSTLY ON ACCELERATION:

– Transmission mount loose or broken
– Cooler line mounts loose or broken
– Cooler lines touching body or frame
4. KNOCKING NOISE WHEN VEHICLE IS STATIONARY:

– Loose flex plate mounting bolts
– Cracked or broken flex plate
– Damaged converter
CHART 15a: POSSIBLE CAUSES OF LOW LINE PRESSURE
Check oil level
OK
Check for defective throttle position sensor

ON-VEHICLE SERVICE
OK
Check for plugged, loose, or damaged oil filter (79)
OK
 Check for force motor plunger (404) stuck. (Remove force motor. Shake and listen for rattle.)
Small 
valve  OK
body 
 Check for feed limit valve (412) stuck
OK
Check for loose bolts (4 & 5)
OK
 Check for pressure regulator valve (208) stuck

TRANSMISSION REMOVED

 OK

Oil
 Check for boost valve (205) stuck
pump


 OK

 Check for intermediate oil passages to pressure regulator valve blocked
OK
Check for defective oil pump (9, 201, 202 & 209)
OK
Check for internal leaks

– Check balls missing or out of location in valve bodies
– Seals cut or damaged
– Gaskets defective, etc.

CHART 15b: POSSIBLE CAUSES OF HIGH LINE PRESSURE

NOTE: If transmission is operating in back-up mode, high line pressure will be
present.
Check for defective throttle position sensor

ON-VEHICLE SERVICE
OK
 Check for force motor plunger (404) stuck

 (Remove force motor. Shake and listen for rattle.)
Small
 (Open circuit/Intermittent)

valve

body  OK


 Check for feed limit valve (412) stuck
OK
Check for loose bolts (4 & 5)
OK
TRANSMISSION REMOVED
 Check for pressure regulator valve (208) stuck



Oil  OK
pump 

 Check for boost valve (205) stuck
OK
Check for internal leaks

– Check balls missing or out of location in valve bodies
– Seals cut or missing
– Gaskets defective, etc.

CHART 16: POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
Before attempting to correct an oil leak, the actual source of the leak must be determined. In many cases,
the source of the leak may be difficult to determine due to “wind flow” around the engine and
transmission.
The suspected area should be wiped clean of all oil before inspecting for the source of the leak.
Oil leaks around the engine and transmission are generally carried toward the rear of the car by the air
stream. In determining the source of an leak, the following two checks should be made:
1. With the engine running, check for external line pressure leaks.
2. With the engine off, check for oil leaks due to the raised oil level caused by drainback of converter oil
into the transmission.
POSSIBLE CAUSES OF FLUID LEAKS

DUE TO SEALING MALFUNCTION
13 14 1 2
3
15 4
12
11
10 9 8 7 6 5
240LW004
1) Electrical connector (Main case) seal

2) Transmission vent (Breather)
3) Speed sensor O-ring
4) Extension (Adapter) lip seal
5) Extension (Adapter) to main case gasket
6) Oil drain plug gasket
7) Oil pan gasket (Main case)
8) Selector shaft seal
9) Oil cooler connectors (2)
10) Oil pan gasket (Adapter case)
11) Converter housing attaching bolts not correctly
torqued
12) Converter housing lip seal
13) Line pressure tap plug
14) Electrical connector (Adapter case) seal
15) Adapter case seal rings (2)
STALL TEST
The stall test allows you to check the transmission for
internal abrasion and the oneway clutch for slippage.
Torque converter performance can also be evaluated.
The stall test results together with the road test results will
identify transmission components requiring servicing or
adjustment.
Stall Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid.
Replenish if necessary.
2. Block the wheels and set the parking brake.
3. Connect a tachometer to the engine.
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 - 80°C (158 - 176°F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Gradually push the accelerator pedal to the floor.
The throttle valve will be fully open.
Note the engine speed at which the tachometer
needle stabilizes.
Stall Speed
Standard
2200 ± 150 rpm
NOTE:
Do not continuously run this test longer than 5
seconds.
8. Release the accelerator pedal.
9. Place the selector in the “N” range.
10. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
11. Repeat Steps 7-10 for the “3”, “2”, “L” and “R”
ranges.
LINE PRESSURE TEST

The line pressure test checks oil pump and control valve
pressure regulator valve function. It will also detect oil
leakage.
Line Pressure Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid.
Replenish if required.
2. Block the wheels and set the parking brake.
3. Remove the pressure detection plug at the left side of
Set pressure gauge, adapter to the pressure detection
plug hole.
Gauge and adapter: 5-8840-0004-0 (J-21867)
4. Start the engine and allow it to idle until the engine

coolant temperature reaches 70 - 80°C (158- 176°F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Note the pressure gauge reading with the engine
idling.
8. Gradually push the accelerator pedal to the floor. The
throttle valve will be fully open.
Note the pressure gauge reading with the accelerator
pedal fully depressed.
NOTE:
Do not continuously run this test longer than 5
seconds.
9. Release the accelerator pedal.
10. Place the selector in the “N” range.
11. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
12. Repeat Steps 7 - 11 for the “3”, “2”, “L”, and “R”
ranges.
13. Install a pressure detection plug to the transmission
case, applying recommended thread locking agent
(LOCTITE 242) or its equivalent to thread of plug.
Make sure that thread is cleaned before applying
locking agents.
14. Tighten the pressure detection plug to the specified
torque.
Pressure Detection Plug Torque N·m (kg·m / lb·ft)
9 – 14 (0.9 – 1.4 / 7 – 10)
Line Pressure and Force Motor Current KPa (kg/cm2 / PSI)

LEVER ENGINE FORCE
MODE LINE PRESSURE MOTOR
POSITION SPEED CURRENT
NORMAL/POWER D, 3, 2, L IDLE 312 – 363 (3.2 – 3.7 / 45.2 – 52.6) VARIABLE
NORMAL/POWER REVERSE IDLE 419 – 486 (4.3 – 5.0 / 60.7 – 70.5) 0.9 – 1.0A
NORMAL/POWER D, 3, 2, L STALL SPEED 1236 – 1320 (12.6 – 13.5 / 179.3 – 191.4) 0.1 – 0.2A
NORMAL/POWER REVERSE STALL SPEED 1634 – 1743 (16.7 – 17.8 / 236.9 – 252.8) 0.1 – 0.2A
SHIFT SPEED CHART

( Transfer gear ratio: High: 1.000
Rear axle ratio: 4.555 )
“Normal mode”
Upshift Km/h (mph)
1→2 2→3 3→4

Range Throttle opening
(First Gear) (Second Gear) (Second Gear) (Third Gear) (Third Gear) (Fourth Gear)
D Fully opened 41 ~ 47 (25 ~ 29) 84 ~ 90 (52 ~ 56) 127 ~ 133 (79 ~ 83)
(Drive) Half throttle 33 ~ 39 (20 ~ 24) 60 ~ 66 (37 ~ 41) 117 ~ 123 (73 ~ 76)
3 Fully opened 49 ~ 55 (30 ~ 34) 99 ~ 105 (62 ~ 66) –
(Third) Half throttle 32 ~ 38 (20 ~ 24) 58 ~ 64 (36 ~ 40) –
2 Fully opened 49 ~ 55 (30 ~ 34) – –
(Second) Half throttle 32 ~ 38 (20 ~ 24) – –
Downshift Km/h (mph)
1←2 2←3 3←4

Fully opened 16 ~ 22 (10 ~ 14) 62 ~ 68 (39 ~ 42) 104 ~ 110 (65 ~ 68)
D
Half throttle 15 ~ 21 (9 ~ 13) 34 ~ 40 (21 ~ 25) 67 ~ 73 (42 ~ 46)
(Drive)
Fully closed 14 ~ 20 (9 ~ 12) 21 ~ 27 (13 ~ 17) 29 ~ 35 (18 ~ 22)
Fully opened 39 ~ 45 (24 ~ 28) 87 ~ 93 (54 ~ 58) –
3
Half throttle 15 ~ 21 (9 ~ 13) 34 ~ 40 (21 ~ 25) –
(Third)
Fully closed 13 ~ 19 (8 ~ 12) 15 ~ 21 (9 ~ 13) –
Fully opened 40 ~ 46 (25 ~ 29) 94 ~ 100 (59 ~ 63) –
2
Half throttle 15 ~ 21 (9 ~ 13) 94 ~ 100 (59 ~ 63) –
(Second)
Fully closed 13 ~ 19 (8 ~ 12) 82 ~ 88 (51 ~ 55) –
L
– 50 ~ 56 (31 ~ 35) – –
(First)
“Power mode”
Upshift Km/h (mph)
1→2 2→3 3→4

D Fully opened 49 ~ 55 (30 ~ 34) 99 ~ 105 (62 ~ 66) 169 ~ 175 (105 ~ 109)
(Drive) Half throttle 37 ~ 43 (23 ~ 27) 74 ~ 80 (46 ~ 50) 124 ~ 130 (77 ~ 81)
3 Fully opened 49 ~ 55 (30 ~ 34) 99 ~ 105 (62 ~ 66) –
(Thire) Half throttle 37 ~ 43 (23 ~ 27) 74 ~ 80 (46 ~ 50) –
2 Fully opened 49 ~ 55 (30 ~ 34) – –
(Second) Half throttle 37 ~ 43 (23 ~ 27) – –
Downshift Km/h (mph)
1←2 2←3 3←4

Fully opened 40 ~ 46 (25 ~ 29) 90 ~ 96 (56 ~ 60) 160 ~ 166 (100 ~ 104)
D
Half throttle 21 ~ 27 (13 ~ 17) 53 ~ 59 (33 ~ 37) 98 ~ 104 (61 ~ 65)
(Drive)
Fully closed 13 ~ 19 (8 ~ 12) 24 ~ 30 (15 ~ 19) 46 ~ 52 (29 ~ 32)
Fully opened 40 ~ 46 (25 ~ 29) 90 ~ 96 (56 ~ 60) –
3
Half throttle 21 ~ 27 (13 ~ 17) 53 ~ 59 (33 ~ 37) –
(Third)
Fully closed 13 ~ 19 (8 ~ 12) 24 ~ 30 (15 ~ 19) –
Fully opened 40 ~ 46 (25 ~ 29) 94 ~ 100 (59 ~ 63) –
2
Half throttle 21 ~ 27 (13 ~ 17) 94 ~ 100 (59 ~ 63) –
(Second)
Fully closed 13 ~ 19 (8 ~ 12) 82 ~ 88 (51 ~ 55) –
L
– 50 ~ 56 (31 ~ 35) – –
(First)
LOCK-UP SPEED CHART

( Transfer gear ratio: High: 1.000
Rear axle ratio: 4.555 )
Km/h (mph)
Lock-Up ON Lock-Up OFF

Mode
D range 2nd 3rd 4th 2nd 3rd 4th
Throttle 75 ~ 81 55 ~ 61 67 ~ 73 70 ~ 76 47 ~ 53 62 ~ 68
opening Normal (47 ~ 50 ) (34 ~ 38) (42 ~ 45) (43 ~ 47) (29 ~ 33) (39 ~ 42)
9%
72 ~ 78 77 ~ 83 77 ~ 83 67 ~ 73 68 ~ 74 72 ~ 78
Power (45 ~ 48 ) (48 ~ 52) (48 ~ 52) (42 ~ 45) (42 ~ 46) (45 ~ 48)
ELECTRONIC DIAGNOSIS
HOW TO DIAGNOSE THE PROBLEM
1. To avoid incorrect diagnostics: this book needs to be
followed accurately. Unless stated: do not jump
directly to a section that could contain the solution:
some important information may be missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The GOTO “SECTION” means to continue to check
going to the “section”.
4. The GOTHROUGH “SECTION” means to go through
the “section” and then to go back to the place the
GOTHROUGH was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory of electricity.
This will include the meaning of voltage, amps,
ohms, and what happens in a circuit with an open or
shorted wire. You should also be able to read and
understand wiring diagrams.
6. IGNITION CYCLE:
When the car is driven a malfunction can occur due to
a car wiring harness problem, in this case the driver
can reset the system (as on a personal computer). To
reset the computer he must:
(1) Stop the car and the engine.
(2) Turn the key ignition OFF.
(3) Turn the key ignition ON.
CHECK TRANS INDICATOR

Find CHECK TRANS indicator and verify if it is:
A. Flashing: GOTO DIAGNOSTIC CHECK.
B. Staying on: GOTHROUGH CHECK TRANS CHECK.
C. Is never ON when the ignition key is turned on:
GOTHROUGH CHECK TRANS CHECK
D. Is ON during 2 to 3 seconds at ignition but OFF after:
CHECK Normal operation. No DTC or malfunction.
TRANS
821LW003
DIAGNOSTIC CHECK
This test determines if the transmission itself or its
inputs or outputs connections or sensors are failing.
IF you have a scan tool TECH2:
NO: Use the CHECK TRANS Indicator diagnostic
codes GOTO FLASHING CODES.
YES:
1. Connect the TECH2: GOTHROUGH TECH2
CONNECTION.
2. Turn on the ignition but not the engine.
3. Push “F2” on TECH2 to see the Diagnostic Trouble
Code (DTC):
4. IF you have DTC?
YES: write down all code numbers and do the DTC
CHECK
NO: the DTC can not help you finding the problem.
(1) GOTHROUGH “CHECK TRANS” CHECK
(2) IF it is flashing and the flash is 0.2 seconds ON
and 0.2 seconds OFF, this means that you should
IGN Key ON have a DTC stored. Please recheck GOTO
ON DIAGNOSTIC CHECK and if you find the same
Normal problem GOTO TCM MEM-CAL REPLACEMENT.
OFF
(3) IF the CHECK TRANS indicator is not flashing
GOTO WITHOUT DTC SET.
3 Sec.
(Lamp check)
IGN Key ON
0.2 Sec.
ON
(2.5 Hz)
Abnormal OFF
0.2 Sec.
3.2 Sec.
3 Sec.
(Lamp check)
“CHECK TRANS” CHECK

1. CASE it is ON during 2 to 3 seconds at ignition (or
when the engine is cranked) but it is OFF after. The
indicator is working normally GOTO DIAGNOSTIC
IGN Key ON
CHECK.
ON
Normal 2. CASE it is flashing and the flash is 0.2 seconds ON
OFF
and 0.2 seconds OFF always when ignition is on
(engine cranked or not). This means that there is a
3 Sec.
(Lamp check) malfunction. GOTO DIAGNOSTIC CHECK.
IGN Key ON
0.2 Sec.
ON
(2.5 Hz)
Abnormal OFF
0.2 Sec.
3.2 Sec.
3 Sec.
(Lamp check)
3. CASE the CHECK TRANS indicator is flashing always

and the flash is 0.4 seconds ON and 0.4 second OFF.
(1) This means that the Transmission Control Module
(TCM) is in flashing code mode. This mode is only
used for service. This mode is set when the
terminal 11 of data link connector C-102 is set to
ground. To go out of this mode.
(2) Check if terminal 11 of data link connector C-102
is shorted to ground. (Voltage is about 0 volts
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 when there is a short to ground instead of 5
volts).
(3) Check if TCM terminal D16 has the same problem.
826RV061
(4) Remove the short circuit to ground due to wiring
problems.
(5) IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO: GOTO TCM MEM-CAL REPLACEMENT.
4. CASE it is staying ON always when Ignition is ON.

(1) This means that connection between the Lamp
and the TCM is shorted to ground.
(2) Verify if instrument panel terminal 8 of connector
B-24 is shorted to ground.
(3) Verify if the TCM connector C-95 terminal C10 is
shorted to ground.
(4) Verify that the instrument panel terminal 2 of con-
nector B-24 is connected to battery.
INDICATOR.
5. CASE it is staying OFF with the ignition ON (engine
OFF).
(1) This means that connection between the lamp
and the TCM is shorted to battery or opened.
(2) Verify if instrument panel terminal 8 of connector
B-24 is shorted to battery or open.
(3) Verify if the TCM connector C-95 terminal C10 is
shorted to battery or open.
(4) Verify that the instrument panel terminal 2 of
connector B-24 is connected to battery. If not
check the fuses and the connections voltage.
INDICATOR.
H-26
ORN/BLU
FUSE FUSE BOX
CB-5
15A
C10(10) C-95
CHECK TRANS TRANSMISSION

INDICATOR CONTROL
CONTROL MODULE
(TCM)
2 B-24
DIAGNOSTIC
INPUT
D16(16) C-95
CHECK TRANS
(METER)
YEL/BLK
8 B-24 4 5
11
DATA LINK
ORN/BLU CONNECTOR
(C-102)
D07LW004
FLASHING CODES
IGN Key ON
1. ON BOARD DIAGNOSIS (SELF-DIAGNOSIS)
ON
(1) The Transmission Control Module (TCM)
Normal conducts a self-test of most of the wiring and
OFF
components in the system each time the key is
turned ON. If a fault is detected the TCM will store
3 Sec.
(Lamp check)
a Diagnostic Trouble Code (DTC) in memory. It’s a
number that corresponds to a specific problem.
(2) When the problem detected is important: the
CHECK TRANS indicator is flashing (turned ON
IGN Key ON 0.2 seconds and OFF 0.2 seconds) until the fault is
0.2 Sec. repaired and the TCM memory is cleared.
ON
(2.5 Hz)
Abnormal OFF
0.2 Sec.
3.2 Sec.
3 Sec.
(Lamp check)
2. DIAGNOSTIC TROUBLE CODES (DTC)

(1) DTC can be displayed by the Transmission
Control Module (TCM) by shorting together
terminals 11 and 4 or 5 (ground) of the TCM
Diagnosis Connector (C-102) located driver
compartment.
(This grounds the TCM pin D16).
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
826RV061
(2) After this, the CHECK TRANS Indicator will be OFF

for 3.2 second and then will flash each DTC 3
times.
1 When there are more than 9 flashes this
means that the indicator is constantly flashing,
OFF for 0.4 seconds, ON for 0.4 seconds. In
this case there is no DTC stored in memory.
• To find the problem without a scan tool and
without DTC GOTO WITHOUT DTC SET.
2 When there are less than 9 flashes you will
see DTC of 2 digits repeated 3 times each and
when all codes have been displayed they are
displayed again beginning from the first one.
3 Do not care about the DTC order : if “21” is
before “22” it does not matter.
4 Write down all codes numbers and GOTO DTC
CHECK.
(3) IF CHECK TRANS indicator is not flashing GOTO
“CHECK TRANS” CHECK.
Diagnostic test start

0.4 Sec. 0.4 Sec.
ON
Normal (1.25 Hz)
OFF
3.2 Sec. 0.4 Sec.

0.4 Sec.
The trouble code(s) will flash 3 times.

Example: DTC 11 x 3 (times), DTC 32 x 3 (times)
Diagnostic test start
0.4 Sec. 0.4 Sec. 0.4 Sec. 0.4 Sec.
Abnormal ON
OFF
3.2 Sec. 1.2 Sec. 0.4 Sec. 1.2 Sec. 0.4 Sec.
TECH2 CONNECTION
In order to access Transmission Control Module (TCM)
data, use of the TECH2 scan tool is required.
1. The electronic diagnosis equipment is composed of:
(1) TECH2 (3000094) hand-held scan tool, and DLC
cable (3000095).
(2) SAE 16/19 adapter (3000098) (1), RS 232 loop back
connector (3000112) (2), and PCMCIA card
(3000117) (3).
901RW176
2
3
F07RW033
3
4
Legend
1. PCMCIA Card
2. RS232 Loop Back Connector
3. SAE 16/19 Adaper
4. DLC Cable
5. Tech2
901RW180
2. Connecting the TECH2

NOTE:
Always observe instructions in the TECH2 and Isuzu
System PCMCIA card.
Before operating the Isuzu PCMCIA card with the TECH2,
the following steps must be performed:
1. The Isuzu98 System PCMCIA card (1) inserts into the
TECH2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable(4).
3. Connect the DLC cable to the TECH2 (5).
4. Make sure the vehicle ignition is off.
5. Connect the TECH2 SAE 16/19 adaptor to the vehicle

DLC.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
826RV061
6. The vehicle ignition turns on.

7. Verify the TECH2 power up display.
NOTE:
The RS232 Loop back connector is only to use for
diagnosis of TECH2 and refer to user guide of the TECH2.
Press (ENTER) To Continue
060RW009
CLEAR DTC
Remark: If you clear the DTC (Diagnosis Trouble
Codes) you will not be able to read any codes
recorded during the last Trouble.
Remark: To be able to use the DTC again to identify a
problem you will need to reproduce the fault or the
problem. This may require a new test drive or just
turning the ignition on (this depends on the nature of
the fault).
1. IF you have a TECH2:
(1) Connect the TECH2 if it is still not connected
GOTHROUGH TECH2 CONNECTION.
(2) Push “F4” and answer “Yes” to the question “Do
you really want to clear the codes?”
1 When a malfunction remains as it is the
TECH2 displays “4L30E CODES NOT
CLEARED”. This means that the problem is
still there or that the recovery was not done
please GOTO DTC CHECK.
2 When a malfunction has been repaired and
the recovery is done the TECH2 displays
“4L30E CODES CLEARED”.
2. IF you have no TECH2:
(1) Short the Data Link Connector C-102 terminal 11
to terminal 4 or 5 (ground).
1 IF it is flashing and the flash is 0.4 seconds ON
and 0.4 second OFF without interruption, this
means that there is no DTC. The DTCs are
1 2 3 4 5 6 7 8
already cleared.
9 10 11 12 13 14 15 16 (2) IF a code is flashed, wait until the lamp is
flashing.
(3) Push POWER SWITCH (do this within 3 second).
826RV061
1 If you continue to have malfunctions: This
means that the problem is still there or that
the recovery was not done please see DTC
CHECK.
(4) IF you can not clear the DTC:
1 GOTHROUGH TCM PRECAUTIONS.
2 Disconnect the TCM.
3 Reconnect the TCM.
4 IF the DTC is not cleared: GOTO TCM MEM-
CAL REPLACEMENT.
DTC CHECK
1 Diagnosis Trouble Codes (DTC) have been identified
by TECH2 or FLASHING CODES.
2. You have written the list of the DTC. The order of the
malfunctions has no meanings for this TCM. Usually
only one or two malfunctions should be set for a
given problem.
3. Check directly the DTCs you identified. The DTC are
sorted by number. See Chart 2:
DIAGNOSTIC TROUBLE CODES (Page 7A1-63).
F0: DATA LIST QUICK CHECK

TECH2 DISPLAY CONDITONS CORRECT VALUE FOR
DIAGNOSIS
SEE*1
BATTERY VOLTAGE Ignition ON 9 V ≤ voltage ≤ 15.5 V DTC 25
(V) or 26
FORCE MOTOR CUR. Engine at idle speed approx. 0.9 A DTC 35
CALCULAT. PRESS. Parking brake on approx. 4.0 bar
Selector lever position ”D“
SOLENOID A Vehicle traveling at a speed of: approx. ACTIVE DTC 31

50 km/h (32 mph) with selector lever in or 41
position ”2“ or approx. 70 km/h (44 mph)
with selector lever in position ”3“
SOLENOID B Vehicle traveling at a speed of: approx. ACTIVE DTC 32
10 km/h (6 mph) with selector lever in or 42
position ”L“ or approx. 30 km/h (18 mph)
with selector lever in position ”2“
BAND APPLY SOL. Engine at idle speed approx. 99% DC DTC 34
Selector lever position ”L“ or 44
TCC SOLENOID Vehicle traveling at a speed of approx. ON DTC 33
80 km/h (50 mph) or 43
TCC SLIP RPM Constant engine speed 0±10 RPM DTC 33
Selector lever position “D” or 43
TCC on
BRAKE SWITCH Ignition ON ACTIVE DTC 55
Brake pedal pressed or 56
AT INPUT SPEED Engine speed ≤ 200 rpm Engine speed: (RPM) DTC 13
Output speed > 1024 rpm or 62
Selector lever position ”D“, ”3“, ”2“, ”L“
AT OUTPUT SPEED Output speed ≤ 0 rpm Output speed: DTC 11
Engine speed > 3000 rpm (RPM) or 13
Selector lever position ”D“, ”3“, ”2“, ”L“
BAROMETER Engine at idle speed 0.9 ~ 1.0 bar –
SENSOR approx. 0.02 V
SELECTOR POS. Ignition ON Dependent on DTC 53
Shift through all selector lever positions selector lever position or 54
P, R, N, D, 3, 2, L
ACTUAL GEAR Vehicle traveling at a speed of approx. -4- DTC 61
100 km/h (62 mph)
NOTE: (*1) FOR DIAGNOSIS OF A DTC SEE CHART 2: DIAGNOSTIC TROUBLE CODES (DTC)
(PAGE 63)
F0: DATA LIST QUICK CHECK (continued)

TECH2 DISPLAY CONDITONS CORRECT VALUE FOR
DIAGNOSIS
SEE*1
SELECTOR PIN A Ignition ON ACTIVE DTC 53
Selector lever position: or 54
”P“, ”R“, ”3“ or ”2“
SELECTOR PIN B Ignition ON ACTIVE DTC 53
”R“, ”N“,”D“ or ”3“
SELECTOR PIN C Ignition ON ACTIVE DTC 53
”D“, ”3“, ”2“ or ”L“
SELECTOR PIN P Ignition ON ACTIVE DTC 53
”P“, ”N“, ”3“ or ”L“
TPS SIGNAL Ignition ON
Throttle body in idle speed position 0.1 V to 0.96 V (0%) DTC 21
Throttle body in full load position 4.9 V or less (99%) or 22
KICK DOWN SWITCH Ignition ON ACTIVE DTC 52
Depress accelerator pedal to stop
A/C REQUEST Engine running. Air conditioning ON. ACTIVE CHECK WIRE
Compressor engaged. FROM TCM
CONNECTOR
C-91
TERMINAL
D8 FOR
OPEN
CIRCUIT.
TRANSM. OIL TEMP. Engine running 70 - 120°C/158 - 248°F DTC 15
approx. 1.00 ~ 3.10 V or 16
COOLANT TEMP SW. Ignition ON: Engine warm COLD (≤ 63°C) DTC 51
WARM (> 70°C)
POWER SWITCH Ignition ON ACTIVE TRANSMIS-
Press “POWER” switch SION
OPERATING
MODE TEST
POWER LAMP Engine running ON SEE PAGE
Press “POWER” switch 133
• IF ALL VALUES ARE CORRECT, CONTINUE DIAGNOSIS WITH F5: ACTUATOR TEST QUICK CHECK.
NOTE: (*1) FOR DIAGNOSIS OF A DTC SEE CHART 2: DIAGNOSTIC TROUBLE CODES (DTC)
(PAGE 63)
CHART 1
DIAGNOSIS CONNECTOR AND VOLTAGE SUPPLY TEST
RELAY &
FUSE FUSE FUSE
EB-12 EB-14 BOX
10A 20A
RED/
GRN
3 2 X-18
ECM
MAIN
RELAY
GRN
5 1 X-18
BLU/ RED/
RED BLU
RED/BLU
TO ECM
A4(4) A7(7) A8(8) C-96
BATTERY TRANSMISSION
IGNITION CONTROL
INPUT INPUT MODULE (TCM)
GROUND DIAGNOSTIC
SERIAL DATA
INPUT
C1 D1 C8 D16 C-95
(1) (17) (8) (32)
BLK BLK
YEL
YEL
YEL/BLK
BLK
YEL
35 E-61 4 5 9 11
DATA LINK CONNECTOR (C-102) 作業番号 10012
ENGINE CONTROL MODULE (ECM) 発注者鈴木発注日 '97/ 12

受注番号希望納期 ''97/ 1
ｲﾗｽﾄｻｲｽﾞ 180 × 230 ｲﾗｽﾄ担当大野 /
ﾊﾟｰﾂｲﾗｽﾄ番号
対象車型 T F R
イラスト区分ＢＫＴＧＳ L D C
資料区分 W O Y T S
D07LW005
CHART 1
DIAGNOSIS CONNECTOR AND VOLTAGE SUPPLY TEST
TECH2 REFERS TO CHART 1 WHEN THE EQUIPMENT IS CORRECTLY CONNECTED, BUT NO DATA (WITH IGNITION ON) IS RECEIVED
FROM TECH2.
• PERFORM TECH2 SELF-TEST.

IS TECH2 OK?
YES NO
• IGNITION SWITCH OFF. SEE TECH2 OPERATOR’S MANUAL.

• DISCONNECT TCM CONNECTOR C-95 AND C-96.
• IGNITION SWITCH ON.
• CONNECT VOLTMETER BETWEEN TERMINAL A4 AND
GROUND TERMINAL C1 OR D1 OF TCM CONNECTOR.
• THEN CONNECT VOLTMETER BETWEEN TERMINAL A7
OR A8 AND GROUND TERMINAL C1 OR D1 OF TCM
CONNECTOR.
DO BOTH DISPLAYS INDICATE BATTERY VOLTAGE?
YES NO
• IGNITON SWITCH OFF. CHECK FUSE OR WIRE FOR OPEN.

• CONNECT OHMMETER BETWEEN TERMINAL 11 OF 16-PIN
DATA LINK CONNECTOR C-102 AND TERMINAL D16 OF
TCM CONNECTOR C-95.
• THEN CONNECT OHMMETER BETWEEN TERMINAL 4 OR 5
OF 16-PIN DATA LINK CONNECTOR C-102 AND GROUND.
DO BOTH DISPLAYS INDICATE APPROXIMATELY 0 OHMS?
YES NO
• CHECK FOR SHORT BETWEEN TERMINAL D16 AND CHECK WIRE FOR OPEN.
GROUND AND BETWEEN TERMINAL D16 AND B+.
IF OK, GOTO TCM MEM-CAL REPLACEMENT.
CHART 2: DIAGNOSTIC TROUBLE CODE (DTC)
FOR
DTC MALFUNCTION DIAGNOSIS
SEE PAGE
11 OUTPUT SPEED FAILURE 7A1 - 66

13 ENGINE SPEED FAILURE 7A1 - 70
15 TRANSMISSION OIL TEMPERATURE SHORT TO PLUS OR OPEN 7A1 - 72
16 TRANSMISSION OIL TEMPERATURE SHORT TO GROUND 7A1 - 74
21 THROTTLE POSITION SENSOR SHORT TO PLUS 7A1 - 76
22 THROTTLE POSITION SENSOR SHORT TO GROUND OR OPEN 7A1 - 78
23 THROTTLE POSITION SENSOR CONNECTOR OPEN 7A1 - 80
25 SUPPLY VOLTAGE TOO LOW 7A1 - 82
26 SUPPLY VOLTAGE TOO HIGH 7A1 - 84
31 SOLENOID A SHORT TO GROUND OR OPEN 7A1 - 86
32 SOLENOID B SHORT TO GROUND OR OPEN 7A1 - 88
33 TCC HIGH SHORT TO PLUS OR OPEN 7A1 - 90
34 BAND APPLY SOLENOID SHORT TO GROUND OR OPEN 7A1 - 94
35 FORCE MOTOR OPEN OR SHORT TO PLUS OR GROUND 7A1 - 96
36 SHIFT HIGH SHORT TO GROUND OR OPEN 7A1 - 98
37 TORQUE MANAGEMENT SERIAL LINE FAULTY 7A1 - 100
41 SOLENOID A SHORT TO PLUS 7A1 - 102
42 SOLENOID B SHORT TO PLUS 7A1 - 104
43 TCC HIGH SHORT TO GROUND 7A1 - 106
44 BAND APPLY SOLENOID SHORT TO PLUS 7A1 - 108
46 SHIFT HIGH SHORT TO PLUS 7A1 - 110
51 ENGINE COOLANT SWITCH SHORT TO GROUND, PLUS OR OPEN 7A1 - 112
52 KICK DOWN ALWAYS ON OR SHORT TO GROUND 7A1 - 114
53 MODE SWITCH IN P OR N OR R BAD POSITION 7A1 - 116
54 MODE SWITCH ILLEGAL POSITION 7A1 - 118
55 BRAKE SWITCH SHORT TO GROUND OR OPEN 7A1 - 120
56 BRAKE SWITCH SHORT TO PLUS 7A1 - 122
61 GEAR ERROR 7A1 - 124
62 DOWNSHIFT PROTECTION 7A1 - 126
63 EPROM CSUM FAILURE 7A1 - 129
82 SHIFT OR BAND APPLY SOLENOIDS FAULTY DURING DRIVING 7A1 - 130
CHART 3: TRANSMISSION AND TCM IDENTIFICATION

Chart 3 contains a list of all important information concerning rear axle ratio, Transmission Control Module
(TCM), and transmission identification.
VEHICLE TCM TRANSMISSION

Rr axle
Ratio Calibration
Type Engine ISUZU Parts No. Isuzu Part No. Model Code
Code
Isuzu/
3.2L V6 4.555 8-09350-909-0 G22 8-96018-434-0 FV (4X2)
TFR
The idenification plate is

located on the left-hand side
of the transmission above the
mode switch. C
A
1 B D
E F
AT Transmission identification on
vehicle identification plate :
HYDRAMATIC PART No.
1. Model code
STRASBOURG
MADE IN FRANCE
96 018 434 2. Calibration code
SAL SERIAL No. TCM IDENTIFICATION:
3. Production serial number
G 22 0000 000
4. Production part number A. ISUZU part number
B. Model of car
C. DELCO part number
2 3 4 D. Application
E. Service TCM number
F. Broadcast code
F07LW001
CHART 5: F5: ACTUATOR TEST QUICK CHECK

Before carrying out the Actuator Test, the selector lever should be placed in selector position ”N“.
The ignition should be switched ON, engine not running.
FOR
TECH2 DISPLAY NOTES CORRECT RESULT DIAGNOSIS
SEE1
SOLENOID A Press arrow up (ON) “Click” heard from DTC 31
Press arrow down (OFF) transmission or 41
SOLENOID B Press arrow up (ON) “Click” heard from DTC 32
SHIFT SOLENOID Press arrow up (ON) “Click” heard from DTC 82
Press arrow down (OFF) transmission
TCC SOLENOID Not used – –
TCC HIGH (D) Press arrow up (ON) “Click” heard from DTC 33
POWER LAMP Press arrow up (ON) POWER lamp ON TRANSMISSION
Press arrow down (OFF) OPERATING
MODE TEST
(PAGE 133)
CHK. TRN. LAMP Press arrow up (ON) CHECK TRANS lamp CHECK TRANS
Press arrow down (OFF) ON CHECK (PAGE 50)
1 FOR DIAGNOSIS OF A DTC SEE CHART 2: DIAGNOSTIC TROUBLE CODES (DTC) (PAGE 63)
DIAGNOSTIC TROUBLE CODE (DTC) 11

OUTPUT SPEED FAILURE
This DTC flashes the CHECK TRANS indicator and Diagnostic Aids:
sets the BACKUP MODE. • This diagnostic is not an electrical test done by
the TCM but a test between different information
Circuit Description: (“logic test”).
The transmission output speed sensor provides • Detection conditions:
information on vehicle speed to the Transmission 1 Output Speed < or = 0 RPM.
Control Module (TCM). The speed sensor circuit 2 Engine Speed > 3000 RPM.
consists of a magnetic induction type sensor. The 3 No Malfunction: Engine Speed DTC 13. Mode
sensor is mounted above a target wheel pressed on Switch DTC54.
the output shaft in the transmission extension. As 4 Selector lever not in Park, Reverse, or Neutral.
the output shaft turns, the target wheel teeth induce 5 The conditions need to be present for at least
a variable voltage in the magnetic pickup. This 5 seconds.
alternating current (AC) signal is provided to the • Action after the detection time:
TCM. The voltage increases with the speed of the 1 CHECK TRANS Indicator is turned ON.
wheel but this is not used to define the speed of the 2 TCM in BACKUP MODE
vehicle. As the vehicle moves faster, the signal • Recovery conditions : To recover do an IGNITION
alternates faster between positive and negative CYCLE.
voltages. The Output speed information is
proportional to the frequency of the signal.
TRANSMISSION SPEED
SENSOR SHIELDS
H-23 PNK TRANSMISSION

C-96 M-15
+ PNK
10 1
SPEED SENSOR
A12(12)
OUTPUT
SPEED
INPUT
BLU BLU
—
B12(24) 11 2
B11(23) 9
GROUND C-95 BLK

C1(1) H-25
BLK BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW006

OUTPUT SPEED FAILURE
CAUTION: If wire to connector C-96 terminal B12 is short to voltage, Transmission Control Module
(TCM) will be damaged.
IF the DTC 53 is set:
YES NO
GOTHROUGH DTC 53 first IF you have a SCAN TOOL: TECH2?

and do a test drive.
YES NO
• Raise drive wheels.

• Connect the TECH2 GOTHROUGH TECH2
• Ignition switch OFF.
CONNECTION.
• Disconnect TCM connector C-95 and C-96.
• Push “F0”: DATALIST: DISPLAY. Read “AT OUTPUT
• Connect ohmmeter between connector C-96 terminal
SPEED”.
A12 and terminal B12.
IF: Output Speed different from 0 RPM when the wheels
IF: display is approx. 3K ohms:
are turning:
YES NO
YES NO
Problem is intermittent.
GOTO INTERMITTENT
CONDITIONS. • Connect ohmmeter between connector • Disconnect transmission speed
C-96 terminal A12 and ground connector sensor connector M-15.
C-95 terminal C1. • Connect ohmmeter between
IF: display indicates an open circuit: terminals 1 and 2 of the speed
sensor.
IF: display approx. 3K ohms:
NO
YES YES NO
Check for faulty TCM connection. • Wires from Connector

IF OK GOTO TCM MEM-CAL C-96 to sensor
REPLACEMENT. connector are open or
shorted together.
• Repair.
HINT: the wire between TCM terminal B12 and sensor connector M-15 terminal 2
can be shorted to ground or open without creating a problem because the TCM
B12 pin is connected to the TCM ground internally and the signal is detected only
Replace transmission
on the A12 input.
speed sensor.
• Check wire for a short to ground between terminal A12 and sensor connector
M-15 terminal 1.
IF: display indicates a short circuit:
A
CONTINUED
ON NEXT PAGE
CONTINUED FROM
PREVIOUS PAGE
A
YES NO
Repair. • Connect voltmeter between connector C-96

terminal A12 and ground connector C-95
terminal C1.
• Ignition switch ON.
IF: display indicates approximately 0 volt:
YES NO
Check for faulty TCM Check wire for a short

connectors. to voltage between
IF OK GOTO TCM terminal A12 and
MEM-CAL speed sensor
REPLACEMENT. connector M-15.
MEMO

ENGINE SPEED FAILURE
This DTC flashes the CHECK TRANS indicator and • Detection conditions:
set the BACKUP MODE. 1 Engine speed < or = 200 RPM.
2 Output Speed > 1024 RPM.
Circuit Description: 3 Acceleration > 2 Km/h/s.
The Engine Control Module (ECM) sends a signal to 4 No DTC: Output Speed DTC11, Downshift
the Transmission Control Module (TCM) that Protection DTC62 or Mode Switch Illegal
indicates engine speed in RPM. When the vehicle is Position DTC54.
in neutral gear and the engine is at idle, the engine 5 Selector Lever not in Park or Neutral.
speed should be approximately 800 RPM.
6 The conditions need to be present for at least
Diagnostic Aids: 0.5 second.
• This Diagnostic is not an electrical test done by • Action after the detection time: BACKUP MODE
the TCM but a test between different information • Recovery conditions: To recover do an IGNITION
(“logic test”). CYCLE
H-6
TACHOMETER ( METER B-24 3 )
C-95 16
BLK/RED H-20 BLK/RED
ENGINE
D12(28) 6 12 E-61
RPM
ECM
INPUT ENGINE
RPM
OUTPUT
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW007

ENGINE SPEED FAILURE
Install scan tool.

• Engine running at idle.

• Brake applied.
• Selector lever position “N” or “P”.
• Selector “F0: DATA LIST: AT INPUT
SPEED”.
IF: TECH2 DISPLAY approximately 800
RPM:
YES NO
This system is functioning correctly. IF: Tachometer displays engine speed?

The problem is probably intermittent.
GOTO
INTERMITTENT CONDITIONS.
YES NO
• Check wire for open or short to ground or short to

voltage between Transmission Control Module (TCM)
and connector C-95 & C-96, and connector C-95
terminal D12 and engine control module (ECM)
connector E-61 terminal 12, and check intermediate
connector H-20 terminal 6.
• Repair harness. If still not working: GOTO TCM MEM-
CAL REPLACEMENT.
• Check wire for open or short to ground or short to

voltage between Tachometer connector B-24
terminal 3 and engine control module (ECM)
connector E-61 terminal 12 or between these
terminals and intermediate connector H-6 terminal
16.
• Repair harness. If still not working:
Check Engine electrical section.
If still problem, replace engine control module
(ECM).

TRANSMISSION OIL TEMPERATURE SHORT TO PLUS OR OPEN
This DTC does NOT flash the CHECK TRANS Table:

indicator and does NOT set the BACKUP MODE. °C °F Resistance (kΩ)
–40 –40 672
Circuit Description: 0 32 65
• The transmission oil temperature sensor is a 20 68 25
thermistor within the internal wiring harness of 80 176 2.5
the transmission in the adaptor case oil pan. The
120 248 0.78
Transmission Control Module (TCM) applies 5
150 304 0.37
volts to the sensor connector M-6 terminal 3(C).
The other side of the sensor is connected to
Diagnostic Aids:
ground through the TCM terminal C14.
• This Diagnostic is an electrical test done by the
When the transmission oil is cold, the sensor
TCM.
resistance is high and the TCM will sense high
• Detection conditions:
signal voltage.
1 Voltage between terminals B3 and C14 > 4.74
• As the transmission oil temperature warms to
normal transmission operating temperature of volts.
80°C (176°F), the sensor resistance becomes less 2 The condition needs to be present for at least
and the voltage decreases at about 3.5 volts. 20 seconds. Note: during the detection time
Note, for more accuracy the measurement is the TCM reads the high voltage that defines a
done differently for low temperature (less than –40°C temperature.
45°C) and high temperature (more than 50°C). • Action after the detection time: Default Trans-
• When DTC15 is set, the transmission will use a mission Oil Temperature is set to 100°C.
warm value for operation, but the scan tool will • Recovery conditions: To recover when voltage <
display the actual oil temperature. or = to 4.74 volts after detection time.
• Table shows thermistor resistance at different
temperatures.
C-96 H-38
GRY GRY
TRANSMISSION M-6
B3(15) 2 3(C)
OIL
AUTOMATIC
TEMPERATURE
TRANSMISSION
SENSOR
INPUT
TRANSMISSION
OIL
TEMPERATURE
SENSOR
C-95 5(D) M-6

BLU BLU
C14(14) 1
GROUND
BLK
C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW008

TRANSMISSION OIL TEMPERATURE SHORT TO PLUS OR OPEN
Install scan tool

• Ignition switch ON. Engine not running.

• Selector lever position “P”.
• Select “F0: DATA LIST: Trans. Oil Temp”.
IF: TECH2 DISPLAY more than 4.74 Volts:
YES NO
• Connect voltmeter between connector DTC 15 is intermittent.

C-96 terminal B3 and connector C-95 GOTO INTERMITTENT CONDITIONS.
ground terminal C1.
IF: If you have more than
approximately 4.74 Volts:
YES NO
• Check for a short to plus or open between connector GOTO TCM MEM-CAL REPLACEMENT.
C-96 terminal B3 and connector C-95 terminal C14.
This faulty connection can be at the connector M-6
terminal 3 (C) or 5 (D). This faulty connection can be
at the intermediate connector H-38 terminals.
• Repair
If not OK: Disconnect sensor.
• Connect ohmmeter between sensor terminals 3(C)
and 5(D).
Refer to the table of the resistance function of the
temperature.
If resistance not correct, replace the transmission oil
temperature sensor.

TRANSMISSION OIL TEMPERATURE SHORT TO GROUND
This DTC does NOT flash the CHECK TRANS warm value for operation, but the scan tool will
indicator and does NOT set the BACKUP MODE. display the actual oil temperature.
• Table shows thermistor resistance at different
Circuit Description: temperatures.
• The transmission oil temperature sensor is a
thermistor within the internal wiring harness of Diagnostic Aids:
the transmission in the adaptor case oil pan. The • This Diagnostic is an electrical test done by the
Transmission Control Module (TCM) applies 5 TCM.
volts to the sensor connector M-6 terminal 3(C). • Detection conditions:
The other side of the sensor is connected to 1 Voltage between terminals B3 and C14 < 0.4
ground through the TCM terminal C14. When the volts.
transmission oil is cold, the sensor resistance is 2 The condition needs to be present for at least
high and the TCM will sense high signal voltage. 20 seconds. Note: during the detection time
• As the transmission oil temperature warms to the TCM reads the low voltage that defines a
normal transmission operating temperature of 170°C temperature.
80°C (176°F), the sensor resistance becomes less • Action after the detection time: Default Trans-
and the voltage decreases at about 3.5 volts. mission Oil Temperature is set to 100°C.
Note, for more accuracy the measurement is • Recovery conditions: To recover when voltage >
done differently for low temperature (less than or = to 0.4 volts after detection time.
45°C) and high temperature (more than 50°C).
• When DTC16 is set, the transmission will use a
C-96 H-38
GRY GRY
TRANSMISSION M-6
B3(15) 2 3(C)
OIL
AUTOMATIC
TEMPERATURE
TRANSMISSION
SENSOR
INPUT
TRANSMISSION
OIL
TEMPERATURE
SENSOR
C-95 5(D) M-6

BLU BLU
C14(14) 1
GROUND
BLK
C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW008

TRANSMISSION OIL TEMPERATURE SHORT TO GROUND
Install scan tool

• Ignition switch ON. Engine not

running.
• Select “F0: DATA LIST: Trans. Oil
Temp”.
IF: TECH2 DISPLAY less than 0.4 Volts:
YES NO

C-96 terminal B3 and connector C-95 GOTO INTERMITTENT CONDITIONS.
ground terminal C1.
IF: If you have less than approximately
0.4 Volts:
YES NO
• Check for a short to ground between GOTO TCM MEM-CAL REPLACEMENT.

connector C-96 terminal B3 and
connector M-6 terminal 3 (C). This
faulty connection can be at the
intermediate connector H-38 terminal
2.
• Repair
• Connect ohmmeter between sensor
terminals 3(C) and 5(D).
Refer to the table of the resistance
function of the temperature (DTC 15).
If resistance not correct, replace
sensor.

THROTTLE POSITION SENSOR SHORT TO PLUS
This DTC flashes the CHECK TRANS indicator and • This TPS is an electrical component and must not
sets the BACKUP MODE. be soaked in any liquid cleaner or solvent, as
damage may result.
• The Throttle Position Sensor (TPS) provides a Diagnostic Aids:
voltage signal that changes relative to the throttle • This Diagnostic is an electrical test done by the
plate position. Signal voltage between connector TCM.
C-95 terminals C5 and C6 will vary from about 0.4 • Detection conditions:
at idle to about 4.6 volts at wide open throttle. 1 Voltage between connector C-95 terminals C5
• The Engine Control Module (ECM) also receives and C6 > 4.9 volts. This detection occurs
this signal. This TPS is a variable resistance with when: The wiper is short to voltage (engine
one side (connector E-68 terminal 1) connected can stall).
only to the ECM connector to have the 5 volts 2 The condition needs to be present for at least
supply voltage. The other side (connector E-68 0.5 seconds. Note: during the detection time
terminal 3) is connected to the Transmission the TCM reads “100% (wide open throttle)”.
Control Module (TCM) (floating ground) and the • Action after the detection time: BACKUP MODE.
ECM (ground). The “middle” (the wiper) (con- • Recovery conditions: To recover when voltage <
nector E-68 terminal 2) is connected to the TCM or = to 4.9 volts and do an IGNITION CYCLE.
and the ECM.
• The ECM monitors output voltage from the TPS
and determines fuel delivery based on throttle
valve angle (driver demand).
GRN
1 E-68
THROTTLE
TPS C-95 BLU H-25 BLU E-68 POSITION
BLU
INPUT C5(5) 2 SENSOR
5
(TPS)
3 E-68
BLU
GRN GRY GRY

GROUND
C6(6) 3
GRY
27 26 39 E-61
TRANSMISSION
CONTROL
MODULE(TCM) 5VOLT TPS GROUND
REFERENCE INPUT ENGINE
CONTROL
MODULE
(ECM)
D07LW009

THROTTLE POSITION SENSOR SHORT TO PLUS
Check Engine Control Module (ECM)

DTC.
IF: DTC on Throttle Position Sensor (TPS)
exists:
YES NO
Check diagnosis of ECM and repair. • Install scan tool GOTHROUGH TECH2
CONNECTION.
• Ignition switch ON, engine not
running.
• Select F0: DATA LIST: “TPS SIGNAL”.
IF: TECH2 DISPLAY more than 4.9 volts:
YES NO

C-95 terminal C5 and TPS ground GOTO INTERMITTENT
terminal C6. CONDITIONS.
IF: If you have more than 4.9 volts:
YES NO
GOTO TCM MEM-CAL

REPLACEMENT.
• Check for a short to voltage or open circuit between connector C-95

terminal C5 and connector E-68 terminal 2.
This faulty connection can be at intermediate connector H-25
terminal 5.
The short to voltage only can be at the ECM connector E-61 terminal
26.
• Repair.
• Connect ohmmeter between sensor terminals 2 wiper and 3 low
side.
If resistance between TPS terminal 2 and 3 does not change when
the throttle valve angle is changed: Replace TPS.

THROTTLE POSITION SENSOR SHORT TO GROUND OR OPEN
This DTC flashes the CHECK TRANS indicator and • This TPS is an electrical component and must not
sets the BACKUP MODE. be soaked in any liquid cleaner or solvent, as
damage may result.
• The Throttle Position Sensor (TPS) provides a Diagnostic Aids:
voltage signal that changes relative to the throttle • This Diagnostic is an electrical test done by the
plate position. Signal voltage between connector TCM.
C-95 terminals C5 and C6 will vary from about 0.4 • Detection conditions:
at idle to about 4.6 volts at wide open throttle. 1 This detects a TPS wiper short to TCM ground
• The Engine Control Module (ECM) also receives (except certain conditions) or open and wiper
this signal. This TPS is a variable resistance with short to TPS low. This also detects a TPS low
one side (connector E-68 terminal 1) connected open.
only to the ECM connector to have the 5 volts 2 Voltage between connector C-95 terminals C5
supply voltage. The other side (connector E-68 and C6 < 0.2 volts.
terminal 3) is connected to the Transmission 3 The condition needs to be present for at least
Control Module (TCM) (floating ground) and the 0.5 seconds. Note: during the detection time
ECM (ground). The “middle” (the wiper) (con- the TCM reads “0% (idle)”.
nector E-68 terminal 2) is connected to the TCM • Action after the detection time: BACKUP MODE.
and the ECM. • Recovery conditions: To recover when voltage >
• The ECM monitors output voltage from the TPS or = to 0.2 volts and do an IGNITION CYCLE.
and determines fuel delivery based on throttle
valve angle (driver demand)
GRN
1 E-68
THROTTLE
BLU
5
(TPS)
3 E-68
BLU
GRN GRY GRY

GROUND
C6(6) 3
GRY
27 26 39 E-61
TRANSMISSION
CONTROL
CONTROL
MODULE
(ECM)
D07LW009

THROTTLE POSITION SENSOR SHORT TO GROUND OR OPEN

DTC.
exists:
YES NO
CONNECTION.
running.
IF: TECH2 DISPLAY less than 0.2 volts:
YES NO

C-95 terminal C5 and TPS ground GOTO INTERMITTENT
terminal C6. CONDITIONS.
IF: If you have less than 0.2 volts:
YES NO
GOTO TCM MEM-CAL

REPLACEMENT.
• Check for a short to ground between connector C-95 terminal C5 and

connector E-68 terminal 2.
This faulty connection can be at the intermediate connector H-25
terminal 5.This faulty connection can be at the ECM connector E-61
terminal 26.
• Repair.
If not OK: Ignition switch OFF. Disconnect sensor connector E-68.
• Connect ohmmeter between connector C-95 terminal C5 and C6.
• Check if the circuit is open.
• Repair.
If not OK: Ignition switch OFF. Disconnect sensor connector E-68.
side.
• If resistance between TPS terminal 2 and 3 does not change when

THROTTLE POSITION SENSOR CONNECTOR OPEN
sets the BACKUP MODE. • This Diagnostic is not an electrical test done by
• The Throttle Position Sensor (TPS) provides a • Detection conditions:
voltage signal that changes relative to the throttle 1 This detects the terminals C5 and C6 open or
plate position. Signal voltage between connector the connector E-68 open.
C-95 terminals C5 and C6 will vary from about 0.4 2 Throttle value opening > 42%.
at idle to about 4.6 volts at wide open throttle. 3 Engine Speed < 2200 RPM.
• The Engine Control Module (ECM) also receives 4 Vehicle Speed <3 Km/h.
this signal. This TPS is a variable resistance with 5 No DTC: Engine Speed DTC13, Output Speed
one side (connector E-68 terminal 1) connected
DTC11. Downshift Protection DTC62.
only to the ECM connector to have the 5 volts
6 Only with Selector Lever in Park or Neutral.
supply voltage. The other side (connector E-68
terminal 3) is connected to the Transmission 7 The detection is authorized only during 6
Control Module (TCM) (floating ground) and the seconds after ignition switch ON.
ECM (ground). The “middle” (the wiper) (con- 8 The conditions need to be present for at least
nector E-68 terminal 2) is connected to the TCM 3 seconds.
and the ECM. • Action after the detection time: BACKUP MODE.
• The ECM monitors output voltage from the TPS • Recovery conditions: To recover do an IGNITION
and determines fuel delivery based on throttle CYCLE.
valve angle (driver demand).
• This TPS is an electrical component and must not
be soaked in any liquid cleaner or solvent, as
damage may result.
GRN
1 E-68
THROTTLE
BLU
5
(TPS)
3 E-68
BLU
GRN GRY GRY

GROUND
C6(6) 3
GRY
27 26 39 E-61
TRANSMISSION
CONTROL
CONTROL
MODULE
(ECM)
D07LW009

THROTTLE POSITION SENSOR CONNECTOR OPEN

DTC.
exists:
YES NO
CONNECTION.
running.
IF: TECH2 DISPLAY approx. 2.5 volts
whatever the throttle valve position:
YES NO
IF: TPS connector E-68 DTC 23 is intermittent.

on the engine is open: GOTO INTERMITTENT
CONDITIONS.
YES NO
Repair.
• Ignition switch OFF. Disconnect connector C-95.

Connect ohmmeter between connector C-95 terminals C5 and C6.
If open circuit:
• Check for an open between connector C-95 terminal C5 to connector
E-68 terminal 2 with a simultaneous open of the terminal C6 to the
connector E-68 terminal 3.
This faulty connection can be at the intermediate connector H-25
terminal 5 and 3.
• Repair.
If not OK: Ignition switch OFF. Disconnect sensor.
side.
If resistance between TPS terminal 2 and 3 does not change when

SUPPLY VOLTAGE TOO LOW
This DTC flashes the CHECK TRANS indicator and Specification decreases with the transmission
sets the BACKUP MODE. oil temperature:
–40°C (–40°F) = 8.7 volts
Circuit Description: 90°C (194°F) = 9.0 volts
The ignition voltage of Transmission Control 150°C (304°F) = 9.2 volts
Module (TCM) terminals A7 and A8 is monitored by 2 The condition needs to be present for at least
the TCM and when the voltage is too low (approx. 9 1 second
volts) the DTC25 is stored and the BACKUP MODE • Action after the detection time: BACKUP MODE
is set. • Recovery conditions: To recover, the ignition
voltage must be higher than specification.
Diagnostic Aids:
Specification decreases with the transmission oil
temperature:
TCM.
• Detection conditions: –40°C (–40°F) = 9.2 volts
1 Ignition voltage measured between TCM
90°C (194°F) = 9.5 volts
terminal A7 or A8 and ground C1 is lower 150°C (304°F) = 9.6 volts
than specification.
+
B
BATTERY
FUSE
EB-12 EB-14
10A 20A RELAY &
B— FUSE BOX
RED/
GRN
X-18 3 2
ECM
MAIN
GRN RELAY
X-18 5 1
BLU/RED
H-25
BLK
RED/BLU RED/BLU
7
D1 C1 A4 A8 A7
C-95 (17) (1) (4) (8) (7) C-96 E-61 19 E-60 28
BATTERY BATTERY INPUT
GROUND INPUT IGNITION
INPUT
TRANSMISSION ENGINE
CONTROL MODULE CONTROL
(TCM) MODULE
(ECM)
D07LW010

SUPPLY VOLTAGE TOO LOW
• Ignition switch ON. Engine OFF.

• Connect voltmeter between B+ and B- terminals of
battery.
IF: Display greater than 9 volts:
YES NO
• Engine running. Check battery.

battery.
IF: display between 13 and 16 volts?
YES NO
• Ignition switch OFF. Check regulator.

• Disconnect Transmission Control Module (TCM)
connector C-95 and C-96.
• Connect voltmeter between connector C-96 terminal
A7 and connector C-95 terminal C1.
IF: Display greater than 9 volts:
YES NO
Check for faulty connection and if OK. Check fuse and wire to A7, A8 and C1 for
GOTO INTERMITTENT CONDITIONS. open circuit.

SUPPLY VOLTAGE TOO HIGH
This DTC flashes the CHECK TRANS indicator and • Detection conditions:
sets the BACKUP MODE. 1 Ignition voltage measured between TCM
terminal A7 or A8 and ground C1 is higher
Circuit Description: than 15.5 volts.
The ignition voltage of Transmission Control 2 The condition needs to be present for at least
Module (TCM) terminals A7 and A8 is monitored by 1 second.
the TCM and when the voltage is too high (approx. • Action after the detection time : BACKUP MODE
16 volts) the DTC26 is stored and the BACKUP • Recovery conditions: To recover, ignition voltage
MODE is set. <
=15.5 volts.
Diagnostic Aids:
TCM.
+
B
BATTERY
FUSE
EB-12 EB-14
10A 20A RELAY &
B— FUSE BOX
RED/
GRN
X-18 3 2
ECM
MAIN
GRN RELAY
X-18 5 1
BLU/RED
H-25
BLK
RED/BLU RED/BLU
7
D1 C1 A4 A8 A7
C-95 (17) (1) (4) (8) (7) C-96 E-61 19 E-60 28
BATTERY BATTERY INPUT
GROUND INPUT IGNITION
INPUT
TRANSMISSION ENGINE
CONTROL MODULE CONTROL
(TCM) MODULE
(ECM)
D07LW010

SUPPLY VOLTAGE TOO HIGH

battery.
IF: Display greater than 15.5 volts:
YES NO
Check battery. • Engine running.

battery.
IF: Display between 3 to 15.5 volts:
YES NO
Check regulator. • Ignition switch OFF.

• Disconnect Transmission Control
Module (TCM) connector C-95 and
C-96.
• Ignition switch ON. Engine ON.
• Connect voltmeter between
connector C-96 terminals A7 and
connector C-95 terminal C1.
IF: Display higher than 15.5 volts:
YES NO
Check regulator. The problem is

intermittent.
GOTO
INTERMITTENT
CONDITIONS.

SOLENOID A SHORT TO GROUND OR OPEN
This DTC flashes the CHECK TRANS indicator and • There are two tests of the LSD: When the engine
sets the BACKUP MODE. is cranked (DTC82) and when the ignition is
turned ON (DTC31).
Circuit Description: • When the ignition is turned ON, and before the
• The solenoid A is a simple ON/OFF solenoid engine is cranked, the TCM activates the shift
located in the main case valve body. The solenoids (A, B and Band) to check for short
solenoid is the normally closed-type. In second or circuits or open circuits. To do so the gear is set
third gear the Transmission Control Module to 4th, 3rd, 1st, 1st with band apply, 4th with no
(TCM) energizes the solenoid to open a fluid inlet HSD. Each one of the 5 tests requires 0.15
port. When the port is open, fluid pressure second. If the engine is cranked before the end of
actuates the shift valve. all tests, the remaining tests are not done.
• The solenoid is activated by a current. This
current is produced by applying a voltage to one Diagnostic Aids:
side (the High side) and a ground to the other • This Diagnostic is an electrical test done by the
side (Low side). TCM.
• The High Side Driver (HSD) is a circuit of the TCM • Detection conditions:
that acts as a switch between the solenoids and 1 The solenoid low side connected to TCM
the supply voltage. The High side of the solenoid terminal A2 is shorted to ground or open.
is permanently supplied with voltage, except in 2 The test is only done when ignition is ON.
BACKUP MODE or when ignition is OFF the HSD 3 Engine Speed < 480 RPM (not cranked) and
is turned OFF. Output Speed = 0 RPM.
• The TCM continually monitors the solenoid 4 The conditions need to be present for 0.15 to
connection to its Low Side Driver (LSD) for either 1.03 second after ignition switch ON.
low or high voltage. The LSD is a circuit of the • Action after the detection time: BACKUP MODE.
TCM that acts as a switch between the solenoid • Recovery conditions: To recover, do an IGNITION
and ground. When the solenoid is commanded CYCLE.
ON the TCM is switching the solenoid to ground.
C-96
YEL/GRN H-23 YEL/GRN
GROUND
A2(2) 13
3(D) M-7
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND

SOLENOID SOLENOID APPLY
A B SOLENOID
SHIFT 4(C) M-7

SOLENOID A C-95 H-23
BRN/WHT BRN/WHT
CONTROL
C12(12) 14
BLK
GROUND C1(1) H-25
BLK BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW011

SOLENOID A SHORT TO GROUND OR OPEN

C12 and connector C-96 terminal A2.
IF: Display between 17.5 and 18.5 ohms?
YES NO
• Connect ohmmeter between connector C-96 Check for an open circuit between connector C-
terminal A2 and connector C-95 terminal C1 96 terminal A2 and connector C-95 terminal C12.
(TCM ground). IF: Wiring problem?
IF: Short circuit:
YES NO
YES NO
Repair.
• Check for faulty connector or
wiring between terminal A2
and ground. • Disconnect solenoid A connector.
• Repair. • IF: Ohmmeter displays between 17.5 and 18.5
ohms on the solenoid A terminals:
The problem is intermittent.

GOTO INTERMITTENT
CONDITIONS.
YES NO
The problems is Replace the solenoid A.

intermittent.
GOTO INTERMITTENT
CONDITIONS.

SOLENOID B SHORT TO GROUND OR OPEN
This DTC flashes the CHECK TRANS indicator and • There are two tests of the LSD: When the engine
turned ON (DTC32).
• The solenoid B is a simple ON/OFF solenoid engine is cranked, the TCM activates the shift
solenoid is the normally open-type. When the circuits or open circuits. To do so the gear is set
port is open, fluid pressure actuates the shift to 4th, 3rd, 1st, 1st with band apply, 4th with no
valve. In first or second gear the Transmission HSD. Each one of the 5 tests requires 0.15
Control Module (TCM) energizes the solenoid to second. If the engine is cranked before the end of
close a fluid inlet port. all tests, the remaining tests are not done.
side (the High side) and a ground to the other • This Diagnostic is an electrical test done by the
that acts as a switch between the solenoids and 1 The solenoid low side connected to TCM
the supply voltage. The High side of the solenoid terminal A3 is shorted to ground or open.
• The TCM continually monitors the solenoid 4 The conditions need to be present for 0.15 to
C-96 H-23
BRN/BLK BRN/BLK
GROUND M-7
A3(3) 6 1(A)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND

A B SOLENOID
SHIFT
SOLENOID B C-95 H-23 BRN/WHT 4(C)
CONTROL BRN/WHT M-7
C12(12) 14
BLK
GROUND C1(1) H-25
BLK BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW012

SOLENOID B SHORT TO GROUND OR OPEN

IF: Display between 17.5 and 18.5 ohms?
YES NO
• Connect ohmmeter between connector C-96 Check for an open circuit between connector C-
terminal A3 and connector C-95 terminal C1 96 terminal A3 and connector C-95 terminal C1.
(TCM ground). IF: Wiring problem?
IF: Short circuit:
YES NO
YES NO
Repair.
• Check for faulty connector or
wiring between terminal A3
and ground. • Disconnect solenoid B connector.
Repair. IF: Ohmmeter displays between 17.5 and 18.5
ohms on the solenoid B terminals:

GOTO INTERMITTENT
CONDITIONS. YES NO
The problems is Replace the

intermittent. solenoid B.
GOTO INTERMITTENT
CONDITIONS.

TCC HIGH SHORT TO PLUS OR OPEN
This DTC flashes the CHECK TRANS indicator and to the ground of the transmission. In BACKUP
does NOT set the BACKUP MODE. MODE or when ignition is turned OFF the TCC
High Side is turned OFF.
Circuit Description: • The TCM continually monitors the solenoid
• The Torque Converter Clutch (TCC) solenoid is a connection to its High Side Driver for either low
simple ON/OFF solenoid connected to the or high voltage.
adapter case valve body. When the solenoid is • There is only one test of the HSD for TCC: when
energized by the Transmission Control Module the engine is cranked and the TCC is turned ON.
(TCM), it opens a fluid port. When the port is • If this circuit is shorted to plus, the TCC solenoid
open, line pressure actuates the converter clutch is constantly commanded ON (shifts can be firm).
control valve which engages the torque converter In 1st gear the TCC is hydraulically OFF, whatever
clutch by exhausting the fluid. The TCM engages the TCC solenoid position. This means that the
the torque converter clutch only when all of the car can be driven even with the TCC shorted to
following conditions exist: voltage. The engine could stall when the driver is
1 The transmission is at operating temperature. braking strongly, if the car is stopped when the
2 The brake pedal is released. transmission is still in second gear with TCC
3 The transmission is operating in second, third applied.
or fourth gear. Note: The 3-2 shifts are very firm.
4 The engine is warm (more than 70°C).
5 The shift pattern requests TCC apply. Diagnostic Aids:
6 Shift finished. • This diagnostic is an electrical test done by the
7 No malfunction which will disable the TCC: TCM.
DTC43, DTC55 (only short to ground). • Detection conditions:
• The solenoid is activated by a current. This 1 The solenoid high side connected to TCM
current is produced by applying a voltage to one terminal C7 is shorted to voltage or open.
side (the High side) and a ground to the other 2 The condition needs to be present for 0.13
side (Low side). second.
• The High Side Driver (HSD) is a circuit of the TCM • Action after the detection time:
that acts as a switch between the solenoid and 1 TCC is turned OFF.
the supply voltage. The High side of the TCC 2 CHECK TRANS indicator turned ON.
solenoid is used to turn the TCC ON or OFF • Recovery conditions: To recover, do an IGNITION
because the Low side is permanently connected CYCLE.
C-95 H-23
RED/YEL RED/YEL
TORQUE M-6
C7(7) 12 4(A)
CONVERTER
AUTOMATIC
CLUTCH
TRANSMISSION
SOLENOID
CONTROL
TORQUE
CONVERTER
CLUTCH
SOLENOID
BLK
C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW013

IF you have a SCAN TOOL: TECH2?
YES NO
• Install scan tool: TECH2 GOTHROUGH TECH2 CONNECTION. Without TECH2 you can not do preliminary test.
While driving the car in 2nd, 3rd or 4th gear check if the TCC is
slipping or not when the TCC solenoid is commanded OFF or
ON by the TCM.
Push F0: DATA LIST:

Read TCC state and SLIP value.
CASE: SLIP > 20 RPM with CASE: SLIP = 0+ OR -10 RPM CASE: DTC43
TCC = ON with TCC = OFF at any TPS: GOTO DTC43.
This means that the TCC valve This means that the TCC valve
is stuck OFF or the TCC is stuck ON or TCC solenoid is
solenoid connections are shorted to plus.
OPEN.
SHORT TO PLUS? SHORT TO PLUS?

• Ignition switch ON. Engine OFF. • Ignition switch ON. Engine OFF.
A • Connect a voltmeter between • Connect a voltmeter between
CONTINUED ON connector C-95 terminal C7 and car connector C-95 terminal C7 and car
NEXT PAGE ground or with TCM ground ground or with TCM ground
terminal C1. terminal C1.
IF: voltage found: IF: voltage found:
NO YES YES NO
GOTO TCM MEM-CAL

REPLACEMENT. A
The TCC is shorted to voltage.
CONTINUED ON
NEXT PAGE
• Check wire for a short to voltage between
terminal C7 and solenoid.
Note: This short can be to another wire of the
adapter case connector M-6.
In this case the problem occurs only when
voltage is present at the second wire.
• Repair.

TCM: Transmission Control Module

(CONTINUED)
CONTINUED FROM
PREVIOUS PAGE
A
OPEN?
C7 and C1 (TCM ground).
IF: Display is between 17.5 and 18.5 ohms.
YES NO
GOTO TCM MEM-CAL • Disconnect transmission adapter case connector M-6.

REPLACEMENT. • Connect ohmmeter between terminal 4(A) of female half of
connector and transmission which is used as ground.
IF: Display between 17.5 and 18.5 ohms:
YES NO
• Wire between connector C-95 terminal C7 and • Disconnect solenoid connector.

adapter case connector is open or shorted to • Connect ohmmeter between the two solenoid
another wire. terminals.
• Repair. IF: Display is between 17.5 and 18.5 ohms.
YES NO
• Wire between adapter case connector and Replace torque converter

solenoid is open. clutch solenoid.
• Or wire between transmission (ground) and
solenoid is open.
• Repair.

MEMO

BAND APPLY SOLENOID SHORT TO GROUND OR OPEN
This DTC flashes the CHECK TRANS indicator and is turned OFF.
sets the BACKUP MODE. • The TCM continually monitors the splenoid
connection to its Low Side Driver (LSD) for either
Circuit Description: low or high voltage. The LSD is a circuit of the
• The band apply solenoid is a normally open TCM that acts as a switch between the solenoid
solenoid which controls the flow of fluid for brake and ground. When the solenoid is commanded
band application. The Transmission Control ON the TCM is switching the solenoid to ground.
Module (TCM) uses Pulse Width Modulation • There are two tests of the LSD: when the engine
(PWM) and changes the duty cycle to control the is cranked (DTC82) and when the ignition is
solenoid. The TCM turns the solenoid ON turned ON (DTC34).
(energized) and OFF (de-energized) at a constant • When the ignition is turned ON, and before the
frequency. The length of time the solenoid is engine is cranked, the TCM activates the shift
energized during each ON/OFF cycle is called the solenoids (A, B and Band) to check for short
pulse width. By varying or “modulating” the circuits or open circuits. To do so the gear is set
pulse width, the solenoid output pressure is to 4th, 3rd, 1st, 1st with band apply, 4th with no
changed. Since the solenoid is normally closed, HSD. Each one of the 5 tests requires 0.15
increasing the pulse width increases the duty second. If the engine is cranked before the end of
cycle and decreases the output pressure. PWM all tests, the remaining tests are not done.
control provides smooth band application
without an accumulator. The band is only applied Diagnostic Aids:
in first and second gears. • This diagnostic is an electrical test done by the
• In the event of an electrical failure (open), the TCM.
solenoid regulates at the maximum oil flow (0% • Detection conditions:
duty cycle). 1 The solenoid Low side connected to TCM
• The solenoid is activated by a current. This terminal A9 is shorted to ground or open.
current is produced by applying a voltage to one 2 The test is only done when ignition is ON.
side (the High side) and a ground to the other 3 Engine Speed <480 RPM (not cranked) and
side (Low side). Output Speed = 0 RPM.
• The High Side Driver (HSD) is a circuit of the TCM 4 The condition needs to be present for 0.15 to
that acts as a switch between the solenoids and 0.75 second after ignition switch ON.
the supply voltage. The High side of the solenoid • Action after the detection time: BACKUP MODE.
is permanently supplied with voltage, except in • Recovery conditions: To recover, do an IGNITION
BACKUP MODE or when Ignition is OFF the HSD CYCLE.
C-96 H-23
YEL/BLK YEL/BLK
GROUND M-7
A9(9) 16 2(B)
AUTOMATIC
TRANSMISSION
BAND SHIFT SHIFT

APPLY SOLENOID SOLENOID
SOLENOID B A
4(C) M-7
BAND
APPLY C-95 H-23
BRN/WHT BRN/WHT
SOLENOID
CONTROL C12(12) 14
BLK
GROUND C1(1) H-25

BLK BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW014

BAND APPLY SOLENOID SHORT TO GROUND OR OPEN
• Ignition switch off.

connector C-95 and C-96
IF: Display is approx. 10 ohms:
YES NO
• Connect ohmmeter between connector C-96 terminal • Check for an open circuit between connector C-96
A9 and connector C-95 terminal C1 (TCM ground) terminal A9 and connector C-95 terminal C12.
IF: Short circuit: IF: Wiring problem?
YES NO YES NO
• Check for faulty Repair.

connector or wiring
between terminal A9
and ground. • Disconnect band apply solenoid connector.
• Repair. IF: Ohmmeter displays approx. 10 ohms on
the band apply solenoid terminals:

GOTO INTERMITTENT
CONDITIONS. YES NO
Replace the band apply solenoid.

GOTO INTERMITTENT
CONDITIONS.

FORCE MOTOR OPEN OR SHORT TO PLUS OR GROUND
sets the BACKUP MODE. • This Diagnostic is an electrical test done by the
TCM.
Circuit Description: • Detection conditions:
• The force motor solenoid is a device used to • The TCM monitors the amperage at the return
regulate transmission line pressure. The TCM line. When the return amperage is more than 0.2
uses TPS information and vehicle speed infor- amp from the commanded amperage, DTC is
mation to determine the line pressure appro- stored.
priate for a given load. The TCM will regulate the • Action after the detection time: BACKUP MODE
pressure by applying a varying amperage to the • Recovery conditions: To recover, do an IGNITION
force motor solenoid. The applied amperage can CYCLE.
vary from 0.1 to 1.1 amp. The TCM then monitors
the amperage at the return line. If the return
amperage is more than 0.2 amp from the
commanded amperage, the DTC is stored.
• The line pressure can vary from less than 50psi to
more than 200 psi. The line pressure varies
inversely to the amount of current. High current
causes low pressure and low current causes high
pressure.
C-96
RED/BLU RED/BLU
IGNITION ECM MAIN RELAY
INPUT A7(7)
C-95 H-23
RED/BLK RED/BLK
FORCE M-6
C15(15) 8 2(B)
MOTOR
SOLENOID AUTOMATIC
CONTROL TRANSMISSION
+
( )
FORCE
MOTOR
SOLENOID
FORCE
MOTOR
SOLENOID 1(E) M-6
CONTROL RED/GRN H-23 RED/GRN
(—)
C16(16) 5
BLK
GROUND C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW015

FORCE MOTOR OPEN OR SHORT TO PLUS OR GROUND

connector C-95 and C-96
• Connect ohmmeter between connector C-95
terminals C15 and C16.
IF: Display is between 3.7 and 4.7 ohms:
YES NO
• Connect ohmmeter between connector C-95 • Disconnect automatic transmission adapter case
terminals C15 and C1 (TCM ground) then between connector M-6.
terminal C15 and connecter C-96 terminal A7 (TCM • Connect ohmmeter between terminals 2(B) and 1(E)
ignition) then between terminals C16 and C1 (TCM of female half of the connector (solenoid side).
ground) then between terminals C16 and A7 (TCM IF: Display between 3.7 and 4.7 ohms:
ignition).
IF: Display indicates a short circuit:
YES NO
YES NO
Repair wires for open between
terminals C15 or C16 and adapter
Repair the short circuit. The problem is case connector.
intermittent.
GOTO INTERMITTENT
CONDITIONS. • Disconnect solenoid connector.
• Connect ohmmeter between solenoid
terminals.
IF: Display between 3.7 and 4.7 ohms:
YES NO
Repair wires for open

between adapter case
connector and solenoid
connector.
Replace force motor solenoid.


SHIFT HIGH SHORT TO GROUND OR OPEN
This DTC flashes the CHECK TRANS indicator and solenoids (A, B and Band) to check for short
sets the BACKUP MODE. circuits or open circuits. To do so the gear is set
to 4th, 3rd, 1st, 1st with band apply, 4th with no
Circuit Description: HSD. Each one of the 5 tests requires 0.15
• The solenoids are activated by a current. This seconds. If the engine is cranked before the end
current is produced by applying a voltage to one of all tests, the remaining tests are not done.
side (the High side) and a ground to the other
side (Low side). Diagnostic Aids:
• The High Side Driver (HSD) is a circuit of the • This diagnostic is an electrical test done by the
Transmission Control Module (TCM) that acts as TCM.
a switch between the solenoids and the supply • Detection conditions:
voltage. The High side of the solenoid is 1 The solenoid High side connected to TCM
permanently supplied with voltage, except in terminal C12 is shorted to ground or open.
BACKUP MODE or when Ignition is OFF the High 2 The test is only done when ignition is ON.
Side Driver is turned OFF. 3 Engine Speed < 480 RPM (not cranked) and
• The TCM continually monitors the solenoid Output Speed = 0 RPM
connection to its High Side Driver for either low 4 The condition needs to be present for 0.15 to
or high voltage. 0.75 second after ignition switch ON.
• There are two tests of the HSD: when the engine • Action after the detection time: BACKUP MODE.
is cranked (DTC82) and when the ignition is • Recovery conditions: To recover, do an IGNITION
turned ON (DTC36). CYCLE.
• When the ignition is turned ON, and before the
engine is cranked, the TCM activates the shift
C-96 H-23
YEL/BLK YEL/BLK
A9(9) 16
BRN/BLK BRN/BLK
GROUND 6
A3(3)
YEL/GRN YEL/GRN
13 1(A) 2(B) M-7
A2(2) 3(D)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND

A B SOLENOID
SHIFT &
BAND APPLY C-95
BRN/WHT H-23 BRN/WHT 4(C) M-7
SOLENOID
CONTROL C12(12) 14
BLK
C1(1)
GROUND BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW016

SHIFT HIGH SHORT TO GROUND OR OPEN

connectors C-95 and C-96.
C12 and connector C-96 terminal A2 and between
C12 and A3 and between C12 and A9.
IF: Display is approx. 10 ohms for the band apply and 18
ohms for the other solenoids:
YES NO
• Connect ohmmeter between connector C-95 terminal • Check for an open circuit between connector C-95
C12 and C1 (TCM ground). terminal C12 and the other terminals A2, A3 and A9.
IF: Short circuit: IF: Wiring problem?
YES NO YES NO

• Check for faulty connector or Repair.
GOTO INTERMITTENT
wiring between terminal C12
CONDITIONS.
and ground.
• Repair.

GOTO INTERMITTENT CONDITIONS.

TORQUE MANAGEMENT SERIAL LINE FAULTY
This DTC flashes the CHECK TRANS indicator and • Action after the detection time: BACKUP MODE
sets the BACKUP MODE. • Recovery conditions: To recover, do an IGNITION
CYCLE.
Circuit Description: NOTE:
• Torque Management is a function that decreases 1 When connecting the TECH2 to the data link
the engine torque during transmission shifts. To connector, be sure to turn off the ignition
do so the Transmission Control Module (TCM) switch.
exchanges information on a wire with the Engine 2 Since the torque management exchanges
Control Module (ECM) that governs the Engine. information between the TCM and the ECM at
This wire is the Data Link Connector which is also all times, the DTC37 is sometimes detects in
used by the Scan tool to communicate with the the following condition.
TCM and the ECM. However, this is not an abnormal condition.
• When the engine stops while driving and
Diagnostic Aids:
then it is restarted.
• This Diagnostic is not an electrical test done by
• When the battery voltage goes down
excessively and the engine does not start
(“logic test”).
again.
When DTC37 is detected in the above
1 Torque control failure detected
conditions, turn off the ignition switch, correct
2 Each time a shift occurs with the Torque
the abnormal condition and erase the trouble
Management active, the TCM sends a
code.
message to the ECM. If the ECM does not
acknowledge this message, the DTC is stored.
C-95 E-61
YEL YEL
SERIAL DATA C2
C8(8) 35
YEL
DIAGNOSIS YEL/BLK
INPUT
D16(32)
16 11 9 ENGINE
GRN CONTROL
C-102 C-102 C-102 MODULE
TRANSMISSION
CONTROL (ECM)
C-102 C-102
MODULE (TCM)
5 4
FUSE (EB-12) BLK

DATA LINK
CONNECTOR
D07LW017

TORQUE MANAGEMENT SERIAL LINE FAULTY
• Peform TECH2 SELF-TEST GOTHROUGH TECH2

CONNECTION.
IF: TECH2 OK:
YES NO
• Ignition switch OFF. See TECH2 OPERATOR’S MANUAL.

• Disconnect TECH2.
4 or 5 and ground.
IF: Display approx. 0 ohms :
YES NO
• Ignition switch ON. Check wire for open.

• Connect voltmeter between connector C-102 terminal
16 and 4 or 5.
IF: Display battery voltage:
YES NO
• Ignition switch OFF. Check Engine Control Module (ECM)

• Connect ohmmeter between connector C-102 terminal and wire to ECM and wire to battery
9 and ECM connector E-61 terminal 35. and data link connector C-102.
• Then connect ohmmeter between TCM connector C-95
terminal C8 and ECM connector E-61 terminal 35.
IF: Display approx. 0 ohms:
YES NO
• Check for short between connector C-102 terminal 9 Check wire for open.
and ground and between connector C-102 terminal 9
and B+.

SOLENOID A SHORT TO PLUS
This DTC flashes the CHECK TRANS indicator and • There are two tests of the LSD: when the engine
turned ON (DTC41).
• The solenoid A is a simple ON/OFF solenoid engine is cranked, the TCM activates the shift
solenoid is the normally closed-type. In second or circuits or open circuits. To do so the gear is set
third gear the Transmission Control Module to 4th, 3rd, 1st, 1st with band apply, 4th with no
(TCM) energizes the solenoid to open a fluid inlet HSD. Each one of the 5 tests requires 0.15
port. When the port is open, fluid pressure second. If the engine is cranked before the end of
actuates the shift valve. all tests, the remaining tests are not done.
side (the High side) and a ground to the other • This diagnostic is an electrical test done by the
that acts as a switch between the solenoids and 1 The solenoid Low side connected to TCM
the supply voltage. The High side of the solenoid terminal A2 is shorted to plus.
• The TCM continually monitors the solenoid 4 The condition needs to be present for 0.15 to
C-96
BATTERY GRN
BATTERY
INPUT A4(4)
IGNITION RED/BLU RED/BLU
ECM MAIN RELAY
INPUT
A7(7)
YEL/BLK H-23 YEL/BLK
A9(9) 16
BRN/BLK BRN/BLK
GROUND
A3(3) 6
YEL/GRN YEL/GRN
1(A) 2(B) M-7
A2(2) 13 3(D)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND
A B SOLENOID
SHIFT &
BAND APPLY C-95 4(C)
BRN/WHT H-23 BRN/WHT M-7
SOLENOID
CONTROL C12(12) 14
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW018

SOLENOID A SHORT TO PLUS

terminals A2 and A7 (TCM ignition) then between A2
and A4 (TCM battery) then between A2 and C12.
IF: Short circuit:
YES NO
• Check for faulty connector or wiring between • Connect ohmmeter between A2 and A3 then between
terminal A2 and the shorted terminal. A2 and A9.
• Repair. IF: Short circuit:
YES NO
Repair. The problem is intermittent.

GOTO INTERMITTENT
CONDITIONS.

SOLENOID B SHORT TO PLUS
This DTC flashes the CHECK TRANS indicator and • There are two tests of the LSD: when the engine
turned ON (DTC42).
• The solenoid B is a simple ON/OFF solenoid engine is cranked, the TCM activates the shift
solenoid is the normally open-type. When the circuits or open circuits. To do so the gear is set
port is open, fluid pressure actuates the shift to 4th, 3rd, 1st, 1st with band apply, 4th with no
valve. In first or second gear the Transmission HSD. Each one of the 5 tests requires 0.15
Control Module (TCM) energizes the solenoid to second. If the engine is cranked before the end of
close a fluid inlet port. all tests, the remaining tests are not done.
side (the High side) and a ground to the other • This diagnostic is an electrical test done by the
that acts as a switch between the solenoids and 1 The solenoid Low side connected to TCM
the supply voltage. The High side of the solenoid terminal A3 shorted to plus.
• The TCM continually monitors the solenoid 4 The condition needs to be present for 0.15 to
C-96
BATTERY GRN
BATTERY
INPUT A4(4)
ECM MAIN RELAY
INPUT
A7(7)
A9(9) 16
BRN/BLK BRN/BLK
GROUND
A3(3) 6
YEL/GRN YEL/GRN
1(A) 2(B) M-7
A2(2) 13 3(D)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND
A B SOLENOID
SHIFT &
SOLENOID
CONTROL C12(12) 14
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW018

SOLENOID B SHORT TO PLUS

IF: Short circuit:
YES NO
• Check for faulty connector or wiring between • Connect ohmmeter between A3 and A2 then between
terminal A3 and the shorted terminal. A3 and A9.
• Repair. IF: Short circuit:
YES NO

GOTO INTERMITTENT
CONDITIONS.

TCC HIGH SHORT TO GROUND
This DTC does NOT flash the CHECK TRANS • The High Side Driver (HSD) is a circuit of the TCM
indicator and does NOT set the BACKUP MODE. that acts as a switch between the solenoid and
the supply voltage. The High side of the TCC
Circuit Description: solenoid is used to turn the TCC ON or OFF
• The Torque Converter Clutch (TCC) solenoid is a because the Low side is permanently connected
simple ON/OFF solenoid connected to the to the ground of the transmission. In BACKUP
adapter case valve body. When the solenoid is MODE or when ignition OFF the TCC High Side is
energized by the Transmission Control Module turned OFF.
(TCM), it opens a fluid port. When the port is • The TCM continually monitors the solenoid
open, line pressure actuates the converter clutch connection of to its High Side Driver for either
control valve which engages the torque converter low or high voltage.
clutch by exhausting the fluid. The TCM engages • There is only one test of the HSD for TCC: when
the torque converter clutch only when all of the the engine is cranked and the TCC is turned ON.
following conditions exist:
1 The transmission is at operating temperature.
Diagnostic Aids:
• This diagnostic is an electrical test done by the
2 The brake pedal is released.
TCM.
3 The transmission is operating in second, third
or fourth gear.
4 The engine is warm (more than 70°C). 1 The solenoid High side connected to TCM
5 The shift pattern requests TCC apply. terminal C7 is shorted to ground.
6 Shift finished. 2 The condition needs to be present for 0.07
7 No malfunction which will disable the TCC: seconds after ignition switch ON.
DTC33, DTC55 (only short to ground). • Action after the detection time: TCC is turned
• The solenoid is activated by a current. This OFF.
current is produced by applying a voltage to one • Recovery conditions: To recover, do an IGNITION
side (the High side) and a ground to the other CYCLE.
side (Low side).
C-95 H-23
RED/YEL RED/YEL
TORQUE M-6
C7(7) 12 4(A)
CONVERTER
AUTOMATIC
CLUTCH
TRANSMISSION
SOLENOID
CONTROL
TORQUE
CONVERTER
CLUTCH
SOLENOID
BLK
C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW013

TCC HIGH SHORT TO GROUND
IF you have a SCAN TOOL: TECH2 ?
YES NO
• Install scan tool: TECH2 GOTHROUGH TECH2 CONNECTION. Without TECH2 you can not do preliminary test.
While driving the car in 2nd, 3rd or 4th gear check if the TCC is
slipping or not when the TCC solenoid is commanded ON by
the TCM.
Push F0: DATA LIST:

Read TCC state and SLIP value.
CASE: SLIP > 20 RPM with CASE: DTC 33

TCC = ON GOTO DTC33.
This means that the TCC valve

is stuck OFF or the TCC
solenoid connections are
shorted to ground.
SHORT TO GROUND?
• Ignition switch OFF. Engine OFF.
• Connect a ohmmeter between connector C-95
terminal C7 and car ground or with TCM ground
terminal C1.
IF: Short circuit:
YES NO
The TCC is shorted to ground. The problem is intermittent.

GOTO INTERMITTENT CONDITIONS.
• Check wiring between

terminal C7 and ground.
• Repair.


BAND APPLY SOLENOID SHORT TO PLUS
This DTC flashes the CHECK TRANS indicator and is turned OFF.
sets the BACKUP MODE. • The TCM continually monitors the solenoid
connection to its Low Side Driver (LSD) for either
Circuit Description: low or high voltage. The LSD is a circuit of the
• The band apply solenoid is a normally open TCM that acts as a switch between the solenoid
solenoid which controls the flow of fluid for brake and ground. When the solenoid is commanded
band application. The Transmission Control ON the TCM is switching the solenoid to ground.
Module (TCM) uses Pulse Width Modulation • There are two tests of the LSD: when the engine
(PWM) and changes the duty cycle to control the is cranked (DTC82) and when the ignition is
solenoid. The TCM turns the solenoid ON turned ON (DTC44).
(energized) and OFF (de-energized) at a constant • When the ignition is turned ON, and before the
frequency. The length of time the solenoid is engine is cranked, the TCM activates the shift
energized during each ON/OFF cycle is called the solenoids (A, B and Band) to check for short
pulse width. By varying or “modulating” the circuits or open circuits. To do so the gear is set
pulse width, the solenoid output pressure is to 4th, 3rd, 1st, 1st with band apply, 4th with no
changed. Since the solenoid is normally closed, HSD. Each one of the 5 tests requires 0.15
increasing the pulse width increases the duty second. If the engine is cranked before the end of
cycle and decreases the output pressure. PWM all tests, the remaining tests are not done.
control provides smooth band application
without an accumulator. The band is only applied Diagnostic Aids:
in first and second gears. • This diagnostic is an electrical test done by the
• In the event of an electrical failure (open), the TCM.
solenoid regulates at the maximum oil flow (0% • Detection conditions:
duty cycle). 1 The solenoid Low side connected to TCM
• The solenoid is activated by a current. This terminal A9 is shorted to voltage.
current is produced by applying a voltage to one 2 The test is only done when ignition is ON.
side (the High side) and a ground to the other 3 Engine Speed < 480 RPM (not cranked) and
side (Low side). Output Speed = 0 RPM.
• The High Side Driver (HSD) is a circuit of the TCM 4 The condition needs to be present for 0.15 to
that acts as a switch between the solenoids and 1.18 second after ignition switch ON.
the supply voltage. The High side of the solenoid • Action after the detection time: BACKUP MODE.
is permanently supplied with voltage, except in • Recovery conditions: To recover, do an IGNITION
BACKUP MODE or when ignition is OFF the HSD CYCLE.
C-96
BATTERY GRN
BATTERY
INPUT A4(4)
ECM MAIN RELAY
INPUT
A7(7)
A9(9) 16
BRN/BLK BRN/BLK
GROUND
A3(3) 6
YEL/GRN YEL/GRN
1(A) 2(B) M-7
A2(2) 13 3(D)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND
A B SOLENOID
SHIFT &
SOLENOID
CONTROL C12(12) 14
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW018

BAND APPLY SOLENOID SHORT TO PLUS

IF: Short circuit:
YES NO
• Check for faulty connector or wiring between • Connect ohmmeter between A9 and A2 then
terminal A9 and the shorted terminal. between A9 and A3.
Repair. IF: Short circuit:
YES NO

GOTO INTERMITTENT
CONDITIONS.

SHIFT HIGH SHORT TO PLUS
This DTC flashes the CHECK TRANS indicator and solenoids (A, B and Band) to check for short
sets the BACKUP MODE. circuits or open circuits. To do so the gear is set
to 4th, 3rd, 1st, 1st with band apply, 4th with no
Circuit Description: HSD. Each one of the 5 tests requires 0.15
• The solenoids are activated by a current. This second. If the engine is cranked before the end of
current is produced by applying a voltage to one all tests, the remaining tests are not done.
side (the High side) and a ground to the other
side (Low side). Diagnostic Aids:
• The High Side Driver (HSD) is a circuit of the • This diagnostic is an electrical test done by the
Transmission Control Module (TCM) that acts as TCM.
a switch between the solenoids and the supply • Detection conditions:
voltage. The High side of the solenoid is per- 1 The solenoid High side connected to TCM
manently supplied with voltage, except in terminal C12 is shorted to voltage.
BACKUP MODE or when ignition is OFF the High 2 The test is only done when ignition is ON.
Side Driver is turned OFF. 3 Engine Speed < 480 RPM (not cranked) and
• The TCM continually monitors the solenoid Output Speed = 0 RPM.
connection to its High Side Driver for either low 4 The condition needs to be present for 0.15 to
or high voltage. 1.34 second after ignition switch ON.
• There are two tests of the HSD: when the engine • Action after the detection time: BACKUP MODE.
is cranked (DTC82) and when the ignition is • Recovery conditions: To recover, do an IGNITION
turned ON (DTC46). CYCLE.
• When the ignition is turned ON, and before the
engine is cranked, the TCM activates the shift
C-96
BATTERY GRN
BATTERY
INPUT A4(4)
ECM MAIN RELAY
INPUT
A7(7)
A9(9) 16
BRN/BLK BRN/BLK
GROUND
A3(3) 6
YEL/GRN YEL/GRN
1(A) 2(B) M-7
A2(2) 13 3(D)
AUTOMATIC
TRANSMISSION
SHIFT SHIFT BAND
A B SOLENOID
SHIFT &
SOLENOID
CONTROL C12(12) 14
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW018

SHIFT HIGH SHORT TO PLUS

C12 and connector C-96 terminal A7 (TCM ignition)
then between C12 and A4 (TCM battery).
IF: Short circuit:
YES NO
• Check for faulty connector or wiring between The problem is intermittent.

terminal C12 and the shorted terminal. GOTO INTERMITTENT CONDITIONS.
Repair.

ENGINE COOLANT SWITCH SHORT TO GROUND, PLUS OR OPEN
This DTC does NOT flash the CHECK TRANS Diagnostic Aids:
indicator and does NOT set the BACKUP MODE. • This Diagnostic is not an electrical test done by
• The Engine Coolant Temperature is measured by • Detection conditions of engine always cold:
a sensor in the coolant system. This information 1 Engine seen as cold: wire short to voltage or
is used by the Engine Control Module (ECM) for open.
the engine. The ECM provides the information: 2 Transmission Oil Temperature >150°C (302°F)
Engine Warm to the Transmission Control or more than 20 minutes since last ignition
Module (TCM) when the ECM measures a cycle.
temperature higher than 70°C (158°F). 3 Detection conditions need to be present for at
• The information is provided using a wire least 25 seconds.
between the ECM terminal 10 and the TCM • Detection conditions of engine always warm:
terminal D14. When the engine is warm the ECM 1 Engine seen as warm: wire short to ground.
connects its terminal 10 to ground using a Low 2 Transmission Oil Temperature < 0°C (32°F).
Side Driver. When the engine is Cold the ECM 3 Without problem on Transmission Tem-
lets this wire open and the TCM pulls it up to 5 perature sensor then: voltage on A/T Oil
volts. Temperature sensor <4.74 V.
• When Ignition is ON and Engine is OFF: the ECM 4 Detection conditions need to be present for at
always sends the information “engine cold” even least 6 seconds.
if the engine is warm. The information is valid • Action after the detection time: No action.
only when the engine is ON. • Recovery conditions: To recover, Engine Coolant
Temperature change information need to be
present for more than 6 seconds.
C-95 H-25 E-61

BRN BRN
ENGINE ENGINE
COOLANT D14(30) 6 10 COOLANT
TEMPERATURE TEMPERATURE
INPUT OUTPUT
BLK
GROUND C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION ENGINE
CONTROL CONTROL
MODULE (TCM) MODULE (ECM)
D07LW019

ENGINE COOLANT SWITCH SHORT TO GROUND, PLUS OR OPEN
• This DTC can be set when there is no problem at • Using the Scan Tool you can check with TECH2:
all. This is due to the fact that when the engine F0: ENG. TEMP. SW information. When the
stalls the ignition is still ON then Engine Control engine is cold or when the engine is OFF the
Module (ECM) provides a false information: TECH2 should show: COLD. When the engine is
engine cold. The Transmission Control Module warm the TECH2 should show WARM.
(TCM), knowing that the last ignition cycle • This DTC is not very important. In the worst case
happened more than 20 minutes ago, then sets it would not allow the Torque Converter Clutch
DTC51. (TCC) to be applied. This will cause low fuel
economy.
IF: You see a problem:
YES NO
• Check voltage between connector C-95 terminal D14 There is not currently a problem.
and connector C-95 terminal C1 (TCM ground). GOTO INTERMITTENT CONDITIONS.
Engine warm.
IF: Voltage higher than 5 volts:
YES NO
• There is a short circuit to voltage. IF: Voltage approx. 5 volts:

• Repair.
YES NO
• This is an open circuit or the ECM • Voltage approx. 0 volts means

is not sending the correct that the signal is OK or that
information. See also ECM there is a short circuit to
information, Section 6E. ground.
• Repair. • Turn the engine OFF with the
ignition ON.
IF: The voltage goes back to 5
volts:
YES NO
There is not currently a • As the voltage is staying at 0

problem. volts, there is a short to
GOTO INTERMITTENT ground.
CONDITIONS. • Repair.

KICK DOWN ALWAYS ON OR SHORT TO GROUND
This DTC does NOT flash the CHECK TRANS • Detection conditions:
indicator and does NOT set the BACKUP MODE. 1 Kick down switch ON (short to ground) and
TPS <70%.
Circuit Description: 2 No malfunction: TPS short to voltage or
• When the driver presses the accelerator pedal ground (DTC21 and DTC22).
down fully, the kick down switch closes, sending 3 The conditions need to be present for at least
a ground signal to the Transmission Control 1 second.
Module (TCM). • Action after the detection time: Kick Down
• This information is used to do shifts with a high information not taken into account.
Engine Speed RPM. • Recovery conditions: To recover, Kick Down
• When the kick down switch is closed the Throttle needs to be seen as OFF during detection time.
Position Sensor (TPS) is already at 100%.
Diagnostic Aids:
• This diagnostic is not an electrical test done by
(“logic test”).
C-96
BLU
KICK
DOWN B5(17)
SWITCH
INPUT
1 C-94
KICK DOWN
SWITCH
C-95 BLK
GROUND C1(1)
BLK H-25 BLK
2 C-94
D1(17) 7
TRANSMISSION BLK
CONTROL
MODULE (TCM)
D07LW020

KICK DOWN ALWAYS ON OR SHORT TO GROUND
IF: DTC 23 Throttle Position Sensor (TPS) connector

open too:
YES NO
GOTO DTC 23. • Ignition switch ON. Engine OFF.

• Accelerator pedal not depressed.
• Connect a voltmeter between connector C-96
terminal B5 and connector C-95 terminal C1 (TCM
ground).
IF: Display approx. 0 volts:
YES NO
• Check the wires and connector The problem is

and the switch to detect the intermittent. GOTO
short to ground. INTERMITTENT
• Repair. CONDITIONS.

MODE SWITCH IN P OR N OR R BAD POSITION
This DTC does NOT flash the CHECK TRANS the TCM but a test between different information
indicator and does NOT set the BACKUP MODE. (“logic test”).
• Detection conditions of P or N bad position:
Circuit Description: 1 A/T Input Speed <3000 RPM
• The mode switch supplies the Transmission 2 TPS > 20%
Control Module (TCM) with information regard- 3 Mode Switch = P or N
ing the selector lever position: P, R, N, D, 3, 2 or 4 No malfunction: TPS short to voltage or
L. The selector lever position is indicated by the ground (DTC 21, DTC22), Engine Speed
state of four ON/OFF contacts. The mode switch (DTC13).
is located on one side of the transmission. It is on 5 The conditions need to be present for at least
the transmission manual shaft and is fixed to the 4 seconds.
main case. • Action after the detection time: Default position
• The mode switch is also used to provide the assumed for pressure calculation and shift
information P or N to the engine crank wiring. pattern = always in D.
The engine can be cranked only if connector M-25 • Recovery Conditions: To recover, have the engine
terminal 4(H) is connected to terminal 1(E), which speed higher than 3000 RPM with a TPS higher
is connected to ground. than 20% when the mode switch is not in P or N.
• The mode switch is also used to provide the back • Detection conditions of R bad position:
up lamp power in reverse. This is the reason why 1 A/T Output Speed > 3200 RPM (approx. 100 KPH)
the mode switch is supplied through a 15A fuse 2 Mode Switch = R
(CB-11). This fuse can burn due to short circuit in 3 No malfunction: Output speed (DTC11).
the back up lamp. Downshift Protection (DTC62).
• When this fuse is open, the mode switch does 4 The conditions need to be present for at least
not work and DTC54 is set. 4 seconds.
• The mode position is defined by the shift linkage • Action after the detection time: Default position
which is a link between the shift lever and the assumed for pressure calculation and shift
mode switch. A bad adjustment of the shift link- pattern = always in D.
age can create a mode switch problem (DTC53). • Recovery conditions: To recover, have the output
speed higher than 3200 RPM when the mode
Diagnostic Aids: switch is not R.
• This Diagnostic is not an electrical test done by
FUSE BOX STARTER RELAY

CB-11
15A
BRN/YEL
AUTOMATIC
WHT
TRANSMISSION 4(H)
MODE M-25 M-25
5(D)
SWITCH
P 1 P 1 P 1 P 1
R 2 R 2 R 2 R 2
N 3 N 3 N 3 N 3
D D D D
PIN F PIN C PIN B PIN A PIN G PIN E
2(F) 6(C) 7(B) 8(A) 3(G) 1(E) M-25

BACK UP RED/YEL
LAMP BLU/WHT BLU/RED BLU BLU/BLK
3 2 1 4 BLK
H-23
BLU/WHT BLU/RED BLU BLU/BLK
D5(21) D6(22) D7(23) D4(20) C-95
TRANSMISSION
CONTROL
TRANSMISSION CONTROL INPUTS MODULE (TCM)
D07LW021

MODE SWITCH IN P OR N OR R BAD POSITION
IF: DTC 23 Throttle Position Sensor (TPS) connector

open or DTC 13 Engine speed, DTC 54 Mode switch
illegal position exists:
YES NO
GOTO DTC13 or • Install scan tool GOTHROUGH TECH2 CONNECTION.

DTC23 or DTC 54 first. • Ignition switch ON. Engine running.
• Select F0: DATALIST: “TOP SIGNAL” or F0: DATA LIST: “AT INPUT SPEED”.
IF: Display does not change with engine speed or TPS:
YES NO
DTC 23 or DTC 13 not detected • Ignition switch ON.

but are the reason for this • Select F0: DATALIST: “SELECTOR POS.”.
DTC 53. • Move shift selector lever through all positions
GOTO DTC13 or DTC23. and compare results with table 1.
IF: all selector pin displays correct:
YES NO
The problem is • Check automatic transmission mode switch

intermittent. GOTO adjustment. GOTHROUGH MODE SWITCH
INTERMITTENT SETTING PROCEDURE (PAGE: 7A1-147)
CONDITIONS. • Repair.
Table 1
SHIFT SELECTOR POSITION
TECH1 DISPLAY P R N D 3 2 L
SELECTOR PIN A X X X X
SELECTOR PIN B X X X X
SELECTOR PIN C X X X X
SELECTOR PIN P X X X X
Note: “X” indicates TECH2 displays “ACTIVE”.

MODE SWITCH ILLEGAL POSITION
This DTC flashes the CHECK TRANS indicator and • When this fuse is open, the mode switch does
sets the BACKUP MODE. not work and DTC54 is set.
• The mode position is defined by the shift linkage
Circuit Description: which is a link between the shift lever and the
• The mode switch supplies the Transmission mode switch. A bad adjustment of the shift
Control Module (TCM) with information re- linkage can create a mode switch problem
garding the selector lever position: P, R, N, D, 3, 2 (DTC53).
or L. The selector lever position is indicated by
the state of four ON/OFF contacts. The mode Diagnostic Aids:
switch is located on one side of the transmission. • This Diagnostic is an electrical test done by the
It is on the transmission manual shaft and is fixed TCM.
to the main case. • Detection conditions:
• The mode switch is also used to provide the 1 Selector Pin A and Pin B and Pin C are not
information P or N to the engine crank wiring. active: no position is identified then.
The engine can be cranked only if connector M-25 2 Based upon Table 1, in Park shift selector
terminal 4(H) is connected to terminal 1(E), which position the code is set when Pin A is open or
is connected to ground. shorted to ground.
• The mode switch is also used to provide the back 3 The conditions need to be present for at least
up lamp power in reverse. This is the reason why 5 seconds.
the mode switch is supplied through a 15A fuse • Action after the detection time: BACKUP MODE
(CB-11). This fuse can burn due to short circuit in • Recovery conditions: To recover, do an IGNITION
the back up lamp. CYCLE.
FUSE BOX STARTER RELAY

CB-11
15A
BRN/YEL
AUTOMATIC
WHT
TRANSMISSION 4(H)
MODE M-25 M-25
5(D)
SWITCH
P 1 P 1 P 1 P 1
R 2 R 2 R 2 R 2
N 3 N 3 N 3 N 3
D D D D
PIN F PIN C PIN B PIN A PIN G PIN E
2(F) 6(C) 7(B) 8(A) 3(G) 1(E) M-25

BACK UP RED/YEL
LAMP BLU/WHT BLU/RED BLU BLU/BLK
3 2 1 4 BLK
H-23
BLU/WHT BLU/RED BLU BLU/BLK
D5(21) D6(22) D7(23) D4(20) C-95
TRANSMISSION
CONTROL
TRANSMISSION CONTROL INPUTS MODULE (TCM)
D07LW021

MODE SWITCH ILLEGAL POSITION
• Install scan tool GOTHROUGH TECH2 CONNECTION.

• Selector F0: DATALIST: “SELECTOR POS”.
• Move shift selector lever through all positions and
compare results with Table 1.
IF: all selector pin displays correct:
YES NO
The problem is IF: all selector pin displays

intermittent. incorrect:
GOTO INTERMITTENT
CONDITIONS.
YES NO
• Check fuse and wire to connector M-25 • Disconnect mode switch connector M-
terminal 5 (D) for opens. 25.
GOTHROUGH MODE SWITCH SETTING • Connect ohmmeter between terminal
PROCEDURE (PAGE: 7A1-147). 5(D) and respectively all terminals of
If problem not solved, replace mode mode switch connector M-25.
switch. • Move shift selector lever through all
positions and compare results with
Table 1.
IF: One selector pin display is incorrect:
YES NO
• Check the wire and connector. • Check wire to cruise control unit and
• Repair. Transmission Control Module (TCM).
• Repair.
Table 1
SHIFT SELECTOR POSITION
TECH1 DISPLAY P R N D 3 2 L
SELECTOR PIN A X X X X
SELECTOR PIN B X X X X
SELECTOR PIN C X X X X
SELECTOR PIN P X X X X
Note: “X” indicates TECH2 displays “ACTIVE”.

BRAKE SWITCH SHORT TO GROUND OR OPEN
• The brake switch is a switch on the brake pedal • Detection conditions:
that is used to provide the information: brakes 1 Brake seen as applied during an acceleration
are applied. This is used by different features: from less than 10 Km/h to more than 60 Km/h
cruise control, stop light and Transmission within 6 seconds.
Control Module (TCM). 2 After this acceleration the vehicle speed was
• The TCM uses the information (brakes applied) higher than 60 Km/h during at least 6
mainly to release the Torque Converter Clutch seconds.
(TCC). 3 No Malfunction: Output Speed (DTC11).
• The brake switch input is constantly connected to Downshift Protection (DTC62).
battery when the pedal is pressed. TCM terminal 4 The conditions need to be present for at least
D9 is connected to Voltage. 5 times during an ignition cycle.
• The brake switch input is opened when the pedal • Action after the detection time: No action but, as
is released. TCM terminal D9 is grounded. the brake is seen as applied, the TCC is never
applied.
• Recovery conditions: To recover, brake has to be
released.
C-95
BRAKE SW RED RED C-44 C-44 GRN
INPUT FUSE EB-10(10A)
D9(25) 2 1
STOP LAMP SW
BLK
GROUND C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW022

BRAKE SWITCH SHORT TO GROUND OR OPEN

• Select F0: DATA LIST: “BRAKE SWITCH”.
• Apply brake.
IF: Display is “NOT ACTIVE”:
YES NO
• Check the short circuit The problem is

to ground or open. intermittent.
• Repair. GOTO INTERMITTENT
CONDITIONS.

BRAKE SWITCH SHORT TO PLUS
• The brake switch is a switch on the brake pedal • Detection conditions:
that is used to provide the information: brakes 1 Brake seen as released during a deceleration
are applied. This is used by different features: from more than 60 Km/h to less than 10 Km/h
cruise control, stop light and Transmission within 6 seconds.
Control Module (TCM). 2 Before this deceleration the car vehicle speed
• The TCM uses the information (brakes applied) was higher than 60 Km/h during at least 6
mainly to release the Torque Converter Clutch seconds.
(TCC). 3 No Malfunction: Output Speed (DTC11).
• The brake switch input is constantly connected to Downshift Protection (DTC62).
battery when the pedal is pressed. TCM terminal 4 The conditions need to be present for at least
D9 is connected to Voltage. 5 times during an ignition cycle.
• The brake switch input is opened when the pedal • Action after the detection time: No action but, as
is released. TCM terminal D9 is grounded. the brake is seen as released, the TCC is applied
even when the brake is applied.
• Recovery conditions: To recover, brake has to be
released.
C-95
BRAKE SW RED RED C-44 C-44 GRN
INPUT FUSE EB-10(10A)
D9(25) 2 1
STOP LAMP SW
BLK
GROUND C1(1)
BLK H-25 BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW022

BRAKE SWITCH SHORT TO PLUS

• Select F0: DATA LIST: “BRAKE SWITCH”.
• Do not touch brake.
IF: Display is “NOT ACTIVE”:
YES NO
The problem is • Check the short circuit

intermittent. to voltage.
GOTO INTERMITTENT • Repair.
CONDITIONS.

GEAR ERROR
This DTC flashes the CHECK TRANS indicator and 3 No malfunction: Engine Speed (DTC 13).
sets the BACKUP MODE. Output Speed (DTC 11). Downshift Protection
(DTC 62).
Circuit Description: 4 The last change of shift solenoid was more
• The Transmission Control Module (TCM) is than 3 seconds ago.
calculating the slippage of the Converter and 5 The conditions need to be present for at least
transmission based upon the Engine Speed, the 5.5 seconds.
Output Speed and the current gear ratio. • Action after the detection time: BACKUP MODE.
• The slippage of the converter at a high enough • Recovery conditions: To recover, do an IGNITION
engine speed is low. Then the transmission CYCLE.
should not slip more than a given value when
there is no shift. NOTE:
The TCC slip data is a calculated value, and not an
Diagnostic Aids: accurate one.
• This Diagnostic is not an electrical test done by This value should be used to see if the TCC is
the TCM but a test between different information engaged or not.
(“logic test”).
1 Engine Speed > 3500 RPM
2 Using the ratio of the current gear the
Converter Slippage is calculated based upon
the engine speed and the output speed. This
slippage must be more than:
528 RPM in 4th gear
536 RPM in 3rd gear
556 RPM in 2nd gear
595 RPM in 1st gear

GEAR ERROR
IF the car has been in BACKUP MODE when the problem

occurred:
YES NO
IF there is another DTC which causes Backup Mode IF there is other DTC:
(DTC20, DTC21, DTC22, DTC23, DTC25, DTC26, DTC31,
DTC32, DTC34, DTC35, DTC36, DTC37, DTC41, DTC42,
DTC44, DTC46, DTC54, DTC63, DTC82):
YES NO
YES NO GOTO next DTCs.
Verify this other diagnosis first (because,

in backup mode the DTC61 is detected in Do a test drive to reproduce the
Manual 2 at high engine speed though problem using the DRIVER
there is no problem). GOTO next DTCs. INFORMATION.
IF reproduced without Backup

Mode:
GOTO TCM MEM-CAL
REPLACEMENT.

DOWNSHIFT PROTECTION
This DTC flashes the CHECK TRANS indicator and voltage in the magnetic pickup. This alternating
sets the BACKUP MODE. current (AC) signal is provided to the TCM. The
voltage increases with the speed of the wheel but
Circuit Description: this is not used to define the speed of the vehicle.
• The output speed information is used to As the vehicle moves faster, the signal alternates
determine if the transmission has to upshift or faster between positive and negative voltages.
downshift. The Output speed information is proportional to
• If this information suddenly changes due to an the frequency of the signal.
open circuit or some electrical interference the
transmission would downshift. Diagnostic Aids:
• To avoid this the Transmission Control Module • This Diagnostic is not an electrical test done by
(TCM) is constantly checking the variations of the the TCM but a test between different information
Output Speed. If this variation is too great (too (“logic test”).
much decrease or increase) DTC62 is set. This • Detection conditions:
variation is taken into amount only when the 1 Variation of Output Speed >512 RPM (approx.
output speed is more than 2900 RPM (approx. 90 16 KPH)/0.025s.
KPH). 2 Ignition ON more than 5 seconds.
• The transmission output speed sensor provides 3 Mode Switch not in P, N or R.
information on vehicle speed to the TCM. The 4 Last Output Speed > 2900 RPM.
speed sensor circuit consists of a magnetic 5 The conditions need to be present for at least
induction type sensor. The sensor is mounted 0.1 second.
above a target wheel pressed on the output shaft • Action after the detection time: BACKUP MODE.
in the transmission extension. As the output shaft • Recovery conditions: To recover, do an IGNITION
turns, the target wheel teeth induce a variable CYCLE.
TRANSMISSION SPEED
SENSOR SHIELDS
H-23 PNK TRANSMISSION

C-96 M-15
+ PNK
10 1
SPEED SENSOR
A12(12)
OUTPUT
SPEED
INPUT
BLU BLU
—
B12(24) 11 2
B11(23) 9
GROUND C-95 BLK

C1(1) H-25
BLK BLK
D1(17) 7
TRANSMISSION
CONTROL
MODULE (TCM)
D07LW006

CAUTION: If wire to connector C-96 terminal B12 is short to voltage,

Transmission Control Module (TCM) will be damaged.
If the DTC 53 is set:
YES NO
GOTHROUGH DTC53 first and do a test drive. If you have a SCAN TOOL: TECH2?
YES NO
• Raise drive wheels.

• Connect the TECH2 GOTHROUGH TECH2
CONNECTION.
• Push F0: DATA LIST: DISPLAY. Read “AT
OUTPUT SPEED”.
IF: Output speed different from 0 RPM when the
wheels are turning:
YES NO
Problem is intermittent. GOTO DTC 11: OUTPUT SPEED

GOTO INTERMITTENT FAILURE:
CONDITIONS. Diagnostic Aids.

• Connect ohmmeter between connector C-96 terminals A12 and B12.
IF: Display is approx. 3K ohms:
YES NO
• Connect ohmmeter between connector C-96 terminal • Disconnect transmission speed sensor
A12 and ground connector C-95 terminal C1. connector M-15.
IF: Display indicates an open circuit: • Connect ohmmeter between terminals 1 and
2 of the speed sensor.
IF: Display approx. 3K ohms:
YES NO
YES NO
• Check for faulty TCM
connection. If OK
GOTO TCM MEM-CAL • Wires from connector Replace
REPLACEMENT. C-96 to sensor transmission
connector are open or speed sensor.
shorted together.
A
• Repair.
CONTINUED
ON NEXT PAGE

(CONTINUED)
CONTINUED FROM
PREVIOUS PAGE
A
HINT:
• The wire between connector C-96 terminal B12 and
speed sensor connector M-15 terminal 2 can be
shorted to ground or open without creating a
problem because the TCM B12 pin is connected to
the TCM ground iternally and the signal is detected
only on the A12 input.
• Check wire for a short to ground between terminal
A12 and sensor connector M-15 terminal 1.
IF: Display indicates a short circuit:
YES NO
Repair. • Connect voltmeter between connector C-96

terminal A12 and ground connector C-95
terminal C1.
IF: Display indicates approximately 0 volt:
YES NO
• Check for faulty TCM • Check wire for a short

connectors. If OK GOTO to voltage between
TCM MEM-CAL terminal A12 and speed
REPLACEMENT. sensor connector M-15.

EPROM CSUM FAILURE
sets the BACKUP MODE. • This Diagnostic is not an electrical test done by
• The Erasable Programmable Read Only Memory • Detection conditions:
(EPROM) is an electronic circuit that contains the 1 Bad EPROM Check Sum.
commands that control the Transmission Control 2 The condition needs to be present for at least
Module (TCM). approx. 1 second.
• The EPROM content is checked automatically • Action after the detection time: BACKUP MODE.
approx. each second by the TCM. This is called • Recovery conditions: To recover, do an IGNITION
Check Sum (CSUM) calculation. If this CSUM is CYCLE.
false this means that one command is altered.
• This can be due to a circuit failure or a bad To Solve the Problem
contact between the EPROM and the TCM and • Check the EPROM MEM-CAL connector.
the DTC63 will be set. • If condition still exists, replace MEM-CAL.
• If all EPROM connections are bad, the TCM does
not work. The CSUM can not be calculated and
detected. Nothing works, not even the CHECK
TRANS indicator.

SHIFT OR BAND APPLY SOLENOIDS FAULTY DURING DRIVING
This DTC flashes the CHECK TRANS indicator and The TCM continually monitors each solenoid
sets the BACKUP MODE. connection to its Low Side Driver and to its High
Side Driver for either low or high voltage.
Circuit Description: • DTC82 is activated when the Shift High Side
• The shift solenoids are simple ON/OFF solenoids Driver or one of the Shift Low Side Drivers
located in the main case valve body. The senses a short circuit or open circuit when the
solenoids are normally closed or open-type. engine is cranked, then when the car is driven.
Depending on gear the Transmission Control DTC82 can be set only when the TCM is
Module (TCM) controls the solenoids to open or activating the solenoids in with the problem
close a fluid inlet port. When the port is open, circuit.
fluid pressure actuates the shift valve. • To know where the fault comes from, do
• The solenoid is activated by a current. This IGNITION CYCLE to use the TCM self-check of
current is produced by applying a voltage to one solenoids when Engine is not cranked but
side (the High side) and a ground to the other Ignition ON.
side (Low side).
• The High Side Driver (HSD) is a circuit of the TCM Diagnostic Aids:
that acts as a switch between the solenoids and • This diagnostic is an electrical test done by the
the supply voltage. The High side of the solenoid TCM.
is permanently supplied with voltage, except in • Detection conditions:
BACKUP MODE or when Ignition is OFF the High 1 HSD or LSD is improperly ON.
Side Driver is turned OFF. 2 The condition needs to be present for at least
• The Low Side Driver (LSD) is a circuit of the TCM 0.15 second.
that acts as a switch between the solenoid and • Action after the detection time: BACKUP MODE
ground. When the solenoid is commanded ON • Recovery conditions: To recover, do after
the TCM is switching the solenoid to ground. IGNITION CYCLE.

SHIFT OR BAND APPLY SOLENOIDS FAULTY DURING DRIVING
This DTC is set when the car is driven (Engine ON) but
the diagnostic is not specific.
To correctly identify the problem, do an IGNITION
CYCLE.
If you have not already done an IGNITION CYCLE:

• Turn ignition switch OFF. Turn ignition switch ON
and wait 3 seconds to have the specific diagnostic
done.
• Then you can turn the engine ON or not.
Check on Scan Tool or Flashing Code what other DTC is

provided. It should be one of the following:
DTC31 or DTC32 or DTC34 or DTC36 or DTC41 or DTC42
or DTC44 or DTC46.
GOTO this DTC.

WITHOUT DTC SET

1. If you have already checked the Diagnostic
Trouble Code (DTC) and the scan tool TECH2
does not provide any DTC, and you have
reproduced the problem and no DTC was
stored:
This means that you have to check the problem
by comparing the way it should work to the
way it works now that the problem exits.
2. To find the problem, perform the following
tests:
• Transmission Operating Mode Test
TRANSMISSION OPERATING MODE TEST
The Transmission Control Module (TCM) can
controls 4L30-E operation in two modes: Power
mode, and Normal mode. The driver determines
the transmission operating mode through the
Power/Normal mode switch.
The Power mode provides better part-throttle ac-
celeration by providing earlier part-throttle upshifts.
HOT IN ON OR START
RED/WHT
CB-5 FUSE BOX
15A
B9(21) C-96
POWER MODE TRANSMISSION
INDICATOR CONTROL
CONTROL MODULE (TCM)
2 B-24 8 H-26 POWER MODE

ENABLE INPUT
METER B8(20) C-96
GRN/YEL
POWER
MODE
INDICATOR
2 C-98
POWER
SWITCH
6 B-23
RED/WHT 1 C-98
BLK
D07LW023
TRANSMISSION OPERATING MODE TEST
IF: When you operated the Power Switch the indicator

turned ON:
YES NO
No Problem. • Install scan tool GOTHROUGH TECH2 CONNECTION.

• Select F0: DATA LIST: POWER SWITCH.
Does TECH2 display “INACTIVE”?
YES NO
• Press and hold down the Power Switch. • Check wire for short to ground between
Does TECH2 display “ACTIVE”? Transmission Control Module (TCM) connector C-96
terminal B8 and the Power Switch.
IF OK, replace the Power Switch.
YES NO
The Power Switch is • Check wire for open between TCM connector C-96
working normally. terminal B8 and the Power Switch.
IF OK, replace the Powe Switch.
• Selector lever in Park.

Does Power mode indicator stay
on all the time?
YES NO
• Check wire for short to ground • Select F5: ACTUATOR TEST:

between TCM connector and CHECK POWER LAMP?”
indicator (SEE SCHEMATIC). • Press YES.
IF OK, GOTO TCM MEM-CAL Does Power Mode Indicator light?
REPLACEMENT.
YES NO
The system is • Check fuse, bulb, and wire for open between
functioning correctly. connector C-96 terminal B9 and indicator and
between indicator and fuse.
• Check wire for short to B+ between connector C-96
terminal B9 and indicator.

TCM PRECAUTONS
The TCM can be damaged by: (2) The TCM must be maintained at a temperature
(1) The Electrostatic discharge below 185°F (85°C) at all times. This is most
(2) The short circuit of some terminals to voltage essential if the vehicle is put through a paint
or to ground. baking process. The TCM will become in-
Electrostatic Discharge Damage Description: operative if its temperature exceeds 85°C
(1) Electronic components used to control systems (185°F). Therefore, it is recommended that the
are often designed to carry very low voltage, TCM be removed or that temporary insulation
and are very susceptible to damage caused by be placed around the TCM during the time the
electrostatic discharge. It is possible for less vehicle is in a paint oven or other high
than 100 volts of static electricity to cause temperature process.
damage to some electronic components. By (3) The TCM is designed to process the various
comparison, it takes as much as 4000 volts for inputs and then respond by sending the
a person to even feel the zap of a static appropriate electrical signals to control trans-
discharge. mission upshift, downshift, shift feel and
(2) There are several ways for a person to become torque converter clutch engagement.
statically charged. The most common methods (4) The TCM constantly interprets information
of charging are by friction and induction. An from the various sensors, and controls the
example of charging by friction is a person systems that affect transmission and vehicle
sliding across a car seat, in which a charge of performance. By analyzing operational prob-
as much as 25,000 volts can build up. lems, the TCM is able to perform a diagnostic
Charging by induction occurs when a person function by displaying DTC(s) and aid the
with well insulated shoes stands near a highly technician in making repairs.
charged object and momentarily touches PROM/MEM-CAL:
ground. Charges for the same polarity are (1) Information for a specific engine and vehicle is
drained off, leaving the person highly charged programmed using an integrated circuit called
with the opposite polarity. Static charges of a Programmable Read-Only Memory (PROM).
either type can cause damage, therefore, it is It is also called a MEM-CAL (Memory Cali-
important to use care when handling and brator). This allows one model of controller to
testing electronic components. be used for many different vehicles. The PROM
NOTICE: To prevent possible Electrostatic is located inside the TCM and has information
Discharge damage: on the engine, transmission, calibration., etc.
(1) Do not touch the TCM connector pins or While one TCM part number can be used by
soldered components on the TCM circuit many vehicle lines, a PROM is more specific
board. and must be used only with the right vehicles.
(2) When handling a Mem-Cal (PROM), do not For this reason, it is very important to check
touch the component leads, and do not the latest parts book and Service Bulletin
remove integrated circuit from carrier. information for the correct part number when
(3) Be sure to follow the guidelines listed below if replacing a PROM.
servicing any of these electronic components:
(4) Do not open the replacement part package
until it is time to install the part.
(5) Avoid touching electrical terminals of the part.
(6) Before removing the part from its package,
ground the package to a known good ground
on the vehicle.
(7) Always touch a known good ground before
handling the part. This step should be repeated
before installing the part if the part has been
handled while sliding across the seat, while
sitting down from a standing position or while
walking some distance.
INFORMATION ON TCM:
(1) The Transmission Control Module (TCM) is
located in the passenger compartment and is
the control center of the electronic trans-
mission control system.
If the TECH2 displays a diagnostic trouble code as Use the F3: SNAPSHOT mode of the TECH2 to help
intermittent, or if after a test drive a DTC does not isolate the cause of an intermittent fault. The
reappear though the detection conditions for this snapshot mode will record information before and
DTC are present: the problem is most likely a faulty after the problem occurs. Set the snapshot to
electrical connection or loose wiring. Terminals and “trigger” on the suspect DTC or, if you notice the
grounds should always be the prime suspect. reported symptom during test drive, trigger the
Intermittents rarely occur inside sophisticated snapshot manually.
electronic components such as the TCM. (1) NOTE: When TECH2 is plugged the shifts are
Use the DTC information to understand which wires always done at the maximum pressure. This
and sensors are involved. means that if you do SNAPSHOT while driving
you will notice firm shifts.
When an intermittent problem is encountered,
check suspect circuits for: After the snapshot has been triggered, command
(1) Poor terminal to wire connection. the TECH2 to play back the flow of data recorded
(2) Terminals not fully seated in the connector from each of the various sensors. Signs of an
body (backed out). intermittent fault in a sensor circuit are sudden
(3) Improperly formed or damaged terminals. unexplainable jump in data values out of the
(4) Loose, dirty, or corroded ground connections: normal range.
HINT: Any time you have an intermittent in CASE: problem still not solved GOTO TCM MEM-
more than one circuit, check whether the circuits CAL REPLACEMENT.
share a common ground connection.
(5) Pinched or damaged wires.
(6) Electro-Magnetic Interference (EMI):
HINT: Check that all wires are properly routed
away from spark plug wires, distributor wires,
radios, etc.
TCM MEM-CAL REPLACEMENT

(TCM: Transmission Control Module)
1. MEM-CAL (Memory and Calibration Unit)
Information for specific transmission and vehicle is
programmed using an integrated circuit called a
MEM-CAL.
This allows one model of controller to be used for
many different vehicles.
The MEM-CAL is located inside the TCM and has
information on the transmission, shift map, etc.
several others.
2. MEM-CAL Replacement
If the diagnostic procedures require MEM-CAL
replacement, the MEM-CAL should be replaced using
the following procedures.
NOTE:
The ignition must be “OFF”, when disconnecting or
reconnecting the TCM connector, to prevent internal
damage to the TCM.
NOTE:
To prevent possible Electrostatic Discharge damage
to the TCM, do not touch the connector pins or
soldered components on the circuit board.
MEM-CAL Replacement Procedure:
1. Remove TCM from passenger compartment:
(1) Disconnect negative (–) battery cable.
(2) Remove connectors from TCM.
(3) Remove TCM from passenger compartment.
(4) Remove MEM-CAL access cover.
NOTE:
Do not remove any of the other screws.
('96&'97)
Access
TCM cover
MEM-CAL
826RV010
2. Remove MEM-CAL from TCM.

• Using two fingers, pinch both retaining clips
and remove MEM-CAL from the MEM-CAL
socket.
Using unapproved MEM-CAL removal
methods may cause damage to the MEM-CAL
or socket.
3. Check new MEM-CAL

• Check the part number of the new MEM-CAL
to make sure it is the correct replacement part.
4. Install new MEM-CAL
(1) Small notches in the MEM-CAL must be
aligned with small notches in the MEM-CAL
socket.
MEM-CAL MEM-CAL SOCKET
(2) Gently press down on the ends of the MEM-

PRESS DOWN
CAL until the clips are locked. Listen for the
click.
5. Install TCM to passenger compartment:

(1) Install MEM-CAL access cover.
(2) Install TCM to passenger compartment.
(3) Connect TCM connectors.
(4) Connect negative (–) battery cable.
(5) Do an IGNITION CYCLE and verify correct
CHECK TRANS indicator operation.
MEMO
WIRING DIAGRAM
STARTER SW
EB-17 OFF
ACC
EB-16 40A CB-11
100A MAIN IGN B-2 1 8 6 15A BUCK TURN
+ 8B/R 3W B2 IG2 3B/Y 3B/Y 0.85W
P-11 C-41 C-41 H-7
P-1 ST CB-5
3 6 4 15A METER GAUGE
3W/B B1 IG1 3B/R 3B/R
P-5 C-41 C-41 H-7
_ EB-15 EB-10
40A 10A STOP LIGHT 0.5G
IGN B-1
5B EB-14
5B
30B
2W 20A ECM 3R/G 0.85R/G
EB-12
10A TCM 2 3
P-10 P-8 P-7
RELAY; ECM MAIN

X-18 X-18
ENG BODY FRAME
CONNECTOR(16)
DATA LINK
X-18 X-18
1 5
0.5L/R
3R/L
2
1
B-24 4
STOP LAMP
STOP LIGHT SW
B-44 H-20
POWER
TRANS
CHECK
0.5G
C-44
B-23 B-24
2
6 8
ECM (B-19)
0.5R
EOM(A28)
0.3R/W
0.3O/L
8 7
H-26 H-26
0.5R/L
0.5R/L
0.5R
0.5R/W
0.5O/L
4 25 21 10 8 7
C-96 C-95 C-96 C-95 C-96 C-96
A4 D9 B9 C10 A8 A7
T C M
D12 D14 C1 D1 D16 C8 C5 C6
C-95 C-95 C-95 C-95 C-95 C-95 C-95 C-95
FUSE STOP
0.5B/R 0.5B/R
28 30 1 17 32 8 5 6
0.5G
0.5L
0.5Y
0.85B
0.8GR
0.5B
0.5BR
0.5Y
0.5B/R
0.5Y/B
1 0.8L
16 6 6 H-25
0.5Y
H-6 H-20 H-25

0.8G
DATA LINK CONNECTOR
35 39 26 27 5 3
TACHOMETER
ECM(B12)
ECM (B10)
16 11 9 H-25 H-25
E-61 E-61 E-61 E-61
C-102 C-102 C-102
7
0.5GR
ECM
0.5L
H-25 C-102 C-102

4 5
E-60 E-61
0.5B
0.5B
1 2 3
4 6
0.85B
E-68 E-68 E-68

OUT
LO
HI
1.25B
THROTTLE POSITION
SENSOR
0.8B/R
COMMON E-72
CHAMBER
0.8BR/L
COMMON E-74
CHAMBER
FENDER-RH C-36
D08RW541
2 8
0.85W 0.85W 0.75W
H-6 H-22
RELAY
STARTER
5 4
M-25 M-25
MODE SW
M-25 M-25 M-25 M-25 M-25 M-25
RELAY:A/C COMPRESSOR(4) 2 8 7 6 3 1
0.75R/L
0.5L/W
0.5L/R
0.5L/B
12
0.5L
1.25B
H-22
0.85R/Y
12 1 2 3 4 7
H-6 H-23 H-23 H-23 H-23 H-23
0.85R/Y
BACK LAMP
1.25BR/L
0.85B
H-15
0.5L/W
0.5L/R
0.5L/B
0.85R/Y
0.5L
1
0.5BR/L
H-17 7
H-25
24 23 22 21 20
C-95 C-95 C-95 C-95 C-95
D8 D7 D6 D5 D4
B5 B8 B6 C7 C14 B3 C16 C15 A9 A2 C12 A3 B11 A12 B12

C-96 C-96 C-95 C-95 C-96 C-95 C-95 C-96 C-96 C-95 C-96 C-96 C-96 C-96
17 20 7 14 15 16 15 9 2 12 3 23 12 24
RELAY;TAIL(4)
0.5BR/W
0.85R/G
0.5BR/B
0.5Y/G
0.5R/Y
0.5R/B
0.5Y/B
0.5GR
0.5L
0.5BR/L
0.5L
0.5G/Y
0.5P
0.5L
12 1 2 5 8 16 13 14 6
1 H-23 H-38 H-38 H-23 H-23 H-23 H-23 H-23 H-23
9 10 11
KICK DOWN SW
C-94
0.5BR/W
0.75R/G
0.5BR/B
H-23 H-23 H-23

0.5Y/G
0.5R/Y
0.5R/B
0.5Y/B
0.5GR
0.5L
2 4
0.5P
0.5L
POWER & WINTER SW
C-94 C-98 C-98 4 5 3 1 2 2 3 4 1

2 M-6 M-6 M-6 M-6 M-6 M-7 M-7 M-7 M-7
TCC SOLENOID
2-3 SOLENOID
(+)
BAND APPLY
1 2
SOLENOID
SENSOR
MOTOR
FORCE
1-2, 3-4
TEMP
M-15 M-15
C-98 C-98 (-)

+ -
0.5B
1 6
MAGNETIC
SENSOR
ADAPTOR CASE MAIN CASE
0.5B
0.5B
(T/MISSION) (T/MISSION)
1.25B
BODY-RH C-2
0.8BR/L
E-74
D08RW542
CONNECTOR LOCATION
H-6
H-7
RELAY & FUSE BOX B-23 H-17
(X-18) B-24
C-2 E-60
E-61 C-36
P-11 C-95 C-41
C-96
C-102 C-98 H-26

E-74 M-15
E-72
C-94 H-15 M-25
H-22 H-20
H-23 H-25
E-68 H-38
M-17
M-7
M-6
D08RW543
CONNECTOR LIST
B-23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 E-61 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 3 5 7 9 11 13 15 1719 21 23 25 27 29 3133 35 37 39
B-24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C-68 1 2 3
C-41 1 2 3 4 4 3 2 1 E-69
5 6 7 8 8 7 6 5
1 2
10 9 8 7 6 5 4 3 2 1
C-44 H-6 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
1 2
1
2 1
C-94 H-7 1 2
2 3 4 5 6 6 5 4 3
4 3 2 1
1 2 3 4
C-95 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10D11D12D13D14D15D16
H-20 5 6 7 8 8 7 6 5
12 11 10 9
9 10 11 12
13 14 15 16 16 15 14 13
1 2 3 4 4 3 2 1
C-96 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12
H-22 5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
1 2 3 4 4 3 2 1
C-98 1 2 H-23 5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
3 4 5 6
13 14 15 16 16 15 14 13
1 2 3 4 4 3 2 1
C-102 1 2 3 4 5 6 7 8 H-25 5 6 7 8 8 7 6 5
9 10 11 12 13 14 15 16
9 10 11 12 12 11 10 9
1 2 3 4
4 3 2 1
E-60 39 3735 33 3129 27 25 23 21 19 17 15 13 11 9 7 5 3 1
40 38 36 34 3230 2826 2422 2018 161412 10 8 6 4 2
H-26 10 9 8 7 6 5
5 6 7 8 9 10
14 13 12 11
11 12 13 14
20 19 18 17 16 15 15 16 17 18 19 20
CONNECTOR LIST
H-38
2 1 1 2
1
M-6 3 2
5 4
M-7 2 1
4 3
M-15
1 2
M-25 1 4
2 3
5 6 7 8
X-18 2
3 4 5
AUTOMATIC TRANSMISSION (4L30-E) 7A1 – 145
ON-VEHICLE SERVICE
SELECTOR LEVER
INSPECTION
1) Make sure that when the shifter control lever is

shifted from “P” to “L”, a “clicking” can be felt at
each shift position. Make sure that the gear
corresponds to that of the position plate indicator.
Button must be pressed. 2) Check to see if the shifter lever can be shifted as
shown.
Button need not be pressed.
REMOVAL
Preparation:
Disconnect negative (–) battery cable.
1. Front Console
745LW001
2. Selector Lever Assembly

1) Disconnect shift lock cable from the selector lever
assembly side.
Shift lock cable 2) Disconnect wiring harness connectors.
3) Disconnect shift control rod from the selector
lever assembly side.
256RV012
4) Remove selector lever assembly.
255LW007
7A1 – 146 AUTOMATIC TRANSMISSION (4L30-E)
INSTALLATION
3
N (1) Place the vehicle on a level surface.
4
N NOTE:
If the vehicle is not on a level surface, the shift select
cable set positions will vary with the movement of
the engine. To prevent possible misadjustment of the
N
cable, the vehicle must be placed on a level surface.
(2) Install the shift control rod (1) to the transmission
2 1
select lever (2), and then place the lever in the “N”
256RW014
position.
(3) Set select lever in the “N” position.
(4) Push select lever forward and secure it (using a
(5) Install the shift control rod (1) to the selector lever
arm (4).
Nut Torque N·m (kg·m / lb·ft)
32 (3.3 / 24)
NOTE:
Do not apply to threaded portions.
(6) After adjustment, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Adjustment of shift lock cable

1) Set IGN key in “LOCK” position and selector lever
5mm
in “P” position.
1 3 2) Adjust cable screw cap on selector lever side to
2 provide a gap (slack for cable) of 1 ~ 2mm
between rod on steering lock side and stopper.
1 Pull screw cap in arrow direction to remove
inner cable slack.
256RW015
2 With cable kept as 1, adjust gap between nut

(1) and bracket to 5mm (0.2in).
3 Lock inner cable by turning nut (2) while
holding nut (1) in place.
Lock Nut Torque N·m (kg·cm / lb·in)
4 (39 / 35)
NOTE:
Clean the rod threads and do not apply oil to them.
3) Check the shift lock operation:

1 Selector lever shall not move out of “P”
position with ignition key in “Lock” position.
2 Selector lever can be moved out of “P”
position with ignition key in “ON” position
only when brake pedal is depressed.
3 Ignition key can be turned to “LOCK” position
only when selector lever is in “P” position
(key can be pulled out).
If 1 and 3 fail, readjust cable. If 2 fails, readjust
MODE SWITCH
4 REMOVAL
3
Preparation:
• Disconnect negative (–) battery cable.
1. Place selector lever in neutral.
2
2. Disconnect battery ground cable.
3. Remove mode switch cover (1).
4. Disconnect selector lever (2) from the mode switch.
5 Disconnect transmission harness from the mode
5 switch connector (3).
1 6 Remove bracket with mode switch connector from
210RW008

7. Remove mode switch connector (3) from the bracket
(4).
8. Remove two mode switch bolts and nut then remove
mode switch(5).
INSTALLATION
1. Mode Switch Bolt Torque N·m (kg·cm / lb·in)
13 (130 / 113)
Selector Lever Nut Torque N·m (kg·m / lb·ft)

23 (2.3 / 17)
2. Mode switch setting procedure

Perform either of the following adjustment
procedures:
Procedure1
1 a. Place selector lever in neutral.
b. Remove selector lever from the mode switch.
c. Remove the mode switch cover.
d. Loosen the two 10 mm screws.
e. Rotate the mode switch until the slot in the mode
switch housing aligns with the selector shaft
249RW001
bushing, and insert a 3/32 in. (2.4 mm) drill bit or
punch (1) into the slot.
Mode switch connector f. Tighten the screws to 13 N·m (113 lb·in).
6 (C) 7 (B) g. After completing adjustment, snap the mode
5 (D) 8 (A) switch cover into place.
h. Reinstall the selector lever.
Procedure2
a. Place selector lever in neutral.
b. Disconnect transmission harness connector from
mode switch connector.
c. Remove mode switch connector with bracket
1 (E) 4 (H) from the transmission case.
2 (F) 3 (G)
F07RW003
d. Connect multimeter (resistance mode) to
terminals 1(E) and 4(H) on mode switch
connector.
e. Loosen two mounting screws.
f. Rotate mode switch slightly in both directions to
determine the range (approx. 5 degrees) of
electrical contact.
g. Position mode switch in middle of contact range.
h. Tighten two mounting screws.
I. Remove multimeter and install mode switch
harness connector with bracket to the
transmission case.
j. Connect transmission harness connector to mode
switch connector.
TRANSMISSION
4 12
8
9
10 11
13
1
240LW002
Removal Steps
1. Exhaust pipe 10. Rear mount nut
2. Rear propeller shaft 11. 3rd crossmember
3. Fuel pipe 12. Engine-transmission bolt
4. ATF oil cooler pipe 13. Transmission assembly
5. Heat protector
7. Starter Installation Steps
8. Flywheel under cover To install, follow the removal steps in the
9. Flywheel-Torque converter bolt reverse order.
REMOVAL
Preparation:
• Remove engine hood.
1. Exhaust Pipe
1) Remove catalytic converter, center pipe and left
front pipe.
2) Disconnect O2 sensor connector from the
transmission harness connector.
2. Rear Propeller Shaft

1) Disconnect shift control rod from the selector
lever assembly side.
256LW004
2) Disconnect rear propeller shaft transmission side.
401LW001
3. Fuel Pipe
Disconnect two fuel pipe clamp bracket from the
transmission case eight side.
141LW001
4. ATF Oil Cooler Pipe

1) Disconnect ATF oil cooler pipe from transmission
side.
2) Remove oil pipe clamp bracket from torque
converter case.
3) Loosen oil pipe clamp bolt at the engine mount
side.
253LW002
5. Heat Protector
815LW001
6. Harness Connector
1) Disconnect transmission harness connectors from
transmission side connectors.
2) Disconnect harness clamp from transmission case
side.
7. Starter
8. Flywheel Under Cover

Remove flywheel under covers (3 pieces) from
transmission case.
210LW001
9. Flywheel – Torque Converter Bolt

Remove flywheel torque converter fixing bolts (6
pieces) by turning crankshaft.
210LW002
10. Rear Mount Nut

1) Support transmission with a jack.
2) Remove two rear mount nuts from the rear
mount.
11. 3rd Crossmember
Remove eight 3rd crossmember bolts.
12. Engine-Transmission Bolt
1) Hoist engine with a chain block.
2) Remove engine-transmission bolts
13. Transmission Assembly
INSTALLATION
13. Transmission Assembly
Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine.
12. Engine-Transmission Bolt
Tighten engine-transmission bolts, to the specified
torque (see next page).
11. 3rd Crossmember
3rd Crossmember Bolt Torque N·m (kg·m / lb·ft)
50 (5.1 / 37)
10 Rear Mount Nut

Rear Mount Nut Torque N·m (kg·m / lb·ft)
41 (4.2 / 30)
9. Flywheel-Torque Converter Bolt

1) Align the flywheel-torque converter bolt boss with
the starter portion of the converter housing by
turning torque converter.
2) Install new flywheel-torque converter bolts (6
pieces) by turning crankshaft.
NOTE:
Do not reuse the flywheel-torque converter bolt.
Flywheel-Torque Converter
Bolt Torque N·m (kg·m / lb·ft)
210LW002
55 (5.6 / 41)
8. Flywheel Under Cover

Flywheel Under Cover
Bolt Torque N·m (kg·cm / lb·in)
8 (80 / 69)
7. Starter
Starter Bolt Torque N·m (kg·m / lb·ft)
40 (4.1 / 30)
6. Harness Connector
1) Connect transmission harness connectors to
transmission side.
2) Connect harness clamp to transmission harness
clamp bracket.
Engine-Transmission Bolt Torque
Torque : N•m(kg•m/lb ft)

45 45 Length : mm
76(7.7/56) 76(7.7/56)
50 21 27 1.2 21 27
Clip;breather hose
76(7.7/56) T/M case T/M case 40
Cylinder block Cylinder block
21 27 2.5
76(7.7/56)
Bracket;fuel pipe
T/M case 17 27
Cylinder block
70 T/M case
50 Cylinder block
76(7.7/56)
76(7.7/56)
32 20 25 30
T/M case
Cylinder block 10 T/M case
10 Cylinder block
8(0.8/69lb in)
8(0.8/69lb in)
10 0.9 20
40 0.9 20
8(0.8/69lb in) T/M case
Under cover 40(4.1/30) T/M case
(6places) 0.9 11 Under cover
25 20
Crank case
Under cover T/M case
Crank case
F07RW041
5. Heat Protector
Heater Protector Bolt Torque N·m (kg·cm / lb·in)
6 (60 / 52)
815LW001
4. ATF Oil Cooler Pipe

1) Install ATF oil cooler pipe to transmission.
ATF Oil Cooler Pipe Nut Torque N·m (kg·m / lb·ft)
54 (5.5 / 40)
2) Install oil pipe clamp bracket to torque converter

case.
3) Tighten oil pipe clamp bolt at engine mount side.
253LW002
3. Fuel Pipe
Connect fuel pipe bracket to transmission side.
141LW001
2. Rear Propeller Shaft

Connect shift control rod to the selector lever assembly.
Propeller Shaft Bolt Torque N·m (kg·m / lb·ft)
63 (6.4 / 46)
1. Exhaust Pipe
Exhaust Pipe Bolt Torque N·m (kg·m / lb·ft)
Exh. pipe to exh. manifold 67 (6.8 / 49)
Exh. pipe flange bolt 43 (4.4 / 32)
Connect O2 sensor connector to transmission harness

connector.
SOLENOID VALVE
(MAIN CASE VALVE BODY)
REMOVAL
Preparation:
• Drain fluid.
Refer to “SERVICING” of the SERVICE
INFORMATION (Section 00).
• Remove exhaust pipe and disconnect oxygen
sensor connector.
• Support transmission case with a jack and remove
third crossmember.
1. Main Case Oil Pan
Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
2. Oil Filter
Remove three 13 mm screws, oil filter.
3. Wiring Harness
Disconnect wiring harness from band control
solenoid, shift solenoids. Pull only on connectors, not
on wiring harness.
4. Spring Pin
Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
210RW010
244RW003
5. Solenoids
Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
INSTALLATION
5. Solenoids
Install 1shift solenoid A, shift solenoid B, band control
solenoid with new gaskets to main case valve body
respectively.
4. Spring Pin
Carefully install spring pin with hammer to avoid
damage to valve body etc.
3. Wiring Harness
Connect wiring harness to solenoids.
2. Oil Filter
Install oil filter with new gasket, three 13 mm screws.
Oil Filter Bolt Torque N·m (kg·m / lb·ft)
20 (2.0 / 15)
243RW004
Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws
Main Case Oil Pan Bolt Torque N·m (kg·cm / lb·in)
11 (110 / 96)
• Install third crossmember and rear mount nuts.

Rear Mount Nut Torque N·m (kg·m / lb·ft)
41 (4.2 / 30)
Third Crossmember Bolt Torque N·m (kg·m / lb·ft)

50 (5.1 / 37)
• Install exhaust pipe and connect oxygen sensor

connector.
Exhaust Pipe Flange Bolt Torque N·m (kg·m / lb·ft)
43 (4.4 / 32)
• Refill the transmission with new ATF DEXRON-III.

• Connect negative (–) battery cable.
SOLENOID VALVE
(ADAPTER CASE VALVE BODY)
REMOVAL
Preparation:
• Drain fluid.
• Remove exhaust pipe and disconnect oxygen
sensor connector.
1. Adapter Case Oil Pan

Remove twelve 10 mm screws, adapter case oil pan,
and gasket.
2. Wiring Harness
Disconnect wiring harness from force motor solenoid,
converter clutch solenoid. Pull only on connectors,
not on wiring harness.
3. Solenoid
• Remove 11 mm bolt and converter clutch solenoid
with two O-rings.
• Remove 11 mm bolt, retainer, and force motor
solenoid.
210RW011
210RW009
INSTALLATION

3. Solenoids
1) Install force motor solenoid, retainer, and 11 mm
bolt to adapter case valve body.
Retainer Bolt Torque N·m (kg·cm / lb·in)
10 (100 / 87)
2) Install converter clutch solenoid with two O-rings.

3) Tighten 11 mm converter clutch solenoid bolt to
adapter case valve body.
Converter Clutch Solenoid
10 (100 / 87)
2. Wiring Harness
Connect wiring harness assembly to solenoids.
Install adapter case oil pan, new gasket, and twelve
10 mm screws.
Adapter Case Oil Pan
11 (110 / 96)
• Install exhaust pipe and connect oxygen sensor

connector.
Exhaust Pipe Flange Bolt Torque N·m (kg·m / lb·ft)
43 (4.4 / 32)
• Refill the transmission with new ATF DEXRON-III.

• Connect negative (–) battery cable.
UNIT REPAIR
TRANSMISSION (4L30-E)
2. O-ring
1. Torque converter
3. Mode switch
and transmission
harness
12.Main
case
valve
body
6. Adapter case
valve body
11. Servo cover
5. Wiring harness
9. Manual detent
4. Adapter case
oil pan
10. Wiring harness
8. Oil filter
7. Main case oil pan
240LW003
DISASSEMBLY
During the disassembly and reassembly of the following
components, perform the following:
• Wash each part thoroughly and blow air through
each oil passage and groove to eliminate blockage.
• Seal rings, roll pins and gaskets should be replaced
with new parts.
• When assembling the components, apply DEXRON-
III Automatic transmission fluid to each seal, rotating
part and sliding part.
• Do not dip those parts having a facing, such as drive
plate for clutch or brake, in the cleaner when washing
it with solvent.
Also, always wash it with new ATF two or three times
after cleaning with solvent.
1. Torque Converter
5-8840-2278-0 1) Drain fluid from torque converter.
5-8840-0003-0
2) Attach holding fixture to the transmission and set
it on holding fixture base.
Holding fixture: 5-8840-2278-0 (J-8763-02)
Fixture base: 5-8840-0003-0 (J-3289-20)
NOTE:
Do not overtighten the tool, as case damage may
result.
2. O-Ring
Remove O-ring from turbine shaft.
3. Mode Switch
1) Remove two 10mm screws, cover and mode
switch.
420RW019

1) Remove twelve 10mm screws, adapter oil pan,
and gasket.
5. Wiring Harness
1) Disconnect electrical connections from solenoids.
Pull on connectors only, not on wiring harness.
6. Adapter Case Valve Body
1) Remove seven 13mm screws, adapter case valve
body assembly, transfer plate and two gaskets.
2) Remove wiring harness and 5 pin connector.
Remove sixteen 10mm screws, main oil pan, magnet,
and gasket.
8. Oil Filter
Remove three 13mm screws, oil filter.
9. Manual Detent
Remove two 13mm screws, roller & spring and
manual detent.
10. Wiring Harness

1) Disconnect harness assembly from band apply
solenoid, shift solenoids and main case 4 pin
connector.
2) Remove 4 pin connector.
11. Servo Cover
Remove four 13mm screws, servo cover and gasket.
12. Main Case Valve Body and Ground Wire
1) Remove seven 13mm valve body screws.
2) Remove ground wire from main case.
3) Remove main valve body assembly with manual
valve link and transfer plate.
NOTE:
Note the position of link, with the long end into valve
short end, into range selector lever.
3) Remove gasket transfer plate from main case.
4) Remove two check balls from main case.
13. Servo Piston
1) Turn transmission to vertical position to drain
fluid. Return back to horizontal position when
drained.
2) Install servo piston spring compressor with offset
to the rear of case.
3) Compress servo piston assembly.
4) Remove servo piston retaining ring.
5) Slowly release servo piston assembly.
6) Remove tool.
7) Remove servo piston assembly, return spring,
and servo apply rod.
Servo piston spring compressor: 5-8840-0501-0
(J-23075)
15.Wheel parking lock 14. Speed Sensor

1) Rotate transmission to horizontal position, pan
Seal ring
side down.
2) Remove one 10mm screw, and speed sensor with
O-ring.
15. Extension Housing and Flange
1) Remove seven 8mm hexagon socket head screws,
extension assembly, and gasket.
14.Speed sensor 2) Remove retaining ring.
NOTE:
Use extra long nose pliers.
3) Remove flange nut.
15.Flange nut 4) Remove flange and O-ring.
15.Flange
5) Remove speed wheel.
15.Extension housing
15.Retaining ring 6) Remove wheel parking lock (with seal ring).
15.Speed wheel
241LW001
16. Converter Housing and Oil Pump Assembly

1) Rotate transmission to vertical position, converter
housing up.
2) Loosen, but not remove, five 13 mm inner screws
if oil pump disassembly required.
3) Remove seven outer screws.
4) Remove converter housing and oil pump
assembly.
5) Remove gasket.
6) Remove selective thrust washer.
17. Fourth Clutch Retainer

Remove fourth clutch retainer.
18. Turbine Shaft and Clutch Plates
Grasp turbine shaft and lift out the overrun clutch
housing assembly and fourth clutch plates.
19. Thrust Bearing Assembly
Remove thrust bearing assembly.
20. Overdrive Internal Gear
Remove overdrive internal gear.
21. Thrust Washer
Remove thrust washer.
22. Adapter Case and Center Support Assembly

1) Remove adapter case and center support
assembly (with fourth clutch piston).
2) Remove seal ring.
3) Remove selective thrust washer and two O-ring
seals from main case.
23. Fourth Clutch Spring Retainer

1) Compress the fourth clutch spring retainer and
springs.
2) Release snap ring from groove.
3) Remove clutch compressor and snap ring.
4) Remove retainer and spring assembly.
Compressor: 5-8840-0195-0 (J-23327) and
5-8840-2263-0 (J-23327-90)
24. Fourth Clutch Piston
1) Insert two converter housing/main case screws to
hold adapter case while pulling out fourth clutch
piston.
2) Remove fourth clutch piston assembly.
3) Remove converter housing/main case screws.
25. Second and Third Clutch Assemblies
1) Grasp intermediate shaft, twist and pull out the
second and third clutch drum assemblies with
reverse clutch plates while holding onto output
shaft.
2) Separate 2nd and 3rd clutch assemblies.
3) Remove thrust washer.
4) Remove reverse clutch plates and reverse clutch
pressure plate.
26. Planetary Carrier Assembly
1) Remove bearing and washer.
2) Remove planetary carrier assembly.
3) Remove thrust bearing.
27. Reaction Sun Gear
1) Remove reaction sun gear
2) Remove needle bearing.
28. Brake Drum
Remove brake drum.
29. Brake Band
1) Remove brake band.
2) Remove thrust bearing.
30. Parking Lock and Selector Lever Assembly

1) Rotate case to horizontal position, valve body side
facing up.
2) Remove spring pin, using cutting pliers.
NOTE:
Insert wire in the center of the spring pin to prevent
it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
3) Remove parking lock and range selector lever 17
mm nut.
4) Remove parking lock and range selector lever and
actuator assembly.
5) Remove selector shaft.
NOTE:
Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
REASSEMBLY
30. Parking Lock and Selector Lever Assembly
1) Inspect selector shaft seal, replace if necessary.
NOTE:
Use a seal installer when replacing the seal.
2) Install selector shaft.
NOTE:
Spring pin groove must be positioned inside the
case.
3) Install spring pin. Be sure the selector shaft can
move freely.
Do not push the pin flush with the case surface.
Leave enough height for removal.
4) Install actuator assembly.
5) Install parking lock and range selector lever and
new 17 mm nut.
Selector Lever Nut Torque N·m (kg·m / lb·ft)
22 (2.2 / 16)
29. Brake Band

1) Rotate main case to vertical position, extension
end facing down.
2) Install brake band assembly.
NOTE:
Be sure to align servo pin area with the servo hole.
3) Install thrust bearing.

NOTE:
The case bushing acts as a guide for the thrust
bearing.
28. Brake Drum
Install brake drum.
27. Reaction Sun Gear
1) Install reaction sun gear.
2) Install needle bearing.
26. Planetary Carrier Assembly
1) Inspect planetary carrier assembly for wear and
damage, if necessary renew.
2) Measure pinion end play clearance (A)with a
feeler gage.
Planetary Carrier Pinion End Play (A) mm (in)
Standard 0.13 – 0.89 (0.005 – 0.035)
If clearance is outside specified valve, replace
planetary carrier assembly.
3) Install the thrust bearing on the output shaft.
NOTE:
Use petroleum jelly to hold the thrust bearing in
place.
4) Align planetary pinions. Each planetary pinion is

marked with double points to indicate the master
tooth space and exactly opposite with a single
point to indicate the master tooth. The markings
on the planetary carrier consist of double lines
which are to be lined-up with the double points
on two opposite pinions; the single lines are to be
lined-up with the single points on the other two
pinions.
5) After all four pinions are lined-up, slide on third
clutch assembly. Rotate third clutch and check
mark alignment. Considering that the ring gear
tooth between the double points of one planetary
pinion is tooth number 1, count the teeth to check
that the single points on the two adjacent pinions
are between teeth 23 and 24 of the ring gear, and
that the ring gear tooth between the double
points of the opposite pinion is tooth number 46.
If it is not so, remove, realign and try again.
6) Install planetary carrier with third clutch.
NOTE:
Do not force. When properly aligned, the parts will fit
together easily.
7) Remove the third clutch.
8) Install bearing and washer.
NOTE:
Use petroleum jelly to hold the washer and bearing
in place.
25. Second and Third Clutch Assemblies

1) Carefully align second clutch plates inner tangs.
2) Install thrust washer, tangs pointing downward,
locating tang positioned in slot on second clutch
hub.
NOTE:
Use petroleum jelly to hold thrust washer in place.
3) Install third clutch and intermediate shaft
assembly into the second clutch drum.
4) Install second and third clutch assemblies into the
main case. Twist output shaft and clutch
assemblies to insure proper fit.
5) Install pressure plate with lip side up, tang facing
valve body face.
6) Install reverse clutch plates. Start with a steel
plate and alternate with lined plates.
7) Install waved clutch plate, center tang facing valve
body side.
Second clutch end play measurement

1) Install the gaging tool on the case flange and
5-8840-2262-0 against the intermediate shaft.
2) Position the inner shaft of the gaging tool against
the thrust surface of the second clutch hub.
3) Tighten thumb screw. Remove the tool.
4) Fit the spacer ring on the inner shaft of the tool.
5) Measure gap (“G”). Select appropriate size
washer as the chart specified.
Selective washer gaging tool: 5-8840-2262-0
247RW007 (J-23085-A)
Selective Thrust Washer
DIM. “G” mm(in) Color

1.53 - 1.63 (0.060 - 0.064) YELLOW
1.72 - 1.82 (0.068 - 0.072) RED
1.91 - 2.01 (0.075 - 0.079) BLACK
2.10 - 2.20 (0.083 - 0.087) NATURAL
2.29 - 2.39 (0.090 - 0.094) GREEN
2.48 - 2.58 (0.098 - 0.102) BLUE
FOLLOWING THE PROCEDURE SHOULD
RESULT IN FINAL END-PLAY FROM
0.36mm TO 0.79 mm (.014” TO .031”)
18. Turbine shaft and overrun clutch
Overrun clutch piston
Overrun clutch drum

Turbine shaft oil seal ring
Turbine shaft
Ratainer and
17. Fourth clutch retainer ball assembly
18. Fourth clutch plates
2. O-ring
20. OD
internal gear
OD 21. Thrust
carrier assembly washer
Backing plate 19. Thrust

bearing
Snap ring
Clutch plate
Overrun clutch relase
spring retainer
Roller clutch
Snap ring
Sun gear
Snap ring
Overrun roller clutch cam
Diaphragm spring
24. Fourth clutch piston
Piston seal
Piston seal
Fourth clutch piston

23. Retainer and spring assembly
23. Snap ring
24. Fourth Clutch Piston

1) Inspect piston seals and replace if necessary.
2) Lubricate fitter and install on fourth clutch piston.
3) Install fourth clutch piston in adapter case.
4) Remove fitter.
Fourth clutch piston fitter: 5-8840-2267-0 (J-38554)
23. Fourth Clutch Spring Retainer

1) Install retainer and spring assembly.
2) Install snap ring in adapter case.
3) Install compressor.
4) Compress retainer and spring assembly.
5) Seat snap ring in groove.
6) Remove compressor.
Fourth clutch spring compressor: 5-8840-0195-0
(J-23327) and 5-8840-2263-0 (J-23327-90)
22. Adapter Case and Center Support Assembly

1) Install selective washer using petroleum jelly.
2) Install two O-ring seals in main case and adapter
case/main case seal ring.
3) Install guide pins.
4) Install adapter case complete to main case.
Guide pin: 5-8840-2268-0 (J-38588)
21. Thrust Washer

Install thrust washer into adapter case, with tangs
pointing downwards.
20. Overdrive Internal Gear
19. Thrust Bearing Assembly
18. Turbine Shaft and Fourth Clutch Plates
1) Preassemble overdrive internal gear and thrust
bearing assembly onto the overrun clutch
assembly complete.
NOTE
Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.
2) Complete overdrive carrier and internal gear
assembly into adapter case.
3) Install fourth clutch plates in the following order.
Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.
17. Fourth Clutch Retainer
Install fourth clutch retainer.
Notch facing up and positioned towards valve body
surface.
OD clutch end play measurement
1) Install the tool on the adapter case flange and

against the input shaft.
2) Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3) Tighten thumb screw. Remove the tool.
4) Measure gap “G”. Select appropriate size washer
as the chart specifies.
5) Set selective thrust washer aside.
Selective washer gaging tool: 5-8840-2262-0
(J-23085-A)
Selective Thrust Washer
DIM. “G” mm(in) Color

1.53 - 1.63 (0.060 - 0.064) YELLOW
1.72 - 1.82 (0.068 - 0.072) RED
1.91 - 2.01 (0.075 - 0.079) BLACK
2.10 - 2.20 (0.083 - 0.087) NATURAL
2.29 - 2.39 (0.090 - 0.094) GREEN
2.48 - 2.58 (0.098 - 0.102) BLUE
FOLLOWING THE PROCEDURE SHOULD
RESULT IN FINAL END-PLAY FROM
0.1 mm TO 0.8 mm (0.004” TO 0.03”)
16. Converter Housing and Oil Pump Assembly

1) Install outer seal ring and gasket.
2) Install selective washer.
NOTE
Use petroleum jelly to hold selective washer in place.
3) Install complete converter housing and oil pump
assembly to adapter case.
4) Fit and tighten seven outer 13 mm screws.
Converter Housing Outer
Screw Torque N·m (kg·m / lb·ft)
39 (4.0 / 29)
5) Ensure free rotation of pump using rotation tool.

Pump rotation tool: 5-8840-2273-0 (J-23082-01)
Overdrive end play measurement
1) Fit puller on turbine shaft.

2) Position axial play checking tool on converter
housing mating face.
3) Pull turbine shaft upwards with puller until first
resistance is met.
(Due to weight of overdrive complete assembly)
Maintain shaft in this position and set indicator to
zero.
4) Pull turbine shaft further upwards with puller.
Read end play shown on indicator.
Overdrive End Play mm (in)
Standard
0.1 – 0.8 (0.004 – 0.031)
5) Remove axial play checking tool and puller.

NOTE:
If end play is not correct, repeat selective washer
selection.
Turbine shaft puller: 5-8840-2271-0 (J-25022) and
5-8840-0618-0 (J-24773-1)
15.Wheel parking lock 15. Extension Housing and Flange

1) Inspect extension housing oil seal and
Seal ring
bearing.Replace if necessary.
Extension housing oil seal installer: 5-8840-2282-0
(J-36797)
2) Rotate transmission to horizontal position, with
valve body side down.
3) Inspect parking wheel seal ring. Replace if
14.Speed sensor necessary.
4) Install wheel parking lock assembly.
5) Install speed wheel and snap ring.
NOTE:
15.Flange nut Use extra long nose pliers.
15.Flange
6) Install gasket onto extension assembly, using a
15.Extension housing
15.Retaining ring thin coating of oil.
15.Speed wheel 7) Install extension housing assembly, and align
241LW001
parking pawl shaft.
8) Install actuator assembly into extension
assembly.
9) Install seven 8 mm hexagon socket head screws.
Extension Housing Bolt Torque N·m (kg·m / lb·ft)
32 (3.3 / 24)
10) Install flange and O-ring.

11) Install flange nut.
Flange Nut Torque N·m (kg·m / lb·ft)
103 (10.5 / 76)
14. Speed Sensor

1) Inspect speed sensor O-ring. Replace if necessary.
2) Install speed sensor assembly and 10 mm screws.
Speed Sensor Bolt Torque N·m (kg·cm / lb·in)
9 (90 / 78)
Main case end play measurement
1) Attach axial play checking tool on the extension

housing and set indicator to zero on output shaft.
2) Manually push output shaft upwards.
Main Case End Play mm (in)
Standard
0.36 – 0.80 (0.014 – 0.031)
3) Remove axial play checking tool.

4) If end play is not correct, repeat selective washer
selection.
13. Servo Piston

1) Inspect piston seal ring. Replace if necessary.
2) Ensure brake band is correctly positioned. Rotate
output shaft if necessary.
3) Install servo piston fitter in servo bore.
4) Install apply rod, round end toward band, return
spring and piston assembly.
5) Install the tool with offset to rear of case.
6) Compress servo piston seal ring, using fitter while
tightening the tool screw.
7) Install servo piston retaining ring.
8) Remove tool.
9) Adjust the brake band by tightening the servo
adjusting screw to 4.5 N·m (46 kg·cm / 40 lb·in)
torque. Be certain the lock nut is loose, then back-
off the screw five turns exactly. Hold piston sleeve
with wrench and tighten lock nut to 18.5 N·m
(1.9 kg·m / 14 lb·ft) torque. Be certain the
adjusting screw does not turn.
Servo spring compressor: 5-8840-0501-0 (J-23075)
Servo piston fitter: 5-8840-2274-0 (J-38428)
2. O-ring
1. Torque converter
3. Mode switch
and transmission
harness
12.Main
case
valve
body
6. Adapter case
valve body
11. Servo cover
5. Wiring harness
9. Manual detent
4. Adapter case
oil pan
10. Wiring harness
8. Oil filter
7. Main case oil pan
作業番号 10012
発注者鈴木発注日 '97/ 11/ 28
240LW003
12. Main Case Valve Body and Ground Wire

1) Install two check balls.
2) Inspect electrical connector and seal, replace if
necessary.
3) Install electrical 4 pin connector/main case and
wiring harness.
4) Install two guide pins into main case.
Guide pin: 5-8840-0022-0 (J-25025-B)
5) Install valve body complete assembly and manual

valve link.
NOTE:
Valve must be extended as the short end of manual
valve link is connected to the range selector lever.
Long end of link goes into valve.
6) Install seven 13 mm screws.
Earth harness 7) Pass ground wire of adapter case wiring harness

assembly through the hole joining adapter fluid
area and main case fluid area.
8) Assemble 8.5 mm connector of ground wire under
the head of this valve body bolt and reinstall it.
Main Case Valve Body

20 (2.0 / 15)
244RV001
9) Remove two guide pins.
11. Servo Cover
Install servo cover gasket, cover and four 13 mm
screws.
Servo Cover Bolt Torque N·m (kg·m / lb·ft)
25 (2.5 / 18)
10. Wiring Harness

Connect harness to band control and shift solenoids.
9. Manual Detent
Install roller and spring assembly with clip.
Install two 13 mm screws.
Manual Detent Screw Torque N·m (kg·m / lb·ft)
20 (2.0 / 15)
8. Oil Filter
Install oil filter, three 13 mm screws.
Oil Filter Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

Install oil pan gasket, magnet, oil pan, sixteen 10 mm
screws.
Main Case Oil Pan Bolt Torque N·m (kg·cm / lb·in)
11 (110 / 96)
6. Adapter Case Valve Body

1) Inspect electrical connector and seal. Replace if
necessary.
Install electrical five pin connector and harness
assembly in bottom of adapter case.
Install gasket, transfer plate, gasket.
2) Install adapter case valve body complete and
seven 13 mm screws.
Adapter Case Valve Body
20 (2.0 / 15)
5. Wiring Harness
1) Connect harness assembly to converter clutch
solenoid, and force motor.
1) Install oil pan gasket, oil pan, twelve 10 mm
screws.
Adapter Case Oil Pan
11 (110 / 96)
2) Rotate transmission, with bottom pan facing

down.
3. Mode Switch
1) Install mode switch, shield and two 10 mm
screws.
2) Adjust using setting tool.
Refer to “MODE SWITCH” in this section.
Selector Shaft Nut Torque N·m (kg·m / lb·ft)
23 (2.3 / 17)
Mode Switch Screw Torque N·m (kg·cm / lb·in)

13 (130 / 113)
2. O-Ring
Install O-ring on turbine shaft.
1. Torque Converter
1) The converter assembly must be replaced under
any of the following conditions:
a. Evidence of damage to the pump assembly
b. Metal particles are found after flushing the
cooler lines
c. External leaks in hub weld area
d. Converter Pilot broken, damaged or poor fit
into crankshaft
e. Converter hub scored or damaged
f. Internal failure in stator
g. Contamination from engine coolant
h. Excess end play
2) Install converter assembly.
Rotate transmission, bell housing up. Spin
converter to insure proper fit.
3) Fill transmission through the overfill screw, using
DEXRON-III ATF.
CONVERTER HOUSING AND OIL PUMP ASSEMBLY
1 2 4 5 3
241RW003
Disassembly Steps Reassembly Steps

1. Converter housing To reassemble, follow the disassembly steps
2. Outer seal ring in the reverse order.
3. Gasket
4. Wear Plate
5. Oil pump assembly
6. Oil seal ring
DISASSEMBLY
1. Converter Housing
Remove five bolts from converter housing.
2. Outer Seal Ring
3. Gasket
4. Wear Plate
5. Oil Pump Assembly
6. Oil Seal Ring
Visual check
If any damage, deformation or local wear is found in a
converter housing, outer seal ring, wear plate or oil seal
ring, replace it.
REASSEMBLY
6. Oil Seal Ring
Install oil seal ring using installer.
Oil Seal Ring Bolt Torque N·m (kg·cm / lb·in)
3 (30 / 26)
5. Oil Pump Assembly

4. Wear Plate
Install wear plate onto oil pump assembly.
3. Gasket
2. Outer Seal Ring
1. Converter Housing
1) Install converter housing onto complete oil pump
assembly. Align with two short guide pins on
outer bolt holes.
2) Loosely install five 13mm bolts.
3) Center converter housing using centering tool.
4) Tighten five inner 13mm bolts in an alternating
pattern.
Converter Housing Bolt Torque N·m (kg·m / lb·ft)
20 (2.0 / 15)
Guide pin: 5-8840-2268-0 (J-38588)

Centering tool: 5-8840-2272-0 (J-38557)
OIL PUMP
14
15
16
17
11
12
13
8 7
9
10
6
1 2 5
3
4
Disassembly Steps 11. Sleeve pin

1. Oil pump drive gear 12. Sleeve
2. Oil pump driven gear 13. Boost valve
3. Pin 14. Spring seat
4. Plug 15. Valve spring
5. Spring 16. Spring seat
6. Converter clutch control valve 17. Pressure regulator valve
7. Snap ring
8. Spring seat
9. Spring Reassembly Steps
10. Throttle signal accumulator piston To reassemble, follow the disassembly steps
in the reverse order.
DISASSEMBLY
1. Oil Pump Drive Gear

2. Oil Pump Driven Gear
3. Pin
4. Plug
5. Spring
6. Converter Clutch Control Valve
7. Snap Ring
8. Spring Seat
9. Spring
10. Throttle Signal Accumulator Piston
11. Sleeve Pin
12. Sleeve
13. Boost Valve
14. Spring Seat
15. Valve Spring
16. Spring Seat
17. Pressure Regulator Valve

Visual check
snap ring, spring, spring retainer valve, gear or oil pump,
replace it.
REASSEMBLY
17. Pressure Regulator Valve

16. Spring Seat
Lubricate and preinstall pressure regulator spring
seat on valve, with the flat side against shoulder.
15. Valve Spring

14. Spring Seat
13. Boost Valve
12. Sleeve
11. Sleeve Pin
10. Throttle Signal Accumulator Piston
9. Spring
8. Spring Seat
Install throttle signal accumulator piston, spring, and
spring seat, with the flat side away from the spring
and snap ring.
7. Snap Ring
6. Converter Clutch Control Valve
5. Spring
4. Plug
3. Pin
2. Oil Pump Driven Gear
1. Oil Pump Drive Gear
MAIN CASE VALVE BODY
23
8 25
26
13
24
10
9 27 3
7 5
6 21
20
15 22
14
11
12 2
19
18
17
16
Disassembly Steps 21. Plug

1. Gaskets and transfer plate 22. Band control screen assembly
2. Manual valve 23. Spring pin
3. Band control solenoid 24. Plug
4. Pin 25. 1-2 accumulator valve
5. Waved washer 26. 1-2 accumulator control valve
6. Spring pin 27. Check ball
7. Solenoid A
8. Retainer
9. 1-2/3-4 shift valve Reassembly Steps
10. Spring To reassemble, follow the disassembly steps
11. Spring pin in the reverse order.
12. Solenoid B
13. Retainer
14. 2-3 shift valve
15. Spring
16. Spring pin
17. Plug
18. Spring
19. Low pressure control valve
20. Spring pin
DISASSEMBLY
1. Gaskets and Transfer Plate
Remove two 11mm bolts from valve body.
2. Manual Valve
3. Band Control Solenoid
4. Pin
5. Waved Washer
6. Spring Pin
7. Solenoid A
Remove solenoids by grasping the metal tip. Do not
grasp the connector housing.
8. Retainer
9. 1-2/3-4 Shift Valve
10. Spring
11. Spring Pin
12. Solenoid B
Remove solenoids by grasping the metal tip. Do not
grasp the connector housing.
13. Retainer
14. 2-3 Shift Valve
15. Spring
16. Spring Pin
17. Plug
18. Spring
19. Low Pressure Control Valve
20. Spring Pin
21. Plug
22. Band Control Screen Assembly
23. Spring Pin
24. Plug
25. 1-2 Accumulator Valve
26. 1-2 Accumulator Control Valve
27. Check Ball
Remove 1 check ball from valve body.
Inspect for the following and replace any damaged or

worn parts:
• Damage or wear to each valve.
• Damage in oil passeges.
• Cracks or damage to valve body.
• Valve operations.
• Spring fatigue.
REASSEMBLY
27. Check Ball
Install 1 check ball to valve body
26. 1-2 Accumulator Control Valve
25. 1-2 Accumulator Valve
24. Plug
23. Spring Pin
22. Band Control Screen Assembly
21. Plug
20. Spring Pin
19. Low Pressure Control Valve
18. Spring
17. Plug
16. Spring Pin
15. Spring
14. 2-3 Shift Valve
13. Retainer
12. Solenoid B
11. Spring Pin
10. Spring
9. 1-2/3-4 Shift Valve
8. Retainer
7. Solenoid A
6. Spring Pin
5. Waved Washer
4. Pin
3. Band Control Solenoid
2. Manual Valve
1. Gaskets and Transfer Plate
1) Install gasket (valve body/transfer plate) and
transfer plate, using two guide pins.
2) Install two 11mm bolts.
Valve Body Bolt Torque N·m (kg·cm / lb·in)
13 (130 / 113)
3) Install gasket (transfer plate/main case).

Guide pins: 5-8840-2270-0 (J-3387-2)
ADAPTER CASE VALVE BODY
2 4
3
7
6
5
10
9
15
14
13
12
11
1
243RW001
Disassembly Steps
1. Converter clutch solenoid 11. Plug retainer
2. Retainer 12. O-ring
3. Force motor solenoid 13. Plug
4. Retainer 14. Force motor screen assembly
5. Plug 15. Adapter case valve body
6. 3/4 accumulator valve
7. 3/4 accumulator control valve
8. Spring Reassembly Steps
9. Retaining ring To reassemble, follow the disassembly steps
10. Feed limit valve in the reverse order.
DISASSEMBLY
1. Converter Clutch Solenoid

1) Remove 11mm bolt from valve body.
2) Remove converter control solenoid assembly with
two O-ring.
2. Retainer
Remove 11mm bolt and retainer from valve body.
3. Force Motor Solenoid
4. Retainer
5. Plug
6. 3/4 Accumulator Valve
7. 3/4 Accumulator Control Valve
8. Spring
9. Retaining Ring
10. Feed Limit Valve
11. Plug Retainer
12. O-ring
13. Plug
14. Force Motor Screen Assembly
Use 5mm bolt to pull plug.
Inspect for the following and replace any damaged or

worn parts:
• Damage or wear to each valve.
• Damage in oil passeges.
• Cracks or damage to valve body.
• Valve operations.
• Spring fatigue
REASSEMBLY
14. Force Motor Screen Assembly

13. Plug
12. O-ring
11. Plug Retainer
10. Feed Limit Valve
9. Retaining Ring
8. Spring
7. 3/4 Accumulator Control Valve
6. 3/4 Accumulator Valve
5. Plug
4. Retainer
3. Force Motor Solenoid
2. Retainer
1) Place solenoid terminals pointing towards mating
face.
2) Install retainer and bolt.
Retainer Bolt Torque N·m (kg·cm / lb·in)
10 (100 / 87)
1. Converter Clutch Solenoid

1) Install converter clutch solenoid assembly with
two O-rings to valve body.
2) Install bolt.
10 (100 / 87)
THIRD CLUTCH AND SPRAG UNIT
6 7
2 1 3 4 5 8
248RW001

2. Input sun gear assembly in the reverse order.
3. Retaining washer
4. Bearing
5. Thrust washer
6. Clutch plates
7. Third clutch drum
DISASSEMBLY
1. Retaining Ring
1) Place the third clutch housing and intermediate
shaft assembly upright, using the overdrive
internal gear as a support.
2) Locate the end of the sprag retaining ring.
Compress near the end, using a screwdriver
through the side slot and slide one tool blade
between ring and housing to hold the ring clear of
the groove.
3) Repeat with a second tool blade near the other
end of the retaining ring.
4) Repeat with a third tool blade opposite the first
two.
5) Repeat with two further blades equally spaced
apart.
Third clutch retaining ring compressor: 5-8840-2258-0
(J-38450)
2. Input Sun Gear Assembly

Pull the input sun gear assembly unit until the sprag
retaining ring clears the ring groove.
3. Retaining Washer
4. Bearing
5. Thrust Washer
6. Clutch Plates
7. Third Clutch Drum
Visual check
bearing, thrust washer, clutch plates or third clutch drum,
replace it.
REASSEMBLY
7. Third Clutch Drum

6. Clutch Plates
1) Place third clutch housing and intermediate shaft
assembly upright, using the overdrive internal
gear as a support.
2) Install third clutch spring cushion plate, bevel face
down.
3) Install third clutch plates into clutch housing.
Start with the steel clutch plate and alternate with
lined plates.
5. Thrust Washer
4. Bearing
3. Retaining Washer
2. Input Sun Gear Assembly
1. Retaining Ring
1) Fully engage the sprag assembly hub splines into
the third clutch inner tangs.
Simultaneously rotate the outer sprag race to
engage into the third clutch housing.
2) Install a tool blade at each extremity of the
retaining ring.
3) Compress the retaining ring with a screw-driver
opposite the tool blades while pushing down on
the outer sprag race.
4) Engage retaining ring into groove.
5) Remove tool blades.
Third clutch retaining ring compressor: 5-8840-2258-0
(J-38450)
THIRD CLUTCH

2. Spring seat in the reverse order.
3. Springs ★; Repair kit
4. Piston
DISASSEMBLY
1. Retaining Ring
1) Compress spring seat using the tool.
NOTE:
Do not over-stress the springs and seat. This will
cause damage to the spring seat.
2) Remove retaining ring.
3) Release the spring seat.
NOTE:
Do not let the spring seat catch in the ring groove.
Adapter: 5-8840-2259-0 (J-23075-12)
2. Spring Seat
3. Springs
4. Piston
Visual check
retaining ring, return spring, piston seals or spring seat,
replace it.
Operation check
Shake piston and listen for check ball movement. Replace
piston if check ball is missing or falls out.
REASSEMBLY
4. Piston
1) The lip of the seals must point toward the front of
the transmission. Lubricate the lip seal with
transmission fluid.
2) Install piston assembly into the third clutch drum.

Use installer to protect the outer seal during
installation.
Third clutch piston installer: 5-8840-2260-0
(J-23084)
3. Springs
2. Spring Seat
1. Retaining Ring
1) Place retaining ring onto spring seat.
2) Compress the piston springs, using the piston
spring compressor.
NOTE:
Do not over-stress the springs and seat. Do not let
the spring seat catch in the ring groove. This may
3) Install spring seat retaining ring.
4) Remove the piston spring compressor.
Adapter: 5-8840-2259-0 (J-23075-12)
SPRAG UNIT
DISASSEMBLY
1. Sprag Outer Race

2. Sprag Assembly
Remove sprag outer race and sprag assembly from
third clutch hub and sun gear assembly.
3. Sun Gear Assembly
Visual check
If any damage, deformation or local wear is found in a sun
gear, sprag assembly or sprag outer race, replace it.
REASSEMBLY
3. Sun Gear Assembly

2. Sprag Assembly
Install sprag assembly onto the sun gear.
NOTE:
Flared shoulder of the sprag cage faces the sun gear.
This procedure must be followed exactly to be sure
that the sprag assembly is installed properly.
1. Sprag Outer Race
1) Install outer sprag race assembly over the sprag
cage assembly.
2) Place third clutch hub and sun gear assembly on a
flat surface, sun gear facing up. Place sprag outer
race and sprag assembly over the sun gear
assembly, push down and turn the input sun
counterclockwise at the same time.
NOTE:
Check correct rotation by holding the sun gear in
your left hand and turning the outer race. The outer
sprag race should turn freely towards you and lock
turning away from you.
SECOND CLUTCH
11 10 9 8 7 6
5 4 3 2 1 ★; Repair kit
247RW001
Disassembly Steps 9. Springs

1. Retaining ring 10. Piston
2. Ring gear 11. Second clutch drum
3. Retaining ring
4. Spacer
5. Clutch plates Removal Steps
6. Waved washer To reassemble, follow the disassembly steps
7. Retaining ring in the reverse order.
8. Spring seat
DISASSEMBLY
1. Retaining Ring
2. Ring Gear
3. Retaining Ring
4. Spacer
5. Clutch Plates
6. Waved Washer
7. Retaining Ring
Compress the spring seat.
Compressor: 5-8840-0195-0 (J-23327)
8. Spring Seat
9. Springs
10. Piston
11. Second Clutch Drum
Visual check
retaining ring, ring gear, spacer, clutch plates, piston
seals, return spring or spring seat, replace it.
Operation check
Shake piston and listen for check ball movement.
Movement indicates proper check ball operation. Replace
piston if check ball is missing or falls out.
REASSEMBLY
11. Second Clutch Drum

10. Piston
Install piston assembly into the second clutch drum.
Lubricate the lip seal with liberal amounts of
transmission fluid. Use the installer to protect the
outer piston lip seal.
NOTE:
Lip of the seals point toward front of transmission.
Second clutch piston installer:5-8840-2261-0
(J-23080-A)
9. Springs
8. Spring Seat
7. Retaining Ring
1) Install twenty-two piston springs and spring seat
on the second clutch piston. Place retaining ring
onto spring seat.
2) Use the compressor to compress the piston
springs.
Compressor: 5-8840-0195-0 (J-23327)
NOTE:
Do not let spring seat catch in ring groove.
6. Waved Plate
5. Clutch Plates
Install clutch plates. Start with a steel plate and
alternate with lined plates.
Align second clutch inner tangs.
4. Spacer
Install spacer, with the fluted end toward clutch
plates.
3. Retaining Ring
2. Ring gear
1. Retaining Ring
3-4 ACCUMULATOR PISTON

DISASSEMBLY
Disassembly steps
1. Snap ring
2. Cover
3. Spring
4. Piston
Reassembly steps
To reassemble, follow the disassembly steps in the
reverse order.
★ Repair kit
1. Snap Ring
Adapter case
Install cover compressor on adapter case.
Compress piston cover. Remove snap ring.
Compressor: 5-8840-2277-1 (J-38559-A)
5-8840-2277-1
Piston cover
2. Cover
Install cover remover to center hole of cover.
Use slide hammer to remove cover.
5-8840-0019-0 Cover remove: 5-8840-2403-0 (J-41096)
Adapter: 5-8840-2266-0 (J-38584)
Slide hammer: 5-8840-0019-0 (J-23907)
5-8840-2266-0 5-8840-2403-0
242LW001
3. Spring
4. Piston
Visual Check
If any damage, deformation or wear is found in a return
spring, piston or piston cover, replace it.
REASSEMBLY
4. Piston
Place the fitter into adaptor case and push the piston
into position, using suitable diameter tube.
Piston fitter: 5-8840-2264-0 (J-38553)
3. Spring
2. Cover
Adapter case
5-8840-2277-1 Install cover, using compressor tool.
Compressor: 5-8840-2277-1 (J-38559-A)
Piston cover
1. Snap ring
Install snap ring in groove.
REVERSE CLUTCH PISTON AND CENTER SUPPORT

2. Spring seat in the reverse order.
3. Springs
4. Piston
5. Center support
6. Gasket
7. Transfer plate
8. Gasket
9. Restrictor
10. Retainer plate
11. Plug
12. Spring
13. Overrun lock out valve
DISASSEMBLY
1. Retaining Ring
1) Install the tool on spring seat.
2) Compress the spring seat.
Compressor: 5-8840-0195-0 (J-23327)
NOTE:
Do not over-stress the springs and seat, as this will
2. Spring Seat
3. Springs
4. Piston
5. Center Support
Remove 8 bolts from center support. Remove center
support from adapter case.
6. Gasket
7. Transfer Plate
8. Gasket
9. Restrictor
10. Retainer Plate
11. Plug
12. Spring
13. Overrun Lock Out Valve
Visual check
retaining ring, return spring, spring retainer, piston or
center support, replace it.
REASSEMBLY
13. Overrun Lock Out Valve

12. Spring
Install overrun lock out valve and spring.
NOTE:
Ensure correct assembly of valve. The spring should
be located over the long small diameter end.
11. Plug
10. Retainer Plate
9. Restrictor
Place in the lube overdrive channel in the adapter
case housing.
8. Gasket
7. Transfer Plate
6. Gasket
5. Center Support
Install center support with 8 bolts.
Center Support Bolt Torque N·m (kg·m / lb·ft)
25 (2.5 / 18)
4. Piston
3. Springs
2. Spring Seat
1. Retaining Ring
1) Install twenty four springs, spring seat and
retaining ring.
2) Install the tool.
3) Compress retaining ring and springs.
4) Seat snap ring in groove.
Compressor: 5-8840-0195-0 (J-23327)
OVERRUN CLUTCH AND TURBINE SHAFT
15 14 13
4
7
12 11 10 9 8 3 6 5 2 1

1. Snap ring To reassemble, follow the disassembly steps
2. Overdrive carrier assembly in the reverse order.
3. Sun gear
4. Turbine shaft
5. Snap ring
6. Backing plate
7. Clutch plates
8. Snap ring
9. Overrun roller clutch cam
10. Roller clutch assembly
11. Overrun clutch release spring
retainer
12. Diaphragm spring
13. Piston
14. Overrun clutch drum
15. Turbine shaft seal rings
DISASSEMBLY
1. Snap Ring
1) Position overrun clutch assembly upright, using
the overdrive internal gear as a support.
2) Remove snap ring.
2. Overdrive Carrier Assembly

3. Sun Gear
4. Turbine Shaft
5. Snap Ring
6. Backing Plate
7. Clutch Plates
8. Snap Ring
Compress piston return spring with compressor.
Compressor: 5-8840-2275-0 (J-23327-91)
9. Overrun Roller Clutch Cam

10. Roller Clutch Assembly
11. Overrun Clutch Release Spring Retainer
12. Diaphragm Spring
13. Piston
14. Overrun Clutch Drum
15. Turbine Shaft Seal Rings
Overdrive carrier check

Check pinion end play with a feeler gage.
Overdrive Carrier Pinion End Play mm (in)
Standard
0.24 – 0.64 (0.0094 – 0.025)
If clearance is outside specified value, replace overdrive
carrier assemlby
Visual check
snap ring, diaphragm spring, or spring retainer, roller
clutch assembly, turbine shaft, piston or clutch plates,
replace it.
REASSEMBLY
15. Turbine Shaft Seal Rings

Install seals with grease (petroleum jelly).
14. Overrun Clutch Drum

13. Piston
1) Install the inner installer on the drum.
2) Pre-install piston into outer installer.
3) Install overrun clutch piston assembly. Use the
outer installer while pushing piston into drum.
Installer: 5-8840-2269-0 (J-38555)
12. Diaphragm Spring

11. Overrun Clutch Release Spring Retainer
10. Roller Clutch Assembly
9. Overrun Roller Clutch Cam
8. Snap Ring
1) Place snap ring loosely on spring retainer.
2) Hold the compressor in a vise. Compress piston
return spring with compressor.
3) Set snap ring in ring groove.
Compressor: 5-8840-2275-0 (J-23327-91)
7. Clutch Plates
Install clutch plates, start with steel plate and
alternate with lined plates.
6. Backing Plate
5. Snap Ring
4. Turbine Shaft
3. Sun Gear
Overdrive sun gear, countersink pointing downwards.
2. Overdrive Carrier Assembly

Complete overdrive carrier assembly.
NOTE:
Turn the assembly in a counter-clockwise direction
only until roller clutch enters the outer race. After
assembly, rotate the assembly and listen for loose
rollers.
1. Snap ring
4L30-E PARTS LIST

CASE AND ASSOCIATED PARTS
11 12
10
9
8
6
23 5
1
4
32 8
12
30 31
28
29
27 28
13
14
15
45 46
44
16 42 43
17 18 37
19
35
36 39 38
20 48 47
104 50 49
34 51
73
54 52
72
53
71 55
57 56
69 70 60
89 61 62
63 64
68 33 85 58 65
67
88
59
23
87
103
86
105 102
85
84 101
82 100
70 99
TRANSMISSION
98
CONTROL MODULE 80
70 97 106
79 78 96
70 95
75 94
74 93
92
23 91
76 76 90
77 77
241LW002
CASE AND ASSOCIATED PARTS

1 Torque converter 36 Case, main 72 Gasket, adapter valve body
2 Screw, seal ring assembly 37 Breather, pipe 73 Plate, adapter valve body/transfer
3 Seal ring assembly, converter 38 Seal, O-ring 74 Pan, bottom/main case
housing 39 Reservoir 75 Gasket, bottom pan/main case
4 Screw, converter housing/main 76 Gasket, screw (’97)
case 77 Screw, oil drain or overfill (’97)
5 Screw, converter housing/oil pump 42 Gasket, extension case 78 Magnet, chip collector
6 Housing, converter 43 Extension assembly 79 Filter oil
7 Plug, converter housing 44 Seal, O-ring/speed sensor 80 Harness assembly, main case
8 Seal, O-ring 45 Sensor assembly, speed 81 Earth harness (’97)
9 Wear plate, oil pump body 46 Screw, speed sensor 82 Roller & spring assembly, manual
10 Pump assembly, oil 47 Nut, output shaft/drive flange detent
11 Gasket 48 Seal, O-ring/drive flange
12 Washer, thrust selective 49 Flange, drive 84 Valve body assembly, main case
13 Ring, snap 50 Seal, extension assembly 85 Ball, check
14 Cover, 3-4 accumulator piston 51 Bearing, needle/extension 86 Gasket, main V.B./Transfer plate
15 Seal, O-ring, 3-4 accumulator 52 Screw, extension/main case 87 Plate, main V.B./Transfer
16 Spring, 3-4 accumulator piston 53 Spring, parking pawl lock 88 Gasket, transfer/main case
17 Pin, 3-4 accumulator piston 54 Pawl, parking lock 89 Screw, transfer plate on V.B.
18 Piston, 3-4 accumulator 55 Connector, electrical/main case 90 Screw, servo cover
19 Ring, 3-4, accumulator piston 56 Actuator assembly, parking lock 91 Cover, servo piston
20 Case, adapter 57 Nut, parking lock lever 92 Gasket, cover/servo piston
22 Connector, electrical/adapter case 58 Link, manual valve 93 Ring, retaining servo piston
59 Pin, spring 94 Clip, servo piston
60 Lever, parking lock & range 95 Nut, servo screw
selelector 96 Screw, servo piston
61 Shaft, selector 97 Piston, servo
27 Restrictor, oil 62 Seal, selector shaft 98 Seal, ring/servo piston
28 Gasket, Transfer plate/adapter 63 Mode switch assembly 99 Spring, cushion/servo piston
29 Plate, transfer adapter/center 64 Screw & conical washer assembly 100 Seat, cushion spring
support 65 Shield, mode switch 101 Sleeve, servo piston adjust
30 Support assembly, center 102 Rod, apply/servo piston
31 Screw, center support 67 Pan, Bottom/Adapter case 103 Spring, return/servo piston
32 Ring, oil seal 68 Gasket, bottom pan/adapter case 104 Gasket, adapter case/transfer plate
33 Seal, O-ring main case 69 Harness assembly, adapter case 105 Transmission control module
34 Fitting, cooler 70 Screw, valve body 106 Servo piston assembly
35 Fitting assembly, cooler 71 Valve body assembly, adapter case
PUMP ASSEMBLY
206 209
207
206
208
203
204
205
216 217
215
214
210
201 202 211

213
201 Gear, oil pump drive 212
202 Gear, oil pump driven 210 Valve, converter clutch control
203 Pin, boost valve sleeve 211 Spring, converter clutch control valve
204 Sleeve, boost valve 212 Plug, converter clutch control valve
205 Valve, boost 213 Pin, spring
206 Seat, spring/pressure regulator valve 214 Piston, throttle signal accumulator
207 Spring, pressure regulator valve 215 Spring, throttle signal accumulator
208 Valve, pressure regulator 216 Seat, spring/throttle signal accumulator
209 Pump assembly, oil 217 Ring, snap/throttle signal accumulator
VALVE BODY ASSEMBLIES

309
320
318
306
310
323
321 325
317
317
309
305
322
304
303
324
317 301
305 326
308
307 312
302 311
310
301 Body, valve main case 302 318 Valve, 1-2 accumulator control
302 Pin, spring 320 Valve, 1-2 accumulator
303 Solenoid assembly, on/off N.C. 321 Washer, waved PWM solenoid
304 Valve, 1-2 & 3-4 shift 322 Pin, solenoid PWM
305 Spring, 1-2 & 3-4 (2-3) shift 323 Solenoid assembly, band control PWM
306 Retainer, valve 324 Screen assembly, PWM solenoid
307 Solenoid assembly, ON/OFF N.O. 325 Plug, screen
308 Valve, 2-3 shift 326 Valve, manual
309 Pin, spring
310 Plug, valve bore
311 Spring, valve low pressure control
312 Valve, low pressure control
317 Ball, check
403 404 406
402
401 Body, valve/adapter case

402 Screw, solenoid force motor
403 Retainer, force motor
404 Solenoid, force motor
409
407 405 Plug, 3-4 accumulator
405 406 Retainer
407 Valve, 3-4 accumulator
410 409 Valve, 3-4 accumulator control
410 Spring, feed limit valve
411 Ring, retainer
412 412 Valve, feed limit
413 Seal, O-ring plug filter
411 414 Plug, screen
415 Screen assembly, force motor
401 416 Solenoid, torque conv. clutch on/off
415 N.C.
414 417 Plug retainer
413
417
416 402
243LW001
OVERDRIVE INTERNAL COMPONENTS
513
510
508
503 506
502 505
504
501
529
528
527
526
525
524
523
522
521
520
519
518
517
516
515
514
534
533
532
531
530
501 Retainer, 4th clutch 521 Plate, overrun clutch (steel)

502 Plate, 4th clutch (steel) 522 Plate assembly, overrun clutch (lined)
503 Plate assembly, 4th clutch (lined) 523 Plate, backing/overrun clutch
504 Retainer & ball assembly, check valve 524 Ring, snap/overrun clutch housing
505 Seal, O-ring/turbine shaft 525 Carrier assembly, overdrive complete
506 Shaft, turbine 526 Ring, snap/turbine shaft/carrier
508 Ring, oil seal/turbine shaft 527 Bearing assembly, thrust
510 Housing, overrun clutch 528 Gear, overdrive internal
513 Piston, overrun clutch 529 Washer, thrust/internal gear/support
514 Spring, overrun clutch release 530 Ring, snap/adapter/4th clutch spring
515 Retainer, release spring/overrun clutch 531 Retainer & spring assembly, 4th clutch
516 Roller assembly, overdrive clutch 532 Piston, 4th clutch
517 Cam, overdrive roller clutch 533 Seal, 4th clutch piston (inner)
518 Ring, snap/overrun clutch hub 534 Seal, 4th clutch piston (outer)
519 Gear, overdrive sun
252RW003
INTERNAL COMPONENTS
INTERNAL COMPONENTS
608 Seal, reverse clutch piston (inner) 638 Piston 3rd clutch
609 Seal, reverse clutch piston (outer) 639 Seat, spring/3rd clutch
610 Piston, reverse clutch 640 Ring, retaining
611 Spring, piston clutch 641 Plate, spring cushion/3rd clutch
612 Seat, spring/reverse clutch 642 Plate, 3rd clutch (Steel)
613 Ring, Retaining 643 Plate assembly, 3rd clutch (Lined)
614 Plate, waved/reverse clutch 644 Washer, thrust/input sun
615 Plate, reverse clutch (steel) 645 Bearing, input shaft/gear assembly
616 Plate assembly, reverse clutch (lined) 646 Gear assembly, input sun
617 Plate, reverse clutch pressure/selective 647 Race assembly, sprag
618 Drum assembly, 2nd clutch 648 Ring, retaining/sprag
620 Seal, 2nd clutch piston (Inner) 649 Ring, retaining
621 Seal, 2nd clutch piston (Outer) 650 Cage assembly, sprag
622 Piston, 2nd clutch 651 Bearing, output shaft/input sun
623 Seat, spring/2nd clutch 652 Washer, output shaft/input sun
625 Plate, waved/2nd clutch 653 Carrier assembly, planetary
626 Plate, 2nd clutch (Steel) 658 Gear, reaction sun
627 Plate assembly, 2nd clutch (Lined) 659 Drum, reaction sun
628 Spacer, 2nd clutch 664 Band assembly, brake
629 Ring, retaining 667 Seal, ring/wheel parking lock
630 Gear, ring 668 Wheel, parking lock
631 Washer, thrust/2nd clutch/3rd clutch
632 Thrust washer, clutch hub 672 Wheel, speedo
634 Drum assembly, 3rd clutch 673 Ring, retaining
635 Seal, 3rd clutch piston (Inner)
636 Washer, retaining 675 Bearing, thrust assembly
637 Seal, 3rd clutch piston (Outer)
CENTER SUPPORT ASSEMBLY
702
703
704
705
701 Center support

701 702 Retainer plate
703 Plug, lockout
704 Spring, overrun lockout
705 Valve, overrun lockout
TF4L3-WE-889AR

This manual is applicable for vehicles in the

Australia.

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
Tokyo, Japan
W/M CoverBasexp3.3J 2001.1.24 16:00PM ページ 1
WORKSHOP MANUAL
TF SERIES
4L30-E
SECTION 7A1
No.TF4L3-WE-889AR PRINTED IN JAPAN

INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
INDEX
ENGINE MECHANICAL (6VD1 3.2L) 6A–1
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . 6A–1 Driveability and Emissions . . . . . . . . . . . . . . . . 6E–1
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 6B–1 Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 6F–1
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–1 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . 6G–1
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . 6D1–1 Engine Speed Control System . . . . . . . . . . . . 6H–1
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–1 Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–1
Starting and Charging System . . . . . . . . . . . . 6D3–1
ENGINE MECHANICAL (6VD1 3.2L)

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–36
General Description . . . . . . . . . . . . . . . . . . . . . 6A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 6A–4 Crankshaft and Main Bearings . . . . . . . . . . . . 6A–38
Cylinder Head Cover LH . . . . . . . . . . . . . . . . . 6A–17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–18 Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–43
Cylinder Head Cover RH . . . . . . . . . . . . . . . . . 6A–19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–19 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A–44
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6A–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–20 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . 6A–22 Cylinder Head and Associated Parts . . . . . 6A–48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–49
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . 6A–23 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–23 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–23 Valve Spring, Oil Controller, Valve, Valve
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Valve Spring, Oil Controller, Valve, Valve
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Guide and Associated Parts . . . . . . . . . . . . 6A–52
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–56
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–30 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–30 Camshaft and Associated Parts . . . . . . . . . 6A–59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–31 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–59
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–60
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–65
Crankshaft and Associated Parts . . . . . . . . 6A–65
Valve Stem Oil Controller , Valve Spring
and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . 6A–35 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–65
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–67
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–69
Piston, Piston Ring and Connecting Rod . . . 6A–36
Piston and Connecting Rod . . . . . . . . . . . . . . . 6A–73
6A–2 ENGINE MECHANICAL (6VD1 3.2L)
Piston, Connecting Rod and Associate Cylinder Block and Associated Parts . . . . . 6A–81
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–73 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–81
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–73 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–82
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–74 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–83
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–78 Main Data and Specification . . . . . . . . . . . . . . 6A–86
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–81 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–92
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description Cylinder Block

The cylinder block is made of aluminum die–cast casting
Engine Cleanliness And Care for 75°V–type six cylinders. It has a rear plate integrated
An automobile engine is a combination of many structure and employs a deep skirt. The cylinder liner is
machined, honed, polished and lapped surfaces with cast and the liner inner diameter and crankshaft journal
tolerances that are measured in the thousandths of a diameter are classified into grades. The crankshaft is
millimeter (ten thousandths of an inch). Accordingly, supported by four bearings of which width is different
when any internal engine parts are serviced, care and between No.2, No.3 and No.1, No.4; the width of No.3
cleanliness are important. Throughout this section, it bearing on the body side is different in order to support the
should be understood that proper cleaning and protection thrust bearing. The bearing cap is made of nodular cast
of machined surfaces and friction areas is part of the iron and each bearing cap uses four bolts and two side
repair procedure. This is considered standard shop bolts.
practice even if not specifically stated.
D A liberal coating of engine oil should be applied to all Cylinder Head
friction areas during assembly to protect and lubricate The cylinder head, made of aluminum alloy casting
the surfaces on initial operation. employs a pent–roof type combustion chamber with a
D Whenever valve train components, pistons, piston spark plug in the center. The intake and exhaust valves
rings, connecting rods, rod bearings, and crankshaft are placed in V–type design. The ports are cross–flow
journal bearings are removed for service, they should type.
be retained in order.
D At the time of installation, they should be installed in Valve Train
the same locations and with the same mating Intake and exhaust camshaft on the both side of banks
surfaces as when removed. are driven through an camshaft drive gear by timing belt.
D Battery cables should be disconnected before any The valves are operated by the camshaft and the valve
major work is performed on the engine. Failure to clearance is adjusted to select suitable thickness shim.
disconnect cables may result in damage to wire
harness or other electrical parts. Intake Manifold
D The six cylinders of this engine are identified by The intake manifold system is composed of the aluminum
numbers; Right side cylinders 1, 3 and 5, Left side cast common chamber and intake manifold attached with
cylinders 2, 4 and 6, as counted from crankshaft six fuel injectors.
pulley side to flywheel side.
Exhaust Manifold
General Information on Engine Service The exhaust manifold is made of nodular cast iron.
The following information on engine service should be
noted carefully, as it is important in preventing damage Pistons and Connecting Rods
and contributing to reliable engine performance. Aluminum pistons are used after selecting the grade that
D When raising or supporting the engine for any reason, meets the cylinder bore diameter. Each piston has two
do not use a jack under the oil pan. Due to the small compression rings and one oil ring. The piston pin made
clearance between the oil pan and the oil pump of chromium steel is offset 1mm toward the thrust side,
strainer, jacking against the oil pan may cause and the thrust pressure of piston to the cylinder wall varies
damage to the oil pick–up unit. gradually as the piston travels. The connecting rods are
D The 12–volt electrical system is capable of damaging made of forged steel. The connecting rod bearings are
circuits. When performing any work where electrical graded for correct size selection.
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the Crankshaft and Bearings
battery. The crankshaft is made of Ductile cast–iron. Pins and
D Any time the intake air duct or air cleaner is removed, journals are graded for correct size selection for their
the intake opening should be covered. This will bearing.
protect against accidental entrance of foreign
material into the cylinder which could cause extensive Engine Control Module (ECM)
damage when the engine is started.
The ECM location is on the common charmber.
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim Battery run down or under charged Recharge or replace battery
considerably
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an ignition coil from any spark plug. Connect tester is properly grounded. To avoid electrical shock, do
the spark plug tester 5–8840–0383–0, start the engine, not touch the part where insulation of the ignition coil is
and check if a spark is generated in the spark plug tester. broken while the engine is running.
Before starting the engine, make sure that the spark plug
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel
engine system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with Replace
module
Poor connections in engine harness Correct
Engine Control Module cable Correct or replace
disconnected or defective
3. Trouble In Fuel System

Starting motor turns over and spark Fuel tank empty Fill
occurs but engine does not start
start.
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control Correct or replace
System circuit clogged
Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection”
section
4. Engine Lacks Compression

Engine lacks compression Spark plug loosely fitted or spark Tighten to specified torque or replace
plug gasket defective gasket
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.
Engine Compression Test Procedure

1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
Rough Engine Idling or Engine Stalling
Trouble in fuel injection system Idle air control valve defective Replace
Throttle shutting off incomplete Correct or replace
Throttle position sensor circuit open Correct or replace
or shorted
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or poor connections
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature Sensor Correct or replace
Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Vehicle Speed Sensor defective Replace
Trouble in emission control system Engine Control Module defective Replace
Canister purge valve circuit open or Correct or replace
poor connections
Canister purge valve defective Replace
Evaporative Emission Canister Replace
Purge control valve defective
Trouble in ignition system Refer to “Hard Start”
Others Engine lacks compression Refer to “Hard Start”
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace
Fast idle solenoid defective Replace
Positive Crankcase Ventilation valve Replace
defective or clogged
Rough Engine Running
Engine misfires periodically Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose leaking Replace
Fuel injector(s) defective Replace
Engine control module faulty Replace
Engine knocks periodically Spark plugs running too hot Install colder type spark plugs
Engine control module faulty Replace
Engine lacks power Spark plugs fouled Clean
Fuel injectors defective Replace
Mass Airflow Sensor or Intake Correct or replace
Airflow Sensor circuit defective
Barometric Pressure (BARO) Correct or replace
Sensor or Barometric Pressure
Sensor circuit defective
or Engine Coolant Temperature
Sensor circuit defective
Engine Control Module faulty Replace
Intake Air Temperature Sensor or Correct or replace
Intake Air Temperature Sensor
circuit defective
Throttle Position Sensor or Throttle Correct or replace
Position Sensor circuit defective
Hesitation
Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Excessive play in accelerator linkage Adjust or replace
poor connections
Barometric Pressure (BARO) Correct or replace
Sensor circuit open or shorted
BARO Sensor defective Replace
Intake Air Temperature (IAT) Sensor Correct or replace
IAT Sensor defective Replace
Hesitation at high speeds Fuel tank strainer clogged Clean or replace
(Fuel pressure too low) Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Hesitation at high speeds Power supply or ground circuit for Check and correct or replace
(Fuel injector not working normally) Multiport Fuel Injection System
shorted or open
Fuel Injector defective Replace
Cable of Multiport Fuel Injection Correct or replace
System circuit open or poor
connections
Hesitation at high speeds Engine Control Module defective Replace
Throttle Position Sensor cable Correct or replace
broken or poor connections
Throttle Position Sensor defective Replace
circuit open or shorted
defective
poor connections
MAP Sensor cable broken or poor Correct or replace
connections
MAP Sensor defective Replace
IAT Sensor circuit open or poor Correct or replace
connections
IAT Sensor defective Replace
Throttle valve not fully opened Check and correct or replace
Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace
Engine Lacks Power
Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative
Emission Control System circuit
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Engine Control Module supplied poor Correct circuit
voltage
Throttle Position Sensor cable Correct or replace
Mass Airflow Sensor not working Replace
normally
not working normally
Intake Air Temperature Sensor not Replace
working normally
defective
Engine Control Module defective Replace
Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element
Air duct kinked or flattened Correct or replace
Ignition failure ———— Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate Install spark plugs of adequate heat
range
Ignition coil defective Replace

Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too Change or replenish
low or wrong engine oil
Resistance in exhaust system Clean exhaust system or replace
increased defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82°C (180°F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil
high
Engine Noisy
Abnormal engine noise often consists of various noises ing parts of the engine. It is, therefore, advisable to locate
originating in rotating parts, sliding parts and other mov- the source of noise systematically.
Noise from crank journals or from Oil clearance increased due to worn Replace crank bearings and
crank bearings crank journals or crank bearings crankshaft or regrind crankshaft and
(Faulty
y crank journals
j and crank install the undersize bearing
bearings usually make dull noise that Crankshaft out of round Replace crank bearings and
becomes more evident when crankshaft or regrind crankshaft and
accelerating) install the undersize bearing
Crank bearing seized Crank bearing seized Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Short out each spark plug in sequence using insulated bearing by listening for abnormal noise that stops when
spark plug wire removers. Locate cylinder with defective spark plug is shorted out.
Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings
connecting rod bearings and crankshaft or regrind crankshaft
(Faulty
y connecting
g rods or pin and install the undersize bearing
connecting rod bearings usually Crankpin out of round Replace connecting rod bearings
make an abnormal noise slightly and crankshaft or regrind crankshaft
higher than the crank bearing noise, pin and install the undersize bearing
which becomes more evident when
engine
g is accelerated)) Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing
Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Piston and cylinder noise Piston clearance increased due to Replace piston and cylinder body
(Faulty piston or cylinder usually cylinder wear
makes
k a combined
bi d mechanical
h i l
Piston seized Replace piston and cylinder body
thumpingg noise which increases
when engine is suddenly accelerated Piston ring broken Replace piston and cylinder body
but diminishes gradually as the
engine warms up) Piston defective Replace pistons and others
Short out each spark plug and listen for change in engine
noise.
Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and
(Piston makes noise each time it connecting rod assy
goes up and down)
The slapping sound stops when spark plug on bad cylin-
der is shorted out.
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive Replace thrust bearing
(noise occurs when clutch is
engaged)
Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range range
Carbon deposits in combustion Clean
chambers
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment Refer to Section 6E
system failure
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Engine overheating Refer to “Engine Lacks Power”
Others Water pump defective Replace
Drive belt slipping Replace auto tentioner or drive belt
Abnormal Combustion
Trouble in fuel system Fuel pressure control valve defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump Reconnect, correct or replace
Mass Airflow (MAF) Sensor circuit Correct or replace
open or defective
MAF Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
defective
Engine Coolant Temperature (ECT) Correct or replace
Sensor circuit open or shorted
ECT Sensor defective Replace
Throttle Position Sensor adjustment Readjust
incorrect
Throttle Position Sensor connector Reconnect
poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong Replace
contact or defective
Engine Control Module cable poor Correct or replace
connections or defective
Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace
Heated Oxygen Sensor defective Replace
Signal vacuum hose loosely fitted or Correct or replace
defective
ECT Sensor circuit open or shorted Correct or replace
Canister Purge Valve circuit open or Correct or replace
shorted
Canister Purge Valve defective Replace
ECT Sensor defective Replace
Positive Crankcase Ventilation Correct or replace
(PCV) valve and hose clogged
Evaporator system Refer to Section 6E
Trouble in ignition system ———— Refer to “Engine Lacks Power”
Trouble in cylinder head parts Carbon deposits in combustion Remove carbon
chamber
Carbon deposit on valve, valve seat Remove carbon
and valve guide
Engine Oil Consumption Excessive
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Crankcase fixing bolts loosened Retighten
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket
gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil cooler adapter cracked Replace
Oil cooler center bolt loose Retighten
Oil cooler O–ring broken Replace
Oil cooler piping loose or broken Retighten or replace
Oil filter adapter cracked Replace
Oil filter attachings bolt loose or Retighten or replace oil filter
rubber gasket broken
Oil cooler broken Replace
Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve Clean
clogged
Engine/Transmission coupling failed Replace oil seal
Oil leaking into combustion Valve stem oil seal defective Replace
chambers due to poor
oor seal in valve
system Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion Cylinders and pistons worn Replace cylinder body assembly and
chambers due to poor seal in cylinder excessively pistons
parts
t Piston ring gaps incorrectly Correct
positioned
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Positive Crankcase Ventilation Positive Crankcase Ventilation Valve Clean
System malfunctioning clogged
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving Continuous high speed operation
and/or severe usage such as trailer and/or severe usage will normally
towing cause increased oil consumption
Fuel Consumption Excessive
Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion”
trouble in fuel injection system
Fuel cut function does not work Refer to “Abnormal Combustion”
Trouble in ignition system Misfiring or abnormal combustion Refer to “Hard Start” or “Abnormal
due to trouble in ignition system Combustion”
Others Engine idle speed too high Reset Idle Air Control Valve
Returning of accelerator control Correct
sluggish
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Lubrication Problems
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting Replace
rod bearing worn
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or Clean or correct
cylinder body clogged
Engine Oil Pressure Check 4. Install an oil pressure gauge.

1. Check for dirt, gasoline or water in the engine oil. 5. Start the engine and allow the engine to reach normal
operating temperature (About 80°C).
a. Check the viscosity of the oil.
6. Measure the oil pressure.
b. Check the viscosity of the oil.
Oil pressure should be:
c. Change the oil if the viscosity is outside the
specified standard. 392–550 kPa (56.9–80.4 psi) at 3000 rpm.
d. Refer to the “Maintenance and Lubrication” section 7. Stop the engine.
of this manual. 8. Remove the oil pressure gauge.
2. Check the engine oil level. 9. Install the oil pressure unit.
The level should fall somewhere between the “ADD” 10. Start the engine and check for leaks.
and the “FULL” marks on the oil level dipstick.
If the oil level does not reach the “ADD” mark on the
oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE” Malfunction In- when the system checks the starting of engine, or senses
dicator Lamp (MIL) illuminates by self diagnostic system malfunctions.
“CHECK ENGINE” MIL does not Bulb defective Replace
illuminate at the starting of engine
MIL circuit open Correct or replace
Command signal circuit to operate Correct or replace
self diagnostic system shorted
Engine Control Module (ECM) cable Correct or replace
loosely connected, disconnected or
defective
ECM defective Replace
“CHECK ENGINE” MIL illuminates, Deterioration of heated oxygen Replace
and stays on sensor internal element
Heated oxygen sensor connector Reconnect properly
terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant Replace
temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open Correct or replace
Manifold absolute pressure sensor Correct or replace
Intake air temperature sensor circuit Correct or replace
open or shorted
Fuel injector circuit open or shorted Correct or replace
ECM driver transistor defective Replace ECM
Malfunctioning of ECM RAM Replace ECM
(Random Access Memory) or ROM
(Read Only Memory)
Cylinder Head Cover LH

Removal
2. Remove air cleaner duct assembly.
060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
060RW079
(3) Ignition Coil Assemblies
Legend
(1) Positive Crankcase Ventilation Hose Connector 7. Remove fixing bolt for fuel injector harness bracket.
(2) Intake Air Temperature Sensor 8. Remove eight fixing bolts, then the cylinder head
(3) Air Cleaner Duct Assembly cover.
(4) Air Cleaner Element
3. Disconnect positive crankcase ventilation hose.

4. Remove camshaft angle sensor connector.
5. Remove ground cable fixing bolt on cylinder head
cover.
6. Ignition coil connector and ignition coil.
D Disconnect the three connectors from the ignition
coils.
D Remove harness bracket bolt on cylinder head
cover.
D Remove fixing bolts on ignition coils.
010RW001
Installation 2. Install fuel injection harness bracket and tighten bolt

1. Install cylinder head cover.
Torque : 9 N·m (0.9 kg·m/80 lb in)
D Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing 3. Connect ignition coil connector and ignition coil, then
materials completely. tighten bolt to the specified torque.
D Apply sealant (TB-1207B or equivalent) of bead Torque : 4 N·m (0.4 kg·m/35 lb in)
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.
D The cylinder head cover must be installed with in 5
minutes after sealant application to prevent
hardning of sealant.
D Tighten bolts to the specified torque.
060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
4. Connect ground cable and tighten bolts to the

specified torque.
010RW006
5. Connect camshaft angle sensor connector.
6. Install positive crankcase ventilation hose.
7. Install air cleaner duct assembly.
Cylinder Head Cover RH

Removal D The cylinder head cover must be installed within 5
1. Disconnect battery ground cable. premature hardening of sealant.
2. Disconnect ventilation hose from cylinder head cover. D Tighten bolts to the specified torque.
3. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder Torque : 9 N·m (0.9 kg·m/80 lb in)
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.
4. Remove heater pipe fixing bolts from the bracket.
5. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head
cover.
014RW019
2. Install exhaust gas recirculation pipe and tighten to

specified torque.
Torque:
Exhaust manifold side: 28 N·m (2.9 kg·m/21 lb ft)
Flare nut: 44 N·m (4.5 kg·m/33 lb ft)
Cylinder head side: 25 N·m (2.6 kg·m/18 lb ft)
010RW002
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector harness
Installation connector.
1. Install cylinder head cover. Torque : 7.8 N·m (0.8 kg·m/5.7 lb ft)
D Clean the sealing surface of cylinder head and 4. Install heater pipe bolt to the specified torque.
cylinder head cover to remove oil and sealing Torque : 21 N·m (2.1 kg·m/15 lb ft)
materials completely.
5. Connect ignition coil connector and tighten ignition
Apply sealant (TB-1207B or equivalent) of bead
coil fixing bolts to specified torque.
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides. Torque : 4 N·m (0.4 kg·m/35 lb in)
6. Connect ventilation hose to cylinder head.
Common Chamber
Removal 6. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
1. Disconnect battery ground cable. position sensor, solenoid valve, electric vacuum
2. Remove air cleaner duct assembly. sensing valve.
7. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
8. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
9. Remove the four throttle body fixing bolts.
10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.
11. Remove two bolts from common chamber rear side
for remove fuel hose bracket.
12. Remove common chamber four bolts and four nuts
then remove the common chamber.
060RW079
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
3. Remove the ECM.

D Disconnect the two connectors from the ECM.
D Remove fixing bolts on the common chamber.
D Remove fixing bolts for ground cable.
025RW001
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
Torque :
Bolt : 25 N·m (2.6 kg·m/18 lb ft)
Nut : 25 N·m (2.6 kg·m/18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
060RW025 3. Install throttle body and tighten bolts to the specified
4. Disconnect accelerator pedal cable from throttle body torque.
and cable bracket. Torque : 25 N·m (2.6 kg·m/18 lb ft)
5. Disconnect vacuum booster hose from common 4. Install ventilating hose to throttle valve and intake
chamber. duct.
5. Connect vacuum hoses on canister VSV and positive 10. Install air cleaner duct assembly.
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 N·m (2.5 kg·m/18 lb ft)
6. Connect each connector without fail.
7. Connect vacuum booster hose.
8. Install the ECM.
D Tighten the four bolts.
D Connect the two connectors.
D Tighten the two ground cable bolts.
9. Connect accelerator pedal cable.
Don’t need accelerator pedal cable adjustment.
D Tighten nut and lock nut.
060RW079
Legend
(4) Air Cleaner Element.
060RW093
Legend
(1) Lock Nut
(2) Nut
Exhaust Manifold LH
Removal 5. Remove heat protector two fixing bolts then the heat
protector.
1. Disconnect battery ground cable. 6. Remove a bolt on engine LH side for air conditioner
2. Remove air cleaner duct assembly. (A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 N·m (5.8 kg·m/42 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque :
Stud nuts: 67 N·m (6.8 kg·m/49 lb ft)
Nuts: 43 N·m (4.4 kg·m/32 lb ft)
060RW079
Legend
3. Disconnect O2 sensor connector.

4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end of exhaust
front pipe.
060RW101
Legend
(1) O2 Sensor
(2) Exhaust Front Pipe LH
4. Set A/C compressor to normal position and tighten

two bolts and a bolt to the specified torque.
5. Reconnect O2 sensor connector.
6. Install air cleaner duct assembly.
060RW101
Legend
(1) Exhaust Front Pipe LH
(2) O2 Sensor
Exhaust Manifold RH
Removal Installation
1. Disconnect battery ground cable. 1. Install exhaust manifold and tighten bolts to the
2. Remove torsion bar. Refer to removal procedure in specified torque.
Front Suspension section. Torque : 57 N·m (5.8 kg·m/42 lb ft)
3. Remove exhaust front pipe three stud nuts and two 2. Install heat protector
nuts then disconnect exhaust front pipe.
3. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque:
4. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for front suspension.
060RW101
Legend
(1) Exhaust Front Pipe RH
(2) O2 Sensor
4. Remove heat protector two fixing bolts then the heat

protector.
5. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Crankshaft Pulley
Removal 4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
2. Remove air cleaner assembly.
850RW001
Legend
060RW079
(1) Crankshaft Pulley
Legend (2) Cooling Fan Pulley
(1) Positive Crankcase Ventilation Hose Connector (3) Tensioner
(2) Intake Air Temperature Sensor (4) Generator
(3) Air Cleaner Duct Assembly (5) Air Conditioner Compressor
(4) Air Cleaner Element (6) Power Steering Oil Pump
(7) Serpentine Belt
3. Remove radiator upper fan shroud from radiator.
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5–8840–0133–0
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
2. Install cooling fan assembly and tighten bolts/nuts to
Torque : 22 N·m (2.2 kg·m/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 N·m (1.0 kg·m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.
Timing Belt
Removal 11. Remove right side timing belt cover then left side
timing belt cover.
1. Disconnect battery ground cable. 12. Remove lower timing belt cover
2. Remove air cleaner assembly. 13. Remove pusher.
3. Remove radiator upper fan shroud from radiator.
CAUTION: The pusher prevents air from entering
4. Move drive belt tensioner to loose side using wrench the oil chamber. Its rod must always be facing
then remove drive belt. upward.
850RW001
014RW011
Legend Legend
(1) Crankshaft Pulley (1) Up Side
(2) Cooling Fan Pulley (2) Down Side
(3) Tensioner (3) Direction For Installation
(4) Generator (4) Locking Pin
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump 14. Remove timing belt.
(7) Drive Belt
CAUTION:
5. Remove cooling fan assembly four nuts, then the 1. Do not bend or twist the belt, otherwise its core
cooling fan assembly. could be damaged. The belt should not be bent at
a radius less than 30 mm.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly. 2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
8. Remove serpentine belt tensioner assembly. the life.
9. Remove power steering pump assembly.
3. Do not attempt to pry or stretch the belt with a
10. Remove crankshaft pulley assembly using J-8614-01 screw driver or any other tool during installation.
crankshaft holder, hold crankshaft pulley remove
center bolt, then the pulley. 4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
014RY00042
Legend 1. Install timing belt.

(1) Crankshaft Timing Pulley 1. Align the mark (notch) of crankshaft timing pulley
(2) RH Bank Camshaft Drive Gear Pulley (2) with mark on oil pump (1).
(3) Water Pump Pulley Align the mark (groove) on the crankshaft timing
(4) Idle Pulley pulley (3) with alignment mark (white dots line) on
(5) LH Bank Camshaft Drive Gear Pulley the timing belt (4).
(6) Tension Pulley NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RY00043
014RW003
Legend Legend
(7) Alignment Mark on Oil Pump. (1) Alignment Mark on Oil Pump
(8) Alignment Mark on Timing Belt (2) Groove on Crankshaft Timing Pulley
(9) Alignment Mark (notch) on Crankshaft Timing (3) Alignment Mark on Crankshaft Timing Pulley
Pulley. (4) Alignment Mark on Timing Belt
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
2. Align the alignment mark on the RH bank NOTE: It is recommended for easy installation that the
camshaft drive gear pulley (2) to the alignment belt be secured with a double clip or equivalent clip after
mark of the cylinder head cover RH (3). it is installed the timing belt to each pulley.
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
014RW00004
6. Install crankshaft pulley temporarily and tighten
Legend center bolt by hand (do not use a wrench).
(1) Alignment Mark on Timing Belt (White line). Turn the crankshaft pulley clockwise to give some
(2) Alignment Mark on Camshaft Drive Gear belt slack between the crankshaft timing pulley
Pulley. and the RH bank camshaft drive gear pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank

camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N·m (2.5 Kg·m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from

timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 N·m (1.9 kg·m/14 lb ft) 020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5–8840–0133–0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
6. Install power steering pump assembly and tighten to
Torque :
M8 bolt : 22 N·m (2.2 kg·m/16 lb ft)
M10 bolt : 46 N·m (4.7 kg·m/34 lb ft)
and fan bracket.
Torque : 10 N·m (1.0 kg·m/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(6) Power Steering Oil Pump
(7) Drive Belt
9. Install radiator upper fan shroud.

Camshaft
Removal 7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
2. Remove crankshaft pulley. retainer, then camshaft drive gear assembly.
D Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
D Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
D Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
014RW027
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
2. Tighten bolt for camshaft drive gear assembly pulley
3. Tighten sub gear setting bolt.
1. Use 5–8840–2443–0 to turn sub gear to right
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
014RW041
4. Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
2. Align timing mark on intake camshaft (one dot for
right bank, two dot for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024
Legend (3) Alignment Mark on Camshaft Drive Gear

(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer
3. Tighten twenty bolts on numerical order an one 8. Install crankshaft pulley.

side bank as shown in the illustration. D Refer to installation procedure for CRANKSHAFT
Torque : 10 N·m (1.0 kg·m/89 lb in) PULLEY in this manual.
D Don’t need accelerator pedal cable adjustment.
D Tighten the accelerator pedal cable nuts.
014RW031
5. Install cylinder head cover RH.

D Refer to installation procedure for CYLINDER 060RW093
HEAD COVER RH in this manual.
Legend
6. Install cylinder head cover LH.
(1) Lock Nut
D Refer to installation procedure for CYLINDER
(2) Nut
HEAD COVER LH in this manual.
7. Install timing belt.
D Refer to installation procedure for TIMING BELT in
this manual.
Cylinder Head
Removal NOTE: There is discrimination mark “R” for right bank
and “L” for left bank on the cylinder head gasket as shown
1. Remove engine hood. in the illustration.
2. Disconnect battery ground cable. Do not reuse cylinder head gasket.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.
D Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.
D Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.
8. Remove cylinder head cover RH.
9. Remove common chamber.
D Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly. 011RW005
1. Loosen eights bolts for tight cylinder head. 2. Align dowel pin hole to dowel pin on the cylinder
block.
2. Remove cylinder head assembly.
3. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
4. Using 9–8511–4209–0 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 N·m (3.0 kg·m/21 lb ft)
Final : 64 N·m (6.5 kg·m/47 lb ft)
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.
014RW029
2. Install common chamber.
D Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
D Refer to installation procedure for Cylinder Head
4. Install cylinder head cover LH.
D Refer to installation procedure for Cylinder Head
D Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
D Refer to installation procedure for Crankshaft
Pulley in this manual.
D Tighten the accelerator pedal cable.
060RW093
Legend
(1) Lock Nut
(2) Nut
Valve Stem Oil Controller , Valve Spring and Valve Guide

Removal Installation
1. Disconnect battery ground cable. 1. Install valve guide using 5–8840–2442–0 valve guide
2. Drain engine oil. installer.
D Drain engine coolant. 2. Install oil controller using 5–8840–0624–0 oil
controller installer.
3. Remove cylinder head assembly.
3. Install lower valve spring seat, valve spring and upper
D Refer to removal procedure for Cylinder Head in
valve spring seat then put split collars on the upper
this manual.
spring seat, using 5–8840–2442–0 valve spring
4. Remove camshaft. compressor and 5–8840–0624–0 valve spring
D Refer to removal procedure for Camshaft in this compressor adapter to install the split collars.
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5–8840–2446–0 valve
spring compressor and 5–8840–2547–0 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.
014RW042
4. Install tappet with shim.

5. Install camshaft assembly.
D Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.
D Refer to installation procedure for Cylinder Head in
014RW042 this manual.
7. Remove oil controller using 5–8840–0623–0 oil 7. Fill engine oil until full level.
controller remover, remove each valve stem oil 8. Fill engine coolant.
controller.
8. Remove valve guide using 5–8840–2549–0 valve
guide replacer.
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend (4) Oil Strainer

(1) Cylinder Head (5) Oil Gallery
(2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly
(3) Oil Pipe
1. Remove cylinder head assembly. 2. Remove crankcase with oil pan.

D Refer to removal procedure for Cylinder Head in D Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
015RW003
Legend
050RW002 (1) Piston Front Mark
Legend (2) Piston Grade
(1) Oil Pump (3) Connecting Rod Front Mark
(2) Oil Strainer
(3) Oil Gallery 2. Install oil gallery and tighten the bolts in two steps, in
(4) From Oil Filter the order shown in illustration.
(5) To Oil Filter Torque :
1st step : 29 N·m (3.0 kg·m/21 lb ft)
4. Remove three fixing bolts, oil pipe with O-ring. 2nd step : 55°–65°
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly, before
removing the bearing cap, remove carbon on the top
of cylinder bore and push piston with connecting rod
out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.
D Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
D The bearing cap number must be the same as
connecting rod number.
D Apply engine oil to the thread and seating surface of
each nut.
D Tighten nuts to the specified torque. 051RS009
Torque : 54 N·m (5.5 kg·m/40 lb ft) 3. Install oil pipe with O-ring.
D After tightening the nuts, make sure that the Torque : 10 N·m (1.0 kg·m/89 lb in)
crankshaft rotates smoothly. 4. Install oil strainer assembly with O-ring.
NOTE: Do not apply engine oil to the bearing back faces Torque : 25 N·m (2.6 kg·m/18 lb ft)
and connecting rod bearing fitting surfaces. 5. Install crankcase with oil pan.
D Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
D Refer to installation procedure for Cylinder Head in
this manual.
Crankshaft and Main Bearings

Removal
F06RW010
Legend (8) Oil Pump Assembly

(1) Engine Assembly (9) Cylinder Body Side Bolt
(2) Crankshaft Pulley (10) Oil Gallery
(3) Timing Belt Cover (11) Flywheel
(4) Timing Belt (12) Rear Oil Seal Retainer
(5) Crankcase with Oil Pan (13) Connecting Rod Cap
(6) Oil Pipe (14) Crankshaft Main Bearing Cap
(7) Oil Strainer (15) Crankshaft and Main Bearing
1. Remove engine assembly. 3. Remove oil pan and crankcase.

D Refer to removal procedure for Engine Assembly in D Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
2. Remove timing belt. 4. Remove oil pipe with O-ring.
D Refer to removal procedure for Timing Belt in this 5. Remove oil strainer assembly with O-ring.
manual.
6. Remove oil pump assembly.
D Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
D Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
D Install main bearing in the cylinder block and main
bearing cap respectively. 015RS013
Apply new engine oil to upper and lower main 2. Install crankshaft main bearing caps.
bearings. D Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
NOTE:
D Do not apply engine oil to the bearing back faces.
D Do not apply engine oil to the bearing back faces.
D Make sure that main bearings are in correct position.
D Install bearing caps in the order of numbers, starting
D Install crankshaft with care. with cylinder block front side.
D Apply engine oil to the thrust washer. D Tighten main bearing fixing bolts to the specified
D Install thrust washer on No.3 journal. torque.
D Oil grooves in thrust washer must face the Torque : 39 N·m (4.0 kg·m/29 lb ft)
crankshaft.
D After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
D The cap number must be same as connecting rod
number.
D Apply engine oil to the thread and seating surface of
each nut.
D Tighten nuts to the specified torque.
D After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.
D Remove oil on cylinder block and retainer fitting
surface.
D Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012
D The oil seal retainer must be installed within 5
premature hardening of sealant.
015RW002 015RS018
Legend 6. Install oil gallery.

(1) Around Bolt Holes D Clean contact surface of oil gallery and main
(2) Around Dowel Pin bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown.
D Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer. Torque :
D Tighten retainer fixing bolts to the specified torque. 1st step : 29 N·m (3.0 kg·m/21 lb ft)
2nd step : 55°–65°
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
NOTE: Do not apply the oil to the bolts.
015RW001
5. Install flywheel.
D Clean tapped holes in the crankshaft.
D Remove oil on crankshaft and flywheel fitting
surface. 012RS007
8. Install oil pump assembly.

NOTE:
D Remove oil on cylinder block and oil pump mounting
D Do not reuse the bolts. surface.
D Do not apply oil or thread lock to the bolts. D Apply sealant (TB1207B or equivalent) to the oil
D Tighten fixing bolts to the specified torque. pump mounting surface.
Torque : 54 N·m (5.5 kg·m/40 lb ft) D The oil pump assembly must be installed within 5
premature hardening of sealant.
D Apply engine oil to oil seal lip. D Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
D Install oil pump in the cylinder block and tighten
mounting surface. The bead must be continuous.
fixing bolts to the specified torque.
D The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
D Tighten fixing bolts to the specified torque.
051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
013RW010
013RW004
051RW001
9. Install oil strainer with O-ring, tighten to the specified 12. Install oil pan
torque. D Remove oil on oil pan mounting surface and dry the
Torque : 25 N·m (2.6 kg·m/18 lb ft) surface.
10. Install oil pipe with O-ring, tighten fixing bolts to the D Properly apply a 4.5 mm (0.7 in) wide bead of
specified torque. sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
D The oil pan must be installed within 5 minutes after
11. Install crankcase. sealant application to prevent premature hardening
D Remove oil on crankcase mounting surface and dry of sealant.
the surface.
013RW003
013RW002

D Refer to installation procedure for Timing Belt in this
manual.
14. Install engine assembly.
D Refer to installation procedure for Engine
Assembly in this manual.
Rear Oil Seal

Removal
1. Remove transmission assembly.
D See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5–8840–2286–0.
015RS018
3. Install transmission.
D See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
015RS017
2. Install flywheel.
D Clean tapped holes in the crankshaft.
D Remove oil on the crankshaft and flywheel
mounting surface.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
012RS009
Engine Assembly
Removal
060RW026
1. Disconnect battery ground and positive cable. 20. Remove radiator upper and lower hoses.
2. Remove battery. 21. Remove upper fan shroud.
3. Make alignment mark on the engine hood and hinges 22. Remove cooling fan assembly four fixing nuts, then
before removal in order to return the hood to original the cooling fan assembly.
position exactly. 23. Move drive belt tensioner to loose side using wrench
4. Remove engine hood. then remove drive belt.
5. Drain radiator coolant. 24. Remove power steering pump fixing bolts, then
6. Disconnect accelerator cable and automatic cruise power steering pump. Place the power steering pump
control cable from throttle valve on common along with piping on the body side.
chamber. 25. Remove air conditioning compressor fixing bolts from
7. Remove the ECM. bracket and place the compressor along with piping
on the body side.
D Disconnect the two connectors from the ECM.
26. Remove four O2 sensor harness connectors (two
D Remove fixing bolts on the common chamber. each bank) from exhaust front pipe.
D Remove fixing bolts for ground cable. 27. Remove three exhaust pipe fixing nuts from each
8. Disconnect air duct with air cleaner cover. bank.
9. Remove air cleaner assembly. 28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
10. Disconnect canister vacuum hose. vehicle.
11. Disconnect vacuum booster hose. 29. Remove flywheel dust covers.
12. Disconnect three engine harness connectors. 30. Disconnect two heater hoses from engine.
13. Disconnect harness connector to transmission (left 31. Disconnect fuel hose from right side of transmission.
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front CAUTION: Plug fuel pipe on engine side and fuel
axle and remove transmission harness bracket from hose from fuel tank.
engine left side. 32. Remove transmission assembly. Refer to
14. Disconnect ground cable between engine and frame. Transmission section in this manual.
15. Disconnect bonding cable connector on the back of 33. Support the engine by engine hoist.
right dash panel. 34. Remove two left side engine mount fixing bolts from
16. Disconnect bonding cable terminal on the left bank. engine mount on chassis side.
17. Disconnect starter harness connector from starter. 35. Remove two right side engine mount fixing bolts from
18. Disconnect generator harness connector from engine mount on chassis side.
generator. 36. Remove engine assembly.
19. Disconnect coolant reserve tank hose from radiator.
Installation Torque:
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherweise, the transmission may be damaged.
060RW107
7. Reconnect O2 sensor connector.

012RS009 and fan bracket.
1. Install engine assembly. Tighten engine mount fixing Torque : 10 N·m (1.0 kg·m/88.5 lb in) for fan and
bolts to frame to the specified torque. clutch assembly.
Torque: 41 N·m (4.2 kg·m/30 lb ft) 9. Install air conditioner compressor to engine and
2. Reconnect fuel hose to fuel pipe on engine. tighten to the specified torque.
3. Install transmission assembly. Refer to Transmission 6VD1
section in this manual. Torque : 43 N·m (4.4 kg·m/32 lb ft)
4. Reconnect two heater hoses to engine. 10. Install power steering pump, tighten fixing bolt to the
5. Install flywheel dust covers. specified torque.
6. Install exhaust pipe and temporally tighten two (each Torque :
bank) rear exhaust flange nuts then tighten three stud M8 bolts : 22 N·m (2.2 kg·m/16 lb ft)
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the M10 bolts : 46 N·m (4.7 kg·m/34 lb ft)
specified torque.
11. Move drive belt tensioner to loose side using wrench, 26. Reconnect accelerator cable to throttle valve on
then install drive belt to normal position. common chamber.
850RW001 060RW083
Legend Legend
(1) Crankshaft Pulley (1) Throttle Valve Assembly
(2) Cooling Fan Pulley (2) Throttle Lever
(3) Tensioner (3) Idle Air Control Valve
(4) Generator (4) Throttle Position Sensor
(6) Power Steering Oil Pump 27. Install the ECM.
(7) Drive Belt D Tighten the four bolts.
12. Install upper fan shroud.
D Connect the two connectors.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator. D Tighten the two ground cable bolts.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
25. Reconnect air duct.
28. Install engine hood to the origine position.
D Refer to installation procedure for Body section in
this manual.
D Tighten the accelerator pedal cable nuts.
060RW093
Legend
(1) Lock Nut
(2) Nut
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend (8) Camshaft Intake

(1) Spark Plug (9) Retainer Fixing Bolt
(2) Cylinder Head Bolt (10) Retainer Assembly
(3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim
(4) Camshaft Drive Gear Pulley (12) Split Collar
(5) Camshaft Bracket Fixing Bolt (13) Valve Spring and Spring Upper Seat
(6) Camshaft Bracket (14) Valve
(7) Camshaft Exhaust
Disassembly D Before removing the cylinder head from the engine

and before disassembling the valve mechanism,
NOTE: perform a compression test and note the results.
D During disassembly, be sure that the valve train 1. Remove camshaft drive gear pulley fixing bolt (3),
components are kept together and identified so that then pulley (4).
they can be reinstalled in their original locations.
2. Remove camshaft bracket fixing bolt (5), camshaft 2. Cylinder head for cracks, especially between valve
bracket (6), then camshaft exhaust (7), and intake seats and in the exhaust ports.
side (8). 3. Cylinder head deck for corrosion, sand particles in
3. Remove tappet with shim (11). head and porosity.
4. Use the 5–8840–2446–0 valve spring compressor CAUTION:
and 5–8840–2547–0 valve spring compressor
D Do not attempt to weld the cylinder head. Replace
adapter to remove the split collar (12), valve spring
it.
with upper seat (13) and valve (14).
D Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyound the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
014RW042
5. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair

1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow–by. If the gasket has failed,
determine the cause. 011RW019
5. Water jacket sealing plugs seating surfaces.

– Insufficient torque on head bolts
– Improper installation
– Loose or warped cylinder head
– Missing dowel pins
– Warped case surface
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
1. Use 5–8840–2443–0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
014RW020
Legend
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW025

three bolts to the specified torque.
Torque: 10 N·m (1.0 kg·m/89 lb in)
torque.
right bank, two dots for left bank) and exhaust
dot).
014RW023
Legend
(4) Dowel Pin
014RW024

3. Tighten twenty bolts in numerical order on each

bank as shown in the illustration.
014RW031

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend (7) Spring Upper Seat

(1) Camshaft Bracket Fixing Bolts (8) Valve Spring
(2) Camshaft Assembly Inlet (9) Oil Controller
(3) Camshaft Assembly Exhaust (10) Spring Lower Seat
(4) Shim (11) Valve Guide
(5) Tappet (12) Valve
(6) Split Collar
Disassembly 3. Remove camshaft assembly (Exhaust side).

4. Remove shim (4) and tappet (5).
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
5. Use the 5–8840–2446–0 valve spring compressor 2. Measure the valve spring squareness with a steel
and 5–8840–2547–0 valve spring compressor square and replace the valve springs if the measured
adapter to remove split collar. value exceeds the specified limit.
Limit : 2 mm (0.079 in)
014RW042
6. Remove valve spring.

014RS005
7. Remove valve. 3. Using a spring tester to compress the springs to the

8. Remove oil controller and spring lower seat. installed height, measure the compressed spring
9. Remove the valve guide using the 5–8840–2442–0 tension, and replace the springs if the measured
valve guide replacer. tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Inspection and Repair Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.756 in)
Limit : 43.6 mm (1.717 in)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
014RS004
1. Measure the valve stem diameter with a micrometer. Valve Guide Replacement
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced 1. Using Valve guide replacer: 5–8840–2442–0, drive
as a set. out the valve guide from the combustion chamber
side.
Diameter of Valve Stem
Intake
Standard : 5.977 mm–5.959 mm
(0.2353 in–0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
(0.2343 in–0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5–8840–2442–0, drive in
a new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RS007
2. Measure the inside diameter of the valve guide with a

micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
(0.0009 in–0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
(0.0012 in–0.0025 in)
Limit : 0.20 mm (0.00787 in)
014RW046
3. Check the clearance. If the clearance is less than the

specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.
Valve Seat Contact Surface Angle on Valve Seat on
1. Measure the protrusion of the valve stem when a new Valve
valve is installed in the cylinder head. If the protrusion 1. Measure contact surface angle on valve seat.
of the valve stem exceeds the limit, replace the valve 2. If the measured value exceeds the limit, replace
seat insert or the cylinder head assembly. valve, valve guide and valve seat as a set.
Protrusion of valve stem Valve contact surface angle: 45°
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Limit: 39.45 mm (1.5531 in)
014RS012
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
014RW047
rough areas. This will bring the contact width back to
2. Measure the valve seat contact width. Make the the standard value. Remove only the scratches and
necessary corrections if the seat contact surface is rough areas. Do not cut away too much. Take care not
damaged or rough or if the contact width wear to cut away unblemished areas of the valve seat
exceeds the limit. surface.
Valve seat contact width Valve seat angle degree: 90°
Limit: 1.7 mm (0.0669 in)
014RW059
014RS011
3. Apply abrasive compound to the valve seat insert 4. Carefully clean the valve seat press–fit section on the
surface. cylinder head side.
4. Insert the valve into the valve guide. 5. Heat the press–fit section with steam or some other
5. Turn the valve while lapping it to fit the valve seat means to cause expansion. Cool the valve seat with
insert. dry ice or some other means.
6. Check that the valve contact width is correct. 6. Insert the press–fit section into the valve seat
horizontally.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve. Standard fitting interference: 0.14 mm–0.09 mm
(0.0055 in–0.0035 in)
7. After insertion, use a seat grinder to grind finish the
seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5–8840–2442–0, drive in a new valve guide
from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5–8840–0623–0, drive in
a new oil controller.
014RS014
Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.
014RW058
014RS015
3. Install valve to valve guide. Before install valve guide Valve Clearance Adjustments
apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve NOTE: To adjust valve clearance, apply engine oil to the
spring to the lower spring seat. The painted area of cam as well as to the adjusting shim (2) with the cylinder
the valve spring should be facing downward. head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illustration
below.
014RS020
5. Install lower valve spring seat, valve spring and upper

valve spring seat then put split collars on the upper
spring seat, using the 5–8840–2446–0 valve spring
compresor and 5–8840–2547–0 valve spring 014RW081
compressor adapter to install the split collars. Legend

(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)

Intake: 0.23 mm–0.33 mm
(0.0091 in–0.0130 in)
Exhaust: 0.25 mm–0.35 mm
(0.0098 in–0.0138 in)
014RW042
6. Install tappet with shim.

7. Install camshaft assembly.
D Refer to installation procedure for Camshaft in this
manual.
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement – Standard valu)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.
Replacement of Shim
Let the cam push down the edge of tappet by using
5–8840–2444–0 valve clearance adjusting tool and push
out the shim with a flat blade screw driver as shown in
illustrations below.
014RW084
014RW082
014RW083
Camshaft
Camshaft and Associated Parts
014RW040
Legend (6) Camshaft Drive Gear Pulley

(1) Camshaft Bracket Fixing Bolt (7) Retainer Fixing Bolt
(2) Camshaft Bracket (8) Retainer
(3) Camshaft Assembly Intake (9) Camshaft Drive Gear
(4) Camshaft Assembly Exhaust (10) Oil Seal
(5) Pulley Fixing Bolt
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using 5–8840–2447–0 universal holder.
014RW060
2. Remove twenty fixing bolts from inlet and exhaust 2. Use a micrometer to measure the diameter and the
camshaft bracket on one side bank, then camshaft uneven wear of the camshaft journals.
brackets (2). Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
(1.0225 in–1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW027
3. Remove camshaft assembly (3), (4).

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.

1. Use a micrometer to measure the cam lobe height 014RS023
and uneven wear. Replace the camshaft if either the 3. Place the camshaft on V–blocks.
lobe height or the uneven wear exceeds the specified Slowly rotate the camshaft and measure the runout
limit. with a dial indicator.
Lobe height : 44.709 mm (1.7602 in) Replace the camshaft if the runout exceeds the
Uneven wear : 0.05 mm (0.0020 in) specified limit.
Run out
Limit : 0.1 mm (0.0039 in)
014RW043
014RW044
4. Measure the camshaft journal oil clearance. 5. Replace the cylinder head and/or camshaft if the
1. Measure the camshaft bracket housing inside measured oil clearance exceeds the specified limit.
diameter. 1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter. 2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
Torque : 10 N·m (1.0 kg·m/89 lb in) the specified torque.
014RW031
2. Subtract the camshaft outside diameter from the

camshaft bracket housing inside diameter. 014RW031
3. Measure the camshaft thrust clearance with a dial

Oil Clearance indicator. Replace the camshaft and/or the
Standard : 0.027 mm–0.078 mm cylinder head if the camshaft thrust clearance
(0.0011 in–0.0031 in) exceeds the specified limit.
Limit : 0.11 mm (0.0043 in) Camshaft thrust Clearance
(0.0012 in.–0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW037
014RW035
Reassembly
three bolts to specified torque.
1. Use 5–8840–2443–0 to turn sub gear to right
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for prevent
moving the sub gear.
014RW020
Legend
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW041

torque.
right bank, two dots for left bank) and exhaust
dot).
014RW023
Legend
(4) Dowel Pin
014RW024

3. Tighten twenty bolts in numerical order on one 4. If the oil seal requires replacement, use the
side bank as shown in the illustration. 5–8840–2445–0 to install the oil seal.
014RW034
014RW031
to the specified torque using the 5–8840–2447–0
universal holder.
014RW060
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend (8) Piston and Connecting Rod Assembly

(1) Cylinder Head Assembly (9) Flywheel
(2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal
(3) Oil Pipe and O-Ring (11) Main Bearing Cap
(4) Oil Strainer and O-Ring (12) Crankshaft
(5) Oil Pump Assembly (13) Main Bearing Cap Fixing Bolts
(6) Cylinder Block Side Bolts (14) Oil Gallery Fixing Bolts
(7) Oil Gallery
Disassembly CAUTION: Take care not to damage or deform the

sealing flange surface of crankcase.
1. Remove cylinder head assembly (1). Refer to 3. Remove oil pipe and O-ring (3).
“Cylinder Head” in this manual.
4. Remove oil strainer and O-ring (4).
2. Remove crankcase with oil pan (2). Refer to “Oil Pan
and Crankcase” in this manual. 5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).

1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm–0.24 mm 015RS004
(0.0024 in–0.0094 in) 3. Remove the crankshaft.

Limit : 0.30 mm (0.0118 in) Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
NOTE: Do not set the plastigage on the oil hole.
015RS003
Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS005
9. Install main bearing caps, oil gallery and crank case

bolts in the order shown, and tighten each bolt to the
specified torque.
NOTE: Do not apply engine oil to the crank case side Limit : 0.08 mm (0.0031 in)
bolts.
Main bearing cap bolts.
Torque: 39 N·m (4.0 Kg·m/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N·m (3.0 Kg·m/21 lb ft)
2nd step 55°∼ 65°
Crank case side bolts
Torque : 39 N·m (4.0 Kg·m/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS008
12. Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.

015RS006
10. Remove the main bearing caps in the sequence 1. Carefully set the crankshaft on the V–blocks. Slowly
shown in the illustration. rotate the crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS004
11. Measure the plastigage width and determine the oil

clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or 015RS007
replace the crankshaft.

(0.0007 in–0.0017 in)
2. Measure the diameter and the uneven wear of main 2. Diameter size mark (1).
journal and crank pin. If the crankshaft wear exceeds The diameter size marks are stamped on the No.1
the specified limit, crankshaft must be replaced. crankshaft balancer as shown in the illustration.
Main journal diameter : 63.918 mm–63.933 mm
(2.5165 in–2.5170 in)
Crank pin diameter : 53.922 mm–53.937 mm
(2.1229 in.–2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS011
NOTE: Take care to ensure the bearings are positioned

correctly.
015RS009
Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
015RS010
Crank Shaft Crank Shaft

Bearing Bearing
1 Size Main Bearing Crank Shaft Main 2 Size Oil Clearance
Size Mark Size Mark
Mark Bore Diameter Journal Diameter Mark (Reference)
(Upper (Lower
Side) Side)
63.918-63.925 0.030-0.049
2 Blue Blue
68.994-69.000 (2.5165-2.5167) (0.0012-0.0019)
1
(2.7163-2.7165) 63.926-63.933 0.028-0.047
1
(2.5168-2.5170) (0.0011-0.0019)
Brown Brown
63.918-63.925 0.029-0.048
2
68.987-68.993 (2.5165-2.5167) (0.0011-0.0019)
2
(2.7160-2.7163) 63.926-63.933 0.027-0.046
1
(2.5168-2.5170)

Manual de Taller GM Chevrolet Luv 1997-2005 Isuzu

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WORKSHOP MANUAL

TFR / TFS SERIES

ENGINE DRIVEABILITY AND EMISSIONS

All material contained in this Manual is based on the latest product

Applicable Model : TFR/S 54/77

This manual is applicable to 2002 year model and later vehicles.

ABBREVIATION CHARTS ........................ 6E-9 PSG CONNECTOR PIN ASSIGNMENT &

No. Connector face No. Connector face

No. Connector face No. Connector face

(Engine Room) (Cabin)

OPTION BOX (Engine Room)

RELAY AND FUSE BOX LOCATION (RHD)

(Engine Room) (Cabin)

OPTION BOX (Engine Room) (4JA1-TC Only)

0.5 2.0 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5

0.85 0.5 0.5

ECM Battery Heater

Glow A/C Blower

Glow A/C A/C

5.0 0.5 0.5

0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5

View Looking Into ECM Case

Signal or Continuity Tester Position

View Looking Into PSG Case

Signal or Continuity Tester Position

View Looking Into ECM Case

Signal or Continuity Tester Position

View Looking Into PSG Case

Signal or Continuity Tester Position

The pump control unit (PSG) receives signals from the

Additional Operations To Timing Control Valve (TCV)

The radial plunger distributor type injection pump uses

Pedal/Throttle Position Sensor (TPS)

Characteristic of IAT Sensor

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

The IAT sensor is a thermistor. A temperature changes

Throttle Angle (%)

delivery based on throttle valve angle.

Crankshaft Position (CKP) Sensor

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

The ECT sensor is a thermistor. A temperature changes

(1) EGR EVRV

The EGR system on this engine is largely responsible

5. Improved Engine Matching

7. Improved Power Performance

1. High Pressure Injection

2. High Pressure Atomization of Fuel Injected from

(1) Rotor Shaft

(1) Fuel Suction (1) Pump Control Unit (PSG)

The main components are as follows.

(1) Cam Ring

The timing device determines the optimum injection

Overview You have maximum efficiency in diagnosis when you

What resources you should use 5c. Technician Self Diagnoses

Hints 3. Water and Moisture

6. Re-examine the complaint

What you should do

What resources you should use

7. Repair and Verify Fix

What resources you should use