4jvp44-we-0112.pdf

WORKSHOP MANUAL TF SERIES, NKR

ENGINE DRIVEABILITY AND EMISSIONS ENGINE with TF 4JA1-TC/TF 4JH1-TC/ NKR 4JH1-TC Bosch VP44 System SECTION 6E

NOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section - 0A under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.

Applicable Model : TFR/S 54, TFR/S 77, NKR 77

This manual is applicable to 2001 year model and later vehicles.

INDEX ENGINE DRIVEABILITY AND EMISSIONS

6E–1

ENGINE with TF 4JA1-TC/TF 4JH1-TC/NKR 4JH1-TC Bosch VP44 system ENGINE DRIVEABILITY AND EMISSIONS CONTENTS ISUZU Strategy Based Diagnostics .............. Overview .................................................... STRATEGY BASED DIAGNOSTICS CHART .................................................... Diagnostic Thought Process ...................... 1. Verify the Complaint .............................. 2. Perform Preliminary Checks .................. 3. Check Bulletins and Troubleshooting Hints ........................................................ 4. Perform Service Manual Diagnostic Checks ..................................................... 5a and 5b. Perform Service Manual Diagnostic Procedures ............................ 5c. Technician Self Diagnoses .................. 5d. Intermittent Diagnosis .......................... 5e. Vehicle Operates as Designed ............ 6. Re-examine the complaint ..................... 7. Repair and Verify Fix ............................. Specification difference ............................. TF 4JA1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission) ............................ TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Automatic Transmission) ........................ TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission) ............................ N*R 4JH1-TC with Bosch VP44 System ECM Wiring Diagram .................. TF 4JA1-TC/4JH1-TC ECM Pinouts .......... N*R 4JH1-TC ECM Pinouts ....................... NKR (4JH1-TC) TF (4JA1-TC, 4JH1-TC) PCU Pinouts ............................................ TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC, Specifications ................................................ Tightening Specifications ........................... TF 4JA1-TC with Bosch VP44 System Component Locator .................... TF 4JA1-TC with Bosch VP44 System Component Locator ....................

6E-4 6E-4 6E-4 6E-5 6E-5 6E-5 6E-6 6E-6 6E-6 6E-6 6E-7 6E-8 6E-9 6E-9 6E-10

6E-11

6E-12

6E-13 6E-14 6E-15 6E-18 6E-21 6E-22 6E-22 6E-23 6E-24

TF 4JA1-TC/4JH1-TC TDC Sensor Location ................................................... TF 4JA1-TC, 4JH1-TC with Bosch VP44 System Component Locator .................... TF 4JH1-TC with Bosch VP44 System Component Locator .................... TF 4JH1-TC with Bosch VP44 System Component Locator .................... N*R 4JH1-TC with Bosch VP44 System Component Locator .................... N*R 4JH1-TC with Bosch System Component Locator ................................. N*R 4JH1-TC with Bosch System Component Locator ................................. N*R 4JH1-TC with Bosch VP44 System Component Locator .................... N*R 4JH1-TC with Bosch VP44 System Component Locator .................... NKR 4JH1-TC with Bosch VP44 System Component Locator .................... TF 4JA1-TC Fuse Box ............................... TF 4JH1-TC Fuse Box ............................... N*R 4JH1-TC Fuse Box ............................. N*R 4JH1-TC Fuse and Relay Panel ........ N*R 4JH1-TC Relay Panel ........................ Abbreviations Charts ................................. Injection pump Control System .................. TDC Sensor ............................................... Engine Coolant Temperature (ECT) Sensor ..................................................... Vehicle Speed Sensor (VSS) ..................... TDC (Engine Speed) Sensor ..................... ECM System Diagram – No.1 .................... ECM System Diagram – No.2 .................... MAF/IAT Sensor Circuit ............................. ECM System Diagram – No.3 .................... ECM System Diagram – No.4 .................... ECM System Diagram – No.5 .................... General Service Information ...................... Serviceability Issues .................................. Non-OEM Parts .........................................

6E-25 6E-26 6E-27 6E-28 6E-29 6E-30 6E-31 6E-32 6E-33 6E-34 6E-35 6E-36 6E-37 6E-38 6E-39 6E-40 6E-41 6E-42 6E-42 6E-42 6E-42 6E-43 6E-44 6E-45 6E-46 6E-47 6E-48 6E-49 6E-49 6E-49

6E–2

ENGINE DRIVEABILITY AND EMISSIONS

Poor Vehicle Maintenance ......................... Related System Faults ............................... On-Board Diagnostic (OBD) ...................... On-Board Diagnostic (Self Diagnosis System) Tests ................ The Diagnostic Executive .......................... Diagnostic Information ............................... Check Engine Lamp .................................. Data Link Connector (DLC) ....................... Reading Flash Diagnostic Trouble Codes . Reading Diagnostic Trouble Codes Using a TECH 2 ................................................. Clearing Diagnostic Trouble Codes ........... History DTC ............................................... Tech2 ........................................................ Tech2 Features ......................................... Getting Started .......................................... Operating Procedure (For Example) ......... DTC ........................................................... DTC Information Mode .............................. Engine ....................................................... History ....................................................... Clear DTC Information ............................... Tech2 Data Display ................................... Plotting Snapshot Graph ........................... Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) ................................. Flow Chart for Snapshot Replay (Plotting Graph) ....................................... How To Use Breaker Box .......................... Breaker Box Connection Type A for Open Circuit Check, Short to Ground Check and Short to Battery Check ..................... Breaker Box Connection Type B for Power, Signal Voltage Check between ECM and Sensors ............................................ How To Use TIS2000 Snapshot Analysis .. Snapshot Display ....................................... Typical Scan Data Values ......................... TF 4JA1-TC .......................................... TF 4JH1-TC (MT) ................................. TF 4JH1-TC (AT) .................................. NKR 4JH1-TC ....................................... Engine Data Definitions ............................. On-Board Diagnostic (OBD) System Check ...................................................... Circuit Description ..................................... Diagnostic Aids .......................................... Test Description ......................................... On Board Diagnostic (OBD) System

6E-49 6E-49 6E-49 6E-49 6E-49 6E-49 6E-49 6E-49 6E-51 6E-51 6E-51 6E-51 6E-52 6E-52 6E-53 6E-53 6E-54 6E-54 6E-54 6E-54 6E-54 6E-54 6E-55

6E-56 6E-57 6E-58

6E-59

6E-60 6E-61 6E-61 6E-65 6E-65 6E-66 6E-67 6E-68 6E-70 6E-83 6E-83 6E-83 6E-83

Check ...................................................... No Check Engine Lamp ............................. Diagnostic Aids .......................................... Test Description ......................................... No Check Engine Lamp ............................. Check Engine Lamp “ON” Steady ............. Circuit description ...................................... Diagnostic Aids .......................................... Test Description ......................................... Check Engine Lamp “ON” Steady ............. DTC P0100 MAF SENSOR MALFUNCTION .............. DTC P0110 IAT Sensor Maifunction ........................... DTC P0115 Engine Coolant Temperature Sensor Malfunction .................................. DTC P0180 SUB CODE 1011 FUEL TEMPARETURE SENSOR CIRCUIT RANGE/PERFORMANCE ....... DTC P0215 FUEL CUTOFF SOLENOID VALVE MALFUNCTION .......................... DTC P0216 TIMING DEVICE DEVIATION ................. DTC P0216 TIMING DEVICE FLUCTUATION ............ DTC P0251 INJECTION MALFUNCTION ................... DTC P0335 TDC MALFUNCTION .............................. DTC P0380 GLOW DEVICE MALFUNCTION ............ DTC P0381 GLOW TIME TELLTALE CIRCUIT MALFUNCTION ....................... DTC P0400 EGR SYSTEM MALFUNCTION .............. DTC P0500 VSS MALFUNCTION ............................... DTC P0560 SYSTEM VOLTAGE MALFUNCTION ..... Circuit Description ...................................... DTC P0561 SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION DTC P0606 ECM Malfunction1 ................................... DTC P0606 ECM Malfunction2 ................................... DTC P0645 A/C COMPRESSOR CUTOFF

6E-84 6E-85 6E-85 6E-85 6E-86 6E-88 6E-88 6E-88 6E-88 6E-89 6E-90 6E-98

6E-102

6E-106

6E-108 6E-114 6E-115 6E-116 6E-119 6E-126

6E-131 6E-134 6E-141 6E-144 6E-144

6E-148 6E-150 6E-150

ENGINE DRIVEABILITY AND EMISSIONS RELAY MALFUNCTION .......................... DTC P0703 BRAKE-LIGHT SWITCH CIRCUIT MAIFUNCTION ........................................ DTC P0704 CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION ....................................... DTC P1105 BAROMETRIC PRESSURE SENSOR (BP) MALFUNCTION .............................. DTC P1110 INTAKE SHUTTER VSV (DIESEL) MALFUNCTION (NKR 4JH1-TC only) ..... DTC P1120 AP SENSOR MAIFUNCTION .................. DTC P1173 FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE ......... Fuel Reduction adjustment ........................ NKR 4JH1-TC ............................................ TF 4JH1-TC, 4JH1-TC .............................. DTC P1173 FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 1 .............. DTC P1173 FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 2 .............. DTC P1345 INJECTION PUMP:CAMSHAFT SPEED MALFUNCTION ......................... DTC P1520 NEUTRAL SWITCH ................................. DTC P1576 EXHAUST BRAKE VALVE1 CIRCUIT MALFUNCTION ....................... DTC P1605 EEPROM DEFECT .................................. 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 ........................... DTC P1625 Power supply relay malfunction ............... DTC P1630 FUEL-INJECTION QUANTITY CIRCUIT MALFUNCTION ....................... DTC P1650 CAN: DEVICE MALFUNCTION ...............

6E-151

6E-157

6E-160

6E-162

6E-163 6E-167

6E-173 6E-173 6E-173 6E-173

6E-175

6E-175

6E-176 6E-177

6E-180 6E-186 6E-187 6E-187

6E-187 6E-187 6E-188

6E-189 6E-190

6E–3

DTC P1651 INJECTION PUMP: CAN MALFUNCTION .............................. DTC P1651 SUB CODE 1010 INJECTION PUMP: CAN MALFUNCTION .............................. DTC P1651 SUB CODE 1011 CAN RECEIVEDS ERROR ..................... DTC P1690 MALFUNCTION INDICATION LAMP (MIL) CIRCUIT MALFUNCTION ..............

6E-195

Symptom chart & perform procedure .......

6E-198

1-1. No cranking happens. ......................... 1-2. Starter can crank engine, but seems to be lower than usual. ........... 1-3. Cranking speed seems to be OK, but no combustion sounds can be heard. 1-4. Engine run as idle speed, but can not raise engine speed to usual engine speed zone. ........................ 1-5. Engine stall after engine speed reach more than 2000 rpm. ............................... 2. Engine stall ............................................ 2-1 Engine stall at idling. ............................ 2-2 Engine stall after engine revolution becomes more than idling speed. Undershoot stall. ...................................... 3. Rough idle .............................................. 4. Excessive white smoke. ......................... 5. Excessive black smoke .......................... 6. Hesitation 7. Surge/Sag ...................... 8. Lack of power ........................................ 9. Poor fuel consumption ........................... SPECIAL SERVICE TOOLS ......................

6E-199

6E-192

6E-192 6E-194

6E-199 6E-200

6E-203 6E-206 6E-208 6E-208

6E-212 6E-214 6E-217 6E-223 6E-227 6E-233 6E-236 6E-240

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

Diagnostic Thought Process As you follow a diagnostic plan, every box on the Strategy Based Diagnostics chart requires you to use the diagnostic thought process. This method of thinking optimizes your diagnosis in the following ways: • Improves your understanding and definition of the customer complaint • Saves time by avoiding testing and/or replacing good parts • Allows you to look at the problem from different perspectives • Guides you to determine what level of understanding about system operation is needed: – Owner’s manual level – Service manual level – In-depth (engineering) level – Owner’s manual level – Service manual level – In-depth (engineering) level

1. Verify the Complaint What you should do To verify the customer complaint, you need to know the correct (normal) operating behavior of the system and verify that the customer complaint is a valid failure of the system. The following information will help you verify the complaint: • WHAT the vehicle model/options are • WHAT aftermarket and dealer-installed accessories exist • WHAT related system(s) operate properly • WHEN the problem occurs • WHERE the problem occurs • HOW the problem occurs • HOW LONG the condition has existed (and if the system ever worked correctly) • HOW OFTEN the problem occurs • Whether the severity of the problem has increased, decreased or stayed the same

What resources you should use Whenever possible, you should use the following resources to assist you in verifying the complaint: • Service manual Theory or Circuit Description sections • Service manual “System Performance Check” • Owner manual operational description • Technician experience • Identical vehicle for comparison

• • • •

6E–5

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, https://www.einet.isuzu. co.jp// • Videotapes • Service manual

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

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

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 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 dealerinstalled equipment (radios, telephone, etc.) Step 2: Isolate the problem At this point, you should have a good idea of what could cause the present condition, as well as could not cause the condition. Actions to take include the following: • Divide (and separate, where possible) the system or circuit into smaller sections • Confine the problem to a smaller area of the vehicle (start with main harness connections while removing panels and trim as necessary in order to eliminate large vehicle sections from further investigation) • For two or more circuits that do not share a common power or ground, concentrate on areas where harnesses are routed together or connectors are shared (refer to the following hints) Hints Though the symptoms may vary, basic electrical failures are generally caused by: • Loose connections: – Open/high resistance 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

6E–7

• 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.

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

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.

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.

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.

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.

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 • • • •

Vehicle service information (service manual, etc.) ISUZU field support Experience Identical vehicle or system for comparison

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

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

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–9

6E–10

ENGINE DRIVEABILITY AND EMISSIONS Specification difference

Vehicle Model

TF

Engine

NKR 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

730rpm± 25rpm at 80°C

700rpm± 25rpm MT, AT at 80°C

700rpm± 25rpm at 80°C

Idle

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

ABS

not available

not available

not available

not available

EC

HK

Taiwan

standard

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)

BATT

RELAY ; ECM MAIN

0.5L/B IC04

VSV ; EXT 1

A-4

B29(105)

A-5

B13(91)

0.5L/R IC17 VSV ; EXT 2

B22(98)

B-3

0.5G/R IC46

A-16

FUEL HEATER

B25(101)

B6(87)

SW ; NEUTRAL 0.5L/R IC09 SW ; BACK UP

B-10

0.5B/W IC10

2B IZ01

A61(2)

2B IZ02

A62(1)

0.5R/L MB11

RESISTER ; NEUTRAL SW (IDLE SW) 0.5B IZ10

0.5B/W IC58

CONT ; IMMOBILIZER(B8)

5B/R HB03

B12(90)

B-10 IZ05

0.5G IC48

2

J/C ; B

0.5G IC07

(OFF)

0.5Y IC08

0.5R CA02

TDC

3

0.5G CA01

(OFF) SW ; CLUTCH

GLOW PULG x4 B-2

0.5W IC45

1

EB STOP 10A

A28(31)

(ON)

0.5W/B IC13 RESISTER ; CLUTCH SW (YZK NO ; 7321-9900) 0.5Y 0.5B 510 IC57 IZ08

ACG(B)

B8(89)

A65(65)

0.85W KA01

B15(93)

BACK 15A

SW ; BRAKE 0.5R IC12

0.5B/R IC50

B-1

JOINT TO SX01

METER 15A 0.85Y MA01

0.5GR IC44

0.5B HY05

0.5B/L HB06 0.5L/Y IC06

B16(94) A36(39)

ENGINE 10A

IZ06

IZ07

ECT sensor

B-7

JOINT TO BA15

A55(57)

A27(30) 0.5B/P IC43

0.5G/R BA26

3B/R PA17

A44(46)

0.5B BX16 0.5BR/R IC14

3W PA16

SW ; ENG WARMING JOINT TO MX01

A35(38)

A-9

0.5B/G IC38

0.5L/R IC15

2

OFF ACC IG2 ST IG1 3B/R

A47(49)

4 5 3 1

RELAY ; GLOW

A-8

A-7

IC27 IC28 IC30 IC39

SW ; THERMO

0.5G/O IC37

A69(69)

0.5W/R 0.5G/R 0.5B/R 0.5B/L

B2(83) B7(88) B14(92) B3(84)

MAF

A-6

3W PA13

0.5 IZ04 T.P.S.&SW ; IDLE (THROTTLE VALVE)

0.5G/B IC35 0.5R/G IC36

0.5L/R IC16

SW ;IGNITION

0.5B/O IC26

B19(97)

3W B2 PA03 3W/B B1 PA02

0.5L/R IC18 EVRV ; EGR

5R/W HB01

0.5 IZ03

0.5W/R IC23

A59(61)

8W PA28

0.5W/B IC22

A37(40)

MAIN 80A

A56(58)

B23(99)

IG2 40A

1

2L/R IC05

GLOW 50A

INJ.PUMP

4

B24(100)

A-3

8B/R PA01

2 3

A41(3)

IG.1 50A

A63(63)

ECM 25A

A-2

0.5B/Y IC03

3B PA28

0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

2L/R IC02

2B/Y IC01

A-15

0.5L/R IC11

2L/R IC02

0.5B IZ05

A-1

0.85Y KA01 B-11 0.85R/Y KA02 A-11 0.85Y MA02

VEHICLE SPEED SENSOR 0.85B MX05 THERMO UNIT

A-12 0.5L/B MA03 B-14 0.5Y/B MA06

A32(35)

METER ENG COOLANT

B6

OIL PSESSURE UNIT

OIL GAGE 0.5Y/G MA09

4WD SW

0.5B IZ06

ECM

B-6

0.5W/R MA11

B15

B-5

0.5L MA10

A10

SW ; OIL

A24(27)

0.5B/R MA05

B3

A68(68)

0.5L/W IC21

A38(41)

0.5O/B MB04

0.5B/L EX02

0.5L IC47

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR) 0.5G HA22 A43(45) A30(33)

SPEED METER A8

A9

RELAY ; A/C COMPRESSOR

B-5

0.5B EX03

B2 ENG

TACHO METER 0.5O/L MB01

JOINT TO EX12

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

CONT ; IMMOBILIZER(B5)

A39(42)

A6

GLOW CHECK

BRAKE LAMP

B8

OIL

BACK UP LAMP

0.5O/L MA28 0.5BR/Y IC29

A40(43)

4WD

0.5G HA18

0.5BR HA23 0.5G/R HA13

ELEC.THERMO 0.5G HA21 RESISTER ; IDLE UP 0.5B 0.5G 270 HA24 HX03

4

1

0.5BR HA19

2

0.5BR HA17

1 0.5L/W HA14 4

FUSE ; BLOOR

2 0.5G/W HA16

RELAY ; A/C THERMO

SW ; PRESSURE ECM

CONT ; IMMOBILIZER(B1)

0.5G IC30

REV

060RY00393

6E–12

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Automatic Transmission)

2L/R IC02

0.5L/R IC15

J/C ; B

3W PA16

3W PA13

EB STOP 10A

ACG(B)

0.5G CA01 BACK 15A 0.85W KA01

0.85Y MA01

SW ; BRAKE 0.5R IC12 0.5W/B A65(65) IC13

METER 15A

ENGINE 10A

IZ05

3B/R PA17

B12(90)

OFF ACC IG2 ST IG1 3B/R

0.5G/W HA16

B22(98)

A-9

FUSE ; BLOOR

B2

1 0.5L/W 2 HA14

4

B1

ELEC.THERMO 0.5G/R HA13 0.5G HA21 RESISTER ; IDLE UP (YZK NO ; 7321-9430) 0.5B 0.5G HX03 HA24 270 0.5B/L HB06 B16(94) 0.5L/Y IC06 A36(39) A30(33)

RELAY ; GLOW

A-8

SW ;IGNITION

0.5G/R IC46

FUSE ; A/C

RELAY ; A/C THERMO

0.5G HA23

A27(30)

2

3W PA03 3W/B PA02

A-7

0.5L/W HB04

0.5W IC45

B8(89)

5R/W HB01

TDC

3

B-6

2 0.5BR HA17

SW ; THERMO

ECT sensor 1

0.5O IC44

B15(93)

4

B-1 0.5G HA18

0.5B HX22

B-5

0.5L/R IC11

1

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR)

0.5B/P IC43

0.5BR HA15

A38(41)

0.5BR HA19

0.5 IZ03

RELAY ; A/C COMPRESSOR

8W PA28

4 5 2 3 MAF 1

MAIN 80A

B13(91)

0.5W/R IC27 0.5G/R IC28 0.5B/R IC30 0.5B/L IC39

8B/R PA01

A-5

0.5L/B IC04

IG2 40A

B29(105)

B2(83) B7(88) B14(92) B3(84)

IG.1 50A

A-4

A56(58)

GLOW 50A

1

B23(99)

2L/R IC05

ECM 25A

4

A-3

A41(3)

IC11 HB04 HA15 IC15 HA19

3B PA28

INJ.PUMP

3

B24(100)

0.5L/R 0.5L/W 0.5L/R 0.5L/R 0.5L/R

2B/Y IC01

0.5B/Y IC03

0.5L/R IC62 A63(63) A-2

0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

2

BATT

RELAY ; ECM MAIN A-15

2L/R IC02

(ON) (OFF)

B25(101) GLOW PULG x4 A-16

A C B

0.5G/B IC35 0.5R/G IC36

C-15

A69(69)

R

A47(49)

N D

A-10 0.85R/Y KA02 C-10 0.5W/R OA57 C-3

2

C-4

1

C-2

N

0.5B/W LA06 C-14 0.5B/G LA09 A-1

0.5G/O IC37

A35(38)

0.5B/G IC38

A55(57) IZ07

B

2B IZ02

A62(1)

0.5R/L MB11

A32(35)

A-11

SW ; MODE VEHICLE SPEED SENSOR

10 11 31 TCM 32 47 48

FUSE ; STARTER RELAY ; STARTER

0.85Y MA02

A-12 0.5L/B MA03

0.85B MX05 THERMO UNIT

0.85R/Y KA02

CONT ; IMMOBILIZER(B8)

A61(2)

0.5R/G OA10 0.5R/Y OA11 0.5W/R OA31 0.5Y/R OA32 0.5Y/L OA58 0.5Y/V OA59

B-4

ECM 2B IZ01

0.5R/B IC61

P

ENG COOLANT B-3

0.5G IC48

T.P.S.&SW ; IDLE (THROTTLE VALVE)

F

0.5R/B IC60

0.5R CA02

0.5 B IZ04 E

B6(87)

5B/R HB03

B6

0.5Y/B MA06

OIL PSESSURE UNIT

OIL GAGE 0.5Y/G MA09 0.5W/R MA11(W/SOF) TB07(W/O SOF)

B15

A-6

0.5L MA10

A10

SW ; OIL

0.5O/L MA18

B8

A39(42)

0.5BR/R IC29

A6

A24(27)

0.5B/R MA05

B3

A40(43)

4WD

OIL GLOW

CHECK

B2 ENG

TACHO METER

0.5L IC47

A68(68) A43(45)

A46(48) A26(28)

OA25

0.5B EX03

0.5L/W IC21 0.5R/Y OA60 0.5B/R OA06

SPEED METER A8

BACK UP LAMP

0.5O/B MB04

B-2

BRAKE LAMP

CONT ; IMMOBILIZER(B5)

0.5B/L EX02

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

JOINT TO EX12

4WD SW

0.5B IZ06

A9

25 37

5

OA05 METER

6 ENG EARTH

0.5B OX01

TCM

0.5O/L MB01

CONT ; IMMOBILIZER(B1)

0.5G IC48

060RY00394

ENGINE DRIVEABILITY AND EMISSIONS

6E–13

TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission)

RELAY ; ECM MAIN A-15

2L/R IC02

8W PA28 BACK 15A

(OFF) SW ; CLUTCH 0.5G IC07

0.5G IC48

T.P.S.&SW ; IDLE (THROTTLE VALVE)

A

0.5G/B IC35 0.5R/G IC36

A69(69)

A-16

5B/R HB03

A-1

0.85Y KA01

A47(49)

C

0.5G/O IC37

A35(38)

B

0.5B/G IC38

A55(57)

SW ; BACK UP

IZ07

A-10 0.85R/Y KA02 A-11 0.85Y MA02

ECM 2B IZ01

0.85B MX05

A61(2)

VEHICLE SPEED SENSOR

A-12 0.5L/B MA03 ENG COOLANT

THERMO UNIT

2B IZ02

A62(1)

0.5R/L MB11

A32(35)

B-3

0.5Y/B MA06

B6

OIL PSESSURE UNIT CONT ; IMMOBILIZER(B8)

OIL GAGE 0.5Y/G MA09

4WD SW

0.5W/R MA11(W/SOF) TB07(W/O SOF)

B15

A-6

0.5L MA10

A10

SW ; OIL

0.5O/L MA18

B8

0.5BR/R IC29

A24(27)

0.5B/R MA05

B3

A68(68)

0.5L/W IC21

A8

OIL

GLOW CHECK

B2 ENG

0.5O/B MB04

0.5L IC47

0.5B/L EX02

1 2 3 4 5 6 7 8

0.5B EX03

SPEED METER

A43(45)

A9 METER

0.5O/L MB01 0.5G IC48

CONT ; IMMOBILIZER(B1)

BACK UP LAMP

A39(42)

A6

4WD

BRAKE LAMP

JOINT TO EX12

B-2

TACHO METER 9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

CONT ; IMMOBILIZER(B5)

0.5B IZ06

A40(43)

EB STOP 10A

0.5G CA01

(ON)

(OFF)

J/C ; B

ACG(B)

SW ; BRAKE

0.5R IC12 0.5W/B IC13 RESISTER ; CLUTCH SW (YZK NO ; 7321-9900) 0.5Y 0.5B IC57 IZ08 510 0.5Y IC08

GLOW PULG x4 F

3W PA16

A28(31)

HB06 0.5L/Y IC06

0.5R CA02

0.5 B IZ04 E

RESISTER ; NEWTRAL SW 0.5B 0.5B/W IZ10 IC58 270 (IDLE SW)

0.85W KA01

A65(65)

3W PA13

A27(30)

0.85Y MA01

A36(39)

A-9

0.5G/W HA16

METER 15A

B16(94)

ENGINE 10A

B25(101)

SW ; NEWTRAL

3B/R PA17

B12(90)

FUSE ; BLOOR

OFF ACC IG2 ST IG1 3B/R

1 0.5L/W 2 HA14

4

B2

TDC

A30(33)

A-9

0.5B/W IC10

0.5G/R HA13 0.5G HA21 RESISTER ; IDLE UP 0.5B 0.5G HX03 HA24 270 0.5B/L

RELAY ; A/C THERMO

ELEC.THERMO

IZ05

0.5L/R IC09

0.5G HA23

FUSE ; A/C

B1

A-8

2 0.5BR HA17

RELAY ; GLOW

0.5G/R IC46

3

0.5B HX22

B22(98)

SW ;IGNITION

A-7

B8(89)

4

0.5L/R HB04

B-6

B-1 0.5G HA18

SW ; THERMO

ECT sensor

0.5O IC44

1

0.5BR/W HA20

B15(93) MAG.CLUTCH (COMPRESSOR)

0.5W IC45

1

2

B-5

3W PA03 3W/B PA02

A38(41) 0.5B/P IC43

5R/W HB01

0.5 IZ03

RELAY ; A/C COMPRESSOR

MAIN 80A

0.5L/R IC15

0.5L/R IC11

B13(91)

8B/R PA01

A-5

4 5 2 3 MAF 1

IG2 40A

B2(83) B7(88) B14(92) B3(84)

B29(105)

2L/B IC04 0.5W/R IC27 0.5G/R IC28 0.5B/R IC30 0.5B/L IC39

IG.1 50A

A56(58)

GLOW 50A

B24(100) B23(99)

2L/R IC05

0.5L/R HA15

1

A-4

A41(3)

IC11 HB04 HA15 IC07 IC15 HA19

3B PA28

INJ.PUMP

4

A-3

A41(63)

0.5L/R 0.5L/R 0.5L/R 0.5G 0.5L/R 0.5L/R

ECM 25A

2 3

A-2

0.5B/Y IC03

2B/Y IC01

2L/R IC05 0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

BATT

2L/R IC02

ENGINE DRIVEABILITY AND EMISSIONS 6E–14

N*R 4JH1-TC with Bosch VP44 System ECM Wiring Diagram

FTX 2L

BATT

TO ELECTRO THERMO

0.85W PA10

TO RELAY ; CHARGE

OFF ACC

KEY SW

5W PA07

B ST

ON

0.5BR HA09

0.5L/R IC39

0.5G/O IC48

RELAY ; HEATER&A/C

RELAY ; A/C COMP.

#20 ECU 25A

5B/L HB01

3B/Y IC01

#17 STOP LAMP 10A

TO RELAY ; CHARGE

0.5L/R IC33

RELAY ; ECU 0.5L/B IC03 2L/R IC02

0.5W IC60 STOP LAMP

SW ; STOP LAMP (BRAKE PEDAL ; ON) 0.5G CA02 0.5L/R IC09 (BRAKE PEDAL ; OFF)

0.5G BB09

SW ; CLUTCH (CLUTCH PEDAL ; OFF)

0.5BR/R IC19

METER

2

1

MAF

TO CONT UNIT ; ABS LAMP (STOP SIGNAL )

A-36 IG (39)

B-7 MAF SIG. (88) B-14 MAF GND (92) B-19 EGR (97)

A-55

B-16

0.5G/O IC43

0.5R/G IC42

0.5B/R HB04

1

2

3

1.25L/R HB03

A-35

0.5B/G IC44

GLOW RELAY (94)

A-47

ACCEL SENSOR (+5V)(57) ACCEL SENSOR (SIG.)(38)

A-69 A-61

2B IZ02

1

3

2

ECT sensor

TDC

B-9

0.85B MX01

RELAY ; G/PULG

5B/Y HB02

GLOW PULG (4 x4)

SW ; IDEL

THERMO UNIT (WATER TEMP)

GND.

SIG.

+

VEHICLE SPEED

0.5Y/G MA33

0.5B/Y MA32

0.5B MX11

WITH ; ABS

ALDL CONNECTOR

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

0.3W/G BB20

7 EXH.B/CUT 29 0.3W/B IN J1850 BB21

CONT.UNIT ; ABS

SPEED

0.5B IZ11

D-4 0.5Y/B MA08

TPS

METER

THERMO

JOINT

ACCEL SENSOR (GND.)(49)

A-62

ACCEL SENSOR (IDEL)(69) GND. (2)

2B IZ01

0.5GR IC51

B-9

0.5LG MA07

TACHO A-24

0.5Y/G IC46

B-8

A-68

0.5LG/B BB07

B-8

0.5B/P IC52

0.3V MX04

A-60

0.5LG/W 8 EXH.B/CUT 4 OUT BB06 FRASH

FRAME EARTH POINT

GND. (1)

ENG.SPEED (OUTPUT-1) (27)

0.5G/B IC62 A-29

B-12

0.5R IC49

B-22 0.5W IC50

B-15

0.5Y IC57

IZ10 (SHIELD)

GND. (93)

A-32

0.5L IC58

0.5B IZ07

ISO-K (35)

A-43

B-25

DIAG (45)

TDC (SHIELDED) (101) WATER TEMP (ECU) (89)

TDC (-) (98)

TDC (+) (90)

ABS (OUT) (62) ABS (IN) (32)

A-44 QWS SW (46) VEHICLE SPEED A-57 METER IND (68) (QWS) (59)(KEY ON;ENABLE) B-2 MAF +5V (83)

METER IND (CHECK ENG.) (42) METER IND (GLOW) (43)

0.5G/B IC45

CONT UNIT ; ENGINE

0.5W IC04

A-27 BARAKE ON (30)

A-56 MAIN RELAY (58) A-41 BAT(+) (3)

0.5G IC10

A-28 CLUTCH (31)

0.5W/B A-65 BARAKE OFF (65) IC11

0.5Y IC12

0.5W/R IC23

METER IND (EXH.BRAKE) (60)(KEY ON;ENABLE)

0.5LG/L A-64 SW;EXH.BRAKE (64) IC13

4

0.5B/R IC25

0.5G/R IC24 3

5

EXH.BRAKE 14V, 2.0W 0.5G/R A-58 0.5LG/L IC64 IC14 CHECK ENG. 14V, 0.5B/Y 1.4W 0.5G/Y A-39 IC17 MA01 14V, GLOW 1.4W 0.5O/L A-40 IC18

SW ; EXH.BRAKE

SW ; ENG.WARM 0.3B IZ09

0.5BR/R IC20 0.5BR IC65 0.5L/R IC22

0.5LG/W IC29

0.5LG IC16

0.5L/R 0.5B/O IC26 IC27 MAG.VALVE ; EXH.BRAKE

EVRV ; EGR

14V, 60mA

0.5LG/R IC21

1.25L/R IC59

0.5G/Y CA01

1.25B/Y IC05

3L/R IC34

GLOW 60A

MAIN 80A

KEY SW 50A

TO BLOWER MOTOR

PDS 0.85G/O HA11

SW ; NEUTRAL (NEUTRAL;ON) 0.5B/W IC31 RESISTER ; NEUTRAL SW (510 ) 0.3B IZ06

B-3 MAT SIG. 0.5B/L (84) IC56 MAG.VALVE A-37 (EXH.BRAKE) (40) B-17 INT.SLOTTLE (95) B-6 SW;NEUTRAL (87) TWIST LINE B-24 INJ.PUMP 0.5Y 2 (CAN-H) IC35 (100) INJ.PUMP 0.5R B-23 INJ.PUMP 1 (CAN-L) IC36 (99) 7 0.5O B-29 INJ.PUMP 5 (MAB) IC37 6 (105) B-13 INJ.PUMP 0.5P 8 (DZG) IC38 (91) A-30 A/C SW (33) A-38 A/C RELAY (41) FRAME EARTH POINT

2B IZ04

5B IZ03

J/C

0.5B IC15 VSV ; INT.THROTTLE 0.5L/R IC28

2L/R IC30

0.5G/Y IC41 0.5W/G IC40 1.25B/Y IC63

0.5B ZZ06

TO RELAY ; TAIL

RESISTER ; IDLE SW (510 )

0.85B MX06

0.5B ZZ05

RELAY ; A/C ON SIGNAL

0.5L/R IC06 0.5L/R IC07 0.5L/R IC08 0.5B/W IC32

TO SW ; BACK UP LAMP TO RELAY ; CORNEING

0.5B IZ12

#19 TURN 10A #2 AIR CON 10A #1 HEATER 25A MAGNET CLUTCH (COMPRESSOR)

RESISTER ; A/C ON SIGNAL(270 ) 0.5B 0.5Y/G IZ08 IC47

#18 GENERATOR 15A #15 H/L LEVELINGA 10A #12 GAUGE, BACK 10A #11 WIPER, WASHER 15A 0.85Y/G HA19

RELAY ; THERMO A/C

0.85G/W HA10

060RY00363

060RY00329

ENGINE DRIVEABILITY AND EMISSIONS

6E–15

TF 4JA1-TC/4JH1-TC ECM Pinouts

3 1

2

43

25

98

105

62

44

90

97

81

63

82

89

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

Manual Transmission only

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

—

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

TF 4JA1TC only

6E–16

ENGINE DRIVEABILITY AND EMISSIONS

Pin No.

Connected car component

Note

47

No Connect

48

Water temperature output signal

TF 4JH1 AT only

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

4JA1-TC only

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

—

ENGINE DRIVEABILITY AND EMISSIONS Pin No.

Connected car component

6E–17 Note

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

—

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

4JA1-TC only

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

—

6E–18

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC ECM Pinouts

3 1

2

43

25

98

105

62

44

90

97

81

63

82

89

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

—

ENGINE DRIVEABILITY AND EMISSIONS Pin No. 47

Connected car component No Connect

48

6E–19 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

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

Pin No.

Connected car component

Note

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

—

ENGINE DRIVEABILITY AND EMISSIONS

6E–21

NKR (4JH1-TC) TF (4JA1-TC, 4JH1-TC) PCU Pinouts

2

4

5

6

9

8

7

3

1

Pin No.

Connected car component

Note

1

CAN1_L (Controler Area Network)

—

2

CAN1_H (Controler Area Network)

—

3

No connect

—

4

No connect

—

5

Solenoid valve shut-off (MAB) output

—

6

Battery minus

—

7

Battery plus

—

8

Camsensor output signal

—

9

No connect

—

6E–22

ENGINE DRIVEABILITY AND EMISSIONS

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

ENGINE DRIVEABILITY AND EMISSIONS

Component Locator TF 4JA1-TC with Bosch VP44 System Component Locator

2

1

Legend (1) Manifold Air Flow (MAF) sensor (2) Engine Coolant Temperature (ECT) sensor EndOFCallout

3

(3) Injection pump

6E–23

6E–24

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JA1-TC with Bosch VP44 System Component Locator

4

1

Legend (1) Mass Air Flow (MAF) sensor (2) EVRV:EGR

2

(3) Fuel Filter (4) Inter Cooler

3

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JA1-TC/4JH1-TC TDC Sensor Location

3

Legend (1) Top Dead Center (TDC) sensor (2) Inter Cooler EndOFCallout

1

(3) Wiper Motor

2

6E–25

6E–26

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JA1-TC, 4JH1-TC with Bosch VP44 System Component Locator

1

Legend (1) Engine Control Module EndOFCallout

2

(2) SRS Control Module

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JH1-TC with Bosch VP44 System Component Locator

2

1

Legend (1) Manifold Air Flow (MAF) Sensor (2) Engine Coolant Temperature (ECT) Sensor EndOFCallout

6E–27

6E–28

ENGINE DRIVEABILITY AND EMISSIONS

TF 4JH1-TC with Bosch VP44 System Component Locator

2

Legend (1) MAF sensor (2) ECT sensor EndOFCallout

1

3

(3) Fuel Filter (4) Inter Cooler

4

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC with Bosch VP44 System Component Locator

4

5

3

Legend (1) Mass Air Flow (MAF) Sensor (2) Engine Coolant Temperature (ECT) Sensor (3) EGR cooler EndOFCallout

2

(4) Injection pump (5) EGR Valve

1

6E–29

6E–30

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC with Bosch System Component Locator

2

Legend (1) MAF sensor (2) Fuel filter/Fuel sedimerter

1

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC with Bosch System Component Locator

1

Legend (1) EGR valve (2) EGR cooler

2

3

4

(3) TDC sensor (4) Turbo waste gate actuator

6E–31

6E–32

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC with Bosch VP44 System Component Locator

1

Legend (1) Intake Shutter VSV (2) EGR EVRV EndOFCallout

2

3

(3) EGR Valve

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC with Bosch VP44 System Component Locator

1

Legend (1) Engine Control Module

.

6E–33

6E–34

ENGINE DRIVEABILITY AND EMISSIONS

NKR 4JH1-TC with Bosch VP44 System Component Locator

1

Legend (1) Vehicle Speed sensor

ENGINE DRIVEABILITY AND EMISSIONS TF 4JA1-TC Fuse Box

STARTER C CONN

BAT

40A

30A

40A

IGN. B1

H/LAMP WASHER

IGN. B2

10A

ALT 10A 10A

100A J/C:B

MAIN

J/C:A

ECM STARTER

DIMMER

A/C ( THERMO )

RR FOG

HEAD LIGHT

(

A/C COMP.

IMMOBILIZER

ECM MAIN

TAIL LIGHT

HORN

)

10A CHARGE

ECM

H/LIGHT LH(LO) H/LIGHT 10A RH(LO) H/LIGHT 10A LH(HI) H/LIGHT 10A RH(HI) 10A

30A

TAIL LH TAIL RH

10A

RR FOG

10A

A/C

20A BLOWER 10A

10A HORN 15A HAZARD

STARTER CUT

(DIODE)

CAUTION

( )···IF EQUIPPED.

HEATER

· 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

STOP LIGHT

Y

6E–35

6E–36

ENGINE DRIVEABILITY AND EMISSIONS TF 4JH1-TC Fuse Box

STARTER C CONN

60A

40A

GIOW

IGN. B2

40A

BAT

IGN. B1

STARTER

MAIN

RR FOG

HEAD LIGHT

ECM

10A

RR FOG

10A

TAIL

ALT

100A J/C:B

10A

J/C:A

10A CHARGE

STOP 20A BLOWER LIGHT H/LIGHT 10A LH(LO) H/LIGHT 10A HORN 10A RH(HI) H/LIGHT 10A 15A HAZARD LH(HI) 10A

A/C ( THERMO )

A/C COMP.

IMMOBILIZER

ECM MAIN

TAIL LIGHT

HORN

STARTER CUT

(DIODE)

CAUTION

( )···IF EQUIPPED.

HEATER

· 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

Y

HEATER

AIR CON

STARTER

CIGAR LIGHTER

HEAD LIGHT (RH)

HEAD LIGHT (LH)

AUDIO, DOOR LOCK

HAZARD, HORN

TAIL LIGHT

FOG LIGHT

WATER, WASHER

GAVGE, BACK

REAR HEATER

FUEL HEATER

HDLP LEVELING

POWER WINDOW

STOP LIGHT

GENERATOR

TURN S/LIGHT

ECM

ENGINE DRIVEABILITY AND EMISSIONS 6E–37

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

6E–38

ENGINE DRIVEABILITY AND EMISSIONS

N*R 4JH1-TC Fuse and Relay Panel

A

E

B

F

G

H

C

D

E NO A

NAME RELAY;STARTER

S/B FUSE;MAIN

TYPE MRB

60A F

S/B FUSE;KEY

--B C D

RELAY;GLCN(1)

MRB

RELAY;GLCN

MRB

RELAY;4WD LND LAMP

ISO

RELAY;REAR FOG

ISO

RELAY;MARKER LAMP

ISO

80A 50A 50A

G

S/B FUSE;GLOW

60A 50A

H

S/B FUSE;ABS IND.

60A 40A

ENGINE DRIVEABILITY AND EMISSIONS

6E–39

N*R 4JH1-TC Relay Panel

I

NO

A

B

NAME

H

C

TYPE

A

RELAY;CHG, WARING

ISO

B

RELAY;LIGHT

ISO

C

RELAY;HEATER & A/C

ISO

D

RELAY;TALE

ISO

E

RELAY;Dimmer

ISO

G

D

E

F

F

RELAY;HDRN

ISO

G

RELAY;P/WINDOW

ISO

H

RELAY;ABS IND

ISO

RELAY;CORNERING LAMP

ISO

RELAY;BUZZER CANSEL

ISO

RELAY;ECU

ISO

I

6E–40

ENGINE DRIVEABILITY AND EMISSIONS

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

ENGINE DRIVEABILITY AND EMISSIONS Injection pump Control System 2 3 1

4

11

6

5

10 9 8

Legend (1) Cam angle sensor (2) Pump control unit (PCU) (3) Distributor head (4) High pressure solenoid valve (5) Delivery holder (6) CPV

(7) (8) (9) (10) (11)

7

TCV Timer Radial pluger high pressure pump Feed pump Drive shaft

6E–41

6E–42

ENGINE DRIVEABILITY AND EMISSIONS

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.

TDC (Engine Speed) Sensor The TDC sensor is magnet type sensor.

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.

Glow plug relay coil

3

µP

58

39

ABS control unit

15A

NKR 4JH1-TC only

µP : Microproccesor

Relay EW

ECM 25A

ON

IG

30

Batt

IC 08

65

NKR 4JH1-TC only

Stop lamp SW

Stop lamp 10A

31

IC 035

SW:clutch Clutch pedal:OFF

µP

60

Batt

µP

SW:Exh Brake (NKR 4JH1-TC only) Meter Exh Brake (NKR 4JH1-TC only)

64

#12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

42

Check Engine

µP

43

Glow

µP

59

IC 035

46

ENGINE DRIVEABILITY AND EMISSIONS

ECM System Diagram – No.1

6E–43

88

5

CPU

IC 08

US

92

3

µP : Microproccesor

84

1

MAF

2

4

83

ECM 25A

µP

97

µP

Batt

EVRV: EGR

97

Batt

µP

VSV : Ext 2 (QWS) TF 4JA1-TC only

40

Batt

µP

95

Batt

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

IC 08

87

Batt

SW:Neutral (MT only)

µP

91

PCU

105

5

µP

Batt

8

6

Batt

CF 150

99 CAN-L

1 2

7

100 CAN-H

6E–44 ENGINE DRIVEABILITY AND EMISSIONS

ECM System Diagram – No.2

ENGINE DRIVEABILITY AND EMISSIONS

MAF/IAT Sensor Circuit

1

IAT sensor

NTC

3

2

4

+5V

Heater

5

MAF sensor

6E–45

6E–46

ENGINE DRIVEABILITY AND EMISSIONS

ECM System Diagram – No.3 Main fuse

ECM relay

HVAC relay

A/C on signal

ECM relay

ECM relay A/C Fuse

AC Thermo relay

TF 4JA1-TC / 4JH1-TC only

NKR 4JH1-TC only Electrical thermo PDS (NKR 4JH1-TC) only

A/C Comp relay

A/C Comp relay

Compressor clutch

Compressor clutch

41

41 Batt

µP

µP : Microproccesor

33 Batt

µP

IC 08

Relay G/plug

Glow 60A

µP

94

Glow plug

ECU Relay

Balt

57

IC 08

+5V 38

APS

49

Register : idle SW

69

1 GND

2 GND

ENGINE DRIVEABILITY AND EMISSIONS

ECM System Diagram – No.4

6E–47

VSS

68

Speed meter

Balt

meter fuse (TF 4JA1-TC/ 4JH1-TC only)

27

Speed meter

68

Balt

VSS (NKR 4JH1-TC only)

µP

62

7

29

32

IC 08

Balt

8

4 ABS

IC 03

90

TDC

98

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

IC 08

Us

89

ECT

93

IC 08

35

IC 08

45

6E–48 ENGINE DRIVEABILITY AND EMISSIONS

ECM System Diagram – No.5

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 System) Tests

(Self

Diagnosis

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.

6E–49

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.

6E–50

ENGINE DRIVEABILITY AND EMISSIONS

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.

6E–51

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.

(example) Two Digit Unique Code Number=32 Diagnostic SW

ON

(1250msec) (500msec)

ON

Lamp

OFF 1

2

3

2

3

2

(500msec)

(3250msec)

(3250msec)

After all the stored error codes are flashed, the same flashing patterns are repeated again.

3

2

6E–52

ENGINE DRIVEABILITY AND EMISSIONS

Tech2 From 98 MY, Isuzu dealer service departments are recommended to use the Tech2 Scan Tool. Please refer to the Tech2 user guide.

901RW180

Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector

(3) SAE 16/19 Adaptor (4) DLC Cable (5) Tech2

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.

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.

6E–53

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.

826RY00058

6. Turn on the vehicle ignition. 7. Power the Tech2 ON and verify the Tech2 power up display.

060RY027

060RW009

NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech2. Refer to user guide of the Tech2.

6E–54

ENGINE DRIVEABILITY AND EMISSIONS Menu • The following table shows, which functions are used the available equipment versions. F0: Diagnostic Trouble Codes F0: DTC Information F0: Engine F1: History F0: Clear DTC Information F1: Data Display F2: Snapshot F3: ID Information

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.

060RY00275

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.

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.

6E–55

6E–56

ENGINE DRIVEABILITY AND EMISSIONS

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

D06RY00167

ENGINE DRIVEABILITY AND EMISSIONS

6E–57

Flow Chart for Snapshot Replay (Plotting Graph)

060RX040

6E–58

ENGINE DRIVEABILITY AND EMISSIONS

How To Use Breaker Box

3

1

Legend (1) ECM

2

(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. Wiring harness connection on the vehicle Engine harness Engine harness ECM Breaker box Insert breaker box

ECM Harness adaptor

ENGINE DRIVEABILITY AND EMISSIONS

6E–59

Breaker Box Connection Type A for Open Circuit Check, Short to Ground Check and Short to Battery Check

3

Legend (1) ECM (2) Harness adaptor

1

5

4

2

(3) Breaker box (4) Digital volt meter (5) ECM – harness adaptor connector disconnected

Breaker box connection type A. ENG. harness

Breaker box

ECM Harness adaptor or DVM Connect to ground

6E–60

ENGINE DRIVEABILITY AND EMISSIONS

Breaker Box Connection Type B for Power, Signal Voltage Check between ECM and Sensors

3

Legend (1) ECM (2) Harness adaptor

1

2

4

(3) Breaker box (4) Digital volt meter

Breaker box connection type B. ENG. harness

Breaker box

ECM Harness adaptor or DVM Connect to ground

ENGINE DRIVEABILITY AND EMISSIONS

6E–61

How To Use TIS2000 Snapshot Analysis Snapshot Display

Fig. 1: [Snapshot Upload] icon

Fig. 2: Data display

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:

C. Snapshot data is displayed with TIS2000 [Snapshot Upload] function.

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.

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.

6E–62

ENGINE DRIVEABILITY AND EMISSIONS

Displayed icons

Regeneration of snapshot

With the below icons, data display can be controlled:

Snapshot can be regenerated with the icons on the screen lower side.

Transfer of snapshot from Tech2 to PC. 1st record: The 1st record of the snapshot is displayed. 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.

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.

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).

Fig. 3: Snapshot regeneration control

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.

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–63

Display of graphs on one screen (Max. 6 graphs): 1. Click the 6 graph icon. [Graph Parameter] window opens.

Fig. 4: [Graph Parameter] window

Fig. 6: [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.

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.

6E–64

ENGINE DRIVEABILITY AND EMISSIONS

Parameter lock/unlock

TIS2000 navigation

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.

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 registered and displayed. With [Help], TIS2000 function is started.

information

integration

is

help

With [Print], copy of the screen can be printed out.

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–65

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 Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) 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

6E–66

ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Display

Item

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) temperature is about 80°C)

Tech 2 parameter

Unit Displayed

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

TF 4JH1-TC (MT) Tech 2 Display

Item

Tech 2 parameter

Unit Displayed

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) 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

ENGINE DRIVEABILITY AND EMISSIONS

6E–67

Tech 2 Display

Item

Tech 2 parameter

25

Main Relay

26

Unit Displayed

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) temperature is about 80°C)

Active/Inactive

Active

Active

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

TF 4JH1-TC (AT) Tech 2 Display

Item

Tech 2 parameter

Unit Displayed

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) temperature is about 80°C)

1

Engine Speed

rpm

700±25

1960~2010

2

Vehicle Speed

rpm

0

0

3

Pump Speed

rpm

340~360

978~1010

4

Acceletor Position

%

0

7.9~9.3

5

Manifold Air Flow

mg/strk

750~795

790~830

6

Barometric Pressure

hPa

Sea level

Sea level

7

Desired Injection Quantity

mg/strk

11~15

12~13

8

Injection quantity

mg/strk

11~13.5

10~11

9

Desired Injection Start

°CA

1.6

3.8~4.0

10

Actual Injection Start

°CA

1.5~1.7

3.8~4.0

11

Coolant Temperature

°C

80~85

80~85

12

Fuel Temperature

°C

32~34

32~34

13

Intake Temperature

°C

25~30

25~30

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

6E–68

ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Display

Item

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) temperature is about 80°C)

Tech 2 parameter

Unit Displayed

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

23.0~24.0

37

A/C Request

Active/Inactive(V)

Inactive

Inactive

NKR 4JH1-TC Tech 2 Display

Item

Tech 2 parameter

Unit Displayed

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) 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

ENGINE DRIVEABILITY AND EMISSIONS

6E–69

Tech 2 Display

Item

Tech 2 parameter

Unit Displayed

Typical Data values Idling Typical Data values after the engine warm up 2000rpm after the engine and A/C “Off” warm up and A/C “Off” (The engine coolant (The engine coolant temperature is about 80°C) temperature is about 80°C)

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

6E–70

ENGINE DRIVEABILITY AND EMISSIONS

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)

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 %

This is displayed current fuel rate (Fuel quantity). The ECM will compensate for fuel rate to basic fuel rate.

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

35

Start of Delivery

36

A/C Request(Air Conditioning)

37

Immobilizer

38

Immobilizer Signal

39

Immobilizer Function Programmed

6E–71

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. This displays the A/C request signal.

6E–72

ENGINE DRIVEABILITY AND EMISSIONS

ENGINE DRIVEABILITY AND EMISSIONS

DTC

Sub code

F/Code

DTC Name

65

Mass Air Flow Sensor Voltage MAF < 4.589V more than N*R 4JH1/TF 4JA1.4JH1--- Default=5V Supply Circuit Low Input 500msec Air flow defaut=1600mg/hub, N*R 4JH1/ TF 4JA1(Excluding TF 4JH1)---, EGR default=10% ( usually 30-40%)

Yes

MAF >= 4.589V more During same ignition than 500msec cycle

ON

X

X

X

0111

Mass Air Flow Sensor Voltage MAF >5.20V Supply Circuit High Input 500msec

than Default=5V Air flow defaut=1600mg/ hub, EGR default=10%

Yes

MAF <= 5.20V more During same ignition than 500msec cycle

ON

X

X

X

1011

Mass Air Flow Sensor Circuit 600RPM<Eng Default=freezed value of immidiate High Input RPM<5000RPM and MAF previous value Air flow defaut=1600mg/ output<-18.6kg/h more than hub, EGR default=10% 5 sec

Yes

MAF output>= -18.6kg/h During same ignition more than 600msec cycle

ON

X

X

X

1100

Mass Air Flow Sensor Circuit 600RPM<Eng Default=freezed value of immidiate Low Input RPM<5000RPM and MAF previous value Air flow defaut=1600mg/ output>806.4kg/h(N*R 4JH1- hub, EGR default=10% TC/TF 4JA1-TC) or 825kg/ h(TF 4JH1-TC) more than 10 sec

Yes

MAF output<=806.4kg/h During same ignition more than 600msec cycle

ON

X

X

X

IAT Signal Volatage Low

IAT(Intake Air Temp--different Default = -50 deg C from Pump IAT) <= 0.318V more than 3 sec

Yes

IAT volt > 0.32V more During same ignition than 3 Sec cycle

ON

X

X

X

IAT Signal Volatage High

IAT(Intake Air Temp--different Default = -50 deg C from Pump IAT) >= 4.7V more than 3 sec

Yes

IAT volt < 4.7V than 3 sec

more During same ignition cycle

ON

X

X

X

ECT Sensor Circuit Low Input ECT volt < 0.32V more than ECT uses fuel pump temp, Injection 3 sec beginning governing use 50deg C, Glow timer use -25 deg C

Yes

ECT volt > 0.32V more During same ignition than 600msec cycle

ON

X

X

X

ECT Sensor Circuit High Input ECT volt > 5.7V more than ECT uses fuel pump temp, Injection 3 sec beginning governing use 50deg C, Glow timer use -25 deg C

Yes

ECT volt < 4.7V more During same ignition than 600msec cycle

ON

X

X

X

P0100 1001

P0110 0010

23

0001

P0115 0010

14

0001

Setting condition

more

Back-up mode

History code Cancel condition

Cancel Mode

MIL light

6E–73

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC

P0180 1011

15

Fuel Temperature Sensor Pump temperature > 150 Fuel temp = default 75deg C Circuit Range/Performance deg C or < -40 deg C more than 3 sec.

Yes

No more failure is During same ignition regognized more than 3 cycle sec.

ON

X

X

X

P0215 1011

52

Fuel cutoff solenoid valve No ECM requests Engine Engine stops, (MAB) circuit high input stop, but PCU recognises MAB shut off High level on MAB line during Initilization.

Yes

No more failure recognized.

is Ignition Key off, no condition matches then canceled.

ON

X

X

X

can not start engine.

1100

Fuel cutoff solenoid valve During afterrun, Ign OFF, Engine stop, MAB shut off (MAB) always active Engine speed <1500 RPM, VSS<5km/h, 2 sec after, still engine rpm.200rpm immidiate action.

Yes

No more failure recognized.

is Ignition Key off, no OFF condition matches during then canceled. DTC set, MIL ON at next Ign cycle.

X

X

X

1010

Fuel cutoff solenoid valve Ign OFF, Engine speed Engine stop, MAB shut off, MIL turn on (MAB) malfunction 1 <1500 RPM, VSS<5km/h, 2 after starts engine. sec after, still engine rpm.200rpm, immidiate action

Yes

No more failure recognized.

is Ignition Key off, no OFF condition matches during then canceled. DTC set, MIL ON at next Ign cycle.

X

X

X

6E– 74 DTC

ENGINE DRIVEABILITY AND EMISSIONS Sub code

F/Code

1101

P0216 1010

54

1011

P0251 0110

53

DTC Name

Setting condition

Back-up mode

History code Cancel condition

Cancel Mode

MIL light

Fuel cutoff solenoid valve During afterrun period, CAN None (MAB) malfunction 2 --- Gate controller can not be bus off Array error mode. Immidiate action.

Yes

No more failure recognized.

Persistant governer deviaton

Conditions: Eng rpm > 700 Limit Q is employed. RPM, Q> 4mg/hub and Judgement :Actual timing and target timing deviation > +3 CA or < -6 CA , more than 12sec.

Yes

No more failure is During the recognized. Return to ignition cycle normal mode immidiately.

same

Timing device fluctuation

Engine RPM > 2014RPM, Limit Q is employed. timing fluctuation becomes more than +-5.2CA and more than for 1 sec.

Yes

No more failure is During the recognized. Return to ignition cycle normal mode immidiately.

same

Injection Pump Malfunction

PCU detects control pulse Engine stops. width.

Yes

No more failure recognized.

speed TDC sensor Engine speed - Engine stops. 2* Cam speed sensor> 800RPM(N*R 4JH1-TC) or 720RPM(TF 4JA1-TC) or 690RPM(TF 4JH1-TC) more than 200msec

Yes

TDC Engine speed 2*Cam speed sensorI<= 800RPM(N*R 4JH1-TC) or 720RPM(TF 4JA1TC) or 690RPM(TF 4JH1-TC).

0111

TDC and CAM comparison error

1001

Injection Pump Malfunction

No pump map programmed Engine stops. MAB shut off. or pump control unit(PCU) RAM defect

Yes

1010

Injection Pump Malfunction

PCU-EEPROM defect or A/D Limit Q is employed. converter defect

1011

Injection Pump Malfunction

1101

1110

is Ignition Key off, at OFF next Ign cycle no during condition matches DTC set, then canceled. MIL ON at next Ign cycle.

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC X

X

X

ON

X

X

X

ON

X

X

X

X

X

X

is Ignition Key off, at OFF next Ign cycle no during condition matches DTC set, then canceled. MIL ON at next Ign cycle. Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

No more failure recognized.

is Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

Yes

No more failure recognized.

is Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

PCU selftest finds None powerstage hardware error.

Yes

No more failure recognized.

is Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

Injection Pump Malfunction

PCU selftest finds internal None voltage check is OK or not.

Yes

No more failure recognized.

is Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

Injection Pump Malfunction

ECM does not accept PCU Engine stops. MAB shut off. message more than 1sec

Yes

No more failure recognized.

is Ignition Key off, at next Ign cycle no condition matches then canceled.

ON

X

X

X

ENGINE DRIVEABILITY AND EMISSIONS DTC

Sub code

P0335 1110

F/Code

DTC Name

Setting condition

Back-up mode

History code Cancel condition

Cancel Mode

MIL light

43

Engine Speed Sensor Input RPM > 5100 RPM more Set rpm backup Circuit Signal Range/ than 20 m sec(sampling 1. If Injection Cam sensor is OK, Engine Performance(Over Speed) time) Speed becomes Injection Pump Cam Signal X 2. (TDC=DZG-Crank angle sensor detects this error)

Yes

RPM <= 5100RPM for > During same ignition 50 m sec cycle

ON

X

6E– 75

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC

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 Injection Cam sensor is OK, Engine Speed becomes Injection Pump Cam Signal X 2. 2. If Injection Cam sensor (IAT)fails, Set default 0 rpm MAB qty becomes 0, and retard Injection. Engine stops. Set Q backup

Yes

If OK condition During same ignition continues more than cycle times, become normal .

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 Injection Cam sensor is OK, Engine Speed becomes Injection Pump Cam Signal X 2. 2. If Injection Cam sensor (IAT)fails, Set default 0 rpm MAB qty becomes 0, and retard Injection. Engine stops. Set Q backup

Yes

If OK condition During same ignition continues more than cycle times, become normal .

ON

X

X

X

Glow Device Voltage High

After Key ON, glow lamp None stays on, Glow Relay circuit is short circuit more than 3 sec

Yes

Detective circuit During same ignition recognized as normal cycle more than 1 sec

ON

X

X

X

Glow Device Voltage Low

After Key ON, glow lamp None stays on, Glow Relay circuit is open circuit more than 3 sec

Yes

Detective circuit During same ignition recognized as normal cycle more than 1 sec

ON

X

X

X

Glow Time Telltale Circuit Lamp circuit power on, IC None Voltage High recognizes short circuit more than 3 sec

Yes

IC recognizes no more During same ignition short circuit more than cycle 1sec

ON

X

X

X

Glow Time Telltale Circuit Lamp circuit power off, IC None Voltage Low recognizes short circuit more than 3 sec

Yes

IC recognizes no more During same ignition open circuit more than cycle 3sec

ON

X

X

X

EGR short to Batt

Powerstage ON, ECM LimitQ is employed. EGR becomes 10% initialized, IC recognises ratio. short to batt more than 3sec

Yes

IC recgnizes no more During same ignition short circuit more than cycle 3sec

ON

X

X

EGR short to grand or open Powerstage ON, ECM LimitQ is employed. EGR becomes 10% circuit initialized, IC recognises ratio. short to ground and open circuit more than 3sec

Yes

IC recgnizes no more During same ignition failure more than 3sec cycle

ON

X

X

P0380 1000

66

0100

P0381 1000

67

0100

P0400 1000

0100

32

6E– 76 DTC

ENGINE DRIVEABILITY AND EMISSIONS 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

0011

EGR Flow Detected

Excessive N*R 4JH1--70deg LimitQ is employed. but EGR operation C<ECT<100, TF 4JA1-- is normal. 55degC<ECT<100degC,N*R 4JH1--16 deg C 150 mg/huv more than 60 sec. N*R 4JH1--judgement is made between 2165 and 3160RPM, and between 1535mg/huv. TF 4JA1-judgement is made between 1500-3100RPM, and between 8 - 32mg/huv.

Yes

Target MAF-Actual During same ignition MAF<=150mg/hub, cycle more than 600msec

ON

X

0101

EGR Flow Detected

Insufficient N*R 4JH1--70deg LimitQ is employed. but EGR operation C<ECT<100, TF 4JA1-- is normal. 55degC<ECT<100degC,N*R 4JH1--16 deg C
Yes

Target MAF-Actual During same ignition MAF>=150mg/hub, cycle more than 600msec

ON

X

VSS out put > 190 km/h(N*R VSS default=5km/h 4JH1-TC) or 200km/h(TF 4JA1-TC,4JH1-TC) more than 5 sec

Yes

VSS <= 190 km/h(N*R During same ignition N*R 4JH14JH1-TC) or 200km/ cycle TC-- OFF h(TF 4JA1-TC,TF 4JH1TF 4JA1TC) more than 5 sec TC,4JH1TC--ON

X

X

VSS input signal frequency VSS signal frequency is too VSS default=5km/h too high high, CPU can not recognise more than 600msec

Yes

VSS signal frequency < During same ignition N*R 4JH1CPU eligible frequency cycle TC-- OFF more than600m sec TF 4JA1TC,4JH1TC--ON

X

X

P0500 0001

1010

24

VSS Circuit High Input

X

ENGINE DRIVEABILITY AND EMISSIONS DTC

Sub code

F/Code

DTC Name

Setting condition

VSS plausibility

Q >= 30 mg / hub, Engine Brake light becomes ON speed>=2500RPM, VSS < 5km/h more than 30 sec

Yes

VSS>=5km/h more than During same ignition N*R 4JH1600msec cycle TC-- OFF TF 4JA1TC,4JH1TC--ON

X

X

System Voltage Too Low

System Volatage < 7 Volt, Back up volate figure 9 Volt is used. more than 100 m sec

Yes

When system volage During same ignition becomes more than 7 cycle volt for 100 m sec.

OFF

X

X

X

0001

System Voltage Too High

System Volatage > 20 Volt, Back up volate figure 9 Volt is used. more than 600 m sec

Yes

When system volage During same ignition becomes less than 20 cycle volt for 600 m sec.

OFF

X

X

X

1010

Extrem voltage input

System voltage < 4.5 V, or > PSG uses default value. 27 V for 0 m sec

Yes

4.5V, System volatage < During same ignition 27 V for 0 m sec cycle

OFF

X

X

X

N*R4JH1- No return to normal During same ignition TC-Yes mode during this driving cycle TF4JA1cycle. TC,4JH1-TC-NO

OFF

X

X

X

Switched System During initialization, quick If condition continue more than 1 sec N*R4JH1- No return to normal During same ignition Voltage(Ignition ON) Circuit motion of ignition ON of after DTC set, ECM goes into afterrun TC-Yes mode during this driving cycle Malfunction ignition OFF triggers this mode. TF4JA1cycle. DTC TC,4JH1-TC-NO

OFF

X

X

X

ECU Malfunction 2

APS <1%, Q > 0 mg/strk, Engine stops, MAB shut off then RPM >2000RPM

Yes

Target Q <= 0 (mg/hub) During same ignition more than 200m sec , cycle or restart

ON

X

X

X

ECU Malfunction 1

Gate array counter reach 5 Engine stops, MAB shut off counts

Yes

No failure happens During same ignition more than 20 sec. cycle

ON

X

X

X

A/C Comp Cutoff Relay AC Power ON at least one None Primary Circuit High Input time after Ign ON, IC recognises short circuit more than 3 sec.

Yes

IC recognises no more During same ignition short circuit more than 3 cycle sec

ON

X

X

X

A/C Comp Cutoff Primary Circuit Open

Relay AC Power OFF at least one None time after Ign ON, IC recognises Open circuit more than 3 sec.

Yes

IC recognises no more During same ignition open circuit more than 3 cycle sec

ON

X

X

X

During Brake SW on, Brake- N*R 4JH1-TC--After start None Light SW Circuit Incorrect engine, Engine Signal(Ignition On) 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.

Yes

BRK SW1 = BRK SW2 During same ignition more than 300sec cycle

ON

X

1011

P0560 0010

P0561 1011

35

18

1010

P0606 1011

28

1010 P0645 1000

46

0100

P0703 1010

25

Back-up mode

Switched System CPU recognises IC circuit Engine stops Voltage(Ignition ON) Circuit error of main relay control. Malfunction

History code Cancel condition

Cancel Mode

MIL light

6E– 77

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC

X

6E– 78 DTC

ENGINE DRIVEABILITY AND EMISSIONS Sub code

F/Code

1011

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

During Brake SW off, Brake- N*R 4JH1-TC--After start None Light SW Circuit Incorrect engine, Engine Signal 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.

Yes

BRK SW1 = BRK SW2 During same ignition more than 300sec cycle

ON

X

Yes

Clutch signal change is During same ignition made more than cycle 500msec

ON

X

X

X

V< Default =1013hpa

Yes

Baro>=1.48V more than During same ignition 1 sec cycle

ON

X

X

X

Baro sensor Circuit High Input Baro V>4.42V(4.42V=- Default =1013hpa 1000M) more than1 sec

Yes

Baro<=4.42V more than During same ignition 1 sec cycle

ON

X

X

X

Intake VSV High Input

Powerstage ON, ECM None initialized, IC recognises short to batt more than 3sec

Yes

IC recognises no more During same ignition failure , more than 3sec cycle

ON

X

X

Intake VSV Open Circuit

Powerstage ON, ECM None initialized, IC recognises short to batt open circuit or short to ground more than 3sec

Yes

IC recognises no more During same ignition failure , more than 3sec cycle

ON

X

Pedal Position Sensor Circuit APS signal volage < 320 mV Use Idle SW position = 0%, Low Input more than 500 m sec acceleration, decceleration becomes limmitted performance. Idle speed becomes 1400 RPM.

Yes

APS signal volage > 320 During same ignition m V more than 500 m cycle sec

ON

X

0001

Pedal Position Sensor Circuit APS signal volage > 4.9 High Input V(N*R 4JH1-TC) or 4.5V(TF4JA1-TC,4JH1-TC) more than 500 m sec

Use Idle SW position = 100%, acceleration, decceleration becomes limmitted performance. Idle speed becomes 1400 RPM.

Yes

APS signal volage < 4.9 Need to check V(N*R 4JH1-TC) or 4.5V(TF 4JA1-TC/4JH1TC) more than 500 m sec

ON

X

X

X

1001

Pedal Position Sensor Voltage APS signal voltage < 4.6 V System volatge is used as 4.9Volt. Idling Supply Circuit Low Input more than 500 m sec speed becomes 1400 RPM. APS uses default 0%.

Yes

APS signal volage > 4.6 During same ignition V more than 500 m sec cycle

ON

X

X

X

0111

Pedal Position Sensor Voltage APS signal voltage > 5.2 V System volatge is used as 4.9Volt. Idling Supply Circuit High Input more than 500 m sec speed becomes 1400 RPM.

Yes

APS signal volage < 5.2 During same ignition V more than 500 m sec cycle

ON

X

X

X

P0704 0110

57

Clutch SW Malfunction

P1105 0010

86

Baro sensor Circuit Low Input Baro 1.48V(1.4794V=6000M) more than1 sec

0001 P1110 1000

72

0100

P1120 0010

21

Input

Circuit N*R 4JH1-TC--This check is Cut off Auto cruise control 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.

X

ENGINE DRIVEABILITY AND EMISSIONS DTC

Sub code

F/Code

DTC Name

Setting condition

Back-up mode

1101

Pedal Position Sensor Brake No brake error DTC indicates Error Brake pedal(sw is ON) and accel pedal (more than 18%(N*R 4JH1-TC) or 8.7%(TF 4JA1/4JH1TC)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.

1110

Pedal Position General Error

History code Cancel condition

Cancel Mode

MIL light

6E– 79

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC

APS value becomes “0%”. Idle speed becomes “1400 rpm”. APS value, idle speed are controlled to reach the above value smoothly.

Yes

Brake OFF, ACC OFF or During same ignition ACC acceleration 20%/ cycle Sec or brake error happens.

ON

X

X

X

Sensor N*R4JH1-TC--Idle SW ON Set to APS value = 0% and idle speed and APS value > 18% , more 1400RPM. 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

Yes

Idle SW OFF and APS Ignition Key off, no 100%, or Idle SW ON condition matches and APS 0%. But N*R then canceled. can not cance.

ON

X

X

X

Fuel Reduction caused by Fuel quantity is not normal None High Coolant Temp condition because ECT indicates more than 100deg C and more than for 30sec.

Yes

No more failure is During same ignition recognized. It returns to cycle normal condition immiditely.

OFF

X

X

X

0111

Fuel Reduction caused by PSG detects fuel temp PCU reduced Q-map is employed. High fuel Temp 1 output becomes more than 100deg C more than 30sec.

Yes

No more failure is During same ignition recognized. It returns to cycle normal condition immiditely.

OFF

X

X

X

1010

Fuel Reduction caused by ECM detects fuel ECM reduced Q-map is employed High fuel Temp 2 temperature is more than 80degC and last more than for 30sec.

Yes

No more failure is During same ignition recognized. It returns to cycle normal condition immiditely.

OFF

X

X

X

Yes

PCU accepts no more During same ignition erro of TDC. Counter cycle becomes 0 from 120.

ON

X

X

X

Yes

No more failure is During same ignition recognized. Return to cycle normal mode by counter reduction, almost immidiately.

ON

X

X

X

Yes

Two no consequetive cycle

ON

X

X

X

P1173 0011

22

P1335 1010

43

Engine Speed Output Circuit PCU Malfunction DZG(TDC)pulse immidiately.

detects Limit Q is employed. error

P1345 1010

41

Injection Pump:Camshaft PCU recognises cam speed None Speed Malfunction sensor(increment angle time system) error more than 1 sec. (Inrement angle time systemIAT)

P1520 1010

47

Neutral Switch ON

During driving condition*1, None Neutral SW on error signals are recognized more than three times and more than 60 sec.

failure The ignition cycle driving after two consecutive no failure igniton cycle makes MIL light off.

6E– 80 DTC

ENGINE DRIVEABILITY AND EMISSIONS Sub code

F/Code

1011

P1576 1000

71

DTC Name

Setting condition

Back-up mode

Neutral Switch OFF

During no driving condition*1, None Neutral SW off error signals are recognized more than three times and more than 60 sec.

History code Cancel condition

Cancel Mode

MIL light

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC

Yes

Two no consequetive cycle

failure The ignition cycle driving after two consecutive no failure igniton cycle makes MIL light off.

ON

X

X

Exh Brake and QWS Valve Powerstage ON, ECM ECM sends reverse phase 1(N*R 4JH1-TC--Exhaust initialized, IC recognises results to turn on ABS light ON. Brake and QWS, TF 4JH1- short to batt more than 1sec TC--QWS system only) Circuit Short to Battery

signal,

Yes

IC recognises no more During same ignition failure, more than cycle 1.5sec

ON

X Exh.Brake

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 ECM sends reverse phase initialized, IC recognises results to turn on ABS light ON. short to ground or open circuit more than 600msec

signal,

Yes

IC recognises no more During same ignition failure, more than cycle 600msec

ON

X NKR 4JH1-TC-Exh.Brake and QWS TF 4JA1-TC-QWS

P1577 1000

Ext VSV 2(TF 4JA1-TC-- Powerstage ON, ECM ECM sends reverse phase QWS) Circuit short to Battery initialized, IC recognises results to turn on ABS light ON. short to batt more than 1sec

signal,

Yes

IC recognises no more During same ignition failure, more than cycle 1.5sec

ON

X TF 4JA1-TC-QWS

P1577 0100

Ext VSV 2 (TF 4JA1-TC-- Powerstage ON, ECM ECM sends reverse phase QWS) Circuit short to Ground initialized, IC recognises results to turn on ABS light ON. or Open Circuit short to ground or open circuit more than 600msec

signal,

Yes

IC recognises no more During same ignition failure, more than cycle 600msec

ON

X TF 4JA1-TC-QWS

0100

P1605 1110

55

X MT Only

X NKR 4JH1-TC-Exh.Brake and QWS TF 4JA2TC--QWS

EEPROM Defect

EEPROM check sum does Engine does not start, idle target Q=0. not match with the check sum during initialization. Becomes back-up immidiately.

Yes

Right after EEPROM During same ignition checksum value cycle matches with initial values.

ON

X

X

X

1101

EEPROM Defect

Fail of read or EEPROM data initialization.

Yes

Right after EEPROM During same ignition checksum value cycle matches with initial values.

ON

X

X

X

1100

Seeds and key file destroyed

When either sees or keys None data is or are destoryed.

Yes

None

During same ignition cycle

ON

X

X

X

write Engine does not start, idle target Q=1. as

P1610 1010

56

Seeds and Key file destroyed

The engine control unit is in Can not start Engine, ECM must be the as-delivered condition reprogrammed.

Yes

No more failure recognized.

is During same ignition cycle

ON

X

X

P1611 1010

56

Wrong Security Code Entered Incorrect security code was The injection qty is immidiately stopped. input with Tech-II

Yes

The engine can first be During same ignition started when the correct cycle security code is input or the ignition is switched OFF/ON.

ON

X

X

P1612 1010

56

Immobiliser No Or Wrong The immo ICU-ECM The injection qty is immidiately stopped. Signal communication could not be The engine can not start. correctly completed.

Yes

No more failure recognized.

is During same ignition cycle

ON

X

X

P1613 1010

56

Immobiliser No Or Wrong The Immo-MSG Q stopped, can not start engine. Signal communication could not be correctedly completed.

Yes

No more failure recognized.

is During same ignition cycle

ON

X

X

ENGINE DRIVEABILITY AND EMISSIONS DTC

Sub code

F/Code

DTC Name

Setting condition

P1614 1010

56

Wrong Transponder Key

The compare response The injection qty is immidiately stopped. calculated in the ECM does The engine can not start. not agree with the response in immo.

P1625 1011

76

1010

P1630 1010

51

1011

P1650 1010

44

1011 P1651 1010

45

1011 P1690 1000

0100

77

Back-up mode

History code Cancel condition

Cancel Mode

Yes

No more failure recognized.

Power Supply Relay Switched During after-run , Main relay ECM command to shut main relay. Off too late shut off more than 2 sec

Yes

Engine can not restart

Ignition Key off, no failure condition matches then canceled.

OFF

Power Supply Relay Switched By thia monitoring function a None Off too Early main relay or control unit defect is recognized which causes a MSG shut off before the Microprocessor has given the shut demand.

Yes

Engine can not restart

Ignition Key off, no failure condition matches then canceled.

Fuel-Injection Quality Circuit Solenoid High Input overcurrent.

Yes

No failure recognised

Fuel-Injection Quality Circuit Solenoid valve has continous Engine stops, MAB operated, High Input energized.

CAN: Device Offline

N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC X

X

X

X

X

ON

X

X

X

During same ignition cycle

ON

X

X

X

Yes

No return to normal Ignition Key off, no mode during this driving failure condition cycle. matches then canceled.

ON

X

X

X

CAN communication is cut Engine stops, MAB operated, more than 200msec

Yes

No more failure more During same ignition than 100msec cycle

ON

X

X

X

CAN: Device Hangup

During driving, CAN lin hang Engine stops, MAB operated, up.

Yes

No more failure more During same ignition than 100msec cycle

ON

X

X

X

Inj Pump:CAN Malfunction

PSG can not receive ECM Engine stops, MAB operated, message or time out.

Yes

No more failure

During same ignition cycle

ON

X

X

X

CAN Receiver Error

Can not read out PSG Engine stops, MAB operated, message during afterrun

Yes

No more failure

During same ignition cycle

ON

X

X

X

MIL Circuit Open

Lamp circuit power on, IC None recognises short circuit more than 1 sec

Yes

IC recgnises no more During sameignition short circuit more than cycle 600msec

OFF

X

X

X

MIL Circuit High Input

Lamp circuit power off, IC None recognises open circuit more than 3 sec

Yes

IC recgnises no more During sameignition open circuit more than 3 cycle sec

OFF

X

X

X

valve

has Limit Q is employed.

is During same ignition cycle

MIL light

6E– 81

*1 Driving condition

No driving condition

TF 4JA1-TC 585

VS>62.9km/h V/N>0.00412 1st gear

VS<1.5km/h Eng rpm>693rpm V/N<0.00412

TF 4JH1-TC 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

N*R 4JH1-TC VS>64.0km/h V/N>0.003398 134

VS<2km/h Eng rpm>665rpm V/N<0.003338

ON

6E– 82

ENGINE DRIVEABILITY AND EMISSIONS

ENGINE DRIVEABILITY AND EMISSIONS

6E–83

On-Board Diagnostic (OBD) System Check

1GN

ECU 25A

Fuse

DLC Ignition Feed Circuit

Check Engine Lamp(CEL)

16 15 14 13 12 11 10 9

ABS NKR 4JH1-TC only Diagnostic Connector

8 7 6 5 4 3 2 1

BRN/ YEL 42

Serial Data Circuit YEL/ GRN 35 Keyword 2000 (Serial Data)

ABS NKR 4JH1-TC only ORN/ BLU 45 Engine Control Module (ECM)

Diag Switch

µP µP : Microproccesor

1,2

ECM Ground

060RY00330

Circuit Description

connection, and damaged harness.

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.

Test Description

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

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”.

6E–84

ENGINE DRIVEABILITY AND EMISSIONS

On Board Diagnostic (OBD) System Check Step 1

2

3

4 5

6

7

8

Action

Value(s)

Yes

No

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”

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

—

Go to Step 4

Go to “Engine Cranking But Won't Run”

—

Go to DTC Chart

Go to Step 5

1. Ignition “On”, engine “On”. Did the engine start and continue to run? 1. Select “Display DTCs” with the Tech 2. Are any DTCs stored? 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

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

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

1. Replace ECM. Is the action complete?

—

Go to Step 2

—

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.

6E–85

6E–86

ENGINE DRIVEABILITY AND EMISSIONS

No Check Engine Lamp Step

Action

1

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

2 3

4

5

6

7

8

9

10

Value(s)

Yes

No

—

Go to Step 2

Go to “On Board Diagnostic (OBD) System Check”

1. Ignition “On”, engine “On” Did the engine start?

—

Go to Step 3

Go to Step 7

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

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

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

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

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

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

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

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

ENGINE DRIVEABILITY AND EMISSIONS Step 11

12

13

14

15

16

17

18 19

Action

6E–87

Value(s)

Yes

No

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

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

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

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

—

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

1. Check ECM ignition feed circuit and ECM battery feed circuit. Was the problem found?

—

Verify repair

Go to Step 18

1. Probe the ignition feed circuit at the cluster connector for open or short to ground. Did it turn on?

—

Verify repair

—

1. Replace ECM. Is the action complete?

—

Verify repair

—

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

6E–88

ENGINE DRIVEABILITY AND EMISSIONS

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–89

Check Engine Lamp “ON” Steady Step

Action

1

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

2

3

4 5

6

Value(s)

Yes

No

—

Go to Step 2

Go to “On Board Diagnostic (OBD) System Check”

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

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

1. Replace instrument panel cluster. Was the malfunction fixed?

—

Verify repair

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

Replace ECM. Is the action complete?

—

Verify repair

—

88

5

CPU

IC 08

US

92

3

µP : Microproccesor

84

1

MAF

2

4

83

ECM 25A

µP

97

µP

Batt

EVRV: EGR

40

Batt

µP

95

Batt

MAG valve VSV: Exh Brake INT. Throttle (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

IC 08

87

Batt

SW:Neutral (MT only)

µP

91

PCU

105

5

µP

Batt

8

6

Batt

CF 150

99 CAN-L

1 2

7

100 CAN-H

6E–90 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0100 MAF SENSOR MALFUNCTION

ENGINE DRIVEABILITY AND EMISSIONS

MAF Circuit

1

IAT sensor

NTC

3

2

4

+5V

Heater

5

Temperature Sensor Power Supply Power Ground Suppliment Voltage Voltage Output

Top view of

mode on page 6E-92.

MAF sensor

6E–91

6E–92

ENGINE DRIVEABILITY AND EMISSIONS

HOTFLM-MASS AIR SENSOR

MTC CILY IN PAST ACC. POS. MO. 2 MCLSED

CYLINDER HOUSING

BUSH

SCREEN FILTER WITH FAN

FLOW GRID

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–93

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

Go to Step 3

Refer to Intermittent Diagnosis

0V

Replace MAF and verify

Go to Step 4

0V

Replace ECM and verify

Repair engine harness and verify

2

3

4

1. Clear the DTC. 2. Observe the DTC. Was the DTC P0100 stored? Breaker box is available Ignition off Install breaker box as type B, see page 6E-58. 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. 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.

6E–94

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Refer to Intermittent Diagnosis

5V

Replace MAF sensor and verify

Go to Step 4

More than 10MΩ

Go to Step 5

Repair engine harness

More than 4.6V

Replace ECM

Repair Engine harness

13.70kΩ

Replace ECM and verify

Replace MAF and verify

2

3

1. Clear the DTC P0100. 2. Observe the DTCs. Was the DTC P0100 stored? Breaker box is available Ignition off Install breaker box as type B, see page 6E-58. Disconnect MAF sensor from engine harness. Measure voltage at ECM pin 83 and ground. Measure the resistance between ECM pin 83 and ground. 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. ECM harness connector

83

4

5

Breaker box is available Ignition off Replace the ECM to the another ECM known as OK. Measure voltage at ECM pin 83 and ground. Breaker box is not available Ignition off Keep disconnected MAF condition. Measure resistance between MAF side connector pin 3 and ground.

1 2 3 4 5

MAF sensor connector

ENGINE DRIVEABILITY AND EMISSIONS

6E–95

DTC P0100 SUB CODE 1100 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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Repair or Replace harness

2

3

1. Clear the DTC P0100. 2. Observe the DTCs. Was the DTC P0100 stored?

—

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect MAF sensor. Make jump wire between MAF 3 pin and MAF 4 pin at engine harness connector. Check continuity between 83 and 92. 1 2 3 4 5

Continuity Make jump wire between MAF 3 and MAF 5 pin at engine harness connector. Check continuity between ECM pin 88 and pin 92. 1 2 3 4 5

Continuity Remove jump wire, MAF sensor should disconnected. Check isolation resistance between ECM pin 88 and ECM pin 92.

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. 1 2 3 4 5

Continuity Make jump wire between MAF 3 and MAF 5 pin at engine harness connector. Check continuity between ECM pin 88 and pin 92. 1 2 3 4 5

Continuity Remove jump wire, MAF sensor should disconnected. Check isolation resistance between ECM pin 88 and ECM pin 92. 88 92

More than 1MΩ

6E–96

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

Yes

No

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

ENGINE DRIVEABILITY AND EMISSIONS

6E–97

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

Go to Step 3

Refer to Intermittent Diagnosis

More than 1MΩ

Go to Step 4

Go to Step 5

0V

Go to Intermittent Diagnosis. (I/D)

Replace MAF

5V

Replace ECM and verify

Repair engine harness

No DTC

No DTC Replace ECM and veirfy

DTC ON Repair engine harness

2

3

1. Clear the DTC P0100. 2. Observe the DTCs. Was the DTC P0100 stored?

—

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect MAF connector from engine harness. Measure voltage between ECM pin 83 and ground.

5V

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.

83

4

Measure voltage at MAF connector.

1 2 3 4 5

5

Breaker box is available Ignition off Replace to the another ECM known as OK. Measure voltage between ECM pin 83 and ground Breaker box is not available Ignition off Replace to the another ECM know as OK. Check DTC turn ON.

6E–98

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0110 IAT Sensor Maifunction

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

DTC P0110 SUB CODE 0010 IAT Sensor Low Voltage 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

Go to Step 3

Refer to Intermittent Diagnosis

2

1. Clear the DTC P0110. 2. Observe the DTCs. Was the DTC P0110 stored?

—

ENGINE DRIVEABILITY AND EMISSIONS Step 3

Action

6E–99

Value(s)

Yes

No

More than 1MΩ

Go to Step 4

Repair wiring

No short circuit Appx 2.0KΩ at 20°C room temperature

Replace ECM

Replace MAF

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect MAF sensor. Measure resistance between 84 and ground. Breaker box is not available Ignition off Disconnect ECM harness and MAF sensor.

84

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.

1 2 3 4 5

6E–100

ENGINE DRIVEABILITY AND EMISSIONS

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Repair engine harness and verify

Go to Step 5

Replace MAF sensor and verify

2

3

1. Clear the DTC P0110. 2. Observe the DTCs. Was the DTC P0110 stored?

—

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect MAF sensor. Make jump wire between MAF 1 and MAF 3 at MAF connector side.

1 2 3 4 5

Check continuity between 84 and 92.

Continuity

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.

1 2 3 4 5

Continuity 4

Breaker box is available Ignition off Disconnect MAF sensor. Measure resistance between MAF pin 1 and pin 3. 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.

2.0KΩ at 20°C room temperature 0V 2.0KΩ at 20°C room temperature 0V

ENGINE DRIVEABILITY AND EMISSIONS Step 5

Action 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.

6E–101

Value(s)

Yes

No

No DTC ON

Replace ECM

—

1 23 4 5

6E–102

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0115 Engine Coolant Temperature Sensor Malfunction

16 15 14 13 12 11 10 9 VSS

8 7 6 5 4 3 2 1

Balt

29

4 ABS ECT

TDC 7

27

68

8

62

32

90

98

89

Balt

Balt

93

35

45

Us IC 08

IC 08

IC 08

µP

IC 08

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.

IC 03

Engine Coolant Temperature Sensor °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–103

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

Go to Step 3

Refer to Intermittent Diagnosis

2

3 4 5

1. Clear the DTC P0115. 2. Observe the DTCs. Was the DTC P0115 stored?

—

Check water temp metor. Does it indicate very low temperature?

Go to Step 4

Check atomosphere temperature? Warm up engine. Check lamp goes off or not.

6

Does water temperature meter indicate still low temperature? and lamp still stay.

7

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

Less than -36°C

Go to Step 5

Go to Step 7

Lamp goes off after warm up

No repair necessary

Go to Step 6

Coolant system check

Peplace ECT sensor

Continuity

Go to Step 8

Repair wire

Compare with ECT sensor table.

Go to Step 9

Replace ECT sensor

0V

Replace ECM

Repair harness

105

8

9

Check ECT resistance.

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.

99

6E–104

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Go to Step 8

More than 136°C DTC turns ON

Follow mechanical section

Go to Step 5

LLC : Water = 50 : 50

Go to Step 6

Change LLC

See the mechanical section

Go to Step 7

See the electrical section

—

Go to Step 9

Repair wiring

2

3

4

5 6

7

8

1. Clear the DTC P0115. 2. Observe the DTCs. Was the DTC P0115 stored?

—

Check water temp meter. Does it indicate very high temperature? or indicate more than max condition. Check engine has over heat condition.

LLC consentration is too high, check reserver tank. Check radiator cap setting pressure.

Check water temp meter indicator.

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

105

No short to ground

ENGINE DRIVEABILITY AND EMISSIONS Step 9

10

Action

6E–105

Value(s)

Yes

No

No short to ground

Go to Step 10

Short to ground replace ECT

See the table

Replace ECM

Replace ECT

Check ECT sensor not short to ground.

Check ECT sensor performance. Does it indicate within the engine coolant temperature sensor resistance table?

6E–106

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0180 SUB CODE 1011 FUEL TEMPARETURE SENSOR CIRCUIT RANGE/PERFORMANCE

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

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.

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Out of specification Replace injection pump

2

3

1. Clear the DTC P0180. 2. Observe the DTCs. Was the DTC P0180 stored? 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
ENGINE DRIVEABILITY AND EMISSIONS Step

Action

4

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Disconnect PCU connector. Make jump wire between PCU connector pin 1 and 2. Check continuity between ECM connector 99 and 100.

6E–107

Value(s)

Yes

No

Continuity

Replace injection pump

Repair wiring

2

1

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.

6E–108

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0215 FUEL CUTOFF SOLENOID VALVE MALFUNCTION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

95

87

5

91

105

TDC Batt

Batt

Batt

Batt

1 2

99 CAN-L

100 CAN-H

MAB Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

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 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

Go to Step 3

Go to Intermittent Diagnosis

2

1. Clear the DTC P0215. 2. Observe the DTCs. Was the DTC P0215 restored?

—

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

3

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Disconnect PCU connector. Check short circuit between ECM pin 105 and power source points, see “reference” on page 6E-110. 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-110. Sample shows only 4JA1-TC, but other 4JH1-TC system should be same points.

6E–109

Value(s)

Yes

No

No short circuit

Go to Step 4

Repair wiring

105

see page 6E-110 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. 2

1

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.

99

Continuity

Repair wiring

6E–110

ENGINE DRIVEABILITY AND EMISSIONS

reference BATT

RELAY ; ECM MAIN 2L/R IC02

B13(91)

SW ; CLUTCH 0.5G IC07

(OFF)

0.5Y IC08

TDC

3 2

0.5W IC45

B-2

0.5G/R IC46

B-3

B22(98)

A-16

FUEL HEATER

B25(101)

B6(87)

SW ; NEUTRAL 0.5L/R IC09 SW ; BACK UP

B-10

0.5B/W IC10

2B IZ01

A61(2)

2B IZ02

A62(1)

0.5R/L MB11

RESISTER ; NEUTRAL SW (IDLE SW) 0.5B IZ10

0.5B/W IC58

CONT ; IMMOBILIZER(B8)

5B/R HB03

B12(90)

B-10 IZ05

0.5G IC48

0.5R CA02

GLOW PULG x4 1

0.5B IZ05

A-1

0.85Y KA01 B-11 0.85R/Y KA02 A-11 0.85Y MA02

VEHICLE SPEED SENSOR 0.85B MX05 THERMO UNIT

A-12 0.5L/B MA03 B-14 0.5Y/B MA06

A32(35)

METER ENG COOLANT

B6

OIL PSESSURE UNIT

OIL GAGE 0.5Y/G MA09

4WD SW

0.5B IZ06

ECM

B-6

0.5W/R MA11

B15

B-5

0.5L MA10

A10

SW ; OIL

A24(27)

0.5B/R MA05

B3

A68(68)

0.5L/W IC21

A38(41)

0.5O/B MB04

0.5B/L EX02

0.5L IC47

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR) 0.5G HA22 A43(45) A30(33)

B2 ENG

SPEED METER A8

A9

RELAY ; A/C COMPRESSOR

B-5

0.5B EX03

GLOW CHECK

TACHO METER 0.5O/L MB01

JOINT TO EX12

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

CONT ; IMMOBILIZER(B5)

A39(42)

A6

OIL

0.5G HA18

0.5BR HA23 0.5G/R HA13

ELEC.THERMO 0.5G HA21 RESISTER ; IDLE UP 0.5B 0.5G 270 HA24 HX03

4

1

0.5BR HA19

2

0.5BR HA17

1 0.5L/W HA14 4

FUSE ; BLOOR

2 0.5G/W HA16

RELAY ; A/C THERMO

SW ; PRESSURE ECM

CONT ; IMMOBILIZER(B1)

REV

0.5G IC30

BACK UP LAMP

B8

4WD

BRAKE LAMP

0.5O/L MA28 0.5BR/Y IC29

A40(43)

EB STOP 10A

(OFF)

J/C ; B

A28(31)

(ON)

0.5W/B IC13 RESISTER ; CLUTCH SW (YZK NO ; 7321-9900) 0.5B 0.5Y 510 IZ08 IC57

BACK 15A

B8(89)

A65(65)

0.5B/R IC50

B-1

B15(93)

0.5G CA01

SW ; BRAKE 0.5R IC12

0.85W KA01

0.5GR IC44

JOINT TO SX01

0.5B/L HB06 0.5L/Y IC06

B16(94) A36(39)

METER 15A 0.85Y MA01

IZ06

IZ07

ECT SENSOR

B-7

0.5B HY05

A55(57)

A27(30) 0.5B/P IC43

JOINT TO BA15

ENGINE 10A

A44(46)

0.5G/R BA26

ACG(B)

A35(38)

0.5B BX16 0.5BR/R IC14

3W PA16

SW ; ENG WARMING JOINT TO MX01

3B/R PA17

A-9

0.5L/R IC15

2

OFF ACC IG2 ST IG1 3B/R

0.5B/G IC38

A47(49)

4 5 3 1

RELAY ; GLOW

A-8

A-7

IC27 IC28 IC30 IC39

SW ;THERMO

0.5G/O IC37

A69(69)

0.5W/R 0.5G/R 0.5B/R 0.5B/L

B2(83) B7(88) B14(92) B3(84)

MAF

A-6

3W PA13

0.5 IZ04 T.P.S.&SW ; IDLE (THROTTLE VALVE)

0.5G/B IC35 0.5R/G IC36

0.5L/R IC16

SW ;IGNITION

0.5B/O IC26

B19(97)

5R/W HB01

EVRV ; EGR

3W B2 PA03 3W/B B1 PA02

0.5L/R IC18

0.5L/R IC11

0.5 IZ03

0.5W/R IC23

A59(61)

8W PA28

A-5

0.5L/R IC17 VSV ; EXT 2

IG2 40A

B29(105)

MAIN 80A

VSV ; EXT 1 0.5W/B IC22

A37(40)

A-4

IG.1 50A

0.5L/B IC04

B23(99)

GLOW 50A

1

A56(58)

ECM 25A

4

A-3

A41(3)

3B PA28

INJ.PUMP

3

B24(100)

0.5B/Y IC03 2L/R IC05

2B/Y IC01

A63(63) A-2

0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

2

8B/R PA01

A-15

2L/R IC02

ENGINE DRIVEABILITY AND EMISSIONS

6E–111

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

—

Go to Step 3

Go to Intermittent Diagnosis

No short circuit

Go to Step 4

Repair wiring

2

3

1. Clear the DTC P0215. 2. Observe the DTCs. Was the DTC P0215 restored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Disconnect PCU connector. Check short circuit between ECM pin 105 and power source points, see “reference” on page 6E-110. 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 6E-110. Sample shows only 4JA1-TC, but other 4JH1-TC system should be same points.

105

see page 6E-110

6E–112

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

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.

Value(s)

Yes

No

Continuity

Go to Step 5

Repair wiring

Replace injection pump

Replace ECM

2

1

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.

99 100

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–113

DTC P0215 SUB CODE 1010 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

—

Replace injection pump

Go to Intermittent Diagnosis

2

1. Clear the DTC P0215. 2. Observe the DTCs. Was the DTC P0215 restored?

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

Replace ECM

Go to Intermittent Diagnosis

2

1. Clear the DTC P0215. 2. Observe the DTCs. Was the DTC P0215 restored?

—

6E–114

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0216 TIMING DEVICE DEVIATION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

95

87

5

91

105

TDC Batt

Batt

Batt

Batt

1 2

99 CAN-L

100 CAN-H

MAB Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

DTC P0216 SUB CODE 1010 PERSISTANT GOVERNER DEVIATION 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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Adjust

Replace injection pump

Replace or Repair TDC sensor or exciter ring

2

3

4

1. Clear the DTC P0216. 2. Observe the DTCs. Was the DTC P0216 stored? Check timing gear positions align between cam and injection pump. See the timing gear check procedure in the mechanical engine section.

—

Check TDC sensor with any damage or exciter ring teeth damage.

ENGINE DRIVEABILITY AND EMISSIONS

6E–115

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

Go to Step 3

Refer to Intermittent Diagnosis

Bleed air in fuel. See the procedure of air bleed in fuel section.

Verify

Verify still DTC appears

Replace injection pump.

Verify

—

2

3 4

1. Clear the DTC P0216. 2. Observe the DTCs. Was the DTC P0216 stored?

—

6E–116

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0251 INJECTION MALFUNCTION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

95

87

5

91

105

TDC Batt

Batt

Batt

Batt

1 2

99 CAN-L

100 CAN-H

MAB Batt CF 150

US µP

CPU

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

DTC P0251 SUB CODE 0110 INJECTION PUMP MALFUNCTION 1 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

Go to Step 3

Refer to Intermittent Diagnosis

2

3

1. Clear the DTC P0251. 2. Observe the DTCs. Was the DTC P0251 stored? Replace injection pump

—

Verify

ENGINE DRIVEABILITY AND EMISSIONS

6E–117

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Replace or Repair TDC sensor or exciter ring

Replace ECM and verify if still DTC appears. Go to Step 5

Repair wiring harness

Verify

—

2

3

4

1. Clear the DTC P0251. 2. Observe the DTCs. Was the DTC P0251 stored?

—

Check TDC sensor with any damage and exciter ring with any damage.

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Disconnect PCU connector. Make jump wire between PCU connector 8 and 5. Measure resistance between 91 and 105. 5

8

Breaker box is not available Ignition off Disconnect ECU and PCU harness. Make junping between 8 and 5.

91

105

Measure resistance between 91 and 105. 5

Replace injection pump.

0Ω

6E–118

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0251 SUB CODE 1001 INJECTION PUMP MALFUNCTION 2 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

Go to Step 3

Refer to Intermittent Diagnosis

2

3

1. Clear the DTC P0251. 2. Observe the DTCs. Was the DTC P0251 stored?

—

Replace injection pump

Verify

DTC P0251 SUB CODE 1010, 1011, 1101 INJECTION PUMP MALFUNCTION 3, 4, 5 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

Go to Step 3

Refer to Intermittent Diagnosis

2

3

1. Clear the DTC P0251. 2. Observe the DTCs. Was the DTC P0251 stored?

—

Replace injection pump

Verify

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

—

Go to Step 3

Refer to Intermittent Diagnosis

Continuity

Replace ECM ↓ Verify ↓ NG Replace injection pump

Repair wiring

2

3

1. Clear the DTC P0251. 2. Observe the DTCs. Was the DTC P0251 stored? Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect PCU connector. Make jump wire between PCU connector 1 and 2. Check continuity between ECM connector 99 and 100. 2

1

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–119

DTC P0335 TDC MALFUNCTION DTC P0335 SUB CODE 1110 TDC INPUT CIRCUIT SIGNAL RANGE/PERFORMANCE (OVER SPEED)

16 15 14 13 12 11 10 9 VSS

8 7 6 5 4 3 2 1

Balt

29

4 ABS TDC

7

27

68

8

62

32

90

98

89

Balt

Balt

93

35

45

Us IC 08

IC 08

IC 08

µP

TDC sensor

IC 08

IC 03

Excitor ring

6E–120

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

1

Ask the customer whether or not he experience over speed condition such as long down slope driving, mis gear shift etc.

2 3

4

Value(s)

Was the “On-Board Diagnostic (OBD) System Check” performed? 1. Clear the DTC P0335. 2. Observe the DTCs. Was the DTC P0335 stored?

Yes

No

Explain customer why DTC turns on

Go to Step 2

Go to Step 3

Go to OBD system check

—

Go to Step 4

Refer to Intermittent Diagnosis

0.9KΩ at 20°C room temp

Go to Step 6

Go to Step 5

Continuity

Replace TDC sensor

Repair wire

Go to Step 7

Repair

Go to Step 8

Remove accessary and verify

—

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

98 90

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.

98 90

6 7

Check shield wire and ground. Check any damage of wire related shield wire. Check any accessary which may cause electric or magnetic interference.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

Value(s)

8

Breaker box is available Ignition off Connect TDC sensor. Connect ECM to breaker box as type B. Run engine. Measure voltage at ECM pin 90 and 98 by digital volt meter AC range.

6E–121

Yes

No

Replace ECM

Go to Step 9

Go to Step 10

Replace TDC sensor and verify

Replace ECM

Replace or Repair excitor ring

98 90

Breaker box is not available Ignition off Skip this step. Go to next step 9. 9

10

Check TDC sensor. Remove TDC sensor. Check any damage or foreign materials on TDC.

18V No damage No foreign material

Check exciter ring whether or not any damage.

6E–122

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Refer to Intermittent Diagnosis

0.9KΩ at 20°C room temp

Go to Step 5

Go to Step 4

2

3

1. Clear the DTC P0335. 2. Observe the DTCs. Was the DTC P0335 stored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

98 90

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

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.

6E–123

Value(s)

Yes

No

Continuity

Replace TDC sensor

Repair wire

Go to Step 6

Repair

Go to Step 7

Remove accessary and verify

Replace ECM

Go to Step 9

Go to Step 9

Replace TDC sensor and verify

Replace ECM

Replace or Repair excitor ring

98 90

5 6

7

Check shield wire and ground. Check any damage of wire related shield wire. Check any accessary which may cause electric or magnetic interference. 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.

98 90

Breaker box is not available Ignition off Skip this step. Go to next step 9. 8

9

Check TDC sensor. Remove TDC sensor. Check any damage or foreign materials on TDC.

NO damage NO foreign material

Check exciter ring whether or not any damage.

6E–124

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Refer to Intermittent Diagnosis

0.9KΩ at 20°C room temp

Go to Step 5

Go to Step 4

2

3

1. Clear the DTC P0335. 2. Observe the DTCs. Was the DTC P0335 stored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

98 90

ENGINE DRIVEABILITY AND EMISSIONS

6E–125

Step

Action

Value(s)

Yes

No

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

Go to Step 6

Repair

Go to Step 7

Remove accessary and verify

Go to Step 9

Replace TDC sensor and verify

Replace ECM

Replace or Repair excitor ring

5 6

7

8

9

Check shield wire and ground. Check any damage of wire related shield wire. Check any accessary which may cause electric or magnetic interference. 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. Check TDC sensor. Remove TDC sensor. Check any damage or foreign materials on TDC.

0V NO damage NO foreign material

Check exciter ring whether or not any damage.

6E–126

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0380 GLOW DEVICE MALFUNCTION

ECU Relay

Glow 60A

Register idle SW

APS

Relay G/plug

Glow plug +5V 94

57

38

Balt

IC 08 µP

49

69

2

1

GND

GND

ENGINE DRIVEABILITY AND EMISSIONS

6E–127

System Description

Pre glow system calibration

8

Example

sec.

Pre glow

7

Time

5 4 3

1 0 -30

-10

10 30 50 Water temperature (°C)

70

90

After glow system calibration

sec.

glow relay on setting curve

Time

24

18

-10

0

10 Water temperature (°C)

30

35

After run glow

100

sec. glow relay on setting curve

45 Time

After run

Lg ON

2

30

After glow

glow current

glow relay on setting curve

6

40

35

0

10 20 Water temperature (°C)

30

Cranking

Vehicle run

Log

6E–128

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Refer to Intermittent Diagnosis

No short circuit

Replace ECM

Repair wiring or G/plug relay

2

3

1. Clear the DTC P0380. 2. Observe the DTCs. Was the DTC P0380 stored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Check short circuit between ECM pin 94 and pour souce line see “reference” on page 6E-129. 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 6E-129.

ENGINE DRIVEABILITY AND EMISSIONS

6E–129

reference

2L/R IC02

0.5L/R IC15

EB STOP 10A

0.5G CA01 BACK 15A 0.85W KA01

0.85Y MA01

(ON) (OFF)

B25(101) GLOW PULG x4 A-16

A C B

0.5G/B IC35 0.5R/G IC36

0.5R/B IC60 C-15

A69(69)

R

A47(49)

N D

A-10 0.85R/Y KA02 C-10 0.5W/R OA57 C-3

2

C-4

1

C-2

N

0.5B/W LA06 C-14 0.5B/G LA09 A-1

0.5G/O IC37

A35(38)

0.5B/G IC38

A55(57) IZ07

B

2B IZ02

A62(1)

0.5R/L MB11

A32(35)

A-11

SW ; MODE VEHICLE SPEED SENSOR

10 11 31 TCM 32 47 48

FUSE ; STARTER RELAY ; STARTER

0.85Y MA02

A-12 0.5L/B MA03

0.85B MX05 THERMO UNIT

0.85R/Y KA02

CONT ; IMMOBILIZER(B8)

A61(2)

0.5R/G OA10 0.5R/Y OA11 0.5W/R OA31 0.5Y/R OA32 0.5Y/L OA58 0.5Y/V OA59

B-4

ECM 2B IZ01

0.5R/B IC61

P

ENG COOLANT B-3

0.5G IC48

T.P.S.&SW ; IDLE (THROTTLE VALVE)

F

5B/R HB03

0.5R CA02

0.5 B IZ04 E

B6(87)

B6

0.5Y/B MA06

OIL PSESSURE UNIT

OIL GAGE 0.5Y/G MA09 0.5W/R MA11(W/SOF) TB07(W/O SOF)

B15

A-6

0.5L MA10

A10

SW ; OIL

0.5O/L MA18

B8

A39(42)

0.5BR/R IC29

A6

A24(27)

0.5B/R MA05

B3

A40(43)

4WD

OIL GLOW

CHECK

B2 ENG

TACHO METER

0.5L IC47

A68(68) A43(45)

A46(48) A26(28)

OA25

0.5B EX03

0.5L/W IC21 0.5R/Y OA60 0.5B/R OA06

SPEED METER A8

A9

25 37

5

OA05 METER

6 ENG EARTH

0.5B OX01

TCM

0.5O/L MB01 0.5G IC48

CONT ; IMMOBILIZER(B1)

BACK UP LAMP

0.5O/B MB04

B-2

BRAKE LAMP

CONT ; IMMOBILIZER(B5)

0.5B/L EX02

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

JOINT TO EX12

4WD SW

0.5B IZ06

J/C ; B

ACG(B)

METER 15A

ENGINE 10A

SW ; BRAKE

3W PA16

3W PA13

3B/R PA17

IZ05

OFF ACC IG2 ST IG1 3B/R

0.5G/W HA16

0.5R IC12 0.5W/B A65(65) IC13

B2

B12(90)

A-9

FUSE ; BLOOR

B1

1 0.5L/W 2 HA14

4

RELAY ; GLOW

ELEC.THERMO 0.5G/R HA13 0.5G HA21 RESISTER ; IDLE UP (YZK NO ; 7321-9430) 0.5B 0.5G HX03 HA24 270 0.5B/L HB06 B16(94) 0.5L/Y IC06 A36(39) A30(33)

B22(98)

A-8

SW ;IGNITION

0.5G/R IC46

FUSE ; A/C

RELAY ; A/C THERMO

0.5G HA23

A27(30)

2

3W PA03 3W/B PA02

A-7

0.5L/W HB04

0.5W IC45

B8(89)

5R/W HB01

TDC

3

B-6

2 0.5BR HA17

SW ; PRESSURE

ECT SENSOR 1

0.5O IC44

B15(93)

4

B-1 0.5G HA18

0.5B HX22

B-5

0.5L/R IC11

1

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR)

0.5B/P IC43

0.5BR HA15

A38(41)

0.5BR HA19

0.5 IZ03

RELAY ; A/C COMPRESSOR

8W PA28

4 5 2 3 MAF 1

MAIN 80A

B13(91)

0.5W/R IC27 0.5G/R IC28 0.5B/R IC30 0.5B/L IC39

8B/R PA01

A-5

0.5L/B IC04

IG2 40A

B29(105)

B2(83) B7(88) B14(92) B3(84)

IG.1 50A

A-4

A56(58)

GLOW 50A

1

B23(99)

2L/R IC05

ECM 25A

4

A-3

A41(3)

IC11 HB04 HA15 IC15 HA19

3B PA28

INJ.PUMP

3

B24(100)

0.5L/R 0.5L/W 0.5L/R 0.5L/R 0.5L/R

2B/Y IC01

0.5B/Y IC03

0.5L/R IC62 A63(63) A-2

0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

2

BATT

RELAY ; ECM MAIN A-15

2L/R IC02

6E–130

ENGINE DRIVEABILITY AND EMISSIONS

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

Go to Step 3

Refer to Intermittent Diagnosis

Replace ECM

Repair wiring

2

3

1. Clear the DTC P0380. 2. Observe the DTCs. Was the DTC P0380 stored?

—

Breaker box is available Ignition off Install breaker box. Disconnect ECM relay. Check continuity between ECM relay socket 87a (NKR 4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) pin and ECM 94 pin. Check short to ground between ECM 94 pin and ground. 87

85

Continuity No short to ground

87a 86

85 30

ECM relay (N∗R)

86

87 30

ECM relay (TF4JA1-TC,4JH1-TC)

Breaker box is not available Ignition off Disconnect ECM connector and ECM relay. Check continuity between ECM relay socket 87a (NKR 4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) pin and ECM 94 pin.

Continuity

Check short to gruons between ECM 94 pin and ground.

94

87 87a 86

85 30

ECM relay 85

86

87 30

No short to ground

ENGINE DRIVEABILITY AND EMISSIONS

6E–131

DTC P0381 GLOW TIME TELLTALE CIRCUIT MALFUNCTION

1G #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

Relay EW

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

SW:ExG Brake Meter ExG Brake

Check Engine

Glow

ABS control unit 3

58

39

30

65

31

64

60

Batt

µP

42

43

59

46

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

DTC P0381 SUB CODE 1000 GLOW TIME TELLTALE CIRCUIT SHORT TO BATTERY VOLTAGE 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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Replace bulb

2

3

1. Clear the DTC P0381. 2. Observe the DTCs. Was the DTC P0381 stored? Check glow lamp bulb is burnt out.

—

6E–132

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

4

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

Value(s)

Yes

No

0V

Replace ECM

Repair wiry

43

ENGINE DRIVEABILITY AND EMISSIONS

6E–133

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

Go to Step 3

Refer to Intermittent Diagnosis

See the P1690 wiring check

Go to Step 4

Go to Step 35

Repair wiring for open circuit

Replace ECM

Repair wiring for short to ground

2

3 4

1. Clear the DTC P0381. 2. Observe the DTCs. Was the DTC P0381 stored? There are two DTC P0381, P1690 ON? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

43

5

—

42

Lamp value NKR 140Ω/ 12V 460Ω/ 24V TF 140Ω/ 12V Continuity

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.

43

More than 10MΩ

6E–134

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0400 EGR SYSTEM MALFUNCTION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Newtral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

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

Go to Step 3

Refer to Intermittent Diagnosis

2

1. Clear the DTC P0400. 2. Observe the DTCs. Was the DTC P0400 stored?

—

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

3

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Remove ECM relay. Check continuity between ECM relay socket 87a (NKR 4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) and ECM pin 97. 87

Value(s)

6E–135

Yes

No

Replace ECM

Repair wiring or Repair EVRV of EGR

85

87a 86

85 30

ECM relay (N∗R)

86

87 30

ECM relay (TF4JA1-TC,4JH1-TC)

Breaker box is not available Ignition off Disconnect ECM connector, ECM relay. Check continuity between ECM relay socket 87a (NKR 4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) and ECM pin 97.

97

87 87a 85

86 30

ECM relay 85

86

87 30

Continuity

6E–136

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Refer to Intermittent Diagnosis

0V

Replace EVRV Go to Step 4

Repair wiring

2

3

1. Clear the DTC P0400. 2. Observe the DTCs. Was the DTC P0400 stored? Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. 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.

EVRV:EGR

Breaker box

check

4

Verify Still DTC ON.

ECM

Replace ECM

ENGINE DRIVEABILITY AND EMISSIONS

6E–137

DTC P0400 SUB CODE 0011 EGR FLOW EXCESSIVE DETECTED

A0 (Air mass mcasured by MAF) Intake shutter Aircleaner Compressor MAF MAF

Output A0

Airduct

EGR A1 (Leakage)

ENG

If A0≠A2, need of cheak leakage A1, because A2=A0+A1

Turbo Silencer

Exh. valve A2 (Air mass goes to cylinders)

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

Go to Step 3

Refer to Intermittent Diagnosis

Repair

Go to Step 4

Repair intake shutter

Go to Step 5

Go to Step 6

Check turbo system

Replace exhaust related brake

Go to Step 7

2

3

1. Clear the DTC P0400. 2. Observe the DTCs. Was the DTC P0400 stored?

—

Check inlet pipe disconnected or loose or hole or detorted.

A0 (Air mass mcasured by MAF)

MAF

A1 (Leakage)

Output A0

If A0≠A2, need of cheak leakage A1, because A2=A0+A1

A2 (Air mass goes to cylinders)

4 5 6

Check intake shutter stack closed with engine running. Check MAF is within typical data. Check exhaust pipe, silensor detorted, or deformed. It may cauese exhaust pressure extremely high.

6E–138

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

7

Check exhaust brake stuck close, if exhaust breake is required.(NKR 4JH1-TC only)

Yes

No

Replace exhaust brake

Go to Step 8

mighty vac Picture Exh. Brake

Open

Apply vacuum by mighty vac. See the valve operation. 8

Check EGR value stuck open.(NKR 4JH1-TC, TF 4JA1-TC only)

check window

Apply vacuum by mighty vac. Check valve operation through window. See page 6E140. 9

Check MAF data within typical data.

10

Replace ECM

Go to Step 9 Go to Step 10 Verify

Replace MAF

ENGINE DRIVEABILITY AND EMISSIONS

6E–139

DTC P0400 SUB CODE 0101 EGR FLOW INSUFFICIENT DETECTED

Intake shutter Aircleaner Compressor MAF

Airduct

EGR ENG

Turbo Silencer

Exh. valve

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

Go to Step 3

Refer to Intermittent Diagnosis

Repair

Go to Step 4

Go to Step 5

Repair

Check EGR pipe disconnected or any leak from EGR pipe, EGR valve.

Repair

Go to Step 6

Check EGR cooler has coolant circulation operation. No circulation or no water?

Repair

Go to Step 7

Replace EGR valve

Go to Step 8

Replace ECM

Replace MAF

2

3 4 5 6 7 8

1. Clear the DTC P0400. 2. Observe the DTCs. Was the DTC P0400 stored?

—

Check exhaust system such exhaust pipe, silensor etc. disconnected. Check wastegete setting pressure. Is it in specification?

—

Check EGR valve stuck closed. Cehck MAF with typical data. Is it within typical data?

See the typical data table

6E–140 reference

ENGINE DRIVEABILITY AND EMISSIONS

ENGINE DRIVEABILITY AND EMISSIONS

6E–141

DTC P0500 VSS MALFUNCTION

16 15 14 13 12 11 10 9

VSS (NKR 4JH1-TC only)

meter fuse (TF 4JA1-TC/ 4JH1-TC only)

8 7 6 5 4 3 2 1

29

4 ABS

VSS

ECT

TDC 7

Speed meter

8

Speed meter

27

68

68

Balt

62

32

90

98

89

Balt

Balt

93

35

45

Us IC 08

IC 08

IC 08

µP

IC 08

IC 03

DTC P0500 SUB CODE 0001 VSS 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

Go to Step 3

Refer to Intermittent Diagnosis

Indicate incorrect speed Go to Step 4

Indicate correct speed Go to Step 7

2

1. Clear the DTC P0500. 2. Observe the DTCs. Was the DTC P0500 stored?

—

3

Check speed meter, whether meter indicate incorrect speed.

4

Check the speed meter. (TF 4JA1-TC/4JH1-TC only) See the electrical section.

Go to Step 5

Repair

Check the vehicle speed sensor wiring. See the electrical section.

Go to Step 6

Repair

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.

Go to Step 7

Repair

5 6

6E–142

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

7

Breaker box is available Ignition off Install a breaker box as type B, see page 6E-58. Remove the connector from the meter. Measure any voltage between ECM pin 68 and ground at breaker box.

No voltage

Breaker box is not available Ignition off No damage at Check the wiring between speed meter output and wiring ECM. harness

Yes

No

Replace ECM and verify

Repair wiring

DTC P0500 SUB CODE 1010 VSS INCORRECT SIGNAL 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

Go to Step 3

Refer to Intermittent Diagnosis

2

3 4 5 6

7

8 9

1. Clear the DTC P0500. 2. Observe the DTCs. Was the DTC P0500 stored?

—

Check speed meter indication. Is the meter indication OK?

Go to Step 4

Check the speed meter. See the electrical section.

Go to Step 5

Repair

Check the vehicle speed sensor wiring. See the electrical section.

Go to Step 6

Repair

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.

Go to Step 7

Repair

Breaker box is not available Ignition off No damage at Check the wiring between speed meter output and wiring ECM. harness

Replace ECM and verify

Repair wiring

Check the meter output. See the electrical section.

Go to Step 9

Breaker box is available Ignition off Install a breaker box as type B, see page 6E-58. Remove the connector from the meter. Measure any voltage between ECM pin 68 and ground at breaker box.

Replace ECM.

No voltage

Verify

ENGINE DRIVEABILITY AND EMISSIONS

6E–143

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

Go to Step 3

Refer to Intermittent Diagnosis

2

3

4

1. Clear the DTC P0500. 2. Observe the DTCs. Was the DTC P0500 stored?

—

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

Check the wiring between signal of speed sensor and ECM.

No open circuit

Replace ECM

Repair wiring harness

6E–144

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0560 SYSTEM VOLTAGE MALFUNCTION

1G #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

Relay EW

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

SW:ExG Brake Meter ExG Brake

Check Engine

Glow

ABS control unit 3

58

39

30

65

31

64

60

Batt

µP

42

43

59

46

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

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 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

—

Go to Step 3

Refer to Intermittent Diagnosis

Battery voltage ≥ 7V

Go to Step 4

Replace battery

2

3

1. Clear the DTC P0560. 2. Observe the DTCs. Was the DTC P0560 stored? Check battery voltage.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

Value(s)

4

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Remove ECM fuse 1. Check resistance of ECM 58 ˜ ECM fuse1. Remove relay. Check continuity between ECM 3 and relay socket B. Check continuity between relay socket A and fuse 1.

Continuity

6E–145

Yes

No

Continuity

Go to Step 4

Repair wiring harness

0

Replace ECM and verify

Replace relay

Breaker box is not available Ignition off Disconnect engine harness at ECM. Remove ECM fuse1. Check resistance of ECM 58 ˜ ECM fuse1. Remove relay. Check continuity between ECM 3 and relay socket B. Check continuity between relay socket A and fuse 1.

Fuse1

58 B

A

3

58

5

Remove relay. Check relay function. 1. Apply 12 V at solenoid terminals. 2. Check continuity between 87 and 30 (TF 4JA1-TC, 4JH1-TC) after applied 12V. Check continuity between 87 and 87a after applied 12V. 3. No continuity means malfunction of relay. 87 86

87a 86

85 30

ECM relay (NKR only)

85 87 30

ECM relay (TF4JA1-TC,4JH1-TC)

6E–146

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Ask the customer whether 24V batterry was installed or used. Refer to Intermittent Diagnosis

Less than 20 V

Replace ECM

Go to Step 4

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.

2

3

1. Clear the DTC P0560. 2. Observe the DTCs. Was the DTC P0560 stored?

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. Fuse1

58 B

A

3

58

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–147

DTC P0560 SUB CODE 1010 PCU SYSTEM VOLTAGE TOO HIGH OR TOO LOW ECM 25A

VSV: MAG valve Exh Brake INT. Throttle (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF 1 3

84

5

92

88

SW:Newtral (MT only)

6 PCU

4

8

83

40

97

Batt

95

Batt

7

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

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

—

Go to Step 3

Refer to Intermittent Diagnosis

27 V ≥ voltage ≥ 4.5 V

Replace Injection pump

Repair wiring

2

3

1. Clear the DTC P0560. 2. Observe the DTCs. Was the DTC P0560 stored? Disconnect PCU connector. Measure voltage at terminal 7 of PCU connector.

7

6E–148

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0561 SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION

IG #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

Relay EW

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

SW:ExG Brake Meter ExG Brake

Check Engine

Glow

ABS control unit 3

58

39

30

65

31

64

60

Batt

µP

42

43

59

46

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

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

1. Clear the DTC P0561. 2. Ignition ON. Wait for . Does the DTC P0561 still appear?

—

Go to Step 3

Verify

OK Replace ECM

Repair wiring or main relay

2

3

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. 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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–149

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

1. Clear the DTC P0561. 2. Ignition ON. Wait for see. Does the DTC P0561 still appear?

—

Go to Step 3

Verify

OK Replace ECM

Repair wiring or main relay

2

3

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. 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.

6E–150

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0606 ECM Malfunction1 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

Replace ECM

Go to Intermittent Diagnosis

2

1. Clear the DTC P0606. 2. Observe the DTCs. Was the DTC P0606 restored?

—

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

Replace ECM

Go to Intermittent Diagnosis

2

1. Clear the DTC P0606. 2. Observe the DTCs. Was the DTC P0606 restored?

—

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0645 A/C COMPRESSOR CUTOFF RELAY MALFUNCTION Main fuse

ECM relay

HVAC relay

A/C on signal

ECM relay

ECM relay A/C Fuse

AC Thermo relay

TF 4JA1-TC / 4JH1-TC only

NKR 4JH1-TC only Electrical thermo PDS (NKR 4JH1-TC) only

A/C Comp relay

A/C Comp relay

Compressor clutch

Compressor clutch

41

41 Batt

µP

µP : Microproccesor

33 Batt

µP

IC 08

6E–151

6E–152

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

Go to Step 3

Refer to Intermittent Diagnosis

Isolation resistance > 1MΩ

Go to intermittent Diagnosis

Go to Step 4

Continuity

Go to Step 5

Replace A/C relay and verify

Continuity

Go to Step 6

Repair wiring and verify

2

3

1. Clear the DTC P0645. 2. Observe the DTCs. Was the DTC P0645 stored?

—

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

41

Resistance _Ω 87 87a or

4 5

86

85

ECM relay connector

30

Check continuity A/C relay. Check continuity between relay : A/C pin 85 and engine harness connector pin 30 at ECM relay.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

Value(s)

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.

6E–153

Yes

No

Intermittent

Repair wiring and verify

41

87 87a 86

85

A/C relay connector

30

0Ω

6E–154

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

—

Go to Step 3

Refer to Intermittent Diagnosis

0V

Go to Step 4

Repair wiring and verify

260 - 310Ω

Go to Step 5

Replace A/C relay and verify

2

3

1. Clear the DTC P0645. 2. Observe the DTCs. Was the DTC P0645 stored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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-156. 87 87a 86

85 30

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-156.

41

87 87a 86

85 30

4

Check resistance A/C relay.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

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.

6E–155

Value(s)

Yes

No

0V

Go to Intermittent Diagnosis

Repair wiring and verify

41

87 87a 86

85 30

6E–156

ENGINE DRIVEABILITY AND EMISSIONS

reference

RELAY ; ECM MAIN A-15

2L/R IC02

8W PA28 BACK 15A

SW ; CLUTCH 0.5G IC07

0.5G IC48

T.P.S.&SW ; IDLE (THROTTLE VALVE)

A

0.5G/B IC35 0.5R/G IC36

A69(69)

A-16

5B/R HB03

A-1

0.85Y KA01

A47(49)

C

0.5G/O IC37

A35(38)

B

0.5B/G IC38

A55(57)

SW ; BACK UP

IZ07

A-10 0.85R/Y KA02 A-11 0.85Y MA02

ECM 2B IZ01

A61(2)

2B IZ02

A62(1)

0.5R/L MB11

A32(35)

0.85B MX05

VEHICLE SPEED SENSOR

A-12 0.5L/B MA03 ENG COOLANT

THERMO UNIT B-3

0.5Y/B MA06

B6

OIL PSESSURE UNIT CONT ; IMMOBILIZER(B8)

OIL GAGE 0.5Y/G MA09

4WD SW

0.5W/R MA11(W/SOF) TB07(W/O SOF)

B15

A-6

0.5L MA10

A10

SW ; OIL

A40(43)

0.5O/L MA18

B8

0.5BR/R IC29

A6

A24(27)

0.5B/R MA05

B3

A68(68)

0.5L/W IC21

A8

OIL

GLOW CHECK

B2 ENG

0.5O/B MB04

0.5L IC47

0.5B/L EX02

1 2 3 4 5 6 7 8

0.5B EX03

SPEED METER

A43(45)

A9 METER

0.5O/L MB01 0.5G IC48

CONT ; IMMOBILIZER(B1)

BACK UP LAMP

A39(42)

4WD

BRAKE LAMP

JOINT TO EX12

B-2

TACHO METER 9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

CONT ; IMMOBILIZER(B5)

0.5B IZ06

EB STOP 10A

0.5G CA01

(OFF)

(OFF)

J/C ; B

ACG(B)

(ON)

GLOW PULG x4 F

3W PA16

A28(31)

SW ; BRAKE

0.5R IC12 0.5W/B IC13 RESISTER ; CLUTCH SW (YZK NO ; 7321-9900) 0.5Y 0.5B IC57 IZ08 510 0.5Y IC08

0.5R CA02

0.5 B IZ04 E

RESISTER ; NEWTRAL SW 0.5B 0.5B/W IZ10 IC58 270 (IDLE SW)

0.85W KA01

A65(65)

3W PA13

A27(30)

0.85Y MA01

A36(39)

A-9

0.5G/W HA16

METER 15A

B16(94)

ENGINE 10A

B25(101)

3B/R PA17

IZ05

FUSE ; BLOOR

OFF ACC IG2 ST IG1 3B/R

1 0.5L/W 2 HA14

4

B2

TDC

B12(90)

SW ; NEWTRAL 0.5B/W IC10

0.5G/R HA13 0.5G HA21 RESISTER ; IDLE UP 0.5B 0.5G HX03 HA24 270 0.5B/L HB06 0.5L/Y IC06

RELAY ; A/C THERMO

ELEC.THERMO A30(33)

A-9

0.5L/R IC09

0.5G HA23

FUSE ; A/C

B1

A-8

2 0.5BR HA17

RELAY ; GLOW

0.5G/R IC46

0.5B HX22

B22(98)

SW ;IGNITION

A-7

3

B8(89)

4

SW ; THERMO

B-6

B15(93)

B-1 0.5G HA18

0.5L/R HB04

ECT SENSOR

0.5O IC44

1

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR)

0.5W IC45

1

2

B-5

3W PA03 3W/B PA02

A38(41) 0.5B/P IC43

5R/W HB01

0.5 IZ03

RELAY ; A/C COMPRESSOR

0.5L/R IC11

B13(91)

0.5L/R IC15

MAIN 80A

A-5

4 5 2 3 MAF 1

8B/R PA01

B29(105)

2L/B IC04 0.5W/R IC27 0.5G/R IC28 0.5B/R IC30 0.5B/L IC39

IG2 40A

B2(83) B7(88) B14(92) B3(84)

IG.1 50A

A56(58)

GLOW 50A

B24(100) B23(99)

2L/R IC05

0.5L/R HA15

1

A-4

A41(3)

IC11 HB04 HA15 IC07 IC15 HA19

3B PA28

INJ.PUMP

4

A-3

A41(63)

0.5L/R 0.5L/R 0.5L/R 0.5G 0.5L/R 0.5L/R

ECM 25A

2 3

A-2

0.5B/Y IC03

2B/Y IC01

2L/R IC05 0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

BATT

2L/R IC02

ENGINE DRIVEABILITY AND EMISSIONS

6E–157

DTC P0703 BRAKE-LIGHT SWITCH CIRCUIT MAIFUNCTION

1G #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

Relay EW

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

NKR 4JH1-TC only

ABS control unit 3

58

39

30

65

31

SW:ExG Brake (NKR 4JH1-TC only) Meter Exh Brake (NKR 4JH1-TC only)

64

60

Check Engine

Glow

42

43

59

46

NKR 4JH1-TC only Batt

µP

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

DTC P0703 BRAKE-LIGHT SWITCH CIRCUIT INCORRECT SIGNAL (IGNITION ON) (Short to battery, short to ground, 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

—

Go to Step 3

Refer to Intermittent Diagnosis

TF with Automatic transmission only

Bulb is OK Go to Step 4

Bulb burn out replace bulb, and verify

Two brake switch condition should be ON/OFF same

OK Go to Step 5

Replace brake switch

2

3

4

1. Clear the DTC P0703. 2. Observe the DTCs. Was the DTC P0703 stored? 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. 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.

6E–158

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

5

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Check any open circuit between ECM pin 30 and ECM relay, and between ECM pin 65 and ECM relay.

No open circuit

Check isolation resistance between ECM pin 30 and ECM relay at brake switch NO (Normal open) open condition, and between ECM pin 65 and ECM relay at brake switch NC (Normal close) open condition. Ignition off install a breaker box as type B, see page 6E-58.

More than 1MΩ

Without applying brake switch ON (NO switch becomes close) Check no voltage to appear between ECM pin 30 and ground.

No voltage

By applying brake switch ON (NO switch becomes close) Check no voltage to appear between ECM pin 65 and ground.

No voltage

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.

No open circuit

Yes

No

All check is OK ↓ Replace ECM and verify

Repair wiring or relay

Check isolation resistance between ECM pin 30 and ECM relay at brake switch NO open condition, and between ECM pin 65 and ECM relay at brake switch NC open condition.

30

65 ECM relay or

More than 1MΩ

ENGINE DRIVEABILITY AND EMISSIONS

6E–159

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

Go to Step 3

Refer to Intermittent Diagnosis

TF with Automatic transmission only

Bulb is OK Go to Step 4

Bulb burn out replace bulb, and verify

Two brake switch condition should be ON/OFF different

OK Go to Step 5

Repalce brake switch

2

3

1. Clear the DTC P0703. 2. Observe the DTCs. Was the DTC P0703 stored?

—

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Check any open circuit between ECM pin 30 and ECM relay, and between ECM pin 65 and ECM relay.

No open circuit

Check isolation resistance between ECM pin 30 and ECM relay at brake switch NO (Normal open) open condition, and between ECM pin 65 and ECM relay at brake switch NC (Normal close) open condition. Ignition off install a breaker box as type B, see page 6E-58.

More than 1MΩ

Without applying brake switch ON (NO switch becomes close) Check no voltage to appear between ECM pin 30 and ground.

No voltage

By applying brake switch ON (NO switch becomes close) Check no voltage to appear between ECM pin 65 and ground.

No voltage

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.

No open circuit

Check isolation resistance between ECM pin 30 and ECM relay at brake switch NO open condition, and between ECM pin 65 and ECM relay at brake switch NC open condition. By applying brake switch OFF (NO switch becomes open) Check no voltage to appear between ECM pin 30 and ground.

30

65 ECM relay or

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.

6E–160

ENGINE DRIVEABILITY AND EMISSIONS

DTC P0704 CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION

1G #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

ECM relay

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

NKR 4JH1-TC only

ABS control unit 3

58

39

30

65

31

SW:ExG Brake (NKR 4JH1-TC only) Meter Exh Brake (NKR 4JH1-TC only)

64

60

Check Engine

Glow

42

43

59

46

NKR 4JH1-TC only Batt

µP

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

DTC P0704 SUB CODE 0110 CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION Step

Action

Value(s)

Yes

No

1

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

—

Go to Step 2

Go to OBD system check

Go to Step 3

Refer to Intermittent Diagnosis

Check clutch switch and clutch pedal adjustment. See section.

Go to Step 4

Replace

Check clutch switch electrical function.

Go to Step 5

Replace

2

3 4

1. Clear the DTC P0704. 2. Observe the DTCs. Was the DTC P0704 stored?

—

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

5

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Check continuity between ECM pin 31 and clutch SW. Check continuity 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 continuity between clutch SW and ECM relar.

6E–161

Value(s)

Yes

No

0Ω (Clutch OFF) ∞ (Clutch ON)

Replace ECM

Repaire wiring

6E–162

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1105 BAROMETRIC PRESSURE SENSOR (BP) MALFUNCTION DTC P1105 SUB CODE 0010 BAROMETRIC PRESSURE SENSOR (BP) 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

Replace ECM

Go to Intermittent Diagnosis

2

1. Clear the DTC P1105. 2. Observe the DTCs. Was the DTC P1105 restored?

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

Replace ECM

Go to Intermittent Diagnosis

2

1. Clear the DTC P1105. 2. Observe the DTCs. Was the DTC P1105 restored?

ENGINE DRIVEABILITY AND EMISSIONS

6E–163

DTC P1110 INTAKE SHUTTER VSV (DIESEL) MALFUNCTION (NKR 4JH1-TC only)

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Neutral (MT only)

6

7

5

1 2

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

91

Batt

105

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

DTC P1110 SUB CODE 1000 INTAKE VSV 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

Go to Step 3

Refer to Intermittent Diagnosis

2

1. Clear the DTC P1110. 2. Observe the DTCs. Was the DTC P1110 stored?

—

6E–164

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

3

Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. 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.

Value(s)

Yes

No

More than 1MΩ

Replace ECM

Repair wiring

95

see page 6E-165

FTX 2L

BATT

TO ELECTRO THERMO

0.85W PA10

TO RELAY ; CHARGE

OFF ACC

KEY SW

5W PA07

B ST

ON

0.5BR HA09

0.5L/R IC39

0.5G/O IC48

RELAY ; HEATER&A/C

RELAY ; A/C COMP.

#20 ECU 25A

5B/L HB01

3B/Y IC01

#17 STOP LAMP 10A

TO RELAY ; CHARGE

0.5L/R IC33

RELAY ; ECU 0.5L/B IC03 2L/R IC02

0.5W IC60 STOP LAMP

SW ; STOP LAMP (BRAKE PEDAL ; ON) 0.5G CA02 0.5L/R IC09 (BRAKE PEDAL ; OFF)

0.5G BB09

SW ; CLUTCH (CLUTCH PEDAL ; OFF)

0.5BR/R IC19

METER

2

1

MAF

TO CONT UNIT ; ABS LAMP (STOP SIGNAL )

A-36 IG (39)

B-7 MAF SIG. (88) B-14 MAF GND (92) B-19 EGR (97)

A-55

B-16

0.5G/O IC43

0.5R/G IC42

0.5B/R HB04

1

2

3

1.25L/R HB03

A-35

0.5B/G IC44

GLOW RELAY (94)

A-47

ACCEL SENSOR (+5V)(57) ACCEL SENSOR (SIG.)(38)

A-69 A-61

2B IZ02

1

3

2

B-9

WATER TEMP

TDC

0.85B MX01

RELAY ; G/PULG

5B/Y HB02

GLOW PULG (4 x4)

SW ; IDEL

THERMO UNIT (WATER TEMP)

GND.

SIG.

+

VEHICLE SPEED

0.5Y/G MA33

0.5B/Y MA32

0.5B MX11

WITH ; ABS

ALDL CONNECTOR

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

0.3W/G BB20

7 EXH.B/CUT 29 0.3W/B IN J1850 BB21

CONT.UNIT ; ABS

SPEED

0.5B IZ11

D-4 0.5Y/B MA08

TPS

METER

THERMO

JOINT

ACCEL SENSOR (GND.)(49)

A-62

ACCEL SENSOR (IDEL)(69) GND. (2)

2B IZ01

0.5GR IC51

B-9

0.5LG MA07

TACHO A-24

0.5Y/G IC46

B-8

A-68

0.5LG/B BB07

B-8

0.5B/P IC52

0.3V MX04

A-60

0.5LG/W 8 EXH.B/CUT 4 OUT BB06 FRASH

FRAME EARTH POINT

GND. (1)

ENG.SPEED (OUTPUT-1) (27)

0.5G/B IC62 A-29

B-12

0.5R IC49

B-22 0.5W IC50

B-15

0.5Y IC57

IZ10 (SHIELD)

GND. (93)

A-32

0.5L IC58

0.5B IZ07

ISO-K (35)

A-43

B-25

DIAG (45)

TDC (SHIELDED) (101) WATER TEMP (ECU) (89)

TDC (-) (98)

TDC (+) (90)

ABS (OUT) (62) ABS (IN) (32)

A-44 QWS SW (46) VEHICLE SPEED A-57 METER IND (68) (QWS) (59)(KEY ON;ENABLE) B-2 MAF +5V (83)

METER IND (CHECK ENG.) (42) METER IND (GLOW) (43)

0.5G/B IC45

CONT UNIT ; ENGINE

0.5W IC04

A-27 BARAKE ON (30)

A-56 MAIN RELAY (58) A-41 BAT(+) (3)

0.5G IC10

A-28 CLUTCH (31)

0.5W/B A-65 BARAKE OFF (65) IC11

0.5Y IC12

0.5W/R IC23

METER IND (EXH.BRAKE) (60)(KEY ON;ENABLE)

0.5LG/L A-64 SW;EXH.BRAKE (64) IC13

4

0.5B/R IC25

0.5G/R IC24 3

5

EXH.BRAKE 14V, 2.0W 0.5G/R A-58 0.5LG/L IC64 IC14 CHECK ENG. 14V, 0.5B/Y 1.4W 0.5G/Y A-39 IC17 MA01 14V, GLOW 1.4W 0.5O/L A-40 IC18

SW ; EXH.BRAKE

SW ; ENG.WARM 0.3B IZ09

0.5BR/R IC20 0.5BR IC65 0.5L/R IC22

0.5LG/W IC29

0.5LG IC16

0.5L/R 0.5B/O IC26 IC27 MAG.VALVE ; EXH.BRAKE

EVRV ; EGR

14V, 60mA

0.5LG/R IC21

1.25L/R IC59

0.5G/Y CA01

1.25B/Y IC05

3L/R IC34

GLOW 60A

MAIN 80A

KEY SW 50A

TO BLOWER MOTOR

PDS 0.85G/O HA11

SW ; NEUTRAL (NEUTRAL;ON) 0.5B/W IC31 RESISTER ; NEUTRAL SW (510 ) 0.3B IZ06

B-3 MAT SIG. 0.5B/L (84) IC56 MAG.VALVE A-37 (EXH.BRAKE) (40) B-17 INT.SLOTTLE (95) B-6 SW;NEUTRAL (87) TWIST LINE B-24 INJ.PUMP 0.5Y 2 (CAN-H) IC35 (100) INJ.PUMP 0.5R B-23 INJ.PUMP 1 (CAN-L) IC36 (99) 7 0.5O B-29 INJ.PUMP 5 (MAB) IC37 6 (105) B-13 INJ.PUMP 0.5P 8 (DZG) IC38 (91) A-30 A/C SW (33) A-38 A/C RELAY (41) FRAME EARTH POINT

2B IZ04

5B IZ03

J/C

0.5B IC15 VSV ; INT.THROTTLE 0.5L/R IC28

2L/R IC30

0.5G/Y IC41 0.5W/G IC40 1.25B/Y IC63

0.5B ZZ06

TO RELAY ; TAIL

RESISTER ; IDLE SW (510 )

0.85B MX06

0.5B ZZ05

RELAY ; A/C ON SIGNAL

0.5L/R IC06 0.5L/R IC07 0.5L/R IC08 0.5B/W IC32

TO SW ; BACK UP LAMP TO RELAY ; CORNEING

0.5B IZ12

#19 TURN 10A #2 AIR CON 10A #1 HEATER 25A MAGNET CLUTCH (COMPRESSOR)

RESISTER ; A/C ON SIGNAL(270 ) 0.5B 0.5Y/G IZ08 IC47

#18 GENERATOR 15A #15 H/L LEVELINGA 10A #12 GAUGE, BACK 10A #11 WIPER, WASHER 15A 0.85Y/G HA19

RELAY ; THERMO A/C

0.85G/W HA10

6E–165 ENGINE DRIVEABILITY AND EMISSIONS referance

6E–166

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

3

4

1. Clear the DTC P1110. 2. Observe the DTCs. Was the DTC P1110 stored?

—

Go to Step 3

Refer to Intermittent Diagnosis

Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Disconnect VSV. Check continuity between ECM pin 95 and

0Ω

Go to Step 4

Repair the harness

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–167

DTC P1120 AP SENSOR MAIFUNCTION

ECU Relay

Glow 60A

Register : idle SW

APS

Relay G/plug

Glow plug +5V 94

57

38

49

69

2

1

GND

GND

Balt

IC 08 µP

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

Output voltage

Circuit Description

+5V

5.0V

3

Signal 2 2.5V

GND 0.0

0

-45

Aps

Avn

2

+45

Turning angle 1

3 Connector view of APS

1

6E–168

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 7

Go to Step 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

• Check APS sensor open circuit between power feed line and signal line.

Repair harness and verify

Go to Step 6

Replace ECM.

Repair harness and verify

2

3

4

5 6

1. Clear the DTC P1120. 2. Observe the DTCs. Was the DTC P1120 stored?

—

1. Ignition “On”, engine “Off”. Idle position 2. Check pedal position % on Tech-II for pedal sensor 0.5– 0.9V WOT posiotn sensor within the value or not. TP1 Between Was a problem found? 4.0V and 4.7V

ENGINE DRIVEABILITY AND EMISSIONS

6E–169

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

—

Go to Step 3

Refer to Intermittent Diagnosis

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

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. 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

Replace ECM

Check short to battery on the APS wiring including APS ↓ Repair including APS ↓ Verify ↓ NG ↓ Replace ECM

2

3

4

5

1. Clear the DTC P1120. 2. Observe the DTCs. Was the DTC P1120 stored?

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 4JH1TC ≤ 4.9V TF 4JH1/ 4JA1 ≤ 4.5V

6E–170

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1120 SUBCODE 0111 AP SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT (Short to battery) Step

Action

1

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

2

3

4

5

6

Value(s)

Yes

No

Go to Step 2

OBD

Go to Step 3

Refer to Intermittent Diagnosis

No more than 5.2V

Replace ECM

Go to Step 4

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Disconnect ECM harness. Check short circuit between ECM pin 57 and power sources, see the attachment on page 6E-171. Breaker box is not available Ignition off Install breaker box as type A, see page 6E-58. Disconnect ECM harness. Check short circuit between ECM pin 57 and power sources, see the attachment on page 6E-171.

No short to battery

Replace ECM

Repair wiring, APS

Disconnect APS. Check voltage at power feed voltage pin of ECM connector.

0V

Go to Step 6

Repari wiring

Check voltage at APS.

0V

Go to Step 4

Replace APS

1. Clear code. 2. Observe DTCs. Was the DTC P1120 stored? Breaker box is available Ignition off Install breaker box as type B, see page 6E-58. Check voltage at power feed pin 57. Breaker box is not available Ignition off Skip to step 4.

FTX 2L

BATT

TO ELECTRO THERMO

0.85W PA10

TO RELAY ; CHARGE

OFF ACC

KEY SW

5W PA07

B ST

ON

0.5BR HA09

0.5L/R IC39

0.5G/O IC48

RELAY ; HEATER&A/C

RELAY ; A/C COMP.

#20 ECU 25A

5B/L HB01

3B/Y IC01

#17 STOP LAMP 10A

TO RELAY ; CHARGE

0.5L/R IC33

RELAY ; ECU 0.5L/B IC03 2L/R IC02

0.5W IC60 STOP LAMP

SW ; STOP LAMP (BRAKE PEDAL ; ON) 0.5G CA02 0.5L/R IC09 (BRAKE PEDAL ; OFF)

0.5G BB09

SW ; CLUTCH (CLUTCH PEDAL ; OFF)

0.5BR/R IC19

METER

2

1

MAF

TO CONT UNIT ; ABS LAMP (STOP SIGNAL )

A-36 IG (39)

B-7 MAF SIG. (88) B-14 MAF GND (92) B-19 EGR (97)

A-55

B-16

0.5G/O IC43

0.5R/G IC42

0.5B/R HB04

1

2

3

1.25L/R HB03

A-35

0.5B/G IC44

GLOW RELAY (94)

A-47

ACCEL SENSOR (+5V)(57) ACCEL SENSOR (SIG.)(38)

A-69 A-61

2B IZ02

1

3

2

B-9

WATER TEMP

TDC

0.85B MX01

RELAY ; G/PULG

5B/Y HB02

GLOW PULG (4 x4)

SW ; IDEL

THERMO UNIT (WATER TEMP)

GND.

SIG.

+

VEHICLE SPEED

0.5Y/G MA33

0.5B/Y MA32

0.5B MX11

WITH ; ABS

ALDL CONNECTOR

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

0.3W/G BB20

7 EXH.B/CUT 29 0.3W/B IN J1850 BB21

CONT.UNIT ; ABS

SPEED

0.5B IZ11

D-4 0.5Y/B MA08

TPS

METER

THERMO

JOINT

ACCEL SENSOR (GND.)(49)

A-62

ACCEL SENSOR (IDEL)(69) GND. (2)

2B IZ01

0.5GR IC51

B-9

0.5LG MA07

TACHO A-24

0.5Y/G IC46

B-8

A-68

0.5LG/B BB07

B-8

0.5B/P IC52

0.3V MX04

A-60

0.5LG/W 8 EXH.B/CUT 4 OUT BB06 FRASH

FRAME EARTH POINT

GND. (1)

ENG.SPEED (OUTPUT-1) (27)

0.5G/B IC62 A-29

B-12

0.5R IC49

B-22 0.5W IC50

B-15

0.5Y IC57

IZ10 (SHIELD)

GND. (93)

A-32

0.5L IC58

0.5B IZ07

ISO-K (35)

A-43

B-25

DIAG (45)

TDC (SHIELDED) (101) WATER TEMP (ECU) (89)

TDC (-) (98)

TDC (+) (90)

ABS (OUT) (62) ABS (IN) (32)

A-44 QWS SW (46) VEHICLE SPEED A-57 METER IND (68) (QWS) (59)(KEY ON;ENABLE) B-2 MAF +5V (83)

METER IND (CHECK ENG.) (42) METER IND (GLOW) (43)

0.5G/B IC45

CONT UNIT ; ENGINE

0.5W IC04

A-27 BARAKE ON (30)

A-56 MAIN RELAY (58) A-41 BAT(+) (3)

0.5G IC10

A-28 CLUTCH (31)

0.5W/B A-65 BARAKE OFF (65) IC11

0.5Y IC12

0.5W/R IC23

METER IND (EXH.BRAKE) (60)(KEY ON;ENABLE)

0.5LG/L A-64 SW;EXH.BRAKE (64) IC13

4

0.5B/R IC25

0.5G/R IC24 3

5

EXH.BRAKE 14V, 2.0W 0.5G/R A-58 0.5LG/L IC64 IC14 CHECK ENG. 14V, 0.5B/Y 1.4W 0.5G/Y A-39 IC17 MA01 14V, GLOW 1.4W 0.5O/L A-40 IC18

SW ; EXH.BRAKE

SW ; ENG.WARM 0.3B IZ09

0.5BR/R IC20 0.5BR IC65 0.5L/R IC22

0.5LG/W IC29

0.5LG IC16

0.5L/R 0.5B/O IC26 IC27 MAG.VALVE ; EXH.BRAKE

EVRV ; EGR

14V, 60mA

0.5LG/R IC21

1.25L/R IC59

0.5G/Y CA01

1.25B/Y IC05

3L/R IC34

GLOW 60A

MAIN 80A

KEY SW 50A

TO BLOWER MOTOR

PDS 0.85G/O HA11

SW ; NEUTRAL (NEUTRAL;ON) 0.5B/W IC31 RESISTER ; NEUTRAL SW (510 ) 0.3B IZ06

B-3 MAT SIG. 0.5B/L (84) IC56 MAG.VALVE A-37 (EXH.BRAKE) (40) B-17 INT.SLOTTLE (95) B-6 SW;NEUTRAL (87) TWIST LINE B-24 INJ.PUMP 0.5Y 2 (CAN-H) IC35 (100) INJ.PUMP 0.5R B-23 INJ.PUMP 1 (CAN-L) IC36 (99) 7 0.5O B-29 INJ.PUMP 5 (MAB) IC37 6 (105) B-13 INJ.PUMP 0.5P 8 (DZG) IC38 (91) A-30 A/C SW (33) A-38 A/C RELAY (41) FRAME EARTH POINT

2B IZ04

5B IZ03

J/C

0.5B IC15 VSV ; INT.THROTTLE 0.5L/R IC28

2L/R IC30

0.5G/Y IC41 0.5W/G IC40 1.25B/Y IC63

0.5B ZZ06

TO RELAY ; TAIL

RESISTER ; IDLE SW (510 )

0.85B MX06

0.5B ZZ05

RELAY ; A/C ON SIGNAL

0.5L/R IC06 0.5L/R IC07 0.5L/R IC08 0.5B/W IC32

TO SW ; BACK UP LAMP TO RELAY ; CORNEING

0.5B IZ12

#19 TURN 10A #2 AIR CON 10A #1 HEATER 25A MAGNET CLUTCH (COMPRESSOR)

RESISTER ; A/C ON SIGNAL(270 ) 0.5B 0.5Y/G IZ08 IC47

#18 GENERATOR 15A #15 H/L LEVELINGA 10A #12 GAUGE, BACK 10A #11 WIPER, WASHER 15A 0.85Y/G HA19

RELAY ; THERMO A/C

0.85G/W HA10

6E–171 ENGINE DRIVEABILITY AND EMISSIONS reference

6E–172

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

3

4

5 6

1. Clear the DTC P1120. 2. Observe the DTCs. Was the DTC P1120 stored?

—

Go to Step 3

Refer to Intermittent Diagnosis

Breaker box is available Ignition off Install breaker box as type B, see page 6E-58. 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

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

Disconnect APS. Check short to ground at APS sensor.

No short to ground

Replace ECM

Replace APS

Go to Step 4

Replace wiring

Check continuity ECM wiring of power feed.

ENGINE DRIVEABILITY AND EMISSIONS

6E–173

DTC P1173 FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE 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

Meet standard resistance

Check coolant temp sensor poor connection and repair

Replace coolant temp sensor

Go to Step 4

Repair

Verify

—

2

Inspect coolant temp sensor.

3

Find out the cause of overheat. See the.

4

Replace ECM.

Fuel Reduction adjustment NKR 4JH1-TC

Q 5%

15%

80°C

90°C

100°C

110°C

TF 4JH1-TC, 4JH1-TC

15%

Q

80°C

90°C

100°C

110°C

6E–174

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1173 SUBCODE 0011 FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE Step

Action

1

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

2

3

4

5 6

Value(s)

Yes

No

No MIL light on

Explain customer and report representative

Go to Step 2

Go to Step 3

Ask the customer, whether fuel level was low?

No DTC comes on

Explain to the customer extremely low fuel caused

Go to Step 4

Less than 100°C

Replace ECM. Verify. If still DTC ON, replace Inj. pump

Go to Step 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

Replace fuel filter. Drive a few min, and stay at idling.

No DTC ON

—

Replace inj pump

Clear DTC P1173. Observe the DTC. Was the DTC P0645 stored? Check fuel level. If it is low, add fuel to the half of tank. Drive a few minutes, and stay at idling. Measure fuel temp by Tech-II.

ENGINE DRIVEABILITY AND EMISSIONS

6E–175

DTC P1173 FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 1 Step

Action

1

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

2

3 4 5

Value(s)

Yes

No

No MIL light on

Explain customer and report representative

Go to Step 2

Go to Step 3

Ask the customer, whether fuel level was low?

Less than 100°C

Replace injection pump

Go to Step 4

Check fuel leakage at fuel routine, pump. Air may cause high temp at inj.pump.

No leakage

Go to Step 6

Repair leakage

Replace fuel filter. Drive a few min, and stay at idling.

No DTC ON

—

Replace inj pump

Clear DTC P1173. Observe the DTC. Was the DTC P0645 stored? Measure fuel temp by Tech-II.

DTC P1173 FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 2 Step

Action

1

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

2

3

4

5 6

Value(s)

Yes

No

No MIL light on

Explain customer and report representative

Go to Step 2

Go to Step 3

Ask the customer, whether fuel level was low?

No DTC comes on

Explain to the customer extremely low fuel caused

Go to Step 4

Less than 80°C

Replace ECM. Verify. If still DTC ON, replace Inj. pump

Go to Step 5

Check fuel leakage at fuel routine, pump. Air may cause high temp at inj.pump.

No leakage

Go to Step 6

Repair leakage

Replace fuel filter. Drive a few min, and stay at idling.

No DTC ON

—

Replace inj pump

Clear DTC P1173. Observe the DTC. Was the DTC P0645 stored? Check fuel level. If it is low, add fuel to the half of tank. Drive a few minutes, and stay at idling. Measure fuel temp by Tech-II. NKR 4JH1-TC reduce Q (fuel quantity). TF 4JH1-TC, 4JA1-TC do not reduce.

6E–176

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

Go to Step 3

Refer to Intermittent Diagnosis

2

3

1. Clear the DTC P1345. 2. Observe the DTCs. Was the DTC P1345 stored? Replace Injection Pump.

—

Verify

ENGINE DRIVEABILITY AND EMISSIONS

6E–177

DTC P1520 NEUTRAL SWITCH

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Neutral (MT only)

6

7

5

1 2

1 3

84

5

92

4

88

8

83

40

97

Batt

95

Batt

87

Batt

91

Batt

105

99 CAN-L

100 CAN-H

Batt CF 150

US µP

CPU

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

DTC P1520 SUB CODE 1010 NEUTRAL SWITCH ON (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

Go to Step 3

Refer to Intermittent Diagnosis

Check the bold circuit

Go to Step 4

Function is OK

Go to Step 5

Replace neutral switch

No short to battery

Replace ECM

Repair wiring

Replace ECM

Repair wiring

2

3 4 5

1. Clear the DTC P1520. 2. Observe the DTCs. Was the DTC P1520 stored?

—

Are there any other DTC on such as P0704, P1576? Check the neutral switch. Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. Check short circuit to battery by ignition on, off. See the see page 6E-178. 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-178.

6E–178

ENGINE DRIVEABILITY AND EMISSIONS

reference

RELAY ; ECM MAIN A-15

2L/R IC02

8W PA28 BACK 15A

SW ; CLUTCH 0.5G IC07

0.5G IC48

T.P.S.&SW ; IDLE (THROTTLE VALVE)

A

0.5G/B IC35 0.5R/G IC36

A69(69)

A-16

5B/R HB03

A-1

0.85Y KA01

A47(49)

C

0.5G/O IC37

A35(38)

B

0.5B/G IC38

A55(57)

SW ; BACK UP

IZ07

A-10 0.85R/Y KA02 A-11 0.85Y MA02

ECM 2B IZ01

A61(2)

2B IZ02

A62(1)

0.5R/L MB11

A32(35)

0.85B MX05

VEHICLE SPEED SENSOR

A-12 0.5L/B MA03 ENG COOLANT

THERMO UNIT B-3

0.5Y/B MA06

B6

OIL PSESSURE UNIT CONT ; IMMOBILIZER(B8)

OIL GAGE 0.5Y/G MA09

4WD SW

0.5W/R MA11(W/SOF) TB07(W/O SOF)

B15

A-6

0.5L MA10

A10

SW ; OIL

A40(43)

0.5O/L MA18

B8

0.5BR/R IC29

A6

A24(27)

0.5B/R MA05

B3

A68(68)

0.5L/W IC21

A8

OIL

GLOW CHECK

B2 ENG

0.5O/B MB04

0.5L IC47

0.5B/L EX02

1 2 3 4 5 6 7 8

0.5B EX03

SPEED METER

A43(45)

A9 METER

0.5O/L MB01 0.5G IC48

CONT ; IMMOBILIZER(B1)

BACK UP LAMP

A39(42)

4WD

BRAKE LAMP

JOINT TO EX12

B-2

TACHO METER 9 10 11 12 13 14 15 16

; ENGINE

; ENG.HARN.-ENGROOM HARN. CONNECTION

CONT ; IMMOBILIZER(B5)

0.5B IZ06

EB STOP 10A

0.5G CA01

(OFF)

(OFF)

J/C ; B

ACG(B)

(ON)

GLOW PULG x4 F

3W PA16

A28(31)

SW ; BRAKE

0.5R IC12 0.5W/B IC13 RESISTER ; CLUTCH SW (YZK NO ; 7321-9900) 0.5Y 0.5B IC57 IZ08 510 0.5Y IC08

0.5R CA02

0.5 B IZ04 E

RESISTER ; NEWTRAL SW 0.5B 0.5B/W IZ10 IC58 270 (IDLE SW)

0.85W KA01

A65(65)

3W PA13

A27(30)

0.85Y MA01

A36(39)

A-9

0.5G/W HA16

METER 15A

B16(94)

ENGINE 10A

B25(101)

3B/R PA17

IZ05

FUSE ; BLOOR

OFF ACC IG2 ST IG1 3B/R

1 0.5L/W 2 HA14

4

B2

TDC

B12(90)

SW ; NEWTRAL 0.5B/W IC10

0.5G/R HA13 0.5G HA21 RESISTER ; IDLE UP 0.5B 0.5G HX03 HA24 270 0.5B/L HB06 0.5L/Y IC06

RELAY ; A/C THERMO

ELEC.THERMO A30(33)

A-9

0.5L/R IC09

0.5G HA23

FUSE ; A/C

B1

A-8

2 0.5BR HA17

RELAY ; GLOW

0.5G/R IC46

0.5B HX22

B22(98)

SW ;IGNITION

A-7

3

B8(89)

4

SW ; THERMO

B-6

B15(93)

B-1 0.5G HA18

0.5L/R HB04

ECT SENSOR

0.5O IC44

1

0.5BR/W HA20

MAG.CLUTCH (COMPRESSOR)

0.5W IC45

1

2

B-5

3W PA03 3W/B PA02

A38(41) 0.5B/P IC43

5R/W HB01

0.5 IZ03

RELAY ; A/C COMPRESSOR

0.5L/R IC11

B13(91)

0.5L/R IC15

MAIN 80A

A-5

4 5 2 3 MAF 1

8B/R PA01

B29(105)

2L/B IC04 0.5W/R IC27 0.5G/R IC28 0.5B/R IC30 0.5B/L IC39

IG2 40A

B2(83) B7(88) B14(92) B3(84)

IG.1 50A

A56(58)

GLOW 50A

B24(100) B23(99)

2L/R IC05

0.5L/R HA15

1

A-4

A41(3)

IC11 HB04 HA15 IC07 IC15 HA19

3B PA28

INJ.PUMP

4

A-3

A41(63)

0.5L/R 0.5L/R 0.5L/R 0.5G 0.5L/R 0.5L/R

ECM 25A

2 3

A-2

0.5B/Y IC03

2B/Y IC01

2L/R IC05 0.5Y IC31 0.5R IC32 0.5O IC33 0.5P IC34

Ω BATT

2L/R IC02

ENGINE DRIVEABILITY AND EMISSIONS

6E–179

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

Go to Step 3

Refer to Intermittent Diagnosis

Check the bold circuit Open circuit

Go to Step 4

Function is OK not always ON

Go to Step 5

Replace Neutral switch

Continuity

Replace ECM

Repair wiring

2

3

4

5

1. Clear the DTC P1520. 2. Observe the DTCs. Was the DTC P1520 stored?

—

Are there any other DTC on such as P0704, P1576?

Check Neutral switch.

Breaker box is available Ignition off Install breaker box as type A, see page 6E-58. 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-58. Check continuity between ECM pin 87 and Neutral sw.

6E–180

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1576 EXHAUST BRAKE VALVE1 CIRCUIT MALFUNCTION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Neutral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

Signal follow

System Description

ECM

ABS control unit

ABS OUT

Exh. Brake cut IN

ABS IN

Exh. Brake cut OUT

Operation ABS activate signal command to cancel Exh. Brake.

ABS

ECM

ECM

ABS

If ECM recognizes any failure, ECM sends 180 deg different phase signal. This reverse phase signal triggers to turn ON ABS light.

5V

5V

reverse phase signal

ENGINE DRIVEABILITY AND EMISSIONS TF 4JA1-TC QWS

6E–181

QWS operation reguirement

vss < 2km/h

+Battery

QWS request switch

Idle switch = ON

ECM Atomasphone temp switch

Ext vsv1

APS ≤ 2% ECT requires ON

Ext vsv2 ON 70ºc

80ºc OFF

IAT requires ON ON IAT

APS Engine speed

ECT

NKR 4JHI-TC Exh. Brake + Intake shutter + QWS

+Battery Mag valve Exh. Brake request sw

ECM VSV : Int

QWS regnest sw

VSS IAT

ECT

APS

Idle sw

Exh. Brake and Intake shutter operate at same time. QWS operate condition.

10ºc

150ºc OFF

6E–182

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

—

Go to Step 3

Refer to Intermittent Diagnosis

No short to battery

Go to Step 4

Repair wiring

Replace ECM

Replace Exh. brake valve or intake shutter

2

3

4

1. Clear the DTC P1576. 2. Observe the DTCs. Was the DTC P1576 stored? Breaker box is available Ignition off Install a breaker box as type A, see page 6E-58. Check short to battery, see on page 6E-183, 6E-184 (NKR 4JH1-TC only). Breaker box is not available Ignition off Disconnect engine harness. Check short to battery, see on page 6E-183, 6E-184 (NKR 4JH1-TC only). Check Exhaust brake valve circuit, intake shutter circuit.

FTX 2L

BATT

TO ELECTRO THERMO

0.85W PA10

TO RELAY ; CHARGE

OFF ACC

KEY SW

5W PA07

B ST

ON

0.5BR HA09

0.5L/R IC39

0.5G/O IC48

RELAY ; HEATER&A/C

RELAY ; A/C COMP.

#20 ECU 25A

5B/L HB01

3B/Y IC01

#17 STOP LAMP 10A

TO RELAY ; CHARGE

0.5L/R IC33

RELAY ; ECU 0.5L/B IC03 2L/R IC02

0.5W IC60 STOP LAMP

SW ; STOP LAMP (BRAKE PEDAL ; ON) 0.5G CA02 0.5L/R IC09 (BRAKE PEDAL ; OFF)

0.5G BB09

SW ; CLUTCH (CLUTCH PEDAL ; OFF)

0.5BR/R IC19

METER

2

1

MAF

TO CONT UNIT ; ABS LAMP (STOP SIGNAL )

A-36 IG (39)

B-7 MAF SIG. (88) B-14 MAF GND (92) B-19 EGR (97)

A-55

B-16

0.5G/O IC43

0.5R/G IC42

0.5B/R HB04

1

2

3

1.25L/R HB03

A-35

0.5B/G IC44

GLOW RELAY (94)

A-47

ACCEL SENSOR (+5V)(57) ACCEL SENSOR (SIG.)(38)

A-69 A-61

2B IZ02

1

3

2

B-9

WATER TEMP

TDC

0.85B MX01

RELAY ; G/PULG

5B/Y HB02

GLOW PULG (4 x4)

SW ; IDEL

THERMO UNIT (WATER TEMP)

GND.

SIG.

+

VEHICLE SPEED

0.5Y/G MA33

0.5B/Y MA32

0.5B MX11

WITH ; ABS

ALDL CONNECTOR

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

0.3W/G BB20

7 EXH.B/CUT 29 0.3W/B IN J1850 BB21

CONT.UNIT ; ABS

SPEED

0.5B IZ11

D-4 0.5Y/B MA08

TPS

METER

THERMO

JOINT

ACCEL SENSOR (GND.)(49)

A-62

ACCEL SENSOR (IDEL)(69) GND. (2)

2B IZ01

0.5GR IC51

B-9

0.5LG MA07

TACHO A-24

0.5Y/G IC46

B-8

A-68

0.5LG/B BB07

B-8

0.5B/P IC52

0.3V MX04

A-60

0.5LG/W 8 EXH.B/CUT 4 OUT BB06 FRASH

FRAME EARTH POINT

GND. (1)

ENG.SPEED (OUTPUT-1) (27)

0.5G/B IC62 A-29

B-12

0.5R IC49

B-22 0.5W IC50

B-15

0.5Y IC57

IZ10 (SHIELD)

GND. (93)

A-32

0.5L IC58

0.5B IZ07

ISO-K (35)

A-43

B-25

DIAG (45)

TDC (SHIELDED) (101) WATER TEMP (ECU) (89)

TDC (-) (98)

TDC (+) (90)

ABS (OUT) (62) ABS (IN) (32)

A-44 QWS SW (46) VEHICLE SPEED A-57 METER IND (68) (QWS) (59)(KEY ON;ENABLE) B-2 MAF +5V (83)

METER IND (CHECK ENG.) (42) METER IND (GLOW) (43)

0.5G/B IC45

CONT UNIT ; ENGINE

0.5W IC04

A-27 BARAKE ON (30)

A-56 MAIN RELAY (58) A-41 BAT(+) (3)

0.5G IC10

A-28 CLUTCH (31)

0.5W/B A-65 BARAKE OFF (65) IC11

0.5Y IC12

0.5W/R IC23

METER IND (EXH.BRAKE) (60)(KEY ON;ENABLE)

0.5LG/L A-64 SW;EXH.BRAKE (64) IC13

4

0.5B/R IC25

0.5G/R IC24 3

5

EXH.BRAKE 14V, 2.0W 0.5G/R A-58 0.5LG/L IC64 IC14 CHECK ENG. 14V, 0.5B/Y 1.4W 0.5G/Y A-39 IC17 MA01 14V, GLOW 1.4W 0.5O/L A-40 IC18

SW ; EXH.BRAKE

SW ; ENG.WARM 0.3B IZ09

0.5BR/R IC20 0.5BR IC65 0.5L/R IC22

0.5LG/W IC29

0.5LG IC16

0.5L/R 0.5B/O IC26 IC27 MAG.VALVE ; EXH.BRAKE

EVRV ; EGR

14V, 60mA

0.5LG/R IC21

1.25L/R IC59

0.5G/Y CA01

1.25B/Y IC05

3L/R IC34

GLOW 60A

MAIN 80A

KEY SW 50A

TO BLOWER MOTOR

PDS 0.85G/O HA11

SW ; NEUTRAL (NEUTRAL;ON) 0.5B/W IC31 RESISTER ; NEUTRAL SW (510 ) 0.3B IZ06

B-3 MAT SIG. 0.5B/L (84) IC56 MAG.VALVE A-37 (EXH.BRAKE) (40) B-17 INT.SLOTTLE (95) B-6 SW;NEUTRAL (87) TWIST LINE B-24 INJ.PUMP 0.5Y 2 (CAN-H) IC35 (100) INJ.PUMP 0.5R B-23 INJ.PUMP 1 (CAN-L) IC36 (99) 7 0.5O B-29 INJ.PUMP 5 (MAB) IC37 6 (105) B-13 INJ.PUMP 0.5P 8 (DZG) IC38 (91) A-30 A/C SW (33) A-38 A/C RELAY (41) FRAME EARTH POINT

5B IZ03

J/C

0.5B IC15 VSV ; INT.THROTTLE 0.5L/R IC28

2L/R IC30

0.5G/Y IC41 0.5W/G IC40 1.25B/Y IC63

0.5B ZZ06

TO RELAY ; TAIL

RESISTER ; IDLE SW (510 )

0.85B MX06

0.5B ZZ05

2B IZ04

0.5L/R IC06 0.5L/R IC07 0.5L/R IC08 0.5B/W IC32

RELAY ; A/C ON SIGNAL MAGNET CLUTCH (COMPRESSOR)

RESISTER ; A/C ON SIGNAL(270 ) 0.5B 0.5Y/G IZ08 IC47

TO SW ; BACK UP LAMP

0.5B IZ12

#19 TURN 10A #2 AIR CON 10A #1 HEATER 25A

TO RELAY ; CORNEING

#18 GENERATOR 15A #15 H/L LEVELINGA 10A #12 GAUGE, BACK 10A #11 WIPER, WASHER 15A 0.85Y/G HA19

RELAY ; THERMO A/C

0.85G/W HA10

6E–183 ENGINE DRIVEABILITY AND EMISSIONS reference

FTX 2L

BATT

TO ELECTRO THERMO

TO RELAY ; CHARGE

0.85W PA10

RELAY ; HEATER&A/C

0.5G/O IC48

0.5L/R IC39

#20 ECU 25A

5B/L HB01

3B/Y IC01

#17 STOP LAMP 10A

TO RELAY ; CHARGE

0.5L/R IC33

0.5W IC60 STOP LAMP 0.5G BB09

METER

TO CONT UNIT ; ABS LAMP (STOP SIGNAL )

A-36 IG (39)

B-7 MAF SIG. (88) B-14 MAF GND (92)

A-55

B-16

0.5G/O IC43

0.5R/G IC42

0.5B/R HB04

1

2

3

1.25L/R HB03

A-35

0.5B/G IC44

GLOW RELAY (94)

A-47

ACCEL SENSOR (+5V)(57) ACCEL SENSOR (SIG.)(38)

A-69 A-61

2B IZ02

TPS

METER

THERMO

JOINT

ACCEL SENSOR (GND.)(49)

A-62

ACCEL SENSOR (IDEL)(69) GND. (2)

2B IZ01

0.5B IZ11

TDC

B-9

WATER TEMP

0.85B MX01

RELAY ; G/PULG

5B/Y HB02

GLOW PULG (4 x4)

THERMO UNIT (WATER TEMP)

0.5Y/G MA33

GND.

SIG.

+

VEHICLE SPEED

0.5B MX11

WITH ; ABS

ALDL CONNECTOR

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

0.3W/G BB20

0.5B/Y MA32

SW ; IDEL

D-4 0.5Y/B MA08

0.5LG MA07

1

3

2

7 EXH.B/CUT 29 0.3W/B IN J1850 BB21

CONT.UNIT ; ABS

SPEED

B-9

A-24

0.5Y/G IC46

B-8

A-68

0.5LG/B BB07

0.5GR IC51

0.3V MX04

A-60

B-12

B-8

0.5B/P IC52

IZ10 (SHIELD)

B-22 0.5W IC50

0.5R IC49

0.5LG/W 8 EXH.B/CUT 4 OUT BB06 FRASH

TACHO

0.5G/B IC62 A-29

FRAME EARTH POINT

GND. (1)

ENG.SPEED (OUTPUT-1) (27)

ABS (OUT) (62) ABS (IN) (32)

A-44 QWS SW (46) VEHICLE SPEED A-57 METER IND (68) (QWS) (59)(KEY ON;ENABLE) B-2 MAF +5V (83)

METER IND (CHECK ENG.) (42) METER IND (GLOW) (43)

0.5G/B IC45

CONT UNIT ; ENGINE

0.5W IC04

A-27 BARAKE ON (30)

A-56 MAIN RELAY (58) A-41 BAT(+) (3)

0.5G IC10

A-28 CLUTCH (31)

0.5W/B A-65 BARAKE OFF (65) IC11

0.5Y IC12

0.5W/R IC23

METER IND (EXH.BRAKE) (60)(KEY ON;ENABLE)

0.5LG/L A-64 SW;EXH.BRAKE (64) IC13

4

0.5G/R IC24 0.5B/R IC25

5 3

B-19 EGR (97)

TDC (+) (90) TDC (-) (98)

B-15

0.5Y IC57

0.5B IZ07

GND. (93)

A-32

0.5L IC58

B-25

ISO-K (35)

A-43

TDC (SHIELDED) (101) WATER TEMP (ECU) (89)

DIAG (45)

RESISTER ; IDLE SW (510 )

RELAY ; ECU 0.5L/B IC03 2L/R IC02

SW ; STOP LAMP (BRAKE PEDAL ; ON) 0.5G CA02 0.5L/R IC09 (BRAKE PEDAL ; OFF)

SW ; CLUTCH (CLUTCH PEDAL ; OFF)

0.5BR/R IC19

2

1

MAF

EXH.BRAKE 14V, 2.0W 0.5G/R A-58 0.5LG/L IC64 IC14 CHECK ENG. 14V, 0.5B/Y 1.4W 0.5G/Y A-39 IC17 MA01 14V, GLOW 1.4W 0.5O/L A-40 IC18

SW ; EXH.BRAKE

SW ; ENG.WARM 0.3B IZ09

0.5BR/R IC20 0.5BR IC65 0.5L/R IC22

0.5LG/W IC29

0.5LG IC16

0.5L/R 0.5B/O IC26 IC27 MAG.VALVE ; EXH.BRAKE

EVRV ; EGR

14V, 60mA

0.5LG/R IC21

1.25L/R IC59

0.5G/Y CA01

1.25B/Y IC05

3L/R IC34

GLOW 60A

MAIN 80A

OFF ACC

KEY SW

5W PA07

B ST

ON

0.5BR HA09

RELAY ; A/C COMP.

0.5B IC15 VSV ; INT.THROTTLE 0.5L/R IC28 SW ; NEUTRAL (NEUTRAL;ON)

0.5B/W IC31

5B IZ03

J/C RESISTER ; NEUTRAL SW (510 ) 0.3B IZ06

B-3 MAT SIG. 0.5B/L (84) IC56 MAG.VALVE A-37 (EXH.BRAKE) (40) B-17 INT.SLOTTLE (95) B-6 SW;NEUTRAL (87) TWIST LINE B-24 INJ.PUMP 0.5Y 2 (CAN-H) IC35 (100) INJ.PUMP 0.5R B-23 INJ.PUMP 1 (CAN-L) IC36 (99) 7 0.5O B-29 INJ.PUMP 5 (MAB) IC37 6 (105) B-13 INJ.PUMP 0.5P 8 (DZG) IC38 (91) A-30 A/C SW (33) A-38 A/C RELAY (41) FRAME EARTH POINT

2B IZ04

KEY SW 50A

TO BLOWER MOTOR

PDS

TO RELAY ; TAIL 2L/R IC30

0.5G/Y IC41 0.5W/G IC40 1.25B/Y IC63

0.5B ZZ06

RELAY ; A/C ON SIGNAL MAGNET CLUTCH (COMPRESSOR)

RESISTER ; A/C ON SIGNAL(270 ) 0.5B 0.5Y/G IZ08 IC47

TO SW ; BACK UP LAMP

0.5B IZ12

#19 TURN 10A #2 AIR CON 10A #1 HEATER 25A

TO RELAY ; CORNEING

#18 GENERATOR 15A #15 H/L LEVELINGA 10A #12 GAUGE, BACK 10A #11 WIPER, WASHER 15A 0.85Y/G HA19

RELAY ; THERMO A/C

0.85G/W HA10

0.5L/R IC06 0.5L/R IC07 0.5L/R IC08 0.5B/W IC32

0.85G/O HA11

ONLY NKR 4JH1-TC

0.85B MX06

0.5B ZZ05

ENGINE DRIVEABILITY AND EMISSIONS 6E–184

reference

ENGINE DRIVEABILITY AND EMISSIONS

6E–185

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

—

Go to Step 3

Refer to Intermittent Diagnosis

12V

Replace ECM

Go to Step 4

Verify repair

—

2

3

1. Clear the DTC P1576. 2. Observe the DTCs. Was the DTC P1576 stored? 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.

40

4

Check the Exhaust Brake circuit. Was the problem found?

6E–186

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1576 SUB CODE 0100 EXHAUST BRAKE VALVE1 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

Go to Step 3

Refer to Intermittent Diagnosis

Replace ECM

Repair the harness

2

3

1. Clear the DTC P1576. 2. Observe the DTCs. Was the DTC P1576 stored?

—

Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. Check continuity between ECM relay and ECM pin 40. • Check no short to ground between ground and ECM pin 40.

Continuity

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

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

1. Clear the DTC P1605. 2. Observe the DTCs. Was the DTC P1605 restored?

—

Replace ECM

Go to Intermittent

2

ENGINE DRIVEABILITY AND EMISSIONS

6E–187

DTC P1610 SEEDS AND KEY FILE DESTROYED Step 1

2

Action

Value(s)

Yes

No

Clear the DTC P1610. Observe the DTCs. Was the DTC P1610 stored?

No DTC

Verify

Go to Step 2

Reprogram ECM by SPS and verify no more DTC.

No DTC

—

Replace ECM

Value(s)

Yes

No

Clear DTC P1611. Observe the DTCs. Was DTC P1610 stored?

No DTC

Verify

Go to Step 2

Write proper security code. See the immobilizer procedure.

No DTC

Verify

Replace ECM

DTC P1611 WRONG SECURITY CODE ENTERED Step 1

2

Action

DTC P1612/P1613 IMMOBILIZER NO OR WRONG SIGNAL Step 1

2

Action Clear the DTC P1612. Observe the DTCs. Was DTC P1612 stored? Check open circuit of wire between ECM - Immobilizer ICU.

Value(s)

Yes

No

No DTC

Verify

Go to Step 2

No open circuit

Check immobilizer section of WSM

Repair wire

Value(s)

Yes

No

No DTC

Verify

Go to Step 2

DTC P1614 Wrong transponder key Step 1

2

Action Clear the DTC P1614. Observe the DTCs. Was DTC P1614 stored? Check immobilizer section of WSM.

6E–188

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1625 Power supply relay malfunction

IGN ON

OFF 2sec ECM relay

OFF

DTC P1625 SUB CODE 1011 POWER SUPPLY RELAY SWITCHED OFF TOO LATE Step

Action

Value(s)

Yes

No

1

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

—

Go to Step 2

Go to OBD system check

—

Go to Step 3

Refer to Intermittent Diagnosis

ECM relay function is OK

Replace ECM

Replace relay

2

3

1. Clear the DTC P1625. 2. Observe the DTCs. Was the DTC P1625 stored? Check ECM relay function.

DTC P1625 SUB CODE 1010 POWER SUPPLY RELAY SWITCHED OFF TOO EARLY Step

Action

Value(s)

Yes

No

1

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

—

Go to Step 2

Go to OBD system check

Go to Step 3

Refer to Intermittent Diagnosis

Replace ECM

Replace felay

2

3

1. Clear the DTC P1625. 2. Observe the DTCs. Was the DTC P1625 stored? Check ECM relay function.

—

ENGINE DRIVEABILITY AND EMISSIONS

6E–189

DTC P1630 FUEL-INJECTION QUANTITY CIRCUIT MALFUNCTION DTC P1630 SUB CODE 1010 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

—

DTC stored Replace injection pump

Go to Intermittent Diagnosis

2

1. Clear the DTC P1630. 2. Observe the DTCs. Was the DTC P1630 restored?

DTC P1630 SUB CODE 1011 FUEL-INJECTION QUANTITY CIRCUIT HIGH INPUT Step

Action

1

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

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?

Value(s)

Yes

No

Go to Step 2

DTC stored Replace injection pump

Go to intermittent diagnosis

6E–190

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

—

Go to Step 3

Go to Intermittent Diagnosis

0Ω and 0V

Go to Step 4

Repair harness

DTC stored Replace injection pump and verify

—

2

3

1. Clear the DTC P1650. 2. Observe the DTCs. Was the DTC P1650 restored? Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Disconnect PCU connector. • Make jumping at PCM pin 1 and pin 2. • Check continuity between ECM pin 99&100. Breaker box is not available Ignition off • Disconnect ECU and PCU connector. • Make jumping at PCM pin 1 and pin 2. • Check continuity between ECM pin 99&100.

and

4

Replace ECU. Was the DTC P1650 restored?

and

ENGINE DRIVEABILITY AND EMISSIONS

6E–191

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

—

Go to Step 3

Go to Intermittent Diagnosis

0Ω and 0V

Go to Step 4

Repair harness

2

3

1. Clear the DTC P1650. 2. Observe the DTCs. Was the DTC P1650 restored? Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • 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.

and

4

Replace ECU. Was the DTC P1650 restored?

and

DTC stored Replace injection pump and verify

6E–192

ENGINE DRIVEABILITY AND EMISSIONS

DTC P1651 INJECTION PUMP: CAN MALFUNCTION

ECM 25A

VSV: MAG valve INT. Throttle Exh Brake (NKR 4JH1-TC only) VSV : Ext 1 (QWS) (TF 4JA1-TC only)

EVRV: EGR

2 MAF

SW:Neutral (MT only)

6

7 PCU

1 3

84

5

92

88

4

8

83

40

97

Batt

95

Batt

87

Batt

5

91

Batt

105

1 2

99 CAN-L

100 CAN-H

Batt CF 150

US CPU

µP

µP

µP

Batt

µP IC 08 µP

IC 08

µP : Microproccesor

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

Go to Step 3

Go to Intermittent Diagnosis

2

1. Clear the DTC P1651. 2. Observe the DTCs. Was the DTC P1651 restored?

—

ENGINE DRIVEABILITY AND EMISSIONS Step 3

4

Action

6E–193

Value(s)

Yes

No

Continuity

Go to Step 4

Repair harness

DTC stored Replace injection pump and verify

—

Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Disconnect PCU connector. • Make jumping at PCU pin 1 and PCU pin 2. • Check continuity between ECM pin 99 and 100. Breaker box is not available Ignition off • Disconnect ECM and PCU connector. • Make jumping at PCU pin 1 and PCU pin 2. • Check continuity between ECM pin 99 and 100.

Replace ECU. Was the DTC P1651 restored?

6E–194

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Go to Intermittent Diagnosis

0Ω

Go to Step 4

Repair harness

2

3

4

1. Clear the DTC P1651. 2. Observe the DTCs. Was the DTC P1651 restored? Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Disconnect PCU connector. • Make jumping at PCU pin 1 and PCU pin 2. • Check continuity between ECM pin 99 and 100. Breaker box is not available Ignition off • Disconnect ECM and PCU connector. • Make jumping at PCU pin 1 and PCU pin 2. • Check continuity between ECM pin 99 and 100.

Replace ECM.

Verify

ENGINE DRIVEABILITY AND EMISSIONS

6E–195

DTC P1690 MALFUNCTION INDICATION LAMP (MIL) CIRCUIT MALFUNCTION

IG #12 Cause / Back fuse NKR onry Meter fuse TF 4JA1-TC,4JH1-TC

ON

ECM 25A

15A

Stop lamp 10A

Relay EW

SW:clutch Clutch pedal:OFF

Stop lamp SW

Glow plug relay coil

SW:ExG Brake Meter ExG Brake

Check Engine

Glow

ABS control unit 3

58

39

30

65

31

64

60

Batt

µP

42

43

59

46

Batt

µP

IC 08

µP

µP

µP

IC 035

IC 035

µP : Microproccesor

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 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

Go to Step 3

Refer to Intermittent Diagnosis

2

1. Clear the DTC P1690. 2. Observe the DTCs. Was the DTC P1690 stored?

—

6E–196

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

3

Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Remove the No.12 fuse (NKR only), meter fuse (TF 4JH1-TC, 4JA1-TC). • Measure voltage between ECM pin 42 and ground. Breaker box is not available Ignition off • Disconnect ECM connector. • Remove the No.12 fuse (NKR only), meter fuse (TF 4JH1-TC, 4JA1-TC). • Measure voltage between ECM pin 42 and ground.

4

5

Disconnect the connector of instrument panel. Check the voltage between the connector instrument panel and the ECM.

Value(s)

Yes

No

0V

Replace ECM

Go to Step 4

0V

Go to Step 5

Repair engine harness

0V

Check the ground the lump

Repair harness verify

of

Check the voltage between the fuse and the lump bulb.

ENGINE DRIVEABILITY AND EMISSIONS

6E–197

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

Go to Step 3

Refer to Intermittent Diagnosis

Go to Step 4

Go to Step 5

Go to Step 5

Replace engine harness

No blown

Go to Step 6

Fuse blown Replace the fuse

Bulb should be OK

Go to Step 7

Replace the bulbs

Replace ECM

Repair or replace body harness

2

3 4

1. Clear the DTC P1690. 2. Observe the DTCs. Was the DTC P1690 stored?

—

• Ignition key “ON”. • Does the “Glow” lamp flash? Breaker box is available Ignition off • Install a breaker box as type A, see page 6E-58. • Remove the No.12 fuse (NKR only), mater fuse (TF 4JA1-TC, 4JH1-TC). • Check continuity between ECM pin 42 and instrument panel side. Breaker box is not available Ignition off • Disconnect ECM connector. • Remove the No.12 (NKR only), meter fuse (TF 4JA1-TC, 4JH1-TC). • Check continuity between ECM pin 42 and instrument panel side.

Instrument panel Continuity 5

6 7

Check the No.12 fuse (NKR only), meter fuse (TF 4JA1-TC, 4JH1-TC) is not blown. Check the “Check Eng” lamp and “Glow” lamp bulbs. Are the bulbs available? Check continuity between the meter panel and No.12 fuse (NKR only), meter fuse (TF 4JA1-TC, 4JH1-TC). Continuity

6E–198

ENGINE DRIVEABILITY AND EMISSIONS

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.

ENGINE DRIVEABILITY AND EMISSIONS

6E–199

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

Clutch system should not drug clutch plate

Go to Step 3

Clutch is drugged check clutch system

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

More than 12V

Go to Step 5

Recharge and follow section

Check the starter circuit. See the electrical section.

Go to Step 6

Repair starter circuit

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

Go to Step 8

Adjust valve gap

Verify

—

2

3

Check the manual transmission position. Should be Neutral. Run the engine. If cranking speed is lower, check the clutch system. Measure cranking speed. Does cranking speed meet standard? Oil temperature

Cranking speed

-20°C

100-150rpm or more

+20°C

200-250rpm or more

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. 4 5 6

7

8

Check battery voltage and battery specific gravity.

Check value gap. If valve gap is close to “zero”, need to be adjusted. Crank engine.

Check engine whether any part has excessive friction. See the overhaul procedure.

Valve gap value can be seen on engine mechanical section

6E–200

ENGINE DRIVEABILITY AND EMISSIONS

1-3. Cranking speed seems to be OK, but no combustion sounds can be heard. Step 1 2

Action

Yes

No

Go to Step 2

Replace and flash well

See the left box

Go to Step 3

Go to “1-2. Starter can crank engine, but seems to be lower than usual”

No fuse blown

Go to Step 4

Repair

Go to Step 5

Add fuel and bleed air

Check fuel feed pipe pinched, deformed or fuel No pinched leakage. No deformed No fuel leakage

Go to Step 6

Repair

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

No air

Go to Step 8

Bleed air

Go to Step 9

Change to winter type fuel

Ask the customer whether use proper fuel. Check cranking speed with following table. Oil temperature

Cranking speed

-20°C

100-150rpm or more

+20°C

200-250rpm or more

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. 3

4 5

6

7 8

Value(s)

Ignition off, check the fuses. ECU fuse 25A Generator fuse 15A Check any poor ground of ECM. Check ECM engine harness poor cnnector pin. Check the fuel level.

Check Air in fuel. See the procedure in section 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

Fuel feed line

Fuel sedimenter/fuel filter

waxing causes plugging fuel flow

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

9

Check any deformation, plugged at inlet air passage.

10

Value(s)

Yes

No

No plugged

Go to Step 10

Repair and verify

Go to Step 11

Clean or replace Air cleaner element

Intake shutter operate smoothly

Go to Step 12

Replace intake shutter and verify

Exhaust system is not deformed plugged. Exhaust system should be ok

Go to Step 13

Repair or Replace

Go to Step 14

Repair or Replace exhaust valve

Check Air cleaner element. Is the element clean? Clean

11

12

13

6E–201

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.

Check whether exhaust system is deformed, plugged.

• 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

Exhaust valve moves smoothly, wide open position by no vacuum

6E–202

ENGINE DRIVEABILITY AND EMISSIONS

Step 14

Action

Value(s)

Yes

No

Go to Step 15

Replace catalytic converter

Check catalytic converter is plugged or not. No plugged

15

Check whether the turbine of turbo isn’t damaged.

Go to Step 16

Repalce turbo

16

Check whether after market Air conditioner compressor is in stalled. If so, check whether Air conditioner compressor is seized by hand.

Go to Step 17

Replace compressure

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

Go to Step 19

Repair engine

Go to Step 20

Replace coolant temperature sensor

Go to Step 21

Replace valve

Verify

Replace pump

17

18

19

Measure compression • Engine coolant temperature 50°C. • Crank 200 to 250 rpm Remove coolant tempereture sensor and check relation between the water temperature and resistance value.

20

Check injection valve, over flow valve.

21

Replace ECM.

Compression 28 kg/cm3 See the ECT sensor Table on page 6E203

ENGINE DRIVEABILITY AND EMISSIONS

6E–203

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

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

Check fuel feed pipe pinched, deformed or fuel No pinched leakage. No deformed No fuel leakage

Go to Step 4

Repair

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

No air

Go to Step 6

Bleed air

—

Change to winter type fuel.

Go to Step 7

No problem See the engine mechanical section

Go to Step 8

Repair & verify

See the left table

Go to Step 9

Replace ECT and verify

No problem

Go to Step 10

Repair

2

3

4

5

Check Air in fuel. See the procedure in section.

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.

7

8

Remove injecter. 1. Check injection patter is OK. 2. Check injection opening specification.

pressure

is

in

Check ECT sensor resistance. See ECT sensor look up table. °C

OHMS

Temperature vs. Resistance Values (approximate)

9

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Inspect if overflow valve is kept open.

6E–204

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

10

Check TPS position by Tech-II. Is data within typical data?

11 12

13

14

15

Value(s)

Yes

No

Within specification

Go to Step 11

Raise engine speed two or three times and check again. If condition still continues, replace injection pump

Typical data

Go to Step 12

Replace or adjust

2.0KΩ at 20°C room temperature

Go to Step 13

Replace MAF

No imitation no deformation or plugged

Go to Step 14

Correct them

See the left 1-4 items

Go to Step 15

Correct it

Operate smoothly

Go to Step 16

Correct it and verify

Check TPS position becomes within typical data. Remove MAF, specification.

check

whether

IAT

works

in

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them

ENGINE DRIVEABILITY AND EMISSIONS Step 16

Action

6E–205

Value(s)

Yes

No

No deformation or plugged

Go to Step 17

Correct it and verify

—

Go to Step 18

Correct it

—

Still does not run well, replace injection pump

Check any deformation, plugged at exhaust system.

17

Check turbine of turbo charger.

18

Repalce ECM and verify.

—

6E–206

ENGINE DRIVEABILITY AND EMISSIONS

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

Engine run more than 2000 rpm

Go to Step 3

Replace to proper fuel and flash it

—

Go to Step 4

Repair it and verify.

No imitation no deformation or no plugged

Go to Step 14

Correct them

See left 1-4 items

Go to Step 15

Correct it

Operate smoothly

Go to Step 16

Correct it and verify

No deformation or plugged

Go to Step 17

Correct it and verify

2

3 4

5

6

7

Even engine run at 1st hand, waxing at fuel filter causes no engine raise, or stall. Check fuel level or any air mixing to fuel line. Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them. Check any deformation, plugged at exhaust system. See the procedure.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

Value(s)

8

Check turbine of turbo charger. See the procedure on engine mechanical section.

Yes

No

Go to Step 18

It any damage, replace turbo charger

No after market accessory

Go to Step 10

Replace to genuine parts or remove it

Within specification

Replace ECM

Repalce ECT sensor

— 9

10

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.

6E–207

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. °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–208

ENGINE DRIVEABILITY AND EMISSIONS

2. Engine stall 2-1 Engine stall at idling. Step

Action

1

Did engine stall happen at lower than 10°C or more than 10°C

2

3

4

5 6 7

8 9

Value(s)

Yes

No

Lower than 10°C

Lower than 10°C Go to Step 2

Go to Step 14

Fuel is sufficient

Go to Step 3

Add fuel and bleed air & verify

Proper fuel

Go to Step 4

Replace and flash 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

See the typical data

Go to Step 9

Go to Step 6

—

Go to Step 7

Correct it and verify.

—

Verify, still simpton exist, Verify Go to Step 9

Go to Step 9

No stuck open

OK Go to Step 10

Repair

No installation.

Go to Step 11

Remove

Check the fuel level in tank.

Ask the customer what kind of fuel the customer use. Cetane index more than specified on owner’s manual. No gasoline No kevocin No bio chemical fuel 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. Check APS position is within typical data. Check any fuel leakage at fuel pipe, injection pipe. Check any damage of fuel pipe or injection pipe. Replace fuel filter, because it maybe caused by fuel filter plugged or resistance fuel flow through fuel filter. Does it fix the problem? Check the over flow valve stuck open. Check any installation of after market accessory especially A/C compressor.

ENGINE DRIVEABILITY AND EMISSIONS Step 11

Action

6E–209

Value(s)

Yes

No

Within specification

Go to Step 12

Replace it and Verify

—

Verify but still condition continues, Go to Step 13

—

Verify

—

Fuel is sufficient

Go to Step 15

Add fuel and bleed air & verify

Proper fuel

Go to Step 16

Replace it.

Inspect ECT is within specification. °C

OHMS

Temperature vs. Resistance Values (approximate)

12

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Replace injection pump.

13

Replace ECM

14

Check the fuel level.

15

16

17 18

Ask the customer what kind of fuel the customer use. Cetane index more than specified on owner’s manual. No gasoline No Kevocin No bio chemical fuel 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

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

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

—

Go to Step 19

Correct them

6E–210 Step 19

20

21

22

ENGINE DRIVEABILITY AND EMISSIONS Action

Value(s)

Yes

No

See the left 1-4 items

Go to Step 20

Correct it

Operate smoothly

Go to Step 21

Correct it and verify

—

Go to Step 22

Correct it and verify

—

Go to Step 23

Correct it

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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them. Check any deformation, plugged at exhaust system.

Check turbine of turbo charger. See the procedure on engine mechanical section.

ENGINE DRIVEABILITY AND EMISSIONS

6E–211

Step

Action

Value(s)

Yes

No

23

Check any installation of after market accessory especially A/C compressor.

No installation.

Go to Step 24

Remove

Within specification

Go to Step 25

Replace it and verify

No foreign material

If no more stall, verify one more time

Go to Step 26

Opening pressure 1st 19.5kpa/ 199kg/cm2 2ns 33.8kpa/ 345kg/cm2

Go to Step 27

Change nozzle

See the left

Go to Step 28

Follow the procedure at engine mechanical section

24

Inspect ECT is within specification. °C

OHMS

Temperature vs. Resistance Values (approximate)

25

26

27

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Run engine again. Foreign material at MAB may cause High pressure soloenoid valve stuck. Check injection nozzle spray pattern and opening pressure.

Check the compression.

28

Replace injection pump.

—

Verify

Go to Step 29

29

Replace ECM

—

Verify

—

6E–212

ENGINE DRIVEABILITY AND EMISSIONS

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

Within specification

Go to Step 3

Replace and verify.

Operation should be smooth

Go to Step 4

Replace it

10w-30 or 10w-40

Go to Step 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

—

—

—

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.) 3

4 5

8

Check exhaust valve operation.

Ask the customer what kind of oil he or she uses.

Replace ECM

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

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.

6E–213

Value(s)

Yes

No

(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

—

Check whether ECM connector, ECT connector PCU connector, glow plug connector have poor connection

No poor connection

Go to Step 13

Repair

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

—

Check PTO system or accessory. How?

—

Go to Step 14

—

Replace ECM

—

—

—

12 13

14 15

6E–214

ENGINE DRIVEABILITY AND EMISSIONS

3. Rough idle Step

Action

1

Use Tech-II to confirm. Compare actual idling speed and target idling speed.

2

Check accessory belt tension.

3

Check any after market accessory, which ECM does not recognize additional engine load of A/C compressor or wrong wring.

4

Ask the customer when it happen. If happens only during night, ACG load fluctuation causes rough idle.

5

6

7 8 9

10

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

Value(s)

Yes

No

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

98 - 118 (V) 10 - 12 (kg)

Go to Step 3

Adjust and verify

No accesay with ECM recogaition

Go to Step 4 happens only during night

Remove after market accessory

—

If happens only during night, ask ISUZU representative

Go to Step 5

No imitation, no plugged, no deformation

Go to Step 6

Correct them.

See the left 1-4 items

Go to Step 7

Replace and verify

—

Go to Step 8

Add fuel and bleed air

—

Go to Step 9

Repair

Proper fuel see the owners manual

Go to Step 10

Replace to proper one

—

Go to Step 11

Repair

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.

Check fuel level. Check fuel feed pipe pinched, deformed, damaged or fuel leakage. Ask the customer what kind of fuel the customer use.

Check APS sensor return to 0% by Tech-II and by DVM.

ENGINE DRIVEABILITY AND EMISSIONS Step 11

12

13

Action Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them.

Value(s)

Yes

No

Operate smoothly

Go to Step 12

Correct it and verify

No deformation, plugged

Go to Step 13

Correct it and verify

No damage

Go to Step 14

Correct it

—

Go to Step 15

—

Oporate smoothly

Go to Step 16

Replace and verify

No more rough idle

Verify

Go to Step 17

Check any deformation, plugged at exhaust system.

Check turbine of turbo charger. See the procedure or engine mechanical see section.

14

Check over flow valve stuck or not.

15

Check EGR valve operation. Apply vacuum by mighty vac. See the valve movement through EGR valve window.

16

6E–215

Replace fuel filter cartridge. Run engine, check rough idle is fixed or not.

6E–216

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

Yes

No

17

Check injection nozzle spray pattern and injection opening pressure.

Opening pressure 1st 19.5kpa/ 199kg/cm2 2ns 33.8kpa/ 345kg/cm2

Go to Step 18

Replace nozzle

No leakoge

Go to Step 19

Repair

More than 28 kg/cm2

Go to Step 20

Compression is not in specification. Check the cause based on engine mechanical section of work shop manual

—

Go to Step 21

Repalce ECT sensor

Ω

Go to Step 22

Replace glow plug

2.0KΩ at 20°C room temp

Go to Step 23

Replace MAF

—

Verify

—

18 19

20

Inspect delivery valve leaking or any damage around seal area. Check the compression.

Inspect ECT sensor with specification table below. °C

OHMS

Temperature vs. Resistance Values (approximate)

21 22

23

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check glow plug. Check IAT sensor.

Replace injection pump.

ENGINE DRIVEABILITY AND EMISSIONS

6E–217

4. Excessive white smoke. Step

Action

1

2

3

4

5

6

Valve(s)

Yes

No

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

—

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

—

Explain to customer

No long hours parking Go to Step 4

Go to Step 5

Correct them

See the left 1-4 Smooth operation

Go to Step 6

Correct it

Operate smoothly

Go to Step 7

Correct it and verify

Ask the customer whether this white smoke happen just one time after soak the vehicle for long hours under cold weather. It is normal.

Check air cleaner element plugged, to use genuine No immitation parts, intake pipe deformation or plugged. no plugged, no deformation 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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them.

6E–218 Step 7

8

9

ENGINE DRIVEABILITY AND EMISSIONS Action

Valve(s)

Yes

No

No damage

Go to Step 8

Correct it and verify

—

Go to Step 9

Correct it

—

Go to Step 12

Remove foreign material

Check any deformation, plugged at exhaust system.

Check turbine of turbo charger. See the procedure on engine mechanical sectin.

Check over flow valve stuck open by 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

ENGINE DRIVEABILITY AND EMISSIONS Step 13

Action

6E–219

Valve(s)

Yes

No

Within specification see the left table

Go to Step 14

Replace ECT

Within specification

Go to Step 15

Replace glow plug

Go to Step 16

Repair wiring

—

Go to Step 17

Replace IAT

Within spec

Go to Step 18

Adjust

Opening pressure 1st 19.5kpa/ 199kg/cm2 2ns 33.8kpa/ 345kg/cm2

Go to Step 19

Replace nozzle

Go to Step 20

—

Check ECT valve by Tech-II with actual condition. If nearly equal, check ECT sensor in specification. °C

OHMS

Temperature vs. Resistance Values (approximate)

14 15

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check glow plug resistance. Check poor connection of glow plug, ECT sensor ECM connector, PCU connector.

16

Check IAT sensor

17

Check valve timing. See the procedure on the engine mechanical.

18

19

Inspect injection nozzle spray pattern, opening pressure.

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.

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

23

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

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

6E–220 Step 24

25

26

27

ENGINE DRIVEABILITY AND EMISSIONS Action

Valve(s)

Yes

No

Go to Step 25

Correct them

See the left 1-4 Smooth operation

Go to Step 26

Correct it

Operate smoothly

Go to Step 27

Correct it and verify

No damage

Go to Step 28

Correct it and verify

Check air cleaner element plugged, to use genuine No immitation parts, intake pipe deformation or plugged. no plugged, no deformation 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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them. Check any deformation, plugged at exhaust system.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

28

Check turbine of turbo charger. See the procedure on engine mechanical sectin.

29

6E–221

Valve(s)

Yes

No

—

Go to Step 29

Correct it

—

Go to Step 30

Remove foreign material

Check over flow valve stuck open by 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

Within specification see the left table

Go to Step 34

Replace ECT

During after run period, Go to step 35

Not during after run period, Go to step 39

Go to Step 36

Replace glow plug

Go to Step 37

Repair wiring

—

Go to Step 38

Replace IAT

Within spec

Go to Step 39

Adjust

33

Check ECT valve by Tech-II with actual condition. If nearly egnal, check ECT sensor in specification. °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

34

Does customer drive after run glow period? See the system description on page of DTC P0380 glow device Malfunction.

35

Check glow plug resistance.

36

Within specification

Check poor connection of glow plug, ECT sensor, ECM connector, PCU connector.

37

Check IAT sensor

38

Check valve timing. See the procedure on the engine mechanical.

6E–222

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Valve(s)

Yes

No

39

Inspect injection nozzle spray pattern, opening pressure.

Opening pressure 1st 19.5kpa/ 199kg/cm2 2ns 33.8kpa/ 345kg/cm2

Go to Step 40

Replace nozzle

Go to Step 41

—

Verify

—

Go to Step 22-41

Go to Step 23-34 37-41

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.

41

Replace ECM

42

Ask the customer whether excessive white smoke occurs during down road slope or flat. Record the condition.

—

ENGINE DRIVEABILITY AND EMISSIONS

6E–223

5. Excessive black smoke Step

Action

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?

2

3 4

5

Value(s)

Yes

No

—

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

—

—

If smoke level is same, explain to the customer

Go to Step 3

—

Go to Step 4

Correct them

—

Go to Step 5

Correct it

Operate smoothly

Go to Step 6

Correct it and verify.

Compare the claimed vehicle with any other vehicle. Smoke level is same or not. Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged. 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.

Check the compressor of turbo charger operation. 1. Remove inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them.

6E–224

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

6

Check any deformation, plugged at exhaust system. See the procedure.

7

8

9

Value(s)

Yes

No

—

Go to Step 7

Correct it and verify

—

Go to Step 8

Engine speed is not proper Repair speed sensor ↓ Still NG ↓ Repalce ECM Coorect it

Crank mode threshold

Go to Step 9

—

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.

Check turbine of turbo charger. See the procedure on engine mechanical section of work shop manual.

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. Compare desire timer piston position (Desired injection start) and actual timer piston position. (Actual injection start)

Within tolerance

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

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.

11

Value(s)

6E–225

Yes

No

—

Go to Step 11

NG Replace EGR valve

Within specification See the left table

OK Go to Step 12

NG Replace ECT

Opening pressure 1st 19.5kpa/ 199kg/cm2 2ns 33.8kpa/ 345kg/cm2

OK Go to Step 13

NG Replace injection nozzle

—

OK Go to Step 14

Replace PCV system

Check ECT sensor resistance. Compare it with the table below. °C

OHMS

Temperature vs. Resistance Values (approximate)

12

13

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check injection nozzle spray pattern and opening pressure. If opening pressure is low than standard, it may cause excessive black smoke.

Check whether excessive PCV oil pass through inlet manifold. If a lot of PCV oil appears, check PCV system.

6E–226

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Value(s)

Yes

No

14

Check compression. See the procedure on the page of engine mechanical section.

—

OK Go to Step 15

Repair

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 Compare with excessive black smoke. typical data

Go to Step 18

Replace MAF

15

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/cm2 2ns 33.8kpa/ 345kg/cm2

Verify

Go to Step 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/cm2 2ns 33.8kpa/ 345kg/cm2

Verify

Go to Step 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

If DTC of ECT appears, back up valve becomes –30°C, black smoke may exhaust.

—

Repair

Go to Step 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

OK Verify

NG Go to 1-1)-2-3) procedure

19

23

26 27

— 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.

—

ENGINE DRIVEABILITY AND EMISSIONS

6. Hesitation Step 1

6E–227

7. Surge/Sag

Action

Value(s)

Yes

No

Verify the customer complain Is the complain hesitation/flatness or sug/surge? rpm

Definifion of engine performance Expectation Surge

Sug

Hesitation/ flatness Go to Step 2

Hesitation

—

Sug/Surge Go to Step 21

—

Within specification

Go to Step 3

Replace to the specified tire

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

No pinched No deformed No fuel leakage

Go to Step 7

Repair

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

Check Air in fuel. See the procedure in engine mechanical section.

No air

Go to Step 9

Bleed air

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

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

Check APS sensor opening angle and Tech-II data. If different, replace it.

—

Go to Step 12

Replace it

ECT sensor indicates same as actual Go to Step 14

ECT sensor shows different valve from actual data Go to Step 13

Flatness

2 3

6

7

8 9

10

11 12

Time

Check the tire specification NKR tire spec.

Check fuel feed pipe pinched, deformed or fuel leakage

Check ETC sensor data by Tech-II, compare with actual engine coolant temperature.

6E–228

ENGINE DRIVEABILITY AND EMISSIONS

Step 13

Action

Value(s)

Yes

No

Within specification

Go to Step 14

Replace and verify

No after marked No plugged, No deformation

Go to Step 15

Correct them

Go to Step 16

Correct it

Go to Step 17

Correct it and verify

Check ECT sensor with the following table. °C

OHMS

Temperature vs. Resistance Values (approximate)

14

15

16

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

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.

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

ENGINE DRIVEABILITY AND EMISSIONS Step 17

18

19

Action

6E–229

Value(s)

Yes

No

—

Go to Step 18

Correct it and verify

—

Go to Step 19

Correct it

Within typical data

Go to Step 20

Repair

Check any deformation, plugged at exhaust system. See the procedure.

Check turbine of turbo charger. See the procedure.

Check MAF actual data with typical data.

6E–230

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

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.

Value(s)

Yes

No

—

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

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

—

Go to Step 25

Replace or repair

Opening pressure 1st 2nd

Go to Step 26

Repair

23

24 25

Check EVRV function. Check injection nozzle spray pattern, 1st/2nd opening pressure.

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

26

Check timer piston movement. Plot graph by SOL, LST. Record engine speed, timer piston SOL IST, ECT sensor, IAT sensor, MAF.

6E–231

Value(s)

Yes

No

—

Go to Step 27

Replace injection pump

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

—

Check any accessory, additional load such as compressor, ITO loads.

—

Go to Step 31

Remove it

Go to 4, 5, 6-27.

—

Verify

—

Timer advance

SOL

IST

rpm

27

30 31

ENGINE DRIVEABILITY AND EMISSIONS

EGR control logic

• Engine Revolution

OFF

• APS Input

+

Atomasphere temp

ON

+5°C

10°C

OFF

+

ON

Atomasphere pressure

1500rpm

+

Water temp

EGR lift control

TF 4JA1

10°C 20°C

80°C

Water temp [°C]

NKR 4JH1-TC

+

Water temp

EGR lift control

6E–232

60°C

65°C

Water temp [°C]

ENGINE DRIVEABILITY AND EMISSIONS

6E–233

8. Lack of power Step 1

2

Action Ask the customer the following condition. 1. During the acceleration 2. During the climbing

Valve(s)

Yes

No

—

1. Go to Step 2 2. Go to Step 25

—

—

In the specification Explain to the customer

Go to Step 3

spec

Go to Step 5

Replace tires

Check the vehicle performance. 0-400m sec 40-60km/h sec

3

Check the tire size.

4

Check APS whether APS moves smoothly or excessive free play.

—

Go to Step 13

—

Compare the complained vehicle with another vehicle about the vehicle speed.

—

Go to Step 6

Repair

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

No pinched No deformed No fuel leakage

Go to Step 10

Repair

No light on

Go to Step 11

Drain water

No air

Go to Step 12

Bleed air

No problem

Go to Step 13

Repair & verify

5 6

9

10

Check fuel feed pipe pinched, deformed or fuel leakage.

Check sedimentary light on or not. If sedimentary light stays on, frozen water may cause plugged fuel line at fuel filter.

Fuel feed line

Fuel sedimenter/fuel filter

11

Check Air in fuel. See the procedure in section.

12

Remove injection nozzle. 1. Check injection patter is OK. 2. Check injection opening pressure.

6E–234

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

Valve(s)

Yes

No

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

Within specification

Go to Step 15

Raise engine speed two or three times and check œ condition still continue Replace injection pump

Replace fuel sedimenter filter. Check TPS position becomes within typical data.

—

verify

Go to Step 16

Remove MAF, specification.

—

Go to Step 17

Replay MAF

—

Go to Step 18

correct them

—

Go to Step 19

Correct it

°C

OHMS

Temperature vs. Resistance Values (approximate)

14

15 16 17 18

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check TPS position by Tech II. Is data within typical data?

check

whether

MAF

works

in

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged. 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.

ENGINE DRIVEABILITY AND EMISSIONS Step 19

20

Action Check the compressor of turbo changer operation. 1. Remove inlet pipe. 2. Turn compressor fins manually 3. Check oil deposit. 4. Clean them.

6E–235

Valve(s)

Yes

No

Operate smoothly

Go to Step 20

Correct it and verify

—

Go to Step 21

Correct it and verify

Check any deformation, plugged at exhaust system. See the procedure.

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

Replace injection pump SPV valve may have foreign materials.

—

Verify

—

—

Go to Step 24

Replace EGR valve

23 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.

25

Check the vehicle performance.

—

—

Go to Step 26

26

Go to Step 3 ~ 24

—

—

—

6E–236

ENGINE DRIVEABILITY AND EMISSIONS

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

—

Go to Step 3

Change to the standard condition

If possible, measure the specific gravity, check the measured specific gravity meet to the standard.

proper fuel

Go to Step 4

Replace

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

2

3

Check the vehicle condition. 1. Tire 2. Accessory installation conditioning 3. Towing or not 4. PTO

after

market

Air

Ask the customer what kind of fuel he or she uses. DIESEL FUELS DIESEL FUEL/APPLICABLE STANDARD JIS Based on K2204 GAS (JAPANESE INDUSTRIAL STANDARD) OIL DIN (DEUTSCHE INDUSTRIE NORMEN)

Based on EN590: 1997

SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)

Based on SAE J-313C

BS (BRITISH STANDARD)

Based on BS EN590: 1997

Use the applicable standard or equivalent for diesel fuels.

4

5

Check any fuel leakage at fuel system.

OK Go to Step Go to Step 6

6

Measure timer piston movement by Tech-II.

Timer advance

SOL

IST

—

Go to Step 7

Raise engine speed and verify it NG. Replace injection pump.

—

Go to Step 8

Correct them

rpm

7

Check air cleaner element plugged, to use genuine parts, intake pipe deformation or plugged.

ENGINE DRIVEABILITY AND EMISSIONS Step 8

9

10

11

Action

6E–237

Value(s)

Yes

No

Operate smoothly See item 1-4 on the left

Go to Step 9

Correct it

operate smoothly

Go to Step 10

Correct it and verify

No deformation, no plugged

Go to Step 11

Correct it and verify

—

Go to Step 12

Correct it

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.

Check the compressor of turbo charger operation. 1. Return inlet pipe. 2. Turn compressor fins manually. 3. Check oil deposit. 4. Clean them. Check any deformation, plugged at exhaust system.

Check turbine of turbo charger see the procedure.

6E–238

ENGINE DRIVEABILITY AND EMISSIONS

Step

Action

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.

Value(s)

Yes

No

—

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

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

—

Go to Step 17

Replace or repair

—

Go to Step 18

—

—

Go to Step 19

15

16

Check EVRV function

17

Inspect APS sensor operation.

18

Inspect MAT sensor output, atmosphere temperature. Use T-II.

comparing

with

ENGINE DRIVEABILITY AND EMISSIONS Step

Action

19

Inspect ECT sensor, compare with the following table.

6E–239

Value(s)

Yes

—

Go to Step 20

Inspect atmosphere sensor with actual atmosphere. Nearly equal is OK.

—

Go to Step 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

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

—

Go to Step 26

Replace or repair

opening pressure 1st 2nd

—

Repair

°C

No

OHMS

Temperature vs. Resistance Values (approximate)

20 21

24

25 26

100

177

80

332

60

667

45

1188

35

1802

25

2796

15

4450

5

7280

-5

12300

-15

21450

-30

52700

-40

100700

Check EVRV function. Check injection nozzle spray pattern, 1st/2nd opening pressure.

6E–240

ENGINE DRIVEABILITY AND EMISSIONS

SPECIAL SERVICE TOOLS ILLUSTRATION

PART NO.

PART NAME

REMARKS

Connector Test Adapter Kit

KM 609

Electronic Kits

Electronic kit

5-8840-2392-0

High Impedance Multimeter (Digital Voltmeter -DVM)

Tech-II

5-8840-0378-0

Pressure Gauge

5-8840-0279-0

Vacuum Pump with Gauge

Refer to the ISUZU service Bulletin

4JVP44-WE-0112

You are requested to order this manual using the manual number that is shown above.

This manual is applicable for vehicles in all countries except the USA, Canada.

All rights reserved, This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by

ISUZU MOTORS LIMITED INTERNATIONAL SERVICE DEPARTMENT Tokyo, Japan Second edition OCT., 2001

No.4JVP44-WE-0112

PRINTED IN JAPAN