ISuU2U 2008-2016MY N SERIES WORKSHOP MANUAL ENGINE CONTROL SYSTEM (43J1 model)Engine Control System (4JJ1) 14-1 Engine Control System (4JJ1) TABLE OF CONTENTS Specifications 143 DTC P0201, Po2o2, PO203 or PODOA “Temperature vs Resistance. 143 (Flash Code 271, 272, 273 01 274) 1As91 Alituds vs Baromotrc Pressure 4&4 DIC POZIT (Flash Cod 542} 1a.139 Diagnostic Trovbie Code (OTC) Type DTC PO29 (Fiash Code 543} saat Definitions a 105 DTC P0234 (Flash Code 42). . 1A-143, Diagnostic Trouble: Code (ore) List|. 1A6 DTC P0299 (Flash Code 65). 10-146 Overview Wings 1&9 DTC POMS (Fash Code 15). iara9 Overviow Wings EINEU Tage pre p0996 (Fash Code 15)... Saatsz Routing Diagrams = TEE Tiaa pre posse (Fash Code 14) tase Fucl Systom Routing Diagram 1AM DTC PO341 (Flash Code 14) 10457 ‘Vacuum Hose Routing Diagram . 1A DTC P0380 (Flash Code 66). . - 10-159 Component Locator 1A12 DTC POBBI (Flash Code 67) 1161 Engine Controls Component Views AZ DTC P0401 (Flash Code 93). . . os TA164 Engine Control Module (ECM) Connector DTC P0404 (Flash Code 45), A167 End Viows 1A18 —_DTE.PO409 (Fiash Code 44) 1170 Engine Contiol Connecior End Views...../. 1-21 DTC PD4ZG (Flash Code 13). sats Diagnoste information and Procecures 132 DTC PO427 oF POA7B (Flash Code 48)... 18-175, Engine Control System Check Sheet 122 DTC PO42B (Flash Cove 145) 18-160 Diagnostic Starting Point - Engine Controls . . 14-33. DTC P042C or P042D (Flash Code 49) 1A-182 Dagostn Sytem Chosk-Engre Care T&M DTC PDA POAT ih Code 8)... 1A87 Scan Tool Daia List... ..- 1A38—_DTC-POSOO (Flash Code 25) 10190 Scan Tool Data Defntions - 1A47 DTC POSO2 oF POSO3 (Flash Code 25)... 1A-193. Scan Tool Output Controls 1A53_DTC POSED (Fiash Code 155) 10-199 ‘Scan Tool Does Not Power Up + 1A-55 DTC P0563 (Flash Code 35). . - «14-202 Scan Tool Does Net Communicate with CAN DTC P0601 (Fiash Code 53) 14-203 Device (Euro 4 Specification). «10-56 DTC P0602 (Flash Code 154). . « 1A-204 Scan Tool Does Not Communicate with DTG Poéo4, POsdE or POEB Keyword Device (Except Euro 4 Specifiation/1A-69 (Flash Code 183, 5107 36) 14206 Lost” Communication with The DTC P0633 (Flash Code 176). 4-207 Engine Cont Module (ECM) DTC POE3E (Flash Code 61) +a.208 {Except Euro 4 Specification). 14-63 DTC P0641 (Flash Code 55). 1A-211 Engine Cranks but Does Not Run. 14-66 DTC P0650 (Flash Code 77). . 10-214 DTC Po0%6 (Flash Code 18) 168 DTC POESI (Flash Code 56) 10217 DIC PO04S (Flash Code 33) ATO DTC PGBS or PUGET (Flash Code 416)... 14.220 DTC P0079 or POO6O (Flasn Code 38)... 18-73. «DTC POSG7 (Flash Code 57) 1a723 DTC P0087 (Flash Code 225), 1A76 DTC P1098 (Flasn Code 227) 1a226 DTC P0088 (Flash Code 118). ...- . 18-81 DTC P1261 of P1262 (Flash Code 34)..... 14-231 DTC P0089 (Flash Code 151). «10-86 DTC P1404 (Flash Code 45). 1A-232 DTC P0091 or P0082 (Flash Code 247)". |. 18-89 DTC P1465 (Flash Code 122) 18205 DTC P0093 (Flash Code 227). 1&92 DTC PI471 (Flash Code 149) 1n2a7 DTC PO101 (Flash Cod 92) 1A98 DTC P1648 (Fiash Coco 179) 1240 DTC P0102 or P0103 (Flash Code 91). . 1A-101 DTC P1621 (Flash Code 54). . . 6 TA241 DTC PO%07 or POT0R (Flash Code 32)... 1A-105 DTC P1664 (Flasn Code 76). sacra DTC PO112 or PO113 (Flash Code 22)... 1A-109 ‘DTC P1660 (Flash Code 75). 18245 DIC PO116 (Fiash Coce 23) 1A413 DTC P2122 or P2123 (Flash Code 121)... 1A-250 DTC P0117 or P0118 (Flash Code 23). . TA-118, DTC P2127 or P2128 (Flash Code 122)... 1A-254 DTC P0122 or P0123 (Flash Code 43). 1At19 DTC P2138 (Flash Code 124). 18-258 DTC P0182 or POT6S (Flash Code 211)... 1A-129. «DTC P2146 or P2140 DTC PO192 or P9183 (Flash Code 245)... 1A-127 (Flash Code 158 or 159) 10260 DTC P2227 (Flash Code 71)... 48-2651A-2 Engine Control System (4JJ1) DTC P2228 or P2229 (Flash Code 71)... 14-268 DTC P242F (Flash Code 131) 10-272 DIC P2452 (Flash Code 142)............ 1274 DIC P2453 (Flash Code 147)............ 18-277 DTC P2454 or P2485 (Flash Code 47)... 14-280 DTC P2456 (Flash Code 47). 14285 DIC P2458 (Flash Code 139), 14.287 DIC P2527 or P2526 (Flash Code 233)... 14-230 DIC P253A (Flash Code 28) 14-205 DTC P256A (Flash Code 31) 14-298 DTC U0073 (Flash Code 84) 14302 DTC UO101 (Flash Code 85) ......22.... 10305, DIC U0167 (Flash Code 177) 14-307 EGR Control Systm Chock 14.308 Glow Control System Check...» 14-312 Engine Warm Up Control System Check . 10-315 Exhaust Brake Control System Check ..... 14-318 Diesel Particulate Defuser (DPD) Controt System Check . 18324 ‘Symptoms - Engine Controls - 14-330 ‘Symptoms - Engine Controls 14-330 Intermittent Condiions ...... eee... WA-B32 Herd Start 14-335 Rough, Unstable, or Incorrect Idle and Stalling cei ceeeeeeeeeeeeeeeees ABST High Idle Speed oo. 18-340 Cuts Out 10341 Surges... 14-343 Lack of Power, Sluggishness or Sponginess 14-345 Hesitation, Sag or Stumble 14-347 ‘Abnormal Combustion Noise 10349 Poor Fuel Economy. 14.350 Excessive Smoke (Black Smoke)......... 14-352, Excessive Smoke (White Smoke). 14-354 DPD System Manual Regeneration Frequently .. 14-356 DPD Systom Regeneration Long Time... 14-358 Repair Instructions 14-360 Engine Control Module (ECM) Replacement 14-360 Service Programming System (SPS) Description... . ce 18-863 Service Programming System (SPS) (Remote Procedure)....... ce 18-363 Service Programming System (SPS) {Pass-Thru Procedure). 10.365 Description and Operation ........ 14-366 Engine Control Module (ECM) Description. 14-366 Engine Control Component Desoription .... 14-369) Fuel System Description 10373 Fuel System Component Description ...... 14-374 Fuel Injection System Description. 10.378 Exhaust Gas Recirculation (EGR) System Description 140.379 Turbocharger Description «2.0.0... eee. 18-380 Diese! Particulate Defuser (DPD) System Description cee 10883, Special Tools and Equipment 14386 ‘Special Tools and Equipment 14386Engine Control System (4JJ1)_1A-3 Specifications ‘Temperature vs Resistance c * ‘Ohms Engine Coolant Temperature vs. Resistance Temperature vs. Resistance Value (Approximately) °c °F ores. (250 482 4300 “Temperature vs. Resistance Value (Approximately) 200 392 6900 120 248 115 150, 302 43900 110 230, 150 100 22 39600 100 212 190 50 122 106000 0 194 250 a 176 0 Fuel Temperature vs. Resistance 70 158 450 ea F ‘Onn 1 am = Temperature va. Resistance Value (Approximately) = iz a 70 230 740 a a mo 100 212 180 30 86 1730, 80 194 240 a = am 3 776 310 7 = 7 7 188 220 a 2 eno 80 140 50 = 7 e200 50 122 310 20 4 18700 40 ‘104 1150 30 22 26500 o & 1680 20 8 2450 Exhaust Temperature vs. Resistance 70 50 3700 *6 F Ohms 7 % 5740 ‘Temperature vs. Resistance Value (Approximately) 10 14 9160 7000 1832 720 20 = 15000 950 1742 735 “30 2 25400 900 652 755 - on a oa Ina Ar Temperature v, Relate Except Euro 200 7472 205 o oF one ic ae = Temperature vs. Resistance Value (Approximately) 700 ee. 2m 100 212 790 850 1202, 348 90 194 240 500 ae 428 80 176 320 i560, 5022 530 70 158 430 ay Bae Ss 60 140 590 460 ane ees 50 122 810) 400 752 200 7 750 350 682 7710 0 = 1680 300 572 2560 7 = iS1A-4 Engine Control System (4JJ1) % F Ons Baronet Tonporatrav,Redance Vas Roprommatayy | | ,,fttude, | Atiuio | Possuo 10, 50 3660 Meters {m) Feet (ft) Kilopascals a 2 5550 (a) = 4 e0T9 Oetaion ory using ani eletence sources 20 4 14700 1829, 6000 ‘77-85 Iniake Air Temperature vs. Resistance (Euro 2 and 154 500 s088 Eo 3 Spectications) =o aan aa °c °F Ohms 314 3000 87-85 “Temperature vs. Resistance Value (Approximately) 0) 200 3008 190) 212, neo) 305 1000 94-102 a0 ‘194 zag 0 Sea Level 96-104 80 78 330 305 “1000 101-105 7 8 270 < 0 70 3 @ 380 7 To 766 Ey % m0 2 we 35% 7% = se00 @ 2 0 = 77 0 2 a 2500 Altitude vs Barometric Pressure Barometric Altitude Altitude Pressure Measured in | Measured in. | Measured in Meters (m) Feet (it) Kilopascals (kPa) Determine your alttude by contacting a local weather, station or by using another reference source. 4267 14000 5-84 3962 13000, 36-66 3658 12000 61-68 3383 11000 64-72 3048 710000 66-74 2748 9000 68-77 2438 8000 71-78 2194) 7000 74-82Engine Control System (4JJ1)_1A-5 Diagnostic Trouble Code (DTC) Type Definitions Emission Related DTC Action Taken When the DTC Sets - Type A + The ECM illuminates the maifunction indicator amp (MIL) when the diagnostic runs and fails. + The ECM records the operating conditions at the time the diagnostic fails. Tho ECM stores this information in the Freeze Frame! Failure Records. (Euto 4 specication) Action Taken When the DTC Sets - Type B + The ECM illuminates the MIL on the second ‘consecutive driving cycle when the diagnostic runs and fails + The ECM records the operating conditions at the time the diagnostic falls. The first time the Giagnostic falls, the ECM stores this information in the Failure Records. If the diagnostic reports @ failure on the second consecutive driving cycle, the ECM records the operating conditions at the time ff failure and stores this information in the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/ DTC - Type A or Type B + The ECM tums OFF the MIL after 3 consecutive ccrving cycles when the diagnostic runs and does not fail, (Euro 4 specification) + The ECM turns OFF the MIL after 1 ignition cycle when the diagnostic runs and doas not fal, (Except Euro 4 specification) + Acurrent DTC clears when the diagnostic runs and passes. + Ahistory DTC clears after 40 consecutive warm-up cycles, if no fallures are reported. (Euro 4 specification) + A history DTC clears after 40 consecutive driving cycles, if no failures are reported. (Except Euro 4 specification) + Use a scan tool to clear the MIL and the DTC. Non-Emissions Related DTCs Action Taken When the DTC Sets - Type C + The ECM illuminates the Service Vehicle Soon (SVS) lamp when the diagnostic runs and falls. + The ECM records the operating conditions at the time the diagnostic fails. The ECM stores this information in the Failure Records. Conditions for Clearing the SVS Lamp/ DTC - Type c + The ECM turns OFF the SVS lamp after 1 driving cycle when the diagnostic runs and doas not fil + Acurrent DTC clears when the diegnostic runs and passes. + Ahistory DTC clears after 40 consecutive warm-up cycles, f no fallures are reported + Use a scan tool to clear the SVS lamp and the orc. Action Taken When the DTC Sets - Type D ‘+ The ECM will not iluminate the MIL or SVS lamp. + The ECM records the operating conditions at the time the diagnostic fails. The ECM stores this information in the Failure Records. (Euro 4 specication) Conditions for Clearing the DTC - Type D + Acurrent DTG clears when the diagnostic runs and passes + Ahistory DTC clears after 40 consecutive warm-up cycles, if no faiures are reported. (Euro 4 specification) + Anistory DTC clears ater 40 consecutive driving cycles, if no fallures are reported. (Except Euro 4 specification) + Use a scan tool to clear the DTC.1-6 Engine Control System (4JJ1) Diagnostic Trouble Code (DTC) List DISTR ore | Goat | Swot | Etro DTC Descriptor cation | SPesif ‘eatlon Posi | 16 | A | A _ | Crankahat Postion - Camshaft Posen Garlation Poows |= [Turbocnarger Boost Cont Solenow Grout Poors | a8 | A | = [Exhaust Valve Conta! Solenoid Greit Low RODE | “35 [A |= [ xaust Valve Con! Solenoid Greit High Pooer | 25| D |B | Fuel Rail System Pressure Too Low PO0sE | 18 | A | A [Fuel Ra System Pressure Too High (Senond Stag) PO0ES | 15 |B |B [Fuel Pressure Regulator Performance poost | a7 [A | A _ [Fuel Prosswe Regulator Gono Gira Low poo | 247 | A] A _ [Fuel Presswe Regulator Convo Gout High PO0sG | 227 _| 8 | 8 | Fuel System Leak Detected Pow | 2 |B | Mass Air Flow Sensor Greul Rangel Perormance POW | 8 | _A | ACY™ | Mass Air Flow Sensor Great Low input PIS | 8 _| A | ACY™ | Mass Air Flow Sensor Great High Input POIOT| a | A | _A | Manfoé Absolute Pressure Sensor Crt Law Input pois | 22| A | A | Manfolé Absolute Pressure Sensor Grout High Input Poa | 2 | A | A | Rake Ar Temperature Sensor Cs Low Po | 22 | A | A Intake A Temperature Sensor Creu High Pome | 2 | 8 | | Enaine Coolant Temperatire Sensor Greuit Rangel Perfomance POT | 2 | A | A | Eneine Gaolnt Temperature Sensor rut Low POTIe | 23 | A | A _ | Enno Coolant Temperature Sensor Gul High Porz2 | 43 | A | A _ | Thole Postion Sensor Ccut Low Poiz | 4 | A | A _ | Throttle Posllon Sensor Creu High Pova2 | 217 | A | A _ [Fuel Temperature Sensor Greult Low Pores | 211] A | A | Fuel Temperature Sensor Creu High POIs | 2A | A | A [Fast Ra Pressure Sensor Creu Low POISG | 245_| A | A | Fuel Rai Pressure Sensor Gre Figh Pox | 271 | A | A _|Injotor Greut Open -Gyindor Pose | 27 | A | A _[Inietor Creit Open Cylinder PoRis | 273 | A | A [Injector Greut Open = Gyinaer3 Poa | 274 | A | A |Injctor Greut Open = Gyinaer a poni7 | 642 |B | D _ [Enaine Goclant Over Temperature Condion POO | 513 |G | D | Enaine Overspeed Gonditon Pox | 42 | A | A _ | Turbocharger Gverboost Conalion pease | 65 | 8 | _ | Tubocharaer UndorboostEngine Control System (4JJ1)_1A-7 DTC Type pre | Flash) euros | PPP DTC Descriptor Coae | Emo | Euro 4 sctptor aton | Sect ‘caton pos | 15 | A 7A__|Grankshat Postion Sensor Creut Pose | 1 | A A __[Crankshaf Poston Sensor Creu Rangel Performance poss | 1 | A A__|Camstiat Postion Sensor Grout post] 1 | A =| Camshaft Postion Senor Grout Range’ Performance P0360 | 66 | C A [Glow Plug Grout poset | 7 | © A [Glow Piug Indicator Gira poai | 3 | A = [EGR Fiow insufcient Detected poo] as | A A__ [EGR Control Circuit Range’ Performance poao9| 4¢ | A | A _ [EGR Position Sensor Circuit Poms | 143 |S = [Catalyst Temperature Sensor Grout Rangel Performance Sensor 1 pow] 48 | A = [Catalyst Temperature Sensor Grout Low Sensor poze] 48 | A = [Catalyst Temperature Sensor raul High Sensor? Poi | 145 | C = [Catalyst Temperature Sensor Greut Range! Performance Sensor 2 Powe] 49 | o =| Catalyst Temperature Sensor Chcult Low Sensor 2 Pow] 45 | o = [Gatayat Temperature Sensor Grau High Sensor? por | 46 | - [Exhaust Pressure Control Valve Low pois | 46 | = [Exhaust Pressure Control Valve High Pos00 | 26 |B A__ [Velie Speed Sensor Pos0 | 25 | A 7A___| Vehicle Speed Sensor Creat Low Input P0503 | 25 | A 7A___| Vehicle Speed Sensor Grout High Input Passo | 765 | A _| ACY [Sistem voltage Poses | 35 |e A__ | System Voltage High Pooor | 8 | A A__|Internal Control Module Memory Check Sum Error PoBo2 | te | © A_|Sonivel Wodule Programming ror Poss | 165 | A [Internal Control Module RAM Error P0606 | st | A 7” [ECM Processor Posos | 36] A 7A__ [Internal Control Madule AD Processing Perormance Po6ss | 176 | > | mmabiizer Not Programmed Posse | ot | 8 A__|Trvote Actuator Contel Rangel Performance poss | 65 | A 7”___ [Sensor Reference Volage 1 Circuit P0650 | 77 | A | Maifanction Indicator Lamp (ML) Control Grout possi | 86 | A A__[ Sensor Reference Voiago 2 Grcut Poses | 416 | C A_ [EON Power Relay Conirol Ccult Open Poss? | 416 | A__ [ECM Power Relay Control Creat High Poe | 7 | A | A _ | Sensor Reference Vollage 3 Gvcut PI0m | BF] _A © [Fuel Rai Pressure Too Low1A-8 Engine Control System (4JJ1) DTC Type pre | Flash) euros | PPP DTC Descriptor Coae | Emo | Euro 4 sctptor aton | Sect ‘caton Piast | 3 | A A__[InesterPostive Voliage Contral Gieut Group 1 Pie | _a@ | A A__| Injector Postve Voltage Control Circuit Group 2 praoe| 45 | A — [EGR Postion Fault (Closed Poston Error) P1404 | 45 | A | ACVB |EGR Posiion Fault (Leamed Position Eror) Piss | 1a | A =| PM Over Accumulation Puri] 49 | A = [OPO Insufficient Regeneration pret] 179 | D D___|immabiizer Wrong Response prea | &@ | _A ‘A__|Contol Module Long Tern Memory Performance prs | 76 | © =| Senvce Vehicle Soon Lamp Control Circuit a —_ [DPD Lamp Contal Creut Poe | wa |B A__ [Pedal Position Sensor 1 Grcult Low input P2123 | 21 |B A__| Pedal Position Sencor 1 Circut High Input Paior | 22 |B A__ | Pedal Postion Sensor 2 Crcult Low input Paia6 | 12 |B A [Pedal Positon Sensor 2 Greuit igh Input paige | 2 |B [Pedal Positon Sensar 1-2 Votage Corelation paa6 | 65 | A 7 _| Fuel injector Group 1 Supply Votage Greut Pao | 169 | A ”_| Fuel njector Group 2 Supply Voltage Greut Paar | |e =___ [Barometric Pressure Sensor Groult Range/ Performance Pama | 7 | A [Barometric Pressure Sensor Grault Low pam | 7 | A 7A [Barometric Pressure Sensor Greut High Paar | Ta | A = [DPD Restcton Paez | a2 | A = [BPD Differential Pressure Sensor Orcut Pass | Ta | A BPO Differential Pressure Sensor Crcuit Range! Performance puss | a7 | A =| BPD Differential Pressure Sensor Creu Low p285 | a7 | A =| DPD Differential Pressure Sensor Grau igh P2486 | a7 | A =| BPD Differential Pressure Sensor Leamed Poston pase | 139 | A = [BPD Regeneration Duration P25q7 | 233 | A | ACY | Vacuum Pressure Sensor Grcull Low P2526 | 233 | A | Acry | Vacuum Preseure Sensor Creuit igh Passa] 28 | C A [PTO Sensor Great PaEEAT aI |e 7A [Engine lle Speed Selector Sensor woo7s [a | 8 | BCVA | Control Module Communication Bus OF uot | 8 | C = [ost Communication with TM woe | 77 | > [Lost Communication With Vehicle immobilizer Conto] Module *: Except Euro 2 and Euro 3 specificationsEngine Control System (4JJ1) _1A-9 Overview Wirings Overview Wirings 42 meeen| Bi g NI nom =i germ ici > om cera] Uf > a sett sero wem| O He _— ese] Oo ; a le M8 Ben Bs 2 4 ever ia games; ECM a ry Ehosansenrn sere 3 exenrat eners |B] le 9 2 le ey seem, eee WOOT mare @ te eprom + \e 280] Cia] Cras a Dos! etn le1A-10 Engine Control System (4JJ1) 212 @ a e ecm a rte ne ee igh enon tegen ser }@ a comme Ob} ees sean 8 Oates ee 3 [oeet a ef : i # a me g | ‘esrEngine Control System (4JJ1)_1A-11 Legend 1. Fuel rail 8. Vent valve 2. Pressure limiter valve 8, Per uel iter with sedimenter 3. Leak off pipe 40. Priming pump 4. Fuel injector +1. Fuel fier wih water separator 5. Fuel rtum pipe 42. Return fue! flow back valve 8. Fuel feed pipe 418. Fuel supply pump 7. Fuel tank Vacuum Hose Routing Diagram 2 r 3 nd Vacuum pressure sensor 5. Vacuum pump >. Turbocharger nozzle control solenoid valve 6. Actuator control vacuum hose ‘Vacuum pipe 7. Turbocharger nazzle contre! actuator Brake booster1A-12_Engine Control System (4JJ1) Component Locator Engine Controls Component Views Legend ‘1. Barometric pressure (BARO) sensor 2. Accelerator pedal position (APP) sensor Legend 1. Fuel injector No.1 cylinder 6. Intake throttle valve 2. Fuel injector No.2 cylinder 7. Turbocharger nozzle control solenoid valve 3. Fuel injector No.3 cylinder (Except Euro 2 and Euro 3 specifications) 4, Fuel injector No.4 oylinder 8. Boost pressure sensor 5. Exhaust gas recirculation (EGR) valveEngine Control System (4JJ1)_1A-13 id 1. Variable nozzle turbocharger (VNT) vacuum 2. Engine coolant temperature (ECT) sensor pressure sensor (Except Euro 2 and Euro 3 3. Camshaft position (CMP) sensor specifications) Legend 1. Fuel rail pressure (FRP) regulator 5. Engine oll pressure switch 2. Fuol temperature (FT) sensor 6. Crankshaft position (CKP) sensor 3. Pressure limiter valve 7. Engine oil level switch 4, Fuel rail pressure (FRP) sensor1A-14 Engine Control System (4JJ1) Legend 1. Exhaust brake valve 4. Exhaust diferential pressure sensor 2. Exhaust temperature sensor 2 (in front of oxygen 5. Exhaust throtte valve catalyst) 6. DPD assembly 3, Exhaust temperature sensor 1 (in front of fiter) Legend 1. Mass air flow (MAF) sensor! intake cir 2. Intake air temperature (IAT) sensor (Euro 2 and temperature (IAT) sensor (Except Euro 2 and Euro 3 specications) Euro 3 specifications)Engine Control System (4JJ1) 14-15 Legend 1. Vehicle speed sensor (VSS) (without ABS model) Legend 1. CAN resistor (LHD) (with immobilizer model) 2. CAN resistor (RHD) (with immobilizer model)44-16 _Engine Control System (4JJ1) NHR, NLR, NMR mode! id 1. Engine control module (ECM) 2. Dropping resistor (Except Euro 2 and Euro 3 spectfcations) NNR, NPR model emonnsromet id 1. Engine control module (ECM) 2. Dropping resistor (Euro 4 specification)Engine Control System (4JJ1) 14-17 NLS model id 1. Engine control module (ECM)41-18 Engine Control System (4JJ1) Engine Control Module (ECM) Connector ‘Conair No. 4 End Views ‘Connector color Black Sete ima at 47 |BRWGRN SVS lamp control (Euro 4 Pee VSS signal (without ABS) or 2) an ee 2 RED/ BLU | (Except Euro 2 and Euro 3 = = a | amen fea — a 2 WHT! | pattery voltage = =m 4 BLK [ECM power ground 9 = _|Netused 5 | WE [eater voase = SS 7 BRN | Exhaust brake lamp control _ ee WHT reust <@ lamp control 33 BLU/ BLK | Refrigerator switch signal oie] oles 10 | WET tow lay cone v6 | = [Rotused eS 2 fT es oe w [euwwmn ees meene 15 WHT! — | Exhaust brake solenoid valve 40; BLUAYEL: | BoM men ielavcontel ey |SEngine Control System (4JJ1) 14-19 APP sensor 1, idle up sensor MAF sensor signal (Except a1 [wxseo|Spemeaete | | im | wn Razors a pega Srtenridemana | | -w| vet [pro meneansr ser 3 BLK __|ECM(sigal ground 72 | BLU/BLK | IAT sensor signal Trem vs |veuneo | rarontanusaas Common 1 (cylinder #1 and UT GRN’ [EGR postion sensor signal $ san | weer [Sommon 1 (ovine At and ee BLK | (except Euro 2 specification) tue! inipetor charge vollaus: a0 | ix | SMP sensor and FRP sensor shield ground 101 | YEL/BLK CMP sensor, FRP sensor and EGR position sensor low reference GRNI ww2 | SRN Exhaust throttle solenoid valve ‘control (Euro 4 specification)Engine Control System (4JJ1) 14-21 Engine Control Connector End Views Accelerator Pedal Posi n (APP) Sensor Barometric Prossure (BARO) Sensor Connector No 35 Connector coir Gray Tes adapter No assem Pin No, | Wire coor Pin fnefon 1 | sw [Breas eterence 7 [VEL [APP sensor? sal 3 [BLU [APP sensor 2 ow eferonce 4 | 2H [eves reornce 3 [RED [APP sensor signa 3 [WHT [APP sensor Tow eforence Conner We a Comair cobr Tack Tost depo He ed Pine [Wie cor | Pin tinaon 7 BLU | arsoriow erence 2 | SER | sorcorsina 3 | eR | Sensor vols refrenee Boost Pressure Sensor414-22 _Engine Control System (4JJ1) ‘Connector No E24 Connector color Black ‘Test adapter No. 135616-33 Pin No. | Wire color Pin function’ 7 RED _ | Sensor signal 2 BLK _ | Sensorlow reference 3 YEL _ | Sensor volts reference Clutch Switch ‘Connector No. Bie Connector color White “Test adapter No. 35618-42 Pin No. | Wire color Pin function| 1 | BLK/ORN | ignition voltage feed 2__ | WHT/BLK | Switch sional Camshaft Position (CMP) Sensor ‘Connector No. E18 ‘Connector color Black “Test adapter No. 735616-33 Pin No. | Wire color Pin function 1 _[ BLU/WAT | Sensor signal YEL/BLK | Sensor ow reference UTGRN ‘Sensor 6 volts reference Crankshaft Position (CKP) SensorEngine Control System (4JJ1) 1-23 ‘Connector No. E20 Connector color Black Test adapter No. ¥35616-33 Pin No. | Wire color Pin function’ 1 _| RED/BLU | Sensor signa BLK _ | Sensor low reference YEL__ | Sensor 5 volts reference Data Link Connector (DLC) ae = a = a 12 BLK/ WHT | (ECM, TCM, HSA contro! unit erases 13 [eux wer Reeae en we [ Rees DPD Regeneration Switch nS Ea ST) BOHOL ‘Connector No. Bat Connector color Blue Test adapter No. 35616-24 resco Pin No. | Wire color Pin function 1 = [Not used Gonnector No Bi6s 2 | ETGRN’ | Class 2 serial data (EHCU Connector color Bue RED _| [ABS module] es neal Test adapter No, 3561633 =| Notused Pin No, | Wire color Pin fonction 4 BLK [Ground 1 _ | BLKTORN | Switch voltage food BLK | Ground 2 _ | BLUI WHT | Switch signal @ | GRN’ [CaN Tigh (Euro4 WHT _ | specification) 2 pau | Not used Keyword serial data (ECM a =] Netuned {except Euro 4 specication) 3 = ___[Notusea 7 | ETBLU | Fc¥, HSA control unit and SRS control unit) 6 =__[Notused = __[Notused 7 BLK | Hlumination lamp ground LT GRNT =| Notused lumination lamp vol jot use 8 FERN! | ttumination lamp voltage feed 10 = [Not used1A-24 Engine Control System (4JJ1) Engino Coolant Temperature (ECT) Sensor ‘Connector No. B166 Connector color Blue Test adapter No. ¥-35616-33 Pin No, | Wire color Pin function 8 = [Not used 10 =__ [Not usec EGR Valve ‘Connector No. E25 ‘Connector color Gray “Test adapter No. 35616-33 Pin No. | Wire color Pin function 1 | GRN/ VEL | Sensor signal owrescrnnei BLK ‘Sensor low reference: =| Retosed Conner NB a Corned aor Back Engine warm Up Switch Test adap Wo TERSTESER Fin No, Wr oor Fintarcon | ur emw [Porsoror 5a 2 | FSR [pst sensor signals EN «| RATT | postion sensoragnl 3 | FELT aLK | Potion sensor ow leone 3 [WaT [Wor consars 7 [ORN | Wotorconrara 3 [ BURTORW [Wot conEngine Control System (4JJ1) 14-25 Exhaust Differential Prossure Sensor Connector No 3168 Connector color Black Test adapter No FI8676 33 Pin No, | Wire color Pin function Engine warmup Switch votege 1 | euxrorn [Ene 2 [BRN/RED | Engine warm up switch signal 3 = [Net used a = _ [Net used 3 = [Not used 3 = [Notused 7_|__BUK __|iiumination famp sround TTGRNT romeo 8 | “SRN | itumination lamp votage food 9 = __[Notuses Connector No. 35 0 = [Notused Tomecior color Black 7 ra50Te Exhaust Brake Solenoid Valve leatndapten No: SBS Pin No. | Wire color Pin function 7 | BLK | Sensor low reference 2_ | GRNIYEL | Sensor signal wat? 3 | WHT | sensor 6 volts reference Exhaust Temperature Sensor 1 y Connector No 125 Connector color Black Test adapter No F866 3S in No, | Wire color Pin function 7 _| GRN’BLK | ignition voltage feed snes WaT? 2 | WHT | solenoid valve convel414-26 Engine Control System (4JJ1) Exhaust Throttle Solenoid Valve Connector Na wa Connector color Tahtorey Test adapior No T3561 Pin No | Wire color Pia fanation 7 _[__BtK _ | SensorTow reference 4 2 YEL/ RED | Sensor signal -_ we Connector No. Connector color Bue “est adapler No F355TE33 Pin No. | Wie color Pin funeton 7_|__BtK [Solenoid vave conta 2 | RED _|gniton voltage fees Fuel injector #1 to #4 Cylinder Connector No 5 Connector lor Dark aay Test adap No 73561633 Pin No, | Wire calor Pin function 1 | __BtK _ | Sonsorfow reference 2 | RED | Sensor signalEngine Control System (4JJ1) 14-27 ‘Connector No. 5, E6, E7 and EB Connector color Gray ‘Test adaptor No. F35616-33 Pin No. | Wire color Pin function’ i GRN/ WHT #2: BL 1 Butretu | Fuel inlector control #8: WHT) YEL #1 and #4: WHT 2 ee te pep | Charge voltage Fuel Rail Pressure (FRP) Regulator Fuol Rall Pressure (FRP) Sensor ‘Connector No. E19 ‘Connector color Black “Test adapter No. 735616-33 Pin No. | Wire color Pin function 1_| YEL/BLK | Sensor low reference BLU/ WHT | Sensor signal LTGRN_ | Sensor 5 volts reference ‘Connestor No, EW Connector color White Test adapter No. -35616-33 Pin No. | Wire color Pin function| 1 WHT) | Regulator control high side RED |(PwM) 2 GRN/RED | Regulator low side Fuel Temperature (FT) Sensor414-28 Engine Control System (4JJ1) Mass Air Flow (MAF) Intake Air Tomperature (IAT) ‘Sensor (Euro 4 specification) ‘Connector No. E22 Connector corer Gray Test adapter No, 1 35616-33 Pin No. | Wire color Pin function’ 1 BLK _ | Sensor low reference UF GRN 2 Wut | Sensor signal Glow Plug ‘Connector No. E14 Connector color = Pin No. | Wire color Pin function’ 1 | BLKIYEL | Power Supply Connector No. 8 ‘Connector color Black "Test adapter No. 735616648 Pin No. | Wire color Pin function 1_| RED/ BLU | MAF sensor 12 volts reference BLK _ | MAF sensor low reference WHT _ | MAF sensor signal BLU/BLK | IAT sensor signal RED __| IAT sensor low reference Intake Air Temperature (IAT) Sensor (Except Euro 4 specification)Engine Control System (4JJ1) 14-29 ‘Connector No 217 Connector color Black ‘Test adapter No. F3616-16 Pin No. | Wire color Pin function 7_ | BLUTBLK [Sensor signal 2 _ | RED/BLU | Sensor low reference Intake Throttle Valve Idle Up Sonsor ‘Connector No. E16 Connector color Black “Test adapter No. 35616-64A Pin No. | Wire color Pin function| i ‘GRN | Motor control low side (PWM) 2 | BLK/GRN | Motor drive voltage 3 BLK | Position sensor low reference 4 = __ [Not used 5 | VIO/WAT | Position sensor signal . vex [Pasion sensor 5 vats ‘Connector No. B87 ‘Connector color Write “Test adapter No, ¥36616-33 Pin No. | Wire color Pin function 1__[ BLU/RED | Sensor low reference YELIGRN | Sensor signal BLU _ | Sensor 5 volts reference PTO Switch14-30 _Engine Control System (4JJ1) ‘Connector No Ed Connector color Black Test adapter No, 135616-33 Pin No. | Wire color Pin function’ 1 _| VIOIWHT [PTO switch signal 2 BLK [PTO switch ground PTO Throttle Sensor Turbocharger Nozzle Control Solenoid Valve SemecorN: ed Comer oar ate Test adapiorNo Fase Bin Ro | Wie car | intention 7 UTR pon vlge food a 2 | WET | scenes cons anny — = NT Vacuum Pressure Sensor Connedar or Bleck Test epi Na FasG1635 Bin No: | Wie solr | Fn faneion 7 [RED | Sosoriow eerone 2 | VEL | Sensor sina 3 | BCU [Sensors vis eteeneeEngine Control System (4JJ1) 14-31 ‘Connector No Eo Connector color Black ‘Test adapter No. 135616-33 Pin No. | Wire color Pin function’ 1 BLK _ | Sensor low reference 2 GRN | Sensor signal 3 YEL _ [Sensor volts reference Vehicle Speed Sensor (VSS) ‘Connector No. 8 Connector color Gray “Test adapter No. 35616-33 Pin No. | Wire color Pin function| i GRY _ | lonition voltage feed 2 BLK | Sensor low reference 3__| YEUGRN | Sensor signal1A-32__Engine Control System (4JJ1) Diagnostic Information and Procedures Engine Control System Check Sheet ENGINE CONTROL SYSTEM CHECK SREET Inspec Nae users Name edo & od Yoo Dive’ Name casi No ae Veil rowan Eng Ne Lins dome Roda eines o & em 1 Engine does not crank No intial combustion No complete combustion aint |. Ene cons doy U onere 1 . Rae ig red Tieng eee RP a ig eed £1 mcoroxise [2 noanions & Other ( | Ele a to em Tae Tata © |D bevenbaty |S Lack of power, sgaieters, sponginess i 3 oe i 5 Son sag 7 race peed Bearman |Z teventopecen B atereccevresfealeamse’ ©. Shing Wi 0 2 om | Saran Twemaz Fearn ey 2 ores |G Amanat contusion rose OPO seen Fey 5 DSropmorton tga 2 Onmt , eed 3 ca 7a Tas aaa) Foy Proven Fey overt A Seamer fe ooaiy Trans Taw 5 oscar [ess tater Fam aa Tea apa Fem [5 toy epee 8 Noe faa a Bas Taye oT ¢ 3 Deal Reh! Bonet ‘ | Boros io Bho os E [tonscontton | 5 acannon, ton) i lem res Tama Tiere Tenet ee eo | ; oS at ar sng Wy Tag E lemw pemon {2 Pech, owe 1 Comartepesd Aeon § [fro op aton | Deeteen © Aoncr onion 3 Om , Foaaront — |e ra Thon iz Coon Terao Fo ra aa aa 2 Rena On irs On Doe alton aru cote rear ate ne 8 Diagnostic Trouble " Nod )| eaters san ce Noting a Rarucode 5 SPD ams or near [Bd oer oeD sikh orate 1 et at ph ccoseun —[OPPasanain ana? a aa uA af pe0 sine ss [ors 2 3 ce OPO hoops aero es ze a aa BPD rash gw i ae a a2 Ems dees presse al sha tins eo rad HAF Win ris err pss nS osEngine Control System (4JJ1) 14-33 Diagnostic Starting Point - Engine Controls Begin the system diagnosis with Diagnostic System Check - Engine Controls. The Diagnostic System Check - Engine Controls will provide the following information| + The Ientiication of the control modules which ‘command the system + The ability of the contral modules to communicate through tne serial data circuit + The identification of any stored diagnostic trouble codes (DTCs) and the their statuses. ‘The use of the Diagnostic System Check - Engine Controis will Identify the correct procedure for diagnosing the system and where the procedure is located. Important: Engine Control System Check Sheet must be used to verify the customer complaint, you need to know the correct (normal) operating behavior of the systom and verify that the customer complaint isa valid failure of the system, 7 Ha Ee “al Reading Flash Diagnostic Trouble Codes (DTC) ‘The provision for communicating with the ECM is the Data Link Connector (DLC). The DTC{s) stored in the ECM memory can be read either through a hand-held diagnostic scanner such as Tech 2 plugged into the DLC ot by counting the number of flashes of the malfunction indicator lamp (MIL) or the service vehicle soon (SVS) lamp when the diagnostic test terminal of the DLC is grounded. The DLC terminal "12" (diagnostic request) is pulled "Low" (grounded) by Jumped to DLC terminal "4", which is @ ground wire. ‘Once terminals "12" and "4" have been connected, turn the ignition switch ON, with the engine OFF. The MIL. {except Euro 4 specification) or the SVS lamp (Euro 4 specication) wil indicato a DTC three times is a DTC 's present and history. I more than one DTC has been stored in the ECM's memory, the DTCs will be output numerical order with each DTC being displayed three times. The flash DTC display will continue as long as the DLC is shorted, Unit: Second Diagnostic Trouble Codes (DTC) Clear Method by Accelerator Pedal Operation (Except Euro 4 Specification) If there is no scan tool, history DTCs can be cleared Using accelerator pedal operation 4. Tum ON the ignition, with the engine OFF. 2, Use a jumper wire and the DLC terminal "12" (Giagnostic request) is pulled "Low" (grounded) by jumped to DLC terminal "s*. Depress accelerator pedal within 1 to 3 seconds. Release accelerator pedal within 1 10 3 seconds, Depress accelerator pedal within 1 to 3 seconds. Release accelerator pedal within 1 to 3 seconds. Depress accelerator pedal within 1 to 3 seconds. Release accelerator pedal within 1 to 3 seconds. eNoane Notice: DO NOT touch the accelerator pedal when it is released. Clearing DTCs may fil1A-34 _ Engine Control System (4JJ1) Diagnostic System Check - Engine Con- trols Description “The Diagnostic System Check - Engine Controls is an organized approach to identifying a condition that is created by a malfunction in the electronic engine control system. The Diagnostic System Check must be the starting point for any criveabilty concer. The Diagnostic System Check directs the service technician to the next logical step in order to diagnose the concem. Understanding and corectly using the diagnostic table reduces diagnostic time, and prevents the replacement of good parts. Test Description ‘The numbers below refer to the step numbers on the diagnostic table, 2. Lack of communication may be because of a partial fr a total malfunction of the serial data circu. 7. The presence of DTCs which begin with U, indicate that some other module is not communicating, 10. If there are other modules with DTCs set, refer to the DTC list. The DTC list directs you to the appropriate diegnostic procedure, If the control module stores multiple DTCs, diagnose the DTCs in the following order: + Component level DTCs, such as sensor DTCs, solenoid DTCs, actuator DTCs, and relay DTCs. Diagnose the multiple DTCs within this category in numerical order. Begin with the lowest numbered DTC, unless the diagnostic table directs you otherwise, Diagnostic System Check Engine Controls Important: + DO NOT perform this diagnostic if there is not a criveability concern, unless another procedure directs you to this ciagnosti. + Before you proceed with diagnosis, search for applicable service bulletins. + Unless a diagnostic procedure instructs you, DO NOT clear the DTCs, + Ifthere is a condition withthe starting system, refer to the Starting System in Section 1E Engine Electrical + Ensure the battery has a full charge, + Engure the battery cables (+) (-) are clean and tight + Ensure the ECM grounds are clean, tight, and in the correct location. + Ensure the ECM hamess connectors are clean ‘and correctly connected. DO NOT attempt to crank the engine with ECM hamess connectors disconnect. + Ensure the ECM terminals are clean and correctly mating, + Ensure the fuel injector ID code data is correctly programmed in to the ECM. + Ensure the Immobilizer security information is conrectly programmed into the ECM and Immobilizer control unit (ICU), + If there are fuel system DTC's (P0087, PODS, P0059, P0093 or P1093), diagnose sensor DTCs, solenoid DTCs, actuator DTCs and relay DTCs first + If thore are DPD systom DTC's (P1495, P1471, P242F, P2452, P2453 or P2458), diagnose sensor DTCs, solenoid DTCs, actuator DTCs and relay DTCs first Diagnostic System Check - Engine Controls (Euro 4 Specification) Sep) ‘ation Value(s) Yes Ne Tnstalla sean tool 1 = Go to Scan Too! Does the scan tool tum ON? Goto step? _| Does Not Power Up 7. Turn ON the ignition, withthe engine OFF 2. Attempt to establish communication with the {Go to Scan Too! 2 ECHL - oes Not ‘Communicate with Does the sean tool communicate with the ECM? Goto Stop 3 CAN Devico Notice: If en immobilizer system is actve the ECM \will disable the fuel injection causing the engine to stall immediately after staring and energze the 3 | starter cut relay to disable cranking. Attempt to > ‘rank the engine. Doos the engin crank? Goto Stop 4 Goto Step 5 ‘Allempt to star the engine (Go 10 Engine a — Cranks but Does Does the engine start and ide? Goto Sep 6 RatEngine Control System (4JJ1) 14-35 Sep ‘Actor Value(s) Yes No Does the scan tool display ECM DTCs P0633, Problem fs relating P1618 or 0167? ta starting systom, 5 = Refer to Starting Goto Appicablo | _systom in Section ore AE Engine Electrical Selact the DTC cisplay funciion for the folowing ‘control modules: ECM + Transmission control module (TCM) (Smoother only) 6 = * Electronic hydraulic control unit (EHCU) (it so equipped) ‘Immobilizer control unt {ICU) (so equipped) oes the scan tool display any DTCs? Goto Step7 Goto Step 11 Does the scan tool display DTCs which begin with 7 | U-or other control module communication fault = Go to Applicable Dros? pre Goto Sep 8 'g | Does the scan tool display ECM DTCs POEOT, _ Go to Applicable P0602, P0604, POBOS, POGUE or P1621? pie Goto Stop 9 ‘| Does the scan tol display ECM DTC POSES? _ Go to Applicable ore Goto Stop 10. 40. | | there any other code in any controler that has: _ (Go to Applicable not been diagnosed? pre Goto Step 11 Te the customers concer withthe Wansmission? Goto Diagnostic ‘System Check " Transmission - CContrels in Section 5A Transmission Control System Goto Step 12 Ts the customers concern with the antilock brake Go to Diagnostic system? ‘System Check - R = ABS Contos in ‘Section 4C1 ABS! ASR Goto Stop 13, Is the customers concem with the immobilizer Go to Diagnostic system? ‘System Check - 8 = Immobilizer Controls in Section 81 Secunty and Lock | Goto Step 141A-36 Engine Control System (4JJ1) Sep ‘Actor Value(s) Yes No 7. Review the following symptoms. 2, Refer to the sppiicable symptom diagnostic table + Hard Start + Rough, Unstable, or Incorrect ile and Stalling + High idle Speed + Cuts Out + Surges + Lack of Power, Siuggishness or 4 Sponginess: = + Hesitation, Sag or Stumble + Abnormal Comaustion Noise + Poor Fuel Economy + Excessive Smoke (Black Smoke) + Excessive Smoke (White Smoke) + DPD. System Manual Regeneration Frequently + DPD System Regeneration Long Time fem Ree a Go to intermittent Did you find and correct the coneltion? System OK Coneitions. Diagnostic System Check - Engine Controls (Except Euro 4 Specification) Sep) Raton Valuels) Yes No Install a sean tool a = Goto Scan Too! Does the scan tool turn ON? Goto Step? _| Does Not Power Up 1. Turn ON the ignition, withthe engine OFF. 2. Attempt to establish communication with the listed control modules, + ECM ‘+ Transmission control module (TCM) {Smoother only} 3 + Hil start aid (HSA) control unit (if so _ equipped) + Supplemental restraint system (SRS) Control unit (if so equipped) ‘+ Immobitizer control unit (ICU) «It so cuipped Goto Scan Too! sre) Does Not Does the scan fol communicate wth all the listed Communicate with contol modes? Gotwsteps | Keyword Device Notice: ifan immobilizer system is acive the EM vil disable the fuel injection causing the engine to stall immediately after staring and energize the 3 | starter cut relay to disable cranking. Attempt to = ‘crank the engine Does the engine crank? Goto step Goto step 5 ‘Allempt to start the engine Goo Engine 4 = Cranks but Does oes the engine start and idle? Goto Step 6 Not Run Does the scan tool display EOM DTCs POESS, Problem i relating P1616 or 0167? to starting system, 5 _ Refer to Starting Goto Applicable | system in Section pre 1E Engine ElectricalEngine Control System (4JJ1) 14-37 Step ‘ston Vauets) Yer Ne Seloct Hie DTC elepay Tunaton forthe folowing control modules: + ECM + ToM (Smoother only) | *EHCU Gr s0 equipped) - + HSA contol unt (if s0 equipped) + SRS control unt (itso equipped) + ICU (ifs0 equippes) Does the scan tol display any DTCs? Goto Step 7 Goto Step 11 Doos the scan tool display DTCs which begin with 7 | U or ether contro! module communication fault Go to Applicable DTCs? ore Goto Step 8 | Sees the sean too! display ECM DTCs PO6OT _ Go Appieabie 062, PO04, PD606, POGOB or P1621? ore. Goto Stop 8 ‘| ees the scan tool display ECM DTC POSER? Go Applicable = ore, Goto Step 10 {0 | there any other code in any controler that has _ Gow Applicable not been dagnosec? ore. Goto step 11 1s the customers concem with the Wersmission Goto Diagnose syste? System Check “Transmission a - Contos in Section 5A Transmission Control System | Goto Step 12 is the customers concam withthe art-lock brake Go to Diagnoste system? System Check - 2 = ABS Controls in Section 4C1 ABS! ASR Got Step 13 Ts the customers concem with the HSA system? Goo Diagnosie 8 _ System Check- ss HSA Controls in Section HSA | Goto Step 14 Ts the customers concer wih the SRS airbag Goto Diagnostic system? System Check - 14 2 SRS Controls in Seaton 8 SRS Contr Systam | Goto Step 15 Ts the customers concem with the Immobilizer Go to Diagnostic system? System Check - 18 - Immobilizer Contes in Section 81 Socuniy and Lock| Goto Stop 181A-38 Engine Control System (4JJ1) Sep ‘Actor Value(s) Yes No 7. Review the following symptoms. 2, Refer to the sppiicable symptom diagnostic table + Hard Start + Rough, Unstable, or Incorrect ile and Stalling + High idle Speed + Cuts Out 16 + Surges - + Lack of Power, Siuggishness or Sponginess, + Hesitation, Sag or Stumble + Abnormal Comaustion Noise + Poor Fuel Economy + Excessive Smoke (Black Smoke) + Excessive Smoke (White Smoke) Go to Intermittent Die you fin and correct the conestion? system OK Gonations.Engine Control System (4JJ1) 14-39 Scan Tool Data List The Engine Scan Tool Data List contains all engine related parameters that are available on the scan tool ‘A given parameter may appear in any one of the data lists, and in some cases may appear more than once, fr in more than one data list in order to group certain related parameters together. Use the Engine Scan Too! Data List only after the following is determines: Euro 2 Specification + The Engine Controls - Diagnostic System Check is completed, + On-board diagnostics are functioning properly. ‘Scan tool values from a properly running engine may be used for comparison with the engine you are diagnosing, The Engine Sean Tool Data List represents values that would be seen on a normal running engine. Only the parameters listed below are referenced in this service manual for use in diagnosis. Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Data Value at 1700 Ile RPM Operating Conditions Engine idling or 1700 RPM/ Engine coolant temperature Is between 75 to 85°C (167 to 185°} Accelerator pedal is constent/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level Engine Speed RPM Nearly 600 RPM Nearly 1700 RPM Desired Idle Speed RPM 600 RPM 600 RPM Calculated Engine Load % Less than 25% Less than 15% Engine Coolant Temperature | __“C!°F 7510 85°C 167 1 185 | 7510 85°C) 167 to 185F Engine Coolant Temperature Vals 04 108 volts 04 to 06 valis Sensor intake Air Temperature “Orr BW ATC CIO 104 | _2OWATCI BIO 104F Intake Air Temperature Vals 741023 volts Ta102.3 vols Sensor Fuel Temperature “oF 2010 60°C/50t MOF | 2010 60GI SOT 40F Fuel Temperature Sensor Valls 08 to 23 volts 0.81023 volts Barometric Pressure KPalpst__| Nearly 100 KPal 14.5 psiat_ | Nearly 100kPal 14.5 psi at sea level sea level Barometric Pressure Sensor Volts Nearly 2.3 volts at sea level_| Nearly 2.3 vlls at sea level Boost Pressure KPalpsi | Nearly 100 kPal 14.5 psiat [Less than 115 kPal 16.7 paiat sea level sea level Boost Pressure Sensor Vols Nearly 1.0 voltat sea level | Less than 1.3 volls at sea level Desired Fuel Rail Pressure | MPa/psi ‘Nearly 30 MPa’ 4,300 psi_| More than 30 MPa’ 4.400 psi Ful Ral Prossure MPai psi | 271033 MPal3,900 psi to _| Mora than 30 MPal 4,400 psi 4,800 psi Fuel Rail Pressure Sensor Vols 7101.5 volts More than 1.6 volts FRP Regulator Command % 30t0 48% 3010 40% (Ful Rail Pressure) FRP Regulator Foodback mA 900 to 1100 mA 00 to 1000 mA (Fuel Rail Pressure) ‘Accelerator Pedal Postion % 0% 1200 20% ‘APP Sensor 1 (Accelerator Volts Nearly 0.5 volts 080 1.4 vals Padal Position} "APP Sensor 2 (Accolarator Volts Nearly 4.8 volis 3.7043 valls Padal Position) Intake Throtle Solenoid % 0% 0% Command14-40 _Engine Control System (4JJ1) Scan Tool Parameter | Units Displayed | Typical Data Value al Engine | Typical Dala Value at 1700 tale RPM Desired intake Throtle % More than 80% Wore than 90% Position Intake Throtle Position % More than 100% More than 100% Intake Thratle Position Volts More than 3.9 vols ‘More than 3.9 volls Sensor Tale Up Sensor Volts 031006 volts 031006 vols Fuel Compensation Gyi. 1 mn 60 10 5.0 mmn(varies) 0.0 ma Fuel Compensation Cyl. 2 min “6.0 10 5.0 mm"(varies) 0.0 mm’ Fuel Compensation Cyl. 3 mn “6.0 to 5.0 mm(varies) 0.0 mm’ Ful Compensation Cyl. 4 am? “5010 5.0 mm®varies) 0.0 mm? Fuel Supply Pump Status | Not Learned? Leamed Leamed Learned Rall Pressure Feedback Mode| Shutoff Mode? Feedback Mode Feedback Mode Slart Mode! Wait Mode! Wait to Restart Feedback Mode Engine Running Status | Of igniton On! Running Running ranking’ Running Vehicle Speed ‘km/h! MPH O kmh! O MPH 0 kmh’ O MPH Tgniion Key START Switch | On OF Of Off Ignition Key ON Switch ‘Onl Off On On Taniion Valage Volts 22016 30.0 vols 22010 30.0 vols Batiory Voltage Volts 22.0 130.0 vols 22.010 30.0 vols hitch Pedal Switch ‘Applied? ‘Applied or Released ‘Applied or Released Released Neal Switch Neutral in Gear Neatal Neutral Park Brake Switch ‘Applied? Applied or Released ‘Applied or Released Released Exhaust Brake Switch ‘On Of OF of Exhaust Brake Valve ‘Oni om oF oF ‘Command Exhaust Brake Gul Request | Inactive! Adve Inactive inactive fiom ABS Module Exhaust Brake Gut Request | Inactive! Active Tnadtve inactive from TOM PTO Switch ‘On Of oF of PTO Remote Throttle. % 0% 0% PTO Remote Throttle Sensor | ___Volls Less than 0.4 vols ess than 0.4 vals Engine Warm Up Switch ‘On om oF of ‘A Signal ‘On OF OF Off Refigorator Switch ‘Ov om Off OffEngine Control System (4JJ1) 14-41 ‘Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Dala Value at 1700 Ide RPM Engine Oil Level Switen | Low/ Normal Normal Normal Glow Plug Relay Command Oni Off Off Off Glow Plug Lamp Command ‘Oni Off Off Off Immobilizer Signal Received! Not Received Received Received ‘Wrong Immobilizer Signal | Received’ Not Not Received Not Received Received Immobilizer Function Yesi No Yes Yes Programmed Security Wait Time Tnactive! Time Tnactive Tnactive (hour: minute: second) Euro 3 Specification ‘Scan Tool Parameter | Urits Displayed | Typical Data Value at Engine | Typical Data Value at 1700 Idle RPM Operating Conditions: Engine 185°F/ Accelerator pedal is co instant’ Neutral or P idling or 1700 RPM/ Engine coolant temperature is between 75 to 85°C (167 to sarki Accessories OFF/ Vehicle located at sea level (Fuel Rall Pressure) Engine Speed RPM Nearly 600 RPM Nearly 1700 RPM Desired idle Speed RPM ‘600 RPM ‘600 RPM Calculated Engine Load % Less than 25% ess than 15% Engine Coolant Temperature °OrF 7510 85°C) 167 19 185F | 7510 85°C) 16710 185F Engine Coolant Temperature Volts 04 t 06 volts Oat 06 volts Sensor Intake Air Temperature “OF 720 t0 40°07 68 0 104°F 20 to 40°C) 68 to 104" Intake Air Temperature Volts 14 102.3 volts 14 t0 2.3 volts Sensor Fuel Temperature =orF 720 10 60°C) 60 10 140"F 720 t0 60°C) 50 to 140°F Fuel Temperature Sensor Volts 08 to 2.3 volts 0810 23volts Barometric Pressure kPal psi Nearly 100 KPa/ 14.5 psiat | Nearly 100 kPa 14.5 psi at sea level sea level Barometric Pressure Sensor Volts Nearly 2.3 volts ai sea level | Noarly 23 volls at sea level Boost Pressure KPal psi Nearly 100 kPa’ 14.5 psi at_| Less than 175 KPa 16.7 psi at sea level sea level Boost Pressure Sensor Volts Nearly 7.0 voltat sea level | Less than 1.3 volts at sea level Desired Fuel Rail Pressure MPal psi Nearly 30 MPa/4,300 psi_| More than 30 MPa’ 4,400 psi Fuel Rail Pressure MPal psi 27 to 33 MPal 3,900 psi to | More than 30 MPa’ 4,400 psi 4,800 psi Fuel Rail Pressure Sensor Volts 7A to 1.5 volts More than 7.6 volts FRP Regulator Command % 30 to 45% 30 10 40% (Fuel Rall Prossuro) FRP Ragulaior Feedback mA {900 to 1100 mA {B00 to 1000 mA1A-42 Engine Control System (4JJ1) Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Data Value at 1700 Ile RPM ‘Accoleraior Pedal Posiion % 0% 1210.20% APP Sensor 1 (Accelerator Volts: Nearly 0.5 volts 0.8 to 1.4 volts Pedal Position) "APP Sensor 2 (Accelerator Volts Nearly 4.5 vols 3.7 104.3 valle Pedal Position} Dosired EGR Position % 0% O% EGR Solenoid Command 1 % 0% 0% EGR Position 1 Low High Low or High Low or High EGR Position 2 Lowi High Low or High Low or High | EGR Position 3 Lowi High Low or High Low or High | Intake Throttle Solenoid % 0% 0% Command Desired Intake Throttle % More than €0% More than 90% Position Intake Throtle Position % More than 100% More than 100% Intake Throtle Position Volts More than 3.9 volts More than 3.9 volts Sensor Idle Up Sensor Volts 0.31006 volts 0.310 0.6 valts Fuel Compensation Gyi. 1 ran “516 5.0 mmovaries) 0.0 rare Ful Compensation Oyl. 2 Tan 76.010 5.0 man(varies) 0.0 mane Fuel Compensation Cyl. 3 mi “60 10 5.0 mm(varies) 0.0 mm’ Fuel Compensation Cyl. 4 mn “60 10 5.0 mm"(varies) 0.0 mm Fuel Supply Pump Status | Not Learned? Leamed Leamed Leamed Ral Pressure Feedback Mode | Shutoff Mode? Feedback Mode Feedback Mode Start Mode! Wait Mode! Wait to Restart Feedback Mode Engine Running Status | Of ignition On! Running Running ranking! Running Vehicle Speed ‘enihi MPH Okman? 0 MPH ‘Okinih/ O MPH Ignition Key START Switch ‘Oni OF Off Off Ignition Key ON Switch ‘Oni Of On On ignition Voltage Volts 22.0 1 30.0 volts 22.010 30.0 vols Batiory Vollage Volts 22015 30.0 vols 22010 80.0 vols ‘Ghuich Pedal Switch Applied? ‘Applied or Released ‘Applied or Released Released Neual Switch Neutal In Gear Neal Neutral Park Brake Switch ‘Applied! ‘Applied oF Released ‘Applied or Released Released Exhaust Brake Switch ‘Oni Of Off OffEngine Control System (4JJ1) 14-43 Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Dala Value at 1700 Idle RPM Exhaust Brake Valve ‘On! Off Of Of ‘Command Exhaust Brake Cut Request | Inactive! Active Inactive Inactive from ABS Module Exhaust Brake Cut Request | Inactive! Active Inactive Inactive from TCM ‘ASR Commanded APP % 100% 100% (Accelerator Pedal Position) PTO Switch ‘On Off Of Of PTO Remote Throttle % 0% 0% PTO Remote Throttle Sensor Volts Less than 0.4 volts ‘Less than 0.4 volts Engine Warm Up Switch On! Off Of Off ‘AIC Signal On! Off Off Off Refrigerator Switch ‘Onl Off Of Off Engine Oli Level Switch | Low/ Normal Normal Normal Glow Plug Relay Command ‘On’ Off ‘Of Off Glow Plug Lamp Command ‘Oni Off OF Off Immobilizer Signal Yesi No Yes Yes Wrong Immobilizer Signal Yes! No No No Immobilizer Function Yesi No Yes Yes Programmed ‘Seourity Wait Time Tnactivel Time Inactive Tnactive (hour: minute: ‘second} Except Euro 2 and Euro 3 Specifications Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle Typical Data Value at 1700 RPM Operating Conditions: Engine 185°F\ Accelerator pedal is co idling or 7700 RPM/ Engine coolant temperature is between 75 to 85°C (167 to ynstan¥ Neutral or Park/ Accessories OFF/ Vehicle located at sea level! DPD is not under regeneration Engine Speed RPM Nearly 600 RPM Nearly 1700 RPM Desired idle Speed RPM ‘600 RPM ‘600 RPM Calculated Engine Load % Tess than 25% Less than 15% ‘Coolant Temperature “OIF 78 t0 85°C) 167 10 185°F | 7510 ASC) 167 to 185°F Engine Coolant Temperature Volts 0.4 06 volts O4t0 06 volts Sensor Intake Air Temperature “Or 20 to 40°07 68 t0 104°F 20 to 40°C/ 68 to 104°F Intake Alr Temperature Volts T4123 volts 14 102.3 volls Sensor Fuel Temperature “OIF 720 10 60°C) 60 to HOF 720 to 60°C) 60 to 140°F Fuel Temperature Sensor Volts 08 to25 volts 081023 volts1A-44 Engine Control System (4JJ1) ‘Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Dala Value at 1700 Idle RPM MAF (Mass Air Flow) acyl More than 0.2g/cylatsea | More than 0.2 g/ cyl at sea, level level ‘Averaged MAF (Mass Air gs ‘More than 5 gi s at sea level | More than 25 g/ s at sea level Flow) MAF Sensor (Mass Air Flow) Vals Morethan 1.2 volts atsea_| More than 2.0 volts at sea level level Barometric Pressure kPal psi Neatly 100 kPa/ 14.5 psiat | Nearly 100 kPa’ 14.5 psi at sea level sea level Barometric Pressure Sensor Volts Nearly 2.3 volts at sea level | Nearly 2.3 volis at sea level Desired Turbocharger % 10 to.20% 25 t0 35% Position Desired Boost Pressure kPal psi Neatly 100 kPa 14.5 psi at_ | Less than 175 kPa/ 16.7 psi at sea level sea level Boast Pressure kPal psi Neatly 100 kPai 14.5 psiat | Less than 175 KPa/ 16.7 psi at ‘sea level sea level Boost Pressure Sensor Volts Nearly 7.0 voltat sea level | Less than 1.3 volts at sea level Desired Fuel Rail Pressure MPai psi Nearly 30 MPa/ 4,300 psi_| More than 60 MPa’ 8,700 psi Fuel Rail Pressure MPai psi 27 to 33 MPal 3,900 psi to_| More than 60 MPa’ 8,700 psi 4,800 psi Fuel Rail Pressure Sensor Volts 1410 15 vols More than 2.0 volts FRP Regulator Command % 30 to 45% 30 t0 40% (Fuel Rall Pressure) FRRP Regulator Commanded | mm/sec More than 650 mm/sec | More than 1600 mm see Fuel Flow FRP Ragulaior Feedback mA {900 to 1100 mA {800 to 1000 mA Current (Fuel Rail Pressure) ‘Aacelerator Pedal Position % 0% 1216 20% ‘APP Sensor 1 (Accelerator Valts Nearly 0.5 volts OBto tavalts Pedal Position) ‘APP Sensor 2 (Accelerator Vals: Nearly 4.5 volts 371043 volts Pedal Position} Desired EGR Position % Less than 95% Less than 55% EGR Position 1 % Less than €5% Less than 55% EGR Position 1 Low! High Tow or High Low or High EGR Position 2 Low/ High Low oF High Low or High EGR Position 3 Low! High Low oF High Low or High Trlake Throttle Solenoid % O% 0% ‘Command Desired Intake Throttle % More than 90% ‘More than 90% Position Intake Throitle Position % More than 100% Mare than 100% Intake Throttle Position Valls More than 3.9 volts ‘Mora than 3.9 volts Sensor