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4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 Outline ....................................................... 6E-70

4JA1-TC .................................................... 6E-10 Cross-section View .................................... 6E-70
4JH1-TC .................................................... 6E-11 Low Pressure Fuel Circuit .......................... 6E-71
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-14 High Pressure Fuel Circuit ......................... 6E-72
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-15 Pump Camshaft Speed Sensor ................. 6E-72
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-16 High Pressure Solenoid Valve ................... 6E-73
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-17 Timing Control Valve (TCV) ....................... 6E-74
GROUND POINT CHART GENERAL EXPORT ISUZU Strategy Based Diagnostics .............. 6E-76
(LHD) (1/4) ............................................... 6E-18 Overview .................................................... 6E-76
LOCATION ................................................ 6E-34 STRATEGY BASED DIAGNOSTICS CHART 6E-76
PARTS LOCATION ................................... 6E-39 Diagnostic Thought Process ...................... 6E-77
CONNECTOR LIST ................................... 6E-40 1. Verify the Complaint .............................. 6E-77
RELAY AND FUSE .................................... 6E-43 2. Perform Preliminary Checks .................. 6E-77
RELAY AND FUSE BOX LOCATION 3. Check Bulletins and Troubleshooting Hints 6E-78
(LHD & RHD) ........................................... 6E-43 4. Perform Service Manual Diagnostic Checks 6E-78
RELAY AND FUSE BOX LOCATION 5a and 5b. Perform Service Manual Diagnostic
(LHD & RHD) ........................................... 6E-44 Procedures .............................................. 6E-78
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45 5c. Technician Self Diagnoses .................. 6E-78
ECM WIRING DIAGRAM (1/7) .................. 6E-46 5d. Intermittent Diagnosis .......................... 6E-79
ECM WIRING DIAGRAM (2/7) .................. 6E-47 5e. Vehicle Operates as Designed ............ 6E-80
ECM WIRING DIAGRAM (3/7) .................. 6E-48 6. Re-examine the complaint ..................... 6E-81
ECM WIRING DIAGRAM (4/7) .................. 6E-49 7. Repair and Verify Fix ............................. 6E-81
ECM WIRING DIAGRAM (5/7) .................. 6E-50 GENERAL SERVICE INFORMATION ....... 6E-82
ECM WIRING DIAGRAM (6/7) .................. 6E-51 ON-BOARD DIAGNOSTIC (OBD) ............. 6E-82
ECM WIRING DIAGRAM (7/7) .................. 6E-52 TECH 2 OPERATING FLOW CART
ECM CONNECTOR PIN ASSIGNMENT & (START UP) ............................................. 6E-86
OUTPUT SIGNAL .................................... 6E-53 TYPICAL SCAN DATA & DEFINITIONS
GENERAL DESCRIPTION FOR ECM AND (ENGINE DATA) ................................... 6E-88
SENSORS ............................................... 6E-64 TYPICAL SCAN DATA & DEFINITIONS
Engine Control Module (ECM) ................... 6E-64 (ENGINE DATA) ................................... 6E-90
Pump Control Unit (PSG) & Data Exchange MISCELLANEOUS TEST .......................... 6E-92
Between Control Module ......................... 6E-64 Plotting Snapshot Graph ............................ 6E-93
Mass Air Flow (MAF) Sensor & Intake Air Plotting Graph Flow Chart (Plotting graph
Temperature (IAT) Sensor ....................... 6E-65 after obtaining vehicle information) .......... 6E-94
Throttle Position Sensor (TPS) .................. 6E-66 Flow Chart for Snapshot Replay
Crankshaft Position (CKP) Sensor ............ 6E-66 (Plotting Graph) ....................................... 6E-95
Engine Coolant Temperature (ECT) Sensor 6E-67 SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-96
Vehicle Speed Sensor (VSS) .................... 6E-67 ON-BOARD DIAGNOSTIC (OBD) SYSTEM
GENERAL DESCRIPTION FOR EGR CHECK .................................................... 6E-105
(EXHAUST GAS RE-CIRCULATION) ..... 6E-68 Circuit Description ...................................... 6E-105
GENERAL DESCRIPTION FOR Diagnostic Aids .......................................... 6E-105
INJECTION PUMP .................................. 6E-70 Test Description ......................................... 6E-105
6E–2 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
On-Board Diagnostic (OBD) System Check 6E-106 VACUUM PRESSURE SENSOR VOLTAGE
NO CHECK ENGINE LAMP (MIL) ............. 6E-109 SUPPLY CIRCUIT HIGH INPUT ............. 6E-140
Circuit Description ..................................... 6E-109 DIAGNOSTIC TROUBLE CODE (DTC) P0105
Diagnostic Aids .......................................... 6E-109 (SYMPTOM CODE 9) (FLASH CODE 34)
No Check Engine Lamp (MIL) ................... 6E-110 VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT .............. 6E-140
CHECK ENGINE LAMP (MIL) “ON” STEADY 6E-112
Circuit description ...................................... 6E-141
Circuit description ...................................... 6E-112
Diagnostic Aids .......................................... 6E-141
Diagnostic Trouble Code (DTC) P0105
Check Engine Lamp (MIL) On Steady ....... 6E-113
(Symptom Code 1) (Flash Code 34) Vacuum
ECM Diagnostic Trouble Codes ................ 6E-114
Pressure Sensor Circuit High Input ......... 6E-142
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
Pressure Sensor Circuit Low Input ........... 6E-145
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128
Pressure Sensor Voltage Supply Circuit
MASS AIR FLOW (MAF) SENSOR
High Input ................................................. 6E-148
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128
(SYMPTOM CODE B) (FLASH CODE 65)
Pressure Sensor Voltage Supply Circuit Low
MASS AIR FLOW (MAF) SENSOR OUTPUT
Input.......................................................... 6E-150
CIRCUIT LOW INPUT ............................. 6E-128
(SYMPTOM CODE C) (FLASH CODE 65)
INTAKE AIR TEMPERATURE (IAT) SENSOR
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................ 6E-152
Circuit Description ..................................... 6E-129
Diagnostic Aids .......................................... 6E-129 INTAKE AIR TEMPERATURE (IAT) SENSOR
Diagnostic Trouble Code (DTC) P0100 CIRCUIT LOW INPUT ............................. 6E-152
(Symptom Code 7) (Flash Code 65) Mass Circuit Description ...................................... 6E-152
Air Flow (MAF) Sensor Voltage Supply
Circuit High Input ..................................... 6E-129
(Symptom Code 1) (Flash Code 23) Intake Air
(Symptom Code 9) (Flash Code 65) Mass
Temperature (IAT) Sensor Circuit High Input 6E-153
Air Flow (MAF) Sensor Voltage Supply
Circuit Low Input ...................................... 6E-132
(Symptom Code 2) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit Low Input 6E-157
(Symptom Code B) (Flash Code 65) Mass
Air Flow (MAF) Sensor Output Circuit Low
Input ......................................................... 6E-134
ENGINE COOLANT TEMPERATURE SENSOR
Diagnostic Trouble Code (DTC) P0100 (Symptom
CIRCUIT HIGHINPUT ............................. 6E-160
Code C) (Flash Code 65) Mass Air Flow (MAF)
Sensor Output Circuit High Input ............. 6E-137
ENGINE COOLANT TEMPERATURE SENSOR
VACUUM PRESSURE SENSOR CIRCUIT HIGH
Circuit Description ...................................... 6E-160
INPUT ...................................................... 6E-140
(SYMPTOM CODE 2) (FLASH CODE 34) Diagnostic Trouble Code (DTC) P0115
VACUUM PRESSURE SENSOR CIRCUIT (Symptom Code 1) (Flash Code 14) Engine
LOW INPUT ............................................. 6E-140 Coolant Temperature Sensor Circuit
HighInput ................................................. 6E-161
(Symptom Code 2) (Flash Code 14) Engine Diagnostic Trouble Code (DTC) P0216
Coolant Temperature Sensor Circuit (Symptom Code A) (Flash Code 54) Injection
LowInput .................................................. 6E-165 Timing Control Circuit Malfunction ........... 6E-180
DIAGNOSTIC TROUBLE CODE (DTC) P0180 Diagnostic Trouble Code (DTC) P0216
(SYMPTOM CODE B) (FLASH CODE 15) (Symptom Code B) (Flash Code 54) Injection
FUEL TEMPERATURE SENSOR CIRCUIT Timing Control Circuit Malfunction ........... 6E-180
RANGE/PERFORMANCE ....................... 6E-168 DIAGNOSTIC TROUBLE CODE (DTC) P0243
Circuit Description ..................................... 6E-168 (SYMPTOM CODE 3) (FLASH CODE 64)
Diagnostic Aids .......................................... 6E-168 TURBOCHARGER WASTEGATE
Diagnostic Trouble Code (DTC) P0180 SOLENOID "A" RANGE/PERFORMANCE 6E-183
(Symptom Code B) (Flash Code 15) Fuel DIAGNOSTIC TROUBLE CODE (DTC) P0243
Temperature Sensor Circuit (SYMPTOM CODE 4) (FLASH CODE 64)
Range/Performance ................................ 6E-169 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID"A" LOW ................................ 6E-183
(SYMPTOM CODE A) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
FUEL CUTOFF SOLENOID VALVE (SYMPTOM CODE 4) (FLASH CODE 64)
MALFUNCTION ....................................... 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" LOW ............................... 6E-183
(SYMPTOM CODE B) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
CIRCUIT HIGH INPUT ............................ 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" RANGE/PERFORMANCE 6E-183
(SYMPTOM CODE C) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
FUEL CUTOFF SOLENOID VALVE ALWAYS (SYMPTOM CODE 6) (FLASH CODE 64)
ACTIVE .................................................... 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" MALFUNCTION ............. 6E-183
(SYMPTOM CODE D) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
MALFUNCTION ....................................... 6E-170 TURBOCHARGER WASTEGATE
Circuit Description ..................................... 6E-171 SOLENOID"A" HIGH ............................... 6E-183
Diagnostic Aids .......................................... 6E-171 Circuit description ...................................... 6E-184
Diagnostic Trouble Code (DTC) P0215 Diagnostic Aids .......................................... 6E-184
(Symptom Code A) (Flash Code 52) Fuel Diagnostic Trouble Code (DTC) P0243
Cutoff Solenoid Valve Malfunction ........... 6E-171 (Symptom Code 3) (Flash Ccode 64)
Diagnostic Trouble Code (DTC) P0215 Turbocharger Wastegate Solenoid
(Symptom Code B) (Flash Code 52) Fuel "A" Range/Performance ........................... 6E-185
Cutoff Solenoid Valve Circuit High Input . 6E-173 Diagnostic Trouble Code (DTC) P0243
Diagnostic Trouble Code (DTC) P0215 (Symptom Code 4) (Flash Code 64)
(Symptom Code C) (Flash Code 52) Fuel Turbocharger Wastegate Solenoid "A" Low 6E-187
Cutoff Solenoid Valve Always Active ....... 6E-175 Diagnostic Trouble Code (DTC) P0243
(Symptom Code D) (Flash Code 52) Fuel Turbocharger Wastegate Solenoid "A"
Cutoff Solenoid Valve Malfunction ........... 6E-177 Range/Performance ................................ 6E-190
(SYMPTOM CODE A) (FLASH CODE 54) (Symptom Code 6) (Flash Code 64)
INJECTION TIMING CONTROL CIRCUIT Turbocharger Wastegate Solenoid "A"
MALFUNCTION ....................................... 6E-178 Malfunction .............................................. 6E-192
(SYMPTOM CODE B) (FLASH CODE 54) (Symptom Code 8) (Flash Code 64)
INJECTION TIMING CONTROL CIRCUIT Turbocharger Wastegate Solenoid "A" High 6E-194
MALFUNCTION ....................................... 6E-178 DIAGNOSTIC TROUBLE CODE (DTC) P0251
Circuit Description ..................................... 6E-179 (SYMPTOM CODE 6)
Diagnostic Aids .......................................... 6E-179 (FLASH CODE 53) INJECTION PUMP
MALFUNCTION ....................................... 6E-196 RANGE/PERFORMANCE ....................... 6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Circuit Description ...................................... 6E-209
(SYMPTOM CODE 7) (FLASH CODE 53) Diagnostic Aids .......................................... 6E-209
INJECTION PUMP MALFUNCTION ....... 6E-196 Diagnostic Trouble Code (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (Symptom Code B) (Flash Code 43)
(SYMPTOM CODE 9) (FLASH CODE 53) Crankshaft Position Sensor Circuit
INJECTION PUMP MALFUNCTION ....... 6E-196 Malfunction .............................................. 6E-209
(SYMPTOM CODE A) (FLASH CODE 53) (Symptom Code D) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-196 Crankshaft Position Sensor Malfunction .. 6E-209
(SYMPTOM CODE B) (FLASH CODE 53) (Symptom Code E) (Flash Code 43) Engine
INJECTION PUMP MALFUNCTION ....... 6E-196 Speed Input Circuit Range/Performance . 6E-214
DIAGNOSTIC TROUBLE CODE (DTC) P0251 DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE D) (FLASH CODE 53) (SYMPTOM CODE 4) (FLASH CODE 66)
INJECTION PUMP MALFUNCTION ....... 6E-196 GLOW RELAY CIRCUIT VOLTAGE LOW 6E-217
(SYMPTOM CODE E) (FLASH CODE 53) (SYMPTOM CODE 8) (FLASH CODE 66)
INJECTION PUMP MALFUNCTION ....... 6E-196 GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
Circuit Description ..................................... 6E-197 Circuit Description ...................................... 6E-217
Diagnostic Aids .......................................... 6E-197 Diagnostic Aids .......................................... 6E-217
Diagnostic Trouble Code (DTC) P0251 Diagnostic Trouble Code (DTC) P0380
(Symptom Code 6) (Flash Code 53) (Symptom Code 4) (Flash Code 66)
Injection Pump Malfunction ..................... 6E-197 Glow Relay Circuit Voltage Low .............. 6E-218
(Symptom Code 7) (Flash Code 53) (Symptom Code 8) (Flash Code 66) Glow
Injection Pump Malfunction ..................... 6E-199 Relay Circuit Voltage High ....................... 6E-221
Diagnostic Trouble Code (DTC) P0251 DIAGNOSTIC TROUBLE CODE (DTC) P0381
(Symptom Code 9) (Flash Code 53) (SUB CODE 4) (FLASH CODE 67) GLOW PLUG
Injection Pump Malfunction ..................... 6E-203 INDICATOR CIRCUIT VOLTAGE LOW .. 6E-222
(Symptom Code A) (Flash Code 53) (SUB CODE 8) (FLASH CODE 67) GLOW PLUG
Injection Pump Malfunction ..................... 6E-204 INDICATOR CIRCUIT VOLTAGE HIGH . 6E-222
Diagnostic Trouble Code (DTC) P0251 Circuit Description ...................................... 6E-222
(Symptom Code B) (Flash Code 53) Diagnostic Aids .......................................... 6E-222
Injection Pump Malfunction ..................... 6E-205 Diagnostic Trouble Code (DTC) P0381
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 4) (Flash Code 67) Glow
(Symptom Code D) (Flash Code 53) Plug Indicator Circuit Voltage Low ........... 6E-222
Injection Pump Malfunction ..................... 6E-206 Diagnostic Trouble Code (DTC) P0381
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 8) (Flash Code 67) Glow
(Symptom Code E) (Flash Code 53) Plug Indicator Circuit Voltage High .......... 6E-226
Injection Pump Malfunction ..................... 6E-207 DIAGNOSTIC TROUBLE CODE (DTC) P0400
DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE 3) (FLASH CODE 32)
(SYMPTOM CODE B) (FLASH CODE 43) EXHAUST GAS RECIRCULATION FLOW
CRANKSHAFT POSITION SENSOR EXCESSIVE DETECTED ........................ 6E-227
CIRCUIT MALFUNCTION ....................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE D) (FLASH CODE 43) EXHAUST GAS RECIRCULATION CIRCUIT
CRANKSHAFT POSITION SENSOR SHORT TO GROUND OR OPEN CIRCUIT 6E-227
MALFUNCTION ....................................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE E) (FLASH CODE 43) EXHAUST GAS RECIRCULATION FLOW
ENGINE SPEED INPUT CIRCUIT INSUFFICIENT DETECTED .................... 6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Diagnostic Aids .......................................... 6E-254
EXHAUST GAS RECIRCULATION CIRCUIT (Symptom Code 1) (Flash Code 35)
SHORT TO BATTERY ............................ 6E-227 System Voltage Too High ........................ 6E-254
Circuit Description ..................................... 6E-228 Diagnostic Trouble Code (DTC) P0560
Diagnostic Aids .......................................... 6E-228 (Symptom Code 2) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Too Low ......................... 6E-256
(Symptom Code 3) (Flash Code 32) Exhaust Diagnostic Trouble Code (DTC) P0560
Gas Recirculation Flow Excessive Detected 6E-228 (Symptom Code A) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Malfunction .................... 6E-258
(Symptom Code 4) (Flash Code 32) Exhaust DIAGNOSTIC TROUBLE CODE (DTC) P0561
Gas Recirculation Circuit Short to Ground or (SYMPTOM CODE A) (FLASH CODE 18)
Open Circuit ............................................. 6E-232 IGNITION SWITCH CIRCUIT
Diagnostic Trouble Code (DTC) P0400 MALFUNCTION ....................................... 6E-260
(Symptom Code 5) (Flash Code 32) Exhaust DIAGNOSTIC TROUBLE CODE (DTC) P0561
Gas Recirculation Flow Insufficient Detected 6E-235 (SYMPTOM CODE B) (FLASH CODE 18)
Diagnostic Trouble Code (DTC) P0400 IGNITION SWITCH CIRCUIT
(Symptom Code 8) (Flash Code 32) Exhaust MALFUNCTION ....................................... 6E-260
Gas Recirculation Circuit Short to Battery 6E-238 Circuit Description ...................................... 6E-261
VEHICLE SPEED SENSOR CIRCUIT HIGH (Symptom Code A) (Flash Code 18)
INPUT ...................................................... 6E-240 Ignition Switch Circuit Malfunction ........... 6E-261
(SYMPTOM CODE A) (FLASH CODE 24) (Symptom Code B) (Flash Code 18)
VEHICLE SPEED SENSOR INPUT SIGNAL Ignition Switch Circuit Malfunction ........... 6E-261
FREQUENCY TOO HIGH ....................... 6E-240 DIAGNOSTIC TROUBLE CODE (DTC) P0602
DIAGNOSTIC TROUBLE CODE (DTC) P0500 CONTROL MODULE PROGRAMMING
(SYMPTOM CODE B) (FLASH CODE 24) ERROR .................................................... 6E-264
VEHICLE SPEED SENSOR INCORRECT Circuit Description & Diagnostic Aids ........ 6E-264
SIGNAL ................................................... 6E-240 Diagnostic Trouble Code (DTC) P0602
Circuit Description ..................................... 6E-241 Control Module Programming Error ......... 6E-264
Diagnostic Aids .......................................... 6E-241 DIAGNOSTIC TROUBLE CODE (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (SYMPTOM CODE A) (FLASH CODE 28)
(Symptom Code 1) (Flash Code 24) Vehicle ECU MALFUNCTION .............................. 6E-265
Speed Sensor Circuit High Input ............. 6E-241 DIAGNOSTIC TROUBLE CODE (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (SYMPTOM CODE B) (FLASH CODE 28)
(Symptom Code A) (Flash Code 24) ECU MALFUNCTION .............................. 6E-265
Vehicle Speed Sensor Input Signal Circuit Description & Diagnostic Aids ........ 6E-265
Frequency Too High ................................ 6E-245 Diagnostic Trouble Code (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 28)
(Symptom Code B) (Flash Code 24) ECU Malfunction ...................................... 6E-265
VehicleSpeed Sensor Incorrect Signal .... 6E-248 Diagnostic Trouble Code (DTC) P0606
DIAGNOSTIC TROUBLE CODE (DTC) P0560 (Symptom Code B) (Flash Code 28)
(SYMPTOM CODE 1) (FLASH CODE 35) ECU Malfunction ...................................... 6E-267
SYSTEM VOLTAGE TOO HIGH ............. 6E-253 DIAGNOSTIC TROUBLE CODE (DTC) P0645
(SYMPTOM CODE 2) (FLASH CODE 35) A/C COMPRESSOR RELAY CIRCUIT
SYSTEM VOLTAGE TOO LOW .............. 6E-253 VOLTAGE LOW ...................................... 6E-268
(SYMPTOM CODE A) (FLASH CODE 35) (SYMPTOM CODE 8) (FLASH CODE 46)
SYSTEM VOLTAGE MALFUNCTION ..... 6E-253 A/C COMPRESSOR RELAY CIRCUIT
Circuit Description ..................................... 6E-253 VOLTAGE HIGH ...................................... 6E-268
Circuit Description ..................................... 6E-268 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Aids .......................................... 6E-268 VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
(Symptom Code 4) (Flash Code 46) A/C (SYMPTOM CODE 9) (FLASH CODE 21)
Compressor Relay Circuit Voltage Low ... 6E-269 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Trouble Code (DTC) P0645 VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
(Symptom Code 8) (Flash Code 46) A/C DIAGNOSTIC TROUBLE CODE (DTC) P1120
Compressor Relay Circuit Voltage High .. 6E-272 (SYMPTOM CODE D) (FLASH CODE 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0703 PEDAL/THROTTLE POSITION SENSOR
(SYMPTOM CODE A) (FLASH CODE 25) BRAKE SWITCH ERROR ....................... 6E-287
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 DIAGNOSTIC TROUBLE CODE (DTC) P1120
DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE E) (FLASH CODE 21)
(SYMPTOM CODE B) (FLASH CODE 25) PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 IDLE POSITION SWITCH ERROR ......... 6E-287
Circuit Description ..................................... 6E-274 Circuit Description ...................................... 6E-288
Diagnostic Aids .......................................... 6E-274 Diagnostic Aids .......................................... 6E-288
(Symptom Code A) (Flash Code 25) Brake (Symptom Code 1) (Flash Code 21)
Switch Circuit Malfunction ....................... 6E-274 Pedal/Throttle Position Sensor
Diagnostic Trouble Code (DTC) P0703 Circuit High Input ..................................... 6E-288
(Symptom Code B) (Flash Code 25) Diagnostic Trouble Code (DTC) P1120
Brake Switch Circuit Malfunction ............. 6E-278 (Symptom Code 7) (Flash Code 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0704 Pedal/Throttle Position Sensor Voltage
(SYMPTOM CODE 6) (FLASH CODE 57) Supply Circuit High Input ......................... 6E-293
CLUTCH SWITCH INPUT CIRCUIT Diagnostic Trouble Code (DTC) P1120
MALFUNCTION ....................................... 6E-281 (Symptom Code 9) (Flash Code 21)
Circuit Description ..................................... 6E-281 Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input .......................... 6E-295
(Symptom Code D) (Flash Code 21)
(Symptom Code 6) (Flash Code 57)
Pedal/Throttle Position Sensor Brake
Clutch Switch Input Circuit Malfunction ... 6E-282
Switch Error ............................................. 6E-298
(Symptom Code E) (Flash Code 21)
BAROMETRIC PRESSURE SENSOR
Pedal/Throttle Position Sensor Idle
Position Switch Error ............................... 6E-300
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
BAROMETRIC PRESSURE SENSOR
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ...................................... 6E-302
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
Diagnostic Trouble Code (DTC) P1105 REDUCTION CAUSED BY HIGH FUEL
(Symptom Code 1) (Flash Code 86) Barometric TEMPERATURE ...................................... 6E-302
Pressure Sensor Circuit High Input ......... 6E-285
Diagnostic Trouble Code (DTC) P1105 (SYMPTOM CODE A) (FLASH CODE 22) FUEL
(Symptom Code 2) (Flash Code 86) Barometric REDUCTION CAUSED BY LOW FUEL
Pressure Sensor Circuit Low Input .......... 6E-285 TEMPERATURE ...................................... 6E-302
PEDAL/THROTTLE POSITION SENSOR
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant
Temperature ............................................ 6E-302 Diagnostic Trouble Code (DTC) P1605
Diagnostic Trouble Code (DTC) P1173 (Symptom Code D) (Flash Code 55)
(Symptom Code 7) (Flash Code 22) Fuel EEPROM Defect ...................................... 6E-318
Reduction Caused By High Fuel Diagnostic Trouble Code (DTC) P1605
Temperature ............................................ 6E-305 (Symptom Code E) (Flash Code 55)
Diagnostic Trouble Code (DTC) P1173 EEPROM Defect ...................................... 6E-318
(Symptom Code A) (Flash Code 22) Fuel DIAGNOSTIC TROUBLE CODE (DTC) P1610
Reduction Caused By Low Fuel (SYMPTOM CODE A) (FLASH CODE 56)
Temperature ............................................ 6E-305 SECURITY KEY AND SECURITY CODE NOT
DIAGNOSTIC TROUBLE CODE (DTC) P1335 PROGRAMMED ...................................... 6E-320
(SYMPTOM CODE A) Circuit Description ...................................... 6E-320
(FLASH CODE 43) ENGINE SPEED OUTPUT Diagnostic Aids .......................................... 6E-320
CIRCUIT MALFUNCTION ....................... 6E-306 Diagnostic Trouble Code (DTC) P1610
Circuit Description ..................................... 6E-306 (Symptom Code A) (Flash Code 56) Security
Diagnostic Aids .......................................... 6E-306 Key and Security Code Not Programmed 6E-320
(Symptom Code A) (Flash Code 43) (SYMPTOM CODE A) (FLASH CODE 56)
Engine Speed Output Circuit Malfunction 6E-307 WRONG SECURITY CODE ENTERED .. 6E-322
(SYMPTOM CODE A) (FLASH CODE 45) Diagnostic Aids .......................................... 6E-322
CAMSHAFT SPEED MALFUNCTION ..... 6E-311 Diagnostic Trouble Code (DTC) P1611
Circuit Description ..................................... 6E-311 (Symptom Code A) (Flash Code 56)
Diagnostic Aids .......................................... 6E-311 Wrong Security Code Entered ................. 6E-323
(Symptom Code A) (Flash Code 45) (SYMPTOM CODE A) (FLASH CODE 56)
Camshaft Speed Malfunction .................. 6E-312 IMMOBILIZER NO OR WRONG SIGNAL 6E-324
(SYMPTOM CODE A) (FLASH CODE 47) Diagnostic Aids .......................................... 6E-324
NEUTRAL SWITCH ON ERROR ............ 6E-313 Diagnostic Trouble Code (DTC) P1612
DIAGNOSTIC TROUBLE CODE (DTC) P1520 (Symptom Code A) (Flash Code 56)
(SYMPTOM CODE B) (FLASH CODE 47) Immobilizer No or Wrong Signal .............. 6E-325
NEUTRAL SWITCH OFF ERROR .......... 6E-313 DIAGNOSTIC TROUBLE CODE (DTC) P1613
Circuit Description ..................................... 6E-313 (SYMPTOM CODE A) (FLASH CODE 56)
Diagnostic Aids .......................................... 6E-313 IMMOBILIZER NO OR WRONG SIGNAL 6E-330
Diagnostic Trouble Code (DTC) P1520 Circuit Description ...................................... 6E-330
(Symptom Code A) (Flash Code 47) Diagnostic Aids .......................................... 6E-330
Neutral Switch ON Error .......................... 6E-314 Diagnostic Trouble Code (DTC) P1613
(Symptom Code B) (Flash Code 47) Immobilizer No or Wrong Signal .............. 6E-331
Neutral Switch OFF Error ........................ 6E-314 DIAGNOSTIC TROUBLE CODE (DTC) P1614
DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE A) (FLASH CODE 56)
(SYMPTOM CODE C) (FLASH CODE 55) WRONG TRANSPONDER KEY .............. 6E-335
SEED AND KEY FILE DESTROYED ...... 6E-318 Circuit Description ...................................... 6E-335
(SYMPTOM CODE D) (FLASH CODE 55) Diagnostic Trouble Code (DTC) P1614
EEPROM DEFECT .................................. 6E-318 (Symptom Code A) (Flash Code 56)
DIAGNOSTIC TROUBLE CODE (DTC) P1605 Wrong Transponder Key .......................... 6E-336
(SYMPTOM CODE E) (FLASH CODE 55) DIAGNOSTIC TROUBLE CODE (DTC) P1625
EEPROM DEFECT .................................. 6E-318 (SYMPTOM CODE A) (FLASH CODE 76) ECM
Circuit Description & Diagnostic Aids ........ 6E-318 MAIN RELAY SWITCHED OFF
Diagnostic Trouble Code (DTC) P1605 TOO EARLY ............................................ 6E-337
(Symptom Code C) (Flash Code 55) DIAGNOSTIC TROUBLE CODE (DTC) P1625
Seed and Key File Destroyed .................. 6E-318
(SYMPTOM CODE B) (FLASH CODE 76) ECM CAN Receives Error ................................ 6E-351
MAIN RELAY SWITCHED OFF TOO LATE 6E-337 DIAGNOSTIC TROUBLE CODE (DTC) P1690
Circuit Description ..................................... 6E-337 (SYMPTOM CODE 4) (FLASH CODE 77)
Diagnostic Aids .......................................... 6E-337 CHECK ENGINE LAMP (MIL) CIRCUIT
Diagnostic Trouble Code (DTC) P1625 VOLTAGE LOW ...................................... 6E-356
(Symptom Code A) (Flash Code 76) ECM DIAGNOSTIC TROUBLE CODE (DTC) P1690
Main Relay Switched Off Too Early ......... 6E-338 (SYMPTOM CODE 8) (FLASH CODE 77)
Diagnostic Trouble Code (DTC) P1625 CHECK ENGINE LAMP (MIL) CIRCUIT
(Symptom Code B) (Flash Code 76) ECM VOLTAGE HIGH ...................................... 6E-356
Main Relay Switched Off Too Late .......... 6E-339 Circuit Description ...................................... 6E-356
(SYMPTOM CODE A) (FLASH CODE 51) Diagnostic Trouble Code (DTC) P1690
FUEL INJECTION QUANTITY CIRCUIT (Symptom Code 4) (Flash Code 77) Check
MALFUNCTION ....................................... 6E-340 Engine Lamp (MIL) Circuit Voltage Low .. 6E-357
(SYMPTOM CODE B) (FLASH CODE 51) (Symptom Code 8) (Flash Code 77) Check
FUEL INJECTION QUANTITY CIRCUIT Engine Lamp (MIL) Circuit Voltage High . 6E-360
MALFUNCTION ....................................... 6E-340 SYMPTOM DIAGNOSIS ............................ 6E-361
Circuit Description ..................................... 6E-340 PRELIMINARY CHECKS .......................... 6E-361
Diagnostic Aids .......................................... 6E-341 VISUAL/PHYSICAL CHECK ...................... 6E-361
Diagnostic Trouble Code (DTC) P1630 INTERMITTENT ........................................ 6E-361
(Symptom Code A) (Flash Code 51) Fuel ENGINE CRANKS BUT WILL NOT RUN .. 6E-362
Injection Quantity Circuit Malfunction ...... 6E-341 HARD START SYMPTOM ......................... 6E-366
Diagnostic Trouble Code (DTC) P1630 ROUGH, UNSTABLE, OR INCORRECT
(Symptom Code B) (Flash Code 51) Fuel IDLE, STALLING SYMPTOM .................. 6E-370
Injection Quantity Circuit Malfunction ...... 6E-341
SURGES AND/OR CHUGS SYMPTOM ... 6E-377
HESITATION, SAG, STUMBLE SYMPTOM 6E-383
(SYMPTOM CODE A)
CUTS OUT, MISSES SYMPTOM .............. 6E-389
(FLASH CODE 44) CAN DEVICE OFFLINE 6E-342
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM .............................. 6E-396
CAN DEVICE HANG-UP ......................... 6E-342 POOR FUEL ECONOMY SYMPTOM ....... 6E-402
Circuit Description ..................................... 6E-342 EXCESSIVE WHITE SMOKE .................... 6E-407
Diagnostic Aids .......................................... 6E-342 EXCESSIVE BLACK SMOKE .................... 6E-413
Diagnostic Trouble Code (DTC) P1650 ON-VEHICLE SERVICE PROCEDURE .... 6E-418
(Symptom Code A) (Flash Code 44) ENGINE CONTROL MODULE (ECM) ... 6E-418
CAN Device Offline .................................. 6E-343 CRANKSHAFT POSITION (CKP) SENSOR 6E-419
Diagnostic Trouble Code (DTC) P1650 ENGINE COOLANT TEMPERATURE
(Symptom Code B) (Flash Code 44) (ECT) SENSOR ....................................... 6E-419
CAN Device Hang-up .............................. 6E-348 MASS AIR FLOW (MAF) & INTAKE AIR
DIAGNOSTIC TROUBLE CODE (DTC) P1651 TEMPERATURE (IAT) SENSOR ............ 6E-420
(SYMPTOM CODE A) (FLASH CODE 45) THROTTLE POSITION SENSOR (TPS) ... 6E-420
CAN MALFUNCTION .............................. 6E-349 EGR EVRV
DIAGNOSTIC TROUBLE CODE (DTC) P1651 (Electrical Vacuum Regulating Valve) ..... 6E-421
CAN RECEIVES ERROR ........................ 6E-349
(Symptom Code A) (Flash Code 45)
CAN Malfunction ...................................... 6E-350
(Symptom Code B) (Flash Code 45)
ABBREVIATION CHARTS
Abbreviations Appellation
A/C Air conditioner
A/T Automatic transmission
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 control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Exhaust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VCC Voltage constunt control
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
Engine Component Locator Table
4JA1-TC
3 1 2 6 4 5
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler
(3) Air Cleaner Case
4JH1-TC
4 5
2 6 4
3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
3 2 4
(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

(2) Pump Control Unit (PSG) (4) Fuel Filter (Except Euro 3)
2 3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (3) Air Cleaner Case
(IAT) Sensor Assembly
(2) EGR EVRV
3 2 1
(1) Engine Control Module (ECM) (1) EGR EVRV

(2) To Vacuum Pump
(3) To EGR Valve
2 1
(1) Engine Coolant Temperature (ECT) Sensor

2 1
(2) Thermo Unit for Water Temperature Gauge
(1) Crankshaft Position (CKP) Sensor
(2) Clutch Housing
(1) Vehicle Speed Sensor (VSS)

ECM CIRCUIT DIAGRAM (4JA1-TC)
ECM CIRCUIT DIAGRAM (4JA1-TC)
ECM CIRCUIT DIAGRAM (4JH1-TC)
ECM CIRCUIT DIAGRAM (4JH1-TC)
GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)
GROUND POINT CHART EUROPE (LHD) (1/4)
GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)
GROUND POINT CHART EUROPE (RHD) (1/4)
LOCATION
CABEL HARNESS & CONNECTOR LOCATION
4JA1-TC & 4JH1-TC ENGINE (LHD)
4JA1-TC & 4JH1-TC ENGINE (RHD)
PARTS LOCATION
CONNECTOR LIST
No. Connector face No. Connector face
B-24 C-56
Green Meter-B ECM-A

B-54 C-57
White J/B I2 ECM-B

B-56 C-77
White J/B I4 Clutch switch

B-58 C-94
Black Check connector White TCM

B-62 C-95
White Ignition switch (IGSUB : G1) White TCM

B-63 C-107
White Ignition switch (IGSUB : G2) White J/B E2

B-68 C-108
Immobilizer White J/B E1

C-2 C-109
Silver Engine room-RH ground Silver Body-LH ; ground

C-36 C-115
Silver Engine room-LH ; Ground Brown EVRV

C-44 C-116
White Stop lamp switch


C-118 E-23
A/C Resister & Neutral switch Gray Idle SW

C-123 E-41
Black Coolant temp sensor

C-124 E-44
Gray Vehicle speed sensor

E-3 E-49
Black Magnetic clutch AC COMP Gray Glow plug

E-6 E-51
Black Inhibiter switch

E-9 H-4
White Engine room ~ Mission

E-10 H-6
Silver Engine ground White Engine room ~ INST

E-11 H-7
Natural
green Neutral switch White Engine room ~ INST
E-12 H-18
Natural
green Neutral switch White Engine room ~ INST
E-22 H-22
Brown TPS 1 main White Engine ~ Engine room C


H-33 X-16
Engine ~ Engine room Black DIODE

P-1 X-17
Silver Battery (+) Black DIODE

P-2
Silver Relay & Fuse box

P-5
Silver Battery (-)

P-6
Silver Body earth (Ground)

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 (LHD & RHD)
LHD
RHD
RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
RELAY
No.
(4JA1-TC/4JH1-TC)
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FRT FOG LIGHT
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; GLOW
X-6 RELAY; COND, FAN
X-7 RELAY; RR FOG
X-8 RELAY; STARTER
X-9 SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-RH (RHD)
X-10 SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-LH (RHD)
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
FUSE
NO.
(4JA1-TC/4JH1-TC)
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
SLOW BLOW FUSE

SLOW BLOW FUSE
NO.
4JA1-TC/4JH1-TC
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 (LHD & RHD)
FUSE BOX
FUSE
No. Capacity Indication on label No. Capacity Indication on label
1 — — 12 15A CIGER
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
SLOW BLOW FUSE
No. Capacity Indication on label
SBF-10 20A RR DEF
SBF-11 30A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
4JA1-TC, 4JH1-TC REAR POWER ACC
DEFOGGER WINDOW SOCKET
ECM WIRING DIAGRAM (1/7)
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Signal or Continuity Tester Position
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
1 1 ECM Ground BLK Continuity - - - Discon- Ohm 1 GND
with nect
ground
2 2 ECM Ground BLK Continuity - - - Discon- Ohm 2 GND
with nect
ground
3 3 Battery Power Supply BLU/ Less than 10-14V Connect DC V 3 GND
RED 1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output LGN - - Approx. Approx. Connect AC V 27 GND
(To Tacho Meter) 23Hz by 67Hz by
wave form wave form
or approx. or approx.
6.3V 6.8V
28 28 No Connection - - - - - - - - -
29 29 No Connection - - - - - - - - -
30 30 Brake Switch 1 Signal GRN Less than Pedal is not stepped on: Less than 1V Connect DC V 30 GND
1V Pedal is stepped on: 10-14V
31 31 Clutch Switch Signal YEL Less than Pedal is not stepped on: 10-14V Connect DC V 31 GND
(MT Only) 1V Pedal is stepped on: Less than 1V
32 32 No Connection - - - - - - - - -
33 33 A/C ON Signal Relay GRN/ Less than A/C request switch is turned on: 10- Connect DC V 33 GND
YEL 1V 14V
A/C request switch is turned off: Less
than 1V
34 34 No Connection - - - - - - - - -
35 35 To Data Link Connec- YEL - - - - - - - -
tor No. 6 & Immobi-
lizer Control Unit (ICU
B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position Sen- GRN/ Less than Less than 1V Approx. Connect DC V 38 49
sor (TPS) Output Sig- ORG 1V 0.5V
nal
39 39 Key Switch Input Sig- WHT Less than 10-14V Connect DC V 39 GND
nal Via Engine Fuse 1V
40 40 No Connection - - - - - - - - -
tion
41 41 A/C Compressor WHT/ Less than 10-14V A/C comp. is operated: Connect DC V 41 GND
Relay GRN 1V Less than 1V
A/C comp. is not oper-
ated: 10 - 14V
42 42 Check Engine Lamp GRN/ Less than Lamp is turned on: Less than 1V Connect DC V 42 GND
YEL 1V Lamp is turned off: 10-14V
43 43 Glow Lamp ORG/ Less than Lamp is turned on: Less than 1V Connect DC V 43 GND
BLU 1V Lamp is turned off: 10-14V
44 44 No Connection - - - - - - - - -
45 45 To Data Link Connec- BLU Less than 10-14V Connect DC V 45 GND
tor No. 6 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position Sen- BLK/ Idle: - - - Discon- Ohm 38 49
sor (TPS) Ground GRN Approx. nect
0.4K ohm /
WOT:
Approx.
4.0K ohm
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 Sen- RED/ Less than Approx. 5V Connect DC V 57 49
sor (TPS) Power Sup- GRN 1V
ply
58 58 ECM Relay BLU/ 10-14V Less than 1V Connect DC V 58 GND
BLK
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply Less than 10-14V - DC V 63 GND
1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/ Less than Pedal is not stepped on: 10-14V Connect DC V 65 GND
BLK 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed 20km/h
69 69 Idle Switch GRN/ Less than Pedal is not stepped on: Less than 1V Connect DC V 69 GND
BLK 1V Pedal is stepped on: Approx. 5V
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
tion
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/ Less than Approx. 5V Connect DC V 83 92
Sensor Power Supply RED 1V
84 84 Intake Air Tempera- BLK/ Less than 0 deg. C: Approx. 3.6V / 20 deg. C: Connect DC V 84 92
ture (IAT) Sensor Sig- BLU 1V Approx. 2.6V / 40 deg. C: Approx.
nal 1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/ Less than In neutral: Less than 1V Connect DC V 87 GND
WHT 1V Other than neutral: 10-14V
88 88 Mass Air Flow (MAF) GRN/ Less than Approx. 1V Approx. Approx. Connect DC V 88 92
Sensor Signal RED 1V 1.8V 2.5V
89 89 Engine Coolant Tem- GRY Less than 0 deg. C: Approx. 4.4V / 20 deg. C: Connect DC V 89 93
perature (ECT) Sen- 1V Approx. 3.8V / 40 deg. C: Approx.
sor Signal 2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 134Hz by
wave form wave form
or approx.
1.1V
91 91 CKP Sensor Output PNK - - Approx. Approx. Connect AC V 91 GND
To Pump Control Unit 47Hz by 134Hz by
(PSG) No.8 wave form wave form
or approx.
0.7V
92 92 Mass Air Flow (MAF) BLK/ Continuity - - - Connect Ohm 92 GND
Sensor Ground RED with
ground
93 93 Engine Coolant Tem- BLK/ Continuity - - - Connect Ohm 93 GND
perature (ECT) Sen- PNK with
sor Ground ground
94 94 Glow Relay BLK/ Less than Glow system is operated: Less than Connect DC V 94 GND
RED 1V 1V
Glow system is not operated: 10 - 14V
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ - - Approx. 140Hz by wave - - - -
ORG form when EVRV is
operated
98 98 CKP Sensor Ground WHT Continuity - - - Connect Ohm 98 GND
with
ground
99 99 CAN (Controller Area BLU - - - - - - - -
Network) to PSG No.1
100 100 CAN (Controller Area YEL - - - - - - - -
Network) to PSG No.2
tion
101 101 CKP Sensor Shield BLK Continuity - - - Connect Ohm 101 GND
Line with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - - - - - - - -
Off (MAB) Output Sig-
nal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM & Rang (+) (-)
No. Box Color Off On Idle 2000rpm PSG Con- e
No. nection
1 99 CAN (Controller Area RED Continu- - - - Discon- Ohm 1 99

Network) to ECM ity nect (EC
No.99 between M)
ECM &
PSG
2 100 CAN (Controller Area WHT Continu- - - - Discon- Ohm 2 100

Network) to ECM ity nect (EC
No.100 between M)
ECM &
PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut ORG Continu- - - - Discon- Ohm 5 105

Off (MAB) Output ity nect (EC
Signal to ECM between M)
No.105 ECM &
PSG
6 - Ground BLK Continu- - - - Discon- Ohm 6 GND

ity with nect
ground
7 - Battery Power Sup- BLU/ Less 10-14V Discon- Ohm 7 GND

ply RED than 1V nect
8 91 CKP Sensor Output PNK Continu- - - - Discon- Ohm 8 91

ECM No.91 to Pump ity nect (EC
Control Unit (PSG) between M)
ECM &
PSG
9 - No Connection - - - - - - - - -
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM Ran (+) (-)
No. Box Color Off On Idle 2000rpm Connec- ge
No. tion
1 1 ECM Ground BLK Continu- - - - Discon- Ohm 1 GND

ity with nect
ground
2 2 ECM Ground BLK Continu- - - - Discon- Ohm 2 GND

ity with nect
ground
3 3 Battery Power Sup- BLU/ Less 10-14V Connect DC V 3 GND

ply RED than 1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output LGN - - Approx. Approx. Connect AC V 27 GND

(To Tacho Meter) 23Hz by 67Hz by
wave wave
form or form or
approx. approx.
6.3V 6.8V
28 28 No Connection - - - - - - - - -
29 29 Throttle Position Sig- - Approx. 140Hz by wave form (Idle: - - - -

nal To TCM (A16) Off duty 10% / WOT: Off duty 90%)
(AT Only)
30 30 Brake Switch 1 Sig- GRN Less Pedal is not stepped on: Less than Connect DC V 30 GND
nal than 1V 1V
Pedal is stepped on: 10-14V
31 31 Clutch Switch Signal YEL Less Pedal is not stepped on: 10-14V Connect DC V 31 GND
(MT Only) than 1V Pedal is stepped on: Less than 1V
32 32 No Connection - - - - - - - - -
33 33 A/C ON Signal Relay GRN/ Less A/C request switch is turned on: 10- Connect DC V 33 GND
YEL than 1V 14V
A/C request switch is turned off:
Less than 1V
34 34 No Connection - - - - - - - - -
35 35 To Data Link Con- YEL - - - - - - - -

nector No. 6 & Immo-
bilizer Control Unit
(ICU B8)
36 36 No Connection - - - - - - - - -
No. tion
37 37 No Connection - - - - - - - - -
38 38 Throttle Position GRN/ Less Less than 1V Approx. Connect DC V 38 49

Sensor (TPS) Out- ORG than 1V 0.5V
put Signal
39 39 Key Switch Input Sig- WHT Less 10-14V Connect DC V 39 GND

nal Via Engine Fuse than 1V
40 40 No Connection - - - - - - - - -
41 41 A/C Compressor WHT/ Less 10-14V A/C comp. is oper- Connect DC V 41 GND
Relay GRN than 1V ated: Less than 1V
A/C comp. is not oper-
ated: 10 - 14V
42 42 Check Engine Lamp GRN/ Less Lamp is turned on: Less than 1V Connect DC V 42 GND
YEL than 1V Lamp is turned off: 10-14V
43 43 Glow Lamp ORG/ Less Lamp is turned on: Less than 1V Connect DC V 43 GND
BLU than 1V Lamp is turned off: 10-14V
44 44 No Connection - - - - - - - - -
45 45 To Data Link Con- BLU Less 10-14V Connect DC V 45 GND

nector No. 6 than 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position BLK/ Idle: - - - Discon- Ohm 38 49

Sensor (TPS) GRN Approx. nect
Ground 0.4K
ohm /
WOT:
Approx.
4.0K
ohm
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 RED/ Less Approx. 5V Connect DC V 57 49

Sensor (TPS) Power GRN than 1V
Supply
58 58 ECM Relay BLU/ 10-14V Less than 1V Connect DC V 58 GND

BLK
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
No. tion
63 63 ECM Power Supply - Less 10-14V - DC V 63 GND

than 1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Sig- WHT/ Less Pedal is not stepped on: 10-14V Connect DC V 65 GND
nal BLK than 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed
20km/h
69 69 Idle Switch GRN/ Less Pedal is not stepped on: Less than Connect DC V 69 GND
BLK than 1V 1V
Pedal is stepped on: Approx. 5V
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- WHT/ Less Approx. 5V Connect DC V 82 93

sor (High Altitude BLU than 1V
Spec. Only)
83 83 Mass Air Flow (MAF) WHT/ Less Approx. 5V Connect DC V 83 92

Sensor Power Sup- RED than 1V
ply
84 84 Intake Air Tempera- BLK/ Less 0 deg. C: Approx. 3.6V / 20 deg. C: Connect DC V 84 92
ture (IAT) Sensor BLU than 1V Approx. 2.6V / 40 deg. C: Approx.
Signal 1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
85 85 Manifold Pressure RED/ Less - - - Connect DC V 85 93

Sensor (High Alti- BLU than 1V
tude Spec. Only)
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/ Less In neutral (A/T: P or N): Less than Connect DC V 87 GND
WHT than 1V 1V
Other than neutral (A/T: other than
P or N): 10-14V
88 88 Mass Air Flow (MAF) GRN/ Less Approx. Approx. Approx. Connect DC V 88 92
Sensor Signal RED than 1V 1V 1.8V 2.5V
No. tion
89 89 Engine Coolant Tem- GRY Less 0 deg. C: Approx. 4.4V / 20 deg. C: Connect DC V 89 93
perature (ECT) Sen- than 1V Approx. 3.8V / 40 deg. C: Approx.
sor Signal 2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98

47Hz by 134Hz by
wave wave
form form or
approx.
1.1V
91 91 CKP Sensor Output PNK - - Approx. Approx. Connect AC V 91 GND

To Pump Control Unit 47Hz by 134Hz by
(PSG) No.8 wave wave
form form or
approx.
0.7V
92 92 Mass Air Flow (MAF) BLK/ Continu- - - - Connect Ohm 92 GND

Sensor Ground RED ity with
ground
93 93 Engine Coolant Tem- BLK/ Continu- - - - Connect Ohm 93 GND

perature (ECT) Sen- PNK ity with
sor & Manifold ground
Pressure Sensor
Ground
94 94 Glow Relay BLK/ Less Glow system is operated: Less than Connect DC V 94 GND
RED than 1V 1V
Glow system is not operated: 10 -
14V
95 95 No Connection - - - - - - - - -
96 96 Turbocharger Waste- BRW/ - - Wave form - - - -

gate Control EVRV RED
97 97 EGR EVRV BLK/ - - Approx. 140Hz by - - - -

ORG wave form when
EVRV is operated
98 98 CKP Sensor Ground WHT Continu- - - - Connect Ohm 98 GND

ity with
ground
99 99 CAN (Controller Area BLU - - - - - - - -

Network) to PSG
No.1
100 100 CAN (Controller Area YEL - - - - - - - -

Network) to PSG
No.2
101 101 CKP Sensor Shield BLK Continu- - - - Connect Ohm 101 GND
Line ity with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - - - - - - - -

Off (MAB) Output
Signal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM & Rang (+) (-)
No. Box Color Off On Idle 2000rp PSG Con- e
No. m nection
1 99 CAN (Controller Area RED Continu- - - - Discon- Ohm 1 99

Network) to ECM ity nect (ECM
No.99 between )
ECM &
PSG
2 100 CAN (Controller Area WHT Continu- - - - Discon- Ohm 2 100

Network) to ECM ity nect (ECM
No.100 between )
ECM &
PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut ORG Continu- - - - Discon- Ohm 5 105

Off (MAB) Output ity nect (ECM
Signal to ECM between )
No.105 ECM &
PSG
6 - Ground BLK Continu- - - - Discon- Ohm 6 GND

ity with nect
ground
7 - Battery Power Sup- BLU/ Less 10-14V Discon- Ohm 7 GND

ply RED than 1V nect
8 91 CKP Sensor Output PNK Continu- - - - Discon- Ohm 8 91

ECM No.91 to Pump ity nect (ECM
Control Unit (PSG) between )
ECM &
PSG
9 - No Connection - - - - - - - - -
Crankshaft Position (CKP) Sensor Reference Wave Form Crankshaft Position (CKP) Sensor & TDC Output Signal
Reference Wave Form
CH1
0V
0V
CH2
0V
Measurement Terminal: 90(+) 98(-)

Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)
Measurement Scale: 20V/div 2ms/div
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div
Measurement Condition: Approximately 2000rpm
Engine Speed Output Signal Reference Wave Form Vehicle Speed Sensor (VSS) Reference Wave Form
0V 0V
Measurement Terminal: 27(+) GND(-) Measurement Terminal: 68(+) GND(-)

Measurement Scale: 5V/div 10ms/div Measurement Scale: 5V/div 50ms/div
Measurement Condition: Approximately 2000rpm Measurement Condition: Approximately 20km/h
GENERAL DESCRIPTION FOR ECM AND management system.
SENSORS • Engine Control Module (ECM)
• Pump Control Unit (PSG) = Pumpen Steuer Great
Engine Control Module (ECM) (German)
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
The engine control module (ECM) is located flower module (ECM) and the pump control unit (PSG) is
panel just under the passenger's seat. perfumed via a CAN-bus system. The abbreviation CAN
The fuel quantity and injection timing related functions stands for Controller Area Network. By having two
are controlled by the pump control unit (PSG). separate control modules, the high pressure solenoid
The engine control module (ECM) performs the valve. This prevents the discharge of any disturbing
following functions. signals.
• Control of the exhaust gas re-circulation (EGR)
The information exchange between the two control
• Control of the quick on start (QOS) glow control modules takes place via two means.
system
• Via analogue signal leads
• Control of the A/C compressor
• Via the CAN-bus
• Execution of the immobilizer function
The analogue signal leads are used to exchange the
Pump Control Unit (PSG) & Data Exchange following information.
Between Control Module
• Engine speed signal (ECM terminal 91)
• Pump Speed (ECM terminal 105)
• Fuel Cutoff solenoid valve signal (MAB signal) (ECM
terminal 105)
The engine speed signal is sent from the ECM to PSG
Self Diagnosis / Interface / Signal
To High Pressure Solenoid based on the input from the crank shaft position (CKP)
Cam Ring Rotational Angle sensor.
Engine Speed Fuel Temperature
Engine
Control Injection Timing The analogue CKP sensor signal is converted by the
Module
Accelerator Pedal (ECM) High Pressure
Solenoid Valve
ECM into a square wave signal.
Injection Quantity
Intake Air Temperature
Pump
Control Fuel Injection
The fuel cutoff solenoid valve signal is also referred to
Unit (Mechanical)
Response Signal
(PSG) as MAB signal.
Mass Air Flow
Additional Signal
MAB in this case, refers to the German abbreviation
Others Timing Device Magnet ventil ABschaltung that stands for high pressure
Additional Operations To Timing Control Valve (TCV)
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.
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
The following signals are exchanged via the CAN-bus:
From ECM to PSG
• Desired injection quantity
• Desired injection timing Characteristic of IAT Sensor -Reference-
100000
• Engine speed
Resistance (ohm) (Solid Line)

From PSG to ECM 10000
• Fuel temperature
1000
• Pump speed
• Cylinder identifier
100
• Control pulse (actual injection quantity + actual

injection timing)
10
• PSG status -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
Intake Air Temp. (deg. C) (Tech2 Reading)
Mass Air Flow (MAF) Sensor & Intake Air

Temperature (IAT) Sensor
The IAT sensor is a thermistor. A temperature changes

the resistance value. And it changes voltage. In other
words it measures a temperature value. Low air
temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is
hot.
1 2

(2) Mass Air Flow (MAF) & Intake Air Temperature
(IAT) Sensor
The mass air flow (MAF) sensor is part of the intake air
system.
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine.
The mass air flow (MAF) sensor uses a hot film element
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both exposed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
Throttle Position Sensor (TPS) Crankshaft Position (CKP) Sensor
1 2
1 2
(1) Throttle Position Sensor (TPS) (1) Crankshaft Position (CKP) Sensor
(2) Idle Switch (2) Fly wheel with sensor slot
The CKP sensor is located on top of the flywheel

housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
Characteristic of TPS -Reference-
4.5 and engine cylinder top dead center (TDC).
4
3.5
3
Output Voltage (V)
2.5
2
1.5
1
0.5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pedal Position (%) (Tech2 Reading
The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
delivery based on throttle valve angle.
Engine Coolant Temperature (ECT) Sensor Vehicle Speed Sensor (VSS)
2 1
M/T & A/T 4WD

(1) Engine Coolant Temperature (ECT) Sensor
(2) Thermo Unit for Water Temperature Gauge
Characteristic of ECT Sensor -Reference-
100000
10000
Resistance (ohm) (Solid Line)
1000
100
10
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Engine Coolant Temp (deg. C) (Tech2 Reading)
A/T 2WD
The VSS is a magnet rotated by the transmission output

The ECT sensor is a thermistor. A temperature changes
shaft. The VSS uses a hall element. It interacts with the
the resistance value. And it changes voltage. In other
magnetic field treated by the rotating magnet. It outputs
words it measures a temperature value. It is installed on
pulse signal. The 12 volts operating supply from the
the coolant stream. Low coolant temperature produces
meter fuse.
a high resistance.
The engine control module (ECM) calculates the vehicle
The ECM supplies 5 volts signal to the ECT sensor
speed by VSS.
The 2WD model fitted with automatic transmission,
The signal voltage will be high when the engine
vehicle speed sensor signal is transmitted to from the
temperature is cold, and it will be low when the engine
TCM to the ECM via vehicle speed meter.
temperature is hot.
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION)
4 5 6
(1) To EGR Valve

(2) From Vacuum Pump
(1) EGR Valve (3) EGR EVRV
(2) EGR Cooler (Euro 3) / EGR Pipe (Except Euro (4) EGR Cooler
3) (5) Thermo Valve
(3) Intercooler (6) EGR Valve
(4) Intake Manifold
(5) Exhaust Manifold The 4JA1-TC & 4JH1-TC engine with Euro 3 regulation
(6) Waste Gate is equipped with the EGR cooler. The EGR cooler
(7) Fresh Air reduces the temperature of the air being drawn into the
(8) Exhaust Gas engine and the combustion temperature. This results in
(9) Turbocharger reducing nitrogen oxide (Nox) emissions. The 4JH1-TC
engine except Euro 3 regulation, it does not have EGR
cooler. It has steel EGR pipe instead of the cooler.
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the following
inputs.
• Engine speed
• Injection quantity
• Mass air flow
• Intake air temperature
• Coolant temperature
• Barometric pressure
1 2 3
7.1ms
Time
0.7ms
Off duty 10% =EGR Pulse Ratio 10%
7.1ms
Time
6.4ms
Off duty 90% =EGR Pulse Ratio 90%
The EVRV is shaped to control vacuum applied to the

diaphragm chamber of the EGR valve based on duty
signal sent from the ECM. The duty ratio is the time that
the EVRV is opened to one cooperate EVRV operating
cycle. A duty ratio change of 90% to 10 % is EGR
amount control.
GENERAL DESCRIPTION FOR INJECTION Cross-section View
PUMP
Outline
(1) Drive Shaft

(2) Feed Pump
(3) Pump Camshaft Speed Sensor
(1) Drive Shaft (4) Pump Control Unit (PSG)
(2) Feed Pump (5) Distributor Head
(3) Pump Camshaft Speed Sensor (6) Constant Pressure Valve (CPV) Holder
(4) Pump Control Unit (PSG) (7) High Pressure Solenoid Valve
(5) Distributor Head (8) Constant Pressure Valve (CPV)
(6) Constant Pressure Valve (CPV) Holder (9) Timing Control Valve (TCV)
(7) High Pressure Solenoid Valve (10) Timer
(8) Constant Pressure Valve (CPV) (11) Radial Plunger High Pressure Pump
(9) Timing Control Valve (TCV)
(10) Timer
(11) Radial Plunger High Pressure Pump
Instead of the previous face cam type, the radial plunger

distributor type injection pump utilizes a cam ring to
enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
smoke, low noise, high output and clear exhaust
emissions.
Low Pressure Fuel Circuit
(1) Rotor Shaft

(2) Radial Plunger (1) Fuel Suction
(3) High Pressure Passage (2) Regulating Valve
(4) Low Pressure Inlet (3) Overflow Valve
(5) Distributor Slit (4) Feed Pump
(6) Valve Needle (5) To Fuel Tank
(7) Barrel
(8) Annular Passage The low pressure fuel circuit must supply sufficient fuel
(9) Fuel Return to the high pressure fuel circuit. The main components
are the feed pump, the regulating valve and the
(10) High Pressure Solenoid Valve
overflow valve.
(11) High Pressure Outlet
(12) Diaphram Chamber
(13) Accumulator Diaphram
High Pressure Fuel Circuit Pump Camshaft Speed Sensor
(1) Pump Control Unit (PSG) (1) Pump Camshaft Speed Sensor
(2) Distributor Head (2) Sensor Wheel
(3) High Pressure Solenoid Valve (3) Pump Camshaft Speed Sensor Retaining Ring
(4) Constant Pressure Valve (CPV) (4) Flexible Connector Harness
(5) Radial Plunger High Pressure Pump (5) Drive Shaft
In addition high pressure generating device, the high When the drive shaft rotates, the pump camshaft speed
pressure circuit also consists of fuel piping, and devices sensor receives signal form the sensor wheel, and an
to set the beginning of injection and fuel injection electric pulse is sent through the flexible connecting
quantity. harness to the pump control unit (PSG).
From these signals the pump control unit (PSG) can
The main components are as follows. determine the average pump speed and the momentary
• High pressure generation: Radial Plunger High pump speed.
Pressure Pump The pump camshaft speed sensor is mounted to the
cam ring. Thus, the relationship between the cam ring
• Fuel distribution: Distributor Head
and the pump camshaft speed sensor signal is
• Beginning of injection timing: Timing Device constant.
• Prevention of secondary injection: Constant Pressure
Valve (CPV)
The pump camshaft speed sensor signal is utilized for High Pressure Solenoid Valve
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.
-Cam Ring Angle

Pump Pump
Sensor -Pump Speed
Camshaft Control
Wheel -Timer Position
Speed Unit
Sensor (PSG)
(1) Valve Needle

(2) Magnet Anchor
(3) Coil
(4) High Pressure Passage
The pump camshaft sensor signal has a tooth gap, and Fuel injection quantity control is performed from the
the crankshaft position (CKP) sensor on the flywheel beginning of pressure delivery at the beginning of cam
housing is used as a reference signal of engine top lift until the high pressure solenoid valve opens at the
dead center (TDC) for the start timing of fuel delivery or end of pressure delivery.
injection which is to be set. This interval is called the pressure delivery interval.
Accordingly, the interval that the high pressure solenoid
valve is closed determines the fuel injection quantity
(high pressure fuel supply ends when the high pressure
solenoid valve opens).
When current from the pump control unit (PSG) flows to Timing Control Valve (TCV)
the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
(1) Cam Ring

(2) Servo Valve
(3) Timer Piston
(4) Outlet
(5) Feed Pump
(6) Inlet
(7) Fuel Suction
(8) Ball Pin
(9) Annular Chamber
(10) Hydraulic Stopper
(1) Valve Needle (11) Return Passage
(2) Coil (12) Timing Control Valve (TCV)
When the fuel injection quantity demanded by the The pressure of the fuel fed from the feed pump is
engine is reached, the current to the coil is cut and the adjusted in accordance with speed by the regulating
valve needle re-opens the valve seat. valve. This delivery pressure acts on the hydraulic
As a result of this, a path is opened for the fuel in the stopper's annular chamber as control pressure.
high pressure passage to the low pressure circuit and The chamber pressure of the annular chamber is
the pressure decreases. With a decrease in injection controlled by the timing control valve (TCV).
pressure the nozzle closes and injection ends. The timing plunger is connected to the cam ring by a
ball pin. Axial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing.
Engine Load
Engine Pump Timing
Control Control Control
Engine Speed Module Unit Valve
(ECM) (PSG) (TCV)
Engine Coolant
Temperature
Pump Camshaft
Speed Sensor
(1) Coil
The engine control module (ECM) contains
(2) From Annular Chamber characteristic maps of the start of injection,
(3) To Feed Pump corresponding to engine operating conditions (engine
(4) Orifice load, engine speed and engine coolant temperature).
(5) Valve Needle The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
When control current flows to the timing control valve injection timing. If there is a difference, the timing
(TCV) coil, the valve needle opens and the fuel annular control valve (TCV) is controlled by the duty ratio. (The
chamber flows through the orifice to the feed pump inlet. actual start of injection timing is determined from the
Consequently, the pressure of the annular chamber pump camshaft speed sensor.)
decreases and the hydraulic stopper is moved to the
retard side.
The timing control valve (TCV) acts as a variable

throttle, using the rapid opening and closing (cycling) of
the valve needle in the timing control valve (TCV).
At normal operation, the TCV controls the pressure
acting on the annular chamber so that the hydraulic
stopper cam move to any position, from the retard
position to the advance position. At this time, the duty
ratio is set by the pump control unit (PSG).
Duty ratio is the ratio of the time that the timing control
valve (TCV) is opened to one complete timing control
valve (TCV) operating cycle. A duty ratio change of
100% to 0% is an advance in injection timing. (The
VP44 displays an ON duty ratio.)
ISUZU Strategy Based Diagnostics
Overview You have maximum efficiency in diagnosis when you

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

• Vehicle road tests
As you follow a diagnostic plan, every box on the
• Complaint check sheet
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking • Contact with the customer
optimizes your diagnosis in the following ways:
• Improves your understanding and definition of the 2. Perform Preliminary Checks
customer complaint
NOTE: An estimated 10 percent of successful vehicle
• Saves time by avoiding testing and/or replacing good repairs are diagnosed with this step!
parts
• Allows you to look at the problem from different What you should do
perspectives
You perform preliminary checks for several reasons:
• Guides you to determine what level of understanding
about system operation is needed: • To detect if the cause of the complaint is VISUALLY
OBVIOUS
– Owner’s manual level
• To identify parts of the system that work correctly
– Service manual level
• To accumulate enough data to correctly and
– In-depth (engineering) level
accurately search for a ISUZU Service Bulletin on
– Owner’s manual level ISUZU Web site.
– Service manual level The initial checks may vary depending on the
– In-depth (engineering) level complexity of the system and may include the following
actions:
• Operate the suspect system
1. Verify the Complaint
• Make a visual inspection of harness routing and
What you should do accessible/visible power and ground circuits
• Check for blown fuses
To verify the customer complaint, you need to know the
• Make a visual inspection for separated connectors
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the • Make a visual inspection of connectors (includes
system. checking terminals for damage and tightness)
The following information will help you verify the • Check for any DTCs stored by the on-board
complaint: computers
• WHAT the vehicle model/options are • Sense unusual noises, smells, vibrations or
• WHAT aftermarket and dealer-installed accessories movements
exist • Investigate the vehicle service history (call other
• WHAT related system(s) operate properly dealerships, if appropriate)
• WHEN the problem occurs
What resources you should use
• WHERE the problem occurs
• HOW the problem occurs Whenever appropriate, you should use the following
resources for assistance in performing preliminary
• HOW LONG the condition has existed (and if the
checks:
system ever worked correctly)
• Tech II or other technical equipment for viewing DTCs
• HOW OFTEN the problem occurs
• Service manual information:
• Whether the severity of the problem has increased,
decreased or stayed the same – Component locations
– Harness routing
What resources you should use – Wiring schematics
Whenever possible, you should use the following – Procedures for viewing DTCs
resources to assist you in verifying the complaint: • Dealership service history file
• Service manual Theory or Circuit Description • Vehicle road test
sections • Identical vehicle or system for comparison
• Service manual “System Performance Check”
• Owner manual operational description
• Technician experience
• Identical vehicle for comparison
3. Check Bulletins and to the customer complaint.

Troubleshooting Hints What resources you should use
NOTE: As estimated 30 percent of successful vehicle Whenever appropriate, you should use the following
repairs are diagnosed with this step! resources to perform service manual diagnostic
procedures:
What you should do • Service manual
You should have enough information gained from • Technical equipment (for analyzing diagnostic data)
preliminary checks to accurately search for a bulletin • Digital multimeter and circuit testing tools
and other related service information. Some service
manual sections provide troubleshooting hints that • Essential and special tools
match symptoms with specific complaints.
5c. Technician Self Diagnoses
When there is no DTC stored and no matching
You should use the following resources for assistance in symptom for the condition identified in the service
checking for bulletins and troubleshooting hints: manual, you must begin with a thorough understanding
• Printed bulletins of how the system(s) operates. Efficient use of the
service manual combined with you experience and a
• Access ISUZU Bulletin Web site.
good process of elimination will result in accurate
• Videotapes diagnosis of the condition.
• Service manual
What you should do
4. Perform Service Manual
Step 1: Identify and understand the suspect
Diagnostic Checks circuit(s)
Having completed steps 1 through 4 of the Strategy
What you should do Based Diagnostics chart, you should have enough
The “System Checks” in most service manual sections information to identify the system(s) or sub-system(s)
and in most cells of section 8A (electrical) provide you involved. Using the service manual, you should
with: determine and investigate the following circuit
• A systematic approach to narrowing down the characteristics:
possible causes of a system fault • Electrical:
• Direction to specific diagnostic procedures in the – How is the circuit powered (power distribution
service manual charts and/or fuse block details)?
• Assistance to identify what systems work correctly – How is the circuit grounded (ground distribution
charts)?
What resources you should use – How is the circuit controlled or sensed (theory of
Whenever possible, you should use the following operation):
resources to perform service manual checks: – If it is a switched circuit, is it normally open or
• Service manual normally closed?
• Technical equipment (for viewing DTCs and – Is the power switched or is the ground
analyzing data) switched?
• Digital multimeter and circuit testing tools – Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
• Other tools as needed
– Is it a signal generating device (MAF sensor of
VSS, for example)?
5a and 5b. Perform Service Manual – Does it rely on some mechanical/vacuum
Diagnostic Procedures device to operate?
NOTE: An estimated 40 percent of successful vehicle • Physical:
repairs are diagnosed with these steps! – Where are the circuit components (component
locators and wire harness routing diagrams):
What you should do – Are there areas where wires could be chafed
When directed by service manual diagnostic checks, or pinched (brackets or frames)?
you must then carefully and accurately perform the – Are there areas subjected to extreme
steps of diagnostic procedures to locate the fault related temperatures?
– Are there areas subjected to vibration or at the component
movement (engine, transmission or • If a number of components do no operate, begin tests
suspension)? at the area of commonality (such as power sources,
– Are there areas exposed to moisture, road salt ground circuits, switches or major connectors)
or other corrosives (battery acid, oil or other
fluids)? What resources you should use
– Are there common mounting areas with other Whenever appropriate, you should use the following
systems/components? resources to assist in the diagnostic process:
– Have previous repairs been performed to wiring, • Service manual
connectors, components or mounting areas
• Technical equipment (for data analysis)
(causing pinched wires between panels and
drivetrain or suspension components without • Experience
causing and immediate problem)? • Technical Assistance
– Does the vehicle have aftermarket or dealer- • Circuit testing tools
installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem

5d. Intermittent Diagnosis
At this point, you should have a good idea of what could By definition, an intermittent problem is one that does
cause the present condition, as well as could not cause not occur continuously and will occur when certain
the condition. Actions to take include the following: conditions are met. All these conditions, however, may
• Divide (and separate, where possible) the system or not be obvious or currently known. Generally,
circuit into smaller sections intermittents are caused by:
• Confine the problem to a smaller area of the vehicle • Faulty electrical connections and wiring
(start with main harness connections while removing • Malfunctioning components (such as sticking relays,
panels and trim as necessary in order to eliminate solenoids, etc.)
large vehicle sections from further investigation) • EMI/RFI (Electromagnetic/radio frequency
• For two or more circuits that do not share a common interference)
power or ground, concentrate on areas where • Aftermarket equipment
harnesses are routed together or connectors are Intermittent diagnosis requires careful analysis of
shared (refer to the following hints) suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
Hints interpret customer complaints and simulating all
Though the symptoms may vary, basic electrical failures external and internal system conditions to duplicate the
are generally caused by: problem.
• Loose connections:
What you should do
– Open/high resistance in terminals, splices,
connectors or grounds
Step 1: Acquire information
• Incorrect connector/harness routing (usually in new
A thorough and comprehensive customer check sheet
vehicles or after a repair has been made):
is critical to intermittent problem diagnosis. You should
– Open/high resistance in terminals, splices, require this, since it will dictate the diagnostic starting
connectors of grounds point. The vehicle service history file is another
• Corrosion and wire damage: source for accumulating information about the
– Open/high resistance in terminals, splices, complaint.
connectors of grounds
Step 2: Analyze the intermittent problem
• Component failure:
Analyze the customer check sheet and service history
– Opens/short and high resistance in relays,
file to determine conditions relevant to the suspect
modules, switches or loads
system(s).
• Aftermarket equipment affecting normal operation of Using service manual information, you must identify,
other systems trace and locate all electrical circuits related to the
You may isolate circuits by: malfunctioning system(s). If there is more than one
• Unplugging connectors or removing a fuse to system failure, you should identify, trace and locate
separate one part of the circuit from another part areas of commonality shared by the suspect circuits.
• Operating shared circuits and eliminating those that
function normally from the suspect circuit
• If only one component fails to operate, begin testing
Step 3: Simulate the symptom and isolate the For parts and sensors, apply slight vibration to the part
problem with a light tap of the finger while monitoring the system
Simulate the symptom and isolate the system by for a malfunction.
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/ 2. Heat
systems to isolate the problem symptom. Begin with the This method is important when the complaint suggests
most logical circuit/component. that the problem occurs in a heated environment. Apply
Isolate the circuit by dividing the suspect system into moderate heat to the component with a hair drier or
simpler circuits. Next, confine the problem into a smaller similar tool while monitoring the system for a
area of the system. Begin at the most logical point (or malfunction.
point of easiest access) and thoroughly check the CAUTION: Care must be take to avoid overheating
isolated circuit for the fault, using basic circuit tests. the component.
Hints 3. Water and Moisture

You can isolate a circuit by: This method may be used when the complaint suggests
• Unplugging connectors or removing a fuse to that the malfunction occurs on a rainy day or under
separate one part of the circuit from another conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
• If only component fails to operate, begin testing the
CAUTION: Care must be take to avoid directly
component
exposing electrical connections to water.
• If a number of components do not operate, begin test
at areas of commonality (such as power sources, 4. Electrical loads
ground circuits, switches, main connectors or major
This method involves turning systems ON (such as the
components)
blower, lights or rear window defogger) to create a load
• Substitute a known good part from the parts on the vehicle electrical system at the same time you
department or the vehicle system are monitoring the suspect circuit/component.
• Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for 5e. Vehicle Operates as Designed
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent This condition refers to instances where a system
diagnosis. Follow procedures for basic circuit testing in operating as designed is perceived to be unsatisfactory
service manual section 8A. or undesirable. In general, this is due to:
• A lack of understanding by the customer
What resources you should use • A conflict between customer expectations and
Whenever appropriate, you should use the following vehicle design intent
resources to assist in the diagnostic process: • A system performance that is unacceptable to the
• Service manual customer
• Bulletins
What you should do
• Digital multimeter (with a MIN/MAX feature)
• Tech II and Tech II upload function You can verify that a system is operating as designed
by:
• Circuit testing tools (including connector kits/
harnesses and jumper wires) • Reviewing service manual functional/diagnostic
checks
• Experience
• Examining bulletins and other service information for
• Intermittent problem solving simulation methods
supplementary information
• Customer complaint check sheet
• Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
Symptom Simulation Tests or a conflict between customer expectation and system
operation, you should explain the system operation to
1. Vibration the customer.
This method is useful when the customer complaint If the complaint is due to a case of unsatisfactory
analysis indicates that the problem occurs when the system performance, you should contact Technical
vehicle/system undergoes some form of vibration. Assistance for the latest information.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint What resources you should use
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful. Whenever possible, you should use the following
resources to facilitate the diagnostic process:
• Vehicle service information (service manual, etc.)
• ISUZU field support
• Experience
• Identical vehicle or system for comparison
6. Re-examine the complaint

When you do not successfully find/isolate the problem
after executing a diagnostic path, you should re-
examine the complaint.
What you should do

In this case, you will need to backtrack and review
information accumulated from step 1 through 4 of
Strategy Based Diagnostics. You also should repeat any
procedures that require additional attention.
A previous path may be eliminated from consideration
only if you are certain that all steps were executed as
directed. You must then select another diagnostic path
(step 5a, 5b, 5c or 5d). If all possible options have been
explored, you may call or seek ISUZU field support.

Whenever possible, you should use the following
resources to facilitate the diagnostic process:
• Service manual
• Accumulated information form a previous diagnostic
path
• Service information and publications
• ISUZU field support
7. Repair and Verify Fix

What you should do
After you have located the cause of the problem, you
must execute a repair by following recommended
service manual procedures.
When the repair is completed, you should verify the fix
by performing the system checks under the conditions
listed in the customer complaint.
If applicable, you should carry out preventive measures
to avoid a repeat complaint.

Whenever possible, you should use the following
resources to facilitate the repair process:
• Electrical repair procedures
• Service manual information and publications
GENERAL SERVICE INFORMATION ON-BOARD DIAGNOSTIC (OBD)

Serviceability Issues On-Board Diagnostic (Self Diagnosis
System) Tests
Non-OEM Parts
A diagnostic test is a series of steps, the result of which
All of the OBD diagnostics have been calibrated to run
is a pass or fail reported to the diagnostic executive.
with OEM parts. Accordingly, if commercially sold
When a diagnostic test reports a pass result, the
sensor or switch is installed, it makes a wrong diagnosis
diagnostic executive records the following data:
and turns on the check engine lamp.
Aftermarket electronics, such as cellular phones, • The diagnostic test has been completed since the
stereos, and anti-theft devices, may radiate EMI into the last ignition cycle.
control system if they are improperly installed. This may • The diagnostic test has passed during the current
cause a false sensor reading and turn on the check ignition cycle.
engine lamp. • The fault identified by the diagnostic test is not
currently active.
Poor Vehicle Maintenance When a diagnostic test reports a fail result, the
The sensitivity of OBD diagnostics will cause the check diagnostic executive records the following data:
engine lamp to turn on if the vehicle is not maintained • The diagnostic test has been completed since the
properly. Restricted oil filters, fuel filters, and crankcase last ignition cycle.
deposits due to lack of oil changes or improper oil
• The fault identified by the diagnostic test is currently
viscosity can trigger actual vehicle faults that were not
active.
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle • The fault has been active during this ignition cycle.
fault”, but with the sensitivity of OBD diagnostics, • The operating conditions at the time of the failure.
vehicle maintenance schedules must be more closely
followed. The Diagnostic Executive
The Diagnostic Executive is a unique segment of
Related System Faults
software which is designed to coordinate and prioritize
Many of the OBD system diagnostics will not run if the the diagnostic procedures as well as define the protocol
ECM detects a fault on a related system or component. for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
Visual/Physical Engine Compartment follows:
Inspection • Commanding the check engine lamp on and off
Perform a careful visual and physical engine • DTC logging and clearing
compartment inspection when performing any • Current status information on each diagnostic
diagnostic procedure or diagnosing the cause of an
emission test failure. This can often lead to repairing a Diagnostic Information
problem without further steps. Use the following
The diagnostic charts and functional checks are
guidelines when performing a visual/physical
designed to locate a faulty circuit or component through
inspection:
a process of logical decisions. The charts are prepared
• Inspect all vacuum hoses for punches, cuts, with the requirement that the vehicle functioned
disconnects, and correct routing. correctly at the time of assembly and that there are not
• Inspect hoses that are difficult to see behind other multiple faults present.
components. There is a continuous self-diagnosis on certain control
• Inspect all wires in the engine compartment for functions. This diagnostic capability is complemented
proper connections, burned or chafed spots, pinched by the diagnostic procedures contained in this manual.
wires, contact with sharp edges or contact with hot The language of communicating the source of the
exhaust manifolds or pipes. malfunction is a system of diagnostic trouble codes.
When a malfunction is detected by the control module, a
Basic Knowledge of Tools Required diagnostic trouble code is set and the check engine
lamp is illuminated.
NOTE: Lack of basic knowledge of this powertrain
when performing diagnostic procedures could result in Check Engine Lamp
an incorrect diagnosis or damage to powertrain The check engine lamp looks the same as the check
components. Do not attempt to diagnose a powertrain engine lamp you are already familiar with, the “Check
problem without this basic knowledge. Engine” lamp.
A basic understanding of hand tools is necessary to Basically, the check engine lamp is turned on when the
effectively use this section of the Service Manual.
ECM detects a DTC that will impact the vehicle Reading Flash Diagnostic Trouble Codes
emissions.
The provision for communicating with the Engine
• When the check engine lamp remains “ON” while the Control Module (ECM) is the Data Link Connector
engine is running, or when a malfunction is (DLC). The DLC is located in the front console box. It is
suspected due to a driveability or emissions problem, used in the assembly plant to receive information in
a Powertrain On-Board Diagnostic (OBD) System checking that the engine is operating properly before it
Check must be performed. The procedures for these leaves the plant.
checks are given in On-Board Diagnostic (OBD) The diagnostic trouble code(s) (DTCs) stored in the
System Check. These checks will expose faults ECM’s memory can be read either through a hand-held
which may not be detected if other diagnostics are diagnostic scanner plugged into the DLC or by counting
performed first. the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
Data Link Connector (DLC)
DLC terminal “6” (diagnostic request) is pulled “Low”
The provision for communication with the contorl (grounded) by jumping to DLC terminal “4 or 5”, which is
module is the Data Link Connector (DLC). It is located a ground wire.
behind the lower front instrument panel. The DLC is This will signal the ECM that you want to “flash” DTC(s),
used to connect to a Tech2. Some common uses of the if any are present. Once terminals “4 or 5” and “6” have
Tech2 are listed below: been connected, the ignition switch must be moved to
• Identifying stored Diagnostic Trouble Codes (DTCs). the “ON” position, with the engine not running.
• Clearing DTCs. The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
• Reading serial data.
stored in the ECM’s memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a

Tech 2
The procedure for reading diagnostic trouble code(s) is
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes

To clear Diagnostic Trouble Codes (DTCs), use the
Tech2 “clear DTCs” or “clear information” function.
When clearing DTCs follow instructions supplied by the
Tech2 manufacturer.
Verifying Vehicle Repair History DTC

Verification of vehicle repair will be more History DTC can be candeled after 40 cycle driving with
comprehensive for vehicles with OBD system no defect. Or history code can be deleted by Tech 2
diagnostic. Following a repair, the technician should “Clear DTCs” function.
perform the following steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the
Fail Records.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps is very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
DIAGNOSIS WITH Tech 2 • Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
If no codes are set:
• Connect the DLC cable (4) to the Tech 2 (5).
• Refer to F1: Data Display and identify the electrical
faults that are not indicated by trouble code. • Connect the SAE 16/19 adapter (3) to the data
link connector of the vehicle.
• Refer to “SYMPTOM DIAGNOSIS”.
If codes are set:

1. Record all trouble codes displayed by Tech 2 and
check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty
status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is
intermittent. In this case, refer to “DIAGNOSIS
AIDS”.
6. If a code is present, refer to DTC Chart for
diagnosis.
7. Check trouble codes again using the Tech 2.
Tech 2 CONNECTION
• Turn the key switch of the vehicle ON and press
the “PWR” key of the Tech 2.
• Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.
Tech 2 scan tool is used to electrically diagnose the

automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Tech 2.
1. Configuration of Tech 2
• Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
• SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
• Check the key switch is turn OFF.
• Insert the PCMCIA card (1) into the Tech 2 (5).
TECH 2 OPERATING FLOW CART (START UP)
Vehicle Identification
(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Press (ENTER) to Continue
Press “ENTER” key. Select “(TF/UC)”.

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

Vehicle Identification Vehicle Identification
(3) 2003 4JH1-TC Bosch
(2) 2002 4JA1-TC Bosch
(1) 2001 4JH1-T Denso
(Y) 2000 3.5L V6 6VE1 Hitachi
(X) 1999 AW30-40LE
(W) 1998 A/T JR405E
Select “(3) 2003”or later. Select “4JA1-TC Bosch” or “4JH1-TC Bosch”.

Select “4JA1-TC Bosch” or “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.
F0: Diagnostic Trouble Codes F1: Data Display

The purpose of the “Data Display” mode is to
F0: Read DTC Infor As Stored By ECU
continuously monitor data parameters.
F1: Clear DTC Information The current actual values of all important sensors and
F1: Data Display signals in the system are display through F1 mode.
See the “Typical Scan Data” section.
F2: Snapshot F2: Snapshot

“Snapshot” allows you to focus on making the condition
occur, rather than trying to view all of the data in
F3: Miscellaneous Test
anticipation of the fault.
F0: Lamps The snapshot will collect parameter information around
F0: Glow Time Telltale Test a trigger point that you select.
F1: Relays
F3: Miscellaneous Test:
F0: Glow Time Relay Test The purpose of “Miscellaneous Test” mode is to check
F2: Solenoids for correct operation of electronic system actuators.
F0: EGR Solenoid Test
F4: Programming (Factory Use Only)
F3: Engine Speed (RPM) Control The purpose of “Programming” is to program VIN in the
ECM and lock the programmed data.
F4: Programming
F0: Program VIN
F1: Lock ECU
F0: Diagnostic Trouble Code

The purpose of the “Diagnostic Trouble Codes” mode is
to display stored trouble code in the ECM.
When “Clear DTC Information” is selected, a “Clear
DTC Information”, warning screen appears.
This screen informs you that by cleaning DTC's “all
stored DTC information in the ECM will be erased”.
After clearing codes, confirm system operation by test
driving the vehicle.
Symptom Code:
Read DTC Infor As Stored By ECU
P0100 Present
(7) Mass Air Flow (MAF) Sensor
DTC No. Voltage Supply Circuit High Input
Symptom Code
This number or alphabet means identification of the

malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JA1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

1 Engine Speed rpm 730 1475 - 1975 - The engine speed is measured by ECM from the CKP
1525 2025 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 345 - 385 725 - 775 975 - 1025 This displays injection pump speed. The injection speed is
measured by ECM from the pump cam sensor.
4 Accelerator Position % 0 4-6 6-8 Throttle position operating angle is measured by the ECM
Sensor Signal from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Active Active Inactive 0V This displays operating status of the idle switch. This
Inactive 0V should display "Active" until the accelerator position nearly
4 - 5%.
6 Mass Air Flow mg/strk 380 - 420 360 - 400 380 - 420 This displays calculated intake air volume for one cylinder
Sensor stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
7 Desired Mass Air mg/strk 350 350 350 - 370 This displays desired intake air volume for one cylinder
Flow stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
8 Barometric Pressure hpa Depends Depends Depends The barometric pressure is measured by ECM from the
on altitude on altitude on altitude sensor in the ECM. This data is changing by altitude.
9 Desired Injection mg/stk 8 - 10 6 - 10 7 - 10 This displays desired value from the ECM. The ECM
Quantity compensates for fuel rate to basic rate.
10 Injection Quantity mg/stk 8 - 10 5 - 10 5-9 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 deg. CA 2-4 2- 5 3-5 This displays desired injection timing from the ECM. The
Start ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12 Actual Injection Start deg. CA 2-4 2-5 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. 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
F 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. Depends Depends Depends The FT is measured by PSG from FT sensor. This data is
F on fuel on fuel on fuel changing by fuel temperature.
temp. temp. temp.
15 Intake Air deg. C / deg. Depends Depends Depends The IAT is measured by ECM from IAT sensor output
Temperature F on ambient on ambient on ambient voltage. This data is changing by intake air temperature.
temp. temp. temp.
16 Ignition Status On12V/ On 12V On 12V On 12V This displays the key switch status indicated by the ECM
Off0V with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
17 Brake Switch 1 Active/ Inactive Inactive Inactive This displays operating status of the brake switch. This
Inactive should display "Active" when the brake pedal is stepped
on.
Tech 2 Parameter Units Idle 1500rpm 2000rpm Description
on.
19 Clutch Switch Active/ Inactive Inactive Inactive This displays operating status of the clutch switch. This
Inactive 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. This
should display "On" when the gear position is neutral.
21 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display "Active 12V" when the air conditioner switch
is switched on.
22 Diagnostic Request Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Inactive 12V 12V 12V 12V display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 14 10 - 14 10 - 14 This displays the system voltage measured by the ECM at
ignition feed.
24 Main Relay Active/ Active Active Active This displays operating status for the ECM main relay. This
Inactive should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display "Inactive 12V" when the engine is warm
upped.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
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 rpm 730 730 730 The desired engine idle speed that the ECM commanding.
Speed The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor. This
Inactive 12V 12V 12V 12V should display "Active 0V" when the compressor relay is
operated.
30 Immobilizer Active/ Inactive Inactive Inactive This should display "Inactive" when the immobilizer is
Inactive correctly operated.
31 Immobilizer Signal Received/ Not Not Not This should display "Not Received" when the immobilizer is
Not Received Received Received not activated.
Received
32 Immobilizer Function Yes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
Programmed programmed.
33 EGR Pulse Ratio % 70 70 70 This displays the duty signal from the ECM to control the
(Exhaust Gas EGR flow amount.
Recirculation)
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition
1 Engine Speed rpm 675 - 725 1475 - 1975 - The engine speed is measured by ECM from the CKP
1525 2025 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 pump speed. The injection speed is
measured by ECM from the pump cam sensor.
4 Accelerator Position % 0 3-5 5-7 Throttle position operating angle is measured by the ECM
Sensor Signal from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Active Active/ Inactive 0V This displays operating status of the idle switch. This
Inactive 0V Inactive 0V should display "Active" until the accelerator position nearly
4 - 5%.
6 Mass Air Flow mg/strk 420 - 490 380 - 460 410 - 480 This displays calculated intake air volume for one cylinder
Sensor stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
7 Desired Mass Air mg/strk 430 - 470 380 - 420 410 - 470 This displays desired intake air volume for one cylinder
Flow stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
8 Barometric Pressure hpa Depends Depends Depends The barometric pressure is measured by ECM from the
on altitude on altitude on altitude sensor in the ECM. This data is changing by altitude.
9 Desired Injection mg/stk 6 - 10 6 - 10 7 - 11 This displays desired value from the ECM. The ECM
Quantity 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 deg. CA 1-3 2-4 3-5 This displays desired injection timing from the ECM. The
Start 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. 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
F 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. Depends Depends Depends The FT is measured by PSG from FT sensor. This data is
F on fuel on fuel on fuel changing by fuel temperature.
temp. temp. temp.
15 Intake Air deg. C / deg. Depends Depends Depends The IAT is measured by ECM from IAT sensor output
Temperature F on ambient on ambient on ambient voltage. This data is changing by intake air temperature.
temp. temp. temp.
16 Ignition Status On12V/ On 12V On 12V On 12V This displays the key switch status indicated by the ECM
Off0V with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
on.
Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition
on.
19 Clutch Switch (M/T Active/ Inactive Inactive Inactive This displays operating status of the clutch switch. This
Only) Inactive 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. This
should display "On" when the gear position is neutral (M/T)
or P, N position (A/T).
21 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display "Active 12V" when the air conditioner switch
is switched on.
22 Diagnostic Request Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Inactive 12V 12V 12V 12V 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/ Active Active Active This displays operating status for the ECM main relay. This
Inactive should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display "Inactive 12V" when the engine is warm
upped.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
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 rpm 700 700 700 The desired engine idle speed that the ECM commanding.
Speed The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor. This
Inactive 12V 12V 12V 12V should display "Active 0V" when the compressor relay is
operated.
30 Immobilizer Active/ Inactive Inactive Inactive This should display "Inactive" when the immobilizer is
Inactive correctly operated.
31 Immobilizer Signal Received/ Not Not Not This should display "Not Received" when the immobilizer is
Not Received Received Received not activated.
Received
32 Immobilizer Function Yes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
Programmed programmed.
33 EGR Pulse Ratio % 85 - 90 85 - 90 85 - 90 This displays the duty signal from the ECM to control the
(Exhaust Gas EGR flow amount.
Recirculation)
MISCELLANEOUS TEST F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
The state of each circuit can be tested by using increases 50rpm-by-50rpm up to 1200rpm.
miscellaneous test menus. Especially when DTC The circuit is correct if engine speed is changed in
cannot be detected, a faulty circuit can be diagnosed by accordance with this operation.
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
Engine Speed (RPM) Control
these menus could help discriminate between a
mechanical trouble and an electrical trouble. Engine Speed 850 rpm
Connect Tech 2 and select "Powertrain", "4JA1-TC Desired Idle Speed 850 rpm
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
Injection Quantity 7.5 mg/ strk
F0: Lamps
F0: Glow Time Telltale Test
• Press "Increase" key.
When the Tech 2 is operated, "Glow Time Indicator
Then, Desired Idle speed is increases
Lamp" is turned on or off.
50rpm-by-50rpm up to 1200rpm. Engine speed is
The circuit is correct if the "Glow Time Indicator Lamp"
also
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
EGR Solenoid Test

Desired Mass Air Flow 470 mg/strk
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%
Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
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 By analyzing these data in various methods, trouble
snapshot data by using TIS2000 [Snapshot Upload] conditions can be checked.
function is described below. Snapshot data is displayed by executing the three steps
Snapshot data can be displayed with [Snapshot Upload] below shown:
function included in TIS2000.
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.

After recording the snapshot in Tech2, transfer the data 3. Snapshot data is displayed with TIS2000
from Tech2 to PC by the below procedures. [Snapshot Upload] function.
1. Start TIS2000. Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
2. Select [Snapshot Upload] on the TIS2000 start
Stored snapshot can be displayed by the below
screen.
procedures.
3. Select [Upload from trouble diagnosis tool (transfer
1. Start TIS2000.
from diagnosis tester)] or click the corresponding
icon of the tool bar. 2. Select [Snapshot Upload] on the TIS2000 start
screen.
4. Select Tech2, and transfer the recorded snapshot
information. 3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
5. Select the transferred snapshot.
4. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen. 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] cursor is changed to the magnifying glass form, click
window opens. the screen. Graph screen is displayed on the whole
2. Click the first graph icon of the window upper part, screen.
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the
parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter. For
displaying the graph display screen in full size,
move the cursor upward on the screen. When the
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window

opens.
2. Click the graph icon, select the parameter to be
displayed from the list and change divisions
according to necessity.
3. Repeat the same procedures with the graph icons,
from the 2nd to 6th.
4. Click the [OK] button to display.
5. In this case, parameters are displayed only in graph
form. All parameters are displayed in one graph.
6. The graph display screen can be moved with the
navigation icon.
SERVICE PROGRAMMING SYSTEM (SPS)
IMPORTANT:
The procedure to program the control unit by using the
Perform the following checks before attempting to
Service Programming System (SPS) software contained
program the control unit:
in TIS2000 is explained below.
• The Tech2 PCMCIA card is programmed with The
NOTE: latest software release.
• If the Engine Control Module (ECM) was • The latest release of TIS2000 is loaded on the PC.
programmed, the Immobilizer System must be • The vehicle battery is fully charged.
linked to the ECM: Refer to section 11 • The control unit to be programmed is connected
“Immobilizer System-ECM replacement” for the to the vehicle.
ECM/Immobilizer linking procedure.
• Should Tech2 display "SPS Procedure was not 1. Preparations of TIS 2000
successful", engine will not start, but no DTCs 1. Connect Tech 2 to P/C.
are present, low battery voltage or poor electrical
2. Check to see if Hardware Key is plugged into Port.
connections should be the primary suspects.
Perform the SPS procedure again after rectifying 3. Activate TIS 2000 by P/C.
the fault/s. 4. On the activating screen of TIS2000, choose
“Service Programming System”
5. On the screen of “Diagnostic Tester and Processing 6. Upon completion of the selection, push the button of
Program Selection”, choose the one that will comply “Next”.
with the following.
• Tech-2 in use
• New programming by the existing module or new
programming by the replaced/new module.
• Fixing position of the control unit.
2. Demand of Data 5. Where vehicle data has been already saved in Tech
1. Connect Tech-2 to the vehicle. When activated by 2, the existing data come on display. In this
turning on the power of Tech-2, push the “Enter” instance, as Tech-2 starts asking whether to keep
switch. the data or to continue obtaining anew data from the
control unit, choose either of them
2. Turn on the ignition switch (without starting the
engine)
3. In the main menu of Diagnostic Tester, push “F1:
Service Programming System (SPS)”.
4. Push “F0: Request Info” of Tech-2.
6. If you select “continue”, you have to select “Model 3. Data Exchange

Year”, “Vehicle Type”. 1. Connect Tech-2 to P/C, turn on the power and click
7. After that. then push button and turn Ignition switch the “Next” button of P/C.
tuned on, off, on following Tech-2 display. Tech-2 2. Check VIN of the vehicle and choose “Next”.
will read information from controller after this
3. Select “System Type” for required control unit.
procedure.
• Engine (Programming for ECM or PCM)
8. During obtaining information, Tech-2 is receiving
information from the control unit ECM and TCM (A/T • Transmission (Programming for TCM)
only) at the same time. With VIN not being 4. When a lack of data is asked from among the
programmed into the new control unit at the time of following menu, enter accordingly.
shipment, "obtaining information" is not complete Select following Menu
(because the vehicle model, engine model and • Model Year
model year are specified from VIN). For the
• Model
procedure get additional information on vehicles,
instruction will be provided in dialog form, when • Engine type
TIS2000 is in operation. • Transmission type
9. Following instructions by Tech-2, push the “Exit” • Destination code (vehicles for general export)*1
switch of Tech-2, turn off the ignition of the vehicle • Immobilizer
and turn off the power of Tech-2, thereby removing Etc.
from the vehicle. * 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. 4. Programming of ECM
6. When all the necessary information is entered, the 1. Check to see if batteries are fully charged, while
“details” of software within the database that match ABS connectors shall be removed from the vehicle.
the entered data will appear for confirmation. Click 2. Connect Tech-2 to Vehicle Diagnostic Connectors.
the “Program” switch and then download the new
3. Turn on the power of Tech-2 and the title screen
software onto Tech-2.
comes on display.
7. “Data Transfer” comes on display. The progress of
4. Turn on the ignition (without allowing the engine to
downloading will be displayed on the screen in the
start)
form of bar graph.
5. On the title screen of Tech-2, push the “Enter”
8. Upon finishing the data transfer, turn off the power
button.
of Tech-2, removing from P/C.
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

(1) Engine Control Module (ECM) (3) Breaker Box

(2) Harness Adapter
The engine control module (ECM) and other connectors

have water proof connector and special terminal. Water
proof terminal does not allow to use back prove. In
addition, the engine control module (ECM) special
terminal can not let regular digital voltage meter prove
to access, because terminal shape is very fin pin type.
In order to prevent damage of female terminal and
connector itself, the breaker box and adapter is the
most suitable special tool.
Breaker Box Connection Type A
3 4 2 5 1
(1) Engine Control Module (ECM) (4) Digital Voltage Meter

(2) Harness Adapter (5) ECM - Harness Adapter Disconnection
(3) Breaker Box
Breaker box connection type A, check for “open circuit”

and “short to ground circuit”.
Breaker Box Connection Type B

(1) Engine Control Module (ECM) (4) Digital Voltage Meter

(2) Harness Adapter (5) ECM - Harness Adapter Connection
(3) Breaker Box
Breaker box connection type B, check for “short to

power supply circuit” and “power, signal voltage check”
between the engine control module (ECM) and
electrical components.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Circuit Description connection, and damaged harness.
The on-board diagnostic system check is the starting

Test Description
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical Number(s) below refer the step number(s) on the
check of the ECM and engine grounds for cleanliness Diagnostic Chart:
and tightness. 1. The Check Engine Lamp (MIL) should be ON steady
The on-board diagnostic system check is an organized with the ignition “On”, engine “Off”. If not, “No Check
approach to identifying a problem created by an Engine Lamp (MIL)” chart should be used to isolate the
electronic engine control system malfunction. malfunction.
2. Checks the Class 2 data circuit and ensures that the
Diagnostic Aids ECM is able to transmit serial data.
An intermittent may be caused by a poor connection, 3. This test ensures that the ECM is capable of
rubbed-through wire insulation or a wire broken inside controlling the Check Engine Lamp (MIL) and the Check
the insulation. Check for poor connections or a Engine Lamp (MIL) driver circuit is not shorted to
damaged harness. Inspect the ECM harness and ground circuit.
connector for improper mating, broken locks, improperly 4. If the engine will not start, “Engine Cranks But Will
formed or damaged terminals, poor terminal-to-wire Not Run” chart should be used to diagnose the fault.
6. The Tech2 parameters which is not within the typical 12. This vehicle is equipped with ECM which utilizes an
range may help to isolate the area which is causing the electrically erasable programmable read only memory
problem. (EEPROM).
On-Board Diagnostic (OBD) System Check

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

ground circuit.
B-58
4 5
Repair faulty
harness and
ground circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
B-58
4 5
Repair faulty
V V
harness and
Less than 1V Go to Step 10 verify repair
communication circuit.
Was the DVM indicated fixed battery voltage?
B-58
6
Repair faulty
V harness and

communication circuit.
2. Disconnect the ECM connector.
3. Check the circuit for open or short to ground
circuit.

C-56

B-58
Repair faulty
harness and
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.
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 —
NO CHECK ENGINE LAMP (MIL)
Circuit Description wire broken inside the insulation. Check for the
following items:
The check engine lamp should be illuminated and
steady for about five seconds with the ignition “ON” and • Inspect the ECM harness and connections for
the engine stopped. Ignition feed voltage is supplied to improper mating, broken locks, improperly formed or
the check engine lamp bulb through the meter fuse. damaged terminals, poor terminal-to-wire connection,
The Engine Control Module (ECM) turns the check and damaged harness.
engine lamp “ON” by grounding the check engine lamp • If the engine runs OK, check for a faulty light bulb, an
driver circuit. open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
Diagnostic Aids • If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
An intermittent check engine lamp may be cased by a
engine ground.
poor connection, rubbed-through wire insulation, or a
No Check Engine Lamp (MIL)

1 Check 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.
3. Ignition “On”.
C-56
42
V
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.
lamp circuit.
2. Disconnect the meter connector and ECM
connector.
C-56
42
B-24
17 — Verify repair Go to Step 5

release?

6 Replace the ECM.
CHECK ENGINE LAMP (MIL) “ON” STEADY
Circuit description Diagnostic Aids

The check engine lamp should always be illuminated An intermittent may be caused by a poor connection,
and steady for about five seconds with ignition “ON” and rubbed-through wire insulation, or a wire broken inside
the engine stopped. Ignition feed voltage is supplied the insulation. Check for the following items:
directly to the check engine lamp indicator. The Engine • Poor connection or damaged harness – Inspect the
Control Module (ECM) turns the check engine lamp ECM harness and connectors for improper mating,
“ON” by grounding the check engine lamp driver circuit. broken locks, improperly formed or damaged
The check engine lamp should not remain “ON” with the terminals, poor terminal-to-wire connection, and
engine running and no DTC(s) set. A steady check damaged harness.
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Check Engine Lamp (MIL) On Steady

1 1. Ignition “Off”, engine “Off”.
Was the “CHECK ENGINE” lamp turned on? — Go to Step 2 Go to Step 4
lamp circuit.
connector.
3. Check the circuit for short to ground circuit.
C-56
42
B-24
17
— Verify repair Go to Step 3

3 Replace the meter assembly.
Is the action complete? — Verify repair —
release?
5 Replace the ECM.
ECM Diagnostic Trouble Codes
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% voltage is below 5.2V. circuit short to battery
Input conditions as substitute. voltage circuit. 83 —
2. MAFsensormalfunction.
3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V. voltage is more than 4.6V. circuit short to ground
Input circuit. 83 —
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is more 1. Sensor power supply
Output Circuit Low Input 600rpmand5000rpm. than -27.4mg/strk. circuit open circuit.
2. MAF sensor output is 2. Sensor signal circuit
below -33.7mg/strk. open or short to ground
circuit.
3. Sensor heater harness 83/
P0110(1)
open circuit. 88
4. Poor connector
connection.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is below 1. Sensor signal circuit
Output Circuit High Input 600rpmand5000rpm. 1378mg/strk (4JA1-TC) or shortto voltagecircuit.
2. MAF sensor output is 1784mg/strk (4JH1-TC). 2. Sensor ground circuit
more than 1378mg/strk open or short to voltage 88/
P0110(1)
(4JA1-TC) or 1784mg/ circuit. 92
strk (4JH1-TC). 3. MAFsensormalfunction.
4. ECM malfunction.
34 P0105 1 ON Vacuum Pressure Sensor Vacuum sensor output 1. Fuel injection quantity is Vacuum sensor output 1. Sensor signal circuit
Circuit High Input voltage is more than 4.4V. reduced. voltage is below 4.4V. shortto voltagecircuit.
2. ECM use 615hpa 2. Sensor ground circuit
conditions for open or short to voltage 85/
turbocharger waste gate circuit. P0115(1) —
93
control. 3. Vacuum sensor
malfunction.
4. ECM malfunction.
2 ON Vacuum Pressure Sensor Vacuum sensor output Vacuum sensor output 1. Sensor power supply
Circuit Low Input voltage is below 0.5V. voltage is more than 0.5V. circuit open circuit.
2. Sensor signal circuit
open or short to ground
circuit. 82/
— —
3. Poor connector 85
connection.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
Related Related
No. DTC
34 P0105 7 ON Vacuum Pressure Sensor Vacuum sensor power 1. Fuel injection quantity is Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit High supply voltage is more than reduced. supply voltage is below 5.2V. circuit short to battery
Input 5.2V. 2. ECM use vacuum sensor voltage circuit.
82 — —
output voltage 5.0V 2. Vacuum sensor
condition as substitute. malfunction.
3. ECM malfunction.
9 ON Vacuum Pressure Sensor Vacuum sensor power Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit Low supply voltage is below 4.5V. supply voltage is more than circuit short to ground
Input 4.5V. circuit.
82 — —
2. Vacuum sensor
malfunction.
3. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0 deg. C conditions IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit High Input more than 4.7V. as substitute. below 4.7V. open or short to voltage
circuit.
2. Sensor ground circuit
open or short to voltage 84/ P0100(B)/
circuit. 92 P0100(C)
3. Poor connector
connection
4. IATsensormalfunction.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit Low Input below 0.3V. more than 0.3V. shortto groundcircuit.
84 —
2. IATsensormalfunction.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit High more than 4.7V. temperature as below 4.7V. open or short to voltage
Input substitute. circuit.
2. ECM uses 60 deg. C 2. Sensor ground circuit
condition for injection open or short to voltage
89/
timing control. circuit. P0105(1)
93
3. ECM uses -25 deg. C 3. Poor connector
condition (4JA1-TC) or - connection
15 deg. C condition 4. ECTsensormalfunction.
(4JH1-TC) for glow time
5. ECM malfunction.
control.
2 ON Engine Coolant Temperature ECT sensor output voltage is ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit Low below 0.3V. more than 0.3V. shortto groundcircuit.
Input 89 —
2. ECTsensormalfunction.
3. ECM malfunction.
15 P0180 B ON Fuel Temperature Sensor FT sensor output is high The ECM use 75 deg. C FT sensor output is correct 1. ECM malfunction.
Circuit Range/Performance temperature (more than 150 conditions as substitute. temperature range between 2. PSG (pump control unit) — —
deg. C) or low temperature 150 deg. C and -40 deg. C. malfunction.
(below -40 deg. C).
Related Related
No. DTC
52 P0215 A ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
Malfunction 2. Engine speed is below valve) is operated. match in the next ignition key malfunction.
1500rpm. 2. Desired injection quantity cycle. 2. MAB (fuel cutoff solenoid
3. Vehicle speed is below becomes 0mg/strk. valve) malfunction.
1.5km/h.
4. PSG (pump control unit) — —
recognizes MAB (fuel
cutoff solenoid valve)
signal from the ECM, but
the MAB could not
operate.
B ON Fuel Cutoff Solenoid Valve ECM does not command Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid
Circuit High Input MAB (fuel cutoff solenoid valve) signal circuit short
valve) signal to the PSG to voltage circuit.
105 —
(pump control unit), but PSG 2. PSG (pump control unit)
detected MAB signal line malfunction.
circuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated. match in the next ignition key valve) signal circuit open
1500rpm. 2. Desired injection quantity cycle. orshorttogroundcircuit.
3. Vehicle speed is below becomes 0mg/strk. 2. PSG (pump control unit)
1.5km/h. malfunction.
105 —
4. PSG (pump control unit)
does not recognize MAB
(fuel cutoff solenoid
valve) signal from the
ECM.
D ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction.
Malfunction 2. CAN controller does not 2. PSG (pump control unit) — —
operate Bus-off. malfunction.
54 P0216 A ON Injection Timing Control 1. Engine speed is more Fuel injection quantity is Deviation of actual injection 1. Timing control valve
Circuit Malfunction than 700rpm. reduced. timing and desired injection malfunction.
2. Fuel injection quantity is timing is more than +3 deg. 2. Timer piston sticking.
more than 4mg/stk. CA or -6 deg. CA for 8
3. Pump camshaft speed
seconds. — —
3. Deviation of actual sensor malfunction.
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8 seconds.
B ON Injection Timing Control 1. Engine speed is more 1. Engine speed is more 1. Insufficient air bleeding of
Circuit Malfunction than 2014rpm. than 2014rpm. fuel line.
2. Fluctuation of actual 2. Fluctuation of actual 2. Fuel filterclogging.
injection timing is more injection timing is more 3. Timing control valve — —
than +-5.2 deg. CA. than +-5.2 deg. CA. malfunction.
4. Pump camshaft speed
sensor malfunction.
Related Related
No. DTC
64 P0243 3 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum line is
temperature is between - vacuum pressure - actual obstructed.
50 deg. C and 150 deg. vacuum pressure is less 3. Vacuum is leaking.
C. than 50hpa.)
4. Vacuum pump 85/
3. Barometric pressure is malfunction. — —
96
between 0hpa and
5. Vacuum sensor
3500hpa.
malfunction.
4. Low vacuum pressure
6. Turbocahrger wastegate
condition. (Desired
valve malfunction.
vacuum pressure - actual
vacuum pressure is more 7. ECM malfunction.
than 50hpa.)
4 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" Low circuit open or short to reduced. circuit is correct condition. circuit open or short to
ground circuit. 2. EGR EVRV becomes ground circuit.
96 — —
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
5 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum regulating valve
temperature is between - vacuum pressure - actual malfunction.
50 deg. C and 150 deg. vacuum pressure is more 3. Vacuum pump
C. than -50hpa.) malfunction. 85/
3. Barometric pressure is 4. Vacuum sensor — —
96
between 0hpa and malfunction.
3500hpa.
5. ECM malfunction.
4. High vacuum pressure
condition. (Desired
vacuum pressure - actual
vacuum pressure is less
than -50hpa.)
6 ON Turbocharger Wastegate 1. Engine coolant 1. Correct amount of mass 1. Turbocharger wastegate
Solenoid "A" Malfunction temperature is between - air flow. (= Correct boost actuator malfunction.
50 deg. C and 150 deg. pressure condition) 2. Vacuumlinemalfunction.
C. (Desired mass air flow -
3. ECM malfunction.
2. EGR control EVRV 0% actual mass air flow is
condition. more than -56mg/strk.)
3. No DTC relating to MAF
sensor, vacuum sensor & — — —
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow -
actual mass air flow is
less than -56mg/strk.)
Related Related
No. DTC
64 P0243 8 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" High circuit short to voltage circuit. reduced. circuit is correct condition. circuit short to voltage
2. EGR EVRV becomes circuit.
96 — —
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
speed sensor error. valve) is operated. match in the next ignition key malfunction.
2. High pressure solenoid 2. Desired injection quantity cycle. 2. Pump camshaft speed
valve control pulse width becomes 0mg/strk. sensor malfunction. — —
does not match with
desired fuel injection
quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft 1. No pump camshaft 1. Missing CKP sensor
speed sensor error. speed sensor error. pulses.
2. No CKP sensor error. 2. No CKP sensor error. 2. Electrical interference.
3. Difference of engine 3. Difference of engine 3. Magneticinterference.
speed and doubled pump speed and doubled pump 4. PSG (pump control unit) 91 —
camshaft speed is more camshaft speed is below malfunction.
than 720rpm (4JA1-TC) 800rpm (4JA1-TC) or
or 690rpm (4JH1-TC). 690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
9 ON Injection Pump Malfunction No pump map programmed No recovery until condition PSG (pump control unit)
in the PSG (pump control match in the next ignition key malfunction. — —
unit) or PSG malfunction. cycle.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is EEPROM or A/D converter PSG (pump control unit)
malfunction in the PSG reduced. no malfunction in the PSG malfunction.
(pump control unit). (pump control unit). — —
No recovery until in the next
ignition key cycle.
B ON Injection Pump Malfunction PSG (pump control unit) No fail-safe function. No recovery until condition PSG (pump control unit)
recognized high pressure match in the next ignition key malfunction.
— —
solenoid valve drive circuit cycle.
error.
D ON Injection Pump Malfunction PSG (pump control unit) PSG (pump control unit)
could not measure the high malfunction.
— —
pressure solenoid valve drive
voltage.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump 1. CAN high circuit open,
(pump control unit) message. valve) is operated. control unit) message. short to ground or short
2. Desired injection quantity to voltage circuit.
becomes 0mg/strk. 2. CAN low circuit open,
short to ground or short 99/ P1650(A)/
to voltage circuit. 100 P1651(B)
3. ECM malfunction.
malfunction.
Related Related
No. DTC
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more When pump camshaft speed ECM detects correct CKP 1. During engine run:
Circuit Malfunction than 665rpm. sensor is OK: pulse width. 1. CKP sensor harness
2. CKP sensor pulse width ECM uses doubled pump open circuit, short to
error. camshaft speed as substitute ground or short to
enginespeed. voltage circuit.
When pump camshaft speed 2. Poor connector
sensor is not OK: connection. 90/
1. MAB (fuel cutoff solenoid 3. CKPsensormalfunction. 98/ P1335 (A)
valve) is operated. 101
4. Pulse sensing gap
2. Desired injection quantity incorrect.
becomes 0mg/strk.
5. Pulser malfunction.
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
D ON Crankshaft Position Sensor 1. No pump camshaft When pump camshaft speed 1. Engine speed is more During engine crank:
Circuit Malfunction speed sensor error. sensor is OK: than 0rpm. 1. CKP sensor harness
2. "Crankshaft Position ECM uses doubled pump 2. Doubled pump camshaft open circuit, short to
Sensor Circuit camshaft speed as substitute speed is below 100rpm. ground or short to
Malfunction (Symptom enginespeed. voltage circuit.
CodeB)" isnotstored. Other than pump camshaft
2. Poor connector
speed sensor is OK:
3. Engine speed is 0rpm. connection. 90/
Fuel injection quantity is
4. Doubled pump camshaft 3. CKPsensormalfunction. 98/ P1135 (A)
reduced.
speed is more than 101
4. Pulse sensing gap
50rpm. incorrect.
8. ECM malfunction.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent Engine speed is below 1. Engine over-running.
Range/Performance 5700rpm. malfunction: 5700rpm. 2. CKPsensormalfunction.
1. MAB (fuel cutoff solenoid 3. Pulser malfunction.
valve) is operated.
4. ECM malfunction.
2. Desired injection quantity 90/
becomes 0mg/strk. 98/ —
When preliminary 101
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function. Glow relay circuit is correct 1. Glow relay circuit open or
Low short to ground circuit. condition. short to groundcircuit.
94 —
2. Glowrelaymalfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to ECM malfunction.
High voltage circuit. — —
Related Related
No. DTC
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function. Glow plug indicator circuit is 1. Glow plug indicator
Voltage Low open or short to ground correct condition. circuit open or short to
circuit. ground circuit.
43 —
2. Glow plug indicator lamp
malfunction.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit ECM malfunction.
Voltage High short to voltage circuit. — —
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Excessive Detected between 15 deg. C and reduced. 1500rpm and 3100rpm open position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGREVRVmalfunction.
2. Engine coolant and3200rpm(4JH1-TC).
3. Air intake is obstructed.
temperature is between 2. Injection quantity is
4. Airintakeisleaking.
55 deg. C and 100 deg. below 32mg/strk (4JA1-
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1- 5. MAFsensormalfunction.
and 100 deg. C (4JH1- TC). 6. ECM malfunction. 88/
TC). —
3. Correct amount of mass 97
3. Barometric pressure is air flow.
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)
4 ON Exhaust Gas Recirculation EGR EVRV circuit open or Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit open
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV condition. orshorttogroundcircuit.
Open Circuit 10% conditions as substitute. 97 —
2. EGREVRVmalfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Insufficient Detected between 15 deg. C and reduced. 1500rpm and 3100rpm close position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGR valve operating
2. Engine coolant and3200rpm(4JH1-TC). vacuum hose is clogged
temperature is between 2. Injection quantity is or disconnected.
55 deg. C and 100 deg. below 32mg/strk (4JA1- 3. EGREVRVmalfunction.
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1-
4. MAF sensor signal circuit
and 100 deg. C (4JH1- TC). 88/
short to voltagecircuit. —
TC). 3. Correct amount of mass 97
3. Barometric pressure is air flow.
between 850hpa and 6. ECM malfunction.
1100hpa.
4. Large mount of mass air
below -150 mg/strk)
8 ON Exhaust Gas Recirculation EGR EVRV circuit short to Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit short
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10% condition. to voltage circuit.
conditions as substitute. 97 —
2. EGREVRVmalfunction.
3. ECM malfunction.
Related Related
No. DTC
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed Vehicle speed is below 1. VSS signal circuit open,
at High Input 200km/h. 5km/h condition as 200km/h. short to ground or short
next substitute. to voltage circuit.
igniti 2. VSS malfunction.
on
3. Speed meter 68 —
cycle
malfunction.
4. TCM malfunction (AT
2WD).
5. ECM malfunction.
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed Correct vehicle speed signal 1. VSS malfunction.
at Signal Frequency Too High high. 5km/h condition as frequency. 2. Speed meter
next substitute. malfunction.
igniti 68 —
on
cycle 4. Magneticinterference.
5. ECM malfunction.
B ON Vehicle Speed Sensor 1. Engine speed is more Fuel injection quantity is Vehicle speed is more than 1. VSS open circuit, short
at Incorrect Signal than 3200rpm (4JA1-TC) reduced. 1.5km/h. to ground or short to
next or3600rpm(4JH1-TC). voltage.
igniti 2. Fuel injection quantity is 2. Poor connector
on more than 30mg/strk connection. 68 —
cycle (4JA1-TC) or 41mg/strk 3. VSS malfunction.
(4JH1-TC).
4. Speed meter
3. Vehicle speed is below malfunction.
1.5km/h.
5. ECM malfunction.
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as System voltage is below 20V. 1. Charge system
20V. substitute. malfunction.
3/
2. Battery jump start cable —
39
misconnect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 1. Battery power feed
7V. harness open circuit or
short to ground circuit.
2. ECM ground harness
openorpoorconnection.
3. Poor connector 3/
—
connection. 39
4. Battery malfunction.
5. Charge system
malfunction.
6. ECM malfunction.
Related Related
No. DTC
35 P0560 A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as System voltage of PSG is 1. Battery power feed
(pump control unit) is below substitute. between 4.5V and 27V. harness open circuit or
4.5V or more than 27V. short to ground circuit.
ground harness open or
poor connection.
3. Poor connector
connection. — —
4. Battery malfunction.
5. Charge system
malfunction.
6. Battery jump start cable
misconnect.
malfunction.
18 P0561 A OFF Ignition Switch Circuit The ECM recognized ignition ECM stops engine. No recovery until condition 1. Ignition switch circuit
Malfunction switch turn off signal during match in the next ignition key open or short to ground
ECM is activated. cycle. circuit.
2. Poor connector
connection. 39 —
3. Ignition switch
malfunction.
4. ECM malfunction.
B OFF Ignition Switch Circuit Ignition switch circuit is 1. Ignition switch circuit
Malfunction malfunction. open or short to ground
circuit.
2. Poor connector
connection. 39 —
3. Ignition switch
malfunction.
4. ECM malfunction.
- P0602 - Control Module ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed.
Programming Error — —
28 P0606 A ON ECU Malfunction Gate Array communication 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction.
error. valve) is operated.
— —
2. Desired injection quantity
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below MAB (fuel cutoff solenoid Desired injection quantity is 1. ECM malfunction.
1%. valve) is operated. below 0mg/strk. 2. PSG (pump control unit)
2. Desired injection quantity malfunction.
— —
is more than 0mg/strk.
3. Engine speed is more
than 2000rpm.
Related Related
No. DTC
46 P0645 4 ON A/C Compressor Relay A/C compressor relay circuit No fail-safe function. A/C compressor relay circuit 1. A/C compressor relay
Circuit Voltage Low open or short to ground is correct condition. circuit open or short to
2. Poor connector
connection. 41 —
3. A/C compressor relay
malfunction.
4. ECM malfunction.
8 ON A/C Compressor Relay A/C compressor relay circuit ECM malfunction.
Circuit Voltage High short to voltage circuit. — —
25 P0703 A ON Brake Switch Circuit 1. Throttle position is more No fail-safe function. Brake switch 1 signal and 1. Brake switch 1 circuit
Malfunction than 0%. brake switch 2 signal are open, short to ground or
2. Engine speed is more correctly inputted to the short to voltage circuit.
than 693rpm (4JA1-TC) ECM. 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 1 30 —
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.
B ON Brake Switch Circuit 1. Throttle position is more 1. Brake switch 2 circuit
Malfunction than 0%. open or short to ground
2. Engine speed is more circuit.
than 693rpm (4JA1-TC) 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 2 65 —
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
ECM.
57 P0704 6 ON Clutch Switch Input Circuit Clutch signal does not No fail-safe function. Clutch signal correctly 1. Clutch switch circuit
Malfunction change between vehicle changes. open, short to ground or
speed 1.5km/h and 80km/h shorttovoltage circuit.
since ignition switch was 2. Poor connector
tuned on. connection. 31 — —
3. Clutch switch
malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa Barometric pressure sensor ECM malfunction.
Circuit High Input output voltage is more than condition as substitute. output voltage is below 4.4V. — —
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor Barometric pressure sensor ECM malfunction.
Circuit Low Input output voltage is below 1.5V. output voltage is more than — —
1.5V.
Related Related
No. DTC
21 P1120 1 ON Pedal/Throttle Position Throttle position sensor ECM increases idle speed up Throttle position sensor 1. Sensor power supply
Sensor Circuit High Input output voltage is more than to 1400rpm. output voltage is below 4.5V. circuit short to voltage
4.5V. circuit.
2. Sensor signal circuit
short to voltagecircuit.
3. Sensor ground circuit 38/
open or short to voltage 49/ —
circuit. 57
4. Poor connector
connection.
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is more power supply voltage is circuit short to battery
Circuit High Input than 5.2V. below 5.2V. voltage circuit. 57 —
2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is power supply voltage is more circuit short to ground
Circuit Low Input below 4.6V. than 4.6V. circuit. 57 —
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position 1. Engine speed is more Throttle position is more than 1. Throttle sticking.
Sensor Brake Switch Error than 1700rpm. 20% or brake pedal is 2. TPSincorrectadjusting.
2. Vehicle speed is more released(switchisinactive).
3. TPS malfunction. 30/
than 1.5km/h.
4. Brake switch 38/ —
3. When brake pedal is malfunction. 65
depressed during
5. ECM malfunction.
accelerator pedal is
depressing.
E ON Pedal/Throttle Position 1. When idle switch is 1. When throttle position 1. TPS malfunction.
Sensor Idle Position Switch turned off, throttle sensor is 100%, idle 2. Idle switch malfunction.
Error position sensor was switch turns off.
3. ECM malfunction.
below 0.35%. 2. When throttle position
or 38/
sensor is 0%, idle switch —
69
2. When idle switch is tuned turns on.
on, throttle position
sensor was more than
7.8%.
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine No fail-safe function. Engine coolant temperature 1. Engine overheat.
High Coolant Temperature coolant temperature is is normal range. 2. ECTsensormalfunction. 89 —
detected.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By Fuel temperature is more PSG (pump control unit) Fuel temperature is below 1. ECM malfunction.
High Fuel Temperature than 100 deg. C. controls fuel injection 100 deg. C. 2. PSG (pump control unit) — —
quantity based on engine malfunction.
speed and fuel temperature.
A OFF Fuel Reduction Caused By Excessive low fuel No fail-safe function. Fuel temperature is normal 1. ECM malfunction.
Low Fuel Temperature temperature is detected. range. 2. PSG (pump control unit) — — —
malfunction.
Related Related
No. DTC
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness
Malfunction is recognized defective reduced. open circuit, short to
engine speed signal form the ground or short to
ECM. voltage.
2. CKP sensor output
harness open circuit,
short to ground or short
to voltage.
3. Poor connector 90/
connection. 91/ P0335(B)/
4. CKPsensormalfunction. 98/ P0335(D)
5. Pulse sensing gap 101
incorrect.
9. ECM malfunction.
malfunction.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed
is recognized incorrect sensor malfunction.
camshaft speed signal. 2. Pulse sensing gap
incorrect.
— —
6. ECM malfunction.
malfunction.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is No fail-safe function. Correct neutral switch signal 1. Neutral switch circuit
inputted "On" three times is inputted two times shorttovoltage circuit.
consecutively under driving consecutively under driving 2. Neutral switch 87 —
conditions. conditions. malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is 1. Neutral switch circuit
inputted "Off" three times open, short to ground
consecutively under driving circuit.
conditions. 2. Poor connector
connection. 87 — —
3. Neutral switch
malfunction.
4. ECM malfunction.
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM No fail-safe function. No recovery. ECM malfunction.
is destroyed. — —
D ON EEPROM Defect Write and read from the ECM uses default values Write and read from the ECM malfunction.
EEPROM are failed during from the EPROM. EEPROM are correct during — —
initialization of the ECM. initialization of the ECM.
Related Related
No. DTC
55 P1605 E ON EEPROM Defect EEPROM checksum does EEPROM checksum match ECM malfunction.
not match with the read with the read check sum
— —
check sum during during initialization of the
initialization of the ECM. ECM.
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start. No recovery. ECM malfunction.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash. — B****
56 P1611 A - Wrong Security Code Received security code is not 1. Engine does not start. No recovery. 1. ECM malfunction.
Entered correct. 2. Check engine lamp flash. 2. Immobilizer control unit
malfunction. — B****
3. Transponder key
malfunction.
56 P1612 A - Immobilizer No or Wrong Received challenge signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1613 A - Immobilizer No or Wrong Received response signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start. No recovery. 1. ECM malfunction.
not correct from the 2. Check engine lamp flash. 2. Immobilizer control unit
transponder key. malfunction. — B****
3. Transponder key
malfunction.
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function. No recovery. ECM malfunction.
Off Too Early turned off, timing of the ECM 3/
—
main relay turning off is too 58
early.
B OFF ECM Main Relay Switched When ignition switch was No recovery. 1. ECM main relay
Off Too Late turned off, timing of the ECM malfunction. 3/
—
main relay turning off is too 2. ECM malfunction. 58
late or does not off.
Related Related
No. DTC
51 P1630 A ON Fuel Injection Quantity The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) PSG (pump control unit)
Circuit Malfunction detects high pressure reduced. detects correct high pressure malfunction.
solenoid valve control circuit solenoid valve control circuit. — —
malfunction due to high
current.
B ON Fuel Injection Quantity The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit)
Circuit Malfunction detects high pressure valve) is operated. malfunction.
solenoid valve control circuit 2. Desired injection quantity — —
malfunction due to becomes 0mg/strk.
continuous current.
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid CAN controller detects 1. CAN high circuit open,
off or canceling. valve) is operated. correct Bus signal. short to ground or short
to voltage circuit.
2. CAN low circuit open,
to voltage circuit. 99/
3. Poor connector P1651(B)
100
connection.
4. Electricalinterference.
5. ECM malfunction.
malfunction.
B ON CAN Device Hang-up CAN controller does not CAN controller reacts 1. ECM malfunction.
react under engine running. correctly under engine 2. PSG (pump control unit) — —
running. malfunction.
45 P1651 A ON CAN Malfunction The PSG (pump control unit) 1. MAB (fuel cutoff solenoid The PSG (pump control unit) 1. ECM malfunction.
does not recognize CAN valve) is operated. recognizes CAN signal from 2. PSG (pump control unit)
signal from the CAN the CAN controller. — —
2. Desired injection quantity malfunction.
controller. becomes 0mg/strk.
B ON CAN Malfunction The ECM does not read CAN The ECM reads CAN signal 1. CAN high circuit open,
signal from the PSG (pump from the PSG (pump control short to ground or short
control unit). unit). to voltage circuit.
2. CAN low circuit open,
to voltage circuit. 99/
3. Poor connector P1650(A)
100
connection.
5. ECM malfunction.
malfunction.
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function. Check engine lamp circuit is 1. Check engine lamp
Circuit Voltage Low open or short to ground correct condition. circuit open or short to
42 B****
2. Check engine lamp
malfunction
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit ECM malfunction.
Circuit Voltage High short to voltage circuit. — —
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)

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

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE B)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW
INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE C)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
Condition for setting the DTC and action taken when the DTC sets
Flash Symptom
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% con-
Input ditions as substitute.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V.
Input
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit Low Input 600rpm and 5000rpm.
2. MAF sensor output is
below -33.7mg/strk.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit High Input 600rpm and 5000rpm.
2. MAF sensor output is more
than 1378mg/strk (4JA1-TC)
or 1784mg/strk (4JH1-TC).
Circuit Description Diagnostic Aids

The mass air flow (MAF) sensor is part of the intake air An intermittent may be caused by the following:
system. It is fitted between the air cleaner and • Poor connections.
turbocharger and measure the mass air flowing into the
• Misrouted harness.
engine.
The mass air flow (MAF) sensor element measures the • Rubbed through wire insulation.
partial air mass through a measurement duct on the • Broken wire inside the insulation.
sensor housing. Check for the following conditions:
The ECM monitors the MAF sensor supply voltage and • Poor connection at ECM-Inspect harness connectors
MAF sensor output voltage. The supply voltage is out of for backed out terminals, improper mating, broken
range, DTC P0100 (Symptom Code 7) or P0100 locks, improperly formed or damaged terminals, and
(Symptom Code 9) will be stored. The output voltage poor terminal to wire connection.
excessively high or low, DTC P0100 (Symptom Code B)
• Damaged harness-Inspect the wiring harness for
or P0100 (Symptom Code C) will be stored.
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.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 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 Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0100 (Symptom Code 7) stored as and Go to Step
“Present Failure”? — Go to Step 3 3

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: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0100 (Symptom Code 7) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
C-57(B) 92 C-116
2 3 4
5
88 83 — Verify repair Go to Step 5

5 Visually check the MAF sensor.
Was the problem found? — Go to Step 11 Go to Step 6
6 Using the DVM and check the MAF sensor power
supply circuit.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for short to battery voltage
circuit.
C-116
4
Less than 1V:

Go to Step 7
More than
V
Approximately specified value:
5.0V Go to Step 11 Go to Step 8
7 Repair the open circuit between the ECM and MAF
sensor.
Was the problem solved?
C-57(B) C-116
4

supply circuit.
2. Disconnect the MAF & IAT sensor connector and
ECM connector.
3. Check the circuit for short to MAF sensor +12V
supply circuit.
C-116
2 4
No continuity Go to Step 10 Go to Step 9

9 Repair the circuit for short to MAF sensor +12V supply
circuit.
10 Repair the short to battery voltage circuit between the
ECM and MAF sensor.
C-57(B) C-116
4
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.
release?
14 Replace the ECM.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
(OBD) System
C-57(B) 92 C-116
2 3 4
5

supply circuit.
C-116
4
V Approximately

supply circuit.
ECM connector.
3. Check the circuit for short to MAF sensor ground
circuit.
C-116
3 4

8 Repair the circuit for short to MAF sensor ground.
9 Repair the short to ground circuit between the ECM
and MAF sensor.
C-57(B) C-116
4
and recheck.
release?
13 Replace the ECM.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
(OBD) System
Is the DTC P0100 (Symptom Code B) stored as and Go to Step
Was the DTC P0100 (Symptom Code B) stored in this and Go to Step
C-57(B) 92 C-116
2 3 4
5


6 Using the DVM and check the MAF sensor signal
circuit.
Breaker box is available:
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
4. Check the circuit for open, short to sensor ground
or short to ground circuit.
Breaker Box C-116

88

Breaker box is not available:

ECM connector.
C-57(B) C-116
88 5
Repair faulty
harness and
supply circuit.
C-116
4
V Approximately

8 Repair the open circuit between the ECM and MAF
sensor.
C-57(B) C-116
4
9 Using the DVM and check the MAF sensor +12V
supply circuit.
C-116
2
V
10 Repair the open circuit between the ECM main relay
and MAF sensor.
and recheck.
release?
14 Replace the ECM.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
(OBD) System
Is the DTC P0100 (Symptom Code C) stored as and Go to Step
Was the DTC P0100 (Symptom Code C) stored in this and Go to Step
C-57(B) 92 C-116
2 3 4
5


6 Using the DVM and check the MAF sensor ground
circuit.
3. Disconnect the MAF sensor connector.
Breaker Box C-116

92

2. Disconnect the MAF sensor connector and ECM
connector.
C-57 C-116
3 Repair faulty
92 harness and
7 Using the DVM and check the MAF sensor ground
circuit.
2. Disconnect the MAF sensor connector .
C-116
3
Repair faulty
V
harness and

circuit.
C-116
5
Repair faulty
V harness and
and recheck.
release?
12 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT

CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH
INPUT

CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW
INPUT
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
34 P0105 1 ON Vacuum Pressure Sensor Vacuum sensor output 1. Fuel injection quantity is
Circuit High Input voltage is more than 4.4V. reduced.
2 ON Vacuum Pressure Sensor Vacuum sensor output 2. ECM use 615hpa
Circuit Low Input voltage is below 0.5V. conditions for
turbocharger waste gate
control.
7 ON Vacuum Pressure Sensor Vacuum sensor power supply 1. Fuel injection quantity is
Voltage Supply Circuit High voltage is more than 5.2V. reduced.
Input 2. ECM use vacuum sensor
9 ON Vacuum Pressure Sensor Vacuum sensor power supply output voltage 5.0V
Voltage Supply Circuit Low voltage is below 4.5V. condition as substitute.
Input

The ECM monitors altitude from the barometric An intermittent may be caused by the following:
pressure sensor. To apply specified vacuum pressure to • Poor connections.
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude. • Rubbed through wire insulation.
Then, apply vacuum pressure to the turbocharger • Broken wire inside insulation.
wastegate valve is monitored by the ECM form the Check for the following conditions:
vacuum pressure sensor output signal. The ECM • Poor connection at ECM-Inspect harness connectors
controls wastegate control solenoid based on signal for backed out terminals, improper mating, broken
from vacuum pressure sensor output. locks, improperly formed or damaged terminals, and
The output voltage excessively high or low, DTC P0105 poor terminal to wire connection.
(Symptom Code 1) or P0105 (Symptom Code 2) will be
stored.
The supply voltage is out of range, DTC P0105
the DTC P0105 display on the Tech 2 while moving
connectors and wiring harnesses. A change in the
stored.
display will indicate the location of the fault.
Vacuum Pressure Sensor Circuit High Input
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
(OBD) System
- Go to Step 2 Check
2 1. 1Connect the Tech 2.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
"Present Failure"? - Go to Step 3 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
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
C-57 C-124

- Verify repair Go to Step 5
5 Visually check the vacuum sensor.
Was the problem found? - Go to Step 9 Go to Step 6

6 Using the DVM and check the vacuum pressure
sensor ground circuit.
1. Ignition "Off", engine "Off".
3. Disconnect the vacuum pressure sensor
connector.
Breaker Box
C-124
93

connector and ECM connector.
C-57 C-124

Repair faulty
harness and

- verify repair Go to Step 7
1. Ignition "On", engine "Off".
connector.
C-124
V Repair faulty
harness and

sensor signal circuit.
connector.
C-124

V Repair faulty
harness and
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 -
release?
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 12
12 Replace the ECM.
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
Vacuum Pressure Sensor Circuit Low Input
(OBD) System
C-57 C-124

5 Visually check the vacuum pressure sensor.

connector.
Breaker Box
C-124
85


C-57 C-124

Repair faulty
harness and
sensor power supply circuit.
connector.
C-124
V
Approximately
8 Repair the open circuit between the ECM and vacuum

pressure sensor.
C-57 C-124

assembly and recheck.
10 Replace the vacuum sensor assembly.
release?
12 Replace the ECM.
Vacuum Pressure Sensor Voltage Supply Circuit High Input
(OBD) System
C-57 C-124

connector.
circuit.
C-124
V
Approximately

ECM and vacuum pressure sensor.
C-57 C-124

9 Replace the vacuum pressure sensor assembly.
release?
11 Replace the ECM.
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
(OBD) System
C-57 C-124

connector.
C-124
V
Approximately

3. Check the circuit for short to vacuum pessure

C-124

8 Repair the circuit for short to vacuum pressure sensor
ground.
9 Repair the short to ground circuit between the vacuum
pressure sensor.
and recheck.
release?
13 Replace the ECM.

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

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
Code Code
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use deg.C conditions as
Sensor Circuit High Input more than 4.7V. substitute.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is
Sensor Circuit Low Input below 0.3V.
Circuit Description the resistance value. And it changes voltage. In other

words it measures a temperature value. Low air
The IAT sensor is a thermistor. A temperature changes temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor • Misrouted harness.
through resisters in the ECM and measures the voltage. • Rubbed through wire insulation.
The signal voltage will be high when the air temperature
• Broken wire inside the insulation.
is cold, and it will be low when the air temperature is
Check for the following conditions:
hot.
The output voltage excessively high or low, DTC P0110 • Poor connection at ECM-Inspect harness connectors
(Symptom Code 1) or P0110 (Symptom Code 2) will be for backed out terminals, improper mating, broken
stored. locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Diagnostic Aids • Damaged harness-Inspect the wiring harness for
An intermittent may be caused by the following: the “Intake Air Temperature” display on the Tech2
• Poor connections. while moving connectors and wiring harness related
to the sensor.
Intake Air Temperature (IAT) Sensor Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the IAT sensor or
C-57(B) C-116
92
84 1 3 — Verify repair Go to Step 5

5 Visually check the IAT sensor.

6 Using the DVM and check the IAT sensor.
2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.
Does the tester indicate standard resistance as shown
in the following table?
Temperature (°C) Resistance (W) (Approximately)

-20 13660
0 5430
20 2433
40 1153
60 598
80 334
100 204
IAT Sensor
5 4 3 2 1
Standard
3 1
resistance Go to Step 7 Go to Step 12
7 Using the DVM and check the IAT sensor signal
circuit.
C-116
Less than 1V:

Go to Step 8
1
More than
V Approximately specified value:
8 Repair the open circuit between the ECM and IAT
sensor.
C-57(B) C-116
84 1

9 Repair the short to voltage circuit between the ECM
and IAT sensor.
C-57(B) C-116
84 1
10 Using the DVM and check the IAT sensor ground
circuit.
C-116
3
Repair faulty
V harness and

11 Using the DVM and check the IAT sensor ground
circuit.
Breaker Box C-116

92

ECM connector.
C-57(B) C-116
3 Repair faulty
92
harness and
and recheck.
release?
15 Replace the ECM.
Intake Air Temperature (IAT) Sensor Circuit Low Input
(OBD) System
4 Check for poor/faulty connection at the IAT sensor or
C-57(B) C-116
92

5 Remove the MAF & IAT sensor assembly and visually
check.

6 Using the DVM and check the IAT sensor.
2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.

-20 13660
0 5430
20 2433
40 1153
60 598
80 334
100 204
IAT Sensor
5 4 3 2 1
Standard
3 1

7 Using the DVM and check the IAT sensor signal
circuit.
4. Check the circuit for short to sensor ground or
ground circuit.
Breaker Box
84 92

ECM connector.
ground circuit.
C-57(B)
92
84
Repair faulty
harness and
and recheck.
release?
11 Replace the ECM.

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
HIGH INPUT

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
Code Code
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel temperature
(ECT) Sensor Circuit High more than 4.7V. as substitute.
Input 2. ECM uses 60 deg.C
condition for injection timing
2 ON Engine Coolant Temperature ECT sensor output voltage is
control.
(ECT) Sensor Circuit Low below 0.3V.
Input 3. ECM uses -25 deg.C
condition (4JA1-TC) or -15
deg.C condition (4JH1-TC)
for glow time control.
Circuit Description the resistance value. And it changes voltage. In other

words it measures a temperature value. It is installed on
The ECT sensor is a thermistor. A temperature changes the coolant stream. Low coolant temperature produces
a high resistance. • Misrouted harness.
The ECM supplies 5 volts signal to the ECT sensor • Rubbed through wire insulation.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot. • Poor connection at ECM-Inspect harness connectors
The output voltage excessively high or low, DTC P0115 for backed out terminals, improper mating, broken
(Symptom Code 1) or P0115 (Symptom Code 2) will be locks, improperly formed or damaged terminals, and
stored. poor terminal to wire connection.
Diagnostic Aids damage. If the harness appears to be OK, observe
the “Coolant Temperature” display on the Tech2 while
An intermittent may be caused by the following: moving connectors and wiring harness related to the
• Poor connections. sensor.
Engine Coolant Temperature Sensor Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the ECT sensor or
C-57(B) E-41
93 1 2

5 Visually check the ECT sensor.

6 Using the DVM and check the ECT sensor.
2. Disconnect ECT sensor connector.
3. Measure the resistance of ECT sensor.

-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
7 Using the DVM and check the ECT sensor signal
circuit.
2. Disconnect the ECT sensor connector.
E-41
Less than 1V:

1 Go to Step 8
More than
V
Approximately specified value:
8 Repair the open circuit between the ECM and ECT
sensor.
C-57(B) E-41


and ECT sensor.
C-57(B) E-41
1
10 Using the DVM and check the ECT sensor ground
circuit.
E-41
2
Repair faulty
V harness and
11 Using the DVM and check the ECT sensor ground
circuit.
Breaker Box E-41
93

2. Disconnect the ECT sensor connector ECM
connector.
C-57 E-41
Repair faulty
2 harness and
93 — verify repair Go to Step 14

12 Substitute a known good ECT sensor assembly and
recheck.
13 Replace the ECT sensor.
release?
15 Replace the ECM.
Engine Coolant Temperature Sensor Circuit Low Input
(OBD) System
4 Check for poor/faulty connection at the ECT sensor or
C-57(B) E-41
93 1 2

5 Visually check the ECT sensor.


-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard

7 Using the DVM and check the ECT sensor signal
circuit.
ground circuit.
Breaker Box
89 93

2. Disconnect the ECT sensor connector and ECM
connector.
ground circuit.
C-57(B)
93
89
Repair faulty
harness and
recheck.
release?
11 Replace the ECM.

(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Code Code
15 P0180 B ON Fuel Temperature Sensor Cir- FT sensor output is high tem- The ECM use 75deg.C condi-
cuit Range/Performance perature (more than tions as substitute.
150deg.C) or low temperature
(below -40deg.C).
Circuit Description • Misrouted harness.

The fuel temperature sensor is assembled inside of the • Rubbed through wire insulation.
pump control unit (PSG). The signal of fuel temperature • Broken wire inside the insulation.
is sent via the CAN-bus from the PSG to ECM. Check for the following conditions:
If the fuel temperature is excessively high or low • Poor connection at ECM and PSG-Inspect harness
condition, DTC P0180 will be stored. connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
Diagnostic Aids terminals, and poor terminal to wire connection.
An intermittent may be caused by the following: • Damaged harness-Inspect the wiring harness for
• Poor connections.
the “Fuel Temperature” display on the Tech2 while
sensor.
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
(OBD) System
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0180 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
release?
5 Substitute a known good ECM and recheck.
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
7 Replace the injection pump assembly.
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION

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

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Code Code
52 P0215 A ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
Malfunction 2. Engine speed is below valve) is operated.
1500rpm. 2. Desired injection quantity
3. Vehicle speed is below becomes 0mg/strk.
1.5km/h.
recognizes MAB (fuel cutoff
solenoid valve) signal from
the ECM, but the MAB
could not operate.
B ON Fuel Cutoff Solenoid Valve ECM does not command Engine does not start.
Circuit High Input MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line cir-
cuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated.
1500rpm. 2. Desired injection quantity
3. Vehicle speed is below becomes 0mg/strk.
1.5km/h.
does not recognize MAB
(fuel cutoff solenoid valve)
signal from the ECM.
D ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. No fail-safe function.
Malfunction 2. CAN controller does not
operate Bus-off.

When the ignition switch is turned “Off”, the fuel An intermittent may be caused by the following:
solenoid valve (MAB) signal is supplied from the ECM to • Poor connections.
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 • Rubbed through wire insulation.
short to ground circuit, DTC P0215 (Symptom Code B) • Broken wire inside the insulation.
or P0215 (Symptom Code C) will be stored. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
(OBD) System
Is the DTC P0215 (Symptom Code A) stored as and Go to Step

Was the DTC P0215 (Symptom Code A) stored in this Refer to
Cutoff Solenoid Valve Circuit High Input
(OBD) System
4 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
105 C-57 E-6

5

5 Visually check the PSG (pump control unit).

6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) circuit.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-104
3. Check the circuit for short to voltage circuit.
Breaker Box
105

C-57
105
V
Less than 1V Go to Step 8 Go to Step 7
and PSG (pump control unit).
C-57 E-6
5
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
(OBD) System
Is the DTC P0215 (Symptom Code C) stored as and Go to Step
Was the DTC P0215 (Symptom Code C) stored in this and Go to Step
105 C-57 E-6

5


6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) circuit.
3. Disconnect the PSG (pump control unit)
connector.
circuit.
Breaker Box
105 E-6


connector.
circuit.
C-57 E-6
105
5
Repair faulty
harness and
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
(OBD) System
Is the DTC P0215 (Symptom Code D) stored as and Go to Step
Was the DTC P0215 (Symptom Code D) stored in this Refer to
release?
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH

CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE B) (FLASH

CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
Code Code
54 P0216 A ON Injection Timing Control 1. Engine speed is more Fuel injection quantity is
Circuit Malfunction than 700rpm. reduced.
2. Fuel injection quantity is
more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8
seconds.
B ON Injection Timing Control 1. Engine speed is more
Circuit Malfunction than 2014rpm.
2. Fluctuation of actual
injection timing is more
than +-5.2 deg. CA.
Circuit Description Air bleeding procedure:
The ECM is calculates an injection quantity and an 1.Operate the priming pump until strong resistance is
injection timing using the various sensors (crankshaft felt.
position sensor, camshaft position sensor, engine 2.Wait 1 minute, and operate the priming pump until
coolant temperature sensor, etc.). The timing control strong resistance is felt.
valve (TCV) operation performs an injection timing 3.Wait 1 minute, and operate the priming pump until
decision. strong resistance is felt.
The TCV performs as a variable throttle, using the rapid 4.Turn the ignition switch to the "ON" position. Wait
opening and closing cycle of the valve needle in the until the glow indicator lamp turns off.
TCV.
5.Turn the ignition switch to the "START" position and
The TCV is assembled in the injection pump. The signal
crank the engine until it starts.
of desired injection timing and actual injection timing are
exchanged via the CAN-bus between the PSG and 6.If the engine does not start, repeat Step 3 - 5.
ECM. 7.Allow the engine to idle for 3 minutes to bleed air
If the timer position is out of tolerance (deviation or completely form the fuel system and check for fuel
fluctuation), DTC P0216 will be stored. leakage.
Diagnostic Aids mating, broken locks, improperly formed or damaged
An intermittent may be caused by the following: terminals, and poor terminal to wire connection.
• Poor connections. • Damaged harness-Inspect the wiring harness for
the "Actual Injection Start" display on the Tech2 while
• Rubbed through wire insulation. moving connectors and wiring harness related to the
• Broken wire inside the insulation. sensor.
• Insufficient air bleeding of fuel line.
• Low fuel quantity in the fuel tank.
• Insufficient air bleeding of fuel line inside, clogged
fuel filter or pinched fuel pipe/hose may cause the
DTC store or improper engine performance.
Injection Timing Control Circuit Malfunction
Injection Timing Control Circuit Malfunction

(OBD) System
Is the DTC P0216 (Symptom Code A) or P0216 and Go to Step
(Symptom Code B) stored as "Present Failure"? - Go to Step 3 3
3 1. 1Using the Tech 2, ignition "On" and engine "Off".
Was the DTC P0216 (Symptom Code A) or P0216 and Go to Step
(Symptom Code B) stored in this ignition cycle? - Go to Step 4 4
4 Perform the air bleeding in the fuel line sufficiently.
Air Bleeding Procedure:
1. Operate the priming pump until strong resistance
is felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump
until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position
and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
DTC Re-check:
1. Using the Tech 2, ignition "On" and engine "Off".
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 Visually/physically inspect for the following conditions.
• Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
• Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 6
6 Replace the fuel filter.
7 Remove the eye bolt with gauze filter from the
injectionpumpandcheckforthefollowingconditions.
• Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.
Replace the
eye bolt with
gauze filter and
release? If
not, download the latest software to the ECM using
the ECM/Immobilizer linking procedure. - Go to Step 10 Go to Step 11

10 Replace the ECM.

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/
PERFORMANCE

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" LOW

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/
PERFORMANCE

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" HIGH
Code Code
64 P0243 3 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is
Solenoid "A" Range/ between -50 deg. C and reduced.
Performance 200 deg. C. 2. EGR EVRV becomes 10%
2. Engine coolant condition.
temperature is between -
50 deg. C and 150 deg.
C.
4 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is
Solenoid "A" Low circuit open or short to ground reduced.
circuit. 2. EGR EVRV becomes 10%
condition.
3. Wastegate control EVRV
becomes 32% condition.
5 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is
Solenoid "A" Range/ between -50 deg. C and reduced.
Performance 200 deg. C. 2. EGR EVRV becomes 10%
2. Engine coolant condition.
temperature is between -
C.
6 ON Turbocharger Wastegate 1. Engine coolant
Solenoid "A" Malfunction temperature is between -
C.
2. EGR control EVRV 0%
condition.
8 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is
Solenoid "A" High circuit short to voltage circuit. reduced.
2. EGR EVRV becomes 10%
condition.
3. Wastegate control EVRV
becomes 32% condition.

The ECM monitors altitude from the barometric An intermittent may be caused by the following:
pressure sensor. To apply specified vacuum pressure to • Poor connections.
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude. • Rubbed through wire insulation.
Then, apply vacuum pressure to the turbocharger • Broken wire inside insulation.
wastegate valve is monitored by the ECM form the • Turbocharger wastegate valve sticking or broken.
vacuum pressure sensor output signal. The ECM
• Misrouted vacuum hose.
controls wastegate control solenoid based on signal
from vacuum pressure sensor output. • Faulty vacuum pump or regulating valve.
If the vacuum pressure sensor detected vacuum Check for the following conditions:
pressure is excessively low or high due to faulty vacuum • Poor connection at ECM-Inspect harness connectors
line, vacuum pump or turbocharger wastegate valve, for backed out terminals, improper mating, broken
DTC P0243 (Symptom Code 3), P0243 (Symptom Code locks, improperly formed or damaged terminals, and
5) or P0243 (Symptom Code 6) will be stored. poor terminal to wire connection.
If the wastegate control solenoid circuit is open or short • Damaged harness-Inspect the wiring harness for
to ground circuit, DTC P0243 (Symptom Code 4) will be damage. If the harness appears to be OK, observe
stored. the DTC P0243 display on the Tech 2 while moving
If the wastegate control solenoid circuit is short to connectors and wiring harnesses. A change in the
voltage circuit, DTC P0243 (Symptom Code 8) will be display will indicate the location of the fault.
stored.
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
(OBD) System
4 Remove the vacuum hose & vacuum regulating valve
and check for the following conditions.
• Objects blocking the vacuum hose.
• Objects blocking the vacuumregulating valve.
• Vacuum leaking at vacuum hose or vacuum
regulating valve.
• Objects blocking at the wastegate solenoidvalve.
Was the problem found? - Verify repair Go to Step 5
5 Remove the vacuum pressure sensor and visually
check.
and recheck.
7 Replace the vacuum pressure sensor.

8 Using the DVM and check the wastegate control
solenoid.
2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid
coil.
Does the tester indicate standard resistance?
Wastegate Solenoid

Approximately
14.7 - 16.1 W
at 20°C Go to Step 11 Go to Step 9
9 Substitute a known good wastegate control solenoid
and recheck.
10 Replace the wastegate control solenoid.
11 Using the pressure gauge and check the turbocharger
wastegate valve operation for broken diaphragm.
Was a problem found? - Go to Step 12 Go to Step 13
12 Replace the turbocharger wastegate valve .
release?
14 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Low
(OBD) System
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty

C-57 C-123

solenoid.
coil.
Wastegate Solenoid

Approximately
14.7 - 16.1 W


solenoid power supply circuit.
2. Remove the wastegate control solenoid
connector.
Was the DVM indicated specified value? 10 - 14.5V Go to Step 8 Go to Step 7
and wastegate control solenoid.
solenoid circuit.
3. Removethewattagecontrolsolenoid connector.
circuit.
Breaker Box
C-123
96


3. Remove the wastegate control solenoid
connector.
circuit.

C-57 C-123
Repair faulty

harness and
and recheck.

release?
12 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Range/Performance
(OBD) System
4 Visually check the vacuum regulating valve.
solenoid.
coil.
Wastegate Solenoid

Approximately
14.7 - 16.1 W
and recheck.
wastegate valve operation for broken diaphragm.
9 Replace the turbocharger wastegate valve .


C-57 C-123

connector.
C-124

V Repair faulty
harness and
14 Replace the vacuum pressure sensor assembly.
release?
16 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Malfunction
(OBD) System
4 Visually check the turbocharger wastegate valve and
hose.
If the hose is clogged or disconnected, repair as
necessary.
wastegate valve operation for broken diaphragm or
restrict shaft operation.
6 Replace the turbocharger wastegate valve.

C-57 C-116


circuit.
C-116

V Repair faulty
harness and
and recheck.
release?
13 Replace the ECM.
Turbocharger Wastegate Solenoid "A" High
(OBD) System
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0243 (Symptom Code 8) stored in this Refer to
ignition cycle? - Go to Step 4 Diagnostic Aids
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty
solenoid.
coil.
Wastegate Solenoid

Approximately
14.7- 16.1 W at
20°C Go to Step 6 Go to Step 8

solenoid circuit.
2. Remove the wastegate control solenoid connector
and ECM connector.
C-123

7 Repair the short to voltage circuit.
and recheck.
release?
11 Replace the ECM.

(FLASH CODE 53) INJECTION PUMP MALFUNCTION





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

Code Code
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed 1. MAB (fuel cutoff solenoid
sensor error. valve) is operated.
2. High pressure solenoid 2. Desired injection quantity
valve control pulse width becomes 0mg/strk.
does not match with
desired fuel injection quan-
tity.
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 cam-
shaft speed is more than
720rpm (4JA1-TC) or 690
rpm (4JH1-TC).
9 ON Injection Pump Malfunction No pump map programmed in
the PSG (pump control unit)
or PSG malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is
malfunction in the PSG (pump reduced.
control unit).
B ON Injection Pump Malfunction PSG (pump control unit) rec- No fail-safe function.
ognized high pressure sole-
noid valve drive circuit error.
D ON Injection Pump Malfunction PSG (pump control unit) could
not measure the high pres-
sure solenoid valve drive volt-
age.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid
(pump control unit) message. valve) is operated.
becomes 0mg/strk.

The ECM is calculates an injection quantity and an An intermittent may be caused by the following:
injection timing using the various sensors. And the PSG • Poor connections.
controls the high pressure solenoid valve depending on
programmed pump map data.
• Rubbed through wire insulation.
The signal of desired injection quantity and actual injec-
tion quantify are exchanged via the CAN-bus between • Broken wire inside the insulation.
the PSG and ECM.
If the relation of engine speed signal and doubled pump • Poor connection at ECM and PSG-Inspect harness
camshaft speed signal excessively large, DTC P0251 connectors for backed out terminals, improper
(Symptom Code 7) will be stored. mating, broken locks, improperly formed or damaged
If the CAN high or low circuit is defected, DTC P0251 terminals, and poor terminal to wire connection.
(Symptom Code E) will be stored. • Damaged harness-Inspect the wiring harness for
the “Injection Quantity” display on the Tech2 while
sensor.
Injection Pump Malfunction
(OBD) System

(OBD) System
4 Was the DTC P0335 (Symptom Code B), P0335 Go to DTC
(Symptom Code D) or P1335 (Symptom Code A) Chart P0335
stored at the same time? (Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
— Code A) Go to Step 5
connection is found, repair the faulty terminal.
C-57(B) 91 E-6


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
Crankshaft Position (CKP) Sensor & TDC Output Signal

Reference Wave Form
CH1
0V®
CH2
0V®
Not available:
Go to Step 7
Fixed at low:
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div
Go to Step 7
Measurement Condition: Approximately 2000rpm Fixed at High:
— Go to Step 13 Go to Step 8

7 Using the DVM and check the CKP sensor output
circuit.
connector.
circuit.
Breaker Box
91 E-6


connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

9 Check any accessory parts which may cause electric Remove the
interference or magnetic interference. accessory parts
Was the problem found? — and verify repair Go to Step 10
release?
12 Replace the ECM.
(OBD) System
(OBD) System
(OBD) System
(OBD) System
Was the DTC P0251 (Symptom Code D) stored in this Refer to
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
(OBD) System
Is the DTC P0251 (Symptom Code E) stored as and Go to Step
Was the DTC P0251 (Symptom Code E) stored in this Refer to
4 Was the DTC P1650 (Symptom Code A) or P1651 Go to DTC
(Symptom Code B) stored at the same time? Chart P1650
(Symptom
release?
7 Replace the ECM.

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION

(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
Code Code
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more than When pump camshaft speed
Circuit Malfunction 665rpm. sensor is OK:
2. CKP sensor pulse width ECM uses doubled pump cam-
error. shaft speed as substitute
engine speed.
When pump camshaft speed
sensor is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
D ON Crankshaft Position Sensor 1. No pump camshaft speed When pump camshaft speed
Circuit Malfunction sensor error. sensor is OK:
2. “Crankshaft Position Sen- ECM uses doubled pump cam-
sor Circuit Malfunction shaft speed as substitute
(Symptom Code B)” is not engine speed.
stored. Other than pump camshaft
3. Engine speed is 0rpm. speed sensor is OK:
4. Doubled pump camshaft Fuel injection quantity is
speed is more than 50rpm. reduced.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent malfunction:
Range/Performance 5700rpm. 1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
When preliminary malfunction:
ECM uses doubled pump cam-
shaft speed as substitute
engine speed.

The CKP sensor is located on top of the flywheel An intermittent may be caused by the following:
housing of the flywheel and fixed with a bolt. The CKP • Poor connections.
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 • Rubbed through wire insulation.
cylinder top dead center. • Broken wire inside the insulation.
If the CKP sensor harness or sensor malfunction is Check for the following conditions:
detected during engine run, DTC P0335 (Symptom • Poor connection at ECM-Inspect harness connectors
Code B) is stored. for backed out terminals, improper mating, broken
If the CKP sensor harness or sensor malfunction is locks, improperly formed or damaged terminals, and
detected during engine cranking, DTC P0335 poor terminal to wire connection.
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
the “Engine Speed” display on the Tech2 while
is stored.
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
(OBD) System

Is the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P0335 (Symptom Code B) or P0335 and Go to Step
(Symptom Code D) stored in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the CKP sensor or
repair the faulty terminal.
C-57(B) 101 E-9
1 2 3
98
90

5 Visually check the CKP sensor. If a faulty installation
is found, repair as necessary.
6 Using the DVM and check the CKP sensor circuit.
3. Check the resistance of the CKP sensor.
Breaker Box
90 98

C-57(B) 98
Approximately
90 0.9k9 at 20°C Go to Step 10 Go to Step 7

2. Disconnect the CKP sensor connector.
E-9
1
2 Approximately
0.9k9 at 20°C Go to Step 8 Go to Step 14
4. Check the circuit for open, short to sensor wire or
Breaker Box
90 98 101

4. Check the circuit for open, short to sensor wire or
Breaker Box
E-9
90 98

Repair faulty

harness and

If the DVM indicated out of specified value, repair
faulty harness and verify repair.
E-9
1
2
V V
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?
Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Approximately 1.1 V at
At ECM C57 connector 90 & 98 2000rpm
If a oscilloscope is available, monitor the CKP sensor

signal. Does the oscilloscope indicate correct wave
form?
Crankshaft Position (CKP) Sensor Reference Wave Form
0V®

Go to Step 13 Go to Step 11
11 Remove the CKP sensor from the flywheel housing
and visually check.
Check for the following conditions.
• Objects sticking the CKP sensor.
• Objects sticking the CKP sensor pulser.
12 Check the CKP sensor shield wire for open or short Repair faulty
circuit. harness and
Was the problem found? — verify repair Go to Step 13

14 Substitute a known good CKP sensor and recheck.
15 Replace the CKP sensor.
release?
17 Replace the ECM.
Engine Speed Input Circuit Range/Performance
(OBD) System
Was the DTC P0335 (Symptom Code E) stored in this and Go to Step
4 Ask to the customer whether over-speed condition Explain the
such as miss-gear shifting etc. has been experienced reason of DTC
or not. — to the customer Go to Step 5
5 Check for poor/faulty connection at the CKP sensor or
C-57(B) 101 E-9

1 2 3
98
90


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?
Measurement Point Voltage (V) (AC Range)

At CKP sensor terminal 2 & 1 Approximately 1.1 V at
At ECM C57 connector 90 & 98 2000rpm
If a oscilloscope is available, monitor the CKP sensor

signal. Does the oscilloscope indicate correct wave
form?
Crankshaft Position (CKP) Sensor Reference Wave Form
0V®

Go to Step 9 Go to Step 7
and visually check.
8 Check the CKP sensor shield wire for open or short Repair faulty
circuit. harness and
Was the problem found? — verify repair Go to Step 9
release?

13 Replace the ECM.

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Code Code
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function.
Low short to ground circuit.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to volt-
High age circuit.

The voltage on the coil of the relay glow plug is supplied An intermittent may be caused by the following:
by the relay engine control module (ECM) main. The • Poor connections.
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but • Rubbed through wire insulation.
the glow plugs remain active for a certain period • Broken wire inside the insulation.
depending on engine coolant temperature. Check for the following conditions:
• Poor connection at ECM-Inspect harness connectors • Damaged harness-Inspect the wiring harness for
for backed out terminals, improper mating, broken damage. If the harness appears to be OK, observe
locks, improperly formed or damaged terminals, and the DTC P0380 display on the Tech2 while moving
poor terminal to wire connection. connectors and wiring harnesses. A change in the
Glow Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the glow relay or
C-57 X-5 3
1
2
4

5 Using the DVM and check the glow relay.
2. Remove the glow relay from the relay box.
3. Check the relay coil.
Grow Relay

Replace glow
Approximately relay and verify
1059 Go to Step 6 repair

6 Using the DVM and check the glow relay power
supply circuit.
circuit.
X-5
V
7 Repair the open or short to ground circuit between the
ECM main relay and glow relay.
8 Using the DVM and check the glow relay ground
circuit.
circuit.
Breaker Box X-5
94


circuit.
C-57 X-5
3
94
Repair faulty
harness and

release?
10 Replace the ECM.
Glow Relay Circuit Voltage High
(OBD) System
release?
the ECM/Immobilizer linking procedure. — Go to Step 6 —
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Code Code
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit
Voltage High short to voltage circuit.
Circuit Description the glow plugs remain active for a certain period
depending on engine coolant temperature.
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
Diagnostic Aids
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer An intermittent may be caused by the following:
activated. • Poor connections.
In the after glow phase the lamp is not illuminated but
• Rubbed through wire insulation. poor terminal to wire connection.
• Broken wire inside the insulation. • Damaged harness-Inspect the wiring harness for
Check for the following conditions: damage. If the harness appears to be OK, observe
• Poor connection at ECM-Inspect harness connectors the DTC P0381 display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
Glow Plug Indicator Circuit Voltage Low
(OBD) System
4 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “On”? — Go to Step 5 Go to Step 6
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.

7 Check for poor/faulty connection at the meter
connector and ECM connector. If a poor/faulty
C-56 43
6 B-24

8 Using the DVM and check the glow time telltale circuit.
3. Remove the meter connector.
circuit.

Breaker Box B-24
43


circuit.
C-56
43
6 B-24
Repair faulty
harness and

release?
10 Replace the ECM.
Glow Plug Indicator Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
GROUND OR OPEN CIRCUIT

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
BATTERY
Code Code
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Excessive Detected between 15 deg.C and 100 reduced.
deg.C.
2. Engine coolant tempera-
ture is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Barometric pressure is
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air flow
- mass air flow is more than
150mg/strk)
4 ON Exhaust Gas Recirculation EGR EVRV circuit open or Fuel injection quantity is
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV 10%
Open Circuit conditions as substitute.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Insufficient Detected between 15deg.C and 100 reduced.
deg.C.
2. Engine coolant tempera-
ture is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Barometric pressure is
between 850hpa and
1100hpa.
4. Large mount of mass air
below 150 mg/strk)
8 ON Exhaust Gas Recirculation EGR EVRV circuit short to Fuel injection quantity is
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10%
conditions as substitute.

The amount of EGR is controlled by EVRV (electrical An intermittent may be caused by the following:
vacuum regulating valve) via the engine control module • Poor connections.
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature. • Rubbed through wire insulation.
The EVRV is shaped to control vacuum applied to the • Broken wire inside the insulation.
diaphragm chamber of the EGR valve based on duty • EGR valve sticking.
signal sent from the ECM.
• Faulty intake air duct connection.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored. • Poor connection at ECM-Inspect harness connectors
If the EGR EVRV circuit is open or short ground circuit, for backed out terminals, improper mating, broken
DTC P0400 (Symptom Code 4) is stored. locks, improperly formed or damaged terminals, and
If the EGR EVRV circuit is short to voltage circuit, DTC poor terminal to wire connection.
P0400 (Symptom Code 8) is stored. • Damaged harness-Inspect the wiring harness for
the DTC P0400 display on the Tech2 while moving
Exhaust Gas Recirculation Flow Excessive Detected
(OBD) System
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.
5 Remove the MAF & IAT sensor assembly and visually
check.
and recheck.
8 Using the DVM and check the EGR EVRV.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
EGR EVRV
2 1
2 1
Approximately
149 at 20°C Go to Step 11 Go to Step 9

9 Substitute a known good EGR EVRV and recheck.
10 Replace the EGR EVRV.
11 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Vacuum Pump Small Window
If a problem is found, repair as necessary. Verify repair or

12 Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is
stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat. Verify repair or
13 Replace the EGR valve.

release?
15 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
(OBD) System
4 Check for poor/faulty connection at the EGR EVRV or
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV power
supply circuit.
2. Remove the EGR EVRV connector.
C-115
V
10-14.5 V Go to Step 8 Go to Step 7
and EGR EVRV.
8 Using the DVM and check the EGR EVRV circuit.
circuit.
Breaker Box C-115

97


circuit.
C-57 C-115
97
Repair faulty
harness and

release?
12 Replace the ECM.
Exhaust Gas Recirculation Flow Insufficient Detected
(OBD) System
4 Visually check the EGR control vacuum hose.
If the hose is clogged or disconnected, repair as
necessary.
coil.
EGR EVRV
2 1
2 1
Approximately

deposit.
Tech 2:
Vacuum Pump:
valve.
If a problem is found, repair as necessary. Verify repair or

9 Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is
stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat. Verify repair or
10 Replace the EGR valve.
Is the action complete? — Verify repair -

C-57(B) 92 C-116
2 3 4
5

circuit.
C-116
5
Repair faulty
V
harness and
and recheck.
release?
17 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Battery
(OBD) System
4 Check for poor/faulty connection at the EGR EVRV or
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV circuit.
2. Remove the EGR EVRV connector and ECM
connector.
3. 3. Check the circuit for short to voltage circuit.
C-115
1 2

7 Repair the short to voltage circuit.
release?
11 Replace the ECM.

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY
TOO HIGH

(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Code Code
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed 5km/
at next High Input 200km/h. h condition as substitute.
ignition
cycle
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed 5km/
at next Signal Frequency Too High high. h condition as substitute.
ignition
cycle
B ON Vehicle Speed Sensor Incor- 1. Engine speed is more than Fuel injection quantity is
at next rect Signal 3200rpm (4JA1-TC) or reduced.
ignition 3600rpm (4JH1-TC).
cycle 2. Fuel injection quantity is
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
3. Vehicle speed is below
1.5km/h.
Circuit Description • Misrouted harness.

The VSS is a magnet rotated by the transmission output • Rubbed through wire insulation.
shaft. The VSS uses a hall element. It interacts with the • Broken wire inside the insulation.
magnetic field treated by the rotating magnet. It outputs Check for the following conditions:
pulse signal. The 12 volts operating supply from the • Poor connection at ECM-Inspect harness connectors
meter fuse. for backed out terminals, improper mating, broken
The engine control module (ECM) calculates the vehicle locks, improperly formed or damaged terminals, and
speed by VSS. poor terminal to wire connection.
An intermittent may be caused by the following: the DTC P0500 display on the Tech2 while moving
• Poor connections.
Vehicle Speed Sensor Circuit High Input
(OBD) System

4 Perform test drive and check the speed meter.
Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6
5 Perform test drive and use the Tech 2.
Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel? — Go to Step 15 Go to Step 7
6 Remove the VSS from the housing case and visually
check.
7 Using the DVM and check the VSS signal.
1. Ignition “On”, vehicle “Run (lift up)”.
2. Measure the VSS output voltage at sensor, TCM
(A/T 2WD), meter and ECM.
Does the tester indicate specified value?
Measurement Position Voltage (V) If No
(AC Range) Good
VSS terminal 3 & GND Approximately 6.0 Go to
V at 20km/h Step 8
TCM C94 connector 10 & Go to
GND (A/T 2WD) Step 9
Meter B24 connector 9 & Go to
GND Step 10
GND Step 12
ECM C56 connector 68 & Go to
GND Step 13
If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope
indicate correct wave form?
Vehicle Speed Sensor (VSS) Reference Wave Form
0V®
Refer to
Measurement Terminal: 68(+) GND(-) Diagnostic Aids
Measurement Scale: 5V/div 50ms/div and Go to Step
Measurement Condition: Approximately 20km/h
15 Refer the table
8 Replace the VSS.
Is the action complete? — Verify repair
9 Replace the TCM.
IMPORTANT: The replacement TCM must be
programmed. “SPS (Service Programming System)
is necessary.” — Verify repair —

10 Using the DVM and check the VSS signal circuit.
2. Disconnect the meter connector.
B-24
9
Repair faulty
V
harness and
2. Disconnect the VSS connector and meter
connector.
circuit.
If a open or short to ground circuit is found, repair the
B-24 E-44
— Verify repair —
12 Replace the speed meter.
connector.
B-24
10
Repair faulty
V
harness and

4. Check the circuit for open or shot to ground circuit.

Breaker Box B-24
68


connector.
circuit.
C-56
68
B-24 10
Repair faulty
harness and
release?
16 Replace the ECM.
Vehicle Speed Sensor Input Signal Frequency Too High
(OBD) System
Was the DTC P0500 (Symptom Code A) stored in this and Go to Step
check.

(AC Range) Good
V at 20km/h Step 8
TCM terminal A10 & B5 Go to
(A/T 2WD) Step 9
GND Step 10
GND Step 11
GND Step 10

0V®
Refer to
10 Refer the table
8 Replace the VSS.
9 Replace the TCM.
release?

13 Replace the ECM.
Vehicle Speed Sensor Incorrect Signal
(OBD) System
6 Check for poor/faulty connection at the VSS, TCM (A/
T 2WD) and meter connectors. If a poor/faulty
E-44
1 3
2
B-24 9 10
C-94(10)


7 Check for poor/faulty connection at the ECM and
other connectors. If a poor/faulty connection is found,
C-56

check.
(AC Range) Good
V at 20km/h Step 10
TCM C94 connector 10 & Go to
GND (A/T 2WD) Step 11
GND Step 12
GND Step 14
GND Step 15

0V®
Refer to
17 Refer the table
10 Replace the VSS.

11 Replace the TCM.
B-24
9
Repair faulty
V
harness and
2. Disconnect the VSS connector and meter
connector.
circuit.
If a open or short to ground circuit is found, repair the
B-24 E-44

connector.
B-24
10
Repair faulty
V
harness and
4. Check the circuit for open or shot to ground circuit.

Breaker Box B-24
68


connector.
circuit.
C-56
68
B-24 10
Repair faulty
harness and

release?
18 Replace the ECM.

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION
Code Code
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as
20V. substitute.
2 OFF System Voltage Too Low System voltage is below 7V.
A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as
(pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
The ECM and PSG monitors the system voltage on the stored. The system voltage to the PSG excessively high
ignition feed terminal to the ECM or PSG. The system
or low, DTC P0560 (Symptom Code A) will be stored. • Poor connection at ECM and PSG-Inspect harness
Diagnostic Aids mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
An intermittent may be caused by the following:
• Poor connections. damage. If the harness appears to be OK, observe
• Misrouted harness. the “System Voltage” display on the Tech2 while
• Rubbed through wire insulation. moving connectors and wiring harness related to the
• Broken wire inside the insulation. sensor.
System Voltage Too High
(OBD) System
4 Was the battery jump start cable incorrectly Verify
connecting? — 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 Check the
headlights, etc.. charging
Does the Tech 2 indicate correct ignition voltage? 10 - 14.5V Go to Step 6 system
release?

7 Replace the ECM.
System Voltage Too Low
(OBD) System
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 Check the
battery terminal. charging
Does the tester indicate enough battery voltage? system, charge
or replace the
10 - 14.5V Go to Step 6 battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
C-56
3


7 Using the DVM and check the ECM main relay.
2. Remove the ECM main relay from the relay box.
ECM Main Relay

Replace ECM
main relay and
120-1509 Go to Step 8 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.
C-109

release?
10 Replace the ECM.
System Voltage Malfunction
(OBD) System
4 Check for poor/faulty connection at the PSG (pump
control unit) connector. If a poor/faulty connection is
found, repair as necessary.
E-6
6

5 Using the DVM and check the PSG (pump control
unit) power supply circuit.
connector.
3. Check the PSG (pump control unit) power supply
circuit.
6 E-6
7 10 - 14.5V Go to Step 7 Go to Step 6


6 Check for poor/faulty connection of the PSG (pump
control unit) ground at the cylinder body. If a poor/
faulty connection is found, repair as necessary.
E-10


(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Code Code
18 P0561 A OFF Ignition Switch Circuit Mal- The ECM recognized ignition ECM stops engine.
function switch turn off signal during
ECM is activated.
B OFF Ignition Switch Circuit Mal- Ignition switch circuit is mal-
function function.
Circuit Description • Rubbed through wire insulation.
The ECM monitors the ignition switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If the ignition switch signal with Check for the following conditions:
malfunction, DTC P0561 (Symptom Code A) or DTC • Poor connection at ECM-Inspect harness connectors
P0561 (Symptom Code B) will be stored. for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Diagnostic Aids poor terminal to wire connection.
• Poor connections. the “Ignition Status” display on the Tech2 while
• Misrouted harness. moving connectors and wiring harness related to the
sensor.
Ignition Switch Circuit Malfunction
Ignition Switch Circuit Malfunction
(OBD) System
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
(Symptom Code B)stored in this ignition cycle? — Go to Step 4 4
4 Check the “Engine fuse (10A)”.

5 Using the DVM and check the ignition power feed
circuit.
disconnected)
circuit.
C-107
Breaker Box
39


circuit.
C-56
39
C-107
Repair faulty
harness and
6 Check the ignition switch.
If a poor/faulty connection is found, repair as
necessary.
release?

8 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE

PROGRAMMING ERROR
Code Code
- P0602 - - Control Module Programming ECM memory area error. Engine control disabled.
Error
Circuit Description & Diagnostic Aids ECM does not programmed.

When the service ECM is used without SPS, DTC
The replacement ECM must be programmed by Service P0602 will appear.
Programming System (SPS). Because, the service
Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error

(OBD) System
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”. Refer to
Is the DTC P0602 stored as “Present Failure”? — Go to Step 3 Diagnostic Aids
3 Download the latest software to the ECM using the
“SPS (Service Programming System)”.

(FLASH CODE 28) ECU MALFUNCTION

(FLASH CODE 28) ECU MALFUNCTION
Code Code
28 P0606 A ON ECM Malfunction Gate Array communication 1. MAB (fuel cutoff solenoid
error. valve) is operated.
becomes 0mg/strk.
B ON ECM Malfunction 1. Throttle position is below MAB (fuel cutoff solenoid
1%. valve) is operated.
2. Desired injection quantity is
more than 0mg/strk.
3. Engine speed is more than
2000rpm.
Circuit Description & Diagnostic Aids

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
(OBD) System
release?

5 Replace the ECM.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit
Voltage High short to voltage circuit.

The voltage on the coil of the A/C compressor is An intermittent may be caused by the following:
supplied by the ECM main relay. The ECM switches A/C • Poor connections.
compressor relay to operate A/C compressor depends
on the A/C request signal and certain setting conditions.
Check for the following conditions: • Damaged harness-Inspect the wiring harness for
• Poor connection at ECM-Inspect harness connectors damage. If the harness appears to be OK, observe
for backed out terminals, improper mating, broken the DTC P0645 display on the Tech2 while moving
locks, improperly formed or damaged terminals, and connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty

X-14
C-56

5 Using the DVM and check the A/C compressor relay.
2. Remove the A/C compressor relay from the relay
box.
A/C Compressor Relay

Replace A/C
compressor

relay and verify
120-1509 Go to Step 6 repair

6 Using the DVM and check the A/C compressor relay
power supply circuit.
box.
circuit.
X-14
V
7 Repair the open or short to ground circuit between the
ECM main relay and A/C compressor relay.

8 Using the DVM and check the A/C compressor relay
ground circuit.
disconnected)
box.
circuit.
X-14
Breaker Box
41


box.
circuit.
X-14
C-56

Repair faulty
harness and
release?
10 Replace the ECM.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
Code Code
25 P0703 A ON Brake Switch Circuit 1. Throttle position is more No fail-safe function.
Malfunction than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
4. Brake switch 1 signal and
ECM since the ignition
switch was turned on.
B ON Brake Switch Circuit 1. Throttle position is more
Malfunction than 0%.
693rpm (4JA1-TC) or 665
rpm (4JH1-TC).
0km/h.
4. Brake switch 1 signal and
ECM.
The ECM monitors the brake switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If brake switch 1 or 2 circuit with Check for the following conditions:
malfunction, DTC P0703 (Symptom Code A) or P0703 • Poor connection at ECM-Inspect harness connectors
(Symptom Code B) will be stored. for backed out terminals, improper mating, broken
Diagnostic Aids poor terminal to wire connection.
• Poor connections. the “Brake Switch 1” and “Brake Switch 2” display on
• Misrouted harness. the Tech2 while moving connectors and wiring
harness related to the sensor.
Brake Switch Circuit Malfunction
(OBD) System

4 Check the “Stop Lamp fuse (15A)”.
5 Check for poor/faulty connection at the brake switch
or ECM connector. If a poor/faulty connection is found,
C-56 C-44
1 2

6 Using the DVM and check the brake switch 1.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 1.
Brake Switch

Pedal is not
stepped on:
Continuity
Pedal stepped Replace pedal

on: No switch and
continuity Go to Step 7 verify repair
7 Using the DVM and check the brake switch 1 power
supply circuit.
2. Remove the brake switch connector from the
brake switch.
C-44
V

8 Repair the open circuit between the “Stop Lamp fuse
(15A)” and brake switch 1.
9 Using the DVM and check the brake switch 1 circuit.
4. Check the circuit for open or short to voltage
circuit.
Breaker Box
105

2. Back probe the DVM to the brake switch 1 and
check the circuit for open or short to voltage
circuit.
C-44
2 Fixed at 10-
Pedal is not 14.5V: Go to
stepped on: Step 10
Less than 1V Fixed at less
V
Pedal stepped than 1V: Go to
on: 10-14.5V Go to Step 12 Step 11
10 Repair the short to voltage circuit between the brake
switch 1 connector and ECM.
C-56 C-44
30 2
11 Repair the open circuit between the brake switch 1
connector and ECM.
C-56 C-44
30 2

release?
13 Replace the ECM.
Brake Switch Circuit Malfunction
(OBD) System
4 Check for poor/faulty connection at the brake switch
C-56 C-44
3 4
5 Using the DVM and check the brake switch 2.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.
Brake Switch

Pedal is not
stepped on:
No continuity Replace pedal

Pedal stepped switch and
on: Continuity Go to Step 6 verify repair

6 Using the DVM and check the brake switch 2 power
supply circuit.
2. Remove the brake switch connector from the
brake switch.
C-44
V
7 Repair the open circuit between the “ECM fuse (10A)”
and brake switch 2.
8 Using the DVM and check the brake switch 2 circuit.
connected)
circuit.
Breaker Box
65

2. Back probe the DVM to the brake switch 2 and
circuit.
C-44
Pedal is not Fixed at 10-

4 stepped on: 14.5V: Go to
10-14.5V Step 9
Pedal stepped Fixed at less
V
on: Less than than 1V: Go to
1V Go to Step 11 Step 10

9 Repair the short to voltage circuit between the brake
switch 2 connector and ECM.
C-56 C-44
65 4
10 Repair the open circuit between the brake switch 2
connector and ECM.
C-56 C-44
65 4
release?
12 Replace the ECM.

(FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Code Code
57 P0704 6 ON Clutch Switch Input Circuit Clutch signal does not change No fail-safe function.
Malfunction between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.
Circuit Description • Broken wire inside the insulation.

The ECM monitors the clutch switch signal on the feed
terminal to the ECM. If clutch switch circuit with • Poor connection at ECM-Inspect harness connectors
malfunction, DTC P0704 (Symptom Code 6) will be for backed out terminals, improper mating, broken
stored. locks, improperly formed or damaged terminals, and
Diagnostic Aids • Damaged harness-Inspect the wiring harness for
An intermittent may be caused by the following: the “Clutch Switch” display on the Tech2 while
• Poor connections. moving connectors and wiring harness related to the
• Misrouted harness. sensor.
Clutch Switch Input Circuit Malfunction
(OBD) System
4 Check for poor/faulty connection at the clutch switch
31 C-56 C-77
1
2

5 Using the DVM and check the clutch switch.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch
Pedal is not
stepped on:
Continuity
Pedal stepped Replace pedal
on: No switch and
continuity Go to Step 6 verify repair

6 Using the DVM and check the clutch switch power
supply circuit.
2. Remove the clutch switch connector from the
clutch switch.
C-77
V
and clutch switch.
8 Using the DVM and check the clutch switch circuit.
circuit.
Breaker Box
31

2. Back probe the DVM to the clutch switch and
circuit.
C-77
Pedal is not Fixed at 10-

2 stepped on: 14.5V: Go to
10-14.5V Step 9
V Pedal stepped Fixed at less
on: Less than than 1V: Go to

9 Repair the short to voltage circuit between the clutch
switch connector and ECM.
C-56 C-77
2
31 — Verify repair —
10 Repair the open circuit between the clutch switch
connector and ECM.
C-56 C-77
2
release?
12 Replace the ECM.

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Code Code
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa condition
Circuit High Input output voltage is more than as substitute.
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor
Circuit Low Input output voltage is below 1.5V.

The ECM monitors the barometric pressure signal at If the DTC P1105 is stored, sensor or circuit of ECM
inside of the ECM. If the sensor with malfunction, DTC inside is failed.
P1105 (Symptom Code 1) or P1105 (Symptom Code 2)
will be stored.
Barometric Pressure Sensor Circuit High Input
Barometric Pressure Sensor Circuit Low Input
(OBD) System
Is the DTC P1105 (Symptom Code 1) or P1105 and Go to Step
(Symptom Code 2) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1105 (Symptom Code 1) or P1105 Refer to
(Symptom Code 2) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?

5 Replace the ECM.

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH
INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH
ERROR

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
Code Code
21 P1120 1 ON Pedal/Throttle Position Sen- Throttle position sensor out- ECM increases idle speed up
sor Circuit High Input put voltage is more than 4.5V. to 1400rpm.
7 ON Pedal/Throttle Position Sen- Throttle position sensor
sor Voltage Supply Circuit power supply voltage is more
High Input than 5.2V.
9 ON Pedal/Throttle Position Sen- Throttle position sensor
sor Voltage Supply Circuit power supply voltage is below
Low Input 4.6V.
D ON Pedal/Throttle Position Sen- 1. Engine speed is more than
sor Brake Switch Error 1700rpm.
1.5km/h.
3. When brake pedal is
depressed during accelera-
tor pedal is depressing.
E ON Pedal/Throttle Position Sen- 1. When idle switch is turned
sor Idle Position Switch Error off, throttle position sensor
was below 0.35%.
or
2. When idle switch is tuned
on, throttle position sensor
was more than 7.8%.

The TPS is a potentiometer connected to throttle shaft An intermittent may be caused by the following:
on the throttle body. It is installed to the main TPS and • Poor connections.
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the • Rubbed through wire insulation.
throttle valve angle is changed when accelerator pedal • Broken wire inside the insulation.
moved. The TPS signal also changed at a moved Check for the following conditions:
throttle valve. As the throttle valve opens, the output • Poor connection at ECM-Inspect harness connectors
increases so that the output voltage should be high. for backed out terminals, improper mating, broken
The ECM monitors the TPS supply voltage and TPS locks, improperly formed or damaged terminals, and
output voltage. The supply voltage is out of range, DTC poor terminal to wire connection.
P1120 (Symptom Code 7) or P1120 (Symptom Code 9)
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
the “Throttle Position”, “Idle Switch”, “Brake Switch 1”
If the brake pedal is depressed during accelerator pedal
and “Brake Switch 2” display on the Tech2 while
is depressing, DTC P1120 (Symptom Code D) will be
stored.
sensor.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.
Pedal/Throttle Position Sensor Circuit High Input
(OBD) System

4 Check for poor/faulty connection at the TPS or ECM
as necessary.
49 C-56 39
57
E-22
1 2 3

5 Visually check the TPS.

6 Using the DVM and check the TPS.
2. Disconnect TPS connector.
3. Measure the resistance of TPS.
Measurement Resistance (W)

Terminal
Approximately 0.4kW at idle position
1-2
Approximately 4.0kW at WOT
Approximately 4.3kW at idle position
2-3
Approximately 0.8kW at WOT
Approximately 4.6kW at idle position &
1-3
WOT
TPS
3 2 1
3 2 1
Standard
7 Using the DVM and check the TPS power supply
circuit.
2. Disconnect the TPS connector.
E-22
3
V
Approximately
and TPS.
C-56
57
E-22


9 Using the DVM and check the TPS signal circuit.
E-22
2
Repair faulty
V
harness and
10 Using the DVM and check the TPS ground circuit.
2. Disconnect the TPS connector .
E-22
1
Repair faulty
V
harness and

11 Using the DVM and check the TPS ground circuit.
Breaker Box
E-22
49


2. Disconnect the TPS connector and ECM
connector.
C-56
49
E-22
Repair faulty
harness and
12 Substitute a known good TPS and recheck.
13 Replace the TPS.
release?
15 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
(OBD) System
as necessary.
49 C-56 39
57
E-22
1 2 3


circuit.
E-22
3
V Approximately
ECM and TPS.
C-56
57
E-22

9 Replace the TPS.
release?
11 Replace the ECM.
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
(OBD) System
as necessary.
49 C-56 39
57
E-22
1 2 3


circuit.
circuit.
E-22
3
V
Approximately
circuit.
2. Disconnect the TPS connector and ECM
connector.
3. Check the circuit for short to TPS ground circuit.
E-22
1 3

8 Repair the circuit for short to TPS ground circuit.
9 Repair the short to ground circuit between the ECM
and TPS.
C-56
57
E-22

11 Replace the TPS.

release?
13 Replace the ECM. Is the action complete?
Pedal/Throttle Position Sensor Brake Switch Error
(OBD) System
Was the DTC P1120 (Symptom Code D) stored in this and Go to Step
• Accelerator pedal sticking.
2. Monitor the “Throttle Position” in the data display.
Does the Tech 2 indicate correct “Throttle Position”
from 0% to 100% depending on accelerator pedal
operation? — Go to Step 7 Go to Step 6
3. Adjust the TPS within 0% to 100%.
2. Monitor the “Brake Switch 1” and “Brake Switch 2”
in the data display.
Does the Tech 2 indicate “Inactive” when the brake
pedal was not stepped on? — Go to Step 13 Go to Step 8
8 Adjust the brake switch.
9 Substitute a known good brake switch and recheck.
10 Replace the brake switch.
12 Replace the TPS.

release?
14 Replace the ECM.
Pedal/Throttle Position Sensor Idle Position Switch Error
(OBD) System
Was the DTC P1120 (Symptom Code E) stored in this and Go to Step
Does the Tech 2 indicate correct “Throttle Position”
from 0% to 100% depending on accelerator pedal Go to Step 6Go
operation? — Go to Step 7 to Step 6
3. Adjust the TPS within 0% to 100%.
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
9 Replace the TPS.
release?

11 Replace the ECM.

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE

(FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW FUEL TEMPERATURE
Code Code
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine cool- No fail-safe function.
High Coolant Temperature ant temperature is detected.
7 OFF Fuel Reduction Caused By Fuel temperature is more than PSG (pump control unit) con-
High Fuel Temperature 100 deg. C. trols fuel injection quantity
based on engine speed and
fuel temperature.
A OFF Fuel Reduction Caused By Excessive low fuel tempera- No fail-safe function.
Low Fuel Temperature ture is detected.

The engine coolant temperature (ECT) sensor is An intermittent may be caused by the following:
installed on the coolant stream. High coolant • Poor connections.
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 • Rubbed through wire insulation.
signal voltage will be low when the engine temperature • Broken wire inside the insulation.
is hot. Check for the following conditions:
The fuel temperature sensor is assembled inside of the • Poor connection at ECM and PSG-Inspect harness
pump control unit (PSG). The signal of fuel temperature connectors for backed out terminals, improper
is sent via the CAN-bus from the PSG to ECM. mating, broken locks, improperly formed or damaged
If the engine coolant temperature is excessively high terminals, and poor terminal to wire connection.
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
the “Coolant Temperature” or “Fuel Temperature”
(Symptom Code A) will be stored.
display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
(OBD) System

4 Check the engine overheat condition. Repair the
Was the problem found? cause of
overheat and
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

-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
recheck.
release?

10 Replace the ECM.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Reduction Caused By Low Fuel Temperature
(OBD) System
Is the DTC P1173 (Symptom Code 7) or P1173 and Go to Step
(Symptom Code A) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1173 (Symptom Code 7) or P1173 Refer to
(Symptom Code A) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
6 Replace the ECM.

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Code Code
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction is recognized defective reduced.
engine speed signal form the
ECM.

The CKP sensor is located on top of the flywheel An intermittent may be caused by the following:
housing of the flywheel and fixed with a bolt. The CKP • Poor connections.
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 • Rubbed through wire insulation.
cylinder top dead center. • Broken wire inside the insulation.
The ECM converts sine wave signal to square wave Check for the following conditions:
signal. And this signal is provided from the ECM to • Poor connection at ECM-Inspect harness connectors
pump control unit (PSG). for backed out terminals, improper mating, broken
• Damaged harness-Inspect the wiring harness for moving connectors and wiring harness related to the
damage. If the harness appears to be OK, observe sensor.
the “Engine Speed” display on the Tech2 while
Engine Speed Output Circuit Malfunction
(OBD) System
4 Was the DTC P0335 (Symptom Code B) or P0335 Go to DTC
(Symptom Code D) stored at the same time? Chart P0335
(Symptom
Code B)
(Symptom
— Code C) Go to Step 5
C-57(B) 91 E-6


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
Crankshaft Position (CKP) Sensor & TDC Output Signal
Reference Wave Form
CH1
0V
CH2
0V
Not available:
Go to Step 7
Fixed at low:
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-) Go to Step 7
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div Fixed at High:

circuit.
connector.
circuit.
Breaker Box
91 E-6


connector.
circuit.
C-57(B) E-6
91 8
Repair faulty
harness and
circuit.
connector.
E-6
8
Repair faulty
V
harness and

release?
12 Replace the ECM.

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Code Code
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function.
is recognized incorrect cam-
shaft speed signal.

The pump camshaft sensor is a magnet with a coil. It • Broken wire inside the insulation.
uses to combine with the pulser. The pulser is attached Check for the following conditions:
main shaft in the pump. It likes a gear shape. • Poor connection at ECM and PSG-Inspect harness
The pump camshaft sensor is attached to the pump connectors for backed out terminals, improper
control unit (PSG). The signal of pump camshaft speed mating, broken locks, improperly formed or damaged
is sent via the CAN-bus from the PSG to ECM. terminals, and poor terminal to wire connection.
the “Pump Speed” display on the Tech2 while moving
• Poor connections. display will indicate the location of the fault.
Camshaft Speed Malfunction
(OBD) System
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
release?
8 Replace the ECM.

(FLASH CODE 47) NEUTRAL SWITCH ON ERROR

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Code Code
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function.
ted “On” three times consecu-
tively under driving
conditions.
B ON Neutral Switch OFF Error Neutral switch signal is input-
ted “Off” three times consecu-
tively under driving
conditions.
Circuit Description (Symptom Code B) will be stored.

The ECM monitors the neutral switch (A/T: N or P
Diagnostic Aids
position switch in inhibitor switch) signal on the feed
terminal to the ECM. If the neutral switch with An intermittent may be caused by the following:
malfunction, DTC P1520 (Symptom Code A) or P1520 • Poor connections.
• Misrouted harness. poor terminal to wire connection.
• Rubbed through wire insulation. • Damaged harness-Inspect the wiring harness for
• Broken wire inside the insulation. damage. If the harness appears to be OK, observe
Check for the following conditions: the “Neutral Switch” display on the Tech2 while
• Poor connection at ECM-Inspect harness connectors
sensor.
for backed out terminals, improper mating, broken
Neutral Switch ON Error
Neutral Switch OFF Error
(OBD) System
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
(Symptom Code B) stored in this ignition cycle? — Go to Step 4 4

4 Check for poor/faulty connection at the neutral switch
(inhibitor switch) or ECM connector. If a poor/faulty
C-57
87
M/T
E-11 E-12
A/T
E-51
2 3

5 Using the DVM and check the neutral switch (inhibitor
switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range N range
switch).
M/T
E-11 E-12
A/T
3 2
Neutral (P or
6 5 4 3 2 1 N): Continuity
Other than Replace neutral
10 9 8 7 neutral (P or switch (inhibitor
N): No switch) and
8 continuity Go to Step 6 verify repair

switch) power supply circuit.
2. Remove the neutral switch (inhibitor switch)
connector from the switch.
M/T A/T
E-12 E-51
V 3
V
and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).
switch) circuit.
circuit.
Breaker Box
87 E-6


2. Back probe the DVM to the neutral switch
(inhibitor switch) and check the circuit for open or
short to voltage circuit.
M/T A/T
E-11 E-51
Neutral (P or Fixed at 10-

N): 10-14.5V 14.5V: Go to
2 8 Other than Step 9
V neutral (P or Fixed at less
V V N): Less than than 1V: Go to

9 Repair the short to voltage circuit between the neutral
switch connector (inhibitor switch connector) and
ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8
10 Repair the open circuit between the neutral switch
connector (inhibitor switch connector) and ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8
release?
12 Replace the ECM.

(FLASH CODE 55) SEED AND KEY FILE DESTROYED

(FLASH CODE 55) EEPROM DEFECT

(FLASH CODE 55) EEPROM DEFECT
Code Code
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM No fail-safe function.
is destroyed.
D ON EEPROM Defect Write and read from the ECM uses default values from
EEPROM are failed during ini- the EPROM.
tialization of the ECM.
E ON EEPROM Defect EEPROM checksum does not
match with the read check
sum during initialization of the
ECM.
Circuit Description & Diagnostic Aids diagnostics operation.

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
The ECM used in this vehicle utilizes an electrically P1605 (Symptom Code C), P1605 (Symptom Code D)
erasable & programmable read only memory or P1605 (Symptom Code E) will be stored.
(EEPROM). The EEPROM contains program
information and the calibrations required for engine and
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
EEPROM Defect
EEPROM Defect
(OBD) System
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”. Refer to
Is the DTC P1605 (Symptom Code C), P1605 Diagnostic Aids
(Symptom Code D) or P1605 (Symptom Code E) and Go to Step
stored as “Present Failure”? — Go to Step 3 3

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E) Refer to
stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
5 Replace the ECM.

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Code Code
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.

The ECM decides whether that is an abnormality in the Check for the following conditions:
immobilizer control system. DTC P1610 (Symptom • Poor connection at ECM and immobilizer control unit-
Code A) is recorded when immobilizer function was not Inspect harness connectors for backed out terminals,
programmed in the ECM. improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
connectors and wiring harnesses.
Security Key and Security Code Not Programmed
(OBD) System
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnostic Trouble Code”. to DTC Chart
Was the any DTC's B0002 or B0009 stored in this B0002 or
ignition cycle? — B0009 Go to Step 5
release?
6 Replace the ECM.

(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Code Code
56 P1611 A - Wrong Security Code Entered Received security code is not 1. Engine does not start.
correct. 2. Check engine lamp flash.

Code A) is recorded when received immobilizer security Inspect harness connectors for backed out terminals,
code was not correct. improper mating, broken locks, improperly formed or
connection.
Wrong Security Code Entered
(OBD) System
Refer to
Was the any DTC's B**** stored in this ignition cycle? — B**** Go to Step 5
release?
6 Replace the ECM.

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Code Code
56 P1612 A - Immobilizer No or Wrong Sig- Received challenge signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

Code A) is recorded when received immobilizer Inspect harness connectors for backed out terminals,
challenge signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobilizer No or Wrong Signal
(OBD) System
Refer to
“Diagnositic Trouble Code”. to DTC Chart
Was the DTC B0007 stored in this ignition cycle? — B0007 Go to Step 5
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68
8

lamp circuit.
2. Disconnect the meter connector and immobilizer
control unit connector.
Was DVM indicated specified value?
B-68
7
Repair faulty
V
harness and

lamp circuit.
3. Disconnect the immobilizer control unit connector.
circuit.
Breaker Box
42 B-68


2. Disconnect the the immobilizer control unit
circuit.
C-56
42
B-68
Repair faulty
harness and

8 Using the DVM and check the ECM and immobilizer
control unit communication circuit.
B-68
8
V Repair faulty
harness and
circuit.
Breaker Box
35 B-68


circuit.
C-56
B-68 35
Repair faulty
harness and

release?
11 Replace the ECM.

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Code Code
56 P1613 A - Immobilizer No or Wrong Sig- Received response signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

response signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobilizer No or Wrong Signal
(OBD) System
Refer to
“Diagnositic Trouble Code”. to DTC Chart
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68
8

lamp circuit.
2. Disconnect the meter connector and immobilizer
control unit connector.
Was DVM indicated specified value?
B-68
7
V Repair faulty
harness and

lamp circuit.
circuit.
Breaker Box
42 B-68


circuit.
C-56
42
B-68
Repair faulty
harness and
B-68
8
Repair faulty
V
harness and

circuit.
Breaker Box
35 B-68


circuit.
C-56
B-68 35
Repair faulty
harness and
release?
11 Replace the ECM.

(FLASH CODE 56) WRONG TRANSPONDER KEY
Code Code
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start.
not correct from the transpon- 2. Check engine lamp flash.
der key.

response signal was not correct from the transponder improper mating, broken locks, improperly formed or
key. damaged terminals, and poor terminal to wire
connection.
Wrong Transponder Key
(OBD) System
Refer to
release?
6 Replace the ECM.
IMPORTANT: The replacement ECM must e

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Code Code
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function.
Off Too Early turned off, timing of the ECM
main relay turning off is too
early.
B OFF ECM Main Relay Switched When ignition switch was
Off Too Late turned off, timing of the ECM
main relay turning off is too
late or does not off.

The ECM switches ECM main relay to operate ECM An intermittent may be caused by the following:
and other sensors or controller. • Poor connections.
• Poor connection at ECM-Inspect harness connectors the “Main Relay” display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
ECM Main Relay Switched Off Too Early
(OBD) System
release?
5 Replace the ECM.
ECM Main Relay Switched Off Too Late
(OBD) System
4 Using the DVM and check the ECM main relay.
2. Remove the ECM main relay from the relay box.
3. Check the relay switch.
ECM Main Relay

Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
release?
6 Replace the ECM.

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
Code Code
51 P1630 A ON Fuel Injection Quantity Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction detects high pressure sole- reduced.
noid valve control circuit mal-
function due to high current.
B ON Fuel Injection Quantity Circuit The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
Malfunction detects high pressure sole- valve) is operated.
noid valve control circuit mal- 2. Desired injection quantity
function due to continuous becomes 0mg/strk.
current.
Circuit Description programmed pump map data.

The ECM is calculates an injection quantity and an
injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
Diagnostic Aids • Broken wire inside the insulation.
• Poor connections. connectors for backed out terminals, improper
• Misrouted harness. mating, broken locks, improperly formed or damaged
• Rubbed through wire insulation. terminals, and poor terminal to wire connection.
Injection Quantity Circuit Malfunction
Injection Quantity Circuit Malfunction
(OBD) System
(symptom Code B) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1630 (Symptom Code A) or P1630 Refer to
(symptom Code B) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids

(FLASH CODE 44) CAN DEVICE OFFLINE

(FLASH CODE 44) CAN DEVICE HANG-UP
Code Code
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid
off or canceling. valve) is operated.
B ON CAN Device Hang-up CAN controller does not react
under engine running.

The interchange of data between the engine control An intermittent may be caused by the following:
module (ECM) and the pump control unit (PSG) is • Poor connections.
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 • Rubbed through wire insulation.
modules that are connected to different CAN-bus • Broken wire inside the insulation.
systems to communicate. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness • Damaged harness-Inspect the wiring harness for
connectors for backed out terminals, improper damage. If the harness appears to be OK, observe
mating, broken locks, improperly formed or damaged the DTC P1650 display on the Tech2 while moving
terminals, and poor terminal to wire connection. connectors and wiring harnesses.
CAN Device Offline
(OBD) System
C-57 E-6 2
1
6 Using the DVM and check the CAN high circuit.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 7 verify repair

connector.
circuit.
Breaker Box

100 E-6


connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

8 Using the DVM and check the CAN low circuit.
connector.
circuit.
Breaker Box
99 E-6


connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
99 1 — Verify repair —
unit) ground circuit.
connector.
E-6
6
Repair faulty
harness and

interference. accessory parts
release?
17 Replace the ECM.
CAN Device Hang-up
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 45) CAN MALFUNCTION

(FLASH CODE 45) CAN RECEIVES ERROR
Code Code
45 P1651 A ON CAN Malfunction The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
does not recognize CAN sig- valve) is operated.
nal from the CAN controller. 2. Desired injection quantity
becomes 0mg/strk.
B ON CAN Malfunction The ECM does not read CAN
signal from the PSG (pump
control unit).
Circuit Description systems to communicate.
The interchange of data between the engine control

Diagnostic Aids
module (ECM) and the pump control unit (PSG) is
performed via a CAN-bus system. The individual CAN- An intermittent may be caused by the following:
bus systems are connected via two interfaces and can • Poor connections.
exchange information and data. This allows control
modules that are connected to different CAN-bus
• Rubbed through wire insulation. terminals, and poor terminal to wire connection.
• Poor connection at ECM and PSG-Inspect harness the DTC P1651 display on the Tech2 while moving
connectors for backed out terminals, improper connectors and wiring harnesses.
CAN Malfunction
(OBD) System
release?
6 Replace the ECM.
CAN Receives Error
(OBD) System
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
C-57 E-6 2
1
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 8 verify repair

connector.
circuit.
Breaker Box

100 E-6


connector.
circuit.
C-57 E-6
100 2
Repair faulty
harness and

connector.
circuit.
Breaker Box
99 E-6


connector.
circuit.
C-57 E-6
99 1
Repair faulty
harness and
connector.
approximately 5V?
E-6
2
V

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
99 1 — Verify repair —
unit) ground circuit.
connector.
E-6
6
Repair faulty
harness and

interference. accessory parts
release?
18 Replace the ECM.

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Code Code
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function.
Circuit Voltage Low open or short to ground cir-
cuit.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit
Circuit Voltage High short to ground circuit.

The Check Engine Lamp (Malfunction Indicator Lamp An intermittent may be caused by the following:
=MIL) should always be illuminated and steady with • Poor connections.
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 • Rubbed through wire insulation.
the check engine lamp driver circuit for a certain time. • Broken wire inside the insulation.
Check for the following conditions: • Damaged harness-Inspect the wiring harness for
• Poor connection at ECM-Inspect harness connectors damage. If the harness appears to be OK, observe
for backed out terminals, improper mating, broken the “Check Engine Lamp” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harnesses. A change
poor terminal to wire connection. in the display will indicate the location of the fault.
Check Engine Lamp (MIL) Circuit Voltage Low
(OBD) System
2. Check the “Check Engine” lamp.
Does the lamp turn “On”? — Go to Step 5 Go to Step 6
2. Check the “Check Engine” lamp.
Does the lamp turn “Off”? — Go to Step 9 Go to Step 7
6 Check the “Check Engine” lamp bulb.
7 Check for poor/faulty connection at the meter
connector and ECM connector. If a poor/faulty
C-56 42
17 B-24


8 Using the DVM and check the “Check Engine” lamp
circuit.
circuit.
Breaker Box B-24

42


circuit.
C-56
42
B-24
Repair faulty
harness and
release?

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

(OBD) System
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 Visual /
— Go to Step 4 physical Check
4 Is the fuel amount enough?
Add fuel to the

— Go to Step 5 tank
5 Is the customer using the incorrect fuel type? Diesel fuel Replace with
only diesel fuel Go to Step 6
6 Check the “ECM” fuse (10A) and “Engine” fuse (15A).
• Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
• Check for objects blocking or excessive deposits in
the throttle bore and on the throttle plate
• Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
• Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
Was a problem found? — Verify repair Go to Step 8
8 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?

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.
14 Check the exhaust system for a possible restriction.
• Damaged or collapsed pipes or catalytic converter.
• Internal muffler failure.
fuel hose/pipe.
fuel.

injection pump and check for the following conditions.
fuel.
Replace the
eye bolt with
gauze filter and
18 Check the engine compression pressure for each
cylinders.
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?
Repair as
— Go to Step 20 necessary

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
release?
23 Replace the ECM.
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.

(OBD) System
intake system
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
8 1. Using the Tech 2, display the FT sensor value.
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”?

10 1. Using the Tech 2, ignition “On”.
2. Monitor the “Glow Time Relay” in the data display
and then, does the supply voltage correctly supply
to the glow plug?
Repair voltage
supply circuit
— Go to Step 11 and verify repair
11 Check the glow plugs for continuity.
Was a problem found?

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and
16 Remove the injection nozzles from the engine and
• Improper splay condition.
• Operating pressure is incorrect.
1 st Stage 2nd Stage

Approximatly Approximatly
4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
Approximatly Approximatly Replace the
19.5 Mpa 33.8 Mpa
injection nozzle
— and verify repair Go to Step 17
cylinders.
More than 2.1

Mpa Verify repair Go to Step 18

18 Check the inlet/exhaust valve clearance for each
valves.
Are the valve clearances within the specified value?
0.4mm at cold Adjust and

(In/Ex) Go to Step 19 verify repair
following:
• Tech 2 data
and/or system
release?
22 Replace the ECM.
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
rpm
enough to stall the engine.
X
Rough Idle
Stall
time

(OBD) System
5 1. Check for incorrect idle speed. Ensure that the
following conditions are present.
• Engine fully warm.
• Accessories are “OFF”. Desired
2. Using a Tech 2, monitor “Desired Engine Idle Engine Idle
Speed” and “Engine Speed”. Speed ± 25
Is the “Engine Speed” within the specified values? rpm Go to Step 7 Go to Step 6
intake system

9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “A/C Information Switch” in the data
display.
Does the Tech 2 indicate correct “A/C Information
Switch” status depending on A/C switch position?
sensor value.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? — Go to Step 16 Go to Step 12
• Objects blocking at the MAF sensor element.
13 Check the MAF sensor harness for the following
conditions.
and recheck.
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

3. Adjust the accelerator cable or TPS within 0% to
100%.
18 Check the TPS harness for the following conditions.
20 Replace the TPS.
conditions.
23 Substitute aknown good CKP sensorand recheck.

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”?
When idling or part-throttle
Desired
High
Actual
Low
Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and

4JA1-TC
19.0 Mpa 33.5 Mpa
Replace the
4JH1-TC injection nozzle
19.5 Mpa 33.8 Mpa
cylinders. Each cylinder must be evenly.
More than 2.1


valves.

following:
• Tech 2 data
and/or system
release?
37 Replace the ECM.
SURGES AND/OR CHUGS SYMPTOM

DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time

(OBD) System
intake system
display.

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
When idling or part-throttle When accelerated
Desired Desired
High High
Actual
Actual
Low Low
Time Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and
following:
• Tech 2 data
and/or system
release?
31 Replace the ECM.

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 Stumble
rpm
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Sug
Hesitation
time

(OBD) System
5 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
intake system

sensor value.
conditions.
and recheck.
100%.
18 Replace the TPS.

conditions.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and
following:
• Tech 2 data
and/or system
release?
32 Replace the ECM.

CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows
engine speed; usually more pronounced as engine load
increases.
rpm
time

(OBD) System
intake system
compressor
wheel or turbine shaft sticking.

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?
When constant vehicle speed

Correct Speed
High
Unstable Data
Low
Time
8 Check the VSS harness for the following conditions.
9 Substitute a known good VSS and recheck.
10 Replace the VSS assembly.
conditions.
and recheck.

100%.
20 Replace the TPS.
conditions.

“Run”.
display.
When idling or part-throttle

Desired
High
Actual
Low
Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and
following:
• Tech 2 data
and/or system
release?
33 Replace the ECM.

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.

(OBD) System
intake system
sensor value.

conditions.
and recheck.
100%.
18 Replace the TPS.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
deposit.
Tech 2:
Vacuum Pump:
valve.


fuel hose/pipe.
fuel.
fuel.
Replace the
eye bolt with
gauze filter and


4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
19.5 Mpa 33.8 Mpa injection nozzle
cylinders.
More than 2.0

valves.

following:
• Tech 2 data
and/or system

release?
31 Replace the ECM.
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.)

(OBD) System
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.
7 Check for incorrect or faulty engine thermostat. Refer
to Engine Cooling.
8 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2? — 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.
11 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.

display.
intake system
sensor value.
conditions.

and recheck.
100%.
26 Replace the TPS.

4JA1-TC
19.0 Mpa 33.5 Mpa
Replace the
4JH1-TC injection nozzle
19.5 Mpa 33.8 Mpa

cylinders.
More than 2.0

valves.

following:
• Tech 2 data
and/or system
release?

33 Replace the ECM.
EXCESSIVE WHITE SMOKE

(OBD) System
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or exhaust through the
gasket.
sensor value.
conditions.

and recheck.
2. Monitor the “Glow Time Relay” in the data display.
Does the Tech 2 indicate correct “Glow Time Relay”
status depending on the time from engine “Run”?
2. Monitor the “Glow Time Relay” in the data display
and then, does the supply voltage correctly supply
to the glow plug?
Repair voltage
supply circuit
— Go to Step 16 and verify repair
16 Check the glow plugs for continuity.
Was a problem found?

conditions.

“Run”.
display.
Desired Desired
High High
Actual
Actu al
Low Low
Time Time
fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and

4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
19.5 Mpa 33.8 Mpa
Replace the
injection nozzle

cylinders.
More than 20
valves.

following:
• Tech 2 data
and/or system
release?

32 Replace the ECM.
EXCESSIVE BLACK SMOKE

(OBD) System
intake system
sensor value.

conditions.
and recheck.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time

deposit.
Tech 2:
Vacuum Pump:
valve.



4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
19.5 Mpa 33.8 Mpa injection nozzle
cylinders.
More than 20
valves.

following:
• Tech 2 data
and/or system

release?
23 Replace the ECM.
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE tightening torque.

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

SENSOR (ECT) SENSOR
Location Location
Installed to the clutch housing. Installed to the thermostat housing.
Removal Procedure Removal Procedure

1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Disconnect connector from the CKP sensor. 2. Drain enough engine coolant so that the coolant
3. Loosen a bolt and remove the CKP sensor from the level will be below the ECT sensor.
clutch housing. 3. Disconnect connector from the ECT sensor.
4. Loosen and remove the ECT sensor from the
thermostat housing.
NOTE: Cool down the engine before above procedures

are carried out.
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
1. Apply sealer to threads of screw at the ECT sensor.
3. Connect a CKP sensor connector to the CKP
sensor. 2. Tighten the ECT sensor with specified tightening
torque.
Tightening Torque
NOTE: Verify any DTCs (diagnosis Trouble Code) are • Bolt: 13N·m (1.3kgf·m)
not stored after replacement. 3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.
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 THROTTLE POSITION SENSOR

AIR TEMPERATURE (IAT) SENSOR (TPS)
Location Location
Installed to the intake duct housing. Installed on the throttle body.
Removal Procedure Removal Procedure

1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Disconnect a MAF & IAT sensor connector from the 2. Disconnect the TPS connector.
MAF & IAT sensor assembly. 3. Loosen two screws and remove TPS from the
3. Loosen the clips and remove the MAF & IAT sensor throttle body.
assembly from the intake duct housing.
Installation Procedure 1. Temporary tighten the TPS by two screws.
1. Install the MAF & IAT sensor assembly into intake 2. Connect a TPS connectors to the TPS.
air duct.
3. Connect the Tech2 to the vehicle.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF
5. Select “Data Display” with the Tech2.
& IAT sensor assembly.
6. Check the throttle position data and adjust the TPS
position.
NOTE: Verify any DTCs (diagnosis Trouble Code) are 7. Tighten two screws.
EGR EVRV (Electrical Vacuum

Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.

Verify proper connection of two hoses.
SPECIAL SERVICE TOOLS

ILLUSTRATION TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge

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4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1

ABBREVIATION CHARTS ........................ 6E-9 Outline ....................................................... 6E-70

(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

(1) Engine Control Module (ECM) (1) EGR EVRV

(1) Engine Coolant Temperature (ECT) Sensor

(1) Vehicle Speed Sensor (VSS)

Green Meter-B ECM-A

White J/B I2 ECM-B

White J/B I4 Clutch switch

Black Check connector White TCM

White Ignition switch (IGSUB : G1) White TCM

White Ignition switch (IGSUB : G2) White J/B E2

Immobilizer White J/B E1

Silver Engine room-RH ground Silver Body-LH ; ground

Silver Engine room-LH ; Ground Brown EVRV

White Stop lamp switch

No. Connector face No. Connector face

A/C Resister & Neutral switch Gray Idle SW

Black Coolant temp sensor

Gray Vehicle speed sensor

Black Magnetic clutch AC COMP Gray Glow plug

Black Inhibiter switch

White Engine room ~ Mission

Silver Engine ground White Engine room ~ INST

Brown TPS 1 main White Engine ~ Engine room C

No. Connector face No. Connector face

Engine ~ Engine room Black DIODE

Silver Battery (+) Black DIODE

Silver Relay & Fuse box

Silver Battery (-)

Silver Body earth (Ground)

Silver Engine ground

Black Relay ; Glow

Black Relay ; ECM MAIN

Black Relay; A/C Compressor

Black Relay; Thermo

SLOW BLOW FUSE

ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

Signal or Continuity Tester Position

Signal or Continuity Tester Position

Signal or Continuity Tester Position

Signal or Continuity Tester Position

Signal or Continuity Tester Position

1 99 CAN (Controller Area RED Continu- - - - Discon- Ohm 1 99

2 100 CAN (Controller Area WHT Continu- - - - Discon- Ohm 2 100

5 105 Solenoid Valve Shut ORG Continu- - - - Discon- Ohm 5 105

6 - Ground BLK Continu- - - - Discon- Ohm 6 GND

7 - Battery Power Sup- BLU/ Less 10-14V Discon- Ohm 7 GND

8 91 CKP Sensor Output PNK Continu- - - - Discon- Ohm 8 91

Signal or Continuity Tester Position

1 1 ECM Ground BLK Continu- - - - Discon- Ohm 1 GND

2 2 ECM Ground BLK Continu- - - - Discon- Ohm 2 GND

3 3 Battery Power Sup- BLU/ Less 10-14V Connect DC V 3 GND

27 27 Engine Speed Output LGN - - Approx. Approx. Connect AC V 27 GND

29 29 Throttle Position Sig- - Approx. 140Hz by wave form (Idle: - - - -

35 35 To Data Link Con- YEL - - - - - - - -

Signal or Continuity Tester Position

38 38 Throttle Position GRN/ Less Less than 1V Approx. Connect DC V 38 49

39 39 Key Switch Input Sig- WHT Less 10-14V Connect DC V 39 GND