Isuzu Dmax Engine Service Manual

WORKSHOP MANUAL TF SERIES

ENGINE

4JA1/4JH1-TC

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

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

2. UNSTABLE IDLING ........................ 6– 5

14. BATTERY CHARGING AND NOISE PROBLEM.............................. 6– 16

4. EXCESSIVE FUEL CONSUMPTION................................. 6– 7

14-2. Battery Overcharging ............ 6– 16

3. INSUFFICIENT POWER ................. 6– 6

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

14-1. Battery No Charging .............. 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

2

Inspection point

Check the check engine lamp

Inspection result

Is the check engine lamp turn ON ?

The battery fluid level and the Was the problem found? gravity

3

The engine coolant capacity

Was the problem found?

4

The engine oil level


5

The air cleaner element


6

The piping fixing condition (oil, Was the problem found? vacuum and fuel piping)

7 8 9

The drive belt tension and break


Go to section 6E “On Board Was the problem found? Diagnostic (OBD) System Check”

Go to mechanical Was the problem found? troubleshooting chart

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

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

Re-adjust the tension or replace

Go to Step 8

Verify repair

Go to Step 9

Verify repair

—


1. Hard Starting

Inspect the following items before diagnosis. 1. The battery conditions. The terminal connection condition. The battery charge condition or battery power weakness. 2. The fan belt loosen or broken. 3. The main fuse condition (open or not). 4. Fuel quantity level. 1–1 Starter motor inoperative Step 1 2 3

4 5

Action

Check the starter switch. Does the starter switch work?

1

—

Check the starter relay. Does the starter relay work?

—

Check the magnetic switch. Does the magnetic switch work?

—

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?

1-2 Starter motor operates but engine does not turn over Step

Value(s)

Action

Check the engine internal seizure. Was the engine seized?

— —

Value(s) —

Yes Go to Step 2 Go to Step 3

Go to Step 4 Go to Step 5

No

Repair or replace the starter switch Repair or replace the starter relay Repair or replace the magnetic switch

Replace the pinion gear

Replace the starter motor assembly

Repair or replace the brush or brush spring

Yes

No

Repair or replace seized parts

Check other DTC by Tech 2 and go to indicated DTC


1-3 Engine turn over but does not start engine

Incase of the fuel not being delivered to the injection pump Step 1 2 3 4 5

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? Was the fuel filter element clogged? Was the fuel line air bled? Are any DTC stored?

Incase of the fuel is being delivered to the injection pump Step

Action

1

Was the water contain in the fuel?

2

Was the fuel line air bled?

3 4

Was the injection spray condition complete? Was the injection nozzle injection starting pressure OK?

Value(s) —

— —

No

Repair replace problem parts.

Go to Step 2

Repair replace the over flow valve

Go to Step 3

Replace the fuel filter element

Go to Step 4

—

Go to indicated DTC

Solved

Value(s)

Yes

—

— — —

(See below)

5

Was the injection nozzle sticking?

—

6

Are any DTC stored?

—

Injection nozzle opening pressure 2 1st = 19.5 MPa (199 kg/cm , 2828 psi)

Yes

Go to Step 5

Bleed the air

No

Replace the fuel

Go to Step 2

Go to Step 4

Replace the injection nozzle

Go to Step 5


Go to Step 5

Replace the injection nozzle Go to indicated DTC

Bleed the air

Go to Step 6 Solved


2. Unstable Idling Step 1 2

Action

Was the fuel line air bled completely?

Was the fuel line leakage or blockage found?

Value(s) — —

3

Was the water contained in the fuel?

—

4

Was the fuel filter element clogged?

—

5

Was the injection starting pressure or the injection spray condition OK?

(See below)

6

Was the injection nozzle sticking?

See Step 6

7

Check the throttle valve condition. Was the idling port clogged in the throttle valve?

8

9

10

Was the valve clearance improper adjusted?

Was the compression pressure OK?

Are any DTC stored?

Injection nozzle opening pressure 2 1st = 19.5 MPa (199 kg/cm , 2828 psi)

— 0.4 mm (0.016 in) both intake and exhaust valves 3,040 kPa 2 (31 kg/cm , 441 psi) at 200rpm

—

Yes

Go to Step 3

Repair or replace relation parts. Replace the fuel

No

Bleed the air Go to Step 4 Go to Step 5

Replace the fuel filter element

Go to Step 6

Go to Step 7



Go to Step 8

Repair or replace the throttle valve

Go to Step 9

Adjust the valve clearance

Go to Step 10

Go to Step 11

Go to indicated DTC

Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and valve seat Solved


3. Insufficient Power Step 1

2

3 4 5 6

7

8 9

10 11 12 13

Action

Was the air cleaner element condition OK? (Clogged or not) Was the intake air leakage found from intake system?

Value(s) —

—

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?

—


Was the exhaust pipe clogged? Was the exhaust gas leakage found from exhaust system? Was the waste gate control actuator hose broken or cracked? Was the waste gate working completely? Was turbocharger working completely? Are any DTC stored?

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

— —

— — — —

Yes

Go to Step 2 Repair or replace the intake air system.

Go to Step 4

Repair or replace the fuel injection pipes. Replace the fuel

Go to Step 7

Go to Step 8

Repair or replace the exhaust pipe. Repair or replace the exhaust system.

Replace the hose. Go to Step 12 Go to Step 13

Go to indicated DTC

No

Clean or replace the air cleaner element.

Go to Step 3

Clean or replace the fuel filter element. 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 Go to Step 9

Go to Step 10 Go to Step 11 Replace the turbocharger assembly. Replace the turbocharger assembly. Solved


4. Excessive Fuel Consumption Step 1

2

Action

Was the air cleaner element clogged?

Was the air leakage found from the air intake side of the turbocharger?

Value(s) —

—

3

Was the turbocharger working completely?

—

4

Was there the fuel leakage?

—

5

6

7


Was the injection nozzle pressure or spray pattern normal?

Are any DTC stored?


—

—

Yes

Clean or replace the air cleaner element.

Repair or replace the air intake side of the turbocharger. Go to Step 4

Repair or replace the fuel leakage part.

No

Go to Step 2

Go to Step 3

Replace the turbocharger Go to Step 5

Go to Step 6

Readjust the valve clearance or replace the cylinder head gasket or cylinder liner or piston or piston ring or valve and valve seat

Go to Step 7


Go to indicated DTC

Solved


5. Excessive Oil Consumption Step 1

2 3

Action

Does the air cleaner element conditon OK? (Clogged or not)

Value(s) —

Does PCV (Positive Crankcase Ventilation) Valve has problem?

—

Was the oil pressure value more than normal value?

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

4

Inspect the front and rear crankshaft oil seal.

5

Was the oil leakage found from any gasket?

—

6

Inspect the valve stem seal, the valve stem and the valve guide for worn. Were any worn found?

—

7 8 9

Was the oil leakage found?

Was the oil leakage found from the turbocharger oil seal? Was the oil drain pipe of the turbocharger restricted?

Was the oil drain passage in the turbocharger center housing restricted?

—

— — —

10

Does turbine wheel has any impact damage?

—

11

Are any DTC stored?

—

Yes

Go to Step 2

Repair or replace the relation parts.

No

Clean or replace the air cleaner element Go to Step 3

Repair or replace the oil relief valve

Go to Step 4

Replace the failure part.

Go to Step 5

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 6 Go to Step 7 Go to Step 8 Go to Step 9 Go to Step 10 Go to Step 11 Solved


6. Overheating Step

Action

Value(s)

1

Was the engine coolant level OK?

2

Was the water leakage or the radiator restriction found? (Include radiator cap)

—

Was the fan belt slippage found?

—

3 4 5

Was the fan clutch working completely? Was the oil leakage found from fan clutch?

—

— —

6

Was the thermostat working normally?

—

7

Was the water pump working OK?

—

8 9

10

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? Are any DTC stored?

— —

Yes Go to Step 2

Repair or replace the leakage part.

Tension or replace the fan belt. Go to Step 5 Replace the fan clutch assembly

Go to Step 7 Go to Step 8 Clean or replace the clog part.

Replace the sealing cap or replace the cylinder body.

—

Go to indicated DTC.

Value(s)

Yes

No

Replenish the coolant Go to Step 3 Go to Step 4 Replace the fan clutch assembly.

Go to Step 6 Replace the thermostat. Replace the water pump assembly. Go to Step 9

Go to Step 10 Solved

7. White Exhaust Smoke Step 1

2

Action



Was the PCV (Positive Crankcase Ventilation) valve working completely?

—

3

Was the turbocharger working completely?

—

4

Are any DTC stored?

—

Go to Step 2 Go to Step 3 Go to Step 4

Go to indicated DTC

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


8. Dark Exhaust Smoke Step 1

Action

Was the air cleaner element normal condition?

Value(s) —

2

Was the EGR valve sticking?

—

3

Was the injection nozzle pressure or the injection spray pattern OK?

—

4 5 6 7 8 9

Was the oil leakage found from the turbocharger oil seal? Was the oil drain pipe of the turbocharger restricted?

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?

—

Yes

Go to Step 2 Replace the EGR valve

Go to Step 4

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

No

Clean or replace the air cleaner element Go to Step 3

Replace the injection nozzle Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 8 Go to Step 9 Solved


9. Oil Pressure Does Not Rise Step 1

Action

Was the oil pressure warning lamp working OK?

Value(s) —

2

Does the oil filter element clog?

—

3

Does the relief valve open?

—

4 5 6

7

8

9

Does the oil strainer clog?

—

Was the oil pump working OK? (The pump related parts worn etc.)

—

Was the rocker arm and/or relation parts worn?

—

Was the camshaft and/or relation parts worn?

Was the crankshaft and/or relation parts worn?

Are any DTC stored?

Table of pressure unit Pressure

Resistance

Electric current

—

—

—

kPa (kg/cm ) 2

ohm A

100 (1.0)

980 (10.0)

63.5

106.7

81

30

Yes Go to Step 2

Replace the oil filter element Repair or replace the relief valve

Clean or replace the oil strainer 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

No

Replace the oil pressure warning lamp Go to Step 3 Go to Step 4 Go to Step 5

Repair or replace the oil pump.

Go to Step 7

Go to Step 8

Go to Step 9 Solved


10. Abnormal Engine Noise 10–1 Engine knocking Step 1

2

3

Was the injection nozzle pressure or injection spray pattern OK?


Are any DTC stored?

10–2 Gas leakage noise Step 1 2

3

4 5

Action

Action

Was the exhaust pipe loose or broken? Was the exhaust manifold loose?

Was the injection nozzle loose?

Was the cylinder head gasket broken? Are any DTC stored?

Value(s) —


Yes

No

Go to Step 2


Go to Step 3

—

Go to indicated DTC

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

Replace the cylinder head gasket or piston ring Solved No Go to Step 2

Go to Step 3

Go to Step 4 Go to Step 5 Solved

TROUBLESHOOTING 6 – 13 10–3 Continuous noise Step 1

Action

Was the fan belt tension OK?

Value(s)

9 – 13 mm (0.35 – 0.51 in)

2

Was the cooling fan loose?

—

3

Was noise coming from the generator?

—

4

Was noise coming from the water pump?

—

5

Was noise coming from the cylinder head cover?

—

6

Are any DTC stored?

10-4 Slapping noise Step 1 2

Action

Was noise coming from the cylinder head cover? Were valve clearances correct?

—

0.4 mm (0.016 in) both intake and exhaust

—

5

Was noise coming from the cylinder body?

—

8

9 10

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?

Tighten the cooling fan

Repair or replace the generator and/or the vacuum pump Replace the water pump

Readjust the valve clearance.

Yes

Was the flywheel fixing bolt loose?

Inspect the connecting rod bearing and/or crankpin. Was the connecting rod bearing and/or crankpin worn?

Adjust the fan belt tension.

Value(s)

4

7

Go to Step 2

Go to indicated DTC

Were the rocker arms damaged?

Inspect the crankshaft bearing and/or crankshaft. Was the crankshaft bearing and/or crankshaft worn?

No

—

3

6

Yes

—

— —

—

— —

Go to Step 3

Go to Step 4 Go to Step 5 Go to Step 6 Solved No

Go to Step 2

Go to Step 4

Adjust the valve clearances

Go to Step 3

Replace the rocker arms Tighten the fixing bolt.

Go to Step 6 Replace the worn parts



Replace the worn parts

Go to Step 8

Replace the worn parts

Go to Step 9

Replace the worn or damaged parts

Go to indicated DTC

Go to Step 10 Solved

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 4 5 6

Was the excessive turbocharger?

Action

noise

coming

from

the

Inspect the fixing bolts and bands. Was any problem found?

Was the intake or exhaust system gasket damaged? Inspect rotation parts condition. Was the turbine wheel rotation rough?

Inspect the turbine wheel. Was the turbine wheel rubbing against housing?

Value(s) — — — — —

Yes

No

Go to Step 2

Go to Step 10

Tighten the loose parts

Replace the damaged gasket.

Replace the turbocharger. Replace the turbocharger.

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?

—

9

Was the turbine shaft bearing worn?

—

10

Are any DTC stored?

—

Go to indicated DTC

Value(s)

Yes

7 8

11. Rotating Part Wear of Turbocharger Step 1 2

3

Action

Inspect engine oil. Was it contaminated with foreign materials?

Was the recommended engine oil grade/viscosity being used?

Was the oil feed pipe restricted?

—

API CD or ISUZU genuine/ 10W–30 —

4

Was the oil seal of turbocharger defective?

—

5

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?

— —

Replace the turbocharger.

Clean or replace the turbocharger.

Repair or replace the oil feed pipe. Replace the turbocharger.

Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 8 Go to Step 9 Go to Step 10 Solved No

Replace the engine oil

Go to Step 2

Go to Step 3

Replace the engine oil

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




12. Oil Leakage from Turbocharger Step 1 2 3 4 5

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?

Was there oil leakage from the flange of the turbine housing?

Value(s) —

— —

Was there oil leakage from the flange of compressor housing?

—

Are any DTC stored?

—

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

13. Insufficient Acceleration and/or Lack of Power due to turbocharger Step 1 2 3

4 5

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?

Inspect the inside of the turbocharger. Was the turbine shaft end nut loose?

Value(s) — — —

—

Were the turbine blades bent?

—

6

Was the turbine wheel rubbing against housing?

—

7

Are any DTC stored?

—

Yes

No Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Solved No

Tighten flange bolts or hose clamp.

Go to Step 2

Replace the turbocharger

Go to Step 3

Repair or replace the actuator pipe or hose/ Replace the turbocharger

Replace the turbocharger Replace the turbocharger

Go to indicated DTC

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


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 2

3 4 5 6 7

Action

Was “Visual/Physical Check" performed.

1 2 3 4

—

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?

14-2 Battery Overcharging Step

Value(s)

Action

Was “Visual/Physical Check" performed. 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?

— — —

Yes Go to Step 2

Repair or replace the brush and/or the slip ring.

Replace the rotor coil.

Go to Step 5

Replace the rectifier

Replace the IC regulator.

Value(s)

Yes

— —



—

Go to visual/physical check

Replace the stator coil.

—

—

No

Go to Step 2 Repair the short circuit.



Go to Step 6 Go to Step 7 Solved 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 2

3 4 5 6 7 8

Action


1 2

3 4 5

6 7

—

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? Are any DTC stored?

14-4 Battery Unstable Charging Current Step

Value(s)

Action


— — —

Repair or replace the stator coil.

Replace the rectifier


Replace more higher capacity generator.

Yes

—

—

Are any DTC stored?

Repair or replace the rotor coil.

Value(s)

Inspect the rotor coil on the generator. Was there the short circuit or an open circuit in the rotor coil?

Inspect the IC regulator on the generator. Was the IC regulator defective?

Repair or replace the brush holder assembly.


—

Inspect the connection between the rectifier and stator coil on the generator. Was there a loose connection between the rectifier and stator coil ?

Go to Step 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 short circuit in the stator coil?

Yes

— —

— —

Go to Step 2

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.



No


Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 8 Solved No




6 – 18 TROUBLESHOOTING 14-5 Charging System Noise Step 1 2 3 4 5 6

Action

Was “Visual/Physical Check" performed. 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?

Value(s) —

— —

Was intermittent sound heard when the generator was running?

—

Was frictional sound heard when generator was running?

—

Are any DTC stored?

—

Yes

No

Go to Step 2


Replace the bearing.

Go to Step 3

Replace the stator coil.

Replace the brush and/or slip ring.

Clean the slip ring or replace the brush.


Go to Step 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 2

3

Action

Was “Visual/Physical Check" performed. Check the contact condition between the brush and the commutator. Was the brush and the commutator contact intermittent?

Value(s) —

—

Yes Go to Step 2

Replace the brush or repair the commutator.

Were the brush and the commutator contact faces dirty?

—

4

Was the pinion clutch slipped?

—

5

Inspect the armature field coil. Was there an open circuit or a short circuit in the armature field coil?

—

Are any DTC stored?

—


Value(s)

Yes

6

15-2 Incorrect pinion and ring gear engagement Step 1 2 3

4

Action

Was “Visual/Physical Check" performed. 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? Are any DTC stored?

—

— —

—

Clean contact face Replace the pinion clutch

Repair or replace the armature field coil.

No



Go to Step 6 Solved No

Go to Step 2


Replace the wron parts.

Go to Step 3

Adjust or replace the movement parts.


Go to Step 4 Solved

6 – 20 TROUBLESHOOTING 15-3 Starter motor continues to run after the starter switch is turned off Step 1 2

3 4

Action

Was “Visual/Physical Check" performed. Inspect the magnetic switch contact point. Was the contact point seized? Inspect the starter switch. Was the starter switch defective? Are any DTC stored?

15-4 Excessive commutator sparking Step 1 2

3

Action

Was “Visual/Physical Check" performed. 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?

Value(s) —

—

—

Repair or replace the magnetic switch.

Replace the starter switch.


Value(s)

Yes

—

—

—

Was the brush holder loose?

—

5

Inspect the commutator. Was there excessive wear or pitting?

—

6

Was there loose the solder on the commutator?

—

7

Inspect the armature shaft. Was the run-out of armature shaft outside the standard value due to worn bearing ?

—

Are any DTC stored?

Go to Step 2

—

4

8

Yes

—

Go to Step 2

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


No


Go to Step 3 Go to Step 4 Solved No


Go to Step 3

Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 8 Solved

ENGINE MECHANICAL 6A – 1

SECTION 6A

ENGINE MECHANICAL TABLE OF CONTENTS PAGE

Main Data and Specifications ....................................................................................... 6A -

4

Standard Bolts ........................................................................................................... 6A -

8

Torque Specifications ................................................................................................... 6A Special Parts Fixing Nuts and Bolts ........................................................................ 6A -

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

4JA1T (L)

Four-cycle, overhead valve, water cooled

Combustion chamber type

Direct injection

Cylinder liner type

Dry type, chrome plated

Timing gear train system

No. of cylinders-bore ! stroke

mm (in)

No. of piston rings

Total piston displacement

Compression ratio (to 1) Compression pressure Engine weight (dry)

cm (in ) 3

3

4 – 93 ! 92 (3.66 ! 3.62)

Compression ring: 2 / Oil ring: 1 2,499(152.4) 18.5

Mpa(kg/cm /psi)

3.0 (31.0/441) – 200 rpm

kg (lb)

Fuel injection timing BTDC

deg

Idling speed

rpm

Specified fuel type

Valve clearances (At cold): Intake

Exhaust

Intake valves

Open at (BTDC)

Exhaust valves

Open at (BBDC)

mm (in)

mm (in) deg

Close at (ABDC)

Approximately 239 (527)

8

1–3–4-2

730 " 25 (A/C Off)

850 " 25 (A/C ON) 0.4 (0.016) 0.4 (0.016) 24.5 55.5

deg

54.0

deg

Injection pump type

26.0 BOSCH distributor VE type

Governor type

Mechanical (Half all speed type)

Injection nozzle type

Injection nozzle opening pressure

Lubricating system

Specified engine oil (API grade)

BOSCH distributor VP44 type Electronically controled

Hole with 5 orifices

Mpa(kg/cm /psi)

Main fuel filter type

-

JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel

deg

Close at (ATDC)

Lubricating method

Gear drive

2

Fuel injection order

Fuel system

4JA1TC

2

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)

Cartridge paper element and water separator Pressure circulation

ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)


Item

Engine model

Oil capacity

Oil cooler type

4JA1TC Gear

Oil pump type Oil filter type

4JA1T (L)

lit (US/UK gal)

Cartridge paper element 6.2 (1.64/1.36) Water cooled

Cooling system

Water pump type

Centrifugal

Thermostat type

Wax pellet with jiggle valve

Air cleaner type

Dry paper element

Battery type/voltage ! No. of units Generator capacity Starter motor output

Turbocharger model

V-A V-Kw

Turbine type

Compressor type *IHI : Ishikawajima-Harima Heavy Industries., Ltd.

Viscous paper element

80D26L ! 1

95D31L ! 1 (OPT) 12 – 60 12 – 80

12 – 2.3

*IHI RHF 4H

Mixed flow type

Backward & rake


MAIN DATA AND SPECIFICATIONS Engine model

Item

Engine type

Four-cycle, overhead valve, water cooled

Combustion chamber type

Direct injection

Cylinder liner type

Dry type, chrome plated

Timing gear train system

No. of cylinders-bore ! stroke

mm (in)

No. of piston rings

Total piston displacement Compression ratio (to 1) Compression pressure Engine weight (dry)

liter MPa(kg/cm /psi) 2

kg (lb)

Fuel injection order Idling speed

rpm

Valve clearances (At cold): Intake

Exhaust

Intake valves

Open at (BTDC)

Exhaust valves

Open at (BBDC)

mm (in)

mm (in) deg

Close at (ABDC)

deg

deg

Close at (ATDC)

deg

Injection pump type

Injection nozzle opening pressure

2

Main fuel filter type

2,999 18.3

3.0 (31.0/441) – 200 rpm

MT : Approximately 249 (549) AT : Approximately 236 (520)

JIS No.2, DIN/EN590, GB252-1944 Diesel fuel 700 ! 25 (A/C OFF) 800 ! 25 (A/C ON) 0.4 (0.016) 0.4 (0.016) 24.5 55.5 54.0 26.0

1st 19.5 (199/2,828)

2nd (Reference) 34.3#35.8 (350#365/4,980#5,197) Cartridge paper element and water separator

Lubricating system

Lubricating method

Pressure circulation

Specified engine oil (API grade)

ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)

Oil pump type

Oil cooler type

Compression ring: 2 / Oil ring: 1

Hole with 5 orifices

MPa(kg/cm /psi)

Oil capacity

4 – 95.4 ! 104.9 (3.76 ! 4.13)

BOSCH distributor VP44 type

Injection nozzle type

Oil filter type

Gear drive

1–3–4-2

Specified fuel type

Fuel system

4JH1TC

Gear

lit (US/UK gal)

Cartridge paper element

6.2 (1.64/1.36) (For 4 ! 2)

7.0 (1.85/1.54) (For 4 ! 4) Water cooled


Item

Engine model

Cooling system

4JH1TC

Centrifugal

Water pump type

Wax pellet with jiggle valve

Thermostat type

Dry paper element (except for Euro3 spec) Viscous paper element (for Euro3 spec)

Air cleaner type

80D26L ! 1

Battery type/voltage ! No. of units

95D31L ! 1 (OPT)

75D26R ! 2 (OPT for EC, MT) 80D26R ! 2 (OPT for EC, AT)

Generator capacity

Starter motor output

Turbocharger model

V-A

V-Kw

Turbine type

Compressor type

*IHI: Ishikawajima-Harima Heavy Industries., Ltd.

12 – 60/12 – 80 12 – 2.3

*IHI RHF5

Mixed flow type Radial-inflow

Backward & rake type Radial-outflow


TORQUE SPECIFICATION STANDARD BOLTS The torque values given in the following table should be applied whenever a particular torque is not specified. N·m (kg·m/lb·ft) Strength Class

4.8 (4T)

(7T)

Bolt Identification

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)

-

7.35 ± 2.45 (0.75 ± 0.25/5.43 ± 1.80)

12.74 ! 4.90 (1.30 ± 0.50/9.40 ± 3.62)

17.15 ± 5.39 (1.75 ! 0.55/12.66 ! 4.00)

23.52 ± 6.86 (2.40 ± 0.70/17.36 ± 5.06)

61.25 ± 12.25 (6.25 ± 1.25/45.21 ± 9.04)

75.95 ± 15.19 (7.75 ± 1.55/56.06 ± 11.21)

94.57 ± 19.11 (9.65 ± 1.95/69.80 ± 14.10)

27.44 ± 6.86 (2.80 ± 0.70/20.25 ± 5.06)

95.55 ± 19.11 (9.75 ±1.95/70.52 ± 14.10)

116.13 ! 23.03 (11.85 ± 2.35/85.71 ± 17.00)

142.10 ± 28.42 (14.50 ± 2.90/104.88 ± 21.00)

244.02 ± 49.00 (24.90 ± 5.00/180.10 ± 36.17)

287.14 ± 57.82 (29.30 ± 5.90/211.93 ± 42.67)

130.34 ± 26.46 (13.30 ± 2.70/96.20 ± 19.53)

169.54 ± 34.30 (17.30 ± 3.50/125.13 ± 25.32)

257.74 ± 51.94 (26.30 ± 5.30/190.23 ± 38.33)

337.12 ± 67.62 (34.40 ± 6.90/248.82 ± 49.41)

188.16 ± 37.24 (19.20 ± 3.80/138.87 ± 27.49)

332.22 ± 81.34 (33.90 ± 8.30/245.20 ± 60.03)

49.98 ± 12.74 (5.10 ± 1.30/36.89 ± 9.40)

36.75 ± 9.31 (3.75 ± 0.95/27.12 ± 6.87)

199.92 ± 40.18 (20.40 ± 4.10/147.55 ± 29.66)

395.92 ± 79.38 (40.40 ± 8.10/292.21 ± 58.59)

453.25 ± 90.65 (46.25 ± 9.25/334.53 ± 66.91)

530.18 ± 105.84 (54.10 ± 10.80/391.30 ± 78.12)

36.26 ± 8.82 (3.70 ± 0.90/26.76 ± 6.50)

48.02 ± 11.76 (4.90 ± 1.20/35.44 ±8.68)

448.84 ± 90.16 (45.80 ± 9.20/331.27 ± 66.54)

570.36 ± 140.14 (58.20 ± 14.30/420.96 ± 103.43)

56.84 ± 11.76 (5.80 ± 1.20/41.95 ± 8.68)

70.56 ± 13.72 (7.20 ± 1.40/52.08 ± 10.13)

26.46 ± 6.86 (2.70 ± 0.70/19.53 ± 5.06)

89.18 ± 17.64 (9.10 ± 1.80/65.82 ± 13.02)

124.46 ± 24.50 (12.70 ± 2.50/91.86 ± 18.08)

109.76 ± 21.56 (11.20 ± 2.20/81.01 ± 15.91)

161.70 ± 32.34 (16.50 ± 3.30/119.34 ± 23.87)

691.88 ± 138.18 (70.60 ± 14.10/510.65 ± 101.99)

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)

N·m (kg·m/lb·ft)

Torque

Pipe diameter mm (in)

Torque

15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8)

10.00 (0.394)

53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)

44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6)

15.00 (0.591)

105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1)

12.00 (0.472)

88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)


SPECIAL PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket N·m (kg·m/lb·ft)

RTW46AXF000501


Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan N·m (kg·m/lb·ft)

RTW36AXF000101


Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft N·m (kg·m/lb·ft)

RTW46AXF000601


Cooling and Lubricating System N·m (kg·m/lb·ft)

RTW46AXF000701


Intake Manifold (4JA1TC / 4JH1TC) N·m (kg·m/lb·ft)

RTW36AXF000201


EGR Valve, EGR Pipe, EGR Cooler

RTW46AXF000801


Exhaust Manifold, and Turbocharger (4JA1L)

RTW46AXF000901


Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC) N·m (kg·m/lb·ft)

RTW46AXF001001


Engine Electricals N·m (kg·m/lb·ft)

RTW36AXF000501


Fuel Injection System (4JA1L)

N·m (kg·m/lb·ft)

RTW46AXF001101


Fuel Injection System (4JA1TC) N·m (kg·m/lb·ft)

RTW46AXF001201


Fuel Injection System (4JH1TC) N·m (kg·m/lb·ft)

RTW46AXF001301


Engine Mounting Bracket

N·m (kg·m/lb·ft)

022R300001


RECOMMENDED LIQUID GASKET Type

RTV* Silicon Base Water Base Solvent

Anaerobic

Brand Name

Manufacturer

ThreeBond 1141E ThreeBond 1215

Three Bond Three Bond

LOCTITE 515 LOCTITE 518 LOCTITE 262

Loctite Loctite Loctite

ThreeBond 1207B ThreeBond 1207C

ThreeBond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402

Three Bond Three Bond

Three Bond Isuzu Isuzu Isuzu

Remarks

Recommended for transaxle repairs

* RTV : Room Temperature Vulcanizer Note: 1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer’s instructions at all times. 3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry. 4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface. Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.


LOCTITE APPLICATION PROCEDURE LOCTITE Type

LOCTITE Color

LOCTITE 242

Blue

1. 2.

LOCTITE 262

Red

LOCTITE 270

Green

LOCTITE 271

LOCTITE 515

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.

3.

Tighten the bolts to the specified torque.

1.

Completely remove lubricant and moisture from the connecting surfaces. The surfaces must be perfectly dry.

4.

Wait at least one hour before continuing the installation procedure.

2.

Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting surfaces. There must be no gaps in the bead.

3.

Tighten the bolts to the specified torque.

Violet

4.

Let the joined parts set for at least thirty minutes.


SERVICING Servicing refers to general maintenance procedures to be performed by qualified service personnel.

MODEL IDENTIFICATION Engine Serial Number

The engine number is stamped on the 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

130RY00003

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)

LUBRICATING SYSTEM

Main Oil Filter (Cartridge Type Paper Element) Replacement Procedure

6A-6

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 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

MAX lit (US/UK gal)

Engine Dry

With oil filter replacement

4!2 4!4 (4JA1L/TC) 4!2 (4JH1TC)

Without oil filter replacement

6.2 (1.64/1.36)

5.2 " 4.2 (1.37 " 1.11 / 1.14 " 0.92)

4.5 " 3.5 (1.19 " 0.93 / 0.99 " 0.77)

4!4 (4JH1TC)

7.0 (1.85/1.54)

Model

6.2 (1.64/1.36)

5.2 " 4.2 (1.37 " 1.11 / 1.14 " 0.92) 6.2 " 5.2 (1.64 " 1.37 / 1.36 " 1.14)

4.5 " 3.5 (1.19 " 0.93 / 0.99 " 0.77) 5.3 " 4.3 (1.72 " 1.14 / 1.17 " 0.95)

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

Except EURO III model RTW46ASH002901

For EURO III model

RTW46ASH000501

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.


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

kPa(kg/cm /psi) 2

150 (1.5/21)

030LX003

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)

1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)

2


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) 030LX014

Oil Cooler Thermo Valve

82 (180)

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) Oil Cooler Thermo Valve

95 (203) 90 (194)


55 (131)

$C ($F) $C ($F)

Valve Lift at Fully Open position

mm (in)

Oil Cooler Thermo Valve

mm (in)

9.5 (0.37) 4.5 (0.18)


3.5 (0.14)

mm in)

Drive Belt Adjustment

033RY00002

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


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)

014RY00014

014RY00015

N·m (kg·m /lb·ft)

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.

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)

014RY00016

014RY00017

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.


COMPRESSION PRESSURE MEASUREMENT

F06XL056

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 N·m (kg·m /lb·ft) 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)

901R100003

MPa (kg/cm /psi) at 200 rpm 2

Limit

2.1 (21.7/309)

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.

RTW46ASH000601

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. 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

RTW46ASH000701

mm (in)

0.5 (0.02)

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 - 80$C (158 - 176$F). 4. Disconnect the engine control cable from the control lever. 5. Set a tachometer to the engine. 6. Check the engine idling speed. If the engine idling speed is outside the specified range, it must be adjusted. Engine Idling Speed : 730 " 25 rpm

Idling Speed Adjustment

1. Loosen the idling set screw lock nut ! on the injection pump idling set bolt. 2. Adjust the idling speed to the specified range by turning the idling set bolt ".

3. Lock the engine set nut ! 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 ! from the fast idle actuator # on the injection pump.

3. Disconnect the other vacuum hose " from the vacuum switching valve $ and connect it to the fast idle actuator #. The vacuum line will now be connected directly from the vacuum pump % 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

RTW36ASH000701

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.

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.

011R100002

011RY00005

Water Bypass Hose Thermostat Housing with Thermo Switch Cylinder Head Cover Injection Nozzle and Bracket 1. Remove the injection nozzle bracket bolts.

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

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

011RY00007

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

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

020L200020

020RY00019

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.

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.

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)

Limit 0.30 (0.012)

mm (in)


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.

RTW36ASH000801

4JA1T(L)

040R300009

4JA1TC/4JH1TC

RTW36ASH001301

Idler Gear End Play Standard 0.07 (0.0028)

mm (in)

14. Idle Gear Shaft 15. Crankshaft Timing Gear

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

015RY00001

Limit 0.2 (0.0079)

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.

014RT0001

901R100008

Camshaft End Play Standard 0.050 - 0.114 (0.002 - 0.0044)

Limit 0.20 (0.008)

mm (in)

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

052RY00001

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.

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

015LX018

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.

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.

015RY00002

Crankshaft End Play Standard 0.10 (0.004)

Limit 0.30 (0.012)

mm (in)

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

015RY00004

015RY00005

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.

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.

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

011RY00010

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


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

011RY00011

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


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

F06MV015

RTW36ASH001601

3. Piston Pin Snap Ring Use a pair of pliers to remove the piston pin snap rings.

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.


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

Limit

mm (in)

0.20 (0.0079)

NOTE:

The cylinder head lower face cannot be reground.

011RY00013

Cylinder Head Height (H) (Reference) Standard

mm (in)

91.95 – 92.05 (3.620 – 3.624)

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. 027RY00001

Manifold Fitting Face Warpage Standard

Limit

0.05 (0.002) or less

0.20 (0.008)

mm (in)

Maximum Grinding Allowance 0.40 (0.016)

Exhaust Manifold Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage. If the measured values exceed the specified limit, the manifold must be replaced. Exhaust Manifold Warpage Standard

027RY00002

0.05 (0.002) or less

Limit

mm (in)

0.20 (0.008)

Valve Stem and Valve Guide Clearance Measuring Method-I

011RY00022

1. With the valve stem inserted in the valve guide, set the dial indicator needle to "0". 2. Move the valve head from side to side. Read the dial indicator. Note the highest dial indication. If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Clearance Intake Valve Exhaust Valve

Standard

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:

mm (in)

If the valve guide has been removed, both the valve and the valve guide must be replaced as a set. 011RY000025


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

Exhaust Valve

7.946 - 7.961 (0.3128 - 0.3134)

7.921 - 7.936 (0.3119 - 0.3124)

mm (in) Limit

7.880 (0.3102)

7.850 (0.3090)

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

Inlet 4JA1TC, 4JH1TC Exhaust

1.8 (0.07)

1.34 (0.054)

1.36 (0.055)

mm (in) Limit

1.5 (0.06)

1.1 (0.045)

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

4JA1T(L)

4JA1TC, 4JH1TC

Standard

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 014RY00027

Intake

Exhaust

Standard

1.7 (0.067)

2.0 (0.079)

mm (in) Limit

2.2 (0.087)

2.5 (0.078)

Valve Seat Insert Replacement

011LX039

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.

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

Degree

NOTE:

Use an adjustable valve cutter pilot.

Do not allow the valve cutter pilot to wobble inside the valve guide.

011LX037

011LX038

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.


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

011LX024

4JA1T (L) 4JA1TC, 4JH1TC

Single spring

mm (in)

Standard

Limit

48.0 (1.89)

47.1 (1.85)

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

014RY00025


Limit Single spring

mm (in)

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

011LX026


Single spring

N (kg/lb)

Compressed Height

Standard

Limit

38.9mm (1.53in)

296.0 (30.2/66.4)

257.7 (26.3/57.9)


ROCKER ARM SHAFT AND ROCKER ARM Rocker Arm Shaft Run-Out

015LX008

1. Place the rocker arm shaft on a V-block. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press. The rocker arm must be at cold condition. If the measured rocker arm shaft run-out exceeds the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Run-Out

mm (in)

Limit

0.3 (0.012)

Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker arm fitting portion outside diameter. If the measured value is less than the specified limit, the rocker arm shaft must be replaced. Rocker Arm Shaft Outside Diameter Standard

015LX009

18.98–19.00 (0.747–0.748)

Limit

mm (in)

18.90 (0.744)

Rocker Arm Shaft and Rocker Arm Clearance 1. Use either a vernier caliper or a dial indicator to measure the rocker arm inside diameter. Rocker Arm Inside Diameter Standard

19.010–19.030 (0.748–0.749)

Limit

mm (in)

19.100 (0.752)

014RY00024

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

0.01–0.05 (0.0004–0.0020)

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

012R100001

0.05 (0.002) or less

Limit

mm (in)

0.20 (0.008)

Cylinder Body Height (H) (Reference) Standard

mm (in)

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. 012RY00010

Cylinder Liner Bore 4JA1T(L), 4JA1TC 4JH1TC

Standard

93.00 (3.6614)

95.40 (3.7559)

mm (in)

Limit

93.08 (3.6646)

95.48 (3.7590)

NOTE:

The inside of the dry type cylinder liner is chrome plated. It cannot be rebored or honed. If the inside of the cylinder liner is scored or scorched, the cylinder liner must be replaced.

Cylinder Liner Projection Inspection 1. Hold a straight edge 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

mm (in)

0-0.1 (0-0.004)

012LX016

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

012RY00012

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. 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

mm (in)

-0.0010*-0.019 (-0.00004*-0.0007) 012RY00013

* 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) 012RY00014

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.

012RY00022

Cylinder Liner Grade 4JA1T (L), 4JA1TC Liner Cylinder Body Outside Bore Diameter Grade

Liner Outside Diameter

Liner Bore Grade

Service Liner Bore Measurement

AX

93.035-93.050 (3.6628-3.6634)

1

95.001-95.010 (3.7402-3.7405)

95.011-95.020 (3.7406-3.7409)

2

95.011-95.020 (3.7406-3.7409)

95.021-95.030 (3.7410-3.7413)

3

95.021-95.030 (3.7410-3.7413)

95.031-95.040 (3.7414-3.7417)

4

95.031-95.040 (3.7414-3.7417)

95.041-95.050 (3.7418-3.7421)

4JH1TC Liner Outside Grade

mm (in)

CX

93.051-93.066 (3.6634-3.6640)

CX

93.051-93.066 (3.6634-3.6640)

CX

93.051-93.066 (3.6634-3.6640)

CX

93.051-93.066 (3.6634-3.6640)

AX AX AX

93.035-93.050 (3.6628-3.6634) 95.035-93.050 (3.6628-3.6634) 93.035-93.050 (3.6628-3.6634) mm (in)

Cylinder Body Bore Diameter

Liner Outside Diameter

Liner Bore Grade

Service Liner Bore Measurement

1

97.001-97.010 (3.8189-3.8193)

97.011-97.020 (3.8193-3.8197)

AX

95.435-95.450 (3.7573-3.7579)

2

97.011-97.020 (3.8193-3.8197)

97.021-97.030 (3.8197-3.8200)

3

97.021-97.030 (3.8197-3.8200)

97.031-97.040 (3.8200-3.8205)

4

97.031-97.040 (3.8200-3.8205)

97.041-97.050 (3.8205-3.8209)

CX

95.451-95.466 (3.7579-3.7585)

CX

95.451-95.466 (3.7579-3.7585)

CX

95.451-95.466 (3.7579-3.7585)

CX

95.451-95.466 (3.7579-3.7585)

AX AX AX

95.435-95.450 (3.7573-3.7579) 95.435-95.450 (3.7573-3.7579) 95.435-95.450 (3.7573-3.7579)


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: 012RY00017

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. 012RY00018

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

4JH1TC

NOTE:

AX CX AX 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)

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

78 (3.07)

70 (2.76)

Piston Grade (Service Part) 015LX021

4JA1T(L) 4JA1TC

4JH1TC

mm (in)

AX CX AX CX

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)

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

014RY00028

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.


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

014RY00029

Limit

12.97 - 12.99 (0.510 - 0.511)

12.95 (0.510)

Tappet and Cylinder Body Clearance Standard

0.01 - 0.046 (0.0004 - 0.0018)

012LX014

mm (in)

Limit

mm (in)

0.10 (0.004)

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

014RY00031

Limit

mm (in)

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

014RY00032

49.945 - 49.975 (1.9663 - 1.9675)

Limit

mm (in)

49.60 (1.953)

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) 014RY00033

Limit

mm (in)

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

0.02 (0.0008)

Limit

mm (in)

0.10 (0.004)


Camshaft and Camshaft Bearing Clearance Use an inside dial indicator to measure the camshaft bearing inside diameter. Crankshaft Bearing Inside Diameter Standard

50.00 - 50.03 (1.968 - 1.970) 014RY00034

Limit

mm (in)

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

mm (in)

0.12 (0.005)

Camshaft Bearing Replacement Camshaft Bearing Removal 1. Remove the cylinder body plug plate. 2. Use the bearing replacer to remove the camshaft bearing. Bearing Replacer: 5-8840-2038-0

014RY00035

014RY00036

Camshaft Bearing Installation 1. Align the bearing oil holes with the cylinder body oil holes. 2. Use the replacer to install the camshaft bearing. Bearing Replacer: 5-8840-2038-0


CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. NOTE:

To increase crankshaft strength, tufftriding (Nitrizing Treatment) has been applied. Because of this, it is not possible to regrind the crankshaft surfaces. Therefore, under size bearing are not available.

Crankshaft 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. 015LX061

Crankshaft Run-Out

Standard

Limit

0.05 (0.002) or less

mm (in)

0.08 (0.003)

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

015RY00007

Creankshaft Bearing Connecting Rod Bearing

4JA1T (L), 4JA1TC 4JH1TC

mm (in) Limit

64.5 (2.54)

74.5 (2.93) 56.5 (2.22)


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. 015RY00008

Crankshaft Journal and Diameter 4JA1T (L), 4JA1TC 4JH1TC

Standard

59.921-59.928 (2.3591-2.3594)

69.917-69.932 (2.7526-2.7532)

Limit

59.91 (2.3586) 69.91(2.7524)

Crankpin Diameter

Standard

52.915 - 52.930 (2.0833 - 2.0839)

mm (in)

Limit

mm (in)

52.90 (2.083)

Crankshaft Journal and Crankpin Uneven Wear Standard

0.05 (0.002) or less

Limit

mm (in)

0.08 (0.003)

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

015RY00009

0.032 - 0.077 (0.0013 - 0.0030)

Limit

mm (in)

0.110 (0.0043)


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.

015RY00011

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 78-88 (8.0/57 – 9.0/65) 4JA1TC 1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2) 4JH1TC 2nd step ; 45!-60! 3. Use an inside dial indicator to measure the connecting rod bearing inside diameter.

Crankpin and Bearing Clearance If the clearance between the measured bearing inside diameter and the crankpin exceeds the specified limit, the bearing and/or the crankshaft must be replaced. Crankpin and Bearing Clearance 4JA1T (L), 4JA1TC 4JH1TC

Standard

0.029-0.066 (0.0011-0.0026) 0.029-0.083 (0.0011-0.033)

Limit

mm (in)

0.100(0.0039) 0.100 (0.0039)

Clearance Measurements (With Plastigage)

015RY00012

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)

mm (in)

Do not allow the crankshaft to turn during bearing cap installation and tightening. 8. Remove the bearing cap. 015RY00013


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

mm (in)

0.110 (0.0043)

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 N·m (kg·m/Ib ft) 4JA1T (L), 78-88 (8.0/57 – 9.0/65) 4JA1TC 1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2) 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 4JA1T (L), 4JA1TC 4JH1TC

Standard

0.029-0.066 (0.0011-0.0026)

0.029-0.083 (0.0011-0.0033)

Limit

mm (in)

0.100 (0.0039) 0.100 (0.0039)

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:

015RY00016

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

015RY00017

Grade Mark

Diamaeter

1

63.99264.000 (2.51942.5197)

2

63.98363.992 (2.51902.5194)

RTW46ASH002501

3

63.97563.983 (2.51872.5190)

mm (in) Crankshaft Journal Grade Mark

Diamaeter

1 or -

59.927-59.932 (2.3593-23.595)

3 or ---

59.917-59.922 Yellow or 5 (2.3589-2.3591)

2 or --

1 or 2 or --

3 or ---

59.922-59.927 (2.3591-2.3539)

59.927-59.932 (2.3593-2.3595)

59.922-59.927 (2.3591-2.3593)

Grade Mark

Diamaeter

1

73.99274.000 (2.91312.9134)

2

3

73.98373.992 (2.91272.9131)

73.97573.983 (2.91242.9127)

Brown or 4

Black or 2 Blue or 3

59.917-59.922 Brown or 4 (2.3589-2.3591)

1 or -

59.927-59.932 Green or 1 (2.3593-2.3595)

3 or ---

59.917-59.922 (2.3598-2.3591)

2 or --

59.922-59.927 (2.3591-2.3593)

4JH1TC

Crankshaft Bearing Housing

Crankshaft Bearing Size Code

Black or 2

mm (in) Crankshaft Journal Grade Mark

Diamaeter

1 or -

69.927-69.932 (2.7530-2.7532)

3 or ---

69.917-69.922 (2.7556-2.7528)

2 or --

1 or 2 or --

3 or ---

69.922-69.927 (2.7528-2.7530)

69.927-69.932 (2.7530-2.7532)

69.922-69.927 (2.7528-2.7530)

69.917-69.922 (2.7556-2.7528)

1 or -

69.927-69.932 (2.7530-2.7532)

3 or ---

69.917-69.922 (2.7526-2.7528)

2 or --

69.922-69.927 (2.7528-2.7530)

Crankshaft Bearing Size Code

4 5 2 3 4 1 2


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

015RY00018

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:

015RY00010

Strike only the crankshaft pilot bearing outer race with the hammer. Do not strike the bearing inner race. Bearing damage and reduced bearing service life will result.

FLYWHEEL AND RING GEAR Flywheel

015RY00019

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) 4JA1T (L), 4JA1TC 4JH1TC

mm (in)

Standard

Limit

20 (0.7874)

21 (0.8267)

18 (0.7087)

19 (0.7480)

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

020LX009

Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 200!C (390!F). 2. Install the ring gear when it is sufficiently heated. The ring gear must be installed with the chamfer facing the clutch.

PISTON Piston Grade Selection and Cylinder Bore Measurement Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore Measurement" for details on piston grade selection and cylinder liner bore measurement.

Piston Ring 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

015RY00020

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)

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 1st Compression Ring 015RY00021

2nd Compression Ring Oil Ring 4JH1TC 1st Compression Ring

2nd Compression Ring Oil Ring

mm (in) Standard 0.3-0.3 (0.0118-0.0197) 0.250-0.450 (0.0098-0.0177)

Standard 0.3-0.5 (0.0118-0.0197) 0.250-0.450 (0.0098-0.0177)

Limit 1.5 (0.059)

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.

015LX025

Piston Ring and Piston Ring Groove Clearance 4JA1T (L), 4JA1TC 1st Compression Ring 2nd Compression Ring Oil Ring 4JH1TC 1st Compression Ring 2nd Compression Ring Oil Ring

mm (in)

Standard

Limit

0.05-0.085 (0.0020-0.0033)

0.15 (0.0059)

Standard

Limit

0.05-0.090 (0.0020-0.0035)

0.15 (0.0059)

0.09-0.125 (0.0035-0.0049)

0.03-0.070 (0.0012-0.0028)

0.09-0.130 (0.0035-0.0051)

0.03-0.070 (0.0012-0.0028)

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

Limit

30.995-31.000 (1.2202-1.2204)

mm (in)

30.97 (1.2193)

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

011LX011

Cylinder head gasket is determined by the piston head projection from the cylinder body upper surface, in order to improve engine performance. Three types of gasket are provided by the difference of thickness. Select the adequet one out of three grades of gasket, according to the following procedure. Before measurement, clear off carbon from the piston head and cylinder body surface and also clean the place where a gasket was installed.


Piston Head Projection Measuring Point 1. Use a dial indicator to measure the piston projection amount. 2. Refer to the illustration for the piston head projection measuring positions. All measuring positions should be as close as possible to the cylinder liner. 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. 011RY00027

Cylinder Head Gasket Combination Cylinder Head Gasket Combination 4JA1T (L), 4JA1TC Gasket Grade Mark Piston Projection A B

011RY00030

C

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

B C NOTE:

mm (in)

Gasket Thickness (Reference) 1.6 (0.0630)

1.65 (0.0650) 1.70 (0.0669) mm (in)

Gasket Grade Mark Piston Projection A

mm (in)

0.215-0.265 (0.0085-0.0104) 0.265-0.315 (0.0104-0.0124) 0.315-0.365 (0.0124-0.0144)

Gasket Thickness (Reference) 1.3 (0.5118)

1.35 (0.5315)

1.4 (0.5512)

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) Distortion

Parallelism

Standard

Limit

0.08 (0.003) or Less

0.20 (0.008)

0.05 (0.002) or Less

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. 011RY00029

Connecting Rod Big End and Crankpin Side Face Clearance mm (in) Standard

Limit

0.23 (0.009)

0.35 (0.014)

Piston Pin and Connecting Rod Small End Bushing Clearance Use a caliper calibrator and a dial indicator to measure the piston pin and connecting rod small end bushing clearance. If the clearance between the piston pin and the connecting rod small end bushing exceeds the specified limit, replace the piston pin and/or the connecting rod.

015LX028

Piston Pin and Connecting Rod Small End Bushing Clearance Standard


0.008-0.020 (0.003-0.0008)

0.005-0.018 (0.0002-0.0007)

Limit

mm (in)

0.050 (0.002) 0.050 (0.002)


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.

020RY00025

Idler Gear "A" Shaft Outside Diameter Standard

44.945-44.975 (1.7695-1.7707)

Limit

mm (in)

44.845 (1.755)

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

Limit

mm (in)

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

mm (in)

0.200 (0.0079)

TIMING GEAR CASE COVER Replace the crankshaft front oil seal if it is excessively worn or damaged.

Crankshaft Front Oil Seal Replacement

020R300004

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.


020R300005

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.


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

014RY00037

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


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

011RW027

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

011LX055

014RY00039

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.

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

RTW46ASH002301

Bolt Nut

19 (1.9/14)

24 (2.4/17)

N·m(kg·m/lbft)


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

010R100014

2 (0.2/17)

N·m(kg·m/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

RTW36ASH001401

6. Oil Filler Cap

19 (1.9/14)

N·m(kg·m/lb in)


MAJOR COMPONENT

014R300004

Reassembly Steps-1 1.

Cylinder body

10.

2.

Tappet

11.

3.

Crankshaft upper bearing

12.

4. 5.

6.

7. 8. 9.

Crankshaft Crankshaft thrust bearing Crankshaft bearing cap with lower bearing Camshaft Timing gear case Camshaft thrust plate

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

015LX127

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: 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)

015LX129

N·m(kg·m/lbft)

5. Check to see the crankshaft turns smoothly by rotating it manually.

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)

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

020RY00032

N·m(kg·m/lbft)

19 (1.9/14)

N·m(kg·m/lbft)

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)

RTW36ASH000901

N·m(kg·m/lbft)

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

015R100006

015LX096

015R100007

3. Apply a coat of molybdenum disulfide grease to the two piston skirts. This will facilitate smooth break-in when the engine is first started after reassembly. 4. Apply a coat of engine oil to the upper bearing surfaces. 5. Apply a coat of engine oil to the cylinder wall.

6. Position the piston head front mark so that it is facing the front of the engine. 7. Use the piston ring compressor to compress the piston rings. Piston Ring Compressor: 5-8840-9018-0 8. Use a hammer grip to push the piston in until the connecting rod makes contact with the crankpin. At the same time, rotate the crankshaft until the crankpin is at BDC. 9. Align the bearing cap cylinder number marks and the connecting rod cylinder number marks. The cylinder number marks must be turned toward the exhaust manifold.

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.

015LX130

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 78-88 (8.0/57 – 9.0/65) 4JA1TC 1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2) 4JH1TC 2nd step ; 45!-60! 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

N·m(kg·m/lbft)

19 (1.9/14)

M8 " 1.25

8 (0.8/6)

M6 " 1.00 052LX010

Relief Valve Torque

29 (3.0/22)

N·m(kg·m/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)

N·m(kg·m/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

013R100001

19 (1.9/14)

N·m(kg·m/lbft)

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

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

82 (8.4/61)

N·m(kg·m/lbft)

118 (12/87)

N·m(kg·m/lbft)

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

020RY00035

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.

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)

N·m(kg·m/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 020R300006

76 (7.7/56)

N·m(kg·m/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


RTW31BSH000401

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).

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 N·m(kg·m/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)

RTW36AMH000101

N·m(kg·m/lbft)

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)

N·m(kg·m/lbft)

Injection pump Bracket Bolt Torque (5)

N·m(kg·m/lbft)

19 (1.9/14)

RTW46ASH002201

40 (4.1/30)

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

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

020R300004

N·m(kg·m/lbft)

M12

N·m(kg·m/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

206 (21/152)

N·m(kg·m/lbft)

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

N·m(kg·m/lbft)

49 (5.0/36) 60! - 75!

3rd step

60! - 75!

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)

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)

031R300002

N·m(kg·m/lbft)

N·m(kg·m/lbft)

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

N·m(kg·m/lbft)

37 (3.8/28)

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)

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

mm(in)

13 (1.3/9.4)

N·m(kg·m/lbft)

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.

Exhaust Manifold Oil Cooler with Oil Filter Generator Bracket Water Inlet Pipe Generator and Adjusting Plate Vacuum Pump Oil Return Hose

19. 20.

8.

Turbocharger

23.

7.

Compressor Bracket

18.

21.

22.

9. 10. 11.

Catalytic Converter Heat Protector Cooling Fan Pulley

24. 25. 26-1.

13.

Fuel Leak Off Pipe

27.

12. 14. 15. 16. 17.

Oil Cooler Water Pipe

Oil Pressure Warning Switch Starter Motor Injection Pump Injection Pump Cover

26-2.

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 N·m(kg·m/Ib ft) 027R100003

27 (2.7/20)

3) Install the exhaust manifold bracket to the manifold and the cylinder body. Manifold Bracket Bolt Torque N·m(kg·m/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 N·m(kg·m/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 N·m(kg·m/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 N·m(kg·m/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 N·m(kg·m/Ib ft) M8!1.25

M10!1.25

042RY00003

19 (1.9/14)

40 (4.1/30)

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 N·m(kg·m/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 N·m(kg·m/Ib ft) M10!1.5

RTW46ASH001501

22 (2.25/16)

M14!1.5

54 (5.5/40)

8) Tighten the turbocharger nut to the specified torque. Turbocharger Nut Torque N·m(kg·m/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 N·m(kg·m/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 N·m(kg·m/Ib ft) 39 (4.0/29)

11) Install the water return pipe with the gaskets and tighten to the specified torque. Water Return Torque N·m(kg·m/Ib ft) 39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the turbocharger. Fixing Bolt (3) Torque N·m(kg·m/Ib ft) 8 (0.8/6)

RTW46ASH001601

13) Install the hoses for the water feed and return. 9. Catalytic Converter Install the catalytic converter with gasket and tighten the nut to the specified torque. Catalytic converter Nut Torque N·m(kg·m/Ib ft) 27 (2.7/20)

Do not install the catalytic converter, if drop down it.

027R100007

10. Heat Protector Install the heat protector and tighten the bolt to the specified torque. Heat Protector Bolt Torque N·m(kg·m/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 N·m(kg·m/Ib ft) 8 (0.8/6)

033R300002

12. Oil Cooler Water Pipe 13. Fuel Leak Off Pipe 14. Oil Pressure Warning Switch

ENGINE MECHANICAL 6A – 123 15. Starter Motor Tighten the starter motor bolts to the specified torque. Starter Motor Bolt Torque N·m(kg·m/Ib ft) 85 (8.7/63)

16. Injection Pump 17. Injection Pump Cover (4JA1TC/4JH1TC only) 18. Engine Foot Install the engine foot to the cylinder body and tighten the bracket bolts to the specified torque. Engine Foot Bolt Torque N·m(kg·m/Ib ft)

4JA1L, 4JH1TC

Right Side Left Side

M10!1.25

40 (4.1/30)

M14!1.50

127 (13/93)

M10!1.25

40 (4.1/30)

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 N·m(kg·m/Ib ft) 19 (1.9/14)

RTW36ASH001001

Intake Manifold Flange Nut Torque

24 (2.4/18)

N·m(kg·m/Ib ft)

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

N·m(kg·m/Ib ft)

1

M10!1.25

2 3

37 (3.8/28)

M8!1.25

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) N·m(kg·m/Ib ft) 40 (4.1/30)

Injection Pipe Sleeve Nuts

N·m(kg·m/Ib ft)

Injection Pipe Clip Nuts

N·m(kg·m/Ib ft)

29 (3.0/22) 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 N·m(kg·m/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 N·m(kg·m/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 N·m(kg·m/Ib ft) M8

M6

19 (1.9/14) 8 (0.8/6)

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 N·m(kg·m/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 N·m(kg·m/Ib ft) 24 (2.4/17)

EGR Pipe Bolts and Nuts

27 (2.7/20)

N·m(kg·m/Ib ft)

025R100008

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 N·m(kg·m/Ib ft) Bolt Nut

RTW36ASH000201

28. Clutch Assembly or Flex Plate

19 (1.9/14)

24 (2.4/17)


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

0.14 (0.0055)

Limit

0.20 (0.0079)

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)

Limit

0.15 (0.0059)

RTW46ASH002701

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 N·m (1.6 kg·m/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 N·m(kg·m/lb ft) A

64 (6.5/48)

RTW46ASH001701

4. Oil Cooler 5. Gasket 6. Bolt Tighten bolt with gasket and oil cooler to the specified torque. Bolt Torque N·m(kg·m/lb ft) 40 (4.1/30)

050R300006

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 N·m(kg·m/lb ft) 18 (1.8/13)

050RY00004


INTER COOLER REMOVAL AND INSTALLATION

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

Tool Name

5-8840-0201-0

Filter Wrench

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 -

3

Coolant Flow .............................................................................................................. 6B -

4

General Description .................................................................................................. 6B -

4

Water Pump................................................................................................................ 6B -

5

Radiator ...................................................................................................................... 6B -

6

Thermostat ................................................................................................................. 6B -

Diagnosis........................................................................................................................ 6B -

Draining and Refilling Cooling System........................................................................ 6B -

5

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


Installation.................................................................................................................. 6B - 14

Radiator .......................................................................................................................... 6B - 15

Removal and Installation .......................................................................................... 6B - 15

Radiator and Associated Parts................................................................................. 6B - 15 Removal...................................................................................................................... 6B - 16


Installation.................................................................................................................. 6B - 18

6B – 2 ENGINE COOLING

PAGE

Engine coolant change ............................................................................................. 6B - 19

Fan Clutch with Cooling Fan ........................................................................................ 6B - 20



MAIN DATA AND SPECIFICATIONS Item

M/T

Water pump type

Delivery volume

Pump speed at 3000 rpm

(To 1)

lit (US/UK gal)/min

Water temperature at 30!C (86!F)

Thermostat type

Valve initial opening temperature

!C (!F)

Valve full opening temperature

!C (!F)

Valve lift at fully open position

mm (in)

(Oil cooler thermo valve) (EGR cooler thermo valve) (Oil cooler thermo valve) (EGR cooler thermo valve) (Oil cooler thermo valve) (EGR cooler thermo valve)

Radiator

Heat radiation capacity Heat radiation area Radiator front area Radiator cap valve opening pressure Engine coolant capacity

Engine coolant total capacity

Centrifugal impeller type 1.2

100 (26.3/22.2)

Double row shaft

Pump bearing type

Radiator dry weight

A/T

Engine coolant forced circulation

Cooling system

Pump to crankshaft speed ratio

Description

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)


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.


WATER PUMP

RTW46ASF000101

A centrifugal type water pump forcefully circulates the coolant through the cooling system. The water pump is not disassembled type.

THERMOSTAT

A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.

030RY00005


RADIATOR

The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 93.3 ! 122.7 kPa (13.5 ! 17.8 psi) pressure. (No oil cooler provided for M/T)

110RS001

Antifreeze Solution

NOTE: Antifreeze solution + Water = Total cooling system capacity. Total Cooling System Capacity Lit (US / UK gal) 9.4 (2.5/21) 4JA1L/TC

M/T 10.1 (2.7/2.2) 4JH1TC

A/T 10.0 (2.6/2.2) 4JH1TC See section 0B MAINTENACE AND LUBRICATION. F06RW005

PTW46BSH000201

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


DIAGNOSIS Engine Cooling Trouble Symptom

Engine overheating

Possible Cause

Low Engine Coolant level

Replenish

Faulty thermostat

Replace

Thermo meter unit faulty

Action

Replace

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

Clean exhaust system or replace faulty parts

Faulty Throttle Position sensor

Replace throttle valve assembly

Damaged cylinder head gasket

Replace

Open or shorted Throttle Position Repair or replace sensor circuit

Engine overcooling

Engine slow to warm–up

Faulty thermostat

Replace

Thermo unit faulty

Replace

Faulty thermostat

Replace


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 5–minute 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.


WATER PUMP REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

Removal 1. Radiator Upper Hose 1) Partially drain the engine coolant. 2) Remove the radiator upper hose.

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


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

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 N·m(kg·m/lb ft) 20 (2.0/14)

030R300002

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 N·m(kg·m/lb in) 8(0.8/69)

4. Upper Fan Shroud

030R300001

6B – 12 ENGINE COOLING 5. Thermostat Install the thermostat to the thermostat housing. 6. Water Outlet Pipe 1) Install the water outlet pipe with new gasket to the thermostat housing. 2) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque N·m(kg·m/lb ft) 19(1.9/14)

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 AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

Removal 1. Radiator Upper Hose 1) Partially drain the engine coolant. 2) Remove the radiator upper hose.

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

Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

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)


! Thermometer " Agitating rod # Wooden piece Installation 1. Thermostat Install the thermostat to the thermostat housing. 2. Water Outlet Pipe 3) Install the water outlet pipe with new gasket to the thermostat housing. 4) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque N·m(kg·m/lb ft) 031R300003

19(1.9/14)

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 REMOVAL AND INSTALLATION

Radiator and Associated Parts

Legend

1. Radiator Hose 2. Drain Plug 3. Fan Guide, Lower 4. Fan Guide 5. Bracket

RTW36BLF000101

6. Reserve Tank Hose 7. Reserve Tank 8. Radiator Cap 9. Radiator Assembly


Removal 1. 2. 3. 4.

P1010064

PTW46BSH000101

RTW36BMH000101

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.

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.

7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade.


Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

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: 5–8840–0277–0 Adapter: 5–8840–2603–0 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 INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection.

033R300001

Visually inspect for damage, leak (sillicon grease) or other abnormal conditions. 1. Inspection (on-vehicle) 1) Turn the fan clutch by hand when in a low temperature condition before starting the engine, and confirm that it can be turned readily. 2) Start the engine to warm it up until the temperature at the fan clutch portion gets to around 80!C. Then stop the engine and confirm that the fan clutch can be turned with considerable effort (clutch torque) when turned by hand. If the fan clutch rotates more readily, however, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one. 2. Inspection (in unit) Warm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 80!C when measured with the thermistor. Then confirm that the fan clutch can be turned with considerable effort (clutch torque). If the fan clutch retates more readily at this time, this indicates that the silicone grease is leaking internally. Replace the fan clutch with a new one.

033RY00011

FUEL SYSTEM

6C – 1

SECTION 6C

FUEL SYSTEM TABLE OF CONTENTS PAGE

Main Data and Specifications ....................................................................................... 6C -

3

Fuel Flow.................................................................................................................... 6C -

4

General Description....................................................................................................... 6C -

4

Fuel Filter and Water Separator ............................................................................... 6C -

5

Injection Nozzle ......................................................................................................... 6C -

8

Injection Pump........................................................................................................... 6C -

Fuel Tank ........................................................................................................................ 6C -

Removal ..................................................................................................................... 6C -

7

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


Fuel Filler Cap ................................................................................................................ 6C - 17

Injection Pump ............................................................................................................... 6C - 18 Removal and Installation .......................................................................................... 6C - 18


6C – 2 FUEL SYSTEM PAGE

Injection Nozzle.............................................................................................................. 6C - 25

Inspection................................................................................................................... 6C - 25

Special Tools.................................................................................................................. 6C - 36

FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS Description

Item

4JA1T (L)

Injection pump type

Bosch distributor VE type

Governor type

Oil pressure

Fuel feed pump type Injection nozzle type

Injection nozzle designed operating 2 pressure MPa (kg/cm ) Main fuel filter type

4JH1TC

Bosch distributor VP44 type Electrical controled Electrical controled

Vane with input shaft Hole type

Number of injection nozzle orifices Inside diameter

4JA1TC

Mechanical variable (Half speed oil pressure)

Timer type

Injection nozzle orifices

6C – 3

5

mm (in) 1st

2nd

0.19 (0.0075)

0.17 (0.0067)

0.21 (0.0083)

25.0 (255)

33.5 (328)

33.8 (331)

19.1 (195)

19.0 (194)

19.5 (199)

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

INJECTION PUMP

FUEL SYSTEM

6C – 7

RTW46CLF000201

4JA1T(L): A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly to the injection nozzles, regardless of the number of cylinders. The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection pump is compact, light weight, and provides reliable high-speed operation. The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to operate the air conditioner. Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum pump. The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed. 4JA1TC/4JH1TC: The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump. Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the ECM selects the optimum fuel injection timing and volume for the existing driving conditions.


INJECTION NOZZLE (4JA1L)

NOTE: ! Injection nozzle adjustment is possible only on the 4JA1L engine.

RTW46CMF000301

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 TANK

FUEL SYSTEM

6C – 9

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)


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, don’t scratch each hose and tube by around other parts.

Installation

1. Raise the fuel tank.

NOTE: When raise the fuel tank to the vehicle, don’t scratch each hose and tube by around other parts.

2. Connect the pump and sender connector to the fuel pump and install the harness to weld clip on the tank.

NOTE: The connector must be certainly connected against stopper. 3. Install the tank band and fasten bolt. Torque 68 (6.9 / 50)

N·m (kg·m / lb ft)

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.

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.


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

Removal

FUEL SYSTEM

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.


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

FUEL TUBE / QUICK – CONNECTOR FITTINGS

6C – 15

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.

Legend

140R100032

(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


2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated. NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector. Use a lubricant (light oil) and/or push and pull the connector until the pipe is disconnected.

140R100037

140R100028

140R100036

Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering.

Reuse of Quick–Connector

! Replace the port and connector if scratch, dent or crack is found. ! Remove any dirt build up on the port when installing the connector. Replace the connector, if there is any forms of rust, dent, scratch. ! After cleaning the port, insert it straight into the connector until it clicks. After it clicks, try pulling at 49N (5kgf) it out to make sure that it is not drawn and is securely locked.

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.

FILLER NECK

FUEL SYSTEM

6C – 17

Removal

1. Remove the fuel tank. NOTE: Refer to "Fuel Tank" in this section. 2. Put a marking the following point as the filler neck assembly is restored. ! Each joint area of the hose (to restore axial direction and insertion length of the hose) ! Each fasten area of the clamp (to restore axial direction and position of the clamp) ! Each bolt in the clamp (to restore fasten length of bolt in the clamp) ! The band clip (to restore position and fasten length of the band clip) NOTE: Cover end of each hose and pipe to prevent any dust entering.

Installation

1. Align each marking and restore the following point. ! Each joint area of the hose (Restore axial direction and insertion length of the hose) ! Each fasten area of the clamp (Restore axial direction and position of the clamp) ! Each bolt in the clamp (Restore fasten length of bolt in the clamp) Torque N·m (kg·m / lb ft) 2.5 (0.25 / 21.7)

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.


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.

Legend

RTW36CSH000401

(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.

INJECTION PUMP

FUEL SYSTEM

6C – 19

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 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


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

020L200017

RTW46CSH000201

6C-7

6C – 21

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.

3) Insert the lock bolt (M6 x 30) into the scissors gear idle gear “B” fixing hole to prevent the scissors gear from turning.

29. Injection Pump Bracket 20. Injection Pump


Installation!! 1. Injection Pump 1) Install the injection pump gear (When gear is removed). Injection Pump Gear Nut N"m (kg"m/lb ft) 64 (6.5 / 47)

RTW46CSH000201

020L200017

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”.

6) Tighten the injection pump fixing bolts to the specified torque. Injection Pump Bolts Torque N·m (kg·m/lb ft) 19 (1.9 / 14)

6C-7

FUEL SYSTEM

6C – 23

4JA1T (L)

4JA1TC/4JH1TC

RTW46CSH000101

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 N·m(kg·m / 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 N·m(kg·m / 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 N·m(kg·m / lb ft) 19 (1.9 / 14)

Intake Manifold Nuts Torque

24 (2.4 / 17)

N·m(kg·m / lb ft)

2) Install the EGR valve to the intake manifold and EGR pipe temporarily. 3) Tighten the nuts and bolts to the specified torque

Torque

Nuts Bolts

N!m (kg!m/lb ft)

24 (2.4/17) 27 (2.8/20)


6. Injection Pipe Install the injection pipe. Injection Pipe Torque

29 (3.0 / 22)

N·m(kg·m / lb ft)

Nozzle Side (4JA1TC/4JH1TC)

N·m(kg·m / lb ft)

Pump Side (4JA1TC/4JH1TC)

N·m(kg·m / lb ft)

29 (3.0 / 22) 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 N·m(kg·m / 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 N·m(kg·m / 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 N·m(kg·m / 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 N·m(kg·m / lb ft) M8: 19 (1.9 / 14) M6: 8 (0.8/6 lb in)

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

Euro I

Euro II

Euro III

4JA1L

without

with

with

4JA1TC

Not used

Not used

Not used

4JH1TC

without

with

with

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


INJECTION NOZZLE (4JA1L) DISASSEMBLY

080L200009

Disassembly Steps 1. 2. 3. 4.

Retaining nut Nozzle & pin Spacer & pin Lift Piece

9. 10. 11. 12.

5. 6. 7.

Spring seat Push rod Shim (Second nozzle opening pressure adjustment) Second spring

13. 14. 15.

8.

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

REASSEMBLY

6C – 27

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.

Spring seat Lift Piece

11. 12. 13. 14. 15.

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.


REASSEMBLY AND ADJUSTMENT PROCEDURE 1 2

First nozzle opening pressure adjustment Full needle valve lift confirmation

3

Pre-lift confirmation

Adjust the first nozzle opening pressure using the shim. 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.

4

Second nozzle opening pressure confirmation

Confirm the second nozzle opening pressure in accordance with the closed method.

5

Second nozzle opening pressure adjustment

Adjust the second nozzle opening pressure using the shim.

6

Final inspection

First nozzle opening pressure adjustment Nozzle needle valve full-lift

Nozzle needle valve pre-lift Nozzle pressure 4JA1T(L)

1st Stage

2nd Stage

Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.

0.25 mm (0.0098 in)

0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm ) 2

19.1 Mpa (2759 psi, 194 kg/cm ) 2

25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )

NOTE: Only 4JA1L can perform adjustment of a nozzle.

2

FUEL SYSTEM

Injection Nozzle Adjustment

6C – 29

First nozzle opening pressure adjustment 1.Clamp the nozzle holder in a vise.

040MV015.tif

2. Install the shim, first spring and spring seat in the nozzle holder.

040MV016.tif

3. Install the collar, second spring, shim, spring seat and pushrod in the nozzle holder.

040MV017.tif

4. Install the pins, lift piece and spacer in the nozzle holder.

040MV018.tif


5. Install the pins in the spacer. 6. Install the nozzle on the spacer.

040MV019.tif

7. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder. Retaining nut: 157892-3200 (Bosch AS) Gasket: 157892-5100 (Bosch AS) (Bosch AS = Bosch Automotive Systems Corporation)

040MV010.tif

8. Tighten the adjustment retaining nut to the specified torque. Torque: 5.1 kg·m (36.9 Ib·ft/50 N·m)

040MV014-1.tif

9. Set the nozzle holder to the nozzle tester. 10. Operate the nozzle tester and measure the first nozzle opening pressure. 11. If the first nozzle opening pressure is not as specified, disassemble the nozzle holder and replace the shim until the pressure is as specified. CAUTION: • Use a micrometer to measure shim thickness. 040MV030.tif

•

FUEL SYSTEM

First nozzle opening pressure adjusting shims Parts No. (ISUZU)

Thickness (mm)

115349-0430

0.50

115349-0420 115349-0440 115349-0450 115349-0460

040LX010.tif

6C – 31

115349-0470 115349-0480 115349-0490

0.40 0.52 0.54 0.56 0.58 0.60 0.70

Full needle valve lift confirmation 1. Install the gasket and plug on the adjustment retaining nut. Gasket: 026508-1140 (Bosch AS) 894227-6020 (ISUZU) Plug: 157892-1600 (Bosch AS)

040MV013.tif

2. Position the nozzle holder with the nozzle facing down and install the dial gauge holder on the nozzle holder. Dial gauge holder: 157892-5000 (Bosch AS)

040MV012.tif

3. Install the nut on the dial gauge holder. Nut: 157892-1000 (Bosch AS)

040MV011.tif


4. Install the pin to the dial gauge. Note: The lengths of the pins do not include the threaded portions. Pin (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 nozzle’s needle valve moves through its full lift. Record full lift ‘L’. (Read dial gauge) Nozzle Full Lift mm (in) 0.25 ! 0.02 (0.0098 ! 0.00008)

040MV008.tif

Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition.

Pre-lift confirmation 1. With the needle valve at full lift, release the nozzle tester handle. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little.

040MV007.tif

040R300008


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 040H100007

4JA1T(L)

Pressure Mpa 2 (psi/ kg/cm )

20.1 (2,858/205)

Lift mm (in) 0.04 (0.0016)

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 nozzle’s 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

4JA1T(L) 040M100006

Pressure Mpa 2 (psi/ kg/cm )

25.5-27.0 (3768-3911/260-275)

Lift mm (in) 0.09 (0.0035)


040MV017.tif

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. •

040LX009.tif

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

Final inspection 1. Remove the dial gauge, nut and dial gauge holder.

040MV028.tif

040MV014-1.tif

2. Remove the adjustment retaining nut and gasket. 3. Install the original retaining nut, confirm that the pins are inserted fully into the nozzle, and then hand-tighten the retaining nut. Then, tighten the original retaining nut to the specified torque. Torque: 7.0 kg·m (50.6 Ib·ft/69 N·m)

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 ILLUSTRATION

SPECIAL TOOLS TOOL NUMBER 5-8840-2602-0 (J-39765)

TOOL NAME

Remover: fuel pump retainer ring

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

MAIN DATA AND SPECIFICATIONS Description

Item

60A

Generator Type Voltage Drive and rotation Ground polarity

Maximum output Engine speed ratio Maximum speed

Weight with vacuum pump

Vacuum Pump Delivery volume Exhaust Characteristic

AC generator with IC regulator and vacuum pump

V A to 1 rpm

kg(lb)

cm /rev 3

Starter Motor Type

Weight

Hitachi LR160-503E

Hitachi LR180-513B

12 V-belt, clockwise viewed from the drive pulley Negative 60

5.8(12.8)

1.788 11,000

80

6.4(14.1)

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

Maximum vacuum

Rated voltage Rated output Load characteristics Terminal voltage Load current

80A

Solenoid controlled V kW V A

kg(Ib)

Hitachi S13-555 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

N!m (kg!m/Ib!ft)

RTW46DLF000201


STARTER MOTOR

N!m (kg!m/Ib!ft)

RTW46DLF000301

GENERATOR


REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

Important Operations-Removal Cooling Fan Belt 1. Disconnect the battery cables at the battery terminals. 2. Loosen and remove the fan belt adjusting plate bolts. 3. Remove the fan belt from the generator drive pulley.

P1010002

Generator 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)

N!m (kg!m/Ib!ft)

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)

N·m (kg·m/lb·ft)

5. Reconnect the battery cable to the battery.


DISASSEMBLY

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

RTW46DLF000401

6D – 10 ENGINE ELECTRICAL Important Operations 1.

Vacuum Pump 1. Loosen the vacuum pump fixing screws. 2. Support the vacuum pump O-ring. 3. Carefully remove the O-ring. 2. Cover

RTW46DSH000101

3.

Through Bolt 1. Remove the M5 through bolt. 2. Separate the front and rear sides of the vacuum pump. 3. Insert the tips of 2 ordinary screwdrivers into the space between the front cover and the stator core. Remove the front cover and rotor together with the rear cover and stator. If removal is difficult, push the rear cover to the side and lightly tap the end of the shaft with a plastic hammer to loosen it. ! The front cover oil seal must be replaced with a new one when the front cover is removed. ! Take care not to damage the stator core with the screwdriver tips.

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.

RTW46DSH000201

RTW46DSH000601

RTW46DSH002101

ENGINE ELECTRICAL 6D – 11 7. Rotor Assembly 1. Remove the rotor from front cover assembly. Remove the front cover stator and rectifier.

RTW46DSH000301

RTW46DSH000701

RTW46DSH000801

RTW46DSH000401

8. Front Cover Assembly 1. Remove the front cover bearing retainer screws. 2. Remove the bearing.

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.


INSPECTION AND REPAIR 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)

Limit

30.6 (1.183)

RTW06DSH000101

If the slip ring diameter is less than the specified limit, the slip rings must be replaced. 3. Measure the rotor coil resistance. Rotor Coil Resistance at 20"C (68"F) 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

066RY00023

0.1

2. Check for continuity between each stator coils and the stator core. If there is continuity, the stator coils must be replaced.

BRUSH Measure the length of the brush. If abrasion has reduced the brush length to less than 6.5 mm, the brush must be replaced with a new one. A wear line is inscribed in the brush. If the line is not visible, the brush must be replaced. Brush Length (Reference) mm (in) Standard

Limit

25 (1.0)

RTW46DSH004801

6.5 (0.25)

Rectifier

RTW46DSH001201

E U, V, and WN

⊕ "

Tester wire

⊕

"

-----

Conductivity

No ----conductivity Negative side diode check

BAT U, V, and WN

⊕ "

⊕ ----Conductivity

Positive side diode check

"

No conductivity -----


RECTIFIER ASSEMBLY

1. 2. 3. 4. 5. 6. 7. 8. 9.

RTW46DSF000301

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

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

No.

Switch 1

Switch 2

Switch 3

1

ON

OFF

OFF

2

ON

ON

OFF

3

ON

ON

OFF

16V

4

OFF

ON

OFF

12V

5

ON

ON

ON

Voltmeter reading 12V

18V

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

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. ! Position the oil seal beneath the shaft and the guide lip. ! 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. ! 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 ! Be sure that no foreign material enters the space between the oil seal and the rotor shaft surfaces during the installation procedure. ! Take care not to damage the D surface. ! Under no circumstances may the original oil seal be reused. ! 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

RTW46DSH002001

3. Install the center plate to the rotor housing. Be sure to use a new O-ring.


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 N#m (kg#m/lb#ft) 83.3 $ 98.0 (8.5 $ 10.0 / 61 $ 72)

RTW46DSH002101

RTW46DSH006001

Remove the tape from the splines.

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

6D – 20 ENGINE ELECTRICAL 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

ENGINE ELECTRICAL 6D – 21 9. Through Bolt 1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover. 2. Install the through bolts and tighten them to the specified torque. Through Bolt Torque N#m (kg#m/lb#ft) 3.1 $ 3.9 (0.32 $ 0.41 / 2.6 $ 3.5)

RTW06DSH000201

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 N#m (kg#m/lb#ft) 5.9 $ 6.9 (0.6 $ 0.7 / 5.2 $ 6.1)

RTW46DSH002501


STARTER MOTOR REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

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 N#m (kg#m/lb#ft) 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

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

RTW460LF000201

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

6D – 24 ENGINE ELECTRICAL Important Operations 1. Lead Wire Disconnect the lead wire at the magnetic switch.

RTW46DSH002601

RTW46DSH002701

RTW46DSH002801

RTW46DSH002901

RTW46DSH003001

3. Magnetic Switch Assembly Remove the magnetic switch bolts, then remove the switch from the shift lever.

Remove the torsion spring from the magnetic switch.

8. Through Bolt 9. Screw 10. Rear Cover Remove the through bolts, then remove the rear cover.

11. Motor Assembly Remove the four brushes from the brush holders.

ENGINE ELECTRICAL 6D – 25 Remove the yoke along with the armature and the brush holder from the gear case. Remove the brushes and commutator carefully so as not to allow them in contact with the adjacent parts.

RTW46DSH003101

RTW46DSH003201

RTW46DSH003301

RTW46DSH003401

12. Brush Holder 13. Yoke 14. Armature Remove the brush holder and pull out the armature assembly free from the yoke.

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.

3. Use a screwdriver to remove the stopper clip. Then disassemble the pinion assembly.


INSPECTION AND REPAIR 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

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)

065RY00025

Limit

Limit

0.2 (0.008)

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

mm (in)

35.5 (1.40)

If the measured outside diameter is less than the specified limit, the commutator must be replaced.

065RY00026

RTW46DSH003601

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.

ENGINE ELECTRICAL 6D – 27 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

RTW46DSH003901

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.


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)

Limit

12 (0.47)

RTW46DSH004001

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

6D – 30 ENGINE ELECTRICAL Important Operations 1. Magnetic Switch Assembly 1. Attach the torsion spring to the hole in the magnetic switch as illustrated. 2. Insert the shift lever into the plunger hole of the magnetic switch.

RTW46DSH005601

7. Gear Case 3,8. Dust Cover 1. Install the magnetic switch assembly in the gear case. 2. Install the dust cover. Dust Cover Bolt Torque

RTW46DSH005701

065RY00041

RTW46DSH004501

8 (0.8/5.4)

N#m (kg#m/lb#ft)

10. Pinion Assembly Apply a coat of grease to the reduction gear and install the pinion assembly to the armature shaft.

21. Brush Holders 1. Install the brushes into the brush holder with raising the spring end of the brush spring. Take care not to damage the commutator face. 2. Install the brush holder with aligning the peripheries of the yoke and the brush holder.

ENGINE ELECTRICAL 6D – 31 24. Through Bolt Install the through bolts in the rear cover and tighten them to the specified torque. Through Bolt Torque N#m (kg#m/lb#ft) 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 N#m (kg#m/lb#ft) 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

RTW46DSH005901

RTW46DSH004701

2. Hold-in Maintenance Test Disconnect the lead at the M terminal. The pinion should continue to flutter.

3. Return Test Disconnect the battery positive lead at the S terminal. The pinion should return to its home position.


PRE-HEATING SYSTEM

INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during inspection.

VISUAL CHECK

Check the main fuses and glow indicator for damage. Replace the part(s) if required.

GLOW RELAY The glow relay is located in the relay box the engine compartment. Use an ohmmeter to measure the resistance between terminals No.2 and No.3. If the measured value is outside the specified range, the glow relay must be replaced. Glow Relay Resistance

825R300046

94 % 114

Ohms

GLOW PLUG Use a circuit tester to test the glow plugs for continuity. Glow Plug Resistance (Reference)

Approximately 0.9

LNW21KSH001401

EGR SYSTEM 4JA1T (L) Refer to 6F-9. (EGR system diagram)

Ohms


MEMO

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS

6E–1

ENGINE 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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

6E–2


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)

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS (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

6E–3

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

6E–4


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

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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

6E–5

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

6E–6


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)

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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

6E–7

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

6E–8


(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)

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


ABBREVIATION CHARTS

Abbreviations

A/C

Air conditioner

A/T

Automatic transmission

BLK

Black

ACC

Accessory

BLU

Blue

CAN

Controller Area Network

BRN

Brown

CEL

Check engine lamp

DLC

Data link connector

CKP

Crankshaft position sensor

DTC

Diagnosis trouble code

ECM

Engine control module

DVM

Digital voltage meter

ECT

Engine coolant temperature

EGR

Exhaust gas recirculation

GND

Ground

EEPROM EVRV

Appellation

Electrically erasable & programmable read only memory Electric vacuum regulating valve

GRY

Gray

IG

Ignition

MAB

High pressure solenoid valve cutoff (German abbreviation)

IAT

M/T

MAF MIL

OBD

Intake air temperature Manual transmission Mass air flow

Malfunction indicator lamp

On-board diagnostic

ORN

Orange

RED

Red

PNK

Pink

PSG

Pump control unit (German abbreviation)

TCM

Transmission control module

TDC

Top dead center

VCC

Voltage constunt control

SW

TCV TPS

Switch

Timing control valve

Throttle position sensor

VIO

Violet

WHT

White

VSS YEL

Vehicle speed sensor

Yellow

6E–9

6E–10


COMPONENT LOCATOR

Engine Component Locator Table 4JA1-TC

3

1

(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) Throttle Cable (3) Air Cleaner Case

2

6

4

(4) Battery (5) Relay & Fuse Box (6) EGR Cooler

5


4JH1-TC

4

3

1

(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) Throttle Cable (3) Air Cleaner Case

2

6

4

6E–11

5

(4) Battery (5) Relay & Fuse Box (6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)

6E–12


1

3

2

4

(1) Throttle Position Sensor (TPS) (2) Pump Control Unit (PSG)

2

(1) Mass Air Flow (MAF) & Intake Air Temperature (IAT) Sensor Assembly (2) EGR EVRV

(3) Injection Pump Assembly (4) Fuel Filter (Except Euro 3)

3

1

(3) Air Cleaner Case


3

(1) Engine Control Module (ECM)

2

2

1

(1) EGR EVRV (2) To Vacuum Pump (3) To EGR Valve

1

(1) Engine Coolant Temperature (ECT) Sensor (2) Thermo Unit for Water Temperature Gauge

(1) Vehicle Speed Sensor (VSS)

2

1

(1) Crankshaft Position (CKP) Sensor (2) Clutch Housing

6E–13

6E–14


ECM CIRCUIT DIAGRAM (4JA1-TC)


ECM CIRCUIT DIAGRAM (4JA1-TC)

6E–15

6E–16


ECM CIRCUIT DIAGRAM (4JH1-TC)


ECM CIRCUIT DIAGRAM (4JH1-TC)

6E–17

6E–18


GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)



6E–19

6E–20





6E–21

6E–22


GROUND POINT CHART EUROPE (LHD) (1/4)



6E–23

6E–24





6E–25

6E–26


GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)



6E–27

6E–28





6E–29

6E–30


GROUND POINT CHART EUROPE (RHD) (1/4)



6E–31

6E–32





6E–33

6E–34


LOCATION


CABEL HARNESS & CONNECTOR LOCATION

6E–35

6E–36


4JA1-TC & 4JH1-TC ENGINE (LHD)


4JA1-TC & 4JH1-TC ENGINE (RHD)

6E–37

6E–38


PARTS LOCATION


6E–39

6E–40


CONNECTOR LIST

No.

Connector face

Green

Meter-B

White

J/B I2

White

J/B I4

Black

Check connector

White

TCM

White

Ignition switch (IGSUB : G1)

White

TCM

White

Ignition switch (IGSUB : G2)

White

J/B E2

White

J/B E1

Silver

Body-LH ; ground

Brown

EVRV

B-24

B-54

B-56

B-58

B-62

B-63

B-68

C-2

Immobilizer

Silver

Engine room-RH ground

Silver

Engine room-LH ; Ground

White

Stop lamp switch

C-36

C-44

No.

C-56

C-57

C-77

C-94

C-95

C-107

C-108

C-109

C-115

C-116

Connector face

ECM-A

ECM-B

Clutch switch

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS No.

C-118

C-123

Connector face

A/C Resister & Neutral switch

C-124

E-6

Connector face

Gray

Idle SW

Black

Coolant temp sensor

Gray

Vehicle speed sensor

Gray

Glow plug

Black

Inhibiter switch

White

Engine room ~ Mission

E-23

E-41

E-44

E-3

Black

No.

E-49

Magnetic clutch AC COMP

E-9

E-51

H-4

E-10

H-6

Silver

Engine ground

White

Engine room ~ INST

Natural green

Neutral switch

White

Engine room ~ INST

Natural green

Neutral switch

White

Engine room ~ INST

Brown

TPS 1 main

White

Engine ~ Engine room C

E-11

E-12

E-22

H-7

H-18

H-22

6E–41

6E–42 No.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS No.

Connector face

Engine ~ Engine room

Black

DIODE

Silver

Battery (+)

Black

DIODE

Silver

Relay & Fuse box

Silver

Battery (-)

Silver

Body earth (Ground)

Silver

Engine ground

Black

Relay ; Glow

Black

Relay ; ECM MAIN

Black

Relay; A/C Compressor

Black

Relay; Thermo

H-33

P-1

P-2

P-5

P-6

P-10

X-5

X-13

X-14

X-15

Connector face

X-16

X-17

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS RELAY AND FUSE

RELAY AND FUSE BOX LOCATION (LHD & RHD)

LHD

RHD

6E–43

6E–44


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 X-10 X-11 X-12 X-13 X-14 X-15

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

FUSE

FUSE (4JA1-TC/4JH1-TC)

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

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS FUSE AND RELAY LOCATION (LHD & RHD) 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

SLOW BLOW FUSE No. Capacity SBF-10 20A SBF-11 30A RELAY Connector No.

4JA1-TC, 4JH1-TC

Indication on label — ABS — BACK UP METER TURN ELEC.IG ENGINE FRT WIPER EGR AUDIO

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 RR DEF POWER WINDOW B-7

B-8

REAR POWER DEFOGGER WINDOW

B-40

ACC SOCKET

Indication on label CIGER AUDIO (+B) DOOR LOCK METER (+B) ROOM ANTI THEFT STOP ACC SOCKET STARTER SRS

6E–45

6E–46


ECM WIRING DIAGRAM (1/7)



6E–47

6E–48





6E–49

6E–50





6E–51

6E–52




6E–53

ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into ECM Case

Signal or Continuity

Tester Position ECM Connection

Range

(+)

(-)

Disconnect

Ohm

1

GND

Disconnect

Ohm

2

GND

Connect

DC V

3

GND

-

-

-

-

-

Approx. 23Hz by wave form or approx. 6.3V


Connect

AC V

27

GND

-

-

-

-

-

-

Connect

DC V

30

GND

Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V

Connect

DC V

31

GND

A/C request switch is turned on: 1014V A/C request switch is turned off: Less than 1V

-

Connect

-

DC V

-

33

-

GND

Pin No.

B/Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

1

1

ECM Ground

BLK

-

-

-

2

2

ECM Ground

BLK

Continuity with ground

-

-

-

3

3

Battery Power Supply

25

25

No Connection

BLU/ RED


-

-

-

27

27

Engine Speed Output (To Tacho Meter)

LGN

-

-

28

28

No Connection

-

-

30

30

Brake Switch 1 Signal

GRN

31

31

YEL

32

32

Clutch Switch Signal (MT Only)

Less than 1V

33

A/C ON Signal Relay

GRN/ YEL

Less than 1V

34

34

No Connection

-

-

No Connection

-

-

Throttle Position Sensor (TPS) Output Signal

GRN/ ORG

Less than 1V

WHT

No Connection

-

Less than 1V

26

29

33

26

29

35

35

36

36

38

38

39

39

40

40

37

37

No Connection

No Connection

No Connection

To Data Link Connector No. 6 & Immobilizer Control Unit (ICU B8) No Connection

Key Switch Input Signal Via Engine Fuse

-

-

-

YEL

-

Less than 1V -

-

Less than 1V -

-

-

-

10-14V

-

-

-

-

-

-

Pedal is not stepped on: Less than 1V Pedal is stepped on: 10-14V

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Approx. 0.5V

Connect

DC V

38

49

Connect

DC V

39

GND

-

-

-

-

-

-

-

-

Less than 1V

-

-

10-14V -

-

-

-

-

-

-

-

-

-

-

6E–54

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Signal or Continuity

Pin No.

B/Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

41

41

A/C Compressor Relay

WHT/ GRN

Less than 1V

10-14V

42

42

Check Engine Lamp

43

43

Glow Lamp

GRN/ YEL

Less than 1V

44

44

45

45

46

46

48

48

47

47

ORG/ BLU

Less than 1V

To Data Link Connector No. 6

BLU

Less than 1V

No Connection

-

No Connection

-

No Connection

-

No Connection

-

49

49

Throttle Position Sensor (TPS) Ground

BLK/ GRN

50

50

No Connection

-

52

52

No Connection

-

51 53 54 55 56

51 53 54 55 56

No Connection No Connection No Connection

-

65


66

66

No Connection

68

68

Vehicle Speed Sensor (VSS)

67

No Connection

Idle: Approx. 0.4K ohm / WOT: Approx. 4.0K ohm

69

69

70

70

No Connection

72

72

No Connection

71 73 74

Idle Switch

No Connection No Connection No Connection

-

-

-

-

GND -

-

-

-

-

-

Disconnect

Ohm

38

49

-

-

-

-

-

-

-

-

-

-

-

-

-

Less than 1V -

-

-

Less than 1V

-

-

-

-

45

-

GRN/ BLK

-

-

DC V

-

-

-

-

Connect

-

-

-

GND

-

-

Less than 1V

YEL/ GRN

43

-

WHT/ BLK -

DC V

-

-

-

-

65

Connect

-

-

-

GND

-

-

No Connection

42

-

-

64

DC V

-

-

No Connection

64

Connect

-

-

61

ECM Power Supply

GND

-

-

-

63

41

-

-

63

DC V

-

-

-

Connect

-

-

No Connection

(-)

-

-

62

(+)

-

-

No Connection

Range

-

No Connection

60

ECM Relay

ECM Connection

-

59

61

74

-

-

10-14V

10-14V

59

73

-

-

BLU/ BLK

58

71

-

Lamp is turned on: Less than 1V Lamp is turned off: 10-14V

Less than 1V

58

67

-


RED/ GRN

57

62

No Connection

-

Engine 2000rpm

A/C comp. is operated: Less than 1V A/C comp. is not operated: 10 - 14V

Throttle Position Sensor (TPS) Power Supply

57

60

No Connection

-

Engine Idle

Tester Position

-

Approx. 5V

-

-

-

10-14V

-

-

-

-

57

49

Connect

DC V

58

GND

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Pedal is not stepped on: 10-14V Pedal is stepped on: Less than 1V -

-

-

-

DC V

-

-

-

-

Connect

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

-

-

-

-

-

DC V

63

GND

-

-

-

-

Connect

DC V

65

GND

-

-

-

-

Connect

AC V

68

GND

Connect

DC V

69

GND

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


Tester Position

Pin No.

B/Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

75

75

No Connection

-

-

-

-

-

77

77

No Connection

-

-

-

-

-

76 78 79 80 81 82

76 78 79 80 81 82

83

83

84

84

85

No Connection No Connection No Connection No Connection No Connection No Connection

-

-

Mass Air Flow (MAF) Sensor Power Supply

WHT/ RED BLK/ BLU

Less than 1V

85

No Connection

-

-

87

87

Neutral Switch

88

88

BLK/ WHT

Less than 1V

89

89

90

86

86

Intake Air Temperature (IAT) Sensor Signal

No Connection

-

Mass Air Flow (MAF) Sensor Signal

GRN/ RED

90

91

Less than 1V

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

DC V

84

92

-

-

-

-

In neutral: Less than 1V Other than neutral: 10-14V

Connect

DC V

87

GND

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

-

-

91

CKP Sensor Output To Pump Control Unit (PSG) No.8

PNK

92

92

Mass Air Flow (MAF) Sensor Ground

BLK/ RED

93

93

BLK/ PNK

94

94

Engine Coolant Temperature (ECT) Sensor Ground

95

-

-

-

-

-

-

Approx. 1.8V

Approx. 2.5V

Connect

DC V

88

92

Connect

DC V

89

93

-

Approx. 47Hz by wave form

Connect

AC V

90

98

-

-



Connect

AC V

91

GND


-

-

-

Connect

Ohm

92

GND

-

-

-

Connect

Ohm

93

GND

Connect

DC V

94

GND

-

-

-

-

-

-

-

-


Glow Relay

BLK/ RED

95

No Connection

-

-

97

97

EGR EVRV

BLK/ ORG

-

98

98

CKP Sensor Ground

WHT

99

99

BLU

100

100

CAN (Controller Area Network) to PSG No.1

YEL

Approx. 5V

-

-

Connect

RED


-

-


CKP Sensor Signal

-

-

-

(-)

92

Less than 1V

No Connection

-

-

(+)

83

GRY

96

-

Range

DC V

Approx. 1V

96

-

-

ECM Connection

Connect

Less than 1V

Engine Coolant Temperature (ECT) Sensor Signal

-

6E–55

Less than 1V

-



Glow system is operated: Less than 1V Glow system is not operated: 10 - 14V -

-

-

-

Approx. 140Hz by wave form when EVRV is operated

-

-

-

-

-

-

Connect

Ohm

98

GND

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

6E–56


Tester Position

Pin No.

B/Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

101

101

CKP Sensor Shield Line

BLK

-

-

-

102

102

No Connection

-

Continuity with ground -

-

-

-

-

-

103 104 105

103 104

105

No Connection No Connection

Solenoid Valve Shut Off (MAB) Output Signal to PSG No.5

-

ORG

-

-

-

ECM Connection

Range

(+)

(-)

Connect

Ohm

101

GND

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


6E–57

PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into PSG Case


Tester Position

Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

ECM & PSG Connection

Rang e

(+)

(-)

1

99

CAN (Controller Area Network) to ECM No.99

RED

Continuity between ECM & PSG

-

-

-

Disconnect

Ohm

1

99 (EC M)

2

100


WHT


-

-

-

Disconnect

Ohm

2

100 (EC M)

3

-

No Connection

-

-

-

-

-

-

-

-

-

4

-

No Connection

-

-

-

-

-

-

-

-

-

5

105

Solenoid Valve Shut Off (MAB) Output Signal to ECM No.105

ORG


-

-

-

Disconnect

Ohm

5

105 (EC M)

6

-

Ground

BLK


-

-

-

Disconnect

Ohm

6

GND

7

-


BLU/ RED

Less than 1V

Disconnect

Ohm

7

GND

8

91

CKP Sensor Output ECM No.91 to Pump Control Unit (PSG)

PNK


-

-

-

Disconnect

Ohm

8

91 (EC M)

9

-

No Connection

-

-

-

-

-

-

-

-

-

10-14V

6E–58


4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into ECM Case


Tester Position

Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

ECM Connection

Ran ge

(+)

(-)

1

1

ECM Ground

BLK


-

-

-

Disconnect

Ohm

1

GND

2

2

ECM Ground

BLK


-

-

-

Disconnect

Ohm

2

GND

3

3


BLU/ RED

Less than 1V

Connect

DC V

3

GND

25

25

No Connection

-

-

-

-

-

-

-

-

-

26

26

No Connection

-

-

-

-

-

-

-

-

-

27

27

Engine Speed Output (To Tacho Meter)

LGN

-

-



Connect

AC V

27

GND

28

28

No Connection

-

-

-

-

-

-

-

-

-

29

29

Throttle Position Signal To TCM (A16) (AT Only)

30

30


31

31

32

10-14V

-

Approx. 140Hz by wave form (Idle: Off duty 10% / WOT: Off duty 90%)

-

-

-

-

GRN

Less than 1V

Pedal is not stepped on: Less than 1V Pedal is stepped on: 10-14V

Connect

DC V

30

GND

Clutch Switch Signal (MT Only)

YEL

Less than 1V


Connect

DC V

31

GND

32

No Connection

-

-

-

-

-

-

33

33

A/C ON Signal Relay

GRN/ YEL

Less than 1V

Connect

DC V

33

GND

34

34

No Connection

-

-

-

-

-

-

-

-

-

35

35

To Data Link Connector No. 6 & Immobilizer Control Unit (ICU B8)

YEL

-

-

-

-

-

-

-

-

36

36

No Connection

-

-

-

-

-

-

-

-

-

-

-

-

A/C request switch is turned on: 1014V A/C request switch is turned off: Less than 1V


6E–59

Tester Position

Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rpm

ECM Connection

Ran ge

(+)

(-)

37

37

No Connection

-

-

-

-

-

-

-

-

-

38

38

Throttle Position Sensor (TPS) Output Signal

GRN/ ORG

Less than 1V

Approx. 0.5V

Connect

DC V

38

49

39

39

Key Switch Input Signal Via Engine Fuse

WHT

Less than 1V

Connect

DC V

39

GND

40

40

No Connection

-

-

-

-

-

-

-

41

41

A/C Compressor Relay

WHT/ GRN

Less than 1V

10-14V

Connect

DC V

41

GND

42

42

Check Engine Lamp

GRN/ YEL

Less than 1V


Connect

DC V

42

GND

43

43

Glow Lamp

ORG/ BLU

Less than 1V


Connect

DC V

43

GND

44

44

No Connection

-

-

-

-

-

-

45

45

To Data Link Connector No. 6

BLU

Less than 1V

Connect

DC V

45

GND

46

46

No Connection

-

-

-

-

-

-

-

-

-

47

47

No Connection

-

-

-

-

-

-

-

-

-

48

48

No Connection

-

-

-

-

-

-

-

-

-

49

49

Throttle Position Sensor (TPS) Ground

BLK/ GRN

Idle: Approx. 0.4K ohm / WOT: Approx. 4.0K ohm

-

-

-

Disconnect

Ohm

38

49

50

50

No Connection

-

-

-

-

-

-

-

-

-

51

51

No Connection

-

-

-

-

-

-

-

-

-

52

52

No Connection

-

-

-

-

-

-

-

-

-

53

53

No Connection

-

-

-

-

-

-

-

-

-

54

54

No Connection

-

-

-

-

-

-

-

-

-

55

55

No Connection

-

-

-

-

-

-

-

-

-

56

56

No Connection

-

-

-

-

-

-

-

-

-

57

57

Throttle Position Sensor (TPS) Power Supply

RED/ GRN

Less than 1V

Approx. 5V

Connect

DC V

57

49

58

58

ECM Relay

BLU/ BLK

10-14V

Less than 1V

Connect

DC V

58

GND

59

59

No Connection

-

-

-

-

-

-

-

-

-

60

60

No Connection

-

-

-

-

-

-

-

-

-

61

61

No Connection

-

-

-

-

-

-

-

-

-

62

62

No Connection

-

-

-

-

-

-

-

-

-

Less than 1V

10-14V

-

-

-

A/C comp. is operated: Less than 1V A/C comp. is not operated: 10 - 14V

-

-

10-14V

6E–60


Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

63

63

ECM Power Supply

-

Less than 1V

10-14V

64

64

No Connection

-

-

-

65

65


WHT/ BLK

Less than 1V

66

66

No Connection

-

-

-

-

67

67

No Connection

-

-

-

-

68

68


YEL/ GRN

-

69

69

Idle Switch

GRN/ BLK

Less than 1V

70

70

No Connection

-

-

-

-

71

71

No Connection

-

-

-

72

72

No Connection

-

-

73

73

No Connection

-

74

74

No Connection

75

75

76

Tester Position ECM Connection

Ran ge

(+)

(-)

-

DC V

63

GND

-

-

-

-

Connect

DC V

65

GND

-

-

-

-

-

-

-

-

-

-

Approx. 14.5Hz by wave form or approx. 6.0V at vehicle speed 20km/h

Connect

AC V

68

GND

Pedal is not stepped on: Less than 1V Pedal is stepped on: Approx. 5V

Connect

DC V

69

GND

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

No Connection

-

-

-

-

-

-

-

-

-

76

No Connection

-

-

-

-

-

-

-

-

-

77

77

No Connection

-

-

-

-

-

-

-

-

-

78

78

No Connection

-

-

-

-

-

-

-

-

-

79

79

No Connection

-

-

-

-

-

-

-

-

-

80

80

No Connection

-

-

-

-

-

-

-

-

-

81

81

No Connection

-

-

-

-

-

-

-

-

-

82

82

Boost Pressure Sensor (High Altitude Spec. Only)

WHT/ BLU

Less than 1V

Approx. 5V

Connect

DC V

82

93

83

83

Mass Air Flow (MAF) Sensor Power Supply

WHT/ RED

Less than 1V

Approx. 5V

Connect

DC V

83

92

84

84

Intake Air Temperature (IAT) Sensor Signal

BLK/ BLU

Less than 1V


Connect

DC V

84

92

85

85

Manifold Pressure Sensor (High Altitude Spec. Only)

RED/ BLU

Less than 1V

-

-

-

Connect

DC V

85

93

86

86

No Connection

-

-

-

-

-

-

-

-

-

87

87

Neutral Switch

BLK/ WHT

Less than 1V

In neutral (A/T: P or N): Less than 1V Other than neutral (A/T: other than P or N): 10-14V

Connect

DC V

87

GND

88

88

Mass Air Flow (MAF) Sensor Signal

GRN/ RED

Less than 1V

Approx. 1V

Connect

DC V

88

92

-

Engine 2000rpm

-


Approx. 1.8V

Approx. 2.5V

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Signal or Continuity Engine Idle

6E–61

Tester Position

Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine 2000rpm

ECM Connection

Ran ge

(+)

(-)

89

89

Engine Coolant Temperature (ECT) Sensor Signal

GRY

Less than 1V


Connect

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

-

-



Connect

AC V

91

GND

92

92

Mass Air Flow (MAF) Sensor Ground

BLK/ RED


-

-

-

Connect

Ohm

92

GND

93

93

Engine Coolant Temperature (ECT) Sensor & Manifold Pressure Sensor Ground

BLK/ PNK


-

-

-

Connect

Ohm

93

GND

94

94

Glow Relay

BLK/ RED

Less than 1V

Connect

DC V

94

GND

95

95

No Connection

-

-

-

-

-

-

-

96

96

Turbocharger Wastegate Control EVRV

BRW/ RED

-

-

Wave form

-

-

-

-

97

97

EGR EVRV

BLK/ ORG

-

-

Approx. 140Hz by wave form when EVRV is operated

-

-

-

-

98

98

CKP Sensor Ground

WHT


-

-

-

Connect

Ohm

98

GND

99

99


BLU

-

-

-

-

-

-

-

-

100

100


YEL

-

-

-

-

-

-

-

-

101

101

CKP Sensor Shield Line

BLK


-

-

-

Connect

Ohm

101

GND

102

102

No Connection

-

-

-

-

-

-

-

-

-

103

103

No Connection

-

-

-

-

-

-

-

-

-

104

104

No Connection

-

-

-

-

-

-

-

-

-

105

105

Solenoid Valve Shut Off (MAB) Output Signal to PSG No.5

ORG

-

-

-

-

-

-

-

-

Glow system is operated: Less than 1V Glow system is not operated: 10 14V -

-

6E–62


PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL View Looking Into PSG Case


Tester Position

Pin No.

B/ Box No.

Pin Function

Wire Color

Key SW Off

Key SW On

Engine Idle

Engine 2000rp m

ECM & PSG Connection

Rang e

(+)

(-)

1

99


RED


-

-

-

Disconnect

Ohm

1

99 (ECM )

2

100


WHT


-

-

-

Disconnect

Ohm

2

100 (ECM )

3

-

No Connection

-

-

-

-

-

-

-

-

-

4

-

No Connection

-

-

-

-

-

-

-

-

-

5

105

Solenoid Valve Shut Off (MAB) Output Signal to ECM No.105

ORG


-

-

-

Disconnect

Ohm

5

105 (ECM )

6

-

Ground

BLK


-

-

-

Disconnect

Ohm

6

GND

7

-


BLU/ RED

Less than 1V

Disconnect

Ohm

7

GND

8

91

CKP Sensor Output ECM No.91 to Pump Control Unit (PSG)

PNK


-

-

-

Disconnect

Ohm

8

91 (ECM )

9

-

No Connection

-

-

-

-

-

-

-

-

-

10-14V

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Crankshaft Position (CKP) Sensor Reference Wave Form

6E–63

Crankshaft Position (CKP) Sensor & TDC Output Signal Reference Wave Form

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

6E–64


GENERAL DESCRIPTION FOR ECM AND SENSORS

management system.

• Engine Control Module (ECM)

Engine Control Module (ECM)

• Pump Control Unit (PSG) = Pumpen Steuer Great (German)

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.

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.

• 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

Engine Speed Accelerator Pedal

Engine Control Module (ECM)

Intake Air Temperature

Injection Timing Injection Quantity Response Signal

Mass Air Flow

Additional Signal

Others Additional Operations

To High Pressure Solenoid Cam Ring Rotational Angle Fuel Temperature

Pump Control Unit (PSG)

• Via analogue signal leads • Via the CAN-bus

Pump Control Unit (PSG) & Data Exchange Between Control Module

Self Diagnosis / Interface / Signal

The information exchange between the two control modules takes place via two means.

High Pressure Solenoid Valve Fuel Injection (Mechanical)

Timing Device To Timing Control Valve (TCV)

The radial plunger distributor type injection pump uses two control modules to execute full control of the engine

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.


6E–65

The following signals are exchanged via the CAN-bus: From ECM to PSG • Desired injection quantity • Desired injection timing • Engine speed

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From PSG to ECM

• Fuel temperature

• Pump speed • Cylinder identifier

• Control pulse (actual injection quantity + actual injection timing) • PSG status

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Mass Air Flow (MAF) Sensor & Intake Air Temperature (IAT) Sensor

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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

2

(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.

6E–66


Throttle Position Sensor (TPS)

Crankshaft Position (CKP) Sensor

1

1

2

(1) Crankshaft Position (CKP) Sensor (2) Fly wheel with sensor slot

(1) Throttle Position Sensor (TPS) (2) Idle Switch

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).

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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.


Engine Coolant Temperature (ECT) Sensor

2


6E–67

1

(1) Engine Coolant Temperature (ECT) Sensor (2) Thermo Unit for Water Temperature Gauge

M/T & A/T 4WD

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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.

6E–68


GENERAL DESCRIPTION FOR EGR (EXHAUST GAS RE-CIRCULATION)

4

(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)

5

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

1

2

3

6

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 7.1ms

0.7ms

Time

Off duty 10% =EGR Pulse Ratio 10% 7.1ms

6.4ms

Time

Off duty 90% =EGR Pulse Ratio 90%

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.

6E–69

6E–70


GENERAL DESCRIPTION FOR INJECTION PUMP

Cross-section View

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

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.

(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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Low Pressure Fuel Circuit

(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)

6E–71

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.

6E–72


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

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)

Pump Camshaft Speed Sensor

(1) (2) (3) (4) (5)

Pump Camshaft Speed Sensor Sensor Wheel Pump Camshaft Speed Sensor Retaining Ring Flexible Connector Harness Drive Shaft

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.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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.

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6E–73

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(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).

6E–74


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.

Timing Control Valve (TCV)

(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.


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6E–75

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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.)

6E–76


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


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: – Owner’s manual level

– Service manual level

– In-depth (engineering) level – Owner’s manual level – Service manual level

– In-depth (engineering) level

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

What resources you should use

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

6E–77

• 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

• Investigate the vehicle service history (call other dealerships, if appropriate)


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

6E–78


3. Check Bulletins and Troubleshooting Hints

to the customer complaint.

NOTE: As estimated 30 percent of successful vehicle repairs are diagnosed with this step!

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.


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

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


Whenever possible, you should use the following resources to perform service manual checks: and

• Other tools as needed

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

• Service manual • Technical equipment (for analyzing diagnostic data) • Digital multimeter and circuit testing tools • Essential and special tools

5c. Technician Self Diagnoses

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.

Step 1: Identify and understand the suspect circuit(s)

What you should do

• Technical equipment (for viewing DTCs analyzing data) • Digital multimeter and circuit testing tools

Whenever appropriate, you should use the following resources to perform service manual diagnostic procedures:

What you should do

4. Perform Service Manual Diagnostic Checks

• Service manual


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

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS – 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,

• 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:

in

terminals,

splices,

terminals,

splices,

– Opens/short and high resistance modules, switches or loads

at the component

• 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

in

relays,

• 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

6E–79

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.

6E–80


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.

• 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.


Whenever appropriate, you should use the following resources to assist in the diagnostic process: • Service manual • Bulletins

connector

kits/

• Experience • Intermittent problem solving simulation methods • Customer complaint check sheet

Symptom Simulation Tests 1. Vibration

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. 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.

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

What you should do

• Digital multimeter (with a MIN/MAX feature) • Circuit testing tools (including harnesses and jumper wires)

2. Heat

3. Water and Moisture

Hints You can isolate a circuit by:

• Tech II and Tech II upload function

For parts and sensors, apply slight vibration to the part with a light tap of the finger while monitoring the system for a malfunction.

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.

You can verify that a system is operating as designed by: • Reviewing checks

service

manual

functional/diagnostic

• 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:

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS • Vehicle service information (service manual, etc.) • ISUZU field support • Experience

• Identical vehicle or system for comparison

6. Re-examine the complaint

When you do not successfully find/isolate the problem after executing a diagnostic path, you should 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

6E–81

6E–82


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.

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.

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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.

6E–83

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 ECM’s 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 ECM’s memory, the DTC(s) will be output from the lowest to the highest, with each DTC being displayed three times. The DTC display will continue as long as the DLC is shorted.

Reading Diagnostic Trouble Codes Using a Tech 2

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

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.

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.

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.

6E–84


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”.

6E–85

• 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.

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

• 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).

6E–86


TECH 2 OPERATING FLOW CART (START UP)

Press (ENTER) to Continue

Press “ENTER” key.

F0: F1: F2: F3: F4:

Main Menu

Diagnostic Service Programming System (SPS) View Capture Data Tool Option Download/ Upload Help

Select “F0: Diagnostic”.

(3) 2003 (2) 2002 (1) 2001 (Y) 2000 (X) 1999 (W) 1998

Vehicle Identification

Select “(3) 2003”or later.

Vehicle Identification (UB) Trooper, Bighorn (UE) Rodeo,/Amigo, Wizard/Mu (TF/UC) LUV, Frontier, LAO-Rodeo (TBR) (N*) ELF, NPR, NQR

Select “(TF/UC)”.

System Selection Menu F0: Powertrain F1: Chassis F3: Body

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 “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.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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

DTC No.

P0100 Present (7) Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input

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.

6E–87

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.

6E–88


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

Units

Idle

1500rpm

2000rpm

0

0

0

1

Engine Speed

rpm

2

Vehicle Speed

km/h / MPH

3

Pump Speed

rpm

4

Accelerator Position Sensor Signal

%

5

Idle Switch

Active/ Inactive 0V

6

Mass Sensor

7

Desired Flow

8

Barometric Pressure

hpa

9

Desired Quantity

mg/stk

Air

730

1475 1525

1975 2025

345 - 385

725 - 775

975 - 1025

0

4-6

6-8

Active

Active

Inactive 0V

Flow

mg/strk

380 - 420

360 - 400

380 - 420

Air

mg/strk

350

350

350 - 370

Depends on altitude

Depends on altitude

Depends on altitude

8 - 10

5 - 10

5-9

Mass

Injection

8 - 10

6 - 10

7 - 10

10

Injection Quantity

mg/stk

11

Desired Fuel Injection Start

deg. CA

2-4

2- 5

3-5

12

Actual Injection Start

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

15

Intake Temperature

Depends on fuel temp.



16

Ignition Status

On12V/ Off0V

17

Brake Switch 1

Active/ Inactive

Air

deg. C / deg. F

Depends on ambient temp.



Inactive

Inactive

Inactive

On 12V

On 12V

On 12V

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.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 18

Brake Switch 2

Active/ Inactive

Inactive

Idle

1500rpm

2000rpm

19

Clutch Switch

Active/ Inactive

Inactive

Inactive

Inactive

20

Neutral Switch

On/Off

On

On

On

21

A/C Switch

Active 12V/ Inactive 0V

Inactive 0V

Inactive 0V

Inactive 0V

22

Diagnostic Request

23

System Voltage


Inactive 12V

Inactive 12V

Inactive 12V

24

Main Relay

Active/ Inactive

Active

Active

Active

25

Glow Time Relay

Active 0V/ Inactive12V

Inactive 12V

Inactive 12V

Inactive 12V

26

Check Engine Light

On/Off

Off

Off

Off

27

Glow Time Telltale

On/Off

Off

Off

Off

28

Desired Engine Idle Speed

rpm

730

730

730

29

A/C Request


Inactive 12V

Inactive 12V

Inactive 12V

30

Immobilizer

Inactive

Inactive

Inactive

31

Immobilizer Signal

Active/ Inactive

Not Received

Not Received

Not Received

32

Immobilizer Function Programmed

Yes/ No

Yes

Yes

Yes

%

70

70

70

33

Tech 2 Parameter

Information

EGR Pulse (Exhaust Recirculation)

Units

V

Ratio Gas

Received/ Not Received

10 - 14

Inactive

10 - 14

Inactive

10 - 14

6E–89

Description


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.

6E–90


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

Units

1

Engine Speed

rpm

2

Vehicle Speed

km/h / MPH

3

Pump Speed

rpm

4

Accelerator Position Sensor Signal

%

5

Idle Switch

Active/ Inactive 0V

6

Mass Sensor

7

Desired Flow

8

Air

Idle

1500rpm

2000rpm

Definition

675 - 725

1475 1525

1975 2025

The engine speed is measured by ECM from the CKP sensor.

335 - 375

725 - 775

975 - 1025

0

3-5

5-7

Active

Active/ Inactive 0V

Inactive 0V

0

0

0

Flow

mg/strk

420 - 490

380 - 460

410 - 480

Air

mg/strk

430 - 470

380 - 420

410 - 470

Barometric Pressure

hpa

9

Desired Quantity

mg/stk

Depends on altitude

Depends on altitude

Depends on altitude

10

Injection Quantity

mg/stk

6 - 10

6 - 10

7 - 11

11

Desired Fuel Injection Start

deg. CA

1-3

2-4

3-5

12

Actual Injection Start

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

15

Intake Temperature




16

Ignition Status

On12V/ Off0V

17

Brake Switch 1

Active/ Inactive

Mass

Injection

Air

deg. C / deg. F

6 - 10

6 - 10

7 - 11




Inactive

Inactive

Inactive

On 12V

On 12V

On 12V

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.


4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Parameter

Units

Idle

1500rpm

2000rpm

Definition This displays operating status of the brake switch. This should display "Active" when the brake pedal is stepped on.

18

Brake Switch 2

Active/ Inactive

Inactive

Inactive

Inactive

19

Clutch Switch (M/T Only)

Active/ Inactive

Inactive

Inactive

Inactive

20

Neutral Switch

On/Off

On

On

On

21

A/C Switch


Inactive 0V

Inactive 0V

Inactive 0V

22

Diagnostic Request

23

System Voltage


Inactive 12V

Inactive 12V

Inactive 12V

24

Main Relay

Active/ Inactive

Active

Active

Active

25

Glow Time Relay

Active 0V/ Inactive12V

Inactive 12V

Inactive 12V

Inactive 12V

26

Check Engine Light

On/Off

Off

Off

Off

27

Glow Time Telltale

On/Off

Off

Off

Off

28

Desired Engine Idle Speed

rpm

700

700

700

29

A/C Request


Inactive 12V

Inactive 12V

Inactive 12V

30

Immobilizer

Inactive

Inactive

Inactive

31

Immobilizer Signal

Active/ Inactive

Not Received

Not Received

Not Received

32

Immobilizer Function Programmed

Yes

Yes

Yes

85 - 90

85 - 90

85 - 90

33

Information

EGR Pulse (Exhaust Recirculation)

V

Ratio Gas

Received/ Not Received Yes/ No %

6E–91

10 - 15

10 - 15

10 - 15

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.

6E–92


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

470 mg/strk

Engine Speed

700 rpm

Exhaust Gas Recirculation

95%

Mass Air Flow

450 mg/strk

• Press "Active" key. Then, EVRV duty ratio increases to 95% • Press "Inactive key". EVRV duty ratio decreases to 5%

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

• Press "Increase" key. Then, Desired Idle speed is increases 50rpm-by-50rpm up to 1200rpm. Engine speed is also


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.

6E–93

6E–94


Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)


Flow Chart for Snapshot Replay (Plotting Graph)

6E–95

6E–96


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:

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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

6E–97

3.

Snapshot data is displayed with TIS2000 [Snapshot Upload] function. Snapshot is stored in the PC hard disk or floppy disk, and can be displayed any time. Stored snapshot can be displayed by the below procedures. 1. Start TIS2000. 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.

6E–98


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.


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.

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.

6E–99

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”

6. Upon completion of the selection, push the button of “Next”.

6E–100


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)

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

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).


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.

6E–101

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.

6E–102


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


Breaker Box Connection Type A

3

4

(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”.

2

5

1

(4) Digital Voltage Meter (5) ECM - Harness Adapter Disconnection

6E–103

6E–104


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


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.

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

6E–105

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.

6E–106


6. The Tech2 parameters which is not within the typical range may help to isolate the area which is causing the problem.

12. This vehicle is equipped with ECM which utilizes an electrically erasable programmable read only memory (EEPROM).

On-Board Diagnostic (OBD) System Check Step 1

2 3

4 5

6 7

Action

Value(s)

1. Ignition “On”, engine “Off”.

Yes

No

2. Check the “CHECK ENGINE” lamp (MIL). Does the “CHECK ENGINE” lamp turn “On”?

—

Go to Step 2

Go to No CHECK ENGINE Lamp

2. Attempt to display “Data Display” with the Tech 2. Does the Tech 2 display engine data?

—

Go to Step 3

Go to Step 7

—

Go to Step 4

Go to CHECK ENGINE LAMP On Steady

—

Go to Step 5

Go to Engine Cranks But Will Not Run

—

Go to DTC Chart

—

Refer to SYMPTOM DIAGNOSIS

Go to Step 6

—

Repair faulty harness and verify repair

Go to Step 8

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”? Attempt to start the engine. Does the engine start and continue to “Run”?


2. Select the “Read DTC Infor As Stored By ECU” in “Diagnostic Trouble Code”. 3. Are any DTCs stored?

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.

Refer to TYPICAL SCAN DATA

1. Ignition “Off”, engine “Off”. 2. Check the circuit for open circuit. Was the problem found?

B-58

!

V

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Step 8

Action

Using the DVM and check the data link connector ground circuit.

6E–107

Value(s)

Yes

No

—


Go to Step 9

Less than 1V

Go to Step 10


—


Go to Step 11

1. Ignition “Off”, engine “Off”. 2. Check the circuit for open circuit. Was the problem found? B-58 4

9

5

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

V V 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

V

6E–108 Step 11

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Action

Using the DVM and check the data link connector communication circuit.

Value(s)

Yes

No

—


Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

—

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

! !

B-58

12

13

#

Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the “SPS (Service Programming System)”. Was the problem solved?

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.


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.

Diagnostic Aids

An intermittent check engine lamp may be cased by a poor connection, rubbed-through wire insulation, or a

wire broken inside the insulation. following items:

6E–109

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.

6E–110 Step 1

2


No Check Engine Lamp (MIL)

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”.

Value(s)

Yes

No

—

Verify repair

Go to Step 2

10-14.5V

Go to Step 5

Go to Step 3

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

2. Disconnect the ECM connector. 3. Ignition “On”.

4. Check the circuit for open circuit. Was the DVM indicated specified value? C-56

42

V 3 4

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?

and

ECM

C-56

42 B-24

5

17



Action


6E–111

Value(s)

Yes

No

—

Verify repair

—

6E–112


Circuit description

CHECK ENGINE LAMP (MIL) “ON” STEADY

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.


Check Engine Lamp (MIL) On Steady Step 1

2

Action

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector. 3. Ignition “On”. Was the “CHECK ENGINE” lamp turned on?

Using the DVM and check the “CHECK ENGINE” lamp circuit. 1. Ignition “Off”, engine “Off”. 2. Disconnect connector.

the

meter connector

and

6E–113

Value(s)

Yes

No

—

Go to Step 2

Go to Step 4

—

Verify repair

Go to Step 3

—

Verify repair

—

—

Verify repair

Go to Step 5

—

Verify repair

—

ECM

3. Check the circuit for short to ground circuit. Was the problem found? C-56

42

B-24

17

3 4

5

Replace the meter assembly. Is the action complete?



Code

P0100

P0105

Flash Code

65

34

ON

ON

C

2

ON

B

ON

ON

9

1

ON

MIL

7

Symptom Code

Vacuum Pressure Sensor Circuit Low Input

Vacuum Pressure Sensor Circuit High Input

Mass Air Flow (MAF) Sensor Output Circuit High Input

Mass Air Flow (MAF) Sensor Output Circuit Low Input

Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input

Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input

DTC Name

Vacuum sensor output voltage is below 0.5V.

Vacuum sensor output voltage is more than 4.4V.

1. Engine speed is between 600rpmand5000rpm. 2. MAF sensor output is more than 1378mg/strk (4JA1-TC) or 1784mg/ strk (4JH1-TC).

1. Engine speed is between 600rpmand5000rpm. 2. MAF sensor output is below -33.7mg/strk.

MAF sensor power supply voltage is below 4.6V.

MAF sensor power supply voltage is more than 5.2V.

DTC Setting Condition


ECM Diagnostic Trouble Codes

6E114

1. Fuel injection quantity is reduced. 2. ECM use 615hpa conditions for turbocharger waste gate control.

ECM uses mass air flow 1600mg/strk & EGR 10% conditions as substitute.

Fail-Safe (Back Up)


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.

82/ 85

85/ 93

1. Sensor signal circuit shortto voltagecircuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Vacuum sensor malfunction. 4. ECM malfunction. Vacuum sensor output voltage is below 4.4V.

88/ 92

1. Sensor signal circuit shortto voltagecircuit. 2. Sensor ground circuit open or short to voltage circuit. 3. MAFsensormalfunction. 4. ECM malfunction.

MAF sensor output is below 1378mg/strk (4JA1-TC) or 1784mg/strk (4JH1-TC).

83/ 88

83

83

Related ECM Pin No.

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 power supply circuit short to ground circuit. 2. MAFsensormalfunction. 3. ECM malfunction.

1. Sensor power supply circuit short to battery voltage circuit. 2. MAFsensormalfunction. 3. ECM malfunction.

Related Failure Parts

MAF sensor output is more than -27.4mg/strk.


MAF sensor power supply voltage is below 5.2V.

Recovery Condition

P0115(1)

P0110(1)

P0110(1)

Related Multiple DTC

4JA1-TC (MT)

4JH1-TC (MT)

4JH1-TC (AT)

Code

P0105

P0110

P0115

P0180

Flash Code

34

23

14

15

ON

ON

2

B

ON

ON

2

1

ON

ON

9

1

ON

MIL

7

Symptom Code

Fuel Temperature Sensor Circuit Range/Performance

Engine Coolant Temperature (ECT) Sensor Circuit Low Input

Engine Coolant Temperature (ECT) Sensor Circuit High Input

Intake Air Temperature (IAT) Sensor Circuit Low Input

Intake Air Temperature (IAT) Sensor Circuit High Input

Vacuum Pressure Sensor Voltage Supply Circuit Low Input

Vacuum Pressure Sensor Voltage Supply Circuit High Input

DTC Name

FT sensor output is high temperature (more than 150 deg. C) or low temperature (below -40 deg. C).

ECT sensor output voltage is below 0.3V.

The ECM use 75 deg. C conditions as substitute.

FT sensor output is correct temperature range between 150 deg. C and -40 deg. C.

ECT sensor output voltage is more than 0.3V.

1. ECM malfunction. 2. PSG (pump control unit) malfunction.

1. Sensor signal circuit shortto groundcircuit. 2. ECTsensormalfunction. 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. 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.


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 power supply circuit short to ground circuit. 2. Vacuum sensor malfunction. 3. ECM malfunction.

1. Sensor power supply circuit short to battery voltage circuit. 2. Vacuum sensor malfunction. 3. ECM malfunction.


1. Sensor signal circuit shortto groundcircuit. 2. IATsensormalfunction. 3. ECM malfunction.

IAT sensor output voltage is below 4.7V.

Vacuum sensor power supply voltage is more than 4.5V.

Vacuum sensor power supply voltage is below 5.2V.

Recovery Condition

IAT sensor output voltage is more than 0.3V.

ECM use 0 deg. C conditions as substitute.

1. Fuel injection quantity is reduced. 2. ECM use vacuum sensor output voltage 5.0V condition as substitute.

Fail-Safe (Back Up)






89

89/ 93

84

84/ 92

82

82

Related ECM Pin No.

P0105(1)

P0100(B)/ P0100(C)


4JA1-TC (MT)

4JH1-TC (MT)


4JH1-TC (AT)

6E115

Code

P0215

P0216

52

54

ON

ON

D

B

ON

C

ON

ON

B

A

ON

MIL

A

Symptom Code

Injection Timing Control Circuit Malfunction


Fuel Cutoff Solenoid Valve Malfunction

Fuel Cutoff Solenoid Valve Always Active

Fuel Cutoff Solenoid Valve Circuit High Input


DTC Name

No fail-safe function.

1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.

1. Engine speed is more than 2014rpm. 2. Fluctuation of actual injection timing is more than +-5.2 deg. CA.

1. Engine speed is more than 2014rpm. 2. Fluctuation of actual injection timing is more than +-5.2 deg. CA.

Deviation of actual injection timing and desired injection timing is more than +3 deg. CA or -6 deg. CA for 8 seconds.

1. MAB (fuel cutoff solenoid valve) signal circuit open orshorttogroundcircuit. 2. PSG (pump control unit) malfunction.

No recovery until condition match in the next ignition key cycle.

1. Insufficient air bleeding of fuel line. 2. Fuel filterclogging. 3. Timing control valve malfunction. 4. Pump camshaft speed sensor malfunction.

1. Timing control valve malfunction. 2. Timer piston sticking. 3. Pump camshaft speed sensor malfunction.


1. MAB (fuel cutoff solenoid valve) signal circuit short to voltage circuit. 2. PSG (pump control unit) malfunction.

1. PSG (pump control unit) malfunction. 2. MAB (fuel cutoff solenoid valve) malfunction.


No recovery.



Engine does not start.

Recovery Condition

Fail-Safe (Back Up)

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. Ignition key switch off. 2. CAN controller does not operate Bus-off.

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.

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) recognizes MAB (fuel cutoff solenoid valve) signal from the ECM, but the MAB could not operate.



Flash Code

6E116

105

105

Related ECM Pin No.

Related Multiple DTC 4JA1-TC (MT)

4JH1-TC (MT)

4JH1-TC (AT)

Code

P0243

Flash Code

64

ON

ON

ON

ON

4

5

6

MIL

3

Symptom Code

Turbocharger Wastegate Solenoid "A" Malfunction

Turbocharger Wastegate Solenoid "A" Range/ Performance

Turbocharger Wastegate Solenoid "A" Low


DTC Name

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. 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.)

Wastegate control EVRV circuit open or short to ground circuit.

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.)


1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition.

1. Turbocharger wastegate control EVRV malfunction. 2. Vacuum regulating valve malfunction. 3. Vacuum pump malfunction. 4. Vacuum sensor malfunction. 5. ECM malfunction.

1. Turbocharger wastegate actuator malfunction. 2. Vacuumlinemalfunction. 3. ECM 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. 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 line is obstructed. 3. Vacuum is leaking. 4. Vacuum pump malfunction. 5. Vacuum sensor malfunction. 6. Turbocahrger wastegate valve malfunction. 7. ECM malfunction.


1. Engine speed is between 500rpm and 6000rpm. 2. Correct vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is more than -50hpa.)

Wastegate control EVRV circuit is correct condition.

1. Engine speed is between 500rpm and 6000rpm. 2. Correct vacuum pressure condition. (Desired vacuum pressure - actual vacuum pressure is less than 50hpa.)

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.

Recovery Condition

Fail-Safe (Back Up)

85/ 96

96

85/ 96

Related ECM Pin No.


4JA1-TC (MT)

4JH1-TC (MT)


4JH1-TC (AT)

6E117

Code

P0243

P0251

64

53

ON

ON

ON

ON

ON

ON

ON

7

9

A

B

D

E

ON

MIL

6

8

Symptom Code

Injection Pump Malfunction







Turbocharger Wastegate Solenoid "A" High

DTC Name

ECM could not accept PSG (pump control unit) message.

PSG (pump control unit) could not measure the high pressure solenoid valve drive voltage.

PSG (pump control unit) recognized high pressure solenoid valve drive circuit error.

EEPROM or A/D converter malfunction in the PSG (pump control unit).

No pump map programmed in the PSG (pump control unit) or PSG malfunction.

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).

1. No pump camshaft speed sensor error. 2. High pressure solenoid valve control pulse width does not match with desired fuel injection quantity.

Wastegate control EVRV circuit short to voltage circuit.



Flash Code

6E118

1. Missing CKP sensor pulses. 2. Electrical interference. 3. Magneticinterference. 4. PSG (pump control unit) malfunction.

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.

ECM accepts PSG (pump control unit) message.




EEPROM or A/D converter no malfunction in the PSG (pump control unit). No recovery until in the next ignition key cycle.

Fuel injection quantity is reduced.

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.

PSG (pump control unit) malfunction.




1. PSG (pump control unit) malfunction. 2. Pump camshaft speed sensor malfunction.




1. Wastegate control EVRV circuit short to voltage circuit. 2. Wastegate control EVRV malfunction. 3. ECM malfunction.


Wastegate control EVRV circuit is correct condition.

Recovery Condition

1. Fuel injection quantity is reduced. 2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition.

Fail-Safe (Back Up)

99/ 100

91

96

Related ECM Pin No.

P1650(A)/ P1651(B)


4JA1-TC (MT)

4JH1-TC (MT)

4JH1-TC (AT)

Code

P0335

P0380

Flash Code

43

66

ON

8

ON

E

ON

ON

D

4

ON

MIL

B

Symptom Code

Glow Relay Circuit Voltage High

Glow Relay Circuit Voltage Low

Engine Speed Input Circuit Range/Performance

Crankshaft Position Sensor Circuit Malfunction


DTC Name

Glow relay circuit short to voltage circuit.

Glow relay circuit open or short to ground circuit.

Engine speed is more than 5700rpm.

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.

1. Engine speed is more than 665rpm. 2. CKP sensor pulse width error.



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.

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.

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.

Fail-Safe (Back Up)

Glow relay circuit is correct condition.

Engine speed is below 5700rpm.

1. Engine speed is more than 0rpm. 2. Doubled pump camshaft speed is below 100rpm.

ECM detects correct CKP pulse width.

Recovery Condition

ECM malfunction.

1. Glow relay circuit open or short to groundcircuit. 2. Glowrelaymalfunction. 3. ECM malfunction.

1. Engine over-running. 2. CKPsensormalfunction. 3. Pulser malfunction. 4. 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. 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.


94

90/ 98/ 101

90/ 98/ 101

90/ 98/ 101

Related ECM Pin No.

P1135 (A)

P1335 (A)


4JH1-TC (MT)


4JH1-TC (AT)

6E119

Code

P0381

P0400

67

32

ON

ON

ON

ON

4

5

8

ON

8

3

ON

MIL

4

Symptom Code

Exhaust Gas Recirculation Circuit Short to Battery

Exhaust Gas Recirculation Flow Insufficient Detected

Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit

Exhaust Gas Recirculation Flow Excessive Detected

Glow Plug Indicator Circuit Voltage High

Glow Plug Indicator Circuit Voltage Low

DTC Name

EGR EVRV 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. Large mount of mass air flow. (Desired mass air flow - mass air flow is below -150 mg/strk)

EGR EVRV circuit open or short to ground 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)

Glow plug indicator circuit short to voltage circuit.

Glow plug indicator circuit open or short to ground circuit.



Flash Code

6E120

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.

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. 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 valve is stuck at open position. 2. EGREVRVmalfunction. 3. Air intake is obstructed. 4. Airintakeisleaking. 5. MAFsensormalfunction. 6. ECM malfunction.

ECM malfunction.

1. Glow plug indicator circuit open or short to ground circuit. 2. Glow plug indicator lamp malfunction. 3. ECM malfunction.


1. EGR EVRV circuit open orshorttogroundcircuit. 2. EGREVRVmalfunction. 3. ECM malfunction.

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.

Glow plug indicator circuit is correct condition.

Recovery Condition

Fuel injection quantity is EGR EVRV circuit is correct reduced and EGR EVRV condition. 10% conditions as substitute.



Fail-Safe (Back Up)

97

88/ 97

97

88/ 97

43

Related ECM Pin No.


4JH1-TC (MT)

4JH1-TC (AT)

Code

P0500

P0560

Flash Code

24

35

OFF

OFF

1

2

System Voltage Too Low

System Voltage Too High

ON Vehicle Speed Sensor Incorrect Signal at next igniti on cycle

B

System voltage is below 7V.

System voltage is more than 20V.

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.

Input signal frequency is too high.

ON Vehicle Speed Sensor Input at Signal Frequency Too High next igniti on cycle

A


Vehicle speed is more than 200km/h.

DTC Name

ON Vehicle Speed Sensor Circuit High Input at next igniti on cycle

MIL

1

Symptom Code



Vehicle speed is more than 1.5km/h.


ECM uses 9V conditions as substitute.

Correct vehicle speed signal frequency.

Vehicle speed is below 200km/h.

Recovery Condition

ECM uses vehicle speed 5km/h condition as substitute.

ECM uses vehicle speed 5km/h condition as substitute.

Fail-Safe (Back Up)

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.

1. Charge system malfunction. 2. Battery jump start cable misconnect. 3. 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. VSS malfunction. 2. Speed meter malfunction. 3. Electrical interference. 4. Magneticinterference. 5. ECM malfunction.

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.


3/ 39

3/ 39

68

68

68

Related ECM Pin No.


4JH1-TC (MT)


4JH1-TC (AT)

6E121

Code

P0560

P0561

P0602

P0606

35

18

-

28

OFF

B

ON

ON

A

B

-

OFF

OFF

MIL

A

A

Symptom Code

ECU Malfunction

ECU Malfunction

Control Module Programming Error

Ignition Switch Circuit Malfunction


System Voltage Malfunction

DTC Name

1. Throttle position is below 1%. 2. Desired injection quantity is more than 0mg/strk. 3. Engine speed is more than 2000rpm.

Gate Array communication error.

ECM memory area error.

Ignition switch circuit is malfunction.

The ECM recognized ignition switch turn off signal during ECM is activated.

System voltage of PSG (pump control unit) is below 4.5V or more than 27V.



Flash Code

6E122

MAB (fuel cutoff solenoid valve) is operated.


Engine control disabled.

ECM stops engine.

PSG uses default voltage as substitute.

Fail-Safe (Back Up)

Desired injection quantity is below 0mg/strk.

No recovery.

Memory are is OK.


System voltage of PSG is between 4.5V and 27V.

Recovery Condition


ECM malfunction.

ECM is not programmed.

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.

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.


39

39

Related ECM Pin No.


4JH1-TC (MT)

4JH1-TC (AT)

Code

P0645

P0703

P0704

P1105

Flash Code

46

25

57

86

ON

ON

1

2

ON

ON

B

6

ON

ON

8

A

ON

MIL

4

Symptom Code

Barometric Pressure Sensor Circuit Low Input

Barometric Pressure Sensor Circuit High Input

Clutch Switch Input Circuit Malfunction

Brake Switch Circuit Malfunction


A/C Compressor Relay Circuit Voltage High

A/C Compressor Relay Circuit Voltage Low

DTC Name

Barometric pressure sensor output voltage is below 1.5V.

Barometric pressure sensor output voltage is more than 4.4V.

Clutch signal does not change between vehicle speed 1.5km/h and 80km/h since ignition switch was tuned 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.

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.

A/C compressor relay circuit short to voltage circuit.

A/C compressor relay circuit open or short to ground circuit.


ECM uses 1013hpa condition as substitute.




Fail-Safe (Back Up)

Barometric pressure sensor output voltage is more than 1.5V.


Clutch signal correctly changes.

Brake switch 1 signal and brake switch 2 signal are correctly inputted to the ECM.

A/C compressor relay circuit is correct condition.

Recovery Condition

ECM malfunction.

ECM malfunction.

1. Clutch switch circuit open, short to ground or shorttovoltage circuit. 2. Poor connector connection. 3. Clutch switch malfunction. 4. ECM malfunction.

1. Brake switch 2 circuit open or short to ground circuit. 2. Poor connector connection. 3. Brake switch 2 malfunction. 4. ECM malfunction.

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.

ECM malfunction.

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.


31

65

30

41

Related ECM Pin No.


4JH1-TC (MT)


4JH1-TC (AT)

6E123

Code

P1120

P1173

21

22

OFF

A

ON

E

OFF

ON

D

7

ON

9

OFF

ON

7

3

ON

MIL

1

Symptom Code

Fuel Reduction Caused By Low Fuel Temperature

Fuel Reduction Caused By High Fuel Temperature

Fuel Reduction Caused By High Coolant Temperature

Pedal/Throttle Position Sensor Idle Position Switch Error

Pedal/Throttle Position Sensor Brake Switch Error

Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input

Pedal/Throttle Position Sensor Voltage Supply Circuit High Input

Pedal/Throttle Position Sensor Circuit High Input

DTC Name

Excessive low fuel temperature is detected.

Fuel temperature is more than 100 deg. C.

Excessive high engine coolant temperature is detected.

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%.

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.

Throttle position sensor power supply voltage is below 4.6V.

Throttle position sensor power supply voltage is more than 5.2V.

Throttle position sensor output voltage is more than 4.5V.



Flash Code

6E124


PSG (pump control unit) controls fuel injection quantity based on engine speed and fuel temperature.


ECM increases idle speed up to 1400rpm.

Fail-Safe (Back Up)

Fuel temperature is normal range.

Fuel temperature is below 100 deg. C.



1. Engine overheat. 2. ECTsensormalfunction. 3. ECM malfunction.

1. TPS malfunction. 2. Idle switch malfunction. 3. ECM malfunction. 1. When throttle position sensor is 100%, idle switch turns off. 2. When throttle position sensor is 0%, idle switch turns on.

Engine coolant temperature is normal range.

1. Throttle sticking. 2. TPSincorrectadjusting. 3. TPS malfunction. 4. Brake switch malfunction. 5. ECM malfunction.

1. Sensor power supply circuit short to ground circuit. 2. TPS malfunction. 3. 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 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.


Throttle position is more than 20% or brake pedal is released(switchisinactive).



Throttle position sensor output voltage is below 4.5V.

Recovery Condition

89

38/ 69

30/ 38/ 65

57

57

38/ 49/ 57

Related ECM Pin No.


4JA1-TC (MT)

4JH1-TC (MT)

4JH1-TC (AT)

Code

P1335

P1345

P1520

P1605

Flash Code

43

45

47

55

ON

ON

D

ON

B

C

ON

ON

ON

MIL

A

A

A

Symptom Code

The PSG (pump control unit) is recognized defective engine speed signal form the ECM.


Neutral switch signal is inputted "Off" three times consecutively under driving conditions.

Neutral switch signal is inputted "On" three times consecutively under driving conditions.

EEPROM Defect

Write and read from the EEPROM are failed during initialization of the ECM.

Seed and Key File Destroyed Seed or key file in EEPROM is destroyed.

Neutral Switch OFF Error

Neutral Switch ON Error

Camshaft Speed Malfunction The PSG (pump control unit) is recognized incorrect camshaft speed signal.

Engine Speed Output Circuit Malfunction

DTC Name

ECM uses default values from the EPROM.

Write and read from the EEPROM are correct during initialization of the ECM.

No recovery.

Correct neutral switch signal is inputted two times consecutively under driving conditions.



Correct camshaft speed.

Correct engine speed signal.

Recovery Condition



Fail-Safe (Back Up)

87

1. Neutral switch circuit open, short to ground circuit. 2. Poor connector connection. 3. Neutral switch malfunction. 4. ECM malfunction.

ECM malfunction.

87

1. Neutral switch circuit shorttovoltage circuit. 2. Neutral switch malfunction. 3. ECM malfunction.

ECM malfunction.

90/ 91/ 98/ 101

Related ECM Pin No.

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. 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.


P0335(B)/ P0335(D)


4JH1-TC (MT)


4JH1-TC (AT)

6E125

Code

P1605

P1610

P1611

P1612

P1613

P1614

P1625

55

56

56

56

56

56

76

OFF

OFF

B

-

-

-

-

-

ON

MIL

A

A

A

A

A

A

E

Symptom Code

ECM Main Relay Switched Off Too Late

ECM Main Relay Switched Off Too Early

Wrong Transponder Key

Immobilizer No or Wrong Signal


Wrong Security Code Entered

Security Key and Security Code not Programmed

EEPROM Defect

DTC Name

When ignition switch was turned off, timing of the ECM main relay turning off is too late or does not off.

When ignition switch was turned off, timing of the ECM main relay turning off is too early.

Received response signal is not correct from the transponder key.

Received response signal is not correct or not received.

Received challenge signal is not correct or not received.

Received security code is not correct.

Immobilizer functions are not programmed in the ECM.

EEPROM checksum does not match with the read check sum during initialization of the ECM.



Flash Code

6E126


1. Engine does not start. 2. Check engine lamp flash.





Fail-Safe (Back Up)

No recovery.

No recovery.

No recovery.

No recovery.

No recovery.

No recovery.

No recovery.

EEPROM checksum match with the read check sum during initialization of the ECM.

Recovery Condition

1. ECM main relay malfunction. 2. ECM malfunction.

ECM malfunction.

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.

ECM malfunction.


3/ 58

3/ 58

27/ 35

27/ 35

Related ECM Pin No.

B****

B****

B****

B****

B****


4JH1-TC (MT)

4JH1-TC (AT)

Code

P1630

P1650

P1651

P1690

Flash Code

51

44

45

77

OFF

OFF

8

ON

B

4

ON

ON

B

A

ON

ON

B

A

ON

MIL

A

Symptom Code

Check Engine Lamp (MIL) Circuit Voltage High

Check Engine Lamp (MIL) Circuit Voltage Low

CAN Malfunction

CAN Malfunction

CAN Device Hang-up

CAN Device Offline

Fuel Injection Quantity Circuit Malfunction


DTC Name

Check engine lamp circuit short to voltage circuit.

Check engine lamp circuit open or short to ground circuit.

The ECM does not read CAN signal from the PSG (pump control unit).

The PSG (pump control unit) does not recognize CAN signal from the CAN controller.

CAN controller does not react under engine running.

CAN controller detects Busoff or canceling.

The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to continuous current.

The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to high current.




MAB (fuel cutoff solenoid valve) is operated.



Fail-Safe (Back Up)


Check engine lamp circuit is correct condition.

ECM malfunction.

1. Check engine lamp circuit open or short to ground circuit. 2. Check engine lamp malfunction 3. ECM 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. The ECM reads CAN signal from the PSG (pump control unit).

42

99/ 100

1. ECM malfunction. 2. PSG (pump control unit) malfunction. 1. ECM malfunction. 2. PSG (pump control unit) malfunction.

99/ 100

Related ECM Pin No.

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.


The PSG (pump control unit) recognizes CAN signal from the CAN controller.

CAN controller reacts correctly under engine running.

CAN controller detects correct Bus signal.

No recovery.

The PSG (pump control unit) PSG (pump control unit) detects correct high pressure malfunction. solenoid valve control circuit.

Recovery Condition

B****

P1650(A)

P1651(B)


4JH1-TC (MT)


4JH1-TC (AT)

6E127

6E–128


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


Condition for setting the DTC and action taken when the DTC sets

6E–129

Flash Code

Code

Symptom Code

MIL

DTC Name


Fail-Safe (Back Up)

65

P0100

7

ON


9

ON

Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input

ECM uses mass air flow 1600mg/strk & EGR 10% conditions as substitute.

B

ON

C

ON

Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input

Mass Air Flow (MAF) Sensor Output Circuit Low Input

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.

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).

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

2

Action

Was the “On-Board Diagnostic (OBD) System Check” performed? 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”?

Value(s)

Yes

—

Go to Step 2

Go to On Board Diagnostic (OBD) System Check

Go to Step 3

Refer to Diagnostic Aids and Go to Step 3

—

No

6E–130 Step 3

4



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?

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)

5 6

Yes

No

—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 11

Go to Step 6

Approximately 5.0V

Go to Step 11

Less than 1V: Go to Step 7 More than specified value: Go to Step 8

—

Verify repair

Go to Step 8

C-116

92 2 3

4

5

83

88

Value(s)

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

4 83


Action

Using the DVM and check the MAF sensor power supply circuit.

6E–131

Value(s)

Yes

No

No continuity

Go to Step 10

Go to Step 9

—

Verify repair

—

—

Verify repair

Go to Step 13

—

Go to Step 12

Go to Step 13

—

Verify repair

—

—

Verify repair

Go to Step 14

—

Verify repair

—

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

2

9 10

4

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

4 83

11 12 13

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?



6E–132


Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65) Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input

Step 1

2

3

4

Action


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”?

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?

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?

—

Go to Step 2


Go to Step 3


—

Go to Step 4


88

—

Verify repair

Go to Step 5

—

Go to Step 10

Go to Step 6

Approximately 5.0V

Go to Step 10

Go to Step 7

—

No

C-116

92 2 3

6

Yes

2. Review and record the failure information.

C-57(B)

5

Value(s)

4

5

83



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

V


Action

Using the DVM and check the MAF sensor power supply circuit.

6E–133

Value(s)

Yes

No

No continuity

Go to Step 9

Go to Step 8

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Go to Step 11

Go to Step 12

—

Verify repair

—

—

Verify repair

Go to Step 13

—

Verify repair

—

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

3

8 9

4

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

4

10 11 12

13

83

Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved?

Replace the MAF & IAT sensor assembly. Is the action complete?



6E–134


Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit Low Input

Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 11

Go to Step 6


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. 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?


88

83


—

No

C-116

92 2 3

5

Value(s)

4

5


Action

Using the DVM and check the MAF sensor signal circuit. Breaker box is available:

6E–135

Value(s)

Yes

No

—


Go to Step 7

Approximately 5.0V

Go to Step 9

Go to Step 8

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 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

5

88

7


2. Disconnect the MAF & IAT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value? C-116 4

V

6E–136 Step 8


Repair the open circuit between the ECM and MAF sensor. Was the problem solved? C-57(B)

Yes

No

—

Verify repair

Go to Step 13

10-14.5V

Go to Step 11

Go to Step 10

—

Verify repair

Go to Step 11

—

Go to Step 12

Go to Step 13

—

Verify repair

—

—

Verify repair

Go to Step 14

—

Verify repair

—

C-116

4 83

9

Value(s)

Using the DVM and check the MAF sensor +12V supply circuit. 1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.


2

V 10 11 12 13

14

Repair the open circuit between the ECM main relay and MAF sensor. Was the problem solved?





6E–137

Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65) Mass Air Flow (MAF) Sensor Output Circuit High Input Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 11

Go to Step 6


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. 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?


88

83


—

No

C-116

92 2 3

5

Value(s)

4

5

6E–138 Step 6


Using the DVM and check the MAF sensor ground circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 7

Go to Step 8


1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the MAF sensor connector.

4. Check the circuit for open circuit. Was the problem found? Breaker Box 92

C-116 !

!

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

3

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

3

V Less than 1V


Action

Using the DVM and check the MAF sensor signal circuit.

Value(s)

6E–139

Yes

No

Less than 1V

Go to Step 9


—

Go to Step 10

Go to Step 11

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Verify repair

—

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

5

V 9 10 11

12




6E–140


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


Condition for setting the DTC and action taken when the DTC sets Flash Code 34

Code P0105

Symptom Code

MIL

1

ON

2

ON

7

ON

9

ON

Circuit description

DTC Name


Vacuum Pressure Sensor Circuit High Input


Vacuum Pressure Sensor Circuit Low Input

Vacuum sensor output voltage is below 0.5V.

Vacuum Pressure Sensor Voltage Supply Circuit High Input


Vacuum Pressure Sensor Voltage Supply Circuit Low Input

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.


6E–141

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.

Diagnostic Aids


• Misrouted harness. • Rubbed through wire insulation. • Broken wire inside insulation. Check for the following conditions:


• 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.

6E–142


Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34) Vacuum Pressure Sensor Circuit High Input

Step 1

2

3

4

Action

Was the "On-Board Diagnostic (OBD) System Check" performed? 1. 1Connect the Tech 2.

Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Verify repair

Go to Step 5

-

Go to Step 9

Go to Step 6


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"? 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?

Check for poor/faulty connection at the vacuum pressure sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?

C-57

-

No

C-124 " & %

%$5

!#

!"

Visually check the vacuum sensor. Was the problem found?


Action

Using the DVM and check the vacuum pressure sensor ground circuit.

6E–143

Value(s)

Yes

No

-


Go to Step 7

Go to Step 8


Breaker box is available:

1. Ignition "Off", engine "Off".

2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect connector.

the

vacuum

pressure

sensor

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.

sensor

3. Check the circuit for open circuit. Was the problem found?

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

3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?

C-124

!

V

Less than 1V

6E–144 Step 8


Using the DVM and check the vacuum pressure sensor signal circuit. 1. Ignition "On", engine "Off". 2. Disconnect the vacuum connector.

pressure

Value(s)

Yes

No

Less than 1V

Go to Step 9


-

Go to Step 10

Go to Step 11

-

Verify repair

-

-

Verify repair

Go to Step 12

-

Verify repair

-

sensor


C-124

!

V

9 10 11

12

Substitute a known good vacuum pressure sensor and recheck. Was the problem solved? Replace the vacuum Is the action complete?

pressure

sensor.

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.


6E–145

Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34) Vacuum Pressure Sensor Circuit Low Input Step 1

2

3

4

Action

Was the "On-Board Diagnostic (OBD) System Check" performed? 1. Connect the Tech 2.

Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Verify repair

Go to Step 5

-

Go to Step 9

Go to Step 6





C-57

-

No

C-124 " & %

%$5

!#

!"

Visually check the vacuum pressure sensor. Was the problem found?

6E–146 6

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 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. (ECM disconnected) Ref. Page 6E-103 3. Disconnect connector.

the

vacuum

pressure

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".


sensor

3. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?

C-57

C-124 $

"#

-


Go to Step 7

Approximately 5.0V

Go to Step 9

Go to Step 8

! !

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

3. Check the circuit for open circuit. Was the DVM indicated specified value?

C-124

V

!


Repair the open circuit between the ECM and vacuum pressure sensor. Was the problem solved?

C-57

C-124

!

"#

9 10 11

12

6E–147

Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved?

Replace the vacuum sensor assembly. Is the action complete?



-

Verify repair

Go to Step 11

-

Go to Step 10

Go to Step 11

-

Verify repair

-

-

Verify repair

Go to Step 12

-

Verify repair

-

6E–148


Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit High Input

Step 1

2

3

4

Action


Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Verify repair

Go to Step 5

-

Go to Step 8

Go to Step 6

Approximately 5.0V

Go to Step 8

Go to Step 7





C-57

-

No

C-124 " & %

!#

%$5 6

!"



the

vacuum

pressure

sensor

3. Check the circuit for short to battery voltage circuit. Was the DVM indicated specified value?

C-124

V

!


Repair the short to battery voltage circuit between the ECM and vacuum pressure sensor. Was the problem solved?

C-57

C-124

!

"#

8 9 10

11

6E–149

Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved? Replace the vacuum pressure sensor assembly. Is the action complete?



-

Verify repair

Go to Step 10

-

Go to Step 9

Go to Step 10

-

Verify repair

-

-

Verify repair

Go to Step 11

-

Verify repair

-

6E–150


Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34) Vacuum Pressure Sensor Voltage Supply Circuit Low Input

Step 1

2

3

4

Action


Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Verify repair

Go to Step 5

-

Go to Step 10

Go to Step 6

Approximately 5.0V

Go to Step 10

Go to Step 7





C-57

-

No

C-124 " & %

!#

%$5 6

!"



the

vacuum

pressure

sensor

3. Check the circuit for short to ground circuit. Was the DVM indicated specified value?

C-124

V

!


6E–151

Using the DVM and check the vacuum pressure sensor power supply circuit. 1. Ignition "Off", engine "Off".


sensor

3. Check the circuit for short to vacuum pessure sensor ground circuit. Was the DVM indicated specified value? #

C-124

!

"

8 9 10 11 12

13

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?



No continuity

Go to Step 9

Go to Step 8

-

Verify repair

-

-

Verify repair

Go to Step 12

-

Go to Step 11

Go to Step 12

-

Verify repair

-

-

Verify repair

Go to Step 13

-

Verify repair

-

6E–152


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


Code P0110

Symptom Code

MIL

1

ON

2

ON

Circuit Description

DTC Name


Intake Air Temperature (IAT) Sensor Circuit High Input

Intake Air Temperature (IAT) Sensor Circuit Low Input

The IAT sensor is a thermistor. A temperature changes



Fail-Safe (Back Up) ECM use deg.C conditions as substitute.

the resistance value. And it changes voltage. In other words it measures a temperature value. Low air temperature produces a high resistance.


6E–153

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.

Diagnostic Aids

• 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.


• Rubbed through wire insulation.



Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit High Input Step 1

2

3

4

Action

Was the “On-Board Diagnostic (OBD) System Check” performed? 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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 12

Go to Step 6

—

No

2. Select “F1: Clear DTC Information” in “F0: Diagnostic Trouble Codes” with the Tech 2 and clear the DTC information.


Check for poor/faulty connection at the IAT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? C-57(B)

C-116 92

5

84

Visually check the IAT sensor. Was the problem found?

1

3

6E–154 Step 6


Using the DVM and check the IAT sensor.

Value(s)

Yes

No

Standard resistance

Go to Step 7

Go to Step 12

Approximately 5.0V

Go to Step 10


—

Verify repair

Go to Step 14

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)

Resistance (!) (Approximately)

-20

13660

0

5430

20

2433

60

598

40

1153

80

334

100

204

IAT Sensor

5

4

3

2

3

7

1 1

Using the DVM and check the IAT sensor signal circuit. 1. Ignition “On”, engine “Off”.



1

V 8

Repair the open circuit between the ECM and IAT sensor. Was the problem solved? C-57(B)

84

C-116

1


Action

Repair the short to voltage circuit between the ECM and IAT sensor. Was the problem solved? C-57(B)

Value(s)

Yes

No

—

Verify repair

Go to Step 14

Go to Step 11


C-116

1

84

10

6E–155

Using the DVM and check the IAT sensor ground circuit. 1. Ignition “On”, engine “Off”.



3

V Less than 1V

6E–156 Step 11


Using the DVM and check the IAT sensor ground circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 14

—

Go to Step 13

Go to Step 14

—

Verify repair

—

—

Verify repair

Go to Step 15

—

Verify repair

—



C-116 !

!


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 13 14

15

3






6E–157

Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23) Intake Air Temperature (IAT) Sensor Circuit Low Input Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6





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)

—

No

C-116 92

84

5

1

3

Remove the MAF & IAT sensor assembly and visually check. Was the problem found?

6E–158 Step 6


Using the DVM and check the IAT sensor.

Value(s)

Yes

No

Standard resistance

Go to Step 7

Go to Step 8

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

13660

0

5430

20

2433

60

598

40

1153

80

334

100

204

IAT Sensor

5

4 3

3

2

1 1


Action

Using the DVM and check the IAT sensor signal circuit. Breaker box is available:

6E–159

Value(s)

Yes

No

—


Go to Step 10

—

Go to Step 9

Go to Step 10

—

Verify repair

—

—

Verify repair

Go to Step 11

—

Verify repair

—


4. Check the circuit for short to sensor ground or ground circuit. Was the problem found? 84

Breaker Box

92

!

!


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 9 10

11




6E–160


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


Code P0115

Symptom Code

MIL

1

ON

2

ON

Circuit Description

DTC Name Engine Coolant Temperature (ECT) Sensor Circuit High Input

Engine Coolant Temperature (ECT) Sensor Circuit Low Input

The ECT sensor is a thermistor. A temperature changes


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.


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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS • Misrouted harness.

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.

6E–161




• 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

2

3

4

Action



Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 12

Go to Step 6

—

No



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

89

5

Value(s)

Visually check the ECT sensor. Was the problem found?

1

E-41

2

6E–162 Step 6


Using the DVM and check the ECT sensor.

Value(s)

Yes

No

Standard resistance

Go to Step 7

Go to Step 12

Approximately 5.0V

Go to Step 10


—

Verify repair

Go to Step 14

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

16100

0

5760

20

2370

60

537

40

1080

80

290

100

161

120

95

ECT Sensor 2

1 2

7

1

Using the DVM and check the ECT sensor signal circuit. 1. Ignition “On”, engine “Off”.

2. Disconnect the ECT sensor connector.

3. Check the circuit for open circuit. Was the DVM indicated specified value? E-41

1

V 8

Repair the open circuit between the ECM and ECT sensor. Was the problem solved? C-57(B)

89

E-41

1


Action

Repair the short to voltage circuit between the ECM and ECT sensor. Was the problem solved? C-57(B)

Value(s)

Yes

No

—

Verify repair

Go to Step 14

Less than 1V

Go to Step 11


—


Go to Step 14

E-41

1

89

10

6E–163

Using the DVM and check the ECT sensor ground circuit. 1. Ignition “On”, engine “Off”.

2. Disconnect the ECT sensor connector.

3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value? E-41

2

V 11

Using the DVM and check the ECT sensor ground circuit. Breaker box is available: 1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the ECT sensor connector.


E-41 !

!


2. Disconnect the ECT sensor connector ECM connector.


E-41

2 93

6E–164 Step 12

13 14

15


Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete?



Value(s)

Yes

No

—

Go to Step 13

Go to Step 14

—

Verify repair

—

—

Verify repair

Go to Step 15

—

Verify repair

—


6E–165

Diagnostic Trouble Code (DTC) P0115 (Symptom Code 2) (Flash Code 14) Engine Coolant Temperature Sensor Circuit Low Input Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6





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

89

5

Value(s)

Visually check the ECT sensor. Was the problem found?

1

E-41

—

No

2

6E–166 Step 6


Using the DVM and check the ECT sensor.

Value(s)

Yes

No

Standard resistance

Go to Step 7

Go to Step 8

1. Ignition “Off”, engine “Off”. 2. Disconnect ECT sensor connector.


-20


16100

0

5760

20

2370

60

537

40

1080

80

290

100

161

120

95

ECT Sensor 2

1 2

1


Action

Using the DVM and check the ECT sensor signal circuit. Breaker box is available:

6E–167

Value(s)

Yes

No

—


Go to Step 10

—

Go to Step 9

Go to Step 10

—

Verify repair

—

—

Verify repair

Go to Step 11

—

Verify repair

—

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the ECT sensor connector.

4. Check the circuit for short to sensor ground or ground circuit. Was the problem found? 89

Breaker Box

93

!

!


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 9 10

11




6E–168


DIAGNOSTIC TROUBLE CODE (DTC) P0180 (SYMPTOM CODE B) (FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE


Code P0180

Symptom Code B

MIL

DTC Name


ON

Fuel Temperature Sensor Circuit Range/Performance

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


Diagnostic Aids

• 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.

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. An intermittent may be caused by the following: • Poor connections.


• Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the “Fuel Temperature” display on the Tech2 while


6E–169

moving connectors and wiring harness related to the sensor.

Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel Temperature Sensor Circuit Range/Performance Step 1

2

3

4

5

6

7

Action


Value(s)

Yes

—

Go to Step 2



No


—

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

—

Verify repair

—

—

Verify repair

—



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?

6E–170


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



Code P0215

Symptom Code

MIL

DTC Name

A

ON


B

ON

Fuel Cutoff Solenoid Valve Circuit High Input

C

ON

Fuel Cutoff Solenoid Valve Always Active

D

ON


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.


Fail-Safe (Back Up)

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.

6E–171


Engine does not start.



Diagnostic Aids



• 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

2

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3



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”?

—

No

6E–172 Step 3

4


Value(s)

Yes

No

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?

—

Go to Step 4


—

Verify repair

—


Replace the injection pump assembly. Is the action complete?


6E–173

Diagnostic Trouble Code (DTC) P0215 (Symptom Code B) (Flash Code 52) Fuel Cutoff Solenoid Valve Circuit High Input Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6





Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? 105

5

Value(s)

C-57

5

—

No

E-6

Visually check the PSG (pump control unit). Was the problem found?

6E–174 Step 6


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 connected) Ref. Page 6E-104

Value(s)

Yes

No

Less than 1V

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

—

type B. (ECM

3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value? Breaker Box 105

V


1. Check the circuit for short to voltage circuit. Was the DVM indicated specified value? C-57

105

V 7

Repair the short to voltage circuit between the ECM and PSG (pump control unit). Was the problem solved? C-57

E-6

5 105

8



6E–175

Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel Cutoff Solenoid Valve Always Active Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 7

Go to Step 6


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. 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?

Check for poor/faulty connection at the ECM or PSG (pump control unit) connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? 105

5

Value(s)

C-57

5

—

No

E-6


6E–176 Step 6


Using the DVM and check the MAB (fuel cutoff solenoid valve) circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 7

—

Verify repair

—

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect connector.

the

PSG

(pump

control

unit)

4. Check the circuit for open or short to ground circuit. Was the problem found? Breaker Box 105

!

E-6

! !


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

105

7


E-6

5


6E–177

Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel Cutoff Solenoid Valve Malfunction Step 1

2

3

4

5

6

7

Action


Value(s)

Yes

—

Go to Step 2



No

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”?

—

Go to Step 3


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?

—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 7

—

Verify repair

—

—

Verify repair

—





6E–178


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


Code P0216

Symptom Code A

B

MIL ON

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.

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.

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.

Diagnostic Aids

An intermittent may be caused by the following: • Poor connections. • Misrouted harness.


• 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.

6E–179

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.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.


• 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.

6E–180


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

2

3

4

Action


Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Go to Step 5

Verify repair


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"? 1. 1Using the Tech 2, ignition "On" and engine "Off".

-

No

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?

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?


6 7

6E–181

Action

Value(s)

Yes

No

• Restrict fuel supply system. Check for a pinched fuel hose/pipe. • Check for a condition that causes fuel waxing or icing, such as the customer is using an incorrect fuel type in winter season or water mixed with the fuel. If a problem is found, repair as necessary. Was a problem found?

-

Verify repair

Go to Step 6

-

Verify repair

Go to Step 7

-

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

Visually/physically inspect for the following conditions.

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?

8

9


Substitute a known good ECM and recheck. Was the problem solved? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System(SPS) in this manual. Following ECM programming, the immobiliser system (if equipped) must be linked to the ECM. Refer to section 11 "Immobilizer System-ECM replacement" for the ECM/Immobilizer linking procedure.

6E–182 Step 10

11




Value(s)

Yes

No

-

Verify repair

-

-

Verify repair

-


6E–183

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

6E–184



Code P0243

Symptom Code 3

4

5

6

8

MIL ON

ON

ON

ON

ON

DTC Name


Fail-Safe (Back Up)


1. Intake air temperature is between -50 deg. C and 200 deg. C.


Turbocharger Wastegate Solenoid "A" Low

Wastegate control EVRV circuit open or short to ground circuit.


Turbocharger Wastegate Solenoid "A" Malfunction

Turbocharger Wastegate Solenoid "A" High

2. Engine coolant temperature is between 50 deg. C and 150 deg. C.

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.

2. EGR EVRV becomes 10% condition.


2. EGR EVRV becomes 10% condition. 3. Wastegate control EVRV becomes 32% condition.



1. Engine coolant temperature is between 50 deg. C and 150 deg. C. 2. EGR control EVRV 0% condition.

Wastegate control EVRV circuit short to voltage circuit.



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


• 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:


• 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.


6E–185

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64) Turbocharger Wastegate Solenoid "A" Range/Performance Step 1

2

3

4

Action


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 7

Go to Step 8

-

Verify repair

-




Remove the vacuum hose & vacuum regulating valve and check for the following conditions.

-

No

• Objects blocking the vacuum hose.

• Objects blocking the vacuumregulating valve. • Vacuum leaking at vacuum hose or vacuum regulating valve.

5

6

7

• Objects blocking at the wastegate solenoidvalve. If a problem is found, repair as necessary. Was the problem found? 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?

6E–186 Step 8


Using the DVM and check the wastegate control solenoid.

Value(s)

Yes

No

Approximately 14.7 - 16.1 ! at 20"C

Go to Step 11

Go to Step 9

-

Go to Step 10

Go to Step 11

-

Verify repair

-

-

Go to Step 12

Go to Step 13

-

Verify repair

-

-

Verify repair

Go to Step 14

-

Verify repair

-

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

" #

#

"

! 9

10 11

12 13

14

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?




6E–187

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Low Step 1

2

3

4

Action


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 9


3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0243 (Symptom Code 4) stored as "Present Failure"? 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.


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? !"

5

Value(s)

C-57

C-123

#

-

No

$

Using the DVM and check the wastegate control solenoid. 1. Ignition "Off", engine "Off". 2. Disconnect thewastegatesolenoid connector.


Wastegate Solenoid " #

#

"

!

6E–188 Step 6


Using the DVM and check the wastegate control solenoid power supply circuit. 1. Ignition "On", engine "Off". 2. Remove the wastegate connector.

7

8

control

Value(s)

Yes

No

10 - 14.5V

Go to Step 8

Go to Step 7

-

Verify repair

-

-


Go to Step 11

-

Go to Step 10

Go to Step 11

-

Verify repair

-

solenoid


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. (ECM disconnected) Ref. Page 6E-103 3. Removethewattagecontrolsolenoid connector.


Breaker Box 96

C-123

" ! !


1. Ignition "Off", engine "Off". 2. Disconnect the ECM connector. 3. Remove the connector.

wastegate

control

solenoid


C-57

!"

C-123

# $ $

9

10



12

Action



6E–189

Value(s)

Yes

No

-

Verify repair

Go to Step 12

-

Verify repair

-

6E–190


Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Range/Performance

Step 1

2

3

4

5

Action


Value(s)

Yes

-

Go to Step 2


Go to Step 3


-

Go to Step 4


-

Verify repair

Go to Step 5


Go to Step 8

Go to Step 6

-

Go to Step 7

Go to Step 8

-

Verify repair

-

-

Go to Step 9

Go to Step 10

-

Verify repair

-




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".

-

No

2. Disconnect thewastegatesolenoid connector.


Wastegate Solenoid

" #

#

"

! 6

7 8

9


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

.


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? !"

11 12

C-57

#

C-123

Using the DVM and check the vacuum pressure sensor signal circuit. 2. Disconnect connector.

the

vacuum

pressure

Value(s)

Yes

No

-

Verify repair

Go to Step 11

-

Go to Step 13

Go to Step 12

Less than 1V

Go to Step 15


-

Go to Step 14

Go to Step 15

-

Verify repair

-

-

Verify repair

Go to Step 16

-

Verify repair

-

$

Visually check the vacuum pressure sensor. Was the problem found? 1. Ignition "On", engine "Off".

6E–191

sensor


C-124

!

V

13

14 15

16

Substitute a known good vacuum pressure sensor assembly and recheck. Was the problem solved? Replace the vacuum pressure sensor assembly. Is the action complete?



6E–192


Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64) Turbocharger Wastegate Solenoid "A" Malfunction

Step 1

2

3

4

5

6 7

Action


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 7

-

Verify repair

-

-

Verify repair

Go to Step 8

-

Go to Step 10

Go to Step 9


3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0243 (Symptom Code 6) stored as "Present Failure"? 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.


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?

C-57

##

%

#$


-

No

C-116

!"

$

8

Value(s)

&

'


Action

Using the DVM and check the MAF sensor signal circuit.

Value(s)

6E–193

Yes

No

Less than 1V

Go to Step 12


-

Go to Step 11

Go to Step 12

-

Verify repair

-

-

Verify repair

Go to Step 13

-

Verify repair

-

1. Ignition "On", engine "Off". 2. Disconnect the MAF sensor connector.


C-116

!

V

10

11 12

13

Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? Replace the MAF & Is the action complete?

IAT

sensor

assembly.



6E–194


Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64) Turbocharger Wastegate Solenoid "A" High

Step 1

2

3

4

5

Action


Value(s)

Yes

-

Go to Step 2



No

3. Select "F0: Read DTC Infor As Stored By ECU" in "F0: Diagnostic Trouble Codes". Is the DTC P0243 (Symptom Code 8) stored as "Present Failure"?

-

Go to Step 3



-

Go to Step 4


-

Verify repair

Go to Step 5

Approximately 14.7- 16.1 ! at 20"C

Go to Step 6

Go to Step 8

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.

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.


Wastegate Solenoid " #

#

"

!


Action

Using the DVM and check the wastegate control solenoid circuit.

6E–195

Value(s)

Yes

No

No continuity

Go to Step 10

Go to Step 7

-

Verify repair

-

-

Go to Step 9

Go to Step 10

-

Verify repair

-

-

Verify repair

Go to Step 11

-

Verify repair

-

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?

C-123

! 7 8

9 10

11

Repair the short Is the action complete?

to

voltage

circuit.




6E–196


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



Code P0251

Symptom Code

MIL

DTC Name

6

ON


7

ON


9

ON


A

ON


B

ON


D

ON


E

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.


6E–197

Fail-Safe (Back Up)

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.


ECM could not accept PSG (pump control unit) message.


PSG (pump control unit) could not measure the high pressure solenoid valve drive voltage.

Diagnostic Aids



• Rubbed through wire insulation. • Broken wire inside the insulation. Check for the following conditions:


• 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?

Value(s)

Yes

—

Go to Step 2

No


6E–198 Step 2

3

4


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

Value(s)

Yes

No

—

Go to Step 3


—

Go to Step 4


—

Verify repair

—


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? Replace the injection pump assembly. Is the action complete?


6E–199


2

3

4

5

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4






Was the DTC P0335 (Symptom Code B), P0335 (Symptom Code D) or P1335 (Symptom Code A) stored at the same time?

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)

—

—

—

Go to DTC Chart P0335 (Symptom Code B) (Symptom Code D) or P1335 (Symptom Code A)

—

Verify repair

No

Go to Step 5

E-6

91

8

Go to Step 6

6E–200 Step 6


If a oscilloscope is available, monitor the CKP sensor output signal. Does the oscilloscope indicate correct wave form?

Value(s)

Yes

No

Go to Step 13

Not available: Go to Step 7 Fixed at low: Go to Step 7 Fixed at High: Go to Step 8


CH1

0V"

CH2 0V"


—


Action

Using the DVM and check the CKP sensor output circuit. Breaker box is available:

6E–201

Value(s)

Yes

No

—


Go to Step 8

Go to Step 9



the

PSG

(pump

control

unit)


!

E-6

! !


2. Disconnect the ECM connector. 3. Disconnect connector.

the

PSG

(pump

control

unit)

4. Check the circuit for open or short to ground circuit. Was the problem found? C-57(B)

E-6

8

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)


8

V Less than 1V

6E–202 Step 9

10

11

12

13


Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found?




Value(s)

Yes

No

—

Remove the accessory parts and verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Go to Step 12

Go to Step 13

—

Verify repair

—

—

Verify repair

—


6E–203


2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

—



6E–204


Diagnostic Trouble Code (DTC) P0251 (Symptom Code A) (Flash Code 53) Injection Pump Malfunction

Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3


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?

—

Go to Step 4


—

Verify repair

—




6E–205

Diagnostic Trouble Code (DTC) P0251 (Symptom Code B) (Flash Code 53) Injection Pump Malfunction Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

—



6E–206


Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53) Injection Pump Malfunction

Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

—




6E–207

Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53) Injection Pump Malfunction Step 1

2

3

4

5

6

7

8

Action


Value(s)

Yes

—

Go to Step 2



No

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”?

—

Go to Step 3


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?

—

Go to Step 4



Was the DTC P1650 (Symptom Code A) or P1651 (Symptom Code B) stored at the same time? 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 DTC Chart P1650 (Symptom Code A)

—

Verify repair

Go to Step 6

—

Go to Step 7

Go to Step 8

—

Verify repair

—

—

Verify repair

—

Go to Step 5

6E–208


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



Code P0335

Symptom Code

MIL

B

ON

D

E

DTC Name

6E–209


Fail-Safe (Back Up)


1. Engine speed is more than 665rpm. 2. CKP sensor pulse width error.

ON


ON

Engine Speed Input Circuit Range/Performance

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.

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.

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.

Engine speed is more than 5700rpm.

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.

Diagnostic Aids





• 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 Step 1

Action


Value(s)

Yes

—

Go to Step 2

No


6E–210 Step 2

3

4


Value(s)


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

Yes

No

Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

Approximately 0.9k! at 20°C

Go to Step 10

Go to Step 7

—


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? 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

E-9

1

2

3

98 90

5 6

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. (ECM disconnected) Ref. Page 6E-103

3. Check the resistance of the CKP sensor. Was the DVM indicated specified value? 90

Breaker Box

98

!


2. Disconnect the ECM connector.

3. Check the resistance of the CKP sensor. Was the DVM indicated specified value? C-57(B)

98

90


Action

Using the DVM and check the CKP sensor circuit.

6E–211

Value(s)

Yes

No

Approximately 0.9k! at 20°C

Go to Step 8

Go to Step 14

—


Go to Step 9

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

1

8

2

Using the DVM and check the CKP sensor circuit. Breaker box is available: 1. Ignition “Off”, engine “Off”.


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 98

90

101

! !



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

E-9

98

!

"

! ! !

6E–212 Step 9


Using the DVM and check the CKP sensor circuit.

Value(s)

Yes

No

Less than 1V

Verify repair

—

Go to Step 13

Go to Step 11

Verify repair

Go to Step 12

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

1

2

V 10

V

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? Crankshaft Position (CKP) Sensor Reference Wave Form

0V"


11

Remove the CKP sensor from the flywheel housing and visually check. Check for the following conditions. • Objects sticking the CKP sensor.

12

• Objects sticking the CKP sensor pulser. If a problem is found, repair as necessary. Was the problem found?

Check the CKP sensor shield wire for open or short circuit. Was the problem found?

— —


Go to Step 13


14 15 16

17

Action


Substitute a known good CKP sensor and recheck. Was the problem solved?

Replace the CKP sensor. Was the problem solved?



Value(s)

Yes

6E–213 No

—


Go to Step 14

—

Go to Step 15

Go to Step 16

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

—

6E–214


Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43) Engine Speed Input Circuit Range/Performance

Step 1

2

3

4 5

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4





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?

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

1

E-9

2

—

— —

Explain the reason of DTC to the customer

—

Verify repair

No

Go to Step 5

3

98 90

Go to Step 6


Action

Using the DVM and check the CKP sensor signal.

Value(s)

6E–215

Yes

No

Go to Step 9

Go to Step 7

Verify repair

Go to Step 8

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


Approximately 1.1 V at 2000rpm

If a oscilloscope is available, monitor the CKP sensor signal. Does the oscilloscope indicate correct wave form? Crankshaft Position (CKP) Sensor Reference Wave Form

0V"


7

Remove the CKP sensor from the flywheel housing and visually check. Check for the following conditions. • Objects sticking the CKP sensor.

8 9 10 11 12


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?


— —


Go to Step 9

—


Go to Step 10

—

Go to Step 11

Go to Step 12

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

6E–216 Step 13



Value(s)

Yes

No

—

Verify repair

—


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


Code P0380

Symptom Code

MIL

4

ON

8

ON

Circuit Description

DTC Name Glow Relay Circuit Voltage Low

Glow Relay Circuit Voltage High

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.

DTC Setting Condition Glow relay circuit open or short to ground circuit.

Fail-Safe (Back Up) No fail-safe function.

Glow relay circuit short to voltage circuit.

Diagnostic Aids





6E–218


• 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.


Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66) Glow Relay Circuit Voltage Low Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

Go to Step 6

Replace glow relay and verify repair





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

X-5

2

94

5

Value(s)

Using the DVM and check the glow relay.

—

No

3 4


2. Remove the glow relay from the relay box.

3. Check the relay coil. Was the DVM indicated specified value?

Grow Relay "

#

!

Approximately 105!


Action

Using the DVM and check the glow relay power supply circuit.

6E–219

Value(s)

Yes

No

10-14.5V

Go to Step 8

Go to Step 7

—

Verify repair

—

—


Go to Step 9

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

V 7 8

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”.


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

!

! !



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

6E–220 Step 9

10




Value(s)

Yes

No

—

Verify repair

Go to Step 10

—

Verify repair

—


6E–221

Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66) Glow Relay Circuit Voltage High Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

—

—

Verify repair

—





6E–222


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


Code P0381

Symptom Code

MIL

4

ON

Glow Plug Indicator Circuit Voltage Low

8

ON

Glow Plug Indicator Circuit Voltage High

Circuit Description

DTC Name

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

DTC Setting Condition Glow plug indicator circuit open or short to ground circuit.


Glow plug indicator circuit short to voltage circuit.

the glow plugs remain active for a certain period depending on engine coolant temperature.

Diagnostic Aids






• Poor connection at ECM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and

6E–223

poor terminal to wire connection.


Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67) Glow Plug Indicator Circuit Voltage Low Step 1

2

3

4 5 6

Action


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



—

No


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? 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”?

Check the glow plug indicator lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found?

6E–224 Step 7


Check for poor/faulty connection at the meter connector and ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? C-56

6

Yes

No

—

Verify repair

Go to Step 8

—


Go to Step 9

43

B-24

30

8

Value(s)

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. (ECM 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 43

B-24

! !



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


10

Action



6E–225

Value(s)

Yes

No

—

Verify repair

Go to Step 10

—

Verify repair

—

6E–226


Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67) Glow Plug Indicator Circuit Voltage High

Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

—

—

Verify repair

—






6E–227

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

6E–228



Code P0400

Symptom Code

MIL

3

ON

Exhaust Gas Recirculation Flow Excessive Detected

4

ON

5

ON

Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit

Exhaust Gas Recirculation Flow Insufficient Detected

8

ON

Exhaust Gas Recirculation Circuit Short to Battery

Circuit Description

DTC Name

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.

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.


Fuel injection quantity is reduced and EGR EVRV 10% conditions as substitute.


Fuel injection quantity is reduced & EGR EVRV 10% conditions as substitute.

Diagnostic Aids



• Broken wire inside the insulation. • EGR valve sticking.

• Faulty intake air duct connection. Check for the following conditions:




6E–229

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32) Exhaust Gas Recirculation Flow Excessive Detected Step 1

2

3

4

Action


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 7

Go to Step 8

—

Verify repair

—

Approximately 14! at 20°C

Go to Step 11

Go to Step 9





Remove the MAF & IAT sensor assembly and check for the following conditions.

—

No

• Objects blocking the air cleaner.

• Objects blocking the MAF sensor. • Vacuum leaking at intake duct.

5 6 7 8

• Objects blocking the turbocharger. If a problem is found, repair as necessary. Was the problem found?

Remove the MAF & IAT sensor assembly and visually check. 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

1 2

1

6E–230 Step 9

10 11


Value(s)

Yes

No

—

Go to Step 10

Go to Step 11

—

Verify repair

—

If a problem is found, repair as necessary. Was the problem found?

—

Verify repair or Go to Step 13

Go to Step 12

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?

—


Go to Step 14

—

Verify repair

—

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. ÅERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit. Tech 2:

1. Using the Tech 2, ignition "On" and engine "On".

2. Select the "Miscellaneous Test" and perform the "EGR Solenoid Test" in the "Solenoid". 3. Operate the Tech 2 in accordance with procedure. • Solenoid 95%: EGR Valve Open • Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original vacuum hose and connect the hose to the EGR valve. 2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve Close

Vacuum Pump

12

13

Small Window

Inspect the EGR valve. 1. Remove the EGR valve from the engine.

Replace the EGR valve. Is the action complete?


15

Action



6E–231

Value(s)

Yes

No

—

Verify repair

Go to Step 15

—

Verify repair

—

6E–232


Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit

Step 1

2

3

4

Action


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 9





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

—

No

C-115

1

2

97

5

Value(s)

Using the DVM and check the EGR EVRV. 1. Ignition “Off”, engine “Off”. 2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid coil. Does the tester indicate standard resistance? EGR EVRV 2

1 2

1


Action

Using the DVM and check the EGR EVRV power supply circuit.

6E–233

Value(s)

Yes

No

10-14.5 V

Go to Step 8

Go to Step 7

—

Verify repair

—

—


Go to Step 11

—

Go to Step 10

Go to Step 11

1. Ignition “On”, engine “Off”. 2. Remove the EGR EVRV connector.


1

V 7 8

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”.


3. Remove the EGR EVRV connector. 4. Check the circuit for open or short to ground circuit. Was the problem found? C-115

Breaker Box 97

!

! !



3. Remove the EGR EVRV connector.


C-115 2

97

9

Substitute a known good EGR EVRV and recheck. Was the problem solved?

6E–234 Step 10 11

12


Replace the EGR EVRV. Is the action complete?



Value(s)

Yes

No

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Verify repair

—


6E–235

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32) Exhaust Gas Recirculation Flow Insufficient Detected Step 1

2

3

4

5

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5


Go to Step 8

Go to Step 6

—

Go to Step 7

Go to Step 8

—

Verify repair

—




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? 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”.

—

No

2. Disconnect the EGR EVRV connector.


1 2

6 7

1


6E–236 Step 8


Using the Tech 2 or the vacuum pump and check the EGR valve operation for the following condition through the small window. ÅERestrict shaft movement. Check for objects sticking the shaft, broken diaphragm or excessive carbon deposit.

Value(s)

Yes

No

—


Go to Step 9

—


Go to Step 11

—

Verify repair

-

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 Pump

9

10

Small Window


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?

Replace the EGR valve. Is the action complete?


Action


12 13

Value(s)

Yes

No

—

Verify repair

Go to Step 12

—

Go to Step 14

Go to Step 13

Less than 1V

Go to Step 16


—

Go to Step 15

Go to Step 16

—

Verify repair

—

—

Verify repair

Go to Step 17

—

Verify repair

—

C-116

92 2 3

88

6E–237

4

5

83


Using the DVM and check the MAF sensor signal circuit. 1. Ignition “On”, engine “Off”.

2. Disconnect the MAF sensor connector.


5

V 14 15 16

17





6E–238


Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32) Exhaust Gas Recirculation Circuit Short to Battery

Step 1

2

3

4

Action


Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5


Go to Step 6

Go to Step 8


Check for poor/faulty connection at the EGR EVRV or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found? C-57

C-115

1

2

97

5

Value(s)

Using the DVM and check the EGR EVRV. 1. Ignition “Off”, engine “Off”. 2. Disconnect the EGR EVRV connector.


1 2

1


Action

Using the DVM and check the EGR EVRV circuit.

6E–239

Value(s)

Yes

No

No continuity

Go to Step 10

Go to Step 7

—

Verify repair

—

—

Go to Step 9

Go to Step 10

—

Verify repair

—

—

Verify repair

Go to Step 11

—

Verify repair

—

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

1

7 8 9 10

11

2

Repair the short to voltage circuit. Is the action complete?




6E–240


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



Code P0500

Symptom Code 1

A

B

MIL

DTC Name

ON at next ignition cycle

Vehicle Speed Sensor Circuit High Input

Vehicle speed is more than 200km/h.

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.





6E–241

Fail-Safe (Back Up)


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.

Diagnostic Aids



• 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 Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24) Vehicle Speed Sensor Circuit High Input Step 1

2

3

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4




—

No



—

6E–242 Step 4

5

6 7


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.

Value(s)

Yes

No

—

Go to Step 5

Go to Step 6

—

Go to Step 15

Go to Step 7

—

Go to Step 8

Go to Step 7


Refer the table

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)


Approximately 6.0 V at 20km/h

If No Good

Go to Step 8

Go to Step 9

Meter B24 connector 9 & GND

Go to Step 10

ECM C56 connector 68 & GND

Go to Step 13


Go to Step 12

If a oscilloscope is available, monitor the VSS signal at each connector connection. Does the oscilloscope indicate correct wave form? Vehicle Speed Sensor (VSS) Reference Wave Form

0V"


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

—

Verify repair

—


Action

Value(s)

Using the DVM and check the VSS signal circuit.

6E–243

Yes

No

Less than 1V

Go to Step 11


—

Verify repair

—

—

Verify repair

—

Go to Step 14


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

9

V 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

9

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


10

V Less than 1V

6E–244 Step 14


Using the DVM and check the VSS signal circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

—

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the meter connector.

4. Check the circuit for open or shot to ground circuit. Was the problem found? B-24

Breaker Box 68

!"

! !

Breaker box is not available: 1. Ignition “Off”, engine “Off”. 2. Disconnect connector.

the

meter connector

and

ECM


68

B-24

15

16

10




6E–245

Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24) Vehicle Speed Sensor Input Signal Frequency Too High Step 1

2

3

4 5

6

Action


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 10

Go to Step 7

—

Go to Step 8

Go to Step 7




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? 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?

—

No

6E–246 Step 7


Value(s)

Using the DVM and check the VSS signal.

Yes

No


Refer the table

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)



If No Good

Go to Step 8

Go to Step 9


Go to Step 10


Go to Step 10


Go to Step 11


0V"


8 9

10 11 12


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?



—

Verify repair

—

Verify repair

—

—


Go to Step 12

—

Verify repair

—

—

Verify repair

Go to Step 13


Action


6E–247

Value(s)

Yes

No

—

Verify repair

—

6E–248


Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24) Vehicle Speed Sensor Incorrect Signal

Step 1

2

3

4 5

6

Action


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 17

Go to Step 7

—

Verify repair

Go to Step 8




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? 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?

—

No

E-44 1

3

2 B-24

9 10

C-94(10)

10


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?

6E–249

Value(s)

Yes

No

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step 9


Refer the table

C-56

68

8 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)



If No Good



Go to Step 12


Go to Step 15


Go to Step 14


0V"


10


—

Verify repair

6E–250 Step 11

12


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”.

Value(s)

Yes

No

—

Verify repair

—

Less than 1V

Go to Step 13


—

Verify repair

—

—

Verify repair

—

2. Disconnect the meter connector.


9

V 13

Using the DVM and check the VSS signal circuit. 1. Ignition “Off”, engine “Off”. 2. Disconnect the VSS connector connector.

and

meter

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

9

14



Action

Value(s)

Using the DVM and check the VSS signal circuit. 1. Ignition “Off”, engine “Off”. 2. Disconnect the meter connector connector.

and

6E–251

Yes

No

Less than 1V

Go to Step 16


—


Go to Step 17

ECM

3. Ignition “On”.


10

V 16

Using the DVM and check the VSS signal circuit. Breaker box is available: 1. Ignition “Off”, engine “Off”.


3. Disconnect the meter connector. 4. Check the circuit for open or shot to ground circuit. Was the problem found? B-24

Breaker Box 68

!"

! !


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

6E–252 Step 17

18




Value(s)

Yes

No

—

Verify repair

Go to Step 18

—

Verify repair

—


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 DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYMPTOM CODE A) (FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION


Code P0560

Symptom Code

DTC Name

1

OFF

System Voltage Too High

2

OFF

System Voltage Too Low

A

Circuit Description

MIL

OFF


System Voltage Malfunction

The ECM and PSG monitors the system voltage on the ignition feed terminal to the ECM or PSG. The system

Fail-Safe (Back Up)


ECM uses 9V conditions as substitute.

System voltage of PSG (pump control unit) is below 4.5V or more than 27V.

PSG uses default voltage as substitute.


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

6E–254


or low, DTC P0560 (Symptom Code A) will be stored.

Diagnostic Aids





• 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.

Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35) System Voltage Too High Step 1

2

3

4 5

6

Action



Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4


—

No



Was the battery connecting?

jump

start

cable

incorrectly

1. Using the Tech 2, ignition “On” and engine “On”.

— —

Verify procedure

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?


Go to Step 5

10 - 14.5V

Go to Step 6

Check the charging system

—

Verify repair

Go to Step 7


Action


6E–255

Value(s)

Yes

No

—

Verify repair

—

6E–256


Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35) System Voltage Too Low

Step 1

2

3

4

5

6

Action


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

10 - 14.5V

Go to Step 6

Check the charging system, charge or replace the battery

—

Verify repair

Go to Step 7




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? 1. Using the Tech 2, ignition “On” and engine “On”.

—

No

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?

Using the DVM and check the battery voltage at the battery terminal. Does the tester indicate enough battery voltage? 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

56

3

2

1


Action

Using the DVM and check the ECM main relay.

Value(s)

6E–257

Yes

No

120-150!

Go to Step 8

Replace ECM main relay and verify repair

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

—

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?

ECM Main Relay $ #

"

# "

!

!

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

9

10



6E–258


Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35) System Voltage Malfunction

Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

10 - 14.5V

Go to Step 7

Go to Step 6





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?

—

No

E-6 6

7

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


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?

6E–259

Value(s)

Yes

No

—

Verify repair

Go to Step 7

—

Verify repair

—

E-10

7


6E–260


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


Code P0561

Symptom Code

MIL

DTC Name

A

OFF


B

OFF


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.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS • Rubbed through wire insulation.

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.

Diagnostic Aids


6E–261



• 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

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

—

No


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? Check the “Engine fuse (10A)”. If the fuse is burnt out, repair as necessary. Was the problem found?

6E–262 Step 5


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

Value(s)

Yes

No

—


Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

type A. (ECM


Breaker Box 39

! ! !


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

9

6

7

Check the ignition switch. If a poor/faulty connection is found, repair as necessary. Was the problem found?



Action


6E–263

Value(s)

Yes

No

—

Verify repair

—

6E–264


DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE PROGRAMMING ERROR

Condition for setting the DTC and action taken when the DTC sets Flash Code -

Code P0602

Symptom Code

MIL

DTC Name

-

Control Module Programming Error

-

Circuit Description & Diagnostic Aids

The replacement ECM must be programmed by Service Programming System (SPS). Because, the service

DTC Setting Condition ECM memory area error.

Fail-Safe (Back Up) Engine control disabled.

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

2

3

Action


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”?

Download the latest software to the ECM using the “SPS (Service Programming System)”. Is the action complete?

Value(s)

Yes

No

—

Go to Step 2


—

Go to Step 3


—

Verify repair

—


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 Condition for setting the DTC and action taken when the DTC sets Flash Code 28

Code P0606

Symptom Code

MIL

DTC Name


Fail-Safe (Back Up)

A

ON

ECM Malfunction

Gate Array communication error.

B

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.

1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk. MAB (fuel cutoff solenoid valve) is operated.


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

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


—

Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

No


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? 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?

6E–266 Step 5



Value(s)

Yes

No

—

Verify repair

—


6E–267

Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU Malfunction Step 1

2

3

4

5

6

7

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 7

—

Verify repair

—

—

Verify repair

—





6E–268


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


Code P0645

Symptom Code

MIL

DTC Name

4

ON

A/C Compressor Relay Circuit Voltage Low

8

ON

A/C Compressor Relay Circuit Voltage High

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.

DTC Setting Condition A/C compressor relay circuit open or short to ground circuit.


A/C compressor relay circuit short to voltage circuit.

Diagnostic Aids





6E–269

• 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.

Check for the following conditions:


Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C Compressor Relay Circuit Voltage Low Step 1

2

3

4

Action


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

Replace A/C compressor relay and verify repair



—

No


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? 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? " C-56

X-14

$ # !

!

!"

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 $ #

"

# "

!

!

120-150!

6E–270 Step 6


Using the DVM and check the A/C compressor relay power supply circuit.

Value(s)

Yes

No

10-14.5V

Go to Step 8

Go to Step 7

—

Verify repair

—

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

3

V 7

Repair the open or short to ground circuit between the ECM main relay and A/C compressor relay. Is the action complete?


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

6E–271

Value(s)

Yes

No

—


Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

—

type A. (ECM

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

Breaker Box 41

!

! " "



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

!

!

!" "

9

10

"



6E–272


Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C Compressor Relay Circuit Voltage High Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

—

—

Verify repair

—






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

6E–273

6E–274



Code P0703

Symptom Code

MIL

DTC Name

A

ON


B

ON



Fail-Safe (Back Up)

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.


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.

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 “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) P0703 (Symptom Code A) (Flash Code 25) Brake Switch Circuit Malfunction Step 1

2

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3




—

No


4 5

Action

Value(s)


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? 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

Yes

No

—

Go to Step 4


—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

Pedal is not stepped on: Continuity Pedal stepped on: No continuity

Go to Step 7

Replace pedal switch and verify repair

10-14.5V

Go to Step 9

Go to Step 8

C-44

1

2

30 6

6E–275

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 "

!

!

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.


1

V

6E–276 Step 8

9


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 connected) Ref. Page 6E-103

Value(s)

Yes

No

—

Verify repair

—

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

—

Verify repair

—

—

Verify repair

—

type B. (ECM


4. Check the circuit for open or short to voltage circuit. Was the DVM indicated specified value? Breaker Box 105

V

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

2

V 10

Repair the short to voltage circuit between the brake switch 1 connector and ECM. Is the action complete? C-56

2

30

11

C-44

Repair the open circuit between the brake switch 1 connector and ECM. Is the action complete? C-56

30

C-44

2


13

Action



6E–277

Value(s)

Yes

No

—

Verify repair

Go to Step 13

—

Verify repair

—

6E–278


Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25) Brake Switch Circuit Malfunction

Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

Go to Step 6





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? 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

—

No

C-44

3

65 5

Value(s)

Using the DVM and check the brake switch 2.

4

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


Action

Using the DVM and check the brake switch 2 power supply circuit.

6E–279

Value(s)

Yes

No

10-14.5V

Go to Step 8

Go to Step 7

—

Verify repair

—

Go to Step 11


1. Ignition “On”, engine “Off”. 2. Remove the brake switch connector from the brake switch.


3

V 7 8

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)

as

type B. (ECM



V


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

4

V

Pedal is not stepped on: 10-14.5V Pedal stepped on: Less than 1V

6E–280 Step 9


Repair the short to voltage circuit between the brake switch 2 connector and ECM. Is the action complete? C-56

10

Repair the open circuit between the brake switch 2 connector and ECM. Is the action complete? C-56

65

11

12

Yes

No

—

Verify repair

—

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Verify repair

—

C-44

4

65

Value(s)

C-44

4




6E–281

DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6) (FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION


Code P0704

Symptom Code 6

MIL ON

DTC Name Clutch Switch Input Circuit Malfunction

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.

Diagnostic Aids



DTC Setting Condition Clutch signal does not change between vehicle speed 1.5km/h and 80km/h since ignition switch was tuned on.




• 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.

6E–282


Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57) Clutch Switch Input Circuit Malfunction Step 1

2

3

4

Action


Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

Go to Step 6





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? 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? C-56

31

5

Value(s)

1 2

Using the DVM and check the clutch switch.

—

No

C-77

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

!

" !

Pedal is not stepped on: Continuity Pedal stepped on: No continuity


Action

Using the DVM and check the clutch switch power supply circuit.

6E–283

Value(s)

Yes

No

10-14.5V

Go to Step 8

Go to Step 7

—

Verify repair

—

Go to Step 11


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

V 7 8

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 connected) Ref. Page 6E-104

type B. (ECM



V


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

2

V

Pedal is not stepped on: 10-14.5V Pedal stepped on: Less than 1V

6E–284 Step 9


Repair the short to voltage circuit between the clutch switch connector and ECM. Is the action complete? C-56

10

Repair the open circuit between the clutch switch connector and ECM. Is the action complete? C-56

31

11

12

Yes

No

—

Verify repair

—

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Verify repair

—

C-77

2

31

Value(s)

C-77

2




6E–285

DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 1) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE CODE (DTC) P1105 (SYMPTOM CODE 2) (FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT Condition for setting the DTC and action taken when the DTC sets Flash Code 86

Code P1105

Symptom Code

MIL

DTC Name

1

ON

Barometric Pressure Sensor Circuit High Input

2

ON

Barometric Pressure Sensor Circuit Low Input

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.

DTC Setting Condition Barometric pressure sensor output voltage is more than 4.4V.

Fail-Safe (Back Up) ECM uses 1013hpa condition as substitute.


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

2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No

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”?

—

Go to Step 3


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?

—

Go to Step 4


—

Verify repair

Go to Step 5



6E–286 Step 5



Value(s)

Yes

No

—

Verify repair

—


6E–287

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

6E–288



Code P1120

Symptom Code

MIL

1

ON

7

ON

9

ON

D

ON

E

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

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.

Fail-Safe (Back Up)

Throttle position sensor output voltage is more than 4.5V.


ECM increases idle speed up to 1400rpm.


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%.

Diagnostic Aids




• 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 1

Action


Value(s)

Yes

—

Go to Step 2

No



3

4

Action

Value(s)



6E–289

Yes

No

Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 12

Go to Step 6

—


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? 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? C-56

49

39

57

1

5

Visually check the TPS. Was the problem found?

E-22

2 3

6E–290 Step 6


Using the DVM and check the TPS.

Value(s)

Yes

No

Standard resistance

Go to Step 7

Go to Step 12

Approximately 5.0V

Go to Step 9

Go to Step 8

—

Verify repair

Go to Step 14

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 (!) Approximately 0.4k! at idle position Approximately 4.0k! at WOT

Approximately 4.3k! at idle position Approximately 0.8k! at WOT

Approximately 4.6k! at idle position & WOT

TPS 3

3

7

1

2 2

1

Using the DVM and check the TPS power supply circuit. 1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector.

3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value? E-22

3

V 8

Repair the short to voltage circuit between the ECM and TPS. Was the problem solved? C-56

57 E-22

3


Action

Using the DVM and check the TPS signal circuit.

Value(s)

6E–291

Yes

No

Go to Step 10


Go to Step 11


1. Ignition “On”, engine “Off”. 2. Disconnect the TPS connector.


2

V 10

Using the DVM and check the TPS ground circuit.

Less than 1V

1. Ignition “On”, engine “Off”. 2. Disconnect the TPS connector .


1

V Less than 1V

6E–292 Step 11


Using the DVM and check the TPS ground circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 14

—

Go to Step 13

Go to Step 14

—

Verify repair

—

—

Verify repair

Go to Step 15

—

Verify repair

—

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the TPS connector.


E-22 !

! !

Breaker box is not available: 1. Ignition “Off”, engine “Off”. 2. Disconnect connector.

the

TPS

connector

and

ECM


49 E-22

1

12 13 14

15

Substitute a known good TPS and recheck. Was the problem solved?

Replace the TPS. Is the action complete?




6E–293

Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit High Input Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6





49

—

No

39

57

1

5


E-22

2 3

6E–294 Step 6


Using the DVM and check the TPS power supply circuit.

Value(s)

Yes

No

Approximately 5.0V

Go to Step 12

Go to Step 7

—

Verify repair

Go to Step 8

—

Go to Step 9

Go to Step 10

—

Verify repair

—

—

Verify repair

Go to Step 11

—

Verify repair

—


3. Check the circuit for short to ground circuit. Was the DVM indicated specified value? E-22

3

V 7

Repair the short to battery voltage circuit between the ECM and TPS. Was the problem solved? C-56

57 E-22

8 9 10

11

3

Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete?




6E–295

Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21) Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2





49

No


Refer to

Diagnostic Aids

Go to Step 3

and Go to Step 3

—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 10

Go to Step 6

—

39

57

1

5


E-22

2 3

6E–296 Step 6


Using the DVM and check the TPS power supply circuit.

Value(s)

Yes

No

Approximately 5.0V

Go to Step 10

Go to Step 7

No continuity

Go to Step 9

Go to Step 8

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Go to Step 11

Go to Step 12

—

Verify repair

—


3. Check the circuit for short to battery voltage circuit. Was the DVM indicated specified value? E-22

3

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

3. Check the circuit for short to TPS ground circuit. Was the DVM indicated specified value? E-22

1

8 9

3

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

57 E-22

10 11

3



13

Action



6E–297

Value(s)

Yes

No

—

Verify repair

Go to Step 13

—

Verify repair

—

6E–298


Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21) Pedal/Throttle Position Sensor Brake Switch Error

Step 1

2

3

4

5

6

7

8 9 10 11 12

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3





—

No


—

Go to Step 4


• Accelerator pedal sticking. If a problem is found, repair as necessary. Was the problem found?

—

Verify repair

Go to Step 5

2. Monitor the “Throttle Position” in the data display. Does the Tech 2 indicate correct “Throttle Position” from 0% to 100% depending on accelerator pedal operation?

—

Go to Step 7

Go to Step 6

3. Adjust the TPS within 0% to 100%. Was the problem solved?

—

Verify repair

Go to Step 11

2. Monitor the “Brake Switch 1” and “Brake Switch 2” in the data display. Does the Tech 2 indicate “Inactive” when the brake pedal was not stepped on?

—

Go to Step 13

Go to Step 8

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step 13

—

Verify repair

—

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Visually check the TPS. Check for the following conditions.



2. Monitor the “Throttle Position” in the data display.


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?



14

Action



6E–299

Value(s)

Yes

No

—

Verify repair

Go to Step 14

—

Verify repair

—

6E–300


Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21) Pedal/Throttle Position Sensor Idle Position Switch Error

Step 1

2

3

4 5

6

7

8 9 10

Action

Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Go to Step 8

Go to Step 5

—

Go to Step 7

Go to Step 6Go to Step 6

3. Adjust the TPS within 0% to 100%. Was the problem solved?

—

Verify repair

Go to Step 8

2. Monitor the “Idle Switch” in the data display. Does the Tech 2 indicate “Inactive” when the accelerator pedal was stepped on?

—

Go to Step 10

Go to Step 8

—

Go to Step 9

Go to Step 10

—

Verify repair

—

—

Verify repair

Go to Step 11





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? 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”.

—

No

2. Monitor the “Throttle Position” in the data display. 1. Using the Tech 2, ignition “On” and engine “Off”.




Action


6E–301

Value(s)

Yes

No

—

Verify repair

—

6E–302


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 Condition for setting the DTC and action taken when the DTC sets Flash Code 22

Code P1173

Symptom Code

MIL

3

OFF

7

OFF

A

OFF

DTC Name


Fuel Reduction Caused By High Coolant Temperature


Fuel Reduction Caused By High Fuel Temperature

Excessive high engine coolant temperature is detected.

Fuel temperature is more than 100 deg. C.

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.

Fail-Safe (Back Up)

PSG (pump control unit) controls fuel injection quantity based on engine speed and fuel temperature.

Diagnostic Aids





• 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

2

Action



Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

No


4

5

6

Action


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? Check the engine overheat condition. Was the problem found?

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? Using the DVM and check the ECT sensor.

Value(s)

—

6E–303

Yes

No

Go to Step 4


—

Repair the cause of overheat and verify repair

—

Go to Step 9

Go to Step 6

Standard resistance

Go to Step 9

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Verify repair

—

—

Verify repair

Go to Step 10

Go to Step 5


2. Disconnect ECT sensor connector.


-20


16100

0

5760

20

2370

60

537

40

1080

80

290

100

161

120

95

ECT Sensor 2

1 2

7 8 9

1



6E–304 Step 10



Value(s)

Yes

No

—

Verify repair

—


6E–305

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

2

3

4

5

6

7

Action


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

Value(s)

Yes

No

—

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 7

—

Verify repair

—

—

Verify repair

—


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? 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?



6E–306


DIAGNOSTIC TROUBLE CODE (DTC) P1335 (SYMPTOM CODE A) (FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION


Code P1335

Symptom Code

Circuit Description

A

MIL ON

DTC Name


Engine Speed Output Circuit Malfunction

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).

The PSG (pump control unit) is recognized defective engine speed signal form the ECM.


Diagnostic Aids




• 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

6E–307

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

2

3

4

5

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4





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? Was the DTC P0335 (Symptom Code B) or P0335 (Symptom Code D) stored at the same time?

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)

—

—

—

Go to DTC Chart P0335 (Symptom Code B) (Symptom Code C)

—

Verify repair

No

Go to Step 5

E-6

91

8

Go to Step 6

6E–308 Step 6


If a oscilloscope is available, monitor the CKP sensor output signal. Does the oscilloscope indicate correct wave form?

Value(s)

Yes

No

Go to Step 13

Not available: Go to Step 7 Fixed at low: Go to Step 7 Fixed at High: Go to Step 8


CH1 0V

CH2 0V


—


Action

Using the DVM and check the CKP sensor output circuit. Breaker box is available:

6E–309

Value(s)

Yes

No

—


Go to Step 8

Go to Step 9



the

PSG

(pump

control

unit)


!

E-6

! !


2. Disconnect the ECM connector. 3. Disconnect connector.

the

PSG

(pump

control

unit)

4. Check the circuit for open or short to ground circuit. Was the problem found? C-57(B)

E-6

8

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

8

V Less than 1V

6E–310 Step 9

10

11

12

13






Value(s)

Yes

No

—


Go to Step 10

—

Verify repair

Go to Step 11

—

Go to Step 12

Go to Step 13

—

Verify repair

—

—

Verify repair

—


DIAGNOSTIC TROUBLE CODE (DTC) P1345 (SYMPTOM CODE A) (FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION

6E–311


Code P1345

Symptom Code A

MIL

DTC Name


ON

Camshaft Speed Malfunction

The PSG (pump control unit) is recognized incorrect camshaft speed signal.

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.

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. • 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.

6E–312


Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45) Camshaft Speed Malfunction

Step 1

2

3

4

5 6

7

8

9

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3





—

No


—

Go to Step 4


2. Monitor the “Pump Speed” in the data display. Does the Tech 2 indicate correct “Pump Speed” depending on engine speed?

—

Go to Step 6

Go to Step 5






—


Go to Step 9

—

Verify repair

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Verify repair

—

—

Verify repair

—


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


Code P1520

Symptom Code

MIL

A

ON

Neutral Switch ON Error

B

ON

Neutral Switch OFF Error

Circuit Description

DTC Name

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

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.

(Symptom Code B) will be stored.

Diagnostic Aids


6E–314





• 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 “Neutral Switch” display on the Tech2 while moving connectors and wiring harness related to the sensor.

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

2

3

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4



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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

—

No


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?

—


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?

6E–315

Value(s)

Yes

No

—

Verify repair

Go to Step 5

Go to Step 6

Replace neutral switch (inhibitor switch) and verify repair

C-57

87 M/T E-11

E-12

A/T E-51 3

2

5

8

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?

N range

M/T E-11

E-12

A/T 3 6

5

2

4

3

2

10 9

8

7 8

1

Neutral (P or N): Continuity Other than neutral (P or N): No continuity

6E–316 Step 6


Using the DVM and check the neutral switch (inhibitor switch) power supply circuit.

Value(s)

Yes

No

10-14.5V

Go to Step 8

Go to Step 7

—

Verify repair

—

Go to Step 11


1. Ignition “On”, engine “Off”. 2. Remove the neutral switch (inhibitor switch) connector from the switch.


A/T E-51

M/T E-12

V

3

V 7

8

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 connected) Ref. Page 6E-104

type B. (ECM



E-6

!

! !


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

2

8

V V

V

Neutral (P or N): 10-14.5V Other than neutral (P or N): Less than 1V


Action

Repair the short to voltage circuit between the neutral switch connector (inhibitor switch connector) and ECM. Is the action complete?

6E–317

Value(s)

Yes

No

—

Verify repair

—

—

Verify repair

—

—

Verify repair

Go to Step 12

—

Verify repair

—

M/T C-57

E-11

87 A/T C-57

2

E-51

8

87

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

87

11

12

2

E-51

8



6E–318


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


Code P1605

Symptom Code

MIL

DTC Name

C

ON

Seed and Key File Destroyed

D

ON

EEPROM Defect

E

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


Fail-Safe (Back Up)

Seed or key file in EEPROM is destroyed.


Write and read from the EEPROM are failed during initialization of the ECM.

ECM uses default values from the EPROM.

EEPROM checksum does not match with the read check sum during initialization of the ECM.

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

2

Action


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”?

Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

No


4

5

6E–319

Action

Value(s)

Yes

No

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?

—

Go to Step 4


—

Verify repair

Go to Step 5

—

Verify repair

—




6E–320


DIAGNOSTIC TROUBLE CODE (DTC) P1610 (SYMPTOM CODE A) (FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED


Code P1610

Symptom Code

Circuit Description

A

MIL -

DTC Name Security Key and Security Code not Programmed

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.

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.

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.



6E–321

Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56) Security Key and Security Code Not Programmed Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2


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

—




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? 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?



No

6E–322


DIAGNOSTIC TROUBLE CODE (DTC) P1611 (SYMPTOM CODE A) (FLASH CODE 56) WRONG SECURITY CODE ENTERED


Code P1611

Symptom Code

Circuit Description

A

MIL

DTC Name


-

Wrong Security Code Entered

Received security code is not correct.

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




6E–323

Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56) Wrong Security Code Entered Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2


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

—





—


3. Select “Read DTC Info Ordered By Priority” in the “Diagnostic Trouble Code”. Was the any DTC's B**** stored in this ignition cycle? 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?


No

6E–324


DIAGNOSTIC TROUBLE CODE (DTC) P1612 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL


Code P1612

Symptom Code

Circuit Description

A

MIL

DTC Name

-


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.

DTC Setting Condition Received challenge signal is not correct or not received.


Diagnostic Aids




6E–325

Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal Step 1

2

3

4

5

Action


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

—

Verify repair

Go to Step 6





—


3. Select “Read DTC Info Ordered By Priority” in the “Diagnositic Trouble Code”. Was the DTC B0007 stored in this ignition cycle?

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

No

42

35 B-68

7

8

6E–326 Step 6


Using the DVM and check the “CHECK ENGINE” lamp circuit.

Value(s)

Yes

No

Go to Step 7


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

7

V Less than 1V


Action

Using the DVM and check the “CHECK ENGINE” lamp circuit. Breaker box is available:

6E–327

Value(s)

Yes

No

—


Go to Step 8

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the immobilizer control unit connector.


B-68

!

! !


2. Disconnect the the immobilizer control unit connector and ECM connector.


42 B-68

7

6E–328 Step 8


Using the DVM and check the ECM and immobilizer control unit communication circuit.

Value(s)

Yes

No

Less than 1V

Go to Step 9


—


Go to Step 10

1. Ignition “Off”, engine “Off”. 2. Disconnect the immobilizer control unit connector. 3. Ignition “On”.


8

V 9

Using the DVM and check the ECM and immobilizer control unit communication circuit. Breaker box is available: 1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Disconnect the immobilizer control unit connector.


B-68

!

! !


1. Ignition “Off”, engine “Off”. 2. Disconnect the the immobilizer control unit connector and ECM connector.


B-68

35

8


11

Action



6E–329

Value(s)

Yes

No

—

Verify repair

Go to Step 11

—

Verify repair

—

6E–330


DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE A) (FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL


Code P1613

Symptom Code

Circuit Description

A

MIL

DTC Name

-


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.

DTC Setting Condition Received response signal is not correct or not received.


Diagnostic Aids




6E–331

Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56) Immobilizer No or Wrong Signal Step 1

2

3

4

5

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—


Go to Step 5

—

Verify repair

Go to Step 6





—


3. Select “Read DTC Info Ordered By Priority” in the “Diagnositic Trouble Code”. Was the any DTC's B**** stored in this ignition cycle? 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

No

42

35 B-68

7

8

6E–332 Step 6


Using the DVM and check the “CHECK ENGINE” lamp circuit.

Value(s)

Yes

No

Go to Step 7


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

7

V Less than 1V


Action

Using the DVM and check the “CHECK ENGINE” lamp circuit. Breaker box is available:

6E–333

Value(s)

Yes

No

—


Go to Step 8

Go to Step 9




B-68

!

! !


2. Disconnect the the immobilizer control unit connector and ECM connector.


42 B-68

8

7

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”.


8

V Less than 1V

6E–334 Step 9


Using the DVM and check the ECM and immobilizer control unit communication circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

—



B-68

!

! !


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

B-68

10

11

35

8




DIAGNOSTIC TROUBLE CODE (DTC) P1614 (SYMPTOM CODE A) (FLASH CODE 56) WRONG TRANSPONDER KEY

6E–335


Code P1614

Symptom Code

Circuit Description

A

MIL -

DTC Name Wrong Transponder Key

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.

DTC Setting Condition Received response signal is not correct from the transponder key.


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.


6E–336


Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56) Wrong Transponder Key

Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—


Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

—





—


3. Select “Read DTC Info Ordered By Priority” in the “Diagnostic Trouble Code”. Was the any DTC's B**** stored in this ignition cycle? 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.

No


6E–337

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


Code P1625

Symptom Code

Circuit Description

MIL

DTC Name

A

OFF

ECM Main Relay Switched Off Too Early

B

OFF

ECM Main Relay Switched Off Too Late

The ECM switches ECM main relay to operate ECM and other sensors or controller.

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.

Diagnostic Aids




6E–338




• 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.

Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM Main Relay Switched Off Too Early Step 1

2

3

4

5

Action


Value(s)

Yes

—

Go to Step 2


—

Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Verify repair

—



No





6E–339

Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM Main Relay Switched Off Too Late Step 1

2

3

4

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


No continuitly

Go to Step 5

Replace ECM main relay and verify repair

—

Verify repair

Go to Step 6

—

Verify repair

—


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?

ECM Main Relay ! " #

5

6



6E–340


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


Code P1630

Symptom Code

MIL

DTC Name


A

ON


B

ON


The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to high current.

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

The PSG (pump control unit) detects high pressure solenoid valve control circuit malfunction due to continuous current.

programmed pump map data.

Fail-Safe (Back Up) Fuel injection quantity is reduced. 1. MAB (fuel cutoff solenoid valve) is operated. 2. Desired injection quantity becomes 0mg/strk.


Diagnostic Aids





6E–341


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

2

3

4

Action


Value(s)

Yes

—

Go to Step 2


—

Go to Step 3


—

Go to Step 4


—

Verify repair

—


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”? 1. Using the Tech 2, ignition “On” and engine “Off”.

No


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? Replace the injection pump assembly. Is the action complete?

6E–342


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


Code P1650

Symptom Code

MIL

A

ON

CAN Device Offline

B

ON

CAN Device Hang-up

Circuit Description

DTC Name

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.

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.

Diagnostic Aids







6E–343


Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN Device Offline Step 1

2

3

4

Action


6

Yes

—

Go to Step 2


Go to Step 3


—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 18

Go to Step 6

Go to Step 7





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? 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

5

Value(s)

E-6

100

2

1

99


Using the DVM and check the CAN high circuit. 1. Ignition “Off”, engine “Off”.

—

No

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

1

No continuity

6E–344 Step 7


Using the DVM and check the CAN high circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 8


the

PSG

(pump

control

unit)


E-6

!

! !


1. Ignition “Off”, engine “Off”. 2. Disconnect the PSG (pump connector.

control

unit)


100

E-6

2


Action

Using the DVM and check the CAN low circuit. Breaker box is available:

6E–345

Value(s)

Yes

No

—


Go to Step 9

—

Go to Step 10

Go to Step 11


the

PSG

(pump

control

unit)


E-6 !

! !



control

unit)


E-6

99

9

1

Using the DVM and check the CAN high circuit. 1. Ignition “On”, engine “Off”. 2. Disconnect connector.

the

PSG

(pump

control

unit)

3. Check the circuit for short to power supply circuit. Was the DVM indicated battery voltage or approximately 5V? E-6

2

V

6E–346 Step 10


Repair the short to voltage circuit between the ECM and PSG (pump control unit). Is the action complete? C-57

Yes

No

—

Verify repair

—

—

Go to Step 12

Go to Step 13

—

Verify repair

—

—


Go to Step 14

E-6

2

100

11

Value(s)

Using the DVM and check the CAN low circuit. 1. Ignition “On”, engine “Off”. 2. Disconnect the PSG (pump connector.

control

unit)


1

V 12


E-6

99

13

1

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)

3. Check the circuit for open circuit. Was the problem found? E-6

6


15

16

17

18

Action

Check any accessory parts which may cause electric interference. Was the problem found?




Value(s)

Yes

6E–347 No

—


Go to Step 15

—

Verify repair

Go to Step 16

—

Go to Step 17

Go to Step 18

—

Verify repair

—

—

Verify repair

—

6E–348


Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN Device Hang-up

Step 1

2

3

4

5

6

7

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 7

—

Verify repair

—

—

Verify repair

—






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


Code P1651

Symptom Code

MIL

A

ON

CAN Malfunction

B

ON

CAN Malfunction

Circuit Description

DTC Name

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

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.

systems to communicate.

Diagnostic Aids


6E–350




• 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) P1651 (Symptom Code A) (Flash Code 45) CAN Malfunction Step 1

2

3

4

5

6

7

Action


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 7

—

Verify repair

—

—

Verify repair

—



No






6E–351

Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45) CAN Receives Error Step 1

2

3

4

5

Action




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? Was the DTC P1650 (Symptom Code A) stored at the same time? 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? E-6

100

7

Yes

—

Go to Step 2


Go to Step 3


Go to Step 4



C-57

6

Value(s)

—

—

Go to DTC Chart P1650 (Symptom Code A)

—

Verify repair

Go to Step 6

—

Go to Step 19

Go to Step 7

Go to Step 8


Go to Step 5

2

1

99

—

No


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

1

No continuity

6E–352 Step 8


Using the DVM and check the CAN high circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 9


the

PSG

(pump

control

unit)


E-6

!

! !



control

unit)


100

E-6

2


Action

Using the DVM and check the CAN low circuit. Breaker box is available:

6E–353

Value(s)

Yes

No

—


Go to Step 10

—

Go to Step 11

Go to Step 12


the

PSG

(pump

control

unit)


E-6 "

! !



control

unit)


E-6

99

10

1

Using the DVM and check the CAN high circuit. 1. Ignition “On”, engine “Off”. 2. Disconnect connector.

the

PSG

(pump

control

unit)


2

V

6E–354 Step 11



2

Using the DVM and check the CAN low circuit. 1. Ignition “On”, engine “Off”. 2. Disconnect connector.

Yes

No

—

Verify repair

—

—

Go to Step 13

Go to Step 14

—

Verify repair

—

—


Go to Step 15

E-6

100

12

Value(s)

the

PSG

(pump

control

unit)


1

V 13


E-6

99

14

1

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)

3. Check the circuit for open circuit. Was the problem found? E-6

6


16

17

18

19

Action

Check any accessory parts which may cause electric interference. Was the problem found?




Value(s)

Yes

6E–355 No

—


Go to Step 16

—

Verify repair

Go to Step 17

—

Go to Step 18

Go to Step 19

—

Verify repair

—

—

Verify repair

—

6E–356


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


Code P1690

Symptom Code

Circuit Description

MIL

DTC Name

4

OFF

Check Engine Lamp (MIL) Circuit Voltage Low

8

OFF

Check Engine Lamp (MIL) Circuit Voltage High

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.

DTC Setting Condition Check engine lamp circuit open or short to ground circuit.


Check engine lamp circuit short to ground circuit.

Diagnostic Aids




4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Check for the following conditions:


6E–357

• 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

2

3

4 5 6 7

Action


Value(s)

Yes

—

Go to Step 2


Go to Step 3




—

No



—

Go to Step 4


2. Check the “Check Engine” lamp. Does the lamp turn “On”?

—

Go to Step 5

Go to Step 6

2. Check the “Check Engine” lamp. Does the lamp turn “Off”?

—

Go to Step 9

Go to Step 7

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8



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

17

42

B-24

6E–358 Step 8


Using the DVM and check the “Check Engine” lamp circuit. Breaker box is available:

Value(s)

Yes

No

—


Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “Off”, engine “Off”. 2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103 3. Remove the meter connector.


!"

B-24

! !


1. Ignition “Off”, engine “Off”. 2. Disconnect the ECM connector. 3. Remove the meter connector.


42

B-24

17

9



Action


6E–359

Value(s)

Yes

No

—

Verify repair

—

6E–360


Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77) Check Engine Lamp (MIL) Circuit Voltage High

Step 1

2

3

4

5

6

Action


Value(s)

Yes

—

Go to Step 2



No


—

Go to Step 3



—

Go to Step 4


—

Verify repair

Go to Step 5

—

Go to Step 6

—

—

Verify repair

—






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.

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.

6E–361

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: 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.

6E–362


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

2

Action

Was the “On-Board Diagnostic (OBD) System Check” performed? 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

Was a visually/physical check performed?

4

Is the fuel amount enough?

5

Is the customer using the incorrect fuel type?

6

Check the “ECM” fuse (10A) and “Engine” fuse (15A). If the fuse is burnt out, repair as necessary. Was the problem found?

7


Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4

Go to Visual / physical Check

—

Go to Step 5

Add fuel to the tank

Diesel fuel only

Replace with diesel fuel

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

Go to Step 6

• 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.

8 9

• 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?

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?


11

Action

6E–363

Value(s)

Yes

No

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Replace the CKP sensor. Is the action complete?

—

Go to Step 13

Go to Step 14

—

Verify repair

—

• 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

—

Verify repair

Go to Step 18

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?

Check the CKP sensor harness for the following conditions. • Check for poor connector connection. • Check for misrouted harness.

12 13 14

15

16

• Check for any accessory parts which may cause electric interference. If a problem is found, repair as necessary. Was a problem found?


Check the exhaust system for a possible restriction. • Damaged or collapsed pipes or catalytic converter.


• 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?


6E–364 Step 17


Remove the eye bolt with gauze filter from the injection pump and check for the following conditions.

Value(s)

Yes

No

—


Go to Step 18

More than 2.1 Mpa (21.0 kg/ cm2)

Verify repair

Go to Step 19

—

Go to Step 20

Repair as necessary


18

19

Check the engine compression pressure for each cylinders. If a problem is found, repair as necessary. Was the problem found?

If the injection pump was replaced, are the timing gears or injection pump correctly installed?


Action

1. Review all diagnostic procedures within this table.

6E–365

Value(s)

Yes

No

—

Verify repair

Go to Step 21

—

Verify repair

Go to Step 22

—

Go to Step 23

Go to Step 24

—

Verify repair

—

—

Verify repair

—

2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: • Visual/physical inspection • Tech 2 data

21

22

23

24

• All electrical connections within a suspected circuit and/or system Was a problem found?




6E–366


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

2

Action

Was the “On-Board Diagnostic (OBD) System Check” performed? 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


Value(s)

Yes

—

Go to Step 2

—

Verify repair

—

Go to Step 4

No


Go to Step 3


Diesel fuel only


—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

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?

—

Verify repair

Go to Step 8


—

Go to Step 20

Go to Step 9

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?

—

Go to Step 20

Go to Step 10

Go to Step 6


• Check for objects blocking or excessive deposits in the throttle bore and on the throttle plate

6 7

8

9

• 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?


1. Using the Tech 2, display the ECT sensor and IAT sensor value.

1. Using the Tech 2, display the FT sensor value.

1. Using the Tech 2, ignition “On”.


11

12

13

14

Action

Yes

No

—

Go to Step 11

Repair voltage supply circuit and verify repair

—

Verify repair

Go to Step 12


—

Verify repair

Go to Step 13


—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

1. Using the Tech 2, ignition “On”.

Value(s)

6E–367

2. Monitor the “Glow Time Relay” in the data display and then, does the supply voltage correctly supply to the glow plug?

Check the glow plugs for continuity. If a problem is found, repair as necessary. Was a problem found?

Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

Visually/physically inspect for the following conditions. • Restrict fuel supply system. Check for a pinched fuel hose/pipe.


6E–368 Step 15



Value(s)

Yes

No

—


Go to Step 16

—

Replace the injection nozzle and verify repair

Go to Step 17

More than 2.1 Mpa

Verify repair

Go to Step 18


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?

1 st Stage

4JA1-TC 4JH1-TC

17

Approximatly 19.0 Mpa


2nd Stage





19

Action

Check the inlet/exhaust valve clearance for each valves. Are the valve clearances within the specified value?


6E–369

Value(s)

Yes

No

0.4mm at cold (In/Ex)

Go to Step 19

Adjust and verify repair

—

Verify repair

Go to Step 20

—

Verify repair

Go to Step 21

—

Go to Step 22

Go to Step 23

—

Verify repair

—

—

Verify repair

—

2. If all procedures have been completed and no malfunctions have been found, review/inspect the following:

• Visual/physical inspection • Tech 2 data

20

21

22

23





6E–370


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

2

Action



3


4


5

1. Check for incorrect idle speed. Ensure that the following conditions are present. • Engine fully warm. • Accessories are “OFF”.

6

2. Using a Tech 2, monitor “Desired Engine Idle Speed” and “Engine Speed”. Is the “Engine Speed” within the specified values? 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

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


Desired Engine Idle Speed ± 25 rpm

Go to Step 7

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Go to Step 5


• Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty crankcase ventilation hose.

7




9

10

11

12

13

6E–371

Action

Value(s)

Yes

No

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?

—

Verify repair

Go to Step 9

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?

—

Verify repair

Go to Step 10


—

Verify repair

Go to Step 11

2. Monitor the “Mass Air Flow” in the data display. Does the Tech 2 indicate correct “Mass Air Flow” depending on accelerator pedal operation?

—

Go to Step 16

Go to Step 12

• Objects blocking at the MAF sensor element. If a problem is found, repair as necessary. Was the problem found?

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Go to Step 15

Go to Step 35

—

Verify repair

—

—

Go to Step 21

Go to Step 17


1. Using the Tech 2, ignition “On” and engine “Run”.




Check the MAF sensor harness for the following conditions. • Check for poor connector connection. • Check for misrouted harness.

14 15 16





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?

6E–372 Step 17

18


Value(s)

Yes

No

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 18

—

Verify repair

Go to Step 19

—

Go to Step 20

Go to Step 36

—

Verify repair

—

—

Verify repair

Go to Step 22

—

Verify repair

Go to Step 23

—

Go to Step 24

Go to Step 25

—

Verify repair

—


Check the TPS harness for the following conditions. • Check for poor connector connection. • Check for misrouted harness.

19 20 21

22





Check the CKP sensor harness for the following conditions. • Check for poor connector connection.

23 24

• 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?

Substitute aknown good CKP sensorand recheck. Was the problem solved? Replace the CKP sensor. Is the action complete?


Action

1. Using the Tech 2 and ignition “On” and engine “Run”.

6E–373

Value(s)

Yes

No

—

Go to Step 29

Go to Step 26

2. Monitor the following parameters in the data display. • “Desired Injection Quantity” & “Injection Quantity” • “Desired Injection Start” & “Actual Injection Start” Are the large gap or unstable parameter displayed between “Desired” and “Actual”?

When idling or part-throttle

High

Desired

Actual Low Time

6E–374 Step 26


Value(s)

Yes

No

—

Verify repair

Go to Step 27


—

Verify repair

Go to Step 28


—

Verify repair

Go to Step 29

—

Verify repair

Go to Step 30



Vacuum Pump:



Vacuum Pump

27

28

29

Small Window







Action


6E–375

Value(s)

Yes

No

—


Go to Step 32

—


Go to Step 32

More than 2.1 Mpa

Verify repair

Go to Step 33


31

Remove the injection nozzles from the engine and check for the following conditions. • Improper splay condition.

• Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?

1 st Stage

4JA1-TC 4JH1-TC

32



2nd Stage



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?

6E–376 Step 33

34




Value(s)

Yes

No


Go to Step 34


—

Verify repair

Go to Step 35

—

Verify repair

Go to Step 36

—

Go to Step 37

Go to Step 38

—

Verify repair

—

—

Verify repair

—


• Visual/physical inspection

35

36

37

38

• Tech 2 data • All electrical connections within a suspected circuit and/or system Was a problem found?





6E–377

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

2

Action



3


4


5

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

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only



—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7


—

Verify repair

Go to Step 8

Go to Step 5



6 7



6E–378 Step 8

9

10

11


Value(s)

Yes

No


—

Verify repair

Go to Step 9


—

Go to Step 14

Go to Step 10


—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Go to Step 13

Go to Step 29

—

Verify repair

—

—

Go to Step 19

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Go to Step 18

Go to Step 29

—

Verify repair

—





12 13 14

15

16





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? 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?


17 18





20

Action


Check the CKP sensor harness for the following conditions.

6E–379

Value(s)

Yes

No

—

Verify repair

Go to Step 20

—

Verify repair

Go to Step 21

—

Go to Step 22

Go to Step 23

—

Verify repair

—

—

Go to Step 25

Go to Step 24

• Check for poor connector connection. • Check for misrouted harness.

21 22 23




1. Using the Tech 2 and ignition “On” and engine “Run”. 2. Monitor the following parameters in the data display.

• “Desired Injection Quantity” & “Injection Quantity”

• “Desired Injection Start” & “Actual Injection Start” Are the large gap or unstable parameter displayed between “Desired” and “Actual”? When idling or part-throttle High

Desired

When accelerated High

Actual Low

Low Time

Desired

Actual Time

6E–380 Step 24



Value(s)

Yes

No

—

Verify repair

Go to Step 25

—

Verify repair

Go to Step 26

—

Verify repair

Go to Step 27

Tech 2:


Vacuum Pump:



Vacuum Pump

25

26

Small Window







Action


6E–381

Value(s)

Yes

No

—


Go to Step 28

—

Verify repair

Go to Step 29

—

Verify repair

Go to Step 30

—

Go to Step 31

Go to Step 32

—

Verify repair

—


28



29

30

31





6E–382 Step 32



Value(s)

Yes

No

—

Verify repair

—


6E–383

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

rpm Sug

Hesitation time

Step 1

2

Action



3


4


5

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?

6


Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Go to Step 5




7



6E–384 Step 8

9

10

11


Value(s)

Yes

No


—

Verify repair

Go to Step 9


—

Go to Step 14

Go to Step 10


—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Go to Step 13

Go to Step 31

—

Verify repair

—

—

Go to Step 19

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Go to Step 18

Go to Step 31

—

Verify repair

—





12 13 14

15

16





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? 1. Using the Tech 2, ignition “On” and engine “Off”.




17 18





20

Action


Check the CKP sensor harness for the following conditions.

6E–385

Value(s)

Yes

No

—

Verify repair

Go to Step 20

—

Verify repair

Go to Step 21

—

Go to Step 22

Go to Step 23

—

Verify repair

—

—

Go to Step 27

Go to Step 24


21 22 23







Desired


Actual Low

Low Time

Desired

Actual Time

6E–386 Step 24


Value(s)

Yes

No

—

Verify repair

Go to Step 25


—

Verify repair

Go to Step 26


—

Verify repair

Go to Step 27

—

Verify repair

Go to Step 28



Vacuum Pump:



Vacuum Pump

25

26

27

Small Window







Action


6E–387

Value(s)

Yes

No

—


Go to Step 29

—

Verify repair

Go to Step 30

—

Verify repair

Go to Step 31

—

Go to Step 32

Go to Step 33

—

Verify repair

—


29



30

31

32





6E–388 Step 33



Value(s)

Yes

No

—

Verify repair

—


CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases.

6E–389

rpm

time

Step 1

2

Action



3


4


5

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

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

Go to Step 5



6



6E–390 Step 7


1. Using the Tech 2, perform test drive.

Value(s)

Yes

No

—

Go to Step 11

Go to Step 8

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step 31

—

Verify repair

—

—

Go to Step 16

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Go to Step 15

Go to Step 31

—

Verify repair

—

2. Monitor the “Vehicle Speed” in the data display. Does the Tech 2 indicate correct “Vehicle Speed” depending on driving speed?

When constant vehicle speed High

Correct Speed

Unstable Data Low Time

8

9 10 11

12

13

Check the VSS harness for the following conditions. • Check for poor connector connection.


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?


14 15





17

18

6E–391

Action

Value(s)

Yes

No


—

Go to Step 21

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

—

Go to Step 20

Go to Step 31

—

Verify repair

—

—

Verify repair

Go to Step 22

—

Verify repair

Go to Step 23

—

Go to Step 24

Go to Step 25

—

Verify repair

—






19 20 21




Remove the CKP sensor from the flywheel housing and check for the following conditions. • Objects sticking the CKP sensor.

22



23 24




6E–392 Step 25



Value(s)

Yes

No

—

Go to Step 29

Go to Step 26

2. Monitor the following parameters in the data display. • “Desired Injection Quantity” & “Injection Quantity” • “Desired Injection Start” & “Actual Injection Start” Are the large gap or unstable parameter displayed between “Desired” and “Actual”?

When idling or part-throttle High

Desired

Actual Low Time


Action


6E–393

Value(s)

Yes

No

—

Verify repair

Go to Step 27

—

Verify repair

Go to Step 28

—

Verify repair

Go to Step 29

Tech 2:


Vacuum Pump:



Vacuum Pump

27

28

Small Window






6E–394 Step 29



Value(s)

Yes

No

—


Go to Step 30

—

Verify repair

Go to Step 31

—

Verify repair

Go to Step 32

—

Go to Step 33

Go to Step 34

—

Verify repair

—


30



• Visual/physical inspection

31

32

33

• Tech 2 data • All electrical connections within a suspected circuit and/or system Was a problem found?





Action


6E–395

Value(s)

Yes

No

—

Verify repair

—

6E–396


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

2

Action



3


4


5


Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


—

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

Go to Step 5



6 7

8

9

• 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?






11

Action

6E–397

Value(s)

Yes

No

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12


—

Go to Step 13

Go to Step 29

—

Verify repair

—


—

Go to Step 19

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Go to Step 18

Go to Step 30

—

Verify repair

—



12 13 14

15

16


Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? 1. Using the Tech 2, ignition “On” and engine “Off”.





17 18




6E–398 Step 19



Value(s)

Yes

No

—

Go to Step 22

Go to Step 20

—

Verify repair

Go to Step 21

2. Monitor the following parameters in the data display. • “Desired Injection Quantity” & “Injection Quantity”

• “Desired Injection Start” & “Actual Injection Start” Are the large gap or unstable parameter displayed between “Desired” and “Actual”? When idling or part-throttle Desired

High

When accelerated Desired

High

Actual Low

Actual

Low Time

20

Time


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



22

23 24

6E–399

Action

Value(s)

Yes

No

• 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 22

—

Verify repair

Go to Step 23

—

Verify repair

Go to Step 24

—


Go to Step 25






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?

6E–400 Step 25


Remove the injection nozzles from the engine and check for the following conditions.

Value(s)

Yes

No

—


Go to Step 26

More than 2.0 Mpa

Verify repair

Go to Step 27


Go to Step 28


—

Verify repair

Go to Step 29

• Improper splay condition. • Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?

1 st Stage

4JA1-TC 4JH1-TC

26

27

28



2nd Stage










30

31

32

Action




6E–401

Value(s)

Yes

No

—

Verify repair

Go to Step 30

—

Go to Step 31

Go to Step 32

—

Verify repair

—

—

Verify repair

—

6E–402


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

2

Action



3


4

Check owner's driving habits.

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


—

Go to Step 5

Go to Step 6

—

System OK

—

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Go to Step 10

Go to Step 9

—

Verify repair

—

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

• Is the A/C “On” full time?

• Are tires at the correct pressure?

• Are excessively heavy loads being carried? 5 6 7 8 9 10 11

12

• Is acceleration too much, too often?

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?


14

6E–403

Action

Value(s)

Yes

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






15

16

17

18

19







6E–404 Step 20 21 22

23

24

25 26 27


Value(s)

Yes

No


—

Go to Step 21

Go to Step 31

—

Verify repair

—


—

Go to Step 27

Go to Step 23


—

Verify repair

Go to Step 24

—

Verify repair

Go to Step 25

—

Go to Step 26

Go to Step 31

—

Verify repair

—

—


Go to Step 28

Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? 1. Using the Tech 2, ignition “On” and engine “Off”.

1. Using the Tech 2, ignition “On” and engine “Off”. 2. Monitor the “Pedal/Throttle Position” and “Idle Switch” in the data display.

Check the TPS harness for the following conditions. • Check for poor connector connection.




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?

1 st Stage

4JA1-TC 4JH1-TC



2nd Stage




29

30

Action




6E–405

Value(s)

Yes

No

More than 2.0 Mpa

Verify repair

Go to Step 29


Go to Step 30


—

Verify repair

Go to Step 31

—

Verify repair

Go to Step 32

—

Go to Step 33

Go to Step 34



31

32




6E–406 Step 33

34



Value(s)

Yes

No

—

Verify repair

—

—

Verify repair

—


EXCESSIVE WHITE SMOKE

Step 1

2

Action



3


4


5

Check the engine coolant consumption to verify that it leaks to combustion chamber or exhaust through the gasket. Was a problem found?

6 7

8

9

10

11




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”.


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.

6E–407

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


—

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

—

Verify repair

Go to Step 12

Go to Step 5



6E–408 Step 12 13 14

15

16

17


Value(s)

Yes

No


—

Go to Step 13

Go to Step 30

—

Verify repair

—

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?

—

Go to Step 30

Go to Step 15

—

Go to Step 16

Repair voltage supply circuit and verify repair

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

Substitute a known good MAF & IAT sensor assembly and recheck. Was the problem solved? 1. Using the Tech 2, ignition “On” and engine “Run”.

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?

Check the glow plugs for continuity. If a problem is found, repair as necessary. Was a problem found?

Remove the CKP sensor from the flywheel housing and check for the following conditions. • Objects sticking the CKP sensor.

18




4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS Step 19 20 21

Action

6E–409

Value(s)

Yes

No

—

Go to Step 20

Go to Step 21

—

Verify repair

—

—

Go to Step 23

Go to Step 22


—

Verify repair

Go to Step 23


—

Verify repair

Go to Step 24

—

Verify repair

Go to Step 25






Desired


Desired

Actual Low

Low Time

22

23

24

Actu al Time





6E–410 Step 25



Value(s)

Yes

No

—


Go to Step 26

—


Go to Step 27


26

Remove the injection nozzles from the engine and check for the following conditions. • Improper splay condition. • Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?

1 st Stage

4JA1-TC 4JH1-TC



2nd Stage




28

29

Action




6E–411

Value(s)

Yes

No

More than 20 Mpa

Verify repair

Go to Step 28


Go to Step 29


—

Verify repair

Go to Step 30

—

Verify repair

Go to Step 31

—

Go to Step 32

Go to Step 33



30

31




6E–412 Step 32

33



Value(s)

Yes

No

—

Verify repair

—

—

Verify repair

—


EXCESSIVE BLACK SMOKE

Step 1

2

Action



3


4


5


6E–413

Value(s)

Yes

No

—

Go to Step 2


—

Verify repair

Go to Step 3

—

Go to Step 4


Diesel fuel only


—

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

Go to Step 5



6 7

8

9

• 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? Check the ECM & PSG grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found?




6E–414 Step 10

11



Check the MAF sensor harness for the following conditions.

Value(s)

Yes

No

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Go to Step 13

Go to Step 21

—

Verify repair

—

—

Go to Step 20

Go to Step 15


12 13 14





2. Monitor the following parameters in the data display. • “Desired Injection Quantity” & “Injection Quantity”


Desired


Actual Low

Low Time

Desired

Actual Time


Action


6E–415

Value(s)

Yes

No

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

Tech 2:


Vacuum Pump:



Vacuum Pump

16

Small Window



• Damaged or collapsed pipes or catalytic converter. • Internal muffler failure. If a problem is found, repair as necessary. Was a problem found?

6E–416 Step 17


Remove the injection nozzles from the engine and check for the following conditions.

Value(s)

Yes

No

—


Go to Step 18

More than 20 Mpa

Verify repair

Go to Step 19


Go to Step 20


—

Verify repair

Go to Step 21

• Improper splay condition. • Operating pressure is incorrect. If a problem is found, repair as necessary. Was the problem found?

1 st Stage

4JA1-TC 4JH1-TC

18

19

20



2nd Stage





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:




22

23

24

Action




6E–417

Value(s)

Yes

No

—

Verify repair

Go to Step 22

—

Go to Step 24

Go to Step 23

—

Verify repair

—

—

Verify repair

—

6E–418


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.

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

tightening torque. Tightening torque

• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m) 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 N·m (4.1 kgf·m)

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.


CRANKSHAFT POSITION (CKP) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Location Installed to the clutch housing.

Location Installed to the thermostat housing.

Removal Procedure

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.

6E–419


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.


1. Install the CKP sensor to the clutch housing.

2. Tighten CKP sensor by a bolt with specified tightening torque. Tightening Torque • Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)

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.


1. Apply sealer to threads of screw at the ECT sensor.

2. Tighten the ECT sensor with specified tightening torque. Tightening Torque

• Bolt: 13N·m (1.3kgf·m) 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.

6E–420


MASS AIR FLOW (MAF) & INTAKE AIR TEMPERATURE (IAT) SENSOR

THROTTLE POSITION SENSOR (TPS)

Location Installed to the intake duct housing.

Location Installed on the throttle body.

Removal Procedure

Removal Procedure


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.


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.


1. Disconnect the negative battery cable. 2. Disconnect the TPS connector.

3. Loosen two screws and remove TPS from the throttle body.


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.



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.


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.

6E–421

6E–422


ILLUSTRATION

SPECIAL SERVICE TOOLS

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

MAIN DATA AND SPECIFICATIONS !"#$%&'(')&

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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.


REMOVAL AND INSTALLATION

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 N!m (kg!m/lb!ft) 67 (6.8/49)

2. Middle pipe Nut (4! !4 only) Connect the middle pipe to the front pipe. Torque N!m (kg!m/lb!ft) 43 (4.4/32)

3. Silencer Front Nut Connect the silencer to the front or middle pipe. Torque N!m (kg!m/lb!ft) 43 (4.4/32)



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.


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


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

Idling

900 " 960

2000

3250

Engine Rear Side VSV-2

ON

OFF

ON

OFF

Engine Front Side VSV-1

ON

ON means VSV should receive signal to move EGR valve. OFF means VSV shouldn’t receive signal to move EGR valve.

ON

ON

OFF


4JA1TC/4JH1TC

The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.

RTW46EMF000701

INSPECTION


4JA1T(L)

Vacuum switch valve (VSV) Use a circuit tester to measure the V.S.V. resistance. V.S.V Resistance # at 20°C 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

Not operation

More than 240 mmHg

Operation

4JA1TC/4JH1TC

EVRV Use a circuit tester to measure the EVRV resistance. EVRV Resistance # at 20°C 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) REMOVAL AND INSTALLATION

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)

N!m(kg!m/lb ft)

5. Gasket 6. EGR Pipe Assembly 7. Bolt Tighten bolts temporarily. 8. Bolt Tighten bolts temporarily. 9. Gasket 10. Bolt Tighten bolts temporarily. 11.Gasket 12.Bolt Tighten bolts temporarily. Finally tighten all bolts to the specified torque. Confirm that there is no misalignment on the sealing surface. Bolt torque (Cooler-pipe) N!m(kg!m/lb ft) 27(2.8/20)

Bolt torque (Cooler-bracket) N!m (kg!m/lb ft) 24(2.4/17)

Bolt torque (Adapter-EGR valve) N!m (kg!m/lb ft) 27(2.8/20)

Bolt torque (Pipe-manifold) N!m (kg!m/lb ft) 27(2.8/20)

TURBOCHARGER


MAIN DATA AND SPECIFICATIONS Engine

Model

Turbine type

Compressor type

Maximum permissible speed rpm IHI : Ishikawajima Harima Heavy Industries., Ltd.

4JA1T(L)

IHI RHF4H

190,000

4JA1TC

IHI RHF4H

Mixed type

Backword & rake type 190,000

4JH1TC

IHI RHF5

180,000


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

150RY00032

134.8/1011

147.7/1108

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

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)

150RY00036

Limit

Limit

0.127 (0.0050)


SPECIAL TOOLS ILLUSTRATION

TOOL NUMBER 5-8840-0075-0

901RX00143

TOOL NAME Pressure Gauge


IHI SERVICE NETWORK For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service Facility. HEADQUARTERS ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI) General Machinery Division Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku Tokyo 100-0005 JAPAN TEL: 81-(3)-3286-2405 to 2407 (3 lines) FAX: 81-(3)-3286-2430 CHINA IHI BEIJING OFFICE Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue Beijing, People’s Republic of CHINA TEL: 86-(1)-505-4997, 0408 FAX: 86-(1)-505-4350 TLX: 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202, Chia Hsin Building, No. 96 Chung Shan North Road, Section 2, Taipei, TAIWAN TEL: 886-(2)-542-5520, 5521, 5523 FAX: 886-(2)-542-4362 TLX: 11320 IHICO THAILAND IHI BANGKOK OFFICE 8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND TEL: 66-(2)-236-3490, 7356, 9099 FAX: 66-(2)-236-7340 TLX: 82375 IHICO TH MALAYSIA IHI KUALA LUMPUR OFFICE Letter Box No. 52, 22nd Floor, UBN Tower, 10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA TEL: 60-(3)-232-1255, 1271 FAX: 60-(3)-232-1418 TLX: IHI KLMA 20257 INDONESIA IHI JAKARTA OFFICE 9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA TEL: 62-(21)-32-2147, 390-2211 FAX: 62-(21)-32-3273 TLX: 44175 IHIJKT

ACCELERATOR CONTROL

6H – 1

SECTION 6H

ACCELERATOR CONTROL TABLE OF CONTENTS PAGE

Removal and Installation............................................................................................... 6H -

2

Removal...................................................................................................................... 6H -

6

Installation.................................................................................................................. 6H -

6

Inspection................................................................................................................... 6H -

6

6H – 2 ACCELERATOR CONTROL

REMOVAL AND INSTALLATION 4JA1T(L)/RHD

RTW46HLF000301

ACCELERATOR CONTROL

6H – 3

4JA1T(L)/LHD

RTW46HLF000601

6H – 4 ACCELERATOR CONTROL 4JA1TC, 4JH1TC/RHD

RTW46HLF000201

ACCELERATOR CONTROL

6H – 5

4JA1TC, 4JH1TC/LHD

PTW46BMF000101

6H – 6 ACCELERATOR CONTROL

Removal

1. Disconnect the accelerator control cable from the accelerator pedal and dash panel. 2. Remove the cable clips. 3. Remove the accelerator control cable from accelerator control cable bracket. 1) Slide the lock in direction A 2) Rotate the ratchet ring in undirection an arrow 90!. 4. Remove the accelerator control cable from the throttle.

Inspection

Check the following items and replace the control cable if any abnormality is found. " The control cable should move smoothly. " The control cable should not be bent or kinked. " The control cable should not be damage or corrosion.

RTW46HMH000201

Installation

1. Install the accelerator control cable to accelerator control pedal dash panel. 2. Install the accelerator control cable to throttle. Attach T-END and inner cable to throttle cam of engine. 3. Install accelerator control cable to accelerator bracket. 1) Rotate the ratchet ring in direction an arrow 90! until both white marking are aligned. 2) Confirm marking of outer cap must be upper side. 3) Slider the lock in direction B. 4) Confirm ratchet ring is locked. 4. Install the cable clips to accelerator control cable. NOTE: Confirm that the throttle (engine side) is at full stroke when the accelerator pedal is at full stroke.

No. TF4JE-WE-0431

Isuzu Dmax Engine Service Manual

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