SECTION 6C1 - 4JH1-TC ENGINE DRIVEABILITY AND

EMISSIONS

Abbreviation Charts

Component Locator

Engine Component Locator Table

ECM Circuit Diagram

Ground Loc ati on

Cable Harness & Connector Location (4JH1-TC

RHD)

Connector List

Relay And Fuse

Relay And Fuse Box Location

Relay & Fuse Location

ECM Wiring Diagram

ECM Connector Pin Assignment & Output

Signal (4JH1-TC)

PSG Connector Pin Assignment & Output

Signal (4JH1-TC)

General Description For ECM And Sensors

Engine Control Module (ECM)

Pump Control Unit (PSG) & Data Exchange Between

Control Module

Mass Air Flow (MAF) Sensor & Intake Air

Temperature (IAT) Sensor

Pedal/throttle Position Sensor (TPS)

Crankshaft Position (CKP) Sensor

Engine Coolant Temperature (ECT) Sensor

Vehicle Speed Sensor (VSS)

General Description - Injection Pump

Outline

Charac ter isti c Of VP44 Inj ec tion System

Cross - se cti on View

Low Pressure Fuel Circuit

High Pressure Fuel Circuit

Timing Control

Start Of Injection

Strategy Based Diagnostics

Overview

Diagnostic Thought Process

1. Verify The Complaint

2. Perform Preliminary Checks

3. Check Bulletins And Troubleshooting Hints

4. Perform Service Manual Diagnostic Checks

5a And 5b. Perform Service Manual Diagnostic

Procedures

5c. Technician Self Diagnoses

5d. Intermittent Diagnosis

5e. Vehicle Operates As Designed

6. Re-examine The Complaint

7. Repair And Verify Fix

General Service Information

Serviceability Issues

Visual/Physical Engine Compartment Inspection

Basic Knowledge of Tools Required

On-Board Diagnostic (OBD)

On Board Diagnostic (Self Diagnosis System) Tests

The Diagnostic Executive

Diagnostic Information

Check Engine Lamp

Verifying Vehicle Repair

Reading Flash Diagnostic Trouble Codes

Reading Diagnostic Trouble Codes Using a Tech 2

Clearing Diagnostic Trouble Codes

Diagnosis With Tech 2

Tech 2 Connection

Typical Scan Data & Definitions 4JH1-TC (Engine Data)

Miscellaneous Test

Plotting Snapshot Graph

Plotting Graph Flow Chart (Plotting graph after

obtaining vehicle information)

Flow Chart‘ for Snapshot Replay (Plotting Graph)

Snapshot Display With TIS2000

Display of Graphs on one screen (Max. 6 graphs):

Service Programming System (SPS)

How To Use Breaker Box

On Board Diagnostic (OBD) System Check

No Check Engine Lamp (MIL)

Check Engine Lamp (MIL) “On” Steady

ECM Diagnostic Trouble Codes

Diagnostic T rouble Code (DTC) P0100 (Symptom Code

7) (Flash Code 65) Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High Input

Diagnostic T rouble Code (DTC) P0100 (Symptom Code

9) (Flash Code 65) Mass Air Flow (MAF) Sensor

Voltage Supply Circuit Low Input

Diagnostic T rouble Code (DTC) P0100 (Symptom Code

B) (Flash Code 65) Mass Air Flow (MAF) Sensor

Output Cir cuit Low Inpu t

Diagnostic T rouble Code (DTC) P0100 (Symptom Code

C) (Flash Code 65) Mass Air Flow (MAF) Sensor

Output Cir cuit Hig h Input

Diagnostic Trouble Code (DTC) P0110 (Symptom Code

1) Flash Code 23) Intake Air T emperature (IA T) Sensor

Circuit High Input

Diagnostic Trouble Code (DTC) P0110 (Symptom Code

2) (Flash Code 23) Intake Air Temperature (IAT)

Sensor Circuit Low Input

Techline

Diagnostic T rouble Code (DTC) P0115 (Symptom Code

1) (Flash Code 14) Engine Coolant Temperature

Sensor Circuit High Input

Diagnostic T rouble Code (DTC) P0115 (Symptom Code

2) Flash Code 14) Engine Coolant Temperature

Sensor Circ uit Low Input

Diagnostic T rouble Code (DTC) P0180 (Symptom Code

B) (Flash Code 15) Fuel Temperature Sensor Circuit

Range/performance

Diagnostic T rouble Code (DTC) P0215 (Symptom Code

A) (Flash Code 52) Fuel Cutoff Solenoid Valve

Malfunction

Diagnostic T rouble Code (DTC) P0215 (Symptom Code

B) (Flash Code 52) Fuel Cutoff Solenoid Valve Circuit

High Input

Diagnostic T rouble Code (DTC) P0215 (Symptom Code

C) (Flash Code 52) Fuel Cutoff Solenoid V alve Always

Active

Diagnostic T rouble Code (DTC) P0215 (Symptom Code

D) (Flash Code 52) Fuel Cutoff Solenoid Valve

Malfunction

Diagnostic T rouble Code (DTC) P0216 (Symptom Code

A) (Flash Code 54) Injection Timing Control Circuit

Malfunction (Timer Deviation)

Diagnostic T rouble Code (DTC) P0216 (Symptom Code

B) (Flash Code 54) Injection Timing Control Circuit

Malfunction (Timer Fluctuation )

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

6) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

7) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

9) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

A) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

B) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

D) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0251 (Symptom Code

E) (Flash Code 53) Injection Pump Malfunction

Diagnostic T rouble Code (DTC) P0335 (Symptom Code

B) (Flash Code 43)crankshaft Position Sensor Circuit

Malfunction

Diagnostic T rouble Code (DTC) P0335 (Symptom Code

D) (Flash Code 43) Crankshaft Position Sensor

Malfunction

Diagnostic T rouble Code (DTC) P0335 (Symptom Code

E) (Flash Code 43) Engine S peed Input Circuit Range/

performance

Diagnostic T rouble Code (DTC) P0380 (Symptom Code

4) (Flash Code 66) Glow Relay Circuit Voltage Low

Diagnostic T rouble Code (DTC) P0380 (Symptom Code

8) Flash Code 66) Glow Relay Circuit Voltage High

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

Diagnostic T rouble Code (DTC) P0500 (Symptom Code

1) (Flash Code 24) V ehicle Speed Sensor Circuit High

Input

Diagnostic T rouble Code (DTC) P0500 (Symptom Code

A) (Flash Code 24) V ehicle Speed Sensor Input Signal

Frequency Too High

Diagnostic T rouble Code (DTC) P0500 (Symptom Code

B) (Flash Code 24) Vehicle Speed Sensor Incorrect

Signal

Diagnostic T rouble Code (DTC) P0560 (Symptom Code

1) (Flash Code 35) System Voltage Too High

Diagnostic T rouble Code (DTC) P0560 (Symptom Code

2) (Flash Code 35) System Voltage Too Low

Diagnostic T rouble Code (DTC) P0560 (Symptom Code

A) (Flash Code 35) System V oltage Malfunction (PSG)

Diagnostic T rouble Code (DTC) P0561 (Symptom Code

A) (Flash Code 18) System V oltage Circuit Malfunction

Diagnostic T rouble Code (DTC) P0561 (Symptom Code

B) (Flash Code 18) System V oltage Circuit Malfunction

Diagnostic Trouble Code (DTC) P0602 ECU

Programming Error

Diagnostic T rouble Code (DTC) P0606 (Symptom Code

A) (Flash Code 28) ECU Malfunction

Diagnostic T rouble Code (DTC) P0606 (Symptom Code

B) (Flash Code 28) ECU Malfunction

Diagnostic T rouble Code (DTC) P0645 (Symptom Code

4) (Flash Code 46) A/C Compressor Relay Circuit

Voltage Low

Diagnostic T rouble Code (DTC) P0645 (Symptom Code

8) (Flash Code 46) A/C Compressor Relay Circuit

Voltage High

Diagnostic T rouble Code (DTC) P0703 (Symptom Code

A) (Flash Code 25) Brake Switch Malfunction

Diagnostic T rouble Code (DTC) P0703 (Symptom Code

B) (Flash Code 25) Brake Switch Malfunction

Diagnostic T rouble Code (DTC) P0704 (Symptom Code

6) (Flash Code 57) Clutch Switch Circuit Malfunction

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

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

Diagnostic T rouble Code (DTC) P1173 (Symptom Code

3) (Flash Code 22) Fuel Reduction Caused By High

Coolant Temperature

Diagnostic T rouble Code (DTC) P1173 (Symptom Code

7) (Flash Code 22) Fuel Reduction Caused By High

Fuel Temperature

Diagnostic T rouble Code (DTC) P1173 (Symptom Code

A) (Flash Code 22) Fuel Reduction Caused By Low

Temperature

Diagnostic T rouble Code (DTC) P1335 (Symptom Code

A) (Flash Code 43) Engine Speed Output Circuit

Malfunction

Diagnostic T rouble Code (DTC) P1345 (Symptom Code

A) (Flash Code 45) Camshaft Speed Malfunction

Diagnostic T rouble Code (DTC) P1520 (Symptom Code

A) (Flash Code 47) Neutral Switch On Error

Diagnostic T rouble Code (DTC) P1520 (Symptom Code

B) (Flash Code 47) Neutral Switch Off Error

Diagnostic T rouble Code (DTC) P1576 (Symptom Code

4) (Flash Code 71) Exhaust Throttle VSV 1 Circuit

Voltage Low

Diagnostic T rouble Code (DTC) P1576 (Symptom Code

8) (Flash Code 71) Exhaust Throttle VSV 1 Circuit

Voltage High

Diagnostic T rouble Code (DTC) P1577 (Symptom Code

4) (Flash Code 71) Exhaust Throttle VSV 2 Circuit

Voltage Low

Diagnostic T rouble Code (DTC) P1577 (Symptom Code

8) (Flash Code 71) Exhaust Throttle VSV 2 Circuit

Voltage High

Diagnostic T rouble Code (DTC) P1605 (Symptom Code

D) (Flash Code 55) Eeprom Defect

Diagnostic T rouble Code (DTC) P1605 (Symptom Code

E) (Flash Code 55) Eeprom Defect

Diagnostic T rouble Code (DTC) P1610 (Symptom Code

A) (Flash Code 56) Security Key And Security Code

Not Programmed

Diagnostic T rouble Code (DTC) P1611 (Symptom Code

A) (Flash Code 56) Wrong Security Code Entered

Diagnostic T rouble Code (DTC) P1612 (Symptom Code

A) (Flash Code 56) Immobiliser No Or Wrong Signal

Diagnostic T rouble Code (DTC) P1613 (Symptom Code

A) (Flash Code 56) Immobiliser No Or Wrong Signal

Diagnostic T rouble Code (DTC) P1614 (Symptom Code

A) (Flash Code 56) Wrong Transponder Key

Diagnostic T rouble Code (DTC) P1625 (Symptom Code

A) (F lash Code 76 ) ECM Main Relay Swit ched Of f Too

Early

Diagnostic T rouble Code (DTC) P1625 (Symptom Code

B) (F lash Code 76 ) ECM Main Relay Swit ched Of f Too

Late

Diagnostic T rouble Code (DTC) P1630 (Symptom Code

A) (Flash Code 51) Fuel Injection Quantity Circuit

Malfunction

Diagnostic T rouble Code (DTC) P1630 (Symptom Code

B) (Flash Code 51) Fuel Injection Quantity Circuit

Malfunction

Diagnostic T rouble Code (DTC) P1650 (Symptom Code

A) (Flash Code 44) Can Device Offline

Diagnostic T rouble Code (DTC) P1650 (Symptom Code

B) (Flash Code 44) Can Device Hang-up

Diagnostic T rouble Code (DTC) P1651 (Symptom Code

A) (Flash Code 45) Can Malfunction (PSG)

Diagnostic T rouble Code (DTC) P1651 (Symptom Code

B) (Flash Code 45) Can Received Error

Diagnostic T rouble Code (DTC) P1690 (Symptom Code

4) (Flash Code 77) Check Engine Lamp (MIL) Circuit

Voltage Low

Diagnostic T rouble Code (DTC) P1690 (Symptom Code

8) (Flash Code 77) Check Engine Lamp (MIL) Circuit

Voltage High

Symptom Diagnosis

Preliminary Checks

Visual/physical Check

Intermittent

Engine Cranks But Will Not Run

Hard Start Symptom

Rough, Unstable, Or Incorrect Idle, Stalling

Symptom

Surges And/or Chugs Symptom

Hesitation, Sag, Stumble Symptom

Cuts Out, Misses Symptom

Lack Of Power, Sluggish Or Spongy Symptom

Poor Fuel Economy Symptom

Excessive White Smoke

Excessive Black Smoke

On-vehicle Service Procedure

Engine Cont ro l Modu le (ECM)

Crankshaft Position (CKP) Sensor

Engine Coolant Temperature (ECT) Sensor

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

Sensor

Pedal (Throttle) Position Sensor (TPS)

Special Service Tools

Abbreviation Charts

Abbreviations Appellation

A/C Air conditioner

A/T Automati c transmi ssio n

ACC Accessory

BLK Black

BLU Blue

BRN Brown

CAN Controller Area Network

CEL Check engine lamp

CKP Crankshaft position sensor

DLC Data link connector

DTC Diagnosis trouble code

DVM Digital voltage meter

ECM Engine co ntr ol module

ECT Engine co ola nt temperature

EEPROM Electrically erasable & programmable read only memory

EGR Exhaust gas recirculation

EVRV Electric vacuum regulating valve

GND Ground

GRY Gray

IAT Intake air temperature

IG Ignition

M/T Manual transmission

MAB High pressure solenoid valve cutoff (German abbreviation)

MAF Mass air flow

MIL Malfunction indicator lamp

OBD On-board diagnostic

ORN Orange

PNK Pink

RED Red

PSG Pump control unit (German abbreviation)

SW Switch

TCM Transmission control module

TCV Timing control valve

TDC Top dead center

TPS Throttle position sensor

VIO Violet

VSS Vehicle speed sensor

WHT White

YEL Yellow

Component Locator

Engine Component Locator Table

4 3 1 2

4JH1-TC

(1) Mass Air Flow (MAF) & Intake Air Temperature

(IAT) Sensor Assembly

(2) Air Cleaner Case

(3) Battery

(4) Relay & Fuse Box

4JH1-TC

(1) Pedal/Throttle Position Sensor (TPS)

(2) A cc el erator Pedal

(3) Brake Pedal

3 2

(1) Engine Control Module (ECM)

(2) S RS Cont ro l Modu le

(1) Vehicle Speed Sensor (VSS)

(1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge

(1) Crankshaft Position (CKP) Sensor

(2) Clutch Housing

2 1

ECM Circuit Diagram

ECM CIRCUIT DIAGRAM (4JH1-TC RHD M/T) (1 /2)

ECM CIRCUIT DIAGRAM (4JH1-TC RHD M/T) (2 /2)

ECM CIRCUIT DIAGRAM (4JH1-TC RHD A/T) (1 /2)

ECM CIRCUIT DIAGRAM (4JH1-TC RHD A/T) (2 /2)

GROUND LOCATION

E10

C36

CABLE HARNESS & CONNECTOR LOCATION (4JH1-TC RHD)

Connector List

NO. CONNECTOR FACE NO. CONNECTOR FACE

B-23 C-41

B-24 C-44

B-25 C-49

B-68

IMMOBILISER

C-51

C-2 C-52

EVRV

C-13 C-53

C-14 C-55

C-23 C-56

C-24 C-57

C-36 C-58

NO. CONNECTOR FACE NO. CONNECTOR FACE

C-92 E-12

C-93

TPS 1 MAIN

E-41

C-96 E-44

E-3 E-49

E-6 E-51

E-7

TPS 1 MAIN

H-4

E-8

IDLE SW

H-5

E-9 H-6

E-10 H-7

(LHD)

E-11 H-7

(RHD)

NO. CONNECTOR FACE NO. CONNECTOR FACE

H-8

(LHD) X-4

ECM

MAIN

H-8

(RHD) X-5

A/C

COMPR

ESSOR

(4JA1)

H-18 X-8

A/C

THERM

H-22

(4JH1-

MT)

X-10

A/C

COMPR

ESSOR

(4JH1)

H-22

(4JH1-

A/T)

X-12

GLOW

(4JH1)

H-23

P-2

P-5

P-6

P-10

Relay And Fuse

Relay And Fuse Box Location

(Engine Room) (Cabin)

OPTION BOX (Engine Room) (4JA1-TC Only)

Relay & Fuse Location

C-49

RELAY 4JH1-TC

X-1 RELAY; HEATER

X-2 RELAY; ST CUT

X-3 RELAY; HONE

X-4 RELAY; ECM MAIN

X-5 RELAY; HATCH GATE

X-6 RELAY; TAIL LI GH T

X-7 RELAY; IMMOBILISER

X-8 RELAY; A/C TH ERM O

X-9 RELAY; HEAD LIGHT

X-10 RELAY; A/C COMP.

X-11 —

X-12 REL AY; GL OW

X-13 REL AY; STARTER

C-49 —

FUSE 4JH1-TC

EB-1 15A HAZARD

EB-2 10A HORN

EB-3 20A BLOWER

EB-4 10A A/C

EB-5 —

EB-6 —

EB-7 10A CHARGE

EB-8 10A H/LIGHT-LH

EB-9 10A H/LIGHT-RH

EB-10 10A STOP LIGHT

EB-11 10A TAIL LIGHT

EB-12 10A TCM

EB-13 —

EB-14 10A ECM

EB-15 30A ECM

EB-16 100A MAIN

EB-17 40A IGN-B2

EB-18 —

EB-19 50A GLOW

EB-20 40A IGN-B1

Relay & Fuse Location

(RHD)

FUSE

CB-1 10A STARTER

CB-2 — —

CB-3 15A ENGINE-1

CB-4 10A ENGINE-2

CB-5 15A METER

CB-6 20A FRONT WIPER

CB-7 — —

CB-8 — —

CB-9 — —

CB-10 — —

CB-11 15A BACK UP, TURN

CB-12 — —

CB-13 15A (RR DEFOG.)

CB-14 10A DOME LIGHT

CB-15 20A (DOOR LOCK)

CB-16 — —

CB-17 — —

CB-18 — —

CB-19 15A AUDIO

CB-20 15A CIGAR

CB-21 20A (POWER

WINDOW)

CB-22 20A (POWER

WINDOW)

CB-23 10A (SRS-2)

CB-24 10A (SRS-1)

ECM Wiring Diagram

ECM Wiring Diagram (1/7)

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

ECM Wiring Diagram (2/7)

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

ECM Wiring Diagram (3/7)

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

ECM Wiring Diagram (4/7)

Resister

A/C

Compressor

ECM

Main Relay Battery

Voltage

Glow

80A

Glow

Relay

Glow

Plug

0.5

BLU/

RED

0.5

BLK/

BLU

0.5

BRN/

RED

0.5

BLK

0.5

GRN

5.0

RED/

WHT

0.5

BLU/

RED

0.5

GRY

0.5

GRN 0.5

GRN

0.5

BRN

0.5

GRY/

YEL

A/C

10A

Heater

Relay

Blower

20A

A/C

Compressor

Relay

A/C

Thermo

Relay

Pressure

5.0

BLK/

RED

Electronic

Thermostat

µP

Batt

µP

Batt

Engine

Control

Module

(ECM)

ECM Wiring Diagram (5/7)

Batt

µP

Batt

µP

Batt

µP

0.5

BLK/

URG

0.5

BRN/

RED

0.5

BLU/

RED

0.5

BLU/

RED

4JA1-TC

0.5

GRY/

YEL

974661

0.5

WHT/

RED

0.5

GRN/

RED

0.5

BLK/

RED

0.5

BLK/

BLU

IAT

Sensor MAF &

IAT

Sensor

Rr Fog

Light

10A

EGR-

EVRV

0.5

WHT/

BLK

0.5

BLU/

RED

0.5

WHT/

BLU

0.5

BLU/

RED

0.5

GRN/

RED

0.5

BLU/

RED

Exhaust

Throttle

VSV2

Exhaust

Throttle

VSV1

Engine

Warming Up

Thermo

4531

Battery

Voltage

ECM

Main Relay

IC ICIC CPU

Engine

Control

Module

(ECM)

ECM Wiring Diagram (6/7)

0.5

BLK

0.5

GRN/

BLK

0.5

RED/

GRN

0.5

GRN/

ORG

0.5

BLK/

GRN

2.0

BLK

2.0

BLK

0.5

BLK/

PNK

0.5

GRY

ECT

Sensor

TPS &

Idle SW

0.5

WHT

98 101

0.5

GRN/

RED

CKP

Sensor

ICIC IC

Engine

Control

Module

(ECM)

ECM Wiring Diagram (7/7)

µP

1.25

BLK

16151413121110 9

87654321

0.5

RED/

YEL

0.5

WHT 0.5

BLU

35 45

0.5

BRN/

YEL

Stop

Light

10A

Meter

15A

Ignition

Check

Engine

Lamp Imnobiliser

Control Unit

Butery

Voltage

Engine

Control

Module

(ECM)

ECM Connector Pin Assignment & Output Signal (4JH1-TC)

View Looking Into ECM Case

NO. B/BOX

NO. PIN FUNCTION WIRE

COLOR

SIGNAL OR CONTINUITY ECM

CONNECTI

TEST ER PO SITION

KEY SW OFF KEY SW

ON ENGINE

IDLE ENGINE

2000RPM RANG

E(+) (-)

ECM Grou nd

BLK CONTINUITY

WITH

GROUND

- - - DISCONNE

CT Ω1GND

ECM Grou nd

BLK CONTINUITY

WITH

GROUND

- - - DISCONNE

CT Ω2GND

Battery Power

Supply

BLU/RED L ES S THAN

1V BATTERY VOLTAGE CONNECT DC V 3 GND

25 25

No Connection

---------

26 26

No Connection

---------

27 27

Engine Speed

Output (To Tacho

Meter)

BLU/RED - - APPROX.

23HZ BY

WAVE

FORM OR

APPROX.

7.2V

APPROX.

68HZ BY

WAVE

FORM OR

APPROX.

7.5V

CONNECT AC V 27 GND

28 28

No Connection

---------

29 29

Throttle Position

Signal (AT Only)

BLK/RED - APPROX . 140HZ BY WAVE FORM

(IDLE: OFF DUTY 10% WOT: OFF

DUTY 90%)

----

30 30

Brake Switch 1

Signal

RED LESS THAN

1V BATTERY VOLTAGE WHEN PEDAL

IS STEP PE D ON CONNECT DC V 30 GND

31 31

Clutch Switch

Signal (MT Only)

YEL LESS THAN

1V BATTERY VOLTAGE WHEN PEDAL

IS NOT STEPPED ON CONNECT DC V 31 GND

32 32

No Connection

---------

33 33

A/C Thermo Relay

GRN LESS THAN

1V BATT ERY VOLTAGE WHEN A/C

REQUEST SWITCH IS TURNED ON CONNECT DC V 33 GND

34 34

No Connection

---------

35 35

Immobiliser

Control Unit (ICU

B8)

RED/BLU - WAVE FOR M - - - -

36 36

No Connection

---------

37 37

No Connection

---------

38 38

Throttle Position

Sensor (TPS)

Output Si gna l

GRN/

ORG LESS THAN

1V LESS THAN 1V APPROX.

1V CONNECT DC V 38 49

39 39

Key Switch Input

Signal Via Engine

Fuse

BLU/Y E L LESS THAN

1V BATTERY VOLTAGE CONNECT DC V 39 G ND

40 40

No Connection

WHT/BLK - - - - - - - -

41 41

A/C Compressor

Relay

BRN/RED LES S THAN

1V BATTERY

VOLTAGE BATTE R Y VO LTAG E

WHEN A/ C

COMPRESSOR IS

NOT ACTI VATED

CONNECT DC V 41 GND

42 42

Check Engine

Lamp

RED/YE L LESS TH AN

1V BATTERY VOLTAGE WHEN LAMP

IS TURNED OFF CONNECT DC V 42 GND

43 43

Glow Lamp

ORG/ BLU L ES S THAN

1V BATTERY VOLTAGE WHEN LAMP

IS TURNED OFF CONNECT DC V 43 GND

44 44

No Connection

---------

45 45

Data Link

Connector (No. 6)

BLU LESS THAN

1V BATTERY VOLTAGE CONNECT DC V 45 G ND

46 46

No Connection

BRN/RED - - - - - - - -

47 47

No Connection

---------

48 48

No Connection

---------

49 49

Throttle Position

Sensor (TPS)

Ground

RED/GRN IDLE:

APPROX.

0.4KΩ/

WOT:

APPROX.

3.8KΩ

- - - DISCONNE

CT Ω38 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

BLK/GRN LESS THAN

1V APPROX. 5V CONNECT DC V 57 49

58 58

ECM Main Relay

BLU/BLK BATTERY

VOLTAGE LESS THAN 1V CONNECT DC V 58 GND

59 59

No Connection

---------

60 60

No Connection

---------

61 61

No Connection

---------

62 62

No Connection

---------

63 63

ECM Power

Supply

BLU/RED L ES S THAN

1V BATTERY VOLTAGE CONNECT DC V 63 G ND

64 64

No Connection

---------

65 65

Brake Switch 2

Signal

WHT/BLK LESS THAN

1V BATTERY VOLTAGE WHEN PEDAL

IS NOT STEPPED ON CONNECT DC V 65 GND

66 66

No Connection

---------

67 67

No Connection

---------

68 68

Vehicle Speed

Sensor (VSS) Via

Speed Meter

BLU/WHT - APPROX. 15HZ BY WAVE FORM

OR APPRO X. 6.4V AT VEHICLE

SPEED 20KM/H

CONNECT AC V 68 GND

69 69

Idle Switch

GRN/B L K LESS TH AN

1V APPROX . 5V WHEN PE D AL IS

STEPPED ON CONNECT DC V 69 GND

NO. B/BOX

NO. PIN FUNCTION WIRE

COLOR

SIGNAL OR CONTINUITY ECM

CONNECTI

TEST ER PO SITION

KEY SW OFF KEY SW

ON ENGINE

IDLE ENGINE

2000RPM RANG

E(+) (-)

70 70

No Connection

---------

71 71

No Connection

---------

72 72

No Connection

---------

73 73

No Connection

---------

74 74

No Connection

---------

75 75

No Connection

---------

76 76

No Connection

---------

77 77

No Connection

---------

78 78

No Connection

---------

79 79

No Connection

---------

80 80

No Connection

---------

81 81

No Connection

---------

82 82

No Connection

---------

83 83

Mass Air Flow

(MAF) 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 APPROX. 2.5V AT IAT 25°C CONNECT DC V 84 92

85 85

No Connection

---------

86 86

No Connection

---------

87 87

Neutral Switch

BLK/ WHT LESS TH AN

1V BATTERY VOLTAGE AT OTHER

THAN NEUTRAL (MT) / BATTERY

VOLTAGE IN P OR N (AT)

CONNECT DC V 87 GND

88 88

Mass Air Flow

(MAF) Sensor

Signal

GRN/R E D LESS THAN

1V APPROX.

2V APPROX.

3V CONNECT DC V 88 92

89 89

Engine Coolant

Temperature

(ECT) Sensor

Signal

GRY L ES S THAN

1V APPROX. 1.3V AT ECT 80°C CONNECT DC V 89 93

90 90

TDC Sensor

Signal

RED - - APPROX.

47HZ BY

WAVE

FORM OR

APPROX.

0.7 V AT

700RPM

APPROX.

133HZ BY

WAVE

FORM OR

APPROX.

1.0V

CONNECT AC V 90 98

91 91

TDC Sensor

Output To Pump

Control Unit (PSG)

No.8

PNK - - APPROX.

47HZ BY

WAVE

FORM

APPROX.

133HZ BY

WAVE

FORM

----

92 92

Mass Air Flow

(MAF) Sensor

Ground

BLK/RED CONTINUITY

WITH

GROUND

- - - CONNECT Ω92 GND

93 93

Engine Coolant

Temperature

(ECT) Sensor

Ground

BLK/PNK CONTINUITY

WITH

GROUND

- - - CONNECT Ω93 GND

NO. B/BOX

NO. PIN FUNCTION WIRE

COLOR

SIGNAL OR CONTINUITY ECM

CONNECTI

TEST ER PO SITION

KEY SW OFF KEY SW

ON ENGINE

IDLE ENGINE

2000RPM RANG

E(+) (-)

94 94

Glow Relay

BLK/BLU LESS THAN

1V BATTERY VOLTAGE WHEN GLOW

SYST EM IS NOT ACTIVATED CONNECT DC V 94 GND

95 95

No Connection

---------

96 96

No Connection

---------

97 97

EGR EVRV

BLK/ORG - APPROX. 140HZ BY

WAVE FORM WHEN

EVRV IS ACTIVATED

----

98 98

TDC Sensor

Ground

WHT CONTINUITY

WITH

GROUND

- - - CONNECT Ω98 GND

99 99

CAN (Controller

Area Network) to

PSG No.1

RED - - - - - - - -

100 100

CAN (Controller

Area Network) to

PSG No.2

WHT - - - - - - - -

101 101

TDC Sensor

Shield Line

- CONTINUITY

WITH

GROUND

- - - CONNECT Ω101 GND

102 102

No Connection

---------

103 103

No Connection

---------

104 104

No Connection

---------

105 105

Soleno id Valve

Shut Off (MAB)

Output Si gna l to

PSG No.5

ORG - WAVE FORM - - - -

NO. B/BOX

NO. PIN FUNCTION WIRE

COLOR

SIGNAL OR CONTINUITY ECM

CONNECTI

TEST ER PO SITION

KEY SW OFF KEY SW

ON ENGINE

IDLE ENGINE

2000RPM RANG

E(+) (-)

PSG Connector Pin Assignment & Output Signal (4JH1-TC)

View Looking Into PSG Case

NO. B/BOX

NO. PIN FUNCTION WIRE

COLOR

SIGNAL OR CONTINUITY PSG

CONNECTION

TESTER POSITION

KEY SW OFF KEY SW ON ENGINE

IDLE ENGINE

2000RPM RANGE (+) (-)

199

CAN (Controller

Area Network) to

ECM No.99

RED CONTINUITY

BETWEEN

ECM & PSG

- - - DISCONNECT Ω199

2 100

CAN (Controller

Area Network) to

ECM No.100

WHT CONTINUITY

BETWEEN

ECM & PSG

- - - DISCONNECT Ω2 100

No Connectio n

-- --- ----

No Connectio n

-- --- ----

5 105

Solenoid Valve

Shut Off (MAB)

Output Signal to

ECM No.105

ORG CONTINUITY

BETWEEN

ECM & PSG

- - - DISCONNECT Ω5 105

Ground

BLK CONTINUITY

WITH GROUND - - - DISCONNECT Ω6GND

Battery Power

Supply

BLU/RED CONTINUITY

BETWEEN

ECM & PSG

- - - DISCONNECT Ω73

891

TDC Sensor

Output ECM

No.91 To Pump

Control Unit

(PSG)

PNK CONTINUITY

BETWEEN

ECM & PSG

- - - DISCONNECT Ω891

No Connectio n

-- --- ----

General Description For ECM And

Sensors

Engine Control Module (ECM)

The engine control module (ECM) is located on the

transmission tunnel.

The fuel quantity and injection timing related functions

are controlled by the pump control unit (PSG).

The engine control module (ECM) performs the

following functions.

• Control of the quick on start (QOS) glow control

system

• Control of the A/C compressor

• Execution of the immobiliser function

Pump Control Unit (PSG) & Data Exchange

Between Control Module

The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine

management system.

• Engine Control Module (ECM)

• Pump Control Unit (PSG) = Pumpen Steuer Great

(German)

The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring

rotation angle, the pump speed and the fuel

temper atur e .

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 engi ne control module ( ECM) processes al l engine

data and data regarding the surrounding environment

received from external sensors to perform any engine

side adjustments.

Maps for both are encoded in both control units. The

control units input circuit process sensor data.

A Microprocessor then determines the operating

conditions and calculates set values for optimum

running.

The interchange of data between the engine control

module (ECM) and the pump control unit (PSG) is

perfumed via a CAN-bus system. The abbreviation CAN

stands for Controller Area Network. By having two

separate control modules, the high pressure solenoid

valve. This prevents the discharge of any disturbing

signals.

The following signals are exchanged via the CAN-bus:

From ECM to PSG

• Desired injection quantity

• Desired injection timing

• Engine speed

From PSG to ECM

• Fuel temperature

• Pump speed

• Cyli nde r identi fie r

• Control pulse (actual injection quantity + actual

inje cti on tim ing )

• PSG status

Self Diagnosis / Interface / Signal

To High Pressure Solenoid

Engine Speed

Injection Timing

Accelerator Pedal

Injection Quantity

Intake Air Tem perature

Response Signal

Mass Air Flow

Additional Signal

Others

Additional Operations To Timing Control Valve (TCV)

Engine

Control

Module

(ECM)

Cam Ring Rotational Angle

Fuel Temperature

High Pressure

Solenoid Valve

Pump

Control Fuel Injection

Unit (Mechanical)

(PSG)

Timing Device

Mass Air Flow (MAF) Sensor & Intake Air

Temperature (IAT) Sensor

The mas s air flo w (MAF) sensor is part of the intake air

system.

It is fitted betw een the air cleaner and turboc harge r 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.

The IAT sensor is a thermistor. A temperat ure 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.

Pedal/Throttle Position Se nsor (TPS)

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Characteristic of IAT Sensor

Temperature (oC)

Resistance ( )

(1) Throttle Position Sensor (TPS)

(2) Idle Switch

1 2

+5V Output Ground +5VGround

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.

Crankshaft Position (CKP) Sensor

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).

Engine Coolant Temperature (ECT) Sensor

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

temper atur e is hot.

Characteristic of TPS

Throttle Angle (%)

Output V oltage (V)

(1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge

-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

Characteristic of ECT Sensor

Temperature (deg. C)

Resistance ( )

Vehicle Speed Sensor (VSS)

The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall ele ment. It in teracts with the

magnetic field treated by the r otating magnet. It out puts

pulse signal. The 12 volts operating supply from the

meter fuse.

The engine control module (ECM) calculates the vehicle

speed by VSS.

General De scription - Injection Pump

Outline

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. T his pump was deve loped to provide the most

suitable fuel injection quantity and injection timing to

satisfy the demand fo r engine reli ability, driveabi lity, low

smoke, low noise, high output and clear exhaust

emissions.

Characteristic of VP44 Injection System

1. HIGH PRESSURE INJECTION

The radial plunger distributor type injection pump is

capable of generating pressure of 100 Mpa

(approximately 1000 Bar) demanded by small, high

speed direct injection diesel engines.

2. HIGH PRESSURE ATOMIZATION OF FUEL

INJECTED FROM THE NOZZLE

Through high pressure fuel injection, the fuel is

atomized at high pressure with a h igh pene trating force

(the fuel droplets penetrate further) and with greater

dispersion and distribution (mixing with air is improved)

and results in better combustion. This contributes to

cleaner emissions.

3. OPTIMUM FUEL INJECTION

High speed control of fuel injection quantity and fuel

injection timing, is performed by the control unit,

enabling lower fuel cost and high output.

4. IMPROVED DURABILITY

The com pon ents used i n the pump are very resis tant to

high pressure, ensuring improved durability.

5. IMPROVED ENGINE MATCHING

As fuel injection is controlled by cylinder selective

adaptation, smooth running is improved.

6. IMPROVED RELIABILITY

As a control unit system with both an engine control

module (ECM) and a pump control unit (PSG) is used,

the control system is extremely reliable.

7. IMPROVED POWER PERFORMANCE

As the control unit controls the optimum fuel injection

quantify corresponding to accelerator position,

increased torque in low accelerator pedal positions is

possible, enabling improved power performance.

8. DECREASED SMOKE AT ACCELERATION

When the amount of injected fuel is increased, to

increase engine power at acceleration, the excess fuel

usually generates smoke. The VP44 fuel injection

pump , accur ately co ntrol s fuel inject ion quan tity ev en in

this range to prevent the generation of smoke without

adversely affecting acceleration.

9. ADDITIONAL DEVICES ARE UNNECESSARY

Such additional devices as the boost compensator and

the aneroid compensator are unnecessary, as the

control unit compensates, based on signals from each

sensor. This results in less “clutter” injection pump.

10. SELF DIAGNOSIS FUNCTION

The system includes a self-diagnosis function, which

displays error codes to facilitate the diagnosis of

malfunctions.

(1) Drive Shaft

(2) Feed Pump

(3) Pump Camshaft Speed Sensor

(4) Pump Control Unit (PSG)

(5) Distributor Head

(6) Constant Pressure Valve (CPV) Holder

(7) High Pressure Solenoid Valve

(8) Constant Pressure Valve (CPV)

(9) Timing Control Valve (TCV)

(10) Timer

(11) Radial Plunger High Pressure Pump

Cross-section View

(1) Drive Shaft

(2) Feed Pump

(3) Pump Camshaft Speed Sensor

(4) Pump Control Unit (PSG)

(5) Distributor Head

(6) Constant Pressure Valve (CPV) Holder

(7) High Pressure Solenoid Valve

(8) Constant Pressure Valve (CPV)

(9) Timing Control Valve (TCV)

(10) Timer

(11) Radial Plunger High Pressure Pump

(1) Rotor Shaft

(2) Radial Plunger

(3) High Pressure Passage

(4) Low Pressure Inlet

(5) Distributor Slit

(6) Valve Needle

(7) Barrel

(8) Annular Passage

(9) Fuel Return

(10) High Pressure Solenoid Valve

(11) High Pressure Outlet

(12) Diaphram Chamber

(13) Accumulator Diaphram

Low Pressure Fuel Circuit

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.

High Pressure Fuel Circuit

In addition high pressure generating device, the high

press ure c irc uit als o c on sists of fu el p iping , and d ev ices

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)

(1) Fuel Suction

(2) Re gul ati ng Valve

(3) Overflow Valve

(4) Feed Pump

(5) To Fuel Tank

(1) Pump Control Unit (PSG)

(2) Distributor Head

(3) High Pressure Solenoid Valve

(4) Constant Pressure Valve (CPV)

(5) Radial Plunger High Pressure Pump

Timing Control

The timing device determines the optimum injection

timing against variations in engine speed.

The pressure of the fuel fed from the feed pump is

adjusted in accordance with speed by the regulating

valve. This delivery pressure acts on the hydraulic

stopper's annular chamber as control pressure.

The chamber pressure of the annular chamber is

controlled by the timing control valve (TCV).

The timing plunger is connected to the cam ring by a

ball pin. Axial movement of the timing plunger is

transferred to the cam ring in the form of rotational

movement. Movement to the right of the timing plunger

(to the spring side) advances injection timing.

The main components are timing plunger, the timing

control valve (TCV) and pump camshaft speed sensor.

St art of Injection

The engine control module (ECM) contains

characteristic maps of the beginning 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 beginning of injection timing and the actual

beginning of injection timing.

If the re is a differen ce, the tim ing contr ol valve ( TCV) is

controlled by the duty ratio. (The actual beginning of

injection timing is determined from the pump camshaft

speed sensor.)

(1) Cam Ring

(2) Servo Valve

(3) Timer Piston

(4) Outlet

(5) Feed Pump

(6) Inlet

(7) Fuel Suction

(8) Ball Pin

(9) Annular Chamber

(10) Hydraulic Stopper

(11) Return Passage

(12) Timing Control Valve (TCV)

Engine Load

Engine Speed

Engine Coolant

Temperature

Engine

Control

Module

(ECM)

Pump

Control

Unit

(PSG)

Pump

Camshaft

Speed Sensor

Timing

Control

Valve

(TCV)

Strategy Based Diagnostics

Overview

As a retail service technician, you are part of the

HOLDEN s ervice tea m. Th e team goal is FIX I T 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.

Str ategy Based Diagnostic s (refer to Figu re 1) provid es

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 diagnos tic thought pr ocess. Thi s method of think ing

optimize s your diagno sis in the following ways:

• Improves your understanding and definition of the

customer complaint

• Sav es tim e by avo iding tes tin g a nd/o r repla ci ng goo d

parts

• Allows you to look at the problem from different

perspectives

• Gui des you to dete rmine what level of unders tanding

about system operation is needed:

– Owner’s manual level

– Service manual level

– In-depth (engineering) level

– O wn er’s manual level

– Service manual level

– In-depth (engineering) level

1. Verify the Complaint

What you should do

To verify the custo mer complai nt, you need to know th e

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

• Techni ci an exper ie nc e

• Identical vehicle for comparison

• Circuit testing tools

• Veh ic le ro ad tes ts

• 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

compl exity of the system and ma y include the fol lowing

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 noises, smells, vibrations or

movements

• Investigate the vehicle service history (call other

dealerships, if appropriate)

What resources you should use

Whenever appropriate, you should use the following

resources for assistance in performing preliminary

checks:

• Tech II or other technical equipment for viewing DTCs

• Service manual information:

– Component locations

– Harness routing

– Wiring schematics

– Procedures for viewing DTCs

• Dealership service history file

• Vehicle road test

• Identical vehicle or system for comparison

3. Check Bulletins and Troubleshooting

Hints

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.

What resources you should use

You should use the following resources for assistance in

checking for bulletins and troubleshooting hints:

• Printed bulletins

• Access ISUZU Bulletin W eb s ite, ht tps: //www.ein et.isuzu .

co.jp//

• Videotapes

• Service manual

4. Perform Service Manual Diagnostic

Checks

What you should do

The “System Checks” in most service manual sections

and in most cells of section 8A (electrical) provide you

with:

• A systematic approach to narrowing down the

possible causes of a system fault

• Direction to specific diagnostic procedures in the

service manual

• Assistance to identify what systems work correctly

What resources you should use

Whenever possible, you should use the following

resources to perform service manual checks:

• Service manual

• Technical equipment (for viewing DTCs and

analyzing data)

• Digital multimeter and circuit testing tools

• 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

When directed by service manual diagnostic checks,

you must then carefully and accurately perform the

steps of diagnostic procedures to locate the fault related

to the customer complaint.

What resources you should use

Whenever appropriate, you should use the following

resources to perform service manual diagnostic

procedures:

• Service manual

• Technical equipment (for analyzing diagnostic data)

• Digital multimeter and circuit testing tools

• Essential and special tools

5c. Technician Self Diagnoses

When there is no DTC stored and no matching

symptom for the condition identified in the service

manual , you must b egin with a thorough understanding

of how the system(s) operates. Efficient use of the

service manual combined with you experience and a

good process of elimination will result in accurate

diagnosis of the condition.

What you should do

Step 1: Identify and understand the suspect

circuit(s)

Having completed steps 1 through 4 of the Strategy

Based Diagnostics chart, you should have enough

information to identify the system(s) or sub-system(s)

involved. Using the service manual, you should

determine and investigate the following circuit

characteristics:

• Electrical:

– How is the circuit powered (power distribution

charts and/or fuse block details)?

– How is the circuit grounded (ground distribution

charts)?

– How is the circuit controlled or sensed (theory of

operation):

– If it is a switched circuit, is it normally open or

normally closed?

– Is the power switched or is the ground

switched?

– Is it a variable resistance circuit (ECT sensor

or TP sensor, for example)?

– I s it a sign al gener ating device (M AF se nsor 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 subjected to extreme

temperatures?

– Are there areas subjected to vibration or

movement (engine, transmission or

suspension)?

– A re the re areas ex posed to moisture, r oad 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 dealer-

installed equipment (radios, telephone, etc.)

Step 2: Isolate the problem

At this point, you should have a good idea of what could

cause th e presen t cond ition, as well a s could not ca use

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 rem oving

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 in terminals, splices,

connectors or grounds

• Incorrect connector/harness routing (usually in new

vehicles or after a repair has been made):

– Open/high resistance in terminals, splices,

connectors of grounds

• Corrosion and wire damage:

– Open/high resistance in terminals, splices,

connectors of grounds

• Compon ent fai lure:

– Opens/short and high resistance in relays,

modules, switches or loads

• 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

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)

What resources you should use

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 ofsuspected systems to help prevent replacing goodparts. This may involve using creativity and ingenuity tointerpret customer complaints and simulating allexternal and internal system conditions to duplicate theproblem.

What you should do

Step 1: Acquire informationA thorough and comprehensive customer check sheetis critical to intermittent problem diagnosis. You shouldrequire this, since it will dictate the diagnostic startingpoint. The vehicle service history file is anothersource for accumulating information about thecomplaint.

Step 2: Analyze the intermittent problemAnalyze the customer check sheet and service historyfile to determine conditions relevant to the suspectsystem(s).Using service manual information, you must identify,trace and locate all electrical circuits related to themalfunctioning system(s). If there is more than onesystem failure, you should identify, trace and locateareas of commonality shared by the suspect circuits.

Step 3: Simulate the symptom and isolate the

problemSimulate the symptom and isolate the system byreproducing all possible conditions suggested in Step 1while monitoring suspected circuits/components/systems to isolate the problem symptom. Begin with themost logical circuit/component.Isolate the circuit by dividing the suspect system intosimpler circuits. Next, confine the problem into a smallerarea of the system. Begin at the most logical point (orpoint of easiest access) and thoroughly check theisolated circuit for the fault, using basic circuit tests.

HintsYou can isolate a circuit by:• Unplugging connectors or removing a fuse toseparate one part of the circuit from another• If only component fails to operate, begin testing thecomponent• If a number of components do not operate, begin testat areas of commonality (such as power sources,ground circuits, switches, main connectors or majorcomponents)• Substitute a known good part from the partsdepartment or the vehicle system• Try the suspect part in a known good vehicleSee Symptom Simulation Tests on the next page for

problem simulation procedures. Refer to service manualsections 6E and 8A for information about intermittentdiagnosis. Follow procedures for basic circuit testing in

service manual section 8A.

What resources you should use

Whenever appropriate, you should use the following

resources to assist in the diagnostic process:

• Service manual

• Bulletins

• Digital multimeter (with a MIN/MAX feature)

• Tech II and Tech II upload function

• Circuit testing tools (including connector kits/

harnesses and jumper wires)

• Experience

• Intermittent problem solving simulation methods

• Customer complaint check sheet

Symptom Simulation Tests

1. Vibration

This method is useful when the customer complaint

analysis indicates that the problem occurs when the

vehicle/system undergoes some form of vibration.

For connectors and wire harness, slightly shake

vertically and horizontally. Inspect the connector joint

and body for damage. Also, tapping lightly along a

suspected circuit may be helpful.

For parts and sensors, apply slight vibration to the part

with a l ig ht tap of the fin ger whi le mo nit oring the s ystem

for a malfunction.

2. Heat

This method is important when the complaint suggests

that th e problem occur s in a heat ed en vironm ent. App ly

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 compone nt.

3. Water and Moisture

This method may be used when the complaint suggests

that the malfunction occurs on a rainy day or under

conditions of high humidity . In this case, apply water in a

light spray on the vehicle to duplicate the problem.

CAUTION: Care must be take to avoid directly

exposing electrical connections to water.

4. Electrical loads

This method involves turning systems ON (such as the

blower, lights o r rear windo w 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 Design ed

This condition refers to instances where a system

operatin g as des igned i s perceiv ed to be unsatis factory

or undesirable. In general, this is due to:

• A lack of understanding by the customer

• A conflict between customer expectations and

vehicle des ig n inten t

• A system performance that is unacceptable to the

customer

What you should do

You can verify that a system is operating as designed

by:

• Reviewing service manual functional/diagnostic

checks

• Exa mining bul letins a nd other ser vice informati on for

supplementary information

• Co mpare sys tem oper a tio n to an identic al vehicl e

If the condition is due to a customer misunderstanding

or a con flict between c ustomer expec tation an d system

operation, you should explain the system operation to

the custo mer.

If the complaint is due to a case of unsatisfactory

system performance, you should contact Technical

Assistance for the latest information.

What resources you should use

Whenever possible, you should use the following

resour ce s to faci li tate the diagno sti c pr oces s:

• Vehicle service information (service manual, etc.)

• ISUZU field support

• Experience

• Identical vehicle or system for comparison

6. Re-examine the complaint

When you do not successfully find/isolate the problem

after executing a diagnostic path, you should re-

examine the complaint.

What you should do

In this case, you will need to backtrack and review

information accumulated from step 1 through 4 of

Strategy Based Diagnostics. You also should repeat any

procedures that require additional attention.

A previous path may be eliminated from consideration

only if you are certain that all steps were executed as

directed. You must then select another diagnostic path

(step 5a, 5 b, 5c or 5d ). I f all po ss ib le o pti ons ha ve b een

explored, you may call or seek ISUZU field support.

What resources you should use

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 applic able, you should ca rry out prev entive me asures

to avoid a repeat complaint.

What resources you should use

Whenever possible, you should use the following

resources to facilitate the repair process:

• Electrical repair procedures

• Service manual information and publications

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 sens itivity of OBD dia gnostics will c ause 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 te st failure. T his 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 c onnection s, burned or chafed spots, pi nched

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 diagno stic test is a serie s of steps, the re sult of whi ch

is a pass or fail reported to the diagnostic executive.

When a diagnostic test reports a pass result, the

diagno sti c ex ec utive re co rd s the foll owi ng 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

diagno sti c ex ec utive re co rd s the foll owi ng 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 coordin ate and prioritize

the diagn os tic proc edu res as wel l as defi ne the protoc ol

for recording and displaying their results. The main

respo ns ibil ities of the Di agn os tic Ex ec uti ve ar e li st ed 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

desig ned to loc ate a faul ty c ircu it or c omp onen t th rough

a proce ss of logica l decis ions . The charts are prepared

with the requirement that the vehicle functioned

correc tly at the time of assembl y 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.

Malfunction Indicator Lamp

The malfunction indicator lamp (MIL) is located in the

instrument pane l clus ter. The MIL will di splay the follow ing

symbol when commanded ‘ON’.

The MIL indicate s that an emissio n relate d fault ha s occurred

and vehicle service is required. The following is a list of the

modes of operation for the MIL:

• The MIL illuminates for about 2.6 seconds when the

ignition switch is turned ‘ON’, with the engine ‘OFF’. This is

a bulb test to ensu re th at the MIL is able to illu mina te.

• The MIL turns ’OFF’ after the engine is started, if a

diagnostic fault i s not present.

• The MIL remains illuminated after the engine is started, i

the engine control module (ECM) detects a fault.

diagnostic trouble code (DTC) is stored any time the ECM

illumina tes the MIL due to an emi ssion re lated fau l t.

Data Link Conne ctor (DLC)

The provision for communication with the control module is the

Data Link Connector (DLC). It is located behind the lower front

instrument pane l. The DLC is used to connect to a Tech2 .

Some common uses of the Tech2 are listed below:

• Identifying stored Diagnosti c Trou ble Codes (D TCs).

• Clearing DTCs.

• Reading serial data.

• Connect the SAE 16/19 adap ter (3 ) to the da ta lin k

connector of the vehicle.

• Connect the DLC ca ble (4 ) to the Tech 2 (5 ).

• Connect the SAE 16/19 adap ter (3 ) to the da ta lin k

connector (DLC) of the vehicle.

Verifying Vehicle Repair

Verifica tion of ve hi cle rep ai r w ill be mo re comprehensi ve fo r

vehicles with OBD system diagnostic. Following a repair, the

technician shoul d perfo rm 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 verifyin

repairs on OBD systems. Failure to follow these step

could result in unnecess ary re pairs.

On-Board Diagnosis (Self-Diagnosis)

The Tech 2 Scan Tool

The Tech 2 scan tool is used to electrically diagnose and

check the vehicle electronic systems. The Tech 2 enhances

the diagnosis efficiency, even though the troubleshooting can

be done without the Tech 2.

1. Tech 2 Components:

• Tech 2 scan tool kit (No. 70 000 86), Tech 2 scan tool

(No. 7000057) a nd DLC cable (No . 3000095).

• SAE 16/19 adapter (No. 3000098) (3), RS232 loop

back connector (No. 3000112 ) (2) and PCMCIA card

(No. 3000117) (1).

Legend

(1) PCMCIA Card

(2) Loop Back Conn ector

(3) SAE 16/19 Pin Adaptor

(4) DLC Cable

(5) Tec h 2 S ca n To ol

2. Connecting Tech 2 to the Vehicle:

• Check the ignition switch is turned OFF.

• Insert the PCMCIA card (1) into th e Te ch 2 (5). Note

that the PCMCIA card must be installed in the slot

closest to the Tech 2 screen.

NOTE: Check that power is not supplied to the Tech 2

when installing or remo vin g the PCMC IA card.

• Turn th e igni tion switch of the veh ic le to ON an d p ress

the "PWR" key of the Tech 2.

• Check the Tech 2 display.

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 position shown next. It is used in the assembl

plant to receive information, checking that the engine is

operating properly before it leaves the plant.

The diagnostic trouble code(s) (DTCs) stored in the ECM

memory can be read either through a hand-held diagnosti

scanner plugged into the DLC or by counting the number o

flashes of the malfunction indicator lamp (MIL) 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 are

ground circui ts.

This will signal the ECM that you want to "flash" DTCs), if an

are present. Once terminals '4’ or ‘5’ and ‘6’ have been

connected, the ignition switch must be turned to the ‘ON’

position, with the engine not running .

The check engine lamp will in di cate a DTC thre e times if a DTC

is present. If more than one DTC has been stored in the ECM

memory, the DTC(s) will be displayed from the lowest to the

highest, with each DTC being disp layed three times.

Shown is the patt ern that a DTC ‘31’ ge nerates and the pattern

of events, when both a DTC ‘31’ and ‘43’ are stored in the

ECM.

The DTC display will continue as long as the DLC is shorted

and the ignition is in the ON position.

Reading Diagnostic Trouble Codes With Tech 2

The preferred method for reading diagnostic trouble code(s) is

to use a Tech2 scan tool. When reading DTC(s), follo

instructions supplied by the Tech 2 manufacturer.

Clearing Diagnostic Trouble Codes

To clear Diagnostic Trouble Codes (DTCs), use the Tech2

"clear DTCs" or "clear information" function. When clearing

DTCs follow instructions supplied by the Tech2 manufacturer.

Flash Code Displays

Diagnosis With Tech 2

If No Codes are Set:

• Refe r to Fl: Data D isplay and iden ti fy the ele ctri cal faul ts

that are not indicated by a trouble code.

• Refer to "SYMPTOM DIAGNOSIS".

If codes are set:

1. Record all tr oubl e co des dis pla yed b y Tec h 2 and c heck i

the codes are intermittent.

2. Clear the codes.

3. Road test the vehicle 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

inte rmi t ten t. In th is ca se , re fe r 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 Operating Flow Cart (Start Up)

Select “4JA1-TC Bosch” or “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the

Tech 2 screen.

Main Menu

F0: Diagnostic

F1: Service Programming System (SPS)

F2: View Capture Data

F3: Tool Optio n

F4: Download/ Upload Help

Press “ENTER” key.

Vehicle Identification

(3) 2003

(2) 2002

(1) 2001

(Y) 2000

(X) 1999

(W) 1998

Select “F0: Diagnostic”.

Select “(2) 2002”or later.

Press (ENTER) to Continue

System Selection Menu

F0: Powertrain

F1: Chassis

F3: Body

Select “(TF/UC)”.

Vehicle Identification

4JH1-TC Bosch

4JA1-TC Bosc h

4JH1-T Denso

3.5L V6 6VE1 Hitachi

AW30-40LE

AT JR405E

Select “F0: Powertrain”.

Select “4JH1-TC Bosch”.

Vehicle Identification

(UB) Trooper, Bighorn

(UE) Rodeo,/Amigo, Wizard/Mu

(TF/UC) LUV, Frontier, LAO-Rodeo

(TBR)

(N*) ELF, NPR, NQR

or “4JH1-TC Bosch”.

F0: Diagnostic Trouble Code

The pur pose of the “D iag nosti c Trouble Codes” m ode 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:

This number or alphabet means identification of the

malfunc tion. Ea ch DTC inc ludes plural symptom s, such

as DTC P0 100 has fou r kinds of sy mptom code (7), (9),

(B) and (C). DTC chart (check procedure) is separated

depending on the symptom code.

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

“Snapsho t” allows you to focus on maki ng the condit ion

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 pu rpose o f “Prog ramming ” is to progr am VI N in the

ECM and lock the programmed data.

F0: Diagnostic Trouble Codes

F0: Read DTC Infor As Stored By ECU

F1: Clear DTC Information

F1: Data Display

F2: Snapshot

F3: Misc ell an eou s Test

F0: Lamps

F0: Check Light

F1: Glow Time Telltale Test

F1: Relays

F0: Glow Time Relay Test

F2: Engine Speed (RPM) Control

F4: Program mi ng

F0: Program VIN

F1: Lock ECU

Read DTC Infor As Stored By ECU

P0100 Present

(7) Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High Input

DTC No.

Symp tom Code

Typical Scan Data & Definitions 4JH1-TC (Engine Data)

Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were

noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a

properly-running engine may be used for comparison with the engine you are diagnosing.

Condition : Vehicle s topp in g, en gin e runn ing , air con ditioning off & after warm- up (Co olant tempera ture a ppr ox im ate ly

80 deg.)

Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

1 Engine Speed rpm 675 - 725 1475 - 1525 1975 - 2025 The engine speed is measured by ECM from the CKP

sensor.

2 Vehicle Speed km/h 0 0 0 This displays vehicle speed. The vehicle speed is

measured by ECM from the vehicle speed sensor.

3 Pump Speed rpm 335 - 375 725 - 775 975 - 1025 This displays injection pump speed. The injection speed

is measured by ECM from the pump cam sensor.

4 Accelerator

Position Signal

Value of ( ) shows

AT model

% 0

(0) 3 - 6

(4 - 7) 5 - 8

(8 - 11) 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.

5 Idle Switch Active/ Inactive Active Active Inactive This displays operating status of the idle switch. This

should display “Active” when the idle condition.

6 Mass Air Flow

Sensor

Value of ( ) shows

AT model

mg/strk 410 - 490

(730 - 785) 380 - 450

(700 - 780) 4 0 0 - 4 8 0

(780 - 830) This displays intake air amount. The mass air flow is

measured by ECM from the MAF sensor output voltage.

7 Barometric

Pressure hpa 990 - 1015 990 - 1015 990 - 1015 The barometric pressure is measured by ECM from the

sensor in the ECM. This data is changing by altitude.

8 Desired Injection

Quantity

Value of ( ) shows

AT model

mg/st k 5 - 8

(10 - 16) 5 - 9

(8 - 12) 6 - 10

(9 - 13) This displays commanded value from the ECM. The

ECM compensates for fuel rate to basic rate.

9 Injection Quantity

Value of ( ) shows

AT model

mg/st k 6 - 8

(10 - 16) 6 - 9

(8 - 12) 7 - 10

(9 - 13) This displays actual fuel quantity. The PSG controls high

pressure solenoid valve to meet commanded value from

the ECM.

10 Desired Fuel

Injection S tart °CA 1 - 3 2 - 4 3 - 6 This displays commanded value from the ECM. The

ECM compensates for fuel injection timing by throttle

position and various sensor signal.

11 Actual Injection

Start °CA 1 - 3 2 - 4 3 - 6 This displays actual injection timing value controlled by

the TCV. The TCV controls duty ratio to meet

commanded value from the PSG.

12 Coolant

Temperature °C 80 - 85 80 - 85 80 - 85 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.

13 Fuel Temperature °C 25 - 50 25 - 50 25 - 50 The FT is measured by PSG from FT sensor. This data is

changing by fuel temperature.

14 Intake Ai r

Temperature °C 25 - 50 25 - 50 25 - 50 The IAT is measured by ECM from IAT sensor output

voltage. This data is changing by intake air temperature.

15 Ignition Status On12V/ Off0V On 12V On 12V On 12V This displays the key s witch s tatus indicat ed by the ECM

with key switch signal. This should display “Off 0V” at key

OFF and “On12V” at key ON.

16 Brake Switch 1 Active/ Inactive I nactive Inactive Inactive This displays operating status of the brake switch 1. This

should display “Active” when the brake pedal is stepped

on.

17 Brake Switch 2 Act ive/ Inactive Inactive I nactive Inactive This displays operating status of the brake switch 2. This

should display “Active” when the brake pedal is stepped

on.

1 8 C l u t c h S w i t c h

Value of ( ) shows

AT model

Active/ Inactive Inactive

( - ) Inactive

( - ) This displays operating status of the clutch switch. This

should display “Active” when the c lutch pedal is stepped

on.

Miscellaneous Test

The state of each circuit can be tested by using

miscellaneous test menus. Especially when DTC

cannot be detected, a faulty circuit can be diagnosed by

testing each circuit by means of these menus.

Even DTC has been detected, the circuit tests using

these menus could help discriminate between a

mechanical trouble and an electrical trouble.

Connect Tech 2 and select “Powertrain”, “4JH1-TC

Bosch” & “Miscellaneous Test”.

F0: Lamps

F0: Check Light

When the Tech 2 is operated, “Malfunction Indicator

Lamp (Check Engine Lamp)” is turned on or off.

The circuit is normal if the “Malfunction Indicator Lamp

(Check E ngine Lamp) ” in the i nstr ument panel is turne d

on or off in accordance with this operation.

F1: Glow Time Te lltale Test

When the Tech 2 is operated, “Glow Indicator Lamp” is

turned on or off.

The ci rcuit is normal if th e “Glow Indicator L amp” in the

instrument panel is turned on or off in accordance with

this operation.

F1: Relays

F0: Glow Time Relay Test

When the Tech 2 is operated, glow relay signal turns

ON or OFF.

The circuit is normal if glow system is activated/

deacti vated in acco rdance with thi s operation when k ey

switch is turned ON.

19 Neutral Switch On/Off On On On This displays operating status of the neutral switch. This

should display “On” when the gear position is neutral.

20 A/C Information

Switch Active 12V/

Inactive 0V Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This

should display “Active 12V” when the air conditioner

switch is switched on.

21 Diagnostic

Request Activ e 0V/

Inactive 12V Inactive

12V Inactive

12V This displays the diagnostic request signal. This should

display “Inactive 12V” when the Tech 2 is connected.

22 System Voltage V 10 -14 10 -14 10 -14 This displays the system voltage measured by the ECM

at ignition feed.

23 Main Relay Active/ Inactive Active Active Active This displays operating status for the ECM main relay.

This should display “I nactive” at key O FF and “Active” a t

key ON.

24 Glow Time Relay Active 0V/

Inactive12V Inactive

12V Inactive

12V This displays operating status for the glow relay. This

should display “Inactive 12V” when the engine is warm

upped.

25 Check Engine

Lamp On/Off Off Off Off This displays operating status for the Check Engine

Lamp. This should display “On” when the Check Engine

Lamp is turned on.

26 Glow T ime Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.

This should display “On” when the glow lamp is turned

on.

27 Desired Engine

Idle Speed rpm 700 700 700 The desired engine idle speed that the ECM

commanding. The ECM compensates for various engine

loads based on engine coolant temperature.

28 Start of Delivery °CA 1 8 - 22 20 - 25 2 2 - 26 This displays commanded value from the ECM when

engine start.

29 A/C Request Active 0V/

Inactive 12V Inactive

12V Inactive

12V This displays operating status of the A/C compressor.

This should display “Active 0V” when the compressor

relay is operated.

30 Immobiliser Active/ Inactive Inactive Inactive Inactive This should display “Inactive” when the immobiliser is

normal.

31 Immobiliser Signal Received/

Not Received Not

Received Not

Received This should display “Not Received” when the immobiliser

is not activated.

32 Immobiliser

Function

Programmed

Yes/No Yes Yes Yes This should display “Yes” when the immobiliser is

programmed.

Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

F2: Engine Speed (RPM) Control

When the Tech 2 is operated, “Desired Idle Speed”

increases 50rpm-by-50rpm up to 1200rpm.

The circuit is normal if engine speed is changed in

accordance with this operation.

• Press “Increase” key.

Then, Desired Idle speed i ncreas es 5 0rpm-by- 50rpm

up to 1200rpm. Engine speed is also changed by this

operation.

• Press “Quit” Key.

Plotting Snapshot Graph

This test selects several necessary items from the data

list to plot graphs and makes data comparison on a long

term basis. It is an effective test particularly in emission

related evaluations.

For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.

You can replay the snapshot data as needed. Therefore,

accura te diagno sis is possi ble, eve n thoug h the ve hicle

is not available.

Engine Speed (RPM) Control

Engine Speed 850 RPM

Desired Idle Speed 850 RPM

Injection Quantity 7.5mg/strk

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

Flow Chart‘ for Snapshot Replay (Plotting Graph)

Snapshot Display With TIS2000

Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]

function is described below.

Snapshot data can be displayed with [Snapshot Upload]

function included in TIS2000.

By analyzing these data in various methods, trouble

conditions can be checked.

Snapshot data is displayed by executing the three steps

below shown:

1. Record the snapshot data, in Tech2.

2. Transfer the snapshot data to PC.

After recordin g the sn apshot in Tech2, transfe r the data

from Tech2 to PC by the below procedures.

1. Start TIS2000.

2. Select [Snapshot Upload] on the TIS2000 start

screen.

3. Select [Upload from trouble diagnosis tool (transfer

from diagnosis tester)] or click the corresponding

icon of the tool bar.

4. Select Tech2, and transfer the recorded snapshot

information.

5. Select the transferred snapshot.

6. After ending transfer of the snapshot, data

parameter list is displayed on the screen.

3. Snapshot data is displayed with TIS2000

[Snapshot Upload] function.

Snapshot is stored in the PC hard disk or floppy disk,

and can be displayed any time.

Stored snapshot can be displayed by the below

procedures.

1. Start TIS2000.

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 th e icon for graph display. [G raph Par ameter]

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. Se lected param eter is displa yed 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 selecti ng all paramet ers to be displ ayed (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 o f the list, drug the mouse to th e 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.

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 Immobiliser System must be linked

to the ECM: Refer to section 11 “Immobiliser System-

ECM replacement” for the ECM/Immobiliser linking

procedure.

Important: Perform the following checks before

attempting to program the control unit:

• The Tech2 PCMCIA card is programmed with The

latest software release.

• The latest release of TIS2000 is loaded on the PC.

• The vehicle battery is fully charged.

• The control unit to be programmed is connected to

the vehicle.

1. Preparations of TIS 2000

1. Connect Tech 2 to P/C.

2. Check to see if Hardware Key is plugged into Port.

3. Activate TIS 2000 by P/C.

4. On the activating screen of TIS2000, choose

“Service Programming System”

5. On the sc reen of “Diag nostic Te ster a nd Proces sing

Program Selection”, choose the one that will comply

with the following .

• Diagnostic tester in use

• New pr ogrammi ng by t he existi ng mod ule or ne w

programming by the replaced/new module.

• Fixing position of the control unit.

6. Upon completion of the selection, push the button of

“Continue”.

2. Demand of Data

1. Connect Tech-2 to the vehicle. When activated by

turning on the power of Tech-2, push the “Enter”

switch.

2. Turn on the ignition switch (without starting the

engine)

3. In the main menu of Diagnostic Tester, push “F1:

Service Programming System (SPS)”.

4. Push “F0: Request Info” of Tech-2.

5. Where ve hic le data has be en a lr ea dy sa ve d in Tech

2, the existing data come on display. In this

instance, as Tech-2 starts asking whether to keep

the data or to continue obtaining anew data from the

control unit, choose either of them.

6. If you select “continue”, you have to select “Model

Year”, “Vehicle Type”, “Controller Type (Engine)”.

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 chosen. In

replacing the control unit, please be sure to

undertake “Obtaining Information” from the new

unit. 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. Conne ct Tech-2 t o P/C, turn on the p ower and click

the “Next” button of P/C.

2. Check VIN of the vehi cle and ch oos e “Next” .

3. 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

• Immobiliser

* 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

Fig.-3, the destination code can be read as “EK4

(Europe)”.

4. After choosing the data, click the “Next” button.

5. 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.

6. “Data Transfer” comes on display. The progress of

downloading will be displayed on the screen in the

form of bar graph.

7. Upon finishing the data transfer, turn off the power

of Tech-2, removing from P/C.

4. Programming of ECM

1. Check to see if batteries are fully charged, while

ABS connectors shall be removed from the vehicle.

2. Connect Tech-2 to Vehicle Diagnostic Connectors.

3. Turn on the power of Tech-2 and the title screen

comes on display.

4. Turn on the ignition (without allowing the engine to

start)

5. On the title screen of Tech-2, push the “Enter”

button.

6. Choose “F: Service Programming System” on the

main screen and then choose “Fl: Programming”.

7. While data is being transferred, “Downloading” will

be displayed on the Tech-2 screen.

8. Upon finishing the data transfer, Tech-2 will display

“Reprogramming Successful”. Push the “Exit”

button to bring program to completion.

9. Following “Procedure 2: Demand of Data”, try over

again “Information Obtaining” and check to confirm

if the data has been correctly re-loaded.

10. Upon finishing confirmation, turn off the ignition of

the vehicle and then turn off the power of Tech-2,

removing from the vehicle.

How To Use Breaker Box

The engine control module (ECM) and other connectors

have water proo f connector and special termina l. 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 1

(1) Engine Control Module (ECM)

(2) Harness Adapter (3) Breaker Box

Breake r Box Connection Type A

Breake r box conne ction type A, check for “o pen circuit”

and “short to ground circuit”.

4 3 25

(1) Engine Control Module (ECM)

(2) Harness Adapter

(3) Breaker Box

(4) Digital Voltage Meter

(5) ECM - Harness Adapter Disconnection

Breake r Box Connection Type B

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 3 52

(1) Engine Control Module (ECM)

(2) Harness Adapter

(3) Breaker Box

(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

connection, and damaged harness.

Test Description

Number(s) below refer the step number(s) on the

Diagnostic Chart:

1. The Check Engi ne Lamp (M IL) shoul d be ON stea dy

with the ignition “On”, engine “Off”. If not, “No Check

Engine Lamp (M IL)” chart s hould be used to isol ate the

malfunction.

2. Check s the Class 2 data ci rcuit an d 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.

6. Th e Tech2 parameter s which is not within the typical

range m ay help to iso late the area wh ich is caus ing the

problem.

µP

1.25

BLK

16151413121110 9

87654321

0.5

RED/

YEL

0.5

WHT 0.5

BLU

35 45

0.5

BRN/

YEL

Stop

Light

10A

Meter

15A

Ignition

Check

Engine

Lamp Imnobiliser

Control Unit

Butery

Voltage

Engine

Control

Module

(ECM)

Techline

12. This vehic le is equip ped wit h ECM w hic h util izes a n

electrically erasable programmable read only memory (EEPROM).

On-Board Diagnostic (OBD) System Check

Step Action Value(s) Yes No

11. Ignition “On”, engine “Off”.

2. Check the “CHECK ENGINE” lamp (MIL).

Does the “CHECK ENGINE” lamp turn “On”? — Go to Step 2

Go to No

CHECK

ENGINE Lamp

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

2. Attempt to display “Data Display” with the Tech 2.

Does the Tech 2 display engine data? — Go to Step 3 Go to Step 7

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

2. Select the “Miscellaneous Test” and perform the

“Check Light” in “Lamps”.

3. Opera te the Tech 2 in ac cord ance with the Tech 2

instru ctions.

Does the “CHECK ENGINE” lamp turn “Off”? — Go to Step 4

Go to CHECK

ENGINE LAMP

On Steady

4Attempt to start the engine.

Does the engine start and continue to “Run”? —Go to Step 5

Go to Engine

Cranks But Will

Not Run

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

2. Select the “Read DTC Info r As Stored B y ECU” in

“Diagnostic Trouble Code”.

3. Are any DTCs stored? — Go to DTC

Chart Go to Step 6

6Compare typical scan data values displayed on the

Tech 2 “Data Display”.

Are the displayed values within the range? —

Refer to

SYMPTOM

DIAGNOSIS

Refer to

TYPICAL

SCAN DATA

7Using the DVM and check the data link connector

power supply circuit.

1. Ignition “Off”, engine “Off”.

2. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harness and

verify repair Go to Step 8

C-96

8Using the DVM and check the data link connector

ground circuit.

1. Ignition “Off”, engine “Off”.

2. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harness and

verify repair Go to Step 9

9Using 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?

Less than 1V Go to Step 10

Repair faulty

harness and

verify repair

10 Using the DVM and check the data link connector

communicati on ci rcui t.

1. Ignition “On”, engine “Off”.

2. Check the circuit for short to power supply circuit.

Was the DVM indicated battery voltage?

—

Repair faulty

harness and

verify repair Go to Step 11

Step Action Value(s) Yes No

C-96

11 Using the DVM and check the data link connector

communicati on ci rcui t.

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?

—

Repair faulty

harness and

verify repair Go to Step 12

12 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 13

13 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-96

C-56

No Check Engine Lamp (MIL)

Circuit Description

The check engine lamp should be illuminated and

steady fo r abou t five se co nds wi th t he i gniti on “ ON” an d

the engi ne s topped. Ig nition feed voltage i s s upplied 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 eng ine 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. Check for the

followi ng ite ms :

• Inspect the ECM harness and connections for

improper mating, broken locks, improp erly 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 i gnition or batt ery feed, or a p oor ECM to

engine ground.

µP

1.25

BLK

16151413121110 9

87654321

0.5

RED/

YEL

0.5

WHT 0.5

BLU

35 45

0.5

BRN/

YEL

Stop

Light

10A

Meter

15A

Ignition

Check

Engine

Lamp Imnobiliser

Control Unit

Butery

Voltage

Engine

Control

Module

(ECM)

No Check Engine Lamp (MIL)

Step Action Value(s) Yes No

1 C h eck the mete r fuse (15A) .

If the fuse is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 2

2 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Ignition “On”.

4. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 5 Go to Step 3

3 Check the “CHECK ENGINE” lamp bulb.

If the bulb is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 4

C-56

4 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Check the circuit for open circuit.

Was the problem found?

— Verify repair Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

B-23

C-56

4JA1-TC

B-23

C-56

4JH1-TC

Check Engine Lamp (MIL) “On” Steady

Circuit Description

The check engine lamp should always be illuminated

and steady for about five seconds with ignition “ON” and

the engine stopped. Ignition feed voltage is supplied

directl y to the ch eck en gine lam p indic ator. The Engin e

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.

µP

1.25

BLK

16151413121110 9

87654321

0.5

RED/

YEL

0.5

WHT 0.5

BLU

35 45

0.5

BRN/

YEL

Stop

Light

10A

Meter

15A

Ignition

Check

Engine

Lamp Imnobiliser

Control Unit

Butery

Voltage

Engine

Control

Module

(ECM)

Check Engine Lamp (MIL) On Steady

Step Action Value(s) Yes No

1 1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Ignition “On”.

Was the “CHECK ENGINE” lamp turned on? — Go to Step 2 Go to Step 4

2 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Check the circuit for short to ground circuit.

Was the problem found?

— Verify repair Go to Step 3

3 Replace the meter assembly.

Is the action complete? — Verify repair —

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

B-23

C-56

4JA1-TC

B-23

4JH1-TC

ECM Diagnostic Trouble Codes

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

65 P0100 7 ON Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High Input MAF sensor power supply

voltage is more than 5.2V. ECM uses mass air flow

1600mg/strk & EGR 10%

(4JA1-TC only) condition(s)

as substitute.

MAF sensor power supply voltage

is below 5.2V. 1. Sensor power supply circuit

short to battery voltage circuit.

2. MAF sensor malfunction.

3. E CM malfunction.

83 -

9 ON Mass Air Flow (MAF) Sensor

Voltage Supply Circuit Low Input MAF sensor power supply

voltage is below 4.6V. MAF sensor power supply voltage

is more than 4.6V. 1. Sensor power supply circuit

short to ground circuit.

2. MAF sensor malfunction.

3. E CM malfunction.

83 -

B ON Mass Air Flow (MAF) Sensor

Output Circuit Low Input 1. Engine spe ed is between

600rpm and 5000rpm.

2. MAF sensor ou tput is below

-33.7mg/strk.

MAF sensor output is more than -

27.4mg/strk. 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. MAF sensor malfunction.

6. E CM malfunction.

83/88 P0110(1)

C ON Mass Air Flow (MAF) Sensor

Output Circuit High Input 1. Engine spe ed is between

600rpm and 5000rpm.

2. MAF sensor output is more

than 1784mg/strk.

MAF sensor output is below

1784mg/strk. 1. Sensor signal circuit short to

voltage circ ui t.

2. Sensor ground circuit open or

short to voltage circuit.

3. MAF sensor malfunction.

4. E CM malfunction.

88/ 92 P0110(1)

23 P0110 1 ON Intake Air Temperature (IAT)

Sensor Circuit High Input IAT sensor output voltage is

more than 4.7V. ECM use 0°C conditions as

substitute. IAT sensor output voltage is below

4.7V. 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. IAT sensor malfunction.

5. E CM malfunction.

84/92 P0100(B)/

P0100(C)

2 ON Intake Air Temperature (IAT)

Sensor Circuit Low Input IAT sensor output voltage is

below 0.3V. IAT sensor output voltage is more

than 0.3V. 1. Sensor signal circuit short to

ground circuit.

2. IAT sensor malfunction.

3. E CM malfunction.

84 -

14 P0115 1 ON Engine Coolant Temperature

(ECT ) Sensor Circuit High Input ECT sensor output voltage is

more than 4.7V. 1. ECM uses fuel

temperatur e as substitute.

2. ECM uses 60°C condition

for injec tion timing con tr ol.

3. ECM uses -1 5°C co ndit io n

for glow time control.

ECT sensor output voltage is below

4.7V. 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. ECT sensor malfunction.

5. E CM malfunction.

89/93 -

2 ON Engine Coolant Temperature

(ECT ) Sensor Circuit Low Input ECT sensor output voltage is

below 0.3V. ECT sensor output voltage is more

than 0.3V. 1. Sensor signal circuit short to

ground circuit.

2. ECT sensor malfunction.

3. E CM malfunction.

89 -

15 P0180 B ON Fuel Temperature Sensor Circuit

Range/Performance FT sens or output is high

temper atur e (mor e than

150°C) or low temperature

(below -40°C).

The ECM use 75°C

conditions as substitute. FT sensor output is correct

temperature range between 150°C

and -40°C.

1. E CM malfunction.

2. PSG (pump control unit)

malfunction.

52 P0215 A ON at

ignitio

cycle

Fuel Cutoff Solenoid Valve

Malfunction 1. Ignition key switch off.

2. Engine spe ed 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.

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

No reco very until conditio n match in

the next ign iti on ke y cy cl e. 1. PSG (pump control unit)

malfunction.

2. MAB (fuel cutoff solenoid

valve) malfunction.

B ON Fuel Cutoff Solenoid V alve Circuit

High Input 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.

Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid

valve) signal circuit short to

voltage circ ui t.

2. PSG (pump control unit)

malfunction.

105 -

C ON Fuel Cutoff Solenoid Valve

Always Active 1. Ignition key switch off.

2. Engine spe ed 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. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

No reco very until conditio n match in

the next ign iti on ke y cy cl e. 1. MAB (fuel cutoff solenoid

valve) signal circuit open or short

to ground circuit.

2. PSG (pump control unit)

malfunction.

105 -

D ON Fuel Cutoff Solenoid Valve

Malfunction 1. Ignition key switch off.

2. CAN controller does not

operate Bus-off.

No fail-safe function. 1. ECM malfunction.

2. PSG (pump control unit)

malfunction.

54 P0216 A ON Inje ction Timing Control Circuit

Malfunction (Timer Deviation) 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°CA or

-6°CA for 8 seconds.

Fuel injection quantity is

reduced. Deviation of actual injection timing

and desired injection timing is

below +3°CA or -6°CA for 8

seconds.

1. Timing control valve

malfunction.

2. Timer piston sticking.

3. Pump camshaft speed sensor

malfunction.

B ON Injection Timing Control Circuit

Malfunction (Timer Fluctuation) 1. Engine speed is more than

2014rpm.

2. Fluctuation of actual

injection timing is more than

±5.2°CA.

1. Engine speed is more than

2014rpm.

2. Fluctuation of actual injection

timing is below ±5.2°CA.

1. Insufficient air bleeding of fuel

line.

2. Fuel filter clogging.

3. Timing control valve

malfunction.

4. Pump camshaft speed sensor

malfunction.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed

sensor error.

2. High pressure solenoid

valve control pulse width does

not match with desired fuel

injection quantity.

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

No reco very until conditio n match in

the next ign iti on ke y cy cl e. 1. PSG (pump control unit)

malfunction.

2. Pump camshaft speed sensor

malfunction.

7 ON Injection Pump Malfunction 1. No pump camshaft speed

sensor error.

2. No CKP sensor error.

3. Difference of engine speed

and doub le d pump cam sh aft

speed is more than 720rpm

(4JA1-TC) or 690rpm (4JH1-

TC).

1. No pump camshaft speed sensor

error.

2. No CKP sensor error.

3. Difference of engine speed and

doubled pump camshaft speed is

below 720rpm (4JA1-TC) or

690rpm (4 JH1 -TC) .

No recovery until in the next ignition

key cycle.

1. Missing CKP sensor pulses.

2. Electrical interference.

3. Magnetic interference.

4. PSG (pump control unit)

malfunction.

91 -

9 ON Injection Pump Malfunction No pump map programmed in

the PSG (pump control unit) or

PSG malfunc ti on.

No reco very until conditio n match in

the next ign iti on ke y cy cl e. PSG (pump control unit)

malfunction. --

A ON Injection Pump Malfunction EEPROM or A/D converter

malfunction in the PSG (pump

contr ol uni t).

Fuel injection quantity is

reduced. EEPROM or A/D converter no

malfunction in the PSG (pump

control unit).

No recovery until in the next ignition

key cycle.

PSG (pump control unit)

malfunction. --

B ON Injection Pump Malfunction PSG (pump control unit)

recognized high pressure

solenoid valve drive circuit

error.

No fail-safe function. No recovery until condition match in

the next ign iti on ke y cy cl e. PSG (pump control unit)

malfunction. --

D ON Injection Pump Malfunction PSG (pump control unit) could

not measure the high pressure

solenoid valve drive voltage.

PSG (pump control unit)

malfunction. --

E ON Injection Pump Malfunction ECM could not accept PSG

(pump control unit) message. 1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

ECM accepts PSG (pump control

unit) message. 1. CAN high circuit open, short to

ground or short to voltage circuit.

2. CAN low circuit open, short to

ground or short to voltage circuit.

3. E CM malfunction.

4. PSG (pump control unit)

malfunction.

99/100 P1650(A)/

P1651(B)

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

43 P0335 B ON Crankshaft Position Sensor

Circuit Malfunction 1. Engine speed is more than

665rpm.

2. CKP sensor pulse width

error.

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.

ECM detects correct CKP pulse

width. During engine run:

1. CKP sensor harness open

circuit, short to ground or short to

voltage circ ui t.

2. Poor connector connection.

3. CKP sensor malfunction.

4. Pulse sensing gap incorrect.

5. Pulser malfunction.

6. Electrical interference.

7. Magnetic interference.

8. E CM malfunction.

90/ 98/

101 P1335 (A)

D ON Crankshaft Position Sens or

Circuit Malfunction 1. No pump camshaft speed

sensor error.

2. “Crankshaft Position Sensor

Circuit Mal fun cti on (Sy mpto m

Code B)” is not stored.

3. Engine spe ed 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.

Other than pump camshaft

speed sensor is OK:

Fuel injection quantity is

reduced.

1. Engine speed is more than 0rpm.

2. Doubled pump camshaft speed is

below 100rpm.

During engine crank:

1. CKP sensor harness open

circuit, short to ground or short to

voltage circ ui t.

2. Poor connector connection.

3. CKP sensor malfunction.

4. Pulse sensing gap incorrect.

5. Pulser malfunction.

6. Electrical interference.

7. Magnetic interference.

8. E CM malfunction.

90/ 98/

101 P1135 (A)

E ON Engine Speed Input Circuit

Range/Performance Engine speed is more than

5700rpm. When intermittent

malfunction:

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

When preliminary

malfunction:

ECM uses doubled pump

camshaft speed as substitute

engine speed.

Engine speed is below 5700rpm. 1. Engine over-running.

2. CKP sensor malfunction.

3. Pulser malfunction.

4. E CM malfunction.

90/ 98/

101 -

66 P0380 4 ON Glow Relay Circuit Voltage Low Glow relay circuit open or

short to ground circuit. No fail-safe function. Glow relay circuit is correct

condition. 1. Glow relay circuit open or short

to ground circuit.

2. Glow relay malfunction.

3. E CM malfunction.

94 -

8 ON Glow Relay Circuit Voltage High Glow relay circuit short to

voltage circuit. ECM malfunction. - -

67 P0381 4 ON Glow Plug Indicator Circuit

Voltage Low Glow plug indicator circuit

open or short to ground circuit. No fail-safe function. Glow plug indicator circuit is correct

condition. 1. Glow plug indicator circuit

open or short to ground circuit.

2. Glow plug indicator lamp

malfunction.

3. E CM malfunction.

43 -

8 ON Glow Plug Indicator Circuit

Voltage High Glow plug indicator circuit

short to voltage circuit. ECM malfunction. - -

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

32 P0400 3 ON Exhaust Gas Recirculation Flow

Excessive Detected 1. Intake air temperature is

between 15°C and 100°C.

2. Engine coolant temperature

is between 55°C and 100°C.

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)

Fuel injection quantity is

reduced. 1. Engine speed is between

1500rpm and 3100rpm.

2. Injection quantity is between

8mg/str k and 32mg/s tr k.

3. Correct amount of mass air flow.

1. EGR valve is stuck at open

position.

2. EGR EVRV malfunction.

3. Air intake is obstructed.

4. Air intake is leaking.

5. MAF sensor malfunction.

6. E CM malfunction.

88/97 - - -

4 ON Exhaust Gas Recirculation Circuit

Short to Ground or Open Circuit EGR EVRV circuit open or

short to ground circuit. Fuel injection quantity is

reduced and EGR EVRV

10% conditions as substitute.

EGR EVRV circuit is correct

condition. 1. EGR EVRV circuit open or

short to ground circuit.

2. EGR EVRV malfunction.

3. E CM malfunction.

97 - - -

5 ON Exhaust Gas Recirculation Flow

Insufficient Detected 1. Intake air temperature is

between 15°C and 100°C.

2. Engine coolant temperature

is between 55°C and 100°C.

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)

Fuel injection quantity is

reduced. 1. Engine speed is between

1500rpm and 3100rpm.

2. Injection quantity is between

8mg/str k and 32mg/s tr k.

3. Correct amount of mass air flow.

1. EGR valve is stuck at close

position.

2. EGR valve operating vacuum

hose is clogged or disconnected.

3. EGR EVRV malfunction.

4. MAF sensor signal circuit short

to voltage circuit.

5. MAF sensor malfunction.

6. E CM malfunction.

88/97 - - -

8 ON Exhaust Gas Recirculation Circuit

Short to Battery EGR EVRV circuit short to

voltage circuit. Fuel injection quantity is

reduced & EGR EVRV 10%

conditions as substitute.

EGR EVRV circuit is correct

condition. 1. EGR EVRV circuit short to

voltage circ ui t.

2. EGR EVRV malfunction.

3. E CM malfunction.

97 - - -

24 P0500 1 ON at

ignitio

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 is below 200km/h. 1. VSS signal circuit open, short

to ground or short to voltage

circuit.

2. VSS malfunction.

3. Speed meter malfunction.

4. E CM malfunction.

68 -

AON at

ignitio

cycle

Vehicle Speed Sensor Input

Signal Frequency Too High Input signal frequency is too

high. ECM uses vehicle speed

5km/h condition as

substitute.

Correct vehic le sp eed si gna l

frequency. 1. VSS malfunction.

2. Speed meter malfunction.

3. Electrical interference.

4. Magnetic interference.

5. E CM malfunction.

68 -

BON at

ignitio

cycle

Vehicle Speed Sensor Incorrect

Signal 1. Engine speed is more than

3600rpm.

2. Fuel injection quantity is

more than 41mg/stk.

3. Vehicle speed is below

1.5km/h.

Fuel injection quantity is

reduced. Vehicle speed is more than 1.5km/

h. 1. VSS open circuit, short to

ground or short to voltage.

2. Poor connector connection.

3. VSS malfunction.

4. Speed meter malfunction.

5. E CM malfunction.

68 - -

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

35 P0560 1 OFF System Voltage Too High System voltage is more than

20V. ECM uses 9V conditions as

substitute. System voltage is below 20V. 1. Charge system malfunction.

2. Battery jump start cable

misconnect.

3. E CM malfunction.

3/39 -

2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 7V. 1. Battery power feed harness

open circuit or short to ground

circuit.

2. ECM ground harness open or

poor connection.

3. Poor connector connection.

4. Battery malfunction.

5. Charge system malfunction.

6. E CM malfunction.

3/39 -

A OFF System Voltage Malfunction

(PSG) System voltage of PSG (pump

control unit) is below 4.5V or

more than 27V.

PSG uses default voltage as

substitute. System voltage of PSG is between

4.5V and 27V. 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.

18 P0561 A OFF System Voltage Circuit

Malfunction The ECM recognized ignition

switch turn off signal during

ECM is activated.

ECM stops engine. No recovery until condition match in

the next ign iti on ke y cy cl e. 1. Ignition switch circuit open or

short to ground circuit.

2. Poor connector connection.

3. Ignition switch malfunction.

4. E CM malfunction.

39 -

B ON System Voltage Circuit

Malfunction Ignition switch circuit is

malfunction. 1. Ignition switch circuit open or

short to ground circuit.

2. Poor connector connection.

3. Ignition switch malfunction.

4. E CM malfunction.

39 -

- P0602 - ECU Programming Error ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed. - -

28 P0606 A ON ECU Malfunction Gate Array communication

error. 1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

No recove ry. ECM malf unc tion. - -

B ON ECU Malfunction 1. Throttle position is below

1%.

2. Desired injection quantity is

more than 0mg/strk.

3. Engine speed is more than

2000rpm.

MAB (fuel cutoff solenoid

valve) is operated. Desired injection quantity is below

0mg/strk. 1. E CM malfunction.

2. PSG (pump control unit)

malfunction.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

46 P0645 4 ON A/C Compressor Relay Circuit

Voltage Low A/C compressor rela y circuit

open or short to ground circuit. No fail-safe function. A/C compressor relay circuit is

correct cond ition. 1. A/C compressor relay circuit

open or short to ground circuit.

2. Poor connector connection.

3. A/C compressor rel ay

malfunction.

4. E CM malfunction.

41 -

8 ON A/C Compressor Relay Circuit

Voltage High A/C compressor rela y circuit

short to voltage circuit. ECM malfunction. - -

25 P0703 A ON Brake Switch Malfunction 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.

No fail-safe function. Brake switch 1 signal and brake

switch 2 signal are correctly

inputted to the ECM.

1. Brake switch 1 circuit open,

short to ground or short to

voltage circ ui t.

2. Poor connector connection.

3. Brake switch 1 malfunction.

4. E CM malfunction.

30 -

B ON Brake Switch Malfunction 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.

1. Brake switch 2 circuit open or

short to ground circuit.

2. Poor connector connection.

3. Brake switch 2 malfunction.

4. E CM malfunction.

65 -

57 P0704 6 ON Clutch Switch Input Circuit

Malfunction Clutch signal does not change

between vehicle speed 1.5km/

h and 80km/h since ignition

switch was tuned on.

No fail-safe function. Clutch signal correctly changes. 1. Clutch switch circuit open,

short to ground or short to

voltage circ ui t.

2. Poor connector connection.

3. Clutch switch malfunction.

4. E CM malfunction.

31 - -

86 P1105 1 ON Barometric Pressure Sensor

Circuit High Input Barometric pressure sensor

output voltage is more than

4.4V.

ECM uses 1013hpa condition

as substitute. Barometric pressure sensor output

voltage is below 4.4V. ECM malfunction. - -

2 ON Barometric Pressure Sensor

Circuit Low Input Barometric pressure sensor

output voltage is below 1.5V. Barometric pressure sensor output

voltage is more than 1.5V. ECM malfunction. - -

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

21 P1120 1 ON Pedal/Throttle Position Sensor

Circuit High Input Throt tle pos ition se nsor out put

voltage is more than 4.5V. ECM increases idle speed up

to 1400rpm. Throttle position sensor output

voltage is below 4.5V. 1. Sensor power supply circuit

short to voltage circuit.

2. Sensor signal circuit short to

voltage circ ui t.

3. Sensor ground circuit open or

short to voltage circuit.

4. Poor connector connection.

5. TPS malfunction.

6. E CM malfunction.

38/ 49/ 57 -

7 ON Pedal/Throttle Position Sensor

Voltage Supply Circuit High Input Throttle position sensor power

supply voltage is more than

5.2V.

Throttle position sensor power

supply voltage is below 5.2V. 1. Sensor power supply circuit

short to battery voltage circuit.

2. TPS malfunction.

3. E CM malfunction.

57 -

9 ON Pedal/Throttle Position Sensor

Voltage Supply Circuit Low Input Throttle position sensor power

supply voltage is below 4.6V. Throttle position sensor power

supply voltage is more than 4.6V. 1. Sensor power supply circuit

short to ground circuit.

2. TPS malfunction.

3. E CM malfunction.

57 -

D ON Pedal/Throttle Position Sensor

Brake Switch Error 1. Engine speed is more than

1700rpm.

2. Throttle position sensor is

more than 8.7%.

3. When brake pedal is

depressed during accelerator

pedal is depressing.

Throttle position is more than 20%

or brake pedal is released (switch is

inactive).

1. Throttle sticking.

2. TPS incorrect adjusting.

3. TPS malfunction.

4. Brake switch malfunction.

5. E CM malfunction.

30/ 38/ 65 -

E ON Pedal/Throttle Position Sensor

Idle Position Switch Error 1. When idle switch is turned

off, throttle position sensor

was below 0.35%.

2. When idle switch is tuned

on, throttle position sensor

was more than 7.8%.

1. When throttle position sensor is

100%, idle switch turns off.

2. When throttle position sensor is

0%, idle switch turns on.

1. TPS malfunction.

2. Idle switch malfunction.

3. E CM malfunction.

38/ 69 -

22 P1173 3 OFF Fuel Reduction Caused By High

Coolant Temperature Excessive high engine coolant

temp eratur e is detected. No fail-safe function. Engine coolant temperature is

normal range. 1. Engine overheat.

2. ECT sensor malfunction.

3. E CM malfunction.

89 -

7 OFF Fuel Reduction Caused By High

Fuel Temperature Fuel temperature is more than

100°C.PSG (pump control unit)

controls fuel injection

quantity based on engine

speed and fuel temperature.

Fuel temperature is below 100°C.1. ECM malfunction.

2. PSG (pump control unit)

malfunction.

A OFF Fuel Reduction Caused By Low

Fuel Temperature Excessive low fuel

temp eratur e is detected. No fail-safe function. Fuel temperature is normal range. 1. ECM malfunction.

2. PSG (pump control unit)

malfunction.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

43 P1335 A ON Engine Speed Output Circuit

Malfunction The PSG (pump control unit)

is recognized defective engine

speed signal form the ECM.

Fuel injection quantity is

reduced. Correct engine speed signal. 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. CKP sensor malfunction.

5. Pulse sensing gap incorrect.

6. Pulser malfunction.

7. Electrical interference.

8. Magnetic interference.

9. E CM malfunction.

10. PSG (pump control unit)

malfunction.

90/91/98/

101 P0335(B)/

P0335(D)

45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit)

is recognized incorrect

camshaft speed signal.

No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed sensor

malfunction.

2. Pulse sensing gap incorrect.

3. Pulser malfunction.

4. Electrical interference.

5. Magnetic interference.

5. E CM malfunction.

6. PSG (pump control unit)

malfunction.

47 P1520 A ON Neutral Switch ON Error Neutral switch signal is

inputted “On” three times

conse cu t ivel y under driving

conditions.

No fail-safe function. Correct neutral switch signal is

inputted two times consecutively

under driving conditions.

1. Neutral switch circuit short to

voltage circ ui t.

2. Neutral switch malfunction.

3. E CM malfunction.

87 - - -

B ON Neutral Switch OFF Error Neutral switch signal is

inputted “Off” three times

conse cu t ivel y under driving

conditions.

1. Neutral switch circuit open,

short to ground circuit.

2. Poor connector connection.

3. Neutral switch malfunction.

4. E CM malfunction.

87 - - -

71 P1576 4 ON Exhaust Throttle VSV 1 Circuit

Voltage Low Exhaust throttle VSV 1 circuit

open or short to ground circuit. No fail-safe function. Exhaust throttle VSV 1 circuit is

correct cond ition. 1. Exhaust throttle VSV 1 circuit

open or short to ground circuit.

2. Poor connector connection.

3. Exhaust throttle VSV 1

malfunction.

4. E CM malfunction.

40 - - -

8 ON Exhaust Throttle VSV 1 Circuit

Voltage High Exhaust throttle VSV 1 circuit

short to voltage circuit.

ECM malfunction.

-- --

71 P1577 4 ON Exhaust Throttle VSV 2 Circuit

Voltage Low Exhaust throttle VSV 2 circuit

open or short to ground circuit. No fail-safe function. Exhaust throttle VSV 2 circuit is

correct cond ition. 1. Exhaust throttle VSV 2 circuit

open or short to ground circuit.

2. Poor connector connection.

3. Exhaust throttle VSV 2

malfunction.

4. E CM malfunction.

61 - - -

8 ON Exhaust Throttle VSV 2 Circuit

Voltage High Exhaust throttle VSV 2 circuit

short to voltage circuit. ECM malfunction.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

55 P1605 D ON EEPROM Defect Write and read from the

EEPROM are failed during

initialization of the ECM.

ECM uses default values

from the EPROM. Write and read from the EEPROM

are correct during initialization of

the ECM.

ECM malfunction. - -

E ON EEPROM D efect EEPROM checks um doe s not

match with the read che ck

sum during initialization of the

ECM.

EEPROM checksum match with the

read check sum during initialization

of the ECM.

ECM malfunction. - -

56 P1610 A - Security Key and Security Code

not Programmed Immobiliser functions are not

programmed in the ECM. 1. Engine does not start.

2. Check engine lamp flash. No recove ry. ECM malfunc ti on. - B****

56 P1611 A - Wrong Security Code Entered Received security code is not

correct. 1. Engine does not start.

2. Check engine lamp flash. No recovery. 1. ECM malfunction.

2. Immobili ser contr ol uni t

malfunction.

3. Transponder key malfunction.

- B****

56 P1612 A - Immobiliser No or Wrong Signal Received challenge signal is

not correct or not received. 1. Engine does not start.

2. Check engine lamp flash. No recovery. 1. ECM and immobiliser control

unit communication circuit open

circuit, short to ground circuit or

short to voltage circuit.

2. E CM malfunction.

3. Immobili ser contr ol uni t

malfunction.

4. Transponder key malfunction.

27/35 B****

56 P1613 A - Immobiliser No or Wrong Signal Received response signal is

not correct or not received. 1. Engine does not start.

2. Check engine lamp flash. No recovery. 1. ECM and immobiliser control

unit communication circuit open

circuit, short to ground circuit or

short to voltage circuit.

2. E CM malfunction.

3. Immobili ser contr ol uni t

malfunction.

4. Transponder key malfunction.

27/35 B****

56 P1614 A - Wrong Transponder Key Received response signal is

not correct from the

transponder key.

1. Engine does not start.

2. Check engine lamp flash. No recovery. 1. ECM malfunction.

2. Immobili ser contr ol uni t

malfunction.

3. Transponder key malfunction.

- B****

76 P1625 A OFF ECM Main Relay Switched Off

Too Early When ignition switch was

turned off, timing of the ECM

main relay turning off is too

early.

No fail-safe func ti on. No reco ve ry. ECM malfunc tion. 3/58 -

B OFF ECM Main Relay Switched Off

Too Late When ignition switch was

turned off, timing of the ECM

main relay turning off is too

late or does not off.

No recovery. 1. ECM main relay malfunction.

2. E CM malfunction. 3/58 -

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

51 P1630 A ON Fuel Injection Quantity Circuit

Malfunction The PSG (pump control unit)

detects high pressure solenoid

valve control circuit

malfunction due to high

current.

Fuel injection quantity is

reduced. The PSG (pump control unit)

detects correct high pressure

solenoid valve control circuit.

PSG (pump control unit)

malfunction. --

B ON Fuel Injection Quantity Circuit

Malfunction The PSG (pump control unit)

detects high pressure solenoid

valve control circuit

malfunction due to continuous

current.

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

No recovery. PSG (pump control unit)

malfunction. --

44 P1650 A ON CAN Device Offline CAN controller detects Bus-off

or canc eli ng. MAB (fuel cutoff solenoid

valve) is operated. CAN controller detects correct Bus

signal. 1. CAN high circuit open, short to

ground or short to voltage circuit.

2. CAN low circuit open, short to

ground or short to voltage circuit.

3. Poor connector connection.

4. Electrical interference.

5. E CM malfunction.

6. PSG (pump control unit)

malfunction.

99/100 P1651(B)

B ON CAN Device Hang-up CAN controller does not react

under eng ine running. CAN controller reacts correctly

under engine running. 1. ECM malfunction.

2. PSG (pump control unit)

malfunction.

45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit)

does not recognize CAN

signal from the CAN controller.

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

The PSG (pump control unit)

recognizes CAN signal from the

CAN controller.

1. E CM malfunction.

2. PSG (pump control unit)

malfunction.

B ON CAN Receives Error The ECM does not read CAN

signal from the PSG (pump

contr ol uni t).

The ECM reads CAN signal from

the PSG (pump control unit). 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. E CM malfunction.

6. PSG (pump control unit)

malfunction.

99/100 P1650(A)

77 P1690 4 OFF Check Engine Lamp (MIL) Circuit

Voltage Low Check engine lamp circuit

open or short to ground circuit. No fail-safe function. Check engine lamp circuit is correct

condition. 1. Check engine lamp circuit

open or short to ground circuit.

2. Check engine lamp

malfunction.

3. E CM malfunction.

42 B****

8 OFF Check Engine Lamp (MIL) Circuit

Voltage High Check engine lamp circuit

short to voltage circuit. ECM malfunction. - -

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related

ECM Pin

No.

Multiple

DTC

4JA1

- T C

(MT)

4JH1

-TC

(MT)

4JH1

-TC

(AT)

Diagnostic Trouble Code (Dtc) P0100 (Symptom Code 7)

(Flash Code 65) Mass Air Flow (MAF) Sensor Volt age 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

Batt

µP

Batt

µP

Batt

µP

0.5

BLK/

URG

0.5

BRN/

RED

0.5

BLU/

RED

0.5

BLU/

RED

4JA1-TC

0.5

GRY/

YEL

974661

0.5

WHT/

RED

0.5

GRN/

RED

0.5

BLK/

RED

0.5

BLK/

BLU

IAT

Sensor MAF &

IAT

Sensor

Rr Fog

Light

10A

EGR-

EVRV

0.5

WHT/

BLK

0.5

BLU/

RED

0.5

WHT/

BLU

0.5

BLU/

RED

0.5

GRN/

RED

0.5

BLU/

RED

Exhaust

Throttle

VSV2

Exhaust

Throttle

VSV1

Engine

Warming Up

Thermo

4531

Battery

Voltage

ECM

Main Relay

IC ICIC CPU

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

The mas s air flo w (MAF) sensor is part of the intake air

system. It is fitted between the air cleaner and

turbocha rger a nd mea sure th e mas s air flo win g into th e

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 s upply voltage an d

MAF sensor output voltage. If fhe supply voltage is out

of range, DTC P0100 (Symptom Code 7) or P0100

(Symptom Code 9) will be stored. If the output voltage

excessively high or low, DTC P0100 (Symptom Code B)

or P0100 (Symptom Code C) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

65 P0100 7 ON Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High

Input

MAF sensor power supply

voltage is more than 5.2V. ECM uses mass air flow

1600mg/strk & EGR 10%

(4JA1-TC only) condition(s) as

substitute.

9 ON M ass Air Flow (M AF ) Sensor

Voltage Supply Circuit Low

Input

MAF sensor power supply

voltage is below 4.6V.

B ON M ass Air Flow (M AF ) Sensor

Output Circuit Low Input 1.Engine speed is between

600rpm and 5000rpm.

2. MAF sensor output is

below -33.7mg/strk.

C ON Mass Air Flow (MAF) Sensor

Output Circuit High Input 1. Engine speed is between

600rpm and 5000rpm.

2. MAF sensor output is more

than 1784mg/strk.

Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65)

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0100 (Symptom Code 7) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 100 (Sy mpt om Code 7) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the MA F sensor.

Was the problem found? — Go to Step 11 Go to Step 6

6 Using the DVM and check the MAF sensor power

supply circuit.

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?

Approximately

5.0V Go to Step 11

Less than 1V:

Go to Step 7

More than

specified value:

Go to Step 8

88 83

2345

C-51C-57(B)

C-51

7 Repair the open circuit between the ECM and MAF

sensor.

Was the problem solved?

— Verify repair Go to Step 8

8 Using the DVM and check the MAF sensor power

supply circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check the circuit for short to MAF sensor heater

circuit.

Was the DVM indicated specified value?

No continuity Go to Step 10 Go to Step 9

9 Repair the circuit for short to MAF sensor heater

circuit.

Is the action complete? — Verify repair —

10 Re pair the short to battery v oltage circuit between the

ECM and MAF se ns or.

Was the problem solved?

— Verify repair Go to Step 13

11 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 12 Go to Step 13

12 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

13 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 14

Step Action Value(s) Yes No

83 4

C-51C-57(B)

C-51

83 4

C-51C-57(B)

Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65)

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

14 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0100 (Symptom Code 9) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 100 (Sy mpt om Code 9) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the MA F sensor.

Was the problem found? — Go to Step 10 Go to Step 6

Step Action Value(s) Yes No

88 83

2345

C-51C-57(B)

6 Using the DVM and check the MAF sensor power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for short to ground circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 10 Go to Step 7

7 Using the DVM and check the MAF sensor power

supply circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check the circuit for short to MAF sensor ground

circuit.

Was the DVM indicated specified value?

No continuity Go to Step 9 Go to Step 8

8 Repair the circuit for short to MAF sensor ground.

Is the action complete? — Verify repair —

9 Repair the short to ground circuit between the ECM

and MAF sensor.

Was the problem solved?

— Verify repair Go to Step 12

10 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 11 Go to Step 12

11 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

12 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 13

Step Action Value(s) Yes No

C-51

83 4

C-51C-57(B)

Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)

Mass Air Flow (MAF) Sensor Output Circuit Low Input

13 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0100 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0100 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the MA F sensor.

Was the problem found? — Go to Step 11 Go to Step 6

Step Action Value(s) Yes No

88 83

2345

C-51C-57(B)

6 Using the DVM and check the MAF sensor signal

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the MAF & IAT sensor connector.

4. Check th e circuit for open, short to sensor gr ound

or short to ground circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check th e circuit for open, short to sensor gr ound

or short to ground circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 7

7 Using the DVM and check the MAF sensor power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 9 Go to Step 8

Step Action Value(s) Yes No

C-51

C-57(B)

C-51

8 Repair the open circuit between the ECM and MAF

sensor.

Was the problem solved?

— Verify repair Go to Step 13

9 Using the DVM and check the MAF sensor heater

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 11 Go to Step 10

10 Repair the open circuit between the ECM main relay

and MAF sensor.

Was the problem solved? — Verify repair Go to Step 11

11 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 12 Go to Step 13

12 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

13 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 14

14 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

83 4

C-51C-57(B)

C-51

Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)

Mass Air Flow (MAF) Sensor Output Circuit High Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0100 (Symptom Code C) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0100 (Symptom Code C) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the MA F sensor.

Was the problem found? — Go to Step 11 Go to Step 6

88 83

2345

C-51C-57(B)

6 Using the DVM and check the MAF sensor ground

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the MAF sensor connector.

4. Check the circuit for open circuit.

Was the problem found?

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?

—

Repair faulty

harnes s and

verify repair G o to Step 7

7 Using the DVM and check the MAF sensor ground

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF sensor connector .

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 8

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

C-51

C-57

C-51

8 Using the DVM and check the MAF sensor signal

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF sensor connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

9 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 10 Go to Step 11

10 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-51

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

Batt

µP

Batt

µP

Batt

µP

0.5

BLK/

URG

0.5

BRN/

RED

0.5

BLU/

RED

0.5

BLU/

RED

4JA1-TC

0.5

GRY/

YEL

974661

0.5

WHT/

RED

0.5

GRN/

RED

0.5

BLK/

RED

0.5

BLK/

BLU

IAT

Sensor MAF &

IAT

Sensor

Rr Fog

Light

10A

EGR-

EVRV

0.5

WHT/

BLK

0.5

BLU/

RED

0.5

WHT/

BLU

0.5

BLU/

RED

0.5

GRN/

RED

0.5

BLU/

RED

Exhaust

Throttle

VSV2

Exhaust

Throttle

VSV1

Engine

Warming Up

Thermo

4531

Battery

Voltage

ECM

Main Relay

IC ICIC CPU

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

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.

If the output voltage excessively high or low, DTC P01 10

(Symptom Code 1) or P0110 (Symptom Code 2) will be

stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Intake Air Temperature” display on the Tech2

while moving connectors and wiring harness related

to the sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

23 P0110 1 ON Intake Air Temperature (IAT)

Sensor Circuit High Input IAT sensor output voltage is

more than 4.7V. ECM use 0°C conditions as

substitute.

2 ON Intake Air Temperature (IAT)

Sensor Circuit Low Input IAT sensor output voltage is

below 0.3V.

Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23)

Intake Air Temperature (IAT) Sensor Circuit High Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0110 (Symptom Code 1) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0110 (Sym ptom Cod e 1) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the IAT sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ually check the IAT sensor.

Was the problem found? — Go to Step 12 Go to Step 6

84 13

C-51

C-57(B)

6 Using the DVM and check the IAT sensor.

1. Ignition “Off”, engine “Off”.

2. Disconnect MAF & IAT sensor connector.

3. Measure the resistance of IAT sensor.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 7 Go to Step 12

7 Using the DVM and check the IAT sensor signal

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 10

Less than 1V:

Go to Step 8

More than

specified value:

Go to Step 9

8 Repair the open circuit between the ECM and IAT

sensor.

Was the problem solved?

— Verify repair Go to Step 14

Step Action Value(s) Yes No

Temperat ure (°C) Resistance (Ω) (Approximately)

-20 14210

0 5402

20 2343

40 1131

60 596

80 338

100 203

1235 4

IAT Sensor

C-51

C-57(B)

9 Repair the short to voltage circuit between the ECM

and IAT sensor.

Was the problem solved?

— Verify repair Go to Step 14

10 Using the DVM and check the IAT sensor ground

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 11

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

C-51

C-57(B)

C-51

11 Using the DVM and check the IAT sensor ground

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the MAF & IAT sensor connector.

4. Check the circuit for open circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 14

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 14

13 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

14 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 15

15 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-51

C-57(B)

Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23)

Intake Air Temperature (IAT) Sensor Circuit Low Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0110 (Symptom Code 2) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0110 (Symptom Code 2) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the IAT sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 R emov e the MAF & IAT sensor asse mbly and visually

check.

Was the problem found? — Go to Step 8 Go to Step 6

84 13

C-51

C-57(B)

6 Using the DVM and check the IAT sensor.

1. Ignition “Off”, engine “Off”.

2. Disconnect MAF & IAT sensor connector.

3. Measure the resistance of IAT sensor.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 7 Go to Step 8

Step Action Value(s) Yes No

Temperat ure (°C) Resistance (Ω) (Approximately)

-20 14210

0 5402

20 2343

40 1131

60 596

80 338

100 203

1235 4

IAT Sensor

7 Using the DVM and check the IAT sensor signal

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the MAF & IAT sensor connector.

4. Check the circuit for short to sensor ground or

ground ci rcui t.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check the circuit for short to sensor ground or

ground ci rcui t.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 10

8 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

84 92

C-57(B)

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

0.5

BLK

0.5

GRN/

BLK

0.5

RED/

GRN

0.5

GRN/

ORG

0.5

BLK/

GRN

2.0

BLK

2.0

BLK

0.5

BLK/

PNK

0.5

GRY

ECT

Sensor

TPS &

Idle SW

0.5

WHT

98 101

0.5

GRN/

RED

CKP

Sensor

ICIC IC

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

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.

If the output voltage excessively high or low, DTC P01 15

(Symptom Code 1) or P0115 (Symptom Code 2) will be

stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Coolant Temperature” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

14 P0115 1 ON Engine Coolant Temperat ure

(ECT) Sensor Circuit High

Input

ECT sensor output voltage is

more than 4.7V. 1. ECM uses fuel temperature

as substitute.

2. ECM uses 60°C condition for

injection timing control.

3. ECM uses -15°C condition

for glow time control.

2 ON Engine Coolant Te mperature

(ECT) Sensor Circuit Low

Input

ECT sensor output voltage is

below 0.3V.

Diagnostic Trouble Code (DTC) P0115 (Symptom Code 1) (Flash Code 14)

Engine Coolant Temperature Sensor Circuit High Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0115 (Symptom Code 1) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0115 (Sym ptom Cod e 1) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the ECT sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ually check the ECT sen so r.

Was the problem found? — Go to Step 12 Go to Step 6

93 21

E-41C-57(B)

6 Using the DVM and check the ECT sensor.

1. Ignition “Off”, engine “Off”.

2. Disconnect ECT sensor connector.

3. Measure the resistance of ECT sensor.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 7 Go to Step 12

7 Using the DVM and check the ECT sensor signal

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the ECT sensor connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 10

Less than 1V:

Go to Step 8

More than

specified value:

Go to Step 9

8 Repair the open circuit between the ECM and ECT

sensor.

Was the problem solved?

— Verify repair Go to Step 14

Step Action Value(s) Yes No

Temperat ure (°C) Resistance (Ω) (Approximately)

-30 27500

-20 16100

0 5760

20 2370

40 1080

60 537

80 290

100 161

120 95

ECT Sensor 12

E-41

89 1

E-41C-57(B)

9 Repair the short to voltage circuit between the ECM

and ECT sensor.

Was the problem solved?

— Verify repair Go to Step 14

10 Using the DVM and check the ECT sensor ground

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the ECT sensor connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 11

Repair faulty

harness and

verify repair

11 Using the DVM and check the ECT sensor ground

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the ECT sensor connector.

4. Check the circuit for open circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECT sensor connector ECM

connector.

3. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 14

Step Action Value(s) Yes No

89 1

E-41C-57(B)

E-41

C-57

12 Substitute a known good ECT sensor assembly and

recheck.

Was the problem solved? — Go to Step 13 Go to Step 14

13 Replace the ECT sensor.

Is the action complete? — Verify repair —

14 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 15

15 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0115 (Symptom Code 2) (Flash Code 14)

Engine Coolant Temperature Sensor Circuit Low Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0115 (Symptom Code 2) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0115 (Sym ptom Cod e 2) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the ECT sensor or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ually check the ECT sen so r.

Was the problem found? — Go to Step 8 Go to Step 6

93 21

E-41C-57(B)

6 Using the DVM and check the ECT sensor.

1. Ignition “Off”, engine “Off”.

2. Disconnect ECT sensor connector.

3. Measure the resistance of ECT sensor.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 7 Go to Step 8

Step Action Value(s) Yes No

Temperat ure (°C) Resistance (Ω) (Approximately)

-30 27500

-20 16100

0 5760

20 2370

40 1080

60 537

80 290

100 161

120 95

ECT Sensor 12

7 Using the DVM and check the ECT sensor signal

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the ECT sensor connector.

4. Check the circuit for short to sensor ground or

ground ci rcui t.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECT sensor connector and ECM

connector.

3. Check the circuit for short to sensor ground or

ground ci rcui t.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 10

8 Substitute a known good ECT sensor assembly and

recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the ECT sensor.

Is the action complete? — Verify repair —

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

89 93

C-57(B)

Diagnostic Trouble Code (DTC) P0180 (Symptom Code B)

(Flash Code 15) Fuel Temperature Sensor Circuit Range/performance

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

Circuit Desc rip tio n

The fuel temp erature sensor is assembled in side of the

pump con tro l uni t (PS G). T he signa l of fuel tem per at ure

is sent via the CAN-bus from the PSG to ECM.

If the fuel temperature is excessively high or low

condition, a DTC P0180 will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Fuel Temperature” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

15 P0180 B ON Fuel Temperature Sensor

Circuit Range/Performance FT sensor output is high

temperature (more than

150°C) or low temperature

(below -40°C).

The ECM use 75°C conditions

as sub stitute.

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15)

Fuel Temperature Sensor Circuit Range/Performance

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0180 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0180 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

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

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Desc rip tio n

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, a DTC P0215 (Symptom Code

B) or P0215 (Symptom Code C) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

52 P0215 A ON at

ignitio

cycle

Fuel Cutoff Solenoid Valve

Malfunction 1. Ignition key switch off.

2. Engine speed is below

1500rpm.

3. Vehicle speed is below

1.5km/h.

4. PS G (pump control unit)

recognizes MAB (fuel cutoff

solenoid valve) signal from

the ECM, but the MAB

could not operate.

1. MA B (f uel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

B ON Fuel Cutoff Solenoid Valve

Circuit High Input 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.

Engine does not start.

C ON Fuel Cutoff Solenoid Valve

Always Active 1. Ignition key switch off.

2. Engine speed is below

1500rpm.

3. Vehicle speed is below

1.5km/h.

4. PS G (pump control unit)

does not recognize MAB

(fuel cutoff solenoid valve)

signal from the ECM.

1. MA B (f uel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

D ON Fuel Cutoff Solenoid Valve

Malfunction 1. Ignition key switch off.

2. CAN controller does not

operate Bus-off.

No fail-safe function.

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0215 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0215 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Visually check the PS G (p ump contro l unit) .

Was the problem found? — Go to Step 8 Go to Step 6

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 type B. (ECM

connected) Ref. Page 6E-81

3. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

Breaker box is not available:

1. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 8 Go to Step 7

7 Repair the short to voltage circuit between the ECM

and PSG (pump control unit).

Was the problem solved?

— Verify repair Go to Step 8

8 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

105 5E-6C-57

105

C-57

105 5

E-6C-57

Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52)

Fuel Cutoff Solenoid Valve Always Active

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code C) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0215 (Symptom Code C) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Visually check the PS G (p ump contro l unit) .

Was the problem found? — Go to Step 7 Go to Step 6

105 5E-6C-57

Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52)

Fuel Cutoff Solenoid Valve Malfunction

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 type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harness and

verify repair Go to Step 7

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code D) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

Step Action Value(s) Yes No

105

E-6

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0215 (Symptom Code D) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0216 (Symptom Code A)

(Flash Code 54) Injection Timing Control Circuit

Malfunction (Timer Deviation)

Diagnostic Trouble Code (DTC) P0216 (Symptom Code B)

(Flash Code 54) Injection Timing Control Circuit

Malfunction (Timer Fluctuation)

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Desc rip tio n

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 pe rfor ms as a v ariab le th ro ttle , using the ra pi d

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), a DTC P0216 will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

• Insufficient air bleeding of fuel line.

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.

• 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 “A ct ual In je ction Start” displ ay o n the Tech2 whi le

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

54 P0216 A ON Injection Timing Control

Circuit Malfunction (Timer

Deviation)

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°CA

or -6°CA for 8 seconds.

Fuel injection quantity is

reduced.

B ON Injection Timing Control

Circuit Malfunction (Timer

Fluctuation)

1. Engine speed is more than

2014rpm.

2. Fluctuation of actual

injection timing is more

than ±5.2°CA.

Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)

Injection Timing Control Circuit Malfunction (Timer Deviation)

Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54)

Injection Timing Control Circuit Malfunction (Timer Fluctuation)

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0216 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0216 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0216 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0216 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Perform the air bleeding in the fuel line sufficiently.

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 B) restored in

this ignition cycle? — Go to Step 5 Verify repair

5 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 6

6 Replace the fuel filter.

Was the problem solved? — Verify repair Go to Step 7

7 Remove the eye bolt with gauze filter from the

injection pump and check for the following conditions.

• Objects blocking at the gauze filter. Check for a

condition that causes contaminated fuel, such as

the customer is using an aftermarket fuel filter or

extended mai nte nan ce int erva l.

• 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?

—

Replace the

eye bolt with

gauze filter and

verify repair G o to Step 8

8 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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 (Symp tom Code E)

(Flash Code 53) Injection Pump Malfunction

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Desc rip tio n

The ECM is calculates an injection quantity and an

injecti on ti min g us ing the v ariou s s ens or s. And the PSG

control s the high pr essure sol enoid val ve depending o n

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 relatio n of eng ine spe ed sign al an d dou ble d pum p

camshaft spe ed signal excessiv ely large , a DTC P025 1

(Symptom Code 7) will be stored.

If the CAN high or low circ uit is defected, a DTC P0251

(Symptom Code E) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Injection Quantity” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed

sensor error.

2. High pressure solenoid

valve control pulse width

does not match with

desired fuel injection

quantity.

1. MA B (f uel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

7 ON Injection Pump Malfunction 1. No pump camshaft speed

sensor error.

2. No CKP sensor error.

3. Difference of engine speed

and doubled pump

camshaft speed is more

than 720rpm (4JA1-TC) or

690rpm (4JH1-TC).

9 ON Injection Pump Malfunction No pump map programmed in

the PSG (pump control unit)

or PSG malfunction.

A ON Injection Pump Malfunction EEPROM or A/D converter

malfunction in the PSG (pump

control unit).

Fuel injection quantity is

reduced.

B ON Injection Pump Malfunction PSG (pump control unit)

recognized high pressure

solenoid valve drive circuit

error.

No fail-safe function.

D ON Injection Pump Malfunction PSG (pump control unit) could

not measure the high

pressure solenoid valve drive

voltage.

E ON Injection Pump Malfunction ECM could not accept PSG

(pump control unit) message. 1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 6) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 251 (Sy mpt om Code 6) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 7) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 251 (Sy mpt om Code 7) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Was the DTC P0335 (Symptom Code B), P0335

(Symptom Code D) or P1335 (Symptom Code A)

stored at the same time?

—

Go to DTC

Chart P0335

(Symptom

Code B)

(Symptom

Code D) or

P1335

(Symptom

Code A) Go to Step 5

5 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 6

6 I f a oscillosc ope is availabl e, monitor the CKP sensor

output signal. Does the oscilloscope indicate correct

wave form?

—Go to Step 13

Not available:

Go to Step 7

Fixed at low:

Go to Step 7

Fixed at High:

Go to Step 8

Step Action Value(s) Yes No

C-57(B) E-6

CKP Sensor Output Reference Wave Form

0V→

Measurement Terminal: 91 (+) 1 (-)

Measurement Scale: 5.0V/div 2.0ms/div

Measurement Condition: Engine speed at 2000rpm

7 Using the DVM and check the CKP sensor output

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 8

8 Using the DVM and check the CKP sensor output

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

E-6

91 8

C-57(B) E-6

E-6

Diagnostic Trouble Code (DTC) P0251 (Symptom Code 9) (Flash Code 53) Injection Pump Malfunction

9 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 10

10 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 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 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Go to Step 12 Go to Step 13

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

13 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 9) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 251 (Sy mpt om Code 9) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0251 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0251 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code D) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0251 (Symptom Code D) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code E) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0251 (Symptom Code E) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Was the DTC P1650 (Symptom Code A) or P1651

(Symptom Code B) stored at the same time?

—

Go to DTC

Chart P1650

(Symptom

Code A) Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 7 Go to Step 8

7 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

8 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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 (Symp tom Code E)

(Flash Code 43) Engine Speed Input Circuit Range/performan ce

0.5

BLK

0.5

GRN/

BLK

0.5

RED/

GRN

0.5

GRN/

ORG

0.5

BLK/

GRN

2.0

BLK

2.0

BLK

0.5

BLK/

PNK

0.5

GRY

ECT

Sensor

TPS &

Idle SW

0.5

WHT

98 101

0.5

GRN/

RED

CKP

Sensor

ICIC IC

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

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, a DTC P0335

(Symptom Code D) is stored.

If the CKP sensor signal frequency is excessively high

or engine over-running, a DTC P0335 (Symptom Code

E) is stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Engine Speed” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

43 P0335 B ON Crank shaft Position Sensor

Circuit Malfunction 1. Engine speed is more than

665rpm.

2. CKP sensor pulse width

error.

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. MA B (f uel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

D ON Crankshaft Position Sensor

Circuit Malfunction 1. No pump cam shaft speed

sensor error.

2. “Crank shaft Position

Sensor Circuit Malfunction

(Symptom Code B)” is not

stored.

3. Engine speed is 0rpm.

4. Doubled pump cam shaft

speed is more than 50rpm.

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.

E ON Engine Speed In put Circuit

Range/Performance En gine speed is more than

5700rpm. When intermittent malfunction:

1. MA B (f uel 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 Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43)

Crankshaft Position Sensor Circuit Malfunction

Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43)

Crankshaft Position Sensor Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0335 (Symptom Code B) or P0335

(Symptom Code D) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0335 (Symptom Code B) or P0335

(Symptom Code D) stored in this ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the CKP sensor or

ECM connector. If a poor/faulty connection is found,

repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 5

5 Visually check the CKP sensor. If a faulty installation

is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 6

101

98 2 31 E-9C-57(B)

6 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-81

3. Check the resistance of the CKP sensor.

Was the DVM indicated specified value?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Check the resistance of the CKP sensor.

Was the DVM indicated specified value?

Approximately

0.9kΩ at 20°C Go to Step 10 Go to Step 7

7 Using the DVM and check the CKP sensor circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the CKP sensor connector.

3. Check the resistance of the CKP sensor.

Was the DVM indicated specified value?

Approximately

0.9kΩ at 20°C Go to Step 8 Go to Step 14

Step Action Value(s) Yes No

90 98

C-57(B)

E-9

8 Using the DVM and check the CKP sensor circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the CKP sensor connector.

4. Check the circui t for open, short to se nsor wire or

short to ground circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Disconnect the CKP sensor connector.

4. Check the circui t for open, short to se nsor wire or

short to ground circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

Step Action Value(s) Yes No

90 98101

E-9

101

E-9C-57(B)

9 Using the DVM and check the CKP sensor circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the CKP sensor connector.

3. Check the circuit for short to power supply circuit.

If the DVM indicated out of specified value, repair

faulty harness and verify repair.

Is the action complete?

Less than 1V Verify repair —

10 Using the DVM and check the CKP sensor signal.

1. Ignition “On”, engine “On”.

2. Measure the CKP output voltage at the sensor

and ECM.

Does the tester indicate standard voltage?

If a osci lloscope is ava ilable, moni tor the CKP sensor

signal. Does the oscilloscope indicate correct wave

form?

Go to Step 13 Go to Step 11

11 Remove the CKP sensor from the flywheel housing

and visually check.

Check for the following conditions.

• Objects sticking the CKP sensor.

• Objects sticking the CKP sensor pulser.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 12

12 Check the CKP sensor shield wire for open or short

circuit.

Was the problem found? —

Repair faulty

harnes s and

verify repair Go to Step 13

Step Action Value(s) Yes No

E-9

Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Appr oximately 1.0 V at

2000rpm

At ECM C57 connector 90 & 98

CKP Sensor Reference Wave Form

0V→

Measurement Terminal: 90 (+) 98(-)

Measurement Scale: 20V/div 2.0ms/div

Measurement Condition: Engine speed at 2000rpm

Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43)

Engine Speed Input Circuit Range/Performance

13 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 14

14 Substitute a known good CKP sensor and recheck.

Was the problem solved? — Go to Step 15 Go to Step 16

15 Replace the CKP sensor.

Was the problem solved? — Verify repair Go to Step 16

16 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 17

17 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0335 (Symptom Code E) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0335 (Symptom Code E) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Ask to the customer whether over-speed condition

such a s miss-gear shifting etc. has been experien ced

or not. —

Expla in the

reason of DTC

to the customer Go to Step 5

Step Action Value(s) Yes No

5 Check for poor/faulty connection at the CKP sensor or

ECM connector. If a poor/faulty connection is found,

repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 6

6 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?

If a osci lloscope is ava ilable, moni tor the CKP sensor

signal. Does the oscilloscope indicate correct wave

form?

Go to Step 9 Go to Step 7

7 Remove the CKP sensor from the flywheel housing

and visually check.

Check for the following conditions.

• Objects sticking the CKP sensor.

• Objects sticking the CKP sensor pulser.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 8

8 Check the CKP sensor shield wire for open or short

circuit.

Was the problem found? —

Repair faulty

harnes s and

verify repair G o to Step 9

9 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 10

10 Substitute a known good CKP sensor and recheck.

Was the problem solved? — Go to Step 11 Go to Step 12

Step Action Value(s) Yes No

101

98 2 31 E-9C-57(B)

Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Appr oximately 1.0 V at

2000rpm

At ECM C57 connector 90 & 98

CKP Sensor Reference Wave Form

0V→

Measurement Terminal: 90 (+) 98(-)

Measurement Scale: 20V/div 2.0ms/div

Measurement Condition: Engine speed at 2000rpm

11 Replace the CKP sensor.

Was the problem solved? — Verify repair Go to Step 12

12 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 13

13 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4)

(Flash Code 66) Glow Relay Circuit Voltage Low

Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8)

(Flash Code 66) Glow Relay Circuit Voltage High

Resister

A/C

Compressor

ECM

Main Relay Battery

Voltage

Glow

80A

Glow

Relay

Glow

Plug

0.5

BLU/

RED

0.5

BLK/

BLU

0.5

BRN/

RED

0.5

BLK

0.5

GRN

5.0

RED/

WHT

0.5

BLU/

RED

0.5

GRY

0.5

GRN 0.5

GRN

0.5

BRN

0.5

GRY/

YEL

A/C

10A

Heater

Relay

Blower

20A

A/C

Compressor

Relay

A/C

Thermo

Relay

Pressure

5.0

BLK/

RED

Electronic

Thermostat

µP

Batt

µP

Batt

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

The voltage on the coil of the relay glow plug is supplied

by the relay engine control module (ECM) main. The

ECM switc hes glow r elay to operate gl ow plug d epends

on the coolant temperature.

In the after glow phase the lamp is not illuminated but

the glow plugs remain active for a certain period

depending on engine coolant temperature.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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 P0380 display on the Tech2 while moving

connectors and wiring harnesses. A change in the

display will indicate the location of the fault.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

66 P0380 4 ON Glow Relay Circuit Voltage

Low Glow relay circuit open or

short to ground circuit. No fail-safe function.

8 ON Glow Relay Circuit Voltage

High Glow relay circuit short to

voltage circuit.

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0380 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 380 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check for poor/faulty connection at the glow relay or

ECM connector. If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the glow relay.

1. Ignition “Off”, engine “Off”.

2. Remove the glow relay from the relay box.

3. Check the relay coil.

Was the DVM indicated specified value?

Continuity Go to Step 6

Replace glow

relay and verify

repair

C-49

4JA1-TC X-12

4JH1-TC

C-57

Glow Relay 23

6 Using the DVM and check the glow relay power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the glow relay from the relay box.

3. Check the circuit for open or short to ground

circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 Repair the open or short to ground circuit between the

ECM main relay and glow relay.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

C-49

4JA1-TC X-12

4JH1-TC

C-49X-4 4JA1-TC X-12

4JH1-TC

8 Using the DVM and check the glow relay ground

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

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 is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the glow relay from the relay box.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

9 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

94 3

C-49

4JA1-TC X-12

4JH1-TC

C-57 C-49

4JA1-TC X-12

4JH1-TC

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

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0380 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 380 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 —

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P0381 (Sub Code 4) (Flash Code 67)

Glow Plug Ind icator Circu it Voltage Low

Diagnostic Trouble Code (DTC) P0381 (Sub Code 8) (Flash Code 67)

Glow Plug Indicator Circuit Voltage High

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

The functio n of the gl ow time ind icato r lamp is to inform

the driver whether the glow system is activated.

When the lamp turned off, the engine can be started.

This does not imply that the glow plugs are no longer

activated.

In the after-glow phase the lamp is not illuminated but

the glow plugs remain active for a certain period

depending on engine coolant temperature.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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 P0381 display on the Tech2 while moving

connectors and wiring harnesses. A change in the

display will indicate the location of the fault.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

67 P0381 4 ON Glow Plug Indicator Circuit

Voltage Low Glow plug indicator circuit

open or short to ground

circuit.

No fail-safe function.

8 ON Glow Plug Indicator Circuit

Voltage High Glow plug indicator circuit

short to voltage circuit.

Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67)

Glow Plug Indicator Circuit Voltage Low

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0381 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 381 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 1. Ignition “On”, engine “Off”.

2. Check the glow plug indicator lamp.

Does the lamp turn “On”? — Go to Step 5 Go to Step 6

5 1. Ignition “On”, engine “Off”.

2. Check the glow plug indicator lamp.

Does the lamp turn “Off”? — Go to Step 9 Go to Step 7

6 Check the glow plug indicator lamp bulb.

If the bulb is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 7

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?

— Verify repair Go to Step 8

B-24

C-56

8 Using the DVM and check the glow time telltale circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Remove the meter connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the meter connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 9

9 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

B-24

8B-24

C-56

Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67)

Glow Plug Indicator Circuit Voltage High

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0381 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 381 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 —

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

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

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall ele ment. It in teracts with the

magnetic field treated by the r otating magnet. It out puts

pulse signal. The 12 volts operating supply from the

meter fuse.

The engine control module (ECM) calculates the vehicle

speed by VSS.

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 con nection at ECM-I nspect harnes s 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.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

24 P0500 1 ON

ignitio

cycle

Vehicle Speed Sensor Circuit

High Input Vehicle speed is more than

200km/h. EC M uses vehicle speed 5km /

h condition as substitute.

AON

ignitio

cycle

Vehicle Speed Sensor Input

Signal Frequency Too High Input signal frequency is too

high. ECM uses vehicle speed 5km/

h condition as substitute.

BON

ignitio

cycle

Vehicle Speed Sensor

Incorrect Signal 1. Engine speed is more than

3600rpm.

2. Fuel injection quantity is

more than 41mg/stk.

3. Vehicle speed is below

1.5km/h.

Fuel injection quantity is

reduced.

Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24)

Vehicle Speed Sensor Circuit High Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code 1) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 500 (Sy mpt om Code 1) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Perform test drive and check the speed meter.

Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6

5 Perform test drive and use the Tech 2.

Monitor the “Vehicle Speed” in the data display.

Does the Tech 2 indicate correct vehicle speed as

same as the speed meter indication in the instrument

panel? — Go to Step 14 Go to Step 7

6 Remove the VSS from the housing case and visually

check.

Was the problem found? — Go to Step 8 Go to Step 7

7 Using the DVM and check the VSS signal.

1. Ignition “On”, vehicle “Run (lift up)”.

2. Measur e the VSS outpu t voltage at sensor, meter

and ECM.

Does the tester indicate specified value?

If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope

indicate correct wave form?

Refer to

Diagnostic

Aids and Go to

Step 14 Refer the table

8 Replace the VSS.

Is the action complete? — Verify repair

9 Using the DVM and check the VSS signal circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the meter connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 10

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Ap proximate ly 6.5

V at 20km/h Go to

Step 8

Meter B23 connector 9 &

GND Go to

Step 9

Meter B23 connector 8 &

GND Go to

Step 11

ECM C56 connector 68 &

GND Go to

Step 12

Vehicle Speed Sensor Reference Wave Form

0V→

Measurement Scale: 10V/div 50ms/div

Measurement Condition: Vehicle Speed 20km/h

Measurement Terminal: At Engine Control Module

B-23

10 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 o r short to gr ound circui t is found, repair the

faulty harness and verify repair.

Is the action complete?

— Verify repair —

11 Replace the speed meter.

Is the action complete? — Verify repair —

12 Using the DVM and check the VSS signal circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 13

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

E-44

B-23

13 Using the DVM and check the VSS signal circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the meter connector.

4. Check the circuit for open or shot to ground circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 14

14 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 15

15 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

B-23

C-56

Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24)

Vehicle Speed Sensor Input Signal Frequency Too High

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0500 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Perform test drive and check the speed meter.

Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6

5 Perform test drive and use the Tech 2.

Monitor the “Vehicle Speed” in the data display.

Does the Tech 2 indicate correct vehicle speed as

same as the speed meter indication in the instrument

panel? — Go to Step 9 Go to Step 7

6 Remove the VSS from the housing case and visually

check.

Was the problem found? — Go to Step 8 Go to Step 7

7 Using the DVM and check the VSS signal.

1. Ignition “On”, vehicle “Run (lift up)”.

2. Measur e the VSS outpu t voltage at sensor, meter

and ECM.

Does the tester indicate specified value?

If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope

indicate correct wave form?

Refer to

Diagnostic

Aids and Go to

Step 9 Refer the table

8 Replace the VSS.

Is the action complete? — Verify repair

9 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 11

10 Replace the speed meter.

Is the action complete? — Verify repair —

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

Step Action Value(s) Yes No

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Ap proximate ly 6.5

V at 20km/h Go to

Step 8

Meter B23 connector 9 &

GND Go to

Step 9

Meter B23 connector 8 &

GND Go to

Step 10

ECM C56 connector 68 &

GND Go to

Step 9

Vehicle Speed Sensor Reference Wave Form

0V→

Measurement Scale: 10V/div 50ms/div

Measurement Condition: Vehicle Speed 20km/h

Measurement Terminal: At Engine Control Module

Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24)

Vehicle Speed Sensor Incorrect Signal

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0500 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Perform test drive and check the speed meter.

Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6

5 Perform test drive and use the Tech 2.

Monitor the “Vehicle Speed” in the data display.

Does the Tech 2 indicate correct vehicle speed as

same as the speed meter indication in the instrument

panel? — Go to Step 16 Go to Step 7

Step Action Value(s) Yes No

6 Check for poor/faulty connection at the VSS and

meter c on nector s . If a po or/fau lty c onn ec tio n i s found ,

repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 8

7 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?

— Verify repair Go to Step 9

8 Remove the VSS from the housing case and visually

check.

Was the problem found? — Go to Step 10 Go to Step 9

Step Action Value(s) Yes No

B-23

E-44

C-56

9 Using the DVM and check the VSS signal.

1. Ignition “On”, vehicle “Run (lift up)”.

2. Measur e the VSS outpu t voltage at sensor, meter

and ECM.

Does the tester indicate specified value?

If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope

indicate correct wave form?

Refer to

Diagnostic

Aids and Go to

Step 16 Refer the table

10 Replace the VSS.

Is the action complete? — Verify repair

11 Using the DVM and check the VSS signal circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the meter connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 12

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Ap proximate ly 6.5

V at 20km/h Go to

Step 10

Meter B23 connector 9 &

GND Go to

Step 11

Meter B23 connector 8 &

GND Go to

Step 13

ECM C56 connector 68 &

GND Go to

Step 14

Vehicle Speed Sensor Reference Wave Form

0V→

Measurement Scale: 10V/div 50ms/div

Measurement Condition: Vehicle Speed 20km/h

Measurement Terminal: At Engine Control Module

B-23

12 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 o r short to gr ound circui t is found, repair the

faulty harness and verify repair.

Is the action complete?

— Verify repair —

13 Replace the speed meter.

Is the action complete? — Verify repair —

14 Using the DVM and check the VSS signal circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 15

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

E-44

B-23

15 Using the DVM and check the VSS signal circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the meter connector.

4. Check the circuit for open or shot to ground circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and ECM

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 16

16 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 17

17 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

B-23

C-56

Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35)

System Voltage Too High

Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35)

System Voltage Too Low

Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35)

System Voltage Malfunction (PSG)

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

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

Circuit Desc rip tio n

The ECM and PSG m onitors th e system vol tage on the

ignition feed terminal to the ECM or PSG. If the system

voltage to the ECM excessively high or low, a DTC

P0560 (Sympt om Code 1) or P0560 (Sympto m Code 2)

will be stored. If the system voltage to the PSG

excess ively hig h or low, a DTC P0560 (Sym ptom Code

A) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “System Voltage” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

35 P0560 1 OFF S yst em Voltage Too High System voltage is more than

20V. ECM uses 9V conditions as

substitute.

2 OFF System Voltage Too Low System voltage is below 7V.

A O FF System Voltage Malfunction

(PSG) System voltage of PSG

(pump control unit) is below

4.5V or more than 27V.

PSG uses default voltage as

substitute.

Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35) System Voltage Too High

Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35) System Voltage Too Low

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0560 (Symptom Code 1) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0560 (Symptom Code 1) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Was the battery jump start cable incorrectly

connecting? —Verify

procedure Go to Step 5

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

2. Monitor the “System Voltage” in the data display.

3. Load the electrical system by turning on the

headlights, etc..

Does the Tech 2 indicate correct ignition voltage? 10 - 14V Go to Step 6

Check the

charging

system

6 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 7

7 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0560 (Symptom Code 2) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 560 (Sy mpt om Code 2) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

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

2. Monitor the “System Voltage” in the data display.

3. Load the electrical system by turning on the

headlights, etc..

Does the Tech 2 indicate enough ignition voltage? 10 - 14V Go to Step 6 Go to Step 5

5 Using the DVM and check the battery voltage at the

battery terminal.

Does the tester indicate enough battery voltage?

10 - 14V Go to Step 6

Check the

charging

system , charge

or replace the

battery

6 Check for poor/faulty connection at the ECM

connector. If a poor/faulty connection is found, repair

as necessary.

Was the problem found?

— Verify repair Go to Step 7

7 Using the DVM and check the ECM main relay.

1. Ignition “Off”, engine “Off”.

2. Remove the ECM main relay from the relay box.

3. Check the relay coil.

Was the DVM indicated specified value?

Continuity Go to Step 8

Replace ECM

main relay and

verify repair

Step Action Value(s) Yes No

C-56

ECM Main Relay

Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35) System Voltage Malfunction (PSG)

8 Check for poor/faulty connection of the ECM ground

at the fender panel. If a poor/faulty connection is

found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 9

9 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0560 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0560 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

Step Action Value(s) Yes No

C-36

4 Check for poor/faulty connection at the PSG (pump

control unit) connector. If a poor/faulty connection is

found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

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?

10 - 14V Go to Step 7 Go to Step 6

6 Check for poor/faulty connection of the PSG (pump

control unit) ground at the cylinder body. If a poor/

faulty co nnec ti on is found, repair as nece ssa ry.

Was the problem found?

— Verify repair Go to Step 7

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

E-6

E-10

Diagnostic Trouble Code (DTC) P0561 (Symptom Code A)

(Flash Code 18) System Voltage Circuit Malfunction

Diagnostic Trouble Code (DTC) P0561 (Symptom Code B)

(Flash Code 18) System Voltage Circuit Malfunction

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

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

Circuit Desc rip tio n

The ECM monitors the ignition switch signal on the feed

terminal to the ECM. If the ignition switch signal with

malfunction, a DTC P0561 (Symptom Code A) or a DTC

P0561 (Symptom Code B) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Ignition Status” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

18 P0561 A OFF S yst em Voltage Circuit

Malfunction The ECM recognized ignition

switch turn off signal during

ECM is activated.

ECM stops engine.

B ON Syst em Voltage Circuit

Malfunction Ignition switch circuit is

malfunction.

Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18) System Voltage Circuit Malfunction

Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18) System Voltage Circuit Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0561 (Symptom Code A) or P0561

(Symptom Code B) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0561 (Symptom Code A) or P0561

(Symptom Code B)stored in this ignition cycle? — Go to Step 4

Refer to

Diagnostic

Aids and Go to

Step 4

4 Check the “Engine-2” fuse (10A).

If the fuse is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 5

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 as type A. (ECM

disconnected)

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 6

6 Check the ignition switch.

If a poor/faulty connection is found, repair as

necessary.

Was the problem found? — Verify repair Go to Step 7

7 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 8

Step Action Value(s) Yes No

C-41

C-56

C-41

8 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

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

Circuit Description & Diagnostic Aids

The replacement ECM must be programmed by the

Service Programming System (SPS). When the service

ECM is used without SPS, a DTC P0602 will be set.

Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

- P0602 - - Programming Error ECM memory area error. Engine control disabled.

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On

Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0602 stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic

Aids

3 Download the latest software to the ECM using the

“SPS (Service Programming System)”.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure.

Is the action complete? — Verify repair —

Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28)

ECU Malfunction

Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28)

ECU Malfunction

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

Circuit Description & Diagnostic Aids

An internal ECM failure (IC, circuit, memory, etc,) will

result in a DTC P0606 (Symptom Code A) or P0606

(Symptom Code B) being stored.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

28 P0606 A ON E CM Malfunction (1) Gate Array com municat ion

error. 1. MA B (fuel cutoff solenoid

valve cutoff) is operated.

2. Desired injection quantity

becomes 0mg/strk.

B ON ECM Malfunction (2) 1. Throttle position is below

1%.

2. Desired injection quantity is

more than 0mg/strk.

3. Engine speed is more than

2000rpm.

MAB (fuel cutoff solenoid valve

cutoff) is operated.

Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0606 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0606 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0606 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0606 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

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

Resister

A/C

Compressor

ECM

Main Relay Battery

Voltage

Glow

80A

Glow

Relay

Glow

Plug

0.5

BLU/

RED

0.5

BLK/

BLU

0.5

BRN/

RED

0.5

BLK

0.5

GRN

5.0

RED/

WHT

0.5

BLU/

RED

0.5

GRY

0.5

GRN 0.5

GRN

0.5

BRN

0.5

GRY/

YEL

A/C

10A

Heater

Relay

Blower

20A

A/C

Compressor

Relay

A/C

Thermo

Relay

Pressure

5.0

BLK/

RED

Electronic

Thermostat

µP

Batt

µP

Batt

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

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 according

to the A/C request signal and certain setting conditions.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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 P0645 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

46 P0645 4 ON A/C Compressor Relay Circuit

Voltage Low A/C compressor relay circuit

open or short to ground

circuit.

No fail-safe function.

8 ON A/C Compressor Relay Circuit

Voltage High A/C compressor relay circuit

short to voltage circuit.

Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46)

A/C Compressor Relay Circuit Voltage Low

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0645 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 645 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the A/C

compressor relay or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the A/C compressor relay.

1. Ignition “Off”, engine “Off”.

2. Remove the A/C compressor relay from the relay

box.

3. Check the relay coil.

Was the DVM indicated specified value?

Continuity Go to Step 6

Replace A/C

compressor

relay and verify

repair

C-56

X-5

4JA1-TC X-10

4JH1-TC

A/C Compressor Relay

6 Using the DVM and check the A/C compressor relay

power supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the A/C compressor relay from the relay

box.

3. Check the circuit for open or short to ground

circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 Repair the open or short to ground circuit between the

ECM main relay and A/C compressor relay.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

X-5

4JA1-TC X-10

4JH1-TC

X-5

4JA1-TC X-10

4JH1-TC

X-4

8 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 as type A. (ECM

disconnected)

3. Remove the A/C compressor relay from the relay

box.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the A/C compressor relay from the relay

box.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

9 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

Step Action Value(s) Yes No

41 3

X-5

4JA1-TC X-10

4JH1-TC

C-56

X-5

4JA1-TC X-10

4JH1-TC

Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46)

A/C Compressor Relay Circuit Voltage High

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0645 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P0 645 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 —

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0703 (Symptom Code A)

(Flash Code 25) Brake Switch Malfunction

Diagnostic Trouble Code (DTC) P0703 (Symptom Code B)

(Flash Code 25) Brake Switch Malfunction

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

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

Circuit Desc rip tio n

The ECM monitors the brake switch signal on the feed

terminal to the ECM. If the brake switch 1 or 2 circuit

malfunctions, a DTC P0703 (Symptom Code A) or

P0703 (Symptom Code B) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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 “Br ake Sw itch 1 ” and “B rake Switch 2” disp lay on

the Tech2 while moving connectors and wiring

harness related to the sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

25 P0703 A ON Brake Switch Malfunction 1. Throttle position is more

than 0%.

2. Engine speed is more than

665rpm

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.

No fail-safe function.

B ON Brake Switch Malfunction 1. Throttle position is more

than 0%.

2. Engine speed is more than

665rpm

3. Vehicle speed is more than

0km/h.

4. Brake switch 1 signal and

brake switch 2 signal are

differently inputted to the

ECM.

Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25) Brake Switch Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0703 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0703 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check the “Stop Light fuse (10A)”.

If the fuse is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 5

5 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?

— Verify repair Go to Step 6

6 Using the DVM and check the brake switch 1.

1. Ignition “Off”, engine “Off”.

2. Remove the brake switch connector at the brake

pedal.

3. Check the brake switch 1.

Was the DVM indicated specified value?

Pedal is not

stepped on:

Continuity

Pedal stepped

on: No

continuity Go to Step 7

Replace pedal

switch and

verify repair

C-56 C-44

Brake Switch 1

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 switc h.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 9 Go to Step 8

8 Repair the open circuit between the “Stop Light fuse

(10A)” and brake switch 1.

Is the action complete? — Verify repair —

9 Using the DVM and check the brake switch 1 circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type B. (ECM

connected) Ref. Page 6E-81

3. Ignition “On”, engine “Off”.

4. Check the circuit for open or short to voltage

circuit.

Was the DVM indicated specified value?

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?

Pedal is not

stepped on:

Less than 1V

Pedal stepped

on: Battery

voltage Go to Step 12

Fixed at battery

voltage: Go to

Step 10

Fixed at less

than 1V: Go to

Step 11

Step Action Value(s) Yes No

C-44

10 Repair the short to voltage circuit between the brake

switch 1 connector and ECM.

Is the action complete?

— Verify repair —

11 Repair the open circuit between the brake switch 1

connector and ECM.

Is the action complete?

— Verify repair —

12 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 13

13 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

30 4

C-56 C-44

30 4

C-56 C-44

Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25) Brake Switch Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0703 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0703 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the brake switch

or ECM connector . If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the brake switch 2.

1. Ignition “Off”, engine “Off”.

2. Remove the brake switch connector at the brake

pedal.

3. Check the brake switch 2.

Was the DVM indicated specified value?

Pedal is not

stepped on:

No continuity

Pedal stepped

on: Continuity Go to Step 6

Replace pedal

switch and

verify repair

C-56 C-44

Brake Switch

6 Using the DVM and check the brake switch 2 power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the brake switch connector from the

brake switc h.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 Repair the open circuit between the “ECM Main

Relay” and brake switch 2.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

C-44

C-44X-4

8 Using the DVM and check the brake switch 2 circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type B. (ECM

connected)

3. Ignition “On”, engine “Off”.

4. Check the circuit for open or short to voltage

circuit.

Was the DVM indicated specified value?

Breaker box is not available:

1. Ignition “On”, engine “Off”.

2. Back probe the DVM to the brake switch 2 and

check the circuit for open or short to voltage

circuit.

Was the problem found?

Pedal is not

stepped on:

Battery

voltage

Pedal stepped

on: Less than

1V Go to Step 11

Fixed at battery

voltage: Go to

Step 9

Fixed at less

than 1V: Go to

Step 10

9 Repair the short to voltage circuit between the brake

switch 2 connector and ECM.

Is the action complete?

— Verify repair —

10 Repair the open circuit between the brake switch 2

connector and ECM.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

C-44

65 3

C-56 C-44

65 3

C-56 C-44

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6)

(Flash Code 57) Clutch Switch Circuit Malf unc tion

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

Circuit Desc rip tio n

The ECM monitors the clutch switch signal on the feed

terminal to the ECM. If the clutch switch circuit with

malfunctions, a DTC P0704 (Symptom Code 6) will be

stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Clutch Switch” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

57 P0704 6 ON Clutch Switch Circuit

Malfunction Clutch signal does not change

between vehicle speed

1.5km/h and 80km/h since

ignition switch was tuned on.

No fail-safe function.

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57) Clutch Switch Circuit Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0704 (Symptom Code 6) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P0704 (Symptom Code 6) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the clutch switch

or ECM connector . If a poor/faulty connection is found,

repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the clutch switch.

1. Ignition “Off”, engine “Off”.

2. Remove the clutch switch connector at the clutch

pedal.

3. Check the clutch switch.

Was the DVM indicated specified value?

Pedal is not

stepped on:

Continuity

Pedal stepped

on: No

continuity Go to Step 6

Replace pedal

switch and

verify repair

C-56 C-53

Clutch Switch

6 Using the DVM and check the clutch switch power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the clutch switch connector from the

clutch switch.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 Repair the open circuit between the “ECM Main

Relay” and clutch switch.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

C-53

X-4 C-53

8 Using the DVM and check the clutch switch circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type B. (ECM

connected) Ref. Page 6E-81

3. Ignition “On”, engine “Off”.

4. Check the circuit for open or short to voltage

circuit.

Was the DVM indicated specified value?

Breaker box is not available:

1. Ignition “On”, engine “Off”.

2. Back probe the DVM to the clutch switch and

check the circuit for open or short to voltage

circuit.

Was the problem found?

Pedal is not

stepped on:

Battery

voltage

Pedal stepped

on: Less than

1V Go to Step 11

Fixed at battery

voltage: Go to

Step 9

Fixed at less

than 1V: Go to

Step 10

9 Repair the short to voltage circuit between the clutch

switch connector and ECM.

Is the action complete?

— Verify repair —

10 Repair the open circuit between the clutch switch

connector and ECM.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

C-53

31 2

C-56 C-53

31 2

C-56 C-53

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

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

Circuit Description

The ECM monitors the barometric pressure signal

internally. If the sensor malfunctions , a DTC P1105

(Symptom Code 1) or P1105 (Symptom Code 2) will be

stored.

Diagnostic Aids

If the DTC P1105 is stored, sensor or circuit of ECM

inside is failed.

Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86)

Barometric Pressure Sensor Circuit High Input

Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86)

Barometric Pressure Sensor Circuit Low Input

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

86 P1105 1 ON Barometric Pressure Sensor

Circuit High InputBarometric pressure sensor

output voltage is more than

4.4V.

ECM uses 1013hpa condition

as substitute.

2 ON Barometric Pressure Sensor

Circuit Low Input Barometric pressure sensor

output voltage is below 1.5V.

Step Action Value(s) Yes No

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

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in “F0:

Diagnostic Trouble Codes”.

Is the DTC P1105 (Symptom Code 1) or P1105 (Symptom

Code 2) stored as “Present Failure”? — Go to

Step 3

Refer to

Diagnostic Aids

and Go to

Step 3

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

2. Select “F1: Clear DTC Information” in “F0: Diagnostic

Trouble Codes” with the Tech 2 and clear the DTC

information.

3. Operate the vehicle and monitor the “F0: Read DTC

Infor As Stored By ECU” in the “F0: Diagnostic Trouble

Codes”.

Was the DTC P1105 (Symptom Code 1) or P1105

(Symptom Code 2) stored in this ignition cycle? — Go to

Step 4

Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software release?

If not, download the latest software to the ECM using the

“SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to

Step 5

5 Replace the ECM.

Is the action com ple te?

IMPORTANT: The replacement ECM must be programmed.

Refer to section of the Service Programming System (SPS)

in this manual .

Following ECM programming, the immobiliser system (if

equipped) must be linked to the ECM. Refer to section 11

“Immobiliser System-ECM replacement” for the ECM/

Immobiliser linking procedure. — Verif y repai r —

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 Err or

Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21)

Peda l/throttle Position Sensor Idle Position Switch Error

0.5

BLK

0.5

GRN/

BLK

0.5

RED/

GRN

0.5

GRN/

ORG

0.5

BLK/

GRN

2.0

BLK

2.0

BLK

0.5

BLK/

PNK

0.5

GRY

ECT

Sensor

TPS &

Idle SW

0.5

WHT

98 101

0.5

GRN/

RED

CKP

Sensor

ICIC IC

Engine

Control

Module

(ECM)

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

Circuit Desc rip tio n

The TPS is a potentiometer connected to the

acceler ator pedal . It is ins talled to the acce lerat or pe dal

bracket inside the cab. It consists of the vatiable

potntiometer and an idle position switch.

The engine control module (ECM) monitors the voltage

on the signal line and calculates throttle position. As the

accelerator pedal moved toward the floor. the output

increases so that the output voltage should be high

when the pedal is at full travel.

The ECM monitors the TPS supply voltage and TPS

output vo ltage. The supply vo ltage is out of range, DTC

P1120 (Sym ptom Cod e 7) or P 0100 (Sy mptom Code 9)

will be stored. The output voltage excessively high, DTC

P1120 (Symptom Code 1) will be stored.

If the brake pedal is depressed during accelerator pedal

is depressing, DTC P1120 (Symptom Code D) will be

stored.

If the relation of idle switch and TPS position are

incorrect, DTC P1120 (Symptom Code E) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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 “Thrott le Po si ti on”, “I dle Switch”, “ Brak e Swi tc h 1”

and “Brake Switch 2” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

21 P1120 1 ON Pedal/Throttle Position

Sensor Circuit High Input Throttle position sensor

output voltage is more than

4.5V.

ECM increases idle speed up

to 1400rpm.

7 ON Pedal/Throttle Position

Sensor V oltage Supply Circuit

High Input

Throttle position sensor

power supply voltage is more

than 5.2V.

9 ON Pedal/Throttle Position

Sensor V oltage Supply Circuit

Low Input

Throttle position sensor

power supply voltage is below

4.6V.

D ON Pedal/Throttle Position

Sensor Brake Switch Error 1. Engine speed is more than

1700rpm.

2. Throttle position sensor is

more than 8.7%.

3. When brake pedal is

depressed during

accelerator pedal is

depressing.

E ON Pedal/Throttle Position

Sensor Idle Position Switch

Error

1. When idle switch is turned

off, throttle position sensor

was below 0.35%.

2. When idle switch is tuned

on, throttle position sensor

was more than 7.8%.

Diagnostic Trouble Code (DTC) P1120 (Symptom Code 1) (Flash Code 21)

Pedal/Throttle Position Sensor Circuit High Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1120 (Symptom Code 1) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1120 (Sym ptom Cod e 1) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the TPS or ECM

connector. If a poor/faulty connection is found, repair

as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the TPS .

Was the problem found? — Go to Step 12 Go to Step 6

49 39

2 31

C-56

4JA1-TC C-93

4JH1-TC

E-7

6 Using the DVM and check the TPS.

1. Ignition “Off”, engine “Off”.

2. Disconnect TPS connector.

3. Measure the resistance of TPS.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 7 Go to Step 12

7 Using the DVM and check the TPS power supply

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector.

3. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 9 Go to Step 8

8 Repair the short to voltage circuit between the ECM

and TPS.

Was the problem solved?

— Verify repair Go to Step 14

Step Action Value(s) Yes No

Measurement

Terminal Resistance (Ω)

1 - 2 Approximately 0.5kΩ at idle position

Approximately 4.0kΩ at WOT

2 - 3 Approximately 4.3kΩ at idle position

Approximately 0.8kΩ at WOT

1 - 3 Approximately 4.6kΩ at idle position &

WOT

TPS

123

4JA1-TC C-93

4JH1-TC

E-7

C-56

4JA1-TC C-93

4JH1-TC

E-7

9 Using the DVM and check the TPS signal circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 10

Repair faulty

harness and

verify repair

10 Using the DVM and check the TPS ground circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector .

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 11

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

4JA1-TC C-93

4JH1-TC

E-7

4JA1-TC C-93

4JH1-TC

E-7

11 Using the DVM and check the TPS ground circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the TPS connector.

4. Check the circuit for open circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the TPS connector and ECM

connector.

3. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 14

12 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 13 Go to Step 14

13 Replace the TPS.

Is the action complete? — Verify repair —

14 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 14

Step Action Value(s) Yes No

4JA1-TC C-93

4JH1-TC

E-7

C-56

4JA1-TC C-93

4JH1-TC

E-7

Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21)

Pedal/Throttle Position Sensor Voltage Supply Circuit High Input

15 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1120 (Symptom Code 7) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1120 (Sym ptom Cod e 7) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the TPS or ECM

connector. If a poor/faulty connection is found, repair

as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the TPS .

Was the problem found? — Go to Step 8 Go to Step 6

Step Action Value(s) Yes No

49 39

2 31

C-56

4JA1-TC C-93

4JH1-TC

E-7

6 Using the DVM and check the TPS power supply

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector.

3. Check the circuit for short to ground circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 12 Go to Step 7

7 R epair the short to batter y voltage circuit bet ween the

ECM and TPS.

Was the problem solved?

— Verify repair Go to Step 8

8 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the TPS.

Is the action complete? — Verify repair —

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

4JA1-TC C-93

4JH1-TC

E-7

C-56

4JA1-TC C-93

4JH1-TC

E-7

Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21)

Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1120 (Symptom Code 9) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1120 (Sym ptom Cod e 9) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the TPS or ECM

connector. If a poor/faulty connection is found, repair

as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Vis ual ly chec k the TPS .

Was the problem found? — Go to Step 10 Go to Step 6

49 39

2 31

C-56

4JA1-TC C-93

4JH1-TC

E-7

6 Using the DVM and check the TPS power supply

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the TPS connector.

3. Check the circuit for short to battery voltage

circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 10 Go to Step 7

7 Using the DVM and check the TPS power supply

circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the TPS connector and ECM

connector.

3. Check the circuit for short to TPS ground circuit.

Was the DVM indicated specified value?

No continuity Go to Step 9 Go to Step 8

8 R e pair the circui t for shor t to TPS groun d circuit .

Is the action complete? — Verify repair —

9 Repair the short to ground circuit between the ECM

and TPS.

Was the problem solved?

— Verify repair Go to Step 12

10 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 11 Go to Step 12

Step Action Value(s) Yes No

4JA1-TC C-93

4JH1-TC

E-7

4JA1-TC C-93

4JH1-TC

E-7

C-56

4JA1-TC C-93

4JH1-TC

E-7

Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21)

Pedal/Throttle Position Sensor Brake Switch Error

11 Replace the TPS.

Is the action complete? — Verify repair —

12 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 13

13 Replace the ECM. Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1120 (Symptom Code D) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1120 (Symptom Code D) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Vis ual ly chec k the TPS .

Check for the following conditions.

• Accelerator pedal sticking.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 5

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

2. Monitor the “Throttle Position” in the data display.

Does the Tech 2 indicate correct “Throttle Position”

from 0% to 100% depending on accelerator pedal

operation? — Go to Step 7 Go to Step 6

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

2. Monitor the “Throttle Position” in the data display.

3. Adjust the TPS within 0% to 100%.

Was the problem solved? — Verify repair Go to Step 11

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21)

Pedal/Throttle Position Sensor Idle Position Switch Error

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

2. Monitor the “Brake Switch 1” and “Brake Switch 2”

in the data display.

Does the Tech 2 indicate “Inactive” when the brake

pedal was not stepped on? — Go to Step 13 Go to Step 8

8 Adjust the brake switch.

Was the problem solved? — Verify repair Go to Step 9

9 Substitute a known good brake switch and recheck.

Was the problem solved? — Go to Step 10 Go to Step 13

10 Replace the brake switch.

Is the action complete? — Verify repair —

11 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 12 Go to Step 13

12 Replace the TPS.

Is the action complete? — Verify repair —

13 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 14

14 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1120 (Symptom Code E) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1120 (S ym ptom Cod e E) s tored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

Step Action Value(s) Yes No

4 Vis ual ly chec k the TPS .

Was the problem found? — Go to Step 8 Go to Step 5

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

2. Monitor the “Throttle Position” in the data display.

Does the Tech 2 indicate correct “Throttle Position”

from 0% to 100% depending on accelerator pedal

operation? — Go to Step 7 Go to Step 6Go

to Step 6

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

2. Monitor the “Throttle Position” in the data display.

3. Adjust the TPS within 0% to 100%.

Was the problem solved? — Verify repair Go to Step 8

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

2. Monitor the “Idle Switch” in the data display.

Does the Tech 2 indicate “Inactive” when the

accelerator pedal was stepped on? — Go to Step 10 Go to Step 8

8 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the TPS.

Is the action complete? — Verify repair —

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

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 Temperature

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

Circuit Desc rip tio n

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 temp erature sensor is assembled in side of the

pump con tro l uni t (PS G). T he signa l of fuel tem per at ure

is sent via the CAN-bus from the PSG to ECM.

If the engine coolant temperature is excessively high

condition, a DTC P1173 (Symptom Code 3) will be

stored.

If the fuel temperature is excessively high or low

condition, a DTC P1173 (Symptom Code 7) or P1173

(Symptom Code A) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Coolant Temperature” or “Fuel Temperature”

display on the Tech2 while moving connectors and

wiring harness related to the sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

22 P1173 3 OFF Fuel Reduction Caused By

High Coolant Temperature Excessive high engine

coolant temperature is

detected.

No fail-safe function.

7 OFF Fuel Reduction Caused By

High Fuel Temperature Fuel temperature is more than

100°C. PSG (pump control unit)

controls fuel injection quantity

based on engine speed and

fuel temperature.

A OFF Fuel Reduction Caused By

Low Fuel Temperature Excessive low fuel

temperature is detected. No fail-safe function.

Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22)

Fuel Reduction Caused By High Coolant Temperature

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1173 (Symptom Code 3) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1173 (Sym ptom Cod e 3) stor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check the engine overheat condition.

Was the problem found?

—

Repair the

cause of

overheat and

verify repair G o to Step 5

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

2. Monitor the “Coolant Temperature” in the data

display.

Does the Tech 2 indicate correct “Coolant

Temperature” depending on warm up time? — Go to Step 9 Go to Step 6

6 Using the DVM and check the ECT sensor.

1. Ignition “Off”, engine “Off”.

2. Disconnect ECT sensor connector.

3. Measure the resistance of ECT sensor.

Does the tester indicate standard resistance as shown

in the following table?

Standard

resistance Go to Step 9 Go to Step 7

Temperat ure (°C) Resistance (Ω) (Approximately)

-30 27500

-20 16100

0 5760

20 2370

40 1080

60 537

80 290

100 161

120 95

ECT Sensor 12

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 Temperature

7 Substitute a known good ECT sensor assembly and

recheck.

Was the problem solved? — Go to Step 8 Go to Step 9

8 Replace the ECT sensor.

Is the action complete? — Verify repair —

9 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1173 (Symptom Code 7) or P1173

(Symptom Code A) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1173 (Symptom Code 7) or P1173

(Symptom Code A) stored in this ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

Step Action Value(s) Yes No

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1335 (Symptom Code A)

(Flash Code 43) Engine Speed Output Circuit Malfunction

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Desc rip tio n

The CKP sensor is located on top of the flywheel

housing of the flywheel and fixed with a bolt. The CKP

sensor is of the magnet coil type. The inductive pickup

sensors four gaps in the flywheel exciter ring and is

used to determine the engine speed and engine

cylinder top dead center.

The ECM converts sine wave signal to square wave

signal. And this signal is provided from the ECM to

pump control unit (PSG).

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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.

• Contaminated sensor - remove and clean the sensor.

• 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.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

43 P1335 A ON Engine Speed Output Circuit

Malfunction The PSG (pump control unit)

is recognized defective

engine speed signal form the

ECM.

Fuel injection quantity is

reduced.

Diagnostic Trouble Code (DTC) P1335 (Symptom Code A) (Flash Code 43)

Engine Speed Output Circuit Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1335 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1335 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Was the DTC P0335 (Symptom Code B) or P0335

(Symptom Code D) stored at the same time?

—

Go to DTC

Chart P0335

(Symptom

Code B)

(Symptom

Code C) Go to Step 5

5 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 6

C-57(B) E-6

6 I f a oscillosc ope is availabl e, monitor the CKP sensor

output signal. Does the oscilloscope indicate correct

wave form?

—Go to Step 13

Not available:

Go to Step 7

Fixed at low:

Go to Step 7

Fixed at High:

Go to Step 8

Step Action Value(s) Yes No

CKP Sensor Output Reference Wave Form

0V→

Measurement Terminal: 91 (+) 1 (-)

Measurement Scale: 5.0V/div 2.0ms/div

Measurement Condition: Engine speed at 2000rpm

7 Using the DVM and check the CKP sensor output

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 8

8 Using the DVM and check the CKP sensor output

circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

E-6

91 8

C-57(B) E-6

E-6

9 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 10

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 12 Go to Step 13

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

13 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1345 (Symptom Code A)

(Flash Code 45) Camshaft Speed Malfunction

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

Circuit Desc rip tio n

The pump camshaft sensor is a magnet with a coil. It

uses to combine with the p ulser. T he 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 s ignal o f pump c amshaft s peed

is sent via the CAN-bus from the PSG to ECM.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Pump Speed” display on the Tech2 while moving

connectors and wiring harnesses. A change in the

display will indicate the location of the fault.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

45 P1345 A ON Cam shaft Speed Malf unction T he PSG (pump cont rol unit)

is recognized incorrect

camshaft speed signal.

No fail-safe function.

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45) Camshaft Speed Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1345 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1345 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Monitor the “Pump Speed” in the data display.

Does the Tech 2 indicate correct “Pump Speed”

depending on engine speed? — Go to Step 6 Go to Step 5

5 Check any accessory parts which may cause electric

interference or magnetic interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 9

6 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 7

7 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 8 Go to Step 9

8 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

9 Replace the injection pump assembly.

Is the action complete? — Verify repair —

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

Battery

Voltage

Battery

Voltage

ECM

Main Relay

Stop

Light

10A

Injection

Pump Stop

Lamp

IC IC CPU

0.5

BLU/

BLK

2.0

BLU/

RED

0.5

BLU/

RED

0.5

WHT/

BLK

0.85

RED

0.85

RED

0.85

GRN

0.5

BLU/

RED

0.5

YEL

0.5

RED/

BLK

0.5

BLU/

RED

0.5

BLU/

RED

0.85

WHT

0.5

WHT/

RED

0.5

RED/

GRN

Clutch

Resister

Neutral

0.5

BLU/

YEL

Brake

M/T A/T

Inhibitor

Ignition

Back,

Turn

15A Engine

15A

µP

Engine

Control

Module

(ECM) Batt Batt

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

Circuit Desc rip tio n

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 malf unctions,

a DTC P1520 (Symptom Code A) or P1520 (Symptom

Code B) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harnes s 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.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

47 P1520 A ON Neutral Switch ON Error Neutral switch signal is

inputted “On” three times

consecutively under driving

conditions.

No fail-safe function.

B ON Neutral Switch OFF Error Neutral switch signal is

inputted “Off” three times

consecutively under driving

conditions.

Diagnostic Trouble Code (DTC) P1520 (Symptom Code A) (Flash Code 47) Neutral Switch ON Error

Diagnostic Trouble Code (DTC) P1520 (Symptom Code B) (Flash Code 47) Neutral Switch OFF Error

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1520 (Symptom Code A) or P1520

(Symptom Code B) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1520 (Symptom Code A) or P1520

(Symptom Code B) stored in this ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 C heck for poor/faulty c onnection at the neutra l switch

(inhibitor switch) or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

C-57

E-11 M/T E-12

E-51

A/T

5 U sing the DVM and ch eck the neutral switc h (inhibi tor

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 N range

switch).

Was the DVM indicated specified value?

Neutral (P or

N): Continuity

Other than

neutral (P or

N): No

continuity Go to Step 6

Replace neutral

switch (inhibitor

switch) and

verify repair

6 U sing the DVM and ch eck the neutral switc h (inhibi tor

switch) power su pply ci rcui t.

1. Ignition “On”, engine “Off”.

2. Remove the neutral switch (inhibitor switch)

connector from the switch.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 R epair the open cir cuit between the E CM Main Relay

and neutral switch (between the “Back, Turn fuse

(15A)” and inhibitor switch).

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

E-11 E-12

M/T

104 3 679 8

A/T

M/T E-51E-11 A/T

8 U sing the DVM and ch eck the neutral switc h (inhibi tor

swi tch) ci rc ui t.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type B. (ECM

connected) Ref. Page 6E-81

3. Ignition “On”, engine “Off”.

4. Check the circuit for open or short to voltage

circuit.

Was the DVM indicated specified value?

Breaker box is not available:

1. Ignition “On”, engine “Off”.

2. Back probe the DVM to the neutral switch

(inhibitor switch) and check the circuit for ope n or

short to voltage circuit.

Was the DVM indicated specified value?

Neutral (P or

N): Battery

voltage

Other than

neutral (P or

N): Less than

1V Go to Step 11

Fixed at battery

voltage: Go to

Step 9

Fixed at less

than 1V: Go to

Step 10

9 R epair the short to voltage ci rcuit between the neutral

switch connector (inhibitor switch connector) and

ECM.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

E-51

A/T

E-12

M/T

87 65

C-57

M/T

A/T

E-12

E-51

10 Repair the open circuit between the neutral switch

connector (inhibitor switch connector) and ECM.

Is the action complete?

— Verify repair —

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

87 65

C-57

M/T

A/T

E-12

E-51

Diagnostic Trouble Code (DTC) P1576 (Symptom Code 4) (Flash Code 71)

Exhaust Throttle Vsv 1 Circuit Voltage Low

Diagnostic Trouble Code (DTC) P1576 (Symptom Code 8) (Flash Code 71)

Exhaust Throttle Vsv 1 Circuit Voltage High

Batt

µP

Batt

µP

Batt

µP

0.5

BLK/

URG

0.5

BRN/

RED

0.5

BLU/

RED

0.5

BLU/

RED

4JA1-TC

0.5

GRY/

YEL

974661

0.5

WHT/

RED

0.5

GRN/

RED

0.5

BLK/

RED

0.5

BLK/

BLU

IAT

Sensor MAF &

IAT

Sensor

Rr Fog

Light

10A

EGR-

EVRV

0.5

WHT/

BLK

0.5

BLU/

RED

0.5

WHT/

BLU

0.5

BLU/

RED

0.5

GRN/

RED

0.5

BLU/

RED

Exhaust

Throttle

VSV2

Exhaust

Throttle

VSV1

Engine

Warming Up

Thermo

4531

Battery

Voltage

ECM

Main Relay

IC ICIC CPU

Engine

Control

Module

(ECM)

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

Circuit Description

The switch engine warming signals the engine control

module (ECM) to activate the quick warm-up system

(QWS).

Switch only provides the request and that the ECM

decides when to activated when certain conditions are

met.

If the exhaust throttle VSV 1 circuit is open or shorted to

ground, a DTC P1576 (Symptom Code 4) is stored.

If the exhaust throttle VSV 1 circuit is shorted to power,

a DTC P1576 (Symptom Code 8) is stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

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 P1576 display on the Tech2 while moving

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P1576 (Symptom Code 4) (Flash Code 71)

Exhaust Throttle VSV 1 Circuit Voltage Low

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

71 P1576 4 ON Exhaust Throttle VSV 1

Circuit Voltage Low Exhaust throttle VSV 1 circuit

open or short to ground

circuit.

No fail-safe function.

8 ON Exhaust Throttle VSV 1

Circuit Voltage High Exhaust throttle VSV 1 circuit

short to voltage circuit.

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1576 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 576 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the exhaust

throttle VSV 1 or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the exhaust throttle VSV 1.

1. Ignition “Off”, engine “Off”.

2. Disconnect the exhaust throttle VSV 1 connector.

3. Measure the resistance of exhaust throttle VSV 1

solenoid coil.

Does the tester indicate standard resistance?

Approximately

40Ω at 20°C Go to Step 6 Go to Step 9

6 U sing the DVM an d check the exh aust throttle VSV 1

power supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the exhaust throttle VSV 1 connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

Step Action Value(s) Yes No

C-56

C-13

2VSV-1

C-13

7 Repair the open circuit between the ECM main relay

and exhaust throttle VSV 1.

Is the action complete?

— Verify repair —

8 U sing the DVM an d check the exh aust throttle VSV 1

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Remove the exhaust throttle VSV 1 connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the exhaust throttle VSV 1 connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 11

9 Substitute a known good exhaust throttle VSV 1 and

recheck.

Was the problem solved? — Go to Step 10 Go to Step 11

Step Action Value(s) Yes No

C-13X-4

C-13

C-56

Diagnostic Trouble Code (DTC) P1576 (Symptom Code 8) (Flash Code 71)

Exhaust Throttle VSV 1 Circuit Voltage High

10 Replace the exhaust throttle VSV 1.

Is the action complete? — Verify repair —

11 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1576 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 576 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

Step Action Value(s) Yes No

4 Check for poor/faulty connection at the exhaust

throttle VSV 1 or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the exhaust throttle VSV 1.

1. Ignition “Off”, engine “Off”.

2. Disconnect the exhaust throttle VSV 1 connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

40Ω at 20°C Go to Step 6 Go to Step 8

6 U sing the DVM an d check the exh aust throttle VSV 1

circuit.

1. Ignition “Off”, engine “Off”.

2. Remove the exhaust throttle VSV 1 connector and

ECM connector.

3. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

No continuity Go to Step 10 Go to Step 7

7 Repair the short to voltage circuit.

Is the action complete? — Verify repair —

8 Substitute a known good exhaust throttle VSV 1 and

recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the exhaust throttle VSV 1.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

C-56

C-13

2VSV-1

21 C-13

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1577 (Symptom Code 4)

(Flash Code 71) Exhaust Throttle VSV 2 Circuit Voltage Low

Diagnostic Trouble Code (DTC) P1577 (Symptom Code 8)

(Flash Code 71) Exhaust Throttle VSV 2 Circuit Voltage High

Batt

µP

Batt

µP

Batt

µP

0.5

BLK/

URG

0.5

BRN/

RED

0.5

BLU/

RED

0.5

BLU/

RED

4JA1-TC

0.5

GRY/

YEL

974661

0.5

WHT/

RED

0.5

GRN/

RED

0.5

BLK/

RED

0.5

BLK/

BLU

IAT

Sensor MAF &

IAT

Sensor

Rr Fog

Light

10A

EGR-

EVRV

0.5

WHT/

BLK

0.5

BLU/

RED

0.5

WHT/

BLU

0.5

BLU/

RED

0.5

GRN/

RED

0.5

BLU/

RED

Exhaust

Throttle

VSV2

Exhaust

Throttle

VSV1

Engine

Warming Up

Thermo

4531

Battery

Voltage

ECM

Main Relay

IC ICIC CPU

Engine

Control

Module

(ECM)

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

Circuit Description

The switch engine warming signals the engine control

module (ECM) to activate the quick warm-up system

(QWS).

Switch only provides the request and that the ECM

decides when to activated when certain conditions are

met.

If the exhaust throttle VSV 2 circuit is open or shorted to

ground, a DTC P1577 (Symptom Code 4) is stored.

If the exhaust throttle VSV 2 circuit is shorted to power,

a DTC P1577 (Symptom Code 8) is stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

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 P1577 display on the Tech2 while moving

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P1577 (Symptom Code 4) (Flash Code 71)

Exhaust Throttle VSV 2 Circuit Voltage Low

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

71 P1577 4 ON Exhaust Throttle VSV 2

Circuit Voltage Low Exhaust throttle VSV 2 circuit

open or short to ground

circuit.

No fail-safe function.

8 ON Exhaust Throttle VSV 2

Circuit Voltage High Exhaust throttle VSV 2 circuit

short to voltage circuit.

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1577 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 577 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the exhaust

throttle VSV 2 or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Using the DVM and check the exhaust throttle VSV 2.

1. Ignition “Off”, engine “Off”.

2. Disconnect the exhaust throttle VSV 2 connector.

3. Measure the resistance of exhaust throttle VSV 2

solenoid coil.

Does the tester indicate standard resistance?

Approximately

40Ω at 20°C Go to Step 6 Go to Step 9

6 U sing the DVM an d check the exh aust throttle VSV 2

power supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the exhaust throttle VSV 2 connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

Battery

voltage Go to Step 8 Go to Step 7

7 Repair the open circuit between the ECM main relay

and exhaust throttle VSV 2.

Is the action complete?

— Verify repair —

Step Action Value(s) Yes No

21 C-14

C-56

2VSV-2

C-14

X-4 C-14

8 U sing the DVM an d check the exh aust throttle VSV 2

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Remove the exhaust throttle VSV 2 connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the exhaust throttle VSV 2 connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 11

9 Substitute a known good exhaust throttle VSV 2 and

recheck.

Was the problem solved? — Go to Step 10 Go to Step 11

10 Replace the exhaust throttle VSV 2.

Is the action complete? — Verify repair —

11 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 12

Step Action Value(s) Yes No

C-14

C-56

C-14

Diagnostic Trouble Code (DTC) P1577 (Symptom Code 8) (Flash Code 71)

Exhaust Throttle VSV 2 Circuit Voltage High

12 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1577 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 577 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Check for poor/faulty connection at the exhaust

throttle VSV 2 or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

Step Action Value(s) Yes No

21 C-14

C-56

5 Using the DVM and check the exhaust throttle VSV 2.

1. Ignition “Off”, engine “Off”.

2. Disconnect the exhaust throttle VSV 2 connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

40Ω at 20°C Go to Step 6 Go to Step 8

6 U sing the DVM an d check the exh aust throttle VSV 2

circuit.

1. Ignition “Off”, engine “Off”.

2. Remove the exhaust throttle VSV 2 connector and

ECM connector.

3. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

No continuity Go to Step 10 Go to Step 7

7 Repair the short to voltage circuit.

Is the action complete? — Verify repair —

8 Substitute a known good exhaust throttle VSV 2 and

recheck.

Was the problem solved? — Go to Step 9 Go to Step 10

9 Replace the exhaust throttle VSV 2.

Is the action complete? — Verify repair —

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

2VSV-2

21 C-14

Diagnostic Trouble Code (DTC) P1605 (Symptom Code D)

(Flash Code 55) EEPROM Defect

Diagnostic Trouble Code (DTC) P1605 (Symp tom Code E)

(Flash Code 55) EEPROM Defect

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

Circuit Description & Diagnostic Aids

The ECM used in this vehicle utilises an Electrically

Erasable & Programmable Read Only Memory

(EEPROM). The EEPROM contains program

informat ion and the cali brations requir ed for engin e and

diagnostics operation.

If the ECM fails internally (IC, circuit, memory, etc,), a

DTC P1605 (Symptom Code C), P1605 (Symptom

Code D) or P1605 (Symptom Code E) will be stored.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

55 P1605 D ON EEPROM Defect Write and read from the

EEPROM are failed during

initialization of the ECM.

ECM uses default values from

the EPROM.

E ON EEPROM Defect EEPROM checksum does not

match with the read check

sum during initialization of the

ECM.

Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55) EEPROM Defect

Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55) EEPROM Defect

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1605 (Symptom Code D) or P1605

(Symptom Code E) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1605 (Symptom Code D) or P1605

(Symptom Code E) stored in this ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P1610 (Symptom Code A)

(Flash Code 56) Security Key & Security Code Not Programmed

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

Circuit Desc rip tio n

The ECM decides if there is an abnormality in the

immobiliser control system. A DTC P1610 (Symptom

Code A) i s recorded whe n immobilis er functio n was not

programmed in the ECM.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobiliser control unit-

Inspect harne ss con nectors for bac ked out terminal s,

improper mating, broken locks, improp erly formed or

damaged terminals, and poor terminal to wire

connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the DTC P1610 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

56 P1610 A - Security Key and Security

Code not Programmed Immobiliser functions are not

programmed in the ECM. 1. Engine does not start.

2. Check engine lamp flash.

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56)

Security Key and Security Code Not Programmed

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1610 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1610 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “Immobiliser” in the system selectio n menu

“Body”.

3. Sele ct “Read D TC Info Or dered By P riority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

“Immobiliser

Workshop

Manual” & Go

to DTC Chart

B**** Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P1611 (Symptom Code A)

(Flash Code 56) W rong Security Code Entered

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

Circuit Desc rip tio n

The ECM decides if there is an abnormality in the

immobiliser control system. A DTC P1611 (Symptom

Code A) is recorded when received immobiliser security

code was not co rrec t.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobiliser control unit-

Inspect harne ss con nectors for bac ked out terminal s,

improper mating, broken locks, improp erly 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 P1611 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

56 P1611 A - Wrong Security Code Entered Received security code is not

correct. 1. Engine does not start.

2. Check engine lamp flash.

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56) Wrong Security Code Entered

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1611 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 611 (Sym ptom Cod e A) s tored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “Immobiliser” in the system selectio n menu

“Body”.

3. Sele ct “Read D TC Info Or dered By P riority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

“Immobiliser

Workshop

Manual” & Go

to DTC Chart

B**** Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P1612 (Symptom Code A)

(Flash Code 56) Immobiliser No Or Wrong Signal

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

Circuit Desc rip tio n

The ECM decides if there is an abnormality in the

immobiliser control system. A DTC P1612 (Symptom

Code A) is recorded when received immobiliser

challenge signal was not correct.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobiliser control unit-

Inspect harne ss con nectors for bac ked out terminal s,

improper mating, broken locks, improp erly 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 P1612 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

56 P1612 A - Immobiliser No or Wrong

Signal Received challenge signal is

not correct or not received. 1. Engine does not start.

2. Check engine lamp flash.

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56) Immobiliser No or Wrong Signal

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1612 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1612 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “Immobiliser” in the system selectio n menu

“Body”.

3. Sele ct “Read D TC Info Or dered By P riority” in the

“Diagnositic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

“Immobiliser

Workshop

Manual” & Go

to DTC Chart

B**** Go to Step 5

5 Check for poor/faulty connection at the immobiliser

control unit connector or ECM connector. If a poor/

faulty co nnec ti on is found, repair as nece ssa ry.

Was the problem found?

— Verify repair Go to Step 6

C-56

B-68

6 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and immobiliser

control unit connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was DVM indicated specified value?

Less than 1V Go to Step 7

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

B-68

7 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the immobiliser control unit connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the the immobiliser control unit

connector and ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 8

Step Action Value(s) Yes No

B-68

C-56

B-68

8 Using the DVM and check the ECM and immobiliser

control unit communication circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the immobiliser control unit connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

9 Using the DVM and check the ECM and immobiliser

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-81

3. Disconnect the immobiliser control unit connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the the immobiliser control unit

connector and ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 10

Step Action Value(s) Yes No

B-68

C-56

B-68

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1613 (Symptom Code A)

(Flash Code 56) Immobiliser No Or Wrong Signal

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

Circuit Desc rip tio n

The ECM decides if there is an abnormality in the

immobiliser control system. A DTC P1613 (Symptom

Code A) is recorded when received immobiliser

response signal was not correct.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobiliser control unit-

Inspect harne ss con nectors for bac ked out terminal s,

improper mating, broken locks, improp erly 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 P1613 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

56 P1613 A - Immobiliser No or Wrong

Signal Received response signal is

not correct or not received. 1. Engine does not start.

2. Check engine lamp flash.

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56) Immobiliser No or Wrong Signal

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1613 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1613 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “Immobiliser” in the system selectio n menu

“Body”.

3. Sele ct “Read D TC Info Or dered By P riority” in the

“Diagnositic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

“Immobiliser

Workshop

Manual” & Go

to DTC Chart

B**** Go to Step 5

5 Check for poor/faulty connection at the immobiliser

control unit connector or ECM connector. If a poor/

faulty co nnec ti on is found, repair as nece ssa ry.

Was the problem found?

— Verify repair Go to Step 6

C-56

B-68

6 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the meter connector and immobiliser

control unit connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was DVM indicated specified value?

Less than 1V Go to Step 7

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

B-68

7 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the immobiliser control unit connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the the immobiliser control unit

connector and ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 8

8 Using the DVM and check the ECM and immobiliser

control unit communication circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the immobiliser control unit connector.

3. Ignition “On”.

4. Check the circuit for short to power supply circuit.

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

B-68

C-56

B-68

9 Using the DVM and check the ECM and immobiliser

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-81

3. Disconnect the immobiliser control unit connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the the immobiliser control unit

connector and ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 10

10 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 11

11 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

B-68

C-56

B-68

Diagnostic Trouble Code (DTC) P1614 (Symptom Code A)

(Flash Code 56) W rong Transponder Key

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

Circuit Desc rip tio n

The ECM decides if there is an abnormality in the

immobiliser control system. A DTC P1614 (Symptom

Code A) is recorded when received immobiliser

response signal was not correct from the transponder

key.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobiliser control unit-

Inspect harne ss con nectors for bac ked out terminal s,

improper mating, broken locks, improp erly 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 P1614 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

56 P1614 A - Wrong Transponder Key Received response signal is

not correct from the

transponder key.

1. Engine does not start.

2. Check engine lamp flash.

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56) Wrong Transponder Key

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1614 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1614 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “Immobiliser” in the system selectio n menu

“Body”.

3. Sele ct “Read D TC Info Or dered By P riority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

“Immobiliser

Workshop

Manual” & Go

to DTC Chart

B**** Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must e

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

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

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

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

76 P1625 A OFF E CM Main Relay Switc hed

Off Too Early When ignition switch was

turned off, the ECM main

relay is turning off too early.

No fail-safe function.

B O FF ECM Main Relay Switched

Off Too Late When ignition switch was

turned off, the ECM main

relay is turning off too late or

does not off.

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

Circuit Description

The ECM switches ECM main relay to operate ECM

and other sensors or controller.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• 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 “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 Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1625 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1625 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76)

ECM Main Relay Switched Off Too Late

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1625 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1625 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Using the DVM and check the ECM main relay.

1. Ignition “Off”, engine “Off”.

2. Remove the ECM main relay from the relay box.

3. Check the relay switch.

Was the DVM indicated specified value?

No continuitly Go to Step 5

Replace ECM

main relay and

verify repair

5 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 6

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

ECM

Main Relay

Diagnostic Trouble Code (DTC) P1630 (Symptom Code A)

(Flash Code 51) Fuel Injection Quantity Circuit Malfunct ion

Diagnostic Trouble Code (DTC) P1630 (Symptom Code B)

(Flash Code 51) Fuel Injection Quantity Circuit Malfunct ion

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

Circuit Desc rip tio n

The ECM is calculates an injection quantity and an

injecti on ti min g us ing the v ariou s s ens or s. And the PSG

control s the high pr essure sol enoid val ve depending o n

programmed pump map data.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition F ail-Safe (Back Up)

51 P1630 A ON Fuel Injection Quantity Circuit

Malfunction The PSG (pump control unit)

detects high pressure

solenoid valve control circuit

malfunction due to high

current.

Fuel injection quantity is

reduced.

B ON Fuel Injection Quantity Circuit

Malfunction The PSG (pump control unit)

detects high pressure

solenoid valve control circuit

malfunction due to continuous

current.

1. MA B (f uel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51)

Fuel Injection Quantity Circuit Malfunction

Diagnostic Trouble Code (DTC) P1630 (Symptom Code B) (Flash Code 51)

Fuel Injection Quantity Circuit Malfunction

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1630 (Symptom Code A) or P1630

(symptom Code B) stored as “Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1630 (Symptom Code A) or P1630

(symptom Code B) stored in this ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Replace the injection pump assembly.

Is the action complete? — Verify repair —

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

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Description

The interchange of data between the engine control

module (ECM) and the pump control unit (PSG) is

performed via a CAN-bus system. The individual CAN-

bus systems are connected via two interfaces and can

exchange information and data. This allows control

modules that are connected to different CAN-bus

systems to communicate.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the DTC P1650 display on the Tech2 while moving

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN Device Offline

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

44 P1650 A ON CAN Device Offline CAN controller detects Bus-

off or canceling. MAB (fuel cutoff solenoid

valve) is operated.

B ON CAN Device Hang-up CAN controller does not react

under engine running.

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1650 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1650 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 5

5 Visually check the PS G (p ump contro l unit) .

Was the problem found? — Go to Step 18 Go to Step 6

6 Using the DVM and check the CAN high circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector and PSG (pump

control unit) connector.

3. Check the circuit for short to CAN low circuit.

Was the DVM indicated specified value?

No continuity Go to Step 7

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

100 99 1

C-57 E-6

E-6

7 Using the DVM and check the CAN high circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 8

Step Action Value(s) Yes No

100

E-6

100 2

C-57 E-6

8 Using the DVM and check the CAN low circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

9 Using the DVM and check the CAN high circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated battery voltage or

approximately 5V?

—Go to Step 10 Go to Step 11

Step Action Value(s) Yes No

E-6

99 1

C-57 E-6

E-6

10 Repair the short to voltage circuit between the ECM

and PSG (pump control unit).

Is the action complete?

— Verify repair —

11 Using the DVM and check the CAN low circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated battery voltage or

approximately 5V?

—Go to Step 12 Go to Step 13

12 Repair the short to voltage circuit between the ECM

and PSG (pump control unit).

Is the action complete?

— Verify repair —

13 Using the DVM and check the PSG (pump control

unit) ground circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 14

Step Action Value(s) Yes No

100 2

C-57 E-6

E-6

99 1

C-57 E-6

E-6

Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN Device Hang-up

14 Check any accessory parts which may cause electric

interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 15

15 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 16

16 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 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 17 Go to Step 18

17 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

18 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1650 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1650 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

Step Action Value(s) Yes No

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1651 (Symptom Code A)

(Flash Code 45) Can Malfunction (PSG)

Diagnostic Trouble Code (DTC) P1651 (Symptom Code B)

(Flash Code 45) Can Received Error

16151413121110 9

87654321

Battery

Voltage Battery

Voltage

0.5

RED/

YEL

2.0

BLU/

RED

PSG(Pump Control Unit) Injection

Pump

21 5 8

0.5

WHT

2.0

BLU/

RED

0.5

BLU/

BLK

0.5

RED 0.5

ORG

100358 99 105 91

0.5

PNK

62.0

BLK

µP

CAN

Controller

Batt

µP

0.5

BLU

Stop

Light

10A

1.25

BLK

µP

Engine

Control

Module

(ECM)

ECM

Main Relay

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

Circuit Description

The interchange of data between the engine control

module (ECM) and the pump control unit (PSG) is

performed via a CAN-bus system. The individual CAN-

bus systems are connected via two interfaces and can

exchange information and data. This allows control

modules that are connected to different CAN-bus

systems to communicate.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the DTC P1651 display on the Tech2 while moving

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45) CAN Malfunction (PSG)

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit)

does not recognize CAN

signal from the CAN

controller.

1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

B ON CAN Receives Error The ECM does not read CAN

signal from the PSG (pump

control unit).

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1651 (Symptom Code A) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1651 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45) CAN Received Error

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 Go to Step 7

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1651 (Symptom Code B) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DTC P1651 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Was the DTC P1 650 ( Sympt om Code A ) sto re d a t th e

same time?

—

Go to DTC

Chart P1650

(Symptom

Code A) Go to Step 5

Step Action Value(s) Yes No

5 Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 6

6 Visually check the PS G (p ump contro l unit) .

Was the problem found? — Go to Step 19 Go to Step 7

7 Using the DVM and check the CAN high circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector and PSG (pump

control unit) connector.

3. Check the circuit for short to CAN low circuit.

Was the DVM indicated specified value?

No continuity Go to Step 8

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

100 99 1

C-57 E-6

E-6

8 Using the DVM and check the CAN high circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

Step Action Value(s) Yes No

100

E-6

100 2

C-57 E-6

9 Using the DVM and check the CAN low circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Disconnect the PSG (pump control unit)

connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 10

10 Using the DVM and check the CAN high circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated battery voltage or

approximately 5V?

— Go to Step 11 Go to Step 12

Step Action Value(s) Yes No

E-6

99 1

C-57 E-6

E-6

11 Repair the short to voltage circuit between the ECM

and PSG (pump control unit).

Is the action complete?

— Verify repair —

12 Using the DVM and check the CAN low circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for short to power supply circuit.

Was the DVM indicated battery voltage or

approximately 5V?

—Go to Step 13 Go to Step 14

13 Repair the short to voltage circuit between the ECM

and PSG (pump control unit).

Is the action complete?

— Verify repair —

14 Using the DVM and check the PSG (pump control

unit) ground circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the PSG (pump control unit)

connector.

3. Check the circuit for open circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go to Step 15

Step Action Value(s) Yes No

100 2

C-57 E-6

E-6

99 1

C-57 E-6

E-6

15 Check any accessory parts which may cause electric

interference.

Was the problem found? —

Remove the

accessory parts

and verify repair Go to Step 16

16 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 17

17 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 18 Go to Step 19

18 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

19 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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

Ignition

Meter

15A

615 7

Batt

0.5

RED/

WHT

0.5

ORG/

BLU

0.5

BRN/

YEL

0.5

BLK/

RED

0.5

BLU/

WHT

0.5 BLU/BLK

0.5

WHT

2.0

BLK

VSS

0.85

YEL

Imnobiliser

Control Unit

0.5

BRN/

YEL

0.85

YEL

Glow

Check

Engine

Tacho

Meter

Speed

Meter

A/T

TCM

µPµPµPµP

Engine

Control

Module

(ECM)

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

Circuit Description

The Check Engine Lamp (Malfunction Indicator Lamp

=MIL) should always be illuminated and steady with

ignition “On” and the engine not running. Ignition feed

voltage is supplied to the Check Engine Lamp bulb

through the meter fuse. The ECM turns the Check

Engine Lamp “On” by grounding the check engine lamp

driver circuit for a certain time.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM-Inspect harness connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• 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

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)

77 P1690 4 OFF Check Engine Lamp (MIL)

Circuit Voltage Low Check engine lamp circuit

open or short to ground

circuit.

No fail-safe function.

8 OFF Check Engine Lamp (MIL)

Circuit Voltage High Check engine lamp circuit

short to ground circuit.

Step Action Value(s) Yes No

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

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. Select “F0: Read DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1690 (Symptom Code 4) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 690 (Sy mpt om Code 4) stor e d i n th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 1. Ignition “On”, engine “Off”.

2. Check the “Check Engine” lamp.

Does the lamp turn “On”? — Go to Step 5 Go to Step 6

5 1. Ignition “On”, engine “Off”.

2. Check the “Check Engine” lamp.

Does the lamp turn “Off”? — Go to Step 9 Go to Step 7

6 Check the “Check Engine” lamp bulb.

If the bulb is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 7

7 Check for poor/faulty connection at the meter

connector and ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found?

— Verify repair Go to Step 8

Step Action Value(s) Yes No

C-56

B-23

4JA1-TC

B-23

4JH1-TC

8 Using the DVM and check the “Check Engine” lamp

circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

2. Install the breaker box as type A. (ECM

disconnected) Ref. Page 6E-81

3. Remove the meter connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the meter connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair G o to Step 9

Step Action Value(s) Yes No

B-234JA1-TC

B-234JH1-TC

C-56

4JA1-TC

B-23

C-56

4JH1-TC

B-23

Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77)

Check Engine Lamp (MIL) Circuit Voltage High

9 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 10

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the Tech 2.

2. Review and record the failure information.

3. S elect “F0: Read DTC I nfor As Stored B y ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1690 (Symptom Code 8) stored as

“Present Failure”? — Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

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

2. Select “F1: Clear DTC Information” in “F0:

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

3. Operate the vehicle and monitor the “F0: Read

DTC Infor As Stored By ECU” in the “F0:

Diagnostic Trouble Codes”.

Was the DT C P1 690 (Sy mpt om Code 8) stor e d i n th is

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 5

5 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. —Go to Step 6 —

Step Action Value(s) Yes No

6 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

Step Action Value(s) Yes No

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.

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 lates t Isuzu servic e 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.

Engine Cranks But Will Not Run

DEFINITIONS: Engine cranks, but will not run. (The engine does not start.)

NOTE: The vehicle has an immobiliser system, this system may be activated. Check the immobiliser system

diagnosis.

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visually/physical check performed? —Go to Step 4 Go to Visual /

physical Check

4 Is there enough fuel in the fuel tank?

—Go to Step 5 Add fuel to the

tank

5 Is the customer using the incorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to Step 6

6 Check the “Engine-1” fuse (15A) and “Engine-2” fuse

(10A).

If the fuse is burnt out, repair as necessary.

Was the problem found? — Verify repair Go to Step 7

7 Visually/physically inspect for the following conditions.

• Restricted air intake system. Check for a restricted

air filter element, o r foreign ob jects blocking th e air

intake system

• Che ck f or o bjects blo cking or e xces siv e depo sits i n

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

crankc as e ven til ati on 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? — Verify repair Go to Step 8

8 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to Step 9

Techline

9 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? — Verify repair Go to Step 10

10 Remove the CKP sensor from the flywheel housing

and check for the following conditions.

• Objects sticking the CKP sensor.

• Objects sticking the CKP sensor pulser.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 11

11 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 12

12 Substitute a known good CKP sensor and recheck.

Was the problem solved? — Go to Step 13 Go to Step 14

13 Replace the CKP sensor.

Is the action complete? — Verify repair —

14 Using the vacuum pump and check the exhaust

throttle valve (if equipped) operation for the following

condition.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

Was a problem found?

— Verify repair Go to Step 15

15 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failure.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 16

Step Action Value(s) Yes No

16 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 17

17 Replace the fuel filter.

Was the problem solved? — Verify repair Go to Step 18

18 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 mai nte nan ce int erva l.

• 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?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to Step 19

19 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to Step 20

Step Action Value(s) Yes No

20 If the injection pump was replaced, are the timing

gears or injection pump correctly installed?

—Go to Step 21 Re pair as

necessary

21 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/ inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to Step 22

22 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 23

23 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Go to Step 24 Go to Step 25

24 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

25 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Hard Start Sy mptom

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

immediately stall.

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visually/physical check performed? —Go to Step 4 Go to Visual /

physical Check

4 Is the customer using the incorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to Step 6

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

• Che ck f or o bjects blo cking or e xces siv e depo sits i n

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

crankc as e ven til ati on 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? — Verify repair Go to Step 6

6 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to Step 7

7 1. Using th e Tec h 2, d ispl ay the ECT sens or an d I AT

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? — Verify repair Go to Step 8

8 1. Using the Tech 2, display the FT sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as necessary.

Was the problem found? — Go to Step 20 Go to Step 9

9 1. Using the Tech 2, ignition “On”.

2. Monitor the “Glow Time Relay” in the data display.

Does the Tech 2 indicate correct “Glow Time Relay”

status depending on the time from ignition switch

“On”?

If a problem is found, repair as necessary.

Was the problem found? — Go to Step 20 Go to Step 10

10 1. Using the Tech 2, ignition “On”.

2. Monitor the “Glow Time Rela y” in the data displ ay

and then, does the supply voltage correctly supply

to the glow plug?

—Go to Step 11

Repair voltage

supply circuit

and verify repair

11 Check the glow plugs for continuity.

If a problem is found, repair as necessary.

Was a problem found?

— Verify repair Go to Step 12

12 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failure.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 13

13 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 14

14 Replace the fuel filter.

Was the problem solved? — Verify repair Go to Step 15

Step Action Value(s) Yes No

15 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 mai nte nan ce int erva l.

• 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?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to Step 16

16 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressure is incorrect.

If a problem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and verify repair Go to Step 17

17 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to Step 18

Step Action Value(s) Yes No

Stage 2

St age

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

18 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the specified value?

0.4mm at cold

(In/Ex) Go to Step 19 Adjust and

verify repair

19 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/ inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to Step 20

20 Is the ECM programmed with the latest software

release?

If not, downlo ad the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 21

21 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Go to Step 22 Go to Step 23

22 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.

Foll owing ECM pr ogramming, the immobi liser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Verify repair —

23 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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.

time

rpm

Rough Idle Stall

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visually/physical check performed? —Go to Step 4 Go to Visual /

physical Check

4 Is the customer using the incorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to Step 5

5 1. Check for incorrect idle speed. Ensure that the

following conditions are present.

• Engine fully warm.

• Accessories are “OFF”.

2. Using a Tech 2, monitor “Desired Engine Idle

Speed” and “Engine Speed”.

Is the “Engine Speed” within the specified values?

Desired

Engine Idl e

Speed ± 25

rpm Go to Step 7 Go to Step 6

6 Visually/physically inspect for the following conditions.

• Restrict air intake system. Check for a restricted air

filter element, or foreign objects blocking the air

intake system

• Che ck f or o bjects blo cking or e xces siv e depo sits i n

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

crankc as e ven til ati on 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? — Verify repair Go to Step 7

7 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to Step 8

8 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? — Verify repair Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “A/C Information Switch” in the data

display.

Does the Tech 2 indicate correct “A/C Information

Switch ” status depend ing on A/C switc h posi tion?

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 10

10 1. Usin g th e Tec h 2, d ispl ay the E CT s ens or an d I AT

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? — Verify repair Go to Step 11

11 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 16 Go to Step 12

12 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 13

13 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 14

14 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 15 Go to Step 36

15 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operation? — Go to Step 21 Go to Step 17

Step Action Value(s) Yes No

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved? — Verify repair Go to Step 18

18 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 19

19 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 20 Go to Step 36

20 Replace the TPS.

Is the action complete? — Verify repair —

21 Remove the CKP sensor from the flywheel housing

and check for the following conditions.

• Objects sticking the CKP sensor.

• Objects sticking the CKP sensor pulser.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 22

22 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 23

23 Substitute a known good CKP sensor and recheck.

Was the problem solved? — Go to Step 24 Go to Step 25

24 Replace the CKP sensor.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

25 1. Using the Tech 2 and ignition “On” and engine

“Run”.

2. Monitor the following parameters in the data

display.

• “Desired Injection Quantity” & “Injection Quantity”

• “Desired Injection Start” & “Actual Injection Start”

Are the large gap or unstable parameter displayed

between “Desired” and “Actual”?

—Go to Step 29 Go to Step 26

26 Us ing the vacuum pump and chec k the EGR valve ( if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a problem is found, repair as necessary.

Was a problem found?

— Verify repair Go to Step 27

Step Action Value(s) Yes No

When idling or part-throttle

High Desired

Low

Time

Actual

Vacuum Pump

Small Window

27 Using the vacuum pump and check the exhaust

throttle valve (if equipped) operation for the following

condition.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

Was a problem found?

— Verify repair Go to

Step 28

28 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic conve rter.

• Internal muffler failure.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 29

29 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 30

30 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 31

Step Action Value(s) Yes No

31 Remove the eye bolt with gauze filter from the

injection pump and check for the followin g 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 mai nte nance int erva l.

• 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 pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 32

32 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressu re is incorrect.

If a pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and ve rify repair Go to

Step 33

33 Check the engine compression pressure for each

cylinders.

If a pro blem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to

Step 34

Step Action Value(s) Yes No

Stage 2

Stage

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

34 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the s p ecified value?

0.4mm at cold

(In/Ex) Go to

Step 35

Adjust and

verify repair

35 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 36

36 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved ? — Verify repair Go to

Step 37

37 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, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 38

Go to

Step 39

38 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, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

39 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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 accelera tor pedal.

time

rpm

Surge

Step Action Value(s) Yes No

1 Was the “On-Boar d Diagnostic (OBD) Sys tem Check”

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses t he symptom? — Verify repair Go to

Step 3

3 Was a visually/phy sical check performed? —Go to

Step 4

Go to

Visual /

physical Check

4 Is the customer using the i ncorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to

Step 5

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

• Che ck for o bjects blo cking or exces sive depo sits in

the throttle bore and o n the thro ttle plate

• Check for a condition that causes a large vacuum

leak, such as an incorrectly installed or faulty

crankcas e ven tilati on hose.

• Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger

compressor wheel or turbine shaft sticking.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 6

6 Check the ECM & PSG groun ds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to

Step 7

7 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “A/C Information Switch” in the data

display.

Does the Tech 2 indicate correct “A/C Information

Switch ” status depend ing on A/C switch posi tion?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 8

8 1. Using th e Tech 2, d ispl ay the E CT sens or an d IAT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 9

9 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 14

Go to

Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 13

Go to

Step 29

13 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operat ion? — Go to

Step 19

Go to

Step 15

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved ? — Verify repair Go to

Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 17

17 Substitute a known good TPS and recheck.

Was the problem solved? — Go to Step 18 Go to

Step 29

18 Replace the TPS.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

19 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 pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 20

20 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 21

21 Substitute a known good CKP sensor and recheck.

Was the problem s olv ed? — Go to

Step 22

Go to

Step 23

22 Replace the CKP sensor.

Is the action complete? — Verify repair —

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”?

—Go to

Step 25

Go to

Step 24

24 Us ing the vacuum pum p and check the EGR valve (if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 25

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

Vacuum Pump

Small Window

25 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 26

26 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 27

27 Remove the eye bolt with gauze filter from the

injection pump and check for the followin g 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 mai nte nance int erva l.

• 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 pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 28

28 1. Re view all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 29

29 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved ? — Verify repair Go to

Step 30

Step Action Value(s) Yes No

30 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 31

Go to

Step 32

31 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

32 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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.

time

rpm

Sug

Hesitation

Stumble

Step Action Value(s) Yes No

1 Was the “On-Boar d Diagnostic (OBD) Sys tem Check”

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses t he symptom? — Verify repair Go to

Step 3

3 Was a visually/phy sical check performed? —Go to

Step 4

Go to Visual /

physical Check

4 Is the customer using the i ncorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to

Step 5

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? — Verify repair Go to

Step 6

6 Visually/physically inspect for the following conditions.

• Restrict air intake system. Check for a restricted air

filter element, or foreign objects blocking the air

intake system

• Che ck for o bjects blo cking or exces sive depo sits in

the throttle bore and o n the thro ttle plate

• Check for a condition that causes a large vacuum

leak, such as an incorrectly installed or faulty

crankcas e ven tilati on hose.

• Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger

compressor wheel or turbine shaft sticking.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 7

7 Check the ECM & PSG groun ds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to

Step 8

8 1. Using th e Tech 2, d ispl ay the E CT sens or an d IAT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 9

9 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 14

Go to

Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 13

Go to

Step 31

13 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operat ion? — Go to

Step 19

Go to

Step 15

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved ? — Verify repair Go to

Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 17

17 Substitute a known good TPS and recheck.

Was the problem s olv ed? — Go to

Step 18

Go to

Step 31

18 Replace the TPS.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

19 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 pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 20

20 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 21

21 Substitute a known good CKP sensor and recheck.

Was the problem s olv ed? — Go to

Step 22

Go to

Step 23

22 Replace the CKP sensor.

Is the action complete? — Verify repair —

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”?

—Go to

Step 27

Go to

Step 24

24 Us ing the vacuum pum p and check the EGR valve (if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 25

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

Vacuum Pump

Small Window

25 Using the vacuum pump and check the exhaust

throttle valve (if equipped) operation for the following

condition.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

Was a problem found?

— Verify repair Go to

Step 26

26 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic conve rter.

• Internal muffler failure.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 27

27 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 28

28 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 29

Step Action Value(s) Yes No

29 Remove the eye bolt with gauze filter from the

injection pump and check for the followin g 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 mai nte nance int erva l.

• 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 pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 30

30 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 31

31 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved ? — Verify repair Go to

Step 32

32 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 33

Go to

Step 34

33 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

Step Action Value(s) Yes No

34 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Cuts Out, Miss es Sympt o m

DEFINITIONS: Steady pulsation or jerking that follows

engine s pee d; us ual ly m or e p ro nou nced as en gin e l oa d

increases.

time

rpm

Step Action Value(s) Yes No

1 Was the “On- Board Diagnos tic (OBD) Sy stem Check”

performed?

—Go to Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visually/physical check performed? —Go to Step 4 Go to Visual /

physical Check

4 Is the customer using the incorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to Step 5

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

• Che ck f or o bjects blo cking or e xces siv e depo sits i n

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

crankc as e ven til ati on 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? — Verify repair Go to Step 6

6 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to Step 7

7 1. Using the Tech 2, perform test drive.

2. Monitor the “Vehicle Speed” in the data display.

Does the Tech 2 indicate correct “Vehicle Speed”

depending on driving speed?

—Go to Step 11 Go to Step 8

8 Check the VSS harness for the following conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 9

9 Substitute a known good VSS and recheck.

Was the problem solved? — Go to Step 10 Go to Step 31

10 Replace the VSS assembly.

Is the action complete? — Verify repair —

11 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 16 Go to Step 12

12 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

Was the problem found? — Verify repair Go to Step 13

13 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 14

14 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 15 Go to Step 31

15 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

When constant vehicle speed

High Correct Speed

Low

Time

Unstable Data

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operat ion? — Go to

Step 21

Go to

Step 17

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved ? — Verify repair Go to

Step 18

18 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 19

19 Substitute a known good TPS and recheck.

Was the problem s olv ed? — Go to

Step 20

Go to

Step 31

20 Replace the TPS.

Is the action complete? — Verify repair —

21 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 pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 22

22 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 23

23 Substitute a known good CKP sensor and recheck.

Was the problem s olv ed? — Go to

Step 24

Go to

Step 25

24 Replace the CKP sensor.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

25 1. Using the Tech 2 and ignition “On” and engine

“Run”.

2. Monitor the following parameters in the data

display.

• “Desired Injection Quantity” & “Injection Quantity”

• “Desired Injection Start” & “Actual Injection Start”

Are the large gap or unstable parameter displayed

between “Desired” and “Actual”?

—Go to

Step 29

Go to

Step 26

26 Us ing the vacuum pum p and check the EGR valve (if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 27

27 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 28

28 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 29

Step Action Value(s) Yes No

When idling or part-throttle

High Desired

Low

Time

Actual

Vacuum Pump

Small Window

29 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?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 30

30 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 31

31 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved? — Verify repair Go to

Step 32

32 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the ECM/Immobiliser linking procedure. — Go to

Step 33

Go to

Step 34

33 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

Step Action Value(s) Yes No

34 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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 Action Value(s) Yes No

1 Was the “On-Boar d Diagnostic (OBD) Sys tem Check”

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses t he symptom? — Verify repair Go to

Step 3

3 Was a visually/phy sical check performed? —Go to

Step 4

Go to

Visual /

physical Check

4 Is the customer using the i ncorrect fuel type? Diesel fuel

only Replace with

diesel fuel Go to

Step 5

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

• Che ck for o bjects blo cking or exces sive depo sits in

the throttle bore and o n the thro ttle plate

• Check for a condition that causes a large vacuum

leak, such as an incorrectly installed or faulty

crankcas e ven tilati on hose.

• Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger

compressor wheel or turbine shaft sticking.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 6

6 Check the ECM & PSG groun ds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to

Step 7

7 1. Using th e Tech 2, d ispl ay the E CT sens or an d IAT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Verify repair Go to

Step 8

8 1. Using the Tech 2, display the FT sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Go to

Step 30

Go to

Step 9

9 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 14

Go to

Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 13

Go to

Step 30

13 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operat ion? — Go to

Step 19

Go to

Step 15

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved ? — Verify repair Go to

Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 17

17 Substitute a known good TPS and recheck.

Was the problem s olv ed? — Go to

Step 18

Go to

Step 30

18 Replace the TPS.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

19 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”?

—Go to

Step 23

Go to

Step 20

20 Us ing the vacuum pum p and check the EGR valve (if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 21

21 Using the vacuum pump and check the exhaust

throttle valve (if equipped) operation for the following

condition.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

Was a problem found?

— Verify repair Go to

Step 22

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

Vacuum Pump

Small Window

22 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic conve rter.

• Internal muffler failure.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 23

23 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 24

24 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 25

25 Remove the eye bolt with gauze filter from the

injection pump and check for the followin g 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 mai nte nance int erva l.

• 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 pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 26

Step Action Value(s) Yes No

26 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressu re is incorrect.

If a pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and ve rify repair Go to

Step 27

27 Check the engine compression pressure for each

cylinders.

If a pro blem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to

Step 28

28 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the s p ecified value?

0.4mm at cold

(In/Ex) Go to

Step 29

Adjust and

verify repair

29 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 30

Step Action Value(s) Yes No

S tage 2

S tage

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

30 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved? — Verify repair Go to

Step 31

31 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 32

Go to

Step 33

32 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

33 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

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 Action Value(s) Yes No

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

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to

Step 3

3 Was a visually/physical check performed? —Go to

Step 4

Go to

Visual /

physical Check.

4 Check owner's driving habits.

• Is the A/C “On” full time?

• Are tires at the correct pressure?

• Are excessively heavy loads being carried?

• Is acceleration too much, too often? — Go to

Step 5

Go to

Step 6

5 Review the items in Step 4 with the customer and

advise as necessary.

Is the action complete? — System OK —

6 Check for low engine coolant level.

Was a problem found? — Verify repair Go to

Step 7

7 Check for incorrect or faulty engine thermostat. Refer

to Engine Cool ing.

Was a problem found? — Verify repair Go to

Step 8

8 Check for proper calibration of th e speedometer.

Does the s peed indicated on the sp eed meter close ly

match the vehicle speed display ed on the Tech 2? — Go to

Step 10

Go to

Step 9

9 Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed

Sensor in Electrical Diagnosis. — Verify repair —

10 Check for proper calibration of the fuel gauge.

Was a problem found? — Verify repair Go to

Step 11

11 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? — Verify repair Go to

Step 12

12 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 depe nding on any shift positions?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 13

13 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “A/C Information Switch” in the data

display.

Does the Tech 2 indicate correct “A/C Information

Switch ” status depend ing on A/C switch posi tion?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 14

14 Visually/physically inspect for the following conditions.

• Restrict air intake system. Check for a restricted air

filter element, or foreign objects blocking the air

intake system

• Che ck for o bjects blo cking or exces sive depo sits in

the throttle bore and o n the thro ttle plate

• Check for a condition that causes a large vacuum

leak, such as an incorrectly installed or faulty

crankcas e ven tilati on hose.

• Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger

compressor wheel or turbine s haft sticking.

If a problem is found, repair as n ecessary.

Was a problem found? — Verify repair Go to

Step 15

15 1. Using th e Tec h 2, displ ay the E CT sens or and I AT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 16

16 1. Usin g 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 pro blem is found, repair as necessary.

Was the problem found? — Go to

Step 31

Go to

Step 17

17 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 22

Go to

Step 18

18 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 19

19 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 20

Step Action Value(s) Yes No

20 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 21

Go to

Step 31

21 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

Does the Tech 2 indicate correct “Pedal/Throttle

Position” from 0% to 100% and correct “Idle Switch”

status depending on accelerator pedal operat ion? — Go to

Step 27

Go to

Step 23

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

2. Monitor the “Pedal/Throttle Position” and “Idle

Switch” in the data display.

3. Adjust the accelerator cable or TPS within 0% to

100%.

Was the problem solved ? — Verify repair Go to

Step 24

24 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 25

25 Substitute a known good TPS and recheck.

Was the problem s olv ed? — Go to

Step 26

Go to

Step 31

26 Replace the TPS.

Is the action complete? — Verify repair —

27 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressu re is incorrect.

If a pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and ve rify repair Go to

Step 28

Step Action Value(s) Yes No

S tage 2

Stage

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

28 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to

Step 29

29 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the specified value?

0.4mm at cold

(In/Ex) Go to

Step 30

Adjust and

verify repair

30 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 31

31 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved? — Verify repair Go to

Step 32

32 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 33

Go to

Step 34

Step Action Value(s) Yes No

33 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

34 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Excessive White Smoke

Step Action Value(s) Yes No

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

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to

Step 3

3 Was a visually/physical check performed? —Go to

Step 4

Go to

Visual /

physical Check.

4 Is the customer using the incorrect fuel type? Diesel fuel

onlyReplace with

diesel fuel Go to

Step 5

5 Check the engine coolant consumption to verify that it

leaks to combustion chamber or exhaust through the

gasket.

Was a problem found? — Verify repair Go to

Step 6

6 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to

Step 7

7 1. Using th e Tech 2, d ispl ay the E CT sens or an d IAT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Verify repair Go to

Step 8

8 1. Using the Tech 2, display the FT sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Go to

Step 30

Go to

Step 9

9 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 14

Go to

Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 13

Go to

Step 30

13 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

14 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Glow Time Relay” in the data display.

Does the Tech 2 indicate correct “Glow Time Relay”

status depending on the time from engine “Run”?

If a pro blem is found, repair as necessary.

Was the problem found? — Go to

Step 30

Go to

Step 15

15 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Mo nitor the “Gl ow Time Relay” in the data display

and th en, does the supply voltage correctly supply

to the glow plug?

—Go to

Step 16

Repair voltage

supply circuit

and verify repair

16 Check the glo w plugs for continuity.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 17

17 Remove the CKP sensor from the flywheel housing

and check for the following conditions.

• Objects sticking the CKP sensor.

• Objects sticking the CKP sensor pulser.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 18

18 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 19

Step Action Value(s) Yes No

19 Substitute a known good CKP sensor and recheck.

Was the problem s olv ed? — Go to

Step 20

Go to

Step 21

20 Replace the CKP sensor.

Is the action complete? — Verify repair —

21 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”?

—Go to

Step 23

Go to

Step 22

22 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic conve rter.

• Internal muffler failure.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 23

23 Visually/physically inspect for the following conditions.

• Restrict fuel supply system. Check for a pinched

fuel hose/pipe.

• Check for a condition that causes fuel waxing or

icing, such as the customer is using an incorrect

fuel type in winter season or water mixed with the

fuel.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 24

24 Replace the fuel f ilter.

Was the problem solved ? — Verify repair Go to

Step 25

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

25 Remove the eye bolt with gauze filter from the

injection pump and check for the followin g 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 mai nte nance int erva l.

• 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 pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

eye bolt with

gauze filter and

verify repair Go to

Step 26

26 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressu re is incorrect.

If a pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and ve rify repair Go to

Step 27

27 Check the engine compression pressure for each

cylinders.

If a pro blem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to

Step 28

Step Action Value(s) Yes No

Stage 2

Stage

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

28 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the specified value?

0.4mm at cold

(In/Ex) Go to

Step 29

Adjust and

verify repair

29 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 30

30 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved? — Verify repair Go to

Step 31

31 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 32

Go to

Step 33

32 Replace the ECM.

Is the action complete?

IMPORTANT:

The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

33 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Excessive Black Smoke

Step Action Value(s) Yes No

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

performed?

—Go to

Step 2

Go to

On Board

Diagnostic

(OBD) System

Check

2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,

correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visually/physical check performed? —Go to

Step 4

Go to

Visual /

physical Check.

4 Is the customer using the incorrect fuel type? Diesel fuel

onlyReplace with

diesel fuel Go to

Step 5

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

• Check for objects blocking or excessive deposits in

the throttle bore and on the throttle plate

• Check for a condition that causes a large vacuum

leak, such as an incorrectly installed or faulty

crankcase ventilation hose.

• Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger

compressor wheel or turbine shaft sticking.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 6

6 Check the ECM & PSG grounds to verify that they are

clean and tight. Refer to the ECM wiring diagrams.

Was a problem found? — Verify repair Go to

Step 7

7 1. Using th e Tech 2, d ispl ay the E CT sens or an d IAT

sensor val ue.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Verify repair Go to

Step 8

8 1. Using the Tech 2, display the FT sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as n ecessary.

Was the problem found? — Go to

Step 22

Go to

Step 9

9 1. Using the Tech 2, ignition “On ” and eng ine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on a cc elerator pedal operation? — Go to

Step 14

Go to

Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a pro blem is found, repair as necessary.

Was the problem found? — Verify repair Go to

Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Che ck for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem s olv ed? — Go to

Step 13

Go to

Step 22

13 Replace the MAF & IAT sensor ass embly.

Is the action complete? — Verify repair —

14 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”?

—Go to

Step 21

Go to

Step 15

15 Us ing the vacuum pum p and check the EGR valve (if

equipped) operation for the following condition

through the small window.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

If a pro blem is found, repair as necessary.

Was a problem found?

— Verify repair Go to

Step 16

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

Vacuum Pump

Small Window

16 Using the vacuum pump and check the exhaust

throttle valve (if equipped) operation for the following

condition.

• Restrict shaft movement. Check for objects sticking

the shaft, broken diaphragm or excessive carbon

deposit.

Was a problem found?

— Verify repair Go to

Step 17

17 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic conve rter.

• Internal muffler failure.

If a pro blem is found, repair as necessary.

Was a problem found? — Verify repair Go to

Step 18

18 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper splay condition.

• Operating pressu re is incorrect.

If a pro blem is found, repair as necessary.

Was the problem found?

—

Replace the

injection nozzle

and ve rify repair Go to

Step 19

Step Action Value(s) Yes No

Stage 2

Stage

4JA1-TC 19.5 - 20.5 Mpa

(199 -209 kg/cm

)34.0 - 35.5 Mpa

(347 - 362 kg/cm

)

4JH1-TC 20.0 - 21.0 Mpa

(204 -214 kg/cm

)34.3 - 35.8 Mpa

(350 - 365 kg/cm

)

19 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 30

Mpa (31.0 kg/

) Verify repair Go to

Step 20

20 Check the inlet/exhaust valve clearance for each

valves.

Are the valve clearances within the specified value?

0.4mm at cold

(In/Ex) Go to

Step 21

Adjust and

verify repair

21 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to

Step 22

22 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the

“SPS (Service Programming System)”

Was the problem solved? — Verify repair Go to

Step 23

23 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, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Go to

Step 24

Go to

Step 25

Step Action Value(s) Yes No

24 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, th e immobiliser system

(if equipped) must be linked to the ECM. Refer to

section 11 “Immobiliser System-ECM replacement” for

the EC M/Immobiliser linking proc edure. — Verify repair —

25 Replace the injecti on pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

On-vehicle Service Procedure

Engine Control Module (ECM)

Location

Upper the transmission tunnel.

Removal Procedure

1. Disconnect the negative battery cable.

2. Remove the ECM cover.

3. Disconnect the two connectors from the ECM.

4. Remove four screws from the ECM braket.

Installation Procedure

1. Put on the ECM to the braket and tighten by four

screws.

2. Connect the two connectors to the ECM.

3. Refit the ECM cover by four screws.

4. 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 immobiliser system (if

equipped) must be linked to the ECM. Refer to section

11 “Immobiliser System-ECM replacement” for the

ECM/Immobiliser linking proc edure.

Crankshaft Position (CKP) Sensor

Location

Installed to the clutch housing.

Removal Procedure

1. Disconnect the negative battery cable.

2. Disconnect connector from the CKP sensor.

3. L oosen a bolt and remov e the CKP sensor fro m the

clutch housing.

Installation Procedure

1. Install the CKP sens or 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 k gf·m)

3. Connect a CKP sensor connector to the CKP

sensor.

4. Connect the negative battery cab le.

NOTE:

Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

Engine Coolant Temperature (ECT) Sensor

Location

Installed to the thermostat housing.

Removal Procedure

1. Disconnect the negativ e battery cable.

2. Drain enough engine coolant so that the coolant

level will be below th e ECT sensor.

3. Disconnect connector from the ECT sensor.

4. Loosen and remove the ECT sensor from the

thermostat housing.

NOTE:

Cool down the en gine before above p rocedures

are carried out.

Installation Procedure

1. Apply sealer to threads of screw at the E CT 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.

Mass Air Flow (MAF) & Intake Air

Temper ature (IAT) Sensor

Location

Installed to the intake duc t housing .

Removal Procedure

1. Disconnect the negative battery cable.

2. Di sconnec t a MA F & IAT se nsor conn ector from the

MAF & IAT sensor assembly.

3. Loosen th e clips and remove the MA F & IAT sensor

assemb ly from the intake duct housing.

Installation Procedure

1. Install the MAF & IAT sensor assembly into intake

air duct.

2. Tighten the clips.

3. Connect a MAF & IAT sens or conne ctor to the MAF

& IAT sensor assembly.

4. Connect the negative battery cab le.

NOTE:

Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

Pedal(Throttle) Position Sensor (TPS)

Location

Installed on the accelerator pedal mou nting bra cket.

Removal Procedure

1. Disconnect the negativ e battery cable.

2. Disco nne ct the TPS co nnec to r.

3. Loosen two screws and remove TPS from the

throttle body.

Installation Procedure

1. Temporary tighten the TPS by two screws.

2. Connect a TPS con nectors to the TPS.

3. Connect the Tech2 to the vehicle.

4. Connect the negative battery cable.

5. Select “Data Display” with the Tech2.

6. Check the throttle position data and adjust the TPS

position.

7. Tighten two screws.

NOTE:

Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

Special Service Tools

ILLUSTRATION TOOL NO.

TOLL NAME

5-8840-0285-0

(J 39200)

High Impeda nce

Multimeter

(Digital Vo ltmeter -DVM)

(1) PCMCIA Card

(2) RS232 Loop Back

Connector

(3) SAE 1 6/19 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 P ump with Gauge