SECTION 6E2 - ENGINE DRIVEABILITY AND EMISSIONS

ABBREVIATION CHARTS

COMPONENT LOCATOR

Engine Component Locator Table

ECM CIRCUIT DIAGRAM

ECM CIRCUIT DIAGRAM (1/2)

ECM CIRCUIT DIAGRAM (2/2)

GROUND POINT

LOCATION

CABLE HARNESS & CONNECTOR LOCATION

PARTS LOCATION

CONNECTOR LIST

RELAY AND FUSE

RELAY AND FUSE BOX LOCATION

FUSE AND RELAY LOCATION

ECM WIRING DIAGRAM

ECM WIRING DIAGRAM (1/7)

ECM WIRING DIAGRAM (2/7)

ECM WIRING DIAGRAM (3/7)

ECM WIRING DIAGRAM (4/7)

ECM WIRING DIAGRAM (5/7)

ECM WIRING DIAGRAM (6/7)

ECM WIRING DIAGRAM (7/7)

ECM CONNECTOR PIN ASSIGNMENT

& OUTPUT SIGNAL

PSG CONNECTOR PIN ASSIGNMENT

& OUTPUT SIGNAL

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

Throttle Position Sensor (T PS)

Crankshaft Position (CKP) Sensor

Engine Coolant Temperature (ECT) Sensor

Vehicle Speed Sensor (VSS)

GENERAL DESCRIPTION FOR EGR

(EXHAUST GAS RE-CIRCULATION)

GENERAL DESCRIPTION FOR INJECTION PUMP

Outline

Cross-section View

Low Pressure Fuel Circuit

High Pressure Fuel Circuit

Pump Camshaft Speed Sensor

High Pressure Solenoid Valve

Timing Control Valve (TCV)

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

Diag nostic 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

Verifying Vehicle Repair

Reading Flash Diagnostic Trouble Codes

Reading Diagnostic Trouble Codes

Using a Tech 2

History DTC

Diagnosis With Tech 2

TECH 2 OPERATING FLOW CHART (START UP)

Typical Scan Data & Definitions (Engine Data)

Miscellaneous Test

Plotting Snapshot Graph

Plotting Graph Flow Chart (Plotting graph

after obtaining vehicle information)

Flow Chart for Snaps hot Replay (Plotting G raph)

Snapshot Display With TIS2000

SERVICE PROGRAMMING SYSTEM (SPS)

ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

NO CHECK ENGINE LAMP (MIL)

CHECK ENGINE LAMP (MIL) “ON” STEADY

Techline

ECM DIAGNOSTIC TROUBLE CODES

DIAGNOSTIC TROUBLE CODE (DTC) P0100

(SYMPTOM CODE 7) (FLASH CODE 65) MASS

AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY

CIRCUIT HIGH INPUT DIAGNOSTIC TROUBLE

CODE (DTC) P0100 (SYMPTOM CODE 9)

(FLASH CODE 65) MASS AIR FLOW (MAF)

SENSOR VOLTAGE SUPPLY CIRCUIT LOW

INPUT DIAGNOSTIC TROUBLE CODE (DTC)

P0100 (SYMPTOM CODE B) (FLASH CODE 65)

MASS AIR FLOW (MAF) SENSOR OUTPUT

CIRCUIT LOW INPUT DIAGNOSTIC TROUBLE

CODE (DTC) P0100 (SYMPTOM CODE C)

(FLASH CODE 65) MASS AIR FLOW (MAF)

SENSOR OUTPUT CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0105

(SYMPTOM CODE 1) (FLASH CODE 34)

VACUUM PRESSURE SENSOR CIRCUIT HIGH

INPUT DIAGNOSTIC TROUBLE CODE (DTC)

P0105 (SYMPTOM CODE 2) (FLASH CODE 34)

VACUUM PRESSURE SENSOR CIRCUIT LOW

INPUT DIAGNOSTIC TROUBLE CODE (DTC)

P0105 (SYMPTOM CODE 7) (FLASH CODE 34)

VACUUM PRESSURE SENSOR VOLTAGE

SUPPLY CIRCUIT HIGH INPUT DIAGNOSTIC

TROUBLE CODE (DTC) P0105 (SYMPTOM

CODE 9) (FLASH CODE 34) VACUUM

PRESSURE SENSOR VOLTAGE SUPPLY

CIRCUIT LOW INPUT

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

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

DIAGNOSTIC TROUBLE CODE (DTC) P0180

(SYMPTOM CODE B) (FLASH CODE 15) FUEL

TEMPERATURE SENSOR CIRCUIT RANGE/

PERFORMANCE

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

DIAGNOSTIC TROUBLE CODE (DTC) P0216

(SYMPTOM CODE A) (FLASH CODE 54)

INJECTION TIMING CONTROL CIRCUIT

MALFUNCTION DIAGNOSTIC TROUBLE CODE

(DTC) P0216 (SYMPTOM CODE B) (FLASH

CODE 54) INJECTION TIMING CONTROL

CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0243

(SYMPTOM CODE 3) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID

"A" RANGE/PERFORMANCE DIAGNOSTIC

TROUBLE CODE (DTC) P0243 (SYMPTOM

CODE 4) (FLASH CODE 64) TURBOCHARGER

WASTEGATE SOLENOID "A" LOW

DIAGNOSTIC TROUBLE CODE (DTC) P0243

(SYMPTOM CODE 5) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID

"A" RANGE/PERFORMANCE DIAGNOSTIC

TROUBLE CODE (DTC) P0243 (SYMPTOM

CODE 6) (FLASH CODE 64) TURBOCHARGER

WASTEGATE SOLENOID "A" MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0243

(SYMPTOM CODE 8) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID

"A" HIGH

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 6) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 7) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 9) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE A) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE B) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE D) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE E) (FLASH CODE 53)

INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0335

(SYMPTOM CODE B) (FLASH CODE

43)CRANKSHAFT POSITION SENSOR CIRCUIT

MALFUNCTION DIAGNOSTIC TROUBLE CODE

(DTC) P0335 (SYMPTOM CODE D) (FLASH

CODE 43) CRANKSHAFT POSITION SENSOR

MALFUNCTION DIAGNOSTIC TROUBLE CODE

(DTC) P0335 (SYMPTOM CODE E) (FLASH

CODE 43) ENGINE SPEED INPUT CIRCUIT

RANGE/PERFORMANCE

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

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 TROUBLE CODE (DTC) P0400

(SYMPTOM CODE 3) (FLASH CODE 32)

EXHAUST GAS RECIRCULATION FLOW

EXCESSIVE DETE CTED DIAGNOSTIC

TROUBLE CODE (DTC) P0400 (SYMPTOM

CODE 4) (FLASH CODE 32) EXHAUST GAS

RECIRCULATION CIRCUIT SHORT TO

GROUND OR OPEN CIRCUIT DIAGNOSTIC

TROUBLE CODE (DTC) P0400 (SYMPTOM

CODE 5) (FLASH CODE 32) EXHAUST GAS

RECIRCULATION FLOW INSUFFICIENT

DETECTED DIAGNOSTIC TROUBLE CODE

(DTC) P0400 (SYMPTOM CODE 8) (FLASH

CODE 32) EXHAUST GAS RECIRCULATION

CIRCUIT SHORT TO BATTERY

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

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

DIAGNOSTIC TROUBLE CODE (DTC) P0561

(SYMPTOM CODE A) (FLASH CODE 18)

IGNITION SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0561

(SYMPTOM CODE B) (FLASH CODE 18)

IGNITION SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0602

CONTROL MODULE PROGRAMMING ERROR

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

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

DIAGNOSTIC TROUBLE CODE (DTC) P0703

(SYMPTOM CODE A) (FLASH CODE 25)

BRAKE SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0703

(SYMPTOM CODE B) (FLASH CODE 25)

BRAKE SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0704

(SYMPTOM CODE 6) (FLASH CODE 57)

CLUTCH SWITCH INPUT 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 TROUBLE CODE (DTC) P1173

(SYMPTOM CODE 3) (FLASH CODE 22) FUEL

REDUCTION CAUSED BY HIGH COOLANT

TEMPERATURE DIAGNOSTIC TROUBLE

CODE (DTC) P1173 (SYMPTOM CODE 7)

(FLASH CODE 22) FUEL REDUCTION CAUSED

BY HIGH FUEL TEMPERATURE DIAGNOSTIC

TROUBLE CODE (DTC) P1173 (SYMPTOM

CODE A) (FLASH CODE 22) FUEL REDUCTION

CAUSED BY LOW FUEL TEMPERATURE

DIAGNOSTIC TROUBLE CODE (DTC) P1335

(SYMPTOM CODE A) (FLASH CODE 43)

ENGINE SPEED OUTPUT CIRCUIT

MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P1345

(SYMPTOM CODE A) (FLASH CODE 45)

CAMSHAFT SPEED MALFUNCTION

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

DIAGNOSTIC TROUBLE CODE (DTC) P1605

(SYMPTOM CODE C) (FLASH CODE 55) SEED

AND KEY FILE DESTROYED DIAGNOSTIC

TROUBLE CODE (DTC) P1605 (SYMPTOM

CODE D) (FLASH CODE 55) EEPROM DEFECT

DIAGNOSTIC TROUBLE CODE (DTC) P1605

(SYMPTOM CODE E) (FLASH CODE 55)

EEPROM DEFECT

DIAGNOSTIC TROUBLE CODE (DTC) P1610

(SYMPTOM CODE A) (FLASH CODE 56)

SECURITY KEY AND SECURITY CODE NOT

PROGRAMMED

DIAGNOSTIC TROUBLE CODE (DTC) P1611

(SYMPTOM CODE A) (FLASH CODE 56)

WRONG SECURITY CODE ENTERED

DIAGNOSTIC TROUBLE CODE (DTC) P1612

(SYMPTOM CODE A) (FLASH CODE 56)

IMMOBILIZER NO OR WRONG SIGNAL

DIAGNOSTIC TROUBLE CODE (DTC) P1613

(SYMPTOM CODE A) (FLASH CODE 56)

IMMOBILIZER NO OR WRONG SIGNAL

DIAGNOSTIC TROUBLE CODE (DTC) P1614

(SYMPTOM CODE A) (FLASH CODE 56)

WRONG TRANSPONDER KEY

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

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

DIAGNOSTIC TROUBLE CODE (DTC) P1650

(SYMPTOM CODE A) (FLASH CODE 44) CAN

DEVICE OFFLINE DIAGNOSTIC TROUBLE

CODE (DTC) P1 650 (SYM PTO M CO DE B)

(FLASH CODE 44) CAN DEVICE HANG-UP

DIAGNOSTIC TROUBLE CODE (DTC) P1651

(SYMPTOM CODE A) (FLASH CODE 45) CAN

MALFUNCTION DIAGNOSTIC TROUBLE CODE

(DTC) P1651 (SYMPTOM CODE B) (FLASH

CODE 45) CAN RECEIVES ERROR

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

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 S YMPTOM

EXCESSIVE WHITE SMOKE

EXCESSIVE BLACK SMOKE

ON-VEHICLE SERVICE PROC EDURE

ENGINE CONTROL MODULE (ECM)

CRANKSHAFT POSITION (CKP) SENSOR

ENGINE COOLANT TEMPERATURE

(ECT) SENSOR

MASS AIR FLOW (MAF) & INTAKE AIR

TEMPERATURE (IAT) SENSOR

THROTTLE POSITION SENSOR (TPS)

EGR EVRV (Electrical Vacuum Regulating Valve)

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 olant tempera tur e

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

VCC Voltage constunt control

VIO Violet

VSS Vehicle speed sensor

WHT White

YEL Yellow

COMPONENT LOCATOR

ENGINE COMPONENT LOCATOR TABLE

PNQO

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

(IAT) Sensor Assembly

(2) Throttle Cable

(3) Air Cleaner Case

(4) EGR Pipe

P O Q

(1) Throttle Position Sensor (TPS)

(2) Pump Control Unit (PSG) (3) Injection Pump Assembly

(4) Fuel Filter

O NP

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

(IAT) Sensor Assembly

(2) EGR EVRV

(3) Air Cleaner Case

(1) Engine Control Module (ECM) (1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge

(1) Vehicle Speed Sensor (VSS)

(1) EGR EVRV

(2) To Vacuum Pump

(3) To EGR Valve

(1) Crankshaft Position (CKP) Sensor

(2) Clutch Housing

P O N

ECM CIRCUIT DIAGRAM

ECM CIRCUIT DIAGRAM (1/2)

ECM CIRCUIT DIAGRAM (2/2)

GROUND POINT

GROUND POINT CHART (1/4)

GROUND POINT CHART (2/4)

GROUND POINT CHART (3/4)

GROUND POINT CHART (4/4)

LOCATION

CABLE HARNESS & CONNECTOR LOCATION

PARTS LOCATION

CONNECTOR LIST

No. Connector face No. Connector face

B-24

Green Meter-B

C-56

ECM-A

B-54

White J/B I2

C-57

ECM-B

B-56

White J/B I4

C-77

Clut ch swi t c h

B-58

Black Check connector

C-94

White TCM

B-62

White Ignition switch (IGSUB : G1)

C-95

White TCM

B-63

White Ignition switch (IGSUB : G2)

C-

White J/B E2

B-68

Immobilizer

C-

White J/B E1

C-2

Silver Engine room-RH ground

C-

Silver Body-LH ; ground

C-36

Silver Engine room-LH ; Ground

C-

Brown EVRV

C-44

White Stop lamp switch

C-

No. Connector face No. Connector face

C-

A/C Resister & Neutral switch

E-23

Gray Idle SW

C- E-41

Black Coolant temp sensor

C- E-44

Gray Vehi cle sp eed sensor

E-3

Black Magnetic clutch AC COMP

E-49

Gray Glow plug

E-6 E-51

Black Inhibiter switch

E-9 H-4

White Engine room ~ Mission

E-10

Silver Engine ground

H-6

White Engine room ~ INST

E-11

Natural

green Neutral switch

H-7

White Engine room ~ INST

E-12

Natural

green Neutral switch

H-18

White Engine room ~ INST

E-22

Brown TPS 1 main

H-22

White Engine ~ Engine room C

No. Connector face No. Connector face

H-33

Engine ~ Engine room

X-16

Black DIODE

P-1

Silver Battery (+)

X-17

Black DIODE

P-2

Silv er Relay & Fuse box

P-5

Silver Battery (-)

P-6

Silver Body earth (Gr oun d)

P-10

Silver Engine ground

X-5

Black Relay ; Glow

X-13

Black Relay ; ECM MAIN

X-14

Black Relay; A/C Compressor

X-15

Black Relay; Thermo

RELAY AND FUSE

RELAY AND FUSE BOX LOCATION

RELAY & FUSE BOX

RELAY

No. RELAY

X-1 RELAY; TAIL LIGHT

X-2 RELAY; FRT FOG LIGHT

X-3 RELAY; HO RN

X-4 RELAY; DI MMER

X-5 RELAY; GLOW

X-6 RELAY; COND, FAN

X-7 R ELAY; RR FO G

X-8 RELAY; STARTER

X-9 RELAY; HAZARD-RH

X-10 RELAY; HAZARD-LH

X-11 RELAY; HEATER

X-12 RELAY; HEAD LIGHT

X-13 RELAY; ECM MAIN

X-14 RELAY; A/C COMP

X-15 RELAY; THERMO

FUSE

SLOW BLOW FUSE

NO. FUSE

EB-1 10A ECM

EB-2 10A RR FOG

EB-3 15A FRT FOG

EB-4 —

EB-5 10A ILLUMI & TAIL-RH

EB-6 10A TAIL-LH

EB-7 10A H/LIGHT RH-LOW

EB-8 10A H/LIGHT LH-LOW

EB-9 10A TRA ILER

EB-10 10A AC G (S)

EB-11 10A H/LIGHT RH-HIGH

EB-12 10A H/LIGHT LH-HIGH

EB-13 10A A/C

EB-14 10A 4WD

EB-15 10A HORN

EB-16 10A HAZARD

NO. SLOW BLOW FUSE

SBF-1 80A MAIN

SBF-2 20A COND, FAN

SBF-3 50A GLOW

SBF-4 30A ECM

SBF-5 40A IG 1

SBF-6 40A ABS-1

SBF-7 30A ABS-2

SBF-8 30A BLOWER

SBF-9 50A IG 2

FUSE AND RELAY LOCATION

FUSE

SLOW BLOW FUS E

RELAY

No. Capacity Indication on label No. Capacity Indication on label

1— — 1215ACIGER

2 10A ABS 13 15A AUDIO (+B)

3 — — 14 20A DOOR LOCK

4 15A BACK UP 15 10A METER (+B)

5 15A METER 16 10A ROOM

6 10A TURN 17 10A ANTI THEFT

7 15A ELEC.IG 18 15A STOP

8 15A ENGINE 19 15A ACC SOCKET

9 20A FRT WIPER 20 10A STARTER

10 15A EGR 21 10A SRS

11 10A AUDIO

No. Capacity Indication on label

SBF-10 20A RR DEF

SBF-11 30A POWER WINDOW

Connector No. B-7 B-8 B-40

REAR

DEFOGGER POWER

WINDOW ACC

SOCKET

FUSE BOX

ECM WIRING DIAGRAM

ECM WIRING DIAGRAM (1/7)

ECM WIRING DIAGRAM (2/7)

ECM WIRING DIAGRAM (3/7)

ECM WIRING DIAGRAM (4/7)

ECM WIRING DIAGRAM (5/7)

ECM WIRING DIAGRAM (6/7)

ECM WIRING DIAGRAM (7/7)

ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into ECM Case

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rpm ECM

Connec-

tion

Ran

ge (+) (-)

1 1 ECM Ground BLK Continu-

ity with

ground

- - - Discon-

nect Ohm 1 GND

2 2 ECM Ground BLK Continu-

ity with

ground

- - - Discon-

nect Ohm 2 GND

3 3 Battery Power Sup-

ply BLU/

RED Less

than 1V 10-14V Connect DC V 3 GND

25 25 No Connection - - - - - - - - -

26 26 No Connection - - - - - - - - -

27 27 Engine Speed Output

(To Tacho Me ter) LGN - - Approx.

23Hz by

wave

form o r

approx.

6.3V

Approx.

67Hz by

wave

form or

approx.

6.8V

Connect AC V 27 GND

28 28 No Connection - - - - - - - - -

29 29 Throttle Position Sig-

nal To TCM (A16)

(AT Only)

- Approx. 140Hz by wave form (Idle:

Off dut y 1 0 % / WOT: Off duty 90%) - ---

30 30 Brake Switch 1 Sig-

nal GRN Less

than 1V Pedal is not stepped on: Less than

Pedal is stepped on: 10-14V

Connect DC V 30 GND

31 31 Clutch Switch Signal

(MT Only) YEL Less

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

Pedal is stepped on: Less than 1V Connect DC V 31 GND

32 32 No Connection - - - - - - - - -

33 33 A/C ON Signal Relay GRN/

YEL Less

than 1V A/C request switch is turned on: 10-

14V

A/C request switch is turned off:

Less than 1V

Connect DC V 33 GND

34 34 No Connection - - - - - - - - -

35 35 To Data Link Con-

nector No. 6 & Immo-

bilizer Control Unit

(ICU B8)

YEL--------

36 36 No Connection - - - - - - - - -

37 37 No Connection - - - - - - - - -

38 38 Throttle Position

Sensor (TPS) Out-

put Signal

GRN/

ORG Less

than 1V Less than 1V Approx.

0.5V Connect DC V 38 49

39 39 Key Switch Input Sig-

nal Via Engine Fuse WHT Less

than 1V 10-14V Connect DC V 39 GND

40 40 No Connection - - - - - - - - -

41 41 A/C Compresso r

Relay WHT/

GRN Less

than 1V 10-14V A/C comp. is oper-

ated: Less than 1V

A/C comp. is not oper-

ated: 10 - 14V

Connect DC V 41 GND

42 42 Check Engine Lamp GRN/

YEL Less

than 1V Lamp is turned on: Less than 1V

Lamp is turned off: 10-14V Connect DC V 42 GND

43 43 Glow Lamp ORG/

BLU Less

than 1V Lamp is turned on: Less than 1V

Lamp is turned off: 10-14V Connect DC V 43 GND

44 44 No Connection - - - - - - - - -

45 45 To Data Link Con-

nector No. 6 BLU Less

than 1V 10-14V Connect DC V 45 GND

46 46 No Connection - - - - - - - - -

47 47 No Connection - - - - - - - - -

48 48 No Connection - - - - - - - - -

49 49 Throttle Position

Sensor (TPS)

Ground

BLK/

GRN Idle:

Approx.

0.4K

ohm /

WOT:

Approx.

4.0K

ohm

- - - Discon-

nect Ohm 38 49

50 50 No Connection - - - - - - - - -

51 51 No Connection - - - - - - - - -

52 52 No Connection - - - - - - - - -

53 53 No Connection - - - - - - - - -

54 54 No Connection - - - - - - - - -

55 55 No Connection - - - - - - - - -

56 56 No Connection - - - - - - - - -

57 57 Throttle Position

Sensor (TPS) Power

Supply

RED/

GRN Less

than 1V Approx. 5V Connect DC V 57 49

58 58 ECM Relay BLU/

BLK 10-14V Less than 1V Connect DC V 58 GND

59 59 No Connection - - - - - - - - -

60 60 No Connection - - - - - - - - -

61 61 No Connection - - - - - - - - -

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rpm ECM

Connec-

tion

Ran

ge (+) (-)

62 62 No Connection - - - - - - - - -

63 63 ECM Power Supply - Less

than 1V 10-14V - DC V 63 GND

64 64 No Connection - - - - - - - - -

65 65 Brake Switch 2 Sig-

nal WHT/

BLK Less

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

Pedal is stepped on: Less than 1V Connect DC V 65 GND

66 66 No Connection - - - - - - - - -

67 67 No Connection - - - - - - - - -

68 68 Vehicle Speed Sen-

sor (VSS) YEL/

GRN - Approx. 14.5Hz by wave form or

approx. 6.0V at vehicle speed

20km/h

Connect AC V 68 GND

69 69 Idle Switch GRN/

BLK Less

than 1V Pedal is not stepped on: Less than

Pedal is stepped on: Approx. 5V

Connect DC V 69 GND

70 70 No Connection - - - - - - - - -

71 71 No Connection - - - - - - - - -

72 72 No Connection - - - - - - - - -

73 73 No Connection - - - - - - - - -

74 74 No Connection - - - - - - - - -

75 75 No Connection - - - - - - - - -

76 76 No Connection - - - - - - - - -

77 77 No Connection - - - - - - - - -

78 78 No Connection - - - - - - - - -

79 79 No Connection - - - - - - - - -

80 80 No Connection - - - - - - - - -

81 81 No Connection - - - - - - - - -

82 82 Boost Pressure Sen-

sor (High Altitude

Spec . Only)

WHT/

BLU Less

than 1V Approx. 5V Connect DC V 82 93

83 83 Mass Air Flow (MAF)

Sensor Power Sup-

ply

WHT/

RED Less

than 1V Approx. 5V Connect DC V 83 92

84 84 Intake Air Tempera-

ture (IAT) Sensor

Signal

BLK/

BLU Less

than 1V 0 deg. C: Approx. 3.6V / 20 deg. C:

Approx. 2.6V / 40 deg. C: Approx.

1.7V / 60 deg. C: 1.1V / 80 deg. C:

0.7V

Connect DC V 84 92

85 85 Manifold Pressure

Sensor (High Altitude

Spec . Only)

RED/

BLU Less

than 1V - - - Connect DC V 85 93

86 86 No Connection - - - - - - - - -

87 87 Neut ral Switch BLK/

WHT Less

than 1V In neutral (A/T: P or N): Less than

Other than neutral (A/T: other than

P or N): 10-14V

Connect DC V 87 GND

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rpm ECM

Connec-

tion

Ran

ge (+) (-)

88 88 Mass Air Flow (MAF)

Sensor Signal GRN/

RED Less

than 1V Approx.

1V Approx.

1.8V Approx.

2.5V Connect DC V 88 92

89 89 Engine Coolant Tem-

perature (ECT) Sen-

sor Signal

GRY Less

than 1V 0 deg. C: Approx. 4.4V / 20 deg. C:

Approx. 3.8V / 40 deg. C: Approx.

2.9V / 60 deg. C: 2.1V / 80 deg. C:

1.4V

Connect DC V 89 93

90 90 CKP Sensor Signal RED - - Approx.

47Hz by

wave

form

Approx.

134Hz by

wave

form or

approx.

1.1V

Connect AC V 90 98

91 91 CKP Sensor Output

T o Pump Control Unit

(PSG) No . 8

PNK - - Approx.

47Hz by

wave

form

Approx.

134Hz by

wave

form or

approx.

0.7V

Connect AC V 91 GND

92 92 Mass Air Flow (MAF)

Sensor Ground BLK/

RED Continu-

ity with

ground

- - - Connect Ohm 92 GND

93 93 Engine Coolant Tem-

perature (ECT) Sen-

sor & Manifold

Pressure Sensor

Ground

BLK/

PNK Continu-

ity with

ground

- - - Connect Ohm 93 GND

94 94 Glow Relay BLK/

RED Less

than 1V Glow system is operated: Less than

Glow system is not operated: 10 -

14V

Connect DC V 94 GND

95 95 No Connection - - - - - - - - -

96 96 T urbocharger W aste

gate Control EVRV BRW/

RED - - Wave form - ---

97 97 EGR EVRV BLK/

ORG - - Approx. 140Hz by

wave form when

EVRV is operated

- ---

98 98 CKP Sensor Ground WHT Continu-

ity with

ground

- - - Connect Ohm 98 GND

99 99 CAN (Controller Area

Netwo rk) to PSG

No.1

BLU--------

100 100 CAN (Controller Area

Netwo rk) to PSG

No.2

YEL--------

101 101 CKP Sens or Shield

Line BLK Continu-

ity with

ground

- - - Connect Ohm 101 GND

102 102 No Connection - - - - - - - - -

103 103 No Connection - - - - - - - - -

104 104 No Connection - - - - - - - - -

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rpm ECM

Connec-

tion

Ran

ge (+) (-)

105 105 Solenoid Valve Shu t

Off (MAB) Output

Signal to PSG No.5

ORG - - - - - - - -

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rpm ECM

Connec-

tion

Ran

ge (+) (-)

PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case

Signal or Continuity Tester Position

No. B/

Box

No.

Pin Function Wire

Color Key SW

Off Key SW

On Engine

Idle Engine

2000rp

ECM &

PSG Con-

nection

Rang

e(+) (-)

1 99 CAN (Controller Area

Network) to ECM

No.99

RED Continu-

ity

between

ECM &

PSG

---Discon-

nect Ohm 1 99

(ECM

)

2 100 CAN (Controller Area

Network) to ECM

No.100

WHT Continu-

ity

between

ECM &

PSG

---Discon-

nect Ohm 2 100

(ECM

)

3 - No Connect ion - ---- ----

4 - No Connect ion - ---- ----

5 105 Solenoid Valve Shut

Off (MAB) Output

Signal to ECM

No.105

ORG Continu-

ity

between

ECM &

PSG

---Discon-

nect Ohm 5 105

(ECM

)

6 - Ground BLK Continu-

ity with

ground

---Discon-

nect Ohm 6 GND

7 - Battery Power Sup-

ply BLU/

RED Less

than 1V 10-14V Discon-

nect Ohm 7 GND

8 91 CKP Sensor Output

ECM No.91 to Pump

Control Unit (PSG)

PNK Continu-

ity

between

ECM &

PSG

---Discon-

nect Ohm 8 91

(ECM

)

9 - No Connect ion - ---- ----

Crankshaft Position (CKP) Sensor Reference Wave Form

Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div

Measurement Condition: Approximately 2000rpm

Engine Speed Output Signal Reference Wave Form

Measurement Terminal: 27(+) GND(-)

Measurement Scale: 5V/div 10ms/div

M eas ur em ent C ond iti on: Approximately 2000r pm

Crank shaft Posit i on (CKP) Sens or & TDC Outpu t Signal

Reference Wave Form

CH1

CH2

Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)

Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div

Measurement Condition: Approximately 2000rpm

Vehicle Speed Sensor (VSS) Reference Wave Form

Measurement Terminal: 68(+) GND(-)

Measurement Scale: 5V/div 50ms/div

M eas ur em ent C ond iti on: Approximately 20km/h

GENERAL DESCRIPTION FOR ECM AND SENSORS

Engine Control Module (ECM)

The engine control module (ECM) is located lower panel

just under the passenger's seat.

The fuel quantity and injection timing related functions

are controlled by the pump control unit (PSG).

The engine control module (ECM) performs the

following functions.

• Control of the exhaust gas re-circulation (EGR)

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

system

• Control of the A/C compressor

• Execution of the immobilizer function

Pump Control Unit (PSG) & Data Exchange

Between Control Module

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

performed via a CAN-bus system. The abbreviation

CAN stands for Controller Area Network. Having two

separate control modules for the high pressure solenoid

valve prevents the discharge of any disturbing signals.

The information exchange between the two control

modules takes place via two means.

• Via analogue signal leads

• Via the CAN-bus

The analogue signal leads are used to exchange the

followi ng inf or mati on .

• Engine speed signal (ECM terminal 91)

• Pump Sp eed (ECM ter minal 105)

• Fuel Cutoff solenoid v alve signal ( MAB signa l) (ECM

terminal 105)

The engine speed signal is sent from the ECM to PSG

based on the input from the crank shaft position (CKP)

sensor.

The analogue CKP sensor signal is converted by the

ECM into a square wave signal.

The fuel cutoff solenoid valve signal is also referred to

as MAB signal.

MAB in this case, refers to the German abbreviation

Magnet ventil ABschaltung that stands for high pressure

solenoid valve cut off.

The MAB signal wire is used for two purposes.

-As a reference for the engine control module (ECM) for

the pump speed (back up for the CKP sensor).

-To turn Off the engine.

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

The following signals are exchanged via the CAN-bus:

From ECM to PSG

• Desired injection quantity

• Desired injection timing

• Engi ne sp eed

From PSG to ECM

• Fuel temperature

• Pump speed

• Cylinder identifier

• Control pulse (actual injection quantity + actual

injection timing)

•PSG status

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 clea ner and turb ocharge 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 t he 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.

Throttle Position Sensor (TPS)

(1) Air Cleaner Case

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

(IAT) Sensor

1 2

(1) Throttle Position Sensor (TPS)

(2) Idle Switch

Characteristic of IAT Sensor -Reference-

100

1000

10000

100000

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

Intake Air Temp. (deg. C) (Tech2 Reading)

Resistance (ohm) (Solid Line)

1 2

The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and

idle switc h.

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. Temperature changes

it’s resistance value, which therefore changes circuit

voltage. In other words it measures a temperature

value . It is installed on the coolant stream. Lo w 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

temp eratur e is hot.

(1) Crankshaft Position (CKP) Sensor

(2) Fly wheel with sensor slot

Characteristic of TPS -Reference-

0.5

1.5

2.5

3.5

4.5

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Pedal Position (%) (Tech2 Readin

Output Voltage (V)

1 2

(1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge

Characteristic of ECT Sensor -Reference-

100

1000

10000

100000

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

Engine Coolant Temp (deg. C) (Tech2 Reading)

Resistance (ohm) (Solid Line)

Vehicle Speed Sensor (VSS)

M/T & A/T 4WD

A/T 2WD

The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall elemen t. It interac ts with the

magnetic field treated by the r otating magnet. It outputs

a pulse signal. The 12 volts operating supply comes

from the meter fuse.

The engine control module (ECM) calculates the vehicle

speed by VSS.

On 2WD models fitt ed with automatic transmission, the

vehicle speed sensor signal is transmitted from the TCM

to the ECM via vehicle speed meter.

GENERAL DESCRIPTION FOR EGR (EXHAUST GAS RE-CIRCULATION)

The amount of EGR is controlled by EVRV (electrical

vacuu m regulati ng valve) via the engin e control mod ule

(ECM) command signal depends on the following

inputs.

• Engine speed

• Injection quantity

• Mass air flow

• Intake air temperature

• Coolant temperature

• Barometric pressure

(1) EGR Valve

(2) EGR Pipe

(3) Intercooler

(4) Intake Manifold

(5) Exhaust Manifold

(6) Waste Gate

(7) Fresh Ai r

(8) Exhaust Gas

(9) Turbocharger

123

(1) To EGR Valve

(2) From Vacuum Pump

(3) EGR EVRV

(4) EGR Valve

(5) EGR Pipe

The EVRV is shaped to control vacuum applied to the

diaphragm chamber of the EGR valve based on duty

signal sent from the ECM. The duty ratio is the time that

the EVRV is opened during one EVRV operating cycle.

A duty ratio change of 90% to 10 % is EGR amount

control range.

7.1ms

Time

0.7ms

Off duty 10% =EGR Pul se Ratio 10%

7.1ms

Time

6.4ms

Off duty 90% =EGR Pu lse Ratio 90%

GENERAL DESCRIPTION FOR 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 prov ide the most

suitable fuel injection quantity and injection timing to

satisfy the demand for en gine reliabi lity, driveabi lity, lo w

smoke, low noise, high output and clear exhaust

emissions.

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) Dr iv e Sha ft

(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

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.

(1) Rotor Shaft

(2) Radial Plunger

(3) Hi gh Pr ess ur e Passag e

(4) Low Pressure Inlet

(5) Distributor Slit

(6) Valv e Need le

(7) Barrel

(8) Annular Passage

(9) Fuel Return

(10) High Pressure Solenoid Valve

(11) Hi gh Pres s ure Outl et

(12) Diaphram Chamber

(13) Accumulator Diaphram

(1) Fuel Suction

(2) Regulating Valve

(3) Overflow Valve

(4) Feed Pump

(5) To Fuel Tank

High Pressure Fuel Circuit

In addition to a high pressure generating device, the

high pressure circuit also consists of fuel piping, and

devices to set the beginning of injection and fuel

injection quantity.

The main components are as follows.

• High pressure generation: Radial Plunger High

Pressure Pump

• Fuel distribution: Distributor Head

• Beginning of injection timing: Timing Device

• Prevention of secondary injection: Constant Pressure

Valve (CPV)

Pump Camshaft Speed Sensor

When the drive shaft rotates, the pump camshaft speed

sensor receives signal form the sensor wheel, and an

electric pulse is sent through the flexible connecting

harness to the pump control unit (PSG).

From these signals the pump control unit (PSG) can

determine the average pump speed and the momentary

pump speed.

The pump camshaft speed sensor is mounted to the

cam ring. Thus, the relationship between the cam ring

and the pump camshaft speed sensor signal is

constant.

The pump camshaft speed sensor signal is utilized for

the following purposes.

To determine the momentary angular position of the

cam ring.

To calculate the actual speed of the fuel injection pump.

To determine the actual timing plunger position.

(1) Pump Control Unit (PSG)

(2) Distributor Head

(3) High Pressure Solenoid Valve

(4) Constant Pressure Valve (CPV)

(5) Radial Plun ger High Pressure Pu mp

(1) Pump Camshaft Speed Sensor

(2) Sensor Wheel

(3) Pump Camshaft Speed Sensor Retaining Ring

(4) Flexible Connector Harness

(5) Dr iv e Sha ft

The pump c amshaft sensor signal has a too th gap, and

the crankshaft position (CKP) sensor on the flywheel

housing is used as a reference signal of engine top

dead cente r (TDC ) for the start tim ing of f uel deliv ery or

injection which is to be set.

High Pressure Solenoid Valve

Fuel injection quantity control is performed from the

beginning of pressure delivery at the beginning of cam

lift until the high pressure solenoid valve opens at the

end of pressure delivery.

This interval is called the pressure delivery interval.

Accor dingly, the inter val that the high press ure solen oid

valve is closed determines the fuel injection quantity

(high pr es sur e fu el supply end s when the high pr essure

solenoid valve opens).

When cu rren t from the pump cont rol uni t (PS G) flows to

the high pressure solenoid valve coil, the magnet

anchor (a movable iron core) pushes the valve needle,

toward the val ve seat.

When the valve seat is completely closed by the valve

needle, the way, of the fuel in the high pressure

passage to the low pressure circuit is closed.

The pressure of the fuel in the high pressure passage is

rapidly increased by radial plunger lift, and the high

press ure fuel is delivered through the co ns tant pressu re

valve (CPV) to the nozzle holder assembly and is

injected into the engine cylinder.

When the fuel injection quantity demanded by the

engine is reached, the current to the coil is cut and the

valve needle re-opens the valve seat.

As a result of this, a path is opened for the fuel in the

high pressure passage to the low pressure circuit and

the pressure decreases. With a decrease in injection

press ure the nozzl e cl oses and injecti on ends .

(1) Valv e Need le

(2) Magnet Anchor

(3) Coil

(4) Hi gh Pr ess ur e Passag e

-Cam Ring Angle

Sensor -Pump Speed

Wheel -Timer Position

Pump

Control

Unit

(PSG)

Pump

Camshaft

Speed

Sensor

(1) Valve Needle

(2) Coil

Timing Control Valve (TCV)

The pressure of the fuel fed from the feed pump is

adjusted in accordance with speed by the regulating

valve. This delivery pressure acts on the hydraulic

stopper's annular chamber as control pressure.

The chamber pressure of the annular chamber is

controlled by the timing control valve (TCV).

The timing plunger is connected to the cam ring by a

ball pin. Axial movement of the timing plunger is

transferred to the cam ring in the form of rotational

movement. Movement to th e right of the timing plunger

(to the spring side) advances injection timing.

When control current flows to the timing control valve

(TCV) coil, the valve need le opens and the fuel annul ar

chamber flows through the orifice to the feed pump inlet.

Consequently, the pressure of the annular chamber

decreases and the hydraulic stopper is moved to the

retard side.

The timing control valve (TCV) acts as a variable

throttl e, using the r apid opening and c losing (cyclin g) o f

the valve needle in the timing control valve (TCV).

At normal operation, the TCV controls the pressure

acting on the annular chamber so that the hydraulic

stopper cam move to any position, from the retard

position to the advance position. At this time, the duty

ratio is set by the pump control unit (PSG).

Duty ratio is the ratio of the time that the timing control

valve (TCV) is opened to one complete timing control

valve (TCV) operating cycle. A duty ratio change of

100% to 0% is an advance in injection timing. (The

VP44 displays an ON duty ratio.)

(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 S topper

(11) Return Passage

(12) Timing Control Valve (TCV)

(1) Coil

(2) From Ann ula r Chamber

(3) To Feed Pump

(4) Orifice

(5) Valve Needle

The engine control module (ECM) contains

characteristic maps of the start of injection,

corresponding to engine operating conditions (engine

load, engine speed and engine coolant temperature).

The pump control unit (PSG) is constantly comparing

the set start of injection timing and the actual start of

injection timing. If there is a difference, the timing

control valve (TCV) is controlled by the duty ratio. (The

actual start of injection timing is determined from the

pump camshaft speed sensor).

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 re tail servic e t e ch ni ci an , y ou are part of th e Ho ld en

service team. The team goal is FIX IT RIGHT THE

FIRST TIME for the satisfa ction of every cust omer. 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.

St rategy 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 though t process. Thi s method of think ing

optimize s your diagno si s in the followi ng ways:

• Improves your understanding and definition of the

customer complaint

• Sav es time by a vo iding tes tin g and/or replacing goo d

parts

• Allows you to look at the problem from different

perspectives

• Gui des you to deter mine what lev el of understand ing

about system operation is needed:

– Owner’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

• Technician experience

• Identical vehicle for comparison

• Circuit testing tools

• Vehicle road tests

• Complaint check sheet

• Contact with the customer

2. Perform Preliminary Checks

NOTE: An estimated 10 percent of successful vehicle

repairs are diagnosed with this step!

What you should do

You perform preliminary checks for several reasons:

• To detect if the cause of the complaint is VISUALLY

OBVIOUS

• To identify parts of the system that work correctly

• To accumulate enough data to correctly and

accurately search for a Holden Service Bulletin.

The initial checks may vary depending on the

compl exity of the system and may in clude the follow ing

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

– Wiri ng sc hem ati cs

– Procedures for viewing DTCs

• Dealership service history file

• Veh ic le ro ad tes t

• Identical vehicle or system for comparison

3. Check Bulletins and Troub leshooting

Hints

NOTE: An 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 Holden Bulletin(s).

• 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 begi n 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)?

– Is it a si gnal ge nerating devic e (MAF sens or 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)?

– Are 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 an 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 cou ld 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 removing

panels and trim as necessary in order to eliminate

large vehicle sections from further investigation)

• For two or more circuits that do not share a common

power or ground, concentrate on areas where

harnesses are routed together or connectors are

shared (refer to the following hints)

Hints

Though the symptoms may vary, basic electrical failures

are generally caused by:

• Loose connections:

– Open/high resistance 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

• Component failure:

– 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 of

suspected systems to help prevent replacing good

parts. This m ay i nvolve using cr eativity a nd i ngenui ty to

interpret customer complaints and simulating all

exter nal and internal system conditi ons to duplicat e the

problem.

What you should do

Step 1: Acquire information

A thorough and comprehensive customer check sheet

is critical to intermittent problem diagnosis. You should

acquire this, since it will dictate the diagnostic starting

point. The vehicle service history file is another

source for accumulating information about the

complaint.

Step 2: Analyze the intermittent problem

Analyze the customer check sheet and service history

file to determine conditions relevant to the suspect

system(s).

Using service manual information, you must identify,

trace and locate all electrical circuits related to the

malfunctioning system(s). If there is more than one

system failure, you should identify, trace and locate

areas of commonality shared by the suspect circuits.

Step 3: Simulate the symptom and isolate the

problem

Simulate the symptom and isolate the system by

reprodu cing all possibl e conditions s uggested in Step 1

while monitoring suspected circuits/components/

systems to isolate the problem symptom. Begin with the

most logical circuit/component.

Isolate the circuit by dividing the suspect system into

simpler circuits. Next, confine the problem into a smaller

area of the system. Begin at the most logical point (or

point of easiest access) and thoroughly check the

isolated circuit for the fault, using basic circuit tests.

Hints

You can isolate a circuit by:

• Unplugging connectors or removing a fuse to

separate one part of the circuit from another

• If only component fails to operate, begin testing the

component

• If a number of co mpo nen ts do not operate , begi n tes t

at areas of commonality (such as power sources,

ground circuits, switches, main connectors or major

components)

• Substitute a known good part from the parts

department or the ve hic le syst em

• Try the suspect part in a known good vehicle

See Symptom Simulation Tests on the next page for

problem simulation procedures. Refer to service manual

sections 6E and 8A for information about intermittent

diagnosis. Follow procedures for basic circuit testing in

service manual section 8A.

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/

harnes se s and jum per 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 or ing the s yst em

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 crea te a load

on the vehicle electrical system at the same time you

are monitoring the suspect circuit/component.

5e. Vehicle Operates as Designed

This condition refers to instances where a system

operat ing as d esigned is perce ived 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 design intent

• 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 betwee n customer expec tation and 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 fa cili tate the dia gno sti c proc es s:

• Vehicle service information (service manual, etc.)

• Holden 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 com pl ain t.

What you should do

In this case, you will need to backtrack and review

information accumulated from step 1 through 4 of

Strategy Based Diagnostics. You also should repeat any

procedures that require additional attention.

A previous path may be eliminated from consideration

only if you are certain that all steps were executed as

directed. You must then select another diagnostic path

(step 5a, 5b, 5 c or 5d ) . If al l po ss i ble opti ons ha ve been

explored, you may call or seek Holden field support.

What resources you should use

Whenever possible, you should use the following

resour ce s to fa cili tate the dia gno sti c proc es s:

• Service manual

• Accumulated information form a previous diagnostic

path

• Service information and publications

• Holden 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 c omplaint.

If applic able, you should ca rry out preven tive meas ures

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/Phy sic al 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. This can often lea d 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 connection s, burne d or chafed s pots, pinched

wires, contact with sharp edges or contact with hot

exhaust manifolds or pipes.

Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain

when performing diagnostic procedures could result in

an incorrect diagnosis or damage to powertrain

components. Do not attempt to diagnose a powertrain

problem without this basic knowledge.

A basic understanding of hand tools is necessary to

effectively use this section of the Service Manual.

ON-BOARD DIAGNOSTIC (OBD)

On-Board Diagnostic (Self Diagnosis

System) Tests

A 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 cycl e.

• 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 Exec utiv e

The Diagnostic Executive is a unique segment of

software which is designed to coo rdinate and prioritize

the diagn os tic proc edu re s as wel l as define the pro toc ol

for recording and displaying their results. The main

respo ns ib iliti es of the Di agn os tic Ex ecuti ve are 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 ti me of assembl y and that th ere 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.

Techline

6E-60 RA – 4JH1-TC

Malfunction Indicator Lamp

The malfunction indicator lamp (MIL) is located in the

instrument pane l cluste r. The MIL will di splay the follow ing

symbol when commanded ‘ON’.

The MIL indicate s that an emissio n relate d faul t 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 a t the MIL is able to illu mi nate .

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

diagnostic fault is n ot 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

illuminate s the MIL due to an emi ssion re lated fau l t.

Data Link Connector (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:

• Identify ing stored Diagno stic Trou ble Code s (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 th e DLC ca ble (4) to th e 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 comprehensive for

vehicles with OBD system diagnostic. Following a repair, the

technician shoul d pe rform 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 repairs.

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. 7000086), 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 PC MCIA card

(No. 3000117) (1).

Legend

(1) PCMCIA Card

(2) Loop Back Connector

(3) SAE 16/19 Pin Adaptor

(4) DLC Cable

(5) Tech 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) in to 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 ti on switch of the veh ic le to ON an d pres s

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.

RA – 4JH1-TC 6E-61

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 th e DLC is g ro unded .

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 eng ine lamp will indi cate a DTC three 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 a nd 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 troub le code .

• Re fe r 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

intermittent. In this case, refer to "DIAGNOSIS AIDS".

6. If a code is present, refer to DTC Chart for diagnosis.

7. Check trouble codes again using the Tech 2.

2. Tech 2 C onnectio n

• Check the key switch is turn OFF.

• Insert the PCMCIA card (1) into the Tech 2 (5).

• Connect the SAE 16/19 adapter (3) to the DLC

cable (4).

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

• Connect the SAE 16/19 adapter (3) to the data

link connector of the vehicle.

• Turn the key switch of the vehicle ON and press

the “PWR” key of the Tech 2.

• Check the display of the Tech 2.

NOTE: Be sur e to check tha t the power is no t supplie d

to the Tech 2 when attaching or removing the PCMCIA

card.

TECH 2 OPERATING FLOW CHART (START UP)

Select “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the Tech 2 screen.

Press (ENTER) to Continue

Main Menu

F0: Diagnostic

F1: Service Programming System (SPS)

F2: View Capture Data

F3: Tool Opti o 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 "(3) 2003" or later.

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

A/T 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

F0: Diagnostic Trouble Code

The pur pose of the “D iag nos ti c Trouble Cod es” 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

malfuncti on. Each DTC inclu des plural s ymptoms, s uch

as DTC P0100 has four kind s of symptom 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 (Factor y Use Only)

The pu rpose o f “Prog rammi ng” is to pr ogram 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: Glow Time Telltale Test

F1: Relays

F0: Glow Time Relay Test

F2: Solenoids

F0: EGR Solenoid Test

F3: Engine Speed (RPM) Control

F4: Program mi ng

F0: Program VIN

F1: Lock ECU

Read DTC Info As Stored By ECU

P0100 Present

(7) Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High Input

DTC No.

Symptom Code

TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)

Use the typi cal values table onl y after the On-Board Di agnostic Syst em check has b een completed , no DTC(s) were

noted, and you have determined that the On-Board Diagnostic are functioning properly.

Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.

Condition : Vehicle s topp in g, en gin e r unn ing , ai r con ditioning off & after war m-up (Co ol ant te mpe ra tur e a pprox im ate ly

80 deg. C)

Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition

1 Engine S peed rpm 675 - 725 1475 -

1525 1975 -

2025 The engine speed is measured by ECM from the CKP

sensor.

2 Vehicle Speed km/h / MPH 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 pu mp speed. The injection s peed is

measured by ECM from the pump cam sensor .

4 Accelerator Position

Sensor Signal % 0 3 - 5 5 - 7 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 0V Active Active/

Inactive 0V Inactive 0V This displays operating status of the idle switch. This

should display "Active" until the accelerator pos ition nearly

4 - 5%.

6 Mass Air Flow

Sensor mg/strk 420 - 490 380 - 460 410 - 480 This displays calculated intake air volume f or one cylinder

stroke. The mass air flow is measured by ECM from the

MAF sensor output voltage.

7 Desired Mass Air

Flow mg/strk 430 - 470 380 - 420 410 - 470 This displays desired intake air volume for one cylinder

stroke. The desired mass air flow is calculated by ECM

depending on engine condition.

8 Barometric Pressur e hpa Depends

on altitude Depends

on altitude The barometric pressure is measured by ECM from the

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

9 Desired Injection

Quantity mg/stk 6 - 10 6 - 10 7 - 11 This displays desired value from the ECM. The ECM

compensates for fuel rate by throttle position and various

sensor signals.

10 Injection Quantity mg/stk 6 - 10 6 - 10 7 - 11 This displays calculated actual fuel quantity from the PSG.

The PSG receives desired injection quantity from the ECM.

And, it compensates actual injection depending on timer

position to determine duration of the high pressure

solenoid valve operation.

11 Desired Fuel Injection

Start deg. CA 1 - 3 2 - 4 3 - 5 This displays desired injection timing from the ECM. The

ECM compensates for fuel injection timing by throttle

position and various sensor signal.

12 Actual Injection Start deg. CA 1 - 3 2 - 4 3 - 5 This displays calculated actual injection timing based on

CKP signal and pump cam signal. The PSG controls TCV

duty ratio to meet desired injection timing from the ECM.

13 Coolant Temperature deg. C / deg.

F80 - 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. C.

14 Fuel Temperature deg. C / deg.

FDepends

on fuel

temp.

Depends

on fuel

temp.

Depends

on fuel

temp.

The FT is meas ured by PSG from FT sens or. This data is

changing by fuel temperature.

15 Intake Air

Temperature deg. C / deg.

FDepends

on ambient

temp.

Depends

on ambient

temp.

Depends

on ambient

temp.

The IAT is measured by ECM from IAT sensor output

voltage. This data is changing by intake air temperature.

16 Ignition Status On12V/

Off0V On 12V On 12V On 12V This displays the key switch status indicated by the ECM

with key switch signal. T his should display "Off 0V" at key

OFF and "On12V" at key ON.

17 Brake Switch 1 Active/

Inactive Inactive Inactive Inactive This displays operating status of the brake switch. This

should display "Active" when the brake pedal is stepped

on.

18 Brake Switch 2 Active/

Inactive Inactive Inactive Inactive This displays operating status of the brake switch. This

should display "Active" when the brake pedal is stepped

on.

19 Clutch Switch (M/T

Only) Active/

Inactive Inactive Inactive Inactive This displays operating status of the clutch switch. This

should display "Active" when the clutch pedal is stepped

on.

20 Neutral Switch On/Off On On On This displays operating status of the neutral switch. Th is

should display "On" when the gear position is neutral (M/T)

or P, N position (A/T).

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: Glow Time Telltale Test

When the Tech 2 is operated, "Glow Time Indicator

Lamp" is turned on or off.

The circuit is correct if the "Glow Time Indicator Lamp"

in the instrument panel is turned on or off in accordance

with this operation.

F1: Relays

F0: Glow Time Relay Test

When the Tech 2 is operated, glow relay turns ON or

OFF.

The circuit is correct if glow relay is operated in

accordance with this operation.

F2: Solenoids

F0: EGR Solenoid Test

When the Tech 2 is oper ated, control dut y ratio of EGR

EVRV changes to 5% to 95%.

The circuit is correct if glow relay is operated in

accordance with this operation.

21 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.

22 Diagnostic Request Active 0V/

Inactive 12V Inactive

12V Inactive

12V This displays the diagnostic request signal. This should

display "Inactive 12V" when the Tech 2 is connected.

23 System Voltage V 10 - 15 10 - 15 10 - 15 This displays the system voltage measured by the ECM at

ignition feed.

24 Main Relay Active/

Inactive Active Active Active This displays operating status for the ECM main relay. This

should display "Active" when the key switch is turned on

and while engine is running.

25 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.

26 Check Engine Light On/Off Off Off Off This displays operating s tatus for the Check E ngine Lamp.

This should display "On" when the Check Engine Lamp is

turned on.

27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.

This should display "On" when the glow lamp is turned on.

28 Desired Engine Idle

Speed rpm 700 700 700 The desired engine idle speed that the ECM commanding.

The ECM compensat es for various engine loads b ased on

engine coolant temperature.

29 A/C Request Ac tive 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 Immobilizer Active/

Inactive Inactive Inactive Inactive This should display "Inactive" when the immobilizer is

correctly operated.

31 Immobilizer Signal Received/

Not

Received

Not

Received Not

Received This should display "Not Received" when the immobilizer is

not activated.

32 Immobilizer Function

Programmed Yes/ No Yes Yes Yes This should display "Yes" when the imm obilizer is correctly

programmed.

33 EGR Pulse Ratio

(Exhaust Gas

Recirculation)

% 85 - 90 85 - 90 85 - 90 This displays the duty signal from the ECM to control the

EGR flow amount.

Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition

EGR Solenoid Test

Desired Mass Air Flow 470 mg/strk

Mass Air Flow 450 mg/strk

Engine Speed 700 rpm

Exhaust Gas Recirculation 95%

• Press "Active" key.

Then, EVRV duty ratio increases to 95%

• Press "Inactive key".

EVRV duty ratio decreases to 5%

F3: Engine Speed (RPM) Control

When the Tech 2 is operated, "Desired Idle Speed"

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

The circuit is correct if engine speed is changed in

accordance with this operation.

• Press "Increase" key.

Then, Desired Idle speed is increases

50rpm-by-50rpm up to 1200rpm. Engine speed is

also

Engine Speed (RPM) Control

Engine Speed 850 rpm

Desired Idle Speed 850 rpm

Injection Quantity 7.5 mg/ strk

PLOT TING SN A PSHOT GR A P H

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 though t he ve hicle

is not available.

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

Flow Chart for Snapshot Replay (Plotting Graph)

Snapshot Display With TIS2000

Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]

function is described below.

Snapshot data can be displayed with [Snapshot Upload]

function included in TIS2000.

1. Record the snapshot data, in Tech2.

2. Transfer the snapshot data to PC.

By analyzing these data in various methods, trouble

conditions can be checked.

Snapshot data is displayed by executing the three steps

below shown:

After recordin g the sn apshot in Tech2, trans fer 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 th e 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 the icon for graph display. [Graph Parameter ]

window opens.

2. Click the first graph icon of the window upper part,

and select one parameter from the list of the window

lower part. Selec ted parameter 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 selec ting all paramet ers to be displayed (Max .

3 parameters), click [OK] button.

5. Parameter selected is displayed in graph form on

the right of the data parameter on the screen.

6. Graph display can be moved with the navigation

icon.

7. For displaying another parameter by graph, click the

parameter of the list, drag the mouse to the d isplay

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 thi s ca se , param eter s ar e d is pl aye d on ly i n gr ap h

form. All parameters are displayed in one graph.

6. The graph display screen can be moved with the

navigation icon.

SERVICE PROGRAMMING SYSTEM (SPS)

The procedure to program the control unit by using the

Service Programming System (SPS) software contained

in TIS2000 is explained below.

NOTE:

• If the Engine Control Module (ECM) was

programmed, the Immobilizer System must be linked

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

ECM replacement” for the ECM/Immobilizer linking

procedure.

• Should Tech2 display "SPS Procedure was not

successful", engine will not start, but no DTCs are

present, low battery voltage or poor electrical

connections should be the primary suspects. Perform

the SPS procedure again after rectifying the fault/s.

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 2

Connect Tech 2 to P/C.

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

2. Activate TIS 2000 by P/C.

3. On the activating screen of TIS2000, choose

“Service Programming System”

4. On th e screen of “Diag nostic Te st er and Pro cessin g

Program Selection”, choose the one that will comply

with the following .

• Tech-2 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.

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

“Next”.

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 been alr 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”.

7. After that. then push button and turn Ignition switch

tuned on, off, on following Tech-2 display. Tech-2

will read information from controller after this

procedure.

8. During obtaining information, Tech-2 is receiving

information from the control unit ECM and TCM (A/T

only) at the same time. With VIN not being

programm ed into the new contr ol unit at the time o f

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 to P/C, turn on the power and cli ck

the “Next” button of P/C.

2. Check VIN of th e vehic le and choos e “Nex t”.

3. Select “System Type” for required control unit.

• Engine (Programming for ECM or PCM)

• Transmission (Programming for TCM)

4. When a lack of data is asked from among the

following menu, enter accordingly.

Select following Menu

• Model Year

• Model

• Engine type

• Tr ansmission type

• Destination code (vehicles for general export)*1

• Immobilizer

Etc.

* 1: How to read the destination code

Destination code can be read from ID Plate affixed on

vehicles, while on VIN plate the destination code is

described at the right-hand edge of Body Type line. In

the figure, the destination code can be read as "RR3"

(Australia).

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

6. When all the necessary information is entered, the

“details” of software within the database that match

the entered data will appear for confirmation. Click

the “Program” switch and then download the new

software onto Tech-2.

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

downloading will be displayed on the screen in the

form of bar graph.

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

of Tech-2, removing from P/C.

4. Programming of EC M

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

ABS connectors shall be removed from the vehicle.

2. Connect Tech-2 to Vehicle Diagnostic Connectors.

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

comes on display.

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

start)

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

button.

6. Choose “F1: Service Programming System” on the

main screen and then choose “Fl: Program ECU”.

7. While data is being transferred, “Programming in

Progress” will be displayed on the Tech-2 screen.

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

“Reprogramming Was Successful”. Push the “Exit”

button to bring program to completion

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

again “Information Obtaining” and check to confirm

if the data has been correctly re-loaded.

10. Upon finishing confirmation, turn off the ignition of

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

removing from the vehicle.

HOW TO USE BREAKER BOX

The engine control module (ECM) and other connectors

have water proo f connector and special termina l. Wa ter

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 fine pin type.

In order to prevent damage of female terminal and

connector itself, the breaker box and adapter is the

most suitable special tool.

312

(1) Engine Control Module (ECM)

(2) Harness Adapter (3) Breaker Box

Breake r Box Connection Type A

Breake r box connect ion type A, c heck for “o pen circuit”

and “short to ground circuit”.

PQORN

(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.

23 45

(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

Diagnosti c Chart:

1. The Ch eck Engine Lamp (MI L) should b e ON steady

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

Engine La mp (MIL) ” chart sho uld be us ed to iso late the

malfunction.

2. Checks the Class 2 data cir cuit and ensure s 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 c ausing the

problem.

12. Th is v ehicle i s equ ipped with EC M wh ich ut ilizes an

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 cordanc e with the Tech 2

instructions.

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

B-58 7

8Using the DVM and check the data link connector

grou nd 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

grou nd 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

commun ic ati on circui t.

1. Ignition “On”, engine “Off”.

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

Was the DVM indicated fixed battery voltage?

—

Repair faulty

harness and

verify repair Go to Step 11

Step Action Value(s) Yes No

B-58

Using the DVM and check the data link connector

communication circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harness and

verify repair Go to Step 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

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 lizer syst em

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

ƒ¶

35 C-56

B-58

NO CHECK ENGINE LAMP (MIL)

Circuit Description

The check engine lamp should be illuminated and

steady fo r about fi ve seconds wi th the igni ti on “ O N” and

the engi ne stopp ed. Ignit ion feed vol tage is sup plied to

the check engine lamp bulb through the meter fuse.

The Engine Control Module (ECM) turns the check

engine lam p “ON” by groundin g the check engine lamp

driver circuit.

Diagnostic Aids

An intermittent check engine lamp may be cased by a

poor connection, rubbed-through wire insulation, or a

wire broken inside the insulation. Check for the

foll owi ng ite ms :

• Inspect the ECM harness and connections for

improper mating, broken locks, improperly formed or

damaged terminals, poor terminal-to-wire connection,

and damaged harness.

• If the engine runs OK, check for a faulty light bulb, an

open in the check engine lamp driver circuit, or an

open in the instrument cluster ignition feed.

• If the engine cranks but will not run, check for an

open ECM i gnition or batt ery feed, or a poor ECM to

engine ground.

No Check Engine Lamp (MIL)

Step Action Value(s) Yes No

1 Chec k the meter fuse (15A).

If the fuse is burnt out, repair as necessary.

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

2 Using the DVM and check the “CHECK ENGINE”

lamp circuit.

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?

10-14.5V 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

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

C-56

B-24

C-56

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 lizer syst em

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

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.

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, 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 complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

B-24

C-56

ECM DIAGNOSTIC TR OUBLE 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

65 P0100 7 ON Mass Air Flow (MAF) Sensor

Voltage Supply Circuit High

Input

MAF sensor power supply

voltage is more tha n 5. 2V. ECM uses mass air flow

1600mg/strk & EGR 10%

condit ions as subs titute.

MAF sensor power supply

voltage is below 5.2V. 1. Sensor power supply

circuit short to battery

voltage circuit.

2. MAF sensor malfunction.

3. ECM 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 tha n 4.6V. 1. Sensor power supply

circuit short to ground

ci r c u i t .

2. MAF sensor malfunction.

3. ECM malfunction.

83 —

B ON Mass Air Flow (MAF) Sensor

Output Circuit Low Inp ut 1. Engine speed is between

600rpm and 5000rpm.

2. MAF sensor output is

below -33.7mg/strk.

MAF sensor output is more

than -27.4mg/strk. 1. Sensor power supply

c i r c ui t o p e n c i r c u i t .

2. Sensor signal circuit

open or short to ground

cir cuit.

3. Sensor heater harness

o p e n c i r cuit.

4. Poor con nec tor

co n n e c t i o n.

5. MAF sensor malfunction.

6. ECM malfunction.

8 3 /

88 P0110(1)

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.

MAF sensor output is below

1784mg/strk. 1. Sensor signal circuit

short to voltage circuit.

2. Sensor ground circuit

open or short to voltage

cir cuit.

3. MAF sensor malfunction.

4. ECM malfunction.

88/

92 P0110(1)

34 P010 5 1 ON Va cuu m Pressure Sens or

Circuit High Input Vacuum sensor output

voltage is more tha n 4. 4V. 1. Fuel injection quantity is

reduced.

2. ECM use 615hpa

conditions for

turbocharger waste gate

control.

Vacuum sensor output

voltage is below 4.4V. 1. Sensor signal circuit

short to voltage circuit.

2. Sensor ground circuit

open or short to voltage

cir cuit.

3. Vacuum sensor

malfunction.

4. ECM malfunction.

85/

93 P0115(1)

2 ON Vacuum Pressure Sen sor

Circuit Low Input Vacuum sensor output

voltage is below 0.5V. Vacuum sensor output

voltage is more tha n 0.5V. 1. Sensor power supply

c i r c ui t o p e n c i r c u i t .

2. Sensor signal circuit

open or short to ground

cir cuit.

3. Poor con nec tor

co n n e c t i o n.

4. Vacuum sensor

malfunction.

5. ECM malfunction.

82/

85 —

34 P010 5 7 ON Va cuu m Pressure Sens or

Voltage Supply Circuit High

Input

Vacuu m sen sor power

supply voltage is more than

5.2V.

1. Fuel injection quantity is

reduced.

2. ECM use vacuum sensor

output voltage 5.0V

condition as substitute.

Vacuum sensor power

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

circuit short to battery

voltage circuit.

2. Vacuum sensor

malfunction.

3. ECM malfunction.

82 —

9 ON Vacuum Pressure Sen sor

Voltage Supply Circuit Low

Input

Vacuu m sen sor power

supply voltage is below 4.5V. Vacuum sensor power

supply voltage is more than

4.5V.

1. Sensor power supply

circuit short to ground

ci r c u i t .

2. Vacuum sensor

malfunction.

3. ECM malfunction.

82 —

23 P0110 1 ON Intake Air Temperature (IAT)

Sensor Circuit High Input IAT sensor output voltage is

more than 4.7V. ECM use 0 deg. C conditions

as substitute. IAT sensor output voltage is

below 4.7V. 1. Sensor signal circuit

open or short to voltage

ci r cui t.

2. Sensor ground circuit

open or short to voltage

cir cuit.

3. Poor con nec tor

connection

4. IAT sensor malfunction.

5. ECM malfunction.

8 4 /

92 P0100(B)/

P0100(C)

2 ON Intake Ai r 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. ECM 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

temper atu re as

substitute.

2. ECM uses 60 deg. C

condition for injection

t i m i ng c o n t r o l .

3. ECM uses -15 deg. C

condition for glow time

control.

ECT sensor output voltage is

below 4.7V. 1. Sensor signal circuit

open or short to voltage

ci r cui t.

2. Sensor ground circuit

open or short to voltage

cir cuit.

3. Poor con nec tor

connection

4. ECT sensor malfunction.

5. ECM malfunction.

89/

93 P0105(1)

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. ECM malfunction.

89 —

15 P018 0 B ON Fuel Temper at ure Sen sor

Circuit Range/Performance FT sensor output is high

temperature (more than 150

deg. C) or low temperature

(below -40 deg. C).

The ECM uses 75 deg. C

condit ions as subs titute. FT sensor output is correct

temperature range between

150 deg. C and -40 deg. C.

1 . E C M m a l f u n c t i o n .

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

52 P0215 A ON Fuel Cutoff Solenoid Valve

Malfunction 1. Ignition key switch off.

2. Engine speed is below

1500rpm.

3. Vehicle speed is below

1.5 km/ h .

4. PSG (pump contro l unit)

recognizes MAB (fuel

cutoff solenoid valve)

signal from the ECM, but

the MAB could not

operate.

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

No recovery until condition

match in the next ignition key

cycle.

1. PSG (pump control unit)

malfunction.

2. MAB (fuel cutoff solenoid

valve) malfunction.

——

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

det ected MAB signal line

circuit is high level.

Engine doe s not start. No recovery. 1. M A B (fuel cutoff solenoid

valve) signal circuit short

t o v o l t a g e c i r c u i t .

2. PSG (pump control unit)

malfunction.

105 —

C ON Fuel Cutoff Solenoid Valve

Always Active 1. Ignition key switch off.

2. Engine speed is below

1500rpm.

3. Vehicle speed is below

1.5 km/ h .

4. PSG (pump contro l unit)

does not recognize MAB

(fuel cutoff solenoid

valve) signal from the

ECM.

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

No recovery until condition

match in the next ignition key

cycle.

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.

N o f ai l - s af e f u n c t i o n . 1 . E C M m a l f u n c t i o n .

2. PSG (pump control unit)

malfunction. ——

54 P0216 A ON Injection Timing Control

Circuit Malfunction 1. Engine speed is more

th a n 70 0 rpm .

2. Fuel injection quantity is

m o r e t h a n 4 m g / s t k .

3. Deviation of actual

injection timing and

desired injection timing is

more than +3 deg. CA or

-6 deg. CA for 8 seconds.

Fuel inject ion qua ntity is

reduced. Deviation of actual injection

timing an d desire d inj ect ion

timing is more than +3 deg.

CA or -6 deg. CA for 8

seconds.

1. Timing control valve

malfunction.

2 . Ti m e r p i s t o n s t i c k i n g .

3. Pump cam sha ft speed

sensor malfunction. ——

B ON Injection Timing Control

Circuit Malfunction 1. Engine speed is more

th a n 20 1 4rp m .

2. F l uctu at ion of actu al

injection timing is more

than +-5.2 deg. CA.

1. Engine speed is more

th a n 20 1 4rp m .

2. Fluctuation of actu al

injection timing is more

than +-5.2 deg. CA.

1. Insufficient air bleeding of

fuel line.

2 . F u e l f i l t e r c l o g g i n g .

3. Timing control valve

m a l f u n c t io n.

4. Pump cam sha ft 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

64 P0243 3 ON Turbocharger Wastegate

Solenoid "A" Range/

Performance

1. Intake air temperature is

between - 50 deg. C and

2 0 0 d e g . C .

2. Engine coolant

temper atu re i s betwe en -

50 deg. C and 150 deg.

3. Barometric pressure is

between 0 hpa and

3500hpa.

4. Low vacuum pressure

condition. (Desired

vacuum pressure - actual

vacuum pressure is more

than 50hpa.)

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes

10% condition.

1. Engine speed is between

500rpm and 6000rpm.

2. Correct vacuum pressure

condition. (Desired

vacuum pressure - actual

vacuum pressur e is less

than 50hpa.)

1. Turbocharger wastegate

control EVRV

malfunction.

2. V acuum line is

obstructed.

3. Vacuum is leaking.

4. Vacuum pump

mal function.

5. Vacuum sensor

malfunction.

6. Turbocharger wastegate

v a l v e m a l fu n c t i o n .

7. ECM malfunction.

85/

96 —

4 ON Turboc harger Was tegate

Solenoid "A" Low Wastegate control EVRV

circuit open or short to

ground circuit.

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes

10% con dition.

3. Wastegate control EVRV

becomes 32% condition.

Wastegate control EVRV

circuit is correct condition. 1. Wastegate control EVRV

circuit ope n or sho rt to

g r o u n d ci rc uit.

2. Wastegate control EVRV

mal function.

3. ECM malfunction.

96 —

5 ON Turboc harger Was tegate

Solenoid "A" Range/

Performance

1. Intake air temperature is

between - 50 deg. C and

2 0 0 d e g . C .

2. Engine coolant

temper atu re i s betwe en -

50 deg. C and 150 deg.

3. Barometric pressure is

between 0 hpa and

3500hpa.

4. High vacuum pressure

condition. (Desired

vacuum pressure - actual

vacuum pressure is less

than -50hpa.)

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes

10% condition.

1. Engine speed is between

500rpm and 6000rpm.

2. Correct vacuum pressure

condition. (Desired

vacuum pressure - actual

vacuum pressure is more

than -50hpa.)

1. Turbocharger wastegate

control EVRV

malfunction.

2. Vacuum regulating valve

malfunction.

3. Vacuum pump

mal function.

4. Vacuum sensor

malfunction.

5. ECM malfunction.

85/

96 —

6 ON Turboc harger Was tegate

Solenoid "A" Malfunction 1. Engine coolant

temper atu re i s betwe en -

50 deg. C and 150 deg.

2. EGR control EVRV 0%

condit ion.

3. No DTC relating to MAF

sensor, vacuum sensor &

IAT sensor.

4. Large amount of mass air

flow. (= Incorrect boost

pressure condition)

(Desired mass air flow -

actual ma ss air flow is

less than -56mg/strk.)

1. Correct amount of mass

air flow. (= Correct boost

pressure condition)

(Desired mass air flow -

actual mass air flow is

more than -56mg/strk.)

1. Turbocharger wastegate

a c t u a t o r m al f u n c t i o n .

2. Vacuum line malfunction.

3. 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

64 P0243 8 ON Turbocharger Wastegate

Solenoid "A" High Wastegate control EVRV

circuit short to voltage circuit. 1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes

10% con dition.

3. Wastegate control EVRV

becomes 32% condition.

Wastegate control EVRV

circuit is correct condition. 1. Wastegate control EVRV

circuit short to voltage

ci r cui t.

2. Wastegate control EVRV

mal function.

3. ECM malfunction.

96 —

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

s p e e d s e n s o r e r r o r.

2. High pressure solenoid

valve control pulse width

does not match with

desired fuel injection

quantity .

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

No recovery until condition

match in the next ignition key

cycle.

1. PSG (pump control unit)

malfunction.

2. Pump cam sha ft speed

sensor malfunction. ——

7 ON Injection Pump Malfunction 1. No pump camshaft

s p e e d s e n s o r e r r o r .

2 . N o C K P s e n s o r e r r o r.

3. Difference of engine

speed and doubled pump

camshaft speed is more

than 690rpm.

1. No pump camshaft

s p e e d s e n s o r er r o r.

2 . N o C K P s e ns o r e r r o r.

3. Difference of engine

speed and doubled pump

camshaft speed is below

690rpm.

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 mal fun ctio n.

No recovery until condition

match in the next ignition key

cycle.

PSG (pump control unit)

malfunction. — —

A ON Injection Pump Malfunction EEPROM or A/D converter

malfunction in the PSG

(pump control unit).

Fuel inject ion qua ntity is

reduced. EEPROM or A/D converter

no malfunction in the PSG

(p ump c o ntr ol u n it ) .

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 re covery until condition

match in the next ignition key

cycle.

PSG (pump control unit)

malfunction. ——

D ON Injection Pump Malfunction PSG (pump cont rol unit)

could no t measure t he high

pressure solenoid valve drive

voltage.

PSG (pump control unit)

malfunction. ——

E ON Injection P ump Malfunction ECM coul d not accept PSG

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

v a l v e) i s o p e r a t e d .

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 v o l ta g e c i r c ui t .

2. CAN low circuit open,

short to ground or short

t o v o l t a g e c i r c u i t .

3 . E C M m a l f u n c t i o n .

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

43 P0335 B ON Crankshaft Position Sensor

Circuit Malfunction 1. Engine speed is more

th a n 6 6 5r pm .

2. CKP sensor pulse width

error.

When pump ca mshaft speed

sensor is OK:

ECM uses doubled pump

camshaft speed as substitute

engine speed.

When pump ca mshaft speed

se n s o r i s no t O K :

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

ECM detects correct CKP

pulse width. 1 . Du r i n g e n g i n e r u n :

1. CKP sensor harness

open circuit, short to

ground or short to

v o l t a g e c i r c u i t .

2. Poor con nec tor

co n n ec tio n .

3. CKP sensor malfunction.

4. Pulse sensing gap

incorrect.

5 . P u l s e r m a l f u n c t i on .

6. Electrical interference.

7. Magnetic interference.

8. ECM malfunction.

90/

98/

101 P1335 (A)

D ON Crankshaft Position Sensor

Circuit Malfunction 1. No pump camshaft

s p e e d s e n s o r er r o r.

2. "Crankshaft Position

Sensor Circuit

Malfunction (S ymptom

Code B)" is not stored.

3 . E n g i ne sp e e d i s 0 r p m .

4. Doubled pump camshaft

speed is more than

50rpm.

When pump ca mshaft speed

sensor is OK:

ECM uses doubled pump

camshaft speed as substitute

engine speed.

Other than pum p cam s ha ft

s p e e d s e n s o r i s O K :

Fuel inject ion qua ntity is

reduced.

1. Engine speed is more

than 0rpm.

2. Doub led pum p cam sha ft

speed is below 100rpm.

Du r i n g e n gine c r a n k :

1. CKP sensor harness

open circuit, short to

ground or short to

v o l t a g e c i r c u i t .

2. Poor con nec tor

co n n ec tio n .

3. CKP sensor malfunction.

4. Pulse sensing gap

incorrect.

5 . P u l s e r m a l f u n c t i on .

6. Electrical interference.

7. Magnetic interference.

8. ECM malfunction.

90/

98/

101 P1135 (A)

E ON E ng ine Speed Input Circui t

Range/Performance Engine spe ed i s more than

5700rpm. When intermittent

malfunction:

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

b e c o m e s 0 m g / st r k .

When prel iminar y

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 . P u l s e r m a l f u nc ti o n .

4. ECM malfunction. 9 0 /

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. ECM malfunction.

94 —

8 ON Glow Relay Circuit Voltage

High Glow relay 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

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 ope n or sho rt to

g r o u nd ci r c u i t .

2. Glow plug indicator lamp

mal function.

3. ECM malfunction.

43 —

8 ON Glow Plug Indicator Circuit

Voltage High Glow plug indicator circuit

short to voltage circuit. ECM malfunction. ——

32 P0400 3 ON Exhaust Gas Recirculation

Flow Excessive Detected 1. Intake air temperature is

between 15 deg. C and

1 0 0 d e g . C .

2. Engine coolant

temper atu re i s betwe en

35 deg. C and 100 deg.

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 inject ion qua ntity is

reduced. 1. Engine speed is between

1500rpm and 3200rpm .

2. In j ect ion qua ntity is

b e l o w o r 4 0 m g/ s t k .

3. Correct amount of mass

air flow.

1. EGR valve is stuck at

open pos iti o n.

2. EGR EVRV malfunction.

3 . A i r i n t a k e i s o b s t r u c t e d .

4. Air intake is leaking.

5. MAF sensor malfunction.

6. ECM 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 i nject ion qua ntity is

reduced and EGR EVRV

10% conditions as substitute.

EGR EVRV circuit is correct

condition. 1. EGR EVRV circuit ope n

or short to ground circuit.

2. EGR EVRV malfunction.

3. ECM malfunction.

97 —

5 ON Exhaust Gas Recirculation

Flow Insufficient Detected 1. Intake air temperature is

between 15 deg. C and

1 0 0 d e g . C .

2. Engine coolant

temper atu re i s betwe en

35 deg. C and 100 deg.

3. Barometric pressure is

between 850hpa and

1100hpa.

4. Large mou nt of ma ss air

flow. (Desired mass air

flow - mass air flow is

below -150 mg/strk)

Fuel inject ion qua ntity is

reduced. 1. Engine speed is between

1500rpm and 3200rpm .

2. In j ect ion qua ntity is

b e l o w 4 0 m g/s t k .

3. Correct amount of mass

air flow.

1. EGR valve is stuck at

cl o se p o sit ion.

2. EGR valve operating

vacuum hose is clogged

o r d i s c o n n e c t e d .

3. EGR EVRV malfunction.

4. MAF sensor signal circuit

short to voltage circuit.

5. MAF sensor malfunction.

6. ECM malfunction.

88/

97 —

8 ON Exhaust Gas Recirculation

Circuit Short to Battery EGR EVRV circuit short to

voltage circuit. Fuel inject i on qua nt ity is

reduced & EGR EVRV 10%

condit ions as subs titute.

EGR EVRV circuit is correct

condition. 1. EGR EVRV circuit short

t o v o l ta g e c ir c u i t .

2. EGR EVRV malfunction.

3. ECM malfunction.

97 —

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

24 P0500 1 ON

igniti

cycle

V eh icle S p eed S ensor Circu it

High Input Vehicle speed is more than

200km/h. ECM us es veh icle speed

5km/h condit ion as

substitute.

Vehicle speed is below

200km/h. 1. VSS signal circuit open,

short to ground or short

to v o l ta g e c i r c ui t .

2. VSS malfunction.

3. Speed meter

mal function.

4. TCM ma lfun c tio n (AT

2WD).

5. ECM malfunction.

68 —

A O N

igniti

cycle

Vehicle Speed Sensor Input

Signal Frequency Too High Input signal frequency is too

high. ECM uses vehicle speed

5km/h condit ion as

substitute.

Correct vehicle speed signal

frequency. 1. VSS malfunction.

2. Speed meter

m a l f u n c t io n.

3. Electrical interference.

4. Magnetic interference.

5. ECM malfunction.

68 —

B O N

igniti

cycle

Vehicle Speed Sensor

Incorrect Signal 1. Engine speed is more

th a n 360 0 rp m .

2. Fuel injection quantity is

m o r e t h a n 4 1 m g / s t r k .

3. Vehicle speed is below

1.5km/h.

Fuel inject ion qua ntity is

reduced. Vehicle speed is more than

1.5km/h. 1. VSS open circuit, short

to ground or short to

vo l ta g e.

2. Poor con nec tor

co n n ec tio n .

3. VSS malfunction.

4. Speed meter

mal function.

5. ECM malfunction.

68 —

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. ECM malfunction.

39 —

2 OFF System Voltage Too Low System voltage i s 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 con nec tor

connection.

4 . B a t t er y m a l f u n c t i on .

5. Ch ar ge syste m

mal function.

6. ECM malfunction.

39 —

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

35 P0560 A OFF System Voltage Malfunction 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

p o o r c o n n e c t i o n .

3. Poor con nec tor

connection.

4 . B a t t e r y m a l f u n c t i o n .

5. Ch ar ge syste m

malfunction.

6. Battery jump start cable

misconnect.

7. PSG (pump control unit)

malfunction.

——

18 P0561 A OFF Ignition Switch 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 ignition key

cycle.

1. Ignition switch circuit

open or short to ground

ci r cui t.

2. Poor con nec tor

connection.

3. Ignition switch

mal function.

4. ECM malfunction.

39 —

B OFF Ignition Switch Circuit

Malfunction Ignition switch circuit is

malfunction. 1. Ignition switch circuit

open or short to ground

ci r cui t.

2. Poor con nec tor

connection.

3. Ignition switch

mal function.

4. ECM malfunction.

39 —

- P0602 - Control Mod ule

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

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

No recovery. ECM malfunction.

——

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

va lv e ) i s o pe r a t e d . Desired injection quantity is

be l o w 0 m g / strk . 1 . E C M ma l f u n c t i o n .

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

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. A/C compressor relay circuit

is correct condition. 1. A/C compr essor relay

circuit ope n or sho rt to

g r o u nd ci r c u i t .

2. Poor con nec tor

connection.

3. A /C compr esso r relay

mal function.

4. ECM malfunction.

41 —

8 ON A/C Compressor Relay

Circuit Voltage High A/C compressor relay circuit

short to voltage circuit. ECM malfunction. ——

25 P0703 A ON Brake Switch Circuit

Malfunction 1. Throttle position is more

than 0%.

2. Engine speed is more

t h a n o r 6 6 5 r p m .

3. Vehicle speed is more

th a n 0k m /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. B r ake switch 1 circu it

open, short to ground or

short to voltage circuit.

2. Poor con nec tor

connection.

3. B r ake swi tch 1

mal functio n.

4. ECM malfunction.

30 —

B ON Brake Switch Circuit

Malfunction 1. Throttle position is more

th a n 0% .

2. Engine speed is more

t h a n 6 6 5 r p m .

3. Vehicle speed is more

th a n 0 km/h .

4. Brake switch 1 signal and

brake switch 2 signal are

differently inputted to the

ECM.

1. B r ake switch 2 circu it

open or short to ground

ci r cui t.

2. Poor con nec tor

co n n e c t i o n.

3. B r ake swi tch 2

mal functio n.

4. ECM 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 circuit.

2. Poor con nec tor

connection.

3. Clu tch switch

mal function.

4. ECM 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

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. Throttle position sensor

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

circuit short to voltage

cir cuit.

2. Sensor signal circuit

short to voltage circuit.

3. Sensor ground circuit

open or short to voltage

ci r cui t.

4. Poor con nec tor

connection.

5 . T P S m a l f u nc t i o n .

6. ECM malfunction.

3 8 /

49/

57 —

7 ON Pedal/Throttle Position

Sens or 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 . T P S m a l f u nc t i o n .

3. ECM malfunction.

57 —

9 ON Pedal/Throttle Position

Sens or 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

ci r c u i t .

2. TP S ma l f u nctio n .

3. ECM malfunction.

57 —

D ON Pedal/Throttle Position

Sensor Brake Switch Error 1. Engine speed is more

than 1700rpm.

2. Vehicle speed is more

th a n 1. 5 km/h.

3. When bra ke pe dal is

depressed duri ng

accelerator pedal is

depres s in g .

Throttle position is more than

20% or brake pedal is

released (switch is inactive).

1. Th r ot t l e stic k i n g .

2. TPS incorrect adjusting.

3 . T P S m al f u n c t i o n .

4. B r ake switch

malfunction.

5. ECM malfunction.

30/

3 8 /

65 —

E ON Pedal/Throttle Position

Sensor Idle Position Switch

Error

1. Wh en idle switch is

turned off, throt tle

position sensor was

bel ow 0 . 35 % .

2. When idle switch is tuned

on, throttle position

sensor was more than

7.8%.

1. W h en thr ott le position

sensor is 100%, idle

switch turns off.

2. W h en thr ott le position

sensor is 0%, idle switch

turns on.

1 . T P S m al f u n c t i o n .

2. Idle switch malfunction.

3. ECM malfunction. 3 8/

69 —

22 P1173 3 OFF Fuel Reduction Caused By

High Coolant Temperature Excessive high engin e

coolant temperature is

detected.

No fail-safe functio n. Eng ine coo lant tempera tur e

is normal range. 1 . En g i n e o v e r h e at .

2. ECT sensor malfunction.

3. ECM malfunction. 89 —

7 OFF Fuel Reduction Caused By

High Fuel Temperature Fuel temperature is more

than 100 deg. C. PSG (pum p cont rol unit)

controls fuel injection

quantity based on engine

speed and fuel temperature.

Fuel temperature is below

100 deg. C. 1 . E C M m a l f u n c t i o n .

2. PSG (pump control unit)

malfunction. ——

A OFF Fuel Reduction Caused By

Low Fuel Temperature Exce ssive low fuel

temperature is detected. No fail-safe function. Fuel temperature is normal

range. 1 . E C M m a l f u n ct i o n .

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

43 P133 5 A ON Eng ine Speed Output Circui t

Malfunction The PSG (pump control unit)

is recognized defective

engine speed signal form the

ECM.

Fuel inject ion qua ntity is

reduced. Correct engine speed si gnal. 1. CKP sensor harness

open circuit, short to

ground or short to

v o l t a g e .

2. CKP sensor output

harness open circuit,

short to ground or short

to v olt ag e .

3. Poor con nec tor

co n n ec tio n .

4. CKP sensor malfunction.

5. Pulse sensing gap

incorrect.

6 . P u l s e r m a l f u n c t i on .

7. Electrical interference.

8. Magnetic interference.

9 . E C M m a l f u n c t i o n .

10. PSG (pump control unit)

malfunction.

90/

9 1 /

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

se n s o r m al fu nctio n .

2. Pulse sensing gap

incorrect.

3 . P u l s e r m a l f u n c t i on .

4. Electrical interference.

5. Magnetic interference.

6 . E C M m a l f u n c t i o n .

7. PSG (pump control unit)

malfunction.

——

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

inputted "On" three times

consecutively 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 circuit.

2. Neutral switch

mal function.

3. ECM malfunction.

87 —

B ON Neutral Switch OFF Error Neutral switch signal is

inputted "Off" three times

consecutively under driving

conditions.

1. Neutral switch circuit

open, short to ground

ci r cui t.

2. Poor con nec tor

connection.

3. Neutral switch

mal function.

4. ECM malfunction.

87 —

55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM

is destroyed. No fail-safe function. No recovery. ECM malfunction. ——

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. ——

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

55 P1605 E ON EEPROM Defect EEPROM checksum does

not match with the read

check 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 Immobilizer functions are not

programmed in the ECM. 1 . E n g i n e d o e s n o t s t a r t .

2. Check engine lamp flash. No recovery. ECM malfunction. — B****

56 P1611 A - Wrong Security Code

Entered Received security code is not

correct. 1 . E n g i n e d o e s n o t s t a r t .

2. Check engine lamp flash. N o r e c o v e r y. 1 . EC M m a l f u n c t i o n .

2. Immobilizer control unit

mal functio n.

3. T ransponder key

malfunction.

— B****

56 P1612 A - Immobilizer No or Wrong

Signal Received challenge signal is

not correct or not recei ve d. 1 . E n g i n e d o e s n o t s t a r t .

2. Check engine lamp flash. No recovery. 1. ECM and immobilizer

control unit

communication circuit

open circuit, short to

ground circuit or short to

v o l t a g e c i r c u i t .

2 . E C M m al f u n ct io n .

3. Immobilizer control unit

mal functio n.

4. T ransponder key

malfunction.

2 7 /

35 B****

56 P1613 A - Immobilizer No or Wrong

Signal Received response signal is

not correct or not recei ve d. 1 . E n g i n e d o e s n o t s t a r t .

2. Check engine lamp flash. No recovery. 1. ECM and immobilizer

control unit

communication circuit

open circuit, short to

ground circuit or short to

v o l t a g e c i r c u i t .

2 . E C M m al f u n ct io n .

3. Immobilizer control unit

mal functio n.

4. T ransponder key

malfunction.

2 7 /

35 B****

56 P1614 A - Wrong Transponder Key Received response signal is

not correct from the

transponder key.

1 . E n g i n e d o e s n o t s t a r t .

2. Check engine lamp flash. N o r e c o v e r y. 1 . EC M m a l f u n c t i o n .

2. Immobilizer control unit

mal functio n.

3. T ransponder 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 function. No re covery. ECM malfunction. 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. ECM malfunction. 3 /

58 —

51 P163 0 A ON Fuel Inje cti on Quant ity

Circuit Malfunction The PSG (pump control unit)

detects high pressure

solenoid valve control circuit

malfunction due to high

current.

Fuel inject ion qua ntity is

reduced. The PSG (pump control unit)

detects correct high pressure

solenoid valve control circuit.

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

B ON F uel Inje cti on Quant ity

Circuit Malfunction The PSG (pump control unit)

detects high pressure

solenoid valve control circuit

malfunction due to

continuous current.

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

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 canceling. MAB (fuel cutoff solenoid

va lv e ) i s o pe r a t e d . CAN controller detects

correct Bus signal. 1. CAN high circuit open,

short to ground or short

to v o l ta g e c i r c ui t .

2. CAN low circuit open,

short to ground or short

t o v o l ta g e c i r c u i t.

3. Poor con nec tor

connection.

4. Electrical interference.

5 . E C M m a l f u n c t i o n .

6. PSG (pump control unit)

malfunction.

99/

100 P1651(B)

B ON CAN Device Hang-up CAN controller does not

react under engine running. CAN controller reacts

correctly under engine

running.

1 . E C M m a l f u n c t i o n .

2. PSG (pump control unit)

malfunction. ——

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

does not recognize CAN

signal from the CAN

controller.

1. MAB (fuel cutoff solenoid

v a l v e) i s o p e r a t e d .

2. Desired injection quantity

becomes 0mg/strk.

The PSG (pump control unit)

recognizes C AN signal from

the CAN controller.

1 . E C M m a l f u n c t i o n .

2. PSG (pump control unit)

malfunction. ——

B ON CAN Malfunction The ECM does not read CAN

signal from the PSG (pump

control unit).

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 con nec tor

connection.

4. Electrical interference.

5. ECM malfunction.

6. PSG (pump control unit)

malfunction.

99/

100 P1650(A)

77 P1690 4 OFF Check Engine Lamp (MIL)

Circuit Voltage Low Check engin e lamp circuit

open or short to ground

circuit.

No fail-safe function. Check engine lamp circuit is

correct condition. 1. Check eng ine lamp

circuit ope n or sho rt to

g r o u nd ci r c u i t .

2. C h eck eng ine lamp

malfunction

3. ECM 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

DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYM PTOM CODE 7)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR V OLTAGE

SUPPLY CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYM PTOM CODE 9)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR V OLTAGE

SUPPLY CIRCUIT LOW INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P01 00 (SYMPTOM CODE B)

(FLASH CODE 65) MASS AIR FLOW (MAF) S EN SOR OUTPUT CIRCUIT LOW IN PUT

DIAGNOSTIC TROUBLE CODE (DTC) P01 00 (SYMPTOM CODE C)

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

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 flowin g into the

engine.

The mass air flow (MAF) sensor element measures the

partial air mass through a measurement duct on the

sensor housing.

The ECM monitors the MAF sensor supply vol tage and

MAF sensor output voltage. The supply voltage is out of

range, DTC P0100 (Symptom Code 7) or P0100

(Symptom Code 9) will be stored. The output voltage

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

or P0100 (Symptom Code C) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harness connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Mass Air Flow” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-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%

conditions as substitute.

9 ON Mass Air Flow (MAF) Sensor

Voltage Supply Circuit Low

Input

MAF sensor power supply

voltage is below 4.6V.

B ON Mass Air Flow (MAF) 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 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 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 Visual ly check the MA F se nso r.

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-116C-57(B)

C-116

7 Repair the open circuit between the ECM and MAF

sensor.

W as 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 +12V

supply 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 +12V supply

circuit.

Is the action complete? — Verify repair —

10 Repair the short to bat tery voltage circu it between the

ECM and MAF se ns or.

W as the problem solved?

— Verify repair Go to Step 13

11 Substitute a known good MAF & IAT sensor assembly

and recheck.

W as the problem solved? — Go to Step 12 Go to S tep 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, download the late st software to the ECM using

the “SPS (Service Programming System)”.

W as the problem solved? — Verify repair Go to Step 14

Step Action Value(s) Yes No

83 4

C-116C-57(B)

C-116

83 4

C-116C-57(B)

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

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

Mass Air Flow (MAF) 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 I nfor 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 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 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 Visual ly check the MA F se nso r.

Was the problem found? — Go to Step 10 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 ground circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 10 Go to Step 7

88 83

2345

C-116C-57(B)

C-116

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, 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-116

83 4

C-116C-57(B)

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

Mass Air Flow (MAF) Sensor Output 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 I nfor As Stored By 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 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 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 Visual ly check the MA F se nso r.

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

88 83

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C-116C-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. to HOW TO USE BREAKER

BOX

3. Disconnect the MAF & IAT sensor connector.

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

or short to ground circuit.

Was the problem found?

—

Repair faulty

harnes s and

verify repair Go 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-116

Breaker Bo x 5

ƒ¶

C-116

C-57(B)

C-116

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 +12V

supply circuit.

1. Ignition “On”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

10-14.5V 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, 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

83 4

C-116C-57(B)

C-116

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 I nfor 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 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 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 Visual ly check the MA F se nso r.

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

88 83

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C-116C-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. to HOW TO USE BREAKER

BOX

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 Go 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-116

Breaker Box 3

ƒ¶

C-116

C-57

C-116

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, 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-116

DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH CODE 34)

VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 2) (FLASH CODE 34)

VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 7) (FLASH CODE 34)

VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 9) (FLASH CODE 34)

VACUUM PRE SSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT

Condition for setting the DTC and action ta ken when the DTC sets

Circuit description

The ECM monitors altitude from the barometric

pressure sensor. To apply specified vacuum pressure to

the turbocharger wastegate valve, ECM sends control

signal to the wastegate control solenoid depending on

altitude.

Then, apply vacuum pressure to the turbocharger

wastegate valve is monitored by the ECM form the

vacuum pressure sensor output signal. The ECM

controls wastegate control solenoid based on signal

from vacuum pressure sensor output.

The outpu t voltage ex cessi vely high o r low, DTC P010 5

(Symptom Co de 1) or P010 5 (Symp tom Cod e 2) w ill be

stored.

The supply voltage is out of range, DTC P0105

(Symptom Co de 7) or P010 5 (Symp tom Cod e 9) w ill be

stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect harness connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the DTC P0105 display on the Tech 2 while moving

connectors and wiring harnesses. A change in the

display will indicate the location of the fault.

Flash

Code Code Symptom

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

34 P0105 1 ON Vacuum Pressure Sens or

Circuit High Input Vacuum sensor output

voltage is more than 4.4V. 1. Fuel injection quantity is

reduced.

2. ECM use 615hpa

conditions for

turbocharger wast e gate

control.

2 ON Vacu u m Pres sure Sens or

Circuit Low Input Vacuum sensor output

voltage is below 0.5V.

7 ON Vacu u m Pres sure Sens or

Voltage Supply Circuit High

Input

Vacuum sensor power supply

voltage is more than 5.2V. 1. Fuel injection quantity is

reduced.

2. ECM use vacuum sensor

output voltage 5.0V

condition as substitute.

9 ON Vacu u m Pres sure Sens or

Voltage Supply Circuit Low

Input

Vacuum sensor power supply

voltage is below 4.5V.

Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34)

Vacuum Pressure 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 T ech 2.

2. Revie w and record th e f ai lure in form atio n.

3. Select "F0: Rea d DTC Infor A s Stor ed By EC U" in

"F0: Diagnostic Trouble Codes".

Is the DTC P0105 (Symptom Code 1) stored as

"Present Failure"? - Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

3 1 . Us in g th e Te ch 2 , ig n i t i o n "O n " a n d en g i n e " O ff " .

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 105 (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 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

con necti on i s f o u n d , re pa i r a s n e c e s s a r y.

Was the problem found?

- Verify repair Go to Step 5

5 Visually check the vacuum sensor.

Was the problem found? - Go to Step 9 Go to Step 6

C-124

C-57

6 Using the DVM and check the vacuum pressure

sensor ground circuit .

Breaker box is available:

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

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

3. Disconnect the vacuum pressure 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 vacuum pressure sensor

connector and ECM connector.

3. Check the circuit for open circuit.

Was the problem found?

Repair faulty

harness and

verify repair Go to Step 7

7 Using the DVM and check the vacuum pressure

sensor ground circuit .

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

2. Disconnect the vacuum pressure sensor

connector.

3 . C h e c k t h e c i r c u i t f o r s h o r t t o p o w e r s u p p l y c i r c u i t .

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

Breaker Box C-124

ƒ¶

C-57 C-124

ƒ¶

C-124

8 Using the DVM and check the vacuum pressure

sensor signal circuit.

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

2. Disconnect the vacuum pressure sensor

connector.

3 . C h e c k t h e c i r c u i t f o r s h o r t t o p o w e r s u p p l y c i r c u i t .

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

9 Substitute a known good vacuum pressure sensor

and recheck.

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

10 Replace the vacuum pressure sensor.

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

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser syst em

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Verify repair -

Step Action Value(s) Yes No

C-124

Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34)

Vacuum Pressure 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 T ech 2.

2. Re vi ew and record th e fai lur e i nfor ma tion.

3. Sele ct "F0: Rea d DTC Info r As Stored By EC U" in

"F0: Diagnostic Trouble Codes".

Is the DTC P0105 (Symptom Code 2) stored as

"Present F ailure"? - Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

3 1. Us in g t h e Te ch 2 , i g n i t i o n "O n " an d e n g i n e "O f f " .

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0105 ( Symptom Code 2) s tor e d i n this

ignition cycle? - Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

con ne c t i o n i s f o und , re pai r a s ne ce s s ar y.

Was the problem found?

- Verify repair Go to Step 5

5 Visually che ck the vacuum pre ss ur e s ensor.

Was the problem found? - Go to Step 9 Go to Step 6

C-124

C-57

6 Using the DVM and check the vacuum pressure

sensor signal circuit.

Breaker box is available:

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

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

3. Disconnect the vacuum pressure sensor

connector.

4. Check th e circuit f or open, s hort to sens or ground

or short to ground circuit.

Was the problem found?

Breaker box is not available:

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

2. Disconnect the vacuum pressure sensor

connector and ECM connector.

3. Check th e circuit f or open, s hort to sens or ground

or short to ground circuit.

Was the problem found?

Repair faulty

harness and

verify repair Go to Step 7

7 Using the DVM and check the vacuum pressure

sensor power supp ly circuit.

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

2. Disconnect the vacuum pressure 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

Breaker Box C-124

ƒ¶

C-57 C-124

ƒ¶

C-124

8 Repair the open circuit between the ECM and vacuum

pressure sensor.

Was the problem solved?

- Verify repair Go to Step 11

9 Substitute a known good vacuum pressure sensor

assembly and recheck.

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

10 Replace the vacuum sensor assembly.

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

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser syst em

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Verify repair -

C-124 3

C-57

Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34)

Vacuum Pressure 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 T ech 2.

2. Re vi ew and re co rd th e f ai lure i nfor ma tion.

3. Sele ct "F0: Rea d DTC Info r As Stored By EC U" in

"F0: Diagnostic Trouble Codes".

Is the DTC P0105 (Symptom Code 7) stored as

"Present Failure"? - Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

3 1. Us in g t h e Te ch 2 , ig n i t io n " On " an d e n g i n e " O f f ".

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0105 ( Symptom Code 7) s tor e d i n this

ignition cycle? - Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

con ne c t i o n i s f o und , repa i r a s ne ce ss ary.

Was the problem found?

- Verify repair Go to Step 5

5 Visually che ck the vacuum pressure s en so r.

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

6 Using the DVM and check the vacuum pressure

sensor power supp ly circuit.

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

2. Disconnect the vacuum pressure sensor

connector.

3. Check the circuit for short to battery voltage

circuit.

Was the DVM indicated specified value?

Approximately

5.0V Go to Step 8 Go to Step 7

C-124

C-57

C-124

7 Repair the short to battery voltage circuit between the

E C M a n d v a c u u m p r e s s u r e s e n s o r.

Was the problem solved?

- Verify repair Go to Step 10

8 Substitute a known good vacuum pressure sensor

assembly and recheck.

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

9 Replace the vacuum pressure sensor assembly.

Is the action complete? - Verify repair -

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 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser syst em

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Verify repair -

C-124 3

C-57

Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34)

Vacuum Pressure 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 T ech 2.

2. Re vi ew and re co rd th e f ai lure i nfor ma tion.

3. Sele ct "F0: Rea d DTC Info r As Stored By EC U" in

"F0: Diagnostic Trouble Codes".

Is the DTC P0105 (Symptom Code 9) stored as

"Present Failure"? - Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

3 1. Us in g t h e Te ch 2 , ig n i t io n " On " an d e n g i n e " O f f ".

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0105 ( Symptom Code 9) s tor e d i n this

ignition cycle? - Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

con ne c t i o n i s f o und , repa i r a s ne ce ss ary.

Was the problem found?

- Verify repair Go to Step 5

5 Visually che ck the vacuum pressure s en so r.

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

6 Using the DVM and check the vacuum pressure

sensor power supp ly circuit.

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

2. Disconnect the vacuum pressure 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

C-124

C-57

C-124

7 Using the DVM and check the vacuum pressure

sensor power supply circuit.

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

2. Disconnect the vacuum pressure sensor

c o n n e c t o r a n d E C M c o n n e c t o r.

3. Check the circuit for short to vacuum pessure

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 vacuum pressure sensor

ground.

Is the action complete? - Verify repair -

9 Repair the short to ground circuit between the vacuum

pressure 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, 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

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser syst em

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Verify repair -

C-124 3

ƒ¶

DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 1)

(FLASH CODE 23) INTAKE AIR TEMPER ATURE (IAT) S ENSOR CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE 2)

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The IAT sensor is a thermistor. A tempe rature changes

the resistance value, which changes the voltage in the

circuit. In other words it measures a temperature value.

Low air temperature produces a high resistance.

The ECM supplies 5 volts signal to the IAT sensor

through resisters in the ECM and measures the voltage.

The signal voltage will be high when the air temperature

is cold, and it will be low when the air temperature is

hot.

The output vol tage excessiv ely high or lo w, DTC P0110

(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 -Inspect har ness connector s

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 Fail-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 deg.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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0110 (Symptom Code 1) stored as

“Pres ent Fa ilure”? — 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 P0 110 (Sym ptom Cod e 1) s tored i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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 Visual ly check the IAT sensor.

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

84 13

C-116

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 t o 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

Temperature (°C) Resistance (Ω) (Approximately)

-20 13660

0 5430

20 2433

40 1153

60 598

80 334

100 204

1235 4

IAT Sensor

C-116

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-116

C-57(B)

C-116

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. to HOW TO USE BREAKER

BOX

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

harness 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, download 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-116

Breaker Box 3

ƒ¶

C-116

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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0110 (Symptom Code 2) stored as

“Pres ent Fa ilure”? — 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 P0 110 (Sym ptom Cod e 2) s tored i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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 Re move the MA F & IAT sensor as sembl y and vis ually

check.

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

84 13

C-116

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 t o Step 7 Go to Step 8

Step Action Value(s) Yes No

Temperature (°C) Resistance (Ω) (Approximately)

-20 13660

0 5430

20 2433

40 1153

60 598

80 334

100 204

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. to HOW TO USE BREAKER

BOX

3. Disconnect the MAF & IAT sensor connector.

4. Check the circuit for short to sensor ground or

ground circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the MAF & IAT sensor connector and

ECM connector.

3. Check the circuit for short to sensor ground or

ground circuit.

Was the problem found?

—

Repair faulty

harness 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, download 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

84 92

ƒ¶

Breaker Box

ƒ¶

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECT sensor is a thermistor . A temperature changes

the resistance value, which changes the voltage in the

circuit. In other words it measures a temperature value.

It is installed on the coolant stream. Low coolant

temperature produces a high resistance.

The ECM supplies 5 volts signal to the ECT sensor

through resisters in the ECM and measures the voltage.

The signal voltage will be high when the engine

temperature is cold, and it will be low when the engine

temperature is hot.

The output vol tage excessiv ely high or lo w, DTC P0115

(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 -Inspect har ness connector s

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 Fail-Safe (Back Up)

14 P0115 1 ON E ngine Coolant Temperature

(ECT) Sensor Circuit High

Input

ECT sensor output voltage is

more than 4.7V. 1. ECM uses fuel temperature

as substitute.

2. ECM uses 60 deg.C

condition for injection timing

control.

3. ECM uses -25 deg.C

condition (4JA1-TC) or -15

deg.C condition (4JH1-TC)

for glow time control.

2 ON Engine Coolant Temperature

(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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0115 (Symptom Code 1) stored as

“Pres ent Fa ilure”? — 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 P0 115 (Sym ptom Cod e 1) s tored i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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 Visual ly 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 t o 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

Temperature (°C) Resistance (Ω) (Approximately)

-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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 14

Step Action Value(s) Yes No

89 1

E-41C-57(B)

E-41

Breaker Box 2

ƒ¶

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, download 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer 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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0115 (Symptom Code 2) stored as

“Pres ent Fa ilure”? — 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 P0 115 (Sym ptom Cod e 2) s tored i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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 Visual ly 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 t o Step 7 Go to Step 8

Step Action Value(s) Yes No

Temperature (°C) Resistance (Ω) (Approximately)

-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. to HOW TO USE BREAKER

BOX

3. Disconnect the ECT sensor connector.

4. Check the circuit for short to sensor ground or

ground circuit.

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 circuit.

Was the problem found?

—

Repair faulty

harness 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, download 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

89 93

ƒ¶

Breaker Box

ƒ¶

C-57(B)

DIAGNOSTIC TROUBLE CODE (DTC) P01 80 (SYMPTOM CODE B)

(FLASH CODE 15) FUEL TEMPERAT URE SENSOR CIRCUIT RANGE/PERFORMANCE

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The fuel temp erature sensor is assembled in side of the

pump con t ro l uni t ( PS G). The si gnal of fu el temperat ur e

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

If the fuel temperature is excessively high or low

condition, DTC P0180 will be stored.

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 c onnectors and wiring harness rela ted to the

sensor.

Flash

Code Code Symptom

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

15 P0180 B ON Fuel Temperature Sensor

Circuit Range/Performance FT sensor output is high

temperature (mo re than

150deg.C) or low temperature

(below -40deg.C).

The ECM use 75deg.C

conditions as substitute.

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 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, download 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.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P02 15 (SYMPTOM CODE A)

(FLASH CODE 52) FUEL CUTOFF SOLEN OID VALVE MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P02 15 (SYMPTOM CODE B)

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

DIAGNOSTIC TROUBLE CODE (DTC) P02 15 (SYMPTOM CODE C)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE

DIAGNOSTIC TROUBLE CODE (DTC) P02 15 (SYMPTOM CODE D)

(FLASH CODE 52) FUEL CUTOFF SOLEN OID VALVE MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

When the ignition switch is turned “Off”, the fuel

solenoid valve (MAB) signal is supplied from the ECM to

the PSG. This signal is the command for the PSG to

turn “Off” the engine.

If the MAB signal circuit is short to voltage circuit or

short to ground circuit, DTC P0215 (Symptom Co de 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 Fail-Safe (Back Up)

52 P0215 A ON Fuel Cutof f Solenoid Valve

Malfunction 1. Ignition key switch off.

2. Engine speed is below

1500rpm.

3. Vehicle speed is below

1.5km/h.

4. PSG (pump control unit)

recognizes MAB (fuel cutoff

solenoid valve) signal from

the ECM, but the MAB

could not operate.

1. MAB (fuel 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. 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.

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

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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code A) stored as

“Pres ent Fa ilure”? — 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 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 —

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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code B) stored as

“Pres ent Fa ilure”? — 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 P0215 (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 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 Visual ly chec k the PS G (p ump contr ol un it).

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

105 5E-6C-57

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. to HOW TO USE BREAKER BOX

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

Breaker Box

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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0215 (Symptom Code C) stored as

“Pres ent Fa ilure”? — 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 P0215 (Symptom Code C) 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 Visual ly chec k the PS G (p ump contr ol un it).

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

105 5E-6C-57

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. to HOW TO USE BREAKER

BOX

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

harn es s 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

E-6

105

Breaker Box 5

ƒ¶

105

E-6

C-57

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

Cutoff Solenoid Valve 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 P0215 (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 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, download 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.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH CODE 54)

INJECTION TIMING CONTROL CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE 54)

INJECTION TIMING CONTROL CIRCUIT MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM is calculates an injection quantity and an

injection timing using the various sensors (crankshaft

position sensor, camshaft position sensor, engine

coolant temperature sensor, etc.). The timing control

valve (TCV) operation performs an injection timing

decision.

The TCV pe rf or ms as a v ar iab le th ro ttle, using the rapi 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), 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.

• Low fuel quantity in the fuel tank.

Check for the following conditions:

• Insufficient air bleeding of fuel line inside, clogged

fuel filter or pinched fuel pipe/hose may cause the

DTC store or improper engine performance.

Air bleeding procedure:

1.Oper ate the primin g pump until str ong resi stance is

felt.

2.Wait 1 minute, and operate the priming pump until

strong resistance is felt.

3.Wait 1 minute, and operate the priming pump until

strong resistance is felt.

4.Turn the ignition switch to the "ON" position. Wait

until the glow indicator lamp turns off.

5.Turn the ignition switch to the "START" position

and crank the engine until it starts.

6.If the engine does not start, repeat S tep 3 - 5.

7.Allow the engine to idle for 3 minutes to bleed air

compl etely f orm th e fuel s ystem and ch eck fo r fuel

leakage.

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the "Ac tua l In jec t i on Start" display on the Tech2 whi le

moving c onnectors and wiring harness rela ted to the

sensor.

Flash

Code Code Symptom

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

54 P0216 A ON Injection Timing Control

Circuit Malfunction 1. Engine speed is more

than 700rpm.

2. Fuel injection quantity is

more than 4mg/stk.

3. Deviation of actual

injection timing and

desired injection timing is

more than +3 deg. CA or

-6 deg. CA for 8

seconds.

Fuel injection quantity is

reduced.

B ON Injection Timing Control

Circuit Malfunction 1. Engine speed is more

than 2014rpm.

2. Fluctuation of actual

injection timing is more

than +-5.2 deg. CA.

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

Injection Timing Control Circuit Malfunction

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

Injection Timing Control Circuit Malfunction

Step Action Value(s) Yes No

1 Was the "On-B oard Diagnos tic ( OBD ) Syste m Chec k"

performed?

-Go to

Step 2

Go to On Board

Diagnostic

(OBD) System

Check

2 1. Connect the T ech 2.

2. Re vi ew and record th e fai lur e i nf or ma tion .

3. Sele ct "F0: Rea d DTC Info r As Stored B y ECU" i n

"F0: Diagnostic Trouble Codes".

Is the DTC P0216 (Symptom Code A) or P0216

(Symp tom Code B) stored as "Present F ailure"? - Go to Step 3

Refer to

Diagnostic Aids

and Go to Step

3 1 . 1 U s i n g t h e Te c h 2 , i g n i t i o n " O n " a n d e n g i n e " O f f " .

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0216 (Symptom Code A) or P0216

(Symptom Code B) stored in this ignition cycle? - Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Pe r f o r m t h e a i r b l e e d i n g i n t h e f u e l l i n e s u ffi ci e nt ly.

Air Bleeding Procedure:

1. Operate the priming pump until strong resistance

is felt .

2. Wait 1 mi nu te, a nd operate the pr im ing pum p un til

strong resistance is felt.

3. Once more wait, and operate the priming pump

until strong resistance is felt.

4. Turn the ignition switch to the "ON" positi on. Wait

until the glow indicator lamp turns off.

5. Turn the ignition switch to the "START" position

and crank the engine until it starts.

6. If the engine does not start, repeat Step 3 - 5.

7. Allow th e engine to idle for 3 minutes to bleed a ir

completely form the fuel system and check for fuel

leakage.

DTC Re-check:

1 . U s in g t h e Te ch 2 , i g n i t i o n "O n " an d e n g i n e "O f f " .

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0216 (Symptom Code A) or P0216

(Symptom Code B) restored in this ignition cycle? - Go to Step 5 Verify repair

5 V i s u a l l y / p h y s i c a l l y i n s p e c t f o r t h e f o l l o w i n g c o n d i t i o n s .

• Restricted 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 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 8

8 Is the ECM programmed with the latest software

release? If

not, download the latest software to the ECM using

the "SPS (Service Programming System)".

Was the problem solved? - Verify repair Go to Step 9

9 S u b s t i t u t e a k n o w n g o o d E C M a n d r e c h e c k .

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser sys tem

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Go to Step 10 Go to Step 11

Step Action Value(s) Yes No

10 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

P r o g r a m m i n g S y s t e m ( S PS ) i n t h i s m a n u a l .

Foll owing ECM pr ogramming, the immobi liser sys tem

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

section 11 "Immobilizer System-ECM replacement"

for the ECM/Immobilizer linking procedure. - Verify repair -

11 Replace the injection pump assembly.

Is the action complete? - Verify repair -

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 3) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/PERF ORM ANCE

DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 4) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID "A" LOW

DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 5) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/PERF ORM ANCE

DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 6) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0243 (SYMPTOM CODE 8) (FLASH CODE 64)

TURBOCHARGER WASTEGATE SOLENOID "A" HIGH

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

Flash

Code Code Symptom

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

3 ON Turbocharger Wastegate

Solenoid “A” Range/

Performance

1. Intake air temperature is

between –50 deg C and

200 deg C.

2. Engine coolant

temperature is between –

50 deg C and 150 deg C.

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes a

10% condition.

4 ON Turbocharger Wastegate

Solenoid “A” Low Wastegate control EVRV

circuit open or short to ground

circuit

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes a

10% condition.

3. Wastegate control EVRV

becomes a 32% condition.

5 ON Turbocharger Wastegate

Solenoid “A” Range/

Performance

1. Intake air temperature is

between –50 deg C and

200 deg C.

2. Engine coolant

temperature is between –

50 deg C and 150 deg C.

6 ON Turbocharger Wastegate

Solenoid “A” Malfunction 1. Engine coolant

temperature is between

–50 deg C and 150 deg

2. EGR control EVRV is a

0% condition.

1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes a

10% condition.

64 P0243

8 ON Turbocharger Wastegate

Solenoid “A” High Wastegate control EVRV

circuit short to voltage. 1. Fuel injection quantity is

reduced.

2. EGR EVRV becomes a

10% condition.

3. Wastegate control EVRV

becomes a 32% condition.

Circuit description

The ECM monitors altitude from the barometric pressure

sensor. To apply specified vacuum pressure to the

turbocharger wastegate valv e, ECM sends control signal to

the wastegate control solenoid depending on altitude.

Then, applied vacuum pressure to the turbocharger

wastegate valve is monitored b y the ECM from the vacu um

pressure sensor output signal. The ECM controls

wastegate control solenoid based on signal from vacuum

pressure sensor output.

If the vacuum pressure sensor detected vacuum pressure

is excessively low or high due to faulty vacuum line,

vacuum pump or turbocharger wastegate valve, DTC

P0243 (Symptom Code 3), P0243 (Symptom Code 5) or

P0243 (Symptom Code 6) will be stored.

If the wastegate control solenoid circuit is open or short to

ground circuit, DTC P0243 (Symptom Code 4) will be

stored.

If the wastegate control solenoid circuit is short to voltage

circuit, DTC P0243 (Symptom Code 8) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside insulation.

• Turbocharger wastegate valve sticking or broken.

• Misrouted vacuum hose.

• Faulty vacuum pump or regulating valve.

Check for the following conditions:

• Poor connection at ECM-Inspect harness connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appear s to be OK, observe the

DTC P0243 display on the Tech 2 while moving

connectors and wiring harnesses. A change in the

display will indicate the location of the fault.

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Code 64)

Turbocharger Wastegate Solenoid "A" 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 C odes".

Is the DTC P0243 (Symptom Code 3) 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 DT C Information" in "F0: Diagnostic

Trouble Codes" with the Tech 2 and clear the DTC

information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0243 (Symptom Code 3) stored in this

ignition cycle? – Go to Step 4

Refer to

Diagnostic Aids

and Go to Step 4

4 Remove the vacuum hose & vacuum regulating valve

and check for the following conditions.

• Objects blocking the vacuum hose.

• Objects blocking the vacuum regul ating valve.

• Vacuum leaking at vacuum hose or vacuum

regulating valve.

• Objects blocking the wastegate solenoid valve.

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

problem found? – Verify repair Go to Step 5

5 Remove the vacuum pressure sensor and visually

check.

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

6 Substitute a known good vacuum pressure sensor and

recheck

Was the problem solved – Go to Step 7 Go to Step 8

7 Replace the vacuum press ure sensor.

Is the action complete? – Verify repair –

8 Using a DMM, check the wastegate control solenoid:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate solenoid connector.

3. Measure the resistance of the wastegate control

solenoid coil.

Does the test indicate the specified resistance?

Approximately

32Ω at 20° C Go to Step 11 Go to Step 9

9 Substitute a known good wastegate control solenoid

and re-check.

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

10 Replace the wastegate control solenoid.

Is the action complete? – Verify repair –

Step Action Value(s) Yes No

11 1 Using a pressure gauge, check the turbocharger

wastegate valve operation for a ruptured

diaphragm.

2 If a problem is found, repair as necessary.

Was a problem found? – Go to Step 12 Go to Step 13

12 Replace the turbocharger wastegate valve.

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 the Service Programming

System (SPS) section, 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 –

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64)

Turbocharger Wastegate Solenoid "A" Low

Step Action Value(s) Yes No

1 W as 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 P0243 (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 DTC P0243 (Symptom Code 4) stored in this

ignition cycle? – Go to Step 4

Refer to

Diagnostic Aids

and Go to Step 4

4 1 Check for p oor/fault y connections at the wastegate

control solenoid or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was the problem found and corrected?

– Verify repair Go to Step 5

5 Using a DMM, check the wastegate control solenoid:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate solenoid connector.

3. Measure the resistance of the wastegate control

solenoid coil.

Does the test indicate the specified resistance?

Approximately

32Ω at 20° C Go to Step 11 Go to Step 9

6 Using a DMM, check the wastegate control solenoid

power supply circuit:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate solenoid connector.

3. Check the circuit integrity.

Does the DMM indicate the specified value? 10 – 14.5 V Go to Step 8 Go to Step 7

7 Repair the open circuit between the ECM main relay

and wastegate control solenoid.

Is the action complete? – Verify repair –

Step Action Value(s) Yes No

8 Using a DMM, check the wastegate control solenoid

circuit.

Breaker box is a vailable:

1 Ignition “On”, engine “Off”.

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

disconnected). Refer to ”How to Use Breaker Box”

in this Section.

3 Remove the wastegate control solenoid

connector.

4. Check the circuit for an open or short to ground.

Was the problem found?

Breaker box is not available:

1 Ignition “On”, engine “Off”.

2. Disconnect the ECM connector.

3. Disconnect the wastegate solenoid connecto r.

4. Using the DMM, check the circuit for a short to

ground or an open.

Was the problem found?

–

Repair faulty

harness and verify

repair Go to Step 11

9 Substitute a known good wastegate control solenoid

and re-check operation.

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

10 Replace the wastegate control solenoid.

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 the Service Programming

System (SPS) section, 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 –

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64)

Turbocharger Wastegate Solenoid "A" Range/Performance

Step Action Value(s) Yes No

1 W as 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 P0243 (Symptom Code 5) stored as

“Present Failure”? – Go to Step 3

Refer to

Diagnostic Aids

and Go to Step 3

3 1 Using Tech 2, with ignition "On" and engine "Off".

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0243 (Symptom Code 5) stored in this

ignition cycle? – Go to Step 4

Refer to

Diagnostic Aids

and Go to Step 4

4 Visually check the vacuum regulating valve. If a

problem is found rectify as necessary.

Was the problem found and corrected? – Verify repair Go to Step 5

5 Using a DMM, check the wastegate control solenoid:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate solenoid connector.

3. Measure the resistance of the wastegate control

solenoid coil.

Does the test indicate the specified resistance?

Approximately

32Ω at 20° C Go to Step 8 Go to Step 6

6 Substitute a known good wastegate control solenoid

and re-check.

Was the problem solved? – Go to Step 7 Go to Step 8

7 Replace the wastegate control solenoid.

Is the action complete? – Verify repair –

8 1 Using a pressure gauge, check the turbocharger

wastegate valve operation for a ruptured

diaphragm.

2 If a problem is found, repair as necessary.

Was a problem found? – Go to Step 9 Go to Step 10

9 Replace the turboch arger wastegate valve.

Is the action complete? – Verify repair –

Step Action Value(s) Yes No

10 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was a problem found and corrected?

– Verify repair Go to Step 11

11 Visually check the vacuum pressure sensor.

Was a problem found? – Go to Step 13 Go to Step 12

12 Using a DMM, check the vacuum pressure sensor

signal circuit:

1 Ignition “On”, engine “Off”.

2 Disconnect the vacuum pressure sensor

connector.

3. Check the circuit for a short to power supply

circuit condition.

Does the DMM indicate the specified value?

Less than 1 V Go to Step 15

Repair faulty

harness and verify

repair.

13 Substitute a known good vacuum pressure sensor

assembly and re-check.

Was the problem resolved? – Go to Step 14 Go to Step 15

14 Replace the vacuum press ure sensor assembly.

Is the action complete? – Verify repair –

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 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to the Service Programming

System (SPS) section, 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 –

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64)

Turbocharger Wastegate Solenoid "A" Malfunction

Step Action Value(s) Yes No

1 W as 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 DT C Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0243 (Symptom Code 6) stored as

“Present Failure”? – Go to Step 3

Refer to

Diagnostic Aids

and Go to Step 3

3 1 Using Tech 2, with ignition "On" and engine "Off".

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0243 (S ymptom Code 5) stored in this

ignition cycle? – Go to Step 4

Refer to

Diagnostic Aids

and Go to Step 4

4 Visually check the turbocharger wastegate valve and

hose.

If the hose is clogged, disconnected or damaged, repair

as necessary.

Was the problem found and corrected? – Verify repair Go to Step 5

5 1 Using a pressure gauge, check the turbocharger

wastegate valve operation for a ruptured

diaphragm.

2 If a problem is found, repair as necessary.

Was a problem found? – Go to Step 6 Go to Step 7

6 Replace the turboch arger wastegate valve.

Is the action complete? – Verify repair –

7 Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was a problem found and corrected?

– Verify repair Go to Step 8

8 Visually check the MAF Sensor

Was a problem found? – Go to Step 10 Go to Step 9

9 Using a DMM, check the MAF sensor signal circuit:

1 Ignition “On”, engine “Off”.

2 Disconnect the MAF sensor connector.

3. Check the circuit for a short to power supply

condition.

Does the DMM indicate the specified value?

Less than 1 V Go to Step 12

Repair faulty

harness and verify

repair

10 Substitute a kno wn good MAF & IAT sensor assembly

and re-check.

Was the problem resolved? – Go to Step 11 Go to Step 12

11 Replace the MAF & IAT sensor assemb ly.

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 the Service Programming

System (SPS) section, 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 –

Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64)

Turbocharger Wastegate Solenoid "A" High

Step Action Value(s) Yes No

1 W as 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 DT C Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0243 (Symptom Code 8) stored as

“Present Failure”? – Go to Step 3

Refer to

Diagnostic Aids

and Go to Step 3

3 1. Using Tech 2, with ignition "On" and engine "Off".

2. Select "F1: Clear DTC Information" in "F0:

Diagnostic Trouble Codes" with the Tech 2 and

clear the DTC information.

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

DTC Infor As Stored By ECU" in the "F0:

Diagnostic Trouble Codes".

Was the DTC P0243 (Symptom Code 8) stored in this

ignition cycle? – Go to Step 4 Refer to

Diagnostic Aids

4 Check for poor/faulty connection at the wastegate

control solenoid or ECM connector. If a poor/faulty

connection is found, repair as necessary.

Was a problem found and corrected? – Verify repair Go to Step 5

5 Using a DMM, check the wastegate control solenoid:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate solenoid connector.

3. Measure the resistance of the wastegate control

solenoid coil.

Does the test indicate the specified resistance?

Approximately

32Ω at 20° C Go to Step 6 Go to Step 8

6 Using a DMM, check the wastegate control solenoid

circuit:

1 Ignition “On”, engine “Off”.

2 Disconnect the wastegate control solenoid and

ECM connectors.

3. Check the circuit for a short to voltage condition.

Does the DMM indicate the specified value?

No continuity Go to Step 10 Go to Step 7

7 Repair the short to voltage co ndition.

Is the action complete? – Verify repair –

8 Substitute a known good wastegate control solenoid

and re-check operation.

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

9 Replace the wastegate control solenoid.

Is the action complete? – Verify repair –

Step Action Value(s) Yes No

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 Replace the ECM.

Is the action complete?

IMPORTANT: The replacement ECM must be

programmed. Refer to the Service Programming

System (SPS) section, 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 –

DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYM PTOM CODE 6)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYM PTOM CODE 7)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYM PTOM CODE 9)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P02 51 (SYMPTOM CODE A)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P02 51 (SYMPTOM CODE B)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P02 51 (SYMPTOM CODE D)

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

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

(FLASH CODE 53) INJECTION PUMP MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM is calculates an injection quantity and an

injection timin g us ing t he v ar iou s s ens ors . And the P SG

control s the high pr essure solenoid valve depe nding on

programmed pump map data.

The signal of desired injection quantity and actual

injection quantity are exchanged via the CAN-bus

between the PSG and ECM.

If the relatio n of eng ine speed sign al and double d pum p

camshaft speed signal excessively large, DTC P0251

(Symptom Code 7) will be stored.

If the CAN high or low circuit is defected, DTC P0251

(Symptom Code E) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Injection Quantity” display on the Tech2 while

moving c onnectors and wiring harn ess related to the

sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-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. MAB (fuel 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 690 rpm.

9 ON Inj ection Pump Malfunction No pump map programmed in

the PSG (pump control unit)

or PSG malfunction.

A ON Inj ection Pump Malfunction EEPROM or A/D converter

malfunction in the PSG (pump

control unit).

Fuel injection quantity is

reduced.

B ON Inj ection 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 (f uel 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

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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 6) stored as

“Pres ent Fa ilure”? — 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 P0251 ( Sy mpt om Code 6) s tor e d i n 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 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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 7) stored as

“Pres ent Fa ilure”? — 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 P0251 ( Sy mpt om Code 7) s tor e d i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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

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

stored at the same time ?

—

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

C-57(B) E-6

6 If an oscilloscope is available, 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

Crankshaft Position (CKP) Sensor & TDC Output Signal

Reference Wave Form

CH1

0V→

CH2

0V→

Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)

Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div

Measurement Condition: Approximately 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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 8

Step Action Value(s) Yes No

E-6

Breaker Box 8

ƒ¶

91 8

C-57(B) E-6

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

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 immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 12 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 lizer syst em

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

13 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

E-6

Diagnostic Trouble Code (DTC) P0251 (Symptom Code 9) (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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code 9) stored as

“Pres ent Fa ilure”? — 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 P0251 ( Sy mpt om Code 9) s tor e d i n 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 A) (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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code A) stored as

“Pres ent Fa ilure”? — 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 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 —

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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code B) stored as

“Pres ent Fa ilure”? — 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 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

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: Rea d DTC Infor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0251 (Symptom Code D) stored as

“Pres ent Fa ilure”? — 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 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 —

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 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 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, download 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 lizer syst em

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

section 11 “Immobilizer System-ECM replacement” for

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

7 Repla ce th e 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 lizer syst em

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

8 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P03 35 (SYMPTOM CODE B)

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P03 35 (SYMPTOM CODE D)

(FLASH CODE 43) CRANKSHA FT POS ITION SENSOR MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE E)

(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The CKP sensor is located on top of the flywheel

housing of the flywheel and fixed with a bolt. The CKP

sensor is of the magnet coil type. The inductive pickup

senses four gaps in the flywheel exciter ring and is used

to determine the engine speed and engine cylinder top

dead center.

If the CKP sensor harness or sensor malfunction is

detected during engine run, DTC P0335 (Symptom

Code B) is stored.

If the CKP sensor harness or sensor malfunction is

detected during engine cranking, DTC P0335

(Sympto m Code D) is stor ed.

If the CKP sensor signal frequency is excessively high

or engine ove r-r unning, DT C P0 335 (S ym pto m 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 -Inspect har ness connector s

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 c onnectors and wiring harn ess related to the

sensor.

Flash

Code Code Symptom

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

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.

D ON Crankshaft Position Sensor

Circuit Malfunction 1. No pump camshaft speed

sensor error.

2. “Crankshaft Position

Sensor Circuit Malfunction

(Symptom Code B)” is not

stored.

3. Engine speed is 0rpm.

4. Doubled pump camshaft

speed is more than 50rpm.

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 Input Circuit

Range/Performance En gine 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.

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: Rea d 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 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 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. to HOW TO USE BREAKER

BOX

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

ƒ¶

Breaker Box

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. to HOW TO USE BREAKER

BOX

3. Disconnect the CKP sensor connector.

4. Check the circuit for open , short to sens or 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 circuit for open , short to sens or wire or

short to ground circuit.

Was the problem found?

—

Repair faulty

harn es s and

verify repair Go to Step 9

Step Action Value(s) Yes No

90 98

Breaker Bo x 101

ƒ¶

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 i s availabl e, monitor 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.

• Obj ects sticki ng the CKP sensor.

• Objects sti cking the CKP sensor pu lser.

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

harn es 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 Approximately 1.1 V at

2000rpm

At ECM C57 connector 90 & 98

Crankshaft Position (CKP) Sensor Reference Wave Form

0V→

Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div

Measurement Condition: Approximately 2000rpm

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

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

Engine Speed Input 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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0335 (Symptom Code E) stored as

“Pres ent Fa ilure”? — 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 Ask to the customer whether over-speed condition

such a s miss-gear shifting etc . has been expe rienced

or not. —

Expla in the

reason of DTC

to the customer Go to Step 5

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

101

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

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 i s availabl e, monitor 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.

• Obj ects sticki ng the CKP sensor.

• Objects sti cking the CKP sensor pu lser.

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

harn es s and

verify repair Go 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

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

Step Action Value(s) Yes No

Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Approximately 1.1 V at

2000rpm

At ECM C57 connector 90 & 98

Crankshaft Position (CKP) Sensor Reference Wave Form

0V→

Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div

Measurement Condition: Approximately 2000rpm

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYM PTOM CODE 4)

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYM PTOM CODE 8)

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

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

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

ECM swit ches gl ow rela y to ope ra te glow pl ug depe nds

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 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 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 Fail-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 V oltage

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0380 (Symptom Code 4) stored as

“Pres ent Fa ilure”? — 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 P0380 ( Sy mpt om Code 4) st ored 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 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?

Approximately

105ΩGo to Step 6

Replace glow

relay and verify

repair

1X-5C-57

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?

10-14.5V 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

X-5

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. to HOW TO USE BREAKER

BOX

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

harness and

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

X-5

Breaker Box 3

ƒ¶

X-5C-57

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

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

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

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

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

Diagnostic Trouble Codes”.

Was the DTC P0380 (Symptom Code 8) stored in this

ignition cycle? — 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 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The function of th e glow time indicato r lamp is to info rm

the driver whether the glow system is activated.

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

This does not imply that the glow plugs are no longer

activated.

In the after glow phase the lamp is not illuminated but

the glow plugs remain active for a certain period

depending on engine coolant temperature.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM - Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• 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 Fail-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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0381 (Symptom Code 4) stored as

“Pres ent Fa ilure”? — 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 P0381 ( Sy mpt om Code 4) st ored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 1. Ignitio n “On”, engi ne “Off”.

2. Check the glow plug indicator lamp.

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

5 1. Ignitio n “On”, engi ne “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. to HOW TO USE BREAKER

BOX

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

harness and

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Breaker Box B-24

ƒ¶

6B-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 1. Using the Tech 2, ignition “On” and engine “Off”.

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

Diagnostic Trouble Codes” with the Tech 2 and

clear the DTC information.

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

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

Diagnostic Trouble Codes”.

Was the DTC P0381 (Symptom Code 8) 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 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYM PTOM CODE 3)

(FLASH CODE 32) EXHAUS T GAS RECIRCULATION FLOW EXCESSIVE DETECTED

DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYM PTOM CODE 4)

(FLASH CODE 32) EXHAUS T GA S RECIRCULATION CIRCUIT SHORT TO GROUND OR

OPEN CIRCUIT

DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYM PTOM CODE 5)

(FLASH CODE 32) EXHAUS T GAS RECIRCULATION FLOW INSU FFICIENT DETECTED

DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYM PTOM CODE 8)

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO BATTERY

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

Flash

Code Code Symptoms

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

3 ON Exhaust Gas Recirculation

Excessive Flow Detected 1. Intake air temperature is

between 15 deg. C and

100 deg. C.

2. Engine coolant

temperature is between

35 deg. C and 100 deg.

3. Barometric pressure is

between 85 kPa and 110

kPa.

4. Small amount of mass

air flow. (Desired mass

air flow - mass air flow is

more than 150 mg/strk.

Fuel injection quantity is

reduced.

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.

5 ON Exhaust Gas Recirculation

Flow Insufficient Detected 1. Intake air temperature

is -between 15 deg. C

and 100 deg. C.

2. Engine coolant

temperature is between

35 deg. C and 100 deg.

3. Barometric pressure is

between 85 kPa and

1100 kPa.

4. Large mount of mass

air flow. (Desired mass

air flow - mass air flow

is below 150 mg/strk).

Fuel injection quantity is

reduced.

32 P0400

8 ON Exhaust Gas Recirculation

Circuit Short to Battery EGR EVRV circuit short to

voltage circuit. Fuel injection quantity is

reduced and EGR EVRV

10% conditions as

substitute.

Circuit Description

The amount of EGR is controlled by EVRV (electrical

vacuum regula ti ng val ve) via the e ngine control module

(ECM) command signal depend s on the engine sp eed,

operating o f the accelerator pedal and engine coolant

temperature.

The EVRV is shaped to control vacuum applied to the

diaphragm chamber of the EGR valve based on du ty signal

sent from the ECM.

If the EGR valve is stu ck at open po siti on or close posi tio n,

DTC P0400 (Symptom Code 3) or DTC P0400 (Symptom

Code 5) i s stored.

If the EGR EVRV circui t is open or sh ort ground circuit, DTC

P0400 (Symptom Code 4) is stored.

If the EGR EVRV circuit is short to voltage circuit, DTC

P0400 (Symptom Code 8) is stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harne ss.

• Rubbed th rough w ire in sula ti on .

• Broken wire inside the insula tion .

• EGR valve sticking.

• Faulty inta ke air duct conn ection.

Check for the fo llow ing co ndition s:

• Poor connection at EC M-Inspect harne ss connector s for

backed out termin al s, improper ma ting , broken locks,

improperly formed or damage d termin al s, and poor

terminal to w ire connection .

Damaged harnes s-Inspect the w iring harne ss for dama ge. If

the harness appears to be OK, obse rve the DTC P0400

display on the Te ch 2 while moving connectors and wiring

harnesses. A change in the display will indicate th e loca tion

of the fault.

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32)

Exhaust Gas Recirculation Flow Excessive Detected

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0400 (Symptom Code 3) stored as

“Pres ent Fa ilure”? — 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 P0400 ( Sy mpt om Code 3) st ored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking the air cleaner.

• Objects blocking the MAF sensor.

• Vacuum leaking at intake duct.

• Objects blocking the turbocharger.

If a problem is found, repair as necessary.

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

5 Re move the MA F & IAT sensor as sembl y and vis ually

check.

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

6 Substitute a known good MAF & IAT sensor assembly

and re check.

Was the problem solved? — Go to Step 7 Go to Step 8

7 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

8 Using the DVM and check the EGR EVRV.

1. Ignition “Off”, engine “Off”.

2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

14Ω at 20°C Go to Step 11 Go to Step 9

EGR EVRV 12

9 Substitute a known good EGR EVRV and recheck.

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

10 Replace the EGR EVRV.

Is the action complete? — Verify repair —

11 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

exce ssive carbon depo sit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum R elease: EGR Valv e Close

If a problem is found, repair as necessary.

Was the problem found? — Verify repair or

Go to Step 13 Go to Step 12

12 Inspect the EGR valve.

1. Remove the EGR valve from the engine.

2. Inspect the EGR valve whether pintle valve is

stuck or damage d.

If excessive carbon deposit is found, clean up the

EGR valve and inspect damage of the pintle and seat.

Was the problem found? — Verify repair or

Go to Step 13 Go to Step 14

13 Replace the EGR valve.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Vacuum Pump Small Window

14 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 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32)

Exhaust Gas Recirculation Circuit Short to Ground or Open 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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0400 (Symptom Code 4) stored as

“Pres ent Fa ilure”? — 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 P0400 ( Sy mpt om Code 4) st ored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Ch eck for p oor/fa ulty c onnect ion at the EGR EVRV 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 EGR EVRV.

1. Ignition “Off”, engine “Off”.

2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

14Ω at 20°C Go to Step 6 Go to Step 9

97 12

C-115C-57

EGR EVRV 12

6 Using the DVM and check the EGR EVRV power

supply circuit.

1. Ignition “On”, engine “Off”.

2. Remove the EGR EVRV connector.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

10-14.5 V Go to Step 8 Go to Step 7

7 Repair the open circuit between the ECM main relay

and EGR EVR V.

Is the action complete? — Verify repair —

8 Using the DVM and check the EGR EVRV circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

3. Remove the EGR EVRV connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

Breaker box is not available:

1. Ignition “Off”, engine “Off”.

2. Disconnect the ECM connector.

3. Remove the EGR EVRV connector.

4. Check the circuit for open or short to ground

circuit.

Was the problem found?

—

Repair faulty

harn es s and

verify repair Go to Step 11

Step Action Value(s) Yes No

C-115

Breaker Box 2

ƒ¶

C-115C-57

9 Substitute a known good EGR EVRV and recheck.

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

10 Replace the EGR EVRV.

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32)

Exhaust Gas Recirculation Flow Insufficient Detected

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0400 (Symptom Code 5) stored as

“Pres ent Fa ilure”? — 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 P0400 ( Sy mpt om Code 5) st ored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Visually check the EGR control vacuum hose.

If the hose is clogged or disconnected, repair as

necessary.

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

5 Using the DVM and check the EGR EVRV.

1. Ignition “Off”, engine “Off”.

2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

14Ω at 20°C Go to Step 8 Go to Step 6

6 Substitute a known good EGR EVRV and recheck.

Was the problem solved? — Go to Step 7 Go to Step 8

7 Replace the EGR EVRV.

Is the action complete? — Verify repair —

EGR EVRV 12

8 Usi ng the Tech 2 o r the vacuu m pump and check the

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

exce ssive carbon depo sit.

Tech 2:

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

4. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

5. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum R elease: EGR Valv e Close

If a problem is found, repair as necessary.

Was the problem found? — Verify repair or

Go to Step 10 Go to Step 9

9 Inspe ct the EGR valv e.

1. Remove the EGR valve from the engine.

2. Inspect the EGR valve whether pintle valve is

stuck or damage d.

If excessive carbon deposit is found, clean up the

EGR valve and inspect damage of the pintle and seat.

Was the problem found? — Verify repair or

Go to Step 10 Go to Step 11

10 Replace the EGR valve.

Is the action complete? — Verify repair -

Step Action Value(s) Yes No

Vacuum Pump Small Window

11 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 12

12 Visually check the MAF sensor.

Was the problem found? —

Go to Step 14 Go to Step 13

13 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 16

Repair faulty

harness and

verify repair

14 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? —

Go to Step 15 Go to Step 16

15 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

88 83

2345

C-116C-57(B)

C-116

Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32)

Exhaust Gas Recirculation Circuit Short to Battery

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0400 (Symptom Code 8) stored as

“Pres ent Fa ilure”? — 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 P0400 ( Sy mpt om Code 8) st ored in th is

ignition cycle? — Go to Step 4 Refer to

Diagnostic Aids

4 Ch eck for p oor/fa ulty c onnect ion at the EGR EVRV 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 EGR EVRV.

1. Ignition “Off”, engine “Off”.

2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid

coil.

Does the tester indicate standard resistance?

Approximately

14Ω at 20°C Go to Step 6 Go to Step 8

97 12

C-115C-57

EGR EVRV 12

6 Using the DVM and check the EGR EVRV circuit.

1. Ignition “Off”, engine “Off”.

2. Remove the EGR EVRV connector and ECM

connector.

3. 3. Check the circuit for short to voltage circuit.

Was the DVM indicated specified value?

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 EGR EVRV and recheck.

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

9 Replace the EGR EVRV.

Is the action complete? — Verify repair —

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 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-115

DIAGNOSTIC TROUBLE CODE (DTC) P0500 (SYM PTOM CODE 1)

(FLASH CODE 24) VEHICLE SP EED SENSOR CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P05 00 (SYMPTOM CODE A)

(FLASH CODE 24) VEHICLE SPE ED SENSOR INPUT SIGNAL FRE Q UENCY TOO HIGH

DIAGNOSTIC TROUBLE CODE (DTC) P05 00 (SYMPTOM CODE B)

(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall element. It interacts with the

magnetic field treated by the rotating magnet. It 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 -Inspect har ness connector s

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 Fail-Safe (Back Up)

24 P0500 1 ON

at next

ignition

cycle

Vehicle Speed Sensor Circuit

High Input Vehicle speed is more than

200km/h. ECM uses vehicle speed 5km/

h condition as substitute.

AON

at next

ignition

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

at next

ignition

cycle

Vehicle Speed Sensor

Incorrect Signal 1. Engine speed is more than

3600rpm.

2. Fuel injection quantity is

more than 41mg/strk.

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code 1) stored as

“Pres ent Fa ilure”? — 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 P0500 ( Sy mpt om Code 1) st ored in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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? — G o to Step 15 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”, have an assistant rotate output shaft

by hand.

2. Measure the VSS output voltage at sensor, TCM

(A/T 2WD), 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

Refer to the

table in the

Action column

(in this step)

8 Replace the VSS.

Is the action complete? — Verify repair

9 Replace the TCM.

Is the action complete?

IMPORTANT: The replacement TCM must be

programmed. “SP S (S ervi ce P rogram min g Sy stem) is

necessary.” — Verify repair —

Step Action Value(s) Yes No

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Fluctuates from 0.0

to 6.0 V Go to

Step 8

TCM C94 connector 10 &

GND (A/T 2WD) Go to

Step 9

Meter B24 connector 9 &

GND Go to

Step 10

Meter B24 connector 10 &

GND Go to

Step 12

ECM C56 connector 68 &

GND Go to

Step 13

Vehicle Speed Sensor (VSS) Reference Wave Form

0V→

Measurement Terminal: 68(+) GND(-)

Measurement Scale: 5V/div 50ms/div

Measurement Condition: Approximately 20km/h

10 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 11

Repair faulty

harness and

verify repair

11 Using the DVM and check the VSS signal circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the VSS connector and meter

connector.

3. Check the circuit for open or short to ground

circuit.

If a op en or short t o ground circ uit is fou nd, repair the

faulty harness and verify repair.

Is the action complete?

— Verify repair —

12 Replace the speed meter.

Is the action complete? — Verify repair —

13 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 14

Repair faulty

harness and

verify repair

Step Action Value(s) Yes No

B-24

E-44

B-24

14 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. to HOW TO USE BREAKER

BOX

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

harness 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 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Breaker Box B-24 10

ƒ¶

B-24

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code A) stored as

“Pres ent Fa ilure”? — 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 P0500 (Symptom Code A) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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? — G o to Step 10 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”, have an assistant rotate output shaft

by hand.

2. Measure the VSS output voltage at sensor, TCM

(A/T 2WD), 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

Refer the table

8 Replace the VSS.

Is the action complete? — Verify repair

9 Replace the TCM.

Is the action complete?

IMPORTANT: The replacement TCM must be

programmed. “SPS (Service Progr amming Sy st em)

is necessary.” — Verify repair —

10 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 12

11 Replace the speed meter.

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

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Fluctuates from 0.0

to 6.0 V Go to

Step 8

TCM terminal A10 & B5

(A/T 2WD) Go to

Step 9

Meter B24 connector 9 &

GND Go to

Step 10

Meter B24 connector 10 &

GND Go to

Step 11

ECM C56 connector 68 &

GND Go to

Step 10

Vehicle Speed Sensor (VSS) Reference Wave Form

0V→

Measurement Terminal: 68(+) GND(-)

Measurement Scale: 5V/div 50ms/div

Measurement Condition: Approximately 20km/h

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24)

Vehicle Speed Sensor Incorrect 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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0500 (Symptom Code B) stored as

“Pres ent Fa ilure”? — 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 P0500 (Symptom Code B) stored in this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

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? — G o to Step 17 Go to Step 7

6 Ch eck for poor /faulty conn ection at the VSS, TCM (A /

T 2WD) and meter connectors. If a poor/faulty

connection is found, repair the faulty terminal.

Was the problem found?

— Verify repair Go to Step 8

910

B-24

C-94(10)

E-44

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

9 Using the DVM and check the VSS signal.

1. Ignition “On”, have an as si s tant rotate output shaft

by hand.

2. Measure the VSS output voltage at sensor, TCM

(A /T 2WD) , 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

17 Refer the table

10 Replace the VSS.

Is the action complete? — Verify repair

Step Action Value(s) Yes No

C-56

Measurement Position Voltage (V)

(AC Range) If No

Good

VSS terminal 3 & GND Fluctuates from 0.0

to 6.0 V Go to

Step 10

TCM C94 connector 10 &

GND (A/T 2WD) Go to

Step 11

Meter B24 connector 9 &

GND Go to

Step 12

Meter B24 connector 10 &

GND Go to

Step 14

ECM C56 connector 68 &

GND Go to

Step 15

Vehicle Speed Sensor (VSS) Reference Wave Form

0V→

Measurement Terminal: 68(+) GND(-)

Measurement Scale: 5V/div 50ms/div

Measurement Condition: Approximately 20km/h

11 Replace the TCM.

Is the action complete?

IMPORTANT: The replacement TCM must be

programmed. “SPS (Service Programming System) is

necessary.” — Verify repair —

12 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 13

Repair faulty

harness and

verify repair

13 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 op en or short t o ground circ uit is fou nd, repair the

faulty harness and verify repair.

Is the action complete?

— Verify repair —

14 Replace the speed meter.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

B-24

E-44

B-24

15 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 16

Repair faulty

harness and

verify repair

16 Using the DVM and check the VSS signal circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 17

Step Action Value(s) Yes No

B-24

Breaker Box B-24 10

ƒ¶

B-24

C-56

17 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 18

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYM PTOM CODE 1)

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

DIAGNOSTIC TROUBLE CODE (DTC) P0560 (SYM PTOM CODE 2)

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

DIAGNOSTIC TROUBLE CODE (DTC) P05 60 (SYMPTOM CODE A)

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM and PSG moni tors th e system vol tage on th e

ignition feed terminal to the ECM or PSG. The system

voltage to the ECM excessively high or low, DTC P0560

(Sympto m Code 1) or P 0560 ( Sympt om Cod e 2) w ill b e

stored. The system voltage to th e PSG excess ively high

or low, DTC P0560 (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 “System Voltage” display on the Tech2 while

moving c onnectors and wiring harn ess related to the

sensor.

Flash

Code Code Symptom

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

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

20V. ECM uses 9V conditions as

substitute.

2 O FF S yst em Voltage Too Low System voltage is below 7V.

A OFF S yst em Voltage Malfunction Sy stem 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

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 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 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 - 14.5V 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0560 (Symptom Code 2) stored as

“Pres ent Fa ilure”? — 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 P0560 ( Sy mpt om Code 2) st ored 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 “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 - 14.5V 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 - 14.5V 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

C-56

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?

120-150Ω Go to Step 8

Replace ECM

main relay and

verify repair

8 Check for poor/faulty connection of the ECM ground

at the body. If a poor/faulty connection is found, repair

as necessary.

Was the problem found?

— 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

ECM Main Relay

ƒ¶

C-109

Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35)

System Voltage 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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0560 (Symptom Code A) stored as

“Pres ent Fa ilure”? — 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 P0560 (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 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 supp ly 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 - 14.5V Go to Step 7 Go to Step 6

E-6

6 Check for poor/faulty connection of the PSG (pump

control unit) ground at the cylinder body. If a poor/

faulty connecti on is found, re pair as necessa 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-10

DIAGNOSTIC TROUBLE CODE (DTC) P05 61 (SYMPTOM CODE A)

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P05 61 (SYMPTOM CODE B)

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM monitors the ignition switch signal on the feed

terminal to the ECM. If the ignition switch signal

malfunctions, DTC P0561 (Symptom Code A) or 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 -Inspect har ness connector s

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 c onnectors and wiring harn ess related to the

sensor.

Flash

Code Code Symptom

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

18 P0561 A OFF Ignition Switch Circuit

Malfunction The ECM recognized ignition

switch turn off signal during

ECM is activated.

ECM stops engine.

B OFF Ignition Switch Circuit

Malfunction Ignition switch circuit is

malfunction.

Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18)

Ignition Switch Circuit Malfunction

Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18)

Ignition Switch Circuit Malfunction

Step 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 I nfor A s Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P0561 (Symptom Code A) or P0561

(Symp tom Code B) stor ed 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 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 Ch eck the “Engi ne fus e (10 A)” .

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

harn es s and

verify repair Go 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 rep air Go to Step 8

Step Action Value(s) Yes No

Breaker Box

ƒ¶

C-107

C-56

C-107

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE 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), because the

service ECM is not programmed.

When the service ECM is used without SPS, DTC

P0602 will appear.

Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error

Flash

Code Code Symptom

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

- P0602 - - Control Module 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 I nfor A s Stored By E CU” 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)”.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P06 06 (SYMPTOM CODE A)

(FLASH CODE 28) ECU MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P06 06 (SYMPTOM CODE B)

(FLASH CODE 28) ECU MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description & Diagnostic Aids

If there is an internal ECM failure (IC, circuit, memory,

etc,), DTC P0606 (Symptom Code A) or P0606

(Symptom Code B) will be stored.

Flash

Code Code Symptom

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

28 P0606 A ON ECM Malf unction Gate Array communication

error. 1. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

B ON ECM Malfunction 1. Throttle position is below

1%.

2. Desired injection quantity is

more than 0mg/strk.

3. Engine speed is more than

2000rpm.

MAB (fuel cutoff solenoid

valve) 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, 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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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, download 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.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYM PTOM CODE 4)

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

DIAGNOSTIC TROUBLE CODE (DTC) P0645 (SYM PTOM CODE 8)

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTA GE HIGH

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The voltage on the coil of the A/C compressor is

supplie d by the ECM main relay. The ECM sw itches A/

C compressor relay to operate A/C compressor

depends on the A/C request signal and certain setting

conditions.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM-I nspect 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 P0645 display on the Tech2 while moving

connectors and wiring harnesses.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-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 I nfor 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?

120-150ΩGo to Step 6

Replace A/C

compressor

relay and verify

repair

C-56 X-14

A/C Compressor Relay

ƒ¶

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?

10-14.5V 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-14

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

harness and

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

X-14

Break e r Box

ƒ¶

ƒ¶ 4

C-56 X-14

ƒ¶

Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C

Compressor 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 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 DTC P0645 (Symptom Code 8) 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 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE A)

(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE B)

(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION

RTW46ELF001401-a

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM monitors the brake switch signal on the feed

terminal to the ECM. If brake switch 1 or 2 circuit with

malfunction, DTC P0703 (Symptom Code A) or P0703

(Symptom Code B) will be stored.

Diagnostic Aids

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 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 “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 Fail-Safe (Back Up)

25 P0703 A ON Brake Switch Circuit

Malfunction 1. Throttle position is more

than 0%.

2. Engine speed is more than

665rpm.

3. V ehicle 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 Circuit

Malfunction 1. Throttle position is more

than 0%.

2. Engine speed is more than

665 rpm.

3. V ehicle 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 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 I nfor 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 Lamp fuse (15A)”.

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

ƒ¶

Brake Switch

7 Using the DVM and check the brake switch 1 power

supply circuit.

1. Ignition “Off”, engine “Off”.

2. Remove the brake switch connector from the

brake switc h.

3. Check the circuit for open circuit.

Was the DVM indicated specified value?

10-14.5V Go to Step 9 Go to Step 8

8 Repair the open circuit between the “Stop Lamp fuse

(15A)” 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. to HOW TO USE BREAKER BOX

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: 10-14.5V Go to Step 12

Fixed at 10-

14.5V: Go to

Step 10

Fixed at less

than 1V: Go to

Step 11

Step Action Value(s) Yes No

C-44

105

Breaker Box

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, 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

C-56 C-44

Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25)

Brake 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 I nfor 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

ƒ¶

Brake Swi tch

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?

10-14.5V Go to Step 8 Go to Step 7

7 Re pair the ope n c irc uit bet ween the “ ECM fus e ( 1 0A)”

and brake switch 2.

Is the action complete? — Verify repair —

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:

10-14.5V

Pedal stepped

on: Less than

1V Go to Step 11

Fixed at 10-

14.5V: Go to

Step 9

Fixed at less

than 1V: Go to

Step 10

Step Action Value(s) Yes No

C-44

Breaker Box

C-44

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 —

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

65 4

C-56 C-44

65 4

C-56 C-44

DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6)

(FLASH CODE 57) CLUTCH SWITCH CIRCUIT MALFUNCTION

RTW46ELF001401-a

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

Flash

Code Code Symptom

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

57 P0704 6 ON Clutch Switch Circuit

Malfunction Clutch signal does not change

between vehicle speed 1.5 km/h

and 80 km/h since ignition switch

was turned on.

No fail-safe function.

Circuit Description

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 insu lati on .

• Broken wire insi de the in sulation .

Check for the fo llow ing co ndition s:

• Poor connection at ECM-Inspect harness connectors fo r

backed out termin al s, improper ma ting , broken locks,

improperly formed or damage d termin al s, and poor

terminal to w ire connection .

• Damaged harness. Inspect the wiring ha rness for

damage. If the harn ess appea rs to be OK, obse rve the

"Clutch Sw itch" d isplay on Te ch 2 w hile moving

connectors and the wiring harness relate d to the sensor.

Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57)

Clutch Switch Input 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 I nfor 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 DT C P0 704 (Sy mpt om Code 6) 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 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-77

Clut ch Swi tch

ƒ¶

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?

10-14.5V Go to Step 8 Go to Step 7

7 Re pair the ope n c irc uit bet ween the “ ECM fus e ( 1 0A)”

and clu tch switch.

Is the action complete? — Verify repair —

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. to HOW TO USE BREAKER BOX

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:

10-14.5V

Pedal stepped

on: Less than

1V Go to Step 11

Fixed at 10-

14.5V: Go to

Step 9

Fixed at less

than 1V: Go to

Step 10

Step Action Value(s) Yes No

C-77

Breaker Box

C-77

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 —

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

31 2

C-56 C-77

31 2

C-56 C-77

DIAGNOSTIC TROUBLE CODE (DTC) P110 5 (SY MP TOM CODE 1)

(FLASH CODE 86 ) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P110 5 (SY MP TOM CODE 2)

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM monitors the barometric pressure signal at

inside of the ECM. If the sensor with malfunction, DTC

P11 05 (Symp tom Code 1) o r P1105 (Symptom Cod e 2)

will be stored.

Diagnostic Aids

If the DTC P1105 is stored, sensor or circuit of ECM

inside is failed.

Flash

Code Code Symptom

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

86 P1105 1 ON Barometric Pressure Sens or

Circuit High Input Barometric press ure sensor

output voltage is more than

4.4V.

ECM uses 1013hpa condition

as sub stitute.

2 ON Barometric Pressure Sensor

Circuit Low Input Baromet ric press ure sensor

output voltage is below 1.5V.

Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86)

Barometric Pressure Sensor Circuit High Input

Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86)

Barometric Pressure Sensor Circuit Low Input

Step 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 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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P112 0 (SY MP TOM CODE 1)

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

DIAGNOSTIC TROUBLE CODE (DTC) P112 0 (SY MP TOM CODE 7)

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

HIGH INPUT

DIAGNOSTIC TROUBLE CODE (DTC) P112 0 (SY MP TOM 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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and

idle switc h.

The engine control module (ECM) monitors the voltage

on the signal line and calculates throttle position. As the

throttle valve angle is changed when accelerator pedal

moved. The TPS signal also changed at a moved

throttle valve. As the throttle valve opens, the output

increases so that the output voltage should be high.

The ECM monitors the TPS supply voltage and TPS

output vo ltage. The supply vo ltage is out of range, DTC

P11 20 (Symp tom Code 7) o r P1120 (Symptom Cod e 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 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 “Thrott le Po si ti on”, “I dle Sw it ch”, “Br ake 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 Fail-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. V ehicle speed is more than

1.5km/h.

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 I nfor 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 Code 1) s tored 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 Visual ly check the TP S.

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

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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 S tep 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.

W as the problem solved?

— Verify repair Go to Step 14

Step Action Value(s) Yes No

Measurement

Terminal Resistance (Ω)

1 - 2 Approximately 0.4kΩ 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

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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

E-22

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. to HOW TO USE BREAKER

BOX

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

harness 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, download 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

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Breaker Box

ƒ¶

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Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21)

Pedal/Throttle Position 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 I nfor As Stored By 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 Code 7) s tored 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 Visual ly check the TP S.

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

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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 Repair the short to battery voltage circuit between 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, download 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

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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 I nfor 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 Code 9) s tored 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 Visual ly check the TP S.

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

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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 Re pair the circui t for sho rt to TPS groun d circ uit .

Is the action complete? — Verify repair —

9 Repair the short to ground circuit between the ECM

and TPS.

W as 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

11 Replace the TPS.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

E-22

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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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21)

Pedal/Throttle Position Sensor Brake Switch 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 I nfor As Stored By 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 Visual ly check the TP S.

Check for the following conditions.

• Accelerator pedal sticking.

If a problem is found, repair as necessary.

W as 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%.

W as the problem solved? — Verify repair Go to Step 11

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 S tep 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.

W as the problem solved? — Go to Step 10 Go to S tep 13

10 Replace the brake switch.

Is the action complete? — Verify repair —

11 Substitute a known good TPS and recheck.

W as the problem solved? — Go to Step 12 Go to S tep 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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

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 I nfor As Stored By 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 tor ed in th is

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 Visual ly check the TP S.

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 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, download the late st software to the ECM using

the “SPS (Service Programming System)”.

W as 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P117 3 (SY MP TOM CODE 3)

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

DIAGNOSTIC TROUBLE CODE (DTC) P117 3 (SY MP TOM CODE 7)

(FLASH CODE 22) FUEL REDUCTION CAUSE D BY HIGH FUEL TEMPERATURE

DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE A)

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The engine coolant temperature (ECT) sensor is

installed on the coolant stream. High coolant

temperature produces a low resistance. The ECM

supplies 5 volts signal to the ECT sensor through

resisters in the ECM and measures the voltage. The

signal voltage will be low when the en gine temperature

is hot.

The fuel temp erature sensor is assembled insi de of the

pump con tro l uni t (PS G ). The si gna l of fu el tem per at ur e

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

If the engine coolant temperature is excessively high

condition, DTC P1173 (Symptom Code 3) will be stored.

If the fuel temperature is excessively high or low

condition, DTC P1173 (Symptom Code 7) or P1173

(Symptom Code A) will be stored.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor connection at ECM and PSG-Inspect harness

connectors for backed out terminals, improper

mating, broken locks, improperly formed or damaged

terminals, and poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Coolant Temperature” or “Fuel Temperature”

display on the Tech2 while moving connectors and

wiring harness related to the sensor.

Flash

Code Code Symptom

Code MIL DTC Name DTC Setting Condition Fail-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 deg. 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 I nfor 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 Code 3) s tored 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 Go 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

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Temperature (°C) Resistance (Ω) (Approximately)

-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 Fuel 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 I nfor As Stored By ECU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1173 (Symptom Code 7) or P1173

(Symptom Code A) stored as “Present Failure”? — 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, download the late st 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.

W as 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P13 35 (SYMPTOM CODE A)

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The CKP sensor is located on top of the flywheel

housing of the flywheel and fixed with a bolt. The CKP

sensor is of the magnet coil type. The inductive pickup

senses 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 harness connectors

for backed out terminals, improper mating, broken

locks, improperly formed or damaged terminals, and

poor terminal to wire connection.

• Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe

the “Engine Speed” display on the Tech2 while

moving connectors and wiring harness related to the

sensor.

Flash

Code Code Symptom

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

43 P1335 A ON Engine Speed Output Circuit

Malfunction The PSG (pump control unit)

detected 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 I nfor 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 If a oscillosc ope is available, m onitor 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

Crankshaft Position (CKP) Sensor & TDC Output Signal

Reference Wave Form

CH1

CH2

Measure ment Terminal: CH1: 90(+) / CH2: 91(+) GND( -)

Measurement Sc ale: CH1: 50V/div / CH2: 10V/div 1ms/div

Measurement Condition: Approximately 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. to HOW TO USE BREAKER

BOX

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 Go to Step 8

Step Action Value(s) Yes No

E-6

Breaker Box 8

ƒ¶

91 8

C-57(B) E-6

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

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 immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 12 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

13 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

E-6

DIAGNOSTIC TROUBLE CODE (DTC) P13 45 (SYMPTOM CODE A)

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The pump camshaft sensor is a magnet with a coil. To

produce a signal, i t combine s with the puls er which is a

gear shaped device attached to the main shaft in the

pump.

The pump camshaft sensor is attached to the pump

control unit (PSG). The pum p camshaft speed signal 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 Fail-Safe (Back Up)

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

is recognized incorrect

camshaft speed signal.

No fail-safe function.

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, download 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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

RTW46ELF001401-a

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

Flash

Code Code Symptom

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

A ON Neutral Switch ON Error Neutral switch signal is inputted

“On” three times consecutively

under driving conditions.

47 P1520

B ON Neutral Switch OFF Error Neutral switch signal is inputted

“Off” three times consecutively

under driving conditions.

No fail-safe function.

Techline

DTC P1520 (Symptom ‘A’ or ‘B’) may remain ‘Active’ after effecting repairs. This DTC is not erasable by using Tech 2. The

following ‘Clear Conditions’ are necessary to clear this DTC after repairs. Following this procedure, clear history DTC, using

Tech 2.

Code S ymptom

Code Transmission

Type Clear Conditions

M/T • Engine speed is higher than 1,500 rpm.

• Vehicle speed is higher than 64 km/h (40 mph)

• Neutral Switch is OFF (= Other than Neutral)

• Clutch switch is OFF (= Pedal is not depressed)

• Above conditions are met for 0.5 seconds.

AND

The above conditions must be met on the next two consecutive driving cycles. (A driving cycle

is; Ignition ON – Engine Run – Vehicle Run – Ignition OFF for 10 seconds.

A/T • Engine speed is higher than 1,500 rpm.

• Vehicle speed is higher than 80 km/h (50 mph)

• Neutral Switch is OFF (= Other than ‘N’ or ‘P’ range).

• Above conditions are met for 0.5 seconds.

AND

The above conditions must be met on the next two consecutive driving cycles. (A driving cycle

is; Ignition ON – Engine Run – Vehicle Run – Ignition OFF for 10 seconds).

P1520

M/T • Engine speed is higher than 665 rpm.

• Vehicle speed is lower than 2 km/h (3 mph)

• Neutral Switch is ON (= Neutral).

• Clutch Switch is OFF-ON-OFF (= Pedal is released after once being depressed).

• Above conditions are met for 0.5 seconds.

AND

The above conditions must be met on the next two consecutive driving cycles. (A driving cycle

is; Ignition ON – Engine Run – Ignition OFF for 10 seconds).

Circuit Description

The ECM monitors the neutral switch (A/T: N or P position

switch in inhib i tor sw itch) sign al on the feed termin al to th e

ECM. If the neutral switch malfunctions, a DTC P1520

(Symptom Code A) or P1520 (Sy mp tom Code B) will be

stored.

Diagnostic Aids

An intermittent may be caused by the follow ing:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insu lati on .

• Broken wire insi de the in sulation .

Check fo r the fo llowing conditions:

• Poor connection at EC M-Inspect ha rness connecto rs for

backed out termin al s, improper ma ting , broken locks,

improperly formed or damage d termin al s, and poor

terminal to w ire connection .

• Damaged harnes s-Inspect the w iring harne ss for

damage. If the harn ess appea rs to be OK, obse rve the

“Neutral Switch” disp lay on the Tech 2 w hile moving

connectors and wiring harness rel a ted to the senso r.

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 Connect Tech 2.

Review and record the failure information.

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

3 Using Tech 2, ignition “On” and engi ne “Off”.

Select “F1: Clear DTC Information” in “F0: Diagnostic

Trouble Codes” with the Tech 2 and clear the DTC

information.

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

4 Check for poor/faulty connection at the neutral switch

(inhibitor switch) or ECM connector. If a poor/faulty

connection is found, repa ir as necessary .

Was the problem found?

– Verify repair Go to Step 5

Step Action Value(s) Yes No

5 Using a DMM, check the neutral switch (or inhibitor

switch).

Ignition "Off", engine Off".

Remove the neutral switch connector (inhibitor switch

connector) from the switch.

Connect a DMM between the relevant terminals of the

neutral switch (or inhibitor switch).

Check the neutral s witch (or P/N range switch).

es the DMM indicate the specified val ue?

M/T

Neutral

(or P/N):

Continuity

Other than

Neutral

(or ‘P’/’N’):

Continuity Go to Step 6

Replace neutral

switch (or inhibitor

switch) and verify

repair

6 Using a DMM, check the neutral switch (or inhibitor

switch) power supply circ uit.

Ignition "On", engine "Off".

Remove the neutral switch (inhibitor switch)

connector from the switch.

Check the circuit for an open circuit.

es the DMM indicate the specified val ue?

E-12

M/T

E-51

A/T

10 – 14.5

volts Go to Step 8 Go to Step 7

7 Repair the open circuit between the “ECM fuse

(10A)” and neutral switch (or between the "Back-Up

fuse (15A)" and inhibitor switch).

Is the action complete? – Verify repair –

1236 5 4

7810 9

A/T

Step Action Value(s) Yes No

8 Using a DMM, check the neutral switch (or inhibitor

switch) circuit.

Breaker box is a vailable:

Ignition "Off", engine "Off".

Install the breaker box as type B. (ECM connected)

refer page 6C1-63, in this Section.

Ignition "On", engine "Off".

Check the circuit for open or short to voltage in the

circuit.

es the DVM indicate the specified val ue?

Breaker box is not available:

Reinstall the neutral switch harness connector to

the neutral switch (or inhibitor s witch).

Ignition "On", engine "Off".

Using a DMM, back probe the neutral switch (or

inhibitor switch) and check the circuit for an open

or short to voltage in the circuit.

s the DMM indicated specified value ?

E-11 E-51

M/T A/T

Neutral

(or P/N):

10 – 14.5

volts

Other than

Neutral

(or P/N):

Less than

1 volt Go to Step 11

Fixed at 10 – 14.5

volts: Go to Step 9.

Fixed at less than 1

volt: Go to Step 10.

9 Repair the short to voltage circuit between the

neutral switch connector (or inhibitor switch

connector) and ECM.

Is the action complete?

87 8

C-57

M/T

A/T

E-11

E-51

– Verify repair –

Step Action Value(s) Yes No

10 Repair the open circuit between the neutral switch

connector (or inhibito r sw itch con nec tor) and ECM.

Is the action complete?

87 8

C-57

M/T

A/T

E-11

E-51

– 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 Sy s tem )".

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.

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 l in king procedure. – Verify repair –

DIAGNOSTIC TROUBLE CODE (DTC) P16 05 (SYMPTOM CODE C)

(FLASH CODE 55) SEED AND KE Y FILE DESTROYED

DIAGNOSTIC TROUBLE CODE (DTC) P16 05 (SYMPTOM CODE D)

(FLASH CODE 55) EEPROM DEFE CT

DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE E)

(FLASH CODE 55) EEPROM DEFE CT

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description & Diagnostic Aids

The ECM used in this vehicle utilizes an electrically erasable & programmable read only memory (EEPROM). The

EEPROM contains program information and the calibrations required for engine and diagnostics operation.

If the ECM fails internally (IC, circuit, memory, etc,), 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 Fail-Safe (Back Up)

55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM

is destroyed. No fail-safe function.

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 C) (Flash Code 55)

Seed and Key File Destroyed

Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55)

EEPROM Defect

Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55)

EEPROM Defect

Step 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 C), 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 C), 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, 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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P16 10 (SYMPTOM CODE A)

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMME D

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM decides that there is an abnormality in the

immobilizer control system. DTC P1610 (Symptom

Code A) i s recorded whe n immobil izer functio n was not

programmed in the ECM.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobilizer control unit-

Inspect harne ss con nectors for bac ked out termi nals,

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 Fail-Safe (Back Up)

56 P1610 A - Security Key and Security

Code not Programmed Immobilizer functions are not

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

2. Check engine lamp flash.

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 “Immobilizer” in the system selection menu

“Body”.

3. Select “Read DTC Info Ordered By Priority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B0002 or B0009 stored in this

ignition cycle? —

Refer to

Section 11

IMMOBILISER

SYSTEM & Go

to DTC Chart

B0002 or

B0009 Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

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

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P1611 (SYMPTOM CODE A)

(FLASH CODE 56 ) WRONG SECURITY CODE ENTERED

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM decides that there is an abnormality in the

immobilizer control system. DTC P1611 (Symptom

Code A) is recorded when received immobilizer security

code was not co rrec t.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobilizer control unit-

Inspect harne ss con nectors for bac ked out termi nals,

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 Fail-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.

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 DTC P1611 (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 “Immobilizer” in the system selection menu

“Body”.

3. Select “Read DTC Info Ordered By Priority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

Section 11

IMMOBILISER

SYSTEM & Go

to DTC Chart

B**** Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

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

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P16 12 (SYMPTOM CODE A)

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM decides that there is an abnormality in the

immobilizer control system. DTC P1612 (Symptom

Code A) is recorded when received immobilizer

challenge signal was not correct.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobilizer control unit-

Inspect harne ss con nectors for bac ked out termi nals,

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 Fail-Safe (Back Up)

56 P1612 A - Imm obilizer No or Wrong

Signal Received challenge signal is

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

2. Check engine lamp flash.

Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56)

Immobilizer 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 I nfor 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 “Immobilizer” in the system selection menu

“Body”.

3. Sele ct “Read D TC Info Or dered B y Priority” in the

“Diagnositic Trouble Code”.

Was the DTC B0007 stored in this ignition cycle? —

Refer to

Section 11

IMMOBILISER

SYSTEM & Go

to DTC Chart

B0007 Go to Step 5

5 Check for poor/faulty connection at the immobilizer

control unit connector or ECM connector. If a poor/

faulty co nnec ti on is found, repair as neces sa 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 immobilizer

control unit connector.

3. Ignition “On”.

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

W as 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. to HOW TO USE BREAKER

BOX

3. Disconnect the immobilizer 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 immobilizer 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 8

Step Action Value(s) Yes No

B-68

Breaker Box

ƒ¶

C-56

B-68

8 Using the DVM and check the ECM and immobilizer

control unit communication circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the immobilizer control unit connector.

3. Ignition “On”.

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

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

9 Using the DVM and check the ECM and immobilizer

control unit communication circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

3. Disconnect the immobilizer 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 immobilizer 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 S tep 10

Step Action Value(s) Yes No

B-68

Breaker Box

ƒ¶

C-56

B-68

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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P16 13 (SYMPTOM CODE A)

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM decides that there is an abnormality in the

immobilizer control system. DTC P1613 (Symptom

Code A) is recorded when received immobilizer

response signal was not correct.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobilizer control unit-

Inspect harne ss con nectors for bac ked out termi nals,

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 Fail-Safe (Back Up)

56 P1613 A - Imm obilizer No or Wrong

Signal Received response signal is

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

2. Check engine lamp flash.

Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56)

Immobilizer 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 I nfor 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 “Immobilizer” in the system selection menu

“Body”.

3. Sele ct “Read D TC Info Or dered B y Priority” in the

“Diagnositic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

Section 11

IMMOBILISER

SYSTEM & Go

to DTC Chart

B**** Go to Step 5

5 Check for poor/faulty connection at the immobilizer

control unit connector or ECM connector. If a poor/

faulty co nnec ti on is found, repair as neces sa 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 immobilizer

control unit connector.

3. Ignition “On”.

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

W as 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. to HOW TO USE BREAKER

BOX

3. Disconnect the immobilizer 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 immobilizer 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 8

Step Action Value(s) Yes No

B-68

Breaker Box

ƒ¶

C-56

B-68

8 Using the DVM and check the ECM and immobilizer

control unit communication circuit.

1. Ignition “Off”, engine “Off”.

2. Disconnect the immobilizer control unit connector.

3. Ignition “On”.

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

Was the DVM indicated specified value?

Less than 1V Go to Step 9

Repair faulty

harness and

verify repair

9 Using the DVM and check the ECM and immobilizer

control unit communication circuit.

Breaker box is available:

1. Ignition “Off”, engine “Off”.

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

disconnected) Ref. to HOW TO USE BREAKER

BOX

3. Disconnect the immobilizer 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 immobilizer 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 S tep 10

Step Action Value(s) Yes No

B-68

Breaker Box

ƒ¶

C-56

B-68

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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

DIAGNOSTIC TROUBLE CODE (DTC) P16 14 (SYMPTOM CODE A)

(FLASH C ODE 56) WRON G TRANSPONDER KE Y

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM decides that there is an abnormality in the

immobilizer control system. DTC P1614 (Symptom

Code A) is recorded when received immobilizer

response signal was not correct from the transponder

key.

Diagnostic Aids

Check for the following conditions:

• Poor connection at ECM and immobilizer control unit-

Inspect harne ss con nectors for bac ked out termi nals,

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 Fail-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.

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 “Immobilizer” in the system selection menu

“Body”.

3. Select “Read DTC Info Ordered By Priority” in the

“Diagnostic Trouble Code”.

Was the any DTC's B**** stored in this ignition cycle? —

Refer to

Section 11

IMMOBILISER

SYSTEM & Go

to DTC Chart

B**** Go to Step 5

5 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

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

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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P16 25 (SYMPTOM CODE A)

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EAR LY

DIAGNOSTIC TROUBLE CODE (DTC) P16 25 (SYMPTOM CODE B)

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

Condition for setting the DTC and action ta ken when the DTC sets

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 con nection at ECM-I nspect 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.

Flash

Code Code Symptom

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

76 P1625 A OFF ECM Main Relay Switched

Of f Too Ea rly When ignition switch was

turned off, timing of the ECM

main relay turning off is too

early.

No fail-safe function.

B OFF E CM 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 turn off.

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, 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 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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, download 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

ECM Main Relay

ƒ¶

DIAGNOSTIC TROUBLE CODE (DTC) P16 30 (SYMPTOM CODE A)

(FLASH CODE 51) FUEL INJECTION QUANT ITY CIRCUIT MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P16 30 (SYMPTOM CODE B)

(FLASH CODE 51) FUEL INJECTION QUANT ITY CIRCUIT MALFUNCTION

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The ECM calculates an injection quantity and injection

timing us ing the va riou s sensors . The PS G controls the

high pressure solenoid valve depending on

programmed pump map data.

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 Fail-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. MAB (fuel cutoff solenoid

valve) is operated.

2. Desired injection quantity

becomes 0mg/strk.

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: Rea d DTC Infor As Stored By E CU” 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) P16 50 (SYMPTOM CODE A)

(FLASH CODE 44) CAN DEVICE OFFLINE

DIAGNOSTIC TROUBLE CODE (DTC) P16 50 (SYMPTOM CODE B)

(FLASH CODE 44) CAN DEVICE HANG-UP

Condition for setting the DTC and action ta ken 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

syste ms 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.

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.

Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44)

CAN Device Offline

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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1650 (Symptom Code A) stored as

“Pres ent Fa ilure”? — 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 Visual ly chec k the PS G (p ump contr ol un it).

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

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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 8

Step Action Value(s) Yes No

E-6

100

Breaker Bo x 2

ƒ¶

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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go 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

Breaker Box

ƒ¶

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

harn es 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

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.

Foll owing ECM pr ogramming, the immobi lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

18 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44)

CAN Device Hang-up

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

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 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

DIAGNOSTIC TROUBLE CODE (DTC) P16 51 (SYMPTOM CODE A)

(FLASH CODE 45) CAN MALFUNCTION

DIAGNOSTIC TROUBLE CODE (DTC) P16 51 (SYMPTOM CODE B)

(FLASH CODE 45) CAN RECEIVES ERROR

Condition for setting the DTC and action ta ken 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

syste ms 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.

Flash

Code Code Symptom

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

45 P1651 A ON CAN Malfunction 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 Malfunction The ECM does not read CAN

signal from the PSG (pump

control unit).

Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45)

CAN 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 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, download 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.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

7 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45)

CAN Receives 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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1651 (Symptom Code B) stored as

“Pres ent Fa ilure”? — 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

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 Visual ly chec k the PS G (p ump contr ol un it).

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

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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 9

Step Action Value(s) Yes No

E-6

100

Breaker Box 2

ƒ¶

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. to HOW TO USE BREAKER

BOX

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

harn es 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

Breaker Box

ƒ¶

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

harn es 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, download 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer 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 (SYM PTOM CODE 4)

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

DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYM PTOM CODE 8)

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

Condition for setting the DTC and action ta ken when the DTC sets

Circuit Description

The Check Engine Lamp (Malfunction Indicator Lamp

=MIL) should always be illuminated and steady with

ignition “On”. Ignition feed voltage is supplied to the

Check Engine Lamp bulb through the meter fuse. The

ECM turns the Check Engine Lamp “On” by grounding

the check engine lamp driver circuit for a certain time.

Diagnostic Aids

An intermittent may be caused by the following:

• Poor connections.

• Misrouted harness.

• Rubbed through wire insulation.

• Broken wire inside the insulation.

Check for the following conditions:

• Poor con nection at ECM -Inspect harnes s connector s

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 “Ch eck Engine La mp” disp lay on the Tec h2 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 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.

Diagnostic Trouble Code (DTC) P1690 (Symptom Code 4) (Flash Code 77)

Check Engine Lamp (MIL) 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: Rea d DTC Infor As Stored By E CU” in

“F0: Diagnostic Trouble Codes”.

Is the DTC P1690 (Symptom Code 4) stored as

“Pres ent Fa ilure”? — 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 P1690 ( Sy mpt om Code 4) s tor e d i n this

ignition cycle? — Go to Step 4

Refer to

Diagnostic Aids

and Go to Step

4 1. Ignitio n “On”, engine “Off”.

2. Check the “Check Engine” lamp.

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

5 1. Ignitio n “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 “C heck Engine” lamp bulb.

If the bulb is burnt out, repair as necessary.

Was the problem found? — V erify 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

C-56

B-24

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. to HOW TO USE BREAKER

BOX

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

harn es s and

verify repair Go to Step 9

9 Is the ECM programmed with the latest software

release?

If not, download the late st 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

Breaker Box B-24

ƒ¶

C-56

B-24

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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

Step Action Value(s) Yes No

Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77)

Check Engine Lamp (MIL) 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 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 DTC P1690 (Symptom Code 8) 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 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. —Go to Step 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 lizer sys tem

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

SYMPTOM DIAGNOSIS

PRELIMINARY CHECKS

Before using this section, perform the “On-Board

Diagnostic (OBD) System Check” and verify all of the

following items:

• The engine control module (ECM) is operating

correctly.

• The check engine lamp, also known as the

malfunction indicator lamp (MIL), is 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) 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) 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) 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 reconnect the MAF sensor, and

clear the Diagnostic Trouble Code P0100 from memory.

An intermittent check engine lamp (MIL) fault with no

stored Diagnostic Trouble Code may be caused by the

following:

• Check engine lamp (MIL) 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 pump control unit (PSG) for poor connections.

Check for an open diode across the A/C compressor

clutch and check for other open diodes (refer to wiring

diagrams in Electrical Diagnosis).

If problem has not been found, refer to ECM connector

symptom tables.

• Check the “Broadcast Code” of the ECM, and

compare it with the latest Holden service bulletins

and/or Holden 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.

Techline

ENGINE CRANKS BUT WILL NOT RUN

DEFINITIONS: Engine cranks, but will not run. (The engine never start.)

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

Step 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 fuel amount enough?

—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 “ECM” fuse (10A) and “Engine” fuse (15A).

If the fuse is burnt out, repair as necessary.

W as 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 9

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.

W as 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.

W as 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.

W as 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 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 16

15 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 17

16 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 18

Step Action Value(s) Yes No

17 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 er val.

• 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 18

18 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 2.1

Mpa (21.0 kg/

cm2) Verify repair Go to Step 19

19 If the injection pump was replaced, are the timing

gears or injection pump correctly installed?

—Go to Step 20 Repair as

necessary

Step Action Value(s) Yes No

20 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to Step 21

21 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 22

22 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 23 Go to Step 24

23 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

24 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

HARD START SYMPTOM

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

immediately stall.

Step 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

only Replace with

diesel fuel Go to Step 6

5 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 7

7 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as 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 “Gl ow Time Rela y” in the data dis play

and then, does the supply voltage correctly supply

to the glow plug?

—Go to St ep 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 failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 13

13 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 14

14 Replace the fuel filter.

W as 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 er val.

• 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 spray 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 2.1

Mpa Verify repair Go to Step 18

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approximately 33.8 Mpa

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, download 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.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

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 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

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.

• Restricted air intake system. Check for a restricted

air filter element, o r foreign ob jects blocking th e air

intake sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as 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.

W as 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.

W as the problem found? — Verify repair Go to Step 10

10 1. Usin g th e Tech 2, d ispl ay the E CT s ens or an d IAT

sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as necessary.

W as 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.

W as 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.

W as 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 35

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%.

W as 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.

W as 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.

W as 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.

W as 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

Step Action Value(s) Yes No

When idling or part-throttle

High Desired

Low

Time

Actual

26 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

excessive carbon deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 27

27 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 28

28 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 29

29 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 30

Step Action Value(s) Yes No

Vacuum Pump Small Window

30 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 er val.

• 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 32

31 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper spray 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 32

32 Check the engine compression pressure for each

cylinders. Each cylinder must be evenly.

If a problem is found, repair as necessary.

Was the problem found?

More than 2.1

Mpa Verify repair Go to Step 33

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approximat ely 33.8 Mpa

33 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 34 Adjust and

verify repair

34 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — Verify repair Go to Step 35

35 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 36

36 Substitute a known good ECM and recheck.

Was the problem solved?

IMPORTANT: The replacement ECM must be

programmed. Refer to section of the Service

Programming System (SPS) in this manual.

Following ECM programming, the immobilizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 37 Go to Step 38

37 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

38 Replace the injection 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 accelerator pedal.

time

rpm

Surge

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

only Replace with

diesel fuel Go to Step 5

5 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 7

7 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.

W as the problem found? — Verify repair Go to Step 8

8 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as the problem found? — Verify repair Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 14 Go to Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 29

13 Replace the MAF & IAT sensor assembly.

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 operation? — 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%.

W as the problem solved? — Verify repair Go to Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as 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 problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 20

20 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 21

21 Substitute a known good CKP sensor and recheck.

Was the problem solved? — 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

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

24 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

excessive carbon deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 25

25 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 26

26 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 27

Step Action Value(s) Yes No

Vacuum Pump Small Window

27 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 28

28 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

Was a problem found? — 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

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

32 Replace the injection 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-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

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.

W as a problem found? — Verify repair Go to Step 6

6 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 8

8 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as the problem found? — Verify repair Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 14 Go to Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 31

13 Replace the MAF & IAT sensor assembly.

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 operation? — 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%.

W as the problem solved? — Verify repair Go to Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as 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 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 problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 20

20 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 21

21 Substitute a known good CKP sensor and recheck.

Was the problem solved? — 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

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

24 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

excessive carbon deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 25

25 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 26

26 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 27

27 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 28

Step Action Value(s) Yes No

Vacuum Pump Small Window

28 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 29

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

33 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows

engine speed; usually more pronounced as engine load

increases.

time

rpm

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

only Replace with

diesel fuel Go to Step 5

5 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as 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.

W as 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.

W as 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.

W as 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 operation? — 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%.

W as 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.

W as 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 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 problem is found, repair as necessary.

W as 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.

W as 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

Step Action Value(s) Yes No

When idling or part-throttle

High Desired

Low

Time

Actual

26 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

excessive carbon deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 27

27 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 28

28 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 29

Step Action Value(s) Yes No

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

34 Replace the injection 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-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

only Replace with

diesel fuel Go to Step 5

5 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 7

7 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as 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 29 Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 14 Go to Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 29

13 Replace the MAF & IAT sensor assembly.

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 operation? — 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%.

W as the problem solved? — Verify repair Go to Step 16

16 Check the TPS harness for the following conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as 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 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 22 Go to Step 20

20 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

ÅERestr ict sh af t mo ve men t . C heck f o r ob je ct s st i cki ng

the shaft, broken diaphragm or excessive carbon

deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 21

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

21 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 22

22 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 23

23 Replace the fuel filter.

W as the problem solved? — Verify repair Go to Step 24

24 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 er val.

• 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 25

Step Action Value(s) Yes No

25 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper spray 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 26

26 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 2.0

Mpa Verify repair Go to Step 27

27 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 28 Adjust and

verify repair

28 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

W as a problem found? — Verify repair Go to Step 29

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approxim ately 33.8 Mpa

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

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

32 Replace the injection 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.

W as a problem found? — Verify repair Go to Step 7

7 Check for inco rrect or faulty engine thermostat. Refer

to Engine Cooling.

W as a problem found? — Verify repair Go to Step 8

8 Check for proper calibration of the speedometer.

Does the s peed indicated on the speed mete r closely

match the vehicle speed displayed on the Tech 2? — Go to Step 10 Go to Step 9

9 Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed

Sensor in Electrical Diagnosis. — Verify repair —

10 Check for proper calibration of the fuel gauge.

W as 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.

W as 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 depending on any shift positions?

If a problem is found, repair as necessary.

W as 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 switc h posi tion?

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 14

14 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as a problem found? — Verify repair Go to Step 15

15 1. Usin g th e Tech 2, d ispl ay the E CT s ens or an d IAT

sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 16

16 1. Using the Tech 2, display the FT sensor value.

2. Check the displayed value.

Does the Tech 2 indicate correct temperature

depending on engine condition?

If a problem is found, repair as necessary.

Was the problem found? — 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 accelerator 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 problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 19

19 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as 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 solved? — Go to Step 21 Go to Step 31

21 Replace the MAF & IAT sensor assembly.

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 operation? — 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%.

W as the problem solved? — Verify repair Go to Step 24

24 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.

W as a problem found? — Verify repair Go to Step 25

25 Substitute a known good TPS and recheck.

Was the problem solved? — 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 spray 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 28

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approximat ely 33.8 Mpa

28 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 2.0

Mpa 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

34 Replace the injection 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

only Replace with

diesel fuel Go to Step 5

5 Check for engine coolant leaking into the combustion

chambers or through the gasket.

W as 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.

W as a problem found? — Verify repair Go to Step 7

7 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as 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 30 Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 14 Go to Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 30

13 Replace the MAF & IAT sensor assembly.

Is the action complete? — Verify repair —

14 1. Using the Tech 2, ignition “On” and engine “Run”.

2. M onitor the “Glow Time Relay” in th e data display.

Does the Tech 2 indicate correct “Glow Time Relay”

status depending on the time from engine “Run”?

If a problem is found, repair as necessary.

Was the problem found? — Go to Step 30 Go to Step 15

15 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Gl ow Time Rela y” in the data dis play

and then, does the supply voltage correctly supply

to the glow plug?

—Go to Step 16

Repair voltage

supply circuit

and verify repair

16 Check the glow plugs for continuity.

If a problem 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 problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 18

18 Check the CKP sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

Was a problem found? — Verify repair Go to Step 19

Step Action Value(s) Yes No

19 Substitute a known good CKP sensor and recheck.

Was the problem solved? — 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 converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 23

23 Visually/physically inspect for the following conditions.

• Restric ted fuel supply s ystem. Che ck for a pinche d

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.

W as a problem found? — Verify repair Go to Step 24

24 Replace the fuel filter.

W as 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 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 er val.

• 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 26

26 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper spray 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 27

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approximat ely 33.8 Mpa

27 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 20

Mpa Verify repair Go to Step 28

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 32 Go to Step 33

Step Action Value(s) Yes No

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.

Foll owing ECM pr ogramming, the immobi lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

33 Replace the injection 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

only Replace with

diesel fuel Go to Step 5

5 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 sy stem

• Che ck f or o bjects block ing or e xces sive d epo 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.

• Restricted 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.

W as 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.

W as a problem found? — Verify repair Go to Step 7

7 1. Usin g th e Tech 2, d ispl ay the EC T s ensor 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.

W as 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 21 Go to Step 9

9 1. Using the Tech 2, ignition “On” and engine “Run”.

2. Monitor the “Mass Air Flow” in the data display.

Does the Tech 2 indicate correct “Mass Air Flow”

depending on accelerator pedal operation? — Go to Step 14 Go to Step 10

10 Remove the MAF & IAT sensor assembly and check

for the following conditions.

• Objects blocking at the MAF sensor element.

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 11

11 Check the MAF sensor harness for the following

conditions.

• Check for poor connector connection.

• Check for misrouted harness.

• Check for any accessory parts which may cause

electric interference.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 12

12 Substitute a known good MAF & IAT sensor assembly

and recheck.

Was the problem solved? — Go to Step 13 Go to Step 21

13 Replace the MAF & IAT sensor assembly.

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 20 Go to Step 15

Step Action Value(s) Yes No

When idling or part-throttle When accelerated

High Desired

Low

Time

Actual

High

Low

Desired

Actual

Time

15 Using the Tec h 2 or the v acuum pump a nd check th e

EGR valve operation for the following condition

through the small window.

• Restricted shaft movement. Check for objects

sticking the shaft, broken diaphragm or

excessive carbon deposit.

Tech 2:

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

2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".

3. Operate the Tech 2 in accordance with procedure.

• Solenoid 95%: EGR Valve Open

• Solenoid 5%: EGR Valve Close

Vacuum Pump:

1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR

valve.

2. Apply vacuum pressure.

• Vacuum Apply: EGR Valve Open

• Vacuum Release: EGR Valve C lose

If a problem is found, repair as necessary.

W as the problem found? — Verify repair Go to Step 16

16 Check the exhaust system for a possible restriction.

• Damaged or collapsed pipes or catalytic converter.

• Internal muffler failur e.

If a problem is found, repair as necessary.

W as a problem found? — Verify repair Go to Step 17

Step Action Value(s) Yes No

Vacuum Pump Small Window

17 Remove the injection nozzles from the engine and

check for the following conditions.

• Improper spray 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 18

18 Check the engine compression pressure for each

cylinders.

If a problem is found, repair as necessary.

Was the problem found?

More than 20

Mpa Verify repair Go to Step 19

19 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 20 Adjust and

verify repair

20 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and no

malfunctions have been found, review/inspect the

following:

• Visual/physical inspection

• Tech 2 data

• All electrical connections within a suspected circuit

and/or system

W as a problem found? — Verify repair Go to Step 21

Step Action Value(s) Yes No

1st Stage 2nd Stage

Approximately 19.5 Mpa Approximately 33.8 Mpa

21 Is the ECM programmed with the latest software

release?

If not, download the latest software to the ECM using

the “SPS (Service Programming System)”.

Was the problem solved? — Verify repair Go to Step 22

22 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Go to Step 24 Go to Step 23

23 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 lizer system

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

section 11 “Immobilizer System-ECM replacement” for

the ECM/Immobilizer linking procedure. — Verify repair —

24 Replace the injection pump assembly.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

ON-VEHICLE SERVICE PROCEDURE

ENGINE CONTROL MODULE (ECM)

Location:

Under the left-hand side seat.

Removal Procedure

1. Disconnect the negative battery cable.

2. Remove the seat left-hand side.

3. Roll up the floor carpet.

4. Remove four bolts from the ECM cover.

5. Disconnect the two connectors from the ECM.

Installation Procedure

1. Connect the two connectors to the ECM.

2. Put on the ECM to the floor panel.

3. Tighten the ECM cover by four bolts with specified

tightening torque.

Tightening torque

• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)

4. Lay the floor carpet exactly.

5. Put on the seat to the floor panel and tighten with

specified tightening torque.

Tightening torque

• Bolts: 40.0 N·m (4.1 kgf·m)

6. Connect the negative battery cable.

NOTE: The replacement ECM must be programmed.

Refer to section of the Service Programming System

(SPS) in this manual.

Following ECM programming, the immobilizer system (if

equipped) must be linked to the ECM. Refer to section

11 “Immobilizer System-ECM replacement” for the

ECM /Imm obi li ze r linki ng proc edu re .

CRANKSHAFT PO SITION (CKP) SENSOR

Location:

Installed to the clutch housing.

Removal Procedure

1. Disconnect the negative battery cable.

2. Disconnect connector from the CKP sensor .

3. Loosen a bolt and r emov e the CKP se nsor from the

clutch housing.

Installation Procedure

1. Install the CKP sensor to the clutch housing.

2. Tighten CKP sensor by a bolt with specified

tighteni ng torque .

Tightening Torque

• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)

3. Connect a CKP sensor connector to the CKP

sensor.

4. Connect the negative battery cable.

NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

ENGINE COOLANT TEMPERATURE (ECT)

SENSOR

Location:

Installed to the thermostat housing.

NOTE: Cool down the engine befo re above pro cedures

are carried out.

Removal Procedure

1. Disconnect the negative battery cable.

2. Drain enough engine coolant so that the coolant

level will be below the ECT sensor.

3. Disconnect connector from the ECT sensor.

4. Loosen and remove the ECT sensor from the

thermostat housing.

Installation Procedure

1. Apply sealer to threads of screw at the ECT sensor.

2. Tighten the ECT sensor with specified tightening

torque.

Tightening Torque

• Bolt: 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

TEMPERATURE (IAT) SENSOR

Location:

Installed to the intake duct housing.

Removal Procedure

1. Disconnect the negative battery cable.

2. Discon nect a MAF & IAT sens or conn ector fr om the

MAF & IAT sensor assembly.

3. Loosen th e clips and rem ove the MA F & IAT sensor

assembly from the intake duct housing.

Installation Procedure

1. Install the MAF & IAT sensor assembly into intake

air duct.

2. Tighten the clips.

3. Conne ct a MA F & IAT se nsor co nnecto r to the MAF

& IAT sensor assembly.

4. Connect the negative battery cable.

NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

THROTTLE POSITION SENSOR (TPS)

Location:

Installed on the throttle body.

Removal Procedure

1. Disconnect the negative battery cable.

2. Disconnect the TPS connector.

3. Loosen two screws and remove TPS from the

throttle body.

Installation Procedure

1. Fit the TPS and temporarily tighten the two TPS

retaining screws.

2. Connect the TPS connectors to the TPS.

3. Connect the negative battery cable.

4. Connect the Tech2 to the vehicle.

5. Select “Data Display” with the Tech2.

6. Check the throttle position data and adjust the TPS

position, refer to Typical Scan Data & Definitions in

this manual.

7. Tight en the two screws.

NOTE: Verify no D TCs (Diagnostic Trouble Codes) are

stored after replacement.

EGR EVRV (Electrical Vacuum Regulating

Valve)

Location:

Back of the air cleaner case.

Removal Procedure

1. Disconenct the negative battery cable.

2. Disconnect the EVRV connector from the EVRV.

3. Disconnect the two hoses from the EVRV.

4. Loosen two bolts and remove the EVRV from the

bracket.

Installation Procedure

1. Tighten the purge solenoid by two bolts.

2. Connect the connector to the EVRV.

3. Connect the two hoses to the EVRV.

4. Connect the negative battery cable.

NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.

Verify proper connection of the two hoses.

SPECIAL SERVICE TOOLS

ILLUSTRATION TOOL NO.

TOOL N AME

5-8840-0285-0

(J 39200)

High Impedance

Multimeter

(Digital Voltmeter -DVM)

(1) PCMCIA Card

(2) RS232 Loop Back

Connector

(3) SAE 16/19 Adapter

(4) DLC Cable

(5) TECH 2

5-8840-0385-0

(J 35616-A/BT-8637)

Connector Test Adapter Kit

Breaker Box

5-8840-0279-0

(J 23738-A)

Vacuum Pump with Gauge