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ENGINE DRIVEABILITY AND EMISSIONS 6E–1

ENGINE with TF 4JA1-TC/TF
4JH1-TC/NKR 4JH1-TC Bosch VP44 system
CONTENTS
ENGINE DRIVEABILITY AND EMISSIONS
ISUZU Strategy Based Diagnostics .............. 6E-4
Overview .................................................... 6E-4
STRATEGY BASED DIAGNOSTICS
CHART .................................................... 6E-4
Diagnostic Thought Process ...................... 6E-5
1. Verify the Complaint .............................. 6E-5
2. Perform Preliminary Checks .................. 6E-5
3. Check Bulletins and Troubleshooting
Hints ........................................................ 6E-6
4. Perform Service Manual Diagnostic
Checks ..................................................... 6E-6
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................ 6E-6
5c. Technician Self Diagnoses .................. 6E-6
5d. Intermittent Diagnosis .......................... 6E-7
5e. Vehicle Operates as Designed ............ 6E-8
6. Re-examine the complaint ..................... 6E-9
7. Repair and Verify Fix ............................. 6E-9
Specification difference ............................. 6E-10
TF 4JA1-TC with Bosch VP44
System ECM Wiring Scheme
(Manual Transmission) ............................ 6E-11
TF 4JH1-TC with Bosch VP44
System ECM Wiring Scheme
(Automatic Transmission) ........................ 6E-12
TF 4JH1-TC with Bosch VP44
System ECM Wiring Scheme
(Manual Transmission) ............................ 6E-13
N*R 4JH1-TC with Bosch VP44
System ECM Wiring Diagram .................. 6E-14
TF 4JA1-TC/4JH1-TC ECM Pinouts .......... 6E-15
N*R 4JH1-TC ECM Pinouts ....................... 6E-18
TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC,
Specifications ................................................ 6E-21
Tightening Specifications ........................... 6E-21
TF 4JA1-TC with Bosch VP44
System Component Locator .................... 6E-22
TF 4JA1-TC with Bosch VP44
System Component Locator .................... 6E-23
TF 4JA1-TC/4JH1-TC TDC Sensor
Location ................................................... 6E-24
TF 4JA1-TC, 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-25
TF 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-26
TF 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-27
N*R 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-28
N*R 4JH1-TC with Bosch System
Component Locator ................................. 6E-29
N*R 4JH1-TC with Bosch System
Component Locator ................................. 6E-30
N*R 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-31
N*R 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-32
NKR 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-33
TF 4JA1-TC Fuse Box ............................... 6E-34
TF 4JH1-TC Fuse Box ............................... 6E-35
N*R 4JH1-TC Fuse Box ............................. 6E-36
N*R 4JH1-TC Fuse and Relay Panel ........ 6E-37
N*R 4JH1-TC Relay Panel ........................ 6E-38
Abbreviations Charts ................................. 6E-39
Injection pump Control System .................. 6E-40
TDC Sensor ............................................... 6E-41
Engine Coolant Temperature (ECT) Sensor 6E-41
Vehicle Speed Sensor (VSS) ..................... 6E-41
TDC (Engine Speed) Sensor ..................... 6E-41
ECM System Diagram – No.1 .................... 6E-42
ECM System Diagram – No.2 .................... 6E-43
MAF/IAT Sensor Circuit ............................. 6E-44
ECM System Diagram – No.3 .................... 6E-45
ECM System Diagram – No.4 .................... 6E-46
ECM System Diagram – No.5 .................... 6E-47
General Service Information ...................... 6E-48
Serviceability Issues .................................. 6E-48
Non-OEM Parts ......................................... 6E-48
Poor Vehicle Maintenance ......................... 6E-48
Related System Faults ............................... 6E-48
On-Board Diagnostic (OBD) ...................... 6E-48
On-Board Diagnostic
(Self Diagnosis System) Tests ................. 6E-48
The Diagnostic Executive .......................... 6E-48
Diagnostic Information ............................... 6E-48
Check Engine Lamp .................................. 6E-48
Data Link Connector (DLC) ....................... 6E-48
Reading Flash Diagnostic Trouble Codes . 6E-50
Reading Diagnostic Trouble Codes Using
a TECH 2 ................................................. 6E-50
Clearing Diagnostic Trouble Codes ........... 6E-50
History DTC ............................................... 6E-50
Tech2 ........................................................ 6E-51
Tech2 Features ......................................... 6E-51
Getting Started ........................................... 6E-52
HOME
6E–2 ENGINE DRIVEABILITY AND EMISSIONS
Operating Procedure (For Example) ......... 6E-52
DTC ........................................................... 6E-53
DTC Information Mode .............................. 6E-53
Engine ....................................................... 6E-53
History ....................................................... 6E-53
Clear DTC Information ............................... 6E-53
Tech2 Data Display ................................... 6E-53
Plotting Snapshot Graph ........................... 6E-54
Plotting Graph Flow Chart
(Plotting graph after obtaining
vehicle information) ................................. 6E-55
Flow Chart for Snapshot Replay
(Plotting Graph) ....................................... 6E-56
How To Use Breaker Box .......................... 6E-57
Breaker Box Connection Type A for Open
Circuit Check, Short to Ground Check
and Short to Battery Check ..................... 6E-58
Breaker Box Connection Type B for Power,
Signal Voltage Check between ECM
and Sensors ............................................ 6E-59
How To Use TIS2000 Snapshot Analysis .. 6E-60
Snapshot Display ....................................... 6E-60
Typical Scan Data Values ......................... 6E-64
TF 4JA1-TC ............................................... 6E-64
TF 4JH1-TC (MT) ...................................... 6E-65
TF 4JH1-TC (AT) ....................................... 6E-66
NKR 4JH1-TC ............................................ 6E-67
Engine Data Definitions ............................. 6E-69
On-Board Diagnostic (OBD) System Check 6E-80
Circuit Description ..................................... 6E-80
Diagnostic Aids .......................................... 6E-80
Test Description ......................................... 6E-80
On Board Diagnostic (OBD) System Check 6E-81
No Check Engine Lamp ............................. 6E-82
Diagnostic Aids .......................................... 6E-82
Test Description ......................................... 6E-82
No Check Engine Lamp ............................. 6E-83
Check Engine Lamp “ON” Steady ............. 6E-85
Circuit description ...................................... 6E-85
Diagnostic Aids .......................................... 6E-85
Test Description ......................................... 6E-85
Check Engine Lamp “ON” Steady ............. 6E-86
DTC P0100
MAF SENSOR MALFUNCTION .............. 6E-87
DTC P0110
IAT Sensor Maifunction ........................... 6E-95
DTC P0115
Engine Coolant Temperature
Sensor Malfunction .................................. 6E-99
DTC P0180 SUB CODE 1011
FUEL TEMPARETURE SENSOR
CIRCUIT RANGE/PERFORMANCE ....... 6E-104
DTC P0215
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION ....................................... 6E-106
DTC P0216
TIMING DEVICE DEVIATION ................. 6E-111
DTC P0216
TIMING DEVICE FLUCTUATION ........... 6E-112
DTC P0251
INJECTION MALFUNCTION ................... 6E-113
DTC P0335
TDC MALFUNCTION .............................. 6E-116
DTC P0380
GLOW DEVICE MALFUNCTION ............ 6E-123
DTC P0381
GLOW TIME TELLTALE CIRCUIT
MALFUNCTION ....................................... 6E-128
DTC P0400
EGR SYSTEM MALFUNCTION .............. 6E-131
DTC P0500
VSS MALFUNCTION ............................... 6E-138
DTC P0560
SYSTEM VOLTAGE MALFUNCTION ..... 6E-141
Circuit Description ...................................... 6E-141
DTC P0561
SWITCHED SYSTEM VOLTAGE
(IGNITION ON) CIRCUIT MALFUNCTION 6E-146
DTC P0606
ECM Malfunction1 ................................... 6E-148
DTC P0606
ECM Malfunction2 ................................... 6E-148
DTC P0645
A/C COMPRESSOR CUTOFF RELAY
MALFUNCTION ....................................... 6E-149
DTC P0703
BRAKE-LIGHT SWITCH CIRCUIT
MAIFUNCTION ........................................ 6E-155
DTC P0704
CLUTCH SWITCH INPUT CIRCUIT
MALFUNCTION ....................................... 6E-158
DTC P1105
BAROMETRIC PRESSURE
SENSOR (BP) MALFUNCTION .............. 6E-160
DTC P1110
INTAKE SHUTTER VSV (DIESEL)
MALFUNCTION (NKR 4JH1-TC only) ..... 6E-161
DTC P1120
AP SENSOR MAIFUNCTION .................. 6E-165
DTC P1173
FUEL REDUCTION CAUSED BY
HIGH COOLANT TEMPERATURE ......... 6E-171
Fuel Reduction adjustment ........................ 6E-171
NKR 4JH1-TC ............................................ 6E-171
TF 4JH1-TC, 4JH1-TC ............................... 6E-171
DTC P1173
FUEL REDUCTION CAUSED BY
HIGH FUEL TEMPERATURE 1 .............. 6E-173
DTC P1173
FUEL REDUCTION CAUSED BY
HIGH FUEL TEMPERATURE 2 .............. 6E-173
DTC P1345
INJECTION PUMP:CAMSHAFT
SPEED MALFUNCTION .......................... 6E-174
DTC P1520
NEUTRAL SWITCH ................................. 6E-175
DTC P1576
EXHAUST BRAKE VALVE1
CIRCUIT MALFUNCTION ....................... 6E-178
DTC P1605
ENGINE DRIVEABILITY AND EMISSIONS 6E–3
EEPROM DEFECT .................................. 6E-184
DTC P1610
SEEDS AND KEY FILE DESTROYED .... 6E-185
DTC P1611
WRONG SECURITY CODE ENTERED .. 6E-185
DTC P1612/P1613
IMMOBILIZER NO OR WRONG SIGNAL 6E-185
DTC P1614
Wrong transponder key ........................... 6E-185
DTC P1625
Power supply relay malfunction ............... 6E-186
DTC P1630
FUEL-INJECTION QUANTITY
CIRCUIT MALFUNCTION ....................... 6E-187
DTC P1650
CAN: DEVICE MALFUNCTION ............... 6E-188
DTC P1651 SUB CODE 1010
INJECTION PUMP: CAN MALFUNCTION 6E-190
DTC P1651 SUB CODE 1011
CAN RECEIVEDS ERROR ..................... 6E-191
DTC P1690
MALFUNCTION INDICATION LAMP (MIL)
CIRCUIT MALFUNCTION ....................... 6E-192
Symptom chart & perform procedure ........ 6E-195
1-1. No cranking happens. ........................ 6E-196
1-2. Starter can crank engine, but seems
to be lower than usual. ............................ 6E-196
1-3. Cranking speed seems to be OK,
but no combustion sounds can be heard. 6E-197
1-4. Engine run as idle speed, but can not
raise engine speed to usual engine
speed zone. ............................................. 6E-200
1-5. Engine stall after engine speed reach
more than 2000 rpm. ............................... 6E-203
2. Engine stall ............................................ 6E-205
2-1 Engine stall at idling. ........................... 6E-205
2-2 Engine stall after engine revolution
becomes more than idling speed.
Undershoot stall. ...................................... 6E-209
3. Rough idle ............................................. 6E-211
4. Excessive white smoke. ........................ 6E-214
5. Excessive black smoke ......................... 6E-220
6. Hesitation 7. Surge/Sag ...................... 6E-224
EGR control logic ....................................... 6E-229
8. Lack of power ........................................ 6E-230
9. Poor fuel consumption ........................... 6E-233
SPECIAL SERVICE TOOLS ..................... 6E-237
6E–4 ENGINE DRIVEABILITY AND EMISSIONS
ISUZU Strategy Based Diagnostics
Overview
As a retail service technician, you are part of the ISUZU
service team. The team goal is FIX IT RIGHT THE
FIRST TIME for the satisfaction of every customer. You
are a very important member of the team as you
diagnose and repair customer vehicles.
You have maximum efficiency in diagnosis when you
have an effective, organized plan for your work. Strategy
Based Diagnostics (refer to Figure 1) provides you with
guidance as you create and follow a plan of action for
each specific diagnostic situation.
STRATEGY BASED DIAGNOSTICS CHART
ENGINE DRIVEABILITY AND EMISSIONS 6E–5
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:
• Improves your understanding and definition of the
customer complaint
• Saves time by avoiding testing and/or replacing good
parts
• Allows you to look at the problem from different
perspectives
• Guides you to determine what level of understanding
about system operation is needed:
– Owner’s manual level
– Service manual level
– In-depth (engineering) level
– Owner’s manual level
– Service manual level
– In-depth (engineering) level
1. Verify the Complaint
What you should do
To verify the customer complaint, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the
system.
The following information will help you verify the
complaint:
• WHAT the vehicle model/options are
• WHAT aftermarket and dealer-installed accessories
exist
• WHAT related system(s) operate properly
• WHEN the problem occurs
• WHERE the problem occurs
• HOW the problem occurs
• HOW LONG the condition has existed (and if the
system ever worked correctly)
• HOW OFTEN the problem occurs
• Whether the severity of the problem has increased,
decreased or stayed the same
What resources you should use
Whenever possible, you should use the following
resources to assist you in verifying the complaint:
• Service manual Theory or Circuit Description
sections
• Service manual “System Performance Check”
• Owner manual operational description
• Technician experience
• Identical vehicle for comparison
• Circuit testing tools
• Vehicle road tests
• Complaint check sheet
• Contact with the customer
2. Perform Preliminary Checks
NOTE: An estimated 10 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
You perform preliminary checks for several reasons:
• To detect if the cause of the complaint is VISUALLY
OBVIOUS
• To identify parts of the system that work correctly
• To accumulate enough data to correctly and
accurately search for a ISUZU Service Bulletin on
ISUZU Web site. http://www.isuzu.co.jp/IDoc/ISB/
2000/
The initial checks may vary depending on the
complexity of the system and may include the following
actions:
• Operate the suspect system
• Make a visual inspection of harness routing and
accessible/visible power and ground circuits
• Check for blown fuses
• Make a visual inspection for separated connectors
• Make a visual inspection of connectors (includes
checking terminals for damage and tightness)
• Check for any DTCs stored by the on-board
computers
• Sense unusual noises, smells, vibrations or
movements
• Investigate the vehicle service history (call other
dealerships, if appropriate)
What resources you should use
Whenever appropriate, you should use the following
resources for assistance in performing preliminary
checks:
• Tech II or other technical equipment for viewing DTCs
• Service manual information:
– Component locations
– Harness routing
– Wiring schematics
– Procedures for viewing DTCs
• Dealership service history file
• Vehicle road test
• Identical vehicle or system for comparison
6E–6 ENGINE DRIVEABILITY AND EMISSIONS
3. Check Bulletins and
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
You should have enough information gained from
preliminary checks to accurately search for a bulletin
and other related service information. Some service
manual sections provide troubleshooting hints that
match symptoms with specific complaints.
What resources you should use
You should use the following resources for assistance in
checking for bulletins and troubleshooting hints:
• Printed bulletins
• Access ISUZU Bulletin Web site, http://www.isuzu.co.jp/
IDoc/ISB/2000/
• Videotapes
• Service manual
4. Perform Service Manual
Diagnostic Checks
What you should do
The “System Checks” in most service manual sections
and in most cells of section 8A (electrical) provide you
with:
• A systematic approach to narrowing down the
possible causes of a system fault
• Direction to specific diagnostic procedures in the
service manual
• Assistance to identify what systems work correctly
What resources you should use
Whenever possible, you should use the following
resources to perform service manual checks:
• Service manual
• Technical equipment (for viewing DTCs and analyzing
data)
• Digital multimeter and circuit testing tools
• Other tools as needed
5a and 5b. Perform Service Manual
Diagnostic Procedures
NOTE: An estimated 40 percent of successful vehicle
repairs are diagnosed with these steps!
What you should do
When directed by service manual diagnostic checks,
you must then carefully and accurately perform the
steps of diagnostic procedures to locate the fault related
to the customer complaint.
What resources you should use
Whenever appropriate, you should use the following
resources to perform service manual diagnostic
procedures:
• Service manual
• Technical equipment (for analyzing diagnostic data)
• Digital multimeter and circuit testing tools
• Essential and special tools
5c. Technician Self Diagnoses
When there is no DTC stored and no matching
symptom for the condition identified in the service
manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
service manual combined with you experience and a
good process of elimination will result in accurate
diagnosis of the condition.
What you should do
Step 1: Identify and understand the suspect
circuit(s)
Having completed steps 1 through 4 of the Strategy
Based Diagnostics chart, you should have enough
information to identify the system(s) or sub-system(s)
involved. Using the service manual, you should
determine and investigate the following circuit
characteristics:
• Electrical:
– How is the circuit powered (power distribution
charts and/or fuse block details)?
– How is the circuit grounded (ground distribution
charts)?
– How is the circuit controlled or sensed (theory of
operation):
– If it is a switched circuit, is it normally open or
normally closed?
– Is the power switched or is the ground
switched?
– Is it a variable resistance circuit (ECT sensor or
TP sensor, for example)?
– Is it a signal generating device (MAF sensor of
VSS, for example)?
– Does it rely on some mechanical/vacuum
device to operate?
• Physical:
– Where are the circuit components (component
locators and wire harness routing diagrams):
– Are there areas where wires could be chafed
or pinched (brackets or frames)?
– Are there areas subjected to extreme
ENGINE DRIVEABILITY AND EMISSIONS 6E–7
temperatures?
– Are there areas subjected to vibration or
movement (engine, transmission or
suspension)?
– Are there areas exposed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
– Are there common mounting areas with other
systems/components?
– Have previous repairs been performed to wiring,
connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
– Does the vehicle have aftermarket or dealer-
installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem
At this point, you should have a good idea of what could
cause the present condition, as well as could not cause
the condition. Actions to take include the following:
• Divide (and separate, where possible) the system or
circuit into smaller sections
• Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
• For two or more circuits that do not share a common
power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
• Loose connections:
– Open/high resistance in terminals, splices,
connectors or grounds
• Incorrect connector/harness routing (usually in new
vehicles or after a repair has been made):
– Open/high resistance in terminals, splices,
connectors of grounds
• Corrosion and wire damage:
– Open/high resistance in terminals, splices,
connectors of grounds
• Component failure:
– Opens/short and high resistance in relays,
modules, switches or loads
• Aftermarket equipment affecting normal operation of
other systems
You may isolate circuits by:
• Unplugging connectors or removing a fuse to
separate one part of the circuit from another part
• Operating shared circuits and eliminating those that
function normally from the suspect circuit
• If only one component fails to operate, begin testing
at the component
• If a number of components do no operate, begin tests
at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
• Service manual
• Technical equipment (for data analysis)
• Experience
• Technical Assistance
• Circuit testing tools
5d. Intermittent Diagnosis
By definition, an intermittent problem is one that does
not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
• Faulty electrical connections and wiring
• Malfunctioning components (such as sticking relays,
solenoids, etc.)
• EMI/RFI (Electromagnetic/radio frequency
interference)
• Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
external and internal system conditions to duplicate the
problem.
What you should do
Step 1: Acquire information
A thorough and comprehensive customer check sheet is
critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
Step 2: Analyze the intermittent problem
Analyze the customer check sheet and service history
file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.
6E–8 ENGINE DRIVEABILITY AND EMISSIONS
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Next, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Hints
You can isolate a circuit by:
• Unplugging connectors or removing a fuse to
separate one part of the circuit from another
• If only component fails to operate, begin testing the
component
• If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
• Substitute a known good part from the parts
department or the vehicle system
• Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
• Service manual
• Bulletins
• Digital multimeter (with a MIN/MAX feature)
• Tech II and Tech II upload function
• Circuit testing tools (including connector kits/
harnesses and jumper wires)
• Experience
• Intermittent problem solving simulation methods
• Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.
For parts and sensors, apply slight vibration to the part
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CAUTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CAUTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
• A lack of understanding by the customer
• A conflict between customer expectations and vehicle
design intent
• A system performance that is unacceptable to the
customer
What you should do
You can verify that a system is operating as designed
by:
• Reviewing service manual functional/diagnostic
checks
• Examining bulletins and other service information for
supplementary information
• Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer expectation and system
operation, you should explain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:
ENGINE DRIVEABILITY AND EMISSIONS 6E–9
• 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.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:
• Service manual
• Accumulated information form a previous diagnostic
path
• Service information and publications
• ISUZU field support
7. Repair and Verify Fix
What you should do
After you have located the cause of the problem, you
must execute a repair by following recommended
service manual procedures.
When the repair is completed, you should verify the fix
by performing the system checks under the conditions
listed in the customer complaint.
If applicable, you should carry out preventive measures
to avoid a repeat complaint.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the repair process:
• Electrical repair procedures
• Service manual information and publications
6E–10 ENGINE DRIVEABILITY AND EMISSIONS
Specification difference
Vehicle Model TF NKR
Engine 4JA1-TC 4JH1-TC 4JH1-TC
Engine desplacemert 2.5L 3.0L 3.0L
Intake shutter N/A N/A standard
Exhaust Brake N/A N/A standard
Idle 730rpm±
25rpm
at 80°C
700rpm±
25rpm
MT, AT
at 80°C
700rpm±
25rpm
at 80°C
Transmission MT MT AT MT
Immobilizer standard standard standard not available
EGR EGR with EGR cooler no EGR no EGR EGR with
EGR cooler
Catalitic
converter
Floor type catatic converter not available not available assembled in silencer
QWS option not available not available EC HK Taiwan
stand-
ard
not
available
not
available
ABS not available not available not available EC HK Taiwan
option not
available
not
available
ENGINE DRIVEABILITY AND EMISSIONS 6E–11
TF 4JA1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission)
060RY00393
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
0
.
5
B
/
R
I
C
5
0
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
0
.
5
L
/
R
I
C
1
1
5
R
/
W
H
B
0
1
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R
IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T

s
e
n
s
o
r
2L/R
IC02
2L/R
IC02
0.5L/B
IC04
I
Z
0
6
0.5B/Y
IC03
0.5L/R
IC17
0.5W/B
IC22
0.5Y
IC31
A37(40)
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
VSV ; EXT 1
RELAY ; A/C COMPRESSOR
R
E
L
A
Y

;
G
L
O
W
S
W

;

T
H
E
R
M
O
SW ; BRAKE
RESISTER ; CLUTCH SW
(YZK NO ; 7321-9900)
RESISTER ; IDLE UP
R
E
S
I
S
T
E
R

;

N
E
U
T
R
A
L

S
W
(
I
D
L
E

S
W
)
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; CLUTCH
SW ; NEUTRAL
SW ; BACK UP
SW ; OIL
0.5L/R
IC18
0.5W/R
IC23
A59(61)
VSV ; EXT 2
0.5L/R
IC16
0.5L/R
IC15
0.5B/O
IC26
B19(97)
0.5W/R IC27
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
0.5B/L HB06
0.5BR/R
IC14
0.5B
BX16
0.5G/R
BA26
0.5B
HY05
1 B3(84)
A44(46)
B24(100)
A63(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
0.5L/Y IC06
A36(39)
0.5R IC12
A27(30)
0.5W/B IC13
(ON)
(OFF)
(OFF)
A65(65)
0.5Y IC08
0.5L/R
IC09
0.5B
IZ05
5B/R
HB03
0.85Y
KA01
0.85R/Y
KA02
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11
0.5L
MA10
GLOW PULG x4
0.5G
IC07
0.5B
IZ08
0.5B/W
IC10
0
.
5
B
/
W
I
C
5
8
0
.
5
B
I
Z
1
0
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5Y
IC57
A28(31)
B6(87)
0.5O/L
MA28
A40(43)
0.5BR/Y
IC29
0.5BR/W HA20
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
0.5G
HA18
0.5G
HA22
0.5BR
HA23
0.5BR HA19
0.5BR HA17
A68(68)
A38(41)
A30(33)
EVRV ; EGR
SW ; ENG WARMING
JOINT
TO MX01
J
O
I
N
T

T
O

E
X
1
2
JOINT
TO BA15
JOINT
TO SX01
2
M
A
F
E
B
S
T
O
P
1
0
A
0.5B
HX03
0.5B
EX03
0.5L
IC47
0.5G
HA24
B-10
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
A-6
0.5R/G
IC36
A-7
0.5G/O
IC37
A-8
0.5B/G
IC38
A-9
A-1
B-11
VEHICLE SPEED
SENSOR
A-11
A-12
B-6
B-5
B-14
OIL PSESSURE UNIT
4WD SW
FUEL
HEATER
MAG.CLUTCH
(COMPRESSOR)
SPEED METER
METER
TACHO METER
OIL GAGE
ENG COOLANT
B6
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
0
.
5
O
/
L
M
B
0
1
CONT ; IMMOBILIZER(B1)
1
2 4
RELAY ; A/C THERMO
0.5G HA21
0.5G
IC30
ECM
REV
0.5G/R
HA13
0.5L/W HA14
0.5G/W HA16
FUSE ; BLOOR
1
2 4
ELEC.THERMO
0.5B/P
IC43
B-7
0.5GR
IC44
B-1
I
Z
0
7
IZ05
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
B-2
0.5G/R
IC46
B-3
B-10
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
B-5
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
SW ; PRESSURE
270
510
6E–12 ENGINE DRIVEABILITY AND EMISSIONS
TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Automatic Transmission)
060RY00394
5
R
/
W
H
B
0
1
0
.
5
L
/
W
H
B
0
4
0
.
5
L
/
R
I
C
1
1
0
.
5
B
R
H
A
1
5
0
.
5
B
R
H
A
1
9
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
R
/
Y
K
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
E
B
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T

s
e
n
s
o
r
2L/R
IC02
2L/R
IC02
0
.
5
L
/
R
I
C
6
2
0.5L/B IC04
0.5B/Y
IC03
0.5Y
IC31
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
R
E
L
A
Y

;
G
L
O
W
S
W

;

T
H
E
R
M
O
SW ; BRAKE
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; OIL
0.5L/R
IC15
0.5W/R IC27
0.5L/R IC11
0.5L/W HB04
0.5L/R HA15
0.5L/R IC15
0.5L/R HA19
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
1 B3(84)
0.5BR/W HA20
A38(41)
B24(100)
A63(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
A30(33)
0.5L/Y IC06
0.5B/L HB06
A36(39)
0.5R
IC12
A27(30)
0.5W/B
IC13
(ON)
ELEC.THERMO
(OFF)
A65(65)
0.5R/B
IC60
B6(87)
5B/R
HB03
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11(W/SOF)
TB07(W/O SOF)
0.5L
MA10
0.5O/L
MB01
GLOW PULG x4
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5O/L
MA18
A40(43)
0.5BR/R
IC29
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
A68(68)
J
O
I
N
T

T
O

E
X
1
2
2
MAF
OA05

O
A
2
5
0.5R/Y
OA60
37
A46(48)
5
25
0.5B/R
OA06
6
A26(28)
0.5B
OX01
ENG
EARTH
TCM
E
B
S
T
O
P
1
0
A
0.5B
EX03
0.5L
IC47
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
0.5R/G
IC36
0.5G/O
IC37
0.5B/G
IC38
A
F
C
B
VEHICLE SPEED
SENSOR
A-11
A-12
B-2
A-6
B-3
OIL PSESSURE UNIT
4WD SW
SPEED METER
METER
TACHO METER
OIL GAGE
TCM
ENG COOLANT
B6
10
11
31
32
47
48
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
CONT ; IMMOBILIZER(B1)
0.5G
IC48
0.5B/P
IC43
B-5
0.5O
IC44
B-6
I
Z
0
7
IZ05
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
A-7
0.5G/R
IC46
A-8
A-9
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
A-1
0.5B/G
LA09
C-14
0.5B/W
LA06
B-4
0.5Y/V
OA59
C-2
0.5Y/L
OA58
C-4
0.5Y/R
OA32
C-3
0.5W/R
OA57
C-10
0.85R/Y
KA02
A-10
0.5R/G
OA10
0.5R/Y
OA11
0.5W/R
OA31
0.5R/B
IC61
C-15
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
RELAY ;
A/C COMPRESSOR
1
2 4 0.5G
HA18
FUSE ;
A/C
FUSE ;
BLOOR
0.5B
HX22
0.5G
HA23
MAG.CLUTCH
(COMPRESSOR)
B-1
0.5G/R
HA13
0.5L/W
HA14
0.5BR
HA17
RELAY ;
A/C THERMO
1
2 4 0.5G HA21
0.5G/W HA16
0.5B
HX03
0.5G
HA24
RESISTER ; IDLE UP
(YZK NO ; 7321-9430)
P
R
N
D
2
1
N B
SW ; MODE
RELAY ; STARTER
FUSE ; STARTER
270
ENGINE DRIVEABILITY AND EMISSIONS 6E–13
TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission)
5
R
/
W
H
B
0
1
0
.
5
L
/
R
H
B
0
4
0
.
5
L
/
R
I
C
1
1
0
.
5
L
/
R
H
A
1
5
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R
IC05
2L/R
IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
E
B
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T

s
e
n
s
o
r
2L/R
IC02
2L/R
IC02
2L/B
IC04
0.5B/Y
IC03
0.5Y
IC31
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
R
E
L
A
Y

;
G
L
O
W
S
W

;

T
H
E
R
M
O
SW ; BRAKE
RESISTER ; CLUTCH SW
(YZK NO ; 7321-9900)
(IDLE SW)
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; CLUTCH
SW ; BACK UP
SW ; OIL
0.5L/R
IC15
0.5W/R IC27
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
0.5L/R IC15
0.5L/R HA19
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
1 B3(84)
0.5BR/W HA20
A38(41)
B24(100)
A41(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
A30(33)
0.5L/Y
IC06
0.5B/L
HB06
A36(39)
0.5R
IC12
A27(30)
0.5W/B
IC13
(ON)
ELEC.THERMO
(OFF)
(OFF)
A65(65)
0.5Y IC08
5B/R
HB03
0.85Y
KA01
0.85R/Y
KA02
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
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IC62
RESISTER ;
IDLE SW
(510 )
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RESISTER ;
A/C ON SIGNAL(270 )
ENGINE DRIVEABILITY AND EMISSIONS 6E–15
TF 4JA1-TC/4JH1-TC ECM Pinouts
060RY00234
Pin No. Connected car component Note
1 Battery minus —
2 Battery minus —
3 Battery plus —
25 No Connect —
26 No Connect —
27 Engine speed output signal —
28 No Connect —
29 Accel position output siganl —
30 Brake switch signal —
31 Clutch switch signal —
32 —
33 Air-conditioning request switch input signal —
34 No Connect —
35 ISO K-line —
36 No Connect —
37 No Connect —
38 Accelerator pedal sensor signal —
39 ignition SW input signal —
40 Exhaust VSV1 —
41 Air conditioning cut request switch signal —
42 Check engine lamp —
43 Glow lamp —
44 No Connect —
45 Diag request signal —
46 QWS request switch signal —
47 No Connect —
48 Water temperature output signal TF 4JH1
AT only
25
44
63
43
62
81
3
1 2
105
97
89
98
90
82
6E–16 ENGINE DRIVEABILITY AND EMISSIONS
Pin No. Connected car component Note
49 Accelerator pedal sensor qround —
50 No Connect —
51 No Connect —
52 No Connect —
53 No Connect —
54 No Connect —
55 No Connect —
56 No Connect —
57 Accelerator pedal sensor supply —
58 System power relay —
59 —
60 EGR Actuator2 4JA1-TC
only
61 VSV EXH.2 —
62 —
63 Vehicle Select Signal —
64 —
65 Redundant Brake switch signal —
66 No Connect —
67 No Connect —
68 Vehicle speed sensor siganl —
69 Lowidle position switch signal —
70 No Connect —
71 No Connect —
72 No Connect —
73 No Connect —
74 No Connect —
75 No Connect —
76 No Connect —
77 No Connect —
78 No Connect —
79 No Connect —
80 No Connect —
81 No Connect —
82 No Connect —
83 MAF Hot-film air mass sensor supply —
84 IAT Air temperature sensor signal —
85 No Connect —
86 No Connect —
87 Neutral switch signal —
88 MAF Hot-film air mass sensor signal —
89 ECT sensor signal —
90 TDC (Engine speed sensor) signal —
91 TDC (Engine speed sensor) output signal —
ENGINE DRIVEABILITY AND EMISSIONS 6E–17
92 MAF Hot-film air mass sensor ground —
93 Analog common ground (LDF, LTF, WTF) —
94 Glow relay —
95 —
96 No Connect —
97 EVRV:EGR —
98 TDC (Engine speed sensor) ground —
99 CAN1-L (Controller Area Network) —
100 CAN1-H (Controller Area Network) —
101 TDC(Engine speed) sensor, shield connection —
102 No Connect —
103 No Connect —
104 No Connect —
105 Solenoid valve shut-off (MAB) output signal —
Pin No. Connected car component Note
6E–18 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC ECM Pinouts
060RY00234
Pin No. Connected car component Note
1 Battery minus —
2 Battery minus —
3 Battery plus —
25 No Connect —
26 No Connect —
27 Engine speed output signal —
28 No Connect —
29 —
30 Brake switch signal —
31 Clutch switch signal —
32 ABS input signal —
33 Air-conditioning request switch input signal —
34 No Connect —
35 ISO K-line —
36 No Connect —
37 No Connect —
38 Accelerator pedal sensor signal —
39 Ignition SW input signal —
40 Exhaust VSV1 —
41 Air conditioning cut request switch signal —
42 Check engine lamp —
43 Glow lamp —
44 No Connect —
45 Diag request signal —
46 QWS request switch signal —
25
44
63
43
62
81
3
1 2
105
97
89
98
90
82
ENGINE DRIVEABILITY AND EMISSIONS 6E–19
Pin No. Connected car component Note
47 No Connect —
48 —
49 Accelerator pedal sensor qround —
50 No Connect —
51 No Connect —
52 No Connect —
53 No Connect —
54 No Connect —
55 No Connect —
56 No Connect —
57 Accelerator pedal sensor supply —
58 System power relay —
59 QWS Lamp —
60 EXH.Brake Lamp —
61 —
62 ABS Out —
63 —
64 EXH.Brake switch signal —
65 Redundant Brake switch signal —
66 No Connect —
67 No Connect —
68 Vehicle speed sensor siganl —
69 Lowidle position switch signal —
70 No Connect —
71 No Connect —
72 No Connect —
73 No Connect —
74 No Connect —
75 No Connect —
76 No Connect —
77 No Connect —
78 No Connect —
79 No Connect —
80 No Connect —
81 No Connect —
82 No Connect —
83 MAF Hot-film air mass sensor supply —
84 IAT Air temperature sensor signal —
85 No Connect —
86 No Connect —
87 Neutral switch signal —
88 MAF Hot-film air mass sensor signal —
89 ECT sensor signal —
90 TDC (Engine speed) sensor signal —
6E–20 ENGINE DRIVEABILITY AND EMISSIONS
91 TDC (Engine speed) sensor output signal —
92 MAF Hot-film air mass sensor ground —
93 Analog common ground (LDF, LTF, WTF) —
94 Glow relay —
95 Intake VSV —
96 —
97 EGR actuator 1 —
98 Engine speed sensor ground —
99 CAN1-L (Controler Area Network) —
100 CAN1-H (Controler Area Network) —
101 TDC (Engine speed) sensor, shield connection —
102 Needle movement sensor ground —
103 No Connect —
104 No Connect —
105 Solenoid valve shut-off (MAB) output signal —
Pin No. Connected car component Note
ENGINE DRIVEABILITY AND EMISSIONS 6E–21
TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC, Specifications
Tightening Specifications
Application Location N·m Kg·m
ECM(Engine Control Modul) Bolt On the ECM bracket 8 0.8
CKP(Crankshaft Position) Sensor Bolt Gear case cover 8 0.8
MAF(Mass Air Flow) Sensor Mounted the intake pipe 3 0.3
ECT(Engine Coolant Temperature) Sensor Mounted the thermostat housing 13 1.3
6E–22 ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
TF 4JA1-TC with Bosch VP44 System Component Locator
EndOFCallout
2 1 3
Legend
(1) Manifold Air Flow (MAF) sensor
(2) Engine Coolant Temperature (ECT) sensor
(3) Injection pump
ENGINE DRIVEABILITY AND EMISSIONS 6E–23
TF 4JA1-TC with Bosch VP44 System Component Locator
1 2 4 3
Legend
(1) Mass Air Flow (MAF) sensor
(2) EVRV:EGR
(3) Fuel Filter
(4) Inter Cooler
6E–24 ENGINE DRIVEABILITY AND EMISSIONS
TF 4JA1-TC/4JH1-TC TDC Sensor Location
EndOFCallout
1 3 2
Legend
(1) Top Dead Center (TDC) sensor
(2) Inter Cooler
(3) Wiper Motor
ENGINE DRIVEABILITY AND EMISSIONS 6E–25
TF 4JA1-TC, 4JH1-TC with Bosch VP44 System Component Locator
EndOFCallout
1 2
Legend
(1) Engine Control Module
(2) SRS Control Module
6E–26 ENGINE DRIVEABILITY AND EMISSIONS
TF 4JH1-TC with Bosch VP44 System Component Locator
EndOFCallout
2 1
Legend
(1) Manifold Air Flow (MAF) Sensor
(2) Engine Coolant Temperature (ECT) Sensor
ENGINE DRIVEABILITY AND EMISSIONS 6E–27
TF 4JH1-TC with Bosch VP44 System Component Locator
EndOFCallout
2 1 3 4
Legend
(1) MAF sensor
(2) ECT sensor
(3) Fuel Filter
(4) Inter Cooler
6E–28 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC with Bosch VP44 System Component Locator
EndOFCallout
4 3 2 1 5
Legend
(1) Mass Air Flow (MAF) Sensor
(2) Engine Coolant Temperature (ECT) Sensor
(3) EGR cooler
(4) Injection pump
(5) EGR Valve
ENGINE DRIVEABILITY AND EMISSIONS 6E–29
N*R 4JH1-TC with Bosch System Component Locator
1 2
Legend
(1) MAF sensor
(2) Fuel filter/Fuel sedimerter
6E–30 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC with Bosch System Component Locator
3 2
1 4
Legend
(1) EGR valve
(2) EGR cooler
(3) TDC sensor
(4) Turbo waste gate actuator
ENGINE DRIVEABILITY AND EMISSIONS 6E–31
N*R 4JH1-TC with Bosch VP44 System Component Locator
EndOFCallout
1 3 2
Legend
(1) Intake Shutter VSV
(2) EGR EVRV
(3) EGR Valve
6E–32 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC with Bosch VP44 System Component Locator
.
1
Legend
(1) Engine Control Module
ENGINE DRIVEABILITY AND EMISSIONS 6E–33
NKR 4JH1-TC with Bosch VP44 System Component Locator
1
Legend
(1) Vehicle Speed sensor
6E–34 ENGINE DRIVEABILITY AND EMISSIONS
TF 4JA1-TC Fuse Box
STARTER
C
CONN
IGN.
B1
40A
J/C:B
HEAD
LIGHT
IMMOBILIZER
TAIL
LIGHT
(DIODE)
( )···IF EQUIPPED.
ECM
MAIN
HORN
RR FOG
A/C
THERMO
STARTER
STARTER
CUT
HEATER
DIMMER
CAUTION
J/C:A
100A
MAIN
80A
GLOW
BAT ALT
Y
IGN.
B2
40A
H/LAMP
WASHER
30A
10A
TAIL
LH
10A
TAIL
RH
10A CHARGE
10A
RR
FOG
10A A/C 20A ECM
10A
H/LIGHT
RH(LO)
20A BLOWER
10A
H/LIGHT
LH(LO)
10A
STOP
LIGHT
10A
H/LIGHT
RH(HI)
10A HORN
10A
H/LIGHT
LH(HI)
15A HAZARD
· USE SPECIFIED FUSES ONLY
UNSPECIFIED FUSES CAN CAUSE FIRE AND
MALFUNCTION OF EQUIPMENTS.
· SPARE FUSES & PULLER ARE LOCATED AT
FUSE BOX IN THE CABIN.
· DROPPING BRAKE OIL, ETC ON THE COVER,
WIPE WITH A CLOTH.
897300 9020
7154-8127
( )
A/C
COMP.
( )
ENGINE DRIVEABILITY AND EMISSIONS 6E–35
TF 4JH1-TC Fuse Box
STARTER
C
CONN
IGN.
B1
40A
J/C:B
HEAD
LIGHT
IMMOBILIZER
TAIL
LIGHT
(DIODE)
( )···IF EQUIPPED.
ECM
MAIN
HORN
STARTER
STARTER
CUT
HEATER
DIMMER
CAUTION
J/C:A
100A
MAIN
BAT ALT
Y
IGN.
B2
40A
25A
TAIL
LH
10A CHARGE
10A ECM
10A
H/LIGHT
RH(LO)
10A BLOWER
10A
H/LIGHT
LH(LO)
20A
STOP
LIGHT
10A
H/LIGHT
RH(HI)
10A HORN
10A
H/LIGHT
LH(HI)
15A HAZARD
· USE SPECIFIED FUSES ONLY
UNSPECIFIED FUSES CAN CAUSE FIRE AND
MALFUNCTION OF EQUIPMENTS.
· SPARE FUSES & PULLER ARE LOCATED AT
FUSE BOX IN THE CABIN.
· DROPPING BRAKE OIL, ETC ON THE COVER,
WIPE WITH A CLOTH.
897300 9020
7154-8127
6E–36 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC Fuse Box
25A 10A 15A 10A 25A 10A 15A 15A 10A 15A 10A 15A 15A 15A 10A 10A 15A 10A 10A 25A
E
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ENGINE DRIVEABILITY AND EMISSIONS 6E–37
N*R 4JH1-TC Fuse and Relay Panel
A B C D E F G H
NO NAME TYPE
A RELAY;STARTER MRB
---
B RELAY;GLCN(1) MRB
RELAY;GLCN MRB
C RELAY;4WD LND LAMP ISO
RELAY;REAR FOG ISO
D RELAY;MARKER LAMP ISO
E S/B FUSE;MAIN 80A
60A
F S/B FUSE;KEY 50A
50A
G S/B FUSE;GLOW 60A
50A
H S/B FUSE;ABS IND. 60A
40A
6E–38 ENGINE DRIVEABILITY AND EMISSIONS
N*R 4JH1-TC Relay Panel
E A B C D F H G I
NO NAME TYPE
A RELAY;CHG, WARING ISO
B RELAY;LIGHT ISO
C RELAY;HEATER & A/C ISO
D RELAY;TALE ISO
E RELAY;Dimmer ISO
F RELAY;HDRN ISO
G RELAY;P/WINDOW ISO
H RELAY;ABS IND ISO
RELAY;CORNERING LAMP ISO
I RELAY;BUZZER CANSEL ISO
RELAY;ECU ISO
ENGINE DRIVEABILITY AND EMISSIONS 6E–39
Abbreviations Charts
List of abbreviations which may be used in this section.
Abbreviations Term
A/C Air Conditioner
A/T Automatic Transmission
ACC Accessory
AP Accel Position
CKP Crank Shaft Position
CMP Pump Camshaft Position
DLC Data Link Connector
DTC Diagnosis Trouble Code
DVM Digital Volt Meter
ECM Engine Control Module
ECT Engine Coolant Temperature
EGR Exhaust Gas Recirculation
EVRV Electric Vacuum Regulating Valve
EXH Exhaust
FT Fuel Temperature
IAT Intake Air Temperature
IG Ignition
ITP Intake Throttle Position
M/T Manual Transmission
OBD On-Board Diagnostic (Self Diagnosis System)
OT Oil Temperature
SW Switch
TCV Timing Control Valve
TEMP Temperature
TP Throttle Position
VSS Vehicle Speed Sensor
VSV Vacuum Switching Valve
MAB Solenoido Valve Switch Off
PCU Ing. Pump Control Unit
MAF Manifold Air Flow
6E–40 ENGINE DRIVEABILITY AND EMISSIONS
Injection pump Control System
11
10
9
8
7
6 5
4
3
2
1
Legend
(1) Cam angle sensor
(2) Pump control unit (PCU)
(3) Distributor head
(4) High pressure solenoid valve
(5) Delivery holder
(6) CPV
(7) TCV
(8) Timer
(9) Radial pluger high pressure pump
(10) Feed pump
(11) Drive shaft
ENGINE DRIVEABILITY AND EMISSIONS 6E–41
TDC Sensor
The TDC Sensor is located at bell housing of flywheel.
TDC sensor is magnet coil type.
TDC sensor is used for deferming top read center of
cylinder.
Flywheel has 4 teeth of excifering.
Engine Coolant Temperature (ECT) Sensor
The ECT Sensor is a thermistor. A temperature
changes the resistance value. And it changes voltage.
In other words it measures a temperature value. It is
installed on the coolant stream. Low coolant
temperature produces a high resistance.
The ECM supplies a 5 volts signal to the ECT Sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot. The ECM uses to this value, and
calculates, a fuel injection timing, a main injection
volume and an EGR VSVs switching.
Vehicle Speed Sensor (VSS)
The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall effect. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The ECM calculates the speed of the vehicle by it. The
ECM uses this signal to operate the speedometer, too
and The TCM (Transmission Control Module) monitors
it.
TDC (Engine Speed) Sensor
The TDC sensor is magnet type sensor.
6E–42 ENGINE DRIVEABILITY AND EMISSIONS
ECM System Diagram – No.1
G
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ENGINE DRIVEABILITY AND EMISSIONS 6E–43
ECM System Diagram – No.2
2
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A
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6
7
5
8
2
1
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1
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6E–44 ENGINE DRIVEABILITY AND EMISSIONS
MAF/IAT Sensor Circuit
Heater
2
3
1
5
4
+5V
NTC IAT sensor
MAF sensor
ENGINE DRIVEABILITY AND EMISSIONS 6E–45
ECM System Diagram – No.3
41 33
Batt
µP
41
Batt
µP
ECM
relay
ECM
relay
ECM
relay
NKR 4JH1-TC only
Main fuse
HVAC
relay
AC
Thermo
relay
A/C Fuse
A/C on
signal
A/C
PDS
(NKR 4JH1-TC)
only
TF 4JA1-TC /
4JH1-TC only
Comp relay
Compressor
clutch
A/C
Comp relay
Compressor
clutch
Electrical
thermo
IC 08
µP : Microproccesor
6E–46 ENGINE DRIVEABILITY AND EMISSIONS
ECM System Diagram – No.4
G
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ENGINE DRIVEABILITY AND EMISSIONS 6E–47
ECM System Diagram – No.5
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6E–48 ENGINE DRIVEABILITY AND EMISSIONS
General Service Information
Serviceability Issues
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Accordingly, if commercially sold
sensor or switch is installed, it makes a wrong diagnosis
and turns on the check engine lamp.
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the check
engine lamp.
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the check
engine lamp to turn on if the vehicle is not maintained
properly. Restricted oil filters, fuel filters, and crankcase
deposits due to lack of oil changes or improper oil
viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle
fault”, but with the sensitivity of OBD diagnostics,
vehicle maintenance schedules must be more closely
followed.
Related System Faults
Many of the OBD system diagnostics will not run if the
ECM detects a fault on a related system or component.
On-Board Diagnostic (OBD)
On-Board Diagnostic (Self Diagnosis
System) Tests
A diagnostic test is a series of steps, the result of which
is a pass or fail reported to the diagnostic executive.
When a diagnostic test reports a pass result, the
diagnostic executive records the following data:
• The diagnostic test has been completed since the
last ignition cycle.
• The diagnostic test has passed during the current
ignition cycle.
• The fault identified by the diagnostic test is not
currently active.
When a diagnostic test reports a fail result, the
diagnostic executive records the following data:
• The diagnostic test has been completed since the
last ignition cycle.
• The fault identified by the diagnostic test is currently
active.
• The fault has been active during this ignition cycle.
• The operating conditions at the time of the failure.
The Diagnostic Executive
The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
• Commanding the check engine lamp on and off
• DTC logging and clearing
• Current status information on each diagnostic
Diagnostic Information
The diagnostic charts and functional checks are
designed to locate a faulty circuit or component through
a process of logical decisions. The charts are prepared
with the requirement that the vehicle functioned
correctly at the time of assembly and that there are not
multiple faults present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented
by the diagnostic procedures contained in this manual.
The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
lamp is illuminated.
Check Engine Lamp
The check engine lamp looks the same as the check
engine lamp you are already familiar with, the “Check
Engine” lamp.
Basically, the check engine lamp is turned on when the
ECM detects a DTC that will impact the vehicle
emissions.
• When the check engine lamp remains “ON” while the
engine is running, or when a malfunction is
suspected due to a driveability or emissions problem,
a Powertrain On-Board Diagnostic (OBD) System
Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
System Check. These checks will expose faults which
may not be detected if other diagnostics are
performed first.
Data Link Connector (DLC)
The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
behind the lower front instrument panel. The DLC is
used to connect to a Tech2. Some common uses of the
Tech2 are listed below:
• Identifying stored Diagnostic Trouble Codes (DTCs).
• Clearing DTCs.
• Reading serial data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–49
6E–50 ENGINE DRIVEABILITY AND EMISSIONS
Reading Flash Diagnostic Trouble Codes
The provision for communicating with the Engine
Control Module (ECM) is the Data Link Connector
(DLC). The DLC is located in the front console box. It is
used in the assembly plant to receive information in
checking that the engine is operating properly before it
leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECM's memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded.
When diagnostic switch (dimDIG) is ON, the Cell
flashing function will start blinking by blink codes
(fbwS...BCO) of each error codes.
The blink codes are flashed in turn, and repeated until
dimDIG is changed to OFF.
When the key switch is turned on, flash once, after
3,250mm second later and twice after 1,250mm second
later and then, flash the stored error codes three times
in sequence of the storing.
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 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.
History DTC
History DTC can be canceled after 40 cycle driving with
no defect. Or history code can be deleted by Tech2
“Clear DTCs” function.
ON
ON
Diagnostic
SW
Lamp OFF
1
(500msec)
(500msec)
(1250msec)
(3250msec) (3250msec)
After all the stored error codes are flashed, the same flashing patterns are repeated again.
(example)
Two Digit Unique Code Number=32
2 3 3 2 3 2 2
ENGINE DRIVEABILITY AND EMISSIONS 6E–51
Tech2
From 98 MY, Isuzu dealer service departments are
recommended to use the Tech2 Scan Tool. Please refer
to the Tech2 user guide.
901RW180
EndOFCallout
Tech2 Features
1. Tech2 is a 12 volt system. Do not apply 24 volts.
2. After connecting and/or installing the Vehicle
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech2, connect the
tool to the vehicle DLC.
3. Make sure the Tech2 is powered OFF when
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the
Tech 1 Mass Storage Cartridge.
5. The Tech2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
handling of the card.
7. The Tech2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the
EXIT key several times before shutting down.
Legend
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
(3) SAE 16/19 Adaptor
(4) DLC Cable
(5) Tech2
6E–52 ENGINE DRIVEABILITY AND EMISSIONS
9. To clear Diagnostic Trouble Codes (DTCs), open
Application Menu and press “F1: Clear DTC Info”.
Getting Started
• Before operating the Isuzu PCMCIA card with the
Tech2, the following steps must be performed:
1. The Isuzu System PCMCIA card (1) inserts into the
Tech2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech2 (5)
4. Make sure the vehicle ignition is off.
5. Connect the Tech2 SAE 16/19 adapter to the
vehicle DLC.
826RY00058
6. Turn on the vehicle ignition.
7. Power the Tech2 ON and verify the Tech2 power up
display.
060RW009
NOTE: The RS232 Loop back connector is only to use
for diagnosis of Tech2. Refer to user guide of the Tech2.
Operating Procedure (For Example)
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card. Follow
the operating procedure below.
060RY027
ENGINE DRIVEABILITY AND EMISSIONS 6E–53
060RY00275
Menu
• The following table shows, which functions are used
the available equipment versions.
DTC
On OBD has two options available in Tech2 DTC mode
to display the enhanced information available. A
description of the new modes, DTC info and Clear DTC
Information. After selecting DTC, the following menu
appears:
• DTC Info
• Clear DTC Infomation
DTC Information Mode
Use the DTC info mode to search for store DTC
information. There are two choices. The service manual
may instruct the technician to test for DTCs is a certain
manner. Always follow published service procedures.
To get a complete description of any status, press the
“Enter” key befor pressing the desired F-key. For
example, ptessing “Enter” then an F-key will display a
definition of the abbreviated scan tool status.
Engine
This selection will display all DTCs that have failed
during the present ignition cycle.
History
This selection will display only DTCs that are stored in
the ECM's history memory.
Clear DTC Information
To clear Diagnostic Trouble Code (DTCs), use the
daiagnostic scan tool “clear DTC information” function.
Tech2 Data Display
Use the tech2 Data Values only after the On-Board
Diagnostic System Check has been completed, no
DTC(s) were noted, and you have determined that the
on-board diagnostics are functioning properly. Tech2
values form a properly-running engine may be used for
comparison with the engine you are diagnosting. The
Tech2 data values represent values that would be seen
on a mormally-running engine.
F0: Diagnostic Trouble Codes
F0: DTC Information
F0: Engine
F1: History
F0: Clear DTC Information
F1: Data Display
F2: Snapshot
F3: ID Information
6E–54 ENGINE DRIVEABILITY AND EMISSIONS
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.
060RX037
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.
ENGINE DRIVEABILITY AND EMISSIONS 6E–55
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
D06RY00167
6E–56 ENGINE DRIVEABILITY AND EMISSIONS
Flow Chart for Snapshot Replay (Plotting Graph)
060RX040
ENGINE DRIVEABILITY AND EMISSIONS 6E–57
How To Use Breaker Box
Wiring harness connection on the vehicle
1 2 3
Legend
(1) ECM
(2) Harness adaptor
(3) Breaker box
Each breaker box terminal has pin No., which is assigned as same an ECM pin
assignment.
When need to check ECM pin No or ECM harness pin refected ECM pin No, you can use
same ECM pin No as breaker box terminal No.
ECM
Engine harness
Insert breaker box
Harness
adaptor
Engine harness
ECM
Breaker
box
6E–58 ENGINE DRIVEABILITY AND EMISSIONS
Breaker Box Connection Type A for Open Circuit Check, Short to Ground
Check and Short to Battery Check
Breaker box connection type A.
1 5 3 4 2
Legend
(1) ECM
(2) Harness adaptor
(3) Breaker box
(4) Digital volt meter
(5) ECM – harness adaptor connector disconnected
or
DVM
Harness
adaptor
ECM
ENG. harness
Connect to ground
Breaker
box
ENGINE DRIVEABILITY AND EMISSIONS 6E–59
Breaker Box Connection Type B for Power, Signal Voltage Check between ECM
and Sensors
Breaker box connection type B.
1 2 3 4
Legend
(1) ECM
(2) Harness adaptor
(3) Breaker box
(4) Digital volt meter
or
DVM
Harness
adaptor
ECM
ENG. harness
Connect to ground
Breaker
box
6E–60 ENGINE DRIVEABILITY AND EMISSIONS
How To Use TIS2000 Snapshot Analysis
Snapshot Display
Fig. 1: [Snapshot Upload] icon
Procedures for transferring and displaying Tech2
snapshot data by using TIS2000 [Snapshot Upload]
function is described below.
Snapshot data can be displayed with [Snapshot Upload]
function included in TIS2000.
By analyzing these data in various methods, trouble
conditions can be checked.
Snapshot data is displayed by executing the three steps
below shown:
A. Record the snapshot data, in Tech2.
(Refer to Repair Manual or Tech2 Instruction
Manual)
B. Transfer the snapshot data to PC.
C. Display the snapshot data with TIS2000
[Snapshot Upload] function.
B. Transfer of snapshot data to PC:
After recording the snapshot in Tech2, transfer the
data from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen.
Fig. 2: Data display
C. Snapshot data is displayed with TIS2000
[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
4. Select the transferred snapshot.
5. Open the snapshot, to display the data parameter
list on the screen.
ENGINE DRIVEABILITY AND EMISSIONS 6E–61
Displayed icons
With the below icons, data display can be controlled:
Fig. 3: Snapshot regeneration control
Regeneration of snapshot
Snapshot can be regenerated with the icons on the
screen lower side.
Graph display
Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter]
window opens.
2. Click the first graph icon of the window upper part,
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
Transfer of snapshot from Tech2 to PC.
Load of snapshot from floppy disk or hard
disk.
Store of snapshot to floppy disk or hard
disk.
Display of data parameters on one screen.
Display of data parameters on 2 screens
Change of units.
Display of data parameters by graph and
list (in graph, Max. 3 parameters ).
Display of data parameters by graph and
list (in graph, Max. 3 parameters).
Display of data parameters by graph (only
in graph, Max. 6 parameters).
Print (printing data parameters).
1st record: The 1st record of the snapshot
is displayed.
Previous record: Changed to the just
previous record of the present one.
Regeneration in reverse direction:
Displayed by returning in the reverse
direction.
Trigger of record: Display by moving to the
set trigger position.
Regeneration in forward direction: The
whole snapshot is regenerated in the
forward direction.
Next record: Changed to the next record of
the present one.
Last record: The last record of the
snapshot is displayed.
End of regeneration: Record regeneration
end at the point clicking the snapshot.
6E–62 ENGINE DRIVEABILITY AND EMISSIONS
Fig. 4: [Graph Parameter] window
Fig. 5: Graph display screen (values and graphs)
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the
parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter. For
displaying the graph display screen in full size, move
the cursor upward on the screen. When the cursor
is changed to the magnifying glass form, click the
screen. Graph screen is displayed on the whole
screen.
Display of graphs on one screen (Max. 6
graphs):
1. Click the 6 graph icon. [Graph Parameter] window
opens.
Fig. 6: [Graph Parameter] Window
Fig. 7: Graph Display screen (6 graphs)
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.
ENGINE DRIVEABILITY AND EMISSIONS 6E–63
Parameter lock/unlock
With parameter lock/unlock function, certain parameters
can be selected from the wide list and the selected
parameters can be displayed at once. At first, click the
parameter to be selected to put marking, then click
[Parameter lock/unlock]. Selected parameter is
displayed at the upper part of the [Lock line] of the data
list upper part. Other parameters can be added in the
same way. By parameter [Lock], continuous display is
possible for comparing data values. For removing
parameters from the list, click the parameter to put
marking, then, click the [Parameter Lock/Unlock] button.
For ending application of [Snapshot Display], question
whether the file is stored or not is automatically
displayed. Here, storing the file in the PC hard disk or in
floppy disk can be selected.
Fig. 8: Locked parameters
Location of stored data
Usually, data is stored in the folder of C:\Program
Files\cosids\DATA\SNAPSHOT\. In case folder is
changed in installing, refer to the changed destination.
Stored data is already stored in installing by 2
(“10000000SUR”, “10000001.SUR”) as samples.
TIS2000 navigation
With the below icons, all TIS2000 applications can be
used.
With [TIS2000 end], all TIS2000
applications are ended, and Windows desk
top is returned.
With [Select page], TIS2000 start page is
returned without ending the application
being used. The application being used is
opened in the background.
With [Vehicle data], [Vehicle data display]
function is opened. This function display all
vehicle technical data.
With [Executed applications end],
applications being used is ended, and
TIS2000 start page is returned.
With [Session], user information is
registered and displayed.
With [Help], TIS2000 integration help
function is started.
With [Print], copy of the screen can be
printed out.
6E–64 ENGINE DRIVEABILITY AND EMISSIONS
Typical Scan Data Values
Use the Typical Values Table only after the On-Board
Diagnostic System Check has been completed, no
DTC(s) were noted, and you have determined that the
on-board diagnostics are functioning properly. Scan tool
values from a properly-running engine may be used for
comparison with the engine you are diagnosing. The
typical scan data values represent values that would be
seen on a normally-running engine.
A Scan tool that displays faulty data should not be
used, and the problem should be reported to the Scan
tool manufacturer. Use of a faulty Scan tool can result
in misdiagnosis and unnecessary replacement of parts.
TF 4JA1-TC
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
1 Engine Speed rpm 730±25 1952~2026
2 Vehicle Speed rpm 0 0
3 Pump Speed rpm 362~367 975~1014
4 Acceletor Position % 0 6.3~7.75
5 Manifold Air Flow mg/strk 379.5~431.5 334.6~383.3
6 Barometric Pressure hPa Sea level Sea level
7 Desired Injection Quantity mg/strk 7.19~8.36 5.54~7.81
8 Injection quantity mg/strk 6.96~8.64 7.38~9.81
9 Desired Injection Start °CA -1.00 -2.00~-1.77
10 Actual Injection Start °CA -1.00 -2.00~-1.77
11 Coolant Temperature °C 83.86~84.66 84.86~86.26
12 Fuel Temperature °C 49.96~50.26 50.46~51.26
13 Intake Temperature °C 49.06~49.86 50.96~55.96
14 Ignition Status On/Off (V) ON12V ON12V
15 Idle Switch Active/Inactive Active Active
16 Brake Switch 1 Active/Inactive Inactive Inactive
17 Brake Switch 2 Active/Inactive Inactive Inactive
18 Clutch Switch Active/Inactive Active Active
19 Neutral Switch Active/Inactive Active Active
20 A/C Information Switch Active/Inactive Inactive Inactive
21 Diagnostic Request Active/Inactive(V) Inactive Inactive
22 System Voltage mVolts 13690.3~13873.6 13832.9~13975.5
23 Main Relay Active/Inactive Active Active
24 Glow Time Relay On/Off Off Off
25 Check Engine Light On/Off Off Off
26 Glow Time Telltale On/Off Off Off
27 ABS Input Signal On/Off Off Off
28 ABS Output Signal On/Off ON ON
29 EGR Pulse Ratio % 70.0 52~53.5
30 EGR command mg/strk – –
31 Intake Manifold valve Active/Inactive Inactive Inactive
32 Exhaust Brake valve 1 Active/Inactive Inactive Inactive
ENGINE DRIVEABILITY AND EMISSIONS 6E–65
TF 4JH1-TC (MT)
33 Exhaust Brake valve 2 Active/Inactive Inactive Inactive
34 Desired Engine Idle Speed rpm 730 730
35 Start of Dlivery °CA 19.45~19.46 21.91~22.07
36 A/C Request Active/Inactive(V) Inactive12V Inactive12V
37 Immobilizer Active/Inactive Inactive Inactive
38 Immobilizer signal Not received Not received
39 Immobilizer Function
program
Yes Yes
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
1 Engine Speed rpm 700±25 1885~2043
2 Vehicle Speed rpm 0 0
3 Pump Speed rpm 347~352 942~1022
4 Acceletor Position % 0 6.6~7.81
5 Manifold Air Flow mg/strk 691~800 691.7~767.4
6 Barometric Pressure hPa Sea level Sea level
7 Desired Injection Quantity mg/strk 7.087.85 5.96~9.26
8 Injection quantity mg/strk 6.87~8.22 6.33~10.89
9 Desired Injection Start °CA 1.00 1.13~1.51
10 Actual Injection Start °CA 1.00 1.13~1.51
11 Coolant Temperature °C 81.46~86.26 83.26~86.26
12 Fuel Temperature °C 28.26~28.56 32.06~34.06
13 Intake Temperature °C 24.06~28.86 47.46~53.56
14 Ignition Status On/Off (V) ON 12V ON 12V
15 Idle Switch Active/Inactive Active Inactive
16 Brake Switch 1 Active/Inactive Inactive Inactive
17 Brake Switch 2 Active/Inactive Inactive Inactive
18 Clutch Switch Active/Inactive Active Active
19 Neutral Switch Active/Inactive Active Active
20 A/C Information Switch Active/Inactive Inactive Inactive
21 Exhaust Brake Switch On/Off – –
22 Diagnostic Request Active/Inactive(V) Inactive 12V Inactive 12V
23 QWS Switch On/Off – –
24 System Voltage mVolts 13894~14097.7 13853.3~13995.9
6E–66 ENGINE DRIVEABILITY AND EMISSIONS
TF 4JH1-TC (AT)
25 Main Relay Active/Inactive Active Active
26 Glow Time Relay On/Off Off Off
27 Check Engine Light On/Off Off Off
28 Glow Time Telltale On/Off Off Off
29 ABS Input Signal On/Off – –
30 ABS Output Signal On/Off – –
31 EGR Pulse Ratio % – –
32 EGR command mg/strk – –
33 Intake Manifold valve Active/Inactive – –
34 Exhaust Brake valve 1 Active/Inactive – –
35 Desired Engine Idle Speed rpm 700 700
36 Start of Dlivery °CA 19.09~19.11 23.13~23.62
37 A/C Request Active/Inactive(V) Inactive Inactive
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
1 Engine Speed rpm 700±25 1960~2010
2 Vehicle Speed rpm 0 0
3 Pump Speed rpm 347~352 978~1010
4 Acceletor Position % 0 7.9~9.3
5 Manifold Air Flow mg/strk 682~757 692745.0
6 Barometric Pressure hPa Sea level Sea level
7 Desired Injection Quantity mg/strk 7.13~8.08 7.05~9.06
8 Injection quantity mg/strk 6.74~9.25 7.78~10.6
9 Desired Injection Start °CA 1.00 1.21~1.43
10 Actual Injection Start °CA 1.00 1.21~1.43
11 Coolant Temperature °C 82.7~83.7 83.7~86.3
12 Fuel Temperature °C 33.3~33.6 33.3~34.1
13 Intake Temperature °C 48.1~50.5 50~56.9
14 Ignition Status On/Off (V) ON 12V ON 12V
15 Idle Switch Active/Inactive Active Inactive
16 Brake Switch 1 Active/Inactive Inactive Inactive
17 Brake Switch 2 Active/Inactive Inactive Inactive
18 Clutch Switch Active/Inactive – –
19 Neutral Switch Active/Inactive Active Active
ENGINE DRIVEABILITY AND EMISSIONS 6E–67
NKR 4JH1-TC
20 A/C Information Switch Active/Inactive Inactive Inactive
21 Exhaust Brake Switch On/Off – –
22 Diagnostic Request Active/Inactive(V) Inactive 12V Inactive 12V
23 QWS Switch On/Off – –
24 System Voltage mVolts 13600~13800 1380013900
25 Main Relay Active/Inactive Active Active
26 Glow Time Relay On/Off Off Off
27 Check Engine Light On/Off Off Off
28 Glow Time Telltale On/Off Off Off
29 ABS Input Signal On/Off – –
30 ABS Output Signal On/Off – –
31 EGR Pulse Ratio % – –
32 EGR command mg/strk – –
33 Intake Manifold valve Active/Inactive – –
34 Exhaust Brake valve 1 Active/Inactive – –
35 Desired Engine Idle Speed rpm 700 700
36 Start of Dlivery °CA 19.10 23.323.5
37 A/C Request Active/Inactive(V) Inactive Inactive
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
1 Engine Speed rpm 700±25 1979∼2058
2 Vehicle Speed rpm 0 0
3 Pump Speed rpm 348∼351 988∼1001
4 Acceletor Position % 0 21.07∼21.84%
5 Manifold Air Flow mg/strk 495.7∼536.4 845.3∼893.2
6 Barometric Pressure hPa Sea level Sea level
7 Desired Injection Quantity mg/strk 9.25∼10.17 5.75∼10
8 Injection quantity mg/strk 8.08∼11.85 12.14∼7.47
9 Desired Injection Start °CA 5∼5.18 6
10 Actual Injection Start °CA 5∼5.18 6
11 Coolant Temperature °C 83.06∼83.86 84∼88
12 Fuel Temperature °C 33.76∼34.96 38.76∼39.26
13 Intake Temperature °C 27.76∼29.76 26.16∼27.46
14 Ignition Status On/Off (V) ON12V ON12V
6E–68 ENGINE DRIVEABILITY AND EMISSIONS
15 Idle Switch Active/Inactive Active Inactive
16 Brake Switch 1 Active/Inactive Inactive Inactive
17 Brake Switch 2 Active/Inactive Inactive Inactive
18 Clutch Switch Active/Inactive Active Active
19 Neutral Switch Active/Inactive Active Active
20 A/C Information Switch Active/Inactive Inactive Inactive
21 Exhaust Brake Switch On/Off Off Off
22 Diagnostic Request Active/Inactive(V) Inactive 12V Inactive 12V
23 QWS Switch On/Off Off Off
24 System Voltage mVolts 13710.6∼13894 13853.3∼13975.5
25 Main Relay Active/Inactive Active Active
26 Glow Time Relay On/Off Off Off
27 Check Engine Light On/Off Off Off
28 Glow Time Telltale On/Off OFF OFF
29 ABS Input Signal On/Off Off Off
30 ABS Output Signal On/Off ON ON
31 EGR Pulse Ratio % 69.95∼70 30
32 EGR command mg/strk 500 1600
33 Intake Manifold valve Active/Inactive Inactive Inactive
34 Exhaust Brake valve 1 Active/Inactive Inactive Inactive
35 Desired Engine Idle Speed rpm 700 700
36 Start of Dlivery °CA 23.28∼23.6 28.04∼28.24
37 A/C Request Active/Inactive(V) Inactive 12Volts Inactive 12Volts
Tech 2 Display
Item Tech 2 parameter Unit Displayed
Typical Data values Idling
after the engine warm up
and A/C “Off”
(The engine coolant
temperature is about 80°C)
Typical Data values
2000rpm after the engine
warm up and A/C “Off”
(The engine coolant
temperature is about 80°C)
ENGINE DRIVEABILITY AND EMISSIONS 6E–69
Engine Data Definitions
Data Display Engine
1 Engine Speed(RPM) Engine speed is computed by the ECM from the TDC sensor.
2 Vehicle Speed This displays vehicle speed.
3 Pump Speed(RPM) This displays operating correlation status for the CKP sensor signal
and the pump cam signal.
This displays jug pump revolution. Jug pump revolution is measured by
jug pump cam IAT senser. Jug pump PCU sends signal of ECM.
4 Accelerator Position Sensor Signal Throttle position sensor is computed by the ECM from TP sensor
voltages.This should display about 0% at idle and about 100% at wide
open throttle.
5 Mass Air Flow This indicates measurement value of Mass Air flow senser.
6 Barometric Pressure(HDS)
7 Desined Injection Quantity
8 Injection Quantity(mg/strk) This is displayed current fuel rate (Fuel quantity). The ECM will
compensate for fuel rate to basic fuel rate.
9 Desired Injection Start(°CA)
10 Actual Injection Start(°CA)
11 Coolant Temperature(°C) Engine Coolant temperature is computed by the ECM with ECT sensor
voltages. The ECM appies 5 volts to the ECT circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the ECM monitors a high
signal voltage and interprets that as a cold engine.
12 Fuel Temperature(°C) The fuel temperature is meassured at jug pump. PCU sends signal of
fuel temperature through SAC of ECM.
13 Intake Air Temperature(°C) Intake air temperature is computed by the ECM with MAF sensor
voltages. The ECM appies 5 volts to the MAF circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the ECM monitors a high
signal voltage and interprets that as a cold intake air.
14 Ignition Status Ignition status is indicated by the ECM with Ignition SW signal .This
should display Off at Key “OFF” and ON at Key “ON”.
15 Idle Switch This indicates idle switch is ON or OFF. Idle switch ON means accel
pedal is at idling condition.
16 Brake Switch 1 This
17 Brake Switch 2
18 Clutch Switch
19 Neutral Switch
20 A/C Information SW
21 Diagnostic Request
22 System Voltage This represents the system voltage measured by the ECM at ignition
feed.
23 Main Relay Main relay is indicated by the ECM to main relay signal .
24 Glow Time Relay This indicates glow timer relay ON or OFF.
25 Check Engine Lamp This displays operating status for the Check engine Light.
26 Glow Time Telltale This indicates glow lamp ON or OFF.
27 ABS Input Signal
28 ABS Output Signal
29 EGR Pulse Ratio %
6E–70 ENGINE DRIVEABILITY AND EMISSIONS
30 EGR 2 Pulse Ratio %
31 Intake Manifold Value
(Intake Throttle)
32 Exh. Brake Valve 1
33 Exh. Brake Valve 2
34 Desired Engine Idle Speed The desired engine idle speed that the ECM is commanding. The
ECM will compensate for various engine loads based on engine
coolant temperature, to keep the engine at the desired idle speed.
35 Start of Delivery
36 A/C Request(Air Conditioning) This displays the A/C request signal.
37 Immobilizer
38 Immobilizer Signal
39 Immobilizer Function Programmed
ENGINE DRIVEABILITY AND EMISSIONS 6E–71
DTC
Sub
code
F/Code DTC Name Setting condition Back-up mode History code Cancel condition Cancel Mode MIL light N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC
P0100 1001 65 Mass Air Flow Sensor Voltage
Supply Circuit Low Input
MAF < 4.589V more than
500msec
N*R 4JH1/TF 4JA1.4JH1--- Default=5V
Air flow defaut=1600mg/hub, N*R 4JH1/
TF 4JA1(Excluding TF 4JH1)---, EGR
default=10% ( usually 30-40%)
Yes MAF >= 4.589V more
than 500msec
During same ignition
cycle
ON X X X
0111 Mass Air Flow Sensor Voltage
Supply Circuit High Input
MAF >5.20V more than
500msec
Default=5V Air flow defaut=1600mg/
hub, EGR default=10%
Yes MAF <= 5.20V more
than 500msec
During same ignition
cycle
ON X X X
1011 Mass Air Flow Sensor Circuit
High Input
600RPM<Eng
RPM<5000RPM and MAF
output<-18.6kg/h more than
5 sec
Default=freezed value of immidiate
previous value Air flow defaut=1600mg/
hub, EGR default=10%
Yes MAF output>= -18.6kg/h
more than 600msec
During same ignition
cycle
ON X X X
1100 Mass Air Flow Sensor Circuit
Low Input
600RPM<Eng
RPM<5000RPM and MAF
output>806.4kg/h(N*R 4JH1-
TC/TF 4JA1-TC) or 825kg/
h(TF 4JH1-TC) more than 10
sec
Default=freezed value of immidiate
previous value Air flow defaut=1600mg/
hub, EGR default=10%
Yes MAF output<=806.4kg/h
more than 600msec
During same ignition
cycle
ON X X X
P0110 0010 23 IAT Signal Volatage Low IAT(Intake Air Temp--different
from Pump IAT) <= 0.318V
more than 3 sec
Default = - 0 deg C Yes IAT volt > 0.32V more
than 3 Sec
During same ignition
cycle
ON X X X
0001 IAT Signal Volatage High IAT(Intake Air Temp--different
from Pump IAT) >= 4.7V
more than 3 sec
Default = - 0 deg C Yes IAT volt < 4.7V more
than 3 sec
During same ignition
cycle
ON X X X
P0115 0010 14 ECT Sensor Circuit Low Input ECT volt < 0.32V more than
3 sec
ECT uses fuel pump temp, Injection
beginning governing use 50deg C, Glow
timer use -25 deg C
Yes ECT volt > 0.32V more
than 600msec
During same ignition
cycle
ON X X X
0001 ECT Sensor Circuit High Input ECT volt > 5.7V more than
3 sec
ECT uses fuel pump temp, Injection
beginning governing use 50deg C, Glow
timer use -25 deg C
Yes ECT volt < 4.7V more
than 600msec
During same ignition
cycle
ON X X X
P0180 1011 15 Fuel Temperature Sensor
Circuit Range/Performance
Pump temperature > 150
deg C or < -40 deg C more
than 3 sec.
Fuel temp = default 75deg C Yes No more failure is
regognized more than 3
sec.
During same ignition
cycle
ON X X X
P0215 1011 52 Fuel cutoff solenoid valve
(MAB) circuit high input
No ECM requests Engine
stop, but PCU recognises
High level on MAB line
during Initilization.
Engine stops, can not start engine.
MAB shut off
Yes No more failure is
recognized.
Ignition Key off, no
condition matches
then canceled.
ON X X X
1100 Fuel cutoff solenoid valve
(MAB) always active
During afterrun, Ign OFF,
Engine speed <1500 RPM,
VSS<5km/h, 2 sec after, still
engine rpm.200rpm
immidiate action.
Engine stop, MAB shut off Yes No more failure is
recognized.
Ignition Key off, no
condition matches
then canceled.
OFF
during
DTC set,
MIL ON at
next Ign
cycle.
X X X
1010 Fuel cutoff solenoid valve
(MAB) malfunction 1
Ign OFF, Engine speed
<1500 RPM, VSS<5km/h, 2
sec after, still engine
rpm.200rpm, immidiate
action
Engine stop, MAB shut off, MIL turn on
after starts engine.
Yes No more failure is
recognized.
Ignition Key off, no
condition matches
then canceled.
OFF
during
DTC set,
MIL ON at
next Ign
cycle.
X X X
6E–72 ENGINE DRIVEABILITY AND EMISSIONS
1101 Fuel cutoff solenoid valve
(MAB) malfunction 2 --- Gate
Array error
During afterrun period, CAN
controller can not be bus off
mode. Immidiate action.
None Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
OFF
during
DTC set,
MIL ON at
next Ign
cycle.
X X X
P0216 1010 54 Persistant governer deviaton Conditions: Eng rpm > 700
RPM, Q> 4mg/hub and
Judgement :Actual timing
and target timing deviation >
+3 CA or < -6 CA , more than
12sec.
Limit Q is employed. Yes No more failure is
recognized. Return to
normal mode
immidiately.
During the same
ignition cycle
ON X X X
1011 Timing device fluctuation Engine RPM > 2014RPM,
timing fluctuation becomes
more than +-5.2CA and more
than for 1 sec.
Limit Q is employed. Yes No more failure is
recognized. Return to
normal mode
immidiately.
During the same
ignition cycle
ON X X X
P0251 0110 53 Inection Pump Malfunction PCU detects control pulse
width.
Engine stops. Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
OFF
during
DTC set,
MIL ON at
next Ign
cycle.
X X X
0111 TDC and CAM speed
comparison error
TDC sensor Engine speed -
2* Cam speed sensor>
800RPM(N*R 4JH1-TC) or
720RPM(TF 4JA1-TC) or
690RPM(TF 4JH1-TC) more
than 200msec
Engine stops. Yes TDC Engine speed -
2*Cam speed sensorI<=
800RPM(N*R 4JH1-TC)
or 720RPM(TF 4JA1-
TC) or 690RPM(TF
4JH1-TC).
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
1001 Inection Pump Malfunction No pump map programmed
or pump control unit(PCU)
RAM defect
Engine stops. MAB shut off. Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
1010 Inection Pump Malfunction PCU-EEPROM defect or A/D
converter defect
Limit Q is employed. Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
1011 Inection Pump Malfunction PCU selftest finds
powerstage hardware error.
None Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
1101 Inection Pump Malfunction PCU selftest finds internal
voltage check is OK or not.
None Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
1110 Inection Pump Malfunction ECM does not accept PCU
message more than 1sec
Engine stops. MAB shut off. Yes No more failure is
recognized.
Ignition Key off, at
next Ign cycle no
condition matches
then canceled.
ON X X X
P0335 1110 43 Engine Speed Sensor Input
Circuit Signal Range/
Performance(Over Speed)
RPM > 5100 RPM more
than 20 m sec(sampling
time)
Set rpm backup
1. If Inj. Cam sensor is OK, Engine
Speed becomes Inj.Pump Cam Signal
X 2.
Yes RPM <= 5100RPM for >
50 m sec
During same ignition
cycle
ON X
ENGINE DRIVEABILITY AND EMISSIONS 6E–73
(TDC=DZG-Crank angle
sensor detects this error)
1011 Dynamic plausibility The immidiate previous
engine speed should be
more than 665 RPM and
then the period btwn pulses
is fluctuated by the thresh
hold more than 16 times
during same ignition cycle.
Set rpm backup
1. If Inj. Cam sensor is OK, Engine
Speed becomes Inj.Pump Cam Signal
X 2. 2. If Inj Cam sensor (IAT)fails,
Set default 0 rpm
MAB qty becomes 0, and retard
Injection. Engine stops. 3.
Set Q backup
Yes If OK condition
continues more than
times, become normal .
During same ignition
cycle
ON X X X
1101 Static Plausibility Conditions to required: IAT
should be OK, CAN
communication should
OK,Dynamic plausibility
should be OK. Judgment:
TDC(DZG) is 0 RPM and IAT
is more than 100 RPM for 10
msec.
Set rpm backup
1. If Inj. Cam sensor is OK, Engine
Speed becomes Inj.Pump Cam Signal
X 2. 2. If Inj Cam sensor (IAT)fails,
Set default 0 rpm
MAB qty becomes 0, and retard
Injection. Engine stops. 3.
Set Q backup
Yes If OK condition
continues more than
times, become normal .
During same ignition
cycle
ON X X X
P0380 1000 66 Glow Device Voltage High After Key ON, glow lamp
stays on, Glow Relay circuit
is short circuit more than 3
sec
None Yes Detective circuit
recognized as normal
more than 1 sec
During same ignition
cycle
ON X X X
0100 Glow Device Voltage Low After Key ON, glow lamp
stays on, Glow Relay circuit
is open circuit more than 3
sec
None Yes Detective circuit
recognized as normal
more than 1 sec
During same ignition
cycle
ON X X X
P0381 1000 67 Glow Time Telltale Circuit
Voltage High
Lamp circuit power on, IC
recognizes short circuit more
than 3 sec
None Yes IC recognizes no more
short circuit more than
1sec
During same ignition
cycle
ON X X X
0100 Glow Time Telltale Circuit
Voltage Low
Lamp circuit power off, IC
recognizes short circuit more
than 3 sec
None Yes IC recognizes no more
open circuit more than
3sec
During same ignition
cycle
ON X X X
P0400 1000 32 EGR short to Batt Powerstage ON, ECM
initialized, IC recognises
short to batt more than 3sec
LimitQ is employed. EGR becomes 10%
ratio.
Yes IC recgnizes no more
short circuit more than
3sec
During same ignition
cycle
ON X X
0100 EGR short to grand or open
circuit
Powerstage ON, ECM
initialized, IC recognises
short to ground and open
circuit more than 3sec
LimitQ is employed. EGR becomes 10%
ratio.
Yes IC recgnizes no more
failure more than 3sec
During same ignition
cycle
ON X X
6E–74 ENGINE DRIVEABILITY AND EMISSIONS
0011 EGR Flow Excessive
Detected
N*R 4JH1--70deg
C<ECT<100, TF 4JA1--
55degC<ECT<100degC,N*R
4JH1--16 deg C<IAT<34,TF
4JA1--
15degC<IAT<100degC,N*R
4JH1--880 hpa<
Baro<1100hpa,TF 4JA1--
850hpa<Baro<1100hpa, 7
sec after start mode, and
Target MAF - Actual MAF >
150 mg/huv more than 60
sec.
N*R 4JH1--judgement is
made between 2165 and
3160RPM, and between 15-
35mg/huv. TF 4JA1--
judgement is made between
1500-3100RPM, and
between 8 - 32mg/huv.
LimitQ is employed. but EGR operation
is normal.
Yes Target MAF-Actual
MAF<=150mg/hub,
more than 600msec
During same ignition
cycle
ON X
0101 EGR Flow Insufficient
Detected
N*R 4JH1--70deg
C<ECT<100, TF 4JA1--
55degC<ECT<100degC,N*R
4JH1--16 deg C<IAT<34,TF
4JA1--
15degC<IAT<100degC,N*R
4JH1--880 hpa<
Baro<1100hpa,TF 4JA1--
850hpa<Baro<1100hpa, 7
sec after start mode, and
Target MAF - Actual MAF < -
150 mg/huv more than 60
sec.
N*R 4JH1--judgement is
made between 2165 and
3160RPM, and between 15-
35mg/huv. TF 4JA1--
judgement is made between
1500-3100RPM, and
between 8 - 32mg/huv.
LimitQ is employed. but EGR operation
is normal.
Yes Target MAF-Actual
MAF>=150mg/hub,
more than 600msec
During same ignition
cycle
ON X
P0500 0001 24 VSS Circuit High Input VSS out put > 190 km/h(N*R
4JH1-TC) or 200km/h(TF
4JA1-TC,4JH1-TC) more
than 5 sec
VSS default=5km/h Yes VSS <= 190 km/h(N*R
4JH1-TC) or 200km/
h(TF 4JA1-TC,TF 4JH1-
TC) more than 5 sec
During same ignition
cycle
N*R 4JH1-
TC-- OFF
TF 4JA1-
TC,4JH1-
TC--ON
X X
1010 VSS input signal frequency
too high
VSS signal frequency is too
high, CPU can not recognise
more than 600msec
VSS default=5km/h Yes VSS signal frequency <
CPU eligible frequency
more than600m sec
During same ignition
cycle
N*R 4JH1-
TC-- OFF
TF 4JA1-
TC,4JH1-
TC--ON
X X X
1011 VSS plausibility Q >= 30 mg / hub, Engine
speed>=2500RPM, VSS <
5km/h more than 30 sec
Brake light becomes ON Yes VSS>=5km/h more than
600msec
During same ignition
cycle
N*R 4JH1-
TC-- OFF
TF 4JA1-
TC,4JH1-
TC--ON
X X
ENGINE DRIVEABILITY AND EMISSIONS 6E–75
P0560 0010 35 System Voltage Too Low System Volatage < 7 Volt,
more than 100 m sec
Back up volate figure 9 Volt is used. Yes When system volage
becomes more than 7
volt for 100 m sec.
During same ignition
cycle
OFF X X X
0001 System Voltage Too High System Volatage > 20 Volt,
more than 600 m sec
Back up volate figure 9 Volt is used. Yes When system volage
becomes less than 20
volt for 600 m sec.
During same ignition
cycle
OFF X X X
1010 Extrem voltage input System voltage < 4.5 V, or >
27 V for 0 m sec
PSG uses default value. Yes 4.5V, System volatage <
27 V for 0 m sec
During same ignition
cycle
OFF X X X
P0561 1011 18 Switched System
Voltage(Ignition ON) Circuit
Malfunction
CPU recognises IC circuit
error of main relay control.
Engine stops N*R4JH1-
TC-- Yes
TF4JA1-
TC,4JH1-TC--
NO
No return to normal
mode during this driving
cycle.
During same ignition
cycle
OFF X X X
1010 Switched System
Voltage(Ignition ON) Circuit
Malfunction
During initialization, quick
motion of ignition ON of
ignition OFF triggers this
DTC
If condition continue more than 1 sec
after DTC set, ECM goes into afterrun
mode.
N*R4JH1-
TC-- Yes
TF4JA1-
TC,4JH1-TC--
NO
No return to normal
mode during this driving
cycle.
During same ignition
cycle
OFF X X X
P0606 1011 28 ECU Malfunction 2 APS <1%, Q > 0 mg/strk,
then RPM >2000RPM
Engine stops, MAB shut off Yes Target Q <= 0 (mg/hub)
more than 200m sec ,
or restart
During same ignition
cycle
ON X X X
1010 ECU Malfunction 1 Gate array counter reach 5
counts
Engine stops, MAB shut off Yes No failure happens
more than 20 sec.
During same ignition
cycle
ON X X X
P0645 1000 46 A/C Comp Cutoff Relay
Primary Circuit High Input
AC Power ON at least one
time after Ign ON, IC
recognises short circuit more
than 3 sec.
None Yes IC recognises no more
short circuit more than 3
sec
During same ignition
cycle
ON X X X
0100 A/C Comp Cutoff Relay
Primary Circuit Open
AC Power OFF at least one
time after Ign ON, IC
recognises Open circuit
more than 3 sec.
None Yes IC recognises no more
open circuit more than 3
sec
During same ignition
cycle
ON X X X
P0703 1010 25 During Brake SW on, Brake-
Light SW Circuit Incorrect
Signal(Ignition On)
N*R 4JH1-TC--After start
engine, Engine
RPM>=1500RPM,
APS>=10%, VSS>=15km/h
TF4JA1-TC--
RPM>=693RPM,APS>=0%,
VSS>=0km/h.TF4JH1-TC--
RPM>=665RPM,APS>=0%,
VSS>=0km/h and Brk SW1 /
Brk Sw2 indicate different
more than 300sec.
None Yes BRK SW1 = BRK SW2
more than 300sec
During same ignition
cycle
ON X X
6E–76 ENGINE DRIVEABILITY AND EMISSIONS
1011 During Brake SW off, Brake-
Light SW Circuit Incorrect
Signal
N*R 4JH1-TC--After start
engine, Engine
RPM>=1500RPM,
APS>=10%, VSS>=15km/h
TF4JA1-TC--
RPM>=693RPM,APS>=0%,
VSS>=0km/h.TF4JH1-TC--
RPM>=665RPM,APS>=0%,
VSS>=0km/h and Brk SW1 /
Brk Sw2 indicate different
more than 300sec.
None Yes BRK SW1 = BRK SW2
more than 300sec
During same ignition
cycle
ON X X
P0704 0110 57 Clutch SW Input Circuit
Malfunction
N*R 4JH1-TC--This check is
measured by only one time
per 1 Ign ON, after
initialization, clutch signal
measured upto 5km/h and
no clutch signal change upto
80km/h more than 60 sec.
TF4JA1-TC/4JH1-TC--
1.5km/h upto 80km/h.
Cut off Auto cruise control Yes Clutch signal change is
made more than
500msec
During same ignition
cycle
ON X X X
P1105 0010 86 Baro sensor Circuit Low Input Baro V<
1.48V(1.4794V=6000M)
more than1 sec
Default =1013hpa Yes Baro>=1.48V more than
1 sec
During same ignition
cycle
ON X X X
0001 Baro sensor Circuit High Input Baro V>4.42V(4.42V=-
1000M) more than1 sec
Default =1013hpa Yes Baro<=4.42V more than
1 sec
During same ignition
cycle
ON X X X
P1110 1000 72 Intake VSV High Input Powerstage ON, ECM
initialized, IC recognises
short to batt more than 3sec
None Yes IC recognises no more
failure , more than 3sec
During same ignition
cycle
ON X X
0100 Intake VSV Open Circuit Powerstage ON, ECM
initialized, IC recognises
short to batt open circuit or
short to ground more than
3sec
None Yes IC recognises no more
failure , more than 3sec
During same ignition
cycle
ON X
P1120 0010 21 Pedal Position Sensor Circuit
Low Input
APS signal volage < 320 mV
more than 500 m sec
Use Idle SW position = 0%,
acceleration, decceleration becomes
limmitted performance. Idle speed
becomes 1400 RPM.
Yes APS signal volage > 320
m V more than 500 m
sec
During same ignition
cycle
ON X
0001 Pedal Position Sensor Circuit
High Input
APS signal volage > 4.9
V(N*R 4JH1-TC) or
4.5V(TF4JA1-TC,4JH1-TC)
more than 500 m sec
Use Idle SW position = 0%,
acceleration, decceleration becomes
limmitted performance. Idle speed
becomes 1400 RPM.
Yes APS signal volage < 4.9
V(N*R 4JH1-TC) or
4.5V(TF 4JA1-TC/4JH1-
TC) more than 500 m
sec
Need to check ON X X X
1001 Pedal Position Sensor Voltage
Supply Circuit Low Input
APS signal voltage < 4.6 V
more than 500 m sec
System volatge is used as 4.9Volt. Idling
speed becomes 1400 RPM. APS uses
default 0%.
Yes APS signal volage > 4.6
V more than 500 m sec
During same ignition
cycle
ON X X X
0111 Pedal Position Sensor Voltage
Supply Circuit High Input
APS signal voltage > 5.2 V
more than 500 m sec
System volatge is used as 4.9Volt. Idling
speed becomes 1400 RPM.
Yes APS signal volage < 5.2
V more than 500 m sec
During same ignition
cycle
ON X X X
ENGINE DRIVEABILITY AND EMISSIONS 6E–77
1101 Pedal Position Sensor Brake
Error
No brake error DTC indicates
Brake pedal(sw is ON) and
accel pedal (more than
18%(N*R 4JH1-TC) or
8.7%(TF 4JA1/4JH1-
TC)accel)are depressed at
same time and Engine
Speed is more than
1700RPM and more than 2
sec. If accel input fluctuates
more than 20% within 1 sec,
it is cancelled.
APS value beccomes 0%, lamp--
accelaration lamp be come 50%/
Sec???? Idle speed becomes 1400
RPM
Yes Brake OFF, ACC OFF or
ACC acceleration 20%/
Sec or brake error
happens.
During same ignition
cycle
ON X X X
1110 Pedal Position Sensor
General Error
N*R4JH1-TC--Idle SW ON
and APS value > 18% , more
than 600msec TF 4JA1/
4JH1-TC--Idle SW OFF and
APS value<0.35% or Idle SW
ON and APS valu>8.7%,
more than 600msec
Set to APS value = 0% and idle speed
1400RPM.
Yes Idle SW OFF and APS
100%, or Idle SW ON
and APS 0%. But 134
can not cance.
Ignition Key off, no
condition matches
then canceled.
ON X X X
P1173 0011 22 Fuel Reduction caused by
High Coolant Temp
Fuel quantity is not normal
condition because ECT
indicates more than 100deg
C and more than for 30sec.
None Yes No more failure is
recognized. It returns to
normal condition
immiditely.
During same ignition
cycle
OFF X X X
0111 Fuel Reduction caused by
High fuel Temp 1
PSG detects fuel temp
output becomes more than
100deg C more than 30sec.
PCU reduced Q-map is employed. Yes No more failure is
recognized. It returns to
normal condition
immiditely.
During same ignition
cycle
OFF X X X
1010 Fuel Reduction caused by
High fuel Temp 2
ECM detects fuel
temperature is more than
80degC and last more than
for 30sec.
ECM reduced Q-map is employed Yes No more failure is
recognized. It returns to
normal condition
immiditely.
During same ignition
cycle
OFF X X X
P1335 1010 43 Engine Speed Output Circuit
Malfunction
PCU detects
DZG(TDC)pulse error
immidiately.
Limit Q is employed. Yes PCU accepts no more
erro of TDC. Counter
becomes 0 from 120.
During same ignition
cycle
ON X X X
P1345 1010 41 Injection Pump:Camshaft
Speed Malfunction
PCU recognises cam speed
sensor(increment angle time
system) error more than 1
sec.
None Yes No more failure is
recognized. Return to
normal mode by counter
reduction, almost
immidiately.
During same ignition
cycle
ON X X X
(Inrement angle time system-
IAT)
P1520 1010 47 Neutral Switch ON During driving condition
*1
,
Neutral SW on error signals
are recognized more than
three times and more than
60 sec.
None Yes Two no failure
consequetive driving
cycle
The ignition cycle
after two consecutive
no failure igniton
cycle makes MIL
light off.
ON X X X
1011 Neutral Switch OFF During no driving condition
*1
,
Neutral SW off error signals
are recognized more than
three times and more than
60 sec.
None Yes Two no failure
consequetive driving
cycle
The ignition cycle
after two consecutive
no failure igniton
cycle makes MIL
light off.
ON X X X
MT Only
6E–78 ENGINE DRIVEABILITY AND EMISSIONS
P1576 1000 71 Exh Brake and QWS Valve
1(N*R 4JH1-TC--Exhaust
Brake and QWS, TF 4JH1-
TC--QWS system only) Circuit
Short to Battery
Powerstage ON, ECM
initialized, IC recognises
short to batt more than 1sec
ECM sends reverse phase signal,
results to turn on ABS light ON.
Yes IC recognises no more
failure, more than
1.5sec
During same ignition
cycle
ON X
Exh.Brake
0100 Exh Brake and QWS Valve
1(N*R 4JH1-TC--Exh Brake
and QWS ,TF4JA1-TC--QWS
only) Circuit Short to Ground
or Open Circuit
Powerstage ON, ECM
initialized, IC recognises
short to ground or open
circuit more than 600msec
ECM sends reverse phase signal,
results to turn on ABS light ON.
Yes IC recognises no more
failure, more than
600msec
During same ignition
cycle
ON X NKR
4JH1-TC--
Exh.Brake
and QWS TF
4JA1-TC--
QWS
X NKR
4JH1-TC--
Exh.Brake
and QWS
TF 4JA2-
TC--QWS
P1577 1000 Ext VSV 2(TF 4JA1-TC--
QWS) Circuit short to Battery
Powerstage ON, ECM
initialized, IC recognises
short to batt more than 1sec
ECM sends reverse phase signal,
results to turn on ABS light ON.
Yes IC recognises no more
failure, more than
1.5sec
During same ignition
cycle
ON X TF
4JA1-TC--
QWS
P1577 0100 Ext VSV 2 (TF 4JA1-TC--
QWS) Circuit short to Ground
or Open Circuit
Powerstage ON, ECM
initialized, IC recognises
short to ground or open
circuit more than 600msec
ECM sends reverse phase signal,
results to turn on ABS light ON.
Yes IC recognises no more
failure, more than
600msec
During same ignition
cycle
ON X TF
4JA1-TC--
QWS
P1605 1110 55 EEPROM Defect EEPROM check sum does
not match with the check
sum during initialization.
Becomes back-up
immidiately.
Engine does not start, idle target Q=0. Yes Right after EEPROM
checksum value
matches with initial
values.
During same ignition
cycle
ON X X X
1101 EEPROM Defect Fail of read or write
EEPROM data as
initialization.
Engine does not start, idle target Q=1. Yes Right after EEPROM
checksum value
matches with initial
values.
During same ignition
cycle
ON X X X
1100 Seeds and key file destroyed When either sees or keys
data is or are destoryed.
None Yes None During same ignition
cycle
ON X X X
P1610 1010 56 Seeds and Key file destroyed The engine control unit is in
the as-delivered condition
Can not start Engine, ECM must be
reprogrammed.
Yes No more failure is
recognized.
During same ignition
cycle
ON X X
P1611 1010 56 Wrong Security Code Entered Incorrect security code was
input with Tech-II
The injection qty is immidiately stopped. Yes The engine can first be
started when the correct
security code is input or
the ignition is switched
OFF/ON.
During same ignition
cycle
ON X X
P1612 1010 56 Immobiliser No Or Wrong
Signal
The immo ICU-ECM
communication could not be
correctly completed.
The injection qty is immidiately stopped.
The engine can not start.
Yes No more failure is
recognized.
During same ignition
cycle
ON X X
P1613 1010 56 Immobiliser No Or Wrong
Signal
The Immo-MSG
communication could not be
correctedly completed.
Q stopped, can not start engine. Yes No more failure is
recognized.
During same ignition
cycle
ON X X
P1614 1010 56 Wrong Transponder Key The compare response
calculated in the ECM does
not agree with the response
in immo.
The injection qty is immidiately stopped.
The engine can not start.
Yes No more failure is
recognized.
During same ignition
cycle
ON X X
P1625 1011 76 Power Supply Relay Switched
Off too late
During after-run , Main relay
shut off more than 2 sec
ECM command to shut main relay. Yes Engine can not restart Ignition Key off, no
failure condition
matches then
canceled.
OFF X X X
ENGINE DRIVEABILITY AND EMISSIONS 6E–79
1010 Power Supply Relay Switched
Off too Early
By thia monitoring function a
main relay or control unit
defect is recognized which
causes a MSG shut off
before the Microprocessor
has given the shut demand.
None Yes Engine can not restart Ignition Key off, no
failure condition
matches then
canceled.
ON X X X
P1630 1010 51 Fuel-Injection Quality Circuit
High Input
Solenoid valve has
overcurrent.
Limit Q is employed. Yes No failure recognised During same ignition
cycle
ON X X X
1011 Fuel-Injection Quality Circuit
High Input
Solenoid valve has continous
energized.
Engine stops, MAB operated, Yes No return to normal
mode during this driving
cycle.
Ignition Key off, no
failure condition
matches then
canceled.
ON X X X
P1650 1010 44 CAN: Device Offline CAN communication is cut
more than 200msec
Engine stops, MAB operated, Yes No more failure more
than 100msec
During same ignition
cycle
ON X X X
1011 CAN: Device Hangup During driving, CAN lin hang
up.
Engine stops, MAB operated, Yes No more failure more
than 100msec
During same ignition
cycle
ON X X X
P1651 1010 45 Inj Pump:CAN Malfunction PSG can not receive ECM
message or time out.
Engine stops, MAB operated, Yes No more failure During same ignition
cycle
ON X X X
1011 CAN Receiver Error Can not read out PSG
message during afterrun
Engine stops, MAB operated, Yes No more failure During same ignition
cycle
ON X X X
P1690 1000 77 MIL Circuit Open Lamp circuit power on, IC
recognises short circuit more
than 1 sec
None Yes IC recgnises no more
short circuit more than
600msec
During sameignition
cycle
OFF X X X
0100 MIL Circuit High Input Lamp circuit power off, IC
recognises open circuit more
than 3 sec
None Yes IC recgnises no more
open circuit more than 3
sec
During sameignition
cycle
OFF X X X
*1
Driving condition No driving condition
585 VS>62.9km/h V/N>0.00412 1st gear VS<1.5km/h Eng rpm>693rpm V/N<0.00412
587 MT VS>62.4km/h V/N>0.0041602
AT VS>65.0km/h V/N>0.0043359
VS<1.5km/h Eng>665 V/N<0.0041602
VS<0km/h Eng>6000rpm V/N<0.0043359
134 VS>64.0km/h V/N>0.003398 VS<2km/h Eng rpm>665rpm V/N<0.003338
6E–80 ENGINE DRIVEABILITY AND EMISSIONS
On-Board Diagnostic (OBD) System Check
060RY00330
Circuit Description
The on-board diagnostic system check is the starting
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical
check of the ECM and engine grounds for cleanliness
and tightness.
The on-board diagnostic system check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness. Inspect the ECM harness and
connector for improper mating, broken locks, improperly
formed or damaged terminals, poor terminal-to-wire
connection, and damaged harness.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
1. The check engine lamp should be “ON” steady with
the ignition “ON” engine “OFF.” If not, the “No Check
Engine Lamp” chart should be used to isolate the
malfunction.
2. Checks the serial data circuit and ensures that the
ECM is able to transmit serial data.
4. If the Tech 2 isn't used, perform “Reading Flash
Diagnostic Trouble Codes”.
Fuse
1GN
ECU
25A
Check
Engine
Lamp(CEL)
BRN/
YEL
YEL/
GRN
ORN/
BLU
Keyword 2000
(Serial Data)
Diag
Switch
Engine
Control
Module
(ECM)
Diagnostic
Connector
ABS
NKR 4JH1-TC
only
ABS
NKR 4JH1-TC
only
DLC Ignition Feed Circuit
Serial
Data
Circuit
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
ECM Ground
42 35 45
1,2
µP
µP : Microproccesor
Fuse
1GN
ECU
25A
Check
Engine
Lamp(CEL)
BRN/
YEL
YEL/
GRN
ORN/
BLU
Keyword 2000
(Serial Data)
Diag
Switch
Engine
Control
Module
(ECM)
Diagnostic
Connector
ABS
NKR 4JH1-TC
only
ABS
NKR 4JH1-TC
only
DLC Ignition Feed Circuit
Serial
Data
Circuit
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
ECM Ground
42 35 45
1,2
µP
µP : Microproccesor
ENGINE DRIVEABILITY AND EMISSIONS 6E–81
On Board Diagnostic (OBD) System Check
Step Action Value(s) Yes No
1 1. Ignition “On”, engine “Off”.
2. Check CHECK ENGINE lamp.
Did the check engine lamp turn on? — Go to Step 2
Go to “No
Check Engine
Lamp”
2 1. Ignition “Off”, engine “Off”.
2. Install the Tech 2.
3. Ignition “On”, engine “Off”.
4. Attempt to display ECM engine data with it.
Did it display ECM data? — Go to Step 3 Go to Step 6
3 1. Ignition “On”, engine “On”.
Did the engine start and continue to run?
— Go to Step 4
Go to “Engine
Cranking But
Won't Run”
4 1. Select “Display DTCs” with the Tech 2.
Are any DTCs stored? —
Go to DTC
Chart Go to Step 5
5 1. Compare ECM data values displayed on the
Tech2 to typical values.
Refer to the typical scan data values.
Are the display values normal or close to it? — Go to Symptom
Refer to
Indicated
Component
System Checks
6 1. Ignition “Off”, engine “Off”.
2. Disconnect ECM
3. Ignition “On”, engine “Off”.
4. Check serial data circuit for an open, short to
ground or short to voltage.
5. Check DLC ignition feed circuit for an open, short
to ground or short to voltage.
6. If the problem is found, repair circuit as necessary.
Was the problem found? — Go to Step 2 Go to Step 7
7 1. Check ECM ground circuit for open or short to
voltage.
2. If the problem is found, repair as necessary.
Was the problem found? — Go to Step 2 Go to Step 8
8 1. Replace ECM.
Is the action complete? — Go to Step 2 —
6E–82 ENGINE DRIVEABILITY AND EMISSIONS
No Check Engine Lamp
Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or a
wire broken inside the insulation. Check for the
following items:
• Inspect the ECM harness and connections for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire
connection, and damaged harness.
• If the engine runs OK, check for a faulty light bulb, an
open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
• If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. A “No Check Engine Lamp” condition accompanied
by a no-start condition suggests a faulty ECM
ignition feed or battery feed circuit.
9. Using a test light connected to B+, probe each of the
ECM ground terminals to ensure that a good ground
is present. Refer to ECM Terminal End Viewfor
terminal locations of the ECM ground circuits.
ENGINE DRIVEABILITY AND EMISSIONS 6E–83
No Check Engine Lamp
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
— Go to Step 2
Go to “On
Board
Diagnostic
(OBD) System
Check”
2 1. Ignition “On”, engine “On”
Did the engine start? — Go to Step 3 Go to Step 7
3 1. Check the meter fuse for the instrument cluster
ignition feed circuit.
2. If the problem is found, replace as necessary.
Was a ploblem found? — Verify repair Go to Step 4
4 1. Ignition “On”, engine “Off”
2. Probe the ignition feed circuit at the cluster
connector with the test light to ground.
Did it turn on? — Go to Step 5 Go to Step 8
5 1. Check the lamp bulb at check engine lamp .
2. If a ploblem is found, replace as necessary.
Was a ploblem found? — Verify repair Go to Step 6
6 1. Ignition “Off”, engine “Off”
2. Disconnect Harness connector from ECM.
3. Jumper the check engine lamp driver circuit at the
ECM connector to ground.
4. Ignition “On”, engine “Off”.
Was the light turn on? — Go to Step 11 Go to Step 8
7 1. Check following fuse.
•Main(80A) •Key SW(50A) •ECM •Meter(15A)
If the problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 10
8 1. Ignition “Off”, engine “Off”
2. Disconnect Harness connector from ECM.
3. Jumper the ignition circuit at the ECM connector to
ground.
4. Ignition “On”, engine “Off”.
Was the light turn on? — Go to Step 9 Go to Step 13
9 1. Ignition “On”, engine “Off”
2. Disconnect Harness connector from ECM.
3. Probe the battery circuit at the cluster connector
with the test light to ground.
Did it turn on? — Go to Step 10 Go to Step 15
10 1. Check ECM ground circuit for an open or short to
voltage.
2. If the problem is found, replace as necessary.
Was the problem found? — Verify repair Go to Step 11
6E–84 ENGINE DRIVEABILITY AND EMISSIONS
11 1. Check ECM connector for condition.
2. If the problem is found, replace as necessary.
Was the problem found? — Verify repair Go to Step 15
12 1. Check check engine lamp driver circuit for an open
or short to ground.
CHECK POINT: Open wire, Coming off connector
Was the problem found? — Verify repair Go to Step 19
13 1. Check ECM relay for a condition.
2. If the problem is found, replace as necessary.
Was the problem found? — Verify repair Go to Step 14
14 1. Check ignition circuit for an open or short to
voltage.
2. Check ignition switch for a condition.
3. If the problem is found, replace as necessary.
Was the problem found? — Verify repair —
15 1. Check ECM battery circuit for an open.
2. If the problem is found, replace as necessary.
Was the problem found? — Verify repair Go to Step 16
16 1. Check ECM ignition feed circuit and ECM battery
feed circuit.
Was the problem found? — Verify repair Go to Step 18
17 1. Probe the ignition feed circuit at the cluster
connector for open or short to ground.
Did it turn on? — Verify repair —
18 1. Replace ECM.
Is the action complete? — Verify repair —
19 1. Probe the cluster connector for a coming off.
Did it turn on?
2. If the problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 17
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–85
Check Engine Lamp “ON” Steady
Circuit description
The check engine lamp should always be illuminated
and steady for about five seconds with ignition “ON” and
the engine stopped. Ignition feed voltage is supplied
directly to the check engine lamp indicator. The Engine
Control Module (ECM) turns the check engine lamp
“ON” by grounding the check engine lamp driver circuit.
The check engine lamp should not remain “ON” with the
engine running and no DTC(s) set. A steady check
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
• Poor connection or damaged harness – Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. If the check engine lamp does not remain “ON”
when the ECM is disconnected, the check engine
lamp driver wiring is not faulty.
3. If the check engine lamp driver circuit is OK, the
instrument panel cluster is faulty.
6E–86 ENGINE DRIVEABILITY AND EMISSIONS
Check Engine Lamp “ON” Steady
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
— Go to Step 2
Go to “On
Board
Diagnostic
(OBD) System
Check”
2 1. Ignition “Off”, engine “Off”
2. Disconnect ECM.
3. Ignistion “On”, observe the check engine lamp.
Did it turn on? — Go to Step 3 Go to Step 5
3 1. Ignition “Off”, engine “Off”
2. Disconnect the instrument panel cluster.
3. Check check engine lamp driver circuit between
ECM to the instrument panel cluster for short to
voltage.
4. If the problem is found, repair circuit as necessary.
Was the problem found? — Verify repair Go to Step 4
4 1. Replace instrument panel cluster.
Was the malfunction fixed? — Verify repair
5 1. Check ECM ground circuit for an open or short to
voltage.
2. If the problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 6
6 Replace ECM.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–87
DTC P0100
MAF SENSOR MALFUNCTION
2
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A
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5
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6E–88 ENGINE DRIVEABILITY AND EMISSIONS
MAF Circuit
Top view of mode on page 6E-89.
Heater
2
3
1
5
4
+5V
NTC IAT sensor
MAF sensor
Power Supply
Temperature Sensor
Power Ground
Suppliment Voltage
Voltage Output
ENGINE DRIVEABILITY AND EMISSIONS 6E–89
Circuit Description
The mass air flow meter uses a platinum hot wire. The
hot wire air flow meter consists of a platinum hot wire,
thermistor and a control circuit installed in a plastic
housing. The hot wire air flow meter works on the
principle that the hot wire and thermistor located in the
intake air bypass of the housing detect any changes in
the intake air temperature.
The hot wire is maintained at the set temperature by
controlling the current flow through the hot wire. This
current flow is ten measured as the output voltage of the
air mass flow meter.
The circuit is constructed so that the platinum hot wire
and thermistor provide a bridge circuit, with the power
transistor controlled so that the potential of A and B
remains equal to maintain the set temperature.
HOTFLM-MASS AIR SENSOR
MTC CILY IN PAST ACC. POS. MO. 2 MCLSED
CYLINDER HOUSING
BUSH
SCREEN FILTER WITH FAN
FLOW GRID
6E–90 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0100 SUB CODE 1100
MAF SENSOR CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC.
2. Observe the DTC.
Was the DTC P0100 stored? Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B see page 6E-57.
Disconnect MAF sensor.
Measure voltage between ECM pin 88 and pin 92.
Breaker box is not available
Ignition off
Disconnect ECM from ECM harness.
Measure voltage at ECM pin 88 and pin 92.
If voltage indicates "0"V, go to step 4.
If voltage indicates more than "0"V, disconnect MAF
sensor. Measure voltage between ECM pin 88 and pin
92. If voltage indicates 0 volt, go to yes column at this
step. If voltage indicates more than 0 volt, repair
Engine harness. 0V
Replace MAF
and verify Go to Step 4
4 Breaker box is available
Ignition off
Replace the ECM to the another ECM known as OK.
Measure voltage between ECM pin 88 and pin 92.
Breaker box is not available
Ignition off
Replace the ECM by the ECM know as OK.
Check DTC turn ON or not. 0V
Replace ECM
and verify
Repair engine
harness and
verify
ENGINE DRIVEABILITY AND EMISSIONS 6E–91
DTC P0100 SUB CODE 1001
MAF SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0100.
2. Observe the DTCs.
Was the DTC P0100 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B see page 6E-57.
Disconnect MAF sensor from engine harness.
Measure voltage at ECM pin 83 and ground.
Measure the resistance between ECM pin 83 and
ground. 5V
Replace MAF
sensor and
verify Go to Step 4
Breaker box is not available
Ignition off
Disconnect engine harness at ECM side and MAF
side both.
Measure resistance between engine harness
connector pin 83 and ground.
More than
10MΩ Go to Step 5
Repair engine
harness
4 Breaker box is available
Ignition off
Replace the ECM to the another ECM known as OK.
Measure voltage at ECM pin 83 and ground.
More than
4.6V Replace ECM
Repair Engine
harness
5 Breaker box is not available
Ignition off
Keep disconnected MAF condition.
Measure resistance between MAF side connector pin
3 and ground.
13.70kΩ
Replace ECM
and verify
Replace MAF
and verify
83
ECM harness connector
4 1 2 3 5
MAF sensor connector
6E–92 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0100 SUB CODE 1011
MAF SENSOR CIRCUIT LOW INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0100.
2. Observe the DTCs.
Was the DTC P0100 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect MAF sensor.
Make jump wire between MAF 3 pin and MAF 4 pin at
engine harness connector.
Check continuity between 83 and 92.
Make jump wire between MAF 3 and MAF 5 pin at
engine harness connector. Continuety
Go to Step 4
Replace
harness
Check continuity between ECM pin 88 and pin 92.
Remove jump wire, MAF sensor should disconnected.
Check isolation resistance between ECM pin 88 and
MAF.
More than
1MΩ
Breaker box is not available
Ignition off
Disconnect engine harness from ECM and MAF.
Make jump wire between MAF 3 pin and MAF 4 pin at
engine harness connector.
Check continuity between 83 and 92.
Make jump wire between MAF 3 and MAF 5 pin at
engine harness connector.
Check continuity between ECM pin 88 and pin 92.
Remove jump wire, MAF sensor should disconnected.
Check isolation resistance between ECM pin 88 and
MAF.
5 1 2 3 4
5 1 2 3 4
5 1 2 3 4
5 1 2 3 4
92
88
ENGINE DRIVEABILITY AND EMISSIONS 6E–93
4 Breaker box is available
Ignition off
Check MAF sensor resistance between MAF pin 5
and 3.
Less than
13.7KΩ Replace ECM Replace MAF
Step Action Value(s) Yes No
6E–94 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0100 SUB CODE 0111
MAF SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0100.
2. Observe the DTCs.
Was the DTC P0100 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect MAF connector from engine harness.
Measure voltage between ECM pin 83 and ground. 5V
Go to Step 4 Go to Step 5
Breaker box is not available
Ignition off
Disconnect engine harness at ECM side.
Measure isolation resistance between ECM pin 83 at
engine harness side and ground.
More than
1MΩ
4 Measure voltage at MAF connector.
0V
Go to
Intermittent
Diagnosis. (I/D) Replace MAF
5 Breaker box is available
Ignition off
Replace to the another ECM known as OK.
Measure voltage between ECM pin 83 and ground 5V
Replace ECM
and verify
Repair engine
harness
Breaker box is not available
Ignition off
Replace to the another ECM know as OK.
Check DTC turn ON. No DTC
No DTC
Replace ECM
and veirfy
DTC ON
Repair engine
harness
83
5 1 2 3 4
ENGINE DRIVEABILITY AND EMISSIONS 6E–95
DTC P0110
IAT Sensor Maifunction
DTC P0110 SUB CODE 0010
IAT Sensor Low Voltage
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
PCU
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0110.
2. Observe the DTCs.
Was the DTC P0110 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
6E–96 ENGINE DRIVEABILITY AND EMISSIONS
3 Breaker box is available
Ignition off
Install breaker box.
Disconnect MAF sensor.
Measure resistance between 84 and ground.
Breaker box is not available
Ignition off
Disconnect ECM harness and MAF sensor.
More than
1MΩ Go to Step 4 Repair wiring
4 Breaker box is available
Ignition off
Connect MAF sensor.
Measure resistance between 84 and 92.
Breaker box is not available
Ignition off
Keep MAF connector disconnected.
Measure resistance between MAF 1 and MAF 3.
No short
circuit Replace ECM Replace MAF
Step Action Value(s) Yes No
84
4 1 2 3 5
ENGINE DRIVEABILITY AND EMISSIONS 6E–97
DTC P0110 SUB CODE 0001
IAT High Voltage (Open Circuit)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0110.
2. Observe the DTCs.
Was the DTC P0110 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect MAF sensor.
Make jump wire between MAF 1 and MAF 3 at MAF
connector side.
Check continuity between 84 and 92 measure voltage
at 84. Continuity
Go to Step 4
Repair engine
harness and
verify
Breaker box is not available
Ignition off
Disconnect ECM, MAF sensor.
Make jump wire between MAF 1 and MAF 3 at MAF
connector side.
Check continuity between 84 and 92 measure voltage
at 84.
0V
4 Breaker box is available
Ignition off
Disconnect MAF sensor.
Measure resistance between MAF pin 1 and pin 3.
2.0KΩ at
20°C room
temperature
Go to Step 5
Replace MAF
sensor and
verify
Measure any voltage at pin 1 or 3.
Breaker box is not available
Ignition off
Disconnect MAF sensor.
Measure resistance between MAF pin 1 and pin 3.
Measure any voltage at pin 1 or 3. 0V
5 1 2 3 4
5 1 2 3 4
6E–98 ENGINE DRIVEABILITY AND EMISSIONS
5 Breaker box is available
Ignition off
Replace to the another ECM know as OK.
Check DTC ON or not.
Breaker box is not available
Ignition off
Replace to the another ECM know as OK.
Check DTC ON or not. No DTC ON Replace ECM —
Step Action Value(s) Yes No
5 4 3 2 1
ENGINE DRIVEABILITY AND EMISSIONS 6E–99
DTC P0115
Engine Coolant Temperature Sensor Malfunction
Circuit Description
The ECT Sensor is a thermistor. A temperature
changes the resistance value. And it changes voltage.
In other words it measures a temperature value. It is
installed on the coolant stream. Low coolant
temperature produces a high resistance.
The ECM supplies a 5 volts signal to the ECT Sensor
through resisters in the ECM and measure the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot. The ECM uses to this value, and
calculates a SPV switching, a fuel injection timing, a
main injection volume and an EGR VSVs switching.
The Scan Tool displays ECT in degrees. After engine
start up, the temperature should rise steadily to about
80°C.
If the engine has not been run for several hours, the
ECT and intake air temperature displays should be
close to each other. An ECT failure with the short to
voltage or ground will set a DTC P0115.
Engine Coolant Temperature Sensor
ABS
TDC
VSS
16 15 14 13 12 11 10 9
8
29 4
7 8
7 6 5 4 3 2 1
IC 08 IC 08
IC 08
IC 03 IC 08
27 68 89 98 32 62 90 93 45 35
Us
Balt
Balt
Balt
µP
ECT
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
−5 12300
−15 21450
−30 52700
−40 100700
6E–100 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0115 SUB CODE: 0001
ECT SENSOR CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0115.
2. Observe the DTCs.
Was the DTC P0115 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check water temp metor.
Does it indicate very low temperature? Go to Step 4
4 Check atomosphere temperature? Less than
-36°C Go to Step 5 Go to Step 7
5 Warm up engine.
Check lamp goes off or not.
Lamp goes off
after warm up
No repair
necessary Go to Step 6
6 Does water temperature meter indicate still low
temperature? and lamp still stay.
Coolant system
check
Peplace ECT
sensor
7 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect ECT sensor.
Make jump wire between ECT connector pins.
Check continuity between ECM pin 93 and 89.
Breaker box is not available
Ignition off
Disconnect ECM connector and ECT sensor.
Make jump wire between ECT connector pins.
Check continuity between ECM pin 93 and 89.
Continuity Go to Step 8 Repair wire
8 Check ECT resistance. Compare with
ECT sensor
table. Go to Step 9
Replace ECT
sensor
9 Breaker box is available
Ignition off
Measure voltage between ECM connector pin 89 and
ground.
Breaker box is not available
Ignition off
Measure voltage between ECM connector pin 89 and
ground.
0V Go to Step 10 Repair harness
105
99
ENGINE DRIVEABILITY AND EMISSIONS 6E–101
10 Remove ETC sensor.
Check ETC sensor performance with the engine
coolant temperature sensor resistance table. See the table Repalce ECM Replace ETC
Step Action Value(s) Yes No
6E–102 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0115 SUB CODE: 0010
ECT SENSOR CIRCUIT LOW INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0115.
2. Observe the DTCs.
Was the DTC P0115 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check water temp meter.
Does it indicate very high temperature? or indicate
more than max condition. Go to Step 4 Go to Step 8
4 Check engine has over heat condition. More than
136°C DTC
turns ON
Follow
mechanical
section Go to Step 5
5 LLC consentration is too high, check reserver tank. LLC : Water =
50 : 50 Go to Step 6 Change LLC
6 Check radiator cap setting pressure. See the
mechanical
section Go to Step 7
7 Check water temp meter indicator. See the
electrical
section —
8 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect ECT sensor.
Make jump wire between ECT sensor connector.
Check short to ground between ECM connector pin 89
and ground.
Breaker box is not available
Ignition off
Disconnect ECM connector and ECT sensor.
Make jump wire between ECT sensor terminal.
Check ECT circuit short to ground.
No short to
ground Go to Step 9 Repair wiring
105
ENGINE DRIVEABILITY AND EMISSIONS 6E–103
9 Check ECT sensor not short to ground.
No short to
ground Go to Step 10
Short to ground
replace ECT
10 Check ECT sensor performance.
Does it indicate within the engine coolant temperature
sensor resistance table? See the table Replace ECM Replace ECT
Step Action Value(s) Yes No
6E–104 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0180 SUB CODE 1011
FUEL TEMPARETURE SENSOR CIRCUIT RANGE/PERFORMANCE
Circuit Description
Fuel temperature sensor is located in injection pump.
Fuel temperature sensor malfunction message is sent
by DSG through CAN communication.
CAN communication failure is indicated by other DTC.
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
PCU
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0180.
2. Observe the DTCs.
Was the DTC P0180 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Ignition on and run engine.
Check Tech-II data within 3 sec right after engine run.
* After 3 sec, fuel temperature becomes back up
default figure, therefore data can not defect.
-40°C<fuel
temp<150°C Go to Step 4
Out of
specification
Replace
injection pump
ENGINE DRIVEABILITY AND EMISSIONS 6E–105
4 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect PCU connector.
Make jump wire between PCU connector pin 1 and 2.
Check continuity between ECM connector 99 and
100.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Disconnect PCU connector.
Make jump wire between PCU connector pin 1 and 2.
Check continuity between ECM connector 99 and
100. Continuity
Replace
injection pump Repair wiring
Step Action Value(s) Yes No
6E–106 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0215
FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Conditions for Clearing the MIL/DTC
• Diagnostic Trouble Code P0215 can be cleared by
using the Scan Tool’s “Clear Info” function.
DTC P0215 SUB CODE 1011
FUEL CUTOFF SOLENOID VALVE (MAB) CIRCUIT HIGH INPUT
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
TDC MAB
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
PCU
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0215.
2. Observe the DTCs.
Was the DTC P0215 restored? —
Replace
injection pump
Go to
Intermittent
Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–107
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect PCU connector.
Check short circuit between ECM pin 105 and power
source points, see “reference” on page 108.
Sample shows only 4JA1-TC, but other 4JH1-TC
system should be same points.
Breaker box is not available
Ignition off
Disconnect ECM and PCU connector.
Disconnect PCU connector.
Check short circuit between ECM pin 105 and power
source points, see page 6E-108.
Sample shows only 4JA1-TC, but other 4JH1-TC
system should be same points.
No short
circuit Go to Step 4 Repair wiring
4 Breaker box is available
Ignition off
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector pin 99 and
connector pin 100.
Breaker box is not available
Ignition off
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector pin 99 and
connector pin 100.
Continuity Repair wiring
Step Action Value(s) Yes No
105
see
page 6E-108
99
6E–108 ENGINE DRIVEABILITY AND EMISSIONS
reference
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
0
.
5
B
/
R
I
C
5
0
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
0
.
5
L
/
R
I
C
1
1
5
R
/
W
H
B
0
1
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R
IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T
S
E
N
S
O
R
2L/R
IC02
2L/R
IC02
0.5L/B
IC04
I
Z
0
6
0.5B/Y
IC03
0.5L/R
IC17
0.5W/B
IC22
0.5Y
IC31
A37(40)
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
VSV ; EXT 1
RELAY ; A/C COMPRESSOR
R
E
L
A
Y

;
G
L
O
W
S
W

;
T
H
E
R
M
O
SW ; BRAKE
RESISTER ; CLUTCH SW
(YZK NO ; 7321-9900)
RESISTER ; IDLE UP
R
E
S
I
S
T
E
R

;

N
E
U
T
R
A
L

S
W
(
I
D
L
E

S
W
)
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; CLUTCH
SW ; NEUTRAL
SW ; BACK UP
SW ; OIL
0.5L/R
IC18
0.5W/R
IC23
A59(61)
VSV ; EXT 2
0.5L/R
IC16
0.5L/R
IC15
0.5B/O
IC26
B19(97)
0.5W/R IC27
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
0.5B/L HB06
0.5BR/R
IC14
0.5B
BX16
0.5G/R
BA26
0.5B
HY05
1 B3(84)
A44(46)
B24(100)
A63(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
0.5L/Y IC06
A36(39)
0.5R IC12
A27(30)
0.5W/B IC13
(ON)
(OFF)
(OFF)
A65(65)
0.5Y IC08
0.5L/R
IC09
0.5B
IZ05
5B/R
HB03
0.85Y
KA01
0.85R/Y
KA02
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11
0.5L
MA10
GLOW PULG x4
0.5G
IC07
0.5B
IZ08
0.5B/W
IC10
0
.
5
B
/
W
I
C
5
8
0
.
5
B
I
Z
1
0
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5Y
IC57
A28(31)
B6(87)
0.5O/L
MA28
A40(43)
0.5BR/Y
IC29
0.5BR/W HA20
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
0.5G
HA18
0.5BR HA19
0.5BR HA17
A68(68)
A38(41)
A30(33)
EVRV ; EGR
SW ; ENG WARMING
JOINT
TO MX01
J
O
I
N
T

T
O

E
X
1
2
JOINT
TO BA15
JOINT
TO SX01
2
M
A
F
E
B
S
T
O
P
1
0
A
0.5B
HX03
0.5B
EX03
0.5L
IC47
0.5G
HA24
B-10
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
A-6
0.5R/G
IC36
A-7
0.5G/O
IC37
A-8
0.5B/G
IC38
A-9
A-1
B-11
VEHICLE SPEED
SENSOR
A-11
A-12
B-6
B-5
B-14
OIL PSESSURE UNIT
4WD SW
FUEL
HEATER
MAG.CLUTCH
(COMPRESSOR)
SPEED METER
METER
TACHO METER
OIL GAGE
ENG COOLANT
B6
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
0
.
5
O
/
L
M
B
0
1
CONT ; IMMOBILIZER(B1)
1
2 4
RELAY ; A/C THERMO
0.5G HA21
0.5G
IC30
REV
0.5G/R
HA13
0.5L/W HA14
0.5G/W HA16
FUSE ; BLOOR
1
2 4
ELEC.THERMO
0.5B/P
IC43
B-7
0.5GR
IC44
B-1
I
Z
0
7
IZ05
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
B-2
0.5G/R
IC46
B-3
B-10
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
B-5
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
270
510
0.5G
HA22
0.5BR
HA23
ECM
SW ; PRESSURE
ENGINE DRIVEABILITY AND EMISSIONS 6E–109
DTC P0215 SUB CODE 1100
FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0215.
2. Observe the DTCs.
Was the DTC P0215 restored? — Go to Step 3
Go to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect PCU connector.
Check short circuit between ECM pin 105 and power
source points, see “reference” on page 108.
Sample shows only 4JA1-TC, but other 4JH1-TC
system should be same points.
Breaker box is not available
Ignition off
Disconnect ECM and PCU connector.
Disconnect PCU connector.
Check short circuit between ECM pin 105 and power
source points, see page 6E-
Sample shows only 4JA1-TC, but other 4JH1-TC
system should be same points.
0V Go to Step 4 Repair wiring
4 Breaker box is available
Ignition off
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector pin 99 and
connector pin 100.
Breaker box is not available
Ignition off
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector pin 99 and
connector pin 100.
Continuity Go to Step 5 Repair wiring
5 Replace to ok ECM run engine for more than 5 sec, if
no DTC occures, goes to ‘NO’ column if DTC occures,
goes to ‘YES’ column.
Replace
injection pump Replace ECM
105
see
page 6E-108
99
100
6E–110 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0215 SUB CODE 1010
FUEL CUTOFF SOLENOID VALVE MALFUNCTION
DTC P0215 SUB CODE 1101
FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0215.
2. Observe the DTCs.
Was the DTC P0215 restored? —
Replace
injection pump
Go to
Intermittent
Diagnosis
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0215.
2. Observe the DTCs.
Was the DTC P0215 restored? — Replace ECM
Go to
Intermittent
Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–111
DTC P0216
TIMING DEVICE DEVIATION
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
TDC MAB
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
PCU
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0216.
2. Observe the DTCs.
Was the DTC P0216 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check timing gear positions align between cam and
injection pump. See the timing gear check procedure
in the mechanical engine section. Go to Step 4 Adjust
4 Check TDC sensor with any damage or exciter ring
teeth damage.
Replace
injection pump
Replace or
Repair
TDC sensor or
exciter ring
6E–112 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0216
TIMING DEVICE FLUCTUATION
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0216.
2. Observe the DTCs.
Was the DTC P0216 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Bleed air in fuel.
See the procedure of air bleed in fuel section. Verify
Verify still DTC
appears
4 Replace injection pump. Verify —
ENGINE DRIVEABILITY AND EMISSIONS 6E–113
DTC P0251
INJECTION MALFUNCTION
DTC P0251 SUB CODE 0110
INJECTION PUMP MALFUNCTION 1
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
TDC MAB
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
PCU
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0251.
2. Observe the DTCs.
Was the DTC P0251 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Replace injection pump Verify
6E–114 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0251 SUB CODE 0111
TDC AND CAM SPEED COMPARSION ERROR
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0251.
2. Observe the DTCs.
Was the DTC P0251 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check TDC sensor with any damage and exciter ring
with any damage.
Go to Step 4
Replace or
Repair TDC
sensor or
exciter ring
4 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect PCU connector.
Make jump wire between PCU connector 8 and 5.
Measure resistance between 91 and 105.
Breaker box is not available
Ignition off
Disconnect ECU and PCU harness.
Make junping between 8 and 5.
Measure resistance between 91 and 105. 0Ω
Replace ECM
and verify if still
DTC appears.
Go to Step 5
Repair wiring
harness
5 Replace injection pump. Verify —
91
105
ENGINE DRIVEABILITY AND EMISSIONS 6E–115
DTC P0251 SUB CODE 1001
INJECTION PUMP MALFUNCTION 2
DTC P0251 SUB CODE 1010, 1011, 1101
INJECTION PUMP MALFUNCTION 3, 4, 5
DTC P0251 SUB CODE 1110
INJECTION PUMP MALFUNCTION 6
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0251.
2. Observe the DTCs.
Was the DTC P0251 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Replace injection pump Verify
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0251.
2. Observe the DTCs.
Was the DTC P0251 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Replace injection pump Verify
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0251.
2. Observe the DTCs.
Was the DTC P0251 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect PCU connector.
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector 99 and
100.
Breaker box is not available
Ignition off
Disconnect ECM, PCU connectors.
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector 99 and
100. Continuity
Replace ECM

Verify

NG
Replace
injection pump Repair wiring
6E–116 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0335
TDC MALFUNCTION
DTC P0335 SUB CODE 1110
TDC INPUT CIRCUIT SIGNAL RANGE/PERFORMANCE (OVER SPEED)
ABS
TDC
VSS
16 15 14 13 12 11 10 9
8
29 4
7 8
7 6 5 4 3 2 1
IC 08 IC 08
IC 08
IC 03 IC 08
27 68 89 98 32 62 90 93 45 35
Us
Balt
Balt
Balt
µP
TDC sensor Excitor ring
ENGINE DRIVEABILITY AND EMISSIONS 6E–117
Step Action Value(s) Yes No
1 Ask the customer whether or not he experience over
speed condition such as long down slope driving, mis
gear shift etc.
Explain
customer why
DTC turns on Go to Step 2
2 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 3
Go to OBD
system check
3 1. Clear the DTC P0335.
2. Observe the DTCs.
Was the DTC P0335 stored? — Go to Step 4
Refer to
Intermittent
Diagnosis
4 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Measure resistance between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Measure resistance between ECM connector 90 and
98.
0.9KΩ
at 20°C room
temp Go to Step 6 Go to Step 5
5 Breaker box is available
Ignition off
Disconnect TDC sensor connector.
Make jump wire between TDC connector pins.
Check continuity between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect TDC sensor.
Make jump wire between TDC connector pins.
Check continuity between ECM connector pin 90 and
98.
Continuity
Replace TDC
sensor Repair wire
6 Check shield wire and ground.
Check any damage of wire related shield wire. Go to Step 7 Repair
7 Check any accessary which may cause electric or
magnetic interference.
Go to Step 8
Remove
accessary and
verify
98
90
98
90
6E–118 ENGINE DRIVEABILITY AND EMISSIONS
8 Breaker box is available
Ignition off
Connect TDC sensor.
Connect ECM to breaker box as type B.
Measure voltage at ECM pin 90 and 98 by digital volt
meter AC range.
Breaker box is not available
Ignition off
Skip this step.
Go to next step 9. Replace ECM Go to Step 9
9 Check TDC sensor.
Remove TDC sensor.
Check any damage or foreign materials on TDC.
No damage
No foreign
material Go to Step 10
Replace TDC
sensor and
verify
10 Check exciter ring whether or not any damage.
Replace ECM
Replace or
Repair excitor
ring
Step Action Value(s) Yes No
98
90
ENGINE DRIVEABILITY AND EMISSIONS 6E–119
DTC P0335 SUB CODE 1011
TDC DYNAMIC PLAUSIBILITY
TDC sensor Excitor ring
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0335.
2. Observe the DTCs.
Was the DTC P0335 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Measure resistance between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Measure resistance between ECM connector 90 and
98.
0.9KΩ at
20°C room
temp Go to Step 5 Go to Step 4
98
90
6E–120 ENGINE DRIVEABILITY AND EMISSIONS
4 Breaker box is available
Ignition off
Disconnect TDC sensor connector.
Make jump wire between TDC connector pins.
Check continuity between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect TDC sensor.
Make jump wire between TDC connector pins.
Check continuity between ECM connector pin 90 and
98.
Continuity
Replace TDC
sensor Repair wire
5 Check shield wire and ground.
Check any damage of wire related shield wire. Go to Step 6 Repair
6 Check any accessary which may cause electric or
magnetic interference.
Go to Step 7
Remove
accessary and
verify
7 Breaker box is available
Ignition off
Connect TDC sensor.
Connect ECM to breaker box as type 13.
Measure voltage at ECM pin 90 and 98 by digital volt
meter AC range.
Breaker box is not available
Ignition off
Skip this step.
Go to next step 9. Replace ECM Go to Step 9
8 Check TDC sensor.
Remove TDC sensor.
Check any damage or foreign materials on TDC.
NO damage
NO foreign
material Go to Step 9
Replace TDC
sensor and
verify
9 Check exciter ring whether or not any damage.
Replace ECM
Replace or
Repair excitor
ring
Step Action Value(s) Yes No
98
90
98
90
ENGINE DRIVEABILITY AND EMISSIONS 6E–121
DTC P0335 SUB CODE 1101
ENGINE SPEED INPUT STATIC PLAUSIBILITY
TDC sensor Excitor ring
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0335.
2. Observe the DTCs.
Was the DTC P0335 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Measure resistance between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Measure resistance between ECM connector 90 and
98.
0.9KΩ at
20°C room
temp Go to Step 5 Go to Step 4
98
90
6E–122 ENGINE DRIVEABILITY AND EMISSIONS
4 Breaker box is available
Ignition off
Disconnect TDC sensor connector.
Make jump wire between TDC connector pins.
Check continuity between ECM pin 90 and 98.
Breaker box is not available
Ignition off
Disconnect TDC sensor.
Make jump wire between TDC connector pins.
Check continuity between ECM connector pin 90 and
98. Continuity
Replace TDC
sensor Repair wire
5 heck shield wire and ground.
Check any damage of wire related shield wire. Go to Step 6 Repair
6 Check any accessary which may cause electric or
magnetic interference.
Go to Step 7
Remove
accessary and
verify
7 Breaker box is available
Ignition off
Connect TDC sensor.
Disconnect ECM from breaker box.
Measure voltage at ECM pin 90 and ground or
between ECM pin 98 and ground.
8 Check TDC sensor.
Remove TDC sensor.
Check any damage or foreign materials on TDC.
NO damage
NO foreign
material Go to Step 9
Replace TDC
sensor and
verify
9 Check exciter ring whether or not any damage.
Replace ECM
Replace or
Repair excitor
ring
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–123
DTC P0380
GLOW DEVICE MALFUNCTION
GND GND
IC 08
94
+5V
ECU
Relay
Relay
G/plug
Glow
plug
Register idle SW
APS
1 2 69 49 38 57
Balt
µP
Glow
60A
6E–124 ENGINE DRIVEABILITY AND EMISSIONS
System Description
Pre glow system calibration
glow relay on setting curve
sec.
8
7
6
5
4
3
2
1
0
Water temperature (°C)
-30 -10 10 30 50 70 90
T
i
m
e
After glow system calibration
sec.
30
24
18
Water temperature (°C)
-10 0 10 30 35
T
i
m
e
glow relay on setting curve
After run glow
sec.
100
35
40
45
Water temperature (°C)
0 10 20 30
T
i
m
e
glow relay on setting curve
Example
Log Vehicle
run
Cranking Lg ON
Pre glow
After glow
After run
g
l
o
w

c
u
r
r
e
n
t
ENGINE DRIVEABILITY AND EMISSIONS 6E–125
DTC P0380 SUB CODE 1000
GLOW DEVICE VOLTAGE HIGH
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0380.
2. Observe the DTCs.
Was the DTC P0380 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check short circuit between ECM pin 94 and pour
souce line see “reference” on page 126.
Breaker box is not available
Ignition off
Disconnect ECM connector and ECM relay.
Check short circuit between ECM pin 94 and pour
souce line see “reference” on page 126.
No short
circuit Replace ECM
Repair wiring or
G/plug relay
6E–126 ENGINE DRIVEABILITY AND EMISSIONS
reference
5
R
/
W
H
B
0
1
0
.
5
L
/
W
H
B
0
4
0
.
5
L
/
R
I
C
1
1
0
.
5
B
R
H
A
1
5
0
.
5
B
R
H
A
1
9
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
R
/
Y
K
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
E
B
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T
S
E
N
S
O
R
2L/R
IC02
2L/R
IC02
0
.
5
L
/
R
I
C
6
2
0.5L/B IC04
0.5B/Y
IC03
0.5Y
IC31
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
R
E
L
A
Y

;
G
L
O
W
S
W

;

P
R
E
S
S
U
R
E
SW ; BRAKE
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; OIL
0.5L/R
IC15
0.5W/R IC27
0.5L/R IC11
0.5L/W HB04
0.5L/R HA15
0.5L/R IC15
0.5L/R HA19
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
1 B3(84)
0.5BR/W HA20
A38(41)
B24(100)
A63(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
A30(33)
0.5L/Y IC06
0.5B/L HB06
A36(39)
0.5R
IC12
A27(30)
0.5W/B
IC13
(ON)
ELEC.THERMO
(OFF)
A65(65)
0.5R/B
IC60
B6(87)
5B/R
HB03
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11(W/SOF)
TB07(W/O SOF)
0.5L
MA10
0.5O/L
MB01
GLOW PULG x4
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5O/L
MA18
A40(43)
0.5BR/R
IC29
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
A68(68)
J
O
I
N
T

T
O

E
X
1
2
2
MAF
OA05

O
A
2
5
0.5R/Y
OA60
37
A46(48)
5
25
0.5B/R
OA06
6
A26(28)
0.5B
OX01
ENG
EARTH
TCM
E
B
S
T
O
P
1
0
A
0.5B
EX03
0.5L
IC47
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
0.5R/G
IC36
0.5G/O
IC37
0.5B/G
IC38
A
F
C
B
VEHICLE SPEED
SENSOR
A-11
A-12
B-2
A-6
B-3
OIL PSESSURE UNIT
4WD SW
SPEED METER
METER
TACHO METER
OIL GAGE
TCM
ENG COOLANT
B6
10
11
31
32
47
48
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
CONT ; IMMOBILIZER(B1)
0.5G
IC48
0.5B/P
IC43
B-5
0.5O
IC44
B-6
I
Z
0
7
IZ05
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
A-7
0.5G/R
IC46
A-8
A-9
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
A-1
0.5B/G
LA09
C-14
0.5B/W
LA06
B-4
0.5Y/V
OA59
C-2
0.5Y/L
OA58
C-4
0.5Y/R
OA32
C-3
0.5W/R
OA57
C-10
0.85R/Y
KA02
A-10
0.5R/G
OA10
0.5R/Y
OA11
0.5W/R
OA31
0.5R/B
IC61
C-15
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
RELAY ;
A/C COMPRESSOR
1
2 4 0.5G
HA18
FUSE ;
A/C
FUSE ;
BLOOR
0.5B
HX22
0.5G
HA23
MAG.CLUTCH
(COMPRESSOR)
B-1
0.5G/R
HA13
0.5L/W
HA14
0.5BR
HA17
RELAY ;
A/C THERMO
1
2 4 0.5G HA21
0.5G/W HA16
0.5B
HX03
0.5G
HA24
RESISTER ; IDLE UP
(YZK NO ; 7321-9430)
P
R
N
D
2
1
N B
SW ; MODE
RELAY ; STARTER
FUSE ; STARTER
270
ENGINE DRIVEABILITY AND EMISSIONS 6E–127
DTC P0380
GLOW DEVICE VOLTAGE LOW (Short to ground or internal ECM to ground)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0380.
2. Observe the DTCs.
Was the DTC P0380 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box.
Disconnect ECM relay.
Check continuity between ECM relay socket 86 pin
and ECM 94 pin.
Check short to ground between ECM 94 pin and
ground.
Breaker box is not available
Ignition off
Disconnect ECM connector and ECM relay.
Check continuity between ECM relay socket 86 pin
and ECM 94 pin.
Check short to gruons between ECM 94 pin and
ground.
Replace ECM Repair wiring
87
86 85
30
ECM relay
94
87
86
ECM relay
85
30
6E–128 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0381
GLOW TIME TELLTALE CIRCUIT MALFUNCTION
DTC P0381 SUB CODE 1000
GLOW TIME TELLTALE CIRCUIT SHORT TO BATTERY VOLTAGE
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
Relay EW
ECM
25A
ON
1G
Stop lamp SW SW:clutch
Clutch pedal:OFF
SW:ExG Brake
Glow
Check
Engine
ExG
Brake
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0381.
2. Observe the DTCs.
Was the DTC P0381 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check glow lamp bulb is burnt out. Go to Step 4 Replace bulb
ENGINE DRIVEABILITY AND EMISSIONS 6E–129
4 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Remove #12 fuse (NKR), meter fuse (TF).
Disconnect ECM connector from the breaker box.
Measure voltage between ECM pin 43 and ground.
Breaker box is not available
Ignition off
Disconnect ECM connector and #12 fuse (NKR) or
meter fuse (TF).
Measure voltage between ECM connector pin 43 and
ground.
0V Replace ECM Repair wiry
Step Action Value(s) Yes No
43
6E–130 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0381 SUB CODE 1000
GLOW TIME TELLTALE CIRCUIT (Open circuit or short to ground)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0381.
2. Observe the DTCs.
Was the DTC P0381 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 There are two DTC P0381, P1690 ON? See the P1690
wiring check Go to Step 4
4 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Remove #12 fuse (NKR) or meter fuse (TF).
Check resistance between ECM pin 42 and 43 or
continuity.
Breaker box is not available
Ignition off
Disconnect ECM connector, and #12 fuse (NKR) or
meter fuse (TF).
Check resistance between ECM connector pin 42 and
43 or continuity.
NKR _Ω
TF 1Ω
Continuity Go to Step 35
Repair wiring
for open circuit
5 Breaker box is available
Ignition off
Check resistance between ECM pin 43 and ground.
Breaker box is not available
Ignition off
Check resistance between ECM connector pin 43 and
ground.
More than
10MΩ Replace ECM
Repair wiring
for short to
ground
43 42
43
ENGINE DRIVEABILITY AND EMISSIONS 6E–131
DTC P0400
EGR SYSTEM MALFUNCTION
DTC P0400 SUB CODE 0100
EGR CIRCUIT OPEN
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0400.
2. Observe the DTCs.
Was the DTC P0400 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
PCU
6E–132 ENGINE DRIVEABILITY AND EMISSIONS
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Remove ECM relay.
Check continuity between ECM relay socket 86 and
ECM pin 97.
Breaker box is not available
Ignition off
Disconnect ECM connector, ECM relay.
Check continuity between ECM relay socket 86 and
ECM pin 97.
Continuity Replace ECM
Repair wiring or
Repair EVRV of
EGR
Step Action Value(s) Yes No
87
86 85
30
ECM relay
87
86
ECM relay
85
30
97
ENGINE DRIVEABILITY AND EMISSIONS 6E–133
DTC P0400 SUB CODE 1000
EGR CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0400.
2. Observe the DTCs.
Was the DTC P0400 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect EVRV:EGR from wiring harness.
Ignition ON, no engine run.
Check voltage between ECM pin 97 and ground.
Breaker box is not available
Ignition off
Disconnect ECM harness and EGR EVRV.
Ignition ON, no engine run.
Check voltage between ECM pin 97 and ground.
0V
Replace EVRV
Go to Step 4 Repair wiring
4 Verify
Still DTC ON. Replace ECM
ECM
EVRV:EGR
Breaker
box
check
6E–134 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0400 SUB CODE 0011
EGR FLOW EXCESSIVE DETECTED
ENG
EGR
Turbo
Exh. valve Silencer
Intake shutter
Compressor
Aircleaner
MAF Airduct
MAF
A1
(Leakage)
A0 (Air mass mcasured by MAF)
A2 (Air mass goes to cylinders)
1f AO≠A2,because
A2=A0+A1
Mvel of cheak
leakage A1
Output A0
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0400.
2. Observe the DTCs.
Was the DTC P0400 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check inlet pipe disconnected or loose or hole or
detorted.
Repair Go to Step 4
4 Check intake shutter stack closed with engine
running.
Repair intake
shutter Go to Step 5
5 Check MAF is within typical data.
Go to Step 6
Check turbo
system
6 Check exhaust pipe, silensor detorted, or deformed.
It may cauese exhaust pressure extremely high.
Replace
exhaust related
brake Go to Step 7
MAF
A1
(Leakage)
A0 (Air mass mcasured by MAF)
A2 (Air mass goes to cylinders)
1f AO≠A2,because
A2=A0+A1
Mvel of cheak
leakage A1
Output A0
ENGINE DRIVEABILITY AND EMISSIONS 6E–135
7 Check exhaust brake stuck close, if exhaust breake is
required.(NKR 4JH1-TC only)
Apply vacuum by mighty vac.
See the valve operation.
Replace
exhaust brake Go to Step 8
8 Check EGR value stuck open.(NKR 4JH1-TC, TF
4JA1-TC only)
Apply vacuum by mighty vac.
Check valve operation through window. See page 6E-
136. Go to Step 9
9 Check MAF data within typical data. Go to Step 10 Replace MAF
10 Replace ECM Verify
Step Action Value(s) Yes No
Open
mighty vac
Picture Exh. Brake
check
window
6E–136 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0400 SUB CODE 0101
EGR FLOW INSUFFICIENT DETECTED
ENG
EGR
Turbo
Exh. valve Silencer
Intake shutter
Compressor
Aircleaner
MAF Airduct
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0400.
2. Observe the DTCs.
Was the DTC P0400 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check exhaust system such exhaust pipe, silensor
etc. disconnected. Repair Go to Step 4
4 Check wastegete setting pressure.
Is it in specification? — Go to Step 5 Repair
5 Check EGR pipe disconnected or any leak from EGR
pipe, EGR valve. Repair Go to Step 6
6 Check EGR cooler has coolant circulation operation.
No circulation or no water? Repair Go to Step 7
7 Check EGR valve stuck closed. Replace EGR
valve Go to Step 8
8 Cehck MAF with typical data.
Is it within typical data?
See the
typical data
table Replace ECM Replace MAF
ENGINE DRIVEABILITY AND EMISSIONS 6E–137
6E–138 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0500
VSS MALFUNCTION
DTC P0500 SUB CODE 0001
VSS CIRCUIT HIGH INPUT
ABS
VSS
NKR
4JH1-TC
only
TF
4JA1-TC
4JH1-TC
4JA1-TC
4JH1-TC
VSS
TDC
ECT
16 15 14 13 12 11 10 9
8
29 4
7 8
7 6 5 4 3 2 1
IC 08 IC 08
IC 08
IC 03 IC 08
27 68 89 98 32 62 90 93 45 35
Us
Balt Balt
27 68
Balt
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0500.
2. Observe the DTCs.
Was the DTC P0500 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check speed meter, whether meter indicate incorrect
speed.
Indicate
incorrect speed
Go to Step 4
Indicate correct
speed
Go to Step 7
4 Check the speed meter. (TF 4JA1-TC/4JH1-TC only)
See the electrical section. Go to Step 5 Repair
5 Check the vehicle speed sensor wiring.
See the electrical section. Go to Step 6 Repair
6 Check the vehicle speed sensor, exciter ring.
Remove the vehicle speed sensor.
Inspect any damage of sensor, exciter ring and foreign
material on the sensor, or on the exciter ring. — Repair
ENGINE DRIVEABILITY AND EMISSIONS 6E–139
DTC P0500 SUB CODE 1010
VSS INCORRECT SIGNAL
7 Breaker box is available
Ignition off
Install a breaker box as type B see page 6E-57.
Remove the connector from the meter.
Measure any voltage at ECM pin 68 at breaker box. No voltage
Replace ECM
and verify Repair wiring
Breaker box is not available
Ignition off
Remove the connector from the meter.
Measure any voltage at ECM pin 68.
Check the wiring between speed meter output and
ECM.
Step Action Value(s) Yes No
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0500.
2. Observe the DTCs.
Was the DTC P0500 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check speed meter indication.
Is the meter indication OK? Go to Step 4
4 Check the speed meter.
See the electrical section. Go to Step 5 Repair
5 Check the vehicle speed sensor wiring.
See the electrical section. Go to Step 6 Repair
6 Check the vehicle speed sensor, exciter ring.
Remove the vehicle speed sensor.
Inspect any damage of sensor, exciter ring and foreign
material on the sensor, or on the exciter ring. — Repair
7 Breaker box is available
Ignition off
Install a breaker box as type B see page 6E-57.
Remove the connector from the meter.
Measure any voltage at ECM pin 68 at breaker box. No voltage
Replace ECM
and verify Repair wiring
Breaker box is not available
Ignition off
Check the wiring between speed meter output and
ECM.
8 Check the meter output.
See the electrical section. Go to Step 9
9 Replace ECM. Verify
6E–140 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0500 SUB CODE 1011
VSS PLAUSIBILITY
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0500.
2. Observe the DTCs.
Was the DTC P0500 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check whether the speed meter is operated correctly.
(NKR 4JH1-TC only)
If not, inspect signal line of VSS.
And inspect VSS sensor, exciter ring.
(TF 4JA1-TC, 4JH-TC)
If not, inspect signal line of VSS.
And inspect VSS sensor, exciting ring.
Check speed meter out put.
The speed
meter is
operating
correctly Go to Step 4
Repair wiring
harness or VSS
or exciter ring
4 Check the wiring between signal of speed sensor and
ECM.
No open
circuit Replace ECM
Repair wiring
harness
ENGINE DRIVEABILITY AND EMISSIONS 6E–141
DTC P0560
SYSTEM VOLTAGE MALFUNCTION
Circuit Description
Battery voltage condition is detected at ECM terminal
NO 3 by ECM internal IC.
DTC P0560 SUB CODE 0010
SYSTEM VOLTAGE TOO LOW
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
Relay EW
ECM
25A
ON
1G
Stop lamp SW SW:clutch
Clutch pedal:OFF
SW:ExG Brake
Glow
Check
Engine
ExG
Brake
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0560.
2. Observe the DTCs.
Was the DTC P0560 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check battery voltage. Battery
voltage ≥ 7V Go to Step 4 Replace battery
6E–142 ENGINE DRIVEABILITY AND EMISSIONS
4 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Remove ECM fuse.
Check resinstance ECM 58 ˜ ECM fuse, ECM 3 ˜ ECM
fuse.
When measure resistance make jumper relay A, B
terminal, resistance can be measured through ECM
58 and 3.
Breaker box is not available
Ignition off
Disconnect engine harness at ECM.
Remove ECM fuse.
Check resinstance ECM 58 ˜ ECM fuse, ECM 3 ˜ ECM
fuse.
When measure resistance make jumper relay A, B
terminal.
Resistance can be measured through ECM 58 and 3.
0Ω Go to Step 4
Repair wiring
harness or
replace relay
5 Remove relay.
Check relay function.
1. Apply 12 V at solenoid terminals.
2. Check continuity between _ and _.
3. No continuety means malfunction of relay.
0 Go to Step 5 Repair harness
6 Check continuity between relay B and engine harness
at ECM side pin_. 0 Go to Step 6 Repair harness
7 Remove relay.
Check relay function.
1. Apply 12 V at solenoid terminals.
2. Check continuity between _ and _.
3. No cintinuity means malfunction of relay. Function OK Go to Step 7 Replace relay
8 Replace ECM. Verify —
Step Action Value(s) Yes No
A
A B
58
3
58
ENGINE DRIVEABILITY AND EMISSIONS 6E–143
DTC P0560 SUB CODE 0001
SYSTEM VOLTAGE TOO HIGH
Step Action Value(s) Yes No
1 Ask the customer whether 24V batterry is used?
Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0560.
2. Observe the DTCs.
Was the DTC P0560 stored?
— Go to Step 3
Ask the
customer
whether 24V
batterry was
installed or
used.
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B.
Install Tech-II.
Ignition ON
Compare system voltage by Tech-II and system
voltage by DVM at ECM pin 3, pin 58 and ground.
If DVM shows less than 20V and Tech-II shows more
than 20V, go to Yes - replace ECM.
If DVM shows more than 20V and Tech-II shows more
than 20V, go to No step 4.
Breaker box is not available
Ignition off
Install OK ECM.
Check DTC, if DTC does not appear, go to Yes -
replace ECM.
If DTC appear, go to No step 4.
Less than
20 V Replace ECM Go to Step 4
4 Breaker box is available
Ignition off
Remove ECM relay.
Measure voltage at ECM pin 3 and ground, ECM pin
58 and ground.
Breaker box is not available
Ignition off
Remove ECM relay.
Disconnect Engine harness at ECM.
Measure voltage at ECM pin 3 and ground, ECM pin
58 and ground.
Less than
20V
Replace ECM
relay and repair
any shortage or
extra power
source between
relay and
ignition sw,
battery.
Repair engine
harness
between ECM
relay and ECM.
A
A B
58
3
58
6E–144 ENGINE DRIVEABILITY AND EMISSIONS
5 Remove relay and fuse ECU.
Measure voltage at relay socket.
Less than
20 V Go to Step 6
Repair Engine
harness
between ECM
fuse, relay, and
diagnosis
connector 16
pin
6 Remove ECU relay and Main fuse.
Disconnect Engine harness at ECM side.
Measure voltage at fuse ECU Battery side.
Less than
20 V
See the
Intermittent
diagnoses
Repair the
circuit at after
column
Step Action Value(s) Yes No
A
A B
58
3
58
ENGINE DRIVEABILITY AND EMISSIONS 6E–145
DTC P0560 SUB CODE 1010
PCU SYSTEM VOLTAGE TOO HIGH OR TOO LOW
2
MAF
6 7
5 8 2 1
PCU
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
ExG Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Newtral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0560.
2. Observe the DTCs.
Was the DTC P0560 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Disconnect PCU connector.
Measure voltage at terminal 7 of PCU connector.
27 V ≥ voltage
≥ 4.5 V
Replace
Injection pump Repair wiring
6E–146 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0561
SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
Relay EW
ECM
25A
ON
IG
Stop lamp SW SW:clutch
Clutch pedal:OFF
SW:ExG Brake
Glow
Check
Engine
ExG
Brake
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0561.
2. Ignition ON. Wait for .
Does the DTC P0561 still appear? — Go to Step 3 Verify
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
Breaker box is not available
Ignition off
Disconnect ECM from Engine harness.
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
OK
Replace ECM
Repair wiring or
main relay
ENGINE DRIVEABILITY AND EMISSIONS 6E–147
DTC P0561
SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION
DURING INITIALIZATION
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0561.
2. Ignition ON. Wait for see.
Does the DTC P0561 still appear? — Go to Step 3 Verify
3 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
Breaker box is not available
Ignition off
Disconnect ECM from Engine harness.
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
OK
Replace ECM
Repair wiring or
main relay
6E–148 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0606
ECM Malfunction1
DTC P0606
ECM Malfunction2
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0606.
2. Observe the DTCs.
Was the DTC P0606 restored? — Replace ECM
Go to
Intermittent
Diagnosis
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0606.
2. Observe the DTCs.
Was the DTC P0606 restored? — Replace ECM
Go to
Intermittent
Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–149
DTC P0645
A/C COMPRESSOR CUTOFF RELAY MALFUNCTION
41 33
Batt
µP
41
Batt
µP
ECM
relay
ECM
relay
ECM
relay
NKR 4JH1-TC only
Main fuse
HVAC
relay
AC
Thermo
relay
A/C Fuse
A/C on
signal
A/C
PDS
(NKR 4JH1-TC)
only
TF 4JA1-TC /
4JH1-TC only
Comp relay
Compressor
clutch
A/C
Comp relay
Compressor
clutch
Electrical
thermo
IC 08
µP : Microproccesor
6E–150 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0645 SUB CODE 0100
A/C COMPRESSOR CUTOFF RELAY PRIMARY CIRCUIT OPEN
(Short to ground)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0645.
2. Observe the DTCs.
Was the DTC P0645 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect breaker box harness adapter from ECM.
Disconnect ECM relay.
Measure a resistance between ECM relay connector
pin 30 and ECM pin 41.
Check isolation resistance between ECM pin 41 and
ground.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Remove ECM relay.
Measure resistance between ECM relay connector pin
30 and ECM connector pin 41.
Check isolation resistance between ECM pin 41 and
ground.
Resistance
_Ω
Isolation
resistance
> 1MΩ
Go to
intermittent Go to Step 4
4 Check continuity A/C relay.
Continuity Go to Step 5
Replace A/C
relay and verify
5 Check continuity between relay : A/C pin 85 and
engine harness connector pin 30 at ECM relay. Continuity Go to Step 6
Repair wiring
and verify
87
87a
86
or
85
30
41
ECM relay
connector
ENGINE DRIVEABILITY AND EMISSIONS 6E–151
6 Breaker box is available
Ignition off
Remove A/C relay.
Check continuity between A/C relay connector pin 87
and ECM pin 41.
Breaker box is not available
Ignition off
Remove A/C relay.
Check continuity between A/C relay connector pin 87
and ECM connector pin 41.
0Ω Intermittent
Repair wiring
and verify
Step Action Value(s) Yes No
87
87a
86 85
30
41
A/C relay
connector
6E–152 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0645 SUB CODE 1000
A/C COMPRESSOR CUTOFF RELAY PRIMARY CIRCUIT HIGH INPUT
(Short to battery)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0645.
2. Observe the DTCs.
Was the DTC P0645 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Disconnect ECM relay, AC compressor relay.
Check short circuit between ECM pin 41 and, ECM
relay socket 30, ignition ON, battery plus. See the
attached circuit.
See the attached circuit on page 6E-154.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Disconnect ECM relay, AC compressor relay.
Check short circuit between ECM pin 41 and, ECM
relay socket 30, ignition ON, battery plus. See the
attached circuit.
See the attached circuit on page 6E-154.
0V Go to Step 4
Repair wiring
and verify
4 Check resistance A/C relay.
_Ω Go to Step 5
Replace A/C
relay and verify
87
87a
86 85
30
87
87a
86 85
30
41
ENGINE DRIVEABILITY AND EMISSIONS 6E–153
5 Breaker box is available
Ignition off
Remove A/C relay.
Measure voltage between ECM pin 41 and A/C relay
connector pin 87.
Breaker box is not available
Ignition off
Remove ECM relay.
Measure voltage between ECM pin 41 and A/C relay
connector pin 87.
0V
Go to
Intermittent
Repair wiring
and verify
Step Action Value(s) Yes No
87
87a
86 85
30
41
6E–154 ENGINE DRIVEABILITY AND EMISSIONS
reference
5
R
/
W
H
B
0
1
0
.
5
L
/
R
H
B
0
4
0
.
5
L
/
R
I
C
1
1
0
.
5
L
/
R
H
A
1
5
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R
IC05
2L/R
IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
E
B
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T
S
E
N
S
O
R
2L/R
IC02
2L/R
IC02
2L/B
IC04
0.5B/Y
IC03
0.5Y
IC31
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
R
E
L
A
Y

;
G
L
O
W
S
W

;

T
H
E
R
M
O
SW ; BRAKE
RESISTER ; CLUTCH SW
(YZK NO ; 7321-9900)
(IDLE SW)
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; CLUTCH
SW ; BACK UP
SW ; OIL
0.5L/R
IC15
0.5W/R IC27
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
0.5L/R IC15
0.5L/R HA19
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
1 B3(84)
0.5BR/W HA20
A38(41)
B24(100)
A41(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
A30(33)
0.5L/Y
IC06
0.5B/L
HB06
A36(39)
0.5R
IC12
A27(30)
0.5W/B
IC13
(ON)
ELEC.THERMO
(OFF)
(OFF)
A65(65)
0.5Y IC08
5B/R
HB03
0.85Y
KA01
0.85R/Y
KA02
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11(W/SOF)
TB07(W/O SOF)
0.5L
MA10
0.5O/L
MB01
GLOW PULG x4
0.5G
IC07
0.5B
IZ08
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5Y
IC57
A28(31)
0.5O/L
MA18
A40(43)
0.5BR/R
IC29
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
A68(68)
J
O
I
N
T

T
O

E
X
1
2
2
MAF
E
B
S
T
O
P
1
0
A
RESISTER ; NEWTRAL SW
0.5B
IZ10
0.5B/W
IC58
0.5B
EX03
0.5L
IC47
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
0.5R/G
IC36
0.5G/O
IC37
0.5B/G
IC38
A
F
C
B
A-1
A-10
VEHICLE SPEED
SENSOR
A-11
A-12
B-2
A-6
B-3
OIL PSESSURE UNIT
4WD SW
SPEED METER
METER
TACHO METER
OIL GAGE
ENG COOLANT
B6
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
CONT ; IMMOBILIZER(B1)
0.5G
IC48
0.5B/P
IC43
B-5
0.5O
IC44
B-6
I
Z
0
7
IZ05
SW ; NEWTRAL
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
A-7
0.5G/R
IC46
0.5B/W
IC10
0.5L/R
IC09
A-8
A-9
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
A-9
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
RELAY ;
A/C COMPRESSOR
1
2 4 0.5G
HA18
FUSE ;
A/C
FUSE ;
BLOOR
0.5B
HX22
0.5G
HA23
MAG.CLUTCH
(COMPRESSOR)
B-1
0.5G/R
HA13
0.5L/W
HA14
0.5BR
HA17
RELAY ;
A/C THERMO
1
2 4 0.5G
HA21 0.5G/W HA16
0.5B
HX03
0.5G
HA24
RESISTER ; IDLE UP
270
510
270
ENGINE DRIVEABILITY AND EMISSIONS 6E–155
DTC P0703
BRAKE-LIGHT SWITCH CIRCUIT MAIFUNCTION
DTC P0703
BRAKE-LIGHT SWITCH CIRCUIT INCORRECT SIGNAL (IGNITION ON)
(Short to battery, short to ground, open circuit)
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
Relay EW
ECM
25A
ON
1G
Stop lamp SW SW:clutch
Clutch pedal:OFF
Glow
Check
Engine
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
SW:ExG Brake
(NKR 4JH1-TC only)
NKR 4JH1-TC
only
NKR 4JH1-TC
only
Exh
Brake
(NKR
4JH1-TC
only)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0703.
2. Observe the DTCs.
Was the DTC P0703 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 In case of TF with Automatic transmission, brake light
bulb burn out triggers DTC P0703.
Before going to further step, check brake light bulb.
Other than TF with Automatic transmission, go to step
4.
TF with
Automatic
transmission
only
Bulb is OK
Go to Step 4
Bulb burn out
replace bulb,
and verify
4 Check two brake switch condition by Tech-II.
When apply brake pedal, and release brake pedal,
check Tech-II indication.
Change ON or OFF, two brake switch indicates ON/
OFF.
Two brake
switch
condition
should be
ON/OFF
same
OK
Go to Step 5
NG
Go to Step 6
6E–156 ENGINE DRIVEABILITY AND EMISSIONS
5 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check any open circuit between ECM pin 30 and ECM
relay, and between ECM pin 65 and ECM relay.
Check isolation resistance between ECM pin 30 and
ECM relay at brake switch NC (Normal close) open
condition, and between ECM pin 65 and ECM relay at
brake switch NO (Normal open) open condition.
By applying brake switch ON (NC switch becomes
open)
Check no voltage to appear between ECM pin 30 and
ground.
By applying brake switch OFF (NO switch becomes
open)
Check no voltage to appear between ECM pin 65 and
ground.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Check any open circuit between ECM pin 30 and ECM
relay, and between ECM pin 65 and ECM relay.
Check isolation resistance between ECM pin 30 and
ECM relay at brake switch NC open condition, and
between ECM pin 65 and ECM relay at brake switch
NO open condition.
By applying brake switch ON (NC switch becomes
open)
Check no voltage to appear between ECM pin 30 and
ground.
Replace ECM
and verify Repair
Step Action Value(s) Yes No
or
65
ECM relay
30
ENGINE DRIVEABILITY AND EMISSIONS 6E–157
DTC P0703 SUB CODE 1011
BRAKE-LIGHT SWITCH CIRCUIT INCORRECT SIGNAL (During Brake SW off)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0703.
2. Observe the DTCs.
Was the DTC P0703 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check any open circuit between ECM pin 30 and ECM
relay, and between ECM pin 65 and ECM relay.
Check isolation resistance between ECM pin 30 and
ECM relay at brake switch NC (Normal calose) open
condition, and between ECM pin 65 and ECM relay at
brake switch NO (Normal open) open condition.
By applying brake switch ON (NC switch becomes
open)
Check no voltage to appear between ECM pin 30 and
ground.
By applying brake switch OFF (NO switch becomes
open)
Check no voltage to appear between ECM pin 65 and
ground.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Check any open circuit between ECM pin 30 and ECM
relay, and between ECM pin 65 and ECM relay.
Check isolation resistance between ECM pin 30 and
ECM relay at brake switch NC open condition, and
between ECM pin 65 and ECM relay at brake switch
NO open condition.
By applying brake switch ON (NC switch becomes
open)
Check no voltage to appear between ECM pin 30 and
ground.
TF with
Automatic
transmission
only
Bulb is OK
Go to Step 4
Bulb burn out
replace bulb,
and verify
4 Check two brake switch condition by Tech-II.
When apply brake pedal, and release brake pedal,
check Tech-II indication.
Change ON or OFF, two brake switch indicates ON/
OFF.
Two brake
switch
condition
should be
ON/OFF
different
OK
Go to Step 5
NG
Go to Step 6
or
65
ECM relay
30
6E–158 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0704
CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
DTC P0704 SUB CODE 0110
CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
ECM relay
ECM
25A
ON
1G
Stop lamp SW SW:clutch
Clutch pedal:OFF
Glow
Check
Engine
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
SW:ExG Brake
(NKR 4JH1-TC only)
NKR 4JH1-TC
only
NKR 4JH1-TC
only
Exh
Brake
(NKR
4JH1-TC
only)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P0704.
2. Observe the DTCs.
Was the DTC P0704 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check clutch switch and clutch pedal adjustment.
See section. Go to Step 4 Replace
4 Check clutch switch electrical function. Go to Step 5 Replace
ENGINE DRIVEABILITY AND EMISSIONS 6E–159
5 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check continuity between ECM pin 31 and clutch SW.
Check continuety between clutch SW and ECM relay.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Check continuity between ECM pin 31 and ground.
Check continuety between clutch SW and ECM relar.
0Ω
(Clutch OFF)

(Clutch ON) Replace ECM Repaire wiring
Step Action Value(s) Yes No
6E–160 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1105
BAROMETRIC PRESSURE SENSOR (BP) MALFUNCTION
DTC P1105 SUB CODE 0010
BAROMETRIC PRESSURE SENSOR (BP) CIRCUIT LOW INPUT
DTC P1105 SUB CODE 0001
BAROMETRIC PRESSURE SENSOR (BP) CIRCUIT HIGH OUTPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1105.
2. Observe the DTCs.
Was the DTC P1105 restored? Replace ECM
Go to
Intermittent
Diagnosis
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1105.
2. Observe the DTCs.
Was the DTC P1105 restored? Replace ECM
Go to
Intermittent
Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–161
DTC P1110
INTAKE SHUTTER VSV (DIESEL) MALFUNCTION (NKR 4JH1-TC only)
DTC P1110 SUB CODE 1000
INTAKE VSV HIGH INPUT (Short to battery)
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
Exh Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Neutral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1110.
2. Observe the DTCs.
Was the DTC P1110 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
6E–162 ENGINE DRIVEABILITY AND EMISSIONS
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check isolation resistance between battery position
and ECM pin 95 by ignition off, ignition ON power
source and ECM pin 95 by ignition off.
See the attached schematic.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Check isolation resistance between battery position
and ECM pin 95 by ignition off, ignition ON power
source and ECM pin 95 by ignition off.
See the attached schematic.
More than
1MΩ Replace ECM Repair wiring
Step Action Value(s) Yes No
95
see page
6E-163
ENGINE DRIVEABILITY AND EMISSIONS 6E–163
referance
A
C
C
B
O
F
F
S
T
O
N
K
E
Y

S
W
5
W
P
A
0
7
0
.
5
B
R
H
A
0
9
0
.
8
5
G
/
O
H
A
1
1
0
.
5
G
/
O
I
C
4
8
0
.
5
L
/
R
I
C
3
9
0
.
5
L
/
R
I
C
3
3
3L/R IC34
M
A
G
N
E
T

C
L
U
T
C
H
(
C
O
M
P
R
E
S
S
O
R
)
P
D
S
0.85G/W
HA10
0.85Y/G
HA19
0.5B
IZ12
5
B
/
L
H
B
0
1
0
.
8
5
W
P
A
1
0
3
B
/
Y
I
C
0
1
1
.
2
5
B
/
Y
I
C
0
5
0
.
5
G
/
Y
C
A
0
1
0
.
5
L
G
/
R
I
C
2
1
0
.
3
B
I
Z
0
9
0
.
5
B
R
/
R
I
C
2
0
1
35
2
4
M
A
F
1
4
V
,
6
0
m
A
0
.
5
B
R
/
R
I
C
1
9
0
.
5
L
/
R
I
C
2
2
0
.
5
B
R
I
C
6
5
0
.
5
B
/
O
I
C
2
7
0
.
5
L
G
I
C
1
6
0
.
5
L
G
/
W
I
C
2
9
0
.
5
B
/
W
I
C
3
1
1
.
2
5
L
/
R
I
C
5
9
0
.
5
B
/
Y
M
A
0
1
0
.
5
L
/
R
I
C
2
6
0
.
5
B
I
C
1
5
0
.
5
L
/
R
I
C
2
8
2
L
/
R
I
C
3
0
0
.
5
G
/
Y


I
C
4
1
0
.
5
W
/
G


I
C
4
0
1
.
2
5
B
/
Y


I
C
6
3
0
.
5
L
/
R
I
C
0
9
2
L
/
R
I
C
0
2
0
.
5
L
/
B
I
C
0
3
0
.
5
G
C
A
0
2
0
.
5
G
I
C
1
0
0
.
5
W
I
C
0
4
A
-
5
6
C
O
N
T

U
N
I
T

;

E
N
G
I
N
E
A
-
4
1
A
-
3
6
A
-
2
7
A
-
6
5
A
-
2
8
A
-
6
4
A
-
5
8
A
-
3
9
A
-
4
0
A
-
4
4
A
-
5
7
B
-
2
B
-
7
B
-
1
4
B
-
1
9
B
-
3
A
-
3
7
B
-
1
7
B
-
6
B
-
2
4
B
-
2
3
B
-
2
9
B
-
1
3
A
-
3
0
A
-
3
8
D
I
A
G
(
4
5
)
M
A
I
N

R
E
L
A
Y
(
5
8
)
B
A
T
(
+
)
(
3
)
I
G
(
3
9
)
B
A
R
A
K
E

O
N
(
3
0
)
B
A
R
A
K
E

O
F
F
(
6
5
)
C
L
U
T
C
H
(
3
1
)
S
W
;
E
X
H
.
B
R
A
K
E
(
6
4
)
M
E
T
E
R

I
N
D
(
E
X
H
.
B
R
A
K
E
)
(
6
0
)
(
K
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IDLE SW
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6E–164 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1110 SUBCODE 0100
(DIESEL) CIRCUIT OPEN (Short to ground)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1110.
2. Observe the DTCs.
Was the DTC P1110 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Disconnect VSV.
Check continuity between ECM pin 95 and 0Ω Go to Step 4
Repair the
harness
4 Check the resistance of harness between the relay of
ECM and Exh. Brake.
Did the DVM indicate at the specified value. 0Ω Replace ECM
Repair the
harness
ENGINE DRIVEABILITY AND EMISSIONS 6E–165
DTC P1120
AP SENSOR MAIFUNCTION
Circuit Description
The APS is a potentio meter connected to the
accelerator pedal. The ECM monitors the voltage on the
signal line and caliculate accel pedal position.
APS caractalistic
GND GND
IC 08
94
+5V
ECU
Relay
Relay
G/plug
Glow
plug
Register : idle SW
APS
1 2 69 49 35 57
Balt
µP
Glow
60A
+5V
Signal
GND
3
2
1
3
2 1
O
u
t
p
u
t

v
o
l
t
a
g
e
5.0V
2.5V
0.0
-45
Aps
0
Avn
+45
Turning
angle
Connector view of APS
6E–166 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1120 SUB CODE 0010
AP SENSOR CIRCUIT LOW INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1120.
2. Observe the DTCs.
Was the DTC P1120 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 1. Ignition “On”, engine “Off”.
2. Check pedal position % on Tech-II for pedal
posiotn sensor within the value or not.
Was a problem found?
Idle position
sensor 0.5–
0.9V WOT
TP1 Between
4.0V and 4.7V Go to Step 7 Go to Step 4
4 • Disconnect APS and ECM from harness.
• Check the signal line open circuit on the harness
between ECM and APS.
• Check the power feed line open circuit on the
harness between ECM and APS.
Repair harness
and verify Go to Step 5
5 • Check APS sensor open circuit between power
feed line and signal line.
Repair harness
and verify Go to Step 6
6 Replace ECM. Repair harness
and verify
ENGINE DRIVEABILITY AND EMISSIONS 6E–167
DTC P1120 SUBCODE 0001
AP SENSOR CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1120.
2. Observe the DTCs.
Was the DTC P1120 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 1. Ignition “ON” engine “OFF” .
2. Check pedal position % on Tech-II for pedal
position sensor within the value or not.
See the
typical data Go to Step 8 Go to Step 4
4 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Check open circuit of ground line between APS and
ECM pin 49.
Breaker box is not available
Ignition off
Disconnect engine harness.
Check open circuit of ground line between APS and
ECM pin 49.
No open
circuit Go to Step 5
Repair wiring or
Replace APS
5 Breaker box is available
Ignition off
Connect ECM to engine harness.
Ignition ON
Measure voltage at signal line at APS, and +5V power
supply, whether the voltage is more than values.
Breaker box is not available
Ignition off
Disconnect Engine harness.
Check short circuit between 38 and power sources by
ignition ON/OFF.
See the attachment on 6E-170.
NKR 4JH1-
TC ≤ 4.9V
TF 4JH1/
4JA1 ≤ 4.5V Replace ECM
Check short to
battery on the
APS wiring
including APS

Repair
including APS

Verify

NG

Replace ECM
6E–168 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1120 SUBCODE 0111
AP SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT (Short to battery)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? Go to Step 2 OBD
2 1. Clear code.
2. Observe DTCs.
Was the DTC P1120 stored? Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B see page 6E-57.
Check voltage at power feed pin 57.
Breaker box is not available
Ignition off
Skip to step 4.
No more than
5.2V Replace ECM Go to Step 4
4 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect ECM harness.
Check short circuit between ECM pin 57 and power
sources, see the attachment on page 6E-169.
Breaker box is not available
Ignition off
Install breaker box as type A see page 6E-57.
Disconnect ECM harness.
Check short circuit between ECM pin 57 and power
sources, see the attachment on page 6E-169.
No short to
battery Replace ECM
Repair wiring,
APS
5 Disconnect APS.
Check voltage at power feed voltage pin of ECM
connector. 0V Go to Step 6 Repari wiring
6 Check voltage at APS. 0V Go to Step 4 Replace APS
ENGINE DRIVEABILITY AND EMISSIONS 6E–169
reference
A
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A/C ON SIGNAL(270 )
6E–170 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1120 SUBCODE 1001
AP SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1120.
2. Observe the DTCs.
Was the DTC P1120 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B see page 6E-57.
Ignition ON
Check voltage at ECM pin 57.
Breaker box is not available
Ignition off
Skip to step 4. 5V Replace ECM Go to Step 4
4 Breaker box is available
Ignition off
Install breaker box as type A.
Disconnect APS sensor.
Make jump wire between ECM pin 57 and 35.
Check short to ground between ECM pin 57 and
ground.
Breaker box is not available
Ignition off
Disconnect ECM harness.
Disconnect APS sensor.
Make jump wire between ECM pin 57 and 35.
Check short to ground between ECM pin 57 and
ground.šNo short to ground
No short to
ground Go to Step 5 Repair wiring
5 Disconnect APS.
Check short to ground at APS sensor.
No short to
ground Replace ECM Replace APS
6 Check continuity ECM wiring of power feed. Go to Step 4 Replace wiring
ENGINE DRIVEABILITY AND EMISSIONS 6E–171
DTC P1173
FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE
Fuel Reduction adjustment
NKR 4JH1-TC
TF 4JH1-TC, 4JH1-TC
Step Action Value(s) Yes No
1 Inspect coolant temp gauge whether needle indicates
high temp.
or
Ask the customer whether experience of overheat? — Go to Step 3 Go to Step 2
2 Inspect coolant temp sensor.
Meet
standard
resistance
Check coolant
temp sensor
poor connection
and repair
Replace
coolant temp
sensor
3 Find out the cause of overheat. See the. Go to Step 4 Repair
4 Replace ECM. Verify —
5%
110°C 100°C 90°C 80°C
15%
Q
110°C 100°C 90°C 80°C
15%
Q
6E–172 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1173 SUBCODE 0011
FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
No MIL light
on
Explain
customer and
report
representative Go to Step 2
2 Clear DTC P1173.
Observe the DTC.
Was the DTC P0645 stored?
Go to Step 3
Ask the
customer,
whether fuel
level was low?
3 Check fuel level.
If it is low, add fuel to the half of tank.
Drive a few minutes, and stay at idling. No DTC
comes on
Explain to the
customer
extremely low
fuel caused Go to Step 4
4 Measure fuel temp by Tech-II.
Less than
100°C
Replace ECM.
Verify. If still
DTC ON,
replace inj
pump Go to Step 5
5 Check fuel leakage at fuel routine.
Air in pump may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
6 Replace fuel filter.
Drive a few min, and stay at idling. No DTC ON —
Replace inj
pump
ENGINE DRIVEABILITY AND EMISSIONS 6E–173
DTC P1173
FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 1
DTC P1173
FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 2
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
No MIL light
on
Explain
customer and
report
representative Go to Step 2
2 Clear DTC P1173.
Observe the DTC.
Was the DTC P0645 stored?
Go to Step 3
Ask the
customer,
whether fuel
level was low?
3 Measure fuel temp by Tech-II. Less than
100°C
Replace
injection pump Go to Step 4
4 Check fuel leakage at fuel routine, pump.
Air may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
5 Replace fuel filter.
Drive a few min, and stay at idling. No DTC ON —
Replace inj
pump
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
No MIL light
on
Explain
customer and
report
representative Go to Step 2
2 Clear DTC P1173.
Observe the DTC.
Was the DTC P0645 stored?
Go to Step 3
Ask the
customer,
whether fuel
level was low?
3 Check fuel level.
If it is low, add fuel to the half of tank.
Drive a few minutes, and stay at idling. No DTC
comes on
Explain to the
customer
extremely low
fuel caused Go to Step 4
4 Measure fuel temp by Tech-II.
NKR 4JH1-TC reduce Q (fuel quantity).
TF 4JH1-TC, 4JA1-TC do not reduce.
Less than
80°C
Replace ECM.
Verify. If still
DTC ON,
replace inj
pump Go to Step 5
5 Check fuel leakage at fuel routine, pump.
Air may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
6 Replace fuel filter.
Drive a few min, and stay at idling. No DTC ON —
Replace inj
pump
6E–174 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1345
INJECTION PUMP:CAMSHAFT SPEED MALFUNCTION
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1345.
2. Observe the DTCs.
Was the DTC P1345 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Replace Injection Pump. Verify
ENGINE DRIVEABILITY AND EMISSIONS 6E–175
DTC P1520
NEUTRAL SWITCH
DTC P1520 SUB CODE 1010
NEUTRAL SWITCH ON (Short to battery)
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
Exh Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Neutral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1520.
2. Observe the DTCs.
Was the DTC P1520 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Are there any other DTC on such as P0704, P1576? Check the bold
circuit Go to Step 4
4 Check the neutral switch. Function is
OK Go to Step 5
Replace neutral
switch
5 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Check short circuit to battery by ignition on, off. See
the see page 6E-176.
No short to
battery Replace ECM Repair wiring
Breaker box is not available
Ignition off
Disconnect engine harness at ECM connector.
Check short circuit to battery by ignition ON, OFF. See
the page 6E-176. Replace ECM Repair wiring
6E–176 ENGINE DRIVEABILITY AND EMISSIONS
reference

5
R
/
W
H
B
0
1
0
.
5
L
/
R
H
B
0
4
0
.
5
L
/
R
I
C
1
1
0
.
5
L
/
R
H
A
1
5
A
C
C
B
2
B
1
O
F
F
I
G
2
S
T
I
G
1
S
W

;
I
G
N
I
T
I
O
N
B
A
T
T
M
A
I
N
8
0
A
I
G
.
1
5
0
A



G
L
O
W
5
0
A
I
G
2
4
0
A
8
B
/
R
P
A
0
1
3
W
P
A
0
3
3
W
P
A
1
3
3
W
P
A
1
6
0
.
5
G
C
A
0
1
0
.
5
G
I
C
4
8
0
.
5
R
C
A
0
2
0
.
8
5
W
K
A
0
1
0
.
8
5
Y
M
A
0
1
J
/
C

;

B
A
C
G
(
B
)
8
W
P
A
2
8
3
W
/
B
P
A
0
2
3
B
/
R
3
B
/
R
P
A
1
7
3
B
P
A
2
8
2
B
/
Y
I
C
0
1
2L/R
IC05
2L/R
IC05
0
.
5
I
Z
0
3
0
.
5
I
Z
0
4
E
B
I
N
J
.
P
U
M
P
T
.
P
.
S
.
&
S
W

;

I
D
L
E
(
T
H
R
O
T
T
L
E

V
A
L
V
E
)
E
C
T
S
E
N
S
O
R
2L/R
IC02
2L/R
IC02
2L/B
IC04
0.5B/Y
IC03
0.5Y
IC31
A56(58)
A41(3)
E
C
M
2
5
A
B
A
C
K
1
5
A
E
N
G
I
N
E
1
0
A
M
E
T
E
R
1
5
A
RELAY ; ECM MAIN
R
E
L
A
Y

;
G
L
O
W
S
W

;

T
H
E
R
M
O
SW ; BRAKE
RESISTER ; CLUTCH SW
(YZK NO ; 7321-9900)
(IDLE SW)
B
A
C
K

U
P

L
A
M
P
B
R
A
K
E

L
A
M
P
SW ; CLUTCH
SW ; BACK UP
SW ; OIL
0.5L/R
IC15
0.5W/R IC27
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
0.5L/R IC15
0.5L/R HA19
4 B2(83)
0.5G/R IC28
5 2 B7(88)
0.5B/R IC30
3 B14(92)
0.5B/L IC39
1 B3(84)
0.5BR/W HA20
A38(41)
B24(100)
A41(63)
B23(99)
B29(105)
B13(91)
A69(69)
A47(49)
A35(38)
A55(57)
B15(93)
B8(89)
B16(94)
A30(33)
0.5L/Y
IC06
0.5B/L
HB06
A36(39)
0.5R
IC12
A27(30)
0.5W/B
IC13
(ON)
ELEC.THERMO
(OFF)
(OFF)
A65(65)
0.5Y IC08
5B/R
HB03
0.85Y
KA01
0.85R/Y
KA02
0.85Y
MA02
0.5L/B
MA03
0.5Y/B
MA06
0.5Y/G
MA09
0.5W/R
MA11(W/SOF)
TB07(W/O SOF)
0.5L
MA10
0.5O/L
MB01
GLOW PULG x4
0.5G
IC07
0.5B
IZ08
0
.
5
B
/
L
E
X
0
2
0
.
5
O
/
B
M
B
0
4
0.85B
MX05
0.5B
IZ06
THERMO UNIT
0.5Y
IC57
A28(31)
0.5O/L
MA18
A40(43)
0.5BR/R
IC29
A39(42)
0.5B/R
MA05
A24(27)
0.5L/W
IC21
A68(68)
J
O
I
N
T

T
O

E
X
1
2
2
MAF
E
B
S
T
O
P
1
0
A
RESISTER ; NEWTRAL SW
0.5B
IZ10
0.5B/W
IC58
0.5B
EX03
0.5L
IC47
A-16
A-15
A-2
0.5R
IC32
3
A-3
0.5O
IC33
4
A-4
0.5P
IC34
1
1
3
2
A-5
0.5G/B
IC35
0.5R/G
IC36
0.5G/O
IC37
0.5B/G
IC38
A
F
C
B
A-1
A-10
VEHICLE SPEED
SENSOR
A-11
A-12
B-2
A-6
B-3
OIL PSESSURE UNIT
4WD SW
SPEED METER
METER
TACHO METER
OIL GAGE
ENG COOLANT
B6
B15
A10
B8
A6
4WD
OIL
GLOW
CHECK ENG
B3
A8
B2
A9
CONT ; IMMOBILIZER(B1)
0.5G
IC48
0.5B/P
IC43
B-5
0.5O
IC44
B-6
I
Z
0
7
IZ05
SW ; NEWTRAL
T
D
C
A61(2)
2B
IZ01
B22(98)
B12(90)
B25(101)
0.5W
IC45
A-7
0.5G/R
IC46
0.5B/W
IC10
0.5L/R
IC09
A-8
A-9
A62(1)
2B
IZ02
A32(35)
ECM
A43(45)
0.5R/L
MB11
CONT ;
IMMOBILIZER(B8)
C
O
N
T

;

I
M
M
O
B
I
L
I
Z
E
R
(
B
5
)
1 9
2
1
0
3
1
1
4
1
2
5
1
3
6
1
4
7
1
5
8
1
6
A-9
;

E
N
G
I
N
E
;

E
N
G
.
H
A
R
N
.
-
E
N
G
R
O
O
M

H
A
R
N
.


C
O
N
N
E
C
T
I
O
N
RELAY ;
A/C COMPRESSOR
1
2 4 0.5G
HA18
FUSE ;
A/C
FUSE ;
BLOOR
0.5B
HX22
0.5G
HA23
MAG.CLUTCH
(COMPRESSOR)
B-1
0.5G/R
HA13
0.5L/W
HA14
0.5BR
HA17
RELAY ;
A/C THERMO
1
2 4 0.5G
HA21 0.5G/W HA16
0.5B
HX03
0.5G
HA24
RESISTER ; IDLE UP
270
510
270
ENGINE DRIVEABILITY AND EMISSIONS 6E–177
DTC P1520 SUB CODE 1011
NEUTRAL SWITCH OFF (Open circuit)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1520.
2. Observe the DTCs.
Was the DTC P1520 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Are there any other DTC on such as P0704, P1576? Check the bold
circuit
Open circuit Go to Step 4
4 Check Neutral switch. Function is
OK not
always ON Go to Step 5
Replace Neutral
switch
5 Breaker box is available
Ignition off
Install breaker box as type A see page 6E-57.
Check continuity between ECM pin 87 and Neutral sw.
Breaker box is not available
Ignition off
Install breaker box as type A see page 6E-57.
Check continuity between ECM pin 87 and Neutral sw. Continuety Replace ECM Repair wiring
6E–178 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1576
EXHAUST BRAKE VALVE1 CIRCUIT MALFUNCTION
System Description
Operation
ABS activate signal command to cancel Exh. Brake.
Signal follow
2
MAF
6 7
5 8 2 1
5 3
1
4
ECM
25A
US
84 92 88 83 97
EVRV:
EGR
MAG valve
Exh Brake
(NKR 4JH1-TC only)
VSV : Ext 1 (QWS)
(TF 4JA1-TC only)
VSV:
INT. Throttle
SW:Neutral
(MT only)
40 95 87 91 105
99
CAN-L
100
CAN-H
Batt Batt Batt Batt Batt
Batt
CPU
IC 08
CF 150
IC 08
µP : Microproccesor
µP µP µP µP
µP
PCU
ECM
ABS
OUT
ABS
IN
Exh. Brake cut
IN
Exh. Brake cut
OUT
ABS
control unit
5V
5V
ECM
If ECM recognizes any
failure, ECM sends 180
deg different phase signal.
This reverse phase signal
triggers to turn ON ABS light.
ABS
ABS
ECM
reverse
phase
signal
ENGINE DRIVEABILITY AND EMISSIONS 6E–179
TF 4JA1-TC QWS
NKR 4JHI-TC Exh. Brake + Intake shutter +
QWS
Exh. Brake and Intake shutter operate at same time.
QWS operate condition.
QWS operation reguirement
QWS
request switch
Atomasphone
temp switch
Ext vsv1
Ext vsv2
ECT IAT APS
Engine
speed
ECM
+Battery
Exh. Brake
request sw
QWS
regnest sw
Mag valve
VSV : Int
ECT IAT
VSS
APS
Idle sw
ECM
+Battery
Idle switch = ON
APS ≤ 2%
ECT requires ON
IAT requires ON
ON
10ºc
150ºc
OFF
vss < 2km/h
ON
70ºc
80ºc
OFF
6E–180 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1576 SUB CODE 1000
EXH. BRAKE AND QWS VALUE 1 CIRCUIT SHORT TO BATTERY
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1576.
2. Observe the DTCs.
Was the DTC P1576 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box as type A see page 6E-57.
Check short to battery, see on page 6E-181, 6E-182
(NKR 4JH1-TC only).
Breaker box is not available
Ignition off
Disconnect engine harness.
Check short to battery, see on page 6E-181, 6E-182
(NKR 4JH1-TC only).
No short to
battery Go to Step 4 Repair wiring
4 Check Exhaust brake valve circuit, intake shutter
circuit.
Replace ECM
Replace Exh.
brake valve or
intake shutter
ENGINE DRIVEABILITY AND EMISSIONS 6E–181
reference
A
C
C
B
O
F
F
S
T
O
N
K
E
Y

S
W
5
W
P
A
0
7
0
.
5
B
R
H
A
0
9
0
.
8
5
G
/
O
H
A
1
1
0
.
5
G
/
O
I
C
4
8
0
.
5
L
/
R
I
C
3
9
0
.
5
L
/
R
I
C
3
3
3L/R IC34
M
A
G
N
E
T

C
L
U
T
C
H
(
C
O
M
P
R
E
S
S
O
R
)
P
D
S
0.85G/W
HA10
0.85Y/G
HA19
0.5B
IZ12
5
B
/
L
H
B
0
1
0
.
8
5
W
P
A
1
0
3
B
/
Y
I
C
0
1
1
.
2
5
B
/
Y
I
C
0
5
0
.
5
G
/
Y
C
A
0
1
0
.
5
L
G
/
R
I
C
2
1
0
.
3
B
I
Z
0
9
0
.
5
B
R
/
R
I
C
2
0
1
35
2
4
M
A
F
1
4
V
,
6
0
m
A
0
.
5
B
R
/
R
I
C
1
9
0
.
5
L
/
R
I
C
2
2
0
.
5
B
R
I
C
6
5
0
.
5
B
/
O
I
C
2
7
0
.
5
L
G
I
C
1
6
0
.
5
L
G
/
W
I
C
2
9
0
.
5
B
/
W
I
C
3
1
1
.
2
5
L
/
R
I
C
5
9
0
.
5
B
/
Y
M
A
0
1
0
.
5
L
/
R
I
C
2
6
0
.
5
B
I
C
1
5
0
.
5
L
/
R
I
C
2
8
2
L
/
R
I
C
3
0
0
.
5
G
/
Y


I
C
4
1
0
.
5
W
/
G


I
C
4
0
1
.
2
5
B
/
Y


I
C
6
3
0
.
5
L
/
R
I
C
0
9
2
L
/
R
I
C
0
2
0
.
5
L
/
B
I
C
0
3
0
.
5
G
C
A
0
2
0
.
5
G
I
C
1
0
0
.
5
W
I
C
0
4
A
-
5
6
C
O
N
T

U
N
I
T

;

E
N
G
I
N
E
A
-
4
1
A
-
3
6
A
-
2
7
A
-
6
5
A
-
2
8
A
-
6
4
A
-
5
8
A
-
3
9
A
-
4
0
A
-
4
4
A
-
5
7
B
-
2
B
-
7
B
-
1
4
B
-
1
9
B
-
3
A
-
3
7
B
-
1
7
B
-
6
B
-
2
4
B
-
2
3
B
-
2
9
B
-
1
3
A
-
3
0
A
-
3
8
D
I
A
G
(
4
5
)
M
A
I
N

R
E
L
A
Y
(
5
8
)
B
A
T
(
+
)
(
3
)
I
G
(
3
9
)
B
A
R
A
K
E

O
N
(
3
0
)
B
A
R
A
K
E

O
F
F
(
6
5
)
C
L
U
T
C
H
(
3
1
)
S
W
;
E
X
H
.
B
R
A
K
E
(
6
4
)
M
E
T
E
R

I
N
D
(
E
X
H
.
B
R
A
K
E
)
(
6
0
)
(
K
E
Y

O
N
;
E
N
A
B
L
E
)
M
E
T
E
R

I
N
D
(
C
H
E
C
K

E
N
G
.
)
(
4
2
)
M
E
T
E
R

I
N
D
(
G
L
O
W
)
(
4
3
)
Q
W
S

S
W
(
4
6
)
M
E
T
E
R

I
N
D
(
Q
W
S
)
(
5
9
)
(
K
E
Y

O
N
;
E
N
A
B
L
E
)
M
A
F

+
5
V
(
8
3
)
M
A
F

S
I
G
.
(
8
8
)
M
A
F

G
N
D
(
9
2
)
E
G
R
(
9
7
)
M
A
T

S
I
G
.
(
8
4
)
M
A
G
.
V
A
L
V
E
(
E
X
H
.
B
R
A
K
E
)
(
4
0
)
I
N
T
.
S
L
O
T
T
L
E
(
9
5
)
S
W
;
N
E
U
T
R
A
L
(
8
7
)
I
N
J
.
P
U
M
P
(
C
A
N
-
H
)
(
1
0
0
)
I
N
J
.
P
U
M
P
(
C
A
N
-
L
)
(
9
9
)
I
N
J
.
P
U
M
P
(
M
A
B
)
(
1
0
5
)
I
N
J
.
P
U
M
P
(
D
Z
G
)
(
9
1
)
A
/
C

S
W
(
3
3
)
A
/
C

R
E
L
A
Y
(
4
1
)
0
.
5
W
/
B
I
C
1
1
0
.
5
Y
I
C
1
2
0
.
5
L
G
/
L
I
C
1
3
0
.
5
G
/
R
I
C
6
4
0
.
5
G
/
Y
I
C
1
7
0
.
5
O
/
L
I
C
1
8
0
.
5
W
/
R
I
C
2
3
0
.
5
G
/
R
I
C
2
4
0
.
5
B
/
R
I
C
2
5
0
.
5
B
/
L
I
C
5
6
0
.
5
W
I
C
6
0
0
.
5
G
B
B
0
9
S
T
O
P

L
A
M
P
0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
S
W

;

C
L
U
T
C
H (
C
L
U
T
C
H

P
E
D
A
L

;

O
F
F
)
(
B
R
A
K
E

P
E
D
A
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A/C ON SIGNAL(270 )
ENGINE DRIVEABILITY AND EMISSIONS 6E–183
DTC P1576 SUB CODE 1000
EXHAUST BRAKE VALVE1 CIRCUIT SHORT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1576.
2. Observe the DTCs.
Was the DTC P1576 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
Install a breaker box.
Disconnect a breaker box adapter harness.
Measure voltage between ECM pin 40 and ground.
Breaker box is not available
Ignition off
Disconnect ECM connector.
Measure voltage between ECM connector pin 40 and
ground.
12V Replace ECM Go to Step 4
4 Check the Exhaust Brake circuit.
Was the problem found? Verify repair —
40
6E–184 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1576 SUB CODE 0100
EXHAUST BRAKE VALVE1 CIRCUIT OPEN (Short to ground)
DTC P1605
EEPROM DEFECT
DTC P1605 SUB CODE 1110&1101
EEPROM DEFECT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1576.
2. Observe the DTCs.
Was the DTC P1576 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
Check continuity between ECM relay and ECM pin 40.
• Check no short to ground between ground and
ECM pin 40. Continuety
Replace ECM
Repair the
harness
Breaker box is not available
Ignition off
• Disconnect ECM connector.
• Check continuity between ECM relay and ECM pin
40.
• Check no short to ground between ground and
ECM pin 40.
No short to
ground
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1605.
2. Observe the DTCs.
Was the DTC P1605 restored? — Replace ECM
Go to
Intermittent
ENGINE DRIVEABILITY AND EMISSIONS 6E–185
DTC P1610
SEEDS AND KEY FILE DESTROYED
DTC P1611
WRONG SECURITY CODE ENTERED
DTC P1612/P1613
IMMOBILIZER NO OR WRONG SIGNAL
DTC P1614
Wrong transponder key
Step Action Value(s) Yes No
1 Clear the DTC P1610.
Observe the DTCs.
Was the DTC P1610 stored? No DTC Verify Go to Step 2
2 Reprogram ECM by SPS and verify no more DTC. No DTC — Replace ECM
Step Action Value(s) Yes No
1 Clear DTC P1611.
Observe the DTCs.
Was DTC P1610 stored? No DTC Verify Go to Step 2
2 Write proper security code.
See the immobilizer procedure. No DTC Verify Replace ECM
Step Action Value(s) Yes No
1 Clear the DTC P1612.
Observe the DTCs.
Was DTC P1612 stored? No DTC Verify Go to Step 2
2 Check open circuit of wire between ECM - Immobilizer
ICU. No open
circuit
Check
immobilizer
section of WSM Repair wire
Step Action Value(s) Yes No
1 Clear the DTC P1614.
Observe the DTCs.
Was DTC P1614 stored? No DTC Verify Go to Step 2
2 Check immobilizer section of WSM.
6E–186 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1625
Power supply relay malfunction
DTC P1625 SUB CODE 1011
POWER SUPPLY RELAY SWITCHED OFF TOO LATE
DTC P1625 SUB CODE 1010
POWER SUPPLY RELAY SWITCHED OFF TOO EARLY
ON
IGN
ECM relay
OFF
OFF
2sec
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1625.
2. Observe the DTCs.
Was the DTC P1625 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check ECM relay function. ECM relay
function is OK Replace ECM Replace relay
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1625.
2. Observe the DTCs.
Was the DTC P1625 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 Check ECM relay function. Replace ECM Replace felay
ENGINE DRIVEABILITY AND EMISSIONS 6E–187
DTC P1630
FUEL-INJECTION QUANTITY CIRCUIT MALFUNCTION
DTC P1630 SUB CODE 1010
FUEL-INJECTION QUANTITY CIRCUIT HIGH INPUT
DTC P1630 SUB CODE 1011
FUEL-INJECTION QUANTITY CIRCUIT HIGH INPUT
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1630.
2. Observe the DTCs.
Was the DTC P1630 restored? —
DTC stored
Replace
injection pump
Go to
Intermittent
Diagnosis
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? Go to Step 2
2 Clear the DTC P1630.
Ignition off and wait for 3 sec. Ignition on.
Run engine.
Raise engine speed.
Observe the DTCs.
Was the DTC P1630 stored?
DTC stored
Replace
injection pump
Go to
intermittent
diagnosis
6E–188 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1650
CAN: DEVICE MALFUNCTION
DTC P1650 SUB CODE 1010
CAN: DEVICE OFF LINE
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1650.
2. Observe the DTCs.
Was the DTC P1650 restored? — Go to Step 3
Go to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Disconnect PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
Breaker box is not available
Ignition off
• Disconnect ECU and PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
0Ω
and
0V Go to Step 4 Repair harness
4 Replace ECU.
Was the DTC P1650 restored?
DTC stored
Replace
injection pump
and verify —
and and
ENGINE DRIVEABILITY AND EMISSIONS 6E–189
DTC P1650 SUB CODE 1011
CAN: DEVICE HANGUP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1650.
2. Observe the DTCs.
Was the DTC P1650 restored? — Go to Step 3
Go to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Disconnect PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
Breaker box is not available
Ignition off
• Disconnect ECU and PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
0Ω
and
0V Go to Step 4 Repair harness
4 Replace ECU.
Was the DTC P1650 restored?
DTC stored
Replace
injection pump
and verify
and and
6E–190 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1651 SUB CODE 1010
INJECTION PUMP: CAN MALFUNCTION
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1651.
2. Observe the DTCs.
Was the DTC P1651 restored? — Go to Step 3
Go to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Disconnect PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
Breaker box is not available
Ignition off
• Disconnect ECM and PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
0Ω
and
0V Go to Step 4 Repair harness
4 Replace ECU.
Was the DTC P1651 restored?
DTC stored
Replace
injection pump
and verify —
and and
ENGINE DRIVEABILITY AND EMISSIONS 6E–191
DTC P1651 SUB CODE 1011
CAN RECEIVEDS ERROR
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1651.
2. Observe the DTCs.
Was the DTC P1651 restored? — Go to Step 3
Go to
Intermittent
Diagnosis
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Disconnect PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
Breaker box is not available
Ignition off
• Disconnect ECM and PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
0Ω
and
0V Go to Step 4 Repair harness
4 Replace ECM. Verify
and and
6E–192 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1690
MALFUNCTION INDICATION LAMP (MIL) CIRCUIT MALFUNCTION
Circuit Description
The check engine lamp should always be illuminated
and steady with the ignition “On” and the engine
stopped. Ignition feed voltage is supplied to the check
engine lamp bulb. The ECM (Engine Control Module)
turns the check engine lamp “On” by grounding the
check engine lamp driver circuit.
DTC P1690 SUB CODE1000
MALFUNCTION INDICATION LAMP (MIL) CIRCUIT HIGH INPUT
Glow
plug
relay
coil
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
Relay EW
ECM
25A
ON
IG
Stop lamp SW SW:clutch
Clutch pedal:OFF
SW:ExG Brake
Glow
Check
Engine
ExG
Brake
Meter
15A
Stop lamp
10A
IC 08
IC 035 IC 035
µP : Microproccesor
µP µP µP µP µP
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1690.
2. Observe the DTCs.
Was the DTC P1690 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–193
3 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Remove the No.12 fuse.
• Measure voltage between ECM pin 39 and ground.
Breaker box is not available
Ignition off
• Disconnect ECM connector.
• Remove the No.12 fuse.
• Measure voltage between ECM pin 39 and ground.
0V Replace ECM Go to Step 4
4 Disconnect the connector of instrument panel.
Check the voltage between the connector of
instrument panel and the ECM. 0V Go to Step 5
Repair engine
harness
5 Check the voltage between the fuse and the lump
bulb.
0V
Check the
ground the
lump
Repair harness
verify
Step Action Value(s) Yes No
6E–194 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1690 SUB CODE 0100
MALFUNCTION INDICATION LAMP (MIL) CIRCUIT OPEN
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed? — Go to Step 2
Go to OBD
system check
2 1. Clear the DTC P1690.
2. Observe the DTCs.
Was the DTC P1690 stored? — Go to Step 3
Refer to
Intermittent
Diagnosis
3 • Ignition key “ON”.
• Does the “Glow” lamp flash? Go to Step 4 Go to Step 5
4 Breaker box is available
Ignition off
• Install a breaker box as type A see page 6E-57.
• Remove the No.12 fuse and instrument panel check
continuity between ECM pin 42 and instrument
panel side.
Breaker box is not available
Ignition off
• Disconnect ECM connector.
• Remove the No.12 fuse and instrument panel check
continuity between ECM pin 42 and instrument
panel side.
0Ω Replace ECM
Replace engine
harness
5 Check the No.12 fuse is the fuse available?
Go to Step 6
Replace the
fuse
6 Check the “Check Eng” lamp and “Glow” lamp bulbs.
Are the bulbs available? Go to Step 7
Replace the
bulbs
7 Disconnect the engine harness at body side.
Check the resistance within engine harness. 0Ω Replace ECM
Replace engine
harness
Instrument panel
ENGINE DRIVEABILITY AND EMISSIONS 6E–195
Symptom chart & perform procedure
1. No start or hard start.
1-1. No cranking happens.
1-2. Starter can crank engine, but seems to lower than usual.
1-3. Cranking speed seems to be OK, but no combustion sounds can be heard.
1-4. Engine run as idling speed, but can raise engine speed to usual engine speed
zone.
1-5. Engine can reach high engine speed, after release accel pedal engine stalls.
2. Engine stall.
2-1. Engine stalls at idling.
2-2. Engine stalls after engine revolution becomes more than idling speed—Under
shoot stall.
3. Rough idle.
4. Excessive white smoke.
5. Excessive black smoke.
6. Hesifation.
7. Surge/sag.
8. Lack of power.
9. Poor fuel consumption.
6E–196 ENGINE DRIVEABILITY AND EMISSIONS
1-1. No cranking happens.
Check starter circuit, following section
1-2. Starter can crank engine, but seems to be lower than usual.
Step Action Value(s) Yes No
1 Ask the customer whether or not they use proper
viscosity oil.
low-30
low-40 Go to Step 2
Replace oil and
flash well
2 Check the manual transmission position.
Should be Neutral.
Run the engine.
If cranking speed is lower, check the clutch system.
Clutch system
should not
drug clutch
plate Go to Step 3
Clutch is
drugged check
clutch system
3 Measure cranking speed.
Does cranking speed meet standard?
If oil temperature can not be measured, water
temperature can be used.
If water temperature can not be measured,
atmosphere temp can be used as reference.
See the left
box
Cranking speed
is OK
Go to 1-3.
“Cranking
speed seems to
be OK, but no
combustion
sounds can be
heard” Go to Step 4
4 Check battery voltage and battery specific gravity. More than
12V Go to Step 5
Recharge and
follow section
5 Check the starter circuit.
See the electrical section. Go to Step 6
Repair starter
circuit
6 Check any accessory including Air conditioner
installed.
Remove or disconnect all accessory which make load
to cranking. No accessory Go to Step 7
Repair
accessory
7 Check value gap.
If valve gap is close to “zero”, need to be adjusted.
Crank engine.
Valve gap
value can be
seen on
engine
mechanical
section Go to Step 8
Adjust valve
gap
8 Check engine whether any part has excessive friction.
See the overhaul procedure. Verify —
Oil temperature Cranking speed
-20°C 100-150rpm or more
+20°C 200-250rpm or more
ENGINE DRIVEABILITY AND EMISSIONS 6E–197
1-3. Cranking speed seems to be OK, but no combustion sounds can be heard.
Step Action Value(s) Yes No
1 Ask the customer whether use proper fuel.
Go to Step 2
Replace and
flash well
2 Check cranking speed with following table.
If oil temperature can not be measured, water
temperature can be used.
If water temperature can not be measured,
atmosphere temp can be used as reference.
See the left
box Go to Step 3
Go to “1-2.
Starter can
crank engine,
but seems to be
lower than
usual”
3 Ignition off, check the fuses.
ECU fuse 25A
Generator fuse 15A
Check any poor ground of ECM.
Check ECM engine harness poor cnnector pin. No fuse blown Go to Step 4 Repair
4 Check the fuel level.
Go to Step 5
Add fuel and
bleed air
5 Check fuel feed pipe pinched, deformed or fuel
leakage.
No pinched
No deformed
No fuel
leakage Go to Step 6 Repair
6 Check sedimentary light on or not
If sedimentary light stays on, frozen water may cause
plugged fuel line at fuel filter. No light on Go to Step 7 Brain water
7 Check Air in fuel.
See the procedure in section No air Go to Step 8 Bleed air
8 Ask customer whether this happens at only around
0°C or less temperature.
Waxing might cause plugged fuel flow at fuel filter and
sedimenter.
If yes, change fuel to winter type fuel.
If no, see the No column.
No Waxing
causes
plugging fuel
flow Go to Step 9
Change to
winter type fuel
Oil temperature Cranking speed
-20°C 100-150rpm or more
+20°C 200-250rpm or more
Fuel sedimenter/fuel filter Fuel feed line
6E–198 ENGINE DRIVEABILITY AND EMISSIONS
9 Check any deformation, plugged at inlet air passage.
No plugged Go to Step 10
Repair and
verify
10 Check Air cleaner element.
Is the element clean?
Clean Go to Step 11
Clean or
replace
Air cleaner
element
11 Operate the intake shutter by hand.
Check the position by no vacuum if intake shutter
position is not wide open position need to replace
intake shutter.
See _page.
Intake shutter
operate
smoothly Go to Step 12
Replace intake
shutter and
verify
12 Check whether exhaust system is deformed, plugged. Exhaust
system is not
deformed
plugged.
Exhaust
system
should be ok Go to Step 13
Repair or
Replace
13 • Operate exhaust valve by mighty vac if that does
not more smoothly, remove and check exhaust
Valve.
• Check the position by no vacuum if exhaust valve
position is not wide open position, need to replace
exhaust Valve.
Exhaust valve
moves
smoothly,
wide open
position by no
vacuum Go to Step 14
Repair or
Replace
exhaust valve
Step Action Value(s) Yes No
Exhaust valve
ENGINE DRIVEABILITY AND EMISSIONS 6E–199
14 Check catalytic converter is plugged or not.
No plugged Go to Step 15
Replace
catalytic
converter
15 Check whether the turbine of turbo isn’t damaged. Go to Step 16 Repalce turbo
16 Check whether AIC of after market isn’t had and
confirm by hand whether AIC isn’t seized up. Go to Step 17
Replace
compressure
17 Remove injection nozzle and confirm injection nozzle
1) Confirm the valve stick by hand tester
2) Confirm nozzle injection pressure Go to Step 18 Repair
18 Measure compression
• Engine coolant temperature 50°C.
• Crank 200 to 250 rpm
Compression
28 kg/cm
3
Go to Step 19 Repair engine
19 Remove coolant tempereture sensor and check
relation between the water temperature and
resistance value.
Go to Step 20
Replace
coolant
temperature
sensor
20 Check injection valve, over flow valve. Go to Step 21 Replace valve
21 Replace ECM. Replace pump
Step Action Value(s) Yes No
6E–200 ENGINE DRIVEABILITY AND EMISSIONS
1-4. Engine run as idle speed, but can not raise engine speed to usual engine
speed zone.
Step Action Value(s) Yes No
1 Ask the customer whether the customer uses proper
fuel. — Go to Step 2 Change fuel
2 Check the fuel level.
If fuel level at tank is low, air can be contained.
Engine can not raise speed. — Go to Step 3
Add fuel and
bleed air
3 Check fuel feed pipe pinched, deformed or fuel
leakage.
No pinched
No deformed
No fuel
leakage Go to Step 4 Repair
4 Check sedimenter light on or not. If sedimenter light
stays on, frozen water may cause plugged fuel line at
fuel filter. No light on Go to Step 5 Drain water
5 Check Air in fuel. See the procedure in section. No air Go to Step 6 Bleed air
6 Ask customer whether this happens at only around
0°C or less temperature. Waxing might cause plugged
fuel flow. If yes, change fuel to winter type fuel. If no,
see the No column. —
Change to
winter type fuel. Go to Step 7
7 Remove injecter.
1. Check injection patter is OK.
2. Check injection opening pressure is in
specification.
No problem
See the
engine
mechanical
section Go to Step 8 Repair & verify
8 Check ECT sensor resistance. See ECT sensor look
up table.
See the left
table Go to Step 9
Replace ECT
and verify
9 Inspect if overflow valve is kept open. No problem Go to Step 10 Repair
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–201
10 Check TPS position by Tech-II. Is data within typical
data?
Within
specification Go to Step 11
Raise engine
speed two or
three times and
check again.
If condition still
continues,
replace
injection pump
11 Check TPS position becomes within typical data.
Typical data Go to Step 12
Replace or
adjust
12 Remove MAF, check whether IAT works in
specification.
2.0KΩ at
20°C room
temperature Go to Step 13 Replace MAF
13 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No imitation
no
deformation
or plugged Go to Step 14 Correct them
14 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See _page.
See the left
1-4 items Go to Step 15 Correct it
15 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them
Operate
smoothly Go to Step 16
Correct it and
verify
Step Action Value(s) Yes No
6E–202 ENGINE DRIVEABILITY AND EMISSIONS
16 Check any deformation, plugged at exhaust system.
No
deformation
or plugged Go to Step 17
Correct it and
verify
17 Check turbine of turbo charger. — Go to Step 18 Correct it
18 Repalce ECM and verify.
— —
Still does not
run well,
replace
injection pump
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–203
1-5. Engine stall after engine speed reach more than 2000 rpm.
Step Action Value(s) Yes No
1 Foreign materials sometimes cause MAB valve stuck.
Stop engine, and raise engine speed more than 2000
rpm. Release accelerator pedal, check the engine
stalls or not. No stall Verify Go to Step 2
2 Even engine run at 1st hand, waxing at fuel filter
causes no engine raise, or stall.
Engine run
more than
2000 rpm Go to Step 3
Replace to
proper fuel and
flash it
3 Check fuel level or any air mixing to fuel line.
— Go to Step 4
Repair it and
verify.
4 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No imitation
no
deformation
or no plugged Go to Step 14 Correct them
5 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See left 1-4
items Go to Step 15 Correct it
6 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 16
Correct it and
verify
7 Check any deformation, plugged at exhaust system.
See the procedure.
No
deformation
or plugged Go to Step 17
Correct it and
verify
6E–204 ENGINE DRIVEABILITY AND EMISSIONS
8 Check turbine of turbo charger. See the procedure on
engine mechanical section.
— Go to Step 18
It any damage,
replace turbo
charger
9 If engine reaches more than 2500 rpm and stall,
check any after market accessory is installed for
engine load. Possible A/C compressor is on after
engine run. If no signal goes to ECM, change after
marked A/C compressor.
No after
market
accessory Go to Step 10
Replace to
genuine parts
or remove it
10 After glow may not work properly because ECM does
not recognize after glow is required. See the DTC
P380 as reference.
Check ECT resistance up is in specification.
See the table.
Within
specification Replace ECM
Repalce ECT
sensor
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–205
2. Engine stall
2-1 Engine stall at idling.
Step Action Value(s) Yes No
1 Did engine stall happen at lower than 10°C or more
than 10°C Lower than
10°C
Lower than
10°C
Go to Step 2 Go to Step 14
2 Check the fuel level in tank.
Fuel is
sufficient Go to Step 3
Add fuel and
bleed air &
verify
3 Ask the customer what kind of fuel the customer use.
cetane index more than
No gasoline
No kevocin
No bio chemical fuel Proper fuel Go to Step 4
Replace and
flash fuel
4 It may be caused by waxing or air mixture in the fuel.
1. Ask the customer what kind of temperature make
this failure. If that happen only around 0°C or a
little more, waxing of fuel may cause. Request to
customer to change the fuel to winter type fuel.
2. Check the sedimentary light is on or not. If it is on,
ice may plug fuel flow.
3. If this is intermittent, ask the customer how is the
level of car at parking. If road or parking lot has
slope, it maybe caused by air mixing in the fuel.
Proper fuel
and no air in
the fuel Go to Step 5
Replace and
flash fuel
Drain water
from
sedimenter
Ask customer to
put more fuel
regularity
5 Check APS position is within typical data. See the
typical data Go to Step 9 Go to Step 6
6 Check any fuel leakage at fuel pipe, injection pipe.
Check any damage of fuel pipe or injection pipe. — Go to Step 7
Correct it and
verify.
7 Replace fuel filter, because it maybe caused by fuel
filter plugged or resistance fuel flow through fuel filter.
Does it fix the problem?

Verify, still
simpton exist,
Verify
Go to Step 9 Go to Step 9
8 Check the over flow valve stuck open. No stuck
open
OK
Go to Step 10 Repair
9 Check any installation of after market accessory
especially A/C compressor.
No
installation. Go to Step 11 Remove
6E–206 ENGINE DRIVEABILITY AND EMISSIONS
11 Inspect ECT is within specification.
Within
specification Go to Step 12
Replace it and
Verify
12 Replace injection pump.

Verify
but still
condition
continues, Go
to Step 13
13 Replace ECM — Verify —
14 Check the fuel level.
Fuel is
sufficient Go to Step 15
Add fuel and
bleed air &
verify
15 Ask the customer what kind of fuel he or she use.
cetane index more than _.
No gasoline
No Kevocin
No bio chemical fuel Proper fuel Go to Step 16 Replace it.
16 It maybe caused by air mixing in the fuel.
1. Check the sedimenter light is on. If so, drain water.
2. If this is intermittent, ask the customer how is the
level of the car at parking. If road or parking lot
has grade, it may be caused by air mixing in the
fuel. — Go to Step 17
Drain water ask
the customer to
put more fuel
regnlary
17 Check any fuel leakage at fuel pipe, injection pipe.
Check any damage of fuel pipe or injection pipe. — Go to Step 18
Correct it and
verify
18 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged. — Go to Step 19 Correct them
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–207
19 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See _page.
See the left
1-4 items Go to Step 20 Correct it
20 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 21
Correct it and
verify
21 Check any deformation, plugged at exhaust system.
— Go to Step 22
Correct it and
verify
22 Check turbine of turbo charger. See the procedure on
engine mechanical section.
— Go to Step 23 Correct it
Step Action Value(s) Yes No
6E–208 ENGINE DRIVEABILITY AND EMISSIONS
23 Check any installation of after market accessory
especially A/C compressor.
No
installation. Go to Step 24 Remove
24 Inspect ECT is within specification.
Within
specification Go to Step 25
Replace it and
verify
25 Run engine again. Foreign material at MAB may
cause High pressure soloenoid valve stuck. No foreign
material
If no more stall,
verify one more
time Go to Step 26
26 Check injection nozzle spray pattern and opening
pressure.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Go to Step 27 Change nozzle
27 Check the compression.
See the left Go to Step 28
Follow the
procedure at
engine
mechanical
section
28 Replace injection pump. — Verify Go to Step 29
29 Replace ECM — Verify —
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–209
2-2 Engine stall after engine revolution becomes more than idling speed.
Undershoot stall.
Step Action Value(s) Yes No
1 Ask the customer, does it happen always or
sometimes. —
Always Go to
Step 2
Sometimes Go
to Step 9
2 Check intake throttle operation. Should be operated
smoothly.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
(Intake throttle is available only NKR 4JH1-TC,
operation should be smooth.)
Within
specification Go to Step 3
Replace and
verify.
3 Check exhaust valve operation. Operation
should be
smooth Go to Step 4 Replace it
4 Ask the customer what kind of oil he or she uses. 10w-30 or
10w-40 Go to Step 5 —
5 Record data of Q–final, rpm, APS, MAF output (Air
weight) by Tech-II. Continuous record from idling to
stall condition is necessary for further engineering
study. Send this record to ISUZU representative. — Go to Step 6 —
6 Check PTO system or accessory. How? — Go to Step 7 —
7 Inspect any mechanical friction increased.
1. Clutch
2. A/C compressor
3. Generator
4. P/S pump
5. Injection system
6. Lubrication system
7. Valve train system
8. Crank shaft
See the
mechanical
section of
workshop
manual Go to Step 8
If any problem,
repair and verify
8 Replace ECM — — —
6E–210 ENGINE DRIVEABILITY AND EMISSIONS
9 Check intake throttle operation. Should be operated
smoothly.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
(Intake throttle is available only NKR 4JH1-TC,
operation should be smooth.) — —
Correct it and
verify
10 Check exhaust valve operation — Go to Step 11 Replace it
11 Ask the customer what kind of oil he or she uses. 10w-30
10w-40 Go to Step 12 —
12 Check whether ECM connector, ECT connector PCU
connector, glow plug connector have poor connection
No poor
connection Go to Step 13 Repair
13 Record data of Q-final, rpm, APS, MAF output(Air
weight) by Tech-II. Continuous record from idling to
stall condition is necessary for further engineering
study. Send this record to ISUZU representative. — Go to Step 13 —
14 Check PTO system or accessory.
How? — Go to Step 14 —
15 Replace ECM — — —
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–211
3. Rough idle
Step Action Value(s) Yes No
1 Use Tech-II to confirm. Compare actual idling speed
and target idling speed.
Actual idle
speed =
target idle
speed Go to Step 2
Repace to OK
ECM
If rough idle is
fixed, replace
ECM
If not, go to
Step 2
2 Check accessory belt tension. 98 - 118 (V)
10 - 12 (kg) Go to Step 3
Adjust and
verify
3 Check any after market accessory, which ECM does
not recognize additional engine load of A/C
compressor or wrong wring.
No accesay
with ECM
recogaition
Go to Step 4
happens only
during night
Remove after
market
accessory
4 Ask the customer when it happen. If happens only
during night, ACG load fluctuation causes rough idle.

happens only
during night
Ask ISUZU
representative Go to Step 5
5 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No imitation,
no plugged,
no
deformation Go to Step 6 Correct them.
6 Check intake shutter operation. (NKR 4JH1-TC only)
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See the left
1-4 items Go to Step 7
Replace and
verify
7 Check fuel level.
— Go to Step 8
Add fuel and
bleed air
8 Check fuel feed pipe pinched, deformed, damaged or
fuel leakage. — Go to Step 9 Repair
9 Ask the customer what kind of fuel the customer use. Proper fuel
see the
owners
manual Go to Step 10
Replace to
proper one
10 Check APS sensor return to 0% by Tech-II and by
DVM. — Go to Step 11 Repair
6E–212 ENGINE DRIVEABILITY AND EMISSIONS
11 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 12
Correct it and
verify
12 Check any deformation, plugged at exhaust system.
No
deformation,
plugged Go to Step 13
Correct it and
verify
13 Check turbine of turbo charger. See the procedure or
engine mechanical see section.
No damage Go to Step 14 Correct it
14 Check over flow valve stuck or not. — Go to Step 15 —
15 Check EGR valve operation. Apply vacuum by mighty
vac.
See the valve movement through EGR valve window.
Oporate
smoothly Go to Step 16
Replace and
verify
16 Replace fuel filter cartridge. Run engine, check rough
idle is fixed or not.
No more
rough idle Verify Go to Step 17
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–213
17 Check injection nozzle spray pattern and injection
opening pressure.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Go to Step 18 Replace nozzle
18 Inspect delivery valve leaking or any damage around
seal area. No leakoge Go to Step 19 Repair
19 Check the compression.
More than
28 kg/cm
2
Go to Step 20
Compression is
not in
specification.
Check the
cause based on
engine
mechanical
section of work
shop manual
20 Inspect ECT sensor with specification table below.
— Go to Step 21
Repalce ECT
sensor
21 Check glow plug.
Ω Go to Step 22
Replace glow
plug
22 Check IAT sensor. 2.0KΩ at
20°C room
temp Go to Step 23 Replace MAF
23 Replace injection pump. — Verify —
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
6E–214 ENGINE DRIVEABILITY AND EMISSIONS
4. Excessive white smoke.
Step Action Valve(s) Yes No
1 Ask the customer when excessive white smoke
happen.
1) When start engine
2) During driving the vehicle
a) Low elevation
b) High elevation —
1-1)→2
1-2)a)→21
1-2)b)→41 —
2 Ask the customer whether he or she use proper fuel.
1. Diesel fuel cetane index.
2. No gasoline.
3. No kelosin.
4. Bio chemical fuel.
5. No high sulfur fuel consult with ISUZU
representative. Proper fuel Go to Step 3
Replace fuel
and flash
3 Ask the customer whether this white smoke happen
just one time after soak the vehicle for long hours
under cold weather. It is normal. —
Explain to
customer
No long hours
parking
Go to Step 4
4 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No immitation
no plugged,
no
deformation Go to Step 5 Correct them
5 Check intake shutter operation. (NKR 4JH1-TC only)
1. Should operate smoothly
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See the left
1-4
Smooth
operation Go to Step 6 Correct it
6 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 7
Correct it and
verify
ENGINE DRIVEABILITY AND EMISSIONS 6E–215
7 Check any deformation, plugged at exhaust system.
No damage Go to Step 8
Correct it and
verify
8 Check turbine of turbo charger. See the procedure on
engine mechanical sectin.
— Go to Step 9 Correct it
9 Check over flow valve stuck open by foreign material.
— Go to Step 12
Remove foreign
material
10 Check injection pipe, fuel feed pipe damaged. No damage Go to Step 10 —
11 Check any fuel leakage. No leakage Go to Step 11 Repair leakage
12 Check TPS timer position by Tech-II. Compare actual
position and target position. If both are same, go to
yes. If both are not same, go to no. — Go to Step 13
Replace
injection pump
Step Action Valve(s) Yes No
6E–216 ENGINE DRIVEABILITY AND EMISSIONS
13 Check ECT valve by Tech-II with actual condition.
If nearly equal, check ECT sensor in specification.
Within
specification
see the left
table Go to Step 14 Replace ECT
14 Check glow plug resistance. Within
specification Go to Step 15
Replace glow
plug
15 Check poor connection of glow plug, ECT sensor
ECM connector, PCU connector. Go to Step 16 Repair wiring
16 Check IAT sensor — Go to Step 17 Replace IAT
17 Check valve timing. See the procedure on the engine
mechanical. Within spec Go to Step 18 Adjust
18 Inspect injection nozzle spray pattern, opening
pressure.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Go to Step 19 Replace nozzle
19 Record data of Q-final, rpm, APS, MAF output(Air
weight) by TechII. Continuous record from idling to
stall condition is necessary for further engineering
study. Send this record to ISE representative. Go to Step 20 —
20 Replace ECM — Verify —
21 Ask the customer whether excessive white smoke
occurs during download slope.
Record download or flat slope. — Go to Step 22 —
22 Compare the particular vehicle with standard vehicle,
if excessive white smoke is confirmed, go to yes. If not
go to no. — Go to Step 25
Explain to the
customer it is
within standard
23 Ask the customer whether he or she use proper fuel.
1. Diesel fuel cetane index.
2. No gasoline.
3. No kelosin.
4. Bio chemical fuel.
5. No high sulfur fuel consult with ISUZU
representative. Proper fuel Go to Step 24
Replace fuel
and flash
Step Action Valve(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–217
24 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No immitation
no plugged,
no
deformation Go to Step 25 Correct them
25 Check intake shutter operation. (NKR 4JH1-TC only)
1. Should operate smoothly
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See the left
1-4
Smooth
operation Go to Step 26 Correct it
26 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 27
Correct it and
verify
27 Check any deformation, plugged at exhaust system.
No damage Go to Step 28
Correct it and
verify
Step Action Valve(s) Yes No
6E–218 ENGINE DRIVEABILITY AND EMISSIONS
28 Check turbine of turbo charger. See the procedure on
engine mechanical sectin.
— Go to Step 29 Correct it
29 Check over flow valve stuck open by foreign material.
— Go to Step 30
Remove foreign
material
30 Check injection pipe, fuel feed pipe damaged. No damage Go to Step 31 —
31 Check any fuel leakage. No leakage Go to Step 32 Repair leakage
32 Check TPS timer position by Tech-II. Compare actual
position and target position. If both are same, go to
yes. If both are not same, go to no. — Go to Step 33
Replace
injection pump
33 Check ECT valve by Tech-II with actual condition.
If nearly egnal, check ECT sensor in specification.
Within
specification
see the left
table Go to Step 34 Replace ECT
34 Does customer drive after run glow period?
See the system description on page of DTC P0380
glow device Malfunction.
During after run
period, Go to
step 35
Not during after
run period, Go
to step 39
35 Check glow plug resistance. Within
specification Go to Step 36
Replace glow
plug
36 Check poor connection of glow plug, ECT sensor,
ECM connector, PCU connector. Go to Step 37 Repair wiring
37 Check IAT sensor — Go to Step 38 Replace IAT
38 Check valve timing. See the procedure on the engine
mechanical. Within spec Go to Step 39 Adjust
Step Action Valve(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–219
39 Inspect injection nozzle spray pattern, opening
pressure.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Go to Step 40 Replace nozzle
40 Record data of Q-final, rpm, APS, MAF output(Air
weight) by TechII. Continuous record from idling to
stall condition is necessary for further engineering
study. Send this record to ISE representative. Go to Step 41 —
41 Replace ECM — Verify —
42 Ask the customer whether excessive white smoke
occurs during down road slope or flat.
Record the condition.
Go to Step
22-41
Go to Step
23-34
37-41
Step Action Valve(s) Yes No
6E–220 ENGINE DRIVEABILITY AND EMISSIONS
5. Excessive black smoke
Step Action Value(s) Yes No
1 Ask the customer what condition make excessive
black smoke.
1. Elevation
1) Sea level.
2) High elevation more than 2500 m.
2. Engine condition
1) Starting
2) Idling
3) Part load (Part throttle)
4) full load (WOT)
3. Does not pass FA smoke test?

1-1)-2-2)
step 2
1-1)-2-3)
step 16
1-1)-2-4)
step 21
1-1)-2-1)
step 25
1-2)-2)
step 29
1-2)-3)
step 29
1-2)-4)
step 29
3
step 30 —
2 Compare the claimed vehicle with any other vehicle.
Smoke level is same or not.

If smoke level is
same, explain
to the customer Go to Step 3
3 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged. — Go to Step 4 Correct them
4 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position
3. Stopper bolt position should be proper.
4. No vacuum stays.
See _page. — Go to Step 5 Correct it
5 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 6
Correct it and
verify.
ENGINE DRIVEABILITY AND EMISSIONS 6E–221
6 Check any deformation, plugged at exhaust system.
See the procedure.
See _page. — Go to Step 7
Correct it and
verify
7 Check turbine of turbo charger. See the procedure on
engine mechanical section of work shop manual.
— Go to Step 8
Engine speed is
not proper
Repair speed
sensor

Still NG

Repalce ECM
Coorect it
8 Check engine mode is in cranking mode or normal
mode.
Even engine speed seems to be high enough for
normal mode, Tech-II may show cranking model.
Check engine speed is OK between Tech-II reading
and revolution meter.
If ECM does not have or recognize right engine
speed, crank mode can continue.
Crank mode requests much more fuel quantity.
Crank mode
threshold Go to Step 9 —
9 Compare desire timer piston position (Desired
injection start) and actual timer piston position. (Actual
injection start)
Within
tolerance Go to Step 10
Raise engine
speed to more
than 3000 rpm
two or three
times and
check again. If
condition still
continue
replace
injection pump.
Step Action Value(s) Yes No
6E–222 ENGINE DRIVEABILITY AND EMISSIONS
10 Check the EGR valve stuck or not.
Procedure
• Remove vacuum hose
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGR valve.
• Check any foreign material at valve seat or stem
area.
— Go to Step 11
NG
Replace EGR
valve
11 Check ECT sensor resistance.
Compare it with the table below.
Within
specification
See the left
table
OK
Go to Step 12
NG
Replace ECT
12 Check injection nozzle spray pattern and opening
pressure.
If opening pressure is low than standard, it may cause
excessive black smoke.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
OK
Go to Step 13
NG
Replace
injection nozzle
13 Check whether excessive PCV oil pass through inlet
manifold.
If a lot of PCV oil appears, check PCV system. —
OK
Go to Step 14
Replace PCV
system
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–223
14 Check compression. See the procedure on the page
of engine mechanical section. —
OK
Go to Step 15 Repair
15 Check any damage at combustion room, piston, any
combustion related area. —
Repair and
verify
Repair and
verify
16 Go to 2, 3, 4, 5, 6, 7, 10, 11 — Go to Step 17 —
17 Check MAF sensor.
If MAT indicates much high than actual, it may cause
excessive black smoke.
Compare with
typical data Go to Step 18 Replace MAF
18 Check injection nozzle spray pattern, 1st/2nd stage
opening pressure.
If 1st stage opening pressure is lower than standard, it
may cause excessive black smoke.
Adjust and check again.
If 2nd stage opening pressure is high than standard, it
may cause excessive black smoke.
Adjust and check again.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Verify Go to Step 19
19 Compare fuel temperature on Tech-II.
If fuel temperature exhibit extremely low temperature,
it may cause excessive black. — Go to Step 20
Replace
injection pump.
20 Go to 13, 14, 15 — Verify Verify
21 Go to 2, 3, 4, 5, 6, 7, 10, 11, 17, 19 — Go to Step 22 —
22 Check injection nozzle spray pattern, 1st/2nd stage
opening pressure.
Lower opening pressure may cause excessive black
smoke.
Adjust and check again.
Opening
pressure
1st 19.5kpa/
199kg/cm
2
2ns 33.8kpa/
345kg/cm
2
Verify Go to Step 23
23 MAB may stuck, wave form may be œ.
Replace and check again. — Verify Go to Step 24
24 Go to 14, 15 — — —
25 Check any fuel leakage which cause air in fuel at fuel
supply, injection line. — Go to Step 26
Repair and
verify
26 If DTC of ECT appears, back up valve becomes
–30°C, black smoke may exhaust. — Repair Go to Step 27
27 If DTC of Timer piston appears, excessive black
smoke may exhaust. — See DTC. Go to Step 28
28 Go to 19, 17 — Verify Verify
29 Atmosphere sensor may indicate wrong data in
comparison with actual condition.
Compare atmosphere data by Tech-II with real
atmosphere.
If compare result shows different, replace ECM.
— Verify
Follow same as
1-1)-2-2)
2
or
1-1)-2-3)
16
or
1-1)-2-4)
21
30 Most of case deposit smoke in the exhaust system
cause temporary excessive smoke. Raise engine
speed to close to no load max. Check it again. — OK Verify
NG
Go to 1-1)-2-3)
procedure
Step Action Value(s) Yes No
6E–224 ENGINE DRIVEABILITY AND EMISSIONS
6. Hesitation 7. Surge/Sag
Step Action Value(s) Yes No
1 Verify the customer complain
Is the complain hesitation/flatness or sug/surge?

Hesitation/
flatness
Go to Step 2
Sug/Surge
Go to Step 21 —
2 Check the tire specification
NKR tire spec.
Within
specification Go to Step 3
Replace to the
specified tire
3 Check the load on the vehicle. Are those exceeded to
the standard?
Within
standard Go to Step 4
Adjust to the
standard weight
4 Ask the customer whether he or she uses proper fuel. Proper fuel Go to Step 5 Change fuel
5 Check the fuel level in the fuel tank. Sufficient
level of, fuel in
the fuel tank Go to Step 6
Add fuel and
bleed air
6 Check fuel feed pipe pinched, deformed or fuel
leakage
No pinched
No deformed
No fuel
leakage Go to Step 7 Repair
7 Check sedimenter light on or not. If sedimenter light
stays on, frozen water may cause plugged fuel line at
fuel filter. No light on Go to Step 8 Drain water
8 Check Air in fuel. See the procedure in engine
mechanical section. No air Go to Step 9 Bleed air
9 Ask customer whether this happens at only around
0°C or less temperature. Waxing might cause
plugged fuel flow. —
Change to
winter type fuel Go to Step 10
10 Check vehicle speed with another vehicle. Possible
different type speed sensor is installed. Gear NKR and
speed sensor NPR. — Go to Step 11 Replace it
11 Check APS sensor opening angle and Tech-II data. If
different, replace it. — Go to Step 12 Replace it
12 Check ETC sensor data by Tech-II, compare with
actual engine coolant temperature. ECT sensor
indicates same
as actual
Go to Step 14
ECT sensor
shows different
valve from
actual data
Go to Step 13
Surgi
rpm
Hesitation
Flatness
Expectation
Time
Sug
Definifion of engine performance
ENGINE DRIVEABILITY AND EMISSIONS 6E–225
13 Check ECT sensor with the following table.
Within
specification Go to Step 14
Replace and
verify
14 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged.
No after
marked
No plugged,
No
deformation Go to Step 15 Correct them
15 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper
4. No vacuum stays.
Go to Step 16 Correct it
16 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 17
Correct it and
verify
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
6E–226 ENGINE DRIVEABILITY AND EMISSIONS
17 Check any deformation, plugged at exhaust system.
See the procedure.
— Go to Step 18
Correct it and
verify
18 Check turbine of turbo charger.
See the procedure.
— Go to Step 19 Correct it
19 Check MAF actual data with typical data. Within typical
data Go to Step 20 Repair
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–227
20 Check the EGR valve stuck or not.
Procedure
• Remove vacuum hose.
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGR valve.
• Check any foreign material at valve seat or stem
area.
— Go to Step 21
NG
Replace EGR
valve.
21 Check turbo waste gate. — Go to Step 22 Repair
22 Compare MAF valve with typical data.
If MAF is not typical data, boost control and EGR
becomes poor. — Go to Step 23 Repair
23 Compare engine revolution by Tech-II and engine
revolution meter.
If different,
1. Check speed sensor,
2. Check ECM.
Repair or replace malfunction parts. — Go to Step 24 Repair
24 Check EVRV function.
— Go to Step 25
Replace or
repair
25 Check injection nozzle spray pattern, 1st/2nd opening
pressure.
Opening
pressure
1st
2nd Go to Step 26 Repair
Step Action Value(s) Yes No
6E–228 ENGINE DRIVEABILITY AND EMISSIONS
26 Check timer piston movement.
Plot graph by SOL, LST.
Record engine speed, timer piston SOL IST, ECT
sensor, IAT sensor, MAF.
— Go to Step 27
Replace
injection pump
27 Raise engine speed up to max two or three times.
Check it again. —
Injection pump
replace verify —
28 Go to 2, 3. — Go to Step 29 —
29 Check A/C compressor wiring harness. If A/C on
request signal harness is cut off, ECM does not
recognize ECM input. It may cause surge or sug. — Go to Step 30 —
30 Check any accessory, additional load such as
compressor, ITO loads. — Go to Step 31 Remove it
31 Go to 4, 5, 6-27. — Verify —
Step Action Value(s) Yes No
rpm
SOL
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ENGINE DRIVEABILITY AND EMISSIONS 6E–229
EGR control logic
ON
+5°C 10°C
OFF
+ Atomasphere
temp
Engine Revolution
APS Input
ON
1500rpm
OFF
+ Atomasphere
pressure
+ Water
temp
6E–230 ENGINE DRIVEABILITY AND EMISSIONS
8. Lack of power
Step Action Valve(s) Yes No
1 Ask the customer the following condition.
1. During the acceleration
2. During the climbing

1. Go to Step
2
2. Go to Step
25 —
2 Check the vehicle performance.
0-400m sec
40-60km/h sec

In the
specification
Explain to the
customer Go to Step 3
3 Check the tire size. spec Go to Step 5 Replace tires
4 Check APS whether APS moves smoothly or
excessive free play. — Go to Step 13 —
5 Compare the complained vehicle with another vehicle
about the vehicle speed. — Go to Step 6 Repair
6 Check the load on the vehicle. If overload, remove
exceeded part of load. Check the power performance. — OK Go to Step 6
7 Ask the customer whether he or she proper fuel — Go to Step 8 Change fuel
8 Check the fuel level.
— Go to Step 9
Add fuel and
bleed air
9 Check fuel feed pipe pinched, deformed or fuel
leakage.
No pinched
No deformed
No fuel
leakage Go to Step 10 Repair
10 Check sedimentary light on or not. If sedimentary light
stays on, frozen water may cause plugged fuel line at
fuel filter.
No light on Go to Step 11 Drain water
11 Check Air in fuel. See the procedure in section. No air Go to Step 12 Bleed air
12 Remove injection nozzle.
1. Check injection patter is OK.
2. Check injection opening pressure. No problem Go to Step 13 Repair & verify
Fuel sedimenter/fuel filter Fuel feed line
ENGINE DRIVEABILITY AND EMISSIONS 6E–231
13 Check ECT sensor resistance. See ECT sensor look
up table.
ECT sensor
within
specification
See the left
table Go to Step 14
Replace &
verify
14 Check TPS position by Tech II. Is data within typical
data?
Within
specification Go to Step 15
Raise engine
speed two or
three times and
check œ
condition still
continue
Replace
injection pump
15 Replace fuel sedimenter filter. Check TPS position
becomes within typical data. — verify Go to Step 16
16 Remove MAF, check whether MAF works in
specification. — Go to Step 17 Replay MAF
17 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged. — Go to Step 18 correct them
18 Check intake shutter operation.
1. Should operate smoothly.
2. Should reform to stop bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
— Go to Step 19 Correct it
Step Action Valve(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
6E–232 ENGINE DRIVEABILITY AND EMISSIONS
19 Check the compressor of turbo changer operation.
1. Remove inlet pipe.
2. Turn compressor fins manually
3. Check oil deposit.
4. Clean them.
Operate
smoothly Go to Step 20
Correct it and
verify
20 Check any deformation, plugged at exhaust system.
See the procedure.
— Go to Step 21
Correct it and
verify
21 Check turbine of tanks changer. See the procedure. — Go to Step 22 Correct it
22 Check waste gate operation. If waste gate stuck open,
power loss may happen. — Go to Step 23 NG Repair
23 Replace injection pump
SPV valve may have foreign materials. — Verify —
24 Check the EGR valve stuck or not.
Procedure
• Remove vacuum hose.
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGR valve.
• Check any freign material at valve seat or stem
area.
— Go to Step 24
Replace EGR
valve
25 Check the vehicle performance. — — Go to Step 26
26 Go to Step 3 ~ 24 — — —
Step Action Valve(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–233
9. Poor fuel consumption
Step Action Value(s) Yes No
1 Ask the customer how many km/l is recorded.
Compare the standard data with claim fuel
consumption. If data indicates difference between
them, drive the following condition.
Note: Set driving course for fuel consumption test.
within
specification
explain to the
customer 2
2 Check the vehicle condition.
1. Tire
2. Accessory installation after market Air
conditioning
3. Towing or not
4. PTO — Go to Step 3
Change to the
standard
condition
3 Ask the customer what kind of fuel he or she uses.
If possible, measure the specific gravity, check the
measured specific gravity meet to the standard. proper fuel Go to Step 4 Replace
4 Ask the customer what kind of engine oil he or she
uses.
oil viscosity 10w–40
10w–30
Ask the customer when change the interval.
Refer to the owner’s manual.
Check oil viscosity by hand.
If oil viscosity is high, replace it.
10w–40
10w–30 Go to Step 5
5 Check any fuel leakage at fuel system. OK Go to Step
Go to Step 6
6 Measure timer piston movement by Tech-II.
— Go to Step 7
Raise engine
speed and
verify it NG.
Replace
injection pump.
7 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged. — Go to Step 8 Correct them
Use the applicable standard or equivalent for diesel fuels.
DIESEL FUELS
DIESEL FUEL/APPLICABLE STANDARD
JIS
(JAPANESE INDUSTRIAL STANDARD)
Based on K2204 GAS
OIL
DIN
(DEUTSCHE INDUSTRIE NORMEN)
Based on EN590: 1997
SAE
(SOCIETY OF AUTOMOTIVE ENGI-
NEERS)
Based on SAE J-313C
BS
(BRITISH STANDARD)
Based on BS EN590:
1997
rpm
SOL
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6E–234 ENGINE DRIVEABILITY AND EMISSIONS
8 Check intake shutter operation.
1. Should operate smoothly.
2. Should reform to stop bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
Operate
smoothly
See item 1-4
on the left Go to Step 9 Correct it
9 Check the compressor of turbo charger operation.
1. Return inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit.
4. Clean them.
operate
smoothly Go to Step 10
Correct it and
verify
10 Check any deformation, plugged at exhaust system.
No
deformation,
no plugged Go to Step 11
Correct it and
verify
11 Check turbine of turbo charger see the procedure. — Go to Step 12 Correct it
Step Action Value(s) Yes No
ENGINE DRIVEABILITY AND EMISSIONS 6E–235
12 Check the EGR valve stuck or not.
Procedure
• Remove vacuum hose.
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGK valve.
• Check any foreign material at valve seat or stew
area.
— Go to Step 13
Replace EGK
valve
13 Check turbo waste gate. — Go to Step 14 Repair
14 Compare MAF valve with typical data.
If MAF is not typical data, boost control and EGK
becomes poor. — Go to Step 15 Repair
15 Compare engine revolution by Tech-II and engine
revolution meter. If different,
1. Check speed sensor,
2. Check ECM. Repair or Replace malfunction parts. — Go to Step 16 Repair
16 Check EVRV function
— Go to Step 17
Replace or
repair
17 Inspect APS sensor operation. — Go to Step 18 —
18 Inspect MAT sensor output, comparing with
atmosphere temperature. Use T-II. — Go to Step 19
Step Action Value(s) Yes No
6E–236 ENGINE DRIVEABILITY AND EMISSIONS
19 Inspect ECT sensor, compare with the following table.
— Go to Step 20
20 Inspect atmosphere sensor with actual atmosphere.
Nearly equal is OK. — Go to Step 21 —
21 Check the EGK valve stuck or not.
Procedure
• Remove vacuum hose.
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGK valve.
• Check any foreign material at valve seat or stew
area. — Go to Step 22
Replace EGK
valve
22 Check turbo waste gate. — Go to Step 23 Replace
23 Compare MAF valve with typical data. If MAF is not
typical data, boost control and EGK becomes poor. — Go to Step 24 Repair
24 Compare engine revolution by Tech-II and engine
revolution meter.
If different,
1. Check speed sensor.
2. Check ECM.
Repair or replace malfunction parts. — Go to Step 25 Repair
25 Check EVRV function.
— Go to Step 26
Replace or
repair
26 Check injection nozzle spray pattern, 1st/2nd opening
pressure.
opening
pressure
1st
2nd — Repair
Step Action Value(s) Yes No
°C OHMS
Temperature vs. Resistance Values (approximate)
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
ENGINE DRIVEABILITY AND EMISSIONS 6E–237
SPECIAL SERVICE TOOLS
ILLUSTRATION PART NO. PART NAME REMARKS
Connector Test Adapter Kit
KM 609 Electronic Kits
5-8840-2392-0 High Impedance Multimeter
(Digital Voltmeter -DVM)
Tech-II Refer to the ISUZU service
Bulletin
5-8840-0378-0 Pressure Gauge
5-8840-0279-0 Vacuum Pump with Gauge
Electronic kit
6E–238 ENGINE DRIVEABILITY AND EMISSIONS