4JX1–TC 3.0L ENGINE DRIVEABILITY AND...

6E–14JX1–TC ENGINE DRIVEABILITY AND EMISSIONS

4JX1–TC 3.0L ENGINE DRIVEABILITY AND EMISSIONS

CONTENTS

Specification 6E–7. . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening Specifications 6E–7. . . . . . . . . . . . . . . Diagrams and Schematics 6E–8. . . . . . . . . . . . . . . .

ECM Wiring Diagram (1 of 6) 6E–8. . . . . . . . . . . .






ECM Pinouts 6E–14. . . . . . . . . . . . . . . . . . . . . . . . . . .

ECM Pinout Table, 32-Way Connector – J1 RED – Upper 6E–14. . . . . . . . . . . . . . . . . . . . . . . . . ECM Pinout Table, 32-Way Connector – J1 RED – Lower 6E–15. . . . . . . . . . . . . . . . . . . . . . . . . ECM Pinout Table, 32-Way Connector – J2 BLUE – Upper 6E–16. . . . . . . . . . . . . . . . . . . . . . . . ECM Pinout Table, 32-Way Connector – J2 BLUE – Lower 6E–17. . . . . . . . . . . . . . . . . . . . . . . . ECM Pinout Table, 5-Way Connector – J3 6E–18

Component Locator 6E–19. . . . . . . . . . . . . . . . . . . . .

Sensors and Miscellaneous Component

Locators 6E–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations Charts 6E–23. . . . . . . . . . . . . . . . . . . .

Diagnosis 6E–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strategy-Based Diagnostics 6E–24. . . . . . . . . . . . .

Strategy-Based Diagnostics 6E–24. . . . . . . . . . . . .

DTC Stored 6E–24. . . . . . . . . . . . . . . . . . . . . . . . . . .

No DTC 6E–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Matching Symptom 6E–24. . . . . . . . . . . . . . . . .

Intermittents 6E–24. . . . . . . . . . . . . . . . . . . . . . . . . .

No Trouble Found 6E–24. . . . . . . . . . . . . . . . . . . . .

Verifying Vehicle Repair 6E–24. . . . . . . . . . . . . . . .

General Service Information 6E–25. . . . . . . . . . . . . .

Serviceability Issues 6E–25. . . . . . . . . . . . . . . . . . .

Visual/Physical Engine Compartment

Inspection 6E–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic Knowledge of Tools Required 6E–25. . . . . .

Serial Data Communications 6E–25. . . . . . . . . . . . . .

Class II Serial Data Communications 6E–25. . . . .

On-Board Diagnostic (OBD) 6E–25. . . . . . . . . . . . . .

On-Board Diagnostic Tests 6E–25. . . . . . . . . . . . .

Comprehensive Component Monitor

Diagnostic Operation 6E–25. . . . . . . . . . . . . . . . . .

Common OBD Terms 6E–26. . . . . . . . . . . . . . . . . .

The Diagnostic Executive 6E–26. . . . . . . . . . . . . . .

DTC Types 6E–26. . . . . . . . . . . . . . . . . . . . . . . . . . .

Verifying Vehicle Repair 6E–27. . . . . . . . . . . . . . . .

Reading Flash Diagnostic Trouble Codes 6E–27.

Reading Diagnostic Trouble Codes Using

a TECH 2 6E–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tech 2 Scan Tool 6E–29. . . . . . . . . . . . . . . . . . . . . .

Getting Started 6E–30. . . . . . . . . . . . . . . . . . . . . . . .

DTC Modes 6E–32. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC Information Mode 6E–32. . . . . . . . . . . . . . . . .

Injector Test 6E–32. . . . . . . . . . . . . . . . . . . . . . . . . .

EGR Valve Test 6E–32. . . . . . . . . . . . . . . . . . . . . . .

Rail Pressure Control Valve Test 6E–32. . . . . . . . .

Injector Balance Test 6E–32. . . . . . . . . . . . . . . . . . .

Data Programming in Case of ECM Change 6E–32

Rail Pressure Sensor Programming 6E–33. . . . . .

Injector Group Sign Programming

(Injector Change) 6E–33. . . . . . . . . . . . . . . . . . . . .

On-Board Diagnostic (OBD) System Check 6E–35.

Circuit Description 6E–37. . . . . . . . . . . . . . . . . . . . .

Diagnostic Aids 6E–37. . . . . . . . . . . . . . . . . . . . . . . .

Engine Control Module ECM Diagnosis 6E–39. . . .

Multiple ECM Information Sensor DTCS Set 6E–39



EGR (Exhaust Gas Recirculation) Diagnosis 6E–41

Tech 2 Data Definitions and Ranges 6E–41. . . . . . .

Typical Scan Data Values 6E–41. . . . . . . . . . . . . . . .

Test Conditions 6E–41. . . . . . . . . . . . . . . . . . . . . . . .

4JX1-TC Engine (Automatic and Manual Transmission) 6E–42. . . . . . . . . . . . . . . . . . . . . . . .

No Malfunction Indicator Lamp (MIL) 6E–44. . . . . . .



Malfunction Indicator Lamp (MIL) “ON”

Steady 6E–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit description 6E–47. . . . . . . . . . . . . . . . . . . . .


Engine Cranks But Will Not Run 6E–49. . . . . . . . . . .



Exhaust Gas Recirculation (EGR) System

Check 6E–52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


ECM Diagnostic Trouble Codes 6E–54. . . . . . . . . . .

ECM Diagnostic Trouble Codes 6E–54. . . . . . . . . Diagnostic Trouble Code (DTC) P0107

(Flash DTC 34)

MAP Sensor Circuit Low Voltage 6E–56. . . . . . . . . .

6E–2 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS


Action Taken When the DTC Sets 6E–56. . . . . . .

Conditions for Clearing the MIL/DTC 6E–56. . . . .


Diagnostic Trouble Code (DTC) P0108

(Flash DTC 34)

MAP Sensor Circuit High Voltage 6E–58. . . . . . . . .






(Flash DTC 23) IAT Sensor Circuit Low

Voltage 6E–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





Test Description 6E–61. . . . . . . . . . . . . . . . . . . . . . .

Intake Air Temperature Sensor 6E–61. . . . . . . . . .


(Flash DTC 23) IAT Sensor Circuit High

Voltage 6E–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Manifold Air Temperature Sensor 6E–63. . . . . . . .


(Flash DTC 14) ECT Sensor Low Voltage 6E–65.






Engine Coolant Temperature Sensor 6E–66. . . . .


(Flash DTC 14) ECT Sensor High Voltage 6E–67.






Engine Coolant Temperature Sensor 6E–68. . . . .


(Flash DTC 33) AP Sensor Rationality 6E–70. . . . .






(Flash DTC 21) AP Sensor Low Voltage 6E–72. . .






(Flash DTC 21) AP Sensor High Voltage 6E–75. . .







(Flash DTC 15) FT Sensor Low Voltage 6E–78. . .







(Flash DTC 15) FT Sensor High Voltage 6E–80. . .







(Flash DTC 63) Rail Pressure Sensor Low

Voltage 6E–82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 63) Rail Pressure Sensor

High Voltage 6E–84. . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 64) RPCV Circuit Open/Short 6E–86. .






(Flash DTC 61) Rail Pressure System

Low Voltage 6E–88. . . . . . . . . . . . . . . . . . . . . . . . . . . .







High Voltage 6E–90. . . . . . . . . . . . . . . . . . . . . . . . . . .








High Warning 6E–92. . . . . . . . . . . . . . . . . . . . . . . . . .







(Flash DTC 16) Oil Temp Sensor Low

Voltage 6E–94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Engine Oil Temperature Sensor 6E–95. . . . . . . . .


(Flash DTC 16) Oil Temp Sensor High

Voltage 6E–96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






Engine Oil Temperature Sensor 6E–97. . . . . . . . .


(Flash DTC 51) Injector # 1 Circuit Fault 6E–99. . .






Injector Test 6E–99. . . . . . . . . . . . . . . . . . . . . . . . . .








Injector Test 6E–101. . . . . . . . . . . . . . . . . . . . . . . . . .








Injector Test 6E–103. . . . . . . . . . . . . . . . . . . . . . . . . .








Injector Test 6E–105. . . . . . . . . . . . . . . . . . . . . . . . . .


(Flash DTC 22) High Coolant Temp Waring 6E–107







(Flash DTC 36) High Oil Temp Warning 6E–109. . . .






(Flash DTC 11) Engine Over Speed Warning 6E–111






(Flash DTC 43) CKP (Crank Position)

Sensor Out of Synchro 6E–114. . . . . . . . . . . . . . . . . .






(Flash DTC 43) CKP (Crank Position)

Sensor No Signal 6E–116. . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 41) CMP (Cam Position)

Sensor Out of Synchro 6E–119. . . . . . . . . . . . . . . . . .







(Flash DTC 41) CMP (Cam Position)

Sensor No Signal 6E–122. . . . . . . . . . . . . . . . . . . . . . .








(Flash DTC 66) Glow Relay Circuit

Open/Short 6E–126. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 67) Glow Lamp Circuit

Open/Short 6E–128. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 32) EGR EVRV Fault 6E–130. . . . . . . . .





(Flash DTC 31) EGR VSV Circuit 6E–132. . . . . . . . .




(Flash DTC 26) EGR Pressure Sensor

Low Voltage 6E–134. . . . . . . . . . . . . . . . . . . . . . . . . . . .





(Flash DTC 37) EGR EVRV Circuit

Open/Short 6E–136. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 26) EGR Pressure Sensor

High Voltage 6E–138. . . . . . . . . . . . . . . . . . . . . . . . . . .





(Flash DTC 71) EXH #1 VSV Circuit 6E–140. . . . . . .






(Flash DTC 71) EXH #2 VSV Circuit

Open/Short 6E–142. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 74) ITP (Intake Thorottle Position)

Sensor Low Voltage 6E–144. . . . . . . . . . . . . . . . . . . . .






(Flash DTC 74) ITP (Intake Throttle Position)

Sensor High Voltage 6E–146. . . . . . . . . . . . . . . . . . . .






(Flash DTC 73) Intake Throttle System

Circuit Open/Start 6E–148. . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 72) Intake Throttle Motor Control

Circuit Signal Gap 6E–150. . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 24) VSS (Vehicle Speed Sensor)

No Signal 6E–152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 75) Idle SW Malfunction, Open

Circuit 6E–155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 75) Idle SW Malfunction

Short Circuit 6E–157. . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 35) System Voltage Too Low 6E–159. .







(Flash DTC 35) System Voltage Too Low

at Cranking 6E–160. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 25) Brake SW Malfunction 6E–161. . . .






(Flash DTC 25) Brake SW Malfunction 6E–163. . . .






(Flash DTC 55) ECM Checksum Error 6E–165. . . . .





(Flash DTC 77) Check Engine Lam Circuit

Open/Short 6E–166. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 27) Tachometer Circuit

Open/Short 6E–168. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 17) Thermo Relay Circuit

Open/Short 6E–170. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 76) ECM Main Relay Circuit

Open/Short 6E–172. . . . . . . . . . . . . . . . . . . . . . . . . . . .






(Flash DTC 47) Transmission SW Circuit

Open/Short 6E–174. . . . . . . . . . . . . . . . . . . . . . . . . . . .





Symptom Diagnosis 6E–176. . . . . . . . . . . . . . . . . . . . .

Default Matrix Table 6E–199. . . . . . . . . . . . . . . . . . . . .

On–Vehicle Service Camshaft Position

(CMP) Sensor 6E–201. . . . . . . . . . . . . . . . . . . . . . . . . .

Removal Procedure 6E–201. . . . . . . . . . . . . . . . . . . .

Inspection Procedure 6E–201. . . . . . . . . . . . . . . . . .

Installation Procedure 6E–201. . . . . . . . . . . . . . . . . .

Crankshaft Position (CKP) Sensor 6E–202. . . . . . . . .



Engine Coolant Temperature (ECT) Sensor 6E–203.



Intake Air Temperature (IAT) Sensor 6E–203. . . . . . .



Manifold Absolute Pressure (MAP) Sensor 6E–204.



Oil Temperature (OT) Sensor 6E–205. . . . . . . . . . . . .



Malfunction Indicator Lamp (MIL) 6E–206. . . . . . . . . .

Removal and Installation Procedure 6E–206. . . . . .

Engine Control Module (ECM) 6E–206. . . . . . . . . . . .

Service Precaution 6E–206. . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge (ESD) Damage 6E–206. . .



EEPROM 6E–208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Description 6E–208. . . . . . . . . . . . . . . . . . . .

Functional Check 6E–208. . . . . . . . . . . . . . . . . . . . . .

Intake Throttle Position (ITP) Sensor 6E–208. . . . . . .


Function Check 6E–209. . . . . . . . . . . . . . . . . . . . . . .


Vehicle Speed Sensor (VSS) 6E–210. . . . . . . . . . . . .




Air Cleaner/Air Filter 6E–211. . . . . . . . . . . . . . . . . . . . .



Accel Position (AP) Sensor 6E–211. . . . . . . . . . . . . . .



Accelerator Pedal Replacement 6E–212. . . . . . . . . . .




Fuel Filter Cap 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . .

General Description 6E–213. . . . . . . . . . . . . . . . . . . .


Fuel Filter 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Fuel Gauge Unit 6E–213. . . . . . . . . . . . . . . . . . . . . . . .



Fuel Injectors 6E–214. . . . . . . . . . . . . . . . . . . . . . . . . . .


Fuel Temperature Sensor 6E–214. . . . . . . . . . . . . . . .



Rail Pressure (RP) Sensor 6E–216. . . . . . . . . . . . . . .



Fuel Tank 6E–216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Throttle Body (TB) 6E–217. . . . . . . . . . . . . . . . . . . . . . .



Air Conditioning (A/C) Relay 6E–217. . . . . . . . . . . . . .



Exhaust Gas Recirculation (EGR) Vacuum

Switch Valve (VSV) 6E–217. . . . . . . . . . . . . . . . . . . . .



Electronic Vacuum Regurating Valve (EVRV) 6E–219



Wiring and Connectors 6E–220. . . . . . . . . . . . . . . . . . .

Wiring Harness Service 6E–220. . . . . . . . . . . . . . . .

Connectors and Terminals 6E–220. . . . . . . . . . . . . .

Wire Harness Repair: Twisted Shielded

Cable 6E–220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Twisted Leads 6E–221. . . . . . . . . . . . . . . . . . . . . . . . . .



Weather-Pack Connector 6E–223. . . . . . . . . . . . . . . . .

Tools Required 6E–223. . . . . . . . . . . . . . . . . . . . . . . .



Com-Pack III 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 6E–224. . . . . . . . . . . . . . . . . . . .

Metri-Pack 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Required 6E–224. . . . . . . . . . . . . . . . . . . . . . . .



General Description

(ECM and Sensors) 6E–225. . . . . . . . . . . . . . . . . . . . .

57X Reference ECM Input 6E–225. . . . . . . . . . . . . .

A/C Request Signal 6E–225. . . . . . . . . . . . . . . . . . . .

Crankshaft Position (CKP) Sensor 6E–225. . . . . . .

Camshaft Position (CMP) Sensor and

Signal 6E–225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant Temperature (ECT) Sensor 6E–225

Electrically Erasable Programmable Read

Only Memory (EEPROM) 6E–225. . . . . . . . . . . . . .

Intake Air Temperature (IAT) Sensor 6E–225. . . . .

Manifold Absolute Pressure (MAP) Sensor 6E–226

Engine Control Module (ECM) 6E–226. . . . . . . . . . .

ECM Function 6E–226. . . . . . . . . . . . . . . . . . . . . . . . .

ECM Components 6E–226. . . . . . . . . . . . . . . . . . . . .

ECM Voltage Description 6E–226. . . . . . . . . . . . . . .

ECM Input/Outputs 6E–226. . . . . . . . . . . . . . . . . . . .

ECM Service Precautions 6E–227. . . . . . . . . . . . . .

Intake Throttle Position (ITP) Sensor 6E–227. . . . .

Transmission Range Switch 6E–227. . . . . . . . . . . . .

Accelerator Position Sensor (AP) 6E–227. . . . . . . .

Aftermarket Electrical and Vacuum

Equipment 6E–227. . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Damage 6E–227. . . . . . . . .

General Description (Air Induction) 6E–228. . . . . . . .

Air Induction System 6E–228. . . . . . . . . . . . . . . . . . .

General Description (Fuel Metering) 6E–228. . . . . . .

Deceleration Mode 6E–228. . . . . . . . . . . . . . . . . . . .

Fuel Injector 6E–228. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Metering System Components 6E–228. . . . . .

A/C Clutch Diagnosis 6E–228. . . . . . . . . . . . . . . . . . . .

A/C Request Signal 6E–228. . . . . . . . . . . . . . . . . . . .

General Description Exhaust Gas

Recirculation (EGR) System 6E–228. . . . . . . . . . . . .

EGR Purpose 6E–228. . . . . . . . . . . . . . . . . . . . . . . . .

Fuse and Relay Panel

(Underhood Electrical Center) RHD 6E–229. . . . . . .

Fuse and Relay Panel

(Underhood Electrical Center) LHD 6E–230. . . . . . .


SpecificationTightening Specifications

Application N·m Kg·m Lb Ft. Lb In.

Camshaft Position Sensor Retaining Screw 9 0.9 — 78

Crankshaft Position Sensor Mounting Bolt 9 0.9 — 78

Engine Coolant Temperature Sensor 19 1.9 14 —

Throttle Body Mounting Nuts 20 2.0 14 —

VSS Retaining Bolt 16 1.6 12 —

MAP Sensor Screw 4 0.4 — 35

EGR VSV Bolts 8 0.8 — 69

Fuel Temp Sensor 19 1.9 14 —

Oil Temp Sensor Bolt 19 1.9 14 —

Rail Pressure Sensor Bolt 20 2.0 14 —


Diagrams and Schematics

ECM Wiring Diagram (1 of 6)

060RW127



060RW125



060RW126



060RW128



060RW123



060RW124


ECM Pinouts

ECM Pinout Table, 32-Way Connector – J1 RED – Upper

060RW138

J1 – RED

PIN SIGNAL

1 FUEL TEMPERATURE

2 SPARE ANALOG 1

3 +5VB1

4 +5VB2

5 SPARE ANALOG 3

6 ACCEL POS OUT 1

7 NOT USED

8 SPARE OUT 2 (TCC)

9 EVRV (EGR)

10 IGN RELAY

11 GLOW PLUG LAMP

12 DIAGNOSTIC LAMP

13 VSV (EXHAUST #2)

14 RAIL PRESS CNTRL VALVE

15 GLOW PLUG RELAY

16 VSV (EXHAUST #1)


ECM Pinout Table, 32-Way Connector – J1 RED – Lower

060RW137

J1 – RED

PIN SIGNAL

17 SPARE ANALOG 4

18 INTAKE SM POSITION

19 VEHICLE SPEED

20 MT NEUTRAL

21 REVERSE SW

22 ACCEL POS OUT 2

23 THERMO SW RELAY

24 SPARE OUT 3 (TURBO)

25 VSV (EGR)

26 TACHOMETER 1

27 BRAKE SW 1

28 NOT USED (BRAKE 2)

29 A/T NEUTRAL SW

30 NO CONNECTION

31 AC REQUEST SW

32 AT SOLENOID


ECM Pinout Table, 32-Way Connector – J2 BLUE – Upper

060RW138

J2 – BLUE

PIN SIGNAL

1 INJECTOR A RTN

2 INJECTOR B RTN

3 INJECTOR C RTN

4 INJECTOR D RTN

5 CLASS 2

6 SDATA

7 RAIL OIL PRESSURE

8 IDLE SW

9 IGN SW

10 BATTERY

11 QUICK WARM REQ. SW

12 PARTIAL IDLE SW

13 CERAMIC HTR REQUEST SW

14 INTAKE SW S2B

15 INTAKE SW S1T

16 INTAKE SW S1B


ECM Pinout Table, 32-Way Connector – J2 BLUE – Lower

060RW137

J2 – BLUE

PIN SIGNAL

17 COOLANT TEMP OUT

18 OIL TEMPERATURE

19 TDC/CAM

20 SPARE ANALOG 2

21 INTAKE AIR TEMPERATURE

22 +5VRTN2

23 BOOST/INLET PRESSURE

24 +5VRTN3

25 ACCELERATOR POSITION

26 +5VRTN1

27 EGR VACUUM PRESSURE

28 INTAKE SM S2T

29 DIAGNOSTIC REQUEST SW

30 COOLANT TEMPERATURE

31 A/T PARK SW

32 CRANKSHAFT


ECM Pinout Table, 5-Way Connector – J3

060RW139

J3

PIN SIGNAL

1 IGNITION

2 IGNITION

3 PWR GND

4 PWR GND

5 INJECTOR H1


Component Locator

Engine Component Locator Table

F06RW051

Number Name Location

1 AP (Accelerator Pedal Position) Sensor AP Bracket

2 CKP (Crankshaft Position) Sensor Inside the right front flywheel Housing

3 Oil Rail Mounted on the camshaft carrier

4 Oil (Rail) Pressure Sensor Mounted on the Oil Rail

5 OT (Oil Temperature) Sensor Mounted on the Oil Rail

6 Fuel Injector In the Cylinder Head Cover

7 Fuel Return Orifice Inside the Cylinder Head

8 FT (Fuel Temperature) Sensor Fuel Return Adaptor

9 Intercooler On the Cylinder Head Cover

10 Intake Throttle Motor Behind the Intake Manifold

11 Intake Throttle Behind the Intake Manifold

12 2 Way Check Valve Below the Intake Manifold

13 VSV (Vacuum Switching Valve) At the left Cylinder Body

14 EGR Pressure Sensor Below the Intake Manifold

15 Fuel Filter At the left Engine Room

16 CMP (Camshaft Position) Sensor On the forward of Timing Gear Case

17 IAT (Intake Air Temperature) Sensor Below the Intake Manifold

18 ECT (Engine Coolant Temperature) Thermostat Housing

19 High Pressure Oil Pump On the back Timing Gear Case


Number Name Location

20 Rail Pressure Control Valve In the High Pressure Oil Pump

21 Fuel Pump In the High Pressure Oil Pump

22 EVRV On the Intake Manifold

23 MAP (Manifold Absolute Pressure) Sensor On the Intake Manifold

24 EGR Valve On the Intake Manifold

25 Air Cleaner At the left Engine Room

26 ECM Behind the Air Cleaner


Sensors and Miscellaneous Component Locators

035RW115

035RW117

060RW179

035RW118

035RW119

035RW120


035RW121

035RW122

035RW116

035RW107


Abbreviations Charts

List of abbreviations which may be used in this section.

Abbreviations Term Abbreviations Term

A/C Air Conditioner BLK Black

A/T Automatic Transmission BLU Blue

ACC Accessory BRN Brown

AP Accel Position GRN Green

ASM Assembly GRY Gray

CKP Crank Position LT BLU Light Blue

CMP Cam Position LT GRN Light Green

DLC Data Link Connector ORN Orange

DTC Diagnosis Trouble Code PNK Pink

DVM Digital Volt Meter RED Red

ECM Engine Control Module VIO Violet

ECT Engine Coolant Temperature WHT White

EGR Exhaust Gas Recircuration YEL Yellow

EVRV Electric Vacuum Regulating Valve

EXH Exhaust

FT Fuel Temperature

IAT Intake Air Temperature

IG Ignition

ITP Intake Throttle Position

M/T Manual Transmission

MAP Manifold Absolute Pressure

MIL Mulfunction Indicator Lamp

OBD On-Board Diagnostic

OT Oil Temperature

QOS Quick on Start System

QWS Quick Warming-Up System

RP Rail Pressure

RPCV Rail Pressure Control Valve

SRS Supplemental Restraint System

ST Start

SW Switch

TEMP Temperature

TOD Torque on Demand

VSS Vehicle Speed Sensor

VSV Vacuum Switching Valve

HEUI Hydraulically Actuated Electronically Controlled UnitInjectorInjector


Diagnosis

Strategy-Based Diagnostics

Strategy-Based Diagnostics

The strategy-based diagnostic is a uniform approach torepair all Electrical/Electronic (E/E) systems. Thediagnostic flow can always be used to resolve an E/Esystem problem and is a starting point when repairs arenecessary. The following steps will instruct the technicianhow to proceed with a diagnosis:

1. Verify the customer complaint.

� To verify the customer complaint, the technicianshould know the normal operation of the system.

2. Perform preliminary checks.

� Conduct a thorough visual inspection.

� Review the service history.

� Detect unusual sounds or odors.

� Gather diagnostic trouble code information toachieve an effective repair.

3. Check bulletins and other service information.

� This includes videos, newsletters, etc.

4. Refer to service information (manual) systemcheck(s).

� “System checks” contain information on a systemthat may not be supported by one or more DTCs.System checks verify proper operation of thesystem. This will lead the technician in anorganized approach to diagnostics.

5. Refer to service diagnostics.

DTC Stored

Follow the designated DTC chart exactly to make aneffective repair.

No DTC

Select the symptom from the symptom tables. Follow thediagnostic paths or suggestions to complete the repair.You may refer to the applicable component/system checkin the system checks.

No Matching Symptom

1. Analyze the complaint.

2. Develop a plan for diagnostics.

3. Utilize the wiring diagrams and the theory ofoperation.

Call technical assistance for similar cases where repairhistory may be available. Combine technician knowledgewith efficient use of the available service information.

Intermittents

Conditions that are not always present are calledintermittents. To resolve intermittents, perform thefollowing steps:

1. Observe history DTCs, DTC modes, and freezeframedata.

2. Evaluate the symptoms and the conditions describedby the customer.

3. Use a check sheet or other method to identify thecircuit or electrical system component.

4. Follow the suggestions for intermittent diagnosisfound in the service documentation.

Most scan tools, such as the Tech 2 and the DVM, havedata-capturing capabilities that can assist in detectingintermittents.

No Trouble Found

This condition exists when the vehicle is found to operatenormally. The condition described by the customer maybe normal. Verify the customer complaint against anothervehicle that is operating normally. The condition may beintermittent. Verify the complaint under the conditionsdescribed by the customer before releasing the vehicle.

1. Re-examine the complaint.

When the complaint cannot be successfully found orisolated, a re-evaluation is necessary. The complaintshould be re-verified and could be intermittent asdefined in Intermittents, or could be normal.

2. Repair and verify.

After isolating the cause, the repairs should be made.Validate for proper operation and verify that thesymptom has been corrected. This may involve roadtesting or other methods to verify that the complainthas been resolved under the following conditions:

� Conditions noted by the customer.

� If a DTC was diagnosed, verify a repair byduplicating conditions present when the DTC wasset as noted in the Failure Records or FreezeFrame data.

Verifying Vehicle Repair

Verification of the vehicle repair will be morecomprehensive for vehicles with OBD systemdiagnostics. Following a repair, the technician shouldperform the following steps:

IMPORTANT: Follow the steps below when you verifyrepairs on OBD systems. Failure to follow these stepscould result in unnecessary repairs.

1. Review and record the Failure Records and theFreeze Frame data for the DTC which has beendiagnosed (Freeze Frame data will only be stored forthe MIL (“Check Engine” lamp) has been requested).

2. Clear the DTC(s).

3. Operate the vehicle within conditions noted in theFailure Records and Freeze Frame data.

4. Monitor the DTC status information for the specificDTC which has been diagnosed until the diagnostictest associated with that DTC runs.


General Service Information

Serviceability Issues

Non-OEM Parts

All of the OBD diagnostics have been calibrated to runwith OEM parts. Accordingly, if commercially sold sensoror switch is installed, it makes a wrong diagnosis and turnon the MIL (“Check Engine” lamp).Aftermarket electronics, such as cellular phones,stereos, and anti-theft devices, may radiate EMI into thecontrol system if they are improperly installed. This maycause a false sensor reading and turn on the MIL (“CheckEngine” lamp).

Poor Vehicle Maintenance

The sensitivity of OBD diagnostics will cause the MIL(“Check Engine” lamp) to turn on if the vehicle is notmaintained properly. Restricted oil filters, fuel filters, andcrankcase deposits due to lack of oil changes or improperoil viscosity can trigger actual vehicle faults that were notpreviously monitored prior to OBD. Poor vehiclemaintenance can not be classified as a “non-vehiclefault”, but with the sensitivity of OBD diagnostics, vehiclemaintenance schedules must be more closely followed.

Related System Faults

Many of the OBD system diagnostics will not run if theECM detects a fault on a related system or component.

Visual/Physical Engine CompartmentInspection

Perform a careful visual and physical enginecompartment inspection when performing any diagnosticprocedure or diagnosing the cause of an emission testfailure. This can often lead to repairing a problem withoutfurther steps. Use the following guidelines whenperforming a visual/physical inspection:

� Inspect all vacuum hoses for punches, cuts,disconnects, and correct routing.

� Inspect hoses that are difficult to see behind othercomponents.

� Inspect all wires in the engine compartment for properconnections, burned or chafed spots, pinched wires,contact with sharp edges or contact with hot exhaustmanifolds or pipes.

Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain whenperforming diagnostic procedures could result in anincorrect diagnosis or damage to powertraincomponents. Do not attempt to diagnose a powertrainproblem without this basic knowledge.

A basic understanding of hand tools is necessary to effec-tively use this section of the Service Manual.

Serial Data Communications

Class II Serial Data Communications

This vehicle utilizes the “Class II” communication system.Each bit of information can have one of two lengths: long

or short. This allows vehicle wiring to be reduced bytransmitting and receiving multiple signals over a singlewire. The messages carried on Class II data streams arealso prioritized. If two messages attempt to establishcommunications on the data line at the same time, onlythe message with higher priority will continue. The devicewith the lower priority message must wait.On this vehicle the Tech 2 displays the actual values forvehicle parameters. It will not be necessary to performany conversions from coded values to actual values.

On-Board Diagnostic (OBD)

On-Board Diagnostic Tests

A diagnostic test is a series of steps, the result of which isa pass or fail reported to the diagnostic executive. Whena diagnostic test reports a pass result, the diagnosticexecutive records the following data:

� The diagnostic test has been completed since the lastignition cycle.

� The diagnostic test has passed during the currentignition cycle.

� The fault identified by the diagnostic test is notcurrently active.

When a diagnostic test reports a fail result, the diagnosticexecutive records the following data:

� The diagnostic test has been completed since the lastignition cycle.

� The fault identified by the diagnostic test is currentlyactive.

� The fault has been active during this ignition cycle.

� The operating conditions at the time of the failure.

Comprehensive Component MonitorDiagnostic Operation

Comprehensive component monitoring diagnostics arerequired to operate engine properly.

Input Components:

Input components are monitored for circuit continuity andout-of-range values. This includes rationality checking.Rationality checking refers to indicating a fault when thesignal from a sensor does not seem reasonable. AccelPosition (AP) sensor that indicates high throttle positionat low engine loads or MAP voltage. Input componentsmay include, but are not limited to the following sensors:

� Intake Air Temperature (IAT) Sensor

� Crankshaft Position (CKP) Sensor

� Intake throttle Position (ITP) Sensor

� Engine Coolant Temperature (ECT) Sensor

� Camshaft Position (CMP) Sensor

� Manifold absolute Pressure (MAP) Sensor

� Accel Position Sensor

� Fuel Temp Sensor

� Rail Pressure Sensor

� Oil Temp Sensor

� EGR Pressure Sensor

� Vehicle Speed Sensor


Output Components:

Output components are diagnosed for proper response tocontrol module commands. Components wherefunctional monitoring is not feasible will be monitored forcircuit continuity and out-of-range values if applicable.Output components to be monitored include, but are notlimited to, the following circuit:

� EGR VSV

� EGR EVRV

� Electronic Transmission controls

� Injector

� Intake throttle

� Glow plug

� MIL control

Refer to ECM and Sensors in General Descriptions.

Passive and Active Diagnostic Tests

A passive test is a diagnostic test which simply monitors avehicle system or component. Conversely, an active test,actually takes some sort of action when performingdiagnostic functions, often in response to a failed passivetest.

Intrusive Diagnostic Tests

This is any on-board test run by the DiagnosticManagement System which may have an effect onvehicle performance or emission levels.

Warm-Up Cycle

A warm-up cycle means that engine at temperature mustreach a minimum of 70�C (160�F) and rise at least 22�C(40�F) over the course of a trip.

Freeze Frame

Freeze Frame is an element of the DiagnosticManagement System which stores various vehicleinformation at the moment an emissions-related fault isstored in memory and when the MIL is commanded on.These data can help to identify the cause of a fault. Referto Storing And Erasing Freeze Fame Data for moredetailed information.

Failure Records

Failure Records data is an enhancement of the OBDFreeze Frame feature. Failure Records store the samevehicle information as does Freeze Frame, but it will storethat information for any fault which is stored in on-boardmemory, while Freeze Frame stores information only foremission-related faults that command the MIL on.

Common OBD Terms

Diagnostic

When used as a noun, the word diagnostic refers to anyon-board test run by the vehicle’s DiagnosticManagement System. A diagnostic is simply a test run ona system or component to determine if the system orcomponent is operating according to specification. Thereare many diagnostics, shown in the following list:

� EGR

� engine speed

� vehicle speed

� ECT

� MAP

� VSV

� IAT

� ITP

� AP

� FT (Fuel Temp)

� RP (Rail Pressure)

� OT (Oil Temp)

� EGR EVRV

� Idle SW

� Brake SW

The Diagnostic Executive

The Diagnostic Executive is a unique segment ofsoftware which is designed to coordinate and prioritizethe diagnostic procedures as well as define the protocolfor recording and displaying their results. The mainresponsibilities of the Diagnostic Executive are listed asfollows:

� Commanding the MIL (“Check Engine” lamp) on andoff

� DTC logging and clearing

� Freeze Frame data for the first emission related DTCrecorded

� Current status information on each diagnostic

Diagnostic Information

The diagnostic charts and functional checks are designedto locate a faulty circuit or component through a processof logical decisions. The charts are prepared with therequirement that the vehicle functioned correctly at thetime of assembly and that there are not multiple faultspresent.There is a continuous self-diagnosis on certain controlfunctions. This diagnostic capability is complemented bythe diagnostic procedures contained in this manual. Thelanguage of communicating the source of the malfunctionis a system of diagnostic trouble codes. When amalfunction is detected by the control module, adiagnostic trouble code is set and the MalfunctionIndicator Lamp (MIL) (“Check Engine” lamp) isilluminated.

Malfunction Indicator Lamp (MIL)

The Malfunction Indicator Lamp (MIL) looks the same asthe MIL you are already familiar with “Check Engine”lamp.Basically, the MIL is turned on when the ECM detects aDTC that will impact the vehicle emissions.

� When the MIL remains “ON” while the engine isrunning, or when a malfunction is suspected due to adriveability or emissions problem, a PowertrainOn-Board Diagnostic (OBD) System Check must beperformed. The procedures for these checks aregiven in On-Board Diagnostic (OBD) System Check.These checks will expose faults which may not bedetected if other diagnostics are performed first.

DTC Types

Characteristic of Code


� Non-Emissions related

� Dose not request illumination of any lamp

� Stores a History DTC on the first trip with a fail

� Stores Fail Record when test fails

� Updates the Fail Record each time the diagnostic testfails

Storing and Erasing Freeze Frame Data and FailureRecords

The data captured is called Freeze Frame data. TheFreeze Frame data is very similar to a single record ofoperating conditions. Whenever the MIL is illuminated,the corresponding record of operating conditions isrecorded to the Freeze Frame buffer.Data from these faults take precedence over dataassociated with any other fault. The Freeze Frame datawill not be erased unless the associated history DTC iscleared.Each time a diagnostic test reports a failure, the currentengine operating conditions are recorded in the FailureRecords buffer. A subsequent failure will update therecorded operating conditions. The following operatingconditions for the diagnostic test which failed typicallyinclude the following parameters:

� Engine Speed

� Engine Load

� Engine Coolant Temperature

� Vehicle Speed

� Intake Throttle Position

� MAP

� Injector Base Pulse Width

� Loop Status

Data Link Connector (DLC)

The provision for communication with the contorl moduleis the Data Link Connector (DLC). It is located at behindthe lower front instrument panel. The DLC is used toconnect to a Tech 2. Some common uses of the Tech 2are listed below:

� Identifying stored Diagnostic Trouble Codes (DTCs).

� Clearing DTCs.

� Performing out put control tests.

� Reading serial data.

060RW046

Verifying Vehicle Repair

Verification of vehicle repair will be more comprehensivefor vehicles with OBD system diagnostic. Following arepair, the technician should perform the following steps:

1. Review and record the Fail Records and/or FreezeFrame data for the DTC which has been diagnosed.

2. Clear DTC(s).

3. Operate the vehicle within conditions noted in the FailRecords and/or Freeze Frame data.

4. Monitor the DTC status information for the specificDTC which has been diagnosed until the diagnostictest associated with that DTC runs.

Following these steps are very important in verifyingrepairs on OBD systems. Failure to follow these stepscould result in unnecessary repairs.

Reading Flash Diagnostic Trouble Codes

The provision for communicating with the Engine ControlModule (ECM) is the Data Link Connector (DLC). TheDLC is located in the front console box. It is used in theassembly plant to receive information in checking that theengine is operating properly before it leaves the plant.The diagnostic trouble code(s) (DTCs) stored in theECM’s memory can be read either through a hand-helddiagnostic scanner plugged into the DLC or by countingthe number of flashes of the “Check Engine” MalfunctionIndicator Lamp (MIL) when the diagnostic test terminal ofthe DLC is grounded. The DLC terminal “6” (diagnosticrequest) is pulled “Low” (grounded) by jumpering to DLCterminal “4”, which is a ground wire.This will signal the ECM that you want to “flash” DTC(s), ifany are present. Once terminals “4” and “6” have beenconnected, the ignition switch must be moved to the “ON”position, with the engine not running.The “Check Engine”MIL will indicate a DTC three times ifa DTC is present. If more than one DTC has been stored


in the ECM’s memory, the DTC(s) will be output from thelowest to the highest, with each DTC being displayedthree times.The DTC display will continue as long as the DLC isshorted.

Reading Diagnostic Trouble Codes Usinga TECH 2

The procedure for reading diagnostic trouble code(s) is toused a diagnostic Tech 2. When reading DTC(s), followinstructions supplied by Tech 2 manufacturer.For the 1998 model year, Isuzu dealer servicedepartments will continue to use Tech 2.

Clearing Diagnostic Trouble Codes

IMPORTANT: Do not clear DTCs unless directed to doso by the service information provided for each diagnosticprocedure. When DTCs are cleared, the Freeze Frameand Failure Record data which may help diagnose anintermittent fault will also be erased from memory.

If the fault that caused the DTC to be stored into memoryhas been corrected, the Diagnostic Executive will begin tocount the “warm-up” cycles with no further faultsdetected, the DTC will automatically be cleared from theECM memory.

To clear Diagnostic Trouble Codes (DTCs), use the Tech2 “clear DTCs” or “clear information” function. Whenclearing DTCs follow instructions supplied by the Tech 2manufacturer.When a Tech 2 is not available, DTCs can also be clearedby disconnecting one of the following sources for at leastthirty (30) seconds.

NOTE: To prevent system damage, the ignition key mustbe “OFF” when disconnecting or reconnecting batterypower.

� The power source to the control module. Examples:fuse, pigtail at battery ECM connectors etc.

� The negative battery cable. (Disconnecting thenegative battery cable will result in the loss of otheron-board memory data, such as preset radio tuning).

060RW169


Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments arerecommended to use Tech 2. Please refer to Tech 2 userguide.

901RW257

Legend

(1) PCMCIA Card

(2) SAE 16/19 Adaptor

(3) DLC Cable

(4) Tech–2


Getting Started

� Before operating the Isuzu PCMCIA card with theTech 2, the following steps must be performed:

1. The Isuzu 98 System PCMCIA card (1) inserts intothe Tech 2 (5).

2. Connect the SAE 16/19 adapter (3) to the DLC cable(4).

3. Connect the DLC cable to the Tech 2 (5)

4. Make sure the vehicle ignition is off.

5. Connect the Tech 2 SAE 16/19 adapter to the vehicleDLC.

6. The vehicle ignition turns on.

7. Verify the Tech 2 power up display.

012RW105

NOTE: The RS232 Loop back connector is only to use fordiagnosis of Tech 2 and refer to user guide of the Tech 2.

Operating Procedure

The power up screen is displayed when you power up thetester with the Isuzu systems PCMCIA card. Follow theoperating procedure below.

060RW014


060RW120

Menu

� The following table shows, which functions are usedthe available equipment versions.

F0: Diagnostic Trouble Codes

F0: Read DTC Info Ordered By Priority

F1: Read DTC Info As Stored By ECU

F2: Clear DTC Information

F3: Freeze Frame / Failure Records

F1: Data Display

F2: Snapshot

F3: Actuator Tests

F0: Checklight

F1: Glow Time Lamp

F2: EGR Switching Valve

F3: Exhaust Switching Valve 1

F4: Exhaust Switching Valve 2

F4: Miscellaneous Tests

F0: Throttle Motor Control

F1: Rail Pressure Control

F2: EGR Regulating Valve Control

F3: Rail Pressure Control Valve

F4: Injector Balance Test

F5: Programming

F0: Injector Calibration

(F1: Rail Pressure Calibration)


DTC Modes

There are three options available in the Tech 2 DTC modeto display the enhanced information available. Adescription of the new modes, DTC Info, follows. Afterselecting DTC, the following menu appears:

� DTC Info

� Clear Info

� Read DTC Info Ordered By Priority

The following is a brief description of each of the submenus in DTC Info. The order in which they appear here isalphabetical and not necessarily the way they will appearon the Tech 2.

DTC Information Mode

Use the DTC info mode to search for a specific type ofstored DTC information.The service manual may instructthe technician to test for DTCs in a certain manner.Always follow published service procedures.

Fail This Ignition

This selection will display all DTCs that have failed duringthe present ignition cycle.

History

This selection will display only DTCs that are stored in theECM’s history memory. It will not display Type B DTCsthat have not requested the MIL (“Check Engine” lamp). Itwill display all type A and B DTCs that have requested theMIL and have failed within the last 40 warm-up cycles. Inaddition, it will display all type C and type D DTCs thathave failed within the last 40 warm-up cycles.

MIL SVC or Message Requested

This selection will display only DTCs that are requestingthe MIL. Type C and type D DTCs cannot be displayedusing this option. This selection will report type B DTCsonly after the MIL has been requested.

Test Failed Since Code Cleared

This selection will display all active and history DTCs thathave reported a test failure since the last time DTCs werecleared.

Injector Test

This test is conducted to make it sure that appropriateelectric signals are being sent to injectors Nos. 1 – 4.Tech–2 must be used for this test.

Test Procedure:

1. Connect Tech–2 to the vehicle DLC.

2. Set Ignition Switch to the “ON” position.

3. Select Control Test.

4. Select Injector Test.

5. Send instructions to each injector(Switch on), makingsure of injector working noise.

NOTE: If injector working noise (Clink) can hardly beconfirmed, remove the engine head cover noiseinsulation.

Refer to Section 6A.

6. In the injector whose working noise has beenconfirmed, its electric circuit can be regarded asnormal.

As for the injector whose working noise has not beenconfirmed, its electric circuit or the injector proper isfaulty.

EGR Valve Test

This test is conducted to check EGR valve for its working.This test needs Tech–2.

Test Procedure

1. Connect Tech–2 to vehicle DLC.

2. Switch on the engine.

3. Select “DIAGNOSIS” from the main menu.

4. Select Miscellaneous Test.

5. Select EGR Valve.

6. Instruct EGR Valve to check a data list.

7. If change in the data list shows a normal valve, theworking of EGR Valve can be judged to be normal.

Rail Pressure Control Valve Test

This test is conducted to check RPC valve for its working.This test needs Tech–2.

Test Procedure


2. Switch on the engine.



5. Select Rail Pressure Control Valve.

6. Instruct RPC Valve to check a data list.

7. If change in the data list shows a normal valve, theworking of RPC Valve can be judged to be normal.

Injector Balance Test

This test is conducted to make it sure that appropriateelectric signals are being sent to injectors Nos. 1-4, whenthe engine is idling.This test needs Tech–2.

Test Procedure


2. The engine is running at idling condition.



5. Select the injector Balance Test.

6. Send instructions to each injector(Switch On),making sure change of the engine vibration.

7. In the injector whose change of the vibration has beenconfirmed, it’s electric circuit can be regarded asnormal.

Data Programming in Case of ECM Change

When replacing ECM, it is necessary to confirm andrecord the group sign of injector beforehand. For thisconfirmation.


Tech–2 must be used. After ECM change, the recordedgroup sign should be programmed. Oil pressure sensordata also should be programmed.

� Group Sign Confirmation Procedure

1 Connect Tech–2 to vehicle DLC.

2 Turn Ignition Switch to the “ON” position.

3 Select “DIAGNOSIS” from the main menu.

4 Select programming.

5 Select Read/store Trim Data.

6 Confirm and record the group sign of injector.

� ECM Change

� Programming Procedure for Injector Group Sign





5 Select ECM change.

6 Select cylinder.

7 Program Injector Group Sign.

8 Confirm the completion of Injector programming.

� Programming Procedure for Oil Pressure Sensor





Rail Pressure Sensor Programming

Rail pressure sensor replacement must be programmed.This programming needs Tech–2.

Programing Procedure


2. Turn Ignition Switch to the “ON” position.


4. Select Programming.

5. Select Oil Pressure Sensor change.

6. Execute Oil Pressure Sensor Program.

7. Confirm the completion of Oil Pressure SensorProgram.

Injector Group Sign Programming (InjectorChange)

In case of Injector change, injector group sign must beprogrammed.This programming needs Tech–2.

Programing Procedure


2. Turn Ignition Switch to the “ON” position.


4. Select Programming.

5. Select Injector change.

6. Select the cylinder changed.

7. Appoint and select Injector Group Sign.

8. Confirm the completion of Injector programming.


Fuel Injection System

060RW178

Legend

(1) ECM

(2) Meter Panel

(3) Battery

(4) Oil Temp Sensor

(5) Rail Pressure Sensor

(6) Glow Relay

(7) Oil Rail

(8) Tech–2

(9) A/C Comp Relay

(10) RPCV

(11) Intake Air Temp Sensor

(12) Engine Coolant Temp Sensor

(13) MAP Sensor

(14) EGR Valve

(15) EGR Pressure Sensor

(16) High Pressure Oil Pump

(17) Fuel Pump

(18) VSV

(19) EXH Throttle VSV1


(21) EVRV

(22) Engine Harness Connector

(23) QWS Relay

(24) APS

(25) T.O.D

(26) ECT

(27) OBD

(28) TDC

(29) Injector

(30) Edge Filter


Guid to the System

� Fuel Injection system is an HEUI (HydraulicallyActuated, Electronically Controlled, Unit, Injector)type. In this type of injector system, the oilpressurized by means of High Pressure Oil Pump(16) is fed through Rail Pressure Control Valve (10)and Oil Rail (7) to Injector (29) from which fuel isinjected under this oil pressure.

For diagnosis, therefore, the Rail Pressure as well asthe Electric Circuit must be inspected.

On-Board Diagnostic (OBD) System CheckA Group

060RW135


B Group

060RW133

C Group

060RW129


D Group

060RW134

Circuit Description

The on-board diagnostic system check is the startingpoint for any driveability complaint diagnosis. Beforeusing this procedure, perform a careful visual/physicalcheck of the ECM and engine grounds for cleanliness andtightness.The on-board diagnostic system check is an organizedapproach to identifying a problem created by anelectronic engine control system malfunction.

Diagnostic Aids

An intermittent may be caused by a poor connection,rubbed-through wire insulation or a wire broken inside theinsulation. Check for poor connections or a damagedharness. Inspect the ECM harness and connector forimproper mating, broken locks, improperly formed ordamaged terminals, poor terminal-to-wire connection,and damaged harness.

Test DescriptionNumber(s) below refer to the step number(s) on theDiagnostic Chart:

1. The MIL (“Check Engine” lamp) should be “ON”steady with the ignition “ON”/engine “OFF.” If not,Chart A-1 should be used to isolate the malfunction.

2. Checks the Class 2 data circuit and ensures that theECM is able to transmit serial data.

3. This test ensures that the ECM is capable ofcontrolling the MIL (“Check Engine” lamp) and theMIL (“Check Engine” lamp) driver circuit is notshorted to ground.

4. If the engine will not start, the Cranks But Will NotRun chart should be used to diagnose the condition.

7. A Tech 2 parameter which is not within the typicalrange may help to isolate the area which is causingthe problem.

9. When the ECM is replaced, the characteristic data ofinjector and rail pressure sensor should be inputted.


On- Board Diagnostic (OBD) System Check�

Step Action Value(s) Yes No

1 1. Ignition “ON,” engine “OFF.”

2. Observe the malfunction indicator lamp (MIL or“Check Engine” lamp).

Is the MIL (“Check Engine” lamp)“ON?” — Go to Step 2

Go to No MIL(“Check

Engine” lamp)

2 1. Ignition “OFF.”

2. Install a Tech 2.

3. Ignition “ON.”

4. Attempt to display ECM engine data with the Tech 2.

Does the Tech 2 display ECM data? — Go to Step 3 Go to Step 8

3 1. Using the Tech 2 output tests function, select MIL(“Check Engine” lamp) dash lamp control andcommand the MIL (“Check Engine” lamp) “OFF.”

2. Observe the MIL (“Check Engine” lamp).

Did the MIL (“Check Engine” lamp) turn “OFF?” — Go to Step 4

Go to MIL(“Check

Engine” lamp)On Steady

4 Attempt to start the engine.

Did the engine start and continue to run?— Go to Step 5

Go to CranksBut Will Not

Run

5 Select “Display DTCs” with the Tech 2.

Are any DTCs stored? — Go to Step 6 Go to Step 7

6 Are two or more of the following DTCs stored? A Group; P0337, P0342, P1193, P1404, P1405,P1488 B Group; P0337, P0342 C Group; P0112, P0117, P0182, P0197 D Group; P0107, P0405, P1194, P1485 —

Go to Chart,“Multiple

ECMInformation

Sensor DTCsSet”

Go toapplicableDTC table

7 Compare ECM data values displayed on the Tech 2 tothe typical engine scan data values.

Are the displayed values normal or close to the typicalvalues?

— Go to Step 8

Refer toindicated

ComponentSystemChecks

8 1. Ignition “OFF,” disconnect the ECM.

2. Ignition “ON,” engine “OFF.”

3. Check the Class 2 data circuit for an open, short toground, or short to voltage. Also, check the DLCignition feed circuit for an open or short to groundand the DLC ground circuit for an open.

4. If a problem is found, repair as necessary.

Was a problem found? — Go to Step 2 Go to Step 9

9 Check the Tech 2 on other vehicle.

Was Tech 2 abnormal? — Go to Step 11 Go to Step 10

10 Replace the ECM (Refer to the Data Programming inCase of ECM change).

Is the action complete? — Go to Step 2 —

11 Repair the Tech 2 or prepare another Tech 2.



Engine Control Module ECMDiagnosis

To read and clear diagnostic trouble codes, use a Tech 2.

IMPORTANT: Use of a Tech 2 is recommended to cleardiagnostic trouble codes from the ECM memory.Diagnostic trouble codes can also be cleared by turningthe ignition “OFF” and disconnecting the battery powerfrom the ECM for 30 seconds. Turning off the ignition anddisconnecting the battery power from the ECM will causeall diagnostic information in the ECM memory to becleared. Therefore, all the diagnostic tests will have to bere-run.

Since the ECM can have a failure which may affect onlyone circuit, following the diagnostic procedures in thissection will determine which circuit has a problem andwhere it is.If a diagnostic chart indicates that the ECM connectionsor the ECM is the cause of a problem, and the ECM isreplaced, but this does not correct the problem, one of thefollowing may be the reason:

� There is a problem with the ECM terminalconnections. The terminals may have to be removedfrom the connector in order to check them properly.

� The problem is intermittent. This means that theproblem is not present at the time the system is beingchecked. In this case, refer to the Symptoms portionof the manual and make a careful physical inspectionof all components and wiring associated with theaffected system.

� There is a shorted solenoid, relay coil, or harness.Solenoids and relays are turned “ON” and “OFF” bythe ECM using internal electronic switches calleddrivers. A shorted solenoid, relay coil, or harness willnot damage the ECM but will cause the solenoid orrelay to be inoperative.

Multiple ECM Information SensorDTCS Set

Circuit Description

The Engine Control Module ECM monitors varioussensors to determine the engine operating conditions.The ECM controls fuel delivery, spark advance,transmission operation, and emission control deviceoperation based on the sensor inputs.The ECM provides a sensor ground to all of the sensors.The ECM applies 5 volts through a pull-up resistor, anddetermines the status of the following sensors bymonitoring the voltage present between the 5-volt supplyand the resistor:

� The fuel temperature (FT) sensor

� The engine coolant temperature (ECT) sensor

� The Intake air temperature (IAT) sensor

The ECM provides the following sensors with a 5-voltreference and a sensor ground signal:

� The Intake throttle position sensor

� The manifold absolute pressure sensor

� The rail pressure sensor

� The accelerator position sensor

� The oil temperature sensor

� The camshaft position sensor

� The crankshaft position sensor

� The EGR pressure sensor

The ECM monitors the signals from these sensors inorder to determine their operating status.

Diagnostic Aids

IMPORTANT: Be sure to inspect ECM and enginegrounds for being secure and clean.

A short to voltage in one of the sensor input circuits maycause one or more of the following DTCs to be set:

� P0337

� P0342

� P1193

� P1404

� P1405

� P1488

IMPORTANT: If a sensor input circuit has been shortedto voltage, ensure that the sensor is not damaged. Adamaged sensor will continue to indicate a high or lowvoltage after the affected circuit has been repaired. If thesensor has been damaged, replace it.

An open in the sensor ground circuit between the ECMand the splice will cause one or more of the followingDTCs to be set:

� P0337

� P0342

� P0117

A short to ground in the 5-volt reference A or B circuit willcause one or more of the following DTCs to be set:

� P0112

� P0117

� P0182

� P0197

An open in the 5-volt reference circuit A, between theECM and the splice will cause one or more of the followingDTCs to be set:

� P0107

� P0405

� P1194

� P0122

An open in the 5-volt reference circuit B, between theECM and the splice will cause one or more of the followingDTCs to be set:

� P1485

Check for the following conditions:

� Poor connection at ECM. Inspect the harnessconnectors for backed-out terminals, impropermating, broken locks, improperly formed or damageterminals, and a poor terminal-to-wire connection.

� Damaged harness. Inspect the wiring harness fordamage. If the harness is not damaged, observe anaffected sensor’s displayed value on the Tech 2 withthe ignition “ON” and the engine “OFF” while youmove the connectors and the wiring harnessesrelated to the following sensors:

� ECT Sensor


� MAP Sensor

� CMP Sensor

� CKP Sensor

� EGR Pressure Sensor

� EGR VSV

� RPCV

� IAT Sensor

� Intake Throttle Motor

� Fuel Temperature Sensor

� Oil Temperature Sensor

� Rail Pressure Sensor

Multiple ECM Information Sensor DTCs Set�


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

— Go to Step 2

Go to OBDSystemCheck

2 1. Turn the ignition “OFF,” disconnect the ECM.

2. Turn the ignition “ON,” check the 5 volt reference Dcircuit for the following conditions:

� D poor connection at the ECM.

� An open between the ECM connector and thesplice.

� D short to ground.

� D short to voltage.

Is there an open or short? — Go to Step 3 Go to Step 4

3 Repair the open or short.

Is the action complete? — Verify repair —

4 Check the sensor ground circuit for the followingconditions:

� A poor connection at the ECM or the affectedsensors.

� An open between the ECM connector and theaffected sensors.

Is there an open or a poor connection? — Go to Step 5 Go to Step 6

5 Repair the open or the poor connection.

Is the action complete? — Verify repair Go to Step 6


Is the action complete? —

Go to OBDSystemCheck —


EGR (Exhaust Gas Recirculation)Diagnosis

� A diagnosis of the EGR system is covered by DTCP1403.

� EGR VSV circuit diagnosis is covered by DTC P1404.

� EGR pressure sensor diagnosis is covered by DTCP405 and/or P406.

� EGR EVRV circuit diagnosis is covered by DTCP1405. Refer to the DTC charts.

Tech 2 Data Definitions and Ranges

A/C CLUTCH–Tech 2 Displays ON or OFF–Indicates whether the A/C has commanded the A/Cclutch ON.

MAP kPa — Tech 2 Range 10-105 kPa/0.00-5.00Volts —The manifold absolute pressure reading is determinedfrom the MAP sensor signal monitored during key up andwide open throttle (WOT) conditions. The manifoldabsolute pressure is used to compensate for altitudedifferences and is normally displayed around “61-104”depending on altitude and manifold absolute pressure.

CMP ACT. COUNTER –Cam Position

DESIRED IDLE — Tech 2 Range 0-3187 RPM —The idle speed that the ECM is commanding. The ECMwill compensate for various engine loads based on enginecoolant temperature, to keep the engine at the desiredspeed.

ECT — (Engine Coolant Temperature) Tech 2Range –40�C to 151�C (–40�F to 304�F) —The engine coolant temperature (ECT) is mounted in thecoolant stream and sends engine temperatureinformation to the ECM. The ECM applies 5 volts to theECT sensor circuit. The sensor is a thermistor whichchanges internal resistance as temperature changes.When the sensor is cold (high resistance), the ECMmonitors a high signal voltage and interprets that as a coldengine. As the sensor warms (decreasing resistance),the voltage signal will decrease and the ECM will interpretthe lower voltage as a warm engine.

ENGINE RUN TIME — Tech 2 Range00:00:00-99:99:99 Hrs:Min:Sec —Indicates the time elapsed since the engine was started.If the engine is stopped, engine run time will be reset to00:00:00.

ENGINE SPEED — Range 0-9999 RPM —Engine speed is computed by the ECM from the 57Xreference input. It should remain close to desired idleunder various engine loads with engine idling.

Air Intake Valve meter POSITION — Tech 2 Range0-100 % —

IAT (INTAKE AIR TEMPERATURE)— Tech 2 Range–40�C to 151�C (–40�F to 304�F) —The ECM converts the resistance of the intake airtemperature sensor to degrees. Intake air temperature(IAT) is used by the ECM to adjust fuel delivery and sparktiming according to incoming air density.

MAP — Tech 2 Range 10-105 kPa (0.00-4.97 Volts)—The manifold absolute pressure (MAP) sensor measuresthe change in the boost pressure.

MIL — Tech 2 Displays ON or OFF —Indicates the ECM commanded state of the malfunctionindicator lamp.

AP — Tech 2 Range 0%-100% —AP (Accelerator position) angle is computed by the ECMfrom the AP sensor voltage. AP angle should display“0%” at idle and “100%” at wide open throttle.

AP SENSOR — Tech 2 Range 0.00-5.00 Volts —The voltage being monitored by the ECM on the APsensor signal circuit.

VEHICLE SPEED—Tech 2 Range 0-255 km/h (0-155mph)–The vehicle speed sensor signal is converted into km/hand mph for display.

Typical Scan Data ValuesUse the Typical Scan Data Values Table only after theOn-Board Diagnostic System Check has beencompleted, no DTC(s) were noted, and you havedetermined that the on-board diagnostics are functioningproperly. Tech 2 values from a properly-running enginemay be used for comparison with the engine you arediagnosing. The typical scan data values representvalues that would be seen on a normally-running engine.

NOTE: A Tech 2 that displays faulty data should not beused, and the problem should be reported to the Tech 2manufacturer. Use of a faulty Tech 2 can result inmisdiagnosis and unnecessary replacement of parts.

Only the parameters listed below are referred to in thisservice manual for use in diagnosis. For furtherinformation on using the Tech 2 to diagnose the ECM andrelated sensors, refer to the applicable reference sectionlisted below. If all values are within the typical rangedescribed below, refer to the Symptoms section fordiagnosis.

Test Conditions

Engine running, lower radiator hose hot, transmission inpark or neutral, accessaries off, brake not applied and airconditioning off.


4JX1-TC Engine (Automatic and Manual Transmission)

Tech 2Parameter

Data List UnitsDisplayed

Typical DataValues (IDLE)

Typical DataValues

(2500 RPM)

Refer To

Battery Voltage Engine Volts 12.5 ∼ 14.5 13 ∼ 15 General Description

Ignition Status Engine On/Off On On General Description

Ignition Relay2 Engine On/Off On On General Description

Idle Switch Engine Inactive/Active

— — DTC P0510, P1510

ManifoldAbsolutePressure

Engine KPa 96 ∼ 106 110 ∼ 150 General DescriptionDTC P0107, P0108

Rail OilPressure

Engine MPa 3.5 ∼ 5 4.5 ∼ 10 General DescriptionDTC P0192, P0193

Desired Rail OilPressure

Engine MPa 4 ∼ 5 5 ∼ 9 General DescriptionDTC P0192, P0193

FuelTemperature

Engine �C (�F) 75 ∼ 85 75 ∼ 85 DTC P0182, P0183

Quick WarmingSwitch

Engine On/Off Off Off DTC P0380

Thermo Relay Engine On/Off — — DTC P1655

Actual EGRPressure

Engine KPa 58 ∼ 60 M/T 63 ∼ 66A/T 95 ∼ 105

DTC P0405, P0406

BarometricPressure

Engine KPa 98 ∼ 102 98 ∼ 102 General Description

Relative EGRPressure

Engine KPa –38 ∼ –45 M/T –34 ∼ –37A/T 0

General Description

Desired EGRPressure

Engine KPa –43 ∼ –40 M/T 36A/T 0

General Description

Brake Switch Engine Inactive/Active

— — DTC P1588

Gear Engine — — — —

Vehicle Speed Engine Km/h 0 0 Transmission Diagnosis

Rail PressureControl Valve

Engine % 17 ∼ 22 18 ∼ 27 DTC P1193

EGR Status Engine Disable/Enable

Enable M/T EnableA/T Disable

General Description

EGR SwitchingValve

Engine On/Off — — General Description

Throttle MotorPosition Sensor

Engine Volts 3.1 ∼ 3.9 0.2 ∼ 0.9 DTC P1485, P1486,P1487

Throttle MotorPosition

Engine Steps0 ∼ 1.0 0 ∼ 1.0

DTC P1488

Delirered FuelQuantity

Engine mm 3/st6 ∼ 10 6 ∼ 12

General Description

Injector Status Engine Disable/Enable

Enable Enable DTC P0201, P0202,P0203, P0204, GeneralDescription

Injector PulseWidth

Engine ms 0.9 ∼ 1.25 0.7 ∼ 1.1 General Description

Injector StartOffset

Engine �CA — — General Description


Tech 2Parameter

Data List UnitsDisplayed

Typical DataValues (IDLE)

Typical DataValues

(2500 RPM)

Refer To

Exhaust VSV1 Engine On/Off Off Off DTC P0475

Exhaust VSV2 Engine On/Off Off Off DTC P1475

DecelevationFuel Cut Off

Engine Inactive/Active

— — General Description

Glow TimeLamp


Glow TimeRelay


DiagnosticRequest

Engine Inactive12V/

Active 0V

— — General Description

A/C Clutch Engine On/Off Off Off General Description

Desired Idle Engine RPM 720 — General Description

ECT (EngineCoolant Temp)

Engine �C (�F) 80 ∼ 90 80 ∼ 90 General DescriptionECT

Engine Speed Engine RPM 720 2500 DTC P0219

MAT (Intake AirTemp)

Engine �C (�F) 65 ∼ 80 65 ∼ 80 DTC P0112, P0113

MAP KPa(ManifoldAbsolutePressure)

Engine Kilopascals — — General DescriptionDTC P0107, P0108

MIL Engine On/Off Off Off General Description

AP (AccelPosition)

Engine Percent 0 8 ∼14 DTC P0121, P0122,P0123

AP (AccelPosition)

Engine Volts 0.25 ∼ 0.45 0.8 ∼ 1.0 DTC P0121, P0122,P0123

Rail OilTemperature

Engine �C (�F) — — DTC P0197, P0198

Desired ThrottleMotor Position

Engine Steps — — —

Learned IdleFuel Quantity

Engine mm 3/st — — —


No Malfunction Indicator Lamp (MIL)

060RW136

Circuit Description

The “Check Engine” lamp (MIL) should always beilluminated and steady with the ignition “ON” and theengine stopped. Ignition feed voltage is supplied to theMIL bulb through the meter fuse. The Engine ControlModule ECM turns the MIL “ON” by grounding the MILdriver circuit.

Diagnostic Aids

An intermittent MIL may be cause by a poor connection,rubbed-through wire insulation, or a wire broken insidethe insulation. Check for the following items:

� Inspect the ECM harness and connections forimproper mating, broken locks, improperly formed ordamaged terminals, poor terminal-to-wireconnection, and damaged harness.

� If the engine runs OK, check for a faulty light bulb, anopen in the MIL driver circuit, or an open in theinstrument cluster ignition feed.

� If the engine cranks but will not run, check for an openECM ignition or battery feed, or a poor ECM to engineground.

Test DescriptionNumber(s) below refer to the step number(s) on theDiagnostic Chart.

2. A “No MIL” condition accompanied by a no-startcondition suggests a faulty ECM ignition feed orbattery feed circuit.

9. Using a test light connected to B+, probe each of theECM ground terminals to ensure that a good groundis present. Refer to ECM Terminal End View forterminal locations of the ECM ground circuits.

12.In this step, temporarily substitute a known goodrelay for the ECM relay. The horn relay is nearby,and it can be verified as “good” simply by honkingthe horn. Replace the horn relay after completingthis step.


No Malfunction Indicator Lamp (MIL)�



— Go to Step 2



Does the engine start? — Go to Step 3 Go to Step 6

3 Check the meter fuse for the instrument cluster ignitionfeed circuit.

Is the fuse OK? — Go to Step 4 Go to Step 16

4 Ignition “ON,” probe the ignition feed circuit at thecluster connector with a test light to ground.

Is the test light “ON?” — Go to Step 5 Go to Step 13


2. Disconnect the ECM.

3. Jumper the MIL driver circuit at the ECM connectorto ground.


Is the MIL “ON?” — Go to Step 10 Go to Step 11

6 Check the ECM ignition feed and battery feed fuses (15A engine fuse and 15 A ECM fuse).

Are both fuses OK? — Go to Step 7 Go to Step 15


2. Disconnect the ECM.


4. Probe the ignition feed circuit at the ECM harnessconnector with a test light to ground.


8 Probe the battery feed circuit at the ECM harnessconnector with a test light to ground.


9 Check for a faulty ECM ground connection.

Was a problem found? — Verify repair Go to Step 10

10 Check for damaged terminals at the ECM.


11 Check for an open MIL driver circuit between the ECMand the MIL.


12 Substitute a known “good” relay for the ECM mainrelay.

Was the malfunction fixed? — Verify repair Go to Step 13

13 Repair the open in the ignition feed circuit.


14 Locate and repair the open ECM battery feed circuit.



No Malfunction Indicator Lamp (MIL)�� !"#$%&'

Step NoYesValue(s)Action

15 Locate and repair the short to ground in the ECMignition feed circuit or ECM battery feed circuit.


16 Locate and repair the short to ground in the ignitionfeed circuit to the instrument cluster, and replace thefuse.




18 Check the MIL driver circuit for a poor connection at theinstrument panel connector.

Was a problem found?

— Verify repair

Go toInstrument

Panel inElectricalDiagnosis


Malfunction Indicator Lamp (MIL) “ON” Steady

060RW136

Circuit description

The “Check Engine” lamp (MIL) should always beilluminated and steady with ignition “ON” and the enginestopped. Ignition feed voltage is supplied directly to theMIL indicator. The Engine Control Module ECM turns theMIL “ON” by grounding the MIL driver circuit.The MIL should not remain “ON” with the engine runningand no DTC(s) set. A steady MIL with the engine runningand no DTC(s) suggests a short to ground in the MILdriver circuit.

Diagnostic Aids

An intermittent may be caused by a poor connection,rubbed–through wire insulation, or a wire broken insidethe insulation. Check for the following items:

� Poor connection or damaged harness – Inspect theECM harness and connectors for improper mating,broken locks, improperly formed or damagedterminals, poor terminal-to-wire connection, anddamaged harness.


2. If the MIL does not remain “ON” when the ECM isdisconnected, the MIL driver wiring is not faulty.

3. If the MIL driver circuit is OK, the instrument panelcluster is faulty.


Malfunction Indicator Lamp (MIL) “ON” Steady�


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

— Go to Step 2


2 1. Ignition “OFF,” disconnect ECM.

2. Ignition “ON,” observe the MIL (CHECK ENGINElamp).

Is the MIL “ON?” — Go to Step 3 Go to Step 5

3 1. Ignition “OFF,” disconnect the instrument panelcluster.

2. Check the MIL driver circuit between the ECM andthe instrument panel cluster for a short to ground.


Was the MIL driver circuit shorted to ground? —

Go to OBDSystemCheck Go to Step 4

4 Replace the instrument panel cluster.

Is the action complete?—


5 1. Ignition “OFF,” reconnect the ECM.

2. Ignition “ON,” reprogram the ECM. Refer toOn-Vehicle Service in Engine Control Module andSensor for procedures.

3. Using the Tech 2 output controls function, selectMIL dash lamp control and command the MIL“OFF.”

Did the MIL turn “OFF?” —

Go to OBDSystemCheck Go to Step 6


Is the action complete? —



Engine Cranks But Will Not RunCircuit Description

In this type of injector system, the Engine Control Module(ECM) triggers the correct driver inside the injector, whichthen triggers the correct injector based on the 57X signalreceived from the crankshaft position sensor (CKP).During crank, the ECM monitors the CKP 57X signal. TheCKP signal is used to determine which cylinder will firefirst. After the CKP 57X signal has been processed by theECM, it will command all four injectors to allow a primingshot of fuel for all the cylinders. After the priming, theinjectors are left “OFF” during the next four 57X referencepulses from the CKP. This allows each cylinder a chanceto use the fuel from the priming shot. During this waitingperiod, a camshaft position (CMP) signal pulse will havebeen received by the ECM. The CMP signal allows theECM to operate the injectors sequentially based oncamshaft position. If the camshaft position signal is notpresent at start-up, the ECM will begin sequential fueldelivery with a 1-in-4 chance that fuel delivery is correct.The engine will run without a CMP signal, but will set aDTC code.

Diagnostic Aids

An intermittent problem may be caused by a poorconnection, rubbed-through wire insulation or a wire

broken inside the insulation. Check for the followingitems:

� Poor connection or damaged harness – Inspect theECM harness and connectors for improper mating,broken locks, improperly formed or damagedterminals, poor terminal-to-wore connection, anddamaged harness.

� Faulty engine coolant temperature sensor – Using aTech 2, compare engine coolant temperature withmanifold air temperature on a completely cool engine.


4. An obvious cause of low fuel pressure would be anempty fuel tank.

5. The engine will easily start and run if a few injectorsare disabled. It is not necessary to test all injectorsat this time since this step is only a test to verify thatall of the injectors have not been disabled by fuelcontamination.

8.If there is an open or shorted driver circuit, DTCs0201-0204 should be set.

Engine Cranks But Will Not Run�



— Go to Step 2


2 Check the 15 A injector fuse, the 15 A engine devicefuse, and the 15A ECM fuse.

Was a fuse blown? — Go to Step 3 Go to Step 4

3 Check for a short to ground and replace the fuse.


4 Is fuel tank empty?—

Fill the fueltank Go to Step 5

5 Is the right fuel using?— Go to Step 6

Replace thefuel

6 Is the right engine oil using?— Go to Step 7

Replace theengine oil

7 Using the Tech–2.

Is DTC P0192 or P0193 set? (Check rail pressuresystem) —

Go to DTCP0192 or

DTC P0193 Go to Step 8


Is DTC P0201 – P0204 set? (Check inject circuit fault)—

Go to DTCP0201 –P0204 Go to Step 9


Is DTC P1657 set? (Check ECM Main relay) —Go to DTC

P1657 Go to Step 10


Engine Cranks But Will Not Run�� !"#$%&'


10 Refer to Engine Mechanical Diagnosis to diagnose thefollowing conditions:

� Faulty camshaft drive belts

� Leaking or sticky valves or rings

� Excessive valve deposits

� Weak valve springs

� Incorrect valve timing

� Leaking head gasket


11 Observe the “Engine Speed” data display on the Tech 2while cranking the engine.

Is the engine RPM indicated? (If the Tech 2 is normallypowered from the cigarette lighter socket, and if theTech 2 display goes blank while cranking the engine, itwill be necessary to power the Tech 2 directly from thevehicle battery.) — Go to Step 12 Go to Step 17

12 1. At the ECM (female) side of the connectormentioned in step, connect a test light between theignition + terminal and one of the injector drivercircuits at the same connector.


3. Observe the test light, and repeat the test for eachinjector driver circuit by oscilloscope.

Did the test light stay on when checking any of the 4injector driver circuits? — Go to Step 13 Go to Step 15


2. Ignition “ON,” observe the test light.


14 Locate and repair the short to ground in the injectordriver circuit.


15 Check for an open injector driver circuit.




17 1. Raise the vehicle and disconnect the CKP sensorharness.


3. With a test light to ground, probe the harnessignition feed terminal.

Did the light illuminate? — Go to Step 19 Go to Step 18

18 Check the ignition feed wire between the sensor andthe ECM for a short to ground or open circuit.



Engine Cranks But Will Not Run�� !"#$%&'


19 1. Ignition “ON.”

2. At the CKP harness connector, connect a test lightbetween the ignition and ground terminals.


20 Check the sensor ground circuit for an open or short tovoltage.


21 Check the signal circuit between the sensor and theECM for a short to ground, short to voltage, or an open.


22 Replace the CKP sensor.



Exhaust Gas Recirculation (EGR) System Check

060RW135

Circuit Description

Introducing exhaust gas into the combustion chamberlowers combustion temperatures and reduces theformation of oxides of nitrogen (NOx) in the exhaust gas.Lower combustion temperatures also prevent detonation.

Diagnostic AidsThe EGR valve chart is a check of the EGR system. AnEGR pintle constantly in the closed position could causedetonation and high emissions of NOx. An EGR pintleconstantly in the open position would cause a rough idle.


System Check�


1 Move the valve up and down to check the slideresistance.

Is the slide resistance large? — Go to Step 8 Go to Step 2

2 1. Set the transmission at “Park” or “Neutral”.

2. Put the engine in warming-up operation by idling.(The engine temperature should be 80�C or more)

3. Disconnect the vacuum hose from the EGR valve.

4. Apply a vacuum of 250 mmHg to the EGR valve bythe vacuum pump (mighty pack).

Does the vibration due to engine operation becomelarger? — Go to Step 3 Go to Step 9

3 1. Check if there is not any damage on the vacuumhose from the vacuum pump to the EGR valve.

2. Install the vacuum pump (mighty pack) to the EGRvalve.

Does the vacuum became 250 mmHg or more at thattime?

250 mmHg ormore Go to Step 4 Go to Step 8

4 Install the EGR valve and the vacuum hose formallyand increase the engine revolution speed to 3000 rpm.

Can both EGR valve 1 and EGR valve 2 be opened andclosed? —

The system isnormal Go to Step 5

5 Measure the resistance of the VSV: EGR coil.

Is the resistance value in the range of 30 � to 50 � ? 30 ∼ 50 � Go to Step 6 Go to Step 10

6 Measure the resistance of the EVRV: EGR coil.

Is the resistance value in the range of 10 � to 13 � ? 10 ∼ 13 � Go to Step 7 Go to Step 11

7 Was the harness open or poor connection? — Go to Step 12 Go to Step 13

8 Replace the EGR valve ASM.


9 Clean or replace the EGR valve ASM.


10 Replace the EGR VSV.


11 Replace the EGR EVSV.


12 Repair the harness.





ECM Diagnostic Trouble CodesThe following table lists the diagnostic trouble codessupported a Tech 2 and to flash.If any DTCs not listed

here are displayed by a Tech 2, the Tech 2 data may befaulty; notify the Tech 2 manufacturer of any DTCsdisplayed that are not included in the following table.

ECM Diagnostic Trouble Codes

DTCusing aTech 2

Flash DTC Description MIL

P0107 34 MAP Sensor Low Voltage ON

P0108 34 MAP Sensor High Voltage ON

P0112 23 Intake Air temp Sensor Low Voltage ON

P0113 23 Intake Air temp Sensor High Voltage ON

P0117 14 Engine Coolant Temp Sensor Low Voltage ON

P0118 14 Engine Coolant Temp Sensor High Voltage ON

P0121 33 Accel Position Sensor Rationality ON

P0122 21 Accel Position Sensor Low Voltage ON

P0123 21 Accel Position Sensor High Voltage ON

P0182 15 Fuel Temp Sensor Low Voltage ON

P0183 15 Fuel Temp Sensor High Voltage ON

P0192 63 Rail Pressure Sensor Low Voltage ON

P0193 63 Rail Pressure Sensor High Voltage ON

P1193 64 RPCV Circuit Open/Short —

P1194 61 Rail Pressure System Low Voltage ON

P1195 61 Rail Pressure System High Voltage ON

P1196 62 Rail Pressure System High Warning ON

P0197 16 Oil Temp sensor Low Voltage ON

P0198 16 Oil Temp sensor High Voltage ON

P0201 51 Injector #1 Circuit Fault ON




P0217 22 High Coolant Temp Warning ON

P1217 36 High Oil Temp Warning ON

P0219 11 Engine Over Speed Warning ON

P0336 43 Crank Position Sensor Out of Syncro ON

P0337 43 Crank Position Sensor No Signal ON

P0341 41 Cam Position Sensor Out of Syncro ON

P0342 41 Cam Position Sensor No Signal ON

P0380 66 Glow Relay Circuit Open/Short —

P0381 67 Glow Lamp Circuit Open/Short —

P1403 32 EGR EVRV Fault —

P1404 31 EGR VSV Circuit —

P0405 26 EGR Pressure Sensor Low Voltage ON

P1405 37 EGR EVRV Circuit Open/Short —

P0406 26 EGR Pressure Sensor High Voltage ON


DTCusing aTech 2

Flash DTC Description MIL

P0475 71 EXH #1 VSV Circuit Open/Short —

P1475 71 EXH #2 VSV Circuit Open/Short —

P1485 74 Intake Throttle Position Sensor Low Voltage ON

P1486 74 Intake Throttle Position Sensor High Voltage ON

P1487 73 Intake Throttle System Circuit Open/Short ON

P1488 72 Intake Throttle Motor Control Circuit Signal Gap —

P0502 24 Vehicle Speed Sensor No Signal ON

P0510 75 Idle SW Malfunction, Open Circuit ON

P1510 75 Idle SW Malfunction, Short Circuit ON

P0562 35 System Voltage Too Low ON

P1562 35 System Voltage Too Low at Cranking ON

P1587 25 Brake SW Malfunction [B] —

P1588 25 Brake SW Malfunction [A] ON

P0601 55 ECM Checksum Error ON

P1626 56 Immobilizer No Signal ON

P1631 56 Immobilizer Wrong Signal ON

P1648 56 No Security Code Entered ON

P1649 56 Immobilizer Function not Programmed ON

P0650 77 Check Engine Lamp Circuit Open/Short —

P0654 27 Techometer Circuit Open/Short —

P1655 17 Thermo Relay Circuit Open/Short —

P1657 76 ECM Main Relay Circuit Open/Short —

P1589 47 TransMission SW Circuit Open/Short —


Diagnostic Trouble Code (DTC) P0107 (Flash DTC 34) MAP Sensor Circuit Low Voltage

060RW134

Circuit Description

The manifold absolute pressure (MAP) sensor respondsto changes in intake manifold pressure (vacuum).The ECM monitors the MAP signals for voltages outsidethe normal range of the MAP sensor. If the ECM detects aMAP signal voltage that is excessively low, DTC P0107will be set.

Action Taken When the DTC Sets

� The ECM will illuminate the malfunction indicator lamp(MIL) the first time the fault is detected.

� The ECM will store conditions which were presentwhen the DTC was set as Freeze Frame and in theFailure Records data.

Conditions for Clearing the MIL/DTC

� DTC P0107 can be cleared by using the Tech 2 “ClearInfo” function or by disconnecting the ECM batteryfeed.

Diagnostic Aids


� Turn on the ignition switch and stop the engine. At thistime, the boost pressure will be equal to theatmospheric pressure and the signal voltage willincrease.

� Check for intermittent codes.

� The MAP sensor shares a ground with the ECT sensor,and the Transmission Fluid Temperature sensor.

� Poor connection at ECM – Inspect harness connectorsfor backed-out terminals, improper mating, brokenlocks, improperly formed or damaged terminals, andpoor terminal-to-wire connection.

� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theMAP display on the Tech 2 while moving connectorsand wiring harnesses related to the sensor. A changein the display will indicate the location of the fault.

If DTC P0107 cannot be duplicated, the informationincluded in the Failure Records data can be useful indetermining vehicle mileage since the DTC was last set.If it is determined that the DTC occurs intermittently,performing the DTC P0107 Diagnostic Chart may isolatethe cause of the fault.


DTC P0107 – MAP Sensor Circuit Low Voltage�



— Go to Step 2


2 Put the engine into an idling status.

Is the MAP voltage value displayed on the Tech 2 belowthe specified value?

0.25 V Go to Step 3

Refer toDiagnosticAids andSymptomDiagnosis

3 1. Turn off the ignition switch.

2. Remove the sensor connector connection.

3. Jumper between harness pins “red” and “blue”wires.

4. Turn on the ignition switch “ON”.

Is the MAP voltage reading above the specified value? 4 V Go to Step 5 Go to Step 4


2. Remove the jumper wire.

3. Connect the relay & solenoid checker(5-8840-0386-0) to the battery voltage, then checkthe MAP signal circuit (blue wire).

4. Turn on the ignition switch.

Is the value displayed on the Tech 2 above the specifiedvalue? 4 V Go to Step 6 Go to Step 7

5 Check the terminal connection at the MAP sensor andrepair or replace terminal if necessary.


6 Repair the 5V power circuit (red) harness or Replacethe ECM (Refer to the Data Programming in Case ofECM change).


7 Repair the signal circuit (blue) harness or Replace theECM (Refer to the Data Programming in Case of ECMchange).



Diagnostic Trouble Code (DTC) P0108 (Flash DTC 34) MAP Sensor Circuit High Voltage

060RW134

Circuit Description

The manifold absolute pressure (MAP) sensor respondsto changes in intake manifold pressure (vacuum).The ECM monitors the MAP signals for voltages outsidethe normal range of the MAP sensor. If the ECM detects aMAP signal voltage that is excessively high, DTC P0108will be set.






Diagnostic Aids


� Turn on the ignition switch and stop the engine. At thistime, the boost pressure will be equal to theatmospheric pressure and the signal voltage willincrease.



If DTC P0108 cannot be duplicated, the informationincluded in the Failure Records data can be useful indetermining vehicle mileage since the DTC was last set. Ifit is determined that the DTC occurs intermittently.


Sensor Circuit High Voltage�



— Go to Step 2



Is the MAP voltage value displayed on the Tech 2above the specified value? 4 V Go to Step 3 Go to Step 4




Is the MAP voltage value displayed on the Tech 2 belowthe specified value? 1 V Go to Step 5 Go to Step 6

4 Is the MAP voltage value displayed on the Tech 2 belowthe specified value?

1 VRefer to

Chart P0107

Refer toDiagnosticAids andSymptomDiagnosis

5 Connect the relay and solenoid checker(5-8840-0386-0) to the battery voltage, then check thesensor grounding circuit.

Does the checker lamp come on? — Go to Step 7 Go to Step 8

6 A voltage short circuit occurs in the MAP signal circuitor this circuit is shorted with the 5V power circuit.

Repair the harness or Replace the ECM (Refer to theData Programming in Case of ECM change).


7 Replace the MAP sensor hose or the MAP sensor.


8 Repair the harness for open ground circuit.



Diagnostic Trouble Code (DTC) P0112 (Flash DTC 23) IAT Sensor Circuit Low Voltage

060RW129

Circuit Description

The Intake air temperature (IAT) sensor is a thermistorwhich measures the temperature of the air entering theengine. The Engine Control Module ECM applies 5 voltsthrough a pull-up resistor to the IAT sensor. When theintake air is cold, the sensor resistance is high and theECM will monitor a high signal voltage on the IAT signalcircuit. If the intake air is warm, the sensor resistance islower, causing the ECM to monitor a lower voltage. DTCP0112 will set when the ECM detects an excessively lowsignal voltage on the Intake air temperature sensor signalcircuit.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theIAT display on the Tech 2 while moving connectors andwiring harnesses related to the IAT sensor. A changein the IAT display will indicate the location of the fault.

If DTC P0112 cannot be duplicated, the informationincluded in the Failure Records data can be useful indetermining vehicle mileage since the DTC was last set.


Test Description

Number(s) below refer to the step number(s) on theDiagnostic Chart:

2. Verifies that the fault is present.

3. If DTC P0112 can be repeated only by duplicatingthe Failure Records condition, refer to theTemperature vs. Resistance Value table. The tablemay be used to test the IAT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be stored above or belowa certain temperature. If this is the case, replacethe IAT sensor. If the IAT sensor appears to be OK,the fault is intermittent; refer to Diagnostic Aids.

Intake Air Temperature Sensor

�C �F Ohms

Temperature vs. Resistance Values(approximate)

25 77 2796

15 59 4450

5 41 7280

DTC P0112 – IAT Sensor Low Voltage�



— Go to Step 2



2. Using a Tech 2, monitor the intake air temperature(IAT).

Is the intake air temperature greater than the specifiedvalue?

148�C(283�F) Go to Step 4 Go to Step 3

3 1. Ignition “ON,” engine “OFF.” Review and recordTech 2 Failure Records data.

2. Operate the vehicle within Failure Recordsconditions as noted.

3. Using a Tech 2, monitor the “ DTC” info for DTCP0112.

Does the Tech 2 indicate DTC P0112 failed thisignition? —

Refer to TestDescription

Refer toDiagnostic

Aids


2. Disconnect the IAT sensor electrical connector.


4. Observe the manifold air temperature on the Tech 2.

Is the manifold air temperature below the specifiedvalue?

–38�C(–36�F) Go to Step 6 Go to Step 5


2. Disconnect the ECM electrical connectors.

3. Check the IAT sensor signal circuit for a short toground.

Is the IAT sensor signal circuit shorted to ground? — Verify repair Go to Step 7

6 Replace the IAT sensor.





Diagnostic Trouble Code (DTC) P0113 (Flash DTC 23) IAT Sensor Circuit High Voltage

060RW129

Circuit Description

The intake air temperature (IAT) sensor is a thermistorwhich measures the temperature of the air entering theengine. The Engine Control Module ECM applies 5 voltsthrough a pull-up resistor to the IAT sensor. When theintake air is cold, the sensor resistance is high and theECM will monitor a high signal voltage on the IAT signalcircuit. If the intake air is warm, the sensor resistance islower causing the ECM to monitor a lower voltage. DTCP0113 will set when the ECM detects an excessively highsignal voltage on the intake air temperature sensor signalcircuit.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theIAT display on the Tech 2 while moving connectors andwiring harnesses related to the IAT sensor. A changein the IAT display will indicate the location of the fault.



Test Description

Number(s) below refer to the step number(s) on theDiagnostic Chart:


3. If DTC P0113 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Values” table. Thetable may be used to test the MAT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be open above or below acertain temperature. If this is the case, replace theMAT sensor. If the MAT sensor appears to be OK,the fault is intermittent; refer to Diagnostic Aids.

Manifold Air Temperature Sensor

�C �F Ohms


25 77 2796

15 59 4450

5 41 7280

DTC P0113 –IAT Sensor Circuit High Voltage�



— Go to Step 2


2 Ignition “ON,” engine “OFF.” Observe the “Intake AirTemp” display on the Tech 2.

Is the “Intake Air Temp” below the specified value?–38�C

(–36�F) Go to Step 4 Go to Step 3


2. Review and record Tech 2 Failure Records dataparameters.


4. Using a Tech 2, monitor “ DTC” info for DTC P0113.

Does the Tech 2 indicate DTC P0113 failed? —Refer to TestDescription

Refer toDiagnostic

Aids


2. Disconnect the IAT sensor electrical connector.

3. Jumper the IAT signal circuit and the sensor groundcircuit together at the IAT sensor harnessconnector.


5. Observe the “Intake Air Temp” display on the Tech2.

Is the “Intake Air Temp” at the specified value?


5 1. Jumper the IAT signal circuit at the IAT sensorharness connector to chassis ground.

2. Observe the “Intake Air Temp” display on the Tech2.

Is the “Intake Air Temp” at the specified value?140�C

(284�F) Go to Step 7 Go to Step 8

6 Check for poor connections at the IAT sensor andreplace terminals if necessary.

Did any terminals require replacement? — Verify repair Go to Step 10


2. Disconnect the ECM, and check the IAT sensorground circuit for an open.

3. If the IAT sensor ground circuit is open, repair it asnecessary.

Was the IAT sensor ground circuit open? — Verify repair Go to Step 9


DTC P0113 –IAT Sensor Circuit High Voltage�� !"#$%&'



2. Disconnect the ECM, and check the IAT signalcircuit for an open.

3. If the IAT sensor signal circuit is open, repair it asnecessary.

Was the IAT signal circuit open? — Verify repair Go to Step 9

9 Check for a poor sensor ground or IAT signal circuitterminal connection at the ECM and replaceterminal(s) if necessary.

Did any of the terminals need to be replaced? — Verify repair Go to Step 11

10 Replace the IAT sensor.





Diagnostic Trouble Code (DTC) P0117 (Flash DTC 14) ECT Sensor Low Voltage

060RW129

Circuit Description

The engine coolant temperature (ECT) sensor is athermistor mounted on a coolant crossover pipe at therear of the engine. The Engine Control Module ECMapplies a voltage (about 5 volts) through a pull-up resistorto the ECT signal circuit. When the engine coolant is cold,the sensor (thermistor) resistance is high, therefore theECM will measure a high signal voltage. As the enginecoolant warms, the sensor resistance becomes lower,and the ECT signal voltage measured at the ECM drops.





Diagnostic Aids


� Poor connection at ECM – Inspect harness connectorsfor backed-out terminals, improper mating, broken

locks, improperly formed or damaged terminals, andpoor terminal-to-wire connection.

� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theECT display on the Tech 2 while moving connectorsand wiring harnesses related to the ECT sensor. Achange in the ECT display will indicate the location ofthe fault.

If DTC P0117 cannot be duplicated, the informationincluded in the Failure Records data can be useful indetermining vehicle mileage since the DTC was last set.If it is determined that the DTC occurs intermittently.

Test Description

Number(s) below refer to the step number(s) on theDiagnostic Chart.


3. If DTC P0117 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Values” table. Thetable may be used to test the ECT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be shorted above or belowa certain temperature. If this is the case, replacethe ECT sensor. If the ECT sensor appears to beOK, the fault is intermittent; refer to Diagnostic Aids.


Engine Coolant Temperature Sensor

�C �F Ohms


25 77 2796

15 59 4450

DTC P0117 – ECT Sensor Low Voltage�



— Go to Step 2



2. Observe the “Eng Cool Temp” display on the Tech 2.

Is the “Eng Cool Temp” below the specified value?



2. Review and record Tech 2 Failure Records data.



Does the Tech 2 indicate DTC P0117 failed thisignition? — Go to Step 4

Refer toDiagnostic

Aids

4 1. Disconnect the ECT sensor electrical connector.


Is the “Eng Cool Temp” at the specified value?



2. Disconnect the ECM and check the ECT signalcircuit for a short to ground or a short to the sensorground circuit.

3. If the ECT signal circuit is shorted. repair it asnecessary.

Was the ECT signal circuit shorted to ground? — Verify repair Go to Step 7

6 Replace the ECT sensor.





Diagnostic Trouble Code (DTC) P0118 (Flash DTC 14) ECT Sensor High Voltage

060RW129

Circuit Description

The engine coolant temperature (ECT) sensor is athermistor mounted in on a coolant crossover pipe at therear of the engine. The Engine Control Module ECMapplies a voltage (about 5 volts) through a pull-up resistorto the ECT signal circuit. When the engine coolant is cold,the sensor (thermistor) resistance is high, therefore theECM will measure a high signal voltage. As the enginecoolant warms, the sensor resistance becomes less, andthe ECT signal voltage measured at the ECM drops.





Diagnostic Aids






Test Description



3. If DTC P0118 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Value” table. Thetable may be used to test the ECT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be shorted above or belowa certain temperature. If this is the case, replacethe ECT sensor. If the ECT sensor appears to beOK, the fault is intermittent; refer to Diagnostic Aids.

Engine Coolant Temperature Sensor

�C �F Ohms


80 176 332

25 77 2796

15 59 4450

DTC P0118 – ECT Sensor High Voltage�



— Go to Step 2











Refer toDiagnostic

Aids

4 1. Disconnect the ECT sensor electrical connector.

2. Jumper the ECT signal circuit and the sensorground circuit together at the ECT sensor harnessconnector.


Is the “Eng Cool Temp” at the specified value?


5 1. Jumper the ECT signal circuit at the ECT sensorharness connector to chassis ground.


Is the “Eng Cool Temp” at the specified value?140�C


6 Check for poor connections at the ECT sensor andreplace terminals if necessary.



2. Disconnect the ECM, and check the ECT sensorground circuit for an open.

3. If the ECT sensor ground circuit is open, repair it asnecessary.

Was the ECT sensor ground circuit open? — Verify repair Go to Step 9


DTC P0118 – ECT Sensor High Voltage�� !"#$%&'



2. Disconnect the ECM, and check the ECT signalcircuit for an open.

3. If the ECT sensor signal circuit is open, repair it asnecessary.

Was the ECT signal circuit open? — Verify repair Go to Step 9

9 Check for a poor sensor ground or ECT signal circuitterminal connection at the ECM and replaceterminal(s) if necessary.







Diagnostic Trouble Code (DTC) P0121 (Flash DTC 33) AP Sensor Rationality

060RW134

Circuit Description

The accel position (AP) sensor circuit provides a voltagesignal that changes relative to throttle blade angle.The AP signal is one of the most important inputs used bythe Engine Control Module ECM for fuel volume controland many of the ECM-controlled outputs. If the ECMdetects an out-of-range condition, DTC P0121 will set.


� The ECM will illuminate the malfunction indicator lamp(MIL) after fault is detected.



� DTC P0121 can be cleared by using the Tech 2 “Clearinfo ” function or by disconnecting the ECM batteryfeed.

Diagnostic Aids


� Poor connection at ECM – Inspect harness connectorsfor backed-out terminals, improper mating, brokenlocks improperly formed or damaged terminals, andpoor terminal-to-wire connection.

� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theECT display on the Tech 2 while moving connectorsand wiring harnesses related to the sensor. A changein the display will indicate the location of the fault.



DTC P0121 –AP Sensor Rationality�



— Go to Step 2


2 Check the Idle SW.

Was the Idle SW circuit open or darmage?—

Replace theIdle SWcircuit Go to Step 3

3 Observe the AP angle reading on the Tech 2 whileslowly opening the throttle.

Does the AP angle increase steadily and evenly fromthe closed throttle value to the wide open throttlevalue?

Closedthrottle = 0%Wide openthrottle =

100%

Refer toDiagnostic

Aids Go to Step 4

4 1. Disconnect the AP sensor.

2. Observe the AP sensor reading on the Tech 2.

Is the AP sensor reading near the specified value? 0 V Go to Step 5 Go to Step 6

5 1. Connect a test light between the 5 volt reference“J2” circuit and the AP sensor signal circuit at the APsensor harness connector.

2. Observe the AP sensor reading on the Tech 2.

Is the AP sensor reading at the specified value? 5 V Go to Step 8 Go to Step 7

6 Check the following items:

1. AP signal circuit for a short to voltage.

2. AP sensor ground circuit for high resistancebetween the ECM and the AP sensor.

3. AP sensor ground circuit for a poor connection.

4. If a problem is found, repair wiring harness asnecessary.


7 Check the following items:

1. AP signal circuit or 5 volt reference “J2” circuit for apoor connection.

2. AP signal circuit or 5 volt reference “J2” circuit forhigh resistance between the ECM and the APsensor.

3. If a problem is found, repair wiring harness asnecessary.


8 Replace the AP sensor.





Diagnostic Trouble Code (DTC) P0122 (Flash DTC 21) AP Sensor Low Voltage

060RW134

Circuit Description

The accelerator position (AP) sensor circuit provides avoltage signal that changes relative to throttle bladeangle.The AP signal is used by the Engine Control Module ECMfor fuel volume control and many of the ECM-controlledoutputs.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe thethrottle position display on the Tech 2 while movingconnectors and wiring harnesses related to the TPsensor. A change in the display will indicate thelocation of the fault.


DTC P0122 –AP Sensor Low Voltage�



— Go to Step 2


2 Check the AP sensor signal circuit.

Was the AP sensor signal circuit open or darmage? —Replace theAPS circuit Go to Step 3


DTC P0122 –AP Sensor Low Voltage�� !"#$%&'



2. With the throttle closed, observe the “AP Sensor”display on the Tech 2.

Is the “AP Sensor” below the specified value? 0.1 V Go to Step 5 Go to Step 4




4. Using a Tech 2, monitor the “DTC” info for DTCP0122.

Does the Tech 2 indicate DTC P0122 failed? — Go to Step 5

Refer toDiagnostic

Aids


2. Disconnect the AP sensor electrical connector.

3. Jumper the 5 volt reference “J2” circuit and the APsignal together at the AP sensor harness connector.


Observe the “AP Sensor” display on the Tech 2.

Is the “AP Sensor” at the specified value? 5 V Go to Step 11 Go to Step 6

6 1. Disconnect jumper.

2. Connect a test light between B+ and the AP sensorsignal circuit at the AP sensor harness connector.

Observe the “AP Sensor” display on the Tech 2.

Is the “AP Sensor” at the specified value? 5 V Go to Step 7 Go to Step 9


2. Disconnect the ECM and check the 5 volt reference“A” circuit for an open or short to ground.

3. If the 5 volt reference “J2” circuit is open or shortedto ground, repair it as necessary.

Was the 5 volt reference “J2” circuit open or shorted toground? — Verify repair Go to Step 8

8 Check the 5 volt reference “J2” circuit for a poorconnection at the ECM and replace the terminal ifnecessary.

Did the terminal require replacement? — Verify repair Go to Step 13


2. Disconnect the ECM, and check the AP signalcircuit for an open, short to ground, or short to thesensor ground circuit.

3. If the AP sensor signal circuit is open or shorted toground, repair it as necessary.

Was the AP signal circuit open or shorted to ground? — Verify repair Go to Step 10

10 Check the AP sensor signal circuit for a poorconnection at the ECM and replace the terminal ifnecessary.


11 Check the AP sensor signal circuit for a poorconnection at the AP sensor and replace the terminal ifnecessary.



DTC P0122 –AP Sensor Low Voltage�� !"#$%&'







Diagnostic Trouble Code (DTC) P0123 (Flash DTC 21) AP Sensor High Voltage

060RW134

Circuit Description

The accelerator position (AP) sensor circuit provides avoltage signal that changes relative to throttle bladeangle.The TP signal is one of the most important inputs used bythe Engine Control Module ECM for fuel volume controland many of the ECM-controlled outputs.





Diagnostic Aids




� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theAP sensor display on the Tech 2 while movingconnectors and wiring harnesses related to the TPsensor. A change in the display will indicate thelocation of the fault.

� Faulty AP sensor – With the ignition key “ON,” engine“OFF,” observe the AP sensor display on the Tech 2while slowly depressing the accelerator to wide openthrottle. If a voltage over 4.88 volts is seen at any pointin normal accelerator travel, replace the AP sensor.


Test Description

Number (s) below refer to the step number(s) on theDiagnostic Chart.8. Components that share the AP sensor 5 volt reference“A” circuit include the following device:


DTC P0123 – AP Sensor High Voltage�



— Go to Step 2


2 Check the AP sensor signal circuit.

Was the AP sensor signal circuit open or darmage? —Replace theAPS circuit Go to Step 3


2. With the throttle closed, observe the “AP Sensor”display on the Tech 2.

Is the “AP Sensor” above the specified value? 4.5 V Go to Step 5 Go to Step 4




4. Using a Tech 2, monitor “DTC” info for DTC P0123.

Does the Tech 2 indicate DTC P0123 failed. — Go to Step 5

Refer toDiagnostic

Aids

5 1. Disconnect the AP sensor electrical connector.

2. Observe the “AP Sensor” display on the Tech 2.

Is the “AP Sensor” near the specified value? 0 V Go to Step 6 Go to Step 7

6 Probe the sensor ground circuit at the AP sensorharness connector with a test light connected to B+.




3. Check for a short to voltage on the AP sensor signalcircuit.

4. If the AP sensor signal circuit is shorted, repair it asnecessary.

Was the AP sensor signal circuit shorted? — Verify repair Go to Step 13


2. Monitor the “AP Sensor” Tech 2 display whiledisconnecting each of the components that sharethe 5 volt reference “J2” circuit (one at a time).

3. If the “AP Sensor” Tech 2 display changes, replacethe component that caused the display to changewhen disconnected.

Does disconnecting any of these components causethe “AP Sensor” display to change? — Verify repair Go to Step 9



3. Check for a short to B+ on the 5 volt reference “A”circuit.

4. If the 5 volt reference “J2” circuit is shorted, repair itas necessary.

Was the 5 volt reference “J2” circuit shorted? — Verify repair Go to Step 10

10 Check for poor electrical connections at the AP sensorand replace terminals if necessary.



DTC P0123 – AP Sensor High Voltage�� !"#$%&'



2. Disconnect the ECM, and check for an open sensorground circuit to the AP sensor.

3. If a problem is found, repair it as necessary.

Was the sensor ground circuit to the AP sensor open? — Verify repair Go to Step 13






Diagnostic Trouble Code (DTC) P0182 (Flash DTC 15) FT Sensor Low Voltage

060RW129

Circuit Description

The fuel temperature (FT) sensor is a thermistor mountedon a coolant crossover pipe at the rear of the engine. TheEngine Control Module ECM applies a voltage (about 5volts) through a pull-up resistor to the FT signal circuit.When the fuel is cold, the sensor (thermistor) resistanceis high, therefore the ECM will measure a high signalvoltage. As the fuel warms, the sensor resistancebecomes lower, and the FT signal voltage measured atthe ECM drops.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theFT display on the Tech 2 while moving connectors andwiring harnesses related to the FT sensor. A changein the FT display will indicate the location of the fault.


Test Description




DTC P0182 – FT Sensor Low Voltage�



— Go to Step 2



2. Observe the “Fuel Temp” display on the Tech 2.

Is the “Fuel Temp” below the specified value?







Refer toDiagnostic

Aids

4 1. Disconnect the FT sensor electrical connector.


Is the “Fuel Temp” at the specified value?



2. Disconnect the ECM and check the FT signal circuitfor a short to ground or a short to the sensor groundcircuit.

3. If the FT signal circuit is shorted. repair it asnecessary.

Was the FT signal circuit shorted to ground? — Verify repair Go to Step 7

6 Replace the FT sensor.





Diagnostic Trouble Code (DTC) P0183 (Flash DTC 15) FT Sensor High Voltage

060RW129

Circuit Description

The fuel temperature (FT) sensor is a thermistor mountedin on a coolant crossover pipe at the rear of the engine.The Engine Control Module ECM applies a voltage (about5 volts) through a pull-up resistor to the FT signal circuit.When the fuel is cold, the sensor (thermistor) resistanceis high, therefore the ECM will measure a high signalvoltage. As the fuel warms, the sensor resistancebecomes less, and the FT signal voltage measured at theECM drops.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theFT display on the Tech 2 while moving connectors andwiring harnesses related to the FT sensor. A changein the FT display will indicate the location of the fault.


Test Description




DTC P0183 – FT Sensor High Voltage�



— Go to Step 2




Is the “Fuel Temp” below the specified value?







Refer toDiagnostic

Aids

4 1. Disconnect the FT sensor electrical connector.

2. Jumper the FT signal circuit and the sensor groundcircuit together at the FT sensor harness connector.


Is the “Fuel Temp” at the specified value?140�C


5 1. Jumper the FT signal circuit at the FT sensorharness connector to chassis ground.


Is the “Fuel Temp” at the specified value?140�C


6 Check for poor connections at the FT sensor andreplace terminals if necessary.



2. Disconnect the ECM, and check the FT sensorground circuit for an open.

3. If the FT sensor ground circuit is open, repair it asnecessary.

Was the FT sensor ground circuit open? — Verify repair Go to Step 9


2. Disconnect the ECM, and check the FT signalcircuit for an open.

3. If the FT sensor signal circuit is open, repair it asnecessary.

Was the FT signal circuit open? — Verify repair Go to Step 9

9 Check for a poor sensor ground or FT signal circuitterminal connection at the ECM and replaceterminal(s) if necessary.


10 Replace the FT sensor.





Diagnostic Trouble Code (DTC) P0192 (Flash DTC 63) Rail Pressure Sensor Low Voltage

060RW135

Circuit Description

The rail pressure (RP) sensor responds to changes in oilmanifold pressure.The ECM monitors the RP signals for voltages outside thenormal range of the RP sensor. If the ECM detects a RPsignal voltage that is excessively low, DTC P0192 will beset.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theRP display on the Tech 2 while moving connectors andwiring harnesses related to the sensor. A change in thedisplay will indicate the location of the fault.



DTC P0192 – RP Sensor Low Voltage�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the RP sensor signal circuit.

Was the RP sensor signal circuit open or darmage? —Replace theRP circuit. Go to Step 4


2. Disconnect the ECM and check the 5 volt reference“J1” circuit for an open or short to ground.






2. Disconnect the ECM, and check the RP signalcircuit for an open, short to ground, or short to thesensor ground circuit.

3. If the RP sensor signal circuit is open or shorted toground, repair it as necessary.

Was the RP signal circuit open or shorted to ground? — Verify repair Go to Step 7

7 Check the RP sensor signal circuit for a poorconnection at the ECM and the RP sensor; replace theterminal if necessary.


8 Replace the RP sensor (Refer to the RP sensorprogramming).





Diagnostic Trouble Code (DTC) P0193 (Flash DTC 63) Rail Pressure Sensor High Voltage

060RW135

Circuit Description

The rail pressure (RP) sensor responds to changes in oilmanifold pressure.The ECM monitors the RP signals for voltages outside thenormal range of the RP sensor. If the ECM detects a RPsignal voltage that is excessively high, DTC P0193 will beset.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theRP display on the Tech 2 while moving connectors andwiring harnesses related to the sensor. A change in thedisplay will indicate the location of the fault.

If DTC P0193 cannot be duplicated, the informationincluded in the Failure Records data can be useful indetermining vehicle mileage since the DTC was last set. Ifit is determined that the DTC occurs intermittently,performing the DTC P0193 Diagnostic Chart may isolatethe cause of the fault.


DTC P0193 – RP Sensor High Voltage�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the RP sensor signal circuit.

Was the RP sensor signal circuit open or darmage? —Replace theRP circuit Go to Step 4

4 Probe the sensor ground circuit with a test light to B+.


5 1. Check the RP signal circuit for a short to voltage or ashort to the 5 volt reference “J1” circuit.

2. If the RP sensor signal circuit is shorted, repaircircuit as necessary.

Was the RP sensor signal circuit shorted? — Verify repair Go to Step 6

6 1. Check for a poor sensor ground terminal connectionat the RP sensor electrical connector.

2. If a problem if found, replace the faulty terminal.


7 1. Check for a poor sensor ground terminal connectionat the ECM.

2. If a problem is found, replace the faulty terminal.


8 1. Check the continuity of the RP sensor groundcircuit.

2. If the RP sensor ground circuit measures over 5ohms, repair open or poor connection.

Was a condition found and corrected? — Verify repair Go to Step 9


Is the action complete? — Verify Repair —


Diagnostic Trouble Code (DTC) P1193 (Flash DTC 64) RPCV Circuit Open/Short

060RW135

Circuit Description

The rail pressure control valve (RPCV) is built in the highpressure oil circuit.RPCV is an important device which is used to control oilpressure in the HEUI system.The circuit receives current through Engine 15A fuse fromthe battery, current flowing in the order of RPCV.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theRPCV display on the Tech 2 while moving connectorsand wiring harnesses related to the RPCV. A changein the RPCV display will indicate the location of thefault.



DTC P1193 – RPCV Circuit Open/Short�



— Go to Step 2


2 1. Ignition “ON,” engine “ON.”

2. Observe the “Rail Oil Pressure” display on the Tech2.

Is the “Rail Oil Pressure” below the specified value? 3.5 ∼ 5 Mpa Go to Step 4 Go to Step 3

3 Replace the RPCV.


4 1. Engine “On”.

2. Using the Tech 2, operate “RPCV”.

3. Check the combustion noise.

Was the combustion noise change? — — Go to Step 5

5 Check the RPCV circuit. (Fuse 15A to J1-14)

Was the RPCV circuit damaged? — Go to Step 6 Go to Step 7

6 Repair the RPCV circuit.




8 Replace the high pressure oil pump.



Diagnostic Trouble Code (DTC) P1194 (Flash DTC 61) Rail Pressure System Low Voltage

060RW134

Circuit Description

The rail pressure (RP) sensor responds to changes in oilrail pressure.The ECM monitors the RP signals for voltages outside thenormal range of the RP sensor. If the ECM detects a RPsignal voltage that is excessively low, DTC P1194 will beset.





Diagnostic Aids







DTC P1194 – RP System Low Voltage�



— Go to Step 2


2 1. Engine is running.





Refer toDiagnostic

Aids

3 Connect a test light between B+ and the RP sensorsignal circuit at the RP sensor harness connector.

Is the RP value near the specified value. 5 V Go to Step 4 Go to Step 6


2. Disconnect the ECM and check the 5 volt reference“J2” circuit for an open or short to ground.






2. Disconnect the ECM, and check the RP signalcircuit for an open, short to ground, or short to thesensor ground circuit.

3. If the RP sensor signal circuit is open or shorted toground, repair it as necessary.

Was the RP signal circuit open or shorted to ground? — Verify repair Go to Step 7





9 Check the 2 way valve.

Was the 2 way valve darmage? —Replace the 2

way valve Go to Step 10

10 Replace the RPCV.


11 Replace the RP sensor.



Diagnostic Trouble Code (DTC) P1195 (Flash DTC 61) Rail Pressure System High Voltage

060RW134

Circuit Description

The rail pressure (RP) sensor responds to changes in oilrail pressure.The ECM monitors the RP signals for voltages outside thenormal range of the RP sensor. If the ECM detects a RPsignal voltage that is excessively low, DTC P1195 will beset.





Diagnostic Aids







DTC P1195 – RP System High Voltage�



— Go to Step 2







Refer toDiagnostic

Aids

3 Connect a test light between B+ and the RP sensorsignal circuit at the RP sensor harness connector.

Is the RP value near the specified value. 0 V Go to Step 4 Go to Step 6


2. Disconnect the ECM and check the ground circuitfor an open.

Was the ground circuit open? — Verify repair Go to Step 5

5 Check the ground circuit for a poor connection at theECM and replace the terminal if necessary.






8 Check the 2 way valve.

Was the 2 way valve darmage? —Replace the 2

way valve Go to Step 9

9 Replace the RPCV.


10 Replace the RP sensor.



Diagnostic Trouble Code (DTC) P1196 (Flash DTC 62) Rail Pressure System High Warning

060RW178

Legend

(1) ECM

(2) Meter Panel

(3) Battery

(4) Oil Temp Sensor

(5) Rail Pressure Sensor

(6) Glow Relay

(7) Oil Rail

(8) Tech–2

(9) A/C Comp Relay

(10) RPCV

(11) Intake Air Temp Sensor

(12) Engine Coolant Temp Sensor

(13) MAP Sensor

(14) EGR Valve

(15) EGR Pressure Sensor

(16) High Pressure Oil Pump

(17) Fuel Pump

(18) VSV



(21) EVRV

(22) Engine Harness Connector

(23) QWS Relay

(24) AP Sensor

(25) T.O.D

(26) ECT

(27) OBD

(28) TDC

(29) Injector

(30) Edge Filter


Circuit Description

The rail pressure control valve (RPCV) is built in the highpressure oil circuit.RPCV is an important device which is used to control oilpressure in the HEUI system.The circuit receives current through Engine 15A fuse fromthe battery, current flowing in the order of RPCV.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theRail Pressure Control display on the Tech 2 whilemoving connectors and wiring harnesses related to theRail Pressure Control. A change in the Rail PressureControl display will indicate the location of the fault.


Test Description



DTC P1196 – RP System High Warning�



— Go to Step 2



2. Observe the “Rail Pressure Control” display on theTech 2.

Is the action correct? — Go to Step 4 Go to Step 3

3 Replace the RPCV.






Does the Tech 2 indicate DTC P1196 failed thisignition? — Go to Step 5 —

5 1. Check the 2 way valve.

2. Observe the “RP Control” display on the Tech 2.

Is the action correct? — Go to Step 4 Go to Step 6

6 Replace the 2 way valve.



Diagnostic Trouble Code (DTC) P0197 (Flash DTC 16) Oil Temp Sensor Low Voltage

060RW129

Circuit Description

The engine oil temperature (OT) sensor is a thermistormounted in the oil rail. The Engine Control Module ECMapplies a voltage (about 5 volts) through a pull-up resistorto the ECT signal circuit. When the engine oil is cold, thesensor (thermistor) resistance is high, therefore the ECMwill measure a high signal voltage. As the engine oilwarms, the sensor resistance becomes lower, and the OTsignal voltage measured at the ECM drops.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theOT display on the Tech 2 while moving connectors andwiring harnesses related to the OT sensor. A changein the OT display will indicate the location of the fault.



Test Description



3. If DTC P0197 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Values” table. Thetable may be used to test the OT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be shorted above or belowa certain temperature. If this is the case, replacethe OT sensor. If the OT sensor appears to be OK,the fault is intermittent; refer to Diagnostic Aids.

Engine Oil Temperature Sensor

�C �F Ohms


80 176 332

25 77 2796

15 59 4450

DTC P0197 – OT Sensor Low Voltage�



— Go to Step 2



2. Observe the “Eng Oil Temp” display on the Tech 2.

Is the “Eng Oil Temp” below the specified value?







Refer toDiagnostic

Aids

4 1. Disconnect the OT sensor electrical connector.


Is the “Eng Oil Temp” at the specified value?



2. Disconnect the ECM and check the OT signal circuitfor a short to ground or a short to the sensor groundcircuit.

3. If the OT signal circuit is shorted. repair it asnecessary.

Was the OT signal circuit shorted to ground? — Verify repair Go to Step 7

6 Replace the OT sensor.





Diagnostic Trouble Code (DTC) P0198 (Flash DTC 16) Oil Temp Sensor High Voltage

060RW129

Circuit Description

The engine oil temperature (OT) sensor is a thermistormounted in the oil rail. The Engine Control Module ECMapplies a voltage (about 5 volts) through a pull-up resistorto the ECT signal circuit. When the engine oil is cold, thesensor (thermistor) resistance is high, therefore the ECMwill measure a high signal voltage. As the engine oilwarms, the sensor resistance becomes lower, and the OTsignal voltage measured at the ECM drops.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theOT display on the Tech 2 while moving connectors andwiring harnesses related to the OT sensor. A changein the OT display will indicate the location of the fault.



Test Description



3. If DTC P0198 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Value” table. Thetable may be used to test the OT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be shorted above or belowa certain temperature. If this is the case, replacethe OT sensor. If the OT sensor appears to be OK,the fault is intermittent; refer to Diagnostic Aids.

Engine Oil Temperature Sensor

�C �F Ohms


80 176 332

25 77 2796

15 59 4450

DTC P0198 – OT Sensor High Voltage�



— Go to Step 2




Is the “Eng Oil Temp” below the specified value?







Refer toDiagnostic

Aids

4 1. Disconnect the OT sensor electrical connector.

2. Jumper the OT signal circuit and the sensor groundcircuit together at the OT sensor harnessconnector.


Is the “Eng Oil Temp” at the specified value?


5 1. Jumper the OT signal circuit at the OT sensorharness connector to chassis ground.


Is the “Eng Oil Temp” at the specified value?140�C


6 Check for poor connections at the OT sensor andreplace terminals if necessary.



2. Disconnect the ECM, and check the OT sensorground circuit for an open.

3. If the OT sensor ground circuit is open, repair it asnecessary.

Was the OT sensor ground circuit open? — Verify repair Go to Step 9


DTC P0198 – OT Sensor High Voltage�� !"#$%&'



2. Disconnect the OT, and check the OT signal circuitfor an open.

3. If the OT sensor signal circuit is open, repair it asnecessary.

Was the OT signal circuit open? — Verify repair Go to Step 9

9 Check for a poor sensor ground or OT signal circuitterminal connection at the ECM and replaceterminal(s) if necessary.







Diagnostic Trouble Code (DTC) P0201 (Flash DTC 51) Injector # 1 Circuit Fault

060RW134

Circuit Description

The Engine Control Module ECM has four individualinjector driver circuits. Each controls an injector. When adriver circuit is grounded by the ECM, the injector isactivated. The ECM monitors the current in each drivercircuit. The voltage on each driver is monitored to detecta fault. If the voltage is not what the ECM expects tomonitor on the circuit, a DTC is set. This DTC is also set ifan injector driver is shorted to voltage or if there is an opencircuit.





Diagnostic Aids

An injector driver circuit that is open or shorted to voltagewill cause a DTC P0201 to set.

Test Description

The number(s) below refer to the step number(s) on theDiagnostic Chart.

3. This step determines if DTC P0201 is the result of ahard failure or an intermittent condition.

Injector Test

This test is conducted to make it sure that appropriateelectric signals are being sent to injectors Nos. 1–4.Tech–2 must be used for this test.

Test Procedure:





5. Send instructions to each injector (Switch on),making sure of injector working noise.




As for the injector whose working noise has notbeen confirmed, its electric circuit or the injectorproper is faulty.


DTC P0201 – Injector # 1 Circuit Fault�



— Go to Step 2


2 Will the engine start?

— Go to Step 3

Go to EngineCranks But

Will Not Runchart

3 1. Install the Tech 2. Clear the DTC.

2. Idle the engine for one minute.

Does DTC P0201 reset? — Go to Step 5 Go to Step 4

4 1. Review the Freeze Frame data with the ignition“ON” and the engine “OFF” and note theparameters.

2. Operate the vehicle within the Freeze Frameconditions as noted.

Does P0201 reset? — Go to Step 5 —

5 Check the Injector test.

Does the working noise confirm? — Go to Step 6 Go to Step 7



Dose DTC P0201 reset? — Verify repair Go to Step 7

7 Check for an open circuit between the injectorconnector and the ECM.

Was there an open circuit? — Go to Step 8 Go to Step 9

8 Repair the open circuit.




10 Replace the Injector (Refer to the Injector Group SignProgramming).




060RW134

Circuit Description

The Engine Control Module ECM has four individualinjector driver circuits. Each controls an injector. When adriver circuit is grounded by the ECM, the injector isactivated. The ECM monitors the current in each drivercircuit. The voltage on each driver is monitored to detecta fault. If the voltage is not what the ECM expects tomonitor on the circuit, a DTC is set. This DTC is also set ifan injector driver is shorted to voltage or if there is an opencircuit.





Diagnostic Aids


Test Description



Injector Test


Test Procedure:














— Go to Step 2



— Go to Step 3


Will Not Runchart






















060RW134

Circuit Description

The Engine Control Module ECM has four individualinjector driver circuits. Each controls an injector. Whenthe driver circuit is grounded by the ECM, the injector isactivated. The ECM monitors the current in each drivercircuit. The voltage on each driver is monitored to detecta fault. If the voltage is not what the ECM expects tomonitor on the circuit, a DTC is set. This DTC is also set ifan injector driver is shorted to voltage or if there is an opencircuit.





Diagnostic Aids


Test Description



Injector Test


Test Procedure:














— Go to Step 2



— Go to Step 3


Will Not Runchart






















060RW134

Circuit Description

The Engine Control Module ECM has four individualinjector driver circuits. Each controls an injector. Whenthe driver circuit is grounded by the ECM, the injector isactivated. The ECM monitors the current in each drivercircuit. The voltage on each driver is monitored to detecta fault. If the voltage is not what the ECM expects tomonitor on the circuit, a DTC is set. This DTC is also set ifan injector driver is shorted to voltage or if there is an opencircuit.





Diagnostic Aids


Test Description



Injector Test


Test Procedure:











DTC P0204 – Injector #4 Circuit Fault�



— Go to Step 2



— Go to Step 3


Will Not Runchart
















9 Is the action complete? — Verify repair Go to Step 10




Diagnostic Trouble Code (DTC) P0217 (Flash DTC 22) High Coolant Temp Waring

060RW129

Circuit Description

The engine coolant temperature (ECT) sensor is athermistor mounted on a coolant crossover pipe at therear of the engine. The Engine Control Module ECMapplies a voltage (about 5 volts) through a pull-up resistorto the ECT signal circuit. When the engine coolant is cold,the sensor (thermistor) resistance is high, therefore theECM will measure a high signal voltage. As the enginecoolant warms, the sensor resistance becomes lower,and the ECT signal voltage measured at the ECM drops.





Diagnostic Aids






Test Description



3. If DTC P0117 can be repeated only by duplicatingthe Failure Records conditions, refer to the“Temperature vs. Resistance Values” table. Thetable may be used to test the ECT sensor at varioustemperatures to evaluate the possibility of a“shifted” sensor that may be shorted above or belowa certain temperature. If this is the case, replacethe ECT sensor. If the ECT sensor appears to beOK, the fault is intermittent; refer to Diagnostic Aids.


DTC P0217 – High Coolant Temp Waring�



— Go to Step 2




Is the “Eng Cool Temp” below the specified value? 110�C Go to Step 6 Go to Step 3

3 Check the engine coolant quantity

Was the engine coolant appropriate quantity? — Go to Step 6 Go to Step 4

4 Check a leak from EC circuit.

Was the EC leaked from EC circuit? — Go to Step 5 Go to Step 6

5 Repair the EC circuit.







7 1. Ignition “OFF”.

2. Check the Thermostat.

3. If the Thermostat is damaged, repair it asnecessary.

Was the Thermostat damaged? — Go to Step 8 Go to Step 9

8 Replace the Thermostat.


9 1. Check the Radiator.

2. If the Radiator is damaged, repair it as necessary.

Was the Radiator damaged? — Go to Step 10 Go to Step 11

10 Repair the Radiator.


11 1. Check the EC circuit in the Engine.

2. Observe the “Eng Data List” display on the Tech 2.

3. If the EC circuit in the Engine is damaged, repair itas necessary.

Was the EC circuit damaged?Refer to Data

List Go to Step 12 Go to Step 6

12 Repair the EC circuit.



Diagnostic Trouble Code (DTC) P1217 (Flash DTC 36) High Oil Temp Warning

060RW129

Circuit Description

The engine oil temperature (OT) sensor is a thermistormounted on a oil manifold. The Engine Control ModuleECM applies a voltage (about 5 volts) through a pull-upresistor to the OT signal circuit. When the engine oil iscold, the sensor (thermistor) resistance is high, thereforethe ECM will measure a high signal voltage. As theengine oil warms, the sensor resistance becomes lower,and the OT signal voltage measured at the ECM drops.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage.

� High Oil Temperature Warning may sometimes begiven due to High Coolant Temp Warning. On thisoccasion, recognize DTC P0217 and give priority toHigh Coolant Temp Warning.


DTC P1217 – High Oil Temp Warning�



— Go to Step 2










Refer toDiagnostic

Aids






Refer toDiagnostic

Aids

5 1. Measure the engine oil quantity by oil level gage.

2. If the engine oil is shortage, fill up it as necessary.

Was the engine oil is shortaged? — Verify repair Go to Step 6

6 Replace the oil temp sensor.


7 Replace the oil cooler.



Diagnostic Trouble Code (DTC) P0219 (Flash DTC 11) Engine Over Speed Warning

060RW133

Circuit Description

The CKP reference signal is produced by the crankshaftposition (CKP) sensor. During one crankshaft revolution,CKP crankshaft reference pulses will be produced. TheEngine Control Module ECM uses the CKP referencesignal to calculate engine RPM and crankshaft position.





Diagnostic Aids

Check for:

� Poor connection – Inspect the CKP harness andconnectors for improper mating, broken locks,improperly formed or damaged terminals, and poorterminal-to-wire connection.

� Damaged X57 – Inspect the X57 for damage.

DTC P0219 – Engine Over Speed Warning�



— Go to Step 2


2 Check the responsibility.

Was the driver responsibility? — Go to Step 3 Go to Chart 4


DTC P0219 – Engine Over Speed Warning�� !"#$%&'


3 1. Review and record Failure Records information.

2. Clear DTC P0219.

3. Start the engine and idle for 1 minute.

4. Observe DTCs.

Is DTC P0219 set? — Go to Step 4 —

4 Observe the AP value displayed on the Tech 2.

Is the AP value near the specified value?

(Idling 720 r.p.m) 0 % Go to Step 3 Go to Step 5

5 Observe the Engine speed displayed on the Tech 2.

Is the Engine speed near the specified value?

(Idling) 720 r.p.m Go to Step 7 Go to Step 6

6 1. Check the CKP sensor.


3. Using a DVM, verify that 5 V reference and groundare being supplied at the sensor connector (ECMside).

Are 4-6 volts and ground available at the sensor? — Go to Step 9 Go to Step 7


2. With a DVM, backprobe the ECM connector 5 Vreference and ground connections.

Are 5 V reference and ground available at the ECM? — Go to Step 8 Go to Step 13

8 Check 5 V reference or ground between the CKPsensor and ECM and repair the open circuit, short toground or short to voltage.



2. Disconnect the ECM and CKP sensor.

3. Check for an open or a short to ground in the CKPreference circuit between the CKP sensorconnector and the ECM harness connector.



10 1. Reconnect the ECM and CKP sensor.

2. Connect a DVM to measure voltage on the CKPreference circuit at the ECM connector.

3. Observe the voltage while cranking the engine.

Is the voltage near the specified value? 2.5 V Go to Step 13 Go to Step 11

11 Check the connections at the CKP sensor and replacethe terminals if necessary.




13 Check the connections at the ECM and replace theterminals if necessary.



DTC P0219 – Engine Over Speed Warning�� !"#$%&'


14 Check the X57 signal plate.

Is the X57 signal plate damage? — Go to Step 15 Go to Step 3

15 Replace the X57 signal plate.



Diagnostic Trouble Code (DTC) P0336 (Flash DTC 43) CKP (Crank Position) Sensor Out of Synchro

060RW133

Circuit Description

The CKP reference signal is produced by the crankshaftposition (CKP) sensor. During one crankshaft revolution,crankshaft pulses will be produced. The Engine ControlModule ECM uses the CKP reference signal to calculateengine RPM and crankshaft position. If the ECM receivesan incorrect number of pulses on the CKP referencecircuit, DTC P0336 will set.





Diagnostic Aids

An intermittent may be caused by a poor connection,rubbed–through wire insulation or a wire broken inside theinsulation. Check for:

� Poor connection – Inspect the ECM harness andconnectors for improper mating, broken locks,improperly formed or damaged terminals, and poorterminal-to-wire connection.

� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, disconnectthe ECM, turn the ignition on and observe a voltmeterconnected to the CKP reference circuit at the ECMharness connector while moving connectors andwiring harnesses related to the ECM. A change involtage will indicate the location of the fault.

Reviewing the Failure Records vehicle mileage since thediagnostic test last failed may help determine how oftenthe condition that caused the DTC to be set occurs. Thismay assist in diagnosing the condition.


DTC P0336 – CKP Sensor Out of Synchro�



— Go to Step 2



Does the engine start?

— Go to Step 3

Go to “EngineCranks But

Will Not Run”chart


2. Clear DTC P0336.


4. Observe DTCs.

Is DTC P0336 set? — Go to Step 4

Refer toDiagnostic

Aids

4 1. Disconnect the ECM and CKP sensor.












8 Check connections at the ECM and replace theterminals if necessary.





Diagnostic Trouble Code (DTC) P0337 (Flash DTC 43) CKP (Crank Position) Sensor No Signal

060RW133

Circuit Description

The CKP reference signal is produced by the crankshaftposition (CKP) sensor. During one crankshaft revolution,CKP crankshaft reference pulses will be produced. TheEngine Control Module ECM uses the CKP referencesignal to calculate engine RPM and crankshaft position. Ifthe ECM does not receive pulses on the CKP referencecircuit, DTC P0337 will set.





Diagnostic Aids

An intermittent may be caused by a poor connection,rubbed-through wire insulation or a wire broken inside theinsulation. Check for:


� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, disconnectthe ECM, turn the ignition on and observe a voltmeterconnected to the CKP reference circuit at the ECMharness connector while moving connectors andwiring harnesses related to the ICM. A change involtage will indicate the location of the fault.



DTC P0337 – CKP Sensor No Signal�



— Go to Step 2



Does the engine start? — Go to Step 3 Go to Chart 3


2. Clear DTC P0337.


4. Observe DTCs.


Refer toDiagnostic

Aid

4 1. Disconnect the CKP sensor.


3. Using a DVM, verify that 5 V reference and groundare being supplied at the sensor connector (ECMside).

Are 4-6 volts and ground available at the sensor? — Go to Step 7 Go to Step 5


2. With a DVM, backprobe the ECM connector 5 Vreference and ground connections.

Are 5 V reference and ground available at the ECM? — Go to Step 6 Go to Step 11

6 Check 5 V reference or ground between the CKPsensor and ECM and repair the open circuit, short toground or short to voltage.



2. Disconnect the ECM and CKP sensor.










10 Replace the CKP sensor. Use caution and avoid hot oilthat may drip out.



DTC P0337 – CKP Sensor No Signal�� !"#$%&'







Diagnostic Trouble Code (DTC) P0341 (Flash DTC 41) CMP (Cam Position) Sensor Out of Synchro

060RW133

Circuit Description

The CMP signal is produced by the camshaft position(CMP) sensor pulses when the engine is running andcrankshaft position (CKP) sync pulses are also beingreceived. The Engine Control Module ECM uses theCMP signal pulses to initiate sequential fuel injection. Ifthe ECM receives an incorrect number of pulses on theCMP reference circuit, DTC P0341 will set.





Diagnostic Aids

An intermittent may be caused by a poor connection,rubbed–through wire insulation or a wire broken inside theinsulation. Check for:

� Poor connection — Inspect the ECM harness andconnectors for improper mating, broken locks,

improperly formed or damaged terminals, and poorterminal-to-wire connection.

� Damaged harness — Inspect the wiring harness fordamage. If the harness appears to be OK, disconnectthe ECM, turn the ignition on and observe a voltmeterconnected to the CMP signal circuit at the ECMharness connector while moving connectors andwiring harnesses related to the ICM and the CMPsensor. A change in voltage will indicate the locationof the fault.


Test Description


2. Ensures that the fault is present.

12.Determines whether the fault is being caused by amissing camshaft magnet or a faulty sensor. Thevoltage measured in this step should read around 4volts, toggling to near 0 volts when the CMP sensorinterfaces with the camshaft magnet.


DTC P0341 —CMP Sensor Out of Synchro�



— Go to Step 2





4. Using a Tech 2, monitor “DTC” info for DTC P0341until the DTC P0341 test runs.

5. Note the test result.


Refer toDiagnostic

Aids

3 1. Disconnect the CMP sensor.

2. Measure the voltage between the sensor feedcircuit and the sensor ground circuit at the CMPsensor harness connector.

Does the voltage measure near the specified value? 4-6 V Go to Step 4 Go to Step 5

4 Measure the voltage between the CMP sensor signalcircuit and the sensor ground circuit at the CMP sensorharness connector.


5 If the voltage measured in step 3 was less than 4-6volts, proceed directly to step 6 without completing thisstep.

If the voltage in step 3 was greater than 4-6 V, repair theshort to voltage in the CMP feed circuit.


6 1. Check for poor connections at the camshaftposition sensor.



7 1. Ignition “OFF,” disconnect the ECM and the CMPsensor.

2. Check the following circuits for an open between theignition control module and the CMP sensor:

� The sensor feed circuit.



8 1. Ignition “OFF,” disconnect the ECM (leave the CMPsensor disconnected).

2. Ignition “ON,” check the following circuits:

� The CMP sensor signal circuit for an open or ashort to voltage.

� The CMP sensor input signal circuit for a shortto ground.



9 Check for a short or open in the sensor ground circuit.



DTC P0341 —CMP Sensor Out of Synchro�� !"#$%&'


10 1. Check for poor connections at the ECM.



11 Backprobe the ECM connector with a DVM to monitorvoltage on the camshaft position input signal circuitwhile cranking the engine with the sensor connected.

(Use rubber band, tape, or an assistant to keep theDVM lead in contact with the sensor terminal during thistest.)

Does the voltage toggle between the specified values? 4-0 V Go to Step 15 Go to Step 12

12 1. Remove the CMP sensor from the engine frontcover (leave the sensor wiring connected).

2. Place a magnet on the CMP sensor.

(If you use a magnet that is too small to cover the faceof the sensor, test on every part of the sensor facebecause only a small area will respond to this test.)

Does the DVM display a voltage near the specifiedvalue? 0 V Go to Step 13 Go to Step 14

13 Replace the faulty or missing camshaft position sensormagnet.


14 Replace the camshaft position sensor.





Diagnostic Trouble Code (DTC) P0342 (Flash DTC 41) CMP (Cam Position) Sensor No Signal

060RW133

Circuit Description

The CMP signal produced by the camshaft position(CMP) sensor pulses when the engine is running andcrankshaft position (CKP) synchro pulses are also beingreceived. The hall type CMP sensor and the CKP sensorshare 5 V and ground connections at the Engine ControlModule ECM. The third wire at the sensor is a signalcircuit to the ECM. The ECM uses the CMP signal pulsesto initiate sequential fuel injection. If the ECM does notreceive pulses on the CMP reference circuit, DTC P0342will set.





Diagnostic Aids


� Poor connection – Inspect the ECM harness andconnectors for improper mating, broken locks,improperly formed or damaged terminals, and poorterminal to wire connection.

� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, disconnectthe ECM, turn the ignition on and observe a voltmeterconnected to the CMP signal circuit at the ECMharness connector while moving connectors andwiring harnesses related to the ICM and the CMPsensor. A change in voltage will indicate the locationof the fault.

Test Description


2. Ensures that the fault is present.

14.Determines whether the fault is being caused by amissing camshaft magnet or a faulty ECM. Thevoltage measured in this step should read around 4volts, toggling to near 0 volts when the CMP sensorinterfaces with the camshaft magnet.


DTC P0342 —CMP Sensor No Signal�



— Go to Step 2





4. Using a Tech 2, monitor “Specific DTC” informationfor DTC P0342 until the DTC P0342 test runs.

5. Note test result.


Refer toDiagnostic

Aids


2. Disconnect the CMP sensor.

3. Measure the voltage between the sensor feedcircuit and the sensor ground circuit at the CMPsensor harness connector.


4 1. Ignition “OFF,” disconnect the ECM and the CMPsensor.

2. Check for poor connections at the camshaftposition sensor.



5 1. Check for poor connections at the ECM.



6 1. Check the following circuits between the ECM andthe CMP sensor:

� The sensor feed circuit. Open or short toground?

� The sensor ground circuit. Open or short tovoltage?


Was a problem found? — Verify repair —


2. Measure the voltage between the CMP sensorsignal circuit and the sensor ground circuit at theCMP sensor harness connector.



DTC P0342 —CMP Sensor No Signal�� !"#$%&'


8 1. Turn the ignition “OFF.”

2. Disconnect the ECM and connect a DVM to monitorvoltage on the camshaft position signal circuit at theECM connector.


4. Monitor the voltage display on the DVM whilerepeatedly touching the CMP sensor signal circuitat the CMP sensor connector with a test light toground.

Does the DVM voltage display switch between 0 andapproximately 5 volts when the test light is touched tothe CMP sensor signal circuit? — Go to Step 12 Go to Step 9


2. Leave the ECM disconnected.


4. Probe the camshaft position signal circuit at theECM connector with a test light to B+.

5. If the test light is “ON,” locate and repair the short toground in the camshaft position input signal circuit.

Was either circuit shorted to ground? — Verify repair Go to Step 10


2. Leave the ECM disconnected.


4. Probe the camshaft position signal circuit with a testlight to ground.

5. If the test light is “ON,” locate and repair the short tovoltage in the camshaft position input signal circuit.

Was the test light “ON”? — Verify repair Go to Step 11

11 1. Ignition “OFF,” disconnect the ECM (leave the CMPsensor disconnected).

2. Ignition “ON,” check the following circuit:

� The CMP sensor signal circuit for an open.




2. Remove the CMP sensor from the engine frontcover (leave the sensor wiring connected).

3. Place a magnet on the CMP sensor. If you use amagnet that is too small to cover the face of thesensor, test on every part of the sensor facebecause only a small area will respond to this test.

Does the DVM display a voltage near the specifiedvalue? 0 V Go to Step 14 Go to Step 13

13 Replace the camshaft position sensor.


14 1. Reinstall the CMP sensor to the engine front cover.

2. Observe the DVM connected to monitor voltage onthe camshaft position signal circuit while crankingthe engine.

Does the voltage toggle between the specified values? 4-0 V Go to Step 15 Go to Step 16


DTC P0342 —CMP Sensor No Signal�� !"#$%&'




16 Replace faulty or missing camshaft magnet.



Diagnostic Trouble Code (DTC) P0380 (Flash DTC 66) Glow Relay Circuit Open/Short

060RW132

Circuit Description

Glow relay circuit receives current through Glow 50A fusefrom the battery. Glow relay is circuited to Glow plug.





Diagnostic Aids





DTC P0380 – Glow Relay Circuit Open/Short�



— Go to Step 2



Does the engine start? — Go to Step 3 Go to Chart 3


2. Clear DTC P0380.


4. Observe DTCs.


Refer toDiagnostic

Aid

4 Check the glow fuse 50A.

Is the glow fuse 50A damage? — Go to Step 5 Go to Step 6

5 Replace the glow fuse 50A.



2. Check for an open or a short to ground in the Glowrelay circuit between the Glow relay connector andthe ECM harness connector.



7 Check the connections at the Glow relay and replacethe terminals if necessary.


8 Replace the Glow relay.







Diagnostic Trouble Code (DTC) P0381 (Flash DTC 67) Glow Lamp Circuit Open/Short

060RW136

Circuit Description

Glow Lamp Circuit receives current through Meter 10Afuse, Glow lamp being circuited to ECM.





Diagnostic Aids





DTC P0381 – Glow Lamp Circuit Open/Short�



— Go to Step 2



2. Clear DTC P0381.

3. Observe DTCs.


Refer toDiagnostic

Aid


2. Remove the Meter assembly.

3. Check for an open or a short to ground in the GlowLamp circuit.


(On electric bulb of the Glow Lamp, The Glow Lampharness circuit)

Was a problem found? —

Refer to theMeter inElectric

section 8 Go to Step 4






Diagnostic Trouble Code (DTC) P1403 (Flash DTC 32) EGR EVRV Fault

060RW135

Circuit Description

EGR EVRV Circuit has a common power source inparallel with EGR, VSV, RPCV, and Intake Throttle Motor.This may cause multiple DTCs. On such occasion, referto “Multiple ECM Information sensor DTCs Set”.

Diagnostic Aids


� Poor connection or damaged EVRV – Inspect thewiring harness for damage.

� Ensure EVRV is correctly mounted. See On-VehicleService.


Test Description

Number(s) below refer to the step number(s) on theDiagnostic Chart

3. A malfunctioning MAP sensor can set an EGR DTC.The MAP sensor could send a constant signal whichis not low enough to set a low MAP DTC. Theconstant signal from the MAP sensor also may notbe high enough to set a high MAP DTC. This stepverifies that the MAP sensor is responding.


DTC P1403 – EGR EVRV Fault�



— Go to Step 2


2 Check the EVRV circuit.

Was the EVRV circuit darmage? —Replace theEVRV circuit Go to Step 3

3 1. Start the engine.

2. Monitor the MAP signal with a scan tool while idling.

3. While idling, jab the accelerator pedal about halfwaydown and immediately let the engine return to idle.

Did the MAP value on the scan tool show an immediatelarge change? — Go to Step 5 Go to Step 4

4 Replace the MAP sensor.


5 1. Inspect the exhaust system for modification oforiginal installed parts or leaks.

2. If a problem was found, repair exhaust system asnecessary.

Was a condition present that required repair? — Go to Step 8 Go to Step 6

6 1. Remove the EGR valve.

2. Visually and physically inspect the pintle, valvepassages and the adapter for excessive deposits orany kind of a restriction.

3. If a problem is found, clean or replace EGR systemcomponents as necessary.

Was a condition present that required repair? — Go to Step 8 Go to Step 7

7 1. Inspect the EGR passages for a blockage causedby excessive deposits or other damage.

2. If a problem is found, correct the condition asnecessary.

Was a condition present that required repair? — Go to Step 8

Refer toDiagnostic

Aids

8 1. Review and record the scan tool Failure Recordsdata.

2. Clear DTC and monitor the scan tool System InfoScreen while operating the vehicle as specified in“Diagnostic Aids.”

3. Using a scan tool, monitor “DTC” info for DTCP1403 until the DTC P1403 test runs.

4. Note the test result.

Does the scan tool indicate DTC P1403 failed thisignition? —

Go to the laststep

completed inthis

diagnosticchart

Repaircomplete


Diagnostic Trouble Code (DTC) P1404 (Flash DTC 31) EGR VSV Circuit

060RW135

Circuit Description

The Engine control module (ECM) monitors the EGRvalve input to ensure that the valve responds properly tocommands from the ECM, and to detect a fault if VSV isstuck open. When the VSV is fixing at closed and openingthe ECM will set DTC P1404.

Diagnostic Aids


� Poor connection or damaged VSV–inspect the wiringharness for damage.

DTC P1404 – EGR VSV Circuit�



— Go to Step 2


2 1. Ignition “ON”, engine “OFF”, review and recordscan tool Failure Records data.


3. Using a scan tool, monitor “Specific DTC” info forDTC P1404 until the DTC P1404 test runs. Note theresult.

Does the scan tool indicates DTC P1404 failed thisignition? — Go to Step 3

Refer toDiagnostic

Aids


DTC P1404 – EGR VSV Circuit�� !"#$%&'


3 Check the VSV circuit.

Was the VSV circuit open or darmage? — Go to Step 4 Go to Step 5

4 Repair the opened VSV circuit or VSV.



Diagnostic Trouble Code (DTC) P0405 (Flash DTC 26) EGR Pressure Sensor Low Voltage

060RW134


� The ECM will illuminate the malfunction indicator lamp(MIL) as soon as failure detected.

� The ECM will store conditions which were presentwhen the DTC was set as Freeze Frame and in FailureRecords data.


� DTC P0405 can be cleared by using the scan tool“Clear Info” function or by disconnecting the ECMbattery feed.

Diagnostic Aids


� Poor connection or damaged harness – Inspect thewiring harness for damage.

DTC P0405 – EGR Pressure Sensor Low Voltage�



— Go to Step 2



Is the EGR pressure sensor voltage value displayed onthe Tech 2 below the specified value?

0.25 V Go to Step 3

Refer toDiagnostic

AidsandSymptom

Diagnosis


DTC P0405 – EGR Pressure Sensor Low Voltage�� !"#$%&'




3. Jumper between harness pins “red” and “blue”wires.


Is the EGR pressure sensor voltage reading above thespecified value? 4 V Go to Step 5 Go to Step 4


2. Remove the jumper wire.

3. Connect the relay & solenoid checker(5-8840-0386-0) to the battery voltage, then checkthe EGR pressure sensor signal circuit (blue wire).

4. Turn on the ignition switch.

Is the value displayed on the Tech 2 above the specifiedvalue? 4 V Go to Step 6 Go to Step 7

5 Check the terminal connection at the EGR pressuresensor and repair or replace terminal if necessary.


6 Repair the 5V power circuit (red) harness or Replacethe ECM (Refer to the Data Programming in Case ofECM change).


7 Repair the signal circuit (blue) harness or Replace theECM (Refer to the Data Programming in Case of ECMchange).



Diagnostic Trouble Code (DTC) P1405 (Flash DTC 37) EGR EVRV Circuit Open/Short

060RW135

Circuit Description

EGR EVRV Circuit has a common power source inparallel with EGR, VSV, RPCV, and Intake Throttle Motor.This may cause multiple DTCs. On such occasion, referto “Multiple ECM Information Sensor DTCs Set”.





Diagnostic Aids





DTC P1405 – EGR EVRV Circuit Open/Short�



— Go to Step 2



2. Clear DTC P1405.


4. Observe DTCs.


Refer toDiagnostic

Aid


2. Disconnect the EVRV.

3. Check for an open or a short to ground in the EVRVcircuit between the EVRV connector and the ECMharness connector.



4 Check the connections at the EVRV and replace theterminals if necessary.




6 Replace the EVRV.





Diagnostic Trouble Code (DTC) P0406 (Flash DTC 26) EGR Pressure Sensor High Voltage

060RW134


� The ECM will illuminate the malfunction indicator lamp(MIL) as soon as failure detected.

� The ECM will store conditions which were presentwhen the DTC was set as Freeze Frame and in FailureRecords data.


� DTC P0404 can be cleared by using the scan tool“Clear Info” function or by disconnecting the ECMbattery feed.

Diagnostic Aids


� Poor connection or damaged harness – Inspect thewiring harness for damage.

DTC P0406 – EGR Pressure Sensor High Voltage�



— Go to Step 2



Is the EGR pressure sensor voltage value displayed onthe Tech 2 above the specified value? 4 V Go to Step 3 Go to Step 4




Is the EGR pressure sensor voltage value displayed onthe Tech 2 below the specified value? 1 V Go to Step 5 Go to Step 6


DTC P0406 – EGR Pressure Sensor High Voltage�� !"#$%&'


4 Is the EGR pressure sensor voltage value displayed onthe Tech 2 below the specified value?

1 VRefer to

Chart P0107

Refer toDiagnostic

AidsandSymptom

Diagnosis

5 Connect the relay and solenoid checker(5-8840-0386-0) to the battery voltage, then check thesensor grounding circuit.

Does the checker lamp come on? — Go to Step 7 Go to Step 8

6 A voltage short circuit occurs in the MAP signal circuitor this circuit is shorted with the 5V power circuit.

Repair the harness or Replace the ECM (Refer to theData Programming in Case of ECM change).


7 Replace the EGR pressure sensor hose or the EGRpressure sensor.


8 Repair the harness for open ground circuit.



Diagnostic Trouble Code (DTC) P0475 (Flash DTC 71) EXH #1 VSV Circuit

060RW135

Circuit Description

EXH. #1, #2 VSV Circuit receives current through Engine15A fuse, #1 and #2 being connected in parallel.






Diagnostic Aids





DTC P0475 – EXH #1 VSV Circuit Open/Short�



— Go to Step 2






Refer toDiagnostic

Aids


2. Disconnect the EXH #1 VSV connectors.

3. Check the EXH #1 VSV circuit for a short to ground.

Is the EXH #1 VSV circuit shorted to ground? — Verify repair Go to Step 4

4 Replace the EXH #1 VSV.









Diagnostic Trouble Code (DTC) P1475 (Flash DTC 71) EXH #2 VSV Circuit Open/Short

060RW135

Circuit Description

EXH. #1, #2 VSV Circuit receives current through Engine15A fuse, #1 and #2 being connected in parallel.






Diagnostic Aids





DTC P1475 – EXH #2 VSV Circuit Open/Short�



— Go to Step 2






Refer toDiagnostic

Aids


2. Disconnect the EXH #2 connectors.

3. Check the EXH #2 circuit for a short to ground.

Is the EXH #2 circuit shorted to ground? — Verify repair Go to Step 4

4 Replace the EXH #2 VSV.









Diagnostic Trouble Code (DTC) P1485 (Flash DTC 74) ITP (Intake Thorottle Position) Sensor Low Voltage

060RW134

Circuit Description

The intake throttle position (ITP) sensor circuit provides avoltage signal that changes relative to throttle bladeangle.






Diagnostic Aids




If the harness appears to be OK, observe thethrottle position display on the Tech 2 whilemoving connectors and wiring harnesses relatedto the ITP sensor. A change in the display willindicate the location of the fault.


DTC P1485 –ITP Sensor Low Voltage�



— Go to Step 2



2. With the throttle closed by the hand, observe the“ITP Sensor” display on the Tech 2.

Is the “ITP Sensor” below the specified value? 0.22 V Go to Step 4 Go to Step 3


DTC P1485 –ITP Sensor Low Voltage�� !"#$%&'







Refer toDiagnostic

Aids

4 Check the ITP sensor signal circuit for a poorconnection at the ECM and replace the terminal ifnecessary.





4. Using a Tech 2 monitor the “Specific DTC” info forDTC P1485.

Dose the Tech 2 indicate DTC P1485 failed? — Go to Step 6

Refer toDiagnostic

Aids

6 Replace the intake throttle.





Diagnostic Trouble Code (DTC) P1486 (Flash DTC 74) ITP (Intake Throttle Position) Sensor High Voltage

060RW134

Circuit Description







Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theITP sensor display on the Tech 2 while movingconnectors and wiring harnesses related to the TPsensor. A change in the display will indicate thelocation of the fault.

� Faulty TP sensor – With the ignition key “ON,” engine“OFF,” observe the TP sensor display on the Tech 2while slowly depressing the accelerator to wide openthrottle.



DTC P1486 – ITP Sensor High Voltage�



— Go to Step 2



2. With the throttle closed by the hand, observe the“ITP Sensor” display on the Tech 2.

Is the “ITP Sensor” above the specified value? 4.88 V Go to Step 4 Go to Step 3





Does the Tech 2 indicate DTC P1486 failed. — Go to Step 4

Refer toDiagnostic

Aids

4 Check for poor electrical connections at the ITP sensorand replace terminals if necessary.





4. Using a Tech 2 monitor the “DTC” info for DTCP1486.

Dose the Tech 2 indicate DTC P1486 failed. — Go to Step 6

Refer toDiagnostic

Aids

6 Replace the intake throttle.





Diagnostic Trouble Code (DTC) P1487 (Flash DTC 73) Intake Throttle System Circuit Open/Start

060RW134

Circuit Description







Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe thethrottle position display on the Tech 2 while movingconnectors and wiring harnesses related to the ITPsensor. A change in the display will indicate thelocation of the fault.



DTC P1487 – Intake Throttle System Circuit Open/Short�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the ITP circuit for a poor connection at the ECMand ITP and replace the terminal if necessary.



2. Operate the throttle by the hand.


5 Replace the ITP Assembly.





Diagnostic Trouble Code (DTC) P1488 (Flash DTC 72) Intake Throttle Motor Control Circuit Signal Gap

060RW135

Circuit Description

The Intake throttle position (ITP) sensor circuit provides avoltage signal that changes relative to throttle bladeangle.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe thethrottle position display on the Tech 2 while movingconnectors and wiring harnesses related to the ITPsensor. A change in the display will indicate thelocation of the fault.



DTC P1488 – Intake Throttle Motor Control Circuit Signal Gap�



— Go to Step 2



2. With the throttle closed, observe the “ITP Sensor”display on the Tech 2.

Is the “ITP Sensor” below the specified value? 0.22 V Go to Step 4 Go to Step 3




4. Using a Tech 2, monitor the “Specific DTC” info forDTC P1488.


Refer toDiagnostic

Aids

4 Check the ITP circuit for a poor connection at the ECMand replace the terminal if necessary.


5 Check the Intake throttle motor circuit for a poorconnection and replace the terminal if necessary.


6 Check the ITP Assembly for a poor connection at theTP sensor and fasten the ITP Assembly if necessary.

Did the ITP Assembly require repair? — Verify repair Go to Step 7




Diagnostic Trouble Code (DTC) P0502 (Flash DTC 24) VSS (Vehicle Speed Sensor) No Signal

060RW136

Circuit Description

The vehicle speed sensor has a magnet rotated by thetransmission output shaft. Attached to the sensor is a halleffect circuit the interacts with the magnetic field treatedby the rotating magnet. A 12-volt operating supply for thespeed sensor hall circuit is supplied from the meter fuse.The VSS pulses to ground the 9-volt signal sent from theengine control module (ECM) on the reference circuit.The ECM interprets vehicle speed by the number ofpulses to ground per second on the reference circuit.







Test Description


10. To avoid backprobing the VSS and possiblydamaging a seal or terminal, the VSS output can betested at the point where the transmission harnessconnected to the engine harness. The green 16-wayconnector is adjacent to a blue 16-way connector,and it can be easily accessed by removing the aircleaner assembly. The green 16-way connector isseparated, and battery voltage is applied to the VSSthrough the yellow wire at one corner of theconnector. The VSS output can be monitored with aDVM connected to the blue wire with a black tracer.The two wires are next to each other in the 16-wayconnector . The test connections are made on thetransmission side of the connector, the side that isnot clipped to the body sheetmetal.

11. The speedometer-to-ECM VSS signal wire isspliced to a wire leading to the cruise controlmodule. If a short to ground or voltage is foundbetween the ECM and speedometer, it could belocated between the splice and the cruise controlmodule.

DTC P0502 –VSS No Signal�



— Go to Step 2


2 Does the speedometer work? — Go to Step 10 Go to Step 3

3 1. Disconnect the VSS connector.


3. Using a test light to battery +, probe the connectorground wire.


4 Repair the sensor ground.


5 1. Ignition “ON,” sensor disconnected.

2. Using a DVM, measure at the VSS connectorbetween ground and voltage supply.

Was the measurement near the specified value?Batteryvoltage Go to Step 7 Go to Step 6

6 Repair the open or short to ground which may haveblown the meter fuse.


7 1. Ignition “ON,” VSS disconnected.

2. Using a DVM, measure at the VSS connectorbetween ground and the blue/black wire from thespeedometer.

Was the measurement near the specified value? 7.5-8 V Go to Step 9 Go to Step 8

8 Check for an open or short circuit between thespeedometer and the VSS.

Was an open or short circuit located? — Verify repair Go to Step 9

9 Replace the VSS.


10 Replace the speedometer.



DTC P0502 –VSS No Signal�� !"#$%&'


11 Check for an open or short between the ECM and thespeedometer.





Diagnostic Trouble Code (DTC) P0510 (Flash DTC 75) Idle SW Malfunction, Open Circuit

060RW134

Circuit Description

The idle switch signal is used by the Engine ControlModule ECM for fuel control.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theIdle SW display on the Tech 2 while moving connectorsand wiring harnesses related to the Idle SW.



DTC P0510 – Idle SW Malfunction, Open Circuit�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the Idle SW circuit for a poor connection andrepair the terminal if necessary.

Did the terminal require repair? — Verify repair Go to Step 4


2. Operate the accel pedal, and check the data list “ONOFF” on the Tech 2.

Is the data list correct? — Verify repair Go to Step 5

5 Replace the Idle SW.



Diagnostic Trouble Code (DTC) P1510 (Flash DTC 75) Idle SW Malfunction Short Circuit

060RW134

Circuit Description

The idle switch signal is used by the Engine ControlModule ECM for fuel control.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theIdle SW display on the Tech 2 while moving connectorsand wiring harnesses related to the Idle SW.



DTC P1510 – Idle SW Malfunction, Short Circuit�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the Idle SW circuit for a poor connection andrepair the terminal if necessary.



2. Operate the accel pedal, and check the data list “ONOFF” on the Tech 2.

Is the data list correct? — Verify repair Go to Step 5

5 Replace the Idle SW.



Diagnostic Trouble Code (DTC) P0562 (Flash DTC 35) System Voltage Too Low

Circuit Description

The engine control module (ECM) monitors the systemvoltage on the ignition feed terminals to the ECM. Asystem voltage DTC will set whenever the voltage isabove a calibrated value.


� The ECM will not illuminate the malfunction indicatorlamp (MIL).

� The ECM will store as Failure Records only conditionswhich were present when the DTC was set. Thisinformation will not be stored as Freeze Frame data.



Diagnostic Aids

If the DTC sets when an accessory is operated, check fora poor connection or defective accessory.

DTC P0562 – System Voltage Too Low�



— Go to Step 2


2 Using a DVM, measure the battery voltage at thebattery.

Is the battery voltage greater than the specified value? 11.5 V Go to Step 3

Chargebattery, thengo to Step 3

3 1. Install a Tech 2.

2. Select “Ignition Volts” on the Tech 2.

3. Start the engine and raise the engine speed to thespecified value.

4. Load the electrical system by turning on theheadlights, high blower, etc.

Is the ignition voltage approximately equal to thespecified value?

2000 RPM12.8-14.1 V Go to Step 4

Go toStarting/Charging


2. Disconnect the ECM connector at the ECM.

3. Using a DVM, measure the battery voltage at theECM connector.

Is it approximately equal to battery voltage? —

Check forexcessive

current drawwith ignition

“OFF,” engine“OFF.” Go to Step 5

5 1. Check for faulty connections at the ECM harnessterminals.

2. Repair as necessary.

Was a repair necessary? — Verify repair Go to Step 6

6 Check for an open battery feed circuit to the ECM.





Diagnostic Trouble Code (DTC) P1562 (Flash DTC 35) System Voltage Too Low at Cranking

Circuit Description

The engine control module (ECM) monitors the systemvoltage on the ignition feed terminals to the ECM. Asystem voltage DTC will set whenever the voltage isabove a calibrated value.


� The ECM will illuminate the malfunction indicator lamp(MIL) at the first time of the fault is detected.



Diagnostic Aids

If the DTC sets when an accessory is operated, check fora poor connection or defective accessory.

DTC P1562 – System Voltage Too Low at Cranking�



— Go to Step 2


2 Using a DVM, measure the battery voltage at thebattery.

Is the battery voltage less than the specified value? 11.5 V Go to Step 3 Go to Step 4

3 1. Charge the battery and clean the battery terminals.

2. Clean the battery ground cable connection ifcorrosion is indicated.

Is the battery voltage less than the specified value? 11.5 VReplacebattery Go to Step 4

4 1. Turn “OFF” all the accessories.

2. Install a Tech 2.

3. Select the ignition voltage parameter on the Tech 2.

4. Start the engine and raise the engine RPM to thespecified value.

Is the voltage more than 2.5 volts greater than themeasurement taken in step 2 or 3? 2000 RPM

Go toStarting/Char

ging Go to Step 5




Diagnostic Trouble Code (DTC) P1587 (Flash DTC 25) Brake SW Malfunction

060RW130

Circuit Description

Brake Stop Lamp SW Circuit receives through Stop Lamp10A fuse from the battery.





Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theBrake SW display on the Tech 2 while movingconnectors and wiring harnesses related to the BrakeSW. A change in the display will indicate the locationof the fault.



DTC P1587 – Brake SW Malfunction�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the Brake SW circuit for a poor connection andreplace the terminal if necessary.


4 Replace the Brake SW.



Diagnostic Trouble Code (DTC) P1588 (Flash DTC 25) Brake SW Malfunction

060RW130

Circuit Description

Brake Stop Lamp SW Circuit receives through Stop Lamp10A fuse from the battery.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe theBrake SW display on the Tech 2 while movingconnectors and wiring harnesses related to the BrakeSW. A change in the display will indicate the locationof the fault.



DTC P1588 – Brake SW Malfunction�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the Brake SW circuit for a poor connection andreplace the terminal if necessary.


4 Replace the Brake SW.



Diagnostic Trouble Code (DTC) P0601 (Flash DTC 55) ECM Checksum Error


� The ECM will not illuminate the malfunction indicatorlamp (MIL).

� The ECM will store conditions which were presentwhen the DTC was set in the Failure Records data only.



Diagnostic Aids

� DTC P0601 indicates that the contents of theEEPROM have changed since the ECM wasprogrammed. The only possible repair is ECMreplacement. Remember to program the replacementECM with the correct software and calibration for thevehicle.

DTC P0601 – ECM Checksum Error�



— Go to Step 2





Diagnostic Trouble Code (DTC) P0650 (Flash DTC 77) Check Engine Lamp Circuit Open/Short

060RW136

Circuit Description

The check engine lamp circuit receives through Meter10A fuse the battery, current flowing in the order of Meterand check engine lamp.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe thelamp test display on the Tech 2 while movingconnectors and wiring harnesses related to the checkengine lamp. A change in the display will indicate thelocation of the fault.

If the Tech 2 indicate DTCs P0650 and P0381, check themeter circuit necessarily.


DTC P0650 – Check Engine Lamp Open/Short�



— Go to Step 2



2. Observe the “Lamp Test” display on the Tech 2.

Is the “Lamp Test” operating? —

Refer toDiagnostic

Aids Go to Step 3





5. If the Tech 2 indicate DTCs P0650 and P0381,check the meter circuit necessarily.


Refer toDiagnostic

Aids

4 Check the Check Engine Lamp circuit for a poorconnection at the Meter and replace the bulb ifnecessary.

Did the bulb require replacement? — Verify repair Go to Step 5

5 Using the Tech 2.

Does the Tech 2 indicate DTC P0650 failed? — Go to Step 6 —

6 Check the Meter circuit for a poor connection.

Did the Meter require repair? — Verify repair Go to Step 7




Diagnostic Trouble Code (DTC) P0654 (Flash DTC 27) Tachometer Circuit Open/Short

060RW136

Circuit Description

The Tach Meter circuit receives through Meter 10A fusefrom the battery, current flowing in the order of Mater andthe Tach Meter.






Diagnostic Aids




� If the Tech 2 indicat DTCs 0654, P0650 and P0381,Check the meter circuit necessarily.


DTC P0654 – Tachometer Circuit Open/Short�



— Go to Step 2







Refer toDiagnostic

Aids

3 Check the Tach meter circuit for a poor connection atthe Meter and replace the terminal if necessary.


4 Using the Tech 2.

Does the Tech 2 indicate DTC P0654 failed? — Verify repair Go to Step 5

5 Check the Tach Meter circuit for a poor connection.


6 Replace the tachometer.





Diagnostic Trouble Code (DTC) P1655 (Flash DTC 17) Thermo Relay Circuit Open/Short

060RW130

Circuit Description

The thermo relay circuit receives current through air con10A fuse from the battery, current flowing in the order ofthe thermo relay and thermo SW.






Diagnostic Aids





DTC P1655 – Thermo Relay Circuit Open/Short�



— Go to Step 2



2. Observe the “Batteri Voltage” display on the Tech 2.

Is the “Batteri Voltage” below the specified value? 11 V Go to Step 4 Go to Step 3




4. Using a Tech 2, monitor the “Specific DTC” info forDTC P1655.


Refer toDiagnostic

Aids

4 Check the Thermo Relay circuit for a poor connectionand replace the terminal if necessary.


5 Check the Thermo Relay for damage.

Did the Thermo Relay require replacement? — Verify repair Go to Step 6

6 Check the Thermo Relay circuit for a poor connectionat the ECM and replace the terminal if necessary.





Diagnostic Trouble Code (DTC) P1657 (Flash DTC 76) ECM Main Relay Circuit Open/Short

060RW135

Circuit Description

The ECM main relay circuit receives current through ECM50A fuse from the battery, current flowing in the order ofthe ECM main relay and ECM.






Diagnostic Aids





DTC P1657 – ECM Main Relay Circuit Open/Short�



— Go to Step 2


2 1. Check the Fuse 50A·ECM and 15A·Eng.

2. If the Fuse is open, replace it as necessary.

Was the Fuse open? — Verify repair Go to Step 3






Refer toDiagnostic

Aids

4 Check the ECM Main Relay circuit between the Fuseand the ECM Main Relay for a poor connection andrepair the terminal if necessary.


5 Check the ECM Main Relay for a damage and Replacethe ECM (Refer to the Data Programming in Case ofECM change) Main Relay if necessary.

Did the ECM Main Relay require replacement? — Verify repair Go to Step 6

6 Check the ECM Main Relay circuit for a poorconnection at the ECM and replace the terminal ifnecessary.


7 Check the ECM Main Relay Ground circuit for a poorconnection and repair the terminal if necessary.


8 Check the ECM Main Relay power circuit for a poorconnection and repair the terminal if necessary.


9 Replace the ECM (Refer to the Data Programming inCase of ECM change) Main Relay.





Diagnostic Trouble Code (DTC) P1589 (Flash DTC 47) Transmission SW Circuit Open/Short

060RW131

Circuit Description

The trans mission SW circuit receives current throughELEC IG 10A fuse from the battery, current flowing in theorder of the trans mission SW and ECM.






Diagnostic Aids



� Damaged harness – Inspect the wiring harness fordamage. If the harness appears to be OK, observe thethrottle position display on the Tech 2 while movingconnectors and wiring harnesses related to the TPsensor. A change in the display will indicate thelocation of the fault.


DTC P1589 – Transmission Circuit Open/Short�



— Go to Step 2


2 Check the Fuse 10A for a open circuit and replace theFuse if necessary.

Did the Fuse require replacement? — Verify repair Go to Step 3


DTC P1589 – Transmission Circuit Open/Short�� !"#$%&'






Does the Tech 2 indicate DTC P1589 failed? —

Go to Step 4(A/T)

Go to Step 6(M/T)

Refer toDiagnostic

Aids

4 Check the Indicator Lamp correct indicated for acorrect indication on the Meter. (A/T only)

Did the Indicator Lamp correct indicated? — Go to Step 5 Go to Step 8

5 Check the Trans Mission SW signal circuit for a poorconnection at the ECM and replace the terminal ifnecessary.


6 Check the Trans Mission SW circuit for a poorconnection at the Trans Mission SW and replace theterminal if necessary.


7 Replace the Trans Mission SW.





Symptom Diagnosis

Preliminary ChecksBefore using this section, perform the “On–BoardDiagnostic (OBD) System Check” and verify all of thefollowing items:

� The powertrain control module (ECM) andmalfunction indicator lamp (MIL) (CHECK ENGINElamp) are operating correctly.

� There are no DTC(s) stored.

� Tech–2 data is within normal operating range. Referto Typical Scan Data Values.

� Verify the customer complaint and locate the correctsymptom in the table of contents. Perform theprocedure included in the symptom chart.

Visual/Physical CheckSeveral of the symptom procedures call for a carefulvisual/physical check. This can lead to correcting aproblem without further checks and can save valuabletime.This check should include the following items:

� ECM grounds for cleanliness, tightness and properlocation.

� Vacuum hoses for splits, kinks, and properconnections, as shown on the “Vehicle EmissionControl Information” label. Check thoroughly for anytype of leak or restriction.

� Air intake ducts for collapsed or damaged areas.

� Injector wires for cracking, hardness, and carbontracking.

� Wiring for proper connections, pinches and cuts.

Intermittents

IMPORTANT: An intermittent problem may or may notturn on the malfunction indicator lamp (MIL) or store aDTC. DO NOT use the Diagnostic Trouble Code (DTC)charts for intermittent problems. The fault must bepresent to locate the problem.

Most intermittent problems are caused by faulty electricalconnections or wiring. Perform a careful visual/physicalcheck for the following conditions:

� Poor mating of the connector halves or a terminal notfully seated in the connector (backed out).

� Improperly formed or damaged terminal.

� All connector terminals in the problem circuit shouldbe carefully checked for proper contact tension.

� Poor terminal–to–wire connection. This requiresremoving the terminal from the connector body tocheck.

Road test the vehicle with a Digital Multimeter(5-8840-0285-0) connected to a suspected circuit. Anabnormal voltage when the malfunction occurs is a goodindication that there is a fault in the circuit beingmonitored.Use a scan tool to help detect intermittent conditions. Thescan tools have several features that can be used tolocate an intermittent condition. Use the following featureto find intermittent faults:

� Using a Tech–2 “Freeze Frame” buffer or “FailureRecords” buffer can aid in locating an intermittentcondition. Review and record the information in thefreeze frame or failure record associated with theintermittent DTC being diagnosed. The vehicle canbe driven within the conditions that were presentwhen the DTC originally set.

To check for loss of diagnostic code memory, disconnectthe MAP sensor and idle the engine until the MIL (CHECKENGINE lamp) comes on. DTC P0107 should be storedand kept in memory when the ignition is turned “OFF.” Ifnot, the ECM is faulty. When this test is completed, makesure that you clear the DTC P0107 from memory.An intermittent MIL (CHECK ENGINE lamp) with nostored DTC may be caused by the following:

� MIL (CHECK ENGINE lamp) wire to ECM shorted toground.

� Poor ECM grounds. Refer to the ECM wiringdiagrams.

Check for improper installation of electrical options suchas lights, cellular phones, etc.Check for an open diode across the A/C compressorclutch and check for other open diodes (refer to wiringdiagrams in Electrical Diagnosis).If problem has not been found, refer to ECM ConnectorSymptom tables.


Hard Start Symptom�


1 DEFINITION:Engine cranks, but does not start for a long time. Doeseventually run, or may start but immediately stalls.

Was the “On-Board Diagnostic (OBD) System Check”performed? — Go to Step 2


2 1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,correct the condition as instructed in the bulletin.

Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3

3 Was a visual/physical check performed?

— Go to Step 4

Go toVisual/Physic

al Check

4 Check engine coolant temperature (ECT) sensor forshift in value. After 8 hours with the hood up and theengine not running, connect the scan tool. With theignition “ON” and the engine not running, compareengine coolant temperature to manifold airtemperature.

Are ECT and MAT within the specified value of eachother? ± 5�C (± 9�F) Go to Step 8 Go to Step 5

5 1. Using Tech–2, display the engine coolanttemperature and note the value.

2. Check the resistance of the engine coolanttemperature sensor.

3. Refer to Engine Coolant Temperature SensorTemperature vs. Resistance chart on DTC P0118Diagnostic Support for resistance specifications.

Is the resistance value near the resistance for thetemperature noted? — Go to Step 7 Go to Step 6



7 Locate and repair high resistance or poor connection inthe ECT signal circuit or the ECT sensor ground.


8 1. Injector Test

Operate the each injector by Tech 2 with theignition “ON” and check if the working noiseconfirm.

2. If a problem is found, check the harness or replacethe injector.


9 Check the oil rail pressure by Tech 2 at the cranking.

Is the pressure near the specified value?

Less than 3MPa Go to Step 10 Go to Step 11

10 Check the oil leakage on the high oil pressure line.

If the oil leakage is found, repair as necessary.

Was the oil leakage found? — Verify repair Go to Step 11

11 1. Check for water-or alcohol-contaminated fuel.




Hard Start Symptom�� !"#$%&'


12 1. Check the battery voltage.



13 1. Check for the following engine mechanicalproblems (Refer to Engine Mechanical):

� Low compression

� Leaking cylinder head gaskets

� Worn or incorrect camshaft

� Camshaft drive belt slipped or stripped



14 1. Review all diagnostic procedures within this table.

2. If all procedures have been completed and nomalfunctions have been found, review/inspect thefollowing:

� Visual/physical inspection

� Tech–2 data

� Freeze Frame data/Failure Records buffer

� All electrical connections within a suspectedcircuit and/or system.


Was a problem found? — Verify repair

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Surges and/or Chuggles Symptom�


1 DEFINITION:Engine power variation under steady throttle or cruise.Feels like the vehicle speeds up and slows down withno change in the accelerator pedal.







— Go to Step 4

Go to Visual/PhysicalCheck

4 Be sure that the driver understands transmissiontorque converter clutch and A/C compressor operationas explained in the owner’s manual.

Inform the customer how the TCC and the A/C clutchoperate.

Is the customer experiencing a normal condition? — System OK Go to Step 5

5 1. Check the priming pump. Refer to Fuel System.

2. If a problem is found, operate the priming pump.


6 1. Injector Test


2. If a problem is found, check the harness and repairas necessary.


7 1. Check ECM grounds for the cleanliness, tightnessand proper locations. Refer to the ECM wiringdiagrams in Electrical Diagnosis.



8 1. Check AP sensor connections.

2. If a problem is found, replace the faulty terminals asnecessary. Refer to Electrical Diagnosis for wiringrepair procedures.


9 1. Visually/physically check vacuum hoses for splits,kinks, and proper connections and routing asshown on the “Vehicle Emission ControlInformation” label.




Surges and/or Chuggles Symptom�� !"#$%&'


10 1. Check the exhaust system for possible restriction:

� Inspect the exhaust system for damaged orcollapsed pipes.

� Inspect the muffler for heat distress or possibleinternal failure.

� Check for a possible plugged catalyticconverter by checking the exhaust systemback pressure. Refer to Restricted ExhaustSystem Check.






� Tech 2 data





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Lack of Power, Sluggish or Spongy Symptom�


1 DEFINITION:Engine delivers less than expected power. Little or noincrease in speed when accelerator pedal is pusheddown part-way.







— Go to Step 4


4 1. Remove and check the air filter element for dirt orrestrictions. Refer to Air Intake System inOn-Vehicle Service.

2. Replace the air filter element if necessary.

Was a repair required? — Verify repair Go to Step 5

5 1. Check AP sensor system. Refer to AP sensordiagnostic.



6 1. Check for water-or alcohol-contaminated fuel.



7 1. Using a Tech 2, Injector test.



8 1. Check the ECM grounds for the cleanliness,tightness and proper locations. Refer to the ECMwiring diagrams in Electrical Diagnosis.






� Check for a possible plugged catalyticconverter by checking the exhaust systemback pressure. Refer to Restricted ExhaustSystem Check.



10 1. Check the torque converter clutch (TCC) for properoperation. Refer to Transmission Diagnosis.




Lack of Power, Sluggish or Spongy Symptom�� !"#$%&'


11 1. Check for an engine mechanical problem. Checkfor low compression, incorrect or worn camshaft,loose timing belt, etc. Refer to Engine Mechanical.






� Tech 2 data





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Rough, Unstable, or Incorrect Idle, Stalling Symptom�


1 DEFINITION:Engine runs unevenly at idle. If severe, the engine orvehicle may shake. Engine idle speed may vary inRPM. Either condition may be severe enough to stallthe engine.





Was a bulletin found that addresses the symptom? — Go to Step 6 Go to Step 3


— Go to Step 4


4 1. Check the ECM grounds for cleanliness, tightnessand proper routing. Refer to the ECM wiringdiagrams in Electrical Diagnosis.



5 1. Check for incorrect idle speed. Ensure that thefollowing conditions are present:

� The engine is fully warm.

� The accessories are “OFF.”

2. Using a Tech 2, monitor the AP position.

Is the AP position within the specified values? 0% Go to Step 10 Go to Step 9

6 1. Visually/physically inspect for the followingconditions:

� Restricted air intake system. Check for apossible collapsed air intake duct, restrictedair filter element, or foreign objects blockingthe air intake system.



7 1. Injector Test




8 1. Check the transmission range switch circuit. Use aTech 2 and be sure the Tech 2 indicates that thevehicle is in drive with the gear selector in drive oroverdrive.

2. If a problem is found, diagnose and repair thetransmission range switch as necessary (Refer toAutomatic Transmission Diagnosis).



Rough, Unstable, or Incorrect Idle, Stalling Symptom�� !"#$%&'


9 1. Check for the following engine mechanical items.

Refer to Engine Mechanical for diagnosisprocedures:

� Low compression

� Sticking or leaking valves

� Worn camshaft lobe(s)



� Valves clearance

� Broken valve springs



10 1. Check for faulty engine mounts. Refer to EngineMechanical for inspection of mounts.






� Tech 2 data





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Poor Fuel Economy Symptom�


1 DEFINITION:Fuel economy, as measured by an actual road test, isnoticeably lower than expected. Also, economy isnoticeably lower than it was on this vehicle at one time,as previously shown by an actual road test. (Larger thanstandard tires will cause odometer readings to beincorrect, and that may cause fuel economy to appearpoor when it is actually normal.)







— Go to Step 4


4 Check owner’s driving habits.

� Is the A/C “ON” full time (defroster mode “ON”)?

� Are tires at the correct pressure?

� Are excessively heavy loads being carried?

� Is acceleration too much, too often?

� Is engine oil correct?

Was a problem found? — Go to Step 5 Go to Step 6

5 Review the items in Step 4 with the customer andadvise as necessary.

Is the action complete? — System OK —

6 1. Visually/physically check: Vacuum hoses for splits,kinks, and improper connections and routing asshown on the “Vehicle Emission ControlInformation” label.



7 1. Remove and check the air filter element for dirt or forrestrictions. Refer to Air Intake System.

2. Replace the air filter element if necessary.


8 1. Check for low engine coolant level. Refer to EngineCooling.



9 1. Check for an incorrect or faulty engine thermostat.Refer to Engine Cooling.



10 1. Check for low engine compression. Refer to EngineMechanical.




Poor Fuel Economy Symptom�� !"#$%&'


11 1. Check the TCC operation. Refer to TransmissionDiagnosis.








13 Check for proper calibration of the speedometer.

Does the speed indicated on the speedometer closelymatch the vehicle speed displayed on the Tech 2? — Go to Step 15 Go to Step 14

14 Diagnose and repair an inaccurate speedometercondition as necessary. Refer to Vehicle SpeedSensor in Electrical Diagnosis.


15 1. Check the air intake system and the crankcase forair leaks. Refer to Air Intake System andCrankcase Ventilation System.




2. When all procedures have been completed and nomalfunctions have been found, review/inspect thefollowing:


� Tech 2 data


� All connections within a suspected circuitand/or system.



17 Perform the procedure in Injector Test.

Was the fuel pressure normal?—

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Excessive Exhaust Emissions or Odors Symptom�


1 DEFINITION:Vehicle fails an emission test. Vehicle has excessive“rotten egg” smell. (Excessive odors do not necessarilyindicate excessive emissions.)






3 Was a thorough visual/physical check performed?

— Go to Step 4


4 1. Check for vacuum leaks. Check vacuum lines,intake manifold, throttle body, etc.


Were any vacuum leaks located? — Verify repair Go to Step 5

5 1. Check the fuel cap for proper installation.

2. Secure the fuel cap if necessary.

Was the fuel cap installed properly? — Go to Step 6 Verify repair

6 1. Injector Test




7 1. Refer to Engine Cooling for cooling systemdiagnosis.



8 1. Check for an engine mechanical problem.

Perform a cylinder compression check (Refer toEngine Mechanical).






� Tech 2 data

� Freeze Frame data/Failure Records butter




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Dieseling, Run-On Symptom�


1 DEFINITION:Engine continues to run after key is turned “OFF,” butruns very rough. If engine runs smooth, check ignitionswitch and adjustment.







— Go to Step 4


4 1. Check for a short between B+ and any of the ignitionfeed circuits.






� Tech 2 data


� All electrical connections within a suspectedcircuit and/or system



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Cuts Out, Symptom�


1 DEFINITION:Steady pulsation or jerking that follows engine speed;usually more pronounced as engine load increases.





Was a bulletin found that addresses the symptom? — Go to Step 7 Go to Step 3


— Go to Step 4


4 1. Check the ECM grounds for clearness, tightnessand proper routing. Refer to the ECM wiringdiagrams in Electrical Diagnosis.



5 1. Check for incorrect idle speed. Ensure that thefollowing conditions are present:

� The engine is fully warm.

� The accessories are “off.”

2. Using a Tech 2, monitor the AP position.

Is the AP position within the specified values? 0% Go to Step 6 Go to Step 7

6 1. Visually/physically inspect for the followingconditions:

� Restricted air intake system. Check for apossible collapsed air intake duct, restrictedair filter element, or foreign objects blockingthe air intake system.

� Check the Throttle body.

� Large vacuum leak. Check for a condition thatcauses a large vacuum leak, such as anincorrectly installed or faulty VSV or brakebooster hose disconnected .



7 Using a Tech 2, monitor the AP angle with the engineidling.

Is the AP angle at the specified value and steady?0% Go to Step 8

Refer to DTCP0123 for

furtherdiagnosis

8 1. Check the transmission range switch circuit. Use aTech 2 and be sure the Tech 2 indicates that thevehicle is in drive with the gear selector in drive oroverdrive.

2. If a problem is found, diagnose and repair thetransmission range switch as necessary.



Cuts Out, Symptom�� !"#$%&'


9 1. Injector Test




10 1. Check the following engine mechanical items.

Refer to Engine Mechanical for diagnosisprocedures:

� Low compression

� Sticking or leaking valves

� Worn camshaft lobe(s)



� Broken valve springs



11 1. Check for faulty motor mounts. Refer to EngineMechanical for inspection of mounts.






� Tech 2 data





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Starter Motor Doesn’t Rotate�


1 DEFINITION:As starter motor doesn’t rotate, engine is not cranked.

1. Perform a bulletin search.


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


— Go to Step 3


3 1. Check battery cord terminal for looseness & poorcontact due to corrosion.

2. Check battery voltage.



4 1. Check fan belt for looseness & damage.

2. If a problem is found, adjust or replace asnecessary.


5 1. Check fuse bull link for disconnection & short.



6 1. Check generator for mount & damage (Refer toEngine Mechanical).



7 1. Check starter SW and starter relay for loosenessand damage.



8 1. Check starter motor for mount and damage. (Referto Engine Mechanical)






� Tech 2 data





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Starting Difficulty In Case Fuel Doesn’t Come to Injector�


1 DEFINITION:Engine is cranked, but not started for a long time. Stepssoon.

Was OBD System check performed? — Go to Step 2


2 1. Perform a bulletin research.


Was a bulletin found? — Verify repair Go to Step 3


— Go to Step 4


4 Check fuel shortage. If short, replenish.

Was fuel short? —Verify

replenish Go to Step 5

5 1. Check fuel pipeline for leak.



6 1. Check fuel pipeline & filter for deformation &clogging.



7 1. Check fuel pump for damage.



8 Check the Injector test by Tech 2.


9 1. Check the injector connector for damage.

2. Check the injector harness for damage.



10 Replace the injector. (Refer to the injector group signprogramming)


11 1. Indicate RPCV Data List by Tech 2 to checkoperation. Perform RPCV test.

2. If a problem is found, replace RP sensor or RPCVas necessary.



Starting Difficulty In Case Fuel Doesn’t Come to Injector�� !"#$%&'





� Tech 2 data





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Lubrication System Trouble�


1 DEFINITION:In road tests oil pressure doesn’t rise, or oil is foul toexcess.






3 1. Check if a correct engine oil is used.

2. If a problem is found, change engine oil.


4 1. Check the oil pressure meter for damage.

2. Check the oil unit harness and connector fordamage.



5 1. Check oil pipe connections for leakage.



6 1. Check oil filter for clogging.



7 1. Check valve clearance.

2. If a problem is found, adjust as necessary.


8 1. Check camshaft bearing for wear.



9 1. Check crankshaft & connecting rod bearings forwear.



10 1. Check oil pump for damage.




Lubrication System Trouble�� !"#$%&'


11 1. Check cylinder head & cam carrier gaskets fordamage.

2. If a problem is found, repair or replace asnecessary.





� Tech 2 data





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QOS System Doesn’t Work�


1 Was OBD System check performed?

— Go to Step 2


2 Check glawplug indicator light. If bulb is broken,replace.


3 1. Connect a circuit tester between glawplug & engineground.

2. With ignition on and engine off, check if the glawindicator and circuit tester indicate power voltagefor 9 to 13 sec. If not indicated, repair terminal & wireharness.

Was repair needed? — Verify repair Go to Step 4

4 1. Connect a circuit tester between glawplug andengine ground.

2. With engine on, check if voltage continues for 180sec. If not, inspect and repair glaw relay.

Was repair needed? — Verify repair Go to Step 5

5 1. Remove the glawplug, and if damaged, replace.

2. Check glawplug resistance.

Was resistance as specified? 0.8 – 1� Go to Step 7 Go to Step 6

6 Replace glawplug.

Was measure completed? — Verify repair Go to Step 7




� Tech 2 data





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Much Black Smoke in Exhaust Gas�


1 DEFINITION:In road tests, much black smoke is mixed.






3 1. Check if a correct fuel is used.

2. If a problem is found, change fuel.


4 1. Check air cleaner element for clogging.



5 1. Connect Tech 2 to the vehicle.

2. Monitor data list to check injector function.




2. Monitor RPCV test to check rpcv function.



7 1. Check valve clearance.

2. If a problem is found, adjust as necessary.


8 1. Review all diagnostic procedures in this table.


� Visual/physical check

� Tech 2 data list

� Freeze Frame data

� All electrical connections in suspected circuits& systems



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Excess Engine Oil Consumption�


1 DEFINITION:Oil consumption measured in road tests is higher thanexpected.






3 1. Check if a correct engine oil is used.

2. If a problem is found, change engine oil.


4 1. Check oil pipe connections for leakage.



5 1. Check oil seals and gaskets for leakage.




2. Perform RPCV test to check its function.



7 1. Check piston ring for damage & groove wear.



8 1. Check valve stem, valve guide and oil controller forwear.



9 1. Check camshaft carrier & cylinder head gaskets forblow-by.



10 1. Review all the diagnostic procedures in this table.


� Visual/physical check

� Tech 2 data list

� Freeze Frame data

� All electrical connections in suspected circuits& systems



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Default Matrix Table

Service Procedure Default StrategyA referral strategy has been established to assist thetechnician with additional information when the cause of

the failure cannot be determined. If no problem is foundafter performing diagnostics, then refer to the defaultmatrix table for further diagnostic information.

Default Matrix Table

Strategy Based Diagnostic Charts Initial Diagnosis Default Section(s)

On-Board Diagnostic (OBD) SystemCheck

Vehicle does not enter diagnostics. Chassis Electrical


Vehicle enters diagnostics andcommunicates with the Tech 2. MIL is“ON” in diagnostics. Engine does notstart and run.

HEUI System Check


Engine starts and runs, no ECM codesset. Customer complains of vibration.

—


Engine starts and runs, no ECM codesset. Customer complains of harsh orsoft shift, poor performance, delayed orno engagement into drive or reverse,transmission fluid leak, transmissionnoise or vibration, or improper TCCoperation.

Automatic Transmission

ECM Power and Ground Check On-Board Diagnostic (OBD) SystemCheck.

Chassis Electrical

ECM Power and Ground Check On-Board Diagnostic (OBD) SystemCheck. ECM power and ground circuitsOK. Data link voltage incorrect.

Chassis Electrical


Engine starts and runs, no ECM codesset. Customer complains of harsh orsoft shift, poor performance, delayed orno engagement into drive or reverse,transmission fluid leak, transmissionnoise or vibration, or improper TCCoperation.

Automatic Transmission

Symptoms Initial Diagnosis Default Section(s)

Intermittents 1. On-board diagnostic (OBD)system check.

2. Careful visual/physical inspections.

Chassis Electrical

Hard Starts 1. OBD system check.

2. Sensors (ECT, MAP, EGR, AP) ;output chart.

3. Fuel system electrical test, fuelsystem diagnosis.

4. Injector system.

Engine Mechanical, InjectorSystem Check, Exhaust SystemDiagnosis

Surges and/or Chuggles 1. OBD system check.

2. Fuel system diagnosis.

3. Injector system.

Calibration ID “Broadcast”/Service Bulletins, IgnitionSystem Check, GeneratorOutput, Exhaust SystemDiagnosis

Lack of Power, Sluggish or Spongy 1. OBD system check.


3. Injector system.

Refer to Exhaust System inEngine Exhaust, TCCOperation, CalibrationID/Service Bulletins


Symptoms Initial Diagnosis Default Section(s)

Hesitation, Sag, Stumble 1. OBD system check.

2. AP.

3. MAP output check.


5. Injector system.

Generator Output Voltage (referto Chassis Electrical),Calibration ID/Service Bulletins,Ignition System Check

Rough, Unstable, or Incorrect Idle,Stalling

1. OBD system check.

2. Fuel injector test.

MAP Output Check, ThrottleLinkage, A/C Clutch ControlCircuit Diagnosis, CalibrationID/Service Bulletins, GeneratorOutput Voltage (refer to ChassisElectrical), Exhaust Diagnosis

Poor Fuel Economy 1. OBD system check.

2. Careful visual/physical inspection.

3. Injector system.

4. Cooling system.

TCC Operation, ExhaustSystem (refer to EngineExhaust)

Engine Cranks But Will Not Run 1. OBD system check. Fuel System ElectricalDiagnosis, Fuel SystemDiagnosis, Fuel Injector Test.

Excessive Exhaust Emissions orOdors

1. OBD system check.

2. Emission test.

3. Cooling system.


5. Fuel injector test.

6. Injector system.

7. MAP output check.

Exhaust Diagnosis, CalibrationID/Service Bulletins

Dieseling, Run-On 1. OBD system check.

2. Careful visual/physical inspection.


—


On–Vehicle Service Camshaft Position (CMP)

Sensor

Removal Procedure

1. Disconnect the negative battery cable.

2. Disconnect the electrical connector to the CMPsensor.

035RW071

3. Remove the CMP sensor retaining bolt from thecylinder head cover.

035RW075

Inspection Procedure

1. Inspect the sensor O-ring for cracks or leaks.

2. Replace the O-ring if it is worn or damaged.

3. Lubricate the new O-ring with engine oil.

4. Install the lubricated O-ring.

Installation Procedure

1. Install the CMP sensor in the cylinder head cover.

2. Install the CMP sensor retaining bolt.

Tighten

� Tighten the retaining bolt to 9 N·m (78 lb in.).

035RW075

3. Connect the electrical connector to the CMP sensor.

035RW071

4. Connect the negative battery cable.


Crankshaft Position (CKP)Sensor

Removal Procedure


2. Remove the under cover.

035RW091

3. Disconnect the electrical connector to the CKPsensor.

4. Remove one bolt and the CKP sensor from the leftside of the engine block.

NOTE: Use caution to avoid any hot oil that might dripout.

035RW090


1. Inspect the sensor O-ring for cracks or leaks.

2. Replace the O-ring if it is worn or damaged.

3. Lubricate the new O-ring with engine oil.

4. Install the lubricated O-ring.


1. Install the CKP sensor in the engine block.

2. Install the CKP sensor mounting bolt.

Tighten

� Tighten the mounting bolt to 9 N·m (78 lb in.).

035RW090

3. Connect the electrical connector to the CKP sensor.

4. Install the under cover.

035RW091



Engine Coolant Temperature(ECT) Sensor

Removal Procedure

NOTE: Care must be taken when handling the enginecoolant temperature (ECT) sensor. Damage to the ECTsensor will affect proper operation of the fuel injectionsystem.


2. Drain the radiator coolant. Refer to Draining andRefilling Cooling System in Engine Cooling.

3. Disconnect the electrical connector.

4. Remove the ECT sensor from the front side of theintake manifold.

035RW058


1. Apply sealer (LOCTITE 262) or the equivalent to thethreads of the ECT sensor.

2. Install the ECT sensor in the front side of the intakemanifold.

Tighten

� Tighten the ECT sensor to 19 N·m (14 lb ft.).

3. Connect the electrical connector.

035RW058

4. Fill the radiator with coolant. Refer to Draining andRefilling Cooling System in Engine Cooling.


Intake Air Temperature (IAT)Sensor

Removal Procedure


2. Disconnect the electrical connector from the IATsensor.

3. Remove the IAT sensor from the intake air duct byusing a rocking motion while pulling the sensor.

035RW056



1. Install the IAT sensor into the grommet in the intakeair duct.

035RW056

2. Correct the IAT electrical connector.


Manifold Absolute Pressure(MAP) Sensor

Removal Procedure


2. Disconnect the EGR valve.

035RW054

3. Disconnect the MAP sensor connector from the MAPsensor.

035RW053

4. Remove the bolts and the MAP sensor from theintake manifold.

035RW057



1. Install the MAP sensor and bolts on the intakemanifold.

Torque: 4 N·m (35 lb in)

035RW057

2. Connect the MAP sensor connector.

035RW053

3. Connect the EGR valve.

035RW054


Oil Temperature (OT) Sensor

Removal Procedure


2. Remove the battery.

035RW095


3. Disconnect the electrical connector from the OTsensor.

4. Remove the OT sensor.

035RW061


1. Install the OT sensor.

035RW061

2. Connect the OT sensor electrical connector.

3. Install the battery.

035RW095


Malfunction Indicator Lamp(MIL)

Removal and Installation ProcedureRefer to Meter in Electrical section.

Engine Control Module (ECM)Service Precaution

NOTE: To prevent possible electrostatic dischargedamage to the ECM, do not touch the connector pins orsoldered components on the circuit board.

When replacing the ECM to prevent possible electrodamage, follow these guidelines:Before removing the ECM, disconnect the negativebattery cable.Before install the ECM, install the negative battery cable.

Electrostatic Discharge (ESD)DamageElectronic components used in the control systems areoften designed to carry very low voltage. Electroniccomponents are susceptible to damage caused byelectrostatic discharge. Less than 100 volts of staticelectricity can cause damage to some electroniccomponents. By comparison, it takes as much as 4,000volts for a person to even feel the zap of a staticdischarge.There are several ways for a person to become staticallycharged. The most common methods of charging are byfriction and by induction. An example of charging byfriction is a person sliding across a car seat.Charging by induction occurs when a person with wellinsulated shoes stands near a highly charged object andmomentarily touches ground. Charges of the samepolarity are drained off leaving the person highly chargedwith the opposite polarity. Static charges can cause


damage, therefore, it is important to use care whenhandling and testing electronic components.

NOTE: To prevent possible Electrostatic Dischargedamage, follow these guidelines:

� Do not touch the control module connector pins orsoldered components on the control module circuitboard.

� Do not open the replacement part package until thepart is ready to be installed.

� Before removing the part from the package, groundthe package to a known good ground on the vehicle.

� If the part has been handled while sliding across theseat, or while sitting down from a standing position, orwhile walking a distance, touch a known good groundbefore installing the part.

NOTE: To prevent internal ECM damage, the ignitionmust be in the “OFF” position in order to disconnect orreconnect power to the ECM (for example: battery cable,ECM pigtail, ECM fuse, jumper cables, etc.).

IMPORTANT: When replacing the production ECMwith a service ECM, it is important to transfer thebroadcast code and production ECM number to theservice ECM label. This will allow positive identification ofECM parts throughout the service life of the vehicle. Donot record this information on the metal ECM cover.

IMPORTANT: The ignition should always be in the“OFF” position in order to install or remove the ECMconnectors.

Service of the ECM should normally consist of either re-placement of the ECM. If the diagnostic procedures callfor the ECM to be replaced, the ECM should be checkedfirst to ensure it is the correct part. If it is, remove thefaulty ECM and install the new service ECM.

DTC P0601 indicates the check sum error.

Removal Procedure


2. Disconnect the ECM connector.

035RW093

3. Remove the bolts ECM bracket and battery bracket.

035RW094

4. Remove the ECM.

035RW092



1. Install the ECM.

035RW092

2. Install the bolts, ECM bracket and battery bracket.

035RW094

3. Connect the ECM connector.

035RW093


If the ECM is replaced, the new ECM will need to beprogrammed.

EEPROM

General DescriptionThe Electronically Erasable Programmable Read OnlyMemory (EEPROM) is a permanent memory that isphysically soldered within the ECM. The EEPROMcontains program and calibration information that theECM needs to control powertrain operation.

Functional Check

1. Perform the On-Board Diagnostic System Check.

2. Start the engine and run for one minute.

3. Scan for DTCs using the Tech 2.

Intake Throttle Position (ITP)Sensor

Removal Procedure



2. Remove the cover of the intercooler.

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3. Remove the bolts and the left side bracket to theintercooler.

4. Remove the air duct with bracket from the intercooler.

5. Remove the throttle body from the intake manifold.

6. Disconnect the ITP sensor electrical connector andthrottle motor control connector.

7. Remove the bolts and the ITP sensor from the throttlebody.

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NOTE: Do not clean the ITP sensor by soaking it insolvent. The sensor will be damaged as a result.

Function CheckUse a Tech 2 to check the ITP sensor output voltage atclosed throttle.

� The voltage should be under 0.85 volt.

� If the reading is greater than 0.85 volt, check thethrottle shaft to see if it is binding.

� If the throttle shaft is not binding and the throttle cableis properly adjusted, install a new ITP sensor.


1. Install the ITP sensor on the throttle body with thebolts.

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2. Install the throttle body to the intake manifold and theair duct with bracket between throttle body andintercooler.

Torque: 20 N·m (14 Ib ft)

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3. Connect the ITP sensor electrical connector andthrottle motor control connector.

4. Install the bracket to the intercooler.

5. Install the cover of intercooler.

6. Install the negative battery cable.


Vehicle Speed Sensor (VSS)

Removal Procedure

CAUTION: The VSS is located on the right side ofthe transfer case just ahead of the rear propellershaft and very close to the exhaust pipes. Be surethat the exhaust pipes are cool enough to touchbefore trying to remove the VSS. If the pipes are hot,you could be burned.


2. Disconnect the VSS electrical connector.

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3. Remove the bolt and the clamp securing the VSS inplace.

IMPORTANT: Have a container ready to catch any fluidthat leaks out when the VSS is removed from the transfercase.

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4. Remove the VSS from the transfer case by wiggling itslightly and pulling it straight out.


1. Inspect the electrical connector for signs of corrosionor warping. Replace the VSS if the electricalconnector is corroded or warped.

2. Inspect the VSS driven gear for chips, breaks, or worncondition. Replace the VSS if the driven gear ischipped, broken or worn.

3. Inspect the O-ring for wear, nicks, tears, orlooseness. Replace the O-ring if necessary.


1. Install the VSS in the transfer case with the notch forthe connector facing the rear.

2. Secure the VSS in place with the clamp and the bolt.

Tighten

� Tighten the bolt to 16 N·m (12 lb ft.).

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3. Connect the VSS electrical connector.

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4. Check the transfer case oil level. Add fluid ifnecessary.



Air Cleaner/Air Filter

Removal Procedure

1. Loosen the clamp between the air cleaner lid and theduct.

2. Release the four latches securing the lid to the aircleaner housing.

3. Remove the air cleaner lid.

4. Remove the air filter element.

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5. Remove the retaining bolts and the air cleanerhousing from the vehicle.


1. Install the air cleaner housing in the vehicle with theretaining bolts.

2. Install the air filter element in the air cleaner housing.

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3. Install the air cleaner lid on the air duct and the aircleaner housing.

4. Tighten the clamp and secure the four latchesbetween the lid and the air cleaner housing.

Accel Position (AP) Sensor

Removal Procedure


2. Disconnect the electrical connector to the AP sensor.

3. Remove the bolts and the accelerator pedalassembly from the bulkhead.

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4. Remove the bolts and AP sensor from the acceleratorpedal assembly.

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1. Install the AP sensor to the accelerator pedalassembly.

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2. Install the accelerator pedal assembly to thebulkhead.

3. Connect the electrical connector to the AP sensor.

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Accelerator Pedal Replacement

Removal Procedure


2. Disconnect the electrical connector to the AP sensor.

3. Remove the bolts and the accelerator pedalassembly from the bulkhead.

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4. Remove the bolts and AP sensor from the acceleratorpedal assembly.

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1. Install the AP sensor to the accelerator pedalassembly.

2. Install the accelerator pedal assembly to thebulkhead.


3. Connect the electrical connector to the AP sensor.

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Fuel Filter Cap

General DescriptionThe fuel filler cap includes a vacuum valve and a pressurevalve.If high vacuum or high pressure occurs in the fuel tank,each valve works to adjust the pressure in order toprevent damage to the tank at the EGR valve.

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NOTE: Replace the fuel filler cap with the same type offiller cap that was originally installed on the vehicle.

� Check the seal ring in the filler cap for any abnormalityand for seal condition.

� Replace the filler cap if any abnormality is found.

Fuel Filter

Removal and Installation ProcedureRefer to the Engine fuel in the 4JX1 Engine section.

Fuel Gauge Unit

Removal Procedure


2. Loosen the fuel filler cap.

3. Drain the fuel from the tank.

Tighten

� Tighten the drain plug to 20 N·m (14 lb ft.).

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4. Disconnect the wiring connector from the fuel gaugeunit.

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5. Remove the fuel gauge unit retaining screws.


6. Remove the fuel gauge unit.

� Cover or plug the fuel tank to prevent dust, dirt, ordebris from entering the tank.

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1. Install the fuel gauge unit.

2. Install the fuel gauge unit retaining screws.

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3. Connect the wiring connector to the fuel gauge unit.

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4. Fill the fuel tank with fuel.

� Tighten the fuel filler cap.

� Check for leaks at the fuel gauge unit gasket.


Fuel Injectors

Removal and Installation ProcedureRefer to Engine Fuel in 4JX1 Engine Section.

Fuel Temperature Sensor

Removal Procedure

CAUTION: To reduce the risk of fire and personalinjury, it is necessary to relieve the fuel systempressure before servicing the fuel systemcomponents.

CAUTION: After relieving the system pressure, asmall amount of fuel may be released when servicingfuel lines or connections. Reduce the chance ofpersonal injury by covering the fuel line fittings witha shop towel before disconnecting the fittings. Thetowels will absorb any fuel that may leak out. Whenthe disconnect is completed, place the towel in anapproved container.


2. Remove the intercooler assembly.

3. Remove the cylinder head. Refer to enginemechanical section.


4. Remove the rear side engine hanger.

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5. Remove the fuel return adapter.

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6. Remove the fuel pressure sensor from the fuel returnadapter.

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1. Install the fuel pressure sensor in the fuel returnadapter.

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2. Install the fuel return adapter.

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3. Install the rear side engine hanger. Tighten the rearside engine hanger fixing bolts to specified torque.

Torque: 19 N·m (14 lb ft)

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4. Install the cylinder head. Refer to engine mechanicalsection.

5. Install the intercooler assembly.


Rail Pressure (RP) Sensor

Removal Procedure


2. Remove the air cleaner cover and air duct.

3. Remove the intercooler assembly.

4. Remove the injector oil pipe.

5. Remove the intake throttle valve.

6. Remove the cylinder head cover noise inselation.

7. Remove the cylinder head cover.

8. Remove the RP sensor.

Installation Procedure� Refer to the RP Sensor Programming.

1. Install the RP sensor.

2. Install the cylinder head cover.

3. Install the cylinder head cover noise inselation.

4. Install the intake throttle valve.

5. Install the injector oil pipe.

6. Install the intercooler assembly and tightenintercooler assembly fixing bolts to specified torque.

Torque: 20 N·m (14 lb ft)

7. Install the air cleaner cover and air duct.


Fuel Tank

Removal ProcedureRefer toEngine Fuel in 4JX1 Engine section.

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Throttle Body (TB)

Removal Procedure


2. Remove the cover of the intercooler.

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3. Remove the bolts and the left side bracket to theintercooler.

4. Remove the air duct with bracket from the intercooler.

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5. Remove the throttle body assembly from the intakemanifold.

6. Disconnect the ITP sensor electrical connector.


NOTE: Do not use solvent of any type when you clean thegasket surfaces on the intake manifold and the throttlebody assembly. The gasket surfaces and the throttle bodyassembly may be damaged as a result.

� If the throttle body gasket needs to be replaced,remove any gasket material that may be stuck to themating surfaces of the manifold.

� Do not leave any scratches in the aluminum casting.

1. Install the throttle body assembly to the intakemanifold and the air duct with bracket betweenthrottle body and intercooler.

Torque: 20 N·m (14 Ib ft)

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2. Connect the ITP sensor electrical connector andthrottle motor control connector.

3. Install the bracket to the intercooler.

4. Install the cover of intercooler.


Air Conditioning (A/C) Relay

Removal Procedure

1. Remove the fuse and relay box cover from under thehood.

2. Consult the diagram on the cover to determine whichis the correct relay.

3. Pull the relay straight up and out of the fuse and relaybox.


1. Insert the relay into the correct place in the fuse andrelay box with the catch slot facing forward.

2. Press down until the catch engages.

� An audible “click” will be heard.

3. Install the fuse and relay box cover.

Exhaust Gas Recirculation(EGR) Vacuum Switch Valve

(VSV)

Removal Procedure



2. Disconnect the EGR VSV connector and vacuumhose from the EGR VSV.

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3. Remove the MAP sensor assembly and EGR VSV.

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4. Remove the EGR VSV from the MAP sensor bracket.

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1. Install the EGR VSV and tighten nut to specifiedtorque.


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2. Install the MAP sensor assembly and EGR VSV andtighten MAP sensor bracket fixing bolts specifiedtorque.


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3. Connect the EGR VSV connector and vacuum hosein the EGR VSV.

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Electronic Vacuum ReguratingValve (EVRV)

Removal Procedure


2. Disconnect the EVRV hose and the EVRV connector.

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3. Remove the EVRV.

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1. Install the EVRV.

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2. Connect the EVRV hose and the EVRV connector.

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Wiring and Connectors

Wiring Harness ServiceThe ECM harness electrically connects the ECM to thevarious solenoids, switches and sensors in the vehicleengine compartment and passenger compartment.Replace wire harnesses with the proper part numberreplacement.Because of the low amperage and voltage levels utilizedin powertrain control systems, it is essential that all wiringin environmentally exposed areas be repaired with crimpand seal splice sleeves.

The following wire harness repair information is intendedas a general guideline only. Refer to Chassis Electrical forall wire harness repair procedures.

Connectors and TerminalsUse care when probing a connector and when replacingterminals. It is possible to short between oppositeterminals. Damage to components could result. Alwaysuse jumper wires between connectors for circuitchecking. NEVER probe through Weather-Pack seals.Use an appropriate connector test adapter kit whichcontains an assortment of flexible connectors used toprobe terminals during diagnosis. Use an appropriatefuse remover and test tool for removing a fuse and toadapt the fuse holder to a meter for diagnosis.Open circuits are often difficult to locate by sight becauseoxidation or terminal misalignment are hidden by theconnectors. Merely wiggling a connector on a sensor, orin the wiring harness, may temporarily correct the opencircuit. Intermittent problems may also be caused byoxidized or loose connections.Be certain of the type of connector/terminal beforemaking any connector or terminal repair. Weather-Packand Com-Pack III terminals look similar, but are serviceddifferently.

Wire Harness Repair: TwistedShielded Cable

Removal Procedure

1. Remove the outer jacket.

2. Unwrap the aluminum/mylar tape. Do not remove themylar.

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3. Untwist the conductors.

4. Strip the insulation as necessary.

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1. Splice the wires using splice clips and rosin coresolder.

2. Wrap each splice to insulate.

3. Wrap the splice with mylar and with the drain(uninsulated) wire.

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4. Tape over the whole bundle to secure.

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Twisted Leads

Removal Procedure

1. Locate the damaged wire.

2. Remove the insulation as required.

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1. Use splice clips and rosin core solder in order to splicethe two wires together.

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2. Cover the splice with tape in order to insulate it fromthe other wires.

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3. Twist the wires as they were before starting thisprocedure.

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4. Tape the wires with electrical tape. Hold in place.

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Weather-Pack Connector

Tools Required5-8840-0388-0 Weather-Pack II Terminal Remover

Removal ProcedureA Weather-Pack connector can be identified by a rubberseal at the rear of the connector. This engine roomconnector protects against moisture and dirt, which couldfrom oxidation and deposits on the terminals. Thisprotection is important, because of the low voltage andthe low amperage found in the electronic systems.

1. Open the secondary lock hinge on the connector.

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2. Use tool 5-8840-0388-0 or the equivalent to removethe pin and the sleeve terminals. Push on5-8840-0388-0 to release.

NOTE: Do the use an ordinary pick or the terminal maybe bent or deformed. Unlike standard blade terminals,these terminals cannot be straightened after they havebeen improperly bent.

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3. Cut the wire immediately behind the cable seal.

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Installation ProcedureMake certain the connectors are properly seated and allof the sealing rings are in place when you reconnect theleads. The secondary lock hinge provides a backuplocking feature for the connector. The secondary lockhinge is used for added reliability. This flap should retainthe terminals even if the small terminal lock tangs are notpositioned properly.Do not replace the Weather-Pack connections withstandard connections. Read the instructions providedwith the Weather-Pack connector and terminal packages.

1. Replace the terminal.

2. Slip the new seal onto the wire.

3. Strip 5 mm (0.2”) of insulation from the wire.

4. Crimp the terminal over the wire and the seal.

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5. Push the terminal and the connector to engage thelocking tangs.

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6. Close the secondary locking hinge.

Com-Pack III

General InformationThe Com-Pack III terminal looks similar to someWeather-Pack terminals. This terminal is not sealed andis used where resistance to the environment is notrequired. Use the standard method when repairing aterminal. Do not use the Weather-Pack terminal tool5-8840-0388-0 or equivalent. These will damage theterminals.

Metri-Pack

Tools Required5-8840-0632-0 Terminal Remover

Removal ProcedureSome connectors use terminals called Metri-Pack Series150. These may be used at the engine coolanttemperature (ECT) sensor.

1. Slide the seal (1) back on the wire.

2. Insert the 5-8840-0632-0 tool or equivalent (3) inorder to release the terminal locking tang (2).

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3. Push the wire and the terminal out through theconnector. If you reuse the terminal, reshape thelocking tang.

Installation ProcedureMetri-Pack terminals are also referred to as “pull-to-seat”terminals.

1. In order to install a terminal on a wire, the wire must beinserted through the seal (2) and through theconnector (3).

2. The terminal (1) is then crimped onto the wire.

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3. Then the terminal is pulled back into the connector toseat it in place.


General Description (ECM and Sensors)

57X Reference ECM Input

The engine control module (ECM) uses this signal fromthe crankshaft position (CKP) sensor to calculate engineRPM and crankshaft position at all engine speeds. TheECM also uses the pulses on this circuit to initiate injectorpulses. If the ECM receives no pulses on this circuit, DTCP0337 will set. The engine will not start and run withoutusing the 57X reference signal.

A/C Request Signal

This signal tells the ECM when the A/C mode is selectedat the A/C control head.Refer to A/C Clutch Circuit Diagnosis for A/C wiringdiagrams and diagnosis for the A/C electrical system.

Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor provides a signalused by the engine control module (ECM) to calculate theignition sequence. The CKP sensor initiates the 57Xreference pulses which the ECM uses to calculate RPMand crankshaft position.Refer to Electronic Ignition System for additionalinformation.

Camshaft Position (CMP) Sensor andSignal

The camshaft position (CMP) sensor sends a CMP signalto the ECM. The ECM uses this signal as a “cylinderdistinction” to trigger the injectors in the power order. If theECM detects an incorrect CMP signal while the engine isrunning, DTC P0341 will set, and the ECM triggers theinjectors in the power order.Refer to DTC P0341.

Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor is athermistor (a resistor which changes value based ontemperature) mounted in the engine coolant stream. Lowcoolant temperature produces a high resistance of100,000 ohms at –40�C (–40�F). High temperaturecauses a low resistance of 70 ohms at 130�C (266�F).The ECM supplies a 5-volt signal to the ECT sensorthrough resistors in the ECM and measures the voltage.The signal voltage will be high when the engine is cold andlow when the engine is hot. By measuring the voltage, theECM calculates the engine coolant temperature. Enginecoolant temperature affects most of the systems that theECM controls.The Tech 2 displays engine coolant temperature indegrees. After engine start-up, the temperature shouldrise steadily to about 85�C (185�F). It then stabilizeswhen the thermostat opens. If the engine has not beenrun for several hours (overnight), the engine coolant

temperature and intake air temperature displays shouldbe close to each other. A hard fault in the engine coolantsensor circuit will set DTC P0117 or DTC P0118.

0016

Electrically Erasable Programmable ReadOnly Memory (EEPROM)

The electrically erasable programmable read onlymemory (EEPROM) is a permanent memory chip that isphysically soldered within the ECM. The EEPROMcontains the program and the calibration information thatthe ECM needs to control powertrain operation.Unlike the PROM used in past applications, the EEPROMis not replaceable. If the ECM is replaced, the new ECMwill need to be programmed. Equipment containing thecorrect program and calibration for the vehicle is requiredto program the ECM.

Intake Air Temperature (IAT) Sensor

The intake air temperature (IAT) sensor is a thermistorwhich changes its resistance based on the temperature ofair entering the engine. Low temperature produces a highresistance of 100,000 ohms at –40�C (–40�F). Hightemperature causes low resistance of 70 ohms at 130�C(266�F) . The ECM supplies a 5-volt signal to the sensorthrough a resistor in the ECM and monitors the signalvoltage. The voltage will be high when the incoming air iscold. The voltage will be low when the incoming air is hot.By measuring the voltage, the ECM calculates theincoming air temperature.The Tech 2 displays the temperature of the air enteringthe engine. The temperature should read close to theambient air temperature when the engine is cold and riseas underhood temperature increases. If the engine hasnot been run for several hours (overnight), the IAT sensortemperature and engine coolant temperature should readclose to each other. A fault in the IAT sensor circuit will setDTC P0112 or DTC P0113.


0018

Manifold Absolute Pressure (MAP) Sensor

The manifold absolute pressure (MAP) sensor respondsto changes in intake manifold pressure. The MAP sensorsignal voltage to the ECM varies from below 2 volts at idle(high vacuum) to above 4 volts.The MAP sensor is used to determine the following:

� Boost pressure for injector control.

� Barometric pressure (BARO).

If the ECM detects a voltage that is lower than thepossible range of the MAP sensor, DTC P0107 will be set.A signal voltage higher than the possible range of thesensor will set DTC P0108. An intermittent low or highvoltage will set DTC P1107 or DTC P1106, respectively.The ECM can detect a shifted MAP sensor. The ECMcompares the MAP sensor signal to a calculated MAPbased on throttle position and various engine load factors.If the ECM detects a MAP signal that varies excessivelyabove or below the calculated value, DTC P0106 will set.

Engine Control Module (ECM)

The engine control module (ECM) is located in the engineroom.The ECM constantly observes the information fromvarious sensors. The ECM controls the systems thataffect vehicle performance. The ECM performs thediagnostic function of the system. It can recognizeoperational problems, alert the driver through the MIL(Service Engine Soon lamp), and store diagnostic troublecodes (DTCs). DTCs identify the problem areas to aid thetechnician in making repairs.

ECM Function

The ECM supplies 5, 12 and 110 volts to power varioussensors or switches. The power is supplied throughresistances in the ECM which are so high in value that atest light will not light when connected to the circuit. Insome cases, even an ordinary shop voltmeter will not givean accurate reading because its resistance is too low.Therefore, a digital voltmeter with at least 10 megohmsinput impedance is required to ensure accurate voltagereadings. The ECM controls output circuits such as the

injectors, glow relays, etc., by controlling the ground orthe power feed circuit through transistors or througheither of the following two devices:

� Output Driver Module (ODM)

� Quad Driver Module (QDM)

ECM Components

The ECM is designed to maintain exhaust emission levelsto government mandated standards while providingexcellent driveability and fuel efficiency. The ECMmonitors numerous engine and vehicle functions viaelectronic sensors such as the crankshaft position (CKP)sensor, and vehicle speed sensor (VSS). The ECM alsocontrols certain engine operations through the following:

� Fuel injector control

� Rail pressure control

ECM Voltage Description

The ECM supplies a buffered voltage to various switchesand sensors. It can do this because resistance in theECM is so high in value that a test light may not illuminatewhen connected to the circuit. An ordinary shopvoltmeter may not give an accurate reading because thevoltmeter input impedance is too low. Use a 10-megohminput impedance digital voltmeter to assure accuratevoltage readings.The input/output devices in the ECM includeanalog-to-digital converters, signal buffers, counters,and special drivers. The ECM controls most componentswith electronic switches which complete a ground circuitwhen turned “ON.” These switches are arranged ingroups of 4 and 7, called either a surface-mounted quaddriver module (QDM), which can independently control upto 4 output terminals, or QDMs which can independentlycontrol up to 7 outputs. Not all outputs are always used.

ECM Input/Outputs

Inputs – Operating Conditions Read

� Air Conditioning “ON” or “OFF”

� Engine Coolant Temperature

� Crankshaft Position

� Electronic Ignition

� Manifold Absolute Pressure

� Battery Voltage

� Intake Throttle Position

� Vehicle Speed

� Fuel Temperature

� Oil Temperature

� Intake Air Temperature

� EGR boost pressure

� Oil rail pressure

� Camshaft Position

� Accelerator position

Outputs – Systems Controlled

� Exhaust Gas Recirculation (EGR)

� Injector Control

� QWS


� QOS

� Diagnostics

– Malfunction Indicator Lamp (Service EngineSoon lamp)

– Data Link Connector (DLC)

– Data Output

ECM Service Precautions

The ECM is designed to withstand normal current drawsassociated with vehicle operation. Avoid overloading anycircuit. When testing for opens and shorts, do not groundor apply voltage to any of the ECM’s circuits unlessinstructed to do so. These circuits should only be testedusing digital voltmeter. The ECM should remainconnected to the ECM or to a recommended breakoutbox.

Intake Throttle Position (ITP) Sensor

ITP sensor is a potentiometer type and installed to theintake throttle valve body. A voltage of 5V is appliedconstantly from ECM to ITP sensor thereby to determineby change in voltage the opening of the intake throttlevalve during warming up.

Transmission Range Switch

IMPORTANT: The vehicle should not be driven with thetransmission range switch disconnected; idle quality willbe affected.

The four inputs from the transmission range switchindicate to the ECM which position is selected by thetransmission selector lever.For more information on the transmission on thetransmission range switch, refer to AutomaticTransmission.

Accelerator Position Sensor (AP)

AP sensor is a potentiometer type and installed toaccelerator pedal bracket. A voltage of 5V constantlyapplied from ECM to the sensor thereby to determine theaccelerator pedaling angle by change in voltage. Further,this sensor is provided with an accelerator switch, whichis set off only when the accelerator pedal is stepped on.

Aftermarket Electrical and VacuumEquipment

Aftermarket (add-on) electrical and vacuum equipment isdefined as any equipment which connects to the vehicle’selectrical or vacuum systems that is installed on a vehicleafter it leaves the factory. No allowances have beenmade in the vehicle design for this type of equipment.

NOTE: No add-on vacuum equipment should be addedto this vehicle.

NOTE: Add-on electrical equipment must only beconnected to the vehicle’s electrical system at the battery(power and ground).

Add-on electrical equipment, even when installed tothese guidelines, may still cause the powertrain system tomalfunction. This may also include equipment notconnected to the vehicle electrical system such as

portable telephones and radios. Therefore, the first stepin diagnosing any powertrain problem is to eliminate allaftermarket electrical equipment from the vehicle. Afterthis is done, if the problem still exists, it may be diagnosedin the normal manner.

Electrostatic Discharge Damage

Electronic components used in the ECM are oftendesigned to carry very low voltage. Electroniccomponents are susceptible to damage caused byelectrostatic discharge. Less than 100 volts of staticelectricity can cause damage to some electroniccomponents. By comparison, it takes as much as 4000volts for a person to feel even the zap of a staticdischarge.

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There are several ways for a person to become staticallycharged. The most common methods of charging are byfriction and induction.

� An example of charging by friction is a person slidingacross a vehicle seat.

� Charge by induction occurs when a person with wellinsulated shoes stands near a highly charged objectand momentary touches ground. Charges of thesame polarity are drained off leaving the personhighly charged with the opposite polarity. Staticcharges can cause damage, therefore it is importantto use care when handling and testing electroniccomponents.

NOTE: To prevent possible electrostatic dischargedamage, follow these guidelines:

� Do not touch the ECM connector pins or solderedcomponents on the ECM circuit board.

� Do not open the replacement part package until thepart is ready to be installed.

� Before removing the part from the package, groundthe package to a known good ground on the vehicle.

� If the part has been handled while sliding across theseat, while sitting down from a standing position, orwhile walking a distance, touch a known good groundbefore installing the part.


General Description (Air Induction)

Air Induction System

The air induction system filters contaminants from theoutside air, and directs the progress of the air as it isdrawn into the engine. A remote-mounted air cleanerprevents dirt and debris in the air from entering theengine. The air duct assembly routes filtered air to thethrottle body. Air enters the engine by to following steps:

1. Through the throttle body.

2. Into the intake manifold.

3. Through the cylinder head intake ports.

4. Into the cylinders.

General Description (Fuel Metering)

Deceleration Mode

The ECM reduces the amount of fuel injected when itdetects a decrease in the Accelerator position.

Fuel Injector

Fuel injector comprises the solenoid, hydraulic line, andfuel line. Fuel injection is controlled by the continuity timesignal and continuity start timing signal from ECM to thesolenoidECM determines the running conditions of engine byinput signals such as engine speed. Accelerator throttlevalve opening, and engine coolant temperature, therebyto send the solenoid the best suited signal to the enginestatus. When current is carried to the solenoid, thearmature opens the poppet valve to alow high pressure oilto run into the injector. Under the pressure of the oil, thepiston and plunger are depressed to compress the fuel inthe combustion chamber of the plunger. Specifically, thepressure of the fuel compressed is increased by a pistontop/ plunger bottom area ratio over the pressure of highpressure oil, thereby lifting the fuel nozzle end needle forinjecting fuel.

Fuel Metering System Components

The fuel metering system is made up of the followingparts:

� The fuel injectors.

� The intake throttle body.

� The Accelerator position (AP) sensor

� The ECM.

� The crankshaft position (CKP) sensor.

� The camshaft position (CMP) sensor.

Basic System Operation

Fuel is supplied through fuel filter to the fuel pump.The fuel pump is installed to the oil pump, and fuel isforced, through the fuel pump outlet, pipe and cylinderhead inside, into the fuel injector.An orifice is provided at the rear fuel outlet of cylinderhead to control the pressure of oil.

The injector is controlled by ECM which givesopening/closing commands to the solenoid installed onthe top of the injector. Opening/closing operation of thepressurized engine oil circuit of the injector controls fuelinjection quantity, fuel injection timing, etc.

A/C Clutch Diagnosis

A/C Request Signal

This signal tells the ECM when the A/C mode is selectedat the A/C control head. The ECM uses this to adjust theidle speed.Refer to A/C Clutch Circuit Diagnosis for A/C wiringdiagrams and diagnosis for A/C electrical system.

General Description Exhaust GasRecirculation (EGR) System

EGR Purpose

The exhaust gas recirculation (EGR) system is use toreduce emission levels of oxides of nitrogen (NOx). NOxemission levels are caused by a high combustiontemperature. The EGR system lowers the NOx emissionlevels by decreasing the combustion temperature.The ECM uses information from the following sensors tocontrol EGR valve boost pressure.

� ECT

� ITP

� Engine Speed

� AP sensor


Fuse and Relay Panel (Underhood Electrical Center) RHD

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Fuse and Relay Panel (Underhood Electrical Center) LHD

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4JX1–TC 3.0L ENGINE DRIVEABILITY AND...

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