Manual Motor 4ja1

WORKSHOP MANUAL
TF SERIES
4JA1/4JH1-TC
ENGINE
SECTION 6
TROUBLESHOOTING 6 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE BASIC INSPECTION PROCEDURE ... 6 2 1. HARD STARTING ........................... 6 3 1-1.Starter Motor Inoperative ......... 6 3 1-2. Starter Motor Operates But Engine Does Not Turn Over .......... 6 3 1-3. Engine Turns Over But Does Not Start Engine ............................. 6 4 2. UNSTABLE IDLING ........................ 6 5 3. INSUFFICIENT POWER ................. 6 6 4. EXCESSIVE FUEL CONSUMPTION................................. 6 7 5. EXCESSIVE OIL CONSUMPTION.. 6 8 6. OVERHEATING............................... 6 9 7. WHITE EXHAUST SMOKE ............. 6 9 8. DARK EXHAUST SMOKE .............. 6 10 9. OIL PRESSURE DOES NOT RISE . 6 11 10. ABNORMAL ENGINE NOISE ....... 6 12 10-1. Engine Knocking.................... 6 12 10-2. Gas Leakage Noise ................ 6 12 10-3. Continuous Noise .................. 6 13 10-4. Slapping Noise ....................... 6 13 10-5. Excessive Turbocharger Noise ............................................... 6 14 PAGE 11. ROTATING PART WEAR OF TURBOCHARGER ............................. 6 14 12. OIL LEAKAGE FROM TURBOCHRGER ............................... 6 15 13. INSUFFICIENT ACCELERATION AND/OR LACK OF POWER DUE TO TURBOCHARGER ....................... 6 15 14. BATTERY CHARGING AND NOISE PROBLEM.............................. 6 16 14-1. Battery No Charging .............. 6 16 14-2. Battery Overcharging ............ 6 16 14-3. Battery Under Charging......... 6 17 14-4. Battery Unstable Charging Current ............................................ 6 17 14-5. Charging System Noise......... 6 18 15. STARTER MOTOR PROBLEM..... 6 19 15-1. Starter Motor Pinion Engages to Ring Gear But Engine Does Not Turn Over ................................. 6 19 15-2. Incorrect Pinion And Ring Gear Engagement .......................... 6 19 15-3. Starter Motor Continues To Run After The Starter Switch Is Turned Off....................................... 6 20 15-4. Excessive Commutator Sparking.......................................... 6 20
6 2 TROUBLESHOOTING
Basic Inspection Procedure

Follow the under inspection procedure, when the problem vehicle comes workshop. Step 1 Inspection point Check the check engine lamp Inspection result Is the check engine lamp turn ON ? YES Go to section 6E On Board Diagnostic (OBD) System Check" Re-charge the battery or replace the battery Replenish the engine coolant Replenish the engine oil Clean or replace Return normal condition Re-adjust the tension or replace NO
Go to Step 2
The battery fluid level and the Was the problem found? gravity
Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7
3 4 5 6 7
The engine coolant capacity The engine oil level The air cleaner element
Was the problem found? Was the problem found? Was the problem found?
The piping fixing condition (oil, Was the problem found? vacuum and fuel piping) The drive belt tension and break Was the problem found?
Go to Step 8
Go to section 6E On Board Was the problem found? Diagnostic (OBD) System Check Go to mechanical Was the problem found? troubleshooting chart
Verify repair Verify repair
Go to Step 9
TROUBLESHOOTING 6 3
1. Hard Starting
Inspect the following items before diagnosis. 1. The battery conditions. The terminal connection condition. The battery charge condition or battery power weakness. 2. The fan belt loosen or broken. 3. The main fuse condition (open or not). 4. Fuel quantity level. 11 Starter motor inoperative Step 1 Action Check the starter switch. Does the starter switch work? Check the starter relay. Does the starter relay work? Check the magnetic switch. Does the magnetic switch work? Value(s) Go to Step 2 2 Go to Step 3 3 Yes No Repair or replace the starter switch Repair or replace the starter relay Repair or replace the magnetic switch Replace the pinion gear Repair or replace the brush or brush spring
Go to Step 4 4 5 Check the pinion gear condition on the starter motor. Was the condition normal? Check the brush wear or brush spring weakness. Was the condition normal? Go to Step 5 Replace the starter motor assembly
1-2 Starter motor operates but engine does not turn over Step 1 Action Check the engine internal seizure. Was the engine seized? Value(s) Repair or replace seized parts Yes No Check other DTC by Tech 2 and go to indicated DTC
6 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine

Incase of the fuel not being delivered to the injection pump Step 1 Action Check clogged, damaged the fuel piping or the connector loosen. Was any problem found? Was the over flow valve on the fuel filter closed? Value(s) Repair replace problem parts. Repair replace the over flow valve Replace the fuel filter element Go to Step 5 Go to indicated DTC Go to Step 2 Yes No
Go to Step 3
Was the fuel filter element clogged?
Go to Step 4 Bleed the air Solved
4 5
Was the fuel line air bled? Are any DTC stored?
Incase of the fuel is being delivered to the injection pump Step 1 2 3 Action Was the water contain in the fuel? Was the fuel line air bled? Was the injection spray condition complete? Value(s) Go to Step 4 4 Was the injection nozzle injection starting pressure OK? Was the injection nozzle sticking? Are any DTC stored? (See below) Go to Step 5 5 6 Replace the injection nozzle Go to indicated DTC Replace the injection nozzle Go to Step 6 Solved Replace the injection nozzle Yes Replace the fuel Go to Step 5 No Go to Step 2 Bleed the air
Injection nozzle opening pressure 2 1st = 19.5 MPa (199 kg/cm , 2828 psi)
TROUBLESHOOTING 6 5
2. Unstable Idling
Step 1 2 Action Was the fuel line air bled completely? Was the fuel line leakage or blockage found? Value(s) Yes Go to Step 3 Repair or replace relation parts. Replace the fuel Replace the fuel filter element No Bleed the air
Go to Step 4 Go to Step 5
3 4
Was the water contained in the fuel? Was the fuel filter element clogged?
Go to Step 6 Replace the injection nozzle Go to Step 8
Was the injection starting pressure or the injection spray condition OK? Was the injection nozzle sticking? Check the throttle valve condition. Was the idling port clogged in the throttle valve? Was the valve clearance improper adjusted?
(See below) Go to Step 7
6 7
See Step 6
Replace the injection nozzle Repair or replace the throttle valve
Go to Step 9
0.4 mm (0.016 in) both intake and exhaust valves 3,040 kPa 2 (31 kg/cm , 441 psi) at 200rpm
Adjust the valve clearance
Go to Step 10 Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and valve seat Solved
Was the compression pressure OK?
Go to Step 11 10 Are any DTC stored? Go to indicated DTC
Injection nozzle opening pressure 2 1st = 19.5 MPa (199 kg/cm , 2828 psi)
6 6 TROUBLESHOOTING
3. Insufficient Power
Step 1 Action Was the air cleaner element condition OK? (Clogged or not) Value(s) Yes No Clean or replace the air cleaner element.
Go to Step 2 2 Was the intake air leakage found from intake system? Repair or replace the intake air system.
Go to Step 3 Clean or replace the fuel filter element.
Was the fuel filter element condition OK? (Clogged or not) Check the fuel injection pipes. Does the injection pipes have obstruction or any damage? Was the water contained in the fuel? Was the injection nozzle pressure or spray pattern normal?
Go to Step 4
Repair or replace the fuel injection pipes. Replace the fuel
Go to Step 5 Go to Step 6 Readjust the injection nozzle pressure or replace the nozzle. Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and valve seat
5 6
Go to Step 7 7 Was the compression pressure OK? 3.0 MPa 2 (31.0 kg/cm , 441 psi) at 200 rpm
Go to Step 8 8 Was the exhaust pipe clogged? Repair or replace the exhaust pipe. Repair or replace the exhaust system. Replace the hose.
Go to Step 9
Was the exhaust gas leakage found from exhaust system?
Go to Step 10 Go to Step 11 Replace the turbocharger assembly. Replace the turbocharger assembly. Solved
10 11
Was the waste gate control actuator hose broken or cracked? Was the waste gate working completely?
Go to Step 12 12 Was turbocharger working completely? Go to Step 13 13 Are any DTC stored? Go to indicated DTC
TROUBLESHOOTING 6 7
4. Excessive Fuel Consumption

Step 1 Action Was the air cleaner element clogged? Value(s) Yes Clean or replace the air cleaner element. Repair or replace the air intake side of the turbocharger. Go to Step 4 4 Was there the fuel leakage? Repair or replace the fuel leakage part. No
Go to Step 2
Was the air leakage found from the air intake side of the turbocharger?
Go to Step 3 Replace the turbocharger
Was the turbocharger working completely?
Go to Step 5 Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and valve seat
Was the compression pressure OK?
3.0 MPa 2 (31.0 kg/cm , 441 psi) at 200 rpm
Go to Step 6 6 Was the injection nozzle pressure or spray pattern normal?
Go to Step 7 7 Are any DTC stored? Go to indicated DTC
Replace the injection nozzle Solved
6 8 TROUBLESHOOTING
5. Excessive Oil Consumption

Step 1 Action Does the air cleaner element conditon OK? (Clogged or not) Value(s) Yes No Clean or replace the air cleaner element
Go to Step 2 2 Does PCV (Positive Crankcase Ventilation) Valve has problem? Was the oil pressure value more than normal value? Repair or replace the relation parts. Repair or replace the oil relief valve Replace the failure part. Replace the wrong gasket Replace the worn part. Replace the oil seal. Repair or replace the oil drain pipe. Clean the center housing Replace the turbocharger Go to indicated DTC
Go to Step 3
Less than 588 kPa (6.0 2 kg/cm , 85 psi)
Go to Step 4 Go to Step 5 Go to Step 6
4 5 6
Inspect the front and rear crankshaft oil seal. Was the oil leakage found? Was the oil leakage found from any gasket? Inspect the valve stem seal, the valve stem and the valve guide for worn. Were any worn found? Was the oil leakage found from the turbocharger oil seal? Was the oil drain pipe of the turbocharger restricted?
7 8
Go to Step 9 Go to Step 10 Go to Step 11 Solved
9 10 11
Was the oil drain passage in the turbocharger center housing restricted? Does turbine wheel has any impact damage? Are any DTC stored?
TROUBLESHOOTING 6 9
6. Overheating
Step 1 2 Action Was the engine coolant level OK? Was the water leakage or the radiator restriction found? (Include radiator cap) Was the fan belt slippage found? Value(s) Go to Step 2 Repair or replace the leakage part. Tension or replace the fan belt. Yes No Replenish the coolant
Go to Step 3
Go to Step 4 Replace the fan clutch assembly.
Was the fan clutch working completely?
Go to Step 5
Was the oil leakage found from fan clutch?
Replace the fan clutch assembly Go to Step 7
Go to Step 6 Replace the thermostat. Replace the water pump assembly.
6 7
Was the thermostat working normally? Was the water pump working OK?
Go to Step 8
Was the restriction by the foreign materials in the cooling system found? For example, clog the water hose between the cylinder body and radiator etc.. Was the water leakage found from the sealing cap on the cylinder body?
Clean or replace the clog part. Replace the sealing cap or replace the cylinder body. Go to indicated DTC.
Go to Step 9
Go to Step 10 Solved
10
Are any DTC stored?
7. White Exhaust Smoke

Step 1 Action Was the compression pressure OK? Value(s) 3.0 MPa 2 (31.0 kg/cm , 441 psi) at 200 rpm Yes No Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and relation parts. Repair or replace the PCV valve. Replace the turbocharger. Solved
Go to Step 2 2 Was the PCV (Positive Crankcase Ventilation) valve working completely? Was the turbocharger working completely? Are any DTC stored? Go to Step 3 3 4 Go to Step 4 Go to indicated DTC
6 10 TROUBLESHOOTING
8. Dark Exhaust Smoke

Step 1 Action Was the air cleaner element normal condition? Value(s) Yes No Clean or replace the air cleaner element Go to Step 3
Go to Step 2 2 3 Was the EGR valve sticking? Was the injection nozzle pressure or the injection spray pattern OK? Replace the EGR valve
Go to Step 4 4 5 Was the oil leakage found from the turbocharger oil seal? Was the oil drain pipe of the turbocharger restricted? Replace the oil seal Repair or replace the oil drain pipe Clean the center housing Replace the turbocharger Repair or replace the relation parts Go to indicated DTC
Replace the injection nozzle Go to Step 5
6 7 8
Was restricted the oil drain passage in the turbocharger center housing restricted? Does turbine wheel has any impact damage? Does PCV (Positive Crankcase Ventilation) Valve has problem? Are any DTC stored?
Go to Step 9 Solved
TROUBLESHOOTING 6 11
9. Oil Pressure Does Not Rise

Step 1 Action Was the oil pressure warning lamp working OK? Value(s) Go to Step 2 2 3 Does the oil filter element clog? Does the relief valve open? Replace the oil filter element Repair or replace the relief valve Clean or replace the oil strainer Yes No Replace the oil pressure warning lamp Go to Step 3
Go to Step 4
Does the oil strainer clog?
Go to Step 5 Repair or replace the oil pump.
Was the oil pump working OK? (The pump related parts worn etc.) Was the rocker arm and/or relation parts worn?
Go to Step 6
Replace the rocker arm and/or relation parts Replace the camshaft and/or relation parts Replace the crankshaft and/or relation parts Go to indicated DTC
Go to Step 7
Was the camshaft and/or relation parts worn?
Go to Step 8
Was the crankshaft and/or relation parts worn?
Go to Step 9 Solved
Are any DTC stored?
Table of pressure unit Pressure Resistance Electric current kPa (kg/cm ) ohm A
2
100 (1.0) 81 63.5
980 (10.0) 30 106.7
10. Abnormal Engine Noise

101 Engine knocking Step 1 Action Was the injection nozzle pressure or injection spray pattern OK? Value(s) Yes No
Go to Step 2 2 Was the compression pressure OK? 3.0 MPa 2 (31.0 kg/cm , 441 psi) at 200 rpm
Replace the injection nozzle Replace the cylinder head gasket or piston ring Solved
Go to Step 3 Go to indicated DTC
Are any DTC stored?
102 Gas leakage noise Step 1 Action Was the exhaust pipe loose or broken? Value(s) Yes Retighten or replace the exhaust pipe Retighten or replace the exhaust manifold. Or replace the exhaust manifold gasket Retighten or replace the injection nozzle fixing bolt Replace the cylinder head gasket Go to indicated DTC No
Go to Step 2
Was the exhaust manifold loose?
Go to Step 3
Was the injection nozzle loose?
Go to Step 4
Was the cylinder head gasket broken?
Go to Step 5 Solved
Are any DTC stored?
TROUBLESHOOTING 6 13 103 Continuous noise Step 1 Action Was the fan belt tension OK? Value(s) 9 13 mm (0.35 0.51 in) Adjust the fan belt tension. Go to Step 3 Yes No
Go to Step 2 2 3 Was the cooling fan loose? Was noise coming from the generator? Tighten the cooling fan Repair or replace the generator and/or the vacuum pump Replace the water pump Readjust the valve clearance. Go to indicated DTC
4 5
Was noise coming from the water pump? Was noise coming from the cylinder head cover?
Go to Step 6 Solved
Are any DTC stored?
10-4 Slapping noise Step 1 2 Action Was noise coming from the cylinder head cover? Were valve clearances correct? Value(s) 0.4 mm (0.016 in) both intake and exhaust Replace the worn parts Replace the worn parts Replace the worn or damaged parts Go to indicated DTC Go to Step 8 Yes Go to Step 2 Adjust the valve clearances Replace the rocker arms Tighten the fixing bolt. Go to Step 6 Replace the worn parts No Go to Step 4
Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 10 Go to Step 7
3 4 5 6 7
Were the rocker arms damaged? Was the flywheel fixing bolt loose? Was noise coming from the cylinder body? Inspect the crankshaft bearing and/or crankshaft. Was the crankshaft bearing and/or crankshaft worn? Inspect the connecting rod bearing and/or crankpin. Was the connecting rod bearing and/or crankpin worn? Inspect the connecting rod small end bushing and/or piston pin. Was the connecting rod small end bushing and/or piston pin worn? Inspect the piston and/or cylinder liner. Was the piston and/or cylinder liner worn or damaged? Are any DTC stored?
Go to Step 9
Go to Step 10 Solved
10
6 14 TROUBLESHOOTING 10-5 Excessive turbocharger noise The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the turbocharger, no necessary any actions. Step 1 2 3 Was the excessive turbocharger? Action noise coming from the Value(s) Go to Step 2 Tighten the loose parts Replace the damaged gasket. Replace the turbocharger. Replace the turbocharger. Replace the turbocharger. Clean or replace the turbocharger. Repair or replace the oil feed pipe. Replace the turbocharger. Go to indicated DTC Go to Step 10 Go to Step 3 Yes No
Inspect the fixing bolts and bands. Was any problem found? Was the intake or exhaust system gasket damaged?
Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7
4 5 6 7
Inspect rotation parts condition. Was the turbine wheel rotation rough? Inspect the turbine wheel. Was the turbine wheel rubbing against housing? Was the turbine wheel damaged? Were there carbon deposits in the turbine or compressor housing? Inspect the oil supply condition. Was the oil feed pipe clogged? Was the turbine shaft bearing worn? Are any DTC stored?
Go to Step 8
Go to Step 9 Go to Step 10 Solved
9 10
11. Rotating Part Wear of Turbocharger

Step 1 2 Action Inspect engine oil. Was it contaminated with foreign materials? Was the recommended engine oil grade/viscosity being used? Value(s) API CD or ISUZU genuine/ 10W30 Go to Step 3 3 Was the oil feed pipe restricted? Clean or replace the oil feed pipe Replace the oil seal Clean center housing or replace the turbocharger Replace the turbocharger Go to indicated DTC Yes Replace the engine oil No Go to Step 2
Replace the engine oil
4 5
Was the oil seal of turbocharger defective? Was the center housing oil drain passage clogged?
6 7
Was there oil sludge and/or coking on the turbine shaft? Are any DTC stored?
12. Oil Leakage from Turbocharger

Step 1 Action Inspect the oil leakage area. Was the oil feed pipe eye bolt loose or the gasket broken? Were the V band fixing faces tight? Value(s) Yes Tighten the eye bolt or replace the gasket. Tighten band or replace the turbocharger Replace the turbocharger Tighten the bolt and/or hose clamp. Go to indicated DTC No
Go to Step 2
3 4
Was there oil leakage from the flange of the turbine housing? Was there oil leakage from the flange of compressor housing? Are any DTC stored?
Go to Step 5 Solved
13. Insufficient Acceleration and/or Lack of Power due to turbocharger

Step 1 Action Inspect the air or exhaust route. Was the air and/or exhaust gas piping loose? Inspect the work of waste gate valve control. Was there rust on the linkage rod or pin of the waste gate valve? Was air leakage found from the actuator piping? Value(s) Yes Tighten flange bolts or hose clamp. Replace the turbocharger Repair or replace the actuator pipe or hose/ Replace the turbocharger Replace the turbocharger Replace the turbocharger Go to indicated DTC No
Go to Step 2
Go to Step 3
Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Solved
4 5 6 7
Inspect the inside of the turbocharger. Was the turbine shaft end nut loose? Were the turbine blades bent? Was the turbine wheel rubbing against housing? Are any DTC stored?
14. Battery Charging and Noise Problem

Visual/physical check the following items before diagnosis. The drive belt tension. The battery terminals connection condition. The ground connection condition. The generator and the battery fastener condition. The battery fluid level and specific gravity. 14-1 Battery No Charging Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the brush contact condition on the generator. Was there poor contact between the brush and the slip ring? Inspect the stator coil on the generator. Was there an open circuit or the scorching on the stator coil? Inspect the rotor coil on the generator. Was there an open circuit or the scorching on the rotor coil? Inspect the rectifier on the generator. Was the rectifier defective? Inspect the IC regulator. Was the IC regulator defective? Are any DTC stored? Repair or replace the brush and/or the slip ring. Replace the stator coil. Replace the rotor coil. Replace the rectifier Replace the IC regulator. Go to indicated DTC. Go to Step 5 Go to Step 6 Go to Step 7 Solved Yes No Go to visual/physical check
Go to Step 3
Go to Step 4
5 6 7
14-2 Battery Overcharging Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 3 4 Inspect the terminal circuit. Were the B and F terminals shorted? Check the regulating voltage. Was the IC regulator voltage excessive? Are any DTC stored? Repair the short circuit. Replace the IC regulator. Go to indicated DTC. Yes No Go to visual/physical check Go to Step 3 Go to Step 4 Solved
TROUBLESHOOTING 6 17 14-3 Battery Under Charging Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the brush contact condition on the generator. Was there intermittent contact between the brush and the slip ring? Inspect the rotor coil on the generator. Was there a short circuit in the rotor coil? Inspect the stator coil on the generator. Was there an open circuit or the short circuit on the stator coil? Inspect the rectifier on the generator. Was the rectifier defective? Inspect the IC regulator on the generator. Was the IC regulator defective? Was the electrical load excessive? Repair or replace the brush holder assembly. Repair or replace the rotor coil. Repair or replace the stator coil. Replace the rectifier Replace the IC regulator. Replace more higher capacity generator. Go to indicated DTC. Yes No Go to visual/physical check
Go to Step 3
Go to Step 4
5 6 7
Go to Step 8 Solved
Are any DTC stored?
14-4 Battery Unstable Charging Current Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the brush contact condition on the generator. Was there poor contact between the brush and the slip ring? Inspect the rotor coil on the generator. Was there the short circuit or an open circuit in the rotor coil? Inspect the stator coil on the generator. Was there an open circuit or the short circuit in the stator coil? Inspect the connection between the rectifier and stator coil on the generator. Was there a loose connection between the rectifier and stator coil ? Inspect the IC regulator on the generator. Was the IC regulator defective? Are any DTC stored? Repair or replace the brush and/or the slip ring. Repair or replace the rotor coil. Repair or replace the stator coil. Repair the loose connection. Replace the IC regulator. Go to indicated DTC. Yes No Go to visual/physical check
Go to Step 3
Go to Step 4
Go to Step 5
6 7
6 18 TROUBLESHOOTING 14-5 Charging System Noise Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Was there intermittent noise or continuous noise and that could be identified clearly by increasing and decreasing engine speed? Was there a growling sound and does this sound stop when the connector was disconnected? Was intermittent sound heard when the generator was running? Was frictional sound heard when generator was running? Are any DTC stored? Replace the bearing. Replace the stator coil. Replace the brush and/or slip ring. Clean the slip ring or replace the brush. Go to indicated DTC. Go to Step 3 Go to Step 4 Yes No Go to visual/physical check
3 4
Go to Step 5
Go to Step 6 Solved
15. Starter Motor Problem

Visual/physical check the following items before diagnosis. The battery terminals connection condition. The ground connection condition. The starter motor or the battery fastener condition. The battery fluid level and specific gravity. 15-1 Starter motor pinion engages to ring gear but engine does not turn over Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Check the contact condition between the brush and the commutator. Was the brush and the commutator contact intermittent? Were the brush and the commutator contact faces dirty? Was the pinion clutch slipped? Inspect the armature field coil. Was there an open circuit or a short circuit in the armature field coil? Are any DTC stored? Replace the brush or repair the commutator. Clean contact face Replace the pinion clutch Repair or replace the armature field coil. Go to indicated DTC. Yes No Go to visual/physical check
Go to Step 3
4 5
Go to Step 6 Solved
15-2 Incorrect pinion and ring gear engagement Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the pinion and the ring gear teeth. Were the pinion and/or the ring gear teeth worn or broken? Inspect the pinion gear return movement. Was the pinion gear return movement incorrect? Replace the wron parts. Adjust or replace the movement parts. Go to indicated DTC. Go to Step 3 Yes No Go to visual/physical check
Go to Step 4 Solved
Are any DTC stored?
6 20 TROUBLESHOOTING 15-3 Starter motor continues to run after the starter switch is turned off Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the magnetic switch contact point. Was the contact point seized? Repair or replace the magnetic switch. Replace the starter switch. Go to indicated DTC. Yes No Go to visual/physical check
3 4
Inspect the starter switch. Was the starter switch defective? Are any DTC stored?
15-4 Excessive commutator sparking Step 1 Action Was Visual/Physical Check" performed. Value(s) Go to Step 2 2 Inspect the contact condition between the brush and the commutator. Was the brush and the commutator contact intermittent? Was there the slag accumulation on the contact face? Replace the brush or repair the commutator. Clean the contact face or replace the brush. Repair the brush holder Repair or replace the commutator. Clean and repair Replace the bearing Go to indicated DTC. Yes No Go to visual/physical check
Go to Step 3
4 5
Was the brush holder loose? Inspect the commutator. Was there excessive wear or pitting? Was there loose the solder on the commutator? Inspect the armature shaft. Was the run-out of armature shaft outside the standard value due to worn bearing ? Are any DTC stored?
6 7
Go to Step 8 Solved
ENGINE MECHANICAL 6A 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE Main Data and Specifications ....................................................................................... 6A Torque Specifications ................................................................................................... 6A Standard Bolts ........................................................................................................... 6A Special Parts Fixing Nuts and Bolts ........................................................................ 6A 4 8 8 9
Recommended Liquid Gasket ...................................................................................... 6A - 22 LOCTITE Application Procedure .................................................................................. 6A - 23 Servicing......................................................................................................................... 6A - 24 Model Identification ................................................................................................... 6A - 24 Air Cleaner .................................................................................................................. 6A - 24 Lubricating System .................................................................................................... 6A - 24 Fuel System ................................................................................................................ 6A - 25 Cooling System .......................................................................................................... 6A - 27 Valve Clearance Adjustment ..................................................................................... 6A - 31 Compression Pressure Measurement...................................................................... 6A - 32 General Description....................................................................................................... 6A- 36 Removal and Installation............................................................................................... 6A- 37 Removal ...................................................................................................................... 6A- 37 Installation .................................................................................................................. 6A- 40 Coolant Replenishment.......................................................................................... 6A- 41 Engine Warm-Up..................................................................................................... 6A- 41 Engine Repair Kit........................................................................................................... 6A- 42 Engine Overhaul ............................................................................................................ 6A- 43 Removal ...................................................................................................................... 6A- 43 External Parts ......................................................................................................... 6A- 43
6A 2 ENGINE MECHANICAL
Disassembly ............................................................................................................... 6A- 47 Internal Parts........................................................................................................... 6A- 47 Major Components.............................................................................................. 6A- 47 Minor Components ............................................................................................. 6A- 56 Rocker Arm Shaft and Rocker Arm................................................................ 6A- 56 Cylinder Head .................................................................................................. 6A- 57 Piston and Connecting Rod ........................................................................... 6A- 59 Inspection and Repair................................................................................................ 6A- 61 Cylinder Head ......................................................................................................... 6A- 61 Rocker Arm Shaft and Rocker Arm....................................................................... 6A- 68 Cylinder Body ......................................................................................................... 6A- 69 Camshaft ................................................................................................................. 6A- 77 Crankshaft and Bearing ......................................................................................... 6A- 79 Crankshaft Bearing Selection................................................................................ 6A- 83 Crankshaft Pilot Bearing........................................................................................ 6A- 85 Flywheel and Ring Gear......................................................................................... 6A- 85 Piston....................................................................................................................... 6A- 86 Cylinder Head Gasket Selection............................................................................ 6A- 88 Connecting Rod ...................................................................................................... 6A- 90 Idler Gear Shaft and Idler Gear.............................................................................. 6A- 91 Timing Gear Case Cover ........................................................................................ 6A- 91 Reassembly ................................................................................................................ 6A- 93 Internal Parts........................................................................................................... 6A- 93 Minor Component ............................................................................................... 6A- 93 Rocker Arm Shaft and Rocker Arm................................................................ 6A- 93 Cylinder Head .................................................................................................. 6A- 94 Piston and Connecting Rod ........................................................................... 6A- 96 Positive Crankcase Ventilation (PCV) Valve ................................................. 6A- 99 Major Component................................................................................................ 6A- 101 Installation .................................................................................................................. 6A- 118 External Parts ......................................................................................................... 6A- 118 Lubrication System........................................................................................................ 6A- 126
Lubricating Flow ........................................................................................................ 6A- 126 Oil Pump and Oil Filter .............................................................................................. 6A- 127 Oil Pump ..................................................................................................................... 6A- 128 Disassembly............................................................................................................ 6A- 128 Inspection and Repair ............................................................................................ 6A- 129 Reassembly............................................................................................................. 6A- 130 Oil Filter and Oil Cooler ............................................................................................. 6A- 131 Disassembly............................................................................................................ 6A- 131 Inspection and Repair ............................................................................................ 6A- 132 Reassembly............................................................................................................. 6A- 133 Inter Cooler .................................................................................................................... 6A- 135 Removal .................................................................................................................. 6A- 136 Installation .............................................................................................................. 6A- 136 Special Tools.................................................................................................................. 6A- 137
MAIN DATA AND SPECIFICATIONS

Engine model Item Engine type Combustion chamber type Cylinder liner type Timing gear train system No. of cylinders-bore stroke No. of piston rings Total piston displacement Compression ratio (to 1) Compression pressure Engine weight (dry) Fuel injection order Fuel injection timing BTDC Specified fuel type Idling speed Valve clearances (At cold): Intake Exhaust Intake valves Exhaust valves Fuel system Injection pump type Governor type Injection nozzle type Injection nozzle opening pressure Mpa(kg/cm /psi)
2
4JA1T (L)
4JA1TC
Four-cycle, overhead valve, water cooled Direct injection Dry type, chrome plated Gear drive mm (in)
3 3
4 93 92 (3.66 3.62) Compression ring: 2 / Oil ring: 1
cm (in )
2
2,499(152.4) 18.5
Mpa(kg/cm /psi) kg (lb)
3.0 (31.0/441) 200 rpm Approximately 239 (527) 134-2
deg rpm mm (in) mm (in) deg deg deg deg
8 730 25 (A/C Off) 850 25 (A/C ON) 0.4 (0.016) 0.4 (0.016) 24.5 55.5 54.0 26.0 BOSCH distributor VE type Mechanical (Half all speed type)
JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
Open at (BTDC) Close at (ABDC) Open at (BBDC) Close at (ATDC)
BOSCH distributor VP44 type Electronically controled
Hole with 5 orifices
1st 19.1 (195 / 2,773) 2nd (Reference) 25.5~27.0 (260~275 / 3,702~3,920)
1st 19.0 (194 / 2,755) 2nd (Reference) 34.0~35.5 (347~362 / 4,936~5,154)
Main fuel filter type Lubricating system Lubricating method Specified engine oil (API grade)
Cartridge paper element and water separator
Pressure circulation ISUZU genuine 10W 30 (API CD of ACEA B2/B3)
ENGINE MECHANICAL 6A 5 Engine model Item Oil pump type Oil filter type Oil capacity Oil cooler type Cooling system Water pump type Thermostat type Air cleaner type Battery type/voltage No. of units Centrifugal Wax pellet with jiggle valve Dry paper element Viscous paper element 80D26L 1 95D31L 1 (OPT) Generator capacity V-A 12 60 12 80 Starter motor output Turbocharger model Turbine type Compressor type *IHI : Ishikawajima-Harima Heavy Industries., Ltd. V-Kw 12 2.3 *IHI RHF 4H Mixed flow type Backward & rake lit (US/UK gal)
4JA1T (L) Gear
4JA1TC
Cartridge paper element 6.2 (1.64/1.36) Water cooled

Engine model Item Engine type Combustion chamber type Cylinder liner type Timing gear train system No. of cylinders-bore stroke No. of piston rings Total piston displacement Compression ratio (to 1) Compression pressure Engine weight (dry) MPa(kg/cm /psi) kg (lb)
2
4JH1TC Four-cycle, overhead valve, water cooled Direct injection Dry type, chrome plated Gear drive
mm (in)
4 95.4 104.9 (3.76 4.13) Compression ring: 2 / Oil ring: 1
liter
2,999 18.3 3.0 (31.0/441) 200 rpm MT : Approximately 249 (549) AT : Approximately 236 (520)
Fuel injection order Specified fuel type Idling speed rpm
134-2 JIS No.2, DIN/EN590, GB252-1944 Diesel fuel 700 H 25 (A/C OFF) 800 H 25 (A/C ON)
Valve clearances (At cold): Intake Exhaust Intake valves Exhaust valves Fuel system Injection pump type Injection nozzle type Injection nozzle opening pressure Open at (BTDC) Close at (ABDC) Open at (BBDC) Close at (ATDC)
mm (in) mm (in) deg deg deg deg
0.4 (0.016) 0.4 (0.016) 24.5 55.5 54.0 26.0 BOSCH distributor VP44 type Hole with 5 orifices
MPa(kg/cm /psi) Main fuel filter type Lubricating system Lubricating method Specified engine oil (API grade) Oil pump type Oil filter type Oil capacity lit (US/UK gal)
1st 19.5 (199/2,828) 2nd (Reference) 34.3~35.8 (350~365/4,980~5,197) Cartridge paper element and water separator Pressure circulation ISUZU genuine 10W 30 (API CD of ACEA B2/B3) Gear Cartridge paper element 6.2 (1.64/1.36) (For 4 2) 7.0 (1.85/1.54) (For 4 4)
Oil cooler type
Water cooled
ENGINE MECHANICAL 6A 7 Engine model Item Cooling system Water pump type Thermostat type Air cleaner type Battery type/voltage No. of units Centrifugal Wax pellet with jiggle valve Dry paper element (except for Euro3 spec) Viscous paper element (for Euro3 spec) 80D26L 1 95D31L 1 (OPT) 75D26R 2 (OPT for EC, MT) 80D26R 2 (OPT for EC, AT) Generator capacity Starter motor output Turbocharger model Turbine type Compressor type *IHI: Ishikawajima-Harima Heavy Industries., Ltd. V-A V-Kw 12 60/12 80 12 2.3 *IHI RHF5 Mixed flow type Radial-inflow Backward & rake type Radial-outflow
4JH1TC
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified. Nm (kgm/lbft)
Strength Class Bolt Identification
4.8 (4T)
(7T) Refined
8.8
Non-Refined
9.8 (9T)
Bolt Diameter Pitch (mm)

M 6 1.0 M 8 1.25 M 10 1.25 M 12 1.25 M 14 1.5 M 16 1.5 M 18 1.5 M 20 1.5 M 22 1.5 M 24 2.0 * M 10 1.5 * M 12 1.5 * M 14 2.0 * M 16 2.0 5.88 1.96 (0.60 0.20/4.33 1.44) 12.74 4.90 (1.30 0.50/9.40 3.62) 27.44 6.86 (2.80 0.70/20.25 5.06) 61.25 12.25 (6.25 1.25/45.21 9.04) 95.55 19.11 (9.75 1.95/70.52 14.10) 130.34 26.46 (13.30 2.70/96.20 19.53) 188.16 37.24 (19.20 3.80/138.87 27.49) 257.74 51.94 (26.30 5.30/190.23 38.33) 332.22 81.34 (33.90 8.30/245.20 60.03) 448.84 90.16 (45.80 9.20/331.27 66.54) 26.46 6.86 (2.70 0.70/19.53 5.06) 56.84 11.76 (5.80 1.20/41.95 8.68) 89.18 17.64 (9.10 1.80/65.82 13.02) 124.46 24.50 (12.70 2.50/91.86 18.08) 7.35 2.45 (0.75 0.25/5.43 1.80) 17.15 5.39 (1.75 0.55/12.66 4.00) 36.75 9.31 (3.75 0.95/27.12 6.87) 75.95 15.19 (7.75 1.55/56.06 11.21) 116.13 23.03 (11.85 2.35/85.71 17.00) 169.54 34.30 (17.30 3.50/125.13 25.32) 244.02 49.00 (24.90 5.00/180.10 36.17) 337.12 67.62 (34.40 6.90/248.82 49.41) 453.25 90.65 (46.25 9.25/334.53 66.91) 570.36 140.14 (58.20 14.30/420.96 103.43) 36.26 8.82 (3.70 0.90/26.76 6.50) 70.56 13.72 (7.20 1.40/52.08 10.13) 109.76 21.56 (11.20 2.20/81.01 15.91) 161.70 32.34 (16.50 3.30/119.34 23.87) 23.52 6.86 (2.40 0.70/17.36 5.06) 49.98 12.74 (5.10 1.30/36.89 9.40) 94.57 19.11 (9.65 1.95/69.80 14.10) 142.10 28.42 (14.50 2.90/104.88 21.00) 199.92 40.18 (20.40 4.10/147.55 29.66) 287.14 57.82 (29.30 5.90/211.93 42.67) 395.92 79.38 (40.40 8.10/292.21 58.59) 530.18 105.84 (54.10 10.80/391.30 78.12) 691.88 138.18 (70.60 14.10/510.65 101.99) 48.02 11.76 (4.90 1.20/35.44 8.68) 89.18 17.64 (9.10 1.80/65.82 13.02) 133.28 26.46 (13.60 2.70/98.37 19.53) 191.10 38.22 (19.50 3.90/141.04 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such as casting. Those shown in parentheses in the strength class indicate the classification by the old standard.
FLARE NUTS
Pipe diameter mm (in) 4.76 (0.187) 6.35 (0.250) 8.00 (0.315) Torque 15.2 2.45(1.55 0.25/11.2 1.8) 26.48 2.94(2.70 0.30/19.5 2.1) 44.14 4.90(4.50 0.50/32.5 3.6) Pipe diameter mm (in) 10.00 (0.394) 12.00 (0.472) 15.00 (0.591)
Nm (kgm/lbft)
Torque 53.95 4.90(5.50 0.5 /39.7 3.6) 88.29 9.80(9.00 1.0/65.0 7.2) 105.45 12.26(10.75 1.25/77.7 9.0)
SPECIAL PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
Nm (kgm/lbft)
RTW46AXF000501
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan
Nm (kgm/lbft)
RTW36AXF000101
Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft

Nm (kgm/lbft)
RTW46AXF000601
Cooling and Lubricating System

Nm (kgm/lbft)
RTW46AXF000701
Intake Manifold (4JA1TC / 4JH1TC)

Nm (kgm/lbft)
RTW36AXF000201
EGR Valve, EGR Pipe, EGR Cooler
RTW46AXF000801
Exhaust Manifold, and Turbocharger (4JA1L)
RTW46AXF000901
Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC)

Nm (kgm/lbft)
RTW46AXF001001
Engine Electricals
Nm (kgm/lbft)
RTW36AXF000501
Fuel Injection System (4JA1L)

Nm (kgm/lbft)
RTW46AXF001101
Fuel Injection System (4JA1TC)

Nm (kgm/lbft)
RTW46AXF001201
Fuel Injection System (4JH1TC)

Nm (kgm/lbft)
RTW46AXF001301
Engine Mounting Bracket

Nm (kgm/lbft)
022R300001
RECOMMENDED LIQUID GASKET

Type RTV* Silicon Base Water Base Solvent Brand Name ThreeBond 1207B ThreeBond 1207C ThreeBond 1141E ThreeBond 1215 ThreeBond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402 LOCTITE 515 LOCTITE 518 LOCTITE 262 Manufacturer Three Bond Three Bond Three Bond Three Bond Three Bond Isuzu Isuzu Isuzu Loctite Loctite Loctite Recommended for transaxle repairs Remarks
Anaerobic
* 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 manufacturers 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 1. LOCTITE 242 Blue 2. LOCTITE 262 Red Application Steps Completely remove all lubricant and moisture from the bolts and the female threaded surfaces of the parts to be joined. The surfaces must be perfectly dry. Apply LOCTITE to the bolts.
LOCTITE 270
Green
3. LOCTITE 271 Red 4.
Tighten the bolts to the specified torque. Wait at least one hour before continuing the installation procedure.
1.
Completely remove lubricant and moisture from the connecting surfaces. The surfaces must be perfectly dry. Apply a 2.0 2.5 mm bead of LOCTITE to one of the connecting surfaces. There must be no gaps in the bead.
2.
LOCTITE 515
Violet
3. 4.
Tighten the bolts to the specified torque. 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 rear left hand side of the cylinder body. The engine number is stamped in the plate in front of the engine room as well.
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the condition of the element.
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 kPa (kg/cm /psi) 392 490 (4 5/57 71)
130RY00003
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element) Replacement Procedure
1. Drain the engine oil. 2. Retighten the drain plug. 3. Loosen the used oil filter by turning it counterclockwise with a filter wrench. Filter Wrench: 5-8840-0200-0
6A-6
4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly. 5. Apply a light coat of engine oil to the filter O-ring. 6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face. 7. Use the filter wrench to turn in the filter an additional 2/3 turns. 8. Check the engine oil level and replenish to the specified level if required.
RTW36ASH000101
ENGINE MECHANICAL 6A 25 Replenished Engine Oil

Condition Engine Dry Model With oil filter replacement 5.2 ~ 4.2 (1.37 ~ 1.11 / 1.14 ~ 0.92) 5.2 ~ 4.2 (1.37 ~ 1.11 / 1.14 ~ 0.92) 6.2 ~ 5.2 (1.64 ~ 1.37 / 1.36 ~ 1.14)
MAX lit (US/UK gal)

Without oil filter replacement 4.5 ~ 3.5 (1.19 ~ 0.93 / 0.99 ~ 0.77) 4.5 ~ 3.5 (1.19 ~ 0.93 / 0.99 ~ 0.77) 5.3 ~ 4.3 (1.72 ~ 1.14 / 1.17 ~ 0.95)
42 44 (4JA1L/TC) 42 (4JH1TC) 44 (4JH1TC)
6.2 (1.64/1.36)
6.2 (1.64/1.36)
7.0 (1.85/1.54)
9. Start the engine and check for oil leakage from the main oil filter.
FUEL SYSTEM
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) Note: Be careful not to spill the fuel in the filter cartridge.
6A-7
RTW46ASH000501
2. Clean the fuel filter cartridge fitting faces. This will allow the new fuel filter to seat properly 3. Apply a light coat of engine oil to the O-ring. 4. Turn in the fuel filter until the sealing face comes in contact with the O-ring. 5. Turn in the fuel filter an additional 2/3 of a turn with a filter wrench. Filter Wrench : 5-8840-0253-0 (J-22700)
041RY00009
6. Operate the priming pump until the air discharged completely from fuel system. 7. Start the engine 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 (inside chassis frame) with the following procedure.
041RY00011
1. 2. 3. 4.
Place the drain pan under the drain plug. Loosen the drain plug and drain water. After draining the water, tighten the drain plug. Operate the priming pump on the fuel filter several times and check for fuel leakage. 5. Check the water separator indicator light. It should be off.
Air Bleeding
1. Operate the priming pump until strong resistance is felt. 2. Wait 1 minute, and operate the priming pump until strong resistance is felt. 3. Once more wait, and operate the priming pump until strong resistance is felt. 4. Turn the ignition switch to the "ON" position. Wait until the glow indicator lamp turns off. 5. Turn the ignition switch to the "START" position and crank the engine until it starts. 6. If the engine does not start, repeat Step 3 - 5. 7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel leakage. Note: Insufficient air bleeding may cause the Diagnostic Trouble Code (DTC) store or improper engine performance.
Except EURO III model

RTW46ASH002901
For EURO III model
RTW46ASH000501
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve tank as necessary. If the coolant level falls below the MIN line, carefully check the cooling system for leakage. Then add enough coolant to bring the level up to the MAX line.
111R300001
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 into heater water system. 6. Check 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 hose for leakage. 8. Pour coolant into the reservoir tank up to MAX line. Engine Coolant Total Capacity Lit (U.S / UK gal) 4JA1 / TC 4JH1TC 9.4 (2.5 / 2.1) M/T: 10.1 (2.7 / 2.2) A/T: 10.0 (2.6 / 2.2) Mixing Ratio (Anti-Freeze Solution/Water) 50 %
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. Testing Pressure 150 (1.5/21)
030LX003
kPa(kg/cm /psi)
Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant 2 pressure in the cooling system at 103 kPa(1.05 kg/cm , 15psi). 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 Cap Valve Opening Pressure 2 kPa(kg/cm /psi)
030LX002
90 120 (0.9 1.2/13 17) Negative Valve (Reference) kPa(kg/cm /psi)

2
1.9 4.9 (0.02 0.05/0.28 0.71)
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)
030LX014
Oil Cooler Thermo Valve 76.5 (170) EGR Cooler Thermo Valve 40 (104)
C (F) C (F)
4. Check the thermostat full opening temperature. Thermostat Full Opening Temperature C (F) 95 (203) Oil Cooler Thermo Valve 90 (194) EGR Cooler Thermo Valve 55 (131) Valve Lift at Fully Open position 9.5 (0.37) Oil Cooler Thermo Valve 4.5 (0.18) EGR Cooler Thermo Valve 3.5 (0.14) mm in) mm (in) mm (in) C (F) C (F)
Drive Belt Adjustment

Check drive belts for wear or damage, and replace with new ones as necessary. Check belts for tension, and adjust as necessary. 1 Crankshaft damper pulley 2 Generator pulley 3 Cooling fan pulley 4 Oil pump pulley or idler pulley 5 Compressor pulley or idler pulley
033RY00002
Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator. Depress the drive belt mid-portion with a 98N (10 kg/22 lb) force. Cooling Fan Drive Belt Deflection mm (in) New belt 4 - 7 (0.16 - 0.28) Reuse belt 6 - 9 (0.24 - 0.35)
033RY00003
1 Crankshaft damper pulley 2 Generator pulley 3 Cooling fan pulley
A/C Compressor Drive Belt

Compressor belt tension is adjusted by moving the P/S pumppulley. Depress the drive belt mid-portion with a 98N (10 kg/22 Ib) force. A/C Compressor Drive Belt Deflection mm (in) New belt 9 - 10 (0.35 - 0.39) Reuse belt 12 - 13 (0.47 - 0.51)
033RY00004
1 Crankshaft damper pulley 2 P/S pump pulley 2 A/C Compressor pulley
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 54 (5.5/40) Nm (kgm /lbft)
014RY00014
8. 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. If the No. 1 cylinder intake and exhaust valve push rods are depressed, the No. 4 piston is at TDC on the compression stroke.
014RY00015
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) 9. Loosen each valve clearance adjusting screw as shown in the illustration. 10. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end. 11. Turn the valve clearance adjusting screw until a slight drag can be felt on the feeler gauge. 12. Tighten the lock nut securely. 13. Rotate the crankshaft 360. 14. Realign the crankshaft damper pulley TDC notched line with the timing pointer. 15. Adjust the clearances for the remaining valves as shown in the illustration.
014RY00017
014RY00016
COMPRESSION PRESSURE MEASUREMENT

1. Start the engine and allow it to idle until the coolant temperature reaches 70 80 C (158 176 F). 2. Remove the following parts. Leak off pipe Injection nozzle holder bracket Injection nozzle holder 3. Install the following parts. Set the adapter and compression gauge (SST) to the No.1 cylinder injection nozzle hole. Injection nozzle holder bracket Injection nozzle holder bracket Bolt Torque Nm (kgm /lbft) 37 (3.8/27) 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. Compression Pressure Standard 3.0 (31.0/441) MPa (kg/cm /psi) at 200 rpm Limit 2.1 (21.7/309)
2
F06XL056
901R100003
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.
INJECTION TIMING ADJUSTMENT (4JA1T(L) only)

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 on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line is aligned with the timing mark. Note: 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.
RTW46ASH000601
3. Disconnect the injection pipe from the injection pump 4. Remove one bolt from the distributor head. 5. Install the static timing gauge. The probe of the gauge should be depressed inward approximately 2 mm (0.079 in). Static Timing Gauge: 5-8840-0145-0 (J-28827)
6. Rotate the crankshaft to bring the piston in the No. 1 cylinder to a point 30 - 40 BTDC. 7. Set the timing gauge needle to zero. 8. Move the crankshaft pulley slightly in both directions to check that the gauge indication is stable.
6A 34 ENGINE MECHANICAL 9. Turn the crankshaft clockwise and read the gauge indication when the crankshaft pulley timing mark (8) is aligned with the pointer. Injection Timing : BTDC 8 2 Standard Reading 0.5 (0.02)
RTW46ASH000701
mm (in)
If the injection timing is outside the specified range, continue with the following steps. 10. Loosen the injection pump fixing nuts and bracket bolts. 11. Adjust the injection pump setting angle. When large than standard value R When smaller than standard value A
A: Move the injection pump toward the engine. R: Move the injection pump away from the engine.
ENGINE CONTROL (4JA1T(L) only)

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 - 80C (158 - 176F).
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 : 730 25 rpm
Idling Speed Adjustment

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 25
Fast Idling Speed Adjustment

1. Loosen the fast idle actuator bracket bolts.
2. 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.). 3. Tighten the bracket bolts.
Accelerator Control Cable Adjustment

Refer to Sec. 6H-6 (Accelerator Control)
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design provides superior fuel economy over a wide range of driving conditions. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Chrome plated dry type cylinder liners provide the highest durability. The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability. The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be reground. The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump. The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump. The engine is turbocharger equipped.
REMOVAL AND INSTALLATION

Read this section carefully before performing any removal and installation procedure. This section gives you important points as well as the order of operation. Be sure that you understand everything in this section before you begin.
Removal
1. Battery 1) Disconnect the battery cable and the grounding cable from the battery terminals. 2) Remove the battery clamp. Take care not to accidentally short the battery with the wrench or some other tool. 3) Remove the battery. 4) Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
P1010011
2. Engine Hood Apply setting marks to the engine hood and the engine hood hinges before removing the engine hood. This will facilitate reinstallation of the engine hood to its original position.
P1010002
3. Supporting the Vehicle 1) Jack up the vehicle. 2) Place chassis stands at the front and the rear of the vehicle.
F06R300006
4. Under cover (for 4x4 model) 5. Rear propeller shaft 1) Remove the propeller shaft flange yoke at the rear differential. 2) Remove the center bearing retainer bolts. 3) Remove the propeller shaft together with the center bearing from the transmission mainshaft spline.
6A 38 ENGINE MECHANICAL 6. Front propeller shaft (for 4x4 model) Remove the spline yoke flange bolt at the transfer output shaft. Do not allow the spline yoke to fall away from the front propeller shaft. If the spline yoke should fall away from the front propeller shaft, align the setting marks on the spline yoke and the propeller shaft to reassemble the two marks. The setting marks are punched circles approx. 3mm (0.12 in) in diameter. 7. Clutch slave cylinder (for M/T model) 8. ATF pipe (for A/T model) 9 Shift control cable (for A/T model) 10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor switch connector (A/T), ATF temperature sensor connector, back up light switch connector (M/T) from transmission. 11. Breather hose (for A/T model) 12. Transmission shift lever (for M/T model) Remove the shift lever from the floor. 13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor. 14. Transmission member 1) Support the transmission with the transmission jack. 2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.
P1010025
15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing. 2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts. 16. Transmission coupling bolt 1) Support the engine with the garage jack. 2) Use the jack to slightly lower the transmission. 3) Remove the transmission coupling bolts. 17. Transmission (and transfer) Separate the transmission (and transfer) from the engine.Take care not to damage the transmission, the engine, and their related parts..
F06R300007
ENGINE MECHANICAL 6A 39 18. Radiator 1) Drain the engine coolant. 2) Remove the reservoir hose. 3) Remove the upper and lower hose. 4) Remove the fan guide. 5) Remove the radiator.
P1010009
19. Fan 20. Air cleaner 1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct. 2) Remove the air cleaner duct and the air cleaner box from engine room. 3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).
P1010034
21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then remove the power steering pump assembly. Place the power steering pump assembly along with piping on the body side. 22. Air conditioner compressor 1) Remove air compressor magnet connector. 2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body side. 23. Engine Control Cable Remove the engine control cable from its bracket (4JA1TC/4JH1TC) or the injection pump (4JA1T(L)). 24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the EGR valve, injection pump FICD (4JA1T(L)). 25. Engine Harness 1) Remove following connectors from engine. TPS connector Oil pressure switch connector Thermo switch connector Injection pump connector Engine earth Thermometer unit connector TDC sensor 2) Remove the clips fixing engine harness.
6A 40 ENGINE MECHANICAL 26. Fuel Hose Remove the fuel hose from the fuel filter (Except EURO III).
140R300001
Remove the fuel hose from injection pump (EURO III only).
RTW46ASH000501
27. Exhaust Pipe Remove the front exhaust pipe bolts and separate the exhaust manifold and the front exhaust pipe. 28. Engine Assembly 1) Remove two right side engine foot bolts. 2) Remove two left side engine mount bolts. 3) Use the hoist to lift the engine from the engine compartment.
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse order.
Coolant Replenishment
Warning: When the coolant is heated to a high temperature, be sure not to loosen or remove the rediator cap. Otherwise you might get scalded by hot vapor or boiling water. To open the radiator cap, put a piece of thick cloth on the cap and loosen the cap slowly to reduce the pressure when the coolant has become cooler. 1. Open rediator cap pour coolant up to filler neck 2. Pour coolant into reservoir tank up to "MAX" line 3. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator cap. If the water level is lower, replenish. 4. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. 5. Check to see the thermometer, continuously idling 5 minutes and stop the engine. 6. When the engine has been cooled, check filler neck for water level and replenish if required. Should extreme shortage of coolant is found, check the coolant system and reservoir tank hose for leakage. 7. Pour coolant into the reservoir tank up to "MAX" line. Coolant Capacity 4JA1 / TC 4JH1TC lit (US/UK gal) 9.4 (2.5 / 2.1) M/T: 10.1 (2.7 / 2.2) A/T: 10.0 (2.6 / 2.2)
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures, start the engine and allow it to idle until it is warm. Check the following: 1. Engine idling speed. 2. Engine noise level. 3. Engine lubricating system and cooling system. Carefully check for oil and coolant leakage. 4. Clutch engagement. 5. Transmission operation. 6. Indicator warning light operation.
ENGINE REPAIR KIT
RTW36ALF000601
Removal Steps
1. Cylinder head gasket 2. Head cover gasket 3. Head cover cap nut gasket 4. Drain cock gasket 5. Crankshaft rear oil seal 6. Gear case gasket 7. Oil pan drain plug gasket 8. Oil pan gasket 9. Oil filter gasket 10. Joint bolt gasket 11. Vacuum pump gasket 12. Water pump O-ring 13. Water outlet pipe gasket 14. Intake pipe gasket 15. Thermostat housing gasket 16. Intake manifold gasket 17. Exhaust manifold gasket 18. Nozzle holder O-ring 19. Nozzle holder gasket 20. Crankshaft front oil seal
NOTE Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of these parts will result in oil, water, and gas leakage.
ENGINE OVERHAUL
REMOVAL EXTERNAL PARTS
RTW36AMF000401
Removal Steps
1. Clutch Assembly or Flex Plate 2. Intake Pipe and Throttle Body 3-1. EGR Pipe 3-2. EGR cooler (EURO III model only) 4. EGR Valve 5. Oil Level Gauge 6. Fuel Filter Assembly (Except EURO III) 7. Fuel Filter Bracket (Except EURO III) 8. Fuel Injection Pipe with Clip 9. Power Steering Oil Pump Bracket 10. Intake Manifold 11. Engine Mounting Bracket and Foot 12. Injection Pump Cover 13. Injection Pump 14. Starter Motor 15. Oil Pressure Warning Switch 16. Fuel Leak Off Pipe 17. Oil Cooler Water Pipe 18. Cooling Fan Pulley 19. Heat Protector 20. Catalytic Converter 21. Turbocharger 22. Compressor Bracket 23. Vacuum Pump Oil Return Hose 24. Generator and Adjusting Plate 25. Water Inlet Pipe 26. Generator Bracket 27. Oil Cooler with Oil Filter 28. Exhaust Manifold
Removal
1. Clutch Assembly or Flex Plate Remove the clutch assembly or the flex plate. 2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) 1) Loosen hose clamp between turbocharger and intake duct. 2) Remove the rubber hose. 3) Remove the intake pipe and the throttle body. (4JA1TC/4JH1TC only)
4JA1L
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
4JA1L
3-1. EGR Pipe 1) Remove two bolts from the exhaust manifold. 2) Remove two nuts from the EGR valve adapter. 3) Remove the EGR pipe with gaskets.
025R100008
4JH1TC
RTW36ASH000301
3-2. EGR Cooler (EURO III model only)
ENGINE MECHANICAL 6A 45 4. EGR Valve 1) Remove four nuts and remove the EGR valve assembly from the intake manifold. 2) Remove four bolts and remove the adapter from the EGR valve assembly.
4JA1*L
RTW46ASH001001
5. Oil Level Gauge 1) Disconnect PCV hose. 2) Remove two bolts and remove the engine oil level gauge.
4JA1*TC
RTW46ASH000901
4JH1*TC
RTW36ASH001201
6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose. 2) Remove two bolts and remove the fuel filter. 7. Fuel Filter Bracket (Except EURO III model) Remove three bolts and remove the fuel filter bracket with leak pipe. 8. Fuel Injection Pipe with Clip 1) Loosen the injection pipe sleeve nuts at pump side and nozzle side. Do not apply excessive force to the injection pipes. 2) Loosen the injection pipe clips. 3) Remove the injection pipe. NOTE: Plug the delivery holder ports with the caps to prevent the entry of foreign material. 9. Power Steering Oil Pump Bracket 10. Intake Manifold 1) Disconnect the PCV hose from the cylinder head cover. 2) Remove the intake manifold with gasket.
RTW36ASH000701
11. Engine Mounting Bracket and Foot 12. Injection Pump Cover
6A 46 ENGINE MECHANICAL 13. Injection Pump 14. 15. 16. 17. 18. 19. Rrefer to secton 6C-19 (Injection Iump) Starter Motor Oil Pressure Warning Switch Fuel Leak Off Pipe Oil Cooler Water Pipe Cooling Fan Pulley Heat Protector
20. Catalytic Converter
027R100007
037RY00001
21. Turbocharger 1) Disconnect the water hose between thermostat housing cover and turbocharger. 2) Disconnect the water hose between water inlet pipe and turbocharger. 3) Remove the oil feed pipe. 4) Remove the oil return pipe. 5) Remove the turbocharger and the gasket. NOTE: Plug the turbocharger body oil ports and water ports after removing the turbocharger assembly to prevent the entry of foreign material. 22. 23. 24. 25. 26. 27. 28. Compressor Bracket Vacuum Pump Oil Return Hose Generator and Adjusting Plate Water Inlet Pipe Generator Bracket Oil Cooler with Oil Filter Exhaust Manifold
ENGINE MECHANICAL 6A 47 1
DISASSEMBLY
INTERNAL PARTS MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1. 2. 3. 4. Water bypass hose Thermostat housing with thermo switch Cylinder head cover Injection nozzle and bracket 5. 6. 7. 8. Rocker arm shaft and rocker arm Push rod Cylinder head Cylinder head gasket
RTW46ALF000101
Disassembly Steps-2
9. 10. 11. 12. 13. 14. 15. 16. Crankshaft damper pulley Timing gear case cove Water pump Idle gear "B" and shaft Idle gear "A" Idle gear shaft Crankshaft timing gear Injection pump
014R300005
Disassembly Steps-3
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Flywheel Crank case Oil pump with oil pipe Camshaft timing gear Camshaft thrust plate Camshaft Timing gear case Cylinder body rear plate Piston cooling oil jet Connecting rod bearing cap with lower bearing 27. 28. 29. 30. 31. 32. 33. 34. Piston and connecting rod with upper bearing Crankshaft bearing cap with lower bearing Crankshaft thrust bearing Crankshaft Crankshaft upper bearing Tappet Crankshaft rear oil seal Cylinder body
Disassembly
1. 2. 3. 4. Water Bypass Hose Thermostat Housing with Thermo Switch Cylinder Head Cover Injection Nozzle and Bracket 1. Remove the injection nozzle bracket bolts.
011R100002
2. Use the injection nozzle remover and the sliding hammer to remove the injection nozzle together. Injection Nozzle Remover: 5-8840-2723-0 Sliding Hammer: 5-8840-0019-0
011RY00005
5. 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 bolts in numerical order a little at a time will adversely affect the rocker arm shaft. 6. Push Rod
011RY00006
7. Cylinder Head Loosen the cylinder head bolts in numerical order a little at a time. Note: Failure to loosen the cylinder head bolts in numerical order a little at a time will adversely affect the cylinder head lower surface. 8. Cylinder Head Gasket 9. Crankshaft Damper Pulley
011RY00007
ENGINE MECHANICAL 6A 51 10. 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. 11. Water Pump
020L200006
12. Idle Gear B and shaft Before removing the idle gear B, install bolt (M6,L=30) to the hole marked with an arrow in the illustration to hold the scissor gear in place.
020L200020
13. 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.
020RY00019
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. If the measured value exceeds the specified limit, the timing gear must be replaced.
020RY00020
Timing Gear Backlash Standard 0.10 - 0.17 (0.0039 - 0.0067)
mm (in) Limit 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. If the measured value exceeds the specified limit, the thrust collar must be replaced. Idler Gear End Play Standard 0.07 (0.0028) mm (in) Limit 0.2 (0.0079)
RTW36ASH000801
4JA1T(L)
14. Idle Gear Shaft 15. Crankshaft Timing Gear
040R300009
4JA1TC/4JH1TC
16. Injection Pump 1. Remove the injection pump cover (4JA1TC/4JH1TC only). 2. Remove the injection pump bracket. 3. Pull the injection pump along with the injection pump timing gear free toward the rear of the engine. NOTE: Plug the injection pump delivery ports with the caps to prevent the entry of foreign material. 17. Flywheel Loosen the flywheel bolts in numerical order a little at a time. Use the gear stoper to stop the flywheel gear. Gear stoper: 5-8840-0214-0 18. Crank Case 19. Oil Pump With Oil Pipe
RTW36ASH001301
015RY00001
ENGINE MECHANICAL 6A 53 20. 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 Standard 0.050 - 0.114 (0.002 - 0.0044) mm (in) Limit 0.20 (0.008)
014RT0001
901R100008
2. Remove the camshaft timing gear bolt from the camshaft. Note: Hold the camshaft stationary to prevent the camshaft from turning. 3. Remove the sensor rotor plate. 4. Use the universal puller to pull out the camshaft timing gear. Universal Puller: 5-8521-0002-0 5. Remove the thrust plate. 21. Camshaft Thrust Plate 22. Camshaft Jiggle the camshaft with your hand as you pull it free from the front of the engine.
23. Timing Gear Case 24. Cylinder Body Rear Plate

014RY00019
25. Piston Cooling Oil Jet 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.
052RY00001
6A 54 ENGINE MECHANICAL 26. 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.
014LX056
27. 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.
015LX018
If the connecting rod upper bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
RTW36ASH001501
28. 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 Standard 0.10 (0.004) mm (in) Limit 0.30 (0.012)
015RY00002
ENGINE MECHANICAL 6A 55 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 cylinder number from which it was removed. 29. Crankshaft Thrust Bearing 30.Crankshaft
015RY00003
31. Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
015RY00004
32. 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.
015RY00005
33. 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: 5-8840-2360-0
34. Cylinder Body

015LV002
MINOR COMPONENTS ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1. 2. 3. 4. Rocker arm shaft snap ring Rocker arm Rocker arm shaft bracket Rocker arm 5. 6. 7. Rocker arm shaft spring Rocker arm shaft snap ring Rocker arm shaft
Disassembly
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. 4. Rocker Arm 5. Rocker Arm Shaft Spring 6. Rocker Arm Shaft Snap Ring 7. Rocker Arm Shaft
011RY00010
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1. 2. 3. 4. 5. Intake manifold Intake manifold gasket Split collar Valve spring upper seat Valve spring 6. 7. 8. 9. Intake and exhaust valve Valve stem oil seal Valve spring lower seat Cylinder head
Disassembly
1. Intake Manifold 2. Intake Manifold Gasket 3. Split Collar 1. Place the cylinder head on a flat wooden surface. 2. Use the spring compressor to remove the split collars. Do not allow the valve to fall from the cylinder head. Spring Compressor: 9-8523-1423-0 4. Valve Spring Upper Seat 5. Valve Spring 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 cylinder number from which it was removed. If the intake and exhaust valves are to be replaced, the valve guides must also be replaced. 7. Valve Stem Oil Seal 8. Valve Spring Lower Seat 9. Cylinder Head
011LX022
011RY00011
PISTON AND CONNECTING ROD
RTW46ALF000301
Disassembly Steps
1. 2. 3. Connecting rod bearing Piston ring Piston pin snap ring 4. 5. 6. Piston pin Connecting rod Piston
Disassembly
1. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed.
RTW36ASH001501
2. Piston Ring 1. Clamp the connecting rod in a vise. Take care not to damage the connecting rod. 2. Use a piston ring replacer to remove the piston rings. Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings. Piston ring stretching will result in reduced piston ring tension.
015RW041
3. Piston Pin Snap Ring Use a pair of pliers to remove the piston pin snap rings.
F06MV015
4. Piston Pin 5. Connecting Rod 6. Piston Tap the piston pin out with a hammer and a brass bar. If the pistons and piston pins are to be reinstalled, mark their installation positions by tagging each piston and piston pin with the cylinder number from which it was removed.
RTW36ASH001601
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face. 2. The cylinder head lower surface warpage is more than the limit, it should be replaced.
011RY00012
Cylinder Head Lower Face Warpage Standard 0.05 (0.002) or less NOTE: Limit 0.20 (0.0079)
mm (in)
The cylinder head lower face cannot be reground.
011RY00013
Cylinder Head Height (H) (Reference) Standard 91.95 92.05 (3.620 3.624)
mm (in)
011RY00014
Positive Crankcase Ventilation (PCV) Valve

1. 2. 3. 4. Remove PCV valve assembly from cylinder head cover. Inspect the diaphragm for broken. Inspect the spring for broken or weaken. If find any abnormal condition, replace the PCV valve assembly.
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
027RY00001
mm (in) Maximum Grinding Allowance 0.40 (0.016)
Standard 0.05 (0.002) or less
Limit 0.20 (0.008)
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 Standard 0.05 (0.002) or less
027RY00002
mm (in) Limit 0.20 (0.008)
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.
011RY00022
Valve Stem Clearance Standard Intake Valve Exhaust Valve 0.039 - 0.071 (0.0015 - 0.0028) 0.064 - 0.096 (0.0025 - 0.0038)
mm (in) Limit 0.200 (0.008) 0.250 (0.0098)
ENGINE MECHANICAL 6A 63 Measuring Method-II 1. Measure the valve stem outside diameter. Refer to the Item "Valve Stem Outside Diameter". 2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.
011RY00023
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
011LX029
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
011RY00024
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) 12.8-13.2 (0.50-0.52) NOTE: If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.
011RY000025
mm (in)
Valve Stem Outside Diameter

Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter Standard Intake Valve
011LX027
mm (in) Limit 7.880 (0.3102) 7.850 (0.3090)
7.946 - 7.961 (0.3128 - 0.3134) 7.921 - 7.936 (0.3119 - 0.3124)
Exhaust Valve
Valve Thickness
Measure the valve thickness. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Intake and Exhaust Valve Thickness Standard 4JA1T (L)
014RY00020
mm (in) Limit 1.5 (0.06) 1.1 (0.045)
1.8 (0.07) 1.34 (0.054) 1.36 (0.055)
Inlet 4JA1TC, 4JH1TC Exhaust
Valve Depression
1. Install the valve (1) to the cylinder head (2). 2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the cylinder head lower surface. If the measured value exceeds the specified limit, the valve seat insert must be replaced. Valve Depression
014RY00021
Standard 4JA1T(L) 4JA1TC, 4JH1TC 0.72 (0.029) 1.17 (0.048)
mm (in) Limit 1.28 (0.050) 1.67 (0.068)
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. If the measured value exceeds the specified limit, the valve seat insert must be replaced. Valve Contact Width Standard
014RY00027
mm (in) Limit 2.2 (0.087) 2.5 (0.078)
Intake Exhaust
1.7 (0.067) 2.0 (0.079)
Valve Seat Insert Replacement

Valve Seat Insert Removal 1. Arc weld the entire inside circumference (1) of the valve seat insert (2). 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 (3) to pry the valve seat insert free. Take care not to damage the cylinder head (4). 4. Carefully remove carbon and other foreign material from the cylinder head insert bore.
011LX039
6A 66 ENGINE MECHANICAL Valve Seat Insert Installation 1. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2). NOTE: The smooth side of the attachment must contact the valve seat insert.
014RY00026
2. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place. NOTE: Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat insert will result.
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.
011LX063
Valve Seat Angle 45 NOTE: Use an adjustable valve cutter pilot.
Degree
Do not allow the valve cutter pilot to wobble inside the valve guide.
011LX037
3. 4. 5. 6. 7.
Apply abrasive compound to the valve seat insert surface. Insert the valve into the valve guide. Turn the valve while tapping it to fit the valve seat insert. Check that the valve contact width is correct. Check that the valve seat insert surface is in contact with the entire circumference of the valve.
011LX038
Valve Spring Free Height

Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Spring Free Height Standard 4JA1T (L) 4JA1TC, 4JH1TC Single spring 48.0 (1.89) mm (in) Limit 47.1 (1.85)
011LX024
Valve Spring Squareness

Use a surface plate and a square to measure the valve spring squareness. If the measured value exceeds the specified limit, the valve spring must be replaced. Spring Squareness Limit
014RY00025
mm (in)
4JA1T (L) 4JA1TC, 4JH1TC
Single spring
1.7 (0.070)
Valve Spring Tension

Use a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, the valve spring must be replaced. Valve Spring Tension Compressed Height
011LX026
N (kg/lb) Standard 296.0 (30.2/66.4) Limit 257.7 (26.3/57.9)
4JA1T (L) 4JA1TC, 4JH1TC
Single spring
38.9mm (1.53in)
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 Limit 0.3 (0.012) mm (in)
015LX008
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting portion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Outside Diameter Standard
015LX009
mm (in) Limit 18.90 (0.744)
18.9819.00 (0.7470.748)
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 Standard 19.01019.030 (0.7480.749)
014RY00024
mm (in) Limit 19.100 (0.752)
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 Standard 0.010.05 (0.00040.0020) Limit 0.20 (0.008) mm (in)
ENGINE MECHANICAL 6A 69 3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port.
014RY00024
Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for step wear (1) and scoring (2). 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.
014RY00023
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 (1) and a feeler gauge (2) 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 Standard 0.05 (0.002) or less
012R100001
mm (in) Limit 0.20 (0.008) mm (in)
Cylinder Body Height (H) (Reference) Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478) 4JH1TC : 269.945-270.055 (10.6277-10.6320) 4. Reinstall the cylinder liner. Refer to "Cylinder Liner Replacement". 5. Reinstall the cylinder body dowel.
012RY00009
Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore at measuring point (1) in the thrust (2-2) and axial (3-3) directions of the crankshaft. Measuring Point (1): 20 mm (0.79 in) If the measured value exceeds the specified limit, the cylinder liner must be replaced. Cylinder Liner Bore
012RY00010
mm (in) Standard Limit 93.08 (3.6646) 95.48 (3.7590)
4JA1T(L), 4JA1TC 4JH1TC NOTE:
93.00 (3.6614) 95.40 (3.7559)
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 along the top edge of the cylinder liner to be measured. 2. Use a feeler gauge to measure each cylinder liner projection. Cylinder Liner Projection Standard
012LX016
mm (in)
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 (1) 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 (4JA1L/TC) : 5-8840-2304-0 (4JH1TC) 2. Use a bench press (2) to slowly force the cylinder liner from the cylinder body.
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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 Standard -0.0010*-0.019 (-0.00004*-0.0007)
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mm (in)
* 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 (1) across positions 1-1 and 2-2. Measuring Point (1): 4JA1T(L), 4JA1TC : 13,48,83,118,153 mm (0.51,1.89,3.27,4.65,6.02 in) 4JH1TC : 18,53,88,123,158 mm (0.71,2.09,3.46,4.84,6.22 in)
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012R300001
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.
6A 72 ENGINE MECHANICAL A mark was stamped on the upper side 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.
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Cylinder Liner Grade 4JA1T (L), 4JA1TC Liner Cylinder Body Outside Bore Diameter Grade 1 2 3 4 4JH1TC Liner Outside Grade 1 2 3 4 95.001-95.010 (3.7402-3.7405) 95.011-95.020 (3.7406-3.7409) 95.021-95.030 (3.7410-3.7413) 95.031-95.040 (3.7414-3.7417)
mm (in) Liner Outside Diameter 95.011-95.020 (3.7406-3.7409) 95.021-95.030 (3.7410-3.7413) 95.031-95.040 (3.7414-3.7417) 95.041-95.050 (3.7418-3.7421) Liner Bore Grade AX CX AX CX AX CX AX CX Service Liner Bore Measurement 93.035-93.050 (3.6628-3.6634) 93.051-93.066 (3.6634-3.6640) 93.035-93.050 (3.6628-3.6634) 93.051-93.066 (3.6634-3.6640) 95.035-93.050 (3.6628-3.6634) 93.051-93.066 (3.6634-3.6640) 93.035-93.050 (3.6628-3.6634) 93.051-93.066 (3.6634-3.6640) mm (in)
Cylinder Body Bore Diameter 97.001-97.010 (3.8189-3.8193) 97.011-97.020 (3.8193-3.8197) 97.021-97.030 (3.8197-3.8200) 97.031-97.040 (3.8200-3.8205)
Liner Outside Diameter 97.011-97.020 (3.8193-3.8197) 97.021-97.030 (3.8197-3.8200) 97.031-97.040 (3.8200-3.8205) 97.041-97.050 (3.8205-3.8209)
Liner Bore Grade AX CX AX CX AX CX AX CX
Service Liner Bore Measurement 95.435-95.450 (3.7573-3.7579) 95.451-95.466 (3.7579-3.7585) 95.435-95.450 (3.7573-3.7579) 95.451-95.466 (3.7579-3.7585) 95.435-95.450 (3.7573-3.7579) 95.451-95.466 (3.7579-3.7585) 95.435-95.450 (3.7573-3.7579) 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:
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All foreign material must be carefully removed from the cylinder liner and the cylinder bore before installation. 3. Insert the cylinder liner (1) into the cylinder body (2) from the top of the cylinder body. 4. Set the cylinder liner installer (3) to the top of the cylinder liner. Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC) : 5-8840-2313-0 (4JH1TC) 5. (3) is directly beneath the bench press shaft center (4). NOTE: Check that the cylinder liner is set perpendicular to the bench press and that there is no wobble.
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6. Use the bench press to apply a seating force of 4,900 N (500 kg/1,100 Ib) to the cylinder liner. 7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully seat the cylinder liner. 8. After installing the cylinder liner, measure the cylinder liner projection. Refer to "Cylinder Liner Projection Inspection".
Piston Grade Selection

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" Cylinder Liner Bore (Service Part) Grade Grade 4JA1T(L) 4JA1TC AX CX AX 4JH1TC CX mm (in)
Bore measurement 93.035-95.050 (3.6628-3.6634) 93.051-95.066 (3.6634-3.6640) 95.435-95.450 (3.7573-3.7579) 95.451-95.466 (3.7579-3.7585)
NOTE: It is most important that the correct piston grade be used. Failure to select the correct piston grade will result in engine failure. Always measure the cylinder bore and select the correct piston grade.
ENGINE MECHANICAL 6A 75 2. Measure the piston diameter. Piston Measuring Point 4JA1T(L) 4JA1TC 4JH1TC Piston Grade (Service Part)
015LX021
mm (in) 78 (3.07) 70 (2.76) mm (in) 92.949 - 92.964 (3.6549 - 3.6600) 92.965 - 92.980 (3.6600 - 3.6606) 95.359 - 95.374 (3.7542 - 3.7548) 95.375 - 95.390 (3.7548 - 3.7555)
4JA1T(L) 4JA1TC
AX CX AX
4JH1TC CX
Cylinder Liner and Piston Clearance mm (in) 4JA1T(L) 0.041-0.071 (0.0016-0.0027) 4JA1TC 4JH1TC 0.047-0.065 (0.0019-0.0026) 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. 1. Normal contact 2. Cracking 3. Pitting 4. Irregular contact Uneven contact 5. 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.
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Tappet Outside Diameter

Measure the tappet outside diameter with a micrometer. If the measured value is less than the specified limit, the tappet must be replaced. Tappet Outside Diameter Standard
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mm (in) Limit 12.95 (0.510)
12.97 - 12.99 (0.510 - 0.511)
Tappet and Cylinder Body Clearance Standard 0.01 - 0.046 (0.0004 - 0.0018) Limit
mm (in)
0.10 (0.004)
012LX014
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. If the measured value exceeds the specified limit, the push rod must be replaced. Pushrod Curvature
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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 (1 and 2). If the measured value is less than the specified limit, the camshaft must be replaced. Camshaft Journal Diameter Standard
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mm (in) Limit 49.60 (1.953)
49.945 - 49.975 (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) Standard 42.016 (1.6542)
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mm (in) Limit 41.65 (1.640)
Camshaft Run-Out
1. Mount the camshaft on V-blocks. 2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the camshaft must be replaced. Camshaft Run-Out Standard
014LX092
mm (in) Limit 0.10 (0.004)
0.02 (0.0008)
Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft bearing inside diameter. Crankshaft Bearing Inside Diameter Standard 50.00 - 50.03 (1.968 - 1.970)
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mm (in) Limit 50.08 (1.972)
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 Standard 0.055 (0.0022) Limit 0.12 (0.005) mm (in)
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
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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
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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 Run-Out
1. Set a dial indicator to the center of the crankshaft journal. 2. Gently turn the crankshaft in the normal direction of rotation. Read the dial indicator as you turn the crankshaft. If the measured value exceeds the specified limit, the crankshaft must be replaced. Crankshaft Run-Out Standard 0.05 (0.002) or less Limit 0.08 (0.003) mm (in)
015LX061
Bearing Spread
Use a vernier caliper to measure the bearing spread. If the measured value is less than the specified limit, the bearing must be replaced. Bearing Spread 4JA1T (L), 4JA1TC 4JH1TC mm (in) Limit 64.5 (2.54) 74.5 (2.93) 56.5 (2.22)
Creankshaft Bearing
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Connecting Rod Bearing
Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal diameter across points 1 - 1 and 2 - 2. 2. Use the micrometer to measure the crankshaft journal diameter at the two points (3 and 4). 3. Repeat Steps 1 and 2 to measure the crankpin diameter. If the measured values are less than the specified limit, the crankshaft must be replaced.
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Crankshaft Journal and Diameter Standard 4JA1T (L), 4JA1TC 4JH1TC 59.921-59.928 (2.3591-2.3594) 69.917-69.932 (2.7526-2.7532) Limit
mm (in)
59.91 (2.3586) 69.91(2.7524)
Crankpin Diameter Standard 52.915 - 52.930 (2.0833 - 2.0839) Limit
mm (in)
52.90 (2.083)
Crankshaft Journal and Crankpin Uneven Wear Standard 0.05 (0.002) or less Limit 0.08 (0.003)
mm (in)
Crankshaft Journal and Crankpin Diameter

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 Standard 0.032 - 0.077 (0.0013 - 0.0030) Limit 0.110 (0.0043) mm (in)
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Connecting Rod Bearing Inside Diameter

1. Install the bearing to the connecting rod big end. 2. Tighten the bearing cap to the two step of anglar tightening method. Connecting Rod Bearing Cap Bolt Torque Nm (kgm/Ib ft) 4JA1T (L), 78-88 (8.0/57 9.0/65) 4JA1TC 1st step ; 29.029.2 (3.00/22.03.01/22.2) 4JH1TC 2nd step ; 45-60 3. Use an inside dial indicator to measure the connecting rod bearing inside diameter.
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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 Standard 4JA1T (L), 4JA1TC 4JH1TC 0.029-0.066 (0.0011-0.0026) 0.029-0.083 (0.0011-0.033) Limit 0.100(0.0039) 0.100 (0.0039) mm (in)
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 167 (17/123) Do not allow the crankshaft to turn during bearing cap installation and tightening. 8. Remove the bearing cap.
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mm (in)
015LX129
015LX060
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 bearing inside diameter. If the crankshaft journal and bearing clearance exceeds the limit, the crankshaft and/or the bearing must be replaced. Crankshaft Journal and Bearing Clearance Standard 0.032 - 0.077 (0.0013 - 0.0030) Limit 0.110 (0.0043) mm (in)
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 two step of anglar tihtening method. Do not allow the connecting rod to move when installing and tightening the bearing cap. Connecting Rod Bearing Cap Bolt Torque Nm (kgm/Ib ft) 4JA1T (L), 78-88 (8.0/57 9.0/65) 4JA1TC 1st step ; 29.029.2 (3.00/22.03.01/22.2) 4JH1TC 2nd step ; 45-60
ENGINE MECHANICAL 6A 83 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 bearing inside diameter. If the crank pin and bearing clearance exceeds the specified limit, the crankshaft and/or the bearing must be replaced. Crankpin and Bearing Clearance Standard 4JA1T (L), 4JA1TC 4JH1TC 0.029-0.066 (0.0011-0.0026) 0.029-0.083 (0.0011-0.0033) Limit 0.100 (0.0039) 0.100 (0.0039) mm (in)
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, 2 or 3 are stamped on the rear right hand side of the cylinder body.
015LX060
Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or -, 2 or --, 3 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:
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The crankshaft journal mark No. 4 is stamped on crankshaft No. 4 journal web front side or rear side.
6A 84 ENGINE MECHANICAL REFERENCE 4JA1T(L), 4JA1TC Crankshaft Bearing Housing Grade Mark Diamaeter Crankshaft Journal Grade Mark 1 or 2 or -3 or --1 or 2 or -3 or --1 or 2 or -3 or --Diamaeter 59.927-59.932 (2.3593-23.595) 59.922-59.927 (2.3591-2.3539) mm (in) Crankshaft Bearing Size Code
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63.99264.000 (2.51942.5197)
Brown or 4
59.917-59.922 Yellow or 5 (2.3589-2.3591) 59.927-59.932 (2.3593-2.3595) 59.922-59.927 (2.3591-2.3593) Black or 2 Blue or 3
63.98363.992 (2.51902.5194)
59.917-59.922 Brown or 4 (2.3589-2.3591) 59.927-59.932 Green or 1 (2.3593-2.3595) 59.922-59.927 (2.3591-2.3593) 59.917-59.922 (2.3598-2.3591)
RTW46ASH002501
63.97563.983 (2.51872.5190)
Black or 2
4JH1TC Crankshaft Bearing Housing Grade Mark Diamaeter Crankshaft Journal Grade Mark 1 or 2 or -3 or --1 or 2 or -3 or --1 or 2 or -3 or --Diamaeter 69.927-69.932 (2.7530-2.7532) 69.922-69.927 (2.7528-2.7530) 69.917-69.922 (2.7556-2.7528) 69.927-69.932 (2.7530-2.7532) 69.922-69.927 (2.7528-2.7530) 69.917-69.922 (2.7556-2.7528) 69.927-69.932 (2.7530-2.7532) 69.922-69.927 (2.7528-2.7530) 69.917-69.922 (2.7526-2.7528)
mm (in) Crankshaft Bearing Size Code
73.99274.000 (2.91312.9134)
5 2 3 4 1
73.98373.992 (2.91272.9131)
73.97573.983 (2.91242.9127)
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
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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:
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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. If the measured value exceeds the specified limit, the flywheel must be replaced. Flywheel Friction Surface Depth (1) Standard 4JA1T (L), 4JA1TC 4JH1TC 20 (0.7874) 18 (0.7087) Limit 21 (0.8267) 19 (0.7480) mm (in)
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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.
020LX008
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 200C (390F). 2. Install the ring gear when it is sufficiently heated. The ring gear must be installed with the chamfer facing the clutch.
020LX009
PISTON
Piston Grade Selection and Cylinder Bore Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore Measurement" for details on piston grade selection and cylinder liner bore measurement.
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.
015LX023
2. Push the piston ring into the cylinder bore until it reaches the measuring point 1 or 2 where the cylinder liner bore is the smallest. Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal. Measuring Point 1 10 mm (0.4 in) or Measuring Point 2 120 mm (4.7 in)
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ENGINE MECHANICAL 6A 87 3. Use a feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced. Piston Ring Gap 4JA1T (L), 4JA1TC Standard 1st Compression Ring
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mm (in) Limit 1.5 (0.059)
2nd Compression Ring Oil Ring
0.3-0.3 (0.0118-0.0197) 0.250-0.450 (0.0098-0.0177)
4JH1TC Standard 1st Compression Ring 2nd Compression Ring Oil Ring 0.3-0.5 (0.0118-0.0197) 0.250-0.450 (0.0098-0.0177) Limit 1.5 (0.059)
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 4JA1T (L), 4JA1TC Standard 1st Compression Ring 2nd Compression Ring Oil Ring 0.09-0.125 (0.0035-0.0049) 0.05-0.085 (0.0020-0.0033) 0.03-0.070 (0.0012-0.0028) 0.15 (0.0059) mm (in) Limit
015LX025
4JH1TC Standard 1st Compression Ring 2nd Compression Ring Oil Ring 0.09-0.130 (0.0035-0.0051) 0.05-0.090 (0.0020-0.0035) 0.03-0.070 (0.0012-0.0028) 0.15 (0.0059) Limit
6A 88 ENGINE MECHANICAL 4. Visually inspect the piston rings. If a piston ring groove is damaged or distorted, the piston must be replaced.
Piston Pin Diameter

Use a micrometer to measure the piston pin diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced. Piston Pin Diameter Standard
015LX026
mm (in) Limit 30.97 (1.2193)
30.995-31.000 (1.2202-1.2204)
Piston Pin and Piston Clearance

Use and inside dial indicator to measure the piston pin hole (in the piston). Piston Pin Hole 4JA1T (L) 4JA1TC, 4JH1TC
015RW048
mm (in) 31.002-31.010 (1.2206-1.2208) 31.005-31.013 (1.2207-1.2210)
Piston Pin and Piston Pin Hole Clearance 4JA1T (L) 4JA1TC, 4JH1TC
mm (in)
0.002-0.015 (0.00008-0.0006) 0.005-0.018 (0.0002-0.0007)
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.
011LX011
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.
RTW36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two differences 12 and 3-4 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.
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Cylinder Head Gasket Combination Cylinder Head Gasket Combination 4JA1T (L), 4JA1TC Gasket Grade Mark Piston Projection A B
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mm (in) mm (in) Gasket Thickness (Reference) 1.6 (0.0630) 1.65 (0.0650) 1.70 (0.0669) mm (in) Gasket Thickness (Reference) 1.3 (0.5118) 1.35 (0.5315) 1.4 (0.5512)
0.718-0.773 (0.0283-0.0304) 0.773-0.819 (0.0304-0.0322) 0.819-0.874 (0.0322-0.0344)
4JH1TC Gasket Grade Mark Piston Projection A B C NOTE: 0.215-0.265 (0.0085-0.0104) 0.265-0.315 (0.0104-0.0124) 0.315-0.365 (0.0124-0.0144)
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.
015LX034
Connecting Rod Alignment Per Length of 100 mm (3.94 in) mm (in) Standard Distortion Parallelism 0.08 (0.003) or Less 0.05 (0.002) or Less Limit 0.20 (0.008) 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. If the measured value exceeds the specified limit, the connecting rod must be replaced. Connecting Rod Big End and Crankpin Side Face Clearance mm (in) Standard 0.23 (0.009) Limit 0.35 (0.014)
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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. Piston Pin and Connecting Rod Small End Bushing Clearance Standard 4JA1T (L) 4JA1TC, 4JH1TC 0.008-0.020 (0.003-0.0008) 0.005-0.018 (0.0002-0.0007) Limit 0.050 (0.002) 0.050 (0.002)
015LX028
mm (in)
IDLER GEAR SHAFT AND IDLER GEAR

Idler Gear "A" Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside diameter. If the measured value is less than the specified limit, the idler gear shaft must be replaced. Idler Gear "A" Shaft Outside Diameter
020RY00025
mm (in) Limit 44.845 (1.755)
Standard 44.945-44.975 (1.7695-1.7707)
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 Standard 45.0-45.03 (1.7717-1.7718)
014LX022
mm (in) Limit 45.10 (1.7756)
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 Standard 0.025-0.085 (0.0010-0.0033) Limit 0.200 (0.0079) mm (in)
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.
020R300004
6A 92 ENGINE MECHANICAL Oil Seal Installation Use the special tool to install the front oil seal. Front Oil Seal Installer: 5-8840-2361-0 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 = 1.0 0.03mm 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.
020R300005
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT ROCKER ARM SHAFT AND ROCKER ARM
020RY00029
Reassembly Steps
1. 2. 3. 4. Rocker arm shaft Rocker arm shaft snap ring Rocker arm Rocker arm shaft bracket 5. 6. 7. Rocker arm Rocker arm shaft spring Rocker arm shaft snap ring
Reassembly
1. Rocker Arm Shaft 1. Position the rocker arm shaft with the large oil hole (4 ) facing the front of the engine. 2. Install the rocker arm shaft together with the rocker arm, the rocker arm shaft bracket, and the spring. 2. Rocker Arm Shaft Snap Ring 3. Rocker Arm 4. Rocker Arm Shaft Bracket 5. Rocker Arm 6. Rocker Arm Shaft Spring 7. Rocker Arm Shaft Snap Ring
014RY00037
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1. 2. 3. 4. 5. Cylinder head Valve spring lower seat Valve stem oil seal Intake and exhaust valve Valve spring 6. 7. 8. 9. Valve spring upper seat Split collar Intake manifold gasket Intake manifold
Reassembly
1. Cylinder Head 2. Valve Spring Lower Seat 3. Valve Stem Oil Seal 1. Apply a coat of engine oil to the oil seal inner face. 2. Use an oil seal installer to install the oil seal to the valve guide. Oil Seal Installer: 5-8840-2033-0 4. Intake and Exhaust Valve 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. 6. Valve Spring Upper Seat
011RW027
011LX055
7. Split Collar 1. Use the spring compressor to compress the valve spring into position. Spring Compressor: 9-8523-1423-0 2. Install the split collars to the valve stem. 3. Set the split collars by tapping around the head of the collar with a rubber hammer.
014RY00039
8. Intake manifold gasket 9. Intake manifold 1. Install the manifold gasket with the end having the sharp corners facing the rear of the engine. 2. Install the intake manifold to the cylinder head. 3. Tighten the manifold bolt/nuts to the specified torque. Manifold Bolt/Nut Torque Bolt
RTW46ASH002301
Nm(kgm/lbft) 19 (1.9/14) 24 (2.4/17)
Nut
PISTON AND CONNECTING ROD
RTW46ALF000301
Reassembly Steps
1. 2. 3. 4. Piston Connecting rod Piston pin snap ring Piston pin 5. 6. 7. Piston pin snap ring Piston ring Connecting rod bearing
Reassembly
1. Piston 2. Connecting Rod 1. Clamp the connecting rod in a vise.Take care not to damage the connecting rod. 2. Use a pair of pliers to install the piston pin snap ring to the piston.
F06MV015
Install the piston to the connecting rod so that the piston head front mark (1) and the connecting rod mark (2) are facing in the same direction. 3. Piston Pin Snap Ring
RTW36ASH001801
4. Piston Pin 1. Apply a coat of engine oil to the piston pin and the piston pin hole. 2. Use your fingers to force the piston pin into the piston until it makes contact with the snap ring.
RTW36ASH001901
5. Piston Pin Snap Ring 1. Use your fingers to force the piston pin snap ring into the piston snap ring groove. 2. Check that the connecting rod moves smoothly on the piston pin.
015R100001
6A 98 ENGINE MECHANICAL 6. Piston Ring 1. Use a piston ring replacer to install the three piston rings. Piston Ring Replacer Install the piston rings in the order shown in the illustration. 1. Oil ring 2. 2nd compression ring 3. 1st compression ring
RTW36ASH002001
NOTE: Install the compression rings with the stamped side facing up. Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring. 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.
015R100006
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
RTW46AMF000101
Reassembly Steps
1. 2. 3. 4. Positive Crankcase Ventilation (PCV) Valve Rubber space Cylinder head insulator cover Breather pipe 5. 6. Fixing bolt Oil filler cap
Reassembly
1. PCV Valve Install the PCV valve and tighten the bolts to specified torque. PCV Valve Bolts Torque 2 (0.2/17)
010R100014
Nm(kgm/lb in)
2. Rubber Spacer 3. Cylinder Head Insulator Cover 4. Breather Hose Apply LOCTITE 262 or equivalent to the new breather pipe. Do not reuse the breather pipe. 5. Fixing Bolt Fixing Bolt Torque 19 (1.9/14) Nm(kgm/lb in)
RTW36ASH001401
6. Oil Filler Cap
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1. 2. 3. 4. 5. 6. 7. 8. 9. Cylinder body Tappet Crankshaft upper bearing Crankshaft Crankshaft thrust bearing Crankshaft bearing cap with lower bearing Camshaft Timing gear case Camshaft thrust plate 10. 11. 12. 13. 14. 15. 16. 17. 18. Camshaft timing gear Piston and connecting rod with upper bearing Connecting rod bearing cap with lower bearing Piston cooling oil pipe Oil pump with oil pipe Crankshaft rear oil seal Crank case Cylinder body rear plate Flywheel
RTW46ALF000501
Reassembly Steps-2
19. 20. 21. 22. Crankshaft timing gear Idler gear shaft Idler gear "A" Idler gear "B" and shaft 23. 24. 25. 26. Injection pump Water pump Timing gear case cover Crankshaft damper pulley
011R300002
Reassembly Steps-3
27. 28. 29. 30. Cylinder head gasket Cylinder head Push rod Rocker arm shaft and rocker arm 31. 32. 33. 34. Thermostat housing with thermo switch Water by-pass hose Injection nozzle and bracket Cylinder head cover with gasket
Reassembly
1. Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body, the oil holes, and the water jackets.
015R100003
2. Tappet 1. Apply a coat of engine oil to the tappet and the cylinder body tappet insert holes. 2. Locate the position mark applied at disassembly (if the tappet is to be reused). NOTE: The tappet must be installed before the camshaft installation.
014LX088
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.
015LX125
2. Locate the position mark applied at disassembly if the removed upper bearings are to be reused. 4. Crankshaft Apply an ample coat of engine oil to the crankshaft journals and the crankshaft bearing surfaces before installing the crankshaft.
015R100004
ENGINE MECHANICAL 6A 105 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.
015LX115
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 cylinder body fitting surfaces at the points shown in the illustration. NOTE:
015LX127
Be sure that the bearing cap fitting surface is completely free of oil before applying the liquid gasket. Three bond 1207B Do not allow the liquid gasket to obstruct the cylinder thread holes and bearings. ThreeBond 1207B is a fast-drying liquid gasket. Tighten the bearing caps immediately after applying the gasket. 2. 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. 3. Apply engine oil to the crankshaft bearing cap bolts.
015LX128
4. Tighten the crankshaft bearing cap bolts to the specified torque a little at time in the sequence shown in the illustration. Crankshaft Bearing Cap Torque 167 (17/123) Nm(kgm/lbft)
5. Check to see the crankshaft turns smoothly by rotating it manually.

015LX129
6A 106 ENGINE MECHANICAL 7. Camshaft 1. Apply a coat of engine oil to the camshaft and the camshaft bearings. 2. Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings.
014RY00019
8. Timing Gear Case Tighten the timing gear case with timing gear case gasket to the specified torque. Timing Gear Case Bolt Torque 19 (1.9/14) Nm(kgm/lbft)
020R300003
9. 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 19 (1.9/14) Nm(kgm/lbft)
020RY00032
10. Camshaft Timing Gear 1. Install the camshaft timing gear to the camshaft. The timing gear mark must be facing outward. 2. Tighten the timing gear to the specified torque. Timing Gear Bolt Torque 110 (11.2/82) Nm(kgm/lbft)
RTW36ASH000901
ENGINE MECHANICAL 6A 107 11. Piston and Connecting Rod with Upper Bearing 12. 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. 1. Oil ring 2. 2nd compression ring 3. 1st compression ring
RTW36ASH002001
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.
015R100006
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 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.
015LX096
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.
015R100007
6A 108 ENGINE MECHANICAL 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 two step of anglar tigthen method. Connecting Rod Bearing Cap Bolt Torque Nm (kgm/Ib ft) 4JA1T (L), 78-88 (8.0/57 9.0/65) 4JA1TC 1st step ; 29.029.2 (3.00/22.03.01/22.2) 4JH1TC 2nd step ; 45-60
015LX130
13. Piston Cooling Oil Jet 1. Install the piston cooling oil jet to the cylinder body. 2. Tighten the oil jet bolts and relief valve to the specified torque. Oil Jet Bolt Torque M8 1.25 M6 1.00
052LX010
Nm(kgm/lbft) 19 (1.9/14) 8 (0.8/6)
Relief Valve Torque 29 (3.0/22)
Nm(kgm/lbft)
NOTE: Check that there is no interference between the piston and the oiling jet by slowly rotating the crankshaft. 14. Oil Pump with Oil Pipe Install the oil pump with the oil pipe and tighten the bolts to the specified torque. Oil Pump Bolt Torque 19 (19/14) Nm(kgm/lbft)
NOTE:
051R100004
Take care not to damage the O-rings when tightening the oil pipe bolts. 15. Crankshaft Rear Oil Seal Use a oil seal install to install the crankshaft rear oil seal. Oil Seal Installer : 5-8840-2359-0
015LX112
ENGINE MECHANICAL 6A 109 16. Crank Case 1. Apply the recommended liquid gasket (Three bond 1207B) or its equivalent to arch gasket fitting surface as shown in the illustration. 2. Install the crankcase front gasket (1) to the timing gear case arches. The gasket projection (2) must be facing forward. NOTE: ThreeBond 1207B is a fast-drying liquid gasket.
013RW012
Install the arch packing to the crankcase immediately aftter applying the gasket. 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 (1207C) or its equivalent to arch gasket fitting area as indicated in the illustration.
013RW011
4. Apply the recommended liquid gasket or its equivalent to groove of the crankcase 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.
013LV003
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 19 (1.9/14) Nm(kgm/lbft)
013R100001
6A 110 ENGINE MECHANICAL 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 82 (8.4/61) Nm(kgm/lbft)
020R100001
18. Flywheel 1. Apply a coat of engine oil to the threads of the flywheel bolts. 2. Align the flywheel with the crankshaft dowel pin. 3. Tighten the flywheel bolts in the numerical order shown in the illustration. Gear stoper: 5-8840-0214-0 Flywheel Bolt Torque
015LX113
Nm(kgm/lbft) 118 (12/87)
19. Crankshaft Timing Gear Use the crankshaft timing gear installer (1) to install the crankshaft timing gear (2). The crankshaft timing gear setting mark must be facing outward. Crankshaft Timing Gear Installer: 9-8522-0020-0
020RY00034
20. Idler Gear Shaft 21. Idler Gear "A" 1. Turn the crankshaft clockwise to set the DTC of the No.1 piston. 2. Apply engine oil to the idler gear and the idler gear shaft. The idler gear shaft oil hole (A) must be facing up. 3. Position the idler gear setting marks so that they are facing the front of the engine.
020RY00035
ENGINE MECHANICAL 6A 111 4. Align the idler gear setting mark with the crankshaft timing gear (1) setting mark. 5. Align the idler gear setting mark with the camshaft timing gear (2) setting mark. 6. 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. 7. Tighten the idler gear bolt to the specified torque.
020RY00036
Idler Gear "A" Bolt Torque 30 (3.1/22)
Nm(kgm/lbft)
22. Idler Gear "B" and Shaft 1. Apply engine oil to the idler gear and the idler gear shaft. 2. Align the idler gear "B" (3) setting mark with the idler gear "A" (4) setting mark. 3. Tighten the idler gear bolt to the specified torque. 4. Be sure to remove the lock bolt (5) from idle gear B. Idler Gear "B" Bolt Torque 76 (7.7/56)
020R300006
Nm(kgm/lbft)
5. If the idle gear "B" is disassembled, reassemble in the following procedure. 1) Drive pins into the main gear, the front gear, and the rear gear.
020L200019
2) Install the main gear bearing from the front side of the main gear (the side with the groove). 3) Place the main gear in a vise with copper plate so that the rear side of the main gear facing up.
020L200007
6A 112 ENGINE MECHANICAL 4) Set the spring as shown in the illustration.
RTW31BSH000101
5) Position the rear gear so that the pin is aligned with the receiving end of the spring.
RTW31BSH000201
6) Install the snap ring to the main gear groove.
RTW31BSH000301
7) Install suitable bolts, nuts and washers to special tool as shown in the illustration to rotate the scissors gear. End yoke holder: 5-8840-2447-0
RTW31BSH000501
ENGINE MECHANICAL 6A 113 8) Insert the bolts of the special tool into the rear gear setting hole. Rotate the rear gear to mesh the teeth of main gear and rear gear. 9) Insert a lock bolt (M6 1 L=30) into scissors gear fixing hole to prevent the scissors gear from turning. 10) Place the main gear in a vise with copper plate so that the front side of the main gear facing up. 11) Repeat steps 4 to 8 to install the front gear. 12) Lock the front gear, the main gear, and the rear gear with lock bolt (inserted at Step 8).
RTW31BSH000401
6A 114 ENGINE MECHANICAL 23. Injection Pump 1. Install the O-ring (1) to the injection pump flange (2). 2. Attach the noise insulator rubber to the cylinder body . 3. Install the injection pump to the timing gear case.Align the idler gear "B" (3) mark with the injection pump timing gear (4) mark.
020RY00039
4JA1TC/4JH1TC: 4. Tighten the injection pump bolts (5) to the specified torque. Injection Pump Bolt Torque Nm(kgm/lbft) 19 (1.9/14)
5. Install the injection pump bracket (6) and the bracket bolts (7) and (8) to the cylinder body. Temporarily tighten the bracket bolts. 6. Tighten the bracket bolts (7) to the specified torque. 7. Tighten the bracket bolt (8) to the specified torque. NOTE: Tighten the bracket bolt (7) first.
Injection Pump Bracket Bolt Torque 19 (1.9/14)
Nm(kgm/lbft)
RTW36AMH000101
ENGINE MECHANICAL 6A 115 4JA1T(L): 4. Tighten the injection pump bolts to the specified torque. 5. Install the injection pump bracket (4) and the bracket bolts (5) and (6) to the cylinder body. Temporarily tighten the bracket bolts. 6. Tighten the bracket bolts (5) to the specified torque. 7. Tighten the bracket bolts (6) to the specified torque. Injection pump Bracket Bolt Torque (6)
RTW46ASH002201
Nm(kgm/lbft)
19 (1.9/14) Injection pump Bracket Bolt Torque (5) 40 (4.1/30) Nm(kgm/lbft)
24. Water Pump 1. Apply the recommended liquid gasket or its equivalent to the water pump at the position shown in the illustration. Do not apply an excessive amount of liquid gasket. 2. Tighten the water pump bolts to the specified torque. Water Pump Bolt Torque 20 (2.0/14)
030RY00007
Nm(kgm/lbft)
25.Timing Gear Case Cover 1. Align the gear case with the timing gear case knock pin and then install the timing gear case cover. 2. Tighten the gear case cover bolts to the specified torque. Gear Case Cover Bolt Torque M8 M12
020R300004
Nm(kgm/lbft) 19 (1.9/14) 76 (7.7/56)
26. Crankshaft Damper Pulley 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 bolt. Crankshaft Damper Pulley Bolt Torque
014R100014
Nm(kgm/lbft)
206 (21/152) Take care not to damage the crankshaft damper pulley boss.
6A 116 ENGINE MECHANICAL 27. 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". 28. Cylinder Head 1. Align the cylinder body dowels and the cylinder head dowel holes. Carefully place the cylinder head on the cylinder head gasket. 2. Apply a coat of engine oil to the cylinder head bolt threads and setting faces. 3. Tighten the cylinder head bolts in three steps of anglar tightening methed. Follow the numerical sequence shown in the illustration. Cylinder Head Bolt Torque 1st step 2nd step
011LX073
Nm(kgm/lbft) 49 (5.0/36) 60 - 75 60 - 75
3rd step
30. Rocker Arm Shaft and Rocker Arm Tighten the rocker arm shaft bracket bolts in the numerical order shown in the illustration. Rocker Arm Shaft Braket Bolt Torque 54 (5.5/40) Nm(kgm/lbft)
014LX083
31. Thermostat Housing 1. Install the thermostat housing. 2. Tighten the thermostat housing bolts to the specified torque. Thermostat Housing Bolt Torque 19 (1.9/14) Nm(kgm/lbft)
031R300002
ENGINE MECHANICAL 6A 117 33. Injection Nozzle Holder 1. Install the injection nozzle gasket and the O-ring to the injection nozzle holder. Be sure that the O-ring fits snugly in the injection nozzle groove. 2. Install the nozzle holder toghther with the nozzle holder bracket to the cylinder head.
RTW46ASH001201
3. Tighten the nozzle holder bracket bolt to the specified torque. Injection Nozzle Holder Bracket Bolt Torque 37 (3.8/28)
Nm(kgm/lbft)
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. Valve Clearance (At Cold) 0.4 (0.0157) mm(in)
014RY00015
34. 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
RTW46ASH001101
Nm(kgm/lbft)
13 (1.3/9.4) 4. Connect the positive crankcase ventilation (PCV) hose to the cylinder head cover.
INSTALLATION EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Exhaust Manifold Oil Cooler with Oil Filter Generator Bracket Water Inlet Pipe Generator and Adjusting Plate Vacuum Pump Oil Return Hose Compressor Bracket Turbocharger Catalytic Converter Heat Protector Cooling Fan Pulley Oil Cooler Water Pipe Fuel Leak Off Pipe Oil Pressure Warning Switch Starter Motor Injection Pump Injection Pump Cover 18. 19. 20. 21. 22. 23. 24. 25. 26-1. 26-2. 27. 28. Engine Mounting Bracket and Foot Intake Manifold Power Steering Oil Pump Bracket Fuel Injection Pipe with Clip Fuel Filter Bracket (Except EURO III) Fuel Filter Assembly (Except EURO III) Oil Level Gauge EGR Valve EGR Pipe EGR Cooler (EURO III model only) Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) Clutch Assembly or Flex Plate
Installation
1. Exhaust Manifold 1) Install the exhaust manifold to the cylinder head with the manifold gasket. 2) Tighten the exhaust manifold bolts and nuts to the specified torque a little at a time. Exhaust Manifold Bolt and Nuts Torque Nm(kgm/Ib ft)
027R100003
27 (2.7/20) 3) Install the exhaust manifold bracket to the manifold and the cylinder body. Manifold Bracket Bolt Torque Nm(kgm/Ib ft) 19 (1.9/14)
027R100004
2. Oil Cooler with Oil Filter 1) Install the O-ring to the oil filter body flange groove. 2) Install the oil filter body to cylinder block and tighten to the specified torque. Oil Filter Body Bolt and Nut Torque Nm(kgm/Ib ft) BOLT 19 (1.9/14) NUT 24 (2.4/17)
RTW46ASH001301
3. Generator Bracket Install the generator bracket to the cylinder body and tighten the bracket bolts to the specified torque. Bracket Bolt Torque Nm(kgm/Ib ft) 40 (4.1/30)
066RY00001
6A 120 ENGINE MECHANICAL 4. Water Inlet Pipe 1) Tighten the water inlet pipe bolts to the specified torque. Suction Pipe Bolt Torque Nm(kgm/Ib ft) 19 (1.9/14)
032R300001
5. Generator and Adjusting Plate 1) Install the generator to the bracket (1). 2) Temporarily tighten the generator bolt (2) and adjusting plate bolts (3). The bolts will be finally tightened after installation of the cooling fan drive belt.
066RY00002
3) Connect the vacuum pump rubber hose (4) to the vacuum pump (5), and the oil pan (6). 6. Vacuum Pump Oil Return Hose Connect the vacuum oil pipe (7) to the vacuum pump, and the cylinder body
052R300001
7. Compressor Bracket 1) Install the compressor bracket to the cylinder head. 2) Tighten the bracket bolts to the specified torque. Bracket Bolt Torque Nm(kgm/Ib ft)
M8b1.25 M10b1.25 19 (1.9/14) 40 (4.1/30)
042RY00003
ENGINE MECHANICAL 6A 121 8. Turbocharger 1) Install the turbocharger and the gasket. 2) Temporarily tighten the turbocharger nuts at this time. They will be fully tightened after the installation of the turbocharger oil pipe. Always install new nuts and new gasket.
027R100002
3) Install the oil return pipe with gasket to the turbocharger. 4) Tighten the turbocharger oil return pipe to the specified torque. Bracket Bolt Torque Nm(kgm/Ib ft) 8 (0.8/6)
036R100001
5) Before installing the oil feed pipe, supply 10 - 20 cc of clean engine oil to the turbocharger center housing through the oil feed opening. 6) Turn the rotating assembly with your hand to thoroughly lubricate the internal parts. 7) Tighten the oil feed pipe to the specified torque. Turbocharger Oil Feed Pipe Joint Bolt Torque Nm(kgm/Ib ft)
M10b1.5
RTW46ASH001501
22 (2.25/16) 54 (5.5/40)
M14b1.5
8) Tighten the turbocharger nut to the specified torque. Turbocharger Nut Torque Nm(kgm/Ib ft) 27 (2.7/20)
027R100005
6A 122 ENGINE MECHANICAL 9) Install the water feed adapter (1) with the gaskets to turbocharger and tighten to the specified torque. Adapter Torque Nm(kgm/Ib ft) 39 (4.0/29) 10) Install the water feed pipe with the gaskets and tighten to the specified torque. Water Return Pipe Torque Nm(kgm/Ib ft) 39 (4.0/29) 11) Install the water return pipe with the gaskets and tighten to the specified torque. Water Return Torque Nm(kgm/Ib ft) 39 (4.0/29) 12) Clamp the water feed pipe to the oil return pipe of the turbocharger. Fixing Bolt (3) Torque Nm(kgm/Ib ft) 8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return. 9. Catalytic Converter Install the catalytic converter with gasket and tighten the nut to the specified torque. Catalytic converter Nut Torque Nm(kgm/Ib ft) 27 (2.7/20) Do not install the catalytic converter, if drop down it. 10. Heat Protector Install the heat protector and tighten the bolt to the specified torque. Heat Protector Bolt Torque Nm(kgm/Ib ft) 9 (0.9/6.5 Ib in) 11. Cooling Fan Pulley 1) Install the cooling fan pulley to the water pump. 2) Tighten the cooling fan pulley nuts to the specified torque. Pulley Nut Torque Nm(kgm/Ib ft) 8 (0.8/6) 12. Oil Cooler Water Pipe 13. Fuel Leak Off Pipe 14. Oil Pressure Warning Switch
027R100007
033R300002
ENGINE MECHANICAL 6A 123 15. Starter Motor Tighten the starter motor bolts to the specified torque. Starter Motor Bolt Torque Nm(kgm/Ib ft) 85 (8.7/63) 16. Injection Pump 17. Injection Pump Cover (4JA1TC/4JH1TC only) 4JA1L, 4JH1TC 18. Engine Foot Install the engine foot to the cylinder body and tighten the bracket bolts to the specified torque. Engine Foot Bolt Torque Nm(kgm/Ib ft)
Right Side Left Side M10b1.25 M10b1.25 M14b1.50 40 (4.1/30) 40 (4.1/30) 127 (13/93)
022R300003
4JA1TC
RTW46ASH002601
19. 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 Nm(kgm/Ib ft) 19 (1.9/14) Intake Manifold Flange Nut Torque
RTW36ASH001001
Nm(kgm/Ib ft)
24 (2.4/18) 4) Connect the PCV hose to the cylinder head cover. 5) Install the fan drive belt and adjust the belt tension referring SERVICING of this section
6A 124 ENGINE MECHANICAL 20. Power Steering Oil Pump Bracket Oil Pump Braket Nut and Bolt Torque
1 2 3
Nm(kgm/Ib ft)
37 (3.8/28)
M10b1.25 M8b1.25
18 (1.8/13) (Bolt ID:8)
431RY00013
040R300005
21. Fuel Injection Pipe with Clip 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. Torque Injection Pump Side (4JA1TC/4JH1TC) Nm(kgm/Ib ft) 40 (4.1/30) Injection Pipe Sleeve Nuts 29 (3.0/22) Injection Pipe Clip Nuts 8 (0.8/6) 22. Fuel Filter Bracket (Except EURO III model) Install the fuel filter bracket and tighten fixing bolts to the specified torque. Fuel Filter Bracket Bolt Torque Nm(kgm/Ib ft) 21 (2.1/15) 23. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly and tighten fixing bolts to the specified torque. Fuel Filter Assembly Bolt Torque Nm(kgm/Ib ft) 21 (2.1/15) 24. Oil Level Gauge Install the oil level gauge and tighten fixing bolts to the specified torque. Oil Level Gauge Bolt Torque Nm(kgm/Ib ft)
M8 M6 19 (1.9/14) 8 (0.8/6)
Nm(kgm/Ib ft)
Nm(kgm/Ib ft)
ENGINE MECHANICAL 6A 125 25. EGR Valve Install the EGR valve assembly to the intake minifold with the two gasket. Tighten the four nuts to the specified torque. Nut Tolque Nm(kgm/Ib ft) 31 (3.1/23) Connector the vacuum hose. 26-1. EGR Pipe Install the EGR valve adapter with the gasket to the EGR valve assembly and install the EGR pipe with the gasket. Tighten fixing bolts and nuts to the specified torque. EGR Valve Adapter Bolts Nm(kgm/Ib ft) 24 (2.4/17) EGR Pipe Bolts and Nuts 27 (2.7/20)
025R100008
Nm(kgm/Ib ft)
RTW36ASH000301
26-2. EGR Cooler (EURO III model only)
RTW48ASH001801
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) Install the throttle body with the gasket to the intake manifold and install the intake duct with the gasket. Tighten the two bolts and the two nuts to the specified torque. Throttle Body and Intake Duct Nm(kgm/Ib ft) Bolt Nut
RTW36ASH000201
19 (1.9/14) 24 (2.4/17)
28. Clutch Assembly or Flex Plate
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1. 2. 3. 4. 5. 6.
Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa) Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa) Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa) Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa) Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa) Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
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
RTW46ALF001501
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
051R100005
Disassembly Steps
1. Oil pipe 2. Strainer 3. Pump cover 4. Driven gear with bushing Disassembly procedure is shown in the illustration above numerical order. 5. 6. 7. 8. Driven gear Relief valve assembly Pinion gear Oil pump body

Gear Teeth and Body Inner Wall Clearance

Use a feeler gauge to measure the clearance between the 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
051RY00001
Limit 0.20 (0.0079)
0.14 (0.0055)
Gear and Body Clearance

Use a feeler gauge to measure the clearance between the 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 0.06 (0.024)
RTW46ASH002701
Limit 0.15 (0.0059)
Drive Shaft and Oil Pump Body Clearance

Use a micrometer to measure the drive shaft outside diameter. Use an inside dial indicator to measure the pump body inside diameter. If the clearance between the drive shaft and the oil pump body exceeds the specified limit, the oil pump assembly must be replaced. Drive Shaft and Oil Pump Body Clearance mm (in)
051RY00003
Standard 0.04 (0.0016)
Limit 0.20 (0.0079)
REASSEMBLY
051R100006
Reassembly Steps
1. Oil pump body 2. Drive gear 3. Driven gear 4. Pump cover Reassembly procedure is shown in the illustration above numerical order. Pump cover fixing bolts torque: 16 Nm (1.6 kgm/12 lb ft) 5. 6. 7. 8. Pinion gear Strainer Relief valve assembly Oil pipe
OIL FILTER AND OIL COOLER DISASSEMBLY
050R300004
Disassembly Steps
1. Oil filter cartridge 5. 2. Bolt 6. 3. Gasket 7. 4. Oil cooler Disassembly procedure is shown in the illustration above numerical order. Body Oil cooler relief valve Regulating valve

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 (200kPa (2kg/cm / 28psi)) to the other side of the oil cooler water passage. If air bubbles rise to the surface, there is water leakage. Should be replaced oil cooler assembly.
050RY00002
REASSEMBLY
050R300003
Reassembly Steps
1. Body 5. 2. Regulating valve 6. 3. Oil cooler relief valve 7. 4. Oil cooler Reassembly procedure is shown in the illustration above numerical order. Gasket Bolt Oil filter cartridge
6A 134 ENGINE MECHANICAL 1. Body 2. Oil Filter Safety Valve 3. Oil Cooler Safety Valve Tighten the oil filter A and oil cooler B relief valve to the specified torque. Regulating Valve Nm(kgm/lb ft)
A
64 (6.5/48)
RTW46ASH001701
4. Oil Cooler 5. Gasket 6. Bolt Tighten bolt with gasket and oil cooler to the specified torque. Bolt Torque Nm(kgm/lb ft) 40 (4.1/30)
050R300006
7. Oil Filter Cartridge 1) Apply engine oil to the O-ring. 2) Tighten the oil filter cartridge to the specified torque. Filter wrench: 5-8840-0201-0 Oil Filter Cartride Torque Nm(kgm/lb ft) 18 (1.8/13)
050RY00004
INTER COOLER
RTW46ALF001001
Removal Steps
1. Radiator grille 2. Front bumper fascia 3. Front bumper inpact support assembly 4. Inter cooler
Installation Steps
4. Inter cooler 3. Front bumper inpact support assembly 2. Front bumper fascia 1. Radiator grille
Removal
1. Radiator Grille Refer to removal procedure in Sheet Metal section.
RTW36ASH000601
2. Front Bumper Fascia Remove the nine clips and four screws. Disconnect the fog light harness connectors.
RTW36ASH000501
3. Front Bumper Impact Support Assembly Remove the nut and two bolts.
RTW46ASH002101
4. Inter Cooler Remove the nut and two bolts. Disconnect the air hose.
Installation
4. Inter Cooler Tighten the nut and two bolts. 3. Front Bumper Impact Support Assembly Tighten the nut and two bolts. 2. Front Bumper Fascia Install the nine clips and four screws. Connect the fog light harness connectors. 1. Radiator grille Refer to installation procedure in Sheet Metal section.
SPECIAL TOOLS
Illustration Tool Number
5-8840-0201-0 Filter Wrench
Tool Name
5-8840-0253-0
Filter Wrench
5-8840-2675-0
Compression Gauge
5-8531-7001-0
Adapter; Compression Gauge
5-8840-2723-0
Nozzle Holder Remover
5-8840-0019-0
Sliding Hammer
5-8521-0002-0
Universal Puller
5-8840-2360-0
Oil Seal Remover
9-8523-1423-0
Spring Compressor
9-8523-1212-0
Valve Guide Replacer
Illustration
Tool Number
5-8840-2040-0 (4JA1L/TC) 5-8840-2313-0 (4JH1TC)
Tool Name
Cylinder Liner Installer
5-8840-2038-0
Bearing Replacer; Camshaft
5-8840-2000-0
Pilot Bearing Remover
5-8522-0024-0
Pilot Bearing Installer
5-8840-2033-0
Oil Seal Installer
5-8840-9018-0
Piston Ring Compressor
5-8840-2359-0
Oil Seal Installer
9-8522-0020-0
Crankshaft Timing Gear Installer
5-8840-0266-0
Angle Gauge
5-8840-0214-0
Gear Stopper
5-8840-2039-0 (4JA1L/TC) 5-8840-2304-0 (4JH1TC)
Cylinder Liner Remover
Illustration
Tool Number
5-8840-2361-0
Tool Name
Front Oil Seal Installation
MEMO
ENGINE COOLING 6B 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE Main Data and Specifications ....................................................................................... 6B General Description .................................................................................................. 6B Coolant Flow .............................................................................................................. 6B Water Pump................................................................................................................ 6B Thermostat ................................................................................................................. 6B Radiator ...................................................................................................................... 6B Diagnosis........................................................................................................................ 6B Draining and Refilling Cooling System........................................................................ 6B 3 4 4 5 5 6 7 8
Water Pump.................................................................................................................... 6B - 10 Removal and Installation .......................................................................................... 6B - 10 Removal...................................................................................................................... 6B - 10 Inspection and Repair ............................................................................................... 6B - 11 Installation.................................................................................................................. 6B - 11 Thermostat ..................................................................................................................... 6B - 13 Removal and Installation .......................................................................................... 6B - 13 Removal...................................................................................................................... 6B - 13 Inspection and Repair ............................................................................................... 6B - 13 Installation.................................................................................................................. 6B - 14 Radiator .......................................................................................................................... 6B - 15 Removal and Installation .......................................................................................... 6B - 15 Radiator and Associated Parts................................................................................. 6B - 15 Removal...................................................................................................................... 6B - 16 Inspection and Repair ............................................................................................... 6B - 17 Installation.................................................................................................................. 6B - 18
6B 2 ENGINE COOLING
PAGE Engine coolant change ............................................................................................. 6B - 19 Fan Clutch with Cooling Fan ........................................................................................ 6B - 20 Inspection and Repair ............................................................................................... 6B - 20
ENGINE COOLING 6B 3

Item M/T Cooling system Water pump type Pump to crankshaft speed ratio Delivery volume Pump speed at 3000 rpm Water temperature at 30C (86F) Pump bearing type Double row shaft (To 1) lit (US/UK gal)/min Description A/T
Engine coolant forced circulation Centrifugal impeller type 1.2 100 (26.3/22.2)
Thermostat type Valve initial opening temperature (Oil cooler thermo valve) (EGR cooler thermo valve) Valve full opening temperature (Oil cooler thermo valve) (EGR cooler thermo valve) Valve lift at fully open position (Oil cooler thermo valve) (EGR cooler thermo valve) Radiator Heat radiation capacity Heat radiation area Radiator front area Radiator dry weight Radiator cap valve opening pressure Engine coolant capacity Engine coolant total capacity mm (in) C (F) C (F)
Wax pellet with jiggle valve 82 (180) 76.5 (170) 40 (104) 95 (203) 90 (194) 55 (131) 9.5 (0.37) 4.5 (0.18) 3.5 (0.14) Tube type corrugated 93.0 kw (79,980 kcal/h) 11.63 m (1.081ft ) 0.28m (0.026 ft ) 52 N (5.3 kg/11.7 lb) 53 N (5.4 kg/11.9 lb) 93.3 ~ 122.7kpa (13.5 ~ 17.8psi) 2.4 lit (5.1 U.S pint) 10.1 lit (21.3 U.S pint) 2.3 lit (4.9 U.S pint) 10.0 lit (21.1 U.S pint)
6B 4 ENGINE COOLING
GENERAL DESCRIPTION
COOLANT FLOW
RTW46ALF001101
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and thermostat through the bypass hose and back to the cylinder body. The coolant does not circulate through the radiator. When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now circulating through the radiator for effective engine cooling.
ENGINE COOLING 6B 5
WATER PUMP
RTW46ASF000101
A centrifugal type water pump forcefully circulates the coolant through the cooling system. The water pump is not disassembled type.
THERMOSTAT
030RY00005
A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.
6B 6 ENGINE COOLING
RADIATOR
The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 93.3 ~ 122.7 kPa (13.5 ~ 17.8 psi) pressure. (No oil cooler provided for M/T)
110RS001
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system capacity. Total Cooling System Capacity Lit (US / UK gal) 9.4 (2.5/21) 4JA1L/TC M/T 10.1 (2.7/2.2) 4JH1TC A/T 10.0 (2.6/2.2) 4JH1TC See section 0B MAINTENACE AND LUBRICATION.
F06RW005
NOITE: To maintain the corrosion resistance of the aluminum radiator, water and antifreeze must be combined in a 1:1 solution (50% antifreeze and 50% water) NOTE
PTW46BSH000201
ENGINE COOLING 6B 7
DIAGNOSIS
Engine Cooling Trouble Symptom Engine overheating Possible Cause Low Engine Coolant level Thermo meter unit faulty Faulty thermostat Replenish Replace Replace Action
Faulty Engine Coolant temperature Repair or replace sensor Clogged radiator Faulty radiator cap Clean or replace Replace
Low engine oil level or use of Replenish or change oil improper engine oil Clogged exhaust system Faulty Throttle Position sensor Clean exhaust system or replace faulty parts Replace throttle valve assembly
Open or shorted Throttle Position Repair or replace sensor circuit Damaged cylinder head gasket Engine overcooling Engine slow to warmup Faulty thermostat Faulty thermostat Thermo unit faulty Replace Replace Replace Replace
6B 8 ENGINE COOLING
Draining and Refilling Cooling System

Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the MIN" and MAX" lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the MAX" line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be free from oil. Replace the EC if excessively dirty. 1. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.
P1010064
2. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the cap while the engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure. 3. Disconnect all hoses from the EC reserve tank. Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it. Install the reserve tank and hoses. 4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze. Procedure for filling with coolant (in case of full change) Make sure that the engine is cool. Open radiator cap pour coolant up to filler neck. Pour coolant into reservoir tank up to MAX" line. 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. WARNING: When the coolant is heated to a high temperature, be sure not to loosen or remove the radiator cap. Otherwise you might get scalded by not 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.
ENGINE COOLING 6B 9 After tightening radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. Check to see the thermostat has opened through the needle position of water thermometer, conduct a 5minute idling again and stop the engine. 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 cooling system and reservoir tank hose for leakage. Pour coolant into the reservoir tank up to MAX" line.
6B 10 ENGINE COOLING
WATER PUMP
Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.
Removal
1. Radiator Upper Hose 1) Partially drain the engine coolant. 2) Remove the radiator upper hose.
2. Water Outlet Pipe 1) Disconnect the turbocharger-cooling pipe from outlet pipe. 2) Loosen the fixing bolt and remove the water outlet bolt. 3. Thermostat Remove the thermostat from the thermostat housing. Take care not to damage the thermostat. 4. Upper Fan Shroud
031R300003
5. Fan and Fan Clutch 1) Loosen the fan clutch nuts. 2) Remove the fan together with the fan clutch. Take care not to damage the radiator core. 6. Fan Drive Belt and Pulley 1) Loosen the tension adjust bolt on the generator. 2) Remove the fan drive belt with the fan pulley.
030R300001
7. Water Pump 1) Remove the water pump bolts. 2) Remove the water pump.
030R300002
ENGINE COOLING 6B 11
Inspection and Repair

The water pump is not disassembled type. Make necessary parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. Cracks in the water pump body Coolant leakage from the seal unit Excessive radial play or abnormal noise in the fan center when rotate by hand Excessive thrust play in the fan center (Standard play: less than 0.2mm) Cracks or corrosion in the impeller
V V V V V
Installation
1. Water Pump 1) Install the water pump with new gasket. 2) Tighten bolts and nuts to specified torque. Water Pump Bolt/Nut Torque Nm(kgm/lb ft) 20 (2.0/14) 2. Fan Drive Belt and Pulley 1) Install the fan drive belt and fan pulley. 2) Apply tension to the fan drive belt by moving the generator. 3) Apply a force of 98N(10kg/22 lb) to the drive belt midportion to check the drive belt deflection. Fan Drive Belt Deflection mm (in) New belt: 4-7(0.16-0.28) Reuse belt: 6-9(0.24-0.35) 3. Fan and Fan Clutch 1) Install the fan and fan clutch to pulley. 2) Tighten the nuts to specified torque. Fan Clutch Nut Torque Nm(kgm/lb in) 8(0.8/69) 4. Upper Fan Shroud
030R300002
030R300001
6B 12 ENGINE COOLING 5. Thermostat Install the thermostat to the thermostat housing. 6. Water Outlet Pipe 1) Install the water outlet pipe with new gasket to the thermostat housing. 2) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque Nm(kgm/lb ft) 19(1.9/14)
031R300003
3) Connect the turbocharger-cooling pipe to outlet pipe. 7. Radiator Upper Hose 1) Connect the radiator upper hose to the water outlet pipe. 2) The knob of clamp shall be dircted to holizonal side. 3) Replenish the engine coolant.
THERMOSTAT
Removal
1. Radiator Upper Hose 1) Partially drain the engine coolant. 2) Remove the radiator upper hose.
2. Water Outlet Pipe 3) Disconnect the turbocharger-cooling pipe from outlet pipe. 4) Loosen the fixing bolt and remove the water outlet bolt. 3. Thermostat Remove the thermostat from the thermostat housing. Take care not to damage the thermostat.
031R300003

Operating Test of Thermostat

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)
031RY00005
4. Check the thermostat full opening temperature. Thermostat Full Opening Temperature C (F) 95 (203) Valve Lift At Fully Open Position 9.5 (0.37) mm (in)
Q Thermometer R Agitating rod S Wooden piece Installation

1. Thermostat Install the thermostat to the thermostat housing. 2. Water Outlet Pipe 3) Install the water outlet pipe with new gasket to the thermostat housing. 4) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque Nm(kgm/lb ft)
031R300003
19(1.9/14) 5) Connect the turbocharger-cooling pipe to outlet pipe. 3. Radiator Upper Hose 1) Connect the radiator upper hose to the water outlet pipe. 2) The knob of clamp shall be directed to holizonal side. 3) Replenish the engine coolant.
RADIATOR
Radiator and Associated Parts
RTW36BLF000101
Legend
1. Radiator Hose 2. Drain Plug 3. Fan Guide, Lower 4. Fan Guide 5. Bracket 6. Reserve Tank Hose 7. Reserve Tank 8. Radiator Cap 9. Radiator Assembly
Removal
1. 2. 3. 4. Disconnect battery ground cable. Loosen a drain plug to drain EC. Disconnect oil cooler hose on automatic transmission (A/T). Disconnect radiator inlet hose and outlet hose from the engine.
P1010064
5. Remove fan guide(1), clips(2) on both sides and the bottom lock, then remove lower fan guide(3) with fan shroud(4). 6. Disconnect the reserve tank hose(6) from radiator.
PTW46BSH000101
7. Remove bracket(5).
RTW36BMH000101
8. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade.

Radiator Cap
Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 93.3 ~17.8)
~ 122.7 (13.5
Cap tester: 5884002770 Adapter: 5884026030 Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap. Valve opening vacuum kPa (psi) 1.96 ~ 4.91 (0.28 ~ 0.71)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, bugs and other foreign material.
Flushing the Radiator

Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.
Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (28.5 psi) with a cap tester: Leakage from the radiator Leakage from the coolant pump Leakage from the water hoses
6B 18 ENGINE COOLING Check the rubber hoses for swelling.
110RS005
Installation
1. Install radiator assembly (9) with hose, taking care not to damage the radiator core with a fan blade. 2. Support the radiator upper tank with the bracket (5) and secure the radiator. 3. Connect reserve tank hose (6). 4. Install lower fan guide (3). 5. Connect radiator inlet hose and outlet hose (1) to the engine. 6. Connect oil cooler hose to automatic transmission. 7. Connect battery ground cable.
RTW36BMH000101
ENGINE COOLING 6B 19 8. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank. Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.
RTW36BSH000101
Engine coolant change

Refer to 6B-8 (Draining and Refilling Cooling System).
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 80C. 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 80C 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.
033RY00011
033R300001
FUEL SYSTEM
6C 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE Main Data and Specifications ....................................................................................... 6C General Description....................................................................................................... 6C Fuel Flow.................................................................................................................... 6C Fuel Filter and Water Separator ............................................................................... 6C Injection Pump........................................................................................................... 6C Injection Nozzle ......................................................................................................... 6C Fuel Tank ........................................................................................................................ 6C Removal ..................................................................................................................... 6C 3 4 4 5 7 8 9 9
Installation ................................................................................................................. 6C - 10 Fuel Pump ...................................................................................................................... 6C - 12 Removal...................................................................................................................... 6C - 13 Installation.................................................................................................................. 6C - 13 Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14 Filler Neck ...................................................................................................................... 6C - 16 Removal...................................................................................................................... 6C - 16 Installation.................................................................................................................. 6C - 16 Fuel Filler Cap ................................................................................................................ 6C - 17 Injection Pump ............................................................................................................... 6C - 18 Removal and Installation .......................................................................................... 6C - 18 Removal...................................................................................................................... 6C - 18 Installation.................................................................................................................. 6C - 21
6C 2 FUEL SYSTEM
PAGE Injection Nozzle.............................................................................................................. 6C - 25 Inspection................................................................................................................... 6C - 25 Special Tools.................................................................................................................. 6C - 36
FUEL SYSTEM
6C 3

Item 4JA1T (L) Injection pump type Governor type Bosch distributor VE type Mechanical variable (Half speed oil pressure) Oil pressure Description 4JA1TC 4JH1TC
Bosch distributor VP44 type Electrical controled
Timer type Fuel feed pump type Injection nozzle type Number of injection nozzle orifices Injection nozzle orifices Inside diameter Injection nozzle designed operating 2 pressure MPa (kg/cm ) mm (in) 1st 2nd Main fuel filter type
Electrical controled Vane with input shaft Hole type 5
0.19 (0.0075) 19.1 (195) 25.0 (255)
0.17 (0.0067) 19.0 (194) 33.5 (328)
0.21 (0.0083) 19.5 (199) 33.8 (331)
Disposable cartridge paper element
Precautions
When working on the fuel system, there are several things to keep in mind: Any time the fuel system is being worked on, disconnect the negative battery cable except for those tests where battery voltage is required. Always keep a dry chemical (Class B) fire extinguisher near the work area. Replace all pipes with the same pipe and fittings that were removed. Clean and inspect O" rings. Replace if required. Always relieve the line pressure before servicing any fuel system components. Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. Adhere to all Notices and Cautions.
NOTE: Injection nozzle adjustment is possible only on the 4JA1L engine.
6C 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
RTW46CMF000201
The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel. Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum timing for efficient engine operation. NOTE: 1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND EMISSIONS. 2 Do not contain "Additive for water drain" with fuel.
FUEL SYSTEM
6C 5
FUEL FILTER AND WATER SEPARATOR

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 fuel filter. It is used during the air bleeding procedures. (Except EURO III model)
RTW36CLF000701
6C 6 FUEL SYSTEM
For EURO III model
RTW46AMF000201
FUEL SYSTEM
6C 7
INJECTION PUMP
RTW46CLF000201
4JA1T(L): A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly to the injection nozzles, regardless of the number of cylinders. The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection pump is compact, light weight, and provides reliable high-speed operation. The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to operate the air conditioner. Fast idler diaphragm movement is caused by changes in the negative pressure created by the engines vacuum pump. The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed. 4JA1TC/4JH1TC: The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump. Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C 8 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
RTW46CMF000301
NOTE: Injection nozzle adjustment is possible only on the 4JA1L engine. A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly. The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice.
FUEL SYSTEM
6C 9
FUEL TANK
Fuel Tank and Associated Parts
RTW46CLF000401
Legend
1. Bolt; Fuel Tank 2. Fuel Tank Band 3. Fuel Tube/Quick Connector 4. Fuel Filler Hose 5. Fuel Tank 6. Under Shield Band 7. Under Shield (only, specified model) 8. Evapo Pipe (only specified model)
6C 10 FUEL SYSTEM Removal

CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission". 1. Disconnect battery ground cable. 2. Loosen slowly the fuel filler cap. NOTE: Be careful not to spouting out fuel because of change the pressure in the fuel tank. NOTE: Cover opening of the filler neck to prevent any dust entering. 3. 4. 5. 6. 7. Jack up the vehicle. Support underneath of the fuel tank with a lifter. Remove the inner liner of the wheel house at rear left side. Remove fixing bolt of the filler neck from the body. Disconnect the quick connector (3) of the fuel tube from the fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering and fuel leakage. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs. 8. Remove fixing bolt (1) of the tank band and remove the tank band (2). 9. Disconnect the pump and sender connector on the fuel pump and remove the harness from weld clip on the fuel tank. 10.Lower the fuel tank (5). NOTE: When lower the fuel tank from the vehicle, dont scratch each hose and tube by around other parts.
Installation
1. Raise the fuel tank. NOTE: When raise the fuel tank to the vehicle, dont scratch each hose and tube by around other parts. 2. Connect the pump and sender connector to the fuel pump and install the harness to weld clip on the tank. NOTE: The connector must be certainly connected against stopper. 3. Install the tank band and fasten bolt. Torque 68 (6.9 / 50) NOTE: The anchor of the tank band must be certainly installed to guide hole on frame. 4. Connect the quick connector of the fuel tube to the fuel pipe and the evapo tube from evapo joint connector. NOTE: Pull off the left checker on the fuel pipe. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs. Nm (kgm / lb ft)
FUEL SYSTEM
6C 11
5. Install the filler neck to the body with bolt. 6. Install the inner liner of the wheel house at rear left side. 7. Remove lifter from the fuel tank. 8. Lower the vehicle. 9. Tigten the filler cap until at least three clicks. 10.Connect the battery ground cable.
6C 12 FUEL SYSTEM
FUEL GAUGE UNIT

Fuel Gauge Unit and Associated Parts
RTW46CLF000501
Legend
1. Fuel Feed Port 2. Fuel Return Port 3. Fuel Emission Port 4. Fuel Gauge Unit and Sender Assembly 5. Connector; Fuel Gauge Unit 6. Fuel Tube/Quick Connector 7. Retainer Ring (Fuel Gauge Unit Lock) 8. Seal; Fuel Gauge Unit 9. Fuel Tank Assembly 10. Evapo Tube/Quick Connector
FUEL SYSTEM Removal
6C 13
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission". 1. Remove fuel tank assembly (9). Refer to Fuel Tank Removal" in this section. 2. Disconnect the quick connector (6) of the fuel tube from fuel gauge unit. 3. Disconnect the quick connector (10) of the evapo tube from fuel gauge unit. 3. Remove the retainer ring (7) from the fuel tank with the removal tool 5-8840-2602-0. 4. Remove slowly the fuel gauge unit (4) from the fuel tank as no bend float arm. NOTE: Cover opening for the fuel gauge unit on fuel tank to prevent any dust entering. 5. Discard fuel gauge unit seal (8) because it cannot be reusable.
140R100035
Installation
1. Clean the seal surface of the fuel tank and the fuel gauge unit. NOTE: If there is dust on the seal surface, it becomes cause of fuel leak. 2. Install the new fuel gauge unit seal (8) to opening of the fuel tank as along the groove. 3. Install slowly the fuel gauge unit (4) into the fuel tank as no bend float arm. 4. Set flange of the fuel gauge unit on fuel gauge unit seal as mating convexity of the fuel gauge unit and reentrant of the fuel tank. 5. Lock slowly the retainer ring (7) to the fuel tank with the remover tool 5-8840-2602-0. 6. Connect the quick connector (10) of the evapo tube from fuel gauge unit. 7. Connect the quick connector (6) of the fuel tube to to gauge unit. NOTE: Pull off the left ckecker of the fuel pipe. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs.
6C 14 FUEL SYSTEM
8. Check leak. Methed of leak check. (1) Plug end of quick connector and breather hose (Pull off the breather hose from fuel tank) and tighten fuel filler cap until at least one click are heard. (2) Apply water soap around the fuel gauge unit seal area. (3) Pressure air into the fuel tank from end of breather pipe 2 at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds. (4) Verify no bubbles around the fuel gauge unit seal area. 9. Install the fuel tank assembly (9). NOTE: Refer to Install the fuel tank in this section.
FUEL SYSTEM
6C 15
FUEL TUBE / QUICK CONNECTOR FITTINGS

Precautions
Do not light a match or create a flame. Keep flames away from your work area to prevent flammable materials from catching fire. Disconnect battery ground cable to prevent electrical shorts. Pre-treat piping system or associated parts from thermal damage or from spattering when welding or similar heat-generating work.
Cautions During Work

Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electrolyte. Piping that has been splattered with battery electrolyte or battery electrolyte soaked cloth that was wiped on the piping cannot be used.
140R100032
Legend (1) O-ring (2) Port (3) Connector (4) Plastic Tube
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank. Use compressed air to remove any dirt on the fuel quick connect fittings prior to disconnecting the fittings. When disconnecting the fuel pipe, cover the area with a cloth to prevent fuel from splashing as the fuel pipe may still have some pressure in it.
141R100002
6C 16 FUEL SYSTEM
2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated. NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector. Use a lubricant (light oil) and/or push and pull the connector until the pipe is disconnected.
140R100037
Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering.
140R100028
Reuse of QuickConnector
Replace the port and connector if scratch, dent or crack is found. Remove any dirt build up on the port when installing the connector. Replace the connector, if there is any forms of rust, dent, scratch. After cleaning the port, insert it straight into the connector until it clicks. After it clicks, try pulling at 49N (5kgf) it out to make sure that it is not drawn and is securely locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe assembly easier. The pipe assembly should take place immediately after applying oil (to prevent dust from sticking to the pipe surface which may decrease sealing ability). Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel injection system. 3. Check for fuel leakage from the connector.
FUEL SYSTEM
6C 17
FILLER NECK
Removal
1. Remove the fuel tank. NOTE: Refer to "Fuel Tank" in this section. 2. Put a marking the following point as the filler neck assembly is restored. Each joint area of the hose (to restore axial direction and insertion length of the hose) Each fasten area of the clamp (to restore axial direction and position of the clamp) Each bolt in the clamp (to restore fasten length of bolt in the clamp) The band clip (to restore position and fasten length of the band clip) NOTE: Cover end of each hose and pipe to prevent any dust entering.
Installation
1. Align each marking and restore the following point. Each joint area of the hose (Restore axial direction and insertion length of the hose) Each fasten area of the clamp (Restore axial direction and position of the clamp) Each bolt in the clamp (Restore fasten length of bolt in the clamp) Torque Nm (kgm / lb ft) 2.5 (0.25 / 21.7) filler neck side except flat deck model. The band clip (Restore position and fasten length of the band clip) 2. Install the fuel tank. NOTE: Refer to "Fuel Tank" in this section.
6C 18 FUEL SYSTEM
FUEL FILLER CAP

General Description
A vacuum valve and pressure valve are built into the fuel filler cap which adjusts the fuel pressure in the fuel tank to prevent fuel tank damage.
RTW36CSH000401
Legend (1) Pressure Valve (2) Vacuum Valve (3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition. The fuel filler cap must be replaced if found defective CAUTION: A replacement fuel filler cap must be the same as the original. The fuel filler cap valve was designed primarily for this application and must be replaced with the same type or decreased engine performance may occur.
FUEL SYSTEM
6C 19
INJECTION PUMP
Removal
1. Battery Remove the battery from the battery tray.
6C-1
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley. 2) Remove the drive belt. 3. Power Steering Pump Assembly 4. Accelerator Control Cable Disconnect the accelerator cable from the intake throttle.
P1010003
5. Vacuum Hose Disconnect the vacuum hose from the EGR valve and the intake throttle. 6. Fan
6C 20 FUEL SYSTEM
7. Power Steering Pump Bracket
6C-4
8. Throttle Position Sensor Harness Connector (4JA1TC/4JH1TC only) Disconnect the harness connector from the throttle position sensor. 9. Oil Level Gauge 10. Fuel Pipe 1) Disconnect the fuel hoses from the fuel filter or priming pump. 2) Disconnect the fuel hoses from the injection pump. 11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model) 13. Leak Off Hose Disconnect the leak off hose at the injection pump. 14. Injection Pipe Clip 15. Injection Pipe 1) Loosen the injection pipe sleeve nuts at the delivery valve side and the injection nozzle side. Note: Do not apply excessive force to the injection pipes. 2) Loosen the injection pipe clip. 3) Remove the injection pipes. Note: Plug the delivery holder ports with the caps to prevent the entry of foreign material. 16. Intake Manifold 1) Remove the EGR valve from the intake manifold and EGR pipe. 2) Loosen the intake rubber hoses clip. 3) Loosen the intake manifold bolts and nuts. 17. Injection Pump Cover (4JA1TC/4JH1TC only)
FUEL SYSTEM
6C 21
020L200017
18. Timing Check Hole Cover 1) Remove the timing check hole cover. 2) For ease in reinstalling the injection pump, align the timing mark on the timing gear case cover by turning the crankshaft using wrench. And bring the piston in the No.1 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line aligned with the timing mark. Note: If the check hole cover is reinstalled with the lock bolt still in place, the crank pulley will not turn.
RTW46CSH000201
3) Insert the lock bolt (M6 x 30) into the scissors gear idle gear B fixing hole to prevent the scissors gear from turning.
6C-7
29. Injection Pump Bracket 20. Injection Pump
6C 22 FUEL SYSTEM
Installation
1. Injection Pump 1) Install the injection pump gear (When gear is removed). Injection Pump Gear Nut Nm (kgm/lb ft) 64 (6.5 / 47) 2) Bring the piston in the No.1 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line aligned with the timing mark. 3) Install the injection pump to the timing gear case with align the timing mark on the pump gear to the arrow mark on the timing gear case cover. 4) Check that the setting marks of the injection pump gear and the idler gear B are aligned. 5) Remove the lock bolt (M6 30) from the idle gear B.
RTW46CSH000201
020L200017
6) Tighten the injection pump fixing bolts to the specified torque. Injection Pump Bolts Torque Nm (kgm/lb ft) 19 (1.9 / 14)
6C-7
FUEL SYSTEM
4JA1T (L)
6C 23
RTW46CSH000101
4JA1TC/4JH1TC
2. Injection Pump Bracket 1) Install the injection pump bracket (6) and the bracket bolts (7) and (8) to the cylinder body. Temporarily tighten the bracket bolts. 2) Tighten the bracket bolts (7) to the specified torque. 3) Tighten the bracket bolts (8) to the specified torque. Note: Tighten the bracket bolt (8) first. Injection Pump Bracket Torque Nm(kgm / lb ft) (8) 19 (1.9 / 14) (7) 40 (4.1 / 30)
RTW36AMH000101
3. Timing Check Hole Cover Install the timing check hole cover and tighten bolts to the specified torque. Timing Check Hole Cover Bolts Torque Nm(kgm / lb ft) 8 (0.8 / 69) 4. Injection Pump Cover (4JA1TC/4JH1TC only) 5. Intake Manifold 1) Install the intake manifold with gasket. Intake Manifold Bolts Torque Nm(kgm / lb ft) 19 (1.9 / 14) Intake Manifold Nuts Torque 24 (2.4 / 17) 2) Install the EGR valve to the intake manifold and EGR pipe temporarily. 3) Tighten the nuts and bolts to the specified torque Nm(kgm / lb ft)
Torque
Nm (kgm/lb ft)
Nuts Bolts
24 (2.4/17) 27 (2.8/20)
6C 24 FUEL SYSTEM
6. Injection Pipe Install the injection pipe. Injection Pipe Torque 29 (3.0 / 22) Nozzle Side (4JA1TC/4JH1TC) 29 (3.0 / 22) Pump Side (4JA1TC/4JH1TC) 40 (4.1 / 30) 7. Injection Pipe Clip Install the injection pipe clip. Note: Make absolutely sure that the clip is correctly positioned. Injection Pipe Clip Torque Nm(kgm / lb in) 8 (0.8 / 69) 8. Leak Off Pipe and Leak Off Hose Install the leak off pipe to injection nozzle and connect the leak off hose to the injection pump. 9. Fuel Filter Bracket (Except EURO III model) Install the fuel filter bracket and tighten bolts to the specified torque. Fuel Filter Bracket Bolts Torque Nm(kgm / lb ft) 21 (2.1 / 15) 10. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly to bracket and tighten bolts to the specified torque. Fuel Filter Assembly Bolts Torque Nm(kgm / lb ft) 21 (2.1 / 15) 11. Fuel Pipe 1) Connect the fuel hoses to the fuel filter or priming pump. 2) Connect the fuel hoses to the injection pump. 12. Oil Level Gauge Install the oil level gauge and tighten bolts to the specified torque. Oil Level Gauge Bolts Torque Nm(kgm / lb ft) M8: 19 (1.9 / 14) M6: 8 (0.8/6 lb in) Nm(kgm / lb ft) Nm(kgm / lb ft)
Nm(kgm / lb ft)
FUEL SYSTEM
6C 25
13. Throttle Position Sensor Harness Connector (4JA1TC/4JH1TC only) Reconnect the harness connector to the throttle position sensor. 14. Power Steering Pump Bracket 15. Fan 16. Vacuum Hose Connect the vacuum hose to the EGR valve and the intake throttle.
Euro under 4JA1L 4JA1TC 4JH1TC without Not used without Euro I with Not used with Euro II with Not used with Euro III Not used With cooler (EGR cooler) With (EGR cooler)
17. Accelerator Control Cable 1) Connect the accelerator cable to the injection pump (4JA1T) the intake throttle. (4JA1TC/4JH1TC only) 18. Power Steering Pump Assembly 19. Drive Belt Install the drive belt and adjust the belt tension. 20. Battery
6C 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)

DISASSEMBLY
080L200009
Disassembly Steps
1. 2. 3. 4. 5. 6. 7. 8. Retaining nut Nozzle & pin Spacer & pin Lift Piece Spring seat Push rod Shim (Second nozzle opening pressure adjustment) Second spring 9. 10. 11. 12. 13. 14. 15. Collar Spring seat First spring Shim (First nozzle pressure adjustment) Nozzle holder body Eye bolt Gasket
opening
Important Operations
Injection nozzle adjustment is possible only on the 4JA1L engine. The two-spring nozzle holder has been developed to reduce NOx (Nitrogen Oxides) and particulates from direct injection diesel engine exhaust. Before disassembly remove carbon deposit from nozzle and nozzle holder using a wire brush and wash the outside nozzle holder assembly. Caution: Do not touch nozzle holes with the wire brush during cleaning it. Disassemble the nozzle holder assembly to numerical order.
FUEL SYSTEM
6C 27
REASSEMBLY
080L200010
Reassembly Steps
1. 2. 3. 4. 5. 6. 7. 8. Nozzle holder body Shim (First opening pressure adjustment) First spring Spring seat Collar Second spring Push rod Shim (Second opening pressure adjustment) 9. 10. 11. 12. 13. 14. 15. Spring seat Lift Piece Spacer & pin Nozzle & pin Retaining nut Gasket Eye bolt
Important Operations
The nozzle holder is adjusted as the components are reassembled in the sequence above. As adjustment of the two-spring nozzle holder is made in hundredths of a millimeter, clean the parts thoroughly in light oil to completely remove any dirt or foreign matter.
6C 28 FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE
1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
Full needle valve lift confirmation
Confirm the full needle valve lift in accordance with the closed method. 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.
Pre-lift confirmation
Second nozzle opening pressure confirmation
Confirm the second nozzle opening pressure in accordance with the closed method.
Second nozzle opening pressure adjustment
Adjust the second nozzle opening pressure using the shim.
6 Final inspection
Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.
First nozzle opening pressure adjustment Nozzle needle valve full-lift Nozzle needle valve pre-lift Nozzle pressure 4JA1T(L) 1st Stage 2nd Stage 19.1 Mpa (2759 psi, 194 kg/cm ) 25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )
2 2
0.25 mm (0.0098 in) 0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm )
2
NOTE: Only 4JA1L can perform adjustment of a nozzle.
FUEL SYSTEM Injection Nozzle Adjustment

First nozzle opening pressure adjustment 1.Clamp the nozzle holder in a vise.
6C 29
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
6C 30 FUEL SYSTEM
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 kgm (36.9 Ibft/50 Nm)
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.
040MV030.tif
FUEL SYSTEM
First nozzle opening pressure adjusting shims Parts No. (ISUZU) 115349-0420 115349-0430 115349-0440 115349-0450 115349-0460
040LX010.tif
6C 31
Thickness (mm) 0.40 0.50 0.52 0.54 0.56 0.58 0.60 0.70
115349-0470 115349-0480 115349-0490
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
6C 32 FUEL SYSTEM
4. Install the pin to the dial gauge. Note: The lengths of the pins do not include the threaded portions. Pin (L=100 mm): 157892-5200 (Bosch AS) Dial gauge: 157954-3800 (Bosch AS) 185317-0150 (ISUZU)
040MV029.tif
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
FUEL SYSTEM
6C 33
8. Operate the nozzle tester and increase the in-line 2 pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that the nozzles needle valve moves through its full lift. Record full lift L. (Read dial gauge) Nozzle Full Lift mm (in) 0.25 H 0.02 (0.0098 H 0.00008) Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition.
040MV008.tif
Pre-lift confirmation 1. With the needle valve at full lift, release the nozzle tester handle. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little.
040MV007.tif
040R300008
6C 34 FUEL SYSTEM
2. Read the needle valve pre-lift point from the dial gauge indication (once the needle valve has descended when the second spring has stopped operating). Pre-lift measuring point: Read the dial gauge at first nozzle opening pressure +approx 2 1 MPa (10 kg/cm ). Pre-lift mm
Pressure Mpa 2 (psi/ kg/cm )
040H100007
Lift mm (in) 0.04 (0.0016)
4JA1T(L)
20.1 (2,858/205)
Note: This point can be found while the pressure is decreasing. 3. Confirm that pre-lift 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 nozzles needle valve moves through its full lift.
040MV030.tif
FUEL SYSTEM
6C 35
2. Release the nozzle tester handle so that in-line pressure decreases. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little.
040MV022.tif
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 + 0.05 mm). Second Nozzle Opening Pressure
Pressure Mpa 2 (psi/ kg/cm ) 4JA1T(L)
040M100006
Lift mm (in) 0.09 (0.0035)
25.5-27.0 (3768-3911/260-275)
6C 36 FUEL SYSTEM
Second nozzle opening pressure adjustment If the second nozzle opening pressure is not as specified, disassemble the nozzle from the nozzle holder and replace the shim until the pressure is as specified. CAUTION: Because the second opening pressure changes when the first opening pressure changes, the second opening pressure must be adjusted when the first opening pressure changes. Use a micrometer to measure shim thickness. Use some combination of 3 adjusting shims to adjust the pressure. Second nozzle opening pressure adjusting shims
Part No. (ISUZU) 897116-0290 897116-0320 897116-0330 897116-0340 897116-0350 897116-0360 897116-0370 Thickness (mm) 0.10 0.20 0.30 0.40 0.50 0.51 0.52 Part No. (ISUZU) 897116-0380 897116-0390 897116-0400 897116-0410 897116-0420 897116-0430 897116-0440 Thickness (mm) 0.53 0.54 0.55 0.56 0.57 0.58 0.59
040MV017.tif
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 kgm (50.6 Ibft/69 Nm)
040MV014-1.tif
FUEL SYSTEM
6C 37
4. Set the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray condition, seat oil tightness and each part for oil leaks. 5. When replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service kit. CAUTION: Pre-lift will not be as specified if only the nozzle is replaced.
040MV030.tif
6C 38 FUEL SYSTEM
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-2602-0 Remover: fuel pump retainer ring (J-39765)
ENGINE ELECTRICAL 6D 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE Main Data and Specifications ......................................................................................... 6D - 2 General Description......................................................................................................... 6D - 3 Torque Specifications ..................................................................................................... 6D - 5 Generator.......................................................................................................................... 6D - 7 Removal and Installation ............................................................................................ 6D - 7 Disassembly................................................................................................................. 6D - 9 Inspection and Repair ................................................................................................. 6D - 12 Reassembly.................................................................................................................. 6D - 18 Starter Motor .................................................................................................................... 6D - 22 Removal and Installation ............................................................................................ 6D - 22 Disassembly................................................................................................................. 6D - 23 Inspection and Repair ................................................................................................. 6D - 26 Reassembly.................................................................................................................. 6D - 29 Pre-heating System ......................................................................................................... 6D -33 Inspection and Repair ................................................................................................. 6D -33 Glow Relay ................................................................................................................... 6D -33 Glow Plug..................................................................................................................... 6D -33 EGR System ................................................................................................................. 6D -33
6D 2 ENGINE ELECTRICAL

Description Item 60A Generator Type 80A
AC generator with IC regulator and vacuum pump Hitachi LR160-503E Hitachi LR180-513B
Voltage Drive and rotation Ground polarity Maximum output Engine speed ratio Maximum speed Weight with vacuum pump Vacuum Pump Delivery volume Exhaust Characteristic
12 V-belt, clockwise viewed from the drive pulley Negative 60 1.788 11,000 5.8(12.8) 6.4(14.1) 80
A to 1 rpm kg(lb) cm /rev

3
50 -66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000 rpm 7 seconds or less at 5,000 rpm -90.7 kPa (-680 mmHg) or more Solenoid controlled Hitachi S13-555
Maximum vacuum Starter Motor Type
Rated voltage Rated output Load characteristics Terminal voltage Load current Weight
V kW V A kg(Ib)
12 2.3 8.76 300 4.7 (10.4)
GENERAL DESCRIPTION
GENERATOR STARTER MOTOR
066L300004
065L300002
The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown in charging circuit diagram. The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame. The generator voltage setting cannot be adjusted. The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit utilizes negative ground polarity.
CHARGING CIRCUIT DIAGRAM
RTW46DSH005101
STARTING CIRCUIT DIAGRAM
RTW46DSH005501
TORQUE SPECIFICATIONS
GENERATOR
Nm (kgm/Ibft)
RTW46DLF000201
STARTER MOTOR
Nm (kgm/Ibft)
RTW46DLF000301
GENERATOR
Important Operations-Removal Cooling Fan Belt

1. Disconnect the battery cables at the battery terminals. 2. Loosen and remove the fan belt adjusting plate bolts. 3. Remove the fan belt from the generator drive pulley.
Generator
P1010002
1. Remove the vacuum pump hose. 2. Remove the generator bolt and the generator from the bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure.
Generator
1. Install the generator to the bracket. 2. Tighten the generator bolt to the specified torque. 3. Install the vacuum pump hose. Generator Bolt Torque 40 (4.1/30) Nm (kgm/Ibft)
6D 8 ENGINE ELECTRICAL Cooling Fan Drive Belt

1. Hold the generator toward the engine. 2. Install the fan belt to the three pulleys. 1 Crankshaft pulley 2 Generator pulley 3 Cooling fan drive pulley
033RY00009
3. Adjust the fan belt tension Fan belt tension is adjusted by moving the generator. Depress the drive belt mid-portion with a 98N (10 kg/22 Ib) force. Cooling Fan Drive Belt Deflection mm (in) New belt 4 - 7 (0.16 - 0.28) Reuse belt 6 - 9 (0.24 - 0.35)
4. Tighten the adjusting plate bolts to the specified torque. Adjusting Plate Bolt 19 (1.9/14) 5. Reconnect the battery cable to the battery. Nm (kgm/lbft)
DISASSEMBLY
RTW46DLF000401
Disassembly Step
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Vacuum pump O-ring Through bolt B Terminal nut Rear cover Pulley Rotor assembly Front cover assembly Rear rotor bearing Rectifier assembly Stator assembly Rotor assembly
6D 10 ENGINE ELECTRICAL Important Operations

1. Vacuum Pump 1. Loosen the vacuum pump fixing screws. 2. Support the vacuum pump O-ring. 3. Carefully remove the O-ring. 2. Cover
RTW46DSH000101
3.
RTW46DSH000201
Through Bolt 1. Remove the M5 through bolt. 2. Separate the front and rear sides of the vacuum pump. 3. Insert the tips of 2 ordinary screwdrivers into the space between the front cover and the stator core. Remove the front cover and rotor together with the rear cover and stator. If removal is difficult, push the rear cover to the side and lightly tap the end of the shaft with a plastic hammer to loosen it. The front cover oil seal must be replaced with a new one when the front cover is removed. Take care not to damage the stator core with the screwdriver tips.
RTW46DSH000601
4.
Pulley 1. Carefully clamp the rotor assembly in a vise. 2. Loosen the pulley nut. 3. Remove the pulley and the front cover from the rotor.
RTW46DSH002101
7. Rotor Assembly 1. Remove the rotor from front cover assembly. Remove the front cover stator and rectifier.
RTW46DSH000301
8. Front Cover Assembly 1. Remove the front cover bearing retainer screws. 2. Remove the bearing.
RTW46DSH000701
9. Rear rotor bearing Re-use improper parts. 10. Rectifier 1. Disconnect the stator coil leads between each rectifier by melting the solder connection. Hold the lead wire between the solder and the rectifier with a pair of long nose pliers. This will prevent heat transfer and resultant damage to the rectifier.
RTW46DSH000801
RTW46DSH000401

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 31.6 (1.245)
RTW06DSH000101
Limit 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 20C (68F) Standard 3.8
ohms
RTW46DSH001001
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.
RTW46DSH001101
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
066RY00022
0.1
2. Check for continuity between each stator coils and the stator core. If there is continuity, the stator coils must be replaced.
066RY00023
BRUSH
Measure the length of the brush. If abrasion has reduced the brush length to less than 6.5 mm, the brush must be replaced with a new one. A wear line is inscribed in the brush. If the line is not visible, the brush must be replaced. Brush Length (Reference) mm (in) Standard
RTW46DSH004801
Limit 6.5 (0.25)
25 (1.0)
Rectifier
RTW46DSH001201
Tester wire E U, V, and WN
----Conductivity
BAT U, V, and WN
----Conductivity No conductivity -----
No ----conductivity Negative side diode check
Positive side diode check
RECTIFIER ASSEMBLY
RTW46DSF000301
1. 2. 3. 4. 5. 6. 7. 8. 9.
Voltmeter Switch 1 DC regulated power supply Lamp 2 Lamp 1 Switch 3 Switch 2 Pulse generator Output signal
Test circuit Refer to the judgment criteria shown in the Table below. Carefully check Items 1~5. If all the items are OK, the IC regulator is normal. Circuit components DC regulated power supply 1 Lamps (2) 2 Switches (3) 3 DC voltmeter 4 Pulse generator (Oscillator) 5 Judgment criteria No. 1 2 3 4 5 Switch 1 ON ON ON OFF ON Switch 2 OFF ON ON ON ON Switch 3 OFF 12V OFF OFF OFF ON 16V 12V 18V Voltmeter reading Lamp condition Lamp 1 Lamp 2 On ON (dim) On or flashing OFF Off or on (dim) On or flashing On ON Remarks Initial excitation check Full excitation check Lamp 1 off or dimly lit when the voltmeter shows less than 12 volts or 16 volts Stator and brush separation check Excess voltage check
0~20 volts variable with output of 1 ampere or more 12 volts, 1.4~3.4 watts ----0~30 volts, 0.5 grade 5~30 volt output at a frequency of 1kHz
ENGINE ELECTRICAL 6D 15 Oil seal

The oil seal must be replaced with a new one whenever the alternator is disassembled.
Oil Seal Replacement

1. Push the old oil seal from the rear bracket outside holes. 2. Use the insertion tool to press the new oil seal into place. Follow the procedure shown in Figures A, B, C and D. V Position the oil seal beneath the shaft and the guide lip. V Position the cradle against the rear cover bosses (3 points) so that the E1 and E2 surfaces fit into the cradle. Take care not to damage the E1 and E2 surfaces. V After completing the procedure, carefully check the oil seal seating. Be absolutely sure that the seal is evenly inserted (no warp) and level with the surrounding surfaces. Caution V Be sure that no foreign material enters the space between the oil seal and the rotor shaft surfaces during the installation procedure. V Take care not to damage the D surface. V Under no circumstances may the original oil seal be reused. V The oil seal must be perfectly flat after being pressed into place. If the oil seal is tilted, there will be oil leakage.
RTW46DSF000101
6D 16 ENGINE ELECTRICAL Vacuum Pump Vacuum Pump Disassembly

1. Remove the center plate from the vacuum pump housing. 2. Remove the vacuum pump rotor and the vanes from the housing.
RTW46DSH000901
Inspection Vacuum Pump Housing and Center Plate

Inspect the vacuum pump housing and the center plate for excessive wear, abrasion, and scoring. If any of these conditions are present, the vacuum pump housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage. Replace all four vanes if either of these conditions are present. Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and scoring. Pay particular attention to the internal spline. Replace the rotor if any of these conditions are present. 2. Inspect the generator rotor shaft splines for backlash. Replace the rotor if backlash is present.
Check Value
1. Carefully force the valve from the B side as shown in the illustration. The valve must move smoothly. If it does not, the check valve must be replaced. 2. Apply compressed air to the A side. 2 Air Pressure kPa (kg/cm /psi) 98 - 490 (1-5/14 71)
RTW46DSH005201
Check for air leakage from the check valve. If there is air leakage, the valve must be replaced.
ENGINE ELECTRICAL 6D 17 Vacuum Pump Reassembly

1. Install the vanes to the rotor slits. The rounded side of the vanes must be facing the rotor housing.
RTW46DSH001801
2. Install the rotor with the concave side facing the center plate.
RTW46DSH001901
3. Install the center plate to the rotor housing. Be sure to use a new O-ring.
RTW46DSH002001
REASSEMBLY
RTW46DLF000501
Reassembly Step
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Front cover Rear rotor bearing Rotor Assembly Pulley Rectifier Assembly Stator Assembly Rear cover B Terminal nuts Through bolt O-ring Vacuum pump
ENGINE ELECTRICAL 6D 19 Important Operations

2. Rear rotor bearing Re-use improper parts.
RTW46DSH000401
5. Rectifier 6. Stator Use a pair of long-nose plier to connect the stator coil leads and the rectifier leads. Finish the work as quickly as possible to prevent the rectifier from heat transferred by the soldering. 3. Rotor Assembly 4. Pulley Assembly Clamp the rotor in a vise and install the pulley nut. Pulley Nut Torque Nm (kgm/lbft) 83.3 ~ 98.0 (8.5 ~ 10.0 / 61 ~ 72)
RTW46DSH002101
Remove the tape from the splines.
RTW46DSH006001
The rear ball bearing is pressed into the wheel eccentric groove. The bearing ring projects from the groove. During installation, rotate the bearing to the point of minimum bearing ring projection. Inspect the rear cover bearing box and replace it if it is damaged.
RTW46DSH004901
NOTE: Be sure to attach a cooler to B terminal.
RTW46DSH002201
Insert the pin from the outside of the rear cover. Press the brushes into the brush holder. Complete the assembly procedure. Remove the pin after completion of the assembly procedure.
RTW46DSH005301
9. Through Bolt 1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover. 2. Install the through bolts and tighten them to the specified torque. Through Bolt Torque Nm (kgm/lbft) 3.1 ~ 3.9 (0.32 ~ 0.41 / 2.6 ~ 3.5)
RTW06DSH000201
11. Vaccum Pump To install the generator 1. Note the direction of the arrow on the vacuum pump. 2. Look forward from the base of the arrow to locate the 3 generator fixing points. 3. Twist the fixing points down and to the left to align them with the middle of the center plate and the rotor. Install vanes into slits in rotor. The vanes should be installed with the chamfered side facing outward.
RTW46DSH006101
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.
RTW46DSH002401
Install the housing in the generator and fix it with the three bolts. Supply engine oil (5cc or so) from the oil port and check that the generator pulley can be turned smoothly with your hand. Generator Housing Bolt Torque Nm (kgm/lbft) 5.9 ~ 6.9 (0.6 ~ 0.7 / 5.2 ~ 6.1)
RTW46DSH002501
STARTER MOTOR
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 the ground cable at the cylinder body. 4. Remove the starter motor from the engine.
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.
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 Nm (kgm/lbft) 85 (8.7/63) 3. Reconnect the battery cable at the starter motor and the ground cable at the cylinder body. 4. Reconnect the battery cable and the ground cable at the battery terminals.
DISASSEMBLY
RTW460LF000201
Disassembly Step
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Lead wire Bolt Magnetic switch assembly Torsion spring Plunger Dust cover Magnetic switch Screw Through bolt Rear cover Motor assembly Brush holder Yoke 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Armature Bolt Bearing retainer Pinion assembly Pinion stopper clip Pinion stopper Return spring Pinion shaft Clutch Dust cover Shift lever Gear case

1. Lead Wire Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
3. Magnetic Switch Assembly Remove the magnetic switch bolts, then remove the switch from the shift lever.
RTW46DSH002701
Remove the torsion spring from the magnetic switch.
RTW46DSH002801
8. Through Bolt 9. Screw 10. Rear Cover Remove the through bolts, then remove the rear cover.
RTW46DSH002901
11. Motor Assembly Remove the four brushes from the brush holders.
RTW46DSH003001
Remove the yoke along with the armature and the brush holder from the gear case. Remove the brushes and commutator carefully so as not to allow them in contact with the adjacent parts.
RTW46DSH003101
12. Brush Holder 13. Yoke 14. Armature Remove the brush holder and pull out the armature assembly free from the yoke.
RTW46DSH003201
16. 17. 23. 24. 25.
Bearing Retainer Pinion Assembly Dust Cover Shift Lever Gear Case 1. Remove the bearing retainer. 2. Remove the pinion from the gear case.
RTW46DSH003301
3. Use a screwdriver to remove the stopper clip. Then disassemble the pinion assembly.
RTW46DSH003401

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during 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 0.05 (0.002)
RTW46DSH003501
Limit 0.2 (0.008)
2. Check the commutator mica segments for excessive wear. 3. Measure the mica segment depth. Mica Segment Depth mm (in) Standard 0.5 ~ 0.8 (0.020 ~ 0.030) Limit 0.2 (0.008)
065RY00025
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 Standard 36.5 (1.44) Limit 35.5 (1.40)
mm (in)
If the measured outside diameter is less than the specified limit, the commutator must be replaced.
065RY00026
5. Use a circuit tester to check the armature for grounding. 1 Hold one probe of the circuit tester against the commutator segment. 2 Hold the other circuit tester probe against the armature core. If the circuit tester indicates continuity, the armature is grounded. The armature must be replaced.
RTW46DSH003601
6. Use the circuit tester to check the armature for continuity. 1 Hold the circuit tester probes against two commutator segments. 2 Repear Step 1 at different segments of the armature core. There should be continuity between all segments of the commutator. If there is not, the armature must be replaced.
RTW46DSH003701
YOKE
1. Use a circuit tester to check the field winding ground. 1 Hold one circuit tester probe against the field winding end or brush. 2 Hold the other circuit tester probe against the bare surface of the yoke body. There should be no continuity. If there is continuity, the field coil is grounded. The yoke must be replaced.
RTW46DSH003801
2. Use the circuit tester to check the field winding continuity. 1 Hold one circuit tester probe against the M 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.
RTW46DSH003901
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 15 (0.59)
RTW46DSH004001
Limit 12 (0.47)
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.
RTW46DSH004101
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, the entire yoke must be replaced.
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.
065RY00035
BEARING
Inspect the bearings for excessive wear and damage. Replace the bearings if necessary.
RTW46DSH004401
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Magnetic switch assembly Magnetic switch Dust cover Plunger Torsion spring Shift lever Gear case Dust cover Bolt Pinion assembly Clutch Pinion shaft Rerurn spring 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Pinion stopper Pinion stopper clip Bearing retainer Bolt Motor assembly Armature Yoke Brush holder Rear cover Screw Through bolt Lead wire

1. Magnetic Switch Assembly 1. Attach the torsion spring to the hole in the magnetic switch as illustrated. 2. Insert the shift lever into the plunger hole of the magnetic switch.
RTW46DSH005601
7. Gear Case 3,8. Dust Cover 1. Install the magnetic switch assembly in the gear case. 2. Install the dust cover. Dust Cover Bolt Torque 8 (0.8/5.4) Nm (kgm/lbft)
RTW46DSH005701
10. Pinion Assembly Apply a coat of grease to the reduction gear and install the pinion assembly to the armature shaft.
065RY00041
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.
RTW46DSH004501
24. Through Bolt Install the through bolts in the rear cover and tighten them to the specified torque. Through Bolt Torque Nm (kgm/lbft) 8.1 (0.83/6.00)
065RY00044
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 Nm (kgm/lbft) 8.6 (0.88/6.40)
RTW46DSH002601
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) 0.1 2.0 (0.004 0.078)
RTW46DSH005801
MAGNETIC SWITCH
The following tests must be performed with the starter motor fully assembled. The yoke lead wire must be disconnected from the M terminal. To prevent coil burning, complete each test as quickly as possible (within three to five seconds). 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 M terminal. When current is applied to the S terminal from the battery positive terminal, the pinion should flutter.
RTW46DSH004601
2. Hold-in Maintenance Test Disconnect the lead at the M terminal. The pinion should continue to flutter.
RTW46DSH005901
3. Return Test Disconnect the battery positive lead at the S terminal. The pinion should return to its home position.
RTW46DSH004701
PRE-HEATING SYSTEM
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during inspection.
VISUAL CHECK
Check the main fuses and glow indicator for damage. Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine compartment. Use an ohmmeter to measure the resistance between terminals No.2 and No.3. If the measured value is outside the specified range, the glow relay must be replaced. Glow Relay Resistance 94 - 114 Ohms
825R300046
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity. Glow Plug Resistance (Reference) Approximately 0.9 Ohms
LNW21KSH001401
EGR SYSTEM 4JA1T (L)

Refer to 6F-9. (EGR system diagram)
MEMO
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6E1
ENGINE
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 4JA1-TC .................................................... 6E-10 4JH1-TC .................................................... 6E-11 ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-14 ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-15 ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-16 ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-17 GROUND POINT CHART GENERAL EXPORT (LHD) (1/4) ............................................... 6E-18 LOCATION ................................................ 6E-34 PARTS LOCATION ................................... 6E-39 CONNECTOR LIST ................................... 6E-40 RELAY AND FUSE .................................... 6E-43 RELAY AND FUSE BOX LOCATION (LHD & RHD) ........................................... 6E-43 RELAY AND FUSE BOX LOCATION (LHD & RHD) ........................................... 6E-44 FUSE AND RELAY LOCATION (LHD & RHD) 6E-45 ECM WIRING DIAGRAM (1/7) .................. 6E-46 ECM WIRING DIAGRAM (2/7) .................. 6E-47 ECM WIRING DIAGRAM (3/7) .................. 6E-48 ECM WIRING DIAGRAM (4/7) .................. 6E-49 ECM WIRING DIAGRAM (5/7) .................. 6E-50 ECM WIRING DIAGRAM (6/7) .................. 6E-51 ECM WIRING DIAGRAM (7/7) .................. 6E-52 ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL .................................... 6E-53 GENERAL DESCRIPTION FOR ECM AND SENSORS ............................................... 6E-64 Engine Control Module (ECM) ................... 6E-64 Pump Control Unit (PSG) & Data Exchange Between Control Module ......................... 6E-64 Mass Air Flow (MAF) Sensor & Intake Air Temperature (IAT) Sensor ....................... 6E-65 Throttle Position Sensor (TPS) .................. 6E-66 Crankshaft Position (CKP) Sensor ............ 6E-66 Engine Coolant Temperature (ECT) Sensor 6E-67 Vehicle Speed Sensor (VSS) .................... 6E-67 GENERAL DESCRIPTION FOR EGR (EXHAUST GAS RE-CIRCULATION) ..... 6E-68 GENERAL DESCRIPTION FOR INJECTION PUMP .................................. 6E-70 Outline ....................................................... 6E-70 Cross-section View .................................... 6E-70 Low Pressure Fuel Circuit .......................... 6E-71 High Pressure Fuel Circuit ......................... 6E-72 Pump Camshaft Speed Sensor ................. 6E-72 High Pressure Solenoid Valve ................... 6E-73 Timing Control Valve (TCV) ....................... 6E-74 ISUZU Strategy Based Diagnostics .............. 6E-76 Overview .................................................... 6E-76 STRATEGY BASED DIAGNOSTICS CHART 6E-76 Diagnostic Thought Process ...................... 6E-77 1. Verify the Complaint .............................. 6E-77 2. Perform Preliminary Checks .................. 6E-77 3. Check Bulletins and Troubleshooting Hints 6E-78 4. Perform Service Manual Diagnostic Checks 6E-78 5a and 5b. Perform Service Manual Diagnostic Procedures .............................................. 6E-78 5c. Technician Self Diagnoses .................. 6E-78 5d. Intermittent Diagnosis .......................... 6E-79 5e. Vehicle Operates as Designed ............ 6E-80 6. Re-examine the complaint ..................... 6E-81 7. Repair and Verify Fix ............................. 6E-81 GENERAL SERVICE INFORMATION ....... 6E-82 ON-BOARD DIAGNOSTIC (OBD) ............. 6E-82 TECH 2 OPERATING FLOW CART (START UP) ............................................. 6E-86 TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA) ................................... 6E-88 TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA) ................................... 6E-90 MISCELLANEOUS TEST .......................... 6E-92 Plotting Snapshot Graph ............................ 6E-93 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) .......... 6E-94 Flow Chart for Snapshot Replay (Plotting Graph) ....................................... 6E-95 SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-96 ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK .................................................... 6E-105 Circuit Description ...................................... 6E-105 Diagnostic Aids .......................................... 6E-105 Test Description ......................................... 6E-105
6E2

VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT ............. 6E-140 DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 9) (FLASH CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT .............. 6E-140 Circuit description ...................................... 6E-141 Diagnostic Aids .......................................... 6E-141 Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34) Vacuum Pressure Sensor Circuit High Input ......... 6E-142 Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34) Vacuum Pressure Sensor Circuit Low Input ........... 6E-145 Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit High Input ................................................. 6E-148 Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit Low Input.......................................................... 6E-150 DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 1) (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT ............................ 6E-152 DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 2) (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT ............................. 6E-152 Circuit Description ...................................... 6E-152 Diagnostic Aids .......................................... 6E-153 Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit High Input 6E-153 Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit Low Input 6E-157 DIAGNOSTIC TROUBLE CODE (DTC) P0115 (SYMPTOM CODE 1) (FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGHINPUT ............................. 6E-160 DIAGNOSTIC TROUBLE CODE (DTC) P0115 (SYMPTOM CODE 2) (FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT ............................. 6E-160 Circuit Description ...................................... 6E-160 Diagnostic Aids .......................................... 6E-161 Diagnostic Trouble Code (DTC) P0115 (Symptom Code 1) (Flash Code 14) Engine Coolant Temperature Sensor Circuit HighInput ................................................. 6E-161 Diagnostic Trouble Code (DTC) P0115
On-Board Diagnostic (OBD) System Check 6E-106 NO CHECK ENGINE LAMP (MIL) ............. 6E-109 Circuit Description ..................................... 6E-109 Diagnostic Aids .......................................... 6E-109 No Check Engine Lamp (MIL) ................... 6E-110 CHECK ENGINE LAMP (MIL) ON STEADY 6E-112 Circuit description ...................................... 6E-112 Diagnostic Aids .......................................... 6E-112 Check Engine Lamp (MIL) On Steady ....... 6E-113 ECM Diagnostic Trouble Codes ................ 6E-114 DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128 DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 9) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128 DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE B) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW INPUT ............................. 6E-128 DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE C) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH INPUT ............................ 6E-128 Circuit Description ..................................... 6E-129 Diagnostic Aids .......................................... 6E-129 Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65) Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input ..................................... 6E-129 Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65) Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input ...................................... 6E-132 Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit Low Input ......................................................... 6E-134 Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit High Input ............. 6E-137 DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT ...................................................... 6E-140 DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 2) (FLASH CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT ............................................. 6E-140 DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 7) (FLASH CODE 34)

(Symptom Code 2) (Flash Code 14) Engine Coolant Temperature Sensor Circuit LowInput .................................................. 6E-165 DIAGNOSTIC TROUBLE CODE (DTC) P0180 (SYMPTOM CODE B) (FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE ....................... 6E-168 Circuit Description ..................................... 6E-168 Diagnostic Aids .......................................... 6E-168 Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel Temperature Sensor Circuit Range/Performance ................................ 6E-169 DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION ....................................... 6E-170 DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE B) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT ............................ 6E-170 DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE C) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE .................................................... 6E-170 DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION ....................................... 6E-170 Circuit Description ..................................... 6E-171 Diagnostic Aids .......................................... 6E-171 Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel Cutoff Solenoid Valve Malfunction ........... 6E-171 Diagnostic Trouble Code (DTC) P0215 (Symptom Code B) (Flash Code 52) Fuel Cutoff Solenoid Valve Circuit High Input . 6E-173 Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel Cutoff Solenoid Valve Always Active ....... 6E-175 Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel Cutoff Solenoid Valve Malfunction ........... 6E-177 DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION ....................................... 6E-178 DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION ....................................... 6E-178 Circuit Description ..................................... 6E-179 Diagnostic Aids .......................................... 6E-179
6E3
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54) Injection Timing Control Circuit Malfunction ........... 6E-180 Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54) Injection Timing Control Circuit Malfunction ........... 6E-180 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 3) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/PERFORMANCE 6E-183 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 4) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID"A" LOW ................................ 6E-183 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 4) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" LOW ............................... 6E-183 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 5) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/PERFORMANCE 6E-183 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 6) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION ............. 6E-183 DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 8) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID"A" HIGH ............................... 6E-183 Circuit description ...................................... 6E-184 Diagnostic Aids .......................................... 6E-184 Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64) Turbocharger Wastegate Solenoid "A" Range/Performance ........................... 6E-185 Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Low 6E-187 Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Range/Performance ................................ 6E-190 Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Malfunction .............................................. 6E-192 Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64) Turbocharger Wastegate Solenoid "A" High 6E-194 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 6) (FLASH CODE 53) INJECTION PUMP
6E4

RANGE/PERFORMANCE ....................... 6E-208 Circuit Description ...................................... 6E-209 Diagnostic Aids .......................................... 6E-209 Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43) Crankshaft Position Sensor Circuit Malfunction .............................................. 6E-209 Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43) Crankshaft Position Sensor Malfunction .. 6E-209 Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43) Engine Speed Input Circuit Range/Performance . 6E-214 DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 4) (FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW 6E-217 DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 8) (FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217 Circuit Description ...................................... 6E-217 Diagnostic Aids .......................................... 6E-217 Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66) Glow Relay Circuit Voltage Low .............. 6E-218 Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66) Glow Relay Circuit Voltage High ....................... 6E-221 DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67) GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW .. 6E-222 DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67) GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH . 6E-222 Circuit Description ...................................... 6E-222 Diagnostic Aids .......................................... 6E-222 Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67) Glow Plug Indicator Circuit Voltage Low ........... 6E-222 Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67) Glow Plug Indicator Circuit Voltage High .......... 6E-226 DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 3) (FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE DETECTED ........................ 6E-227 DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 4) (FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO GROUND OR OPEN CIRCUIT 6E-227 DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 5) (FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT DETECTED .................... 6E-227
MALFUNCTION ....................................... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 7) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 9) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE A) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE B) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE D) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E) (FLASH CODE 53) INJECTION PUMP MALFUNCTION ....... 6E-196 Circuit Description ..................................... 6E-197 Diagnostic Aids .......................................... 6E-197 Diagnostic Trouble Code (DTC) P0251 (Symptom Code 6) (Flash Code 53) Injection Pump Malfunction ..................... 6E-197 Diagnostic Trouble Code (DTC) P0251 (Symptom Code 7) (Flash Code 53) Injection Pump Malfunction ..................... 6E-199 Diagnostic Trouble Code (DTC) P0251 (Symptom Code 9) (Flash Code 53) Injection Pump Malfunction ..................... 6E-203 Diagnostic Trouble Code (DTC) P0251 (Symptom Code A) (Flash Code 53) Injection Pump Malfunction ..................... 6E-204 Diagnostic Trouble Code (DTC) P0251 (Symptom Code B) (Flash Code 53) Injection Pump Malfunction ..................... 6E-205 Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53) Injection Pump Malfunction ..................... 6E-206 Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53) Injection Pump Malfunction ..................... 6E-207 DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE B) (FLASH CODE 43) CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION ....................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE D) (FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION ....................................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE E) (FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT

DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 8) (FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO BATTERY ............................ 6E-227 Circuit Description ..................................... 6E-228 Diagnostic Aids .......................................... 6E-228 Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32) Exhaust Gas Recirculation Flow Excessive Detected 6E-228 Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit ............................................. 6E-232 Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32) Exhaust Gas Recirculation Flow Insufficient Detected 6E-235 Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Battery 6E-238 DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE 1) (FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT ...................................................... 6E-240 DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE A) (FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY TOO HIGH ....................... 6E-240 DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE B) (FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL ................................................... 6E-240 Circuit Description ..................................... 6E-241 Diagnostic Aids .......................................... 6E-241 Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24) Vehicle Speed Sensor Circuit High Input ............. 6E-241 Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24) Vehicle Speed Sensor Input Signal Frequency Too High ................................ 6E-245 Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24) VehicleSpeed Sensor Incorrect Signal .... 6E-248 DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE 1) (FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH ............. 6E-253 DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE 2) (FLASH CODE 35) SYSTEM VOLTAGE TOO LOW .............. 6E-253 DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE A) (FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION ..... 6E-253 Circuit Description ..................................... 6E-253
6E5
Diagnostic Aids .......................................... 6E-254 Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35) System Voltage Too High ........................ 6E-254 Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35) System Voltage Too Low ......................... 6E-256 Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35) System Voltage Malfunction .................... 6E-258 DIAGNOSTIC TROUBLE CODE (DTC) P0561 (SYMPTOM CODE A) (FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION ....................................... 6E-260 DIAGNOSTIC TROUBLE CODE (DTC) P0561 (SYMPTOM CODE B) (FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION ....................................... 6E-260 Circuit Description ...................................... 6E-261 Diagnostic Aids .......................................... 6E-261 Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18) Ignition Switch Circuit Malfunction ........... 6E-261 Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18) Ignition Switch Circuit Malfunction ........... 6E-261 DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE PROGRAMMING ERROR .................................................... 6E-264 Circuit Description & Diagnostic Aids ........ 6E-264 Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error ......... 6E-264 DIAGNOSTIC TROUBLE CODE (DTC) P0606 (SYMPTOM CODE A) (FLASH CODE 28) ECU MALFUNCTION .............................. 6E-265 DIAGNOSTIC TROUBLE CODE (DTC) P0606 (SYMPTOM CODE B) (FLASH CODE 28) ECU MALFUNCTION .............................. 6E-265 Circuit Description & Diagnostic Aids ........ 6E-265 Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU Malfunction ...................................... 6E-265 Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU Malfunction ...................................... 6E-267 DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYMPTOM CODE 4) (FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW ...................................... 6E-268 DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYMPTOM CODE 8) (FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH ...................................... 6E-268
6E6

PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287 DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 9) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287 DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE D) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH ERROR ....................... 6E-287 DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE E) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION SWITCH ERROR ......... 6E-287 Circuit Description ...................................... 6E-288 Diagnostic Aids .......................................... 6E-288 Diagnostic Trouble Code (DTC) P1120 (Symptom Code 1) (Flash Code 21) Pedal/Throttle Position Sensor Circuit High Input ..................................... 6E-288 Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit High Input ......................... 6E-293 Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input .......................... 6E-295 Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21) Pedal/Throttle Position Sensor Brake Switch Error ............................................. 6E-298 Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21) Pedal/Throttle Position Sensor Idle Position Switch Error ............................... 6E-300 DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE 3) (FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE ...................................... 6E-302 DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE 7) (FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE ...................................... 6E-302 DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE A) (FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW FUEL TEMPERATURE ...................................... 6E-302 Circuit Description ...................................... 6E-302 Diagnostic Aids .......................................... 6E-302 Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel Reduction Caused By High Coolant
Circuit Description ..................................... 6E-268 Diagnostic Aids .......................................... 6E-268 Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C Compressor Relay Circuit Voltage Low ... 6E-269 Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C Compressor Relay Circuit Voltage High .. 6E-272 DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE A) (FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE B) (FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 Circuit Description ..................................... 6E-274 Diagnostic Aids .......................................... 6E-274 Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25) Brake Switch Circuit Malfunction ....................... 6E-274 Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25) Brake Switch Circuit Malfunction ............. 6E-278 DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6) (FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION ....................................... 6E-281 Circuit Description ..................................... 6E-281 Diagnostic Aids .......................................... 6E-281 Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57) Clutch Switch Input Circuit Malfunction ... 6E-282 DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 1) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT ............................ 6E-285 DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 2) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT ............................. 6E-285 Circuit Description ..................................... 6E-285 Diagnostic Aids .......................................... 6E-285 Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86) Barometric Pressure Sensor Circuit High Input ......... 6E-285 Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86) Barometric Pressure Sensor Circuit Low Input .......... 6E-285 DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 1) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT ............................ 6E-287 DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 7) (FLASH CODE 21)

Temperature ............................................ 6E-302 Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel Reduction Caused By High Fuel Temperature ............................................ 6E-305 Diagnostic Trouble Code (DTC) P1173 (Symptom Code A) (Flash Code 22) Fuel Reduction Caused By Low Fuel Temperature ............................................ 6E-305 DIAGNOSTIC TROUBLE CODE (DTC) P1335 (SYMPTOM CODE A) (FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION ....................... 6E-306 Circuit Description ..................................... 6E-306 Diagnostic Aids .......................................... 6E-306 Diagnostic Trouble Code (DTC) P1335 (Symptom Code A) (Flash Code 43) Engine Speed Output Circuit Malfunction 6E-307 DIAGNOSTIC TROUBLE CODE (DTC) P1345 (SYMPTOM CODE A) (FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION ..... 6E-311 Circuit Description ..................................... 6E-311 Diagnostic Aids .......................................... 6E-311 Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45) Camshaft Speed Malfunction .................. 6E-312 DIAGNOSTIC TROUBLE CODE (DTC) P1520 (SYMPTOM CODE A) (FLASH CODE 47) NEUTRAL SWITCH ON ERROR ............ 6E-313 DIAGNOSTIC TROUBLE CODE (DTC) P1520 (SYMPTOM CODE B) (FLASH CODE 47) NEUTRAL SWITCH OFF ERROR .......... 6E-313 Circuit Description ..................................... 6E-313 Diagnostic Aids .......................................... 6E-313 Diagnostic Trouble Code (DTC) P1520 (Symptom Code A) (Flash Code 47) Neutral Switch ON Error .......................... 6E-314 Diagnostic Trouble Code (DTC) P1520 (Symptom Code B) (Flash Code 47) Neutral Switch OFF Error ........................ 6E-314 DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE C) (FLASH CODE 55) SEED AND KEY FILE DESTROYED ...... 6E-318 DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE D) (FLASH CODE 55) EEPROM DEFECT .................................. 6E-318 DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE E) (FLASH CODE 55) EEPROM DEFECT .................................. 6E-318 Circuit Description & Diagnostic Aids ........ 6E-318 Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55) Seed and Key File Destroyed .................. 6E-318
6E7
Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55) EEPROM Defect ...................................... 6E-318 Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55) EEPROM Defect ...................................... 6E-318 DIAGNOSTIC TROUBLE CODE (DTC) P1610 (SYMPTOM CODE A) (FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED ...................................... 6E-320 Circuit Description ...................................... 6E-320 Diagnostic Aids .......................................... 6E-320 Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56) Security Key and Security Code Not Programmed 6E-320 DIAGNOSTIC TROUBLE CODE (DTC) P1611 (SYMPTOM CODE A) (FLASH CODE 56) WRONG SECURITY CODE ENTERED .. 6E-322 Circuit Description ...................................... 6E-322 Diagnostic Aids .......................................... 6E-322 Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56) Wrong Security Code Entered ................. 6E-323 DIAGNOSTIC TROUBLE CODE (DTC) P1612 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL 6E-324 Circuit Description ...................................... 6E-324 Diagnostic Aids .......................................... 6E-324 Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal .............. 6E-325 DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL 6E-330 Circuit Description ...................................... 6E-330 Diagnostic Aids .......................................... 6E-330 Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal .............. 6E-331 DIAGNOSTIC TROUBLE CODE (DTC) P1614 (SYMPTOM CODE A) (FLASH CODE 56) WRONG TRANSPONDER KEY .............. 6E-335 Circuit Description ...................................... 6E-335 Diagnostic Aids .......................................... 6E-335 Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56) Wrong Transponder Key .......................... 6E-336 DIAGNOSTIC TROUBLE CODE (DTC) P1625 (SYMPTOM CODE A) (FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY ............................................ 6E-337 DIAGNOSTIC TROUBLE CODE (DTC) P1625
6E8

CAN Receives Error ................................ 6E-351 DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 4) (FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW ...................................... 6E-356 DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 8) (FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH ...................................... 6E-356 Circuit Description ...................................... 6E-356 Diagnostic Aids .......................................... 6E-356 Diagnostic Trouble Code (DTC) P1690 (Symptom Code 4) (Flash Code 77) Check Engine Lamp (MIL) Circuit Voltage Low .. 6E-357 Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77) Check Engine Lamp (MIL) Circuit Voltage High . 6E-360 SYMPTOM DIAGNOSIS ............................ 6E-361 PRELIMINARY CHECKS .......................... 6E-361 VISUAL/PHYSICAL CHECK ...................... 6E-361 INTERMITTENT ........................................ 6E-361 ENGINE CRANKS BUT WILL NOT RUN .. 6E-362 HARD START SYMPTOM ......................... 6E-366 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM .................. 6E-370 SURGES AND/OR CHUGS SYMPTOM ... 6E-377 HESITATION, SAG, STUMBLE SYMPTOM 6E-383 CUTS OUT, MISSES SYMPTOM .............. 6E-389 LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM .............................. 6E-396 POOR FUEL ECONOMY SYMPTOM ....... 6E-402 EXCESSIVE WHITE SMOKE .................... 6E-407 EXCESSIVE BLACK SMOKE .................... 6E-413 ON-VEHICLE SERVICE PROCEDURE .... 6E-418 ENGINE CONTROL MODULE (ECM) ... 6E-418 CRANKSHAFT POSITION (CKP) SENSOR 6E-419 ENGINE COOLANT TEMPERATURE (ECT) SENSOR ....................................... 6E-419 MASS AIR FLOW (MAF) & INTAKE AIR TEMPERATURE (IAT) SENSOR ............ 6E-420 THROTTLE POSITION SENSOR (TPS) ... 6E-420 EGR EVRV (Electrical Vacuum Regulating Valve) ..... 6E-421
(SYMPTOM CODE B) (FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE 6E-337 Circuit Description ..................................... 6E-337 Diagnostic Aids .......................................... 6E-337 Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM Main Relay Switched Off Too Early ......... 6E-338 Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM Main Relay Switched Off Too Late .......... 6E-339 DIAGNOSTIC TROUBLE CODE (DTC) P1630 (SYMPTOM CODE A) (FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION ....................................... 6E-340 DIAGNOSTIC TROUBLE CODE (DTC) P1630 (SYMPTOM CODE B) (FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION ....................................... 6E-340 Circuit Description ..................................... 6E-340 Diagnostic Aids .......................................... 6E-341 Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51) Fuel Injection Quantity Circuit Malfunction ...... 6E-341 Diagnostic Trouble Code (DTC) P1630 (Symptom Code B) (Flash Code 51) Fuel Injection Quantity Circuit Malfunction ...... 6E-341 DIAGNOSTIC TROUBLE CODE (DTC) P1650 (SYMPTOM CODE A) (FLASH CODE 44) CAN DEVICE OFFLINE 6E-342 DIAGNOSTIC TROUBLE CODE (DTC) P1650 (SYMPTOM CODE B) (FLASH CODE 44) CAN DEVICE HANG-UP ......................... 6E-342 Circuit Description ..................................... 6E-342 Diagnostic Aids .......................................... 6E-342 Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN Device Offline .................................. 6E-343 Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN Device Hang-up .............................. 6E-348 DIAGNOSTIC TROUBLE CODE (DTC) P1651 (SYMPTOM CODE A) (FLASH CODE 45) CAN MALFUNCTION .............................. 6E-349 DIAGNOSTIC TROUBLE CODE (DTC) P1651 (SYMPTOM CODE B) (FLASH CODE 45) CAN RECEIVES ERROR ........................ 6E-349 Circuit Description ..................................... 6E-349 Diagnostic Aids .......................................... 6E-349 Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45) CAN Malfunction ...................................... 6E-350 Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45)
6E9
ABBREVIATION CHARTS
Abbreviations A/C A/T ACC BLK BLU BRN CAN CEL CKP DLC DTC DVM ECM ECT EEPROM EGR EVRV GND GRY IAT IG M/T MAB MAF MIL OBD ORN PNK RED PSG SW TCM TCV TDC TPS VCC VIO VSS WHT YEL Air conditioner Automatic transmission Accessory Black Blue Brown Controller Area Network Check engine lamp Crankshaft position sensor Data link connector Diagnosis trouble code Digital voltage meter Engine control module Engine coolant temperature Electrically erasable & programmable read only memory Exhaust gas recirculation Electric vacuum regulating valve Ground Gray Intake air temperature Ignition Manual transmission High pressure solenoid valve cutoff (German abbreviation) Mass air flow Malfunction indicator lamp On-board diagnostic Orange Pink Red Pump control unit (German abbreviation) Switch Transmission control module Timing control valve Top dead center Throttle position sensor Voltage constunt control Violet Vehicle speed sensor White Yellow Appellation
6E10
COMPONENT LOCATOR Engine Component Locator Table

4JA1-TC
(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) Throttle Cable (3) Air Cleaner Case
(4) Battery (5) Relay & Fuse Box (6) EGR Cooler
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 4JH1-TC
6E11
4 3 1
5 4
(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) Throttle Cable (3) Air Cleaner Case
(4) Battery (5) Relay & Fuse Box (6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
6E12
(1) Throttle Position Sensor (TPS) (2) Pump Control Unit (PSG)
(3) Injection Pump Assembly (4) Fuel Filter (Except Euro 3)
(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) EGR EVRV
(3) Air Cleaner Case
6E13
(1) Engine Control Module (ECM)
(1) EGR EVRV (2) To Vacuum Pump (3) To EGR Valve
1 2 1
(1) Engine Coolant Temperature (ECT) Sensor (2) Thermo Unit for Water Temperature Gauge
(1) Crankshaft Position (CKP) Sensor (2) Clutch Housing
(1) Vehicle Speed Sensor (VSS)
6E14
ECM CIRCUIT DIAGRAM (4JA1-TC)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS ECM CIRCUIT DIAGRAM (4JA1-TC)
6E15
6E16
ECM CIRCUIT DIAGRAM (4JH1-TC)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS ECM CIRCUIT DIAGRAM (4JH1-TC)
6E17
6E18
GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART GENERAL EXPORT (LHD) (2/4)
6E19
6E20
GROUND POINT CHART GENERAL EXPORT (LHD) (3/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART GENERAL EXPORT (LHD) (4/4)
6E21
6E22
GROUND POINT CHART EUROPE (LHD) (1/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART EUROPE (LHD) (2/4)
6E23
6E24
GROUND POINT CHART EUROPE (LHD) (3/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART EUROPE (LHD) (4/4)
6E25
6E26
GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART GENERAL EXPORT (RHD) (2/4)
6E27
6E28
GROUND POINT CHART GENERAL EXPORT (RHD) (3/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART GENERAL EXPORT (RHD) (4/4)
6E29
6E30
GROUND POINT CHART EUROPE (RHD) (1/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART EUROPE (RHD) (2/4)
6E31
6E32
GROUND POINT CHART EUROPE (RHD) (3/4)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART EUROPE (RHD) (4/4)
6E33
6E34
LOCATION
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS CABEL HARNESS & CONNECTOR LOCATION
6E35
6E36
4JA1-TC & 4JH1-TC ENGINE (LHD)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 4JA1-TC & 4JH1-TC ENGINE (RHD)
6E37
6E38
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS PARTS LOCATION
6E39
6E40
CONNECTOR LIST
No. B-24 Connector face No. C-56 Connector face
Green B-54
Meter-B C-57
ECM-A
White B-56
J/B I2 C-77
ECM-B
White B-58
J/B I4 C-94
Clutch switch
Black B-62
Check connector
White C-95
TCM
White B-63
Ignition switch (IGSUB : G1)
White C-107
TCM
White B-68
Ignition switch (IGSUB : G2)
White C-108
J/B E2
Immobilizer C-2
White C-109
J/B E1
Silver C-36
Engine room-RH ground
Silver C-115
Body-LH ; ground
Silver C-44
Engine room-LH ; Ground
Brown C-116
EVRV
White
Stop lamp switch
6E41
No. C-118
Connector face
No. E-23
Connector face
A/C Resister & Neutral switch C-123
Gray E-41
Idle SW
Black C-124 E-44
Coolant temp sensor
Gray E-3 E-49
Vehicle speed sensor
Black E-6
Magnetic clutch AC COMP
Gray E-51
Glow plug
Black E-9 H-4
Inhibiter switch
White E-10 H-6
Engine room ~ Mission
Silver E-11
Engine ground
White H-7
Engine room ~ INST
Natural green E-12
Neutral switch
White H-18
Engine room ~ INST
Natural green E-22
Neutral switch
White H-22
Engine room ~ INST
Brown
TPS 1 main
White
Engine ~ Engine room C
6E42
No. H-33
Connector face
No. X-16
Connector face
Engine ~ Engine room P-1
Black X-17
DIODE
Silver P-2
Battery (+)
Black
DIODE
Silver P-5
Relay & Fuse box
Silver P-6
Battery (-)
Silver P-10
Body earth (Ground)
Silver X-5
Engine ground
Black X-13
Relay ; Glow
Black X-14
Relay ; ECM MAIN
Black X-15
Relay; A/C Compressor
Black
Relay; Thermo
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS RELAY AND FUSE

RELAY AND FUSE BOX LOCATION (LHD & RHD)
6E43
LHD
RHD
6E44
RELAY AND FUSE BOX LOCATION (LHD & RHD) RELAY & FUSE BOX RELAY
No. X-1 X-2 X-3 X-4 X-5 X-6 X-7 X-8 X-9 RELAY (4JA1-TC/4JH1-TC) RELAY; TAIL LIGHT RELAY; FRT FOG LIGHT RELAY; HORN RELAY; DIMMER RELAY; GLOW RELAY; COND, FAN RELAY; RR FOG RELAY; STARTER SHORT CONNECTOR (with Cooler) (LHD) RELAY; HAZARD-RH (RHD) SHORT CONNECTOR (with Cooler) (LHD) RELAY; HAZARD-LH (RHD) RELAY; HEATER RELAY; HEAD LIGHT RELAY; ECM MAIN RELAY; A/C COMP RELAY; THERMO
X-10
X-11 X-12 X-13 X-14 X-15
FUSE
NO. EB-1 EB-2 EB-3 EB-4 EB-5 EB-6 EB-7 EB-8 EB-9 EB-10 EB-11 EB-12 EB-13 EB-14 EB-15 EB-16 FUSE (4JA1-TC/4JH1-TC) 10A ECM 10A RR FOG 15A FRT FOG 10A ILLUMI & TAIL-RH 10A TAIL-LH 10A H/LIGHT RH-LOW 10A H/LIGHT LH-LOW 10A TRA ILER 10A AC G (S) 10A H/LIGHT RH-HIGH 10A H/LIGHT LH-HIGH 10A A/C 10A 4WD 10A HORN 10A HAZARD
SLOW BLOW FUSE

NO. SBF-1 SBF-2 SBF-3 SBF-4 SBF-5 SBF-6 SBF-7 SBF-8 SBF-9 SLOW BLOW FUSE 4JA1-TC/4JH1-TC 80A MAIN 20A COND, FAN 50A GLOW 30A ECM 40A IG 1 40A ABS-1 30A ABS-2 30A BLOWER 50A IG 2

FUSE AND RELAY LOCATION (LHD & RHD)
6E45
FUSE BOX
FUSE No. 1 2 3 4 5 6 7 8 9 10 11
Capacity 10A 15A 15A 10A 15A 15A 20A 15A 10A
Indication on label ABS BACK UP METER TURN ELEC.IG ENGINE FRT WIPER EGR AUDIO Indication on label RR DEF POWER WINDOW B-7 B-8
No. 12 13 14 15 16 17 18 19 20 21
Capacity 15A 15A 20A 10A 10A 10A 15A 15A 10A 10A
Indication on label CIGER AUDIO (+B) DOOR LOCK METER (+B) ROOM ANTI THEFT STOP ACC SOCKET STARTER SRS
SLOW BLOW FUSE No. Capacity SBF-10 20A SBF-11 30A RELAY Connector No. 4JA1-TC, 4JH1-TC
B-40 ACC SOCKET
REAR POWER DEFOGGER WINDOW
6E46
ECM WIRING DIAGRAM (1/7)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS ECM WIRING DIAGRAM (2/7)
6E47
6E48
6E49
6E50
6E51
6E52
6E53
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into ECM Case
Signal or Continuity Pin No. 1 B/Box No. 1 Pin Function Wire Color BLK Key SW Off Continuity with ground Continuity with ground Less than 1V Key SW On Engine Idle Engine 2000rpm ECM Connection Disconnect Disconnect Connect Approx. 67Hz by wave form or approx. 6.8V Connect
Tester Position Range (+) (-)
ECM Ground
Ohm
GND
ECM Ground
BLK
Ohm
GND
3 25 26 27
3 25 26 27
Battery Power Supply No Connection No Connection Engine Speed Output (To Tacho Meter)
BLU/ RED LGN
10-14V Approx. 23Hz by wave form or approx. 6.3V -
DC V AC V
3 27
GND GND
28 29 30 31 32 33
28 29 30 31 32 33
No Connection No Connection Brake Switch 1 Signal Clutch Switch Signal (MT Only) No Connection A/C ON Signal Relay
GRN YEL GRN/ YEL
Less than 1V Less than 1V Less than 1V
Connect Connect Connect
DC V DC V DC V
30 31 33
GND GND GND
Pedal is not stepped on: Less than 1V Pedal is stepped on: 10-14V Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V -
A/C request switch is turned on: 1014V A/C request switch is turned off: Less than 1V -
34 35
34 35
No Connection To Data Link Connector No. 6 & Immobilizer Control Unit (ICU B8) No Connection No Connection Throttle Position Sensor (TPS) Output Signal Key Switch Input Signal Via Engine Fuse No Connection
YEL
36 37 38
36 37 38
GRN/ ORG WHT -
Less than 1V Less than 1V -
Approx. 0.5V
Connect
DC V
38
49
Less than 1V
39 40
39 40
10-14V -
Connect -
DC V -
39 -
GND -
6E54

Signal or Continuity Tester Position Engine 2000rpm ECM Connection Connect Range (+) (-)
Pin No. 41
B/Box No. 41
Pin Function
Wire Color WHT/ GRN
Key SW Off Less than 1V
Key SW On 10-14V
Engine Idle
A/C Compressor Relay
A/C comp. is operated: Less than 1V A/C comp. is not operated: 10 - 14V
DC V
41
GND
42 43 44 45 46 47 48 49
42 43 44 45 46 47 48 49
Check Engine Lamp Glow Lamp No Connection To Data Link Connector No. 6 No Connection No Connection No Connection Throttle Position Sensor (TPS) Ground
GRN/ YEL ORG/ BLU BLU BLK/ GRN
Less than 1V Less than 1V Less than 1V Idle: Approx. 0.4K ohm / WOT: Approx. 4.0K ohm Less than 1V 10-14V Less than 1V
Lamp is turned on: Less than 1V Lamp is turned off: 10-14V Lamp is turned on: Less than 1V Lamp is turned off: 10-14V 10-14V -
Connect Connect Connect Disconnect
DC V DC V DC V Ohm
42 43 45 38
GND GND GND 49
50 51 52 53 54 55 56 57
50 51 52 53 54 55 56 57
No Connection No Connection No Connection No Connection No Connection No Connection No Connection Throttle Position Sensor (TPS) Power Supply ECM Relay No Connection No Connection No Connection No Connection ECM Power Supply No Connection Brake Switch 2 Signal No Connection No Connection Vehicle Speed Sensor (VSS) Idle Switch No Connection No Connection No Connection No Connection No Connection
RED/ GRN BLU/ BLK -
Approx. 5V
Connect
DC V
57
49
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
Less than 1V 10-14V -
Connect Connect Connect Connect -
DC V DC V DC V AC V DC V -
58 63 65 68 69 -
GND GND GND GND GND -
WHT/ BLK YEL/ GRN GRN/ BLK -
Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V -
Approx. 14.5Hz by wave form or approx. 6.0V at vehicle speed 20km/h Pedal is not stepped on: Less than 1V Pedal is stepped on: Approx. 5V -

Signal or Continuity Pin No. 75 76 77 78 79 80 81 82 83 84 B/Box No. 75 76 77 78 79 80 81 82 83 84 Pin Function Wire Color WHT/ RED BLK/ BLU Key SW Off Less than 1V Less than 1V Key SW On Engine Idle Approx. 5V 0 deg. C: Approx. 3.6V / 20 deg. C: Approx. 2.6V / 40 deg. C: Approx. 1.7V / 60 deg. C: 1.1V / 80 deg. C: 0.7V Engine 2000rpm ECM Connection Connect Connect
6E55
Tester Position Range (+) (-)
No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection Mass Air Flow (MAF) Sensor Power Supply Intake Air Temperature (IAT) Sensor Signal No Connection No Connection Neutral Switch Mass Air Flow (MAF) Sensor Signal Engine Coolant Temperature (ECT) Sensor Signal CKP Sensor Signal
DC V DC V
83 84
92 92
85 86 87 88 89
85 86 87 88 89
BLK/ WHT GRN/ RED GRY
Less than 1V Less than 1V Less than 1V
Connect Connect Connect
DC V DC V DC V
87 88 89
GND 92 93
In neutral: Less than 1V Other than neutral: 10-14V Approx. 1V Approx. 1.8V Approx. 2.5V
0 deg. C: Approx. 4.4V / 20 deg. C: Approx. 3.8V / 40 deg. C: Approx. 2.9V / 60 deg. C: 2.1V / 80 deg. C: 1.4V Approx. 47Hz by wave form Approx. 134Hz by wave form or approx. 1.1V Approx. 134Hz by wave form or approx. 0.7V -
90
90
RED
Connect
AC V
90
98
91
91
CKP Sensor Output To Pump Control Unit (PSG) No.8
PNK
Approx. 47Hz by wave form
Connect
AC V
91
GND
92
92
Mass Air Flow (MAF) Sensor Ground Engine Coolant Temperature (ECT) Sensor Ground Glow Relay
BLK/ RED BLK/ PNK BLK/ RED BLK/ ORG WHT
Continuity with ground Continuity with ground Less than 1V -
Connect
Ohm
92
GND
93
93
Connect
Ohm
93
GND
94
94
Glow system is operated: Less than 1V Glow system is not operated: 10 - 14V -
Connect
DC V
94
GND
95 96 97
95 96 97
No Connection No Connection EGR EVRV
Approx. 140Hz by wave form when EVRV is operated -
98
98
CKP Sensor Ground
Continuity with ground -
Connect
Ohm
98
GND
99 100
99 100
CAN (Controller Area Network) to PSG No.1 CAN (Controller Area Network) to PSG No.2
BLU YEL
6E56

Signal or Continuity Tester Position Engine 2000rpm ECM Connection Connect Range (+) (-)
Pin No. 101
B/Box No. 101
Pin Function
Wire Color BLK
Key SW Off Continuity with ground -
Key SW On -
Engine Idle -
CKP Sensor Shield Line No Connection No Connection No Connection Solenoid Valve Shut Off (MAB) Output Signal to PSG No.5
Ohm
101
GND
102 103 104 105
102 103 104 105
ORG

PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into PSG Case
6E57
Signal or Continuity Pin No. B/ Box No. 99 Pin Function Wire Color Key SW Off Key SW On Engine Idle Engine 2000rpm ECM & PSG Connection Disconnect
Tester Position Rang e (+) (-)
CAN (Controller Area Network) to ECM No.99
RED
Continuity between ECM & PSG Continuity between ECM & PSG Continuity between ECM & PSG Continuity with ground Less than 1V Continuity between ECM & PSG -
Ohm
99 (EC M)
100
WHT
Disconnect
Ohm
100 (EC M)
3 4 5
105
No Connection No Connection Solenoid Valve Shut Off (MAB) Output Signal to ECM No.105
ORG
Disconnect
Ohm
105 (EC M)
Ground
BLK
Disconnect
Ohm
GND
Battery Power Supply CKP Sensor Output ECM No.91 to Pump Control Unit (PSG)
BLU/ RED PNK
10-14V
Disconnect Disconnect
Ohm
GND
91
Ohm
91 (EC M)
No Connection
6E58
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into ECM Case
Signal or Continuity Pin No. B/ Box No. 1 Pin Function Wire Color Key SW Off Key SW On Engine Idle Engine 2000rpm ECM Connection Disconnect
Tester Position Ran ge (+) (-)
ECM Ground
BLK
Continuity with ground Continuity with ground Less than 1V -
Ohm
GND
ECM Ground
BLK
Disconnect
Ohm
GND
Battery Power Supply No Connection No Connection Engine Speed Output (To Tacho Meter)
BLU/ RED LGN
10-14V
Connect
DC V
GND
25 26 27
25 26 27
Approx. 23Hz by wave form or approx. 6.3V -
Approx. 67Hz by wave form or approx. 6.8V -
Connect
AC V
27
GND
28 29
28 29
No Connection Throttle Position Signal To TCM (A16) (AT Only) Brake Switch 1 Signal
Approx. 140Hz by wave form (Idle: Off duty 10% / WOT: Off duty 90%)
30
30
GRN
Less than 1V
Pedal is not stepped on: Less than 1V Pedal is stepped on: 10-14V Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V -
Connect
DC V
30
GND
31
31
Clutch Switch Signal (MT Only) No Connection A/C ON Signal Relay
YEL
Less than 1V Less than 1V
Connect
DC V
31
GND
32 33
32 33
GRN/ YEL
Connect
DC V
33
GND
A/C request switch is turned on: 1014V A/C request switch is turned off: Less than 1V -
34 35
34 35
No Connection To Data Link Connector No. 6 & Immobilizer Control Unit (ICU B8) No Connection
YEL
36
36

Signal or Continuity Pin No. B/ Box No. 37 38 Pin Function Wire Color Key SW Off Key SW On Engine Idle Engine 2000rpm ECM Connection Connect
6E59
37 38
No Connection Throttle Position Sensor (TPS) Output Signal Key Switch Input Signal Via Engine Fuse No Connection A/C Compressor Relay
GRN/ ORG
Less than 1V
Approx. 0.5V
DC V
38
49
Less than 1V
39
39
WHT
Less than 1V Less than 1V 10-14V
10-14V
Connect
DC V
39
GND
40 41
40 41
WHT/ GRN
Connect
DC V
41
GND
A/C comp. is operated: Less than 1V A/C comp. is not operated: 10 - 14V
42
42
Check Engine Lamp
GRN/ YEL ORG/ BLU BLU
Less than 1V Less than 1V Less than 1V Idle: Approx. 0.4K ohm / WOT: Approx. 4.0K ohm Less than 1V
Lamp is turned on: Less than 1V Lamp is turned off: 10-14V Lamp is turned on: Less than 1V Lamp is turned off: 10-14V 10-14V -
Connect
DC V
42
GND
43
43
Glow Lamp
Connect
DC V
43
GND
44 45
44 45
No Connection To Data Link Connector No. 6 No Connection No Connection No Connection Throttle Position Sensor (TPS) Ground
Connect
DC V
45
GND
46 47 48 49
46 47 48 49
BLK/ GRN
Disconnect
Ohm
38
49
50 51 52 53 54 55 56 57
50 51 52 53 54 55 56 57
No Connection No Connection No Connection No Connection No Connection No Connection No Connection Throttle Position Sensor (TPS) Power Supply ECM Relay
RED/ GRN
Approx. 5V
Connect
DC V
57
49
58
58
BLU/ BLK -
10-14V
Less than 1V
Connect
DC V
58
GND
59 60 61 62
59 60 61 62
No Connection No Connection No Connection No Connection
6E60

Signal or Continuity Tester Position Engine 2000rpm ECM Connection Ran ge (+) (-)
Pin No.
B/ Box No. 63
Pin Function
Wire Color
Key SW Off
Key SW On
Engine Idle
63
ECM Power Supply
10-14V
DC V
63
GND
64 65
64 65
No Connection Brake Switch 2 Signal No Connection No Connection Vehicle Speed Sensor (VSS)
WHT/ BLK YEL/ GRN
Connect
DC V
65
GND
Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V -
66 67 68
66 67 68
Connect
AC V
68
GND
Approx. 14.5Hz by wave form or approx. 6.0V at vehicle speed 20km/h Pedal is not stepped on: Less than 1V Pedal is stepped on: Approx. 5V Approx. 5V -
69
69
Idle Switch
GRN/ BLK
Less than 1V
Connect
DC V
69
GND
70 71 72 73 74 75 76 77 78 79 80 81 82
70 71 72 73 74 75 76 77 78 79 80 81 82
No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection No Connection Boost Pressure Sensor (High Altitude Spec. Only) Mass Air Flow (MAF) Sensor Power Supply Intake Air Temperature (IAT) Sensor Signal
WHT/ BLU
Less than 1V
Connect
DC V
82
93
83
83
WHT/ RED
Less than 1V
Approx. 5V
Connect
DC V
83
92
84
84
BLK/ BLU
Less than 1V
0 deg. C: Approx. 3.6V / 20 deg. C: Approx. 2.6V / 40 deg. C: Approx. 1.7V / 60 deg. C: 1.1V / 80 deg. C: 0.7V -
Connect
DC V
84
92
85
85
Manifold Pressure Sensor (High Altitude Spec. Only) No Connection Neutral Switch
RED/ BLU
Less than 1V
Connect
DC V
85
93
86 87
86 87
BLK/ WHT
Less than 1V
Connect
DC V
87
GND
In neutral (A/T: P or N): Less than 1V Other than neutral (A/T: other than P or N): 10-14V Approx. 1V Approx. 1.8V Approx. 2.5V
88
88
Mass Air Flow (MAF) Sensor Signal
GRN/ RED
Less than 1V
Connect
DC V
88
92

Signal or Continuity Pin No. B/ Box No. 89 Pin Function Wire Color Key SW Off Key SW On Engine Idle Engine 2000rpm ECM Connection Connect
6E61
89
Engine Coolant Temperature (ECT) Sensor Signal
GRY
Less than 1V
0 deg. C: Approx. 4.4V / 20 deg. C: Approx. 3.8V / 40 deg. C: Approx. 2.9V / 60 deg. C: 2.1V / 80 deg. C: 1.4V Approx. 47Hz by wave form Approx. 134Hz by wave form or approx. 1.1V Approx. 134Hz by wave form or approx. 0.7V -
DC V
89
93
90
90
CKP Sensor Signal
RED
Connect
AC V
90
98
91
91
CKP Sensor Output To Pump Control Unit (PSG) No.8
PNK
Approx. 47Hz by wave form
Connect
AC V
91
GND
92
92
Mass Air Flow (MAF) Sensor Ground
BLK/ RED
Continuity with ground Continuity with ground
Connect
Ohm
92
GND
93
93
Engine Coolant Temperature (ECT) Sensor & Manifold Pressure Sensor Ground Glow Relay
BLK/ PNK
Connect
Ohm
93
GND
94
94
BLK/ RED
Less than 1V
Glow system is operated: Less than 1V Glow system is not operated: 10 14V Wave form -
Connect
DC V
94
GND
95 96
95 96
No Connection Turbocharger Wastegate Control EVRV EGR EVRV
BRW/ RED BLK/ ORG
97
97
Approx. 140Hz by wave form when EVRV is operated -
98
98
CKP Sensor Ground
WHT
Connect
Ohm
98
GND
99
99
CAN (Controller Area Network) to PSG No.1 CAN (Controller Area Network) to PSG No.2 CKP Sensor Shield Line
BLU
100
100
YEL
101
101
BLK
Connect
Ohm
101
GND
102 103 104 105
102 103 104 105
No Connection No Connection No Connection Solenoid Valve Shut Off (MAB) Output Signal to PSG No.5
ORG
6E62
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into PSG Case
Signal or Continuity Pin No. B/ Box No. 99 Pin Function Wire Color Key SW Off Key SW On Engine Idle Engine 2000rp m ECM & PSG Connection Disconnect
Tester Position Rang e (+) (-)
RED
Continuity between ECM & PSG Continuity between ECM & PSG Continuity between ECM & PSG Continuity with ground Less than 1V Continuity between ECM & PSG -
Ohm
99 (ECM )
100
WHT
Disconnect
Ohm
100 (ECM )
3 4 5
105
No Connection No Connection Solenoid Valve Shut Off (MAB) Output Signal to ECM No.105
ORG
Disconnect
Ohm
105 (ECM )
Ground
BLK
Disconnect
Ohm
GND
Battery Power Supply CKP Sensor Output ECM No.91 to Pump Control Unit (PSG)
BLU/ RED PNK
10-14V
Disconnect Disconnect
Ohm
GND
91
Ohm
91 (ECM )
No Connection

Crankshaft Position (CKP) Sensor Reference Wave Form
Crankshaft Position (CKP) Sensor & TDC Output Signal Reference Wave Form
6E63
CH1 0V
0V
CH2 0V
Measurement Terminal: 90(+) 98(-) Measurement Scale: 20V/div 2ms/div Measurement Condition: Approximately 2000rpm
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-) Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div Measurement Condition: Approximately 2000rpm
Engine Speed Output Signal Reference Wave Form
Vehicle Speed Sensor (VSS) Reference Wave Form
0V
0V
Measurement Terminal: 27(+) GND(-) Measurement Scale: 5V/div 10ms/div Measurement Condition: Approximately 2000rpm
Measurement Terminal: 68(+) GND(-) Measurement Scale: 5V/div 50ms/div Measurement Condition: Approximately 20km/h
6E64

management system. Engine Control Module (ECM) Pump Control Unit (PSG) = Pumpen Steuer Great (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 module (ECM) and the pump control unit (PSG) is perfumed via a CAN-bus system. The abbreviation CAN stands for Controller Area Network. By having two separate control modules, the high pressure solenoid valve. This prevents the discharge of any disturbing signals. The information exchange between the two control modules takes place via two means. Via analogue signal leads Via the CAN-bus The analogue signal leads are used to exchange the following information. Engine speed signal (ECM terminal 91) Pump Speed (ECM terminal 105) Fuel Cutoff solenoid valve signal (MAB signal) (ECM terminal 105) The engine speed signal is sent from the ECM to PSG based on the input from the crank shaft position (CKP) sensor. The analogue CKP sensor signal is converted by the ECM into a square wave signal. The fuel cutoff solenoid valve signal is also referred to as MAB signal. MAB in this case, refers to the German abbreviation Magnet ventil ABschaltung that stands for high pressure solenoid valve cut off. The MAB signal wire is used for two purposes. -As a reference for the engine control module (ECM) for the pump speed (back up for the CKP sensor). -To turn Off the engine.
GENERAL DESCRIPTION FOR ECM AND SENSORS Engine Control Module (ECM)
The engine control module (ECM) is located flower panel just under the passenger's seat. The fuel quantity and injection timing related functions are controlled by the pump control unit (PSG). The engine control module (ECM) performs the following functions. Control of the exhaust gas re-circulation (EGR) Control of the quick on start (QOS) glow control system Control of the A/C compressor Execution of the immobilizer function
Pump Control Unit (PSG) & Data Exchange Between Control Module
Self Diagnosis / Interface / Signal To High Pressure Solenoid Cam Ring Rotational Angle Fuel Temperature Injection Timing High Pressure Solenoid Valve Pump Control Unit (PSG) Fuel Injection (Mechanical)
Engine Speed
Accelerator Pedal
Engine Control Module (ECM)
Injection Quantity Intake Air Temperature Response Signal 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

The following signals are exchanged via the CAN-bus: From ECM to PSG Desired injection quantity Desired injection timing Engine speed From PSG to ECM Fuel temperature Pump speed Cylinder identifier Control pulse (actual injection quantity + actual injection timing) PSG status
Resistance (ohm) (Solid Line) 100000 Characteristic of IAT Sensor -Reference-
6E65
10000
1000
100
10 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
Intake Air Temp. (deg. C) (Tech2 Reading)
Mass Air Flow (MAF) Sensor & Intake Air Temperature (IAT) Sensor
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. The ECM supplies 5 volts signal to the 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.
(1) Air Cleaner Case (2) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor The mass air flow (MAF) sensor is part of the intake air system. It is fitted between the air cleaner and turbocharger and measure the mass air flowing into the engine. The mass air flow (MAF) sensor uses a hot film element to determine the amount of air flowing into the engine. The mass air flow (MAF) sensor assembly consist of a mass air flow (MAF) sensor element and an intake air temperature sensor that are both exposed to the air flow to be measured. The mass air flow (MAF) sensor element measures the partial air mass through a measurement duct on the sensor housing. Using calibration, there is an extrapolation to the entire mass air flow to the engine.
6E66
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Crankshaft Position (CKP) Sensor
Throttle Position Sensor (TPS)
(1) Throttle Position Sensor (TPS) (2) Idle Switch
(1) Crankshaft Position (CKP) Sensor (2) Fly wheel with sensor slot 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).
4.5 4 3.5 3 2.5 2 1.5 1 0.5 0
Characteristic of TPS -Reference-
Output Voltage (V)
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Pedal Position (%) (Tech2 Reading
The TPS is a potentiometer connected to throttle shaft on the throttle body. It is installed to the main TPS and idle switch. The engine control module (ECM) monitors the voltage on the signal line and calculates throttle position. As the 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 delivery based on throttle valve angle.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Engine Coolant Temperature (ECT) Sensor Vehicle Speed Sensor (VSS)
6E67
(1) Engine Coolant Temperature (ECT) Sensor (2) Thermo Unit for Water Temperature Gauge
M/T & A/T 4WD
Characteristic of ECT Sensor -Reference100000
10000 Resistance (ohm) (Solid Line)
1000
100
10 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Engine Coolant Temp (deg. C) (Tech2 Reading)
A/T 2WD The ECT sensor is a thermistor. A temperature changes the resistance value. And it changes voltage. In other 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 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 pulse signal. The 12 volts operating supply from the meter fuse. The engine control module (ECM) calculates the vehicle speed by VSS. The 2WD model fitted with automatic transmission, vehicle speed sensor signal is transmitted to from the TCM to the ECM via vehicle speed meter.
6E68
GENERAL DESCRIPTION FOR EGR (EXHAUST GAS RE-CIRCULATION)
(1) EGR Valve (2) EGR Cooler (Euro 3) / EGR Pipe (Except Euro 3) (3) Intercooler (4) Intake Manifold (5) Exhaust Manifold (6) Waste Gate (7) Fresh Air (8) Exhaust Gas (9) Turbocharger
(1) (2) (3) (4) (5) (6)
To EGR Valve From Vacuum Pump EGR EVRV EGR Cooler Thermo Valve EGR Valve
The 4JA1-TC & 4JH1-TC engine with Euro 3 regulation is equipped with the EGR cooler. The EGR cooler reduces the temperature of the air being drawn into the engine and the combustion temperature. This results in reducing nitrogen oxide (Nox) emissions. The 4JH1-TC engine except Euro 3 regulation, it does not have EGR cooler. It has steel EGR pipe instead of the cooler. The amount of EGR is controlled by EVRV (electrical vacuum regulating valve) via the engine control module (ECM) command signal depends on the following inputs. Engine speed Injection quantity Mass air flow Intake air temperature Coolant temperature Barometric pressure
6E69
7.1ms
0.7ms Off duty 10% =EGR Pulse Ratio 10%
Time
7.1ms
6.4ms Off duty 90% =EGR Pulse Ratio 90%
Time
The EVRV is shaped to control vacuum applied to the diaphragm chamber of the EGR valve based on duty signal sent from the ECM. The duty ratio is the time that the EVRV is opened to one cooperate EVRV operating cycle. A duty ratio change of 90% to 10 % is EGR amount control.
6E70
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Cross-section View
GENERAL DESCRIPTION FOR INJECTION PUMP Outline
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Drive Shaft Feed Pump Pump Camshaft Speed Sensor Pump Control Unit (PSG) Distributor Head Constant Pressure Valve (CPV) Holder High Pressure Solenoid Valve Constant Pressure Valve (CPV) Timing Control Valve (TCV) Timer Radial Plunger High Pressure Pump
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Drive Shaft Feed Pump Pump Camshaft Speed Sensor Pump Control Unit (PSG) Distributor Head Constant Pressure Valve (CPV) Holder High Pressure Solenoid Valve Constant Pressure Valve (CPV) Timing Control Valve (TCV) Timer Radial Plunger High Pressure Pump
Instead of the previous face cam type, the radial plunger distributor type injection pump utilizes a cam ring to enable fuel injection at high-pressures, marking it suitable for small, high-speed direct injection diesel engines. This pump was developed to provide the most suitable fuel injection quantity and injection timing to satisfy the demand for engine reliability, driveability, low smoke, low noise, high output and clear exhaust emissions.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Low Pressure Fuel Circuit
6E71
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Rotor Shaft Radial Plunger High Pressure Passage Low Pressure Inlet Distributor Slit Valve Needle Barrel Annular Passage Fuel Return High Pressure Solenoid Valve High Pressure Outlet Diaphram Chamber Accumulator Diaphram
(1) (2) (3) (4) (5)
Fuel Suction Regulating Valve Overflow Valve Feed Pump To Fuel Tank
The low pressure fuel circuit must supply sufficient fuel to the high pressure fuel circuit. The main components are the feed pump, the regulating valve and the overflow valve.
6E72
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Pump Camshaft Speed Sensor
High Pressure Fuel Circuit
(1) (2) (3) (4) (5)
Pump Control Unit (PSG) Distributor Head High Pressure Solenoid Valve Constant Pressure Valve (CPV) Radial Plunger High Pressure Pump
(1) (2) (3) (4) (5)
Pump Camshaft Speed Sensor Sensor Wheel Pump Camshaft Speed Sensor Retaining Ring Flexible Connector Harness Drive Shaft
In addition high pressure generating device, the high pressure circuit also consists of fuel piping, and devices to set the beginning of injection and fuel injection 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)
When the drive shaft rotates, the pump camshaft speed sensor receives signal form the sensor wheel, and an electric pulse is sent through the flexible connecting harness to the pump control unit (PSG). From these signals the pump control unit (PSG) can determine the average pump speed and the momentary pump speed. The pump camshaft speed sensor is mounted to the cam ring. Thus, the relationship between the cam ring and the pump camshaft speed sensor signal is constant.

The pump camshaft speed sensor signal is utilized for the following purposes. To determine the momentary angular position of the cam ring. To calculate the actual speed of the fuel injection pump. To determine the actual timing plunger position.
6E73
High Pressure Solenoid Valve
Sensor Wheel
Pump Camshaft Speed Sensor
Pump Control Unit (PSG)
-Cam Ring Angle -Pump Speed -Timer Position
(1) (2) (3) (4) The pump camshaft sensor signal has a tooth gap, and the crankshaft position (CKP) sensor on the flywheel housing is used as a reference signal of engine top dead center (TDC) for the start timing of fuel delivery or injection which is to be set.
Valve Needle Magnet Anchor Coil High Pressure Passage
Fuel injection quantity control is performed from the beginning of pressure delivery at the beginning of cam lift until the high pressure solenoid valve opens at the end of pressure delivery. This interval is called the pressure delivery interval. Accordingly, the interval that the high pressure solenoid valve is closed determines the fuel injection quantity (high pressure fuel supply ends when the high pressure solenoid valve opens).
6E74
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Timing Control Valve (TCV)
When current from the pump control unit (PSG) flows to the high pressure solenoid valve coil, the magnet anchor (a movable iron core) pushes the valve needle, toward the valve seat. When the valve seat is completely closed by the valve needle, the way, of the fuel in the high pressure passage to the low pressure circuit is closed. The pressure of the fuel in the high pressure passage is rapidly increased by radial plunger lift, and the high pressure fuel is delivered through the constant pressure valve (CPV) to the nozzle holder assembly and is injected into the engine cylinder.
(1) Valve Needle (2) Coil When the fuel injection quantity demanded by the engine is reached, the current to the coil is cut and the valve needle re-opens the valve seat. As a result of this, a path is opened for the fuel in the high pressure passage to the low pressure circuit and the pressure decreases. With a decrease in injection pressure the nozzle closes and injection ends.
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Cam Ring Servo Valve Timer Piston Outlet Feed Pump Inlet Fuel Suction Ball Pin Annular Chamber Hydraulic Stopper Return Passage Timing Control Valve (TCV)
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.
6E75
Engine Load Engine Control Engine Speed Module (ECM) Engine Coolant Temperature Pump Control Unit (PSG) Timing Control Valve (TCV)
Pump Camshaft Speed Sensor
(1) (2) (3) (4) (5)
Coil From Annular Chamber To Feed Pump Orifice Valve Needle
When control current flows to the timing control valve (TCV) coil, the valve needle opens and the fuel annular chamber flows through the orifice to the feed pump inlet. Consequently, the pressure of the annular chamber decreases and the hydraulic stopper is moved to the retard side. The timing control valve (TCV) acts as a variable throttle, using the rapid opening and closing (cycling) of the valve needle in the timing control valve (TCV). At normal operation, the TCV controls the pressure acting on the annular chamber so that the hydraulic stopper cam move to any position, from the retard position to the advance position. At this time, the duty ratio is set by the pump control unit (PSG). Duty ratio is the ratio of the time that the timing control valve (TCV) is opened to one complete timing control valve (TCV) operating cycle. A duty ratio change of 100% to 0% is an advance in injection timing. (The VP44 displays an ON duty ratio.)
The engine control module (ECM) contains characteristic maps of the start of injection, corresponding to engine operating conditions (engine load, engine speed and engine coolant temperature). The pump control unit (PSG) is constantly comparing the set start of injection timing and the actual start of injection timing. If there is a difference, the timing control valve (TCV) is controlled by the duty ratio. (The actual start of injection timing is determined from the pump camshaft speed sensor.)
6E76
ISUZU Strategy Based Diagnostics Overview

As a retail service technician, you are part of the ISUZU service team. The team goal is FIX IT RIGHT THE FIRST TIME for the satisfaction of every customer. You are a very important member of the team as you diagnose and repair customer vehicles. You have maximum efficiency in diagnosis when you have an effective, organized plan for your work. Strategy Based Diagnostics (refer to Figure 1) provides you with guidance as you create and follow a plan of action for each specific diagnostic situation.
STRATEGY BASED DIAGNOSTICS CHART
6E77
Diagnostic Thought Process

As you follow a diagnostic plan, every box on the Strategy Based Diagnostics chart requires you to use the diagnostic thought process. This method of thinking optimizes your diagnosis in the following ways: Improves your understanding and definition of the customer complaint Saves time by avoiding testing and/or replacing good parts Allows you to look at the problem from different perspectives Guides you to determine what level of understanding about system operation is needed: Owners manual level Service manual level In-depth (engineering) level Owners manual level Service manual level In-depth (engineering) level
Circuit testing tools Vehicle road tests Complaint check sheet Contact with the customer
2. Perform Preliminary Checks

NOTE: An estimated 10 percent of successful vehicle repairs are diagnosed with this step!
What you should do

You perform preliminary checks for several reasons: To detect if the cause of the complaint is VISUALLY OBVIOUS To identify parts of the system that work correctly To accumulate enough data to correctly and accurately search for a ISUZU Service Bulletin on ISUZU Web site. The initial checks may vary depending on the complexity of the system and may include the following actions: Operate the suspect system Make a visual inspection of harness routing and accessible/visible power and ground circuits Check for blown fuses Make a visual inspection for separated connectors Make a visual inspection of connectors (includes checking terminals for damage and tightness) Check for any DTCs stored by the on-board computers Sense unusual movements noises, smells, vibrations or
1. Verify the Complaint

What you should do
To verify the customer complaint, you need to know the correct (normal) operating behavior of the system and verify that the customer complaint is a valid failure of the system. The following information will help you verify the complaint: WHAT the vehicle model/options are WHAT aftermarket and dealer-installed accessories exist WHAT related system(s) operate properly WHEN the problem occurs WHERE the problem occurs HOW the problem occurs HOW LONG the condition has existed (and if the system ever worked correctly) HOW OFTEN the problem occurs Whether the severity of the problem has increased, decreased or stayed the same
Investigate the vehicle service history (call other dealerships, if appropriate)
What resources you should use

Whenever appropriate, you should use the following resources for assistance in performing preliminary checks: Tech II or other technical equipment for viewing DTCs Service manual information: Component locations Harness routing Wiring schematics Procedures for viewing DTCs Dealership service history file Vehicle road test Identical vehicle or system for comparison

Whenever possible, you should use the following resources to assist you in verifying the complaint: Service manual Theory or Circuit Description sections Service manual System Performance Check Owner manual operational description Technician experience Identical vehicle for comparison
6E78
3. Check Bulletins and Troubleshooting Hints

NOTE: As estimated 30 percent of successful vehicle repairs are diagnosed with this step!
to the customer complaint.

Whenever appropriate, you should use the following resources to perform service manual diagnostic procedures: Service manual Technical equipment (for analyzing diagnostic data) Digital multimeter and circuit testing tools Essential and special tools
What you should do

You should have enough information gained from preliminary checks to accurately search for a bulletin and other related service information. Some service manual sections provide troubleshooting hints that match symptoms with specific complaints.
5c. Technician Self Diagnoses

You should use the following resources for assistance in checking for bulletins and troubleshooting hints: Printed bulletins Access ISUZU Bulletin Web site. Videotapes Service manual When there is no DTC stored and no matching symptom for the condition identified in the service manual, you must begin with a thorough understanding of how the system(s) operates. Efficient use of the service manual combined with you experience and a good process of elimination will result in accurate diagnosis of the condition.
What you should do
4. Perform Service Manual Diagnostic Checks

What you should do
The System Checks in most service manual sections and in most cells of section 8A (electrical) provide you with: A systematic approach to narrowing down the possible causes of a system fault Direction to specific diagnostic procedures in the service manual Assistance to identify what systems work correctly
Step 1: Identify and understand the suspect circuit(s) Having completed steps 1 through 4 of the Strategy Based Diagnostics chart, you should have enough information to identify the system(s) or sub-system(s) involved. Using the service manual, you should determine and investigate the following circuit characteristics: Electrical: How is the circuit powered (power distribution charts and/or fuse block details)? How is the circuit grounded (ground distribution charts)? How is the circuit controlled or sensed (theory of operation): If it is a switched circuit, is it normally open or normally closed? Is the power switched or is the ground switched? Is it a variable resistance circuit (ECT sensor or TP sensor, for example)? Is it a signal generating device (MAF sensor of VSS, for example)? Does it rely on some mechanical/vacuum device to operate? Physical: Where are the circuit components (component locators and wire harness routing diagrams): Are there areas where wires could be chafed or pinched (brackets or frames)? Are there areas temperatures? subjected to extreme

Whenever possible, you should use the following resources to perform service manual checks: Service manual Technical equipment (for viewing DTCs analyzing data) Digital multimeter and circuit testing tools Other tools as needed and
5a and 5b. Perform Service Manual Diagnostic Procedures

NOTE: An estimated 40 percent of successful vehicle repairs are diagnosed with these steps!
What you should do

When directed by service manual diagnostic checks, you must then carefully and accurately perform the steps of diagnostic procedures to locate the fault related

Are there areas subjected to vibration or movement (engine, transmission or suspension)? Are there areas exposed to moisture, road salt or other corrosives (battery acid, oil or other fluids)? Are there common mounting areas with other systems/components? Have previous repairs been performed to wiring, connectors, components or mounting areas (causing pinched wires between panels and drivetrain or suspension components without causing and immediate problem)? Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.) Step 2: Isolate the problem At this point, you should have a good idea of what could cause the present condition, as well as could not cause the condition. Actions to take include the following: Divide (and separate, where possible) the system or circuit into smaller sections Confine the problem to a smaller area of the vehicle (start with main harness connections while removing panels and trim as necessary in order to eliminate large vehicle sections from further investigation) For two or more circuits that do not share a common power or ground, concentrate on areas where harnesses are routed together or connectors are shared (refer to the following hints) Hints Though the symptoms may vary, basic electrical failures are generally caused by: Loose connections: Open/high resistance connectors or grounds in terminals, splices, at the component
6E79
If a number of components do no operate, begin tests at the area of commonality (such as power sources, ground circuits, switches or major connectors)

Whenever appropriate, you should use the following resources to assist in the diagnostic process: Service manual Technical equipment (for data analysis) Experience Technical Assistance Circuit testing tools
5d. Intermittent Diagnosis

By definition, an intermittent problem is one that does not occur continuously and will occur when certain conditions are met. All these conditions, however, may not be obvious or currently known. Generally, intermittents are caused by: Faulty electrical connections and wiring Malfunctioning components (such as sticking relays, solenoids, etc.) EMI/RFI (Electromagnetic/radio frequency interference) Aftermarket equipment Intermittent diagnosis requires careful analysis of suspected systems to help prevent replacing good parts. This may involve using creativity and ingenuity to interpret customer complaints and simulating all external and internal system conditions to duplicate the problem.
What you should do

Step 1: Acquire information A thorough and comprehensive customer check sheet is critical to intermittent problem diagnosis. You should require this, since it will dictate the diagnostic starting point. The vehicle service history file is another source for accumulating information about the complaint. Step 2: Analyze the intermittent problem
Incorrect connector/harness routing (usually in new vehicles or after a repair has been made): Open/high resistance in connectors of grounds Corrosion and wire damage: Open/high resistance connectors of grounds Component failure: Opens/short and high resistance modules, switches or loads in relays, in terminals, splices,
terminals,
splices,
Aftermarket equipment affecting normal operation of other systems You may isolate circuits by: Unplugging connectors or removing a fuse to separate one part of the circuit from another part Operating shared circuits and eliminating those that function normally from the suspect circuit If only one component fails to operate, begin testing
Analyze the customer check sheet and service history file to determine conditions relevant to the suspect system(s). Using service manual information, you must identify, trace and locate all electrical circuits related to the malfunctioning system(s). If there is more than one system failure, you should identify, trace and locate areas of commonality shared by the suspect circuits.
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For parts and sensors, apply slight vibration to the part with a light tap of the finger while monitoring the system for a malfunction. 2. Heat This method is important when the complaint suggests that the problem occurs in a heated environment. Apply moderate heat to the component with a hair drier or similar tool while monitoring the system for a malfunction. CAUTION: Care must be take to avoid overheating the component. 3. Water and Moisture This method may be used when the complaint suggests that the malfunction occurs on a rainy day or under conditions of high humidity. In this case, apply water in a light spray on the vehicle to duplicate the problem. CAUTION: Care must be take to avoid directly exposing electrical connections to water. 4. Electrical loads This method involves turning systems ON (such as the blower, lights or rear window defogger) to create a load on the vehicle electrical system at the same time you are monitoring the suspect circuit/component.
Step 3: Simulate the symptom and isolate the problem Simulate the symptom and isolate the system by reproducing all possible conditions suggested in Step 1 while monitoring suspected circuits/components/ systems to isolate the problem symptom. Begin with the most logical circuit/component. Isolate the circuit by dividing the suspect system into simpler circuits. Next, confine the problem into a smaller area of the system. Begin at the most logical point (or point of easiest access) and thoroughly check the isolated circuit for the fault, using basic circuit tests. Hints You can isolate a circuit by: Unplugging connectors or removing a fuse to separate one part of the circuit from another If only component fails to operate, begin testing the component If a number of components do not operate, begin test at areas of commonality (such as power sources, ground circuits, switches, main connectors or major components) Substitute a known good part from the parts department or the vehicle system Try the suspect part in a known good vehicle See Symptom Simulation Tests on the next page for problem simulation procedures. Refer to service manual sections 6E and 8A for information about intermittent diagnosis. Follow procedures for basic circuit testing in service manual section 8A.
5e. Vehicle Operates as Designed

This condition refers to instances where a system operating as designed is perceived to be unsatisfactory or undesirable. In general, this is due to: A lack of understanding by the customer A conflict between customer expectations and vehicle design intent A system performance that is unacceptable to the customer

Whenever appropriate, you should use the following resources to assist in the diagnostic process: Service manual Bulletins Digital multimeter (with a MIN/MAX feature) Tech II and Tech II upload function Circuit testing tools (including harnesses and jumper wires) connector kits/
What you should do

You can verify that a system is operating as designed by: Reviewing checks service manual functional/diagnostic
Experience Intermittent problem solving simulation methods Customer complaint check sheet
Symptom Simulation Tests

1. Vibration This method is useful when the customer complaint analysis indicates that the problem occurs when the vehicle/system undergoes some form of vibration. For connectors and wire harness, slightly shake vertically and horizontally. Inspect the connector joint and body for damage. Also, tapping lightly along a suspected circuit may be helpful.
Examining bulletins and other service information for supplementary information Compare system operation to an identical vehicle If the condition is due to a customer misunderstanding or a conflict between customer expectation and system operation, you should explain the system operation to the customer. If the complaint is due to a case of unsatisfactory system performance, you should contact Technical Assistance for the latest information.

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
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6. Re-examine the complaint

When you do not successfully find/isolate the problem after executing a diagnostic path, you should reexamine 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 resources to facilitate the diagnostic process: Service manual Accumulated information form a previous diagnostic path Service information and publications ISUZU field support
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.

Whenever possible, you should use the following resources to facilitate the repair process: Electrical repair procedures Service manual information and publications
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GENERAL SERVICE INFORMATION

Serviceability Issues
Non-OEM Parts All of the OBD diagnostics have been calibrated to run with OEM parts. Accordingly, if commercially sold sensor or switch is installed, it makes a wrong diagnosis and turns on the check engine lamp. Aftermarket electronics, such as cellular phones, stereos, and anti-theft devices, may radiate EMI into the control system if they are improperly installed. This may cause a false sensor reading and turn on the check engine lamp. Poor Vehicle Maintenance The sensitivity of OBD diagnostics will cause the check engine lamp to turn on if the vehicle is not maintained properly. Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD. Poor vehicle maintenance can not be classified as a non-vehicle fault, but with the sensitivity of OBD diagnostics, vehicle maintenance schedules must be more closely followed. Related System Faults Many of the OBD system diagnostics will not run if the ECM detects a fault on a related system or component.
ON-BOARD DIAGNOSTIC (OBD)

On-Board Diagnostic (Self Diagnosis System) Tests
A diagnostic test is a series of steps, the result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data: The diagnostic test has been completed since the last ignition cycle. The diagnostic test has passed during the current ignition cycle. The fault identified by the diagnostic test is not currently active. When a diagnostic test reports a fail result, the diagnostic executive records the following data: The diagnostic test has been completed since the last ignition cycle. The fault identified by the diagnostic test is currently active. The fault has been active during this ignition cycle. The operating conditions at the time of the failure.
The Diagnostic Executive

The Diagnostic Executive is a unique segment of software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The main responsibilities of the Diagnostic Executive are listed as follows: Commanding the check engine lamp on and off DTC logging and clearing Current status information on each diagnostic Diagnostic Information The diagnostic charts and functional checks are designed to locate a faulty circuit or component through a process of logical decisions. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are not multiple faults present. There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code is set and the check engine lamp is illuminated. Check Engine Lamp 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
Visual/Physical Engine Compartment Inspection

Perform a careful visual and physical engine compartment inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual/physical inspection: Inspect all vacuum hoses for punches, cuts, disconnects, and correct routing. Inspect hoses that are difficult to see behind other components. Inspect all wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, contact with sharp edges or contact with hot exhaust manifolds or pipes.
Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in an incorrect diagnosis or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.

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 suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first. Data Link Connector (DLC) The provision for communication with the contorl module is the Data Link Connector (DLC). It is located behind the lower front instrument panel. The DLC is used to connect to a Tech2. Some common uses of the Tech2 are listed below: Identifying stored Diagnostic Trouble Codes (DTCs). Clearing DTCs. Reading serial data.
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Reading Flash Diagnostic Trouble Codes

The provision for communicating with the Engine Control Module (ECM) is the Data Link Connector (DLC). The DLC is located in the front console box. It is used in the assembly plant to receive information in checking that the engine is operating properly before it leaves the plant. The diagnostic trouble code(s) (DTCs) stored in the ECMs memory can be read either through a hand-held diagnostic scanner plugged into the DLC or by counting the number of flashes of the check engine lamp when the diagnostic test terminal of the DLC is grounded. The DLC terminal 6 (diagnostic request) is pulled Low (grounded) by jumping to DLC terminal 4 or 5, which is a ground wire. This will signal the ECM that you want to flash DTC(s), if any are present. Once terminals 4 or 5 and 6 have been connected, the ignition switch must be moved to the ON position, with the engine not running. The check engine lamp will indicate a DTC three times if a DTC is present. If more than one DTC has been stored in the ECMs 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

Verification of vehicle repair will be more comprehensive for vehicles with OBD system diagnostic. Following a repair, the technician should perform the following 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.
History DTC
History DTC can be candeled after 40 cycle driving with no defect. Or history code can be deleted by Tech 2 Clear DTCs function.
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4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS DIAGNOSIS WITH Tech 2

If no codes are set: Refer to F1: Data Display and identify the electrical faults that are not indicated by trouble code. 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. 7. Check trouble codes again using the Tech 2. Tech 2 CONNECTION
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Connect the SAE 16/19 adapter (3) to the DLC cable (4). Connect the DLC cable (4) to the Tech 2 (5). Connect the SAE 16/19 adapter (3) to the data link connector of the vehicle.
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).
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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.

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

Vehicle Identification (3) 2003 (2) 2002 (1) 2001 (Y) 2000 (X) 1999 (W) 1998
Select F0: Powertrain.

Vehicle Identification 4JH1-TC Bosch 4JA1-TC Bosch 4JH1-T Denso 3.5L V6 6VE1 Hitachi AW30-40LE A/T JR405E
Select (3) 2003or later.
Select 4JA1-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 F0: Read DTC Infor As Stored By ECU F1: Clear DTC Information F1: Data Display F2: Snapshot F3: Miscellaneous Test F0: Lamps F0: Glow Time Telltale Test F1: Relays F0: Glow Time Relay Test F2: Solenoids F0: EGR Solenoid Test F3: Engine Speed (RPM) Control F4: Programming 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. Symptom Code:
Read DTC Infor As Stored By ECU P0100 Present (7) Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
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F1: Data Display The purpose of the Data Display mode is to continuously monitor data parameters. The current actual values of all important sensors and signals in the system are display through F1 mode. See the Typical Scan Data section. F2: Snapshot Snapshot allows you to focus on making the condition occur, rather than trying to view all of the data in anticipation of the fault. The snapshot will collect parameter information around a trigger point that you select. F3: Miscellaneous Test: The purpose of Miscellaneous Test mode is to check for correct operation of electronic system actuators. F4: Programming (Factory Use Only) The purpose of Programming is to program VIN in the ECM and lock the programmed data.
DTC No.
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.
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4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JA1-TC ENGINE Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were noted, and you have determined that the On-Board Diagnostic are functioning properly. Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing. Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately 80 deg. C)
Tech 2 Parameter 1 2 3 4 Engine Speed Vehicle Speed Pump Speed Accelerator Position Sensor Signal Idle Switch
Units rpm km/h / MPH rpm %
Idle 730 0 345 - 385 0
1500rpm 1475 1525 0 725 - 775 4-6
2000rpm 1975 2025 0 975 - 1025 6-8
Description The engine speed is measured by ECM from the CKP sensor. This displays vehicle speed. The vehicle speed is measured by ECM from the vehicle speed sensor. This displays injection pump speed. The injection speed is measured by ECM from the pump cam sensor. Throttle position operating angle is measured by the ECM from throttle position output voltage. This should display 0% at idle and 99 - 100% at full throttle. This displays operating status of the idle switch. This should display "Active" until the accelerator position nearly 4 - 5%. This displays calculated intake air volume for one cylinder stroke. The mass air flow is measured by ECM from the MAF sensor output voltage. This displays desired intake air volume for one cylinder stroke. The desired mass air flow is calculated by ECM depending on engine condition. The barometric pressure is measured by ECM from the sensor in the ECM. This data is changing by altitude. This displays desired value from the ECM. The ECM compensates for fuel rate to basic rate. This displays calculated actual fuel quantity from the PSG. The PSG receives desired injection quantity from the ECM. And, it compensates actual injection depending on timer position to determine duration of the high pressure solenoid valve operation. This displays desired injection timing from the ECM. The ECM compensates for fuel injection timing by throttle position and various sensor signal. This displays calculated actual injection timing based on CKP signal and pump cam signal. The PSG controls TCV duty ratio to meet desired injection timing from the ECM. The ECT is measured by ECM from ECT sensor output voltage. This data is changing by coolant temperature. When the engine is normally warm upped, this data displays approximately 80 deg. C. The FT is measured by PSG from FT sensor. This data is changing by fuel temperature. The IAT is measured by ECM from IAT sensor output voltage. This data is changing by intake air temperature. 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. This displays operating status of the brake switch. This should display "Active" when the brake pedal is stepped on.
Active/ Inactive 0V Flow mg/strk
Active
Active
Inactive 0V
Mass Sensor Desired Flow
Air
380 - 420
360 - 400
380 - 420
Mass
Air
mg/strk
350
350
350 - 370
8 9 10
Barometric Pressure Desired Quantity Injection
hpa mg/stk mg/stk
Depends on altitude 8 - 10 8 - 10
Depends on altitude 6 - 10 5 - 10
Depends on altitude 7 - 10 5-9
Injection Quantity
11
Desired Fuel Injection Start Actual Injection Start
deg. CA
2-4
2- 5
3-5
12
deg. CA
2-4
2-5
3-5
13
Coolant Temperature
deg. C / deg. F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg. F Air deg. C / deg. F On12V/ Off0V Active/ Inactive
Depends on fuel temp. Depends on ambient temp. On 12V
15
Intake Temperature Ignition Status
16
17
Brake Switch 1
Inactive
Inactive
Inactive

Tech 2 Parameter 18 Brake Switch 2 Units Active/ Inactive Active/ Inactive On/Off Active 12V/ Inactive 0V Active 0V/ Inactive 12V V Active/ Inactive Active 0V/ Inactive12V On/Off Idle Inactive 1500rpm Inactive 2000rpm Inactive Description
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This displays operating status of the brake switch. This should display "Active" when the brake pedal is stepped on. This displays operating status of the clutch switch. This should display "Active" when the clutch pedal is stepped on. This displays operating status of the neutral switch. This should display "On" when the gear position is neutral. This displays the air conditioner request signal. This should display "Active 12V" when the air conditioner switch is switched on. This displays the diagnostic request signal. This should display "Inactive 12V" when the Tech 2 is connected. This displays the system voltage measured by the ECM at ignition feed. This displays operating status for the ECM main relay. This should display "Active" when the key switch is turned on and while engine is running. This displays operating status for the glow relay. This should display "Inactive 12V" when the engine is warm upped. This displays operating status for the Check Engine Lamp. This should display "On" when the Check Engine Lamp is turned on. This displays operating status for the glow indicator lamp. This should display "On" when the glow lamp is turned on. The desired engine idle speed that the ECM commanding. The ECM compensates for various engine loads based on engine coolant temperature. This displays operating status of the A/C compressor. This should display "Active 0V" when the compressor relay is operated. This should display "Inactive" when the immobilizer is correctly operated. This should display "Not Received" when the immobilizer is not activated. This should display "Yes" when the immobilizer is correctly programmed. This displays the duty signal from the ECM to control the EGR flow amount.
19
Clutch Switch
Inactive
Inactive
Inactive
20 21
Neutral Switch A/C Switch Information
On Inactive 0V
On Inactive 0V
On Inactive 0V
22 23 24
Diagnostic Request System Voltage Main Relay
Inactive 12V 10 - 14 Active
25
Glow Time Relay
Inactive 12V Off
Inactive 12V Off
Inactive 12V Off
26
Check Engine Light
27 28
Glow Time Telltale Desired Engine Idle Speed A/C Request
On/Off rpm
Off 730
Off 730
Off 730
29
Active 0V/ Inactive 12V Active/ Inactive Received/ Not Received Yes/ No %
Inactive 12V Inactive Not Received Yes 70
30 31
Immobilizer Immobilizer Signal
32 33
Immobilizer Function Programmed EGR Pulse (Exhaust Recirculation) Ratio Gas
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4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JH1-TC ENGINE Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were noted, and you have determined that the On-Board Diagnostic are functioning properly. Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing. Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately 80 deg. C)
Tech 2 Parameter 1 2 3 4 Engine Speed Vehicle Speed Pump Speed Accelerator Position Sensor Signal Idle Switch Units rpm km/h / MPH rpm % Idle 675 - 725 0 335 - 375 0 1500rpm 1475 1525 0 725 - 775 3-5 2000rpm 1975 2025 0 975 - 1025 5-7 Definition The engine speed is measured by ECM from the CKP sensor. This displays vehicle speed. The vehicle speed is measured by ECM from the vehicle speed sensor. This displays injection pump speed. The injection speed is measured by ECM from the pump cam sensor. Throttle position operating angle is measured by the ECM from throttle position output voltage. This should display 0% at idle and 99 - 100% at full throttle. This displays operating status of the idle switch. This should display "Active" until the accelerator position nearly 4 - 5%. This displays calculated intake air volume for one cylinder stroke. The mass air flow is measured by ECM from the MAF sensor output voltage. This displays desired intake air volume for one cylinder stroke. The desired mass air flow is calculated by ECM depending on engine condition. The barometric pressure is measured by ECM from the sensor in the ECM. This data is changing by altitude. This displays desired value from the ECM. The ECM compensates for fuel rate by throttle position and various sensor signals. This displays calculated actual fuel quantity from the PSG. The PSG receives desired injection quantity from the ECM. And, it compensates actual injection depending on timer position to determine duration of the high pressure solenoid valve operation. This displays desired injection timing from the ECM. The ECM compensates for fuel injection timing by throttle position and various sensor signal. This displays calculated actual injection timing based on CKP signal and pump cam signal. The PSG controls TCV duty ratio to meet desired injection timing from the ECM. The ECT is measured by ECM from ECT sensor output voltage. This data is changing by coolant temperature. When the engine is normally warm upped, this data displays approximately 80 deg. C. The FT is measured by PSG from FT sensor. This data is changing by fuel temperature. The IAT is measured by ECM from IAT sensor output voltage. This data is changing by intake air temperature. 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. This displays operating status of the brake switch. This should display "Active" when the brake pedal is stepped on.
Active/ Inactive 0V Flow mg/strk
Active
Active/ Inactive 0V 380 - 460
Inactive 0V
Mass Sensor Desired Flow
Air
420 - 490
410 - 480
Mass
Air
mg/strk
430 - 470
380 - 420
410 - 470
8 9
Barometric Pressure Desired Quantity Injection
hpa mg/stk
Depends on altitude 6 - 10
10
Injection Quantity
mg/stk
6 - 10
6 - 10
7 - 11
11
Desired Fuel Injection Start Actual Injection Start
deg. CA
1-3
2-4
3-5
12
deg. CA
1-3
2-4
3-5
13
Coolant Temperature
deg. C / deg. F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg. F Air deg. C / deg. F On12V/ Off0V Active/ Inactive
15
Intake Temperature Ignition Status
16
17
Brake Switch 1
Inactive
Inactive
Inactive

Tech 2 Parameter 18 Brake Switch 2 Units Active/ Inactive Active/ Inactive On/Off Idle Inactive 1500rpm Inactive 2000rpm Inactive Definition
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This displays operating status of the brake switch. This should display "Active" when the brake pedal is stepped on. This displays operating status of the clutch switch. This should display "Active" when the clutch pedal is stepped on. This displays operating status of the neutral switch. This should display "On" when the gear position is neutral (M/T) or P, N position (A/T). This displays the air conditioner request signal. This should display "Active 12V" when the air conditioner switch is switched on. This displays the diagnostic request signal. This should display "Inactive 12V" when the Tech 2 is connected. This displays the system voltage measured by the ECM at ignition feed. This displays operating status for the ECM main relay. This should display "Active" when the key switch is turned on and while engine is running. This displays operating status for the glow relay. This should display "Inactive 12V" when the engine is warm upped. This displays operating status for the Check Engine Lamp. This should display "On" when the Check Engine Lamp is turned on. This displays operating status for the glow indicator lamp. This should display "On" when the glow lamp is turned on. The desired engine idle speed that the ECM commanding. The ECM compensates for various engine loads based on engine coolant temperature. This displays operating status of the A/C compressor. This should display "Active 0V" when the compressor relay is operated. This should display "Inactive" when the immobilizer is correctly operated. This should display "Not Received" when the immobilizer is not activated. This should display "Yes" when the immobilizer is correctly programmed. This displays the duty signal from the ECM to control the EGR flow amount.
19
Clutch Switch (M/T Only) Neutral Switch
Inactive
Inactive
Inactive
20
On
On
On
21
A/C Switch
Information
Active 12V/ Inactive 0V Active 0V/ Inactive 12V V Active/ Inactive Active 0V/ Inactive12V On/Off
Inactive 0V
Inactive 0V
Inactive 0V
22 23 24
Diagnostic Request System Voltage Main Relay
25
Glow Time Relay
Inactive 12V Off
Inactive 12V Off
Inactive 12V Off
26
Check Engine Light
27 28
Glow Time Telltale Desired Engine Idle Speed A/C Request
On/Off rpm
Off 700
Off 700
Off 700
29
Active 0V/ Inactive 12V Active/ Inactive Received/ Not Received Yes/ No %
Inactive 12V Inactive Not Received Yes 85 - 90
30 31
Immobilizer Immobilizer Signal
32 33
Immobilizer Function Programmed EGR Pulse (Exhaust Recirculation) Ratio Gas
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F3: Engine Speed (RPM) Control When the Tech 2 is operated, "Desired Idle Speed" increases 50rpm-by-50rpm up to 1200rpm. The circuit is correct if engine speed is changed in accordance with this operation. Engine Speed (RPM) Control Engine Speed Desired Idle Speed Injection Quantity 850 rpm 850 rpm 7.5 mg/ strk
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", "4JA1-TC Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test". F0: Lamps F0: Glow Time Telltale Test When the Tech 2 is operated, "Glow Time Indicator Lamp" is turned on or off. The circuit is correct if the "Glow Time 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 turns ON or OFF. The circuit is correct if glow relay is operated in accordance with this operation. F2: Solenoids F0: EGR Solenoid Test When the Tech 2 is operated, control duty ratio of EGR EVRV changes to 5% to 95%. The circuit is correct if glow relay is operated in accordance with this operation. EGR Solenoid Test Desired Mass Air Flow Mass Air Flow Engine Speed Exhaust Gas Recirculation 470 mg/strk 450 mg/strk 700 rpm 95%
Press "Increase" key. Then, Desired Idle speed is increases 50rpm-by-50rpm up to 1200rpm. Engine speed is also
Press "Active" key. Then, EVRV duty ratio increases to 95% Press "Inactive key". EVRV duty ratio decreases to 5%
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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.
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Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Flow Chart for Snapshot Replay (Plotting Graph)
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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. 1. Record the snapshot data, in Tech2. 2. Transfer the snapshot data to PC.
By analyzing these data in various methods, trouble conditions can be checked. Snapshot data is displayed by executing the three steps below shown:

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, parameter list is displayed on the screen. data 3.
6E97
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. 2. Select [Snapshot Upload] on the TIS2000 start screen. 3. Select [Open the existing files] or click the corresponding icon of the tool bar. 4. Select the transferred snapshot. 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] window opens. 2. Click the first graph icon of the window upper part, and select one parameter from the list of the window lower part. Selected parameter is displayed nest to the graph icon. Graph division can be selected in the field on the parameter right side. 3. Repeat the same procedures with the 2nd and 3rd icons. 4. After selecting all parameters to be displayed (Max. 3 parameters), click [OK] button. 5. Parameter selected is displayed in graph form on the right of the data parameter on the screen. 6. Graph display can be moved with the navigation icon. 7. For displaying another parameter by graph, click the parameter of the list, drug the mouse to the display screen while pressing the mouse button and release the mouse button. New parameter is displayed at the position of the previous parameter. For displaying the graph display screen in full size, move the cursor upward on the screen. When the
cursor is changed to the magnifying glass form, click the screen. Graph screen is displayed on the whole screen.
6E98
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window opens. 2. Click the graph icon, select the parameter to be displayed from the list and change divisions according to necessity. 3. Repeat the same procedures with the graph icons, from the 2nd to 6th. 4. Click the [OK] button to display. 5. In this case, parameters are displayed only in graph form. All parameters are displayed in one graph. 6. The graph display screen can be moved with the navigation icon.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS SERVICE PROGRAMMING SYSTEM (SPS)

The procedure to program the control unit by using the Service Programming System (SPS) software contained in TIS2000 is explained below. NOTE: If the Engine Control Module (ECM) was programmed, the Immobilizer System must be linked to the ECM: Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Should Tech2 display "SPS Procedure was not successful", engine will not start, but no DTCs are present, low battery voltage or poor electrical connections should be the primary suspects. Perform the SPS procedure again after rectifying the fault/s.
6E99
IMPORTANT: Perform the following checks before attempting to program the control unit: The Tech2 PCMCIA card is programmed with The latest software release. The latest release of TIS2000 is loaded on the PC. The vehicle battery is fully charged. The control unit to be programmed is connected to the vehicle. 1. Preparations of TIS 2000 1. Connect Tech 2 to P/C. 2. Check to see if Hardware Key is plugged into Port. 3. Activate TIS 2000 by P/C. 4. On the activating screen of TIS2000, choose Service Programming System
5. On the screen of Diagnostic Tester and Processing Program Selection, choose the one that will comply with the following. Tech-2 in use New programming by the existing module or new programming by the replaced/new module. Fixing position of the control unit.
6. Upon completion of the selection, push the button of Next.
6E100

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
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.
6. If you select continue, you have to select Model Year, Vehicle Type. 7. After that. then push button and turn Ignition switch tuned on, off, on following Tech-2 display. Tech-2 will read information from controller after this procedure. 8. During obtaining information, Tech-2 is receiving information from the control unit ECM and TCM (A/T only) at the same time. With VIN not being programmed into the new control unit at the time of shipment, "obtaining information" is not complete (because the vehicle model, engine model and model year are specified from VIN). For the procedure get additional information on vehicles, instruction will be provided in dialog form, when TIS2000 is in operation. 9. Following instructions by Tech-2, push the Exit switch of Tech-2, turn off the ignition of the vehicle and turn off the power of Tech-2, thereby removing from the vehicle.
3. Data Exchange 1. Connect Tech-2 to P/C, turn on the power and click the Next button of P/C. 2. Check VIN of the vehicle and choose Next. 3. Select System Type for required control unit. Engine (Programming for ECM or PCM) Transmission (Programming for TCM) 4. When a lack of data is asked from among the following menu, enter accordingly. Select following Menu Model Year Model Engine type Transmission type Destination code (vehicles for general export)*1 Immobilizer Etc. * 1: How to read the destination code Destination code can be read from ID Plate affixed on vehicles, while on VIN plate the destination code is described at the right-hand edge of Body Type line. In the figure, the destination code can be read as "RR3" (Australia).
6E101
5. After choosing the data, click the Next button. 6. When all the necessary information is entered, the details of software within the database that match the entered data will appear for confirmation. Click the Program switch and then download the new software onto Tech-2. 7. Data Transfer comes on display. The progress of downloading will be displayed on the screen in the form of bar graph. 8. 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 F1: Service Programming System on the main screen and then choose Fl: Program ECU. 7. While data is being transferred, Programming in Progress will be displayed on the Tech-2 screen. 8. Upon finishing the data transfer, Tech-2 will display Reprogramming Was Successful. Push the Exit button to bring program to completion 9. Following Procedure 2: Demand of Data, try over again Information Obtaining and check to confirm if the data has been correctly re-loaded. 10. Upon finishing confirmation, turn off the ignition of the vehicle and then turn off the power of Tech-2, removing from the vehicle.
6E102
HOW TO USE BREAKER BOX
(1) Engine Control Module (ECM) (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.
(3) Breaker Box
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Breaker Box Connection Type A
6E103
(1) Engine Control Module (ECM) (2) Harness Adapter (3) Breaker Box Breaker box connection type A, check for open circuit and short to ground circuit.
(4) Digital Voltage Meter (5) ECM - Harness Adapter Disconnection
6E104
Breaker Box Connection Type B
(1) Engine Control Module (ECM) (2) Harness Adapter (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.
(4) Digital Voltage Meter (5) ECM - Harness Adapter Connection
6E105
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Circuit Description
The on-board diagnostic system check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical check of the ECM and engine grounds for cleanliness and tightness. The on-board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction.
connection, and damaged harness.
Test Description
Number(s) below refer the step number(s) on the Diagnostic Chart: 1. The Check Engine Lamp (MIL) should be ON steady with the ignition On, engine Off. If not, No Check Engine Lamp (MIL) chart should be used to isolate the malfunction. 2. Checks the Class 2 data circuit and ensures that the ECM is able to transmit serial data. 3. This test ensures that the ECM is capable of controlling the Check Engine Lamp (MIL) and the Check Engine Lamp (MIL) driver circuit is not shorted to ground circuit. 4. If the engine will not start, Engine Cranks But Will Not Run chart should be used to diagnose the fault.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the ECM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire
6E106

12. This vehicle is equipped with ECM which utilizes an electrically erasable programmable read only memory (EEPROM).
6. The Tech2 parameters which is not within the typical range may help to isolate the area which is causing the problem.
On-Board Diagnostic (OBD) System Check

Step 1 Action 1. Ignition On, engine Off. 2. Check the CHECK ENGINE lamp (MIL). Does the CHECK ENGINE lamp turn On? 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? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select the Miscellaneous Test and perform the Check Light in Lamps. 3. Operate the Tech 2 in accordance with the Tech 2 instructions. Does the CHECK ENGINE lamp turn Off? 4 Attempt to start the engine. Does the engine start and continue to Run? 5 1. Using the Tech 2, ignition On and engine Off. 2. Select the Read DTC Infor As Stored By ECU in Diagnostic Trouble Code. 3. Are any DTCs stored? 6 Compare typical scan data values displayed on the Tech 2 Data Display. Are the displayed values within the range? 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? Go to DTC Chart Refer to SYMPTOM DIAGNOSIS Go to Step 5 Go to Step 3 Go to Step 7 Go to Step 2 Value(s) Yes No Go to No CHECK ENGINE Lamp
Go to Step 4
Go to CHECK ENGINE LAMP On Steady Go to Engine Cranks But Will Not Run
Go to Step 6 Refer to TYPICAL SCAN DATA
B-58
Repair faulty harness and verify repair
Go to Step 8

Step 8 Action Using the DVM and check the data link connector ground circuit. 1. Ignition Off, engine Off. 2. Check the circuit for open circuit. Was the problem found?
B-58 4 5
6E107
No
Value(s)
Yes
9 Using the DVM and check the data link connector ground circuit. 1. Ignition On, engine Off. 2. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-58 4 5
Go to Step 9
V V
Less than 1V 10 Using the DVM and check the data link connector communication circuit. 1. Ignition On, engine Off. 2. Check the circuit for short to power supply circuit. Was the DVM indicated fixed battery voltage?
B-58 6
Go to Step 10
Go to Step 11
6E108
Step 11

Action Using the DVM and check the data link connector communication circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found? Value(s) Yes No
C-56
B-58
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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 12
Verify repair
Go to Step 13
13
Verify repair
6E109
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and steady for about five seconds with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the check engine lamp bulb through the meter fuse. The Engine Control Module (ECM) turns the check engine lamp ON by grounding the check engine lamp driver circuit.
wire broken inside the insulation. following items:
Check for the
Inspect the ECM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. If the engine runs OK, check for a faulty light bulb, an open in the check engine lamp driver circuit, or an open in the instrument cluster ignition feed. If the engine cranks but will not run, check for an open ECM ignition or battery feed, or a poor ECM to engine ground.
Diagnostic Aids
An intermittent check engine lamp may be cased by a poor connection, rubbed-through wire insulation, or a
6E110
No Check Engine Lamp (MIL)

Step 1 Action Check the meter fuse (15A). If the fuse is burnt out, repair as necessary. Was the problem found? Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Ignition On. 4. Check the circuit for open circuit. Was the DVM indicated specified value?
C-56
Value(s)
Yes
No
Verify repair
Go to Step 2
42
V
10-14.5V 3 Check the CHECK ENGINE lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found? Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector connector. 3. Check the circuit for open circuit. Was the problem found?
C-56
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
and
ECM
42 B-24
17
Verify repair
Go to Step 5
Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved?
Verify repair
Go to Step 6

Step 6 Action Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E111
No
Verify repair
6E112
CHECK ENGINE LAMP (MIL) ON STEADY
Circuit description
The check engine lamp should always be illuminated and steady for about five seconds with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the check engine lamp indicator. The Engine Control Module (ECM) turns the check engine lamp ON by grounding the check engine lamp driver circuit. The check engine lamp should not remain ON with the engine running and no DTC(s) set. A steady check engine lamp with the engine running and no DTC(s) suggests a short to ground in the check engine lamp driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
6E113
Check Engine Lamp (MIL) On Steady

Step 1 Action 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Ignition On. Was the CHECK ENGINE lamp turned on? 2 Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect connector. the meter connector and ECM Value(s) Yes No
Go to Step 2
Go to Step 4
3. Check the circuit for short to ground circuit. Was the problem found?
C-56
42
B-24
17
3 4 Replace the meter assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 3
Verify repair
Go to Step 5
Verify repair
6E114
ECM Diagnostic Trouble Codes

Flash Code 65 Symptom Code 7 Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
Code P0100
MIL ON
DTC Name Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
DTC Setting Condition MAF sensor power supply voltage is more than 5.2V.
Fail-Safe (Back Up) ECM uses mass air flow 1600mg/strk & EGR 10% conditions as substitute.
Recovery Condition MAF sensor power supply voltage is below 5.2V.
Related Failure Parts 1. Sensor power supply circuit short to battery voltage circuit. 2. MAFsensormalfunction. 3. ECM malfunction. 1. Sensor power supply circuit short to ground circuit. 2. MAFsensormalfunction. 3. ECM malfunction. 1. Sensor power supply circuit open circuit. 2. Sensor signal circuit open or short to ground circuit. 3. Sensor heater harness open circuit. 4. Poor connector connection. 5. MAFsensormalfunction. 6. ECM malfunction. 1. Sensor signal circuit shortto voltagecircuit. 2. Sensor ground circuit open or short to voltage circuit. 3. MAFsensormalfunction. 4. ECM malfunction. 1. Sensor signal circuit shortto voltagecircuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Vacuum sensor malfunction. 4. ECM malfunction. 1. Sensor power supply circuit open circuit. 2. Sensor signal circuit open or short to ground circuit. 3. Poor connector connection. 4. Vacuum sensor malfunction. 5. ECM malfunction.
83
ON
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
MAF sensor power supply voltage is below 4.6V.
MAF sensor power supply voltage is more than 4.6V.
83
ON
Mass Air Flow (MAF) Sensor Output Circuit Low Input
1. Engine speed is between 600rpmand5000rpm. 2. MAF sensor output is below -33.7mg/strk.
MAF sensor output is more than -27.4mg/strk.
83/ 88
P0110(1)
ON
Mass Air Flow (MAF) Sensor Output Circuit High Input
1. Engine speed is between 600rpmand5000rpm. 2. MAF sensor output is more than 1378mg/strk (4JA1-TC) or 1784mg/ strk (4JH1-TC). Vacuum sensor output voltage is more than 4.4V. 1. Fuel injection quantity is reduced. 2. ECM use 615hpa conditions for turbocharger waste gate control.
MAF sensor output is below 1378mg/strk (4JA1-TC) or 1784mg/strk (4JH1-TC).
88/ 92
P0110(1)
34
P0105
ON
Vacuum Pressure Sensor Circuit High Input
Vacuum sensor output voltage is below 4.4V.
85/ 93
P0115(1)
ON
Vacuum Pressure Sensor Circuit Low Input
Vacuum sensor output voltage is below 0.5V.
Vacuum sensor output voltage is more than 0.5V.
82/ 85

Flash Code 34 Code P0105 Symptom Code 7 MIL ON DTC Name Vacuum Pressure Sensor Voltage Supply Circuit High Input DTC Setting Condition Vacuum sensor power supply voltage is more than 5.2V. Fail-Safe (Back Up) 1. Fuel injection quantity is reduced. 2. ECM use vacuum sensor output voltage 5.0V condition as substitute. Recovery Condition Vacuum sensor power supply voltage is below 5.2V. Related Failure Parts 1. Sensor power supply circuit short to battery voltage circuit. 2. Vacuum sensor malfunction. 3. ECM malfunction. 1. Sensor power supply circuit short to ground circuit. 2. Vacuum sensor malfunction. 3. ECM malfunction. 1. Sensor signal circuit open or short to voltage circuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Poor connector connection 4. IATsensormalfunction. 5. ECM malfunction. 1. Sensor signal circuit shortto groundcircuit. 2. IATsensormalfunction. 3. ECM malfunction. 1. Sensor signal circuit open or short to voltage circuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Poor connector connection 4. ECTsensormalfunction. 5. ECM malfunction. 1. Sensor signal circuit shortto groundcircuit. 2. ECTsensormalfunction. 3. ECM malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
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4JH1-TC (AT)
82
ON
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Vacuum sensor power supply voltage is below 4.5V.
Vacuum sensor power supply voltage is more than 4.5V.
82
23
P0110
ON
Intake Air Temperature (IAT) Sensor Circuit High Input
IAT sensor output voltage is more than 4.7V.
ECM use 0 deg. C conditions as substitute.
IAT sensor output voltage is below 4.7V.
84/ 92
P0100(B)/ P0100(C)
ON
Intake Air Temperature (IAT) Sensor Circuit Low Input
IAT sensor output voltage is below 0.3V.
IAT sensor output voltage is more than 0.3V.
84
14
P0115
ON
Engine Coolant Temperature (ECT) Sensor Circuit High Input
ECT sensor output voltage is more than 4.7V.
1. ECM uses fuel temperature as substitute. 2. ECM uses 60 deg. C condition for injection timing control. 3. ECM uses -25 deg. C condition (4JA1-TC) or 15 deg. C condition (4JH1-TC) for glow time control.
ECT sensor output voltage is below 4.7V.
89/ 93
P0105(1)
ON
Engine Coolant Temperature (ECT) Sensor Circuit Low Input Fuel Temperature Sensor Circuit Range/Performance
ECT sensor output voltage is below 0.3V.
ECT sensor output voltage is more than 0.3V.
89
15
P0180
ON
FT sensor output is high temperature (more than 150 deg. C) or low temperature (below -40 deg. C).
The ECM use 75 deg. C conditions as substitute.
FT sensor output is correct temperature range between 150 deg. C and -40 deg. C.
6E116
Flash Code 52

Code P0215 Symptom Code A MIL ON DTC Name Fuel Cutoff Solenoid Valve Malfunction DTC Setting Condition 1. Ignition key switchoff. 2. Engine speed is below 1500rpm. 3. Vehicle speed is below 1.5km/h. 4. PSG (pump control unit) recognizes MAB (fuel cutoff solenoid valve) signal from the ECM, but the MAB could not operate. ECM does not command MAB (fuel cutoff solenoid valve) signal to the PSG (pump control unit), but PSG detected MAB signal line circuit is high level. 1. Ignition key switchoff. 2. Engine speed is below 1500rpm. 3. Vehicle speed is below 1.5km/h. 4. PSG (pump control unit) does not recognize MAB (fuel cutoff solenoid valve) signal from the ECM. 1. Ignition key switch off. 2. CAN controller does not operate Bus-off. Fail-Safe (Back Up) 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. Recovery Condition No recovery until condition match in the next ignition key cycle. Related Failure Parts 1. PSG (pump control unit) malfunction. 2. MAB (fuel cutoff solenoid valve) malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
ON
Fuel Cutoff Solenoid Valve Circuit High Input
Engine does not start.
No recovery.
1. MAB (fuel cutoff solenoid valve) signal circuit short to voltage circuit. 2. PSG (pump control unit) malfunction. 1. MAB (fuel cutoff solenoid valve) signal circuit open orshorttogroundcircuit. 2. PSG (pump control unit) malfunction.
105
ON
Fuel Cutoff Solenoid Valve Always Active
1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.
No recovery until condition match in the next ignition key cycle.
105
ON
Fuel Cutoff Solenoid Valve Malfunction Injection Timing Control Circuit Malfunction
No fail-safe function.
1. ECM malfunction. 2. PSG (pump control unit) malfunction. Deviation of actual injection timing and desired injection timing is more than +3 deg. CA or -6 deg. CA for 8 seconds. 1. Timing control valve malfunction. 2. Timer piston sticking. 3. Pump camshaft speed sensor malfunction.
54
P0216
ON
Fuel injection quantity is 1. Engine speed is more reduced. than 700rpm. 2. Fuel injection quantity is more than 4mg/stk. 3. Deviation of actual injection timing and desired injection timing is more than +3 deg. CA or -6 deg. CA for 8 seconds. 1. Engine speed is more than 2014rpm. 2. Fluctuation of actual injection timing is more than +-5.2 deg. CA.
ON
Injection Timing Control Circuit Malfunction
1. Engine speed is more than 2014rpm. 2. Fluctuation of actual injection timing is more than +-5.2 deg. CA.
1. Insufficient air bleeding of fuel line. 2. Fuel filterclogging. 3. Timing control valve malfunction. 4. Pump camshaft speed sensor malfunction.

Flash Code 64 Code P0243 Symptom Code 3 MIL ON DTC Name Turbocharger Wastegate Solenoid "A" Range/ Performance DTC Setting Condition 1. Intake air temperature is between -50 deg. C and 200 deg. C. 2. Engine coolant temperature is between 50 deg. C and 150 deg. C. 3. Barometric pressure is between 0hpa and 3500hpa. 4. Low vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is more than 50hpa.) Wastegate control EVRV circuit open or short to ground circuit. Fail-Safe (Back Up) 1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. Recovery Condition 1. Engine speed is between 500rpm and 6000rpm. 2. Correct vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is less than 50hpa.) Related Failure Parts 1. Turbocharger wastegate control EVRV malfunction. 2. Vacuum line is obstructed. 3. Vacuum is leaking. 4. Vacuum pump malfunction. 5. Vacuum sensor malfunction. 6. Turbocahrger wastegate valve malfunction. 7. ECM malfunction. 1. Wastegate control EVRV circuit open or short to ground circuit. 2. Wastegate control EVRV malfunction. 3. ECM malfunction. 1. Turbocharger wastegate control EVRV malfunction. 2. Vacuum regulating valve malfunction. 3. Vacuum pump malfunction. 4. Vacuum sensor malfunction. 5. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E117
4JH1-TC (AT)
85/ 96
ON
Turbocharger Wastegate Solenoid "A" Low
1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition. 1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition.
Wastegate control EVRV circuit is correct condition.
96
ON
Turbocharger Wastegate Solenoid "A" Range/ Performance
1. Intake air temperature is between -50 deg. C and 200 deg. C. 2. Engine coolant temperature is between 50 deg. C and 150 deg. C. 3. Barometric pressure is between 0hpa and 3500hpa. 4. High vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is less than -50hpa.) 1. Engine coolant temperature is between 50 deg. C and 150 deg. C. 2. EGR control EVRV 0% condition. 3. No DTC relating to MAF sensor, vacuum sensor & IAT sensor. 4. Large amount of mass air flow. (= Incorrect boost pressure condition) (Desired mass air flow actual mass air flow is less than -56mg/strk.)
1. Engine speed is between 500rpm and 6000rpm. 2. Correct vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is more than -50hpa.)
85/ 96
ON
Turbocharger Wastegate Solenoid "A" Malfunction
1. Correct amount of mass air flow. (= Correct boost pressure condition) (Desired mass air flow actual mass air flow is more than -56mg/strk.)
1. Turbocharger wastegate actuator malfunction. 2. Vacuumlinemalfunction. 3. ECM malfunction.
6E118
Flash Code 64

Code P0243 Symptom Code 8 MIL ON DTC Name Turbocharger Wastegate Solenoid "A" High DTC Setting Condition Wastegate control EVRV circuit short to voltage circuit. Fail-Safe (Back Up) 1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition. 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. Recovery Condition Wastegate control EVRV circuit is correct condition. Related Failure Parts 1. Wastegate control EVRV circuit short to voltage circuit. 2. Wastegate control EVRV malfunction. 3. ECM malfunction. 1. PSG (pump control unit) malfunction. 2. Pump camshaft speed sensor malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
96
53
P0251
ON
Injection Pump Malfunction
1. No pump camshaft speed sensor error. 2. High pressure solenoid valve control pulse width does not match with desired fuel injection quantity. 1. No pump camshaft speed sensor error. 2. No CKP sensor error. 3. Difference of engine speed and doubled pump camshaft speed is more than 720rpm (4JA1-TC) or 690rpm (4JH1-TC).
ON
1. No pump camshaft speed sensor error. 2. No CKP sensor error. 3. Difference of engine speed and doubled pump camshaft speed is below 800rpm (4JA1-TC) or 690rpm (4JH1-TC). No recovery until in the next ignition key cycle. No recovery until condition match in the next ignition key cycle. Fuel injection quantity is reduced. EEPROM or A/D converter no malfunction in the PSG (pump control unit). No recovery until in the next ignition key cycle. No recovery until condition match in the next ignition key cycle.
1. Missing CKP sensor pulses. 2. Electrical interference. 3. Magneticinterference. 4. PSG (pump control unit) malfunction.
91
ON
No pump map programmed in the PSG (pump control unit) or PSG malfunction. EEPROM or A/D converter malfunction in the PSG (pump control unit).
PSG (pump control unit) malfunction. PSG (pump control unit) malfunction.
ON
ON
PSG (pump control unit) recognized high pressure solenoid valve drive circuit error. PSG (pump control unit) could not measure the high pressure solenoid valve drive voltage. ECM could not accept PSG (pump control unit) message.
PSG (pump control unit) malfunction.
ON
ON
ECM accepts PSG (pump control unit) message.
1. CAN high circuit open, short to ground or short to voltage circuit. 2. CAN low circuit open, short to ground or short to voltage circuit. 3. ECM malfunction. 4. PSG (pump control unit) malfunction.
99/ 100
P1650(A)/ P1651(B)

Flash Code 43 Code P0335 Symptom Code B MIL ON DTC Name Crankshaft Position Sensor Circuit Malfunction DTC Setting Condition 1. Engine speed is more than 665rpm. 2. CKP sensor pulse width error. Fail-Safe (Back Up) When pump camshaft speed sensor is OK: ECM uses doubled pump camshaft speed as substitute enginespeed. When pump camshaft speed sensor is not OK: 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. Recovery Condition ECM detects correct CKP pulse width. Related Failure Parts 1. During engine run: 1. CKP sensor harness open circuit, short to ground or short to voltage circuit. 2. Poor connector connection. 3. CKPsensormalfunction. 4. Pulse sensing gap incorrect. 5. Pulser malfunction. 6. Electrical interference. 7. Magnetic interference. 8. ECM malfunction. During engine crank: 1. CKP sensor harness open circuit, short to ground or short to voltage circuit. 2. Poor connector connection. 3. CKPsensormalfunction. 4. Pulse sensing gap incorrect. 5. Pulser malfunction. 6. Electrical interference. 7. Magnetic interference. 8. ECM malfunction. 1. Engine over-running. 2. CKPsensormalfunction. 3. Pulser malfunction. 4. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E119
4JH1-TC (AT)
90/ 98/ 101
P1335 (A)
ON
Crankshaft Position Sensor Circuit Malfunction
1. No pump camshaft speed sensor error. 2. "Crankshaft Position Sensor Circuit Malfunction (Symptom CodeB)" isnotstored. 3. Engine speed is 0rpm. 4. Doubled pump camshaft speed is more than 50rpm.
When pump camshaft speed sensor is OK: ECM uses doubled pump camshaft speed as substitute enginespeed. Other than pump camshaft speed sensor is OK: Fuel injection quantity is reduced.
1. Engine speed is more than 0rpm. 2. Doubled pump camshaft speed is below 100rpm.
90/ 98/ 101
P1135 (A)
ON
Engine Speed Input Circuit Range/Performance
Engine speed is more than 5700rpm.
When intermittent malfunction: 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. When preliminary malfunction: ECM uses doubled pump camshaft speed as substitute engine speed. No fail-safe function.
Engine speed is below 5700rpm.
90/ 98/ 101
66
P0380
ON
Glow Relay Circuit Voltage Low
Glow relay circuit open or short to ground circuit.
Glow relay circuit is correct condition.
1. Glow relay circuit open or short to groundcircuit. 2. Glowrelaymalfunction. 3. ECM malfunction. ECM malfunction.
94
ON
Glow Relay Circuit Voltage High
Glow relay circuit short to voltage circuit.
6E120
Flash Code 67

Code P0381 Symptom Code 4 MIL ON DTC Name Glow Plug Indicator Circuit Voltage Low DTC Setting Condition Glow plug indicator circuit open or short to ground circuit. Fail-Safe (Back Up) No fail-safe function. Recovery Condition Glow plug indicator circuit is correct condition. Related Failure Parts 1. Glow plug indicator circuit open or short to ground circuit. 2. Glow plug indicator lamp malfunction. 3. ECM malfunction. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
43
ON
Glow Plug Indicator Circuit Voltage High Exhaust Gas Recirculation Flow Excessive Detected
Glow plug indicator circuit short to voltage circuit. 1. Intake air temperature is between 15 deg. C and 100 deg. C. 2. Engine coolant temperature is between 55 deg. C and 100 deg. C (4JA1-TC) or 35 deg. C and 100 deg. C (4JH1TC). 3. Barometric pressure is between 850hpa and 1100hpa. 4. Small amount of mass air flow. (Desired mass air flow - mass air flow is more than 150mg/strk) EGR EVRV circuit open or short to ground circuit. Fuel injection quantity is reduced. 1. Engine speed is between 1500rpm and 3100rpm (4JA1-TC) or 1500rpm and3200rpm(4JH1-TC). 2. Injection quantity is below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC). 3. Correct amount of mass air flow.
32
P0400
ON
1. EGR valve is stuck at open position. 2. EGREVRVmalfunction. 3. Air intake is obstructed. 4. Airintakeisleaking. 5. MAFsensormalfunction. 6. ECM malfunction.
88/ 97
ON
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit Exhaust Gas Recirculation Flow Insufficient Detected
Fuel injection quantity is EGR EVRV circuit is correct reduced and EGR EVRV condition. 10% conditions as substitute. Fuel injection quantity is reduced. 1. Engine speed is between 1500rpm and 3100rpm (4JA1-TC) or 1500rpm and3200rpm(4JH1-TC). 2. Injection quantity is below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC). 3. Correct amount of mass air flow.
1. EGR EVRV circuit open orshorttogroundcircuit. 2. EGREVRVmalfunction. 3. ECM malfunction. 1. EGR valve is stuck at close position. 2. EGR valve operating vacuum hose is clogged or disconnected. 3. EGREVRVmalfunction. 4. MAF sensor signal circuit short to voltagecircuit. 5. MAFsensormalfunction. 6. ECM malfunction.
97
ON
1. Intake air temperature is between 15 deg. C and 100 deg. C. 2. Engine coolant temperature is between 55 deg. C and 100 deg. C (4JA1-TC) or 35 deg. C and 100 deg. C (4JH1TC). 3. Barometric pressure is between 850hpa and 1100hpa. 4. Large mount of mass air flow. (Desired mass air flow - mass air flow is below -150 mg/strk) EGR EVRV circuit short to voltage circuit.
88/ 97
ON
Exhaust Gas Recirculation Circuit Short to Battery
Fuel injection quantity is reduced & EGR EVRV 10% conditions as substitute.
EGR EVRV circuit is correct condition.
1. EGR EVRV circuit short to voltage circuit. 2. EGREVRVmalfunction. 3. ECM malfunction.
97

Flash Code 24 Code P0500 Symptom Code 1 MIL DTC Name DTC Setting Condition Vehicle speed is more than 200km/h. Fail-Safe (Back Up) ECM uses vehicle speed 5km/h condition as substitute. Recovery Condition Vehicle speed is below 200km/h. Related Failure Parts 1. VSS signal circuit open, short to ground or short to voltage circuit. 2. VSS malfunction. 3. Speed meter malfunction. 4. TCM malfunction (AT 2WD). 5. ECM malfunction. 1. VSS malfunction. 2. Speed meter malfunction. 3. Electrical interference. 4. Magneticinterference. 5. ECM malfunction. 1. VSS open circuit, short to ground or short to voltage. 2. Poor connector connection. 3. VSS malfunction. 4. Speed meter malfunction. 5. ECM malfunction. 1. Charge system malfunction. 2. Battery jump start cable misconnect. 3. ECM malfunction. 1. Battery power feed harness open circuit or short to ground circuit. 2. ECM ground harness openorpoorconnection. 3. Poor connector connection. 4. Battery malfunction. 5. Charge system malfunction. 6. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E121
4JH1-TC (AT)
ON Vehicle Speed Sensor Circuit High Input at next igniti on cycle
68
ON Vehicle Speed Sensor Input Signal Frequency Too High at next igniti on cycle ON Vehicle Speed Sensor Incorrect Signal at next igniti on cycle
Input signal frequency is too high.
ECM uses vehicle speed 5km/h condition as substitute.
Correct vehicle speed signal frequency.
68
1. Engine speed is more than 3200rpm (4JA1-TC) or3600rpm(4JH1-TC). 2. Fuel injection quantity is more than 30mg/strk (4JA1-TC) or 41mg/strk (4JH1-TC). 3. Vehicle speed is below 1.5km/h. System voltage is more than 20V.
Fuel injection quantity is reduced.
Vehicle speed is more than 1.5km/h.
68
35
P0560
OFF
System Voltage Too High
ECM uses 9V conditions as substitute.
System voltage is below 20V.
3/ 39
OFF
System Voltage Too Low
System voltage is below 7V.
System voltage is more than 7V.
3/ 39
6E122
Flash Code 35

Code P0560 Symptom Code A MIL OFF DTC Name System Voltage Malfunction DTC Setting Condition System voltage of PSG (pump control unit) is below 4.5V or more than 27V. Fail-Safe (Back Up) PSG uses default voltage as substitute. Recovery Condition System voltage of PSG is between 4.5V and 27V. Related Failure Parts 1. Battery power feed harness open circuit or short to ground circuit. 2. PSG (pump control unit) ground harness open or poor connection. 3. Poor connector connection. 4. Battery malfunction. 5. Charge system malfunction. 6. Battery jump start cable misconnect. 7. PSG (pump control unit) malfunction. 1. Ignition switch circuit open or short to ground circuit. 2. Poor connector connection. 3. Ignition switch malfunction. 4. ECM malfunction. 1. Ignition switch circuit open or short to ground circuit. 2. Poor connector connection. 3. Ignition switch malfunction. 4. ECM malfunction. Engine control disabled. Memory are is OK. ECM is not programmed. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
18
P0561
OFF
Ignition Switch Circuit Malfunction
The ECM recognized ignition switch turn off signal during ECM is activated.
ECM stops engine.
39
OFF
Ignition Switch Circuit Malfunction
Ignition switch circuit is malfunction.
39
P0602
Control Module Programming Error ECU Malfunction
ECM memory area error.
28
P0606
ON
Gate Array communication error.
1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. MAB (fuel cutoff solenoid valve) is operated.
No recovery.
ECM malfunction.
ON
ECU Malfunction
1. Throttle position is below 1%. 2. Desired injection quantity is more than 0mg/strk. 3. Engine speed is more than 2000rpm.
Desired injection quantity is below 0mg/strk.
1. ECM malfunction. 2. PSG (pump control unit) malfunction.

Flash Code 46 Code P0645 Symptom Code 4 MIL ON DTC Name A/C Compressor Relay Circuit Voltage Low DTC Setting Condition A/C compressor relay circuit open or short to ground circuit. Fail-Safe (Back Up) No fail-safe function. Recovery Condition A/C compressor relay circuit is correct condition. Related Failure Parts 1. A/C compressor relay circuit open or short to ground circuit. 2. Poor connector connection. 3. A/C compressor relay malfunction. 4. ECM malfunction. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E123
4JH1-TC (AT)
41
ON
A/C Compressor Relay Circuit Voltage High Brake Switch Circuit Malfunction
A/C compressor relay circuit short to voltage circuit. 1. Throttle position is more than 0%. 2. Engine speed is more than 693rpm (4JA1-TC) or665rpm(4JH1-TC). 3. Vehicle speed is more than 0km/h. 4. Brake switch 1 signal and brake switch 2 signal are differently inputted to the ECM since the ignition switch was turned on. 1. Throttle position is more than 0%. 2. Engine speed is more than 693rpm (4JA1-TC) or665rpm(4JH1-TC). 3. Vehicle speed is more than 0km/h. 4. Brake switch 1 signal and brake switch 2 signal are differently inputted to the ECM. Clutch signal does not change between vehicle speed 1.5km/h and 80km/h since ignition switch was tuned on. No fail-safe function. Clutch signal correctly changes. No fail-safe function. Brake switch 1 signal and brake switch 2 signal are correctly inputted to the ECM.
25
P0703
ON
1. Brake switch 1 circuit open, short to ground or short to voltage circuit. 2. Poor connector connection. 3. Brake switch 1 malfunction. 4. ECM malfunction.
30
ON
Brake Switch Circuit Malfunction
1. Brake switch 2 circuit open or short to ground circuit. 2. Poor connector connection. 3. Brake switch 2 malfunction. 4. ECM malfunction.
65
57
P0704
ON
Clutch Switch Input Circuit Malfunction
1. Clutch switch circuit open, short to ground or shorttovoltage circuit. 2. Poor connector connection. 3. Clutch switch malfunction. 4. ECM malfunction. ECM malfunction.
31
86
P1105
ON
Barometric Pressure Sensor Circuit High Input Barometric Pressure Sensor Circuit Low Input
Barometric pressure sensor output voltage is more than 4.4V. Barometric pressure sensor output voltage is below 1.5V.
ECM uses 1013hpa condition as substitute.
Barometric pressure sensor output voltage is below 4.4V. Barometric pressure sensor output voltage is more than 1.5V.
ECM malfunction.
ON
6E124
Flash Code 21

Code P1120 Symptom Code 1 MIL ON DTC Name Pedal/Throttle Position Sensor Circuit High Input DTC Setting Condition Throttle position sensor output voltage is more than 4.5V. Fail-Safe (Back Up) ECM increases idle speed up to 1400rpm. Recovery Condition Throttle position sensor output voltage is below 4.5V. Related Failure Parts 1. Sensor power supply circuit short to voltage circuit. 2. Sensor signal circuit short to voltagecircuit. 3. Sensor ground circuit open or short to voltage circuit. 4. Poor connector connection. 5. TPS malfunction. 6. ECM malfunction. 1. Sensor power supply circuit short to battery voltage circuit. 2. TPS malfunction. 3. ECM malfunction. 1. Sensor power supply circuit short to ground circuit. 2. TPS malfunction. 3. ECM malfunction. 1. Throttle sticking. 2. TPSincorrectadjusting. 3. TPS malfunction. 4. Brake switch malfunction. 5. ECM malfunction. 1. TPS malfunction. 2. Idle switch malfunction. 3. ECM malfunction. 38/ 69 Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
38/ 49/ 57
ON
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Throttle position sensor power supply voltage is more than 5.2V.
Throttle position sensor power supply voltage is below 5.2V.
57
ON
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Throttle position sensor power supply voltage is below 4.6V.
Throttle position sensor power supply voltage is more than 4.6V.
57
ON
Pedal/Throttle Position Sensor Brake Switch Error
1. Engine speed is more than 1700rpm. 2. Vehicle speed is more than 1.5km/h. 3. When brake pedal is depressed during accelerator pedal is depressing. 1. When idle switch is turned off, throttle position sensor was below 0.35%. or 2. When idle switch is tuned on, throttle position sensor was more than 7.8%. Excessive high engine coolant temperature is detected. Fuel temperature is more than 100 deg. C. No fail-safe function.
Throttle position is more than 20% or brake pedal is released(switchisinactive).
30/ 38/ 65
ON
Pedal/Throttle Position Sensor Idle Position Switch Error
1. When throttle position sensor is 100%, idle switch turns off. 2. When throttle position sensor is 0%, idle switch turns on.
22
P1173
OFF
Fuel Reduction Caused By High Coolant Temperature Fuel Reduction Caused By High Fuel Temperature
Engine coolant temperature is normal range. Fuel temperature is below 100 deg. C.
1. Engine overheat. 2. ECTsensormalfunction. 3. ECM malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction.
89
OFF
PSG (pump control unit) controls fuel injection quantity based on engine speed and fuel temperature. No fail-safe function.
OFF
Fuel Reduction Caused By Low Fuel Temperature
Excessive low fuel temperature is detected.
Fuel temperature is normal range.

Flash Code 43 Code P1335 Symptom Code A MIL ON DTC Name Engine Speed Output Circuit Malfunction DTC Setting Condition The PSG (pump control unit) is recognized defective engine speed signal form the ECM. Fail-Safe (Back Up) Fuel injection quantity is reduced. Recovery Condition Correct engine speed signal. Related Failure Parts 1. CKP sensor harness open circuit, short to ground or short to voltage. 2. CKP sensor output harness open circuit, short to ground or short to voltage. 3. Poor connector connection. 4. CKPsensormalfunction. 5. Pulse sensing gap incorrect. 6. Pulser malfunction. 7. Electrical interference. 8. Magnetic interference. 9. ECM malfunction. 10. PSG (pump control unit) malfunction. 1. Pump camshaft speed sensor malfunction. 2. Pulse sensing gap incorrect. 3. Pulser malfunction. 4. Electrical interference. 5. Magnetic interference. 6. ECM malfunction. 7. PSG (pump control unit) malfunction. 1. Neutral switch circuit shorttovoltage circuit. 2. Neutral switch malfunction. 3. ECM malfunction. 1. Neutral switch circuit open, short to ground circuit. 2. Poor connector connection. 3. Neutral switch malfunction. 4. ECM malfunction. No fail-safe function. No recovery. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E125
4JH1-TC (AT)
90/ 91/ 98/ 101
P0335(B)/ P0335(D)
45
P1345
ON
Camshaft Speed Malfunction The PSG (pump control unit) is recognized incorrect camshaft speed signal.
Correct camshaft speed.
47
P1520
ON
Neutral Switch ON Error
Neutral switch signal is inputted "On" three times consecutively under driving conditions. Neutral switch signal is inputted "Off" three times consecutively under driving conditions.
Correct neutral switch signal is inputted two times consecutively under driving conditions.
87
ON
Neutral Switch OFF Error
87
55
P1605
ON
Seed and Key File Destroyed Seed or key file in EEPROM is destroyed. EEPROM Defect Write and read from the EEPROM are failed during initialization of the ECM.
ON
ECM uses default values from the EPROM.
Write and read from the EEPROM are correct during initialization of the ECM.
ECM malfunction.
6E126
Flash Code 55

Code P1605 Symptom Code E MIL ON DTC Name EEPROM Defect DTC Setting Condition EEPROM checksum does not match with the read check sum during initialization of the ECM. Immobilizer functions are not programmed in the ECM. Received security code is not correct. 1. Engine does not start. 2. Check engine lamp flash. 1. Engine does not start. 2. Check engine lamp flash. Fail-Safe (Back Up) Recovery Condition EEPROM checksum match with the read check sum during initialization of the ECM. No recovery. Related Failure Parts ECM malfunction. ECM malfunction. Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT) 4JH1-TC (AT)
56
P1610
Security Key and Security Code not Programmed Wrong Security Code Entered
B****
56
P1611
No recovery.
1. ECM malfunction. 2. Immobilizer control unit malfunction. 3. Transponder key malfunction. 1. ECM and immobilizer control unit communication circuit open circuit, short to ground circuit or short to voltage circuit. 2. ECM malfunction. 3. Immobilizer control unit malfunction. 4. Transponder key malfunction. 1. ECM and immobilizer control unit communication circuit open circuit, short to ground circuit or short to voltage circuit. 2. ECM malfunction. 3. Immobilizer control unit malfunction. 4. Transponder key malfunction. 1. ECM malfunction. 2. Immobilizer control unit malfunction. 3. Transponder key malfunction. ECM malfunction.
B****
56
P1612
Immobilizer No or Wrong Signal
Received challenge signal is not correct or not received.
1. Engine does not start. 2. Check engine lamp flash.
No recovery.
27/ 35
B****
56
P1613
Immobilizer No or Wrong Signal
Received response signal is not correct or not received.
No recovery.
27/ 35
B****
56
P1614
Wrong Transponder Key
Received response signal is not correct from the transponder key.
No recovery.
B****
76
P1625
OFF
ECM Main Relay Switched Off Too Early
When ignition switch was turned off, timing of the ECM main relay turning off is too early. When ignition switch was turned off, timing of the ECM main relay turning off is too late or does not off.
No recovery.
3/ 58 No recovery. 1. ECM main relay malfunction. 2. ECM malfunction.
OFF
ECM Main Relay Switched Off Too Late
3/ 58

Flash Code 51 Code P1630 Symptom Code A MIL ON DTC Name Fuel Injection Quantity Circuit Malfunction DTC Setting Condition The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to high current. The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to continuous current. CAN controller detects Busoff or canceling. Fail-Safe (Back Up) Fuel injection quantity is reduced. Recovery Condition Related Failure Parts Related ECM Pin No. Related Multiple DTC 4JA1-TC (MT) 4JH1-TC (MT)
6E127
4JH1-TC (AT)
The PSG (pump control unit) PSG (pump control unit) detects correct high pressure malfunction. solenoid valve control circuit.
ON
Fuel Injection Quantity Circuit Malfunction
1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. MAB (fuel cutoff solenoid valve) is operated.
No recovery.
44
P1650
ON
CAN Device Offline
CAN controller detects correct Bus signal.
1. CAN high circuit open, short to ground or short to voltage circuit. 2. CAN low circuit open, short to ground or short to voltage circuit. 3. Poor connector connection. 4. Electricalinterference. 5. ECM malfunction. 6. PSG (pump control unit) malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction. 1. CAN high circuit open, short to ground or short to voltage circuit. 2. CAN low circuit open, short to ground or short to voltage circuit. 3. Poor connector connection. 4. Electrical interference. 5. ECM malfunction. 6. PSG (pump control unit) malfunction. 1. Check engine lamp circuit open or short to ground circuit. 2. Check engine lamp malfunction 3. ECM malfunction. ECM malfunction.
99/ 100
P1651(B)
ON
CAN Device Hang-up
CAN controller does not react under engine running. The PSG (pump control unit) does not recognize CAN signal from the CAN controller. The ECM does not read CAN signal from the PSG (pump control unit). 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.
CAN controller reacts correctly under engine running. The PSG (pump control unit) recognizes CAN signal from the CAN controller. The ECM reads CAN signal from the PSG (pump control unit).
45
P1651
ON
CAN Malfunction
ON
CAN Malfunction
99/ 100
P1650(A)
77
P1690
OFF
Check Engine Lamp (MIL) Circuit Voltage Low
Check engine lamp circuit open or short to ground circuit.
Check engine lamp circuit is correct condition.
42
B****
OFF
Check Engine Lamp (MIL) Circuit Voltage High
Check engine lamp circuit short to voltage circuit.
6E128
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 9) (FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY 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
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Condition for setting the DTC and action taken when the DTC sets
Flash Code 65 Code P0100 Symptom Code 7 MIL ON DTC Name Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input Mass Air Flow (MAF) Sensor Output Circuit Low Input DTC Setting Condition MAF sensor power supply voltage is more than 5.2V. MAF sensor power supply voltage is below 4.6V. 1. Engine speed is between 600rpm and 5000rpm. 2. MAF sensor output is below -33.7mg/strk. 1. Engine speed is between 600rpm and 5000rpm. 2. MAF sensor output is more than 1378mg/strk (4JA1-TC) or 1784mg/strk (4JH1-TC).
6E129
Fail-Safe (Back Up) ECM uses mass air flow 1600mg/strk & EGR 10% conditions as substitute.
ON
ON
ON
Mass Air Flow (MAF) Sensor Output Circuit High Input
Circuit Description
The mass air flow (MAF) sensor is part of the intake air system. It is fitted between the air cleaner and turbocharger and measure the mass air flowing into the engine. The mass air flow (MAF) sensor element measures the partial air mass through a measurement duct on the sensor housing. The ECM monitors the MAF sensor supply voltage and MAF sensor output voltage. The supply voltage is out of range, DTC P0100 (Symptom Code 7) or P0100 (Symptom Code 9) will be stored. The output voltage excessively high or low, DTC P0100 (Symptom Code B) or P0100 (Symptom Code C) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for 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.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65) Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0100 (Symptom Code 7) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E130
Step 3

Action 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0100 (Symptom Code 7) stored in this ignition cycle? Value(s) Yes No
Go to Step 4
Refer to Diagnostic Aids and Go to Step 4
Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 2 3 C-116 4 5
88
83
Verify repair Go to Step 11
5 6
Visually check the MAF sensor. Was the problem found? Using the DVM and check the MAF sensor power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for short to battery voltage circuit. Was the DVM indicated specified value?
C-116 4
V
7 Repair the open circuit between the ECM and MAF sensor. Was the problem solved?
C-57(B) C-116
Approximately 5.0V
Go to Step 11
Less than 1V: Go to Step 7 More than specified value: Go to Step 8
4 83
Verify repair
Go to Step 8

Step 8 Action Using the DVM and check the MAF sensor power supply circuit. 1. Ignition Off, engine Off. 2. Disconnect the MAF & IAT sensor connector and ECM connector. 3. Check the circuit for short to MAF sensor +12V supply circuit. Was the DVM indicated specified value?
C-116
6E131
No
Value(s)
Yes
No continuity 9 Repair the circuit for short to MAF sensor +12V supply circuit. Is the action complete? Repair the short to battery voltage circuit between the ECM and MAF sensor. Was the problem solved?
C-57(B) C-116
Go to Step 10
Go to Step 9
Verify repair
10
4 83
Verify repair
Go to Step 13
11
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 12 Verify repair
Go to Step 13
12 13
Verify repair
Go to Step 14
14
Verify repair
6E132
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65) Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0100 (Symptom Code 9) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0100 (Symptom Code 9) stored in this ignition cycle? 4 Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 2 3 C-116 4 5
Value(s)
Yes
No Go to On Board Diagnostic (OBD) System Check
Go to Step 2
Go to Step 3
Go to Step 4
88
83
5 6
Visually check the MAF sensor. Was the problem found? Using the DVM and check the MAF sensor power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for short to ground circuit. Was the DVM indicated specified value?
C-116 4
Approximately 5.0V
Go to Step 10
Go to Step 7

Step 7 Action Using the DVM and check the MAF sensor power supply circuit. 1. Ignition Off, engine Off. 2. Disconnect the MAF & IAT sensor connector and ECM connector. 3. Check the circuit for short to MAF sensor ground circuit. Was the DVM indicated specified value?
C-116
6E133
No
Value(s)
Yes
No continuity 8 9 Repair the circuit for short to MAF sensor ground. Is the action complete? Repair the short to ground circuit between the ECM and MAF sensor. Was the problem solved?
C-57(B) C-116
Go to Step 8
4 83
Verify repair
Go to Step 12
10
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 12
11 12
Verify repair
Go to Step 13
13
Verify repair
6E134
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0100 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0100 (Symptom Code B) stored in this ignition cycle? 4 Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 2 3 C-116 4 5
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
88
83
Visually check the MAF sensor. Was the problem found?

Step 6 Action Using the DVM and check the MAF sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Value(s) Yes
6E135
No
3. Disconnect the MAF & IAT sensor connector. 4. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
Breaker Box 88 C-116
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAF & IAT sensor connector and ECM connector. 3. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
C-57(B) C-116
88
7 Using the DVM and check the MAF sensor power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-116 4
Go to Step 7
Approximately 5.0V
Go to Step 9
Go to Step 8
6E136
Step 8

Action Repair the open circuit between the ECM and MAF sensor. Was the problem solved?
C-57(B) C-116
Value(s)
Yes
No
4 83
Verify repair
Go to Step 13
Using the DVM and check the MAF sensor +12V supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-116
V
10-14.5V 10 Repair the open circuit between the ECM main relay and MAF sensor. Was the problem solved? Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 11 Go to Step 10
Verify repair
Go to Step 11
11
Go to Step 13
12 13
Verify repair
Go to Step 14
14
Verify repair
6E137
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0100 (Symptom Code C) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0100 (Symptom Code C) stored in this ignition cycle? 4 Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 2 3 C-116 4 5
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
88
83
6E138
Step 6

Action Using the DVM and check the MAF sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect the MAF sensor connector. 4. Check the circuit for open circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAF sensor connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found?
C-57 C-116
92
7 Using the DVM and check the MAF sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF sensor connector . 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-116
Go to Step 7
V
Less than 1V Go to Step 8

Step 8 Action Using the DVM and check the MAF sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-116
6E139
No
Value(s)
Yes
V
Less than 1V 9 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 9
Go to Step 11
10 11
Verify repair
Go to Step 12
12
Verify repair
6E140
DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 2) (FLASH CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 7) (FLASH CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 9) (FLASH CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT
Flash Code 34 Code P0105 Symptom Code 1 2 MIL ON ON DTC Name Vacuum Pressure Sensor Circuit High Input Vacuum Pressure Sensor Circuit Low Input DTC Setting Condition Vacuum sensor output voltage is more than 4.4V. Vacuum sensor output voltage is below 0.5V.
6E141
Fail-Safe (Back Up) 1. Fuel injection quantity is reduced. 2. ECM use 615hpa conditions for turbocharger waste gate control. 1. Fuel injection quantity is reduced. 2. ECM use vacuum sensor output voltage 5.0V condition as substitute.
ON
Vacuum Pressure Sensor Voltage Supply Circuit High Input Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Vacuum sensor power supply voltage is more than 5.2V. Vacuum sensor power supply voltage is below 4.5V.
ON
Circuit description
The ECM monitors altitude from the barometric pressure sensor. To apply specified vacuum pressure to the turbocharger wastegate valve, ECM sends control signal to the wastegate control solenoid depending on altitude. Then, apply vacuum pressure to the turbocharger wastegate valve is monitored by the ECM form the vacuum pressure sensor output signal. The ECM controls wastegate control solenoid based on signal from vacuum pressure sensor output. The output voltage excessively high or low, DTC P0105 (Symptom Code 1) or P0105 (Symptom Code 2) will be stored. The supply voltage is out of range, DTC P0105 (Symptom Code 7) or P0105 (Symptom Code 9) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0105 display on the Tech 2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
6E142
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34) Vacuum Pressure Sensor Circuit High Input
Step 1 Action Was the "On-Board Diagnostic (OBD) System Check" performed? 2 1. 1Connect the Tech 2. 2. Review and record the failure information. 3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0105 (Symptom Code 1) stored as "Present Failure"? 3 1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0105 (Symptom Code 1) stored in this ignition cycle? 4 Check for poor/faulty connection at the vacuum pressure sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
C-57
C-124
5 Visually check the vacuum sensor. Was the problem found? -

Step 6 Action Using the DVM and check the vacuum pressure sensor ground circuit. Breaker box is available: 1. Ignition "Off", engine "Off". 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the vacuum pressure (ECM sensor Value(s) Yes
6E143
No
4. Check the circuit for open circuit. Was the problem found?
Breaker Box 93
C-124
Breaker box is not available: 1. Ignition "Off", engine "Off". 2. Disconnect the vacuum pressure connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found? sensor
C-57
C-124
7 Using the DVM and check the vacuum pressure sensor ground circuit. 1. Ignition "On", engine "Off". 2. Disconnect connector. the vacuum pressure sensor
Go to Step 7
3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-124
Less than 1V
Go to Step 8
6E144
Step 8

Action Using the DVM and check the vacuum pressure sensor signal circuit. 1. Ignition "On", engine "Off". 2. Disconnect the vacuum connector. pressure sensor Value(s) Yes No
C-124
Less than 1V 9 Substitute a known good vacuum pressure sensor and recheck. Was the problem solved? Replace the vacuum Is the action complete? pressure sensor. -
Go to Step 9
Go to Step 11 -
10 11
Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the "SPS (Service Programming System)". Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 12
12
Verify repair
6E145
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34) Vacuum Pressure Sensor Circuit Low Input
Step 1 Action Was the "On-Board Diagnostic (OBD) System Check" performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0105 (Symptom Code 2) stored as "Present Failure"? 3 1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0105 (Symptom Code 2) stored in this ignition cycle? 4 Check for poor/faulty connection at the vacuum pressure sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
C-57
C-124
5 Visually check the vacuum pressure sensor. Was the problem found? -
6E146
6

Using the DVM and check the vacuum pressure sensor signal circuit. Breaker box is available: 1. Ignition "Off", engine "Off". 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the vacuum pressure (ECM sensor
4. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
Breaker Box 85
C-124
Breaker box is not available: 1. Ignition "Off", engine "Off". 2. Disconnect the vacuum pressure connector and ECM connector. sensor
3. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
C-57
C-124
7 Using the DVM and check the vacuum pressure sensor power supply circuit. 1. Ignition "On", engine "Off". 2. Disconnect connector. the vacuum pressure sensor
Go to Step 7
3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-124
Approximately 5.0V
Go to Step 9
Go to Step 8

8 Repair the open circuit between the ECM and vacuum pressure sensor. Was the problem solved?
6E147
C-57
C-124
9 Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved? Replace the vacuum sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 11
Go to Step 11 -
10 11
Verify repair
Go to Step 12
12
Verify repair
6E148
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit High Input
Go to Step 3
Go to Step 4
C-57
C-124
5 6 Visually check the vacuum pressure sensor. Was the problem found? Using the DVM and check the vacuum pressure sensor power supply circuit. 1. Ignition "On", engine "Off". 2. Disconnect connector. the vacuum pressure sensor -
3. Check the circuit for short to battery voltage circuit. Was the DVM indicated specified value?
C-124
Approximately 5.0V
Go to Step 8
Go to Step 7

7 Repair the short to battery voltage circuit between the ECM and vacuum pressure sensor. Was the problem solved?
6E149
C-57
C-124
8 Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved? Replace the vacuum pressure sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 10
Go to Step 10 -
9 10
Verify repair
Go to Step 11
11
Verify repair
6E150
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Go to Step 3
Go to Step 4
C-57
C-124
5 6 Visually check the vacuum pressure sensor. Was the problem found? Using the DVM and check the vacuum pressure sensor power supply circuit. 1. Ignition "On", engine "Off". 2. Disconnect connector. the vacuum pressure sensor -
3. Check the circuit for short to ground circuit. Was the DVM indicated specified value?
C-124
Approximately 5.0V
Go to Step 10
Go to Step 7

7 Using the DVM and check the vacuum pressure sensor power supply circuit. 1. Ignition "Off", engine "Off". 2. Disconnect the vacuum pressure connector and ECM connector. sensor
6E151
3. Check the circuit for short to vacuum pessure sensor ground circuit. Was the DVM indicated specified value?
C-124
No continuity 8 Repair the circuit for short to vacuum pressure sensor ground. Is the action complete? Repair the short to ground circuit between the vacuum pressure sensor. Was the problem solved? Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
10
Go to Step 12 -
11 12
Verify repair
Go to Step 13
13
Verify repair
6E152
DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 1) (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 2) (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT
Condition for setting the DTC and action taken when the DTC sets
Flash Code 23 Code P0110 Symptom Code 1 2 MIL ON ON DTC Name Intake Air Temperature (IAT) Sensor Circuit High Input Intake Air Temperature (IAT) Sensor Circuit Low Input DTC Setting Condition IAT sensor output voltage is more than 4.7V. IAT sensor output voltage is below 0.3V. Fail-Safe (Back Up) ECM use deg.C conditions as substitute.
Circuit Description
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.

The ECM supplies 5 volts signal to the 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. The output voltage excessively high or low, DTC P0110 (Symptom Code 1) or P0110 (Symptom Code 2) will be stored. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions:
6E153
Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Intake Air Temperature display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections.
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0110 (Symptom Code 1) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0110 (Symptom Code 1) stored in this ignition cycle? 4 Check for poor/faulty connection at the IAT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 C-116
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
84
Visually check the IAT sensor. Was the problem found?
6E154
Step 6

Action Using the DVM and check the IAT sensor. 1. Ignition Off, engine Off. 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) -20 0 20 40 60 80 100 Resistance (W) (Approximately) 13660 5430 2433 1153 598 334 204
Value(s)
Yes
No
IAT Sensor
5 3
1 1
Standard resistance
Go to Step 7
Go to Step 12
Using the DVM and check the IAT sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-116
V
8 Repair the open circuit between the ECM and IAT sensor. Was the problem solved?
C-57(B) C-116
Approximately 5.0V
Go to Step 10
84
Verify repair
Go to Step 14

Step 9 Action Repair the short to voltage circuit between the ECM and IAT sensor. Was the problem solved?
C-57(B) C-116
6E155
No
Value(s)
Yes
84
10 Using the DVM and check the IAT sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-116
Verify repair
Go to Step 14
V
6E156
Step 11

Action Using the DVM and check the IAT sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 4. Check the circuit for open circuit. Was the problem found?
Value(s)
Yes
No
(ECM
3. Disconnect the MAF & IAT sensor connector.
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAF & IAT sensor connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found?
C-57(B) C-116
92
12 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 14
Go to Step 14
13 14
Verify repair
Go to Step 15
15
Verify repair
6E157
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0110 (Symptom Code 2) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0110 (Symptom Code 2) stored in this ignition cycle? 4 Check for poor/faulty connection at the IAT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 C-116
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
84
Verify repair
Go to Step 5
Remove the MAF & IAT sensor assembly and visually check. Was the problem found?
Go to Step 8
Go to Step 6
6E158
Step 6

Action Using the DVM and check the IAT sensor. 1. Ignition Off, engine Off. 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) -20 0 20 40 60 80 100 Resistance (W) (Approximately) 13660 5430 2433 1153 598 334 204
Value(s)
Yes
No
IAT Sensor
5 3
1 1
Standard resistance
Go to Step 7
Go to Step 8

Step 7 Action Using the DVM and check the IAT sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Value(s) Yes
6E159
No
3. Disconnect the MAF & IAT sensor connector. 4. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
Breaker Box 84 92
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAF & IAT sensor connector and ECM connector. 3. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
C-57(B)
92 84
8 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 10
Go to Step 10
9 10
Verify repair
Go to Step 11
11
Verify repair
6E160
DIAGNOSTIC TROUBLE CODE (DTC) P0115 (SYMPTOM CODE 1) (FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0115 (SYMPTOM CODE 2) (FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT
Flash Code 14 Code P0115 Symptom Code 1 MIL ON DTC Name Engine Coolant Temperature (ECT) Sensor Circuit High Input Engine Coolant Temperature (ECT) Sensor Circuit Low Input DTC Setting Condition ECT sensor output voltage is more than 4.7V. ECT sensor output voltage is below 0.3V. Fail-Safe (Back Up) 1. ECM uses fuel temperature as substitute. 2. ECM uses 60 deg.C condition for injection timing control. 3. ECM uses -25 deg.C condition (4JA1-TC) or -15 deg.C condition (4JH1-TC) for glow time control.
ON
Circuit Description
The ECT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other 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 output voltage excessively high or low, DTC P0115 (Symptom Code 1) or P0115 (Symptom Code 2) will be stored. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions:
6E161
Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Coolant Temperature display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 1) (Flash Code 14) Engine Coolant Temperature Sensor Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0115 (Symptom Code 1) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0115 (Symptom Code 1) stored in this ignition cycle? 4 Check for poor/faulty connection at the ECT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 93 1 E-41 2
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
89
Visually check the ECT sensor. Was the problem found?
6E162
Step 6

Action Using the DVM and check the ECT sensor. 1. Ignition Off, engine Off. 2. Disconnect ECT sensor connector. 3. Measure the resistance of ECT sensor. Does the tester indicate standard resistance as shown in the following table?
Temperature (C) -20 0 20 40 60 80 100 120 Resistance (W) (Approximately) 16100 5760 2370 1080 537 290 161 95
Value(s)
Yes
No
ECT Sensor 2 2 1 1
Standard resistance 7 Using the DVM and check the ECT sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E-41
Go to Step 7
Go to Step 12
V
8 Repair the open circuit between the ECM and ECT sensor. Was the problem solved?
C-57(B) E-41
Approximately 5.0V
Go to Step 10
89
Verify repair
Go to Step 14

Step 9 Action Repair the short to voltage circuit between the ECM and ECT sensor. Was the problem solved?
C-57(B) E-41
6E163
No
Value(s)
Yes
89
Verify repair
Go to Step 14
10
Using the DVM and check the ECT sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E-41
V
Less than 1V 11 Using the DVM and check the ECT sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect the ECT sensor connector. 4. Check the circuit for open circuit. Was the problem found?
Breaker Box 93 E-41
Go to Step 11
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECT sensor connector ECM connector. 3. Check the circuit for open circuit. Was the problem found?
C-57 E-41
2 93
Go to Step 14
6E164
Step 12

Action Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Go to Step 14
13 14
Verify repair
Go to Step 15
15
Verify repair
6E165
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 2) (Flash Code 14) Engine Coolant Temperature Sensor Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0115 (Symptom Code 2) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0115 (Symptom Code 2) stored in this ignition cycle? 4 Check for poor/faulty connection at the ECT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 93 1 E-41 2
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
89
Visually check the ECT sensor. Was the problem found?
6E166
Step 6

Action Using the DVM and check the ECT sensor. 1. Ignition Off, engine Off. 2. Disconnect ECT sensor connector. 3. Measure the resistance of ECT sensor. Does the tester indicate standard resistance as shown in the following table?
Value(s)
Yes
No
ECT Sensor 2 2 1 1
Standard resistance
Go to Step 7
Go to Step 8

Step 7 Action Using the DVM and check the ECT sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect the ECT sensor connector. 4. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
Breaker Box 89 93
6E167
No
Value(s)
Yes
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECT sensor connector and ECM connector. 3. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
C-57(B)
93 89
8 Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 10
Go to Step 10
9 10
Verify repair
Go to Step 11
11
Verify repair
6E168
DIAGNOSTIC TROUBLE CODE (DTC) P0180 (SYMPTOM CODE B) (FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE
Flash Code 15 Code P0180 Symptom Code B MIL ON DTC Name Fuel Temperature Sensor Circuit Range/Performance DTC Setting Condition FT sensor output is high temperature (more than 150deg.C) or low temperature (below -40deg.C). Fail-Safe (Back Up) The ECM use 75deg.C conditions as substitute.
Circuit Description
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 fuel temperature is excessively high or low condition, DTC P0180 will be stored.
Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Fuel Temperature display on the Tech2 while
Diagnostic Aids

moving connectors and wiring harness related to the sensor.
6E169
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel Temperature Sensor Circuit Range/Performance
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0180 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0180 (Symptom Code B) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Refer to Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E170
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE B) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE C) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D) (FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Flash Code 52 Code P0215 Symptom Code A MIL ON DTC Name Fuel Cutoff Solenoid Valve Malfunction DTC Setting Condition 1. Ignition key switch off. 2. Engine speed is below 1500rpm. 3. Vehicle speed is below 1.5km/h. 4. PSG (pump control unit) recognizes MAB (fuel cutoff solenoid valve) signal from the ECM, but the MAB could not operate. ECM does not command MAB (fuel cutoff solenoid valve) signal to the PSG (pump control unit), but PSG detected MAB signal line circuit is high level. 1. Ignition key switch off. 2. Engine speed is below 1500rpm. 3. Vehicle speed is below 1.5km/h. 4. PSG (pump control unit) does not recognize MAB (fuel cutoff solenoid valve) signal from the ECM. 1. Ignition key switch off. 2. CAN controller does not operate Bus-off.
6E171
Fail-Safe (Back Up) 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.
ON
Fuel Cutoff Solenoid Valve Circuit High Input
Engine does not start.
ON
Fuel Cutoff Solenoid Valve Always Active
ON
Fuel Cutoff Solenoid Valve Malfunction
Circuit Description
When the ignition switch is turned Off, the fuel solenoid valve (MAB) signal is supplied from the ECM to 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 short to ground circuit, DTC P0215 (Symptom Code B) or P0215 (Symptom Code C) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel Cutoff Solenoid Valve Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0215 (Symptom Code A) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E172
Step 3

Action 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0215 (Symptom Code A) stored in this ignition cycle? Value(s) Yes No
Replace the injection pump assembly. Is the action complete?
6E173
Diagnostic Trouble Code (DTC) P0215 (Symptom Code B) (Flash Code 52) Fuel Cutoff Solenoid Valve Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0215 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0215 (Symptom Code B) stored in this ignition cycle? 4 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
105 C-57 5 E-6
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
5 Visually check the PSG (pump control unit). Was the problem found?
6E174
Step 6

Action Using the DVM and check the MAB (fuel cutoff solenoid valve) circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type B. connected) Ref. Page 6E-104 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
Breaker Box 105
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
C-57
105
V
Less than 1V 7 Repair the short to voltage circuit between the ECM and PSG (pump control unit). Was the problem solved?
C-57 E-6
Go to Step 8
Go to Step 7
5 105
Go to Step 8
6E175
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel Cutoff Solenoid Valve Always Active
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0215 (Symptom Code C) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0215 (Symptom Code C) stored in this ignition cycle? 4 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
105 C-57 5 E-6
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
5 Visually check the PSG (pump control unit). Was the problem found?
6E176
Step 6

Action Using the DVM and check the MAB (fuel cutoff solenoid valve) circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes No
4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 105 E-6
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the PSG (pump control unit) connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-57 E-6
105
7 Replace the injection pump assembly. Is the action complete?
Repair faulty harness and verify repair Verify repair
Go to Step 7
6E177
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel Cutoff Solenoid Valve Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0215 (Symptom Code D) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0215 (Symptom Code D) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E178
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
Flash Code 54 Code P0216 Symptom Code A MIL ON DTC Name Injection Timing Control Circuit Malfunction DTC Setting Condition 1. Engine speed is more than 700rpm. 2. Fuel injection quantity is more than 4mg/stk. 3. Deviation of actual injection timing and desired injection timing is more than +3 deg. CA or -6 deg. CA for 8 seconds. B ON Injection Timing Control Circuit Malfunction 1. Engine speed is more than 2014rpm. 2. Fluctuation of actual injection timing is more than +-5.2 deg. CA. Fail-Safe (Back Up) Fuel injection quantity is reduced.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Circuit Description

The ECM is calculates an injection quantity and an injection timing using the various sensors (crankshaft position sensor, camshaft position sensor, engine coolant temperature sensor, etc.). The timing control valve (TCV) operation performs an injection timing decision. The TCV performs as a variable throttle, using the rapid opening and closing cycle of the valve needle in the TCV. The TCV is assembled in the injection pump. The signal of desired injection timing and actual injection timing are exchanged via the CAN-bus between the PSG and ECM. If the timer position is out of tolerance (deviation or fluctuation), DTC P0216 will be stored. Air bleeding procedure:
6E179
1.Operate the priming pump until strong resistance is felt. 2.Wait 1 minute, and operate the priming pump until strong resistance is felt. 3.Wait 1 minute, and operate the priming pump until strong resistance is felt. 4.Turn the ignition switch to the "ON" position. Wait until the glow indicator lamp turns off. 5.Turn the ignition switch to the "START" position and crank the engine until it starts. 6.If the engine does not start, repeat Step 3 - 5. 7.Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel leakage. Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the "Actual Injection Start" display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Insufficient air bleeding of fuel line. Low fuel quantity in the fuel tank. Check for the following conditions: Insufficient air bleeding of fuel line inside, clogged fuel filter or pinched fuel pipe/hose may cause the DTC store or improper engine performance.
6E180
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54) Injection Timing Control Circuit Malfunction Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54) Injection Timing Control Circuit Malfunction
Step 1 Action Was the "On-Board Diagnostic (OBD) System Check" performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0216 (Symptom Code A) or P0216 (Symptom Code B) stored as "Present Failure"? 3 1. 1Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0216 (Symptom Code A) or P0216 (Symptom Code B) stored in this ignition cycle? 4 Perform the air bleeding in the fuel line sufficiently. Air Bleeding Procedure: 1. Operate the priming pump until strong resistance is felt. 2. Wait 1 minute, and operate the priming pump until strong resistance is felt. 3. Once more wait, and operate the priming pump until strong resistance is felt. 4. Turn the ignition switch to the "ON" position. Wait until the glow indicator lamp turns off. 5. Turn the ignition switch to the "START" position and crank the engine until it starts. 6. If the engine does not start, repeat Step 3 - 5. 7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel leakage. DTC Re-check: 1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0216 (Symptom Code A) or P0216 (Symptom Code B) restored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Go to Step 5
Verify repair

Step 5 Action 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? 6 7 Replace the fuel filter. Was the problem solved? Remove the eye bolt with gauze filter from the injectionpumpandcheckforthefollowingconditions. 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. 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 the problem found? Value(s) Yes
6E181
No
8 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the "SPS (Service Programming System)". Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Replace the eye bolt with gauze filter and verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
6E182
Step 10

Action Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes No
11
6E183
DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 3) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/ PERFORMANCE DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 4) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" LOW DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 5) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/ PERFORMANCE DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 6) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 8) (FLASH CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" HIGH
6E184
Flash Code 64 Code P0243 Symptom Code 3 MIL ON DTC Name Turbocharger Wastegate Solenoid "A" Range/ Performance DTC Setting Condition 1. Intake air temperature is between -50 deg. C and 200 deg. C. 2. Engine coolant temperature is between 50 deg. C and 150 deg. C. 4 ON Turbocharger Wastegate Solenoid "A" Low Wastegate control EVRV circuit open or short to ground circuit. Fail-Safe (Back Up) 1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition.
1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition.
ON
Turbocharger Wastegate Solenoid "A" Range/ Performance
1. Intake air temperature is between -50 deg. C and 200 deg. C. 2. Engine coolant temperature is between 50 deg. C and 150 deg. C.
1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition.
ON
Turbocharger Wastegate Solenoid "A" Malfunction
1. Engine coolant temperature is between 50 deg. C and 150 deg. C. 2. EGR control EVRV 0% condition.
ON
Turbocharger Wastegate Solenoid "A" High
Wastegate control EVRV circuit short to voltage circuit.
1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition.
Circuit description
The ECM monitors altitude from the barometric pressure sensor. To apply specified vacuum pressure to the turbocharger wastegate valve, ECM sends control signal to the wastegate control solenoid depending on altitude. Then, apply vacuum pressure to the turbocharger wastegate valve is monitored by the ECM form the vacuum pressure sensor output signal. The ECM controls wastegate control solenoid based on signal from vacuum pressure sensor output. If the vacuum pressure sensor detected vacuum pressure is excessively low or high due to faulty vacuum line, vacuum pump or turbocharger wastegate valve, DTC P0243 (Symptom Code 3), P0243 (Symptom Code 5) or P0243 (Symptom Code 6) will be stored. If the wastegate control solenoid circuit is open or short to ground circuit, DTC P0243 (Symptom Code 4) will be stored. If the wastegate control solenoid circuit is short to voltage circuit, DTC P0243 (Symptom Code 8) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside insulation. Turbocharger wastegate valve sticking or broken. Misrouted vacuum hose. Faulty vacuum pump or regulating valve. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0243 display on the Tech 2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
6E185
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64) Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Action Was the "On-Board Diagnostic (OBD) System Check" performed?
Value(s)
Yes
Go to Step 2
1. Connect the Tech 2. 2. Review and record the failure information. 3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0243 (Symptom Code 3) stored as "Present Failure"? Refer to Diagnostic Aids and Go to Step 3
Go to Step 3
1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0243 (Symptom Code 3) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4
Go to Step 4
Remove the vacuum hose & vacuum regulating valve and check for the following conditions. Objects blocking the vacuum hose. Objects blocking the vacuumregulating valve. Vacuum leaking at vacuum hose or vacuum regulating valve. Objects blocking at the wastegate solenoidvalve. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 5
Remove the vacuum pressure sensor and visually check. Was the problem found? Substitute a known good vacuum pressure sensor and recheck. Was the problem solved? Replace the vacuum pressure sensor. Is the action complete?
Go to Step 6
Go to Step 8
Go to Step 8 -
6E186
Step
8

Action Using the DVM and check the wastegate control solenoid. 1. Ignition "Off", engine "Off". 2. Disconnect thewastegatesolenoid connector. 3. Measure the resistance of wastegate solenoid coil. Does the tester indicate standard resistance? Value(s) Yes No
Wastegate Solenoid
Approximately 14.7 - 16.1 W at 20C

9
Go to Step 11
Go to Step 9
Substitute a known good wastegate control solenoid and recheck. Was the problem solved? Replace the wastegate control solenoid. Is the action complete? Using the pressure gauge and check the turbocharger wastegate valve operation for broken diaphragm. If a problem is found, repair as necessary. Was a problem found? Replace the turbocharger wastegate valve . Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Go to Step 11 -
10
11
Go to Step 13 -
12
13
Verify repair
Go to Step 14
14
Verify repair
6E187
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Low
Step
1
Value(s)
Yes
Go to Step 2
Go to Step 3
1. 1Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0243 (Symptom Code 4) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4
Go to Step 4
Check for poor/faulty connection at the wastegate control solenoid or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57
C-123
Verify repair
Go to Step 5
Using the DVM and check the wastegate control solenoid. 1. Ignition "Off", engine "Off". 2. Disconnect thewastegatesolenoid connector. 3. Measure the resistance of wastegate solenoid coil. Does the tester indicate standard resistance?
Wastegate Solenoid
Go to Step 6
Go to Step 9
6E188
Step
6

Action Using the DVM and check the wastegate control solenoid power supply circuit. 1. Ignition "On", engine "Off". 2. Remove the wastegate connector. control solenoid Value(s) Yes No
3. Check the circuit for open circuit. Was the DVM indicated specified value?
7
10 - 14.5V
Go to Step 8
Go to Step 7
Repair the open circuit between the ECM main relay and wastegate control solenoid. Is the action complete? Using the DVM and check the wastegate control solenoid circuit. Breaker box is available: 1. Ignition "Off", engine "Off". 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM
Verify repair
3. Removethewattagecontrolsolenoid connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 96
C-123
Breaker box is not available: 1. Ignition "Off", engine "Off". 2. Disconnect the ECM connector. 3. Remove the connector. wastegate control solenoid
C-57
C-123
Go to Step 11
Substitute a known good wastegate control solenoid and recheck. Was the problem solved? Replace the wastegate control solenoid. Is the action complete?
Go to Step 11 -
10

Step
11
6E189
No
Action 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Value(s)
Yes
Verify repair
Go to Step 12
12
Verify repair
6E190
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Value(s)
Yes
Go to Step 2
Go to Step 3
1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0243 (Symptom Code 5) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4
Go to Step 4
Visually check the vacuum regulating valve. If a problem is found, repair as necessary. Was the problem found? Using the DVM and check the wastegate control solenoid. 1. Ignition "Off", engine "Off". 2. Disconnect thewastegatesolenoid connector. 3. Measure the resistance of wastegate solenoid coil. Does the tester indicate standard resistance?
Verify repair
Go to Step 5
Wastegate Solenoid

6
Go to Step 8
Go to Step 6
Substitute a known good wastegate control solenoid and recheck. Was the problem solved? Replace the wastegate control solenoid. Is the action complete? Using the pressure gauge and check the turbocharger wastegate valve operation for broken diaphragm. If a problem is found, repair as necessary. Was a problem found? Replace the turbocharger Is the action complete? wastegate valve .
Go to Step 8 -
Go to Step 10 -

Step
10
6E191
No
Action Check for poor/faulty connection at the vacuum pressure sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
Value(s)
Yes
C-57
C-123
11
Visually check the vacuum pressure sensor. Was the problem found? Using the DVM and check the vacuum pressure sensor signal circuit. 1. Ignition "On", engine "Off". 2. Disconnect connector. the vacuum pressure sensor
12
C-124
Less than 1V
13
Go to Step 15
Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved? Replace the vacuum pressure sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Go to Step 15 -
14
15
Verify repair
Go to Step 16
16
Verify repair
6E192
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Malfunction
Step
1
Value(s)
Yes
Go to Step 2
Go to Step 3
1. 1Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0243 (Symptom Code 6) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4
Go to Step 4
Visually check the turbocharger wastegate valve and hose. If the hose is clogged or disconnected, repair as necessary. Was the problem found? Using the pressure gauge and check the turbocharger wastegate valve operation for broken diaphragm or restrict shaft operation. If a problem is found, repair as necessary. Was a problem found? Replace the turbocharger wastegate valve. Is the action complete? Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 5
Go to Step 7 -
C-57
C-116

Step
9
6E193
No
Action Using the DVM and check the MAF sensor signal circuit. 1. Ignition "On", engine "Off". 2. Disconnect the MAF sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
Value(s)
Yes
C-116
Less than 1V
10
Go to Step 12
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & Is the action complete? IAT sensor assembly.
Go to Step 12 -
11
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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 13
13
Verify repair
6E194
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64) Turbocharger Wastegate Solenoid "A" High
Step
1
Value(s)
Yes
Go to Step 2
Go to Step 3
1. Using the Tech 2, ignition "On" and engine "Off". 2. Select "F1: Clear DTC Information" in "F0: Diagnostic Trouble Codes" with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the "F0: Read DTC Infor As Stored By ECU" in the "F0: Diagnostic Trouble Codes". Was the DTC P0243 (Symptom Code 8) stored in this ignition cycle?
Go to Step 4
Check for poor/faulty connection at the wastegate control solenoid or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? Using the DVM and check the wastegate control solenoid. 1. Ignition "Off", engine "Off". 2. Disconnect thewastegatesolenoid connector. 3. Measure the resistance of wastegate solenoid coil. Does the tester indicate standard resistance?
Verify repair
Go to Step 5
Wastegate Solenoid
Approximately 14.7- 16.1 W at 20C
Go to Step 6
Go to Step 8

Step
6
6E195
No
Action Using the DVM and check the wastegate control solenoid circuit. 1. Ignition "Off", engine "Off". 2. Remove the wastegate control solenoid connector and ECM connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
Value(s)
Yes
C-123
No continuity
7
Go to Step 7 -
Repair the short Is the action complete?
to
voltage
circuit. -
Substitute a known good wastegate control solenoid and recheck. Was the problem solved? Replace the wastegate control solenoid. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.
Go to Step 10 -
10
Verify repair
Go to Step 11
11
Verify repair
6E196
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 6) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 7) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE 9) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE A) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE B) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE D) (FLASH CODE 53) INJECTION PUMP MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E) (FLASH CODE 53) INJECTION PUMP MALFUNCTION
Flash Code 53 Code P0251 Symptom Code 6 MIL ON DTC Name Injection Pump Malfunction DTC Setting Condition 1. No pump camshaft speed sensor error. 2. High pressure solenoid valve control pulse width does not match with desired fuel injection quantity. 1. No pump camshaft speed sensor error. 2. No CKP sensor error. 3. Difference of engine speed and doubled pump camshaft speed is more than 720rpm (4JA1-TC) or 690 rpm (4JH1-TC). No pump map programmed in the PSG (pump control unit) or PSG malfunction. EEPROM or A/D converter malfunction in the PSG (pump control unit). PSG (pump control unit) recognized high pressure solenoid valve drive circuit error. PSG (pump control unit) could not measure the high pressure solenoid valve drive voltage. ECM could not accept PSG (pump control unit) message.
6E197
Fail-Safe (Back Up) 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.
ON
ON
ON
Fuel injection quantity is reduced. No fail-safe function.
ON
ON
ON
Circuit Description
The ECM is calculates an injection quantity and an injection timing using the various sensors. And the PSG controls the high pressure solenoid valve depending on programmed pump map data. The signal of desired injection quantity and actual injection quantify are exchanged via the CAN-bus between the PSG and ECM. If the relation of engine speed signal and doubled pump camshaft speed signal excessively large, DTC P0251 (Symptom Code 7) will be stored. If the CAN high or low circuit is defected, DTC P0251 (Symptom Code E) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Injection Quantity display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 6) (Flash Code 53) Injection Pump Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
6E198
Step 2

Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code 6) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Value(s) Yes No
Go to Step 3
1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code 6) stored in this ignition cycle?
6E199
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code 7) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code 7) stored in this ignition cycle? 4 Was the DTC P0335 (Symptom Code B), P0335 (Symptom Code D) or P1335 (Symptom Code A) stored at the same time? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Go to DTC Chart P0335 (Symptom Code B) (Symptom Code D) or P1335 (Symptom Code A)
5 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-57(B) 91 E-6
Go to Step 5
Verify repair
Go to Step 6
6E200
Step 6

Action If a oscilloscope is available, monitor the CKP sensor output signal. Does the oscilloscope indicate correct wave form?
Value(s)
Yes
No
CH1 0V
CH2 0V
Go to Step 13
Not available: Go to Step 7 Fixed at low: Go to Step 7 Fixed at High: Go to Step 8

Step 7 Action Using the DVM and check the CKP sensor output circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes
6E201
No
Breaker Box 91 E-6
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Disconnect connector. the PSG (pump control unit)
C-57(B) E-6
91
8 Using the DVM and check the CKP sensor output circuit. 1. Ignition On, engine Off. 2. Disconnect connector. the PSG (pump control unit)
Go to Step 8
E-6
V
6E202
Step 9

Action Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes Remove the accessory parts and verify repair No
Go to Step 10
10
Verify repair
Go to Step 11
11
Go to Step 12
Go to Step 13
12
13
6E203
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code 9) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code 9) stored in this ignition cycle? 4 Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E204
Diagnostic Trouble Code (DTC) P0251 (Symptom Code A) (Flash Code 53) Injection Pump Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code A) stored in this ignition cycle? 4 Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E205
Diagnostic Trouble Code (DTC) P0251 (Symptom Code B) (Flash Code 53) Injection Pump Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code B) stored in this ignition cycle? 4 Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E206
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53) Injection Pump Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code D) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code D) stored in this ignition cycle? 4 Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E207
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53) Injection Pump Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0251 (Symptom Code E) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0251 (Symptom Code E) stored in this ignition cycle? 4 Was the DTC P1650 (Symptom Code A) or P1651 (Symptom Code B) stored at the same time? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Go to DTC Chart P1650 (Symptom Code A)
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
6E208
DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE B) (FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE D) (FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE E) (FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
Flash Code 43 Code P0335 Symptom Code B MIL ON DTC Name Crankshaft Position Sensor Circuit Malfunction DTC Setting Condition 1. Engine speed is more than 665rpm. 2. CKP sensor pulse width error.
6E209
Fail-Safe (Back Up) When pump camshaft speed sensor is OK: ECM uses doubled pump camshaft speed as substitute engine speed. When pump camshaft speed sensor is not OK: 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. When pump camshaft speed sensor is OK: ECM uses doubled pump camshaft speed as substitute engine speed. Other than pump camshaft speed sensor is OK: Fuel injection quantity is reduced. When intermittent malfunction: 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. When preliminary malfunction: ECM uses doubled pump camshaft speed as substitute engine speed.
ON
Crankshaft Position Sensor Circuit Malfunction
1. No pump camshaft speed sensor error. 2. Crankshaft Position Sensor Circuit Malfunction (Symptom Code B) is not stored. 3. Engine speed is 0rpm. 4. Doubled pump camshaft speed is more than 50rpm. Engine speed is more than 5700rpm.
ON
Engine Speed Input Circuit Range/Performance
Circuit Description
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. If the CKP sensor harness or sensor malfunction is detected during engine run, DTC P0335 (Symptom Code B) is stored. If the CKP sensor harness or sensor malfunction is detected during engine cranking, DTC P0335 (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.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Engine Speed display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43) Crankshaft Position Sensor Circuit Malfunction Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43) Crankshaft Position Sensor Malfunction
6E210
Step 2

Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0335 (Symptom Code B) or P0335 (Symptom Code D) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Value(s) Yes No
Go to Step 3
1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0335 (Symptom Code B) or P0335 (Symptom Code D) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4
Go to Step 4
Check for poor/faulty connection at the CKP sensor or ECM connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-57(B) 101 98 90 1 E-9 2 3
5 Visually check the CKP sensor. If a faulty installation is found, repair as necessary. Was the problem found? Using the DVM and check the CKP sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
Breaker Box 90 98
Verify repair
Go to Step 5
Verify repair
Go to Step 6
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
C-57(B) 98
90
Approximately 0.9k9 at 20C
Go to Step 10
Go to Step 7

Step 7 Action Using the DVM and check the CKP sensor circuit. 1. Ignition Off, engine Off. 2. Disconnect the CKP sensor connector. 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
E-9
6E211
No
Value(s)
Yes
Approximately 0.9k9 at 20C
Go to Step 8
Go to Step 14
Using the DVM and check the CKP sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM
3. Disconnect the CKP sensor connector. 4. Check the circuit for open, short to sensor wire or short to ground circuit. Was the problem found?
90
Breaker Box 98
101
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Disconnect the CKP sensor connector. 4. Check the circuit for open, short to sensor wire or short to ground circuit. Was the problem found?
Breaker Box 90 98 E-9
Go to Step 9
6E212
Step 9

Action Using the DVM and check the CKP sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the CKP sensor connector. 3. Check the circuit for short to power supply circuit. If the DVM indicated out of specified value, repair faulty harness and verify repair. Is the action complete?
E-9
Value(s)
Yes
No
V
10
V
Less than 1V Verify repair
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 At CKP sensor terminal 2 & 1 At ECM C57 connector 90 & 98 Voltage (V) (AC Range) Approximately 1.1 V at 2000rpm
If a oscilloscope is available, monitor the CKP sensor signal. Does the oscilloscope indicate correct wave form?
0V
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. If a problem is found, repair as necessary. Was the problem found?
Verify repair Repair faulty harness and verify repair
Go to Step 12
12
Check the CKP sensor shield wire for open or short circuit. Was the problem found?
Go to Step 13

Step 13 Action Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Was the problem solved? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Remove the accessory parts and verify repair Go to Step 15 Verify repair
6E213
No
14 15 16
Verify repair
Go to Step 17
17
Verify repair
6E214
Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43) Engine Speed Input Circuit Range/Performance
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0335 (Symptom Code E) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0335 (Symptom Code E) stored in this ignition cycle? 4 Ask to the customer whether over-speed condition such as miss-gear shifting etc. has been experienced or not. Check for poor/faulty connection at the CKP sensor or ECM connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-57(B) 101 98 90 1 E-9 2 3
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4 Explain the reason of DTC to the customer
Go to Step 5
Verify repair
Go to Step 6

Step 6 Action 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 At CKP sensor terminal 2 & 1 At ECM C57 connector 90 & 98 Voltage (V) (AC Range) Approximately 1.1 V at 2000rpm
6E215
No
Value(s)
Yes
If a oscilloscope is available, monitor the CKP sensor signal. Does the oscilloscope indicate correct wave form?
0V
Go to Step 9
Go to Step 7
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. If a problem is found, repair as necessary. Was the problem found?
Verify repair Repair faulty harness and verify repair Remove the accessory parts and verify repair Go to Step 11 Verify repair
Go to Step 8
Check the CKP sensor shield wire for open or short circuit. Was the problem found? Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Was the problem solved? 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?
Go to Step 9
10 11 12
Verify repair
Go to Step 13
6E216
Step 13

Action Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Verify repair
6E217
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 4) (FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 8) (FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Flash Code 66 Code P0380 Symptom Code 4 8 MIL ON ON DTC Name Glow Relay Circuit Voltage Low Glow Relay Circuit Voltage High DTC Setting Condition Glow relay circuit open or short to ground circuit. Glow relay circuit short to voltage circuit. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The voltage on the coil of the relay glow plug is supplied by the relay engine control module (ECM) main. The ECM switches glow relay to operate glow plug depends on the coolant temperature. In the after glow phase the lamp is not illuminated but the glow plugs remain active for a certain period depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions:
6E218

Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0380 display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66) Glow Relay Circuit Voltage Low
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0380 (Symptom Code 4) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0380 (Symptom Code 4) stored in this ignition cycle? 4 Check for poor/faulty connection at the glow relay or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57 1 2 X-5 3 4
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
94
Verify repair
Go to Step 5
Using the DVM and check the glow relay. 1. Ignition Off, engine Off. 2. Remove the glow relay from the relay box. 3. Check the relay coil. Was the DVM indicated specified value?
Grow Relay
Approximately 1059
Go to Step 6
Replace glow relay and verify repair

Step 6 Action Using the DVM and check the glow relay power supply circuit. 1. Ignition On, engine Off. 2. Remove the glow relay from the relay box. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
X-5 2
6E219
No
Value(s)
Yes
V
10-14.5V 7 Repair the open or short to ground circuit between the ECM main relay and glow relay. Is the action complete? Using the DVM and check the glow relay ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Go to Step 8 Go to Step 7
Verify repair
3. Remove the glow relay from the relay box. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 94 X-5
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the glow relay from the relay box. 4. Check the circuit for open or short to ground circuit. Was the problem found?
C-57 X-5 3
94
Go to Step 9
6E220
Step 9

Action 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Verify repair
Go to Step 10
10
Verify repair
6E221
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66) Glow Relay Circuit Voltage High
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0380 (Symptom Code 8) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0380 (Symptom Code 8) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E222
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67) GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67) GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Flash Code 67 Code P0381 Symptom Code 4 MIL ON DTC Name Glow Plug Indicator Circuit Voltage Low Glow Plug Indicator Circuit Voltage High DTC Setting Condition Glow plug indicator circuit open or short to ground circuit. Glow plug indicator circuit short to voltage circuit. Fail-Safe (Back Up) No fail-safe function.
ON
Circuit Description
The function of the glow time indicator lamp is to inform the driver whether the glow system is activated. When the lamp turned off, the engine can be started. This does not imply that the glow plugs are no longer activated. In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness.

Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
6E223
Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0381 display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67) Glow Plug Indicator Circuit Voltage Low
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0381 (Symptom Code 4) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0381 (Symptom Code 4) stored in this ignition cycle? 4 1. Ignition On, engine Off. 2. Check the glow plug indicator lamp. Does the lamp turn On? 1. Ignition On, engine Off. 2. Check the glow plug indicator lamp. Does the lamp turn Off? 6 Check the glow plug indicator lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found? Go to Step 9 Go to Step 7 Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Verify repair
Go to Step 7
6E224
Step 7

Action Check for poor/faulty connection at the meter connector and ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56 43
Value(s)
Yes
No
B-24
30
Verify repair
Go to Step 8
Using the DVM and check the glow time telltale circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Remove the meter connector. (ECM
Breaker Box 43 B-24
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
C-56
43 6 B-24
Go to Step 9

Step 9 Action 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E225
No
Verify repair
Go to Step 10
10
Verify repair
6E226
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67) Glow Plug Indicator Circuit Voltage High
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E227
DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 3) (FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE DETECTED DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 4) (FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO GROUND OR OPEN CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 5) (FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT DETECTED DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE 8) (FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO BATTERY
6E228
Flash Code 32 Code P0400 Symptom Code 3 MIL ON DTC Name Exhaust Gas Recirculation Flow Excessive Detected DTC Setting Condition 1. Intake air temperature is between 15 deg.C and 100 deg.C. 2. Engine coolant temperature is between 55 deg.C and 100 deg.C (4JA1-TC) or 35 deg.C and 100 deg.C (4JH1-TC). 3. Barometric pressure is between 850hpa and 1100hpa. 4. Small amount of mass air flow. (Desired mass air flow - mass air flow is more than 150mg/strk) EGR EVRV circuit open or short to ground circuit. 1. Intake air temperature is between 15deg.C and 100 deg.C. 2. Engine coolant temperature is between 55 deg.C and 100 deg.C (4JA1-TC) or 35 deg.C and 100 deg.C (4JH1-TC). 3. Barometric pressure is between 850hpa and 1100hpa. 4. Large mount of mass air flow. (Desired mass air flow - mass air flow is below 150 mg/strk) EGR EVRV circuit short to voltage circuit. Fail-Safe (Back Up) Fuel injection quantity is reduced.
ON
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit Exhaust Gas Recirculation Flow Insufficient Detected
Fuel injection quantity is reduced and EGR EVRV 10% conditions as substitute. Fuel injection quantity is reduced.
ON
ON
Exhaust Gas Recirculation Circuit Short to Battery
Fuel injection quantity is reduced & EGR EVRV 10% conditions as substitute.
Circuit Description
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. 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. If the EGR EVRV circuit is open or short ground circuit, DTC P0400 (Symptom Code 4) is stored. If the EGR EVRV circuit is short to voltage circuit, DTC P0400 (Symptom Code 8) is stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. EGR valve sticking. Faulty intake air duct connection. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0400 display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
6E229
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32) Exhaust Gas Recirculation Flow Excessive Detected
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0400 (Symptom Code 3) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0400 (Symptom Code 3) stored in this ignition cycle? 4 Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAF sensor. Vacuum leaking at intake duct. Objects blocking the turbocharger. If a problem is found, repair as necessary. Was the problem found? 5 Remove the MAF & IAT sensor assembly and visually check. Was the problem found? Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? Using the DVM and check the EGR EVRV. 1. Ignition Off, engine Off. 2. Disconnect the EGR EVRV connector. 3. Measure the resistance of EGR EVRV solenoid coil. Does the tester indicate standard resistance?
EGR EVRV 2 2 1 1
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 8
7 8
Approximately 149 at 20C
Go to Step 11
Go to Step 9
6E230
Step 9 10 11

Action Substitute a known good EGR EVRV and recheck. Was the problem solved? Replace the EGR EVRV. Is the action complete? Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2: 1. Using the Tech 2, ignition "On" and engine "On". 2. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 3. Operate the Tech 2 in accordance with procedure. Solenoid 95%: EGR Valve Open Solenoid 5%: EGR Valve Close Vacuum Pump: 1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure. Vacuum Apply: EGR Valve Open Vacuum Release: EGR Valve Close Value(s) Yes Go to Step 10 Verify repair No Go to Step 11
Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 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. Was the problem found? 13 Replace the EGR valve. Is the action complete?
Verify repair or Go to Step 13
Go to Step 12
Verify repair or Go to Step 13 Verify repair
Go to Step 14

6E231
No
Verify repair
Go to Step 15
15
Verify repair
6E232
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0400 (Symptom Code 4) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0400 (Symptom Code 4) stored in this ignition cycle? 4 Check for poor/faulty connection at the EGR EVRV or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57 C-115
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
1 97
Verify repair
Go to Step 5
Using the DVM and check the EGR EVRV. 1. Ignition Off, engine Off. 2. Disconnect the EGR EVRV connector. 3. Measure the resistance of EGR EVRV solenoid coil. Does the tester indicate standard resistance?
EGR EVRV 2 2 1 1
Go to Step 6
Go to Step 9

Step 6 Action Using the DVM and check the EGR EVRV power supply circuit. 1. Ignition On, engine Off. 2. Remove the EGR EVRV connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-115
6E233
No
Value(s)
Yes
V
10-14.5 V 7 Repair the open circuit between the ECM main relay and EGR EVRV. Is the action complete? Using the DVM and check the EGR EVRV circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Go to Step 8 Go to Step 7
Verify repair
3. Remove the EGR EVRV connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the EGR EVRV connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
C-57 C-115 2
97
9 Substitute a known good EGR EVRV and recheck. Was the problem solved?
Repair faulty harness and verify repair Go to Step 10
6E234
Step 10 11

Action Replace the EGR EVRV. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Verify repair No
Verify repair
Go to Step 12
12
Verify repair
6E235
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32) Exhaust Gas Recirculation Flow Insufficient Detected
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0400 (Symptom Code 5) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0400 (Symptom Code 5) stored in this ignition cycle? 4 Visually check the EGR control vacuum hose. If the hose is clogged or disconnected, repair as necessary. Was the problem found? Using the DVM and check the EGR EVRV. 1. Ignition Off, engine Off. 2. Disconnect the EGR EVRV connector. 3. Measure the resistance of EGR EVRV solenoid coil. Does the tester indicate standard resistance?
EGR EVRV 2 2 1 1
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Approximately 149 at 20C 6 7 Substitute a known good EGR EVRV and recheck. Was the problem solved? Replace the EGR EVRV. Is the action complete?
Go to Step 8 Go to Step 7 Verify repair
6E236
Step 8

Action Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2: 3. Using the Tech 2, ignition "On" and engine "On". 4. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 5. Operate the Tech 2 in accordance with procedure. Solenoid 95%: EGR Valve Open Solenoid 5%: EGR Valve Close Vacuum Pump: 1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure. Vacuum Apply: EGR Valve Open Vacuum Release: EGR Valve Close Value(s) Yes No
Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 9 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. Was the problem found? 10 Replace the EGR valve. Is the action complete?
Verify repair or Go to Step 10
Go to Step 9
Verify repair or Go to Step 10 Verify repair
Go to Step 11 -

Step 11 Action Check for poor/faulty connection at the MAF sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57(B) 92 2 3 C-116 4 5
6E237
No
Value(s)
Yes
88
83
12 13
Visually check the MAF sensor. Was the problem found? Using the DVM and check the MAF sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the MAF sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-116
V
Less than 1V 14 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 16
Go to Step 16
15 16
Verify repair
Go to Step 17
17
Verify repair
6E238
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Battery
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0400 (Symptom Code 8) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0400 (Symptom Code 8) stored in this ignition cycle? 4 Check for poor/faulty connection at the EGR EVRV or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57 C-115
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
1 97
Verify repair
Go to Step 5
Using the DVM and check the EGR EVRV. 1. Ignition Off, engine Off. 2. Disconnect the EGR EVRV connector. 3. Measure the resistance of EGR EVRV solenoid coil. Does the tester indicate standard resistance?
EGR EVRV 2 2 1 1
Go to Step 6
Go to Step 8

Step 6 Action Using the DVM and check the EGR EVRV circuit. 1. Ignition Off, engine Off. 2. Remove the EGR EVRV connector and ECM connector. 3. 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
C-115
6E239
No
Value(s)
Yes
No continuity 7 8 9 10 Repair the short to voltage circuit. Is the action complete? Substitute a known good EGR EVRV and recheck. Was the problem solved? Replace the EGR EVRV. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 10 Verify repair Go to Step 9 Verify repair
Verify repair
Go to Step 11
11
Verify repair
6E240
DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE 1) (FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE A) (FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY TOO HIGH DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYMPTOM CODE B) (FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Flash Code 24 Code P0500 Symptom Code 1 MIL ON at next ignition cycle ON at next ignition cycle ON at next ignition cycle DTC Name Vehicle Speed Sensor Circuit High Input DTC Setting Condition Vehicle speed is more than 200km/h.
6E241
Fail-Safe (Back Up) ECM uses vehicle speed 5km/ h condition as substitute.
Vehicle Speed Sensor Input Signal Frequency Too High
Input signal frequency is too high.
ECM uses vehicle speed 5km/ h condition as substitute.
Vehicle Speed Sensor Incorrect Signal
1. Engine speed is more than 3200rpm (4JA1-TC) or 3600rpm (4JH1-TC). 2. Fuel injection quantity is more than 30mg/strk (4JA1-TC) or 41mg/strk (4JH1-TC). 3. Vehicle speed is below 1.5km/h.
Fuel injection quantity is reduced.
Circuit Description
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 pulse signal. The 12 volts operating supply from the meter fuse. The engine control module (ECM) calculates the vehicle speed by VSS.
Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0500 display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24) Vehicle Speed Sensor Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0500 (Symptom Code 1) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0500 (Symptom Code 1) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
6E242
Step 4 5

Action Perform test drive and check the speed meter. Does the speed meter indicate correct vehicle speed. 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? Remove the VSS from the housing case and visually check. Was the problem found? Using the DVM and check the VSS signal. 1. Ignition On, vehicle Run (lift up). 2. Measure the VSS output voltage at sensor, TCM (A/T 2WD), meter and ECM. Does the tester indicate specified value?
Measurement Position VSS terminal 3 & GND TCM C94 connector 10 & GND (A/T 2WD) Meter B24 connector 9 & GND Meter B24 connector 10 & GND ECM C56 connector 68 & GND Voltage (V) (AC Range) Approximately 6.0 V at 20km/h If No Good Go to Step 8 Go to Step 9 Go to Step 10 Go to Step 12 Go to Step 13
Value(s)
Yes Go to Step 5
No Go to Step 6
Go to Step 15
Go to Step 7
Go to Step 8
Go to Step 7
If a oscilloscope is available, monitor the VSS signal at each connector connection. Does the oscilloscope indicate correct wave form?
0V
Refer to Diagnostic Aids and Go to Step 15 Verify repair
Refer the table
8 9
Replace the VSS. Is the action complete? Replace the TCM. Is the action complete? IMPORTANT: The replacement TCM must be programmed. SPS (Service Programming System) is necessary.
Verify repair

Step 10 Action Using the DVM and check the VSS signal circuit. 1. Ignition On, engine Off. 2. Disconnect the meter connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-24
6E243
No
Value(s)
Yes
V
Less than 1V 11 Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the VSS connector and meter connector. 3. Check the circuit for open or short to ground circuit. If a open or short to ground circuit is found, repair the faulty harness and verify repair. Is the action complete?
B-24 E-44 3
Go to Step 11
12 13 Replace the speed meter. Is the action complete? Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the connector. 3. Ignition On. meter connector and ECM
B-24
10
V
6E244
Step 14

Action Using the DVM and check the VSS signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect the meter connector. 4. Check the circuit for open or shot to ground circuit. Was the problem found?
Breaker Box 68 B-24
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect connector. the meter connector and ECM
C-56
68
B-24
10
Go to Step 15
Verify repair
Go to Step 16
16
Verify repair
6E245
Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24) Vehicle Speed Sensor Input Signal Frequency Too High
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0500 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0500 (Symptom Code A) stored in this ignition cycle? 4 5 Perform test drive and check the speed meter. Does the speed meter indicate correct vehicle speed. 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? Remove the VSS from the housing case and visually check. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Go to Step 6 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 10
Go to Step 7
Go to Step 8
Go to Step 7
6E246
Step 7

Action Using the DVM and check the VSS signal. 1. Ignition On, vehicle Run (lift up). 2. Measure the VSS output voltage at sensor, TCM (A/T 2WD), meter and ECM. Does the tester indicate specified value?
Measurement Position VSS terminal 3 & GND TCM terminal A10 & B5 (A/T 2WD) Meter B24 connector 9 & GND Meter B24 connector 10 & GND ECM C56 connector 68 & GND Voltage (V) (AC Range) Approximately 6.0 V at 20km/h If No Good Go to Step 8 Go to Step 9 Go to Step 10 Go to Step 11 Go to Step 10
Value(s)
Yes
No
0V
Refer the table
8 9
Replace the VSS. Is the action complete? Replace the TCM. Is the action complete? IMPORTANT: The replacement TCM must be programmed. SPS (Service Programming System) is necessary. Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? Replace the speed meter. Is the action complete? 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 Remove the accessory parts and verify repair Verify repair
10
Go to Step 12
11 12
Verify repair
Go to Step 13

6E247
No
Verify repair
6E248
Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24) Vehicle Speed Sensor Incorrect Signal
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0500 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0500 (Symptom Code B) stored in this ignition cycle? 4 5 Perform test drive and check the speed meter. Does the speed meter indicate correct vehicle speed. 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? Check for poor/faulty connection at the VSS, TCM (A/ T 2WD) and meter connectors. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
E-44 1 3
Value(s)
Yes
Go to Step 2
Go to Step 3
Refer to Diagnostic Aids and Go to Step 4 Go to Step 6
Go to Step 17
Go to Step 7
2 B-24 9 10
C-94(10)
10
Verify repair
Go to Step 8

Step 7 Action Check for poor/faulty connection at the ECM and other connectors. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-56
6E249
No
Value(s)
Yes
68
Verify repair
Go to Step 9
Remove the VSS from the housing case and visually check. Was the problem found? Using the DVM and check the VSS signal. 1. Ignition On, vehicle Run (lift up). 2. Measure the VSS output voltage at sensor, TCM (A/T 2WD), meter and ECM. Does the tester indicate specified value?
Measurement Position VSS terminal 3 & GND TCM C94 connector 10 & GND (A/T 2WD) Meter B24 connector 9 & GND Meter B24 connector 10 & GND ECM C56 connector 68 & GND Voltage (V) (AC Range) Approximately 6.0 V at 20km/h If No Good Go to Step 10 Go to Step 11 Go to Step 12 Go to Step 14 Go to Step 15
Go to Step 10
Go to Step 9
0V
Refer the table
10
Replace the VSS. Is the action complete?
6E250
Step 11

Action Replace the TCM. Is the action complete? IMPORTANT: The replacement TCM must be programmed. SPS (Service Programming System) is necessary. Using the DVM and check the VSS signal circuit. 1. Ignition On, engine Off. 2. Disconnect the meter connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-24
Value(s)
Yes
No
Verify repair
12
V
Less than 1V 13 Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the VSS connector connector. and meter Go to Step 13
3. Check the circuit for open or short to ground circuit. If a open or short to ground circuit is found, repair the faulty harness and verify repair. Is the action complete?
B-24 E-44 3
14 Replace the speed meter. Is the action complete?

Step 15 Action Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-24
6E251
No
Value(s)
Yes
and
ECM
10
V
Less than 1V 16 Using the DVM and check the VSS signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Go to Step 16
3. Disconnect the meter connector. 4. Check the circuit for open or shot to ground circuit. Was the problem found?
Breaker Box 68 B-24
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the meter connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-56
68
B-24
10
Go to Step 17
6E252
Step 17

Action 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Verify repair
Go to Step 18
18
Verify repair
6E253
DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE 1) (FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE 2) (FLASH CODE 35) SYSTEM VOLTAGE TOO LOW DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE A) (FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION
Flash Code 35 Code P0560 Symptom Code 1 2 A MIL OFF OFF OFF DTC Name System Voltage Too High System Voltage Too Low System Voltage Malfunction DTC Setting Condition System voltage is more than 20V. System voltage is below 7V. System voltage of PSG (pump control unit) is below 4.5V or more than 27V. PSG uses default voltage as substitute. Fail-Safe (Back Up) ECM uses 9V conditions as substitute.
Circuit Description
The ECM and PSG monitors the system voltage on the ignition feed terminal to the ECM or PSG. The system
voltage to the ECM excessively high or low, DTC P0560 (Symptom Code 1) or P0560 (Symptom Code 2) will be stored. The system voltage to the PSG excessively high
6E254

Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the System Voltage display on the Tech2 while moving connectors and wiring harness related to the sensor.
or low, DTC P0560 (Symptom Code A) will be stored.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35) System Voltage Too High
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0560 (Symptom Code 1) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0560 (Symptom Code 1) stored in this ignition cycle? 4 5 Was the battery connecting? jump start cable incorrectly Refer to Diagnostic Aids and Go to Step 4 Go to Step 5 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Verify procedure
1. Using the Tech 2, ignition On and engine On. 2. Monitor the System Voltage in the data display. 3. Load the electrical system by turning on the headlights, etc.. Does the Tech 2 indicate correct ignition voltage? Check the charging system
10 - 14.5V
Go to Step 6
Verify repair
Go to Step 7

6E255
No
Verify repair
6E256
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35) System Voltage Too Low
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0560 (Symptom Code 2) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0560 (Symptom Code 2) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine On. 2. Monitor the System Voltage in the data display. 3. Load the electrical system by turning on the headlights, etc.. Does the Tech 2 indicate enough ignition voltage? 5 Using the DVM and check the battery voltage at the battery terminal. Does the tester indicate enough battery voltage? 10 - 14.5V 6 Check for poor/faulty connection at the ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56 3
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
10 - 14.5V
Go to Step 6
Go to Step 5 Check the charging system, charge or replace the battery
Go to Step 6
56
Verify repair
Go to Step 7

Step 7 Action Using the DVM and check the ECM main relay. 1. Ignition Off, engine Off. 2. Remove the ECM main relay from the relay box. 3. Check the relay coil. Was the DVM indicated specified value? Value(s) Yes
6E257
No
ECM Main Relay

120-1509 8 Check for poor/faulty connection of the ECM ground at the body. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-109
Go to Step 8
Replace ECM main relay and verify repair
Verify repair
Go to Step 9
Verify repair
Go to Step 10
10
Verify repair
6E258
Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35) System Voltage Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0560 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0560 (Symptom Code A) stored in this ignition cycle? 4 Check for poor/faulty connection at the PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-6 6
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Using the DVM and check the PSG (pump control unit) power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the PSG (pump control unit) connector. 3. Check the PSG (pump control unit) power supply circuit. Was the DVM indicated specified value?
6
E-6
V
7
10 - 14.5V
Go to Step 7
Go to Step 6

Step 6 Action 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. Was the problem found?
E-10
6E259
No
Value(s)
Yes
7 Replace the injection pump assembly. Is the action complete?
Go to Step 7
6E260
DIAGNOSTIC TROUBLE CODE (DTC) P0561 (SYMPTOM CODE A) (FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0561 (SYMPTOM CODE B) (FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Flash Code 18 Code P0561 Symptom Code A MIL OFF DTC Name Ignition Switch Circuit Malfunction Ignition Switch Circuit Malfunction DTC Setting Condition The ECM recognized ignition switch turn off signal during ECM is activated. Ignition switch circuit is malfunction. Fail-Safe (Back Up) ECM stops engine.
OFF
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Circuit Description

The ECM monitors the ignition switch signal on the feed terminal to the ECM. If the ignition switch signal with malfunction, DTC P0561 (Symptom Code A) or DTC P0561 (Symptom Code B) will be stored. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions:
6E261
Diagnostic Aids
Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Ignition Status display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18) Ignition Switch Circuit Malfunction Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18) Ignition Switch Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0561 (Symptom Code A) or P0561 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0561 (Symptom Code A) or P0561 (Symptom Code B)stored in this ignition cycle? 4 Check the Engine fuse (10A). If the fuse is burnt out, repair as necessary. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
6E262
Step 5

Action Using the DVM and check the ignition power feed circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box disconnected) as type A. (ECM Value(s) Yes No
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-56
39
C-107
Go to Step 6
Check the ignition switch. If a poor/faulty connection is found, repair as necessary. Was the problem found? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved?
Verify repair
Go to Step 7
Verify repair
Go to Step 8

6E263
No
Verify repair
6E264
DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE PROGRAMMING ERROR

Flash Code Code P0602 Symptom Code MIL DTC Name Control Module Programming Error DTC Setting Condition ECM memory area error. Fail-Safe (Back Up) Engine control disabled.
Circuit Description & Diagnostic Aids

The replacement ECM must be programmed by Service Programming System (SPS). Because, the service
ECM does not programmed. When the service ECM is used without SPS, DTC P0602 will appear.
Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0602 stored as Present Failure? 3 Download the latest software to the ECM using the SPS (Service Programming System). Is the action complete? Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Verify repair
6E265
DIAGNOSTIC TROUBLE CODE (DTC) P0606 (SYMPTOM CODE A) (FLASH CODE 28) ECU MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0606 (SYMPTOM CODE B) (FLASH CODE 28) ECU MALFUNCTION
Flash Code 28 Code P0606 Symptom Code A MIL ON DTC Name ECM Malfunction DTC Setting Condition Gate Array communication error. Fail-Safe (Back Up) 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. MAB (fuel cutoff solenoid valve) is operated.
ON
ECM Malfunction
1. Throttle position is below 1%. 2. Desired injection quantity is more than 0mg/strk. 3. Engine speed is more than 2000rpm.

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
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0606 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0606 (Symptom Code A) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
6E266
Step 5

Verify repair
6E267
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU Malfunction
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E268
DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYMPTOM CODE 4) (FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYMPTOM CODE 8) (FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
Flash Code 46 Code P0645 Symptom Code 4 MIL ON DTC Name A/C Compressor Relay Circuit Voltage Low A/C Compressor Relay Circuit Voltage High DTC Setting Condition A/C compressor relay circuit open or short to ground circuit. A/C compressor relay circuit short to voltage circuit. Fail-Safe (Back Up) No fail-safe function.
ON
Circuit Description
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 on the A/C request signal and certain setting conditions.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation.

Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
6E269
Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P0645 display on the Tech2 while moving connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C Compressor Relay Circuit Voltage Low
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0645 (Symptom Code 4) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0645 (Symptom Code 4) stored in this ignition cycle? 4 Check for poor/faulty connection at the A/C compressor relay or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
X-14 C-56
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
5 Using the DVM and check the A/C compressor relay. 1. Ignition Off, engine Off. 2. Remove the A/C compressor relay from the relay box. 3. Check the relay coil. Was the DVM indicated specified value?
A/C Compressor Relay

Verify repair
Go to Step 5
120-1509
Go to Step 6
Replace A/C compressor relay and verify repair
6E270
Step 6

Action Using the DVM and check the A/C compressor relay power supply circuit. 1. Ignition On, engine Off. 2. Remove the A/C compressor relay from the relay box. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
X-14
Value(s)
Yes
No
V
10-14.5V 7 Repair the open or short to ground circuit between the ECM main relay and A/C compressor relay. Is the action complete? Go to Step 8 Go to Step 7
Verify repair

Step 8 Action Using the DVM and check the A/C compressor relay ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box disconnected) as type A. (ECM Value(s) Yes
6E271
No
3. Remove the A/C compressor relay from the relay box. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 41 X-14
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the A/C compressor relay from the relay box. 4. Check the circuit for open or short to ground circuit. Was the problem found?
X-14 C-56
Go to Step 9
Verify repair
Go to Step 10
10
Verify repair
6E272
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C Compressor Relay Circuit Voltage High
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E273
DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE A) (FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE B) (FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
6E274
Flash Code 25 Code P0703 Symptom Code A MIL ON DTC Name Brake Switch Circuit Malfunction DTC Setting Condition 1. Throttle position is more than 0%. 2. Engine speed is more than 693rpm (4JA1-TC) or 665rpm (4JH1-TC). 3. Vehicle speed is more than 0km/h. 4. Brake switch 1 signal and brake switch 2 signal are differently inputted to the ECM since the ignition switch was turned on. 1. Throttle position is more than 0%. 2. Engine speed is more than 693rpm (4JA1-TC) or 665 rpm (4JH1-TC). 3. Vehicle speed is more than 0km/h. 4. Brake switch 1 signal and brake switch 2 signal are differently inputted to the ECM. Fail-Safe (Back Up) No fail-safe function.
ON
Brake Switch Circuit Malfunction
Circuit Description
The ECM monitors the brake switch signal on the feed terminal to the ECM. If brake switch 1 or 2 circuit with malfunction, DTC P0703 (Symptom Code A) or P0703 (Symptom Code B) will be stored.
Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Brake Switch 1 and Brake Switch 2 display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25) Brake Switch Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0703 (Symptom Code A) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3

Step 3 Action 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0703 (Symptom Code A) stored in this ignition cycle? 4 Check the Stop Lamp fuse (15A). If the fuse is burnt out, repair as necessary. Was the problem found? Check for poor/faulty connection at the brake switch or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56 C-44
6E275
No
Value(s)
Yes
Go to Step 4
Verify repair
Go to Step 5
30
6 Using the DVM and check the brake switch 1. 1. Ignition Off, engine Off. 2. Remove the brake switch connector at the brake pedal. 3. Check the brake switch 1. Was the DVM indicated specified value?
Brake Switch
Verify repair
Go to Step 6
Pedal is not stepped on: Continuity Pedal stepped on: No continuity 7 Using the DVM and check the brake switch 1 power supply circuit. 1. Ignition Off, engine Off. 2. Remove the brake switch connector from the brake switch. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-44
Go to Step 7
Replace pedal switch and verify repair
V
10-14.5V Go to Step 9 Go to Step 8
6E276
Step 8

Action Repair the open circuit between the Stop Lamp fuse (15A) and brake switch 1. Is the action complete? Using the DVM and check the brake switch 1 circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type B. connected) Ref. Page 6E-103 3. Ignition On, engine Off. 4. Check the circuit for open or short to voltage circuit. Was the DVM indicated specified value?
Breaker Box 105
Value(s)
Yes
No
Verify repair
(ECM
Breaker box is not available: 1. Ignition On, engine Off. 2. Back probe the DVM to the brake switch 1 and check the circuit for open or short to voltage circuit. Was the problem found?
C-44
V
10 Repair the short to voltage circuit between the brake switch 1 connector and ECM. Is the action complete?
C-56 C-44
Pedal is not stepped on: Less than 1V Pedal stepped on: 10-14.5V
Go to Step 12
Fixed at 1014.5V: Go to Step 10 Fixed at less than 1V: Go to Step 11
30
Verify repair
11
Repair the open circuit between the brake switch 1 connector and ECM. Is the action complete?
C-56 C-44
30
Verify repair

6E277
No
Verify repair
Go to Step 13
13
Verify repair
6E278
Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25) Brake Switch Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0703 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0703 (Symptom Code B) stored in this ignition cycle? 4 Check for poor/faulty connection at the brake switch or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56 C-44
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
65
5
Verify repair
Go to Step 5
Using the DVM and check the brake switch 2. 1. Ignition Off, engine Off. 2. Remove the brake switch connector at the brake pedal. 3. Check the brake switch 2. Was the DVM indicated specified value?
Brake Switch
Pedal is not stepped on: No continuity Pedal stepped on: Continuity
Go to Step 6

Step 6 Action Using the DVM and check the brake switch 2 power supply circuit. 1. Ignition On, engine Off. 2. Remove the brake switch connector from the brake switch. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-44
6E279
No
Value(s)
Yes
V
10-14.5V 7 Repair the open circuit between the ECM fuse (10A) and brake switch 2. Is the action complete? Using the DVM and check the brake switch 2 circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box connected) 3. Ignition On, engine Off. 4. Check the circuit for open or short to voltage circuit. Was the DVM indicated specified value?
Breaker Box 65
Go to Step 8
Go to Step 7
Verify repair
as type B.
(ECM
Breaker box is not available: 1. Ignition On, engine Off. 2. Back probe the DVM to the brake switch 2 and check the circuit for open or short to voltage circuit. Was the problem found?
C-44
Pedal is not stepped on: 10-14.5V Pedal stepped on: Less than 1V
Go to Step 11
6E280
Step 9

Action Repair the short to voltage circuit between the brake switch 2 connector and ECM. Is the action complete?
C-56 C-44
Value(s)
Yes
No
65
Verify repair
10
Repair the open circuit between the brake switch 2 connector and ECM. Is the action complete?
C-56 C-44
65
Verify repair
11
Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 12
12
Verify repair
6E281
DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6) (FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Flash Code 57 Code P0704 Symptom Code 6 MIL ON DTC Name Clutch Switch Input Circuit Malfunction DTC Setting Condition Clutch signal does not change between vehicle speed 1.5km/h and 80km/h since ignition switch was tuned on. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The ECM monitors the clutch switch signal on the feed terminal to the ECM. If clutch switch circuit with malfunction, DTC P0704 (Symptom Code 6) will be stored.
Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Clutch Switch display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation.
6E282
Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57) Clutch Switch Input Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P0704 (Symptom Code 6) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P0704 (Symptom Code 6) stored in this ignition cycle? 4 Check for poor/faulty connection at the clutch switch or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
31
C-56 1 2
C-77
5 Using the DVM and check the clutch switch. 1. Ignition Off, engine Off. 2. Remove the clutch switch connector at the clutch pedal. 3. Check the clutch switch. Was the DVM indicated specified value?
Clutch Switch
Verify repair
Go to Step 5
Pedal is not stepped on: Continuity Pedal stepped on: No continuity
Go to Step 6

Step 6 Action Using the DVM and check the clutch switch power supply circuit. 1. Ignition On, engine Off. 2. Remove the clutch switch connector from the clutch switch. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
C-77 1 2
6E283
No
Value(s)
Yes
V
10-14.5V 7 Repair the open circuit between the ECM fuse (10A) and clutch switch. Is the action complete? Using the DVM and check the clutch switch circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type B. connected) Ref. Page 6E-104 3. Ignition On, engine Off. 4. Check the circuit for open or short to voltage circuit. Was the DVM indicated specified value?
Breaker Box 31
Go to Step 8
Go to Step 7
Verify repair
(ECM
Breaker box is not available: 1. Ignition On, engine Off. 2. Back probe the DVM to the clutch switch and check the circuit for open or short to voltage circuit. Was the problem found?
C-77
Pedal is not stepped on: 10-14.5V Pedal stepped on: Less than 1V
Go to Step 11
6E284
Step 9

Action Repair the short to voltage circuit between the clutch switch connector and ECM. Is the action complete?
C-56 C-77
Value(s)
Yes
No
31
Verify repair
10
Repair the open circuit between the clutch switch connector and ECM. Is the action complete?
C-56 C-77
31
Verify repair
11
Verify repair
Go to Step 12
12
Verify repair
6E285
DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 1) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 2) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Flash Code 86 Code P1105 Symptom Code 1 MIL ON DTC Name Barometric Pressure Sensor Circuit High Input Barometric Pressure Sensor Circuit Low Input DTC Setting Condition Barometric pressure sensor output voltage is more than 4.4V. Barometric pressure sensor output voltage is below 1.5V. Fail-Safe (Back Up) ECM uses 1013hpa condition as substitute.
ON
Circuit Description
The ECM monitors the barometric pressure signal at inside of the ECM. If the sensor with malfunction, DTC P1105 (Symptom Code 1) or P1105 (Symptom Code 2) will be stored.
Diagnostic Aids
If the DTC P1105 is stored, sensor or circuit of ECM inside is failed.
Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86) Barometric Pressure Sensor Circuit High Input Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86) Barometric Pressure Sensor Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1105 (Symptom Code 1) or P1105 (Symptom Code 2) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1105 (Symptom Code 1) or P1105 (Symptom Code 2) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
6E286
Step 5

Verify repair
6E287
DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 1) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 7) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE 9) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE D) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH ERROR DIAGNOSTIC TROUBLE CODE (DTC) P1120 (SYMPTOM CODE E) (FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION SWITCH ERROR
6E288
Flash Code 21 Code P1120 Symptom Code 1 7 MIL ON ON DTC Name Pedal/Throttle Position Sensor Circuit High Input Pedal/Throttle Position Sensor Voltage Supply Circuit High Input Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input Pedal/Throttle Position Sensor Brake Switch Error DTC Setting Condition Throttle position sensor output voltage is more than 4.5V. Throttle position sensor power supply voltage is more than 5.2V. Throttle position sensor power supply voltage is below 4.6V. 1. Engine speed is more than 1700rpm. 2. Vehicle speed is more than 1.5km/h. 3. When brake pedal is depressed during accelerator pedal is depressing. 1. When idle switch is turned off, throttle position sensor was below 0.35%. or 2. When idle switch is tuned on, throttle position sensor was more than 7.8%. Fail-Safe (Back Up) ECM increases idle speed up to 1400rpm.
ON
ON
ON
Pedal/Throttle Position Sensor Idle Position Switch Error
Circuit Description
The TPS is a potentiometer connected to throttle shaft on the throttle body. It is installed to the main TPS and idle switch. The engine control module (ECM) monitors the voltage on the signal line and calculates throttle position. As the 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 ECM monitors the TPS supply voltage and TPS output voltage. The supply voltage is out of range, DTC P1120 (Symptom Code 7) or P1120 (Symptom Code 9) will be stored. The output voltage excessively high, DTC P1120 (Symptom Code 1) will be stored. If the brake pedal is depressed during accelerator pedal is depressing, DTC P1120 (Symptom Code D) will be stored. If the relation of idle switch and TPS position are incorrect, DTC P1120 (Symptom Code E) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Throttle Position, Idle Switch, Brake Switch 1 and Brake Switch 2 display on the Tech2 while moving connectors and wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 1) (Flash Code 21) Pedal/Throttle Position Sensor Circuit High Input

Step 2 Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1120 (Symptom Code 1) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1120 (Symptom Code 1) stored in this ignition cycle? 4 Check for poor/faulty connection at the TPS or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
49 C-56 39
6E289
No
Value(s)
Yes
Go to Step 3
Go to Step 4
57
E-22
2 3
5 Visually check the TPS. Was the problem found?
6E290
Step 6

Action Using the DVM and check the TPS. 1. Ignition Off, engine Off. 2. Disconnect TPS connector. 3. Measure the resistance of TPS. Does the tester indicate standard resistance as shown in the following table?
Measurement Terminal 1-2 2-3 1-3 Resistance (W) Approximately 0.4kW at idle position Approximately 4.0kW at WOT Approximately 4.3kW at idle position Approximately 0.8kW at WOT Approximately 4.6kW at idle position & WOT
Value(s)
Yes
No
TPS 3 2 3 2 1 1
Standard resistance 7 Using the DVM and check the TPS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
E-22
Go to Step 7
Go to Step 12
V
8 Repair the short to voltage circuit between the ECM and TPS. Was the problem solved?
C-56
Approximately 5.0V
Go to Step 9
Go to Step 8
57 E-22
Verify repair
Go to Step 14

Step 9 Action Using the DVM and check the TPS signal circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E-22
6E291
No
Value(s)
Yes
V
Less than 1V 10 Using the DVM and check the TPS ground circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector . 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E-22
Go to Step 10
V
6E292
Step 11

Action Using the DVM and check the TPS ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect the TPS connector. 4. Check the circuit for open circuit. Was the problem found?
Breaker Box 49 E-22
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect connector. the TPS connector and ECM
C-56
49 E-22
Repair faulty harness and verify repair Go to Step 13 Verify repair
12 13 14
Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 15
15
Verify repair
6E293
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1120 (Symptom Code 7) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1120 (Symptom Code 7) stored in this ignition cycle? 4 Check for poor/faulty connection at the TPS or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
49 C-56 39
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
57
E-22
2 3
6E294
Step 6

Action Using the DVM and check the TPS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to ground circuit. Was the DVM indicated specified value?
E-22
Value(s)
Yes
No
V
7 Repair the short to battery voltage circuit between the ECM and TPS. Was the problem solved?
C-56
Approximately 5.0V
Go to Step 12
Go to Step 7
57 E-22
Verify repair Go to Step 9 Verify repair
8 9 10
Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? 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? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 11
11
Verify repair
6E295
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1120 (Symptom Code 9) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1120 (Symptom Code 9) stored in this ignition cycle? 4 Check for poor/faulty connection at the TPS or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
49 C-56 39
Value(s)
Yes
Go to Step 2
Refer to
Diagnostic Aids
Go to Step 3
and Go to Step 3
Go to Step 4
57
E-22
2 3
6E296
Step 6

Action Using the DVM and check the TPS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to battery voltage circuit. Was the DVM indicated specified value?
E-22
Value(s)
Yes
No
V
7 Using the DVM and check the TPS power supply circuit. 1. Ignition Off, engine Off. 2. Disconnect the TPS connector connector. and ECM
Approximately 5.0V
Go to Step 10
Go to Step 7
3. Check the circuit for short to TPS ground circuit. Was the DVM indicated specified value?
E-22
No continuity 8 9 Repair the circuit for short to TPS ground circuit. Is the action complete? Repair the short to ground circuit between the ECM and TPS. Was the problem solved?
C-56
Go to Step 8
57 E-22
10 11
Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete?

6E297
No
Verify repair
Go to Step 13
13
Verify repair
6E298
Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21) Pedal/Throttle Position Sensor Brake Switch Error
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1120 (Symptom Code D) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1120 (Symptom Code D) stored in this ignition cycle? 4 Visually check the TPS. Check for the following conditions. Accelerator pedal sticking. If a problem is found, repair as necessary. Was the problem found? 5 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. Does the Tech 2 indicate correct Throttle Position from 0% to 100% depending on accelerator pedal operation? 6 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. 3. Adjust the TPS within 0% to 100%. Was the problem solved? 7 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Brake Switch 1 and Brake Switch 2 in the data display. Does the Tech 2 indicate Inactive when the brake pedal was not stepped on? 8 9 10 11 12 Adjust the brake switch. Was the problem solved? Substitute a known good brake switch and recheck. Was the problem solved? Replace the brake switch. Is the action complete? Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Verify repair Go to Step 11 Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 13 Verify repair Go to Step 10 Verify repair Go to Step 12 Verify repair
Go to Step 8 Go to Step 9 Go to Step 13 Go to Step 13

6E299
No
Verify repair
Go to Step 14
14
Verify repair
6E300
Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21) Pedal/Throttle Position Sensor Idle Position Switch Error
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1120 (Symptom Code E) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1120 (Symptom Code E) stored in this ignition cycle? 4 5 Visually check the TPS. Was the problem found? 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. Does the Tech 2 indicate correct Throttle Position from 0% to 100% depending on accelerator pedal operation? 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. 3. Adjust the TPS within 0% to 100%. Was the problem solved? 7 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Idle Switch in the data display. Does the Tech 2 indicate Inactive when the accelerator pedal was stepped on? 8 9 10 Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Verify repair Go to Step 8 Refer to Diagnostic Aids and Go to Step 4 Go to Step 5 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 7
Go to Step 6Go to Step 6
Go to Step 10 Go to Step 9 Verify repair
Verify repair
Go to Step 11

6E301
No
Verify repair
6E302
DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE 3) (FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE 7) (FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE A) (FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW FUEL TEMPERATURE
Flash Code 22 Code P1173 Symptom Code 3 7 MIL OFF OFF DTC Name Fuel Reduction Caused By High Coolant Temperature Fuel Reduction Caused By High Fuel Temperature DTC Setting Condition Excessive high engine coolant temperature is detected. Fuel temperature is more than 100 deg. C. Fail-Safe (Back Up) No fail-safe function. PSG (pump control unit) controls fuel injection quantity based on engine speed and fuel temperature. No fail-safe function.
OFF
Fuel Reduction Caused By Low Fuel Temperature
Excessive low fuel temperature is detected.
Circuit Description
The engine coolant temperature (ECT) sensor is installed on the coolant stream. High coolant 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 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 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 (Symptom Code A) will be stored.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Coolant Temperature or Fuel Temperature 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
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1173 (Symptom Code 3) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3

Step 3 Action 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1173 (Symptom Code 3) stored in this ignition cycle? 4 Check the engine overheat condition. Was the problem found? 5 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Coolant Temperature in the data display. Does the Tech 2 indicate correct Coolant Temperature depending on warm up time? 6 Using the DVM and check the ECT sensor. 1. Ignition Off, engine Off. 2. Disconnect ECT sensor connector. 3. Measure the resistance of ECT sensor. Does the tester indicate standard resistance as shown in the following table?
6E303
No
Value(s)
Yes
Go to Step 4 Repair the cause of overheat and verify repair
Go to Step 5
Go to Step 9
Go to Step 6
ECT Sensor 2 2 1 1
Standard resistance 7 Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete? 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?
Go to Step 9
Go to Step 7
Go to Step 9
8 9
Verify repair
Go to Step 10
6E304
Step 10

Verify repair
6E305
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel Reduction Caused By High Fuel Temperature Diagnostic Trouble Code (DTC) P1173 (Symptom Code A) (Flash Code 22) Fuel Reduction Caused By Low Fuel Temperature
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1173 (Symptom Code 7) or P1173 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1173 (Symptom Code 7) or P1173 (Symptom Code A) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E306
DIAGNOSTIC TROUBLE CODE (DTC) P1335 (SYMPTOM CODE A) (FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Flash Code 43 Code P1335 Symptom Code A MIL ON DTC Name Engine Speed Output Circuit Malfunction DTC Setting Condition The PSG (pump control unit) is recognized defective engine speed signal form the ECM. Fail-Safe (Back Up) Fuel injection quantity is reduced.
Circuit Description
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. The ECM converts sine wave signal to square wave signal. And this signal is provided from the ECM to pump control unit (PSG).
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.

Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Engine Speed display on the Tech2 while
6E307
moving connectors and wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1335 (Symptom Code A) (Flash Code 43) Engine Speed Output Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1335 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1335 (Symptom Code A) stored in this ignition cycle? 4 Was the DTC P0335 (Symptom Code B) or P0335 (Symptom Code D) stored at the same time? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Go to DTC Chart P0335 (Symptom Code B) (Symptom Code C)
5 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-57(B) 91 E-6
Go to Step 5
Verify repair
Go to Step 6
6E308
Step 6

Action If a oscilloscope is available, monitor the CKP sensor output signal. Does the oscilloscope indicate correct wave form?
Value(s)
Yes
No
CH1 0V
CH2 0V
Go to Step 13
Not available: Go to Step 7 Fixed at low: Go to Step 7 Fixed at High: Go to Step 8

Step 7 Action Using the DVM and check the CKP sensor output circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes
6E309
No
Breaker Box 91 E-6
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Disconnect connector. the PSG (pump control unit)
C-57(B) E-6
91
8 Using the DVM and check the CKP sensor output circuit. 1. Ignition On, engine Off. 2. Disconnect the PSG (pump control unit) connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E-6
Go to Step 8
V
6E310
Step 9

Action Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes Remove the accessory parts and verify repair No
Go to Step 10
10
Verify repair
Go to Step 11
11
Go to Step 12
Go to Step 13
12
13
6E311
DIAGNOSTIC TROUBLE CODE (DTC) P1345 (SYMPTOM CODE A) (FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Flash Code 45 Code P1345 Symptom Code A MIL ON DTC Name Camshaft Speed Malfunction DTC Setting Condition The PSG (pump control unit) is recognized incorrect camshaft speed signal. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The pump camshaft sensor is a magnet with a coil. It uses to combine with the pulser. The pulser is attached main shaft in the pump. It likes a gear shape. The pump camshaft sensor is attached to the pump control unit (PSG). The signal of pump camshaft speed is sent via the CAN-bus from the PSG to ECM.
Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Pump Speed display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Diagnostic Aids
6E312
Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45) Camshaft Speed Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1345 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1345 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Pump Speed in the data display. Does the Tech 2 indicate correct Pump Speed depending on engine speed? 5 Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Go to Step 6 Remove the accessory parts and verify repair
Go to Step 5
Go to Step 9
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
6E313
DIAGNOSTIC TROUBLE CODE (DTC) P1520 (SYMPTOM CODE A) (FLASH CODE 47) NEUTRAL SWITCH ON ERROR DIAGNOSTIC TROUBLE CODE (DTC) P1520 (SYMPTOM CODE B) (FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Flash Code 47 Code P1520 Symptom Code A MIL ON DTC Name Neutral Switch ON Error DTC Setting Condition Neutral switch signal is inputted On three times consecutively under driving conditions. Neutral switch signal is inputted Off three times consecutively under driving conditions. Fail-Safe (Back Up) No fail-safe function.
ON
Neutral Switch OFF Error
Circuit Description
The ECM monitors the neutral switch (A/T: N or P position switch in inhibitor switch) signal on the feed terminal to the ECM. If the neutral switch with malfunction, DTC P1520 (Symptom Code A) or P1520
(Symptom Code B) will be stored.
Diagnostic Aids
6E314

poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Neutral Switch display on the Tech2 while moving connectors and wiring harness related to the sensor.
Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and
Diagnostic Trouble Code (DTC) P1520 (Symptom Code A) (Flash Code 47) Neutral Switch ON Error Diagnostic Trouble Code (DTC) P1520 (Symptom Code B) (Flash Code 47) Neutral Switch OFF Error
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1520 (Symptom Code A) or P1520 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1520 (Symptom Code A) or P1520 (Symptom Code B) stored in this ignition cycle? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4

Step 4 Action Check for poor/faulty connection at the neutral switch (inhibitor switch) or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57
6E315
No
Value(s)
Yes
87 M/T E-11 E-12
A/T E-51 2 3
Verify repair
Go to Step 5
Using the DVM and check the neutral switch (inhibitor switch). 1. Ignition Off, engine Off. 2. Remove the neutral switch connector (inhibitor switch connector) at the transmission. 3. Check the neutral switch (P range switch). Was the DVM indicated specified value?
M/T E-11 E-12
N range
A/T 3 6 5 4 3 8 8 2 7 1 2
10 9
Neutral (P or N): Continuity Other than neutral (P or N): No continuity
Go to Step 6
Replace neutral switch (inhibitor switch) and verify repair
6E316
Step 6

Action Using the DVM and check the neutral switch (inhibitor switch) power supply circuit. 1. Ignition On, engine Off. 2. Remove the neutral switch (inhibitor switch) connector from the switch. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
M/T E-12 A/T E-51
Value(s)
Yes
No
V
10-14.5V 7 Repair the open circuit between the ECM fuse (10A) and neutral switch (between the Back Up fuse (15A) and inhibitor switch). Is the action complete? Using the DVM and check the neutral switch (inhibitor switch) circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type B. connected) Ref. Page 6E-104 3. Ignition On, engine Off. 4. Check the circuit for open or short to voltage circuit. Was the DVM indicated specified value?
Breaker Box 87 E-6
Go to Step 8
Go to Step 7
Verify repair
(ECM
Breaker box is not available: 1. Ignition On, engine Off. 2. Back probe the DVM to the neutral switch (inhibitor switch) and check the circuit for open or short to voltage circuit. Was the DVM indicated specified value?
M/T E-11 A/T E-51
V V V
Neutral (P or N): 10-14.5V Other than neutral (P or N): Less than 1V
Go to Step 11

Step 9 Action Repair the short to voltage circuit between the neutral switch connector (inhibitor switch connector) and ECM. Is the action complete?
M/T C-57 E-11
6E317
No
Value(s)
Yes
87 A/T C-57 2 E-51
87
Verify repair
10
Repair the open circuit between the neutral switch connector (inhibitor switch connector) and ECM. Is the action complete?
M/T C-57 E-11
87 A/T C-57 2 E-51
87
Verify repair
11
Verify repair
Go to Step 12
12
Verify repair
6E318
DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE C) (FLASH CODE 55) SEED AND KEY FILE DESTROYED DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE D) (FLASH CODE 55) EEPROM DEFECT DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE E) (FLASH CODE 55) EEPROM DEFECT
Flash Code 55 Code P1605 Symptom Code C D MIL ON ON DTC Name Seed and Key File Destroyed EEPROM Defect DTC Setting Condition Seed or key file in EEPROM is destroyed. Write and read from the EEPROM are failed during initialization of the ECM. EEPROM checksum does not match with the read check sum during initialization of the ECM. Fail-Safe (Back Up) No fail-safe function. ECM uses default values from the EPROM.
ON
EEPROM Defect

The ECM used in this vehicle utilizes an electrically erasable & programmable read only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine and
diagnostics operation. If the ECM inside (IC, circuit, memory, etc,) failed, DTC P1605 (Symptom Code C), P1605 (Symptom Code D) or P1605 (Symptom Code E) will be stored.
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55) Seed and Key File Destroyed Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55) EEPROM Defect Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55) EEPROM Defect
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1605 (Symptom Code C), P1605 (Symptom Code D) or P1605 (Symptom Code E) stored as Present Failure? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3

Step 3 Action 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1605 (Symptom Code C), P1605 (Symptom Code D) or P1605 (Symptom Code E) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E319
No
Go to Step 4
Verify repair
Go to Step 5
Verify repair
6E320
DIAGNOSTIC TROUBLE CODE (DTC) P1610 (SYMPTOM CODE A) (FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Flash Code 56 Code P1610 Symptom Code A MIL DTC Name Security Key and Security Code not Programmed DTC Setting Condition Immobilizer functions are not programmed in the ECM. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnormality in the immobilizer control system. DTC P1610 (Symptom Code A) is recorded when immobilizer function was not programmed in the ECM.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM and immobilizer control unitInspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P1610 display on the Tech2 while moving connectors and wiring harnesses.
6E321
Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56) Security Key and Security Code Not Programmed
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1610 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1610 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body. 3. Select Read DTC Info Ordered By Priority in the Diagnostic Trouble Code. Was the any DTC's B0002 or B0009 stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Refer to Immobilizer Workshop Manual & Go to DTC Chart B0002 or B0009
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E322
DIAGNOSTIC TROUBLE CODE (DTC) P1611 (SYMPTOM CODE A) (FLASH CODE 56) WRONG SECURITY CODE ENTERED
Flash Code 56 Code P1611 Symptom Code A MIL DTC Name Wrong Security Code Entered DTC Setting Condition Received security code is not correct. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnormality in the immobilizer control system. DTC P1611 (Symptom Code A) is recorded when received immobilizer security code was not correct.
Diagnostic Aids
6E323
Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56) Wrong Security Code Entered
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1611 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1611 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body. 3. Select Read DTC Info Ordered By Priority in the Diagnostic Trouble Code. Was the any DTC's B**** stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4 Refer to Immobilizer Workshop Manual & Go to DTC Chart B****
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E324
DIAGNOSTIC TROUBLE CODE (DTC) P1612 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash Code 56 Code P1612 Symptom Code A MIL DTC Name Immobilizer No or Wrong Signal DTC Setting Condition Received challenge signal is not correct or not received. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnormality in the immobilizer control system. DTC P1612 (Symptom Code A) is recorded when received immobilizer challenge signal was not correct.
Diagnostic Aids
6E325
Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1612 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1612 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body. 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Was the DTC B0007 stored in this ignition cycle? 5 Check for poor/faulty connection at the immobilizer control unit connector or ECM connector. If a poor/ faulty connection is found, repair as necessary. Was the problem found?
C-56 42
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4 Refer to Immobilizer Workshop Manual & Go to DTC Chart B0007
Go to Step 5
35 B-68
8 7
Verify repair
Go to Step 6
6E326
Step 6

Action Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector and immobilizer control unit connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was DVM indicated specified value?
B-68
Value(s)
Yes
No
V

Step 7 Action Using the DVM and check the CHECK ENGINE lamp circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Value(s) Yes
6E327
No
3. Disconnect the immobilizer control unit connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 42 B-68
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the the immobilizer control unit connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-56
42 B-68
Go to Step 8
6E328
Step 8

Action Using the DVM and check the ECM and immobilizer control unit communication circuit. 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-68
Value(s)
Yes
No
V
Less than 1V 9 Using the DVM and check the ECM and immobilizer control unit communication circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Go to Step 9
Breaker Box 35 B-68
C-56
B-68
35
Go to Step 10

6E329
No
Verify repair
Go to Step 11
11
Verify repair
6E330
DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash Code 56 Code P1613 Symptom Code A MIL DTC Name Immobilizer No or Wrong Signal DTC Setting Condition Received response signal is not correct or not received. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnormality in the immobilizer control system. DTC P1613 (Symptom Code A) is recorded when received immobilizer response signal was not correct.
Diagnostic Aids
6E331
Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1613 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1613 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body. 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Was the any DTC's B**** stored in this ignition cycle? 5 Check for poor/faulty connection at the immobilizer control unit connector or ECM connector. If a poor/ faulty connection is found, repair as necessary. Was the problem found?
C-56 42
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 5
35 B-68
8 7
Verify repair
Go to Step 6
6E332
Step 6

Action Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector and immobilizer control unit connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was DVM indicated specified value?
B-68
Value(s)
Yes
No
V

Step 7 Action Using the DVM and check the CHECK ENGINE lamp circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Value(s) Yes
6E333
No
Breaker Box 42 B-68
C-56
42 B-68
Go to Step 8
Using the DVM and check the ECM and immobilizer control unit communication circuit. 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-68
V
6E334
Step 9

Action Using the DVM and check the ECM and immobilizer control unit communication circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 (ECM Value(s) Yes No
Breaker Box 35 B-68
C-56
B-68
35
Go to Step 10
10
Verify repair
Go to Step 11
11
Verify repair
6E335
DIAGNOSTIC TROUBLE CODE (DTC) P1614 (SYMPTOM CODE A) (FLASH CODE 56) WRONG TRANSPONDER KEY
Flash Code 56 Code P1614 Symptom Code A MIL DTC Name Wrong Transponder Key DTC Setting Condition Received response signal is not correct from the transponder key. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnormality in the immobilizer control system. DTC P1614 (Symptom Code A) is recorded when received immobilizer response signal was not correct from the transponder key.
Diagnostic Aids
6E336
Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56) Wrong Transponder Key
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1614 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1614 (Symptom Code A) stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body. 3. Select Read DTC Info Ordered By Priority in the Diagnostic Trouble Code. Was the any DTC's B**** stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must e programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E337
DIAGNOSTIC TROUBLE CODE (DTC) P1625 (SYMPTOM CODE A) (FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY DIAGNOSTIC TROUBLE CODE (DTC) P1625 (SYMPTOM CODE B) (FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Flash Code 76 Code P1625 Symptom Code A MIL OFF DTC Name ECM Main Relay Switched Off Too Early DTC Setting Condition When ignition switch was turned off, timing of the ECM main relay turning off is too early. When ignition switch was turned off, timing of the ECM main relay turning off is too late or does not off. Fail-Safe (Back Up) No fail-safe function.
OFF
ECM Main Relay Switched Off Too Late
Circuit Description
The ECM switches ECM main relay to operate ECM and other sensors or controller.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation.
6E338

Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Main Relay display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM Main Relay Switched Off Too Early
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1625 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1625 (Symptom Code A) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Verify repair
6E339
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM Main Relay Switched Off Too Late
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1625 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1625 (Symptom Code B) stored in this ignition cycle? 4 Using the DVM and check the ECM main relay. 1. Ignition Off, engine Off. 2. Remove the ECM main relay from the relay box. 3. Check the relay switch. Was the DVM indicated specified value? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
ECM Main Relay
No continuitly 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 5
Replace ECM main relay and verify repair
Verify repair
Go to Step 6
Verify repair
6E340
DIAGNOSTIC TROUBLE CODE (DTC) P1630 (SYMPTOM CODE A) (FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P1630 (SYMPTOM CODE B) (FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
Flash Code 51 Code P1630 Symptom Code A MIL ON DTC Name Fuel Injection Quantity Circuit Malfunction DTC Setting Condition The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to high current. The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to continuous current. Fail-Safe (Back Up) Fuel injection quantity is reduced.
ON
Fuel Injection Quantity Circuit Malfunction
Circuit Description
The ECM is calculates an injection quantity and an injection timing using the various sensors. And the PSG controls the high pressure solenoid valve depending on
programmed pump map data.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Aids

6E341
Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51) Fuel Injection Quantity Circuit Malfunction Diagnostic Trouble Code (DTC) P1630 (Symptom Code B) (Flash Code 51) Fuel Injection Quantity Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1630 (Symptom Code A) or P1630 (symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1630 (Symptom Code A) or P1630 (symptom Code B) stored in this ignition cycle? 4 Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
6E342
DIAGNOSTIC TROUBLE CODE (DTC) P1650 (SYMPTOM CODE A) (FLASH CODE 44) CAN DEVICE OFFLINE DIAGNOSTIC TROUBLE CODE (DTC) P1650 (SYMPTOM CODE B) (FLASH CODE 44) CAN DEVICE HANG-UP
Flash Code 44 Code P1650 Symptom Code A B MIL ON ON DTC Name CAN Device Offline CAN Device Hang-up DTC Setting Condition CAN controller detects Busoff or canceling. CAN controller does not react under engine running. Fail-Safe (Back Up) MAB (fuel cutoff solenoid valve) is operated.
Circuit Description
The interchange of data between the engine control module (ECM) and the pump control unit (PSG) is performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can exchange information and data. This allows control modules that are connected to different CAN-bus systems to communicate.
Diagnostic Aids

Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
6E343
Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P1650 display on the Tech2 while moving connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN Device Offline
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1650 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1650 (Symptom Code A) stored in this ignition cycle? 4 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57 E-6 2
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
100
99
5 6
Visually check the PSG (pump control unit). Was the problem found? Using the DVM and check the CAN high circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector and PSG (pump control unit) connector. 3. Check the circuit for short to CAN low circuit. Was the DVM indicated specified value?
E-6 2
No continuity
Go to Step 7
6E344
Step 7

Action Using the DVM and check the CAN high circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes No
Breaker Box 100 E-6
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the PSG (pump connector. control unit)
C-57 E-6
100
Go to Step 8

Step 8 Action Using the DVM and check the CAN low circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes
6E345
No
Breaker Box 99 E-6
C-57 E-6
99
9 Using the DVM and check the CAN high circuit. 1. Ignition On, engine Off. 2. Disconnect connector. the PSG (pump control unit)
Go to Step 9
3. Check the circuit for short to power supply circuit. Was the DVM indicated battery voltage or approximately 5V?
E-6
V
6E346
Step 10

Action Repair the short to voltage circuit between the ECM and PSG (pump control unit). Is the action complete?
C-57 E-6
Value(s)
Yes
No
100
Verify repair
11
Using the DVM and check the CAN low circuit. 1. Ignition On, engine Off. 2. Disconnect the PSG (pump connector. control unit)
E-6
V
12 Repair the short to voltage circuit between the ECM and PSG (pump control unit). Is the action complete?
C-57 E-6
Go to Step 12
Go to Step 13
99
Verify repair
13
Using the DVM and check the PSG (pump control unit) ground circuit. 1. Ignition Off, engine Off. 2. Disconnect connector. the PSG (pump control unit)
E-6
Go to Step 14

Step 14 Action Check any accessory parts which may cause electric interference. Was the problem found? 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes Remove the accessory parts and verify repair
6E347
No
Go to Step 15
15
Verify repair
Go to Step 16
16
Go to Step 17
Go to Step 18
17
18
6E348
Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN Device Hang-up
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E349
DIAGNOSTIC TROUBLE CODE (DTC) P1651 (SYMPTOM CODE A) (FLASH CODE 45) CAN MALFUNCTION DIAGNOSTIC TROUBLE CODE (DTC) P1651 (SYMPTOM CODE B) (FLASH CODE 45) CAN RECEIVES ERROR
Flash Code 45 Code P1651 Symptom Code A MIL ON DTC Name CAN Malfunction DTC Setting Condition The PSG (pump control unit) does not recognize CAN signal from the CAN controller. The ECM does not read CAN signal from the PSG (pump control unit). Fail-Safe (Back Up) 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.
ON
CAN Malfunction
Circuit Description
The interchange of data between the engine control module (ECM) and the pump control unit (PSG) is performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can exchange information and data. This allows control modules that are connected to different CAN-bus
systems to communicate.
Diagnostic Aids
6E350

terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the DTC P1651 display on the Tech2 while moving connectors and wiring harnesses.
Rubbed through wire insulation. Broken wire inside the insulation. Check for the following conditions: Poor connection at ECM and PSG-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged
Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45) CAN Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1651 (Symptom Code A) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1651 (Symptom Code A) stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
6E351
Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45) CAN Receives Error
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1651 (Symptom Code B) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1651 (Symptom Code B) stored in this ignition cycle? 4 Was the DTC P1650 (Symptom Code A) stored at the same time? 5 Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-57 E-6 2
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4 Go to DTC Chart P1650 (Symptom Code A)
Go to Step 5
100
99
6 7
Visually check the PSG (pump control unit). Was the problem found? Using the DVM and check the CAN high circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector and PSG (pump control unit) connector. 3. Check the circuit for short to CAN low circuit. Was the DVM indicated specified value?
E-6 2
No continuity
Go to Step 8
6E352
Step 8

Action Using the DVM and check the CAN high circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes No
Breaker Box 100 E-6
C-57 E-6
100
Go to Step 9

Step 9 Action Using the DVM and check the CAN low circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Disconnect connector. the PSG (pump control (ECM unit) Value(s) Yes
6E353
No
Breaker Box 99 E-6
C-57 E-6
99
10 Using the DVM and check the CAN high circuit. 1. Ignition On, engine Off. 2. Disconnect connector. the PSG (pump control unit)
Go to Step 10
E-6
V
6E354
Step 11

Action Repair the short to voltage circuit between the ECM and PSG (pump control unit). Is the action complete?
C-57 E-6
Value(s)
Yes
No
100
Verify repair
12
Using the DVM and check the CAN low circuit. 1. Ignition On, engine Off. 2. Disconnect connector. the PSG (pump control unit)
E-6
V
13 Repair the short to voltage circuit between the ECM and PSG (pump control unit). Is the action complete?
C-57 E-6
Go to Step 13
Go to Step 14
99
Verify repair
14
Using the DVM and check the PSG (pump control unit) ground circuit. 1. Ignition Off, engine Off. 2. Disconnect connector. the PSG (pump control unit)
E-6
Go to Step 15

Step 15 Action Check any accessory parts which may cause electric interference. Was the problem found? 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes Remove the accessory parts and verify repair
6E355
No
Go to Step 16
16
Verify repair
Go to Step 17
17
Go to Step 18
Go to Step 19
18
19
6E356
DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 4) (FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 8) (FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Flash Code 77 Code P1690 Symptom Code 4 MIL OFF DTC Name Check Engine Lamp (MIL) Circuit Voltage Low Check Engine Lamp (MIL) Circuit Voltage High DTC Setting Condition Check engine lamp circuit open or short to ground circuit. Check engine lamp circuit short to ground circuit. Fail-Safe (Back Up) No fail-safe function.
OFF
Circuit Description
The Check Engine Lamp (Malfunction Indicator Lamp =MIL) should always be illuminated and steady with 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 the check engine lamp driver circuit for a certain time.
Diagnostic Aids
An intermittent may be caused by the following: Poor connections. Misrouted harness. Rubbed through wire insulation. Broken wire inside the insulation.

Check for the following conditions: Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
6E357
Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the Check Engine Lamp display on the Tech2 while moving connectors and wiring harnesses. A change in the display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 4) (Flash Code 77) Check Engine Lamp (MIL) Circuit Voltage Low
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor As Stored By ECU in F0: Diagnostic Trouble Codes. Is the DTC P1690 (Symptom Code 4) stored as Present Failure? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select F1: Clear DTC Information in F0: Diagnostic Trouble Codes with the Tech 2 and clear the DTC information. 3. Operate the vehicle and monitor the F0: Read DTC Infor As Stored By ECU in the F0: Diagnostic Trouble Codes. Was the DTC P1690 (Symptom Code 4) stored in this ignition cycle? 4 1. Ignition On, engine Off. 2. Check the Check Engine lamp. Does the lamp turn On? 5 1. Ignition On, engine Off. 2. Check the Check Engine lamp. Does the lamp turn Off? 6 Check the Check Engine lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found? Check for poor/faulty connection at the meter connector and ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56 42
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7
17
B-24
Verify repair
Go to Step 8
6E358
Step 8

Action Using the DVM and check the Check Engine lamp circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Ref. Page 6E-103 3. Remove the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker Box 42 B-24
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
C-56
42
B-24
17
Go to Step 9
Verify repair
Go to Step 10

6E359
No
Verify repair
6E360
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77) Check Engine Lamp (MIL) Circuit Voltage High
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E361
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the On-Board Diagnostic (OBD) System Check and verify all of the following items: The engine control module (ECM) and check engine lamp (MIL=malfunction indicator lamp are operating correctly. There are no Diagnostic Trouble Code(s) stored. Tech 2 data is within normal operating range. Refer to Typical Scan Data Values. Verify the customer complaint and locate the correct symptom in the table of contents. Perform the procedure included in the symptom chart. To check for loss of diagnostic code memory, disconnect the MAF sensor and idle the engine until the check engine lamp (MIL=malfunction indicator lamp) comes on. Diagnostic Trouble Code P0100 should be stored and kept in memory when the ignition is turned OFF. If not, the ECM is faulty. When this test is completed, make sure that you clear the Diagnostic Trouble Code P0100 from memory. An intermittent check engine lamp (MIL=malfunction indicator lamp) with no stored Diagnostic Trouble Code may be caused by the following: Check engine lamp (MIL=malfunction indicator lamp) wire to ECM short to ground. Poor ECM grounds. Refer to the ECM wiring diagrams. Check for improper installation of electrical options such as light, cellular phones, etc. Check all wires from ECM to the ignition control module for poor connections. Check for an open diode across the A/C compressor clutch and check for other open diodes (refer to wiring diagrams in Electrical Diagnosis). If problem has not been found, refer to ECM connector symptom tables. Check the Broadcast Code of the ECM, and compare it with the latest Isuzu service bulletins and/ or Isuzu EEPROM reprogramming equipment to determine if an update to the ECM's reprogrammable memory has been released. This identifies the contents of the reprogrammable software and calibration contained in the ECM. If the Broadcast Code is not the most current available, it is advisable to reprogram the ECM's EEPROM memory, which may either help identify a hard-to find problem or may fix the problem. The Service Programming System (SPS) will not allow incorrect software programming or incorrect calibration changes. Road test the vehicle with a Digital Multimeter connected to a suspected circuit. An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored. Using Tech 2 to help detect intermittent conditions. The Tech 2 have several features that can be used to located an intermittent condition. Use the following features to find intermittent faults:
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful visual/physical check. This can lead to correcting a problem without further checks and can save valuable time. This check should include the following items: ECM grounds for cleanliness, tightness and proper location. Vacuum hoses for splits, kinks, and proper connection. Check thoroughly for any type of leak or restriction. Air intake ducts for collapsed or damaged areas. Air leaks at throttle body mounting area, mass air flow (MAF) sensor and intake manifold sealing surfaces. Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn on the check engine lamp (MIL=malfunction indicator lamp) or store a Diagnostic Trouble Code. Do NOT use the Diagnostic Trouble Code (DTC) charts for intermittent problems. The fault must be present to locate the problem. Most intermittent problems are cased by faulty electrical connections or wiring. Perform a careful visual/physical check for the following conditions. Poor mating of the connector halves or a terminal not fully seated in the connector (backed out). Improperly formed or damaged terminal. 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. Check engine lamp (MIL=malfunction indicator lamp) wire to ECM shorted to ground. Poor ECM grounds. Refer to the ECM wiring diagrams.
6E362
ENGINE CRANKS BUT WILL NOT RUN

DEFINITIONS: Engine cranks, but will not run. (The engine never start.) NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis. Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? Was a visually/physical check performed? 4 Is the fuel amount enough? Go to Step 4 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Go to Step 3 Go to Visual / physical Check
5 6 Is the customer using the incorrect fuel type? Check the ECM fuse (10A) and Engine fuse (15A). If the fuse is burnt out, repair as necessary. Was the problem found? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 8 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Neutral Switch in the data display. Does the Tech 2 indicate correct Neutral Switch status depending on any shift positions? If a problem is found, repair as necessary. Was the problem found? Diesel fuel only
Go to Step 5 Replace with diesel fuel
Add fuel to the tank Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

Step 10 Action Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found? 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. If a problem is found, repair as necessary. Was a problem found? 12 13 14 Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Is the action complete? Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found? 15 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? 16 Replace the fuel filter. Was the problem solved? Value(s) Yes
6E363
No
Verify repair
Go to Step 11
Verify repair
Go to Step 16
6E364
Step 17

Action 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. 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 the problem found? Value(s) Yes No
18 Check the engine compression pressure for each cylinders. If a problem is found, repair as necessary. Was the problem found?
Go to Step 18
More than 2.1 Mpa (21.0 kg/ cm2) 19 If the injection pump was replaced, are the timing gears or injection pump correctly installed?
Verify repair
Go to Step 19
Go to Step 20
Repair as necessary

Step 20 Action 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 21 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes
6E365
No
Verify repair
Go to Step 21
Verify repair
Go to Step 22
22
Go to Step 23
Go to Step 24
23
24
6E366
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then immediately stall. Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 6 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 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? If a problem is found, repair as necessary. Was the problem found? 8 1. Using the Tech 2, display the FT sensor value. 2. Check the displayed value. Does the Tech 2 indicate correct temperature depending on engine condition? If a problem is found, repair as necessary. Was the problem found? 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? If a problem is found, repair as necessary. Was the problem found? Diesel fuel only Go to Step 4 Replace with diesel fuel Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Go to Step 3 Go to Visual / physical Check Go to Step 6
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 20
Go to Step 9
Go to Step 20
Go to Step 10

Step 10 Action 1. Using the Tech 2, ignition On. 2. Monitor the Glow Time Relay in the data display and then, does the supply voltage correctly supply to the glow plug? Value(s) Yes
6E367
No
11 Check the glow plugs for continuity. If a problem is found, repair as necessary. Was a problem found?
Go to Step 11
Repair voltage supply circuit and verify repair
12 Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found? 13 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? 14 Replace the fuel filter. Was the problem solved?
Verify repair
Go to Step 12
Verify repair
Go to Step 13
6E368
Step 15

16 Remove the injection nozzles from the engine and check for the following conditions. Improper splay condition. Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?
Go to Step 16
1 st Stage 4JA1-TC 4JH1-TC Approximatly 19.0 Mpa Approximatly 19.5 Mpa
2nd Stage Approximatly 33.5 Mpa Approximatly 33.8 Mpa
Replace the injection nozzle and verify repair
Go to Step 17
More than 2.1 Mpa
Verify repair
Go to Step 18

Step 18 Action Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value? Value(s) Yes
6E369
No
0.4mm at cold (In/Ex) 19 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 20 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete?
Go to Step 19
Adjust and verify repair
Verify repair
Go to Step 20
Verify repair
Go to Step 21
21
Go to Step 22
Go to Step 23
22
23
6E370
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 stall the engine.
rpm
X Rough Idle Stall
time
Step 1
Action Was the On-Board Diagnostic (OBD) System Check performed?
Value(s)
Yes
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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? 1. Check for incorrect idle speed. Ensure that the following conditions are present. Engine fully warm. Accessories are OFF. 2. Using a Tech 2, monitor Desired Engine Idle Speed and Engine Speed. Is the Engine Speed within the specified values? 6 Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 7 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? Desired Engine Idle Speed 25 rpm Diesel fuel only
Go to Step 2
Verify repair Go to Step 4 Replace with diesel fuel
Go to Step 7
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8

Step 8 Action 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Neutral Switch in the data display. Does the Tech 2 indicate correct Neutral Switch status depending on any shift positions? If a problem is found, repair as necessary. Was the problem found? 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? If a problem is found, repair as necessary. Was the problem found? 10 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? If a problem is found, repair as necessary. Was the problem found? 11 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? 12 Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? 13 Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 14 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Off. 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? Value(s) Yes
6E371
No
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 16
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 35
15 16
Go to Step 21
Go to Step 17
6E372
Step 17

Action 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Pedal/Throttle Position and Idle Switch in the data display. 3. Adjust the accelerator cable or TPS within 0% to 100%. Was the problem solved? Value(s) Yes No
Verify repair
Go to Step 18
18
Check the TPS harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found?
19 20 21
Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 22
22
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. If a problem is found, repair as necessary. Was a problem found?
23 24
Substitute aknown good CKP sensorand recheck. Was the problem solved? Replace the CKP sensor. Is the action complete?

Step 25 Action 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? Value(s) Yes
6E373
No
When idling or part-throttle

Desired High
Actual Low Time
Go to Step 29
Go to Step 26
6E374
Step 26

Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 27 Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found? 28 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? 29 Replace the fuel filter. Was the problem solved?
Verify repair
Go to Step 27
Verify repair
Go to Step 28

Step 30 Action 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. 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 the problem found? Value(s) Yes
6E375
No
Go to Step 32
32 Check the engine compression pressure for each cylinders. Each cylinder must be evenly. If a problem is found, repair as necessary. Was the problem found?
Go to Step 32
More than 2.1 Mpa
Verify repair
Go to Step 33
6E376
Step 33

Action Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value? Value(s) Yes No
0.4mm at cold (In/Ex) 34 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 35 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete?
Go to Step 34
Verify repair
Go to Step 35
Verify repair
Go to Step 36
36
Go to Step 37
Go to Step 38
37
38
6E377
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
Step 1
Value(s)
Yes
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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 6 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 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? If a problem is found, repair as necessary. Was the problem found? Diesel fuel only
Go to Step 2
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E378
Step 8

Action 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? If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
Go to Step 9
1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation?
Go to Step 14
Go to Step 10
10
Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 11
11
Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 12
12
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Off. 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 29
13 14
Go to Step 19
Go to Step 15
15
1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Pedal/Throttle Position and Idle Switch in the data display. 3. Adjust the accelerator cable or TPS within 0% to 100%. Was the problem solved?
Verify repair
Go to Step 16
16
17 18

Step 19 Action Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found? 20 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. If a problem is found, repair as necessary. Was a problem found? 21 22 23 Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Is the action complete? 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?
Desired High High
6E379
No
Value(s)
Yes
Verify repair
Go to Step 20
When accelerated
Desired
Actual Actual Low Time Low Time
Go to Step 25
Go to Step 24
6E380
Step 24

Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 25 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? 26 Replace the fuel filter. Was the problem solved?
Verify repair
Go to Step 25

6E381
No
28 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 29 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 28
Verify repair
Go to Step 29
Verify repair
Go to Step 30
30
Go to Step 31
Go to Step 32
31
Verify repair
6E382
Step 32

Action Replace the injection pump assembly. Is the action complete? Value(s) Yes Verify repair No
6E383
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 make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough.
Stumble Sug
rpm
Hesitation time
Step 1
Value(s)
Yes
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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Check the torque converter clutch (TCC) for proper operation (if A/T model). If a problem is found, repair as necessary. Was a problem found? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 7 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? Diesel fuel only
Go to Step 2
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
6E384
Step 8

Action 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? If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
Go to Step 9
1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation?
Go to Step 14
Go to Step 10
10
Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12
12
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Off. 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 31
13 14
Go to Step 19
Go to Step 15
15
Verify repair
Go to Step 16
16
17 18

Step 19 Action Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found? 20 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. If a problem is found, repair as necessary. Was a problem found? 21 22 23 Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Is the action complete? 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?
Desired High High
6E385
No
Value(s)
Yes
Verify repair
Go to Step 20
When accelerated
Desired
Go to Step 27
Go to Step 24
6E386
Step 24

Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 25 Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found? 26 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? 27 Replace the fuel filter. Was the problem solved?
Verify repair
Go to Step 25
Verify repair
Go to Step 26

6E387
No
Go to Step 29
Verify repair
Go to Step 30
Verify repair
Go to Step 31
31
Go to Step 32
Go to Step 33
32
Verify repair
6E388
Step 33

Action Replace the injection pump assembly. Is the action complete? Value(s) Yes Verify repair No
6E389
CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases.
rpm
time
Step 1
Value(s)
Yes
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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 6 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? Diesel fuel only
Go to Step 2
Verify repair
Go to Step 6
Verify repair
Go to Step 7
6E390
Step 7

Action 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? Value(s) Yes No
When constant vehicle speed

Correct Speed High
Unstable Data Low Time
8 Check the VSS harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 9 10 11 Substitute a known good VSS and recheck. Was the problem solved? Replace the VSS assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? 13 Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 14 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete?
Go to Step 11
Go to Step 8
Go to Step 16
Go to Step 12
12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 31
15

Step 16 Action 1. Using the Tech 2, ignition On and engine Off. 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? 17 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Pedal/Throttle Position and Idle Switch in the data display. 3. Adjust the accelerator cable or TPS within 0% to 100%. Was the problem solved? 18 Check the TPS harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 19 20 21 Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found? 22 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. If a problem is found, repair as necessary. Was a problem found? 23 24 Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Is the action complete? Value(s) Yes
6E391
No
Go to Step 21
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 22
6E392
Step 25

Action 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? Value(s) Yes No

Desired High
Actual Low Time
Go to Step 29
Go to Step 26

Step 26 Action Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2: 1. Using the Tech 2, ignition "On" and engine "On". 2. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 3. Operate the Tech 2 in accordance with procedure. Solenoid 95%: EGR Valve Open Solenoid 5%: EGR Valve Close Vacuum Pump: 1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure. Vacuum Apply: EGR Valve Open Vacuum Release: EGR Valve Close Value(s) Yes
6E393
No
Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 27 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? 28 Replace the fuel filter. Was the problem solved?
Verify repair
Go to Step 27
6E394
Step 29

Go to Step 30
Verify repair
Go to Step 31
Verify repair
Go to Step 32
32
Go to Step 33
Go to Step 34
33
Verify repair

Step 34 Action Replace the injection pump assembly. Is the action complete? Value(s) Yes Verify repair
6E395
No
6E396
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. Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 6 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 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? If a problem is found, repair as necessary. Was the problem found? 8 1. Using the Tech 2, display the FT sensor value. 2. Check the displayed value. Does the Tech 2 indicate correct temperature depending on engine condition? If a problem is found, repair as necessary. Was the problem found? 9 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? Diesel fuel only Go to Step 4 Replace with diesel fuel Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 29
Go to Step 9
Go to Step 14
Go to Step 10

Step 10 Action Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? 11 Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 12 Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Off. 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? 15 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Pedal/Throttle Position and Idle Switch in the data display. 3. Adjust the accelerator cable or TPS within 0% to 100%. Was the problem solved? 16 Check the TPS harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? 17 18 Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Value(s) Yes
6E397
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 29
13 14
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
6E398
Step 19

Action 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?
Desired High High
Value(s)
Yes
No
When accelerated
Desired
Go to Step 22
Go to Step 20
20
Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2: 1. Using the Tech 2, ignition "On" and engine "On". 2. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 3. Operate the Tech 2 in accordance with procedure. Solenoid 95%: EGR Valve Open Solenoid 5%: EGR Valve Close Vacuum Pump: 1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure. Vacuum Apply: EGR Valve Open Vacuum Release: EGR Valve Close
Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 21

Step 21 Action Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found? 22 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? 23 24 Replace the fuel filter. Was the problem solved? 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. 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 the problem found? Value(s) Yes
6E399
No
Verify repair
Go to Step 22
Go to Step 25
6E400
Step 25

Action Remove the injection nozzles from the engine and check for the following conditions. Improper splay condition. Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Go to Step 26
More than 2.0 Mpa 27 Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value?
Verify repair
Go to Step 27
0.4mm at cold (In/Ex) 28 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found?
Go to Step 28
Verify repair
Go to Step 29

Step 29 Action 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes
6E401
No
Verify repair
Go to Step 30
30
Go to Step 31
Go to Step 32
31
32
6E402
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.) Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? 3 4 Was a visually/physical check performed? 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? 5 Review the items in Step 4 with the customer and advise as necessary. Is the action complete? Check for low engine coolant level. Was a problem found? Check for incorrect or faulty engine thermostat. Refer to Engine Cooling. Was a problem found? 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? Diagnose and repair the inaccurate speedometer condition as necessary. Refer to Vehicle Speed Sensor in Electrical Diagnosis. Check for proper calibration of the fuel gauge. Was a problem found? Check the torque converter clutch (TCC) for proper operation (if A/T model). If a problem is found, repair as necessary. Was a problem found? 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Neutral Switch in the data display. Does the Tech 2 indicate correct Neutral Switch status depending on any shift positions? If a problem is found, repair as necessary. Was the problem found? Go to Step 5 Go to Step 6 Go to Step 4 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Go to Step 3 Go to Visual / physical Check
System OK Verify repair
Go to Step 7
6 7
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9
Go to Step 11
10 11
Verify repair
Go to Step 12
12
Verify repair
Go to Step 13

Step 13 Action 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? If a problem is found, repair as necessary. Was the problem found? 14 Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 15 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? If a problem is found, repair as necessary. Was the problem found? 16 1. Using the Tech 2, display the FT sensor value. 2. Check the displayed value. Does the Tech 2 indicate correct temperature depending on engine condition? If a problem is found, repair as necessary. Was the problem found? 17 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? 18 Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? 19 Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? Value(s) Yes
6E403
No
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Go to Step 31
Go to Step 17
Go to Step 22
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
6E404
Step 20

Action Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Off. 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? Value(s) Yes No
Go to Step 31
21 22
Go to Step 27
Go to Step 23
23
Verify repair
Go to Step 24
24
25 26 27
Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Remove the injection nozzles from the engine and check for the following conditions. Improper splay condition. Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?
Go to Step 28

Step 28 Action Check the engine compression pressure for each cylinders. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes
6E405
No
More than 2.0 Mpa 29 Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value?
Verify repair
Go to Step 29
0.4mm at cold (In/Ex) 30 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 31 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 30
Verify repair
Go to Step 31
Verify repair
Go to Step 32
32
Go to Step 33
Go to Step 34
6E406
Step 33

Action Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes No
34
6E407
EXCESSIVE WHITE SMOKE

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Check the engine coolant consumption to verify that it leaks to combustion chamber or exhaust through the gasket. Was a problem found? Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 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? If a problem is found, repair as necessary. Was the problem found? 8 1. Using the Tech 2, display the FT sensor value. 2. Check the displayed value. Does the Tech 2 indicate correct temperature depending on engine condition? If a problem is found, repair as necessary. Was the problem found? 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? 10 Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? Check the MAF sensor harness for the following conditions. Check for poor connector connection. Check for misrouted harness. Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found? Diesel fuel only Go to Step 4 Replace with diesel fuel Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 30
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12
6E408
Step 12

Action Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 1. Using the Tech 2, ignition On and engine Run. 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 engine Run? If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Go to Step 30
13 14
Go to Step 30
Go to Step 15
15
1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Glow Time Relay in the data display and then, does the supply voltage correctly supply to the glow plug?
16 Check the glow plugs for continuity. If a problem is found, repair as necessary. Was a problem found?
Go to Step 16
Repair voltage supply circuit and verify repair
17 Remove the CKP sensor from the flywheel housing and check for the following conditions. Objects sticking the CKP sensor. Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found? 18 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. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19

Step 19 20 21 Action Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Is the action complete? 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?
Desired High High
6E409
No
Value(s)
Yes Go to Step 20 Verify repair
Go to Step 21
When accelerated
Desired
Actual Actu al Low Time Low Time
Go to Step 23
Go to Step 22
22
Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 23
23
Visually/physically inspect for the following conditions. Restrict fuel supply system. Check for a pinched fuel hose/pipe. Check for a condition that causes fuel waxing or icing, such as the customer is using an incorrect fuel type in winter season or water mixed with the fuel. If a problem is found, repair as necessary. Was a problem found?
24
Replace the fuel filter. Was the problem solved?
6E410
Step 25

Go to Step 26
Go to Step 27

Step 27 Action Check the engine compression pressure for each cylinders. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes
6E411
No
More than 20 Mpa 28 Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value?
Verify repair
Go to Step 28
0.4mm at cold (In/Ex) 29 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found? 30 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 29
Verify repair
Go to Step 30
Verify repair
Go to Step 31
31
Go to Step 32
Go to Step 33
6E412
Step 32

Action Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes No
33
6E413
EXCESSIVE BLACK SMOKE

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 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? 3 4 5 Was a visually/physical check performed? Is the customer using the incorrect fuel type? Visually/physically inspect for the following conditions. 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. If a problem is found, repair as necessary. Was a problem found? 6 Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 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? If a problem is found, repair as necessary. Was the problem found? 8 1. Using the Tech 2, display the FT sensor value. 2. Check the displayed value. Does the Tech 2 indicate correct temperature depending on engine condition? If a problem is found, repair as necessary. Was the problem found? 9 1. Using the Tech 2, ignition On and engine Run. 2. Monitor the Mass Air Flow in the data display. Does the Tech 2 indicate correct Mass Air Flow depending on accelerator pedal operation? Diesel fuel only Go to Step 4 Replace with diesel fuel Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 21
Go to Step 9
Go to Step 14
Go to Step 10
6E414
Step 10

Action Remove the MAF & IAT sensor assembly and check for the following conditions. Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12
12
Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & IAT sensor assembly. Is the action complete? 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?
Desired High High
Go to Step 21
13 14
When accelerated
Desired
Go to Step 20
Go to Step 15

Step 15 Action Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2: 1. Using the Tech 2, ignition "On" and engine "On". 2. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 3. Operate the Tech 2 in accordance with procedure. Solenoid 95%: EGR Valve Open Solenoid 5%: EGR Valve Close Vacuum Pump: 1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure. Vacuum Apply: EGR Valve Open Vacuum Release: EGR Valve Close Value(s) Yes
6E415
No
Vacuum Pump
Small Window
If a problem is found, repair as necessary. Was the problem found? 16 Check the exhaust system for a possible restriction. Damaged or collapsed pipes or catalytic converter. Internal muffler failure. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 16
Verify repair
Go to Step 17
6E416
Step 17

Action Remove the injection nozzles from the engine and check for the following conditions. Improper splay condition. Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Go to Step 18
More than 20 Mpa 19 Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value?
Verify repair
Go to Step 19
0.4mm at cold (In/Ex) 20 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: Visual/physical inspection Tech 2 data All electrical connections within a suspected circuit and/or system Was a problem found?
Go to Step 20
Verify repair
Go to Step 21

Step 21 Action 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? Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Replace the injection pump assembly. Is the action complete? Value(s) Yes
6E417
No
Verify repair
Go to Step 22
22
Go to Step 24
Go to Step 23
23
24
6E418
ON-VEHICLE SERVICE PROCEDURE ENGINE CONTROL MODULE (ECM)

Location Under the left-hand side seat. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the seat left-hand side. 3. Roll up the floor carpet. 4. Remove four bolts from the ECM cover. 5. Disconnect the two connectors from the ECM. tightening torque. Tightening torque Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm) 4. Lay the floor carpet exactly. 5. Put on the seat to the floor panel and tighten with specified tightening torque. Tightening torque Bolts: 40.0 Nm (4.1 kgfm) 6. Connect the negative battery cable. NOTE: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Installation Procedure 1. Connect the two connectors to the ECM. 2. Put on the ECM to the floor panel. 3. Tighten the ECM cover by four bolts with specified
6E419
CRANKSHAFT POSITION (CKP) SENSOR

Location Installed to the clutch housing. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect connector from the CKP sensor. 3. Loosen a bolt and remove the CKP sensor from the clutch housing.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Location Installed to the thermostat housing. Removal Procedure 1. Disconnect the negative battery cable. 2. Drain enough engine coolant so that the coolant level will be below the ECT sensor. 3. Disconnect connector from the ECT sensor. 4. Loosen and remove the ECT sensor from the thermostat housing. NOTE: Cool down the engine before above procedures are carried out.
Installation Procedure 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 Nm (0.8 - 1.2 kgfm) 3. Connect a CKP sensor connector to the CKP sensor. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Installation Procedure 1. Apply sealer to threads of screw at the ECT sensor. 2. Tighten the ECT sensor with specified tightening torque. Tightening Torque Bolt: 13Nm (1.3kgfm) 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.
6E420
MASS AIR FLOW (MAF) & INTAKE AIR TEMPERATURE (IAT) SENSOR
Location Installed to the intake duct housing. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect a MAF & IAT sensor connector from the MAF & IAT sensor assembly. 3. Loosen the clips and remove the MAF & IAT sensor assembly from the intake duct housing.
THROTTLE POSITION SENSOR (TPS)

Location Installed on the throttle body. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the TPS connector. 3. Loosen two screws and remove TPS from the throttle body.
Installation Procedure Installation Procedure 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 & IAT sensor assembly. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. 1. Temporary tighten the TPS by two screws. 2. Connect a TPS connectors to the TPS. 3. Connect the Tech2 to the vehicle. 4. Connect the negative battery cable. 5. Select Data Display with the Tech2. 6. Check the throttle position data and adjust the TPS position. 7. Tighten two screws. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
6E421
EGR EVRV (Electrical Vacuum 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.
Installation Procedure 1. Tighten the purge solenoid by tow bolts. 2. Connect a connector to the EVRV. 3. Connect two hoses to the EVRV. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify proper connection of two hoses.
6E422
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
EXHAUST SYSTEM 6F 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE Main Data and Specifications ........................................................................................... 6F - 2 General Description........................................................................................................... 6F - 3 Removal and Installation................................................................................................... 6F - 4 Inspection and Repair ....................................................................................................... 6F - 6 General Description........................................................................................................... 6F -7 EGR System Diagram ........................................................................................................ 6F 9 Inspection........................................................................................................................... 6F-11 EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12 Turbocharger ..................................................................................................................... 6F -15 Main Data and Specifications....................................................................................... 6F -15 General Description........................................................................................................... 6F -16 Inspection and Repair ....................................................................................................... 6F -17 Special Tools...................................................................................................................... 6F -19 IHI Service Network ........................................................................................................... 6F -20
6F 2 EXHAUST SYSTEM
EXHAUST SYSTEM 6F 3
GENERAL DESCRIPTION
RTW46FLF000201
The exhaust pipe layout is described in the above illustration. The catalytic coverter is installed between the turbocharger and the front pipe.
6F 4 EXHAUST SYSTEM
RTW46FLF000101
Removal Steps
1. Rear hanger rubber 2. Silencer front nut 3. Exhaust silencer 4. Silencer hanger rubber 5. Middle pipe nut 6. Front hanger rubber 7. Front pipe nut 8. Exhaust pipe gasket
EXHAUST SYSTEM 6F 5 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. 1. Front Pipe Nut Connect the exhaust pipe to the catalytic converter. Torque Nm (kgm/lbft) 67 (6.8/49) 2. Middle pipe Nut (44 only) Connect the middle pipe to the front pipe. Torque Nm (kgm/lbft) 43 (4.4/32) 3. Silencer Front Nut Connect the silencer to the front or middle pipe. Torque Nm (kgm/lbft) 43 (4.4/32)
6F 6 EXHAUST SYSTEM

Front 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.
Catalytic Converter
1. Inspect outside the catalytic converter for any hitting mark. 2. Visual check inside the catalytic converter for crack or break converter element. 3. If find any problem during the inspection, replace the catalytic converter assembly.
EXHAUST SYSTEM 6F 7
GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. 4JA1T(L): The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to signals from various sensors. The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
RTW46ELF001201
6F 8 EXHAUST SYSTEM
4JA1TC/4JH1TC The EGR system engine is controlled by ECM. Refer to Engine driveability and emissions section for detail.
RTW46ELF001101
EXHAUST SYSTEM 6F 9
EGR SYSTEM DIAGRAM 4JA1T (L)
RTW46AMF000301
EGR System Operation

Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up. Inspection point (Engine RPM) RPM Engine Front Side VSV-1 Engine Rear Side VSV-2 Idling ON ON 900 ~ 960 ON OFF 2000 ON ON 3250 OFF OFF
ON means VSV should receive signal to move EGR valve. OFF means VSV shouldnt receive signal to move EGR valve.
6F 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and emissions section for detail.
RTW46EMF000701
EXHAUST SYSTEM 6F 11
INSPECTION
4JA1T(L)
Vacuum switch valve (VSV) Use a circuit tester to measure the V.S.V. resistance. V.S.V Resistance W at 20C 37 ~ 44 If the resistance is not within specification, replace it.
EGR Valve Apply vacuum to the EGR valve, check to see the valve operation. Negative Pressure Less then 180 mmHg More than 240 mmHg Not operation Operation
4JA1TC/4JH1TC
EVRV Use a circuit tester to measure the EVRV resistance. EVRV Resistance W at 20C 14 If the resistance is not within specification, replace it.
RTW46ESH000301
EGR Valve Apply vacuum to the EGR valve, check to see the valve operation. Negative Pressure 4JH1TC Less than 250 mmHg More than 300 mmHg Not operation Operation
Negative Pressure 4JA1TC Less than 100 mmHg More than 170 mmHg Not operation Operation
EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)

RTW46EMF000201
Removal Steps
1. Bolt 2. Gasket 3. Bolt 4. Gasket 5. Bolt 6. Bolt 7. EGR Pipe Assembly 8. Gasket 9. Bolt 10. EGR Cooler Assembly 11. Gasket 12. EGR Cooler Adapter
Removal
1. Bolt 2. Gasket 3. Bolt 4. Gasket 5. Bolt 6. Bolt 7. EGR Pipe Assembly 8. Gasket 9. Bolt 10. EGR Cooler Assembly 11.Gasket 12.EGR Cooler Adapter
RTW46EMF000901
Installation steps
1. EGR Cooler Adapter 2. Gasket 3. EGR Cooler Assembly 4. Gasket 5. Bolt 6. EGR Pipe Assembly 7. Bolt 8. Bolt 9. Gasket 10. EGR Valve Assembly 11. Bolt 12. EXH Manifold 13. Gasket 14. Bolt
Installation
1. 2. 3. 4. EGR Cooler Adapter Gasket EGR Cooler Assembly Bolt Tighten the bolts to the specified torque. EGR adapter bolt torque 27(2.8/20) 5. Gasket 6. EGR Pipe Assembly 7. Bolt Tighten bolts temporarily. 8. Bolt Tighten bolts temporarily. 9. Gasket 10. Bolt Tighten bolts temporarily. 11.Gasket 12.Bolt Tighten bolts temporarily. Finally tighten all bolts to the specified torque. Confirm that there is no misalignment on the sealing surface. Bolt torque (Cooler-pipe) Nm(kgm/lb ft) 27(2.8/20) Bolt torque (Cooler-bracket) Nm (kgm/lb ft) 24(2.4/17) Bolt torque (Adapter-EGR valve) Nm (kgm/lb ft) 27(2.8/20) Bolt torque (Pipe-manifold) Nm (kgm/lb ft) 27(2.8/20)
Nm(kgm/lb ft)
TURBOCHARGER
Engine Model Turbine type Compressor type Maximum permissible speed rpm IHI : Ishikawajima Harima Heavy Industries., Ltd. 190,000 4JA1T(L) IHI RHF4H 4JA1TC IHI RHF4H Mixed type Backword & rake type 190,000 180,000 4JH1TC IHI RHF5
GENERAL DESCRIPTION
036LV002
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings. These parts are supported by the bearing housing. The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air exhaust port. The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption, and minimal engine noise. The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and machined to extremely high precision. Turbocharger servicing requires great care and expertise. If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or wear, trouble with the turbocharger is indicated.

Turbocharger pressure check

1. Remove the hose between the master gate and the compressor outlet pipe. 2. Connect the pressure gauge. To compressor outlet pipe. 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
150RY00030
Waste gate operation check

1. Remove the hose between the waste gate and the compressor outlet pipe. 2. Connect the pressure gauge. To waste gate actuator. 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.
150RY00031
Unit Inspection (Remove Turbo. from engine)

Check to see the pressure required to move the control rod 2 mm is within the limits shown below. Kpa/mmHg 4JH1TC 4JA1TC 134.8/1011 147.7/1108
150RY00032
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.
6F 18 EXHAUST SYSTEM 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 0.03 - 0.06 (0.001 - 0.002)
150RY00034
Limit 0.09 (0.004)
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 0.056 - 0.127 (0.0022 - 0.0050) Limit 0.127 (0.0050)
150RY00036
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-0075-0
901RX00143
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, Peoples Republic of CHINA TEL: 86-(1)-505-4997, 0408 FAX: 86-(1)-505-4350 TLX: 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202, Chia Hsin Building, No. 96 Chung Shan North Road, Section 2, Taipei, TAIWAN TEL: 886-(2)-542-5520, 5521, 5523 FAX: 886-(2)-542-4362 TLX: 11320 IHICO THAILAND IHI BANGKOK OFFICE 8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND TEL: 66-(2)-236-3490, 7356, 9099 FAX: 66-(2)-236-7340 TLX: 82375 IHICO TH MALAYSIA IHI KUALA LUMPUR OFFICE Letter Box No. 52, 22nd Floor, UBN Tower, 10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA TEL: 60-(3)-232-1255, 1271 FAX: 60-(3)-232-1418 TLX: IHI KLMA 20257 INDONESIA IHI JAKARTA OFFICE 9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA TEL: 62-(21)-32-2147, 390-2211 FAX: 62-(21)-32-3273 TLX: 44175 IHIJKT
ACCELERATOR CONTROL
6H 1
SECTION 6H
ACCELERATOR CONTROL
TABLE OF CONTENTS
PAGE Removal and Installation............................................................................................... 6H Removal...................................................................................................................... 6H Inspection................................................................................................................... 6H Installation.................................................................................................................. 6H 2 6 6 6
6H 2 ACCELERATOR CONTROL

4JA1T(L)/RHD
RTW46HLF000301
ACCELERATOR CONTROL
6H 3
4JA1T(L)/LHD
RTW46HLF000601
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
ACCELERATOR CONTROL
6H 5
4JA1TC, 4JH1TC/LHD
PTW46BMF000101
Removal
1. Disconnect the accelerator control cable from the accelerator pedal and dash panel. 2. Remove the cable clips. 3. Remove the accelerator control cable from accelerator control cable bracket. 1) Slide the lock in direction A 2) Rotate the ratchet ring in undirection an arrow 90. 4. Remove the accelerator control cable from the throttle. Check the following items and replace the control cable if any abnormality is found. The control cable should move smoothly. The control cable should not be bent or kinked. The control cable should not be damage or corrosion.
Inspection
RTW46HMH000201
Installation
1. Install the accelerator control cable to accelerator control pedal dash panel. 2. Install the accelerator control cable to throttle. Attach T-END and inner cable to throttle cam of engine. 3. Install accelerator control cable to accelerator bracket. 1) Rotate the ratchet ring in direction an arrow 90 until both white marking are aligned. 2) Confirm marking of outer cap must be upper side. 3) Slider the lock in direction B. 4) Confirm ratchet ring is locked. 4. Install the cable clips to accelerator control cable.
NOTE: Confirm that the throttle (engine side) is at full stroke when the accelerator pedal is at full stroke.
No. TF4JE-WE-0431

Manual Motor 4ja1

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Manual Motor 4ja1

Uploaded by

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Available Formats

WORKSHOP MANUAL

Basic Inspection Procedure

Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7

Verify repair Verify repair

1-3 Engine turn over but does not start engine

Was the fuel filter element clogged?

Go to Step 4 Bleed the air Solved

Go to Step 6 Replace the injection nozzle Go to Step 8

(See below) Go to Step 7

Replace the injection nozzle Repair or replace the throttle valve

Adjust the valve clearance

Was the compression pressure OK?

Go to Step 11 10 Are any DTC stored? Go to indicated DTC

Go to Step 3 Clean or replace the fuel filter element.

Repair or replace the fuel injection pipes. Replace the fuel

Was the exhaust gas leakage found from exhaust system?

4. Excessive Fuel Consumption

Go to Step 3 Replace the turbocharger

Was the turbocharger working completely?

Was the compression pressure OK?

3.0 MPa 2 (31.0 kg/cm , 441 psi) at 200 rpm

Go to Step 6 6 Was the injection nozzle pressure or spray pattern normal?

Go to Step 7 7 Are any DTC stored? Go to indicated DTC

Replace the injection nozzle Solved

5. Excessive Oil Consumption

Less than 588 kPa (6.0 2 kg/cm , 85 psi)

Go to Step 4 Go to Step 5 Go to Step 6

Go to Step 9 Go to Step 10 Go to Step 11 Solved

Go to Step 4 Replace the fan clutch assembly.

Was the fan clutch working completely?

Was the oil leakage found from fan clutch?

Replace the fan clutch assembly Go to Step 7

Go to Step 6 Replace the thermostat. Replace the water pump assembly.

Are any DTC stored?

7. White Exhaust Smoke

8. Dark Exhaust Smoke

Replace the injection nozzle Go to Step 5

Go to Step 6 Go to Step 7 Go to Step 8

9. Oil Pressure Does Not Rise

Does the oil strainer clog?

Go to Step 5 Repair or replace the oil pump.

Was the camshaft and/or relation parts worn?

Was the crankshaft and/or relation parts worn?

Are any DTC stored?

100 (1.0) 81 63.5

980 (10.0) 30 106.7

10. Abnormal Engine Noise

Go to Step 3 Go to indicated DTC

Are any DTC stored?

Was the exhaust manifold loose?

Was the injection nozzle loose?

Was the cylinder head gasket broken?

Are any DTC stored?

Are any DTC stored?

Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 10 Go to Step 7

Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7

Go to Step 9 Go to Step 10 Solved

11. Rotating Part Wear of Turbocharger

Replace the engine oil

Go to Step 6 Go to Step 7 Solved

12. Oil Leakage from Turbocharger

13. Insufficient Acceleration and/or Lack of Power due to turbocharger

Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Solved

14. Battery Charging and Noise Problem