Isuzu Dmax Engine Service Manual

WORKSHOP MANUAL
TF SERIES
ENGINE
4JA1/4JH1-TC
SECTION 6
TROUBLESHOOTING 6 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE
BASIC INSPECTION PROCEDURE ... 6 2
1. HARD STARTING ........................... 6 3

1-1.Starter Motor Inoperative ......... 6 3
1-2. Starter Motor Operates But

Engine Does Not Turn Over .......... 6 3
1-3. Engine Turns Over But Does

Not Start Engine ............................. 6 4
PAGE
11. ROTATING PART WEAR OF

TURBOCHARGER ............................. 6 14
12. OIL LEAKAGE FROM

TURBOCHRGER ............................... 6 15
13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER ....................... 6 15
2. UNSTABLE IDLING ........................ 6 5
14. BATTERY CHARGING AND

NOISE PROBLEM.............................. 6 16
4. EXCESSIVE FUEL
CONSUMPTION................................. 6 7
14-2. Battery Overcharging ............ 6 16
3. INSUFFICIENT POWER ................. 6 6
5. EXCESSIVE OIL CONSUMPTION.. 6 8
6. OVERHEATING............................... 6 9
7. WHITE EXHAUST SMOKE ............. 6 9
8. DARK EXHAUST SMOKE .............. 6 10

9. OIL PRESSURE DOES NOT RISE . 6 11
10. ABNORMAL ENGINE NOISE ....... 6 12
10-1. Engine Knocking.................... 6 12

10-2. Gas Leakage Noise ................ 6 12
10-3. Continuous Noise .................. 6 13
10-4. Slapping Noise ....................... 6 13
10-5. Excessive Turbocharger

Noise ............................................... 6 14
14-1. Battery No Charging .............. 6 16

14-3. Battery Under Charging......... 6 17
14-4. Battery Unstable Charging

Current ............................................ 6 17
14-5. Charging System Noise......... 6 18
15. STARTER MOTOR PROBLEM..... 6 19
15-1. Starter Motor Pinion Engages

to Ring Gear But Engine Does
Not Turn Over ................................. 6 19
15-2. Incorrect Pinion And Ring
Gear Engagement .......................... 6 19
15-3. Starter Motor Continues To

Run After The Starter Switch Is
Turned Off....................................... 6 20
15-4. Excessive Commutator

Sparking.......................................... 6 20
6 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step
1
Inspection point
Check the check engine lamp
Inspection result
Is the check engine lamp turn

ON ?
The battery fluid level and the Was the problem found?
gravity
The engine coolant capacity
Was the problem found?
The engine oil level
The air cleaner element
The piping fixing condition (oil, Was the problem found?

vacuum and fuel piping)
7
8
9
The drive belt tension and break
Go to section 6E On Board Was the problem found?

Diagnostic
(OBD)
System
Check
Go
to
mechanical Was the problem found?
troubleshooting chart
YES
Go to section
6E On Board
Diagnostic
(OBD) System
Check"
Re-charge the
battery or
replace the
battery
Replenish the
engine coolant
Replenish the
engine oil
Clean or
replace
Return normal
condition
NO
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Re-adjust the
tension or
replace
Go to Step 8
Verify repair
Go to Step 9
Verify repair
TROUBLESHOOTING 6 3
1. Hard Starting
Inspect the following items before diagnosis.

1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
11 Starter motor inoperative
Step
1
2
3
4
5
Action
Check the starter switch.

Does the starter switch work?
Check the starter relay.

Does the starter relay work?
Check the magnetic switch.

Does the magnetic switch work?
Check the pinion gear condition on the starter motor.

Was the condition normal?
Check the brush wear or brush spring weakness.
Was the condition normal?
1-2 Starter motor operates but engine does not turn over
Step
Value(s)
Action
Check the engine internal seizure.

Was the engine seized?
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
No
Repair or
replace the
starter switch
Repair or
replace the
starter relay
Repair or
replace the
magnetic
switch
Replace the
pinion gear
Replace the
starter motor
assembly
Repair or
replace the
brush or brush
spring
Yes
No
Repair or
replace seized
parts
Check other
DTC by Tech
2 and go to
indicated DTC
6 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump

Step
1
2
3
4
5
Action
Check clogged, damaged the fuel piping or the

connector loosen.
Was any problem found?
Was the over flow valve on the fuel filter closed?
Was the fuel filter element clogged?
Was the fuel line air bled?
Are any DTC stored?
Incase of the fuel is being delivered to the injection pump

Step
Action
Was the water contain in the fuel?
Was the fuel line air bled?
3
4
Was the injection spray condition complete?

Was the injection nozzle injection starting pressure
OK?
Value(s)
No
Repair replace
problem parts.
Go to Step 2
Repair replace
the over flow
valve
Go to Step 3
Replace the
fuel filter
element
Go to Step 4
Go to indicated
DTC
Solved
Value(s)
Yes
(See below)
Was the injection nozzle sticking?
Are any DTC stored?
Injection nozzle opening pressure

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
Yes
Go to Step 5
Bleed the air
No
Replace the
fuel
Go to Step 2
Go to Step 4
Replace the
injection nozzle
Go to Step 5
Replace the
injection nozzle
Go to Step 5
Replace the
injection nozzle
Go to indicated
DTC
Bleed the air
Go to Step 6
Solved
TROUBLESHOOTING 6 5
2. Unstable Idling
Step
1
2
Action
Was the fuel line air bled completely?
Was the fuel line leakage or blockage found?
Value(s)
Was the water contained in the fuel?
Was the fuel filter element clogged?
Was the injection starting pressure or the injection

spray condition OK?
(See below)
Was the injection nozzle sticking?
See Step 6
Check the throttle valve condition.

Was the idling port clogged in the throttle valve?
10
Was the valve clearance improper adjusted?
Was the compression pressure OK?
Are any DTC stored?

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
0.4 mm
(0.016 in)
both intake
and exhaust
valves
3,040 kPa
2
(31 kg/cm ,
441 psi) at
200rpm
Yes
Go to Step 3
Repair or
replace relation
parts.
Replace the
fuel
No
Bleed the air

Go to Step 4
Go to Step 5
Replace the
fuel filter
element
Go to Step 6
Go to Step 7
Replace the
injection nozzle
Replace the
injection nozzle
Go to Step 8
Repair or
replace the
throttle valve
Go to Step 9
Adjust the
valve clearance
Go to Step 10
Go to Step 11
Go to indicated
DTC
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Solved
6 6 TROUBLESHOOTING
3. Insufficient Power
Step
1
3
4
5
6
8
9
10
11
12
13
Action
Was the air cleaner element condition OK? (Clogged

or not)
Was the intake air leakage found from intake
system?
Value(s)
Was the fuel filter element condition OK? (Clogged

or not)
Check the fuel injection pipes.

Does the injection pipes have obstruction or any
damage?
Was the water contained in the fuel?
Was the injection nozzle pressure or spray pattern

normal?
Was the exhaust pipe clogged?

Was the exhaust gas leakage found from exhaust
system?
Was the waste gate control actuator hose broken or
cracked?
Was the waste gate working completely?
Was turbocharger working completely?
Are any DTC stored?
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
Go to Step 2
Repair or
replace the
intake air
system.
Go to Step 4
Repair or
replace the fuel
injection pipes.
Replace the
fuel
Go to Step 7
Go to Step 8
Repair or
replace the
exhaust pipe.
Repair or
replace the
exhaust
system.
Replace the
hose.
Go to Step 12
Go to Step 13
Go to indicated
DTC
No
Clean or
replace the air
cleaner
element.
Go to Step 3
Clean or
replace the fuel
filter element.
Go to Step 5
Go to Step 6
Readjust the
injection nozzle
pressure or
replace the
nozzle.
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to Step 9
Go to Step 10
Go to Step 11
Replace the
turbocharger
assembly.
Replace the
turbocharger
assembly.
Solved
TROUBLESHOOTING 6 7
4. Excessive Fuel Consumption

Step
1
Action
Was the air cleaner element clogged?
Was the air leakage found from the air intake side of
the turbocharger?
Value(s)
Was the turbocharger working completely?
Was there the fuel leakage?
Was the injection nozzle pressure or spray pattern

normal?
Are any DTC stored?
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
Clean or
replace the air
cleaner
element.
Repair or
replace the air
intake side of
the
turbocharger.
Go to Step 4
Repair or
replace the fuel
leakage part.
No
Go to Step 2
Go to Step 3
Replace the
turbocharger
Go to Step 5
Go to Step 6
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to Step 7
Replace the
injection nozzle
Go to indicated
DTC
Solved
6 8 TROUBLESHOOTING
5. Excessive Oil Consumption

Step
1
2
3
Action
Does the air cleaner element conditon OK? (Clogged

or not)
Value(s)
Does PCV (Positive Crankcase Ventilation) Valve

has problem?
Was the oil pressure value more than normal value?
Less than
588 kPa (6.0
2
kg/cm , 85
psi)
Inspect the front and rear crankshaft oil seal.
Was the oil leakage found from any gasket?
Inspect the valve stem seal, the valve stem and the
valve guide for worn.
Were any worn found?
7
8
9
Was the oil leakage found?
Was the oil leakage found from the turbocharger oil

seal?
Was the oil drain pipe of the turbocharger restricted?
Was the oil drain passage in the turbocharger center

housing restricted?
10
Does turbine wheel has any impact damage?
11
Are any DTC stored?
Yes
Go to Step 2
Repair or
replace the
relation parts.
No
Clean or
replace the air
cleaner
element
Go to Step 3
Repair or
replace the oil
relief valve
Go to Step 4
Replace the
failure part.
Go to Step 5
Replace the
wrong gasket
Replace the
worn part.
Replace the oil

seal.
Repair or
replace the oil
drain pipe.
Clean the
center housing
Replace the
turbocharger
Go to indicated
DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 11
Solved
TROUBLESHOOTING 6 9
6. Overheating
Step
Action
Value(s)
Was the engine coolant level OK?
Was the water leakage or the radiator restriction

found? (Include radiator cap)
Was the fan belt slippage found?
3
4
5
Was the fan clutch working completely?

Was the oil leakage found from fan clutch?
Was the thermostat working normally?
Was the water pump working OK?
8
9
10
Was the restriction by the foreign materials in the

cooling system found? For example, clog the water
hose between the cylinder body and radiator etc..
Was the water leakage found from the sealing cap
on the cylinder body?
Are any DTC stored?
Yes
Go to Step 2
Repair or
replace the
leakage part.
Tension or
replace the fan
belt.
Go to Step 5
Replace the
fan clutch
assembly
Go to Step 7
Go to Step 8
Clean or
replace the
clog part.
Replace the
sealing cap or
replace the
cylinder body.
Go to indicated
DTC.
Value(s)
Yes
No
Replenish the
coolant
Go to Step 3
Go to Step 4
Replace the
fan clutch
assembly.
Go to Step 6
Replace the
thermostat.
Replace the
water pump
assembly.
Go to Step 9
Go to Step 10
Solved
7. White Exhaust Smoke

Step
1
Action
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Was the PCV (Positive Crankcase Ventilation) valve

working completely?
Was the turbocharger working completely?
Are any DTC stored?
Go to Step 2
Go to Step 3
Go to Step 4
Go to indicated
DTC
No
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
Repair or
replace the
PCV valve.
Replace the
turbocharger.
Solved
6 10 TROUBLESHOOTING
8. Dark Exhaust Smoke

Step
1
Action
Was the air cleaner element normal condition?
Value(s)
Was the EGR valve sticking?
Was the injection nozzle pressure or the injection

spray pattern OK?
4
5
6
7
8
9
Was the oil leakage found from the turbocharger oil

seal?
Was the oil drain pipe of the turbocharger restricted?
Was restricted the oil drain passage in the

turbocharger center housing restricted?
Does turbine wheel has any impact damage?
Does PCV (Positive Crankcase Ventilation) Valve

has problem?
Are any DTC stored?
Yes
Go to Step 2
Replace the
EGR valve
Go to Step 4
Replace the oil

seal
Repair or
replace the oil
drain pipe
Clean the
center housing
Replace the
turbocharger
Repair or
replace the
relation parts
Go to indicated
DTC
No
Clean or
replace the air
cleaner
element
Go to Step 3
Replace the
injection nozzle
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Solved
TROUBLESHOOTING 6 11
9. Oil Pressure Does Not Rise

Step
1
Action
Was the oil pressure warning lamp working OK?
Value(s)
Does the oil filter element clog?
Does the relief valve open?
4
5
6
Does the oil strainer clog?
Was the oil pump working OK? (The pump related

parts worn etc.)
Was the rocker arm and/or relation parts worn?
Was the camshaft and/or relation parts worn?
Was the crankshaft and/or relation parts worn?
Are any DTC stored?
Table of pressure unit

Pressure
Resistance
Electric current
kPa (kg/cm )
2
ohm
A
100
(1.0)
980
(10.0)
63.5
106.7
81
30
Yes
Go to Step 2
Replace the oil

filter element
Repair or
replace the
relief valve
Clean or
replace the oil
strainer
Go to Step 6
Replace the
rocker arm
and/or relation
parts
Replace the
camshaft
and/or relation
parts
Replace the
crankshaft
and/or relation
parts
Go to indicated
DTC
No
Replace the oil

pressure
warning lamp
Go to Step 3
Go to Step 4
Go to Step 5
Repair or
replace the oil
pump.
Go to Step 7
Go to Step 8
Go to Step 9
Solved
10. Abnormal Engine Noise

101 Engine knocking
Step
1
Was the injection nozzle pressure or injection spray

pattern OK?
Are any DTC stored?
102 Gas leakage noise

Step
1
2
4
5
Action
Action
Was the exhaust pipe loose or broken?

Was the exhaust manifold loose?
Was the injection nozzle loose?
Was the cylinder head gasket broken?

Are any DTC stored?
Value(s)
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
No
Go to Step 2
Replace the
injection nozzle
Go to Step 3
Go to indicated
DTC
Value(s)
Yes
Retighten or
replace the
exhaust pipe
Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket
Retighten or
replace the
injection nozzle
fixing bolt
Replace the
cylinder head
gasket
Go to indicated
DTC
Replace the
cylinder head
gasket or
piston ring
Solved
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Solved
103 Continuous noise
Step
1
Action
Was the fan belt tension OK?
Value(s)
9 13 mm
(0.35 0.51
in)
Was the cooling fan loose?
Was noise coming from the generator?
Was noise coming from the water pump?
Was noise coming from the cylinder head cover?
Are any DTC stored?
10-4 Slapping noise

Step
1
2
Action
Was noise coming from the cylinder head cover?

Were valve clearances correct?
0.4 mm
(0.016 in)
both intake
and exhaust
Was noise coming from the cylinder body?
9
10
Inspect the connecting rod small end bushing and/or

piston pin.
Was the connecting rod small end bushing and/or
piston pin worn?
Inspect the piston and/or cylinder liner.
Was the piston and/or cylinder liner worn or
damaged?
Are any DTC stored?
Tighten the
cooling fan
Repair or
replace the
generator
and/or the
vacuum pump
Replace the
water pump
Readjust the
valve
clearance.
Yes
Was the flywheel fixing bolt loose?
Inspect the connecting rod bearing and/or crankpin.

Was the connecting rod bearing and/or crankpin
worn?
Adjust the fan

belt tension.
Value(s)
Go to Step 2
Go to indicated
DTC
Were the rocker arms damaged?
Inspect the crankshaft bearing and/or crankshaft.

Was the crankshaft bearing and/or crankshaft worn?
No
Yes
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Solved
No
Go to Step 2
Go to Step 4
Adjust the
valve
clearances
Go to Step 3
Replace the
rocker arms
Tighten the
fixing bolt.
Go to Step 6
Replace the
worn parts
Go to Step 4
Go to Step 5
Go to Step 10
Go to Step 7
Replace the
worn parts
Go to Step 8
Replace the
worn parts
Go to Step 9
Replace the
worn or
damaged parts
Go to indicated
DTC
Go to Step 10
Solved
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step
1
2
3
4
5
6
Was the excessive

turbocharger?
Action
noise
coming
from
the
Inspect the fixing bolts and bands.

Was any problem found?
Was the intake or exhaust system gasket damaged?

Inspect rotation parts condition.
Was the turbine wheel rotation rough?
Inspect the turbine wheel.

Was the turbine wheel rubbing against housing?
Value(s)
Yes
No
Go to Step 2
Go to Step 10
Tighten the
loose parts
Replace the
damaged
gasket.
Replace the
turbocharger.
Replace the
turbocharger.
Was the turbine wheel damaged?
Were there carbon deposits in the turbine or

compressor housing?
Inspect the oil supply condition.

Was the oil feed pipe clogged?
Was the turbine shaft bearing worn?
10
Are any DTC stored?
Go to indicated
DTC
Value(s)
Yes
7
8
11. Rotating Part Wear of Turbocharger

Step
1
2
Action
Inspect engine oil.

Was it contaminated with foreign materials?
Was the recommended engine oil grade/viscosity

being used?
Was the oil feed pipe restricted?
API CD or
ISUZU
genuine/
10W30
Was the oil seal of turbocharger defective?
Was the center housing oil drain passage clogged?
6
7
Was there oil sludge and/or coking on the turbine

shaft?
Are any DTC stored?
Replace the
turbocharger.
Clean or
replace the
turbocharger.
Repair or
replace the oil
feed pipe.
Replace the
turbocharger.
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Solved
No
Replace the
engine oil
Go to Step 2
Go to Step 3
Replace the
engine oil
Clean or
replace the oil
feed pipe
Replace the oil

seal
Clean center
housing or
replace the
turbocharger
Replace the
turbocharger
Go to indicated
DTC
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
12. Oil Leakage from Turbocharger

Step
1
2
3
4
5
Action
Inspect the oil leakage area.

Was the oil feed pipe eye bolt loose or the gasket
broken?
Were the V band fixing faces tight?
Was there oil leakage from the flange of the turbine

housing?
Value(s)
Was there oil leakage from the flange of compressor

housing?
Are any DTC stored?
Yes
Tighten the eye

bolt or replace
the gasket.
Tighten band
or replace the
turbocharger
Replace the
turbocharger
Tighten the bolt

and/or hose
clamp.
Go to indicated
DTC
13. Insufficient Acceleration and/or Lack of Power due to turbocharger

Step
1
2
3
4
5
Action
Inspect the air or exhaust route.

Was the air and/or exhaust gas piping loose?
Inspect the work of waste gate valve control.
Was there rust on the linkage rod or pin of the waste
gate valve?
Was air leakage found from the actuator piping?
Inspect the inside of the turbocharger.

Was the turbine shaft end nut loose?
Value(s)
Were the turbine blades bent?
Was the turbine wheel rubbing against housing?
Are any DTC stored?
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Solved
No
Tighten flange
bolts or hose
clamp.
Go to Step 2
Replace the
turbocharger
Go to Step 3
Repair or
replace the
actuator pipe or
hose/
Replace the
turbocharger
Replace the
turbocharger
Replace the
turbocharger
Go to indicated
DTC
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
14. Battery Charging and Noise Problem
Visual/physical check the following items before diagnosis.

The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step
1
2
3
4
5
6
7
Action
Was Visual/Physical Check" performed.
1
2
3
4
Inspect the brush contact condition on the generator.

Was there poor contact between the brush and the
slip ring?
Inspect the stator coil on the generator.

Was there an open circuit or the scorching on the
stator coil?
Inspect the rotor coil on the generator.

Was there an open circuit or the scorching on the
rotor coil?
Inspect the rectifier on the generator.
Was the rectifier defective?
Inspect the IC regulator.

Was the IC regulator defective?
Are any DTC stored?
14-2 Battery Overcharging

Step
Value(s)
Action

Inspect the terminal circuit.
Were the B and F terminals shorted?
Check the regulating voltage.

Was the IC regulator voltage excessive?
Are any DTC stored?
Yes
Go to Step 2
Repair or
replace the
brush and/or
the slip ring.
Replace the
rotor coil.
Go to Step 5
Replace the
rectifier
Replace the IC
regulator.
Value(s)
Yes
Go to Step 3
Go to Step 4
Go to indicated
DTC.
Go to
visual/physical
check
Replace the
stator coil.
No
Go to Step 2
Repair the
short circuit.
Replace the IC
regulator.
Go to indicated
DTC.
Go to Step 6
Go to Step 7
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Solved
14-3 Battery Under Charging
Step
1
2
3
4
5
6
7
8
Action
1
2
3
4
5
6
7

Was there intermittent contact between the brush
and the slip ring?

Was there a short circuit in the rotor coil?

Was there an open circuit or the short circuit on the
stator coil?
Inspect the rectifier on the generator.

Was the rectifier defective?
Inspect the IC regulator on the generator.

Was the electrical load excessive?
Are any DTC stored?
14-4 Battery Unstable Charging Current

Step
Value(s)
Action
Repair or
replace the
stator coil.
Replace the
rectifier
Replace the IC
regulator.
Replace more
higher capacity
generator.
Yes
Are any DTC stored?
Repair or
replace the
rotor coil.
Value(s)

Was there the short circuit or an open circuit in the
rotor coil?
Inspect the IC regulator on the generator.

Repair or
replace the
brush holder
assembly.
Go to indicated
DTC.
Inspect the connection between the rectifier and

stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ?
Go to Step 2

Was there poor contact between the brush and the
slip ring?

Was there an open circuit or the short circuit in the
stator coil?
Yes
Go to Step 2
Repair or
replace the
brush and/or
the slip ring.
Repair or
replace the
rotor coil.
Repair or
replace the
stator coil.
Repair the
loose
connection.
Replace the IC
regulator.
Go to indicated
DTC.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
14-5 Charging System Noise
Step
1
2
3
4
5
6
Action

Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and
decreasing engine speed?
Was there a growling sound and does this sound
stop when the connector was disconnected?
Value(s)
Was intermittent sound heard when the generator

was running?
Was frictional sound heard when generator was

running?
Are any DTC stored?
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
bearing.
Go to Step 3
Replace the
stator coil.
Replace the
brush and/or
slip ring.
Clean the slip

ring or replace
the brush.
Go to indicated
DTC.
Go to Step 4
Go to Step 5
Go to Step 6
Solved
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.

The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step
1
2
Action

Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent?
Value(s)
Yes
Go to Step 2
Replace the
brush or repair
the
commutator.
Were the brush and the commutator contact faces

dirty?
Was the pinion clutch slipped?
Inspect the armature field coil.

Was there an open circuit or a short circuit in the
armature field coil?
Are any DTC stored?
Go to indicated
DTC.
Value(s)
Yes
15-2 Incorrect pinion and ring gear engagement

Step
1
2
3
Action

Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken?
Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect?
Are any DTC stored?
Clean contact
face
Replace the
pinion clutch
Repair or
replace the
armature field
coil.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Solved
No
Go to Step 2
Go to
visual/physical
check
Replace the
wron parts.
Go to Step 3
Adjust or
replace the
movement
parts.
Go to indicated
DTC.
Go to Step 4
Solved
15-3 Starter motor continues to run after the starter switch is turned off
Step
1
2
3
4
Action

Inspect the magnetic switch contact point.
Was the contact point seized?
Inspect the starter switch.
Was the starter switch defective?
Are any DTC stored?
15-4 Excessive commutator sparking

Step
1
2
Action

Inspect the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent?
Was there the slag accumulation on the contact
face?
Value(s)
Repair or
replace the
magnetic
switch.
Replace the
starter switch.
Go to indicated
DTC.
Value(s)
Yes
Was the brush holder loose?
Inspect the commutator.

Was there excessive wear or pitting?
Was there loose the solder on the commutator?
Inspect the armature shaft.

Was the run-out of armature shaft outside the
standard value due to worn bearing ?
Are any DTC stored?
Go to Step 2
Yes
Go to Step 2
Replace the
brush or repair
the
commutator.
Clean the
contact face or
replace the
brush.
Repair the
brush holder
Repair or
replace the
commutator.
Clean and
repair
Replace the
bearing
Go to indicated
DTC.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Solved
ENGINE MECHANICAL 6A 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A -
Standard Bolts ........................................................................................................... 6A -
Torque Specifications ................................................................................................... 6A Special Parts Fixing Nuts and Bolts ........................................................................ 6A -
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23

Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25

Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37

Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43

Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43
6A 2 ENGINE MECHANICAL
Disassembly ............................................................................................................... 6A- 47
Internal Parts........................................................................................................... 6A- 47
Major Components.............................................................................................. 6A- 47
Minor Components ............................................................................................. 6A- 56

Rocker Arm Shaft and Rocker Arm................................................................ 6A- 56
Cylinder Head .................................................................................................. 6A- 57
Piston and Connecting Rod ........................................................................... 6A- 59
Inspection and Repair................................................................................................ 6A- 61
Cylinder Head ......................................................................................................... 6A- 61

Rocker Arm Shaft and Rocker Arm....................................................................... 6A- 68
Cylinder Body ......................................................................................................... 6A- 69

Camshaft ................................................................................................................. 6A- 77
Crankshaft and Bearing ......................................................................................... 6A- 79
Crankshaft Bearing Selection................................................................................ 6A- 83

Crankshaft Pilot Bearing........................................................................................ 6A- 85
Flywheel and Ring Gear......................................................................................... 6A- 85

Piston....................................................................................................................... 6A- 86
Cylinder Head Gasket Selection............................................................................ 6A- 88
Connecting Rod ...................................................................................................... 6A- 90

Idler Gear Shaft and Idler Gear.............................................................................. 6A- 91
Timing Gear Case Cover ........................................................................................ 6A- 91
Reassembly ................................................................................................................ 6A- 93
Internal Parts........................................................................................................... 6A- 93
Minor Component ............................................................................................... 6A- 93

Rocker Arm Shaft and Rocker Arm................................................................ 6A- 93
Cylinder Head .................................................................................................. 6A- 94
Piston and Connecting Rod ........................................................................... 6A- 96

Positive Crankcase Ventilation (PCV) Valve ................................................. 6A- 99
Major Component................................................................................................ 6A- 101
Installation .................................................................................................................. 6A- 118
External Parts ......................................................................................................... 6A- 118
Lubrication System........................................................................................................ 6A- 126
Lubricating Flow ........................................................................................................ 6A- 126
Oil Pump and Oil Filter .............................................................................................. 6A- 127

Oil Pump ..................................................................................................................... 6A- 128
Disassembly............................................................................................................ 6A- 128

Inspection and Repair ............................................................................................ 6A- 129
Reassembly............................................................................................................. 6A- 130
Oil Filter and Oil Cooler ............................................................................................. 6A- 131
Disassembly............................................................................................................ 6A- 131

Inspection and Repair ............................................................................................ 6A- 132
Reassembly............................................................................................................. 6A- 133
Inter Cooler .................................................................................................................... 6A- 135

Removal .................................................................................................................. 6A- 136
Installation .............................................................................................................. 6A- 136
Special Tools.................................................................................................................. 6A- 137
MAIN DATA AND SPECIFICATIONS

Engine model
Item
Engine type
4JA1T (L)
Four-cycle, overhead valve, water cooled
Combustion chamber type
Direct injection
Cylinder liner type
Dry type, chrome plated
Timing gear train system
No. of cylinders-bore ! stroke
mm (in)
No. of piston rings
Total piston displacement
Compression ratio (to 1)

Compression pressure
Engine weight (dry)
cm (in )
3
4 93 ! 92 (3.66 ! 3.62)
Compression ring: 2 / Oil ring: 1

2,499(152.4)
18.5
Mpa(kg/cm /psi)
3.0 (31.0/441) 200 rpm
kg (lb)
Fuel injection timing BTDC
deg
Idling speed
rpm
Specified fuel type
Valve clearances (At cold): Intake
Exhaust
Intake valves
Open at (BTDC)
Exhaust valves
Open at (BBDC)
mm (in)
mm (in)
deg
Close at (ABDC)
Approximately 239 (527)
134-2
730 " 25 (A/C Off)
850 " 25 (A/C ON)

0.4 (0.016)
0.4 (0.016)
24.5
55.5
deg
54.0
deg
Injection pump type
26.0
BOSCH distributor VE type
Governor type
Mechanical (Half all speed

type)
Injection nozzle type
Lubricating system
Specified engine oil (API grade)
BOSCH distributor VP44 type

Electronically controled
Hole with 5 orifices
Mpa(kg/cm /psi)
Main fuel filter type
JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
deg
Close at (ATDC)
Lubricating method
Gear drive
Fuel injection order
Fuel system
4JA1TC
1st 19.1 (195 / 2,773)
2nd (Reference)
25.5#27.0
(260#275 / 3,702#3,920)
1st 19.0 (194 / 2,755)
2nd (Reference)
34.0#35.5
(347#362 / 4,936#5,154)
Cartridge paper element and water separator

Pressure circulation
ISUZU genuine 10W 30 (API CD of ACEA B2/B3)
Item
Engine model
Oil capacity
Oil cooler type
4JA1TC
Gear
Oil pump type

Oil filter type
4JA1T (L)
lit (US/UK gal)
Cartridge paper element

6.2 (1.64/1.36)
Water cooled
Cooling system
Water pump type
Centrifugal
Thermostat type
Wax pellet with jiggle valve
Air cleaner type
Dry paper element
Battery type/voltage ! No. of units

Generator capacity
Starter motor output
Turbocharger model
V-A
V-Kw
Turbine type
Compressor type
*IHI : Ishikawajima-Harima Heavy Industries., Ltd.
Viscous paper element
80D26L ! 1
95D31L ! 1 (OPT)
12 60
12 80
12 2.3
*IHI RHF 4H
Mixed flow type
Backward & rake

Engine model
Item
Engine type
Four-cycle, overhead valve, water cooled
Combustion chamber type
Direct injection
Cylinder liner type
Dry type, chrome plated
Timing gear train system
No. of cylinders-bore ! stroke
mm (in)
No. of piston rings
Total piston displacement

Compression ratio (to 1)
Compression pressure
Engine weight (dry)
liter
MPa(kg/cm /psi)
2
kg (lb)
Fuel injection order

Idling speed
rpm
Valve clearances (At cold): Intake
Exhaust
Intake valves
Open at (BTDC)
Exhaust valves
Open at (BBDC)
mm (in)
mm (in)
deg
Close at (ABDC)
deg
deg
Close at (ATDC)
deg
Injection pump type
2,999
18.3
3.0 (31.0/441) 200 rpm
MT : Approximately 249 (549)

AT : Approximately 236 (520)
JIS No.2, DIN/EN590, GB252-1944 Diesel fuel

700 ! 25 (A/C OFF)
800 ! 25 (A/C ON)
0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0
1st 19.5 (199/2,828)
2nd (Reference) 34.3#35.8 (350#365/4,980#5,197)

Cartridge paper element and water separator
Lubricating system
Lubricating method
Pressure circulation
Specified engine oil (API grade)
ISUZU genuine 10W 30 (API CD of ACEA B2/B3)
Oil pump type
Oil cooler type
Compression ring: 2 / Oil ring: 1
Hole with 5 orifices
MPa(kg/cm /psi)
Oil capacity
4 95.4 ! 104.9 (3.76 ! 4.13)
BOSCH distributor VP44 type
Oil filter type
Gear drive
134-2
Specified fuel type
Fuel system
4JH1TC
Gear
lit (US/UK gal)
Cartridge paper element
6.2 (1.64/1.36) (For 4 ! 2)
7.0 (1.85/1.54) (For 4 ! 4)

Water cooled
Item
Engine model
Cooling system
4JH1TC
Centrifugal
Water pump type
Thermostat type
Dry paper element (except for Euro3 spec)

Viscous paper element (for Euro3 spec)
Air cleaner type
80D26L ! 1
Battery type/voltage ! No. of units
95D31L ! 1 (OPT)
75D26R ! 2 (OPT for EC, MT)

80D26R ! 2 (OPT for EC, AT)
Generator capacity
Starter motor output
Turbocharger model
V-A
V-Kw
Turbine type
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
12 60/12 80
12 2.3
*IHI RHF5
Mixed flow type Radial-inflow
Backward & rake type Radial-outflow
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
Nm (kgm/lbft)
Strength
Class
4.8 (4T)
(7T)
Bolt
Identification
Refined
8.8
Non-Refined
9.8 (9T)
Bolt
Diameter !
Pitch (mm)
M 6 ! 1.0
M 8 ! 1.25
M 10 ! 1.25
M 12 ! 1.25
M 14 ! 1.5
M 16 ! 1.5
M 18 ! 1.5
M 20 ! 1.5
M 22 ! 1.5
M 24 ! 2.0
* M 10 ! 1.5
* M 12 ! 1.5
* M 14 ! 2.0
* M 16 ! 2.0
5.88 1.96
(0.60 0.20/4.33 1.44)
7.35 2.45
(0.75 0.25/5.43 1.80)
12.74 ! 4.90
(1.30 0.50/9.40 3.62)
17.15 5.39
(1.75 ! 0.55/12.66 ! 4.00)
23.52 6.86
(2.40 0.70/17.36 5.06)
61.25 12.25
(6.25 1.25/45.21 9.04)
75.95 15.19
(7.75 1.55/56.06 11.21)
94.57 19.11
(9.65 1.95/69.80 14.10)
27.44 6.86
(2.80 0.70/20.25 5.06)
95.55 19.11
(9.75 1.95/70.52 14.10)
116.13 ! 23.03
(11.85 2.35/85.71 17.00)
142.10 28.42
(14.50 2.90/104.88 21.00)
244.02 49.00
(24.90 5.00/180.10 36.17)
287.14 57.82
(29.30 5.90/211.93 42.67)
130.34 26.46
(13.30 2.70/96.20 19.53)
169.54 34.30
(17.30 3.50/125.13 25.32)
257.74 51.94
(26.30 5.30/190.23 38.33)
337.12 67.62
(34.40 6.90/248.82 49.41)
188.16 37.24
(19.20 3.80/138.87 27.49)
332.22 81.34
(33.90 8.30/245.20 60.03)
49.98 12.74
(5.10 1.30/36.89 9.40)
36.75 9.31
(3.75 0.95/27.12 6.87)
199.92 40.18
(20.40 4.10/147.55 29.66)
395.92 79.38
(40.40 8.10/292.21 58.59)
453.25 90.65
(46.25 9.25/334.53 66.91)
530.18 105.84
(54.10 10.80/391.30 78.12)
36.26 8.82
(3.70 0.90/26.76 6.50)
48.02 11.76
(4.90 1.20/35.44 8.68)
448.84 90.16
(45.80 9.20/331.27 66.54)
570.36 140.14
(58.20 14.30/420.96 103.43)
56.84 11.76
(5.80 1.20/41.95 8.68)
70.56 13.72
(7.20 1.40/52.08 10.13)
26.46 6.86
(2.70 0.70/19.53 5.06)
89.18 17.64
(9.10 1.80/65.82 13.02)
124.46 24.50
(12.70 2.50/91.86 18.08)
109.76 21.56
(11.20 2.20/81.01 15.91)
161.70 32.34
(16.50 3.30/119.34 23.87)
691.88 138.18
(70.60 14.10/510.65 101.99)
89.18 17.64
(9.10 1.80/65.82 13.02)
133.28 26.46
(13.60 2.70/98.37 19.53)
191.10 38.22
(19.50 3.90/141.04 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS
Pipe diameter mm
(in)
4.76 (0.187)
6.35 (0.250)
8.00 (0.315)
Nm (kgm/lbft)
Torque
Pipe diameter mm
(in)
Torque
15.2 2.45(1.55 0.25/11.2 1.8)
10.00 (0.394)
53.95 4.90(5.50 0.5 /39.7 3.6)
44.14 4.90(4.50 0.50/32.5 3.6)
15.00 (0.591)
105.45 12.26(10.75 1.25/77.7 9.0)
26.48 2.94(2.70 0.30/19.5 2.1)
12.00 (0.472)
88.29 9.80(9.00 1.0/65.0 7.2)
SPECIAL PARTS FIXING NUTS AND BOLTS
Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
Nm (kgm/lbft)
RTW46AXF000501
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
Nm (kgm/lbft)
RTW36AXF000101
Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft

Nm (kgm/lbft)
RTW46AXF000601
Cooling and Lubricating System

Nm (kgm/lbft)
RTW46AXF000701
Intake Manifold (4JA1TC / 4JH1TC)

Nm (kgm/lbft)
RTW36AXF000201
EGR Valve, EGR Pipe, EGR Cooler
RTW46AXF000801
Exhaust Manifold, and Turbocharger (4JA1L)
RTW46AXF000901
Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC)

Nm (kgm/lbft)
RTW46AXF001001
Engine Electricals
Nm (kgm/lbft)
RTW36AXF000501
Fuel Injection System (4JA1L)
Nm (kgm/lbft)
RTW46AXF001101
Fuel Injection System (4JA1TC)

Nm (kgm/lbft)
RTW46AXF001201
Fuel Injection System (4JH1TC)

Nm (kgm/lbft)
RTW46AXF001301
Engine Mounting Bracket
Nm (kgm/lbft)
022R300001
RECOMMENDED LIQUID GASKET

Type
RTV*
Silicon Base
Water Base
Solvent
Anaerobic
Brand Name
Manufacturer
ThreeBond 1141E
ThreeBond 1215
Three Bond
Three Bond
LOCTITE 515
LOCTITE 518
LOCTITE 262
Loctite
Loctite
Loctite
ThreeBond 1207B
ThreeBond 1207C
ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Three Bond
Three Bond
Isuzu
Isuzu
Isuzu
Remarks
Recommended for
transaxle repairs
* RTV : Room Temperature Vulcanizer

Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturers instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.
LOCTITE APPLICATION PROCEDURE

LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
1.
2.
LOCTITE 262
Red
LOCTITE 270
Green
LOCTITE 271
LOCTITE 515
Red
Application Steps
Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
Apply LOCTITE to the bolts.
3.
Tighten the bolts to the specified torque.
1.
Completely remove lubricant and moisture from the connecting

surfaces.
The surfaces must be perfectly dry.
4.
Wait at least one hour before continuing the installation procedure.
2.
Apply a 2.0 2.5 mm bead of LOCTITE to one of the connecting

surfaces.
There must be no gaps in the bead.
3.
Violet
4.
Let the joined parts set for at least thirty minutes.
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side

of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
Dust Fouled Element
130RY00003
Rotate the element with your hand while applying

compressed air to the inside of the element. This will blow
the dust free.
2
Compressed air pressure
kPa (kg/cm /psi)
392 490 (4 5/57 71)
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)

Replacement Procedure
6A-6
1. Drain the engine oil.

2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0
4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
RTW36ASH000101
Replenished Engine Oil
Condition
MAX lit (US/UK gal)
Engine Dry
With oil filter

replacement
4!2
4!4
(4JA1L/TC)
4!2
(4JH1TC)
Without oil
filter
replacement
6.2 (1.64/1.36)
5.2 " 4.2

(1.37 " 1.11
/ 1.14 " 0.92)
4.5 " 3.5

(1.19 " 0.93
/ 0.99 " 0.77)
4!4
(4JH1TC)
7.0 (1.85/1.54)
Model
6.2 (1.64/1.36)
5.2 " 4.2

(1.37 " 1.11
/ 1.14 " 0.92)
6.2 " 5.2
(1.64 " 1.37
/ 1.36 " 1.14)
4.5 " 3.5

(1.19 " 0.93
/ 0.99 " 0.77)
5.3 " 4.3
(1.72 " 1.14
/ 1.17 " 0.95)
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel Filter Replacement Procedure

1. Remove the fuel filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.
6A-7
RTW46ASH000501
2. Clean the fuel filter cartridge fitting faces.

This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench : 5-8840-0253-0 (J-22700)
041RY00009
6. Operate the priming pump until the air discharged

completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.
041RY00011
1.
2.
3.
4.
Place the drain pan under the drain plug.

Loosen the drain plug and drain water.
After draining the water, tighten the drain plug.
Operate the priming pump on the fuel filter several
times and check for fuel leakage.
5. Check the water separator indicator light. It should be
off.
Air Bleeding
Except EURO III model

RTW46ASH002901
For EURO III model
RTW46ASH000501
1. Operate the priming pump until strong resistance is

felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
4. Turn the ignition switch to the "ON" position. Wait until
the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and
crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve

tank as necessary.
If the coolant level falls below the MIN line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the MAX line.
111R300001
Engine coolant Filling up procedure

1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to MAX line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to MAX line.
Engine Coolant Total Capacity
Lit (U.S / UK gal)
4JA1 / TC
4JH1TC
9.4 (2.5 / 2.1)
M/T: 10.1 (2.7 / 2.2)

A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)

50 %
Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage. The testing pressure must not exceed the
specified pressure.
Testing Pressure
kPa(kg/cm /psi)
2
150 (1.5/21)
030LX003
Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant
2
pressure in the cooling system at 103 kPa(1.05 kg/cm ,
15psi).
Check the radiator filler cap with a radiator filler cap tester.
The radiator filler cap must be replaced if it fails to hold the
specified pressure during the test procedure.
Radiator Cap Valve Opening Pressure
2
kPa(kg/cm /psi)
030LX002
90 120 (0.9 1.2/13 17)
Negative Valve (Reference)
kPa(kg/cm /psi)
1.9 4.9 (0.02 0.05/0.28 0.71)
Thermostat Operating Test

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
$C ($F)
030LX014
Oil Cooler Thermo Valve
82 (180)
76.5 (170)
EGR Cooler Thermo Valve
40 (104)
$C ($F)
$C ($F)
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature
$C ($F)
95 (203)
90 (194)
55 (131)
$C ($F)
$C ($F)
Valve Lift at Fully Open position
mm (in)
mm (in)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
mm in)
Drive Belt Adjustment
033RY00002
Check drive belts for wear or damage, and replace with

new ones as necessary. Check belts for tension, and
adjust as necessary.
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
4 Oil pump pulley or idler pulley
5 Compressor pulley or idler pulley
Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10 kg/22 lb)
force.
Cooling Fan Drive Belt Deflection
mm (in)
New belt
4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
033RY00003

2 Generator pulley
3 Cooling fan pulley
A/C Compressor Drive Belt

Compressor belt tension is adjusted by moving the P/S
pumppulley.
Depress the drive belt mid-portion with a 98N (10 kg/22 Ib)
force.
A/C Compressor Drive Belt Deflection
mm (in)
New belt
9 - 10 (0.35 - 0.39)
Reuse belt 12 - 13 (0.47 - 0.51)
033RY00004

2 P/S pump pulley
2 A/C Compressor pulley
VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No. 4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.
2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.
Rocker Arm Shaft Bracket Nut Torque
54 (5.5/40)
014RY00014
014RY00015
Nm (kgm /lbft)
8. Check for play in the No. 1 intake and exhaust valve

push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.
Adjust the No.1 or the No. 4 cylinder valve clearances

while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold)
mm (in)
0.4 (0.016)
014RY00016
014RY00017
9. Loosen each valve clearance adjusting screw as

shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
11. Turn the valve clearance adjusting screw until a slight

drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360$.
14. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
15. Adjust the clearances for the remaining valves as
shown in the illustration.
COMPRESSION PRESSURE
MEASUREMENT
F06XL056
1. Start the engine and allow it to idle until the coolant

temperature reaches 70 80 $C (158 176 $F).
2. Remove the following parts.
% Leak off pipe
% Injection nozzle holder bracket
% Injection nozzle holder
3. Install the following parts.
% Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
% Injection nozzle holder bracket
Injection nozzle holder bracket Bolt Torque
Nm (kgm /lbft)
37 (3.8/27)
Compression Gauge: 5-8840-2675-0

Adapter; Compression Gauge: 5-8531-7001-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure
Standard
3.0 (31.0/441)
901R100003
MPa (kg/cm /psi) at 200 rpm

2
Limit
2.1 (21.7/309)
5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.
If the measured value is less than the specified limit,
refer to Troubleshooting in this Manual.
INJECTION TIMING ADJUSTMENT

(4JA1T(L) only)
1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.
RTW46ASH000601
2. Bring the piston in the No. 1 cylinder to TDC on the

compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark.
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
rods have play, the No. 1 piston is at TDC on the
compression stroke.
3. Disconnect the injection pipe from the injection pump
4. Remove one bolt from the distributor head.
5. Install the static timing gauge.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)
6. Rotate the crankshaft to bring the piston in the No. 1

cylinder to a point 30 - 40$ BTDC.
7. Set the timing gauge needle to zero.
8. Move the crankshaft pulley slightly in both directions to
check that the gauge indication is stable.
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8$)
is aligned with the pointer.
Injection Timing : BTDC 8$ " 2$
Standard Reading
RTW46ASH000701
mm (in)
0.5 (0.02)
If the injection timing is outside the specified range,

continue with the following steps.
10. Loosen the injection pump fixing nuts and bracket
bolts.
11. Adjust the injection pump setting angle.
When large than standard
value
R
When smaller than standard

value
A
A: Move the injection pump toward the engine.

R: Move the injection pump away from the engine.
ENGINE CONTROL (4JA1T(L) only)

Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive

wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80$C (158 - 176$F).
4. Disconnect the engine control cable from the control
lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 " 25 rpm
Idling Speed Adjustment
1. Loosen the idling set screw lock nut ! on the injection

pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt ".
3. Lock the engine set nut ! with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.
Fast Idling Speed Inspection

1. Set tachometer to the engine.
2. Disconnect the vacuum hose ! from the fast idle
actuator # on the injection pump.
3. Disconnect the other vacuum hose " from the

vacuum switching valve $ and connect it to the fast
idle actuator #.
The vacuum line will now be connected directly from
the vacuum pump % to the fast idle actuator.
4. Check the engine fast idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Fast Idling Speed
rpm
850 " 25
Fast Idling Speed Adjustment

1. Loosen the fast idle actuator bracket bolts.
2. Adjust the fast idling speed by moving the actuator

bracket, so that the clearance S can be 1 ~ 2 mm
(0.04 ~ 0.08 in.).
3. Tighten the bracket bolts.
Accelerator Control Cable Adjustment

Refer to Sec. 6H-6 (Accelerator Control)
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.
REMOVAL AND INSTALLATION

Read this section carefully before performing any removal and installation procedure. This section gives
you important points as well as the order of operation. Be sure that you understand everything in this section before
you begin.
Removal
1. Battery
1) Disconnect the battery cable and the grounding cable
from the battery terminals.
2) Remove the battery clamp. Take care not to
accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
P1010011
2. Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.
P1010002
3. Supporting the Vehicle

1) Jack up the vehicle.
2) Place chassis stands at the front and the rear of the
vehicle.
F06R300006
4. Under cover (for 4x4 model)

5. Rear propeller shaft
1) Remove the propeller shaft flange yoke at the rear
differential.
2) Remove the center bearing retainer bolts.
3) Remove the propeller shaft together with the center
bearing from the transmission mainshaft spline.
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.
7. Clutch slave cylinder (for M/T model)

8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness
Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)

12. Transmission shift lever (for M/T model)
Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model)
Remove the shift lever from the floor.
14. Transmission member

1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts
fixing the transmission member to the chassis frame.
P1010025
15. Torque converter bolt (for A/T model)

1) Remove the under cover under the torque converter
housing.
2) Rotate the flywheel by using tire lever or some other
tool, and then remove the torque converter bolts.
16. Transmission coupling bolt

1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer)

Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..
F06R300007
18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.
P1010009
19. Fan
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC)
from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box
from engine room.
3) Remove the two air ducts from inter cooler
(4JA1TC/4JH1TC).
P1010034
21. Power Steering Pump

Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor

1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air
conditioner compressor along with piping on the body
side.
23. Engine Control Cable

Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).
24. Vacuum Piping

Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).
25. Engine Harness

1) Remove following connectors from engine.
! TPS connector
! Oil pressure switch connector
! Thermo switch connector
! Injection pump connector
! Engine earth
! Thermometer unit connector
! TDC sensor
2) Remove the clips fixing engine harness.
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).
140R300001
Remove the fuel hose from injection pump (EURO III

only).
RTW46ASH000501
27. Exhaust Pipe

Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.
28. Engine Assembly

1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine
compartment.
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse
order.
Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity
4JA1 / TC
4JH1TC
lit (US/UK gal)
9.4 (2.5 / 2.1)
M/T: 10.1 (2.7 / 2.2)

A/T: 10.0 (2.6 / 2.2)
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.
ENGINE REPAIR KIT
RTW36ALF000601
Removal Steps
1. Cylinder head gasket

2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket
11. Vacuum pump gasket

12. Water pump O-ring
13. Water outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal
NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
RTW36AMF000401
Removal Steps
1. Clutch Assembly or Flex Plate

2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch

16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold
Removal
Remove the clutch assembly or the flex plate.
2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
1) Loosen hose clamp between turbocharger and intake
duct.
2) Remove the rubber hose.
3) Remove the intake pipe and the throttle body.
(4JA1TC/4JH1TC only)
4JA1L
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
4JA1L
3-1. EGR Pipe

1) Remove two bolts from the exhaust manifold.
2) Remove two nuts from the EGR valve adapter.
3) Remove the EGR pipe with gaskets.
025R100008
4JH1TC
RTW36ASH000301
3-2. EGR Cooler (EURO III model only)
4. EGR Valve
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.
4JA1"L
RTW46ASH001001
5. Oil Level Gauge

1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level
gauge.
4JA1"TC
RTW46ASH000901
4JH1"TC
RTW36ASH001201
RTW36ASH000701
6. Fuel Filter Assembly (Except EURO III model)

1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.
7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.
1) Loosen the injection pipe sleeve nuts at pump side
and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Remove the intake manifold with gasket.
11. Engine Mounting Bracket and Foot

12. Injection Pump Cover
13. Injection Pump
14.
15.
16.
17.
18.
19.
Rrefer to secton 6C-19 (Injection Iump)

Starter Motor
Oil Pressure Warning Switch
Fuel Leak Off Pipe
Oil Cooler Water Pipe
Cooling Fan Pulley
Heat Protector
027R100007
037RY00001
21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
22.
23.
24.
25.
26.
27.
28.
Compressor Bracket
Vacuum Pump Oil Return Hose
Generator and Adjusting Plate
Water Inlet Pipe
Generator Bracket
Oil Cooler with Oil Filter
Exhaust Manifold
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1.
2.
3.
4.
Water bypass hose

Thermostat housing with thermo
switch
Cylinder head cover
Injection nozzle and bracket
5.
6.
7.
8.
Rocker arm shaft and rocker

arm
Push rod
Cylinder head
Cylinder head gasket
RTW46ALF000101
Disassembly Steps-2
9.
10.
11.
12.
13.
14.
15.
16.
Crankshaft damper pulley

Timing gear case cove
Water pump
Idle gear "B" and shaft
Idle gear "A"
Idle gear shaft
Crankshaft timing gear
Injection pump
014R300005
Disassembly Steps-3
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Flywheel
Crank case
Oil pump with oil pipe
Camshaft timing gear
Camshaft thrust plate
Camshaft
Timing gear case
Cylinder body rear plate
Piston cooling oil jet
Connecting rod bearing cap with
lower bearing
27.
28.
29.
30.
31.
32.
33.
34.
Piston and connecting rod with

upper bearing
Crankshaft bearing cap with
lower bearing
Crankshaft thrust bearing
Crankshaft
Crankshaft upper bearing
Tappet
Crankshaft rear oil seal
Cylinder body
Disassembly
1.
2.
3.
4.
011R100002
011RY00005
Water Bypass Hose

Thermostat Housing with Thermo Switch
Cylinder Head Cover
Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.
2. Use the injection nozzle remover and the sliding

hammer to remove the injection nozzle together.
Injection Nozzle Remover: 5-8840-2723-0
Sliding Hammer:
5-8840-0019-0
5. Rocker Arm Shaft and Rocker Arm

Loosen the rocker arm shaft bracket bolts in numerical
order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bolts in
numerical order a little at a time will adversely affect the
rocker arm shaft.
6. Push Rod
011RY00006
011RY00007
7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
8. Cylinder Head Gasket
9. Crankshaft Damper Pulley
10. Timing Gear Case Cover
The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.
11. Water Pump
020L200006
020L200020
020RY00019
12. Idle Gear B and shaft

Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.
13. Idler Gear "A"

1. Measure the camshaft timing gear backlash and the
crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the
idler gear.
NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.
Timing Gear Backlash Measurement

1. Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.
020RY00020
Timing Gear Backlash

Standard
0.10 - 0.17 (0.0039 - 0.0067)
Limit
0.30 (0.012)
mm (in)
Idler Gear "A" End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
thrust collar must be replaced.
RTW36ASH000801
4JA1T(L)
040R300009
4JA1TC/4JH1TC
RTW36ASH001301
Idler Gear End Play

Standard
0.07 (0.0028)
mm (in)
14. Idle Gear Shaft

15. Crankshaft Timing Gear
16. Injection Pump

1. Remove the injection pump cover (4JA1TC/4JH1TC
only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.
17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0
18. Crank Case
19. Oil Pump With Oil Pipe
015RY00001
Limit
0.2 (0.0079)
20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
014RT0001
901R100008
Camshaft End Play

Standard
0.050 - 0.114
(0.002 - 0.0044)
Limit
0.20
(0.008)
mm (in)
2. Remove the camshaft timing gear bolt from the

camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft
timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.
21. Camshaft Thrust Plate
22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.
23. Timing Gear Case

24. Cylinder Body Rear Plate
014RY00019
052RY00001
25. Piston Cooling Oil Jet

The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.
26. Connecting Rod Bearing Cap with Lower Bearing
If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
014LX056
015LX018
27. Piston and Connecting Rod with Upper Bearing

1. Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
2. Move the piston to the top of the cylinder and tap it
with a hammer grip or a similar object from the
connecting rod lower side to drive it out.
If the connecting rod upper bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with the
RTW36ASH001501
28. Crankshaft Bearing Cap with Lower Bearing

1. Measure the crankshaft end play at the center journal
of the crankshaft.
Do this before removing the crankshaft bearing caps.
crankshaft thrust bearing must be replaced.
015RY00002
Crankshaft End Play

Standard
0.10 (0.004)
Limit
0.30 (0.012)
mm (in)
2. Loosen the crankshaft bearing cap bolts in numerical
order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
29. Crankshaft Thrust Bearing
30.Crankshaft
015RY00003
015RY00004
015RY00005
31. Crankshaft Upper Bearing

If the crankshaft upper bearings are to be reinstalled, mark
32. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.
33. Crankshaft Rear Oil Seal

! With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover: 5-8840-2360-0
34. Cylinder Body

015LV002
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1.
2.
3.
4.
Rocker arm shaft snap ring

Rocker arm
Rocker arm shaft bracket
Rocker arm
5.
6.
7.
Rocker arm shaft spring

Rocker arm shaft
Disassembly
011RY00010
1. Rocker Arm Shaft Snap Ring

2. Rocker Arm
3. Rocker Arm Shaft Bracket
1. Use a pair of pliers to remove the snap rings.
2. Remove the rocker arms.
3. Remove the rocker arm shaft brackets.
If the rocker arms and rocker arm shaft brackets are to
be reinstalled, mark their installation positions by
tagging each rocker arm and rocker arm shaft bracket
with the cylinder number from which it was removed.
4. Rocker Arm
5. Rocker Arm Shaft Spring
7. Rocker Arm Shaft
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1.
2.
3.
4.
5.
Intake manifold
Intake manifold gasket
Split collar
Valve spring upper seat
Valve spring
6.
7.
8.
9.
Intake and exhaust valve

Valve stem oil seal
Valve spring lower seat
Cylinder head
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
011RY00011
1. Place the cylinder head on a flat wooden surface.

2. Use the spring compressor to remove the split collars.
Do not allow the valve to fall from the cylinder head.
Spring Compressor: 9-8523-1423-0
4. Valve Spring Upper Seat
5. Valve Spring
6. Intake and Exhaust Valve
If the intake and exhaust valves are to be reinstalled, mark
their installation positions by tagging each valve with the
If the intake and exhaust valves are to be replaced, the
valve guides must also be replaced.
7. Valve Stem Oil Seal
8. Valve Spring Lower Seat
9. Cylinder Head
011LX022
PISTON AND CONNECTING ROD
RTW46ALF000301
Disassembly Steps
1.
2.
3.
Connecting rod bearing

Piston ring
Piston pin snap ring
4.
5.
6.
Piston pin
Connecting rod
Piston
Disassembly
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
RTW36ASH001501
2. Piston Ring
1. Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2. Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
015RW041
F06MV015
RTW36ASH001601
3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.
4. Piston Pin
5. Connecting Rod
6. Piston
Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled, mark
their installation positions by tagging each piston and piston
pin with the cylinder number from which it was removed.
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the
limit, it should be replaced.
011RY00012
Cylinder Head Lower Face Warpage

Standard
0.05
(0.002) or less
Limit
mm (in)
0.20
(0.0079)
NOTE:
The cylinder head lower face cannot be reground.
011RY00013
Cylinder Head Height (H) (Reference)

Standard
mm (in)
91.95 92.05
(3.620 3.624)
011RY00014
Positive Crankcase Ventilation (PCV) Valve

1.
2.
3.
4.
Remove PCV valve assembly from cylinder head cover.

Inspect the diaphragm for broken.
Inspect the spring for broken or weaken.
If find any abnormal condition, replace the PCV valve
assembly.
Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but less
than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
027RY00001
Manifold Fitting Face Warpage

Standard
Limit
0.05
(0.002) or less
0.20
(0.008)
mm (in)
Maximum Grinding
Allowance
0.40
(0.016)
Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the manifold
must be replaced.
Exhaust Manifold Warpage
Standard
027RY00002
0.05 (0.002) or less
Limit
mm (in)
0.20 (0.008)
Valve Stem and Valve Guide Clearance

Measuring Method-I
011RY00022
1. With the valve stem inserted in the valve guide, set the dial
indicator needle to "0".
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the valve
and the valve guide must be replaced as a set.
Valve Stem Clearance
Intake Valve
Exhaust Valve
Standard
0.039 - 0.071
(0.0015 - 0.0028)
0.064 - 0.096
(0.0025 - 0.0038)
mm (in)
Limit
0.200
(0.008)
0.250
(0.0098)
Measuring Method-II
1. Measure the valve stem outside diameter.

Refer to the Item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to measure
the valve guide inside diameter.
011RY00023
Valve Guide Replacement

Valve Guide Removal
Use a hammer and the valve guide replacer to drive out the
valve guide from the cylinder head lower face.
Valve Guide Replacer: 9-8523-1212-0
011LX029
Valve Guide Installation
1. Apply engine oil to the valve guide outer circumference.

2. Attach the valve guide installer to the valve guide.
3. Use a hammer to drive the valve guide into position from
the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0
011RY00024
4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference)
12.8-13.2 (0.50-0.52)
NOTE:
mm (in)
If the valve guide has been removed, both the valve

011RY000025
Valve Stem Outside Diameter

Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the valve
Valve Stem Outside Diameter
Standard
Intake Valve
011LX027
Exhaust Valve
7.946 - 7.961
(0.3128 - 0.3134)
7.921 - 7.936
(0.3119 - 0.3124)
mm (in)
Limit
7.880
(0.3102)
7.850
(0.3090)
Valve Thickness
Measure the valve thickness.
Intake and Exhaust Valve Thickness
Standard
4JA1T (L)
014RY00020
Inlet
4JA1TC,
4JH1TC Exhaust
1.8 (0.07)
1.34 (0.054)
1.36 (0.055)
mm (in)
Limit
1.5 (0.06)
1.1 (0.045)
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head lower
surface.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.
Valve Depression
014RY00021
4JA1T(L)
4JA1TC, 4JH1TC
Standard
0.72 (0.029)
1.17 (0.048)
mm (in)
Limit
1.28 (0.050)
1.67 (0.068)
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width.
seat insert must be replaced.
Valve Contact Width
014RY00027
Intake
Exhaust
Standard
1.7 (0.067)
2.0 (0.079)
mm (in)
Limit
2.2 (0.087)
2.5 (0.078)
Valve Seat Insert Replacement
011LX039
Valve Seat Insert Removal

1. Arc weld the entire inside circumference (1) of the valve
seat insert (2).
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the valve
seat insert easier.
3. Use a screwdriver (3) to pry the valve seat insert free.
Take care not to damage the cylinder head (4).
4. Carefully remove carbon and other foreign material from
the cylinder head insert bore.
Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller

outside diameter than the valve seat insert) on the valve
seat insert (2).
NOTE:
The smooth side of the attachment must contact the

valve seat insert.
014RY00026
2. Use a bench press (3) to gradually apply pressure to the

attachment and press the valve seat insert into place.
NOTE:
Do not apply an excessive amount of pressure with

the bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15!, 45!, and 75! blades) to minimize
scratches and other rough areas. This will bring the
contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away unblemished
areas of the valve seat surface.
011LX063
Valve Seat Angle
45
Degree
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the

valve guide.
011LX037
011LX038
3.
4.
5.
6.
7.
Apply abrasive compound to the valve seat insert surface.

Insert the valve into the valve guide.
Turn the valve while tapping it to fit the valve seat insert.
Check that the valve contact width is correct.
Check that the valve seat insert surface is in contact with
the entire circumference of the valve.
Valve Spring Free Height

Use a vernier caliper to measure the valve spring free height.
spring must be replaced.
Spring Free Height
011LX024
4JA1T (L)
4JA1TC,
4JH1TC
Single spring
mm (in)
Standard
Limit
48.0 (1.89)
47.1 (1.85)
Valve Spring Squareness

Use a surface plate and a square to measure the valve spring
squareness.
Spring Squareness
014RY00025
4JA1T (L)
4JA1TC,
4JH1TC
Limit
Single spring
mm (in)
1.7 (0.070)
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
Valve Spring Tension
011LX026
4JA1T (L)
4JA1TC,
4JH1TC
Single
spring
N (kg/lb)
Compressed
Height
Standard
Limit
38.9mm
(1.53in)
296.0
(30.2/66.4)
257.7
(26.3/57.9)

Rocker Arm Shaft Run-Out
015LX008
1. Place the rocker arm shaft on a V-block.

2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm shaft
run-out with a bench press. The rocker arm must be at cold
condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.
Rocker Arm Shaft Run-Out
mm (in)
Limit
0.3 (0.012)
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting portion
outside diameter.
If the measured value is less than the specified limit, the rocker
arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter
Standard
015LX009
18.9819.00 (0.7470.748)
Limit
mm (in)
18.90 (0.744)
Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier caliper or a dial indicator to measure
the rocker arm inside diameter.
Rocker Arm Inside Diameter
Standard
19.01019.030
(0.7480.749)
Limit
mm (in)
19.100 (0.752)
014RY00024
2. Measure the rocker arm shaft outside diameter.

If the measured value exceeds the specified limit, replace
either the rocker arm or the rocker arm shaft.
Rocker Arm Shaft and Rocker Arm Clearance
Standard
0.010.05
(0.00040.0020)
Limit
0.20 (0.008)
mm (in)
3. Check that the rocker arm oil port is free of obstructions.
If necessary, use compressed air to clean the rocker arm
oil port.
014RY00024
Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.
014RY00023
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to "Cylinder Liner Replacement".
3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.
Cylinder Body Upper Face Warpage
Standard
012R100001
0.05 (0.002) or less
Limit
mm (in)
0.20 (0.008)
Cylinder Body Height (H) (Reference)

Standard
mm (in)
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)

4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner.

Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.
012RY00009
Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore at
measuring point (1) in the thrust (2-2) and axial (3-3) directions
of the crankshaft.
Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder
liner must be replaced.
012RY00010
Cylinder Liner Bore

4JA1T(L), 4JA1TC
4JH1TC
Standard
93.00 (3.6614)
95.40 (3.7559)
mm (in)
Limit
93.08 (3.6646)
95.48 (3.7590)
NOTE:
The inside of the dry type cylinder liner is chrome

plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection

1. Hold a straight edge along the top edge of the cylinder liner
to be measured.
2. Use a feeler gauge to measure each cylinder liner
projection.
Cylinder Liner Projection
Standard
mm (in)
0-0.1 (0-0.004)
012LX016
The difference in the cylinder liner projection height

between any two adjacent cylinders must not exceed 0.03
mm (0.0012 in).
Cylinder Liner Replacement
012RY00012
Cylinder Liner Removal

1. Insert the cylinder liner remover (1) into the cylinder body
(from the lower side of the cylinder body) until it makes firm
contact with the cylinder liner.
Cylinder Liner Remover : 5-8840-2039-0 (4JA1L/TC)
: 5-8840-2304-0 (4JH1TC)
2. Use a bench press (2) to slowly force the cylinder liner
from the cylinder body.
NOTE:
Take care not to damage the cylinder body upper face

during the cylinder liner removal procedure.
3. Measure the cylinder body upper face warpage.
Refer to "Cylinder Body Upper Face Warpage".
Cylinder Liner Grade Selection

Subtract the average cylinder body bore from the average
cylinder liner outside diameter to obtain the fitting interference.
Fitting Interference
Standard
mm (in)
-0.0010*-0.019 (-0.00004*-0.0007)
012RY00013
* A minus (-) value indicates that the cylinder body bore is

smaller than the liner outside diameter.
Cylinder Body Bore Measurement

1. Take measurements at measuring point (1) across
positions 1-1 and 2-2.
Measuring Point (1):
4JA1T(L), 4JA1TC : 13,48,83,118,153 mm
(0.51,1.89,3.27,4.65,6.02 in)
4JH1TC : 18,53,88,123,158 mm (0.71,2.09,3.46,4.84,6.22
in)
012RY00014
012R300001
Cylinder Liner Grade Selection and Standard

Fitting Interference
Accurately measured fitting interference and proper cylinder
liner grade selection are extremely important.
If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will be
difficult to insert the cylinder liner into the cylinder body.
A mark was stamped on the upper side of the cylinder block
during production to indicate the correct liner.
The liner grade (i.e.1.2.3.4) is indicated in metal stamp.
012RY00022
Cylinder Liner Grade

4JA1T (L), 4JA1TC
Liner
Cylinder Body
Outside
Bore Diameter
Grade
Liner Outside
Diameter
Liner Bore
Grade
Service Liner Bore Measurement
AX
93.035-93.050 (3.6628-3.6634)
95.001-95.010
(3.7402-3.7405)
95.011-95.020
(3.7406-3.7409)
95.011-95.020
(3.7406-3.7409)
95.021-95.030
(3.7410-3.7413)
95.021-95.030
(3.7410-3.7413)
95.031-95.040
(3.7414-3.7417)
95.031-95.040
(3.7414-3.7417)
95.041-95.050
(3.7418-3.7421)
4JH1TC
Liner
Outside
Grade
mm (in)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
AX
AX
AX
93.035-93.050 (3.6628-3.6634)
95.035-93.050 (3.6628-3.6634)
93.035-93.050 (3.6628-3.6634)
mm (in)
Cylinder Body
Bore Diameter
Liner Outside
Diameter
Liner Bore
Grade
Service Liner Bore Measurement
97.001-97.010
(3.8189-3.8193)
97.011-97.020
(3.8193-3.8197)
AX
95.435-95.450 (3.7573-3.7579)
97.011-97.020
(3.8193-3.8197)
97.021-97.030
(3.8197-3.8200)
97.021-97.030
(3.8197-3.8200)
97.031-97.040
(3.8200-3.8205)
97.031-97.040
(3.8200-3.8205)
97.041-97.050
(3.8205-3.8209)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
AX
AX
AX
95.435-95.450 (3.7573-3.7579)
95.435-95.450 (3.7573-3.7579)
95.435-95.450 (3.7573-3.7579)
Cylinder Liner Installation

1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the
cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and
bore surfaces.
NOTE:
012RY00017
All foreign material must be carefully removed from

the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2)
from the top of the cylinder body.
4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).
NOTE:
Check that the cylinder liner is set perpendicular to

the bench press and that there is no wobble.
012RY00018
6. Use the bench press to apply a seating force of 4,900

N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully
seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder
liner projection.
Refer to "Cylinder Liner Projection Inspection".
Piston Grade Selection

Measure the cylinder liner bore after installing the cylinder liner.
Then select the appropriate piston grade for the installed
cylinder liner.
1. Measure the cylinder liner bore.
Refer to "Cylinder Liner Bore Measurement"
Cylinder Liner Bore (Service Part) Grade
Grade
4JA1T(L)
4JA1TC
4JH1TC
NOTE:
AX
CX
AX
CX
mm (in)
Bore measurement
93.035-95.050
(3.6628-3.6634)
93.051-95.066
(3.6634-3.6640)
95.435-95.450
(3.7573-3.7579)
95.451-95.466
(3.7579-3.7585)
It is most important that the correct piston grade be

used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
2. Measure the piston diameter.
Piston Measuring Point
4JA1T(L)
4JA1TC
4JH1TC
78 (3.07)
70 (2.76)
Piston Grade (Service Part)

015LX021
4JA1T(L)
4JA1TC
4JH1TC
mm (in)
AX
CX
AX
CX
mm (in)
92.949 - 92.964
(3.6549 - 3.6600)
92.965 - 92.980
(3.6600 - 3.6606)
95.359 - 95.374
(3.7542 - 3.7548)
95.375 - 95.390
(3.7548 - 3.7555)
Cylinder Liner and Piston Clearance

mm (in)
4JA1T(L)
0.041-0.071 (0.0016-0.0027)
4JA1TC
4JH1TC
0.047-0.065 (0.0019-0.0026)
NOTE:
Cylinder liner kit clearances are preset. However, the

cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.
TAPPET AND PUSH ROD
014RY00028
Visually inspect the tappet contact surfaces for pitting,

cracking, and other abnormal conditions. The tappet must be
replaced if any of these conditions are present.
Refer to the illustration at the left.
1. Normal contact
2. Cracking
3. Pitting
4. Irregular contact Uneven contact
5. Irregular contact One-sided contact
NOTE:
The tappet surfaces are spherical. Do not attempt to

grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
Tappet Outside Diameter

Measure the tappet outside diameter with a micrometer.
If the measured value is less than the specified limit, the tappet
must be replaced.
Tappet Outside Diameter
Standard
014RY00029
Limit
12.97 - 12.99
(0.510 - 0.511)
12.95 (0.510)
Tappet and Cylinder Body Clearance

Standard
0.01 - 0.046
(0.0004 - 0.0018)
012LX014
mm (in)
Limit
mm (in)
0.10 (0.004)
Push Rod Curvature

1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and measure the
push rod curvature with a thickness gauge.
If the measured value exceeds the specified limit, the push
rod must be replaced.
Pushrod Curvature
014RY00031
Limit
mm (in)
0.3 (0.012)
3. Visually inspect both ends of the push rod for excessive
wear and damage. The push rod must be replaced if these
conditions are discovered during inspection.
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.
Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal diameter
in two directions (1 and 2). If the measured value is less than
the specified limit, the camshaft must be replaced.
Camshaft Journal Diameter
Standard
014RY00032
49.945 - 49.975
(1.9663 - 1.9675)
Limit
mm (in)
49.60 (1.953)
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.
Cam Height (H)
Standard
42.016 (1.6542)
014RY00033
Limit
mm (in)
41.65 (1.640)
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
camshaft must be replaced.
Camshaft Run-Out
Standard
014LX092
0.02 (0.0008)
Limit
mm (in)
0.10 (0.004)
Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft bearing
inside diameter.
Crankshaft Bearing Inside Diameter
Standard
50.00 - 50.03
(1.968 - 1.970)
014RY00034
Limit
mm (in)
50.08 (1.972)
If the clearance between the camshaft bearing inside diameter

and the journal exceeds the specified limit, the camshaft
bearing must be replaced.
Camshaft Bearing Clearance
Standard
0.055 (0.0022)
Limit
mm (in)
0.12 (0.005)
Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
014RY00035
014RY00036
Camshaft Bearing Installation

1. Align the bearing oil holes with the cylinder body oil holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and crankpins for
excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and
damage.
Inspect the oil ports for obstructions.
NOTE:
To increase crankshaft strength, tufftriding (Nitrizing

Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.
Therefore, under size bearing are not available.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft journal.

2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
crankshaft must be replaced.
015LX061
Crankshaft Run-Out
Standard
Limit
0.05 (0.002) or less
mm (in)
0.08 (0.003)
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
Bearing Spread
015RY00007
Creankshaft Bearing
Connecting Rod Bearing
4JA1T (L),
4JA1TC
4JH1TC
mm (in)
Limit
64.5 (2.54)
74.5 (2.93)
56.5 (2.22)
Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal
diameter across points 1 - 1 and 2 - 2.
2. Use the micrometer to measure the crankshaft journal
diameter at the two points (3 and 4).
3. Repeat Steps 1 and 2 to measure the crankpin diameter.
If the measured values are less than the specified limit, the
crankshaft must be replaced.
015RY00008
Crankshaft Journal and Diameter

4JA1T (L),
4JA1TC
4JH1TC
Standard
59.921-59.928
(2.3591-2.3594)
69.917-69.932
(2.7526-2.7532)
Limit
59.91 (2.3586)
69.91(2.7524)
Crankpin Diameter
Standard
52.915 - 52.930
(2.0833 - 2.0839)
mm (in)
Limit
mm (in)
52.90 (2.083)
Crankshaft Journal and Crankpin Uneven Wear

Standard
0.05 (0.002) or less
Limit
mm (in)
0.08 (0.003)
Crankshaft Journal and Crankpin Diameter

If the clearance between the measured bearing inside diameter
and the crankshaft journal diameter exceeds the specified limit,
the bearing and/or the crankshaft must be replaced.
Crankshaft Journal and Bearing Clearance
Standard
015RY00009
0.032 - 0.077
(0.0013 - 0.0030)
Limit
mm (in)
0.110 (0.0043)
Connecting Rod Bearing Inside Diameter

1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening
method.
015RY00011
Connecting Rod Bearing Cap Bolt Torque

Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45!-60!
3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.
Crankpin and Bearing Clearance

If the clearance between the measured bearing inside diameter
and the crankpin exceeds the specified limit, the bearing
and/or the crankshaft must be replaced.
4JA1T (L),
4JA1TC
4JH1TC
Standard
0.029-0.066
(0.0011-0.0026)
0.029-0.083
(0.0011-0.033)
Limit
mm (in)
0.100(0.0039)
0.100 (0.0039)
Clearance Measurements (With Plastigage)
015RY00012

1. Clean the cylinder body, the journal bearing fitting surface,
the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30! to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal
across the full width of the bearing.
6. Install the bearing caps with the bearing.
7. Tighten the bearing caps to the specified torque.
Crankshaft Bearing Cap Bolt Torque
167 (17/123)
mm (in)
Do not allow the crankshaft to turn during bearing cap

installation and tightening.
8. Remove the bearing cap.
015RY00013
015LX129
015LX060
9. Compare the width of the Plastigage attached to either the

crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1. Use a micrometer to measure the crankshaft outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the bearing
must be replaced.
Standard
0.032 - 0.077
(0.0013 - 0.0030)
Limit
mm (in)
0.110 (0.0043)

1. Clean the crankshaft, the connecting rod, the bearing cap,
and the bearings.
2. Install the bearing to the connecting rod and the bearing
cap.
Do not allow the crankshaft to move when installing the
bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from falling.
5. Install the bearing cap and tighten it to the two step of
anglar tihtening method.
Do not allow the connecting rod to move when installing
and tightening the bearing cap.
Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45!-60!
6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the specified limit, perform
the following additional steps.
1. Use a micrometer to measure the crankpin outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing must
be replaced.
4JA1T (L),
4JA1TC
4JH1TC
Standard
0.029-0.066
(0.0011-0.0026)
0.029-0.083
(0.0011-0.0033)
Limit
mm (in)
0.100 (0.0039)
0.100 (0.0039)
CRANKSHAFT BEARING SELECTION

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing inserts.
Match the crankshaft bearing housing grade marks and the
crankshaft journal grade marks in the table below to determine
the correct crankshaft bearing size.
Crankshaft Bearing Housing Grade Mark

Position
Crankshaft bearing housing grade marks 1, 2 or 3 are stamped
on the rear right hand side of the cylinder body.
015LX060
Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or -, 2 or --, 3 or ---) are
stamped on each crankshaft journal web.
The crankshaft journal and bearing clearance must be the
same for each position after installation of the crankshaft and
the crankshaft bearings.
NOTE:
015RY00016
The crankshaft journal mark No. 4 is stamped on

crankshaft No. 4 journal web front side or rear side.
REFERENCE
4JA1T(L), 4JA1TC
Crankshaft
Bearing Housing
015RY00017
Grade
Mark
Diamaeter
63.99264.000
(2.51942.5197)
63.98363.992
(2.51902.5194)
RTW46ASH002501
63.97563.983
(2.51872.5190)
mm (in)
Crankshaft Journal
Grade
Mark
Diamaeter
1 or
-
59.927-59.932
(2.3593-23.595)
3 or
---
59.917-59.922
Yellow or 5
(2.3589-2.3591)
2 or
--
1 or
2 or
--
3 or
---
59.922-59.927
(2.3591-2.3539)
59.927-59.932
(2.3593-2.3595)
59.922-59.927
(2.3591-2.3593)
Grade
Mark
Diamaeter
73.99274.000
(2.91312.9134)
73.98373.992
(2.91272.9131)
73.97573.983
(2.91242.9127)
Brown or 4
Black or 2
Blue or 3
59.917-59.922
Brown or 4
(2.3589-2.3591)
1 or
-
59.927-59.932
Green or 1
(2.3593-2.3595)
3 or
---
59.917-59.922
(2.3598-2.3591)
2 or
--
59.922-59.927
(2.3591-2.3593)
4JH1TC
Crankshaft
Bearing Housing
Crankshaft
Bearing
Size Code
Black or 2
mm (in)
Crankshaft Journal
Grade
Mark
Diamaeter
1 or
-
69.927-69.932
(2.7530-2.7532)
3 or
---
69.917-69.922
(2.7556-2.7528)
2 or
--
1 or
2 or
--
3 or
---
69.922-69.927
(2.7528-2.7530)
69.927-69.932
(2.7530-2.7532)
69.922-69.927
(2.7528-2.7530)
69.917-69.922
(2.7556-2.7528)
1 or
-
69.927-69.932
(2.7530-2.7532)
3 or
---
69.917-69.922
(2.7526-2.7528)
2 or
--
69.922-69.927
(2.7528-2.7530)
Crankshaft
Bearing
Size Code
4
5
2
3
4
1
2
CRANKSHAFT PILOT BEARING

Check the crankshaft pilot bearing for excessive wear and
damage and replace it if necessary.
Crankshaft Pilot Bearing Replacement

Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the crankshaft pilot
bearing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
015RY00018
Crankshaft Pilot Bearing Installation

1. Place the crankshaft pilot bearing right angle across the
crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing outer
races with a brass hammer to drive the bearing into the
crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0
NOTE:
015RY00010
Strike only the crankshaft pilot bearing outer race with

the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.
FLYWHEEL AND RING GEAR

Flywheel
015RY00019
1. Inspect the flywheel friction surface for excessive wear and

heat cracks.
2. Measure the flywheel friction surface depth.
If the measured value is within the specified limit, the
flywheel may be reground.
flywheel must be replaced.
Flywheel Friction Surface Depth (1)
4JA1T (L),
4JA1TC
4JH1TC
mm (in)
Standard
Limit
20 (0.7874)
21 (0.8267)
18 (0.7087)
19 (0.7480)
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
Ring Gear Replacement

Ring Gear Removal
Strike around the edges of the ring gear with a hammer and
chisel to remove it.
020LX008
020LX009
Ring Gear Installation

1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to exceed
200!C (390!F).
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer facing the
clutch.
PISTON
Piston Grade Selection and Cylinder Bore
Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore
Measurement" for details on piston grade selection and
cylinder liner bore measurement.
Piston Ring Gap

1. Insert the piston ring horizontally (in the position it would
assume if it were installed to the piston) into the cylinder
liner.
015LX023
015RY00020
2. Push the piston ring into the cylinder bore until it reaches
the measuring point 1 or 2 where the cylinder liner bore is
the smallest.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in)
3. Use a feeler gauge to measure the piston ring gap.
piston ring must be replaced.
Piston Ring Gap
4JA1T (L), 4JA1TC
1st Compression Ring
015RY00021
2nd Compression Ring

Oil Ring
4JH1TC

Oil Ring
mm (in)
Standard
0.3-0.3
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Standard
0.3-0.5
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Limit
1.5
(0.059)
Limit
1.5
(0.059)
Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between the
piston ring and the piston ring groove at several points around
the piston.
If the clearance between the piston ring and the piston ring
groove exceeds the specified limit, the piston ring must be
replaced.
015LX025
Piston Ring and Piston Ring Groove Clearance

4JA1T (L), 4JA1TC
Oil Ring
4JH1TC
Oil Ring
mm (in)
Standard
Limit
0.05-0.085
(0.0020-0.0033)
0.15
(0.0059)
Standard
Limit
0.05-0.090
(0.0020-0.0035)
0.15
(0.0059)
0.09-0.125
(0.0035-0.0049)
0.03-0.070
(0.0012-0.0028)
0.09-0.130
(0.0035-0.0051)
0.03-0.070
(0.0012-0.0028)
4. Visually inspect the piston rings.
If a piston ring groove is damaged or distorted, the piston
must be replaced.
Piston Pin Diameter

Use a micrometer to measure the piston pin diameter at
several points.
If the measured value is less than the specified limit, the piston
pin must be replaced.
Piston Pin Diameter
Standard
015LX026
Limit
30.995-31.000
(1.2202-1.2204)
mm (in)
30.97
(1.2193)
Piston Pin and Piston Clearance

Use and inside dial indicator to measure the piston pin hole (in
the piston).
Piston Pin Hole
4JA1T (L)
4JA1TC, 4JH1TC
015RW048
mm (in)
31.002-31.010 (1.2206-1.2208)
31.005-31.013 (1.2207-1.2210)
Piston Pin and Piston Pin Hole Clearance

4JA1T (L)
4JA1TC, 4JH1TC
mm (in)
0.002-0.015 (0.00008-0.0006)
0.005-0.018 (0.0002-0.0007)
CYLINDER HEAD GASKET SELECTION
011LX011
Cylinder head gasket is determined by the piston head

projection from the cylinder body upper surface, in order to
improve engine performance.
Three types of gasket are provided by the difference of
thickness. Select the adequet one out of three grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston head
and cylinder body surface and also clean the place where a
gasket was installed.
Piston Head Projection Measuring Point

1. Use a dial indicator to measure the piston projection
amount.
2. Refer to the illustration for the piston head projection
measuring positions.
All measuring positions should be as close as possible to
the cylinder liner.
RTW36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two differences 12 and 3-4 on each cylinder.
Calculate the average value of the piston head projection
on each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum
value described above in accordance with the following
table.
011RY00027
Cylinder Head Gasket Combination

Cylinder Head Gasket Combination
4JA1T (L), 4JA1TC
Gasket Grade Mark Piston Projection
A
B
011RY00030
0.718-0.773
(0.0283-0.0304)
0.773-0.819
(0.0304-0.0322)
0.819-0.874
(0.0322-0.0344)
4JH1TC
B
C
NOTE:
mm (in)
Gasket Thickness
(Reference)
1.6
(0.0630)
1.65
(0.0650)
1.70
(0.0669)
mm (in)
Gasket Grade Mark Piston Projection

A
mm (in)
0.215-0.265
(0.0085-0.0104)
0.265-0.315
(0.0104-0.0124)
0.315-0.365
(0.0124-0.0144)
Gasket Thickness
(Reference)
1.3
(0.5118)
1.35
(0.5315)
1.4
(0.5512)
Difference of the each piston projection and must be

equal or within 0.1 mm (0.004 in).
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.
015LX034
Connecting Rod Alignment Per Length of 100 mm (3.94 in)

mm (in)
Distortion
Parallelism
Standard
Limit
0.08 (0.003) or Less
0.20 (0.008)
0.05 (0.002) or Less
0.15 (0.006)
Connecting Rod Side Face Clearance

1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance between the
connecting rod big end side face and the crankpin side
face.
connecting rod must be replaced.
011RY00029
Connecting Rod Big End and Crankpin Side Face Clearance

mm (in)
Standard
Limit
0.23 (0.009)
0.35 (0.014)
Piston Pin and Connecting Rod Small End

Bushing Clearance
Use a caliper calibrator and a dial indicator to measure the
piston pin and connecting rod small end bushing clearance.
If the clearance between the piston pin and the connecting rod
small end bushing exceeds the specified limit, replace the
piston pin and/or the connecting rod.
015LX028
Piston Pin and Connecting Rod Small End

Bushing Clearance
Standard
4JA1T (L)
4JA1TC,
4JH1TC
0.008-0.020
(0.003-0.0008)
0.005-0.018
(0.0002-0.0007)
Limit
mm (in)
0.050 (0.002)
0.050 (0.002)
IDLER GEAR SHAFT AND IDLER GEAR

Idler Gear "A" Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside
diameter.
If the measured value is less than the specified limit, the idler
gear shaft must be replaced.
020RY00025
Idler Gear "A" Shaft Outside Diameter

Standard
44.945-44.975
(1.7695-1.7707)
Limit
mm (in)
44.845 (1.755)
Idler Gear "A" Shaft inside Diameter

1. Use an inside dial indicator or an inside micrometer to
measure the idler gear inside diameter.
Idler Gear Inside Diameter
Standard
45.0-45.03
(1.7717-1.7718)
014LX022
Limit
mm (in)
45.10 (1.7756)
If the clearance between the idler gear shaft outside diameter

and the idler gear inside diameter exceeds the limit, the idler
gear must be replaced.
Idler Gear Shaft and Idler Gear Clearance
Standard
0.025-0.085
(0.0010-0.0033)
Limit
mm (in)
0.200 (0.0079)
TIMING GEAR CASE COVER

Replace the crankshaft front oil seal if it is excessively worn or
damaged.
Crankshaft Front Oil Seal Replacement
020R300004
Oil Seal Removal

Use a plastic hammer and a screwdriver to tap around the oil
seal to free it from the gear case cover.
Take care not to damage the oil seal lip surfaces.
020R300005
Oil Seal Installation

Use the special tool to install the front oil seal.
Front Oil Seal Installer: 5-8840-2361-0
1. With the oil seal attached to the sleeve, insert it into the
front end section of the crankshaft.
2. With the oil seal end section attached securely to the
crankshaft, tighten up the center bolt until the sleeve hits
the front end reference plane of the crankshaft securely.
3. Remove the sleeve.
4. With the seal pressed in, check the dimension of the oil
seal section.
Standard Dimension = 1.0 " 0.03mm
NOTE:
Install the oil seal after assembling the timing pulley

housing. The oil seal lip section is applied with oil.
Take notice of the press-in direction of the oil seal.
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
020RY00029
Reassembly Steps
1.
2.
3.
4.
Rocker arm shaft

Rocker arm
Rocker arm shaft bracket
5.
6.
7.
Rocker arm
Rocker arm shaft spring
Reassembly
014RY00037
1. Rocker Arm Shaft

1. Position the rocker arm shaft with the large oil hole (4
!) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1.
2.
3.
4.
5.
Cylinder head
Valve spring lower seat
Valve stem oil seal
Intake and exhaust valve
Valve spring
6.
7.
8.
9.
Valve spring upper seat

Split collar
Intake manifold gasket
Intake manifold
Reassembly
011RW027
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
6. Valve Spring Upper Seat
011LX055
014RY00039
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
8. Intake manifold gasket

9. Intake manifold
1. Install the manifold gasket with the end having the
sharp corners facing the rear of the engine.
2. Install the intake manifold to the cylinder head.
3. Tighten the manifold bolt/nuts to the specified torque.
Manifold Bolt/Nut Torque
RTW46ASH002301
Bolt
Nut
19 (1.9/14)
24 (2.4/17)
Nm(kgm/lbft)
PISTON AND CONNECTING ROD
RTW46ALF000301
Reassembly Steps
1.
2.
3.
4.
Piston
Connecting rod
Piston pin
5.
6.
7.

Piston ring
Connecting rod bearing
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
F06MV015
Install the piston to the connecting rod so that the piston

head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
RTW36ASH001801
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
RTW36ASH001901

1. Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the
piston pin.
015R100001
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
NOTE:
Install the compression rings with the stamped side

facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the
piston ring grooves
7. Connecting Rod Bearing

Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
015R100006
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
RTW46AMF000101
Reassembly Steps
1.
2.
3.
4.
Positive Crankcase Ventilation

(PCV) Valve
Rubber space
Cylinder head insulator cover
Breather pipe
5.
6.
Fixing bolt
Oil filler cap
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
PCV Valve Bolts Torque
010R100014
2 (0.2/17)
Nm(kgm/lb in)
2. Rubber Spacer
3. Cylinder Head Insulator Cover
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
Fixing Bolt Torque
RTW36ASH001401
6. Oil Filler Cap
19 (1.9/14)
Nm(kgm/lb in)
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1.
Cylinder body
10.
2.
Tappet
11.
3.
Crankshaft upper bearing
12.
4.
5.
6.
7.
8.
9.
Crankshaft
Crankshaft thrust bearing
Crankshaft bearing cap with
lower bearing
Camshaft
Timing gear case
Camshaft thrust plate
13.
14.
15.
16.
17.
18.
Camshaft timing gear

Piston and connecting rod with
upper bearing
Connecting rod bearing cap with
lower bearing
Piston cooling oil pipe
Oil pump with oil pipe
Crankshaft rear oil seal
Crank case
Cylinder body rear plate
Flywheel
RTW46ALF000501
Reassembly Steps-2
19.
20.
21.
22.
Crankshaft timing gear

Idler gear shaft
Idler gear "A"
Idler gear "B" and shaft
23.
24.
25.
26.
Injection pump
Water pump
Timing gear case cover
Crankshaft damper pulley
011R300002
Reassembly Steps-3
27.
28.
29.
30.
Cylinder head gasket
Cylinder head
Push rod
Rocker arm shaft and rocker
arm
31.
32.
33.
34.
Thermostat housing with thermo

switch
Water by-pass hose
Injection nozzle and bracket
Cylinder head cover with gasket
Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
015R100003
2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).
NOTE:
The tappet must be installed before the camshaft

installation.
014LX088
3. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and an oil
groove. The lower bearings do not.
1. Carefully wipe any foreign material from the upper
bearing.
NOTE:
Do not apply engine oil to the bearing back faces and

the cylinder body bearing fitting surfaces.
015LX125
2. Locate the position mark applied at disassembly if the

removed upper bearings are to be reused.
4. Crankshaft
Apply an ample coat of engine oil to the crankshaft journals
and the crankshaft bearing surfaces before installing the
crankshaft.
015R100004

5. Crankshaft Thrust Bearing
Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
015LX115
015LX127
6. Crankshaft Bearing Cap With Lower Bearing

Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. Apply the recommended liquid gasket or its equivalent
to the No. 5 crankshaft bearing cap cylinder body fitting
surfaces at the points shown in the illustration.
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket. Three bond 1207B Do not allow the liquid
gasket to obstruct the cylinder thread holes and
bearings.
ThreeBond 1207B is a fast-drying liquid gasket.
Tighten the bearing caps immediately after applying

the gasket.
2. Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.The bearing
cap numbers must be facing up.
3. Apply engine oil to the crankshaft bearing cap bolts.
015LX128
4. Tighten the crankshaft bearing cap bolts to the

specified torque a little at time in the sequence shown
in the illustration.
Crankshaft Bearing Cap Torque
167 (17/123)
015LX129
Nm(kgm/lbft)
5. Check to see the crankshaft turns smoothly by rotating

it manually.

7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
014RY00019
8. Timing Gear Case

Tighten the timing gear case with timing gear case gasket
to the specified torque.
Timing Gear Case Bolt Torque
19 (1.9/14)
020R300003
9. Camshaft Thrust Plate

Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.
Thrust Plate Bolt Torque
020RY00032
Nm(kgm/lbft)
19 (1.9/14)
Nm(kgm/lbft)
10. Camshaft Timing Gear
1. Install the camshaft timing gear to the camshaft. The

timing gear mark must be facing outward.
2. Tighten the timing gear to the specified torque.
Timing Gear Bolt Torque
110 (11.2/82)
RTW36ASH000901
Nm(kgm/lbft)

11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
015R100006
015LX096
015R100007
3. Apply a coat of molybdenum disulfide grease to the two

piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.
6. Position the piston head front mark so that it is facing

the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
9. Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.

10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of
anglar tigthen method.
015LX130

Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45!-60!
13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified
torque.
Oil Jet Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
M8 " 1.25
8 (0.8/6)
M6 " 1.00
052LX010
Relief Valve Torque
29 (3.0/22)
Nm(kgm/lbft)
NOTE:
Check that there is no interference between the piston

and the oiling jet by slowly rotating the crankshaft.
14. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.
Oil Pump Bolt Torque
19 (19/14)
Nm(kgm/lbft)
NOTE:
051R100004
Take care not to damage the O-rings when tightening

the oil pipe bolts.
15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer : 5-8840-2359-0
015LX112

16. Crank Case
1. Apply the recommended liquid gasket (Three bond
1207B) or its equivalent to arch gasket fitting surface
as shown in the illustration.
2. Install the crankcase front gasket (1) to the timing gear
case arches.
The gasket projection (2) must be facing forward.
NOTE:
ThreeBond 1207B is a fast-drying liquid gasket.
013RW012
Install the arch packing to the crankcase immediately

aftter applying the gasket.
3. Install the rear arch gasket (2) to the No. 5 bearing
cap. Use your fingers to push the arch gasket into the
bearing cap groove.Take care not to scratch the arch
gasket outer surface.
Also apply the recommended liquid gasket (1207C) or
its equivalent to arch gasket fitting area as indicated in
the illustration.
013RW011

to groove of the crankcase fitting surface as shown in
the illustration.
NOTE:
Be sure that the crank case fitting surface is

completely free of oil and dust before applying the
liquid gasket.
013LV003
5. Install the crank case to the cylinder body.

6. Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.
Crank Case Bolt Torque
013R100001
19 (1.9/14)
Nm(kgm/lbft)

17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.
Rear Plate Torque
020R100001
18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0
Flywheel Bolt Torque
015LX113
82 (8.4/61)
Nm(kgm/lbft)
118 (12/87)
Nm(kgm/lbft)
19. Crankshaft Timing Gear

Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0
020RY00034
020RY00035
20. Idler Gear Shaft

21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.

4. Align the idler gear setting mark with the crankshaft
timing gear (1) setting mark.
5. Align the idler gear setting mark with the camshaft
timing gear (2) setting mark.
6. Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
7. Tighten the idler gear bolt to the specified torque.
020RY00036
Idler Gear "A" Bolt Torque
30 (3.1/22)
Nm(kgm/lbft)
22. Idler Gear "B" and Shaft
1. Apply engine oil to the idler gear and the idler gear shaft.
2. Align the idler gear "B" (3) setting mark with the idler
gear "A" (4) setting mark.
3. Tighten the idler gear bolt to the specified torque.
4. Be sure to remove the lock bolt (5) from idle gear B.
Idler Gear "B" Bolt Torque

020R300006
76 (7.7/56)
Nm(kgm/lbft)
5. If the idle gear "B" is disassembled, reassemble in the

following procedure.
1) Drive pins into the main gear, the front gear, and the
rear gear.
020L200019
2) Install the main gear bearing from the front side of

the main gear (the side with the groove).
3) Place the main gear in a vise with copper plate so
that the rear side of the main gear facing up.
020L200007

4) Set the spring as shown in the illustration.
RTW31BSH000101
5) Position the rear gear so that the pin is aligned with

the receiving end of the spring.
RTW31BSH000201
6) Install the snap ring to the main gear groove.
RTW31BSH000301
7) Install suitable bolts, nuts and washers to special tool

as shown in the illustration to rotate the scissors
gear.
End yoke holder: 5-8840-2447-0
RTW31BSH000501
RTW31BSH000401
8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6 " 1 L=30) into scissors gear
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gear
with lock bolt (inserted at Step 8).

23. Injection Pump
1. Install the O-ring (1) to the injection pump flange (2).

2. Attach the noise insulator rubber to the cylinder body .
3. Install the injection pump to the timing gear case.Align
the idler gear "B" (3) mark with the injection pump timing
gear (4) mark.
020RY00039
4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified

torque.
Injection Pump Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
5. Install the injection pump bracket (6) and the bracket

bolts (7) and (8) to the cylinder body.
Temporarily tighten the bracket bolts.
6. Tighten the bracket bolts (7) to the specified torque.
7. Tighten the bracket bolt (8) to the specified torque.
NOTE:
Tighten the bracket bolt (7) first.
Injection Pump Bracket Bolt Torque
19 (1.9/14)
RTW36AMH000101
Nm(kgm/lbft)

4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.

5. Install the injection pump bracket (4) and the bracket
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
Injection pump Bracket Bolt Torque (6)
Nm(kgm/lbft)
Injection pump Bracket Bolt Torque (5)
Nm(kgm/lbft)
19 (1.9/14)
RTW46ASH002201
40 (4.1/30)
24. Water Pump

to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.
Water Pump Bolt Torque
20 (2.0/14)
030RY00007
25.Timing Gear Case Cover

1. Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.
Gear Case Cover Bolt Torque
M8
020R300004
Nm(kgm/lbft)
M12
Nm(kgm/lbft)
19 (1.9/14)
76 (7.7/56)
26. Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.
Crankshaft Damper Pulley Bolt Torque

014R100014
206 (21/152)
Nm(kgm/lbft)
Take care not to damage the crankshaft damper pulley

boss.

27. Cylinder Head Gasket
The cylinder head gasket "TOP" mark must be facing up.
NOTE:
Before the gasket installation, measure the piston

head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head

Gasket Selection".
28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.
3. Tighten the cylinder head bolts in three steps of anglar
tightening methed.
Follow the numerical sequence shown in the
illustration.
Cylinder Head Bolt Torque
1st step
2nd step
011LX073
Nm(kgm/lbft)
49 (5.0/36)
60! - 75!
3rd step
60! - 75!
30. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.
Rocker Arm Shaft Braket Bolt Torque
54 (5.5/40)
014LX083
31. Thermostat Housing

1. Install the thermostat housing.
2. Tighten the thermostat housing bolts to the specified
torque.
Thermostat Housing Bolt Torque
19 (1.9/14)
031R300002
Nm(kgm/lbft)
Nm(kgm/lbft)

33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the
injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder
bracket to the cylinder head.
RTW46ASH001201
3. Tighten the nozzle holder bracket bolt to the specified

torque.
Injection Nozzle Holder Bracket Bolt
Torque
Nm(kgm/lbft)
37 (3.8/28)
Note on Valve Clearance Adjustment

Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.
Valve Clearance (At Cold)
0.4 (0.0157)
014RY00015
34. Cylinder Head Cover

1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head
cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical
order shown in the illustration.
Cylinder Head Cover Bolt Torque
RTW46ASH001101
mm(in)
13 (1.3/9.4)
Nm(kgm/lbft)
4. Connect the positive crankcase ventilation (PCV) hose

to the cylinder head cover.
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1.
2.
3.
4.
5.
6.
Exhaust Manifold
Oil Cooler with Oil Filter
Generator Bracket
Water Inlet Pipe
Generator and Adjusting Plate
Vacuum Pump Oil Return Hose
19.
20.
8.
Turbocharger
23.
7.
Compressor Bracket
18.
21.
22.
9.
10.
11.
Catalytic Converter
Heat Protector
Cooling Fan Pulley
24.
25.
26-1.
13.
Fuel Leak Off Pipe
27.
12.
14.
15.
16.
17.
Oil Cooler Water Pipe
Oil Pressure Warning Switch

Starter Motor
Injection Pump
Injection Pump Cover
26-2.
28.
Engine Mounting Bracket and

Foot
Intake Manifold
Power Steering Oil Pump
Bracket
Fuel Injection Pipe with Clip
Fuel Filter Bracket (Except
EURO III)
Fuel Filter Assembly (Except
EURO III)
Oil Level Gauge
EGR Valve
EGR Pipe
EGR Cooler (EURO III model
only)
Intake Pipe and Throttle Body
Clutch Assembly or Flex Plate
Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque
Nm(kgm/Ib ft)
027R100003
27 (2.7/20)
3) Install the exhaust manifold bracket to the manifold

and the cylinder body.
Manifold Bracket Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
027R100004
2. Oil Cooler with Oil Filter

1) Install the O-ring to the oil filter body flange groove.
2) Install the oil filter body to cylinder block and tighten to
the specified torque.
Oil Filter Body Bolt and Nut
Torque
Nm(kgm/Ib ft)
BOLT 19 (1.9/14)
NUT 24 (2.4/17)
RTW46ASH001301
3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
40 (4.1/30)
066RY00001

4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified
torque.
Suction Pipe Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
032R300001
5. Generator and Adjusting Plate

1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and
adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.
066RY00002
3) Connect the vacuum pump rubber hose (4) to the

vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose

Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body
052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
M8!1.25
M10!1.25
042RY00003
19 (1.9/14)
40 (4.1/30)

8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.
027R100002
3) Install the oil return pipe with gasket to the

turbocharger.
4) Tighten the turbocharger oil return pipe to the
specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
8 (0.8/6)
036R100001
5) Before installing the oil feed pipe, supply 10 - 20 cc of

clean engine oil to the turbocharger center housing
through the oil feed opening.
6) Turn the rotating assembly with your hand to
thoroughly lubricate the internal parts.
7) Tighten the oil feed pipe to the specified torque.
Turbocharger Oil Feed Pipe Joint
Bolt Torque
Nm(kgm/Ib ft)
M10!1.5
RTW46ASH001501
22 (2.25/16)
M14!1.5
54 (5.5/40)
8) Tighten the turbocharger nut to the specified torque.

Turbocharger Nut Torque
Nm(kgm/Ib ft)
27 (2.7/20)
027R100005

9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque
Nm(kgm/Ib ft)
39 (4.0/29)
10) Install the water feed pipe with the gaskets and tighten
Water Return Pipe Torque
Nm(kgm/Ib ft)
39 (4.0/29)
11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque
Nm(kgm/Ib ft)
39 (4.0/29)
12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque
Nm(kgm/Ib ft)
8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return.
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque
Nm(kgm/Ib ft)
27 (2.7/20)
Do not install the catalytic converter, if drop down it.
027R100007
10. Heat Protector

Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque
Nm(kgm/Ib ft)
9 (0.9/6.5 Ib in)
11. Cooling Fan Pulley

1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified
torque.
Pulley Nut Torque
Nm(kgm/Ib ft)
8 (0.8/6)
033R300002
12. Oil Cooler Water Pipe

13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch

15. Starter Motor
Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque
Nm(kgm/Ib ft)
85 (8.7/63)
16. Injection Pump

17. Injection Pump Cover (4JA1TC/4JH1TC only)
18. Engine Foot
Install the engine foot to the cylinder body and tighten the
bracket bolts to the specified torque.
Engine Foot Bolt Torque
Nm(kgm/Ib ft)
4JA1L, 4JH1TC
Right Side
Left Side
M10!1.25
40 (4.1/30)
M14!1.50
127 (13/93)
M10!1.25
40 (4.1/30)
022R300003
4JA1TC
RTW46ASH002601
19. Intake Manifold

1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts
Intake Manifold Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
RTW36ASH001001
Intake Manifold Flange Nut Torque
24 (2.4/18)
Nm(kgm/Ib ft)
4) Connect the PCV hose to the cylinder head cover.

5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section

Oil Pump Braket Nut and Bolt Torque
Nm(kgm/Ib ft)
M10!1.25
2
3
37 (3.8/28)
M8!1.25
18 (1.8/13) (Bolt ID:8)
431RY00013
040R300005

1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) Nm(kgm/Ib ft)
40 (4.1/30)
Injection Pipe Sleeve Nuts
Nm(kgm/Ib ft)
Injection Pipe Clip Nuts
Nm(kgm/Ib ft)
29 (3.0/22)
8 (0.8/6)

Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque
Nm(kgm/Ib ft)
21 (2.1/15)

Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque
Nm(kgm/Ib ft)
21 (2.1/15)
24. Oil Level Gauge

Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque
Nm(kgm/Ib ft)
M8
M6
19 (1.9/14)
8 (0.8/6)

25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque
Nm(kgm/Ib ft)
31 (3.1/23)
Connector the vacuum hose.
26-1. EGR Pipe

Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts
Nm(kgm/Ib ft)
24 (2.4/17)
EGR Pipe Bolts and Nuts
27 (2.7/20)
Nm(kgm/Ib ft)
025R100008
RTW36ASH000301
26-2. EGR Cooler (EURO III model only)
RTW48ASH001801
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)

Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct
Nm(kgm/Ib ft)
Bolt
Nut
RTW36ASH000201
19 (1.9/14)
24 (2.4/17)
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1.
2.
3.
4.
5.
6.
Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
The 4J series engine has a full flow type lubricating system.

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.
OIL PUMP AND OIL FILTER
RTW46ALF001501
The 4J series engine is equipped with a gear type oil pump.

The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.
OIL PUMP
DISASSEMBLY
051R100005
Disassembly Steps
1.
Oil pipe
2.
Strainer
3.
Pump cover
4.
Driven gear with bushing
Disassembly procedure is shown in the illustration above numerical order.
5.
6.
7.
8.
Driven gear
Relief valve assembly
Pinion gear
Oil pump body

inspection.
Gear Teeth and Body Inner Wall Clearance

gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, either the gear or the body
must be replaced.
Gear Teeth and Body Inner Wall Clearance
mm (in)
Standard
051RY00001
0.14 (0.0055)
Limit
0.20 (0.0079)
Gear and Body Clearance

body and the gear.
If the clearance between the gear and the body exceeds
the specified limit, the body must be replaced.
Gear and Body Clearance
mm (in)
Standard
0.06 (0.024)
Limit
0.15 (0.0059)
RTW46ASH002701
Drive Shaft and Oil Pump Body Clearance

Use a micrometer to measure the drive shaft outside
diameter.
Use an inside dial indicator to measure the pump body
inside diameter.
If the clearance between the drive shaft and the oil pump
body exceeds the specified limit, the oil pump assembly
must be replaced.
Drive Shaft and Oil Pump Body Clearance
mm (in)
051RY00003
Standard
0.04 (0.0016)
Limit
0.20 (0.0079)
REASSEMBLY
051R100006
Reassembly Steps
1.
Oil pump body
2.
Drive gear
3.
Driven gear
4.
Pump cover
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 Nm (1.6 kgm/12 lb ft)
5.
6.
7.
8.
Pinion gear
Strainer
Relief valve assembly
Oil pipe
OIL FILTER AND OIL COOLER

DISASSEMBLY
050R300004
Disassembly Steps
1.
Oil filter cartridge
5.
2.
Bolt
6.
3.
Gasket
7.
4.
Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
Body
Oil cooler relief valve
Regulating valve

inspection.
Oil Cooler
Water Leakage at Water Passage

1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
2
3. Apply compressed air (200kPa (2kg/cm / 28psi)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water leakage.
Should be replaced oil cooler assembly.
050RY00002
REASSEMBLY
050R300003
Reassembly Steps
1.
Body
5.
2.
Regulating valve
6.
3.
Oil cooler relief valve
7.
4.
Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
Gasket
Bolt
Oil filter cartridge

1. Body
2. Oil Filter Safety Valve
3. Oil Cooler Safety Valve
Tighten the oil filter A and oil cooler B relief valve to the
specified torque.
Regulating Valve
Nm(kgm/lb ft)
A
64 (6.5/48)
RTW46ASH001701
4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque
Nm(kgm/lb ft)
40 (4.1/30)
050R300006
7. Oil Filter Cartridge

1) Apply engine oil to the O-ring.
2) Tighten the oil filter cartridge to the specified torque.
Filter wrench: 5-8840-0201-0
Oil Filter Cartride Torque
Nm(kgm/lb ft)
18 (1.8/13)
050RY00004
INTER COOLER
RTW46ALF001001
Removal Steps
1. Radiator grille
2. Front bumper fascia
3. Front bumper inpact support assembly
4. Inter cooler
Installation Steps
4. Inter cooler
3. Front bumper inpact support assembly
2. Front bumper fascia
1. Radiator grille
Removal
1. Radiator Grille
! Refer to removal procedure in Sheet Metal section.
RTW36ASH000601
2. Front Bumper Fascia

! Remove the nine clips and four screws.
! Disconnect the fog light harness connectors.
RTW36ASH000501
3. Front Bumper Impact Support Assembly

! Remove the nut and two bolts.
RTW46ASH002101
4. Inter Cooler
! Remove the nut and two bolts.
! Disconnect the air hose.
Installation
4. Inter Cooler
! Tighten the nut and two bolts.
3. Front Bumper Impact Support Assembly
! Tighten the nut and two bolts.
2. Front Bumper Fascia

! Install the nine clips and four screws.
! Connect the fog light harness connectors.
1. Radiator grille
! Refer to installation procedure in Sheet Metal section.
SPECIAL TOOLS
Illustration
Tool Number
Tool Name
5-8840-0201-0
Filter Wrench
5-8840-0253-0
Filter Wrench
5-8840-2675-0
Compression Gauge
5-8531-7001-0
Adapter; Compression Gauge
5-8840-2723-0
Nozzle Holder Remover
5-8840-0019-0
Sliding Hammer
5-8521-0002-0
Universal Puller
5-8840-2360-0
Oil Seal Remover
9-8523-1423-0
Spring Compressor
9-8523-1212-0
Valve Guide Replacer
Illustration
Tool Number
5-8840-2040-0 (4JA1L/TC)
5-8840-2313-0 (4JH1TC)
Tool Name
Cylinder Liner Installer
5-8840-2038-0
Bearing Replacer; Camshaft
5-8840-2000-0
Pilot Bearing Remover
5-8522-0024-0
Pilot Bearing Installer
5-8840-2033-0
Oil Seal Installer
5-8840-9018-0
Piston Ring Compressor
5-8840-2359-0
Oil Seal Installer
9-8522-0020-0
Crankshaft Timing Gear Installer
5-8840-0266-0
Angle Gauge
5-8840-0214-0
Gear Stopper
5-8840-2039-0 (4JA1L/TC)
5-8840-2304-0 (4JH1TC)
Cylinder Liner Remover
Illustration
Tool Number
5-8840-2361-0
Tool Name
Front Oil Seal Installation
MEMO
ENGINE COOLING 6B 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B -
Coolant Flow .............................................................................................................. 6B -
General Description .................................................................................................. 6B -
Water Pump................................................................................................................ 6B -
Radiator ...................................................................................................................... 6B -
Thermostat ................................................................................................................. 6B -
Diagnosis........................................................................................................................ 6B -
Draining and Refilling Cooling System........................................................................ 6B -
Water Pump.................................................................................................................... 6B - 10
Removal and Installation .......................................................................................... 6B - 10

Removal...................................................................................................................... 6B - 10
Inspection and Repair ............................................................................................... 6B - 11
Installation.................................................................................................................. 6B - 11
Thermostat ..................................................................................................................... 6B - 13

Removal...................................................................................................................... 6B - 13
Installation.................................................................................................................. 6B - 14
Radiator .......................................................................................................................... 6B - 15
Radiator and Associated Parts................................................................................. 6B - 15

Removal...................................................................................................................... 6B - 16
Installation.................................................................................................................. 6B - 18
6B 2 ENGINE COOLING
PAGE
Engine coolant change ............................................................................................. 6B - 19
Fan Clutch with Cooling Fan ........................................................................................ 6B - 20
ENGINE COOLING 6B 3

Item
M/T
Water pump type
Delivery volume
Pump speed at 3000 rpm
(To 1)
lit (US/UK gal)/min
Water temperature at 30!C (86!F)
Thermostat type
Valve initial opening temperature
!C (!F)
Valve full opening temperature
!C (!F)
Valve lift at fully open position
mm (in)
(Oil cooler thermo valve)

(EGR cooler thermo valve)
Radiator
Heat radiation capacity

Heat radiation area
Radiator front area
Radiator cap valve opening pressure
Engine coolant capacity
Engine coolant total capacity
Centrifugal impeller type

1.2
100 (26.3/22.2)
Double row shaft
Pump bearing type
Radiator dry weight
A/T
Engine coolant forced circulation
Cooling system
Pump to crankshaft speed ratio
Description

82 (180)
76.5 (170)
40 (104)
95 (203)
90 (194)
55 (131)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
Tube type corrugated
93.0 kw (79,980 kcal/h)

!
11.63 m (1.081ft )
!
0.28m (0.026 ft )
52 N (5.3 kg/11.7 lb)
53 N (5.4 kg/11.9 lb)
93.3 ! 122.7kpa (13.5 ! 17.8psi)
2.4 lit (5.1 U.S pint)
10.1 lit (21.3 U.S pint)
2.3 lit (4.9 U.S pint)
10.0 lit (21.1 U.S pint)
6B 4 ENGINE COOLING
GENERAL DESCRIPTION
COOLANT FLOW
RTW46ALF001101
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and thermostat through the bypass hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing
amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now
circulating through the radiator for effective engine cooling.
ENGINE COOLING 6B 5
WATER PUMP
RTW46ASF000101
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.
THERMOSTAT
A wax pellet type thermostat is used.

The jiggle valve accelerates engine warm-up.
030RY00005
6B 6 ENGINE COOLING
RADIATOR
The radiator is a tube type with corrugated fins. In order to

raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3 ! 122.7 kPa (13.5 !
17.8 psi) pressure. (No oil cooler provided for M/T)
110RS001
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system

capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC

See section 0B MAINTENACE AND LUBRICATION.
F06RW005
PTW46BSH000201
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE
ENGINE COOLING 6B 7
DIAGNOSIS
Engine Cooling Trouble
Symptom
Engine overheating
Possible Cause
Low Engine Coolant level
Replenish
Faulty thermostat
Replace
Thermo meter unit faulty
Action
Replace
Faulty Engine Coolant temperature Repair or replace

sensor
Clogged radiator
Faulty radiator cap
Clean or replace
Replace
Low engine oil level or use of Replenish or change oil

improper engine oil
Clogged exhaust system
Clean exhaust system or replace

faulty parts
Faulty Throttle Position sensor
Replace throttle valve assembly
Damaged cylinder head gasket
Replace
Open or shorted Throttle Position Repair or replace

sensor circuit
Engine overcooling
Engine slow to warmup
Faulty thermostat
Replace
Thermo unit faulty
Replace
Faulty thermostat
Replace
6B 8 ENGINE COOLING
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and

perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the MIN" and MAX" lines of
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the MAX" line.
There should not be any excessive deposit of rust or scales
around the radiator cap or radiator filler hole, and the EC
should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
P1010064
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do not

remove the cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out under
pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap
and water. Flush it well with clean water, then drain it.
Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is
at least 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
" Make sure that the engine is cool.
" Open radiator cap pour coolant up to filler neck.
" Pour coolant into reservoir tank up to MAX" line.
" Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high

temperature, be sure not to loosen or remove the radiator
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to reduce
the pressure when the coolant has become cooler.
ENGINE COOLING 6B 9
" After tightening radiator cap, warm up the engine at about
2000 rpm. Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heater water
system.
" Check to see the thermostat has opened through the
needle position of water thermometer, conduct a 5minute
idling again and stop the engine.
" When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the cooling system and
reservoir tank hose for leakage.
" Pour coolant into the reservoir tank up to MAX" line.
6B 10 ENGINE COOLING
WATER PUMP
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
2. Water Outlet Pipe

1) Disconnect the turbocharger-cooling pipe from outlet
pipe.
2) Loosen the fixing bolt and remove the water outlet
bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud
031R300003
5. Fan and Fan Clutch

1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take
care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.
030R300001
7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.
030R300002
ENGINE COOLING 6B 11
Inspection and Repair

The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.
!" Cracks in the water pump body
!" Coolant leakage from the seal unit
!" Excessive radial play or abnormal noise in the fan center
when rotate by hand
!" Excessive thrust play in the fan center (Standard play: less
than 0.2mm)
!" Cracks or corrosion in the impeller
Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque
Nm(kgm/lb ft)
20 (2.0/14)
030R300002
2. Fan Drive Belt and Pulley

1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the
generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt midportion to check the drive belt deflection.
Fan Drive Belt Deflection
mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
3. Fan and Fan Clutch

1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque
Nm(kgm/lb in)
8(0.8/69)
4. Upper Fan Shroud
030R300001
5. Thermostat
Install the thermostat to the thermostat housing.
1) Install the water outlet pipe with new gasket to the
thermostat housing.
2) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
19(1.9/14)
031R300003
3) Connect the turbocharger-cooling pipe to outlet pipe.

1) Connect the radiator upper hose to the water outlet
pipe.
2) The knob of clamp shall be dircted to holizonal side.
3) Replenish the engine coolant.
THERMOSTAT
begin.
Removal
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.

3) Disconnect the turbocharger-cooling pipe from outlet
pipe.
4) Loosen the fixing bolt and remove the water outlet
bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
031R300003

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Operating Test of Thermostat

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
!C (!F)
82 (180)
031RY00005
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature
!C (!F)
95 (203)
Valve Lift At Fully Open Position
9.5 (0.37)
mm (in)
! Thermometer
" Agitating rod
# Wooden piece
Installation
1. Thermostat
Install the thermostat to the thermostat housing.
3) Install the water outlet pipe with new gasket to the
thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
031R300003
19(1.9/14)
5) Connect the turbocharger-cooling pipe to outlet pipe.

1) Connect the radiator upper hose to the water outlet
pipe.
2) The knob of clamp shall be directed to holizonal side.
3) Replenish the engine coolant.
RADIATOR
Radiator and Associated Parts
Legend
1. Radiator Hose
2. Drain Plug
3. Fan Guide, Lower
4. Fan Guide
5. Bracket
RTW36BLF000101
6. Reserve Tank Hose

7. Reserve Tank
8. Radiator Cap
9. Radiator Assembly
Removal
1.
2.
3.
4.
P1010064
PTW46BSH000101
RTW36BMH000101
Disconnect battery ground cable.

Loosen a drain plug to drain EC.
Disconnect oil cooler hose on automatic transmission (A/T).
Disconnect radiator inlet hose and outlet hose from the
engine.
5. Remove fan guide(1), clips(2) on both sides and the bottom

lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.
7. Remove bracket(5).
8. Lift up and remove the radiator assembly with hose, taking

care not to damage the radiator core with a fan blade.

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing valve

with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 93.3
!17.8)
! 122.7 (13.5
Cap tester: 5884002770

Adapter: 5884026030
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.
Valve opening vacuum kPa (psi) 1.96 ! 4.91 (0.28 ! 0.71)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and overheating

may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine

coolant passages with cold water and mild detergent. Remove
all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
" Leakage from the radiator
" Leakage from the coolant pump
" Leakage from the water hoses
" Check the rubber hoses for swelling.
110RS005
Installation
1. Install radiator assembly (9) with hose, taking care not to

damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and
secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the
engine.
6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.
RTW36BMH000101
8. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolant

change) procedure for filling with engine coolant.
RTW36BSH000101
Engine coolant change
Refer to 6B-8 (Draining and Refilling Cooling System).
FAN CLUTCH WITH COOLING FAN

Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.
033R300001
Visually inspect for damage, leak (sillicon grease) or other

abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at
the fan clutch portion gets to around 80!C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.
2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80!C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.
033RY00011
FUEL SYSTEM
6C 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C -
Fuel Flow.................................................................................................................... 6C -
General Description....................................................................................................... 6C -
Fuel Filter and Water Separator ............................................................................... 6C -
Injection Nozzle ......................................................................................................... 6C -
Injection Pump........................................................................................................... 6C -
Fuel Tank ........................................................................................................................ 6C -
Removal ..................................................................................................................... 6C -
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18

Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
6C 2 FUEL SYSTEM
PAGE
Injection Nozzle.............................................................................................................. 6C - 25
Inspection................................................................................................................... 6C - 25
Special Tools.................................................................................................................. 6C - 36
FUEL SYSTEM

Description
Item
4JA1T (L)
Injection pump type
Bosch distributor
VE type
Governor type
Oil pressure
Fuel feed pump type

Injection nozzle designed operating

2
pressure MPa (kg/cm )
4JH1TC
Bosch distributor VP44 type

Electrical controled
Electrical controled
Vane with input shaft

Hole type
Number of injection nozzle orifices

Inside diameter
4JA1TC
Mechanical variable
(Half speed oil
pressure)
Timer type
Injection nozzle orifices
6C 3
mm (in)
1st
2nd
0.19 (0.0075)
0.17 (0.0067)
0.21 (0.0083)
25.0 (255)
33.5 (328)
33.8 (331)
19.1 (195)
19.0 (194)
19.5 (199)
Disposable cartridge paper element
Precautions
When working on the fuel system, there are several things
to keep in mind:
Any time the fuel system is being worked on,

disconnect the negative battery cable except for
those tests where battery voltage is required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and fittings that
were removed.
Clean and inspect O" rings. Replace if required.
Always relieve the line pressure before servicing any
fuel system components.
Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
Adhere to all Notices and Cautions.
NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.
6C 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
RTW46CMF000201
The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.
FUEL SYSTEM
6C 5
FUEL FILTER AND WATER SEPARATOR

As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the fuel filter. It is used during the air bleeding procedures.
(Except EURO III model)
RTW36CLF000701
6C 6 FUEL SYSTEM
For EURO III model
RTW46AMF000201
INJECTION PUMP
FUEL SYSTEM
6C 7
RTW46CLF000201
4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engines vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.
4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C 8 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
NOTE:
! Injection nozzle adjustment is possible only on the 4JA1L engine.
RTW46CMF000301
A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through
the nozzle body injection orifice.
FUEL TANK
FUEL SYSTEM
6C 9
Fuel Tank and Associated Parts
RTW46CLF000401
Legend
1. Bolt; Fuel Tank

2. Fuel Tank Band
3. Fuel Tube/Quick Connector
4. Fuel Filler Hose
5. Fuel Tank
6. Under Shield Band
7. Under Shield (only, specified model)
8. Evapo Pipe (only specified model)
6C 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been

completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change

the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dust

entering.
3.
4.
5.
6.
7.
Jack up the vehicle.

Support underneath of the fuel tank with a lifter.
Remove the inner liner of the wheel house at rear left side.
Remove fixing bolt of the filler neck from the body.
Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering

and fuel leakage.
NOTE: Refer to Fuel Tube/Quick Connector Fittings in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, dont scratch
each hose and tube by around other parts.
Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, dont scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump

and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected against

stopper.
3. Install the tank band and fasten bolt.
Torque
68 (6.9 / 50)
Nm (kgm / lb ft)
NOTE: The anchor of the tank band must be certainly installed

to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.

FUEL SYSTEM
6C 11
5. Install the filler neck to the body with bolt.

6. Install the inner liner of the wheel house at rear left side.
7. Remove lifter from the fuel tank.
8. Lower the vehicle.
9. Tigten the filler cap until at least three clicks.
10.Connect the battery ground cable.
6C 12 FUEL SYSTEM
FUEL GAUGE UNIT
Fuel Gauge Unit and Associated Parts
RTW46CLF000501
Legend
1. Fuel Feed Port

2. Fuel Return Port
3. Fuel Emission Port
4. Fuel Gauge Unit and Sender Assembly
5. Connector; Fuel Gauge Unit
6. Fuel Tube/Quick Connector

7. Retainer Ring (Fuel Gauge Unit Lock)
8. Seal; Fuel Gauge Unit
9. Fuel Tank Assembly
10. Evapo Tube/Quick Connector
Removal
FUEL SYSTEM
6C 13
CAUTION: When repair to the fuel system has been

completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.
140R100035
Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause of

fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.

6C 14 FUEL SYSTEM
8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose (Pull off
the breather hose from fuel tank) and tighten fuel filler
cap until at least one click are heard.
(2) Apply water soap around the fuel gauge unit seal area.
(3) Pressure air into the fuel tank from end of breather pipe
2
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
(4) Verify no bubbles around the fuel gauge unit seal area.
9. Install the fuel tank assembly (9).
NOTE: Refer to Install the fuel tank in this section.
FUEL SYSTEM
FUEL TUBE / QUICK CONNECTOR FITTINGS
6C 15
Precautions
! Do not light a match or create a flame.

! Keep flames away from your work area to prevent
flammable materials from catching fire.
! Disconnect battery ground cable to prevent electrical shorts.
! Pre-treat piping system or associated parts from thermal
damage or from spattering when welding or similar
heat-generating work.
Cautions During Work
Do not expose the assembly to battery electrolyte or do not

wipe the assembly with a cloth used to wipe off spilt battery
electrolyte.
Piping that has been splattered with battery electrolyte or
battery electrolyte soaked cloth that was wiped on the piping
cannot be used.
Legend
140R100032
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the
fuel pipe may
still have some pressure in it.
141R100002
6C 16 FUEL SYSTEM
2. For removal of the quick connector, hold the quick

connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.
140R100037
140R100028
140R100036
Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.
Reuse of QuickConnector
! Replace the port and connector if scratch, dent or crack is

found.
! Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms of
rust, dent, scratch.
! After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.
Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.
FILLER NECK
FUEL SYSTEM
6C 17
Removal
1. Remove the fuel tank.

NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck assembly
is restored.
! Each joint area of the hose (to restore axial direction and
insertion length of the hose)
! Each fasten area of the clamp (to restore axial direction
and position of the clamp)
! Each bolt in the clamp (to restore fasten length of bolt in
the clamp)
! The band clip (to restore position and fasten length of
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.
Installation
1. Align each marking and restore the following point.

! Each joint area of the hose (Restore axial direction and
insertion length of the hose)
! Each fasten area of the clamp (Restore axial direction
and position of the clamp)
! Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque
Nm (kgm / lb ft)
2.5 (0.25 / 21.7)
filler neck side except flat deck model.

! The band clip (Restore position and fasten length of the
band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
6C 18 FUEL SYSTEM
FUEL FILLER CAP

General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.
Legend
RTW36CSH000401
(1) Pressure Valve

(2) Vacuum Valve
(3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition.

The fuel filler cap must be replaced if found defective
CAUTION: A replacement fuel filler cap must be the same
as the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.
INJECTION PUMP
FUEL SYSTEM
6C 19

begin.
Removal
1. Battery
Remove the battery from the battery tray.
6C-1
2. Drive Belt
1) Loosen the adjust bolt of the power steering pump
pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly
4. Accelerator Control Cable

Disconnect the accelerator cable from the intake throttle.
P1010003
5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the
intake throttle.
6. Fan
6C 20 FUEL SYSTEM
7. Power Steering Pump Bracket
6C-4
8. Throttle
Position
Sensor
Harness
Connector
Disconnect the harness connector from the throttle
position sensor.
9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.
6C-5

13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.
16. Intake Manifold
1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
FUEL SYSTEM
020L200017
RTW46CSH000201
6C-7
6C 21
18. Timing Check Hole Cover

1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the
timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear B fixing hole to prevent the scissors gear from
turning.
29. Injection Pump Bracket

20. Injection Pump
6C 22 FUEL SYSTEM
Installation!!
1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut
N"m (kg"m/lb ft)
64 (6.5 / 47)
RTW46CSH000201
020L200017
2) Bring the piston in the No.1 cylinder to TDC on the

crankshaft pulley TDC line aligned with the timing
mark.
3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump
gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 # 30) from the idle gear B.
6) Tighten the injection pump fixing bolts to the specified

torque.
Injection Pump Bolts Torque
Nm (kgm/lb ft)
19 (1.9 / 14)
6C-7
FUEL SYSTEM
6C 23
4JA1T (L)
4JA1TC/4JH1TC
RTW46CSH000101
2. Injection Pump Bracket

1) Install the injection pump bracket (6) and the bracket
bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque
Nm(kgm / lb ft)
(8) 19 (1.9 / 14)
(7) 40 (4.1 / 30)
RTW36AMH000101
3. Timing Check Hole Cover

Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque
Nm(kgm / lb ft)
8 (0.8 / 69)

5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque
Nm(kgm / lb ft)
19 (1.9 / 14)
Intake Manifold Nuts Torque
24 (2.4 / 17)
Nm(kgm / lb ft)
2) Install the EGR valve to the intake manifold and EGR

pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque
Nuts
Bolts
N!m (kg!m/lb ft)
24 (2.4/17)
27 (2.8/20)
6C 24 FUEL SYSTEM
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque
29 (3.0 / 22)
Nm(kgm / lb ft)
Nozzle Side (4JA1TC/4JH1TC)
Nm(kgm / lb ft)
Pump Side (4JA1TC/4JH1TC)
Nm(kgm / lb ft)
29 (3.0 / 22)
40 (4.1 / 30)
7. Injection Pipe Clip

Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque
Nm(kgm / lb in)
8 (0.8 / 69)
8. Leak Off Pipe and Leak Off Hose

Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque
Nm(kgm / lb ft)
21 (2.1 / 15)

Install the fuel filter assembly to bracket and tighten bolts
Fuel Filter Assembly Bolts
Torque
Nm(kgm / lb ft)
21 (2.1 / 15)
11. Fuel Pipe

1) Connect the fuel hoses to the fuel filter or priming
pump.
2) Connect the fuel hoses to the injection pump.
12. Oil Level Gauge
Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque
Nm(kgm / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)
FUEL SYSTEM
6C 25
13. Throttle Position Sensor Harness Connector

Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket
15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.
Euro under
Euro I
Euro II
Euro III
4JA1L
without
with
with
4JA1TC
Not used
Not used
Not used
4JH1TC
without
with
with
Not used
With cooler
(EGR cooler)
With
(EGR cooler)
17. Accelerator Control Cable

1) Connect the accelerator cable to the injection pump
(4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery
6C 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)

DISASSEMBLY
080L200009
Disassembly Steps
1.
2.
3.
4.
Retaining nut
Nozzle & pin
Spacer & pin
Lift Piece
9.
10.
11.
12.
5.
6.
7.
Spring seat
Push rod
Shim (Second nozzle opening
pressure adjustment)
Second spring
13.
14.
15.
8.
Collar
Spring seat
First spring
Shim (First nozzle
pressure adjustment)
Nozzle holder body
Eye bolt
Gasket
opening
Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
FUEL SYSTEM
REASSEMBLY
6C 27
080L200010
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
Nozzle holder body

Shim (First opening pressure
adjustment)
First spring
Spring seat
Collar
Second spring
Push rod
Shim (Second opening pressure
adjustment)
9.
10.
Spring seat
Lift Piece
11.
12.
13.
14.
15.
Spacer & pin

Nozzle & pin
Retaining nut
Gasket
Eye bolt
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
6C 28 FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE

1
2
First nozzle opening pressure adjustment

Full needle valve lift confirmation
Pre-lift confirmation
Adjust the first nozzle opening pressure using the shim.

Confirm the full needle valve lift in accordance with the
closed method.
Confirm pre-lift in accordance with the closed method.
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
Second nozzle opening pressure

confirmation
Confirm the second nozzle opening pressure in accordance

with the closed method.
Second nozzle opening pressure

adjustment
Adjust the second nozzle opening pressure using the shim.
Final inspection

Nozzle needle valve full-lift
Nozzle needle valve pre-lift

Nozzle pressure
4JA1T(L)
1st Stage
2nd Stage
Confirm the condition of the fuel spray with the nozzle and
nozzle holder assembled.
0.25 mm (0.0098 in)
0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm )

2
19.1 Mpa (2759 psi, 194 kg/cm )

2
25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )
NOTE: Only 4JA1L can perform adjustment of a nozzle.
FUEL SYSTEM
Injection Nozzle Adjustment
6C 29

1.Clamp the nozzle holder in a vise.
040MV015.tif
2. Install the shim, first spring and spring seat in the

nozzle holder.
040MV016.tif
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017.tif
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018.tif
6C 30 FUEL SYSTEM
5. Install the pins in the spacer.

6. Install the nozzle on the spacer.
040MV019.tif
7. Hand-tighten the adjustment retaining nut together

with the gasket to the nozzle holder.
Retaining nut: 157892-3200 (Bosch AS)
Gasket:
157892-5100 (Bosch AS)
(Bosch AS = Bosch Automotive Systems Corporation)
040MV010.tif
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 5.1 kgm (36.9 Ibft/50 Nm)
040MV014-1.tif
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.

040MV030.tif
FUEL SYSTEM
First nozzle opening pressure adjusting shims

Parts No. (ISUZU)
Thickness (mm)
115349-0430
0.50
115349-0420
115349-0440
115349-0450
115349-0460
040LX010.tif
6C 31
115349-0470
115349-0480
115349-0490
0.40
0.52
0.54
0.56
0.58
0.60
0.70
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket:
026508-1140 (Bosch AS)
894227-6020 (ISUZU)
Plug:
157892-1600 (Bosch AS)
040MV013.tif
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (Bosch AS)
040MV012.tif
3. Install the nut on the dial gauge holder.

Nut: 157892-1000 (Bosch AS)
040MV011.tif
6C 32 FUEL SYSTEM
4. Install the pin to the dial gauge.

Note:
The lengths of the pins do not include the
threaded portions.
Pin (L=100 mm): 157892-5200 (Bosch AS)
Dial gauge:
157954-3800 (Bosch AS)
185317-0150 (ISUZU)
040MV029.tif
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
CAUTION:
Secure the dial gauge so that a stroke of 2 mm can
be measured.
Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
040MV009.tif
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030.tif
FUEL SYSTEM
6C 33
8. Operate the nozzle tester and increase the in-line

2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzles needle valve moves through its full lift.
Record full lift L. (Read dial gauge)
Nozzle Full Lift
mm (in)
0.25 ! 0.02 (0.0098 ! 0.00008)
040MV008.tif
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040R300008
6C 34 FUEL SYSTEM
2. Read the needle valve pre-lift point from the dial

gauge indication (once the needle valve has
descended when the second spring has stopped
operating).
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
2
1 MPa (10 kg/cm ).
Pre-lift
mm
040H100007
4JA1T(L)
Pressure Mpa
2
(psi/ kg/cm )
20.1 (2,858/205)
Lift mm (in)
0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.
3. Confirm that pre-lift is as specified.
040MV005.tif
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit
105017-2990 (Bosch AS)
897302-3070 (ISUZU)
040MV031.tif
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzles needle valve moves
through its full lift.
040MV030.tif
FUEL SYSTEM
6C 35
2. Release the nozzle tester handle so that in-line

pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV022.tif
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift + 0.05 mm).
Second Nozzle Opening Pressure
4JA1T(L)
040M100006
Pressure Mpa
2
(psi/ kg/cm )
25.5-27.0
(3768-3911/260-275)
Lift mm (in)
0.09 (0.0035)
6C 36 FUEL SYSTEM
040MV017.tif
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
Use a micrometer to measure shim thickness.
Use some combination of 3 adjusting shims to
adjust the pressure.
040LX009.tif
Second nozzle opening pressure adjusting shims

Part No.
(ISUZU)
897116-0290
897116-0320
897116-0330
897116-0340
897116-0350
897116-0360
897116-0370
Thickness
(mm)
0.10
0.20
0.30
0.40
0.50
0.51
0.52
Part No.
(ISUZU)
897116-0380
897116-0390
897116-0400
897116-0410
897116-0420
897116-0430
897116-0440
Thickness
(mm)
0.53
0.54
0.55
0.56
0.57
0.58
0.59
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
040MV014-1.tif
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 7.0 kgm (50.6 Ibft/69 Nm)
FUEL SYSTEM
6C 37
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030.tif
6C 38 FUEL SYSTEM
ILLUSTRATION
SPECIAL TOOLS
TOOL NUMBER
5-8840-2602-0
(J-39765)
TOOL NAME
Remover: fuel pump retainer ring
ENGINE ELECTRICAL 6D 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2

General Description......................................................................................................... 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator.......................................................................................................................... 6D - 7
Removal and Installation ............................................................................................ 6D - 7

Disassembly................................................................................................................. 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly.................................................................................................................. 6D - 18
Starter Motor .................................................................................................................... 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly................................................................................................................. 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly.................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33
6D 2 ENGINE ELECTRICAL

Description
Item
60A
Generator
Type
Voltage
Drive and rotation
Ground polarity
Maximum output
Engine speed ratio
Maximum speed
Weight with vacuum pump
Vacuum Pump
Delivery volume
Exhaust Characteristic
AC generator with IC regulator and vacuum pump
V
A
to 1
rpm
kg(lb)
cm /rev
3
Starter Motor
Type
Weight
Hitachi LR160-503E
Hitachi LR180-513B
12
V-belt, clockwise viewed from the drive pulley
Negative
60
5.8(12.8)
1.788
11,000
80
6.4(14.1)
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000
rpm
7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Maximum vacuum
Rated voltage
Rated output
Load characteristics
Terminal voltage
Load current
80A
Solenoid controlled
V
kW
V
A
kg(Ib)
Hitachi S13-555
12
2.3
8.76
300
4.7 (10.4)
GENERAL DESCRIPTION
GENERATOR
STARTER MOTOR
066L300004
065L300002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.
CHARGING CIRCUIT DIAGRAM
RTW46DSH005101
STARTING CIRCUIT DIAGRAM
RTW46DSH005501
TORQUE SPECIFICATIONS
GENERATOR
N!m (kg!m/Ib!ft)
RTW46DLF000201
STARTER MOTOR
N!m (kg!m/Ib!ft)
RTW46DLF000301
GENERATOR

begin.
Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.
P1010002
Generator
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the
bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque
40 (4.1/30)
N!m (kg!m/Ib!ft)
Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys.
1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley
033RY00009
3. Adjust the fan belt tension

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection
mm (in)
New belt
4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
4. Tighten the adjusting plate bolts to the specified

torque.
Adjusting Plate Bolt
19 (1.9/14)
Nm (kgm/lbft)
5. Reconnect the battery cable to the battery.
DISASSEMBLY
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Vacuum pump
O-ring
Through bolt
B Terminal nut
Rear cover
Pulley
Rotor assembly
Front cover assembly
Rear rotor bearing
Rectifier assembly
Stator assembly
Rotor assembly
RTW46DLF000401
1.
Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover
RTW46DSH000101
3.
Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space
between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
! The front cover oil seal must be replaced with a new
one when the front cover is removed.
! Take care not to damage the stator core with the
screwdriver tips.
4.
Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.
RTW46DSH000201
RTW46DSH000601
RTW46DSH002101
7. Rotor Assembly
1. Remove the rotor from front cover assembly.
Remove the front cover stator and rectifier.
RTW46DSH000301
RTW46DSH000701
RTW46DSH000801
RTW46DSH000401
8. Front Cover Assembly

1. Remove the front cover bearing retainer screws.
2. Remove the bearing.
9. Rear rotor bearing

! Re-use improper parts.
10. Rectifier
1. Disconnect the stator coil leads between each rectifier
by melting the solder connection.
Hold the lead wire between the solder and the rectifier
with a pair of long nose pliers.
This will prevent heat transfer and resultant damage to
the rectifier.

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.
ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting.
Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter
mm (in)
Standard
31.6 (1.245)
Limit
30.6 (1.183)
RTW06DSH000101
If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.
3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20"C (68"F)
Standard
3.8
ohms
RTW46DSH001001
4. Check for continuity between the slip rings and the

rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.
RTW46DSH001101
STATOR COIL ASSEMBLY

1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal N and the Coil Ends
(Reference)
ohms
Standard
066RY00022
066RY00023
0.1
2. Check for continuity between each stator coils and the

stator core.
If there is continuity, the stator coils must be replaced.
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference)
mm (in)
Standard
Limit
25 (1.0)
RTW46DSH004801
6.5 (0.25)
Rectifier
RTW46DSH001201
E
U, V, and WN
"
Tester wire
"
-----
Conductivity
No
----conductivity
Negative side diode check
BAT
U, V, and WN
"
----Conductivity
Positive side diode check
"
No
conductivity
-----
RECTIFIER ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
RTW46DSF000301
Voltmeter
Switch 1
DC regulated power supply
Lamp 2
Lamp 1
Switch 3
Switch 2
Pulse generator
Output signal
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.
Circuit components
DC regulated power supply
1
Lamps (2)
2
Switches (3)
3
DC voltmeter
4
Pulse generator (Oscillator)
5
Judgment criteria
0~20 volts variable with output of 1 ampere or more

12 volts, 1.4~3.4 watts
----0~30 volts, 0.5 grade
5~30 volt output at a frequency of 1kHz
No.
Switch
1
Switch
2
Switch
3
ON
OFF
OFF
ON
ON
OFF
ON
ON
OFF
16V
OFF
ON
OFF
12V
ON
ON
ON
Voltmeter
reading
12V
18V
Lamp condition
Lamp 1 Lamp 2
On
ON
(dim)
On or
flashing
OFF
Off or
on (dim)
On or
flashing
On
ON
Remarks
Initial excitation check
Full excitation check
Lamp 1 off or dimly lit when the

voltmeter shows less than 12 volts or
16 volts
Stator and brush separation check

Excess voltage check
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.
Oil Seal Replacement

1. Push the old oil seal from the rear bracket outside
holes.
2. Use the insertion tool to press the new oil seal into
place. Follow the procedure shown in Figures A, B, C
and D.
! Position the oil seal beneath the shaft and the
guide lip.
! Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.
! After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution
! Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.
! Take care not to damage the D surface.
! Under no circumstances may the original oil seal
be reused.
! The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.
RTW46DSF000101
Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump

housing.
2. Remove the vacuum pump rotor and the vanes from
the housing.
RTW46DSH000901
Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and
scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash.
Replace the rotor if backlash is present.
Check Value
1. Carefully force the valve from the B side as shown in

the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the A side.
2
Air Pressure
kPa (kg/cm /psi)
98 - 490 (1-5/14 71)
RTW46DSH005201
Check for air leakage from the check valve.

If there is air leakage, the valve must be replaced.
Vacuum Pump Reassembly
1. Install the vanes to the rotor slits.

The rounded side of the vanes must be facing the
rotor housing.
RTW46DSH001801
2. Install the rotor with the concave side facing the center
plate.
RTW46DSH001901
RTW46DSH002001
3. Install the center plate to the rotor housing.

Be sure to use a new O-ring.
REASSEMBLY
RTW46DLF000501
Reassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Front cover
Rear rotor bearing
Rotor Assembly
Pulley
Rectifier Assembly
Stator Assembly
Rear cover
B Terminal nuts
Through bolt
O-ring
Vacuum pump
2. Rear rotor bearing
! Re-use improper parts.
RTW46DSH000401
5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.
3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque
N#m (kg#m/lb#ft)
83.3 $ 98.0 (8.5 $ 10.0 / 61 $ 72)
RTW46DSH002101
RTW46DSH006001
Remove the tape from the splines.
The rear ball bearing is pressed into the wheel eccentric

groove. The bearing ring projects from the groove.
During installation, rotate the bearing to the point of
minimum bearing ring projection.
Inspect the rear cover bearing box and replace it if it is
damaged.
RTW46DSH004901
NOTE: Be sure to attach a cooler to B terminal.
RTW46DSH002201
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.
Remove the pin after completion of the assembly
procedure.
RTW46DSH005301
9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque
N#m (kg#m/lb#ft)
3.1 $ 3.9 (0.32 $ 0.41 / 2.6 $ 3.5)
RTW06DSH000201
11. Vaccum Pump

To install the generator 1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the
3 generator fixing points.
3. Twist the fixing points down and to the left to align
them with the middle of the center plate and the rotor.
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.
RTW46DSH006101
Install the vacuum pump housing.

Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.
RTW46DSH002401
Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque
N#m (kg#m/lb#ft)
5.9 $ 6.9 (0.6 $ 0.7 / 5.2 $ 6.1)
RTW46DSH002501
STARTER MOTOR
begin.
Important Operations - Removal

Starter Motor
1. Disconnect the battery cable and the ground cable at
the battery terminals.
2. Disconnect the magnetic switch cable at the terminal
bolts.
3. Disconnect the battery cable at the starter motor and
4. Remove the starter motor from the engine.
Important Operations Installation

Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque
N#m (kg#m/lb#ft)
85 (8.7/63)
3. Reconnect the battery cable at the starter motor and

4. Reconnect the battery cable and the ground cable at
the battery terminals.
DISASSEMBLY
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lead wire
Bolt
Magnetic switch assembly
Torsion spring
Plunger
Dust cover
Magnetic switch
Screw
Through bolt
Rear cover
Motor assembly
Brush holder
Yoke
RTW460LF000201
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Armature
Bolt
Bearing retainer
Pinion assembly
Pinion stopper clip
Pinion stopper
Return spring
Pinion shaft
Clutch
Dust cover
Shift lever
Gear case
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
RTW46DSH002701
RTW46DSH002801
RTW46DSH002901
RTW46DSH003001
3. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove the
switch from the shift lever.
Remove the torsion spring from the magnetic switch.
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.
11. Motor Assembly

Remove the four brushes from the brush holders.
Remove the yoke along with the armature and the brush
holder from the gear case.
Remove the brushes and commutator carefully so as not
to allow them in contact with the adjacent parts.
RTW46DSH003101
RTW46DSH003201
RTW46DSH003301
RTW46DSH003401
12. Brush Holder

13. Yoke
14. Armature
Remove the brush holder and pull out the armature
assembly free from the yoke.
16.
17.
23.
24.
25.
Bearing Retainer
Pinion Assembly
Dust Cover
Shift Lever
Gear Case
1. Remove the bearing retainer.
2. Remove the pinion from the gear case.
3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.
ARMATURE
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out
mm (in)
Standard
0.05 (0.002)
RTW46DSH003501
0.2 (0.008)
2. Check the commutator mica segments for excessive

wear.
3. Measure the mica segment depth.
Mica Segment Depth
mm (in)
Standard
0.5 $ 0.8 (0.020 $ 0.030)
065RY00025
Limit
Limit
0.2 (0.008)
If the mica segment depth is less than the standard but

more than the limit, the commutator may be reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
4. Measure the commutator outside diameter.
Commutator Outside Diameter
Standard
36.5 (1.44)
Limit
mm (in)
35.5 (1.40)
If the measured outside diameter is less than the specified

limit, the commutator must be replaced.
065RY00026
RTW46DSH003601
5. Use a circuit tester to check the armature for

grounding.
1 Hold one probe of the circuit tester against the
commutator segment.
2 Hold the other circuit tester probe against the
armature core.
If the circuit tester indicates continuity, the armature is
grounded.
The armature must be replaced.
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two
commutator segments.
2 Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the commutator.
If there is not, the armature must be replaced.
RTW46DSH003701
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.
RTW46DSH003801
RTW46DSH003901
2. Use the circuit tester to check the field winding

continuity.
1 Hold one circuit tester probe against the M
terminal lead wire.
2 Hold the other circuit tester probe against the field
winding brush.
There should be continuity.
If there is no continuity, the yoke must be replaced.
BRUSH AND BRUSH HOLDER

1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length
mm (in)
Standard
15 (0.59)
Limit
12 (0.47)
RTW46DSH004001
2. Use a circuit tester to check the brush holder

insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.
RTW46DSH004101
3. Inspect the brushes for excessive wear.

If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.
OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for

excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
065RY00035
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
RTW46DSH004401
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Magnetic switch assembly

Magnetic switch
Dust cover
Plunger
Torsion spring
Shift lever
Gear case
Dust cover
Bolt
Pinion assembly
Clutch
Pinion shaft
Rerurn spring
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Pinion stopper
Pinion stopper clip
Bearing retainer
Bolt
Motor assembly
Armature
Yoke
Brush holder
Rear cover
Screw
Through bolt
Lead wire
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.
RTW46DSH005601
7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
Dust Cover Bolt Torque
RTW46DSH005701
065RY00041
RTW46DSH004501
8 (0.8/5.4)
N#m (kg#m/lb#ft)
10. Pinion Assembly

Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
21. Brush Holders

1. Install the brushes into the brush holder with raising
the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of
the yoke and the brush holder.
24. Through Bolt
Install the through bolts in the rear cover and tighten them
Through Bolt Torque
N#m (kg#m/lb#ft)
8.1 (0.83/6.00)
065RY00044
25. Lead Wire

Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque
N#m (kg#m/lb#ft)
8.6 (0.88/6.40)
RTW46DSH002601
Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play
mm (in)
0.1 2.0 (0.004 0.078)
RTW46DSH005801
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the M
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.
RTW46DSH004601
RTW46DSH005901
RTW46DSH004701
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion should
continue to flutter.
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
PRE-HEATING SYSTEM

Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.
VISUAL CHECK
Check the main fuses and glow indicator for damage.

Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance
825R300046
94 % 114
Ohms
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference)
Approximately 0.9
LNW21KSH001401
EGR SYSTEM 4JA1T (L)

Refer to 6F-9. (EGR system diagram)
Ohms
MEMO
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6E1
ENGINE
CONTENTS
ABBREVIATION CHARTS ........................
6E-9
4JA1-TC ....................................................
6E-10
4JH1-TC ....................................................
6E-11
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-14
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-15
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-16
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-17
GROUND POINT CHART GENERAL EXPORT
(LHD) (1/4) ...............................................
6E-18
LOCATION ................................................
6E-34
PARTS LOCATION ...................................
6E-39
CONNECTOR LIST ...................................
6E-40
RELAY AND FUSE ....................................
6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ...........................................
6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ...........................................
6E-44
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45
ECM WIRING DIAGRAM (1/7) ..................
6E-46
6E-47
6E-48
6E-49
6E-50
6E-51
6E-52
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL ....................................
6E-53
GENERAL DESCRIPTION FOR ECM AND
SENSORS ...............................................
6E-64
Engine Control Module (ECM) ...................
6E-64
Pump Control Unit (PSG) & Data Exchange
Between Control Module .........................
6E-64
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor .......................
6E-65
Throttle Position Sensor (TPS) ..................
6E-66
Crankshaft Position (CKP) Sensor ............
6E-66
Engine Coolant Temperature (ECT) Sensor
6E-67
Vehicle Speed Sensor (VSS) ....................
6E-67
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION) .....
6E-68
GENERAL DESCRIPTION FOR
INJECTION PUMP ..................................
6E-70
Outline .......................................................
6E-70
Cross-section View ....................................
6E-70
Low Pressure Fuel Circuit ..........................
6E-71
High Pressure Fuel Circuit .........................
6E-72
Pump Camshaft Speed Sensor .................
6E-72
High Pressure Solenoid Valve ...................
6E-73
Timing Control Valve (TCV) .......................
6E-74
ISUZU Strategy Based Diagnostics ..............
6E-76
Overview ....................................................
6E-76
STRATEGY BASED DIAGNOSTICS CHART 6E-76
Diagnostic Thought Process ......................
6E-77
1. Verify the Complaint ..............................
6E-77
2. Perform Preliminary Checks ..................
6E-77
3. Check Bulletins and Troubleshooting Hints 6E-78
4. Perform Service Manual Diagnostic Checks 6E-78
5a and 5b. Perform Service Manual Diagnostic
Procedures ..............................................
6E-78
5c. Technician Self Diagnoses ..................
6E-78
5d. Intermittent Diagnosis ..........................
6E-79
5e. Vehicle Operates as Designed ............
6E-80
6. Re-examine the complaint .....................
6E-81
7. Repair and Verify Fix .............................
6E-81
GENERAL SERVICE INFORMATION .......
6E-82
ON-BOARD DIAGNOSTIC (OBD) .............
6E-82
TECH 2 OPERATING FLOW CART
(START UP) .............................................
6E-86
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ...................................
6E-88
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ...................................
6E-90
MISCELLANEOUS TEST ..........................
6E-92
Plotting Snapshot Graph ............................
6E-93
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) ..........
6E-94
Flow Chart for Snapshot Replay
(Plotting Graph) .......................................
6E-95
SNAPSHOT DISPLAY WITH TIS2000 ......
6E-96
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK ....................................................
6E-105
Circuit Description ......................................
6E-105
Diagnostic Aids ..........................................
6E-105
Test Description .........................................
6E-105
6E2
On-Board Diagnostic (OBD) System Check

6E-106
NO CHECK ENGINE LAMP (MIL) .............
6E-109
Circuit Description .....................................
6E-109
Diagnostic Aids ..........................................
6E-109
No Check Engine Lamp (MIL) ...................
6E-110
CHECK ENGINE LAMP (MIL) ON STEADY 6E-112
Circuit description ......................................
6E-112
Diagnostic Aids ..........................................
6E-112
Check Engine Lamp (MIL) On Steady .......
6E-113
ECM Diagnostic Trouble Codes ................
6E-114
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128
(SYMPTOM CODE B) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT LOW INPUT .............................
6E-128
(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................
6E-128
6E-129
Diagnostic Aids ..........................................
6E-129
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit High Input .....................................
6E-129
(Symptom Code 9) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit Low Input ......................................
6E-132
(Symptom Code B) (Flash Code 65) Mass
Air Flow (MAF) Sensor Output Circuit Low
Input .........................................................
6E-134
Diagnostic Trouble Code (DTC) P0100 (Symptom
Code C) (Flash Code 65) Mass Air Flow (MAF)
Sensor Output Circuit High Input .............
6E-137
VACUUM PRESSURE SENSOR CIRCUIT HIGH
INPUT ......................................................
6E-140
VACUUM PRESSURE SENSOR CIRCUIT
LOW INPUT .............................................
6E-140
VACUUM PRESSURE SENSOR VOLTAGE

SUPPLY CIRCUIT HIGH INPUT .............
6E-140
VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT ..............
6E-140
6E-141
Diagnostic Aids ..........................................
6E-141
(Symptom Code 1) (Flash Code 34) Vacuum
Pressure Sensor Circuit High Input .........
6E-142
Pressure Sensor Circuit Low Input ...........
6E-145
Pressure Sensor Voltage Supply Circuit
High Input .................................................
6E-148
Pressure Sensor Voltage Supply Circuit Low
Input..........................................................
6E-150
INTAKE AIR TEMPERATURE (IAT) SENSOR
6E-152
INTAKE AIR TEMPERATURE (IAT) SENSOR
6E-152
6E-152
Diagnostic Aids ..........................................
6E-153
(Symptom Code 1) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit High Input 6E-153
(Symptom Code 2) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit Low Input 6E-157
ENGINE COOLANT TEMPERATURE SENSOR
CIRCUIT HIGHINPUT .............................
6E-160
ENGINE COOLANT TEMPERATURE SENSOR
6E-160
6E-160
Diagnostic Aids ..........................................
6E-161
(Symptom Code 1) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
HighInput .................................................
6E-161

(Symptom Code 2) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
LowInput ..................................................
6E-165
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE .......................
6E-168
6E-168
Diagnostic Aids ..........................................
6E-168
(Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit
Range/Performance ................................
6E-169
(SYMPTOM CODE A) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION .......................................
6E-170
6E-170
FUEL CUTOFF SOLENOID VALVE ALWAYS
ACTIVE ....................................................
6E-170
(SYMPTOM CODE D) (FLASH CODE 52)
MALFUNCTION .......................................
6E-170
6E-171
Diagnostic Aids ..........................................
6E-171
(Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ...........
6E-171
Cutoff Solenoid Valve Circuit High Input .
6E-173
(Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active .......
6E-175
(Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ...........
6E-177
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION .......................................
6E-178
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION .......................................
6E-178
6E-179
Diagnostic Aids ..........................................
6E-179
6E3

(Symptom Code A) (Flash Code 54) Injection
Timing Control Circuit Malfunction ...........
6E-180
(Symptom Code B) (Flash Code 54) Injection
Timing Control Circuit Malfunction ...........
6E-180
TURBOCHARGER WASTEGATE
SOLENOID "A" RANGE/PERFORMANCE 6E-183
SOLENOID"A" LOW ................................
6E-183
SOLENOID "A" LOW ...............................
6E-183
SOLENOID "A" RANGE/PERFORMANCE 6E-183
SOLENOID "A" MALFUNCTION .............
6E-183
SOLENOID"A" HIGH ...............................
6E-183
6E-184
Diagnostic Aids ..........................................
6E-184
(Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid
"A" Range/Performance ...........................
6E-185
(Symptom Code 4) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Low 6E-187
Turbocharger Wastegate Solenoid "A"
Range/Performance ................................
6E-190
Turbocharger Wastegate Solenoid "A"
Malfunction ..............................................
6E-192
Turbocharger Wastegate Solenoid "A" High 6E-194
(SYMPTOM CODE 6)
(FLASH CODE 53) INJECTION PUMP
6E4
MALFUNCTION .......................................
6E-196
INJECTION PUMP MALFUNCTION .......
6E-196
6E-196
6E-196
6E-196
6E-196
(SYMPTOM CODE E) (FLASH CODE 53)
6E-196
6E-197
Diagnostic Aids ..........................................
6E-197
Injection Pump Malfunction .....................
6E-197
6E-199
6E-203
(Symptom Code A) (Flash Code 53)
6E-204
(Symptom Code B) (Flash Code 53)
6E-205
(Symptom Code D) (Flash Code 53)
6E-206
(Symptom Code E) (Flash Code 53)
6E-207
CRANKSHAFT POSITION SENSOR
CIRCUIT MALFUNCTION .......................
6E-208
CRANKSHAFT POSITION SENSOR
MALFUNCTION .......................................
6E-208
ENGINE SPEED INPUT CIRCUIT
RANGE/PERFORMANCE .......................
6E-208
6E-209
Diagnostic Aids ..........................................
6E-209
Crankshaft Position Sensor Circuit
Malfunction ..............................................
6E-209
Crankshaft Position Sensor Malfunction ..
6E-209
(Symptom Code E) (Flash Code 43) Engine
Speed Input Circuit Range/Performance .
6E-214
GLOW RELAY CIRCUIT VOLTAGE LOW
6E-217
GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
6E-217
Diagnostic Aids ..........................................
6E-217
Glow Relay Circuit Voltage Low ..............
6E-218
(Symptom Code 8) (Flash Code 66) Glow
Relay Circuit Voltage High .......................
6E-221
(SUB CODE 4) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE LOW ..
6E-222
(SUB CODE 8) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE HIGH .
6E-222
6E-222
Diagnostic Aids ..........................................
6E-222
Plug Indicator Circuit Voltage Low ...........
6E-222
Plug Indicator Circuit Voltage High ..........
6E-226
EXHAUST GAS RECIRCULATION FLOW
EXCESSIVE DETECTED ........................
6E-227
EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO GROUND OR OPEN CIRCUIT 6E-227
EXHAUST GAS RECIRCULATION FLOW
INSUFFICIENT DETECTED ....................
6E-227

EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO BATTERY ............................
6E-227
6E-228
Diagnostic Aids ..........................................
6E-228
(Symptom Code 3) (Flash Code 32) Exhaust
Gas Recirculation Flow Excessive Detected 6E-228
Gas Recirculation Circuit Short to Ground or
Open Circuit .............................................
6E-232
Gas Recirculation Flow Insufficient Detected 6E-235
Gas Recirculation Circuit Short to Battery
6E-238
VEHICLE SPEED SENSOR CIRCUIT HIGH
INPUT ......................................................
6E-240
VEHICLE SPEED SENSOR INPUT SIGNAL
FREQUENCY TOO HIGH .......................
6E-240
VEHICLE SPEED SENSOR INCORRECT
SIGNAL ...................................................
6E-240
6E-241
Diagnostic Aids ..........................................
6E-241
(Symptom Code 1) (Flash Code 24) Vehicle
Speed Sensor Circuit High Input .............
6E-241
Vehicle Speed Sensor Input Signal
Frequency Too High ................................
6E-245
VehicleSpeed Sensor Incorrect Signal ....
6E-248
SYSTEM VOLTAGE TOO HIGH .............
6E-253
SYSTEM VOLTAGE TOO LOW ..............
6E-253
SYSTEM VOLTAGE MALFUNCTION .....
6E-253
6E-253
6E5
Diagnostic Aids ..........................................

6E-254
System Voltage Too High ........................
6E-254
System Voltage Too Low .........................
6E-256
System Voltage Malfunction ....................
6E-258
IGNITION SWITCH CIRCUIT
MALFUNCTION .......................................
6E-260
IGNITION SWITCH CIRCUIT
MALFUNCTION .......................................
6E-260
6E-261
Diagnostic Aids ..........................................
6E-261
Ignition Switch Circuit Malfunction ...........
6E-261
Ignition Switch Circuit Malfunction ...........
6E-261
CONTROL MODULE PROGRAMMING
ERROR ....................................................
6E-264
Circuit Description & Diagnostic Aids ........
6E-264
Control Module Programming Error .........
6E-264
ECU MALFUNCTION ..............................
6E-265
ECU MALFUNCTION ..............................
6E-265
6E-265
ECU Malfunction ......................................
6E-265
ECU Malfunction ......................................
6E-267
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE LOW ......................................
6E-268
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE HIGH ......................................
6E-268
6E6

6E-268
Diagnostic Aids ..........................................
6E-268
(Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low ...
6E-269
(Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High ..
6E-272
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
6E-274
Diagnostic Aids ..........................................
6E-274
(Symptom Code A) (Flash Code 25) Brake
Switch Circuit Malfunction .......................
6E-274
Brake Switch Circuit Malfunction .............
6E-278
CLUTCH SWITCH INPUT CIRCUIT
MALFUNCTION .......................................
6E-281
6E-281
Diagnostic Aids ..........................................
6E-281
Clutch Switch Input Circuit Malfunction ...
6E-282
BAROMETRIC PRESSURE SENSOR
6E-285
BAROMETRIC PRESSURE SENSOR
6E-285
6E-285
Diagnostic Aids ..........................................
6E-285
(Symptom Code 1) (Flash Code 86) Barometric
Pressure Sensor Circuit High Input .........
6E-285
(Symptom Code 2) (Flash Code 86) Barometric
Pressure Sensor Circuit Low Input ..........
6E-285
PEDAL/THROTTLE POSITION SENSOR
6E-287

VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
BRAKE SWITCH ERROR .......................
6E-287
IDLE POSITION SWITCH ERROR .........
6E-287
6E-288
Diagnostic Aids ..........................................
6E-288
Pedal/Throttle Position Sensor
Circuit High Input .....................................
6E-288
Pedal/Throttle Position Sensor Voltage
Supply Circuit High Input .........................
6E-293
Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input ..........................
6E-295
Pedal/Throttle Position Sensor Brake
Switch Error .............................................
6E-298
Pedal/Throttle Position Sensor Idle
Position Switch Error ...............................
6E-300
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ......................................
6E-302
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ......................................
6E-302
(SYMPTOM CODE A) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY LOW FUEL
TEMPERATURE ......................................
6E-302
6E-302
Diagnostic Aids ..........................................
6E-302
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant

Temperature ............................................
6E-302
(Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel
Temperature ............................................
6E-305
Reduction Caused By Low Fuel
Temperature ............................................
6E-305
(SYMPTOM CODE A)
(FLASH CODE 43) ENGINE SPEED OUTPUT
CIRCUIT MALFUNCTION .......................
6E-306
6E-306
Diagnostic Aids ..........................................
6E-306
Engine Speed Output Circuit Malfunction
6E-307
CAMSHAFT SPEED MALFUNCTION .....
6E-311
6E-311
Diagnostic Aids ..........................................
6E-311
Camshaft Speed Malfunction ..................
6E-312
NEUTRAL SWITCH ON ERROR ............
6E-313
NEUTRAL SWITCH OFF ERROR ..........
6E-313
6E-313
Diagnostic Aids ..........................................
6E-313
Neutral Switch ON Error ..........................
6E-314
Neutral Switch OFF Error ........................
6E-314
SEED AND KEY FILE DESTROYED ......
6E-318
EEPROM DEFECT ..................................
6E-318
EEPROM DEFECT ..................................
6E-318
6E-318
(Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed ..................
6E-318
6E7

EEPROM Defect ......................................
6E-318
EEPROM Defect ......................................
6E-318
SECURITY KEY AND SECURITY CODE NOT
PROGRAMMED ......................................
6E-320
6E-320
Diagnostic Aids ..........................................
6E-320
(Symptom Code A) (Flash Code 56) Security
Key and Security Code Not Programmed
6E-320
WRONG SECURITY CODE ENTERED ..
6E-322
6E-322
Diagnostic Aids ..........................................
6E-322
Wrong Security Code Entered .................
6E-323
IMMOBILIZER NO OR WRONG SIGNAL
6E-324
6E-324
Diagnostic Aids ..........................................
6E-324
Immobilizer No or Wrong Signal ..............
6E-325
IMMOBILIZER NO OR WRONG SIGNAL
6E-330
6E-330
Diagnostic Aids ..........................................
6E-330
Immobilizer No or Wrong Signal ..............
6E-331
WRONG TRANSPONDER KEY ..............
6E-335
6E-335
Diagnostic Aids ..........................................
6E-335
Wrong Transponder Key ..........................
6E-336
(SYMPTOM CODE A) (FLASH CODE 76) ECM
MAIN RELAY SWITCHED OFF
TOO EARLY ............................................
6E-337
6E8
(SYMPTOM CODE B) (FLASH CODE 76) ECM

MAIN RELAY SWITCHED OFF TOO LATE 6E-337
6E-337
Diagnostic Aids ..........................................
6E-337
(Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early .........
6E-338
(Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late ..........
6E-339
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION .......................................
6E-340
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION .......................................
6E-340
6E-340
Diagnostic Aids ..........................................
6E-341
Injection Quantity Circuit Malfunction ......
6E-341
Injection Quantity Circuit Malfunction ......
6E-341
(SYMPTOM CODE A)
(FLASH CODE 44) CAN DEVICE OFFLINE 6E-342
CAN DEVICE HANG-UP .........................
6E-342
6E-342
Diagnostic Aids ..........................................
6E-342
CAN Device Offline ..................................
6E-343
CAN Device Hang-up ..............................
6E-348
CAN MALFUNCTION ..............................
6E-349
CAN RECEIVES ERROR ........................
6E-349
6E-349
Diagnostic Aids ..........................................
6E-349
CAN Malfunction ......................................
6E-350
CAN Receives Error ................................

6E-351
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE LOW ......................................
6E-356
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE HIGH ......................................
6E-356
6E-356
Diagnostic Aids ..........................................
6E-356
(Symptom Code 4) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage Low ..
6E-357
(Symptom Code 8) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage High .
6E-360
SYMPTOM DIAGNOSIS ............................
6E-361
PRELIMINARY CHECKS ..........................
6E-361
VISUAL/PHYSICAL CHECK ......................
6E-361
INTERMITTENT ........................................
6E-361
ENGINE CRANKS BUT WILL NOT RUN ..
6E-362
HARD START SYMPTOM .........................
6E-366
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM ..................
6E-370
SURGES AND/OR CHUGS SYMPTOM ...
6E-377
HESITATION, SAG, STUMBLE SYMPTOM 6E-383
CUTS OUT, MISSES SYMPTOM ..............
6E-389
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM ..............................
6E-396
POOR FUEL ECONOMY SYMPTOM .......
6E-402
EXCESSIVE WHITE SMOKE ....................
6E-407
EXCESSIVE BLACK SMOKE ....................
6E-413
ON-VEHICLE SERVICE PROCEDURE ....
6E-418
ENGINE CONTROL MODULE (ECM) ...
6E-418
CRANKSHAFT POSITION (CKP) SENSOR 6E-419
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR .......................................
6E-419
MASS AIR FLOW (MAF) & INTAKE AIR
TEMPERATURE (IAT) SENSOR ............
6E-420
THROTTLE POSITION SENSOR (TPS) ...
6E-420
EGR EVRV
(Electrical Vacuum Regulating Valve) .....
6E-421
ABBREVIATION CHARTS
Abbreviations
A/C
Air conditioner
A/T
Automatic transmission
BLK
Black
ACC
Accessory
BLU
Blue
CAN
Controller Area Network
BRN
Brown
CEL
Check engine lamp
DLC
Data link connector
CKP
Crankshaft position sensor
DTC
Diagnosis trouble code
ECM
Engine control module
DVM
Digital voltage meter
ECT
Engine coolant temperature
EGR
Exhaust gas recirculation
GND
Ground
EEPROM
EVRV
Appellation
Electrically erasable & programmable read only memory

Electric vacuum regulating valve
GRY
Gray
IG
Ignition
MAB
High pressure solenoid valve cutoff (German abbreviation)
IAT
M/T
MAF
MIL
OBD
Intake air temperature

Manual transmission
Mass air flow
Malfunction indicator lamp
On-board diagnostic
ORN
Orange
RED
Red
PNK
Pink
PSG
Pump control unit (German abbreviation)
TCM
Transmission control module
TDC
Top dead center
VCC
Voltage constunt control
SW
TCV
TPS
Switch
Timing control valve
Throttle position sensor
VIO
Violet
WHT
White
VSS
YEL
Vehicle speed sensor
Yellow
6E9
6E10
COMPONENT LOCATOR
Engine Component Locator Table

4JA1-TC
(1) Mass Air Flow (MAF) & Intake Air Temperature

(IAT) Sensor Assembly
(2) Throttle Cable
(3) Air Cleaner Case
(4) Battery
(5) Relay & Fuse Box
(6) EGR Cooler
4JH1-TC

(2) Throttle Cable
6E11
(4) Battery
(5) Relay & Fuse Box
(6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
6E12
(1) Throttle Position Sensor (TPS)

(2) Pump Control Unit (PSG)

(2) EGR EVRV
(3) Injection Pump Assembly

(4) Fuel Filter (Except Euro 3)
(1) Engine Control Module (ECM)
(1) EGR EVRV

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

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

(2) Clutch Housing
6E13
6E14
ECM CIRCUIT DIAGRAM (4JA1-TC)
ECM CIRCUIT DIAGRAM (4JA1-TC)
6E15
6E16
ECM CIRCUIT DIAGRAM (4JH1-TC)
ECM CIRCUIT DIAGRAM (4JH1-TC)
6E17
6E18
GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)
6E19
6E20
6E21
6E22
GROUND POINT CHART EUROPE (LHD) (1/4)
6E23
6E24
6E25
6E26
GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)
6E27
6E28
6E29
6E30
GROUND POINT CHART EUROPE (RHD) (1/4)
6E31
6E32
6E33
6E34
LOCATION
CABEL HARNESS & CONNECTOR LOCATION
6E35
6E36
4JA1-TC & 4JH1-TC ENGINE (LHD)
4JA1-TC & 4JH1-TC ENGINE (RHD)
6E37
6E38
PARTS LOCATION
6E39
6E40
CONNECTOR LIST
No.
Connector face
Green
Meter-B
White
J/B I2
White
J/B I4
Black
Check connector
White
TCM
White
Ignition switch (IGSUB : G1)
White
TCM
White
Ignition switch (IGSUB : G2)
White
J/B E2
White
J/B E1
Silver
Body-LH ; ground
Brown
EVRV
B-24
B-54
B-56
B-58
B-62
B-63
B-68
C-2
Immobilizer
Silver
Engine room-RH ground
Silver
Engine room-LH ; Ground
White
Stop lamp switch
C-36
C-44
No.
C-56
C-57
C-77
C-94
C-95
C-107
C-108
C-109
C-115
C-116
Connector face
ECM-A
ECM-B
Clutch switch

No.
C-118
C-123
Connector face
A/C Resister & Neutral switch
C-124
E-6
Connector face
Gray
Idle SW
Black
Coolant temp sensor
Gray
Vehicle speed sensor
Gray
Glow plug
Black
Inhibiter switch
White
Engine room ~ Mission
E-23
E-41
E-44
E-3
Black
No.
E-49
Magnetic clutch AC COMP
E-9
E-51
H-4
E-10
H-6
Silver
Engine ground
White
Engine room ~ INST
Natural
green
Neutral switch
White
Engine room ~ INST
Natural
green
Neutral switch
White
Engine room ~ INST
Brown
TPS 1 main
White
Engine ~ Engine room C
E-11
E-12
E-22
H-7
H-18
H-22
6E41
6E42
No.

No.
Connector face
Engine ~ Engine room
Black
DIODE
Silver
Battery (+)
Black
DIODE
Silver
Relay & Fuse box
Silver
Battery (-)
Silver
Body earth (Ground)
Silver
Engine ground
Black
Relay ; Glow
Black
Relay ; ECM MAIN
Black
Relay; A/C Compressor
Black
Relay; Thermo
H-33
P-1
P-2
P-5
P-6
P-10
X-5
X-13
X-14
X-15
Connector face
X-16
X-17

RELAY AND FUSE
RELAY AND FUSE BOX LOCATION (LHD & RHD)
LHD
RHD
6E43
6E44
RELAY AND FUSE BOX LOCATION (LHD & RHD)

RELAY & FUSE BOX
RELAY
No.
X-1
X-2
X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
X-13
X-14
X-15
RELAY
(4JA1-TC/4JH1-TC)
RELAY; TAIL LIGHT
RELAY; FRT FOG LIGHT
RELAY; HORN
RELAY; DIMMER
RELAY; GLOW
RELAY; COND, FAN
RELAY; RR FOG
RELAY; STARTER
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-RH (RHD)
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-LH (RHD)
RELAY; HEATER
RELAY; HEAD LIGHT
RELAY; ECM MAIN
RELAY; A/C COMP
RELAY; THERMO
FUSE
FUSE
(4JA1-TC/4JH1-TC)
NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
EB-7
EB-8
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
10A ECM
10A RR FOG
15A FRT FOG
10A ILLUMI & TAIL-RH

10A TAIL-LH
10A H/LIGHT RH-LOW
10A H/LIGHT LH-LOW
10A TRA ILER
10A AC G (S)
10A H/LIGHT RH-HIGH
10A H/LIGHT LH-HIGH
10A A/C
10A 4WD
10A HORN
10A HAZARD
SLOW BLOW FUSE

NO.
SBF-1
SBF-2
SBF-3
SBF-4
SBF-5
SBF-6
SBF-7
SBF-8
SBF-9
SLOW BLOW FUSE

4JA1-TC/4JH1-TC
80A MAIN
20A COND, FAN
50A GLOW
30A ECM
40A IG 1
40A ABS-1
30A ABS-2
30A BLOWER
50A IG 2

FUSE AND RELAY LOCATION (LHD & RHD)
FUSE BOX
FUSE
No.
1
2
3
4
5
6
7
8
9
10
11
Capacity
10A
15A
15A
10A
15A
15A
20A
15A
10A
SLOW BLOW FUSE

No.
Capacity
SBF-10
20A
SBF-11
30A
RELAY
Connector No.
4JA1-TC, 4JH1-TC
Indication on label
ABS
BACK UP
METER
TURN
ELEC.IG
ENGINE
FRT WIPER
EGR
AUDIO
No.
12
13
14
15
16
17
18
19
20
21
Capacity
15A
15A
20A
10A
10A
10A
15A
15A
10A
10A
Indication on label
RR DEF
POWER WINDOW
B-7
B-8
REAR
POWER
DEFOGGER WINDOW
B-40
ACC
SOCKET
Indication on label
CIGER
AUDIO (+B)
DOOR LOCK
METER (+B)
ROOM
ANTI THEFT
STOP
ACC SOCKET
STARTER
SRS
6E45
6E46
ECM WIRING DIAGRAM (1/7)
6E47
6E48
6E49
6E50
6E51
6E52
6E53
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into ECM Case
Signal or Continuity
Tester Position
ECM
Connection
Range
(+)
(-)
Disconnect
Ohm
GND
Disconnect
Ohm
GND
Connect
DC V
GND
Approx.
23Hz by
wave form
or approx.
6.3V
Approx.
67Hz by
wave form
or approx.
6.8V
Connect
AC V
27
GND
Connect
DC V
30
GND
Pedal is not stepped on: 10-14V

Pedal is stepped on: Less than 1V
Connect
DC V
31
GND
A/C request switch is turned on: 1014V

A/C request switch is turned off: Less
than 1V
Connect
DC V
33
GND
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM Ground
BLK
ECM Ground
BLK
Continuity
with
ground
Battery Power Supply
25
25
No Connection
BLU/
RED
Continuity
with
ground
27
27
Engine Speed Output

(To Tacho Meter)
LGN
28
28
No Connection
30
30
Brake Switch 1 Signal
GRN
31
31
YEL
32
32
Clutch Switch Signal

(MT Only)
Less than
1V
33
A/C ON Signal Relay
GRN/
YEL
Less than
1V
34
34
No Connection
No Connection
Throttle Position Sensor (TPS) Output Signal
GRN/
ORG
Less than
1V
WHT
No Connection
Less than
1V
26
29
33
26
29
35
35
36
36
38
38
39
39
40
40
37
37
No Connection
No Connection
No Connection
To Data Link Connector No. 6 & Immobilizer Control Unit (ICU

B8)
No Connection
Key Switch Input Signal Via Engine Fuse
YEL
Less than
1V
-
Less than
1V
-
10-14V
Pedal is not stepped on: Less than 1V

Pedal is stepped on: 10-14V
Approx.
0.5V
Connect
DC V
38
49
Connect
DC V
39
GND
Less than 1V
10-14V
-
6E54

Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
41
41
A/C Compressor
Relay
WHT/
GRN
Less than
1V
10-14V
42
42
Check Engine Lamp
43
43
Glow Lamp
GRN/
YEL
Less than
1V
44
44
45
45
46
46
48
48
47
47
ORG/
BLU
Less than
1V
To Data Link Connector No. 6
BLU
Less than
1V
No Connection
No Connection
No Connection
No Connection
49
49
Throttle Position Sensor (TPS) Ground
BLK/
GRN
50
50
No Connection
52
52
No Connection
51
53
54
55
56
51
53
54
55
56
No Connection
No Connection
No Connection
65
66
66
No Connection
68
68
Vehicle Speed Sensor (VSS)
67
No Connection
Idle:
Approx.
0.4K ohm /
WOT:
Approx.
4.0K ohm
69
69
70
70
No Connection
72
72
No Connection
71
73
74
Idle Switch
No Connection
No Connection
No Connection
GND
-
Disconnect
Ohm
38
49
Less than
1V
-
Less than
1V
45
GRN/
BLK
DC V
Connect
GND
Less than
1V
YEL/
GRN
43
WHT/
BLK
-
DC V
65
Connect
GND
No Connection
42
64
DC V
No Connection
64
Connect
61
ECM Power Supply
GND
63
41
63
DC V
Connect
No Connection
(-)
62
(+)
No Connection
Range
No Connection
60
ECM Relay
ECM
Connection
59
61
74
10-14V
10-14V
59
73
BLU/
BLK
58
71
Lamp is turned on: Less than 1V

Lamp is turned off: 10-14V
Less than
1V
58
67

RED/
GRN
57
62
No Connection
Engine
2000rpm
A/C comp. is operated:

Less than 1V
A/C comp. is not operated: 10 - 14V
Throttle Position Sensor (TPS) Power Supply
57
60
No Connection
Engine
Idle
Tester Position
Approx. 5V
10-14V
57
49
Connect
DC V
58
GND

-
DC V
Connect
Less than 1V
Approx. 14.5Hz by wave form or

approx. 6.0V at vehicle speed 20km/h
Pedal is not stepped on: Less than 1V

Pedal is stepped on: Approx. 5V
DC V
63
GND
Connect
DC V
65
GND
Connect
AC V
68
GND
Connect
DC V
69
GND

Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
75
75
No Connection
77
77
No Connection
76
78
79
80
81
82
76
78
79
80
81
82
83
83
84
84
85
No Connection
No Connection
No Connection
No Connection
No Connection
No Connection
Mass Air Flow (MAF)

Sensor Power Supply
WHT/
RED
BLK/
BLU
Less than
1V
85
No Connection
87
87
Neutral Switch
88
88
BLK/
WHT
Less than
1V
89
89
90
86
86
Intake Air Temperature (IAT) Sensor Signal
No Connection
Mass Air Flow (MAF)

Sensor Signal
GRN/
RED
90
91
Less than
1V
DC V
84
92
In neutral: Less than 1V

Other than neutral: 10-14V
Connect
DC V
87
GND
0 deg. C: Approx. 4.4V / 20 deg. C:

Approx. 3.8V / 40 deg. C: Approx.
2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
91
CKP Sensor Output

To Pump Control Unit
(PSG) No.8
PNK
92
92
Mass Air Flow (MAF)

Sensor Ground
BLK/
RED
93
93
BLK/
PNK
94
94
Engine Coolant Temperature (ECT) Sensor Ground
95
Approx.
1.8V
Approx.
2.5V
Connect
DC V
88
92
Connect
DC V
89
93
Approx.
47Hz by
wave form
Connect
AC V
90
98
Approx.
47Hz by
wave form
Approx.
134Hz by
wave form
or approx.
1.1V
Connect
AC V
91
GND
Continuity
with
ground
Connect
Ohm
92
GND
Connect
Ohm
93
GND
Connect
DC V
94
GND
Continuity
with
ground
Glow Relay
BLK/
RED
95
No Connection
97
97
EGR EVRV
BLK/
ORG
98
98
CKP Sensor Ground
WHT
99
99
BLU
100
100
CAN (Controller Area

Network) to PSG No.1
YEL
Approx. 5V
Connect
RED

Network) to PSG No.2

1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
CKP Sensor Signal
(-)
92
Less than
1V
No Connection
(+)
83
GRY
96
Range
DC V
Approx. 1V
96
ECM
Connection
Connect
Less than
1V
Engine Coolant Temperature (ECT) Sensor Signal
6E55
Less than
1V
Continuity
with
ground
Approx.
134Hz by
wave form
or approx.
0.7V
Glow system is operated: Less than

1V
Glow system is not operated: 10 - 14V
-
Approx. 140Hz by wave

form when EVRV is
operated
Connect
Ohm
98
GND
6E56

Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
101
101
CKP Sensor Shield

Line
BLK
102
102
No Connection
Continuity
with
ground
-
103
104
105
103
104
105
No Connection
No Connection
Solenoid Valve Shut

Off (MAB) Output Signal to PSG No.5
ORG
ECM
Connection
Range
(+)
(-)
Connect
Ohm
101
GND
6E57
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM &
PSG Connection
Rang
e
(+)
(-)
99

Network) to ECM
No.99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(EC
M)
100

Network) to ECM
No.100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(EC
M)
No Connection
No Connection
105
Solenoid Valve Shut

Off (MAB) Output
Signal to ECM
No.105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(EC
M)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
CKP Sensor Output

ECM No.91 to Pump
Control Unit (PSG)
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(EC
M)
No Connection
10-14V
6E58
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into ECM Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Connect
DC V
GND
25
25
No Connection
26
26
No Connection
27
27
Engine Speed Output

(To Tacho Meter)
LGN
Approx.
23Hz by
wave
form or
approx.
6.3V
Approx.
67Hz by
wave
form or
approx.
6.8V
Connect
AC V
27
GND
28
28
No Connection
29
29
Throttle Position Signal To TCM (A16)

(AT Only)
30
30
31
31
32
10-14V
Approx. 140Hz by wave form (Idle:

Off duty 10% / WOT: Off duty 90%)
GRN
Less
than 1V
Pedal is not stepped on: Less than

1V
Pedal is stepped on: 10-14V
Connect
DC V
30
GND
Clutch Switch Signal

(MT Only)
YEL
Less
than 1V

Connect
DC V
31
GND
32
No Connection
33
33
A/C ON Signal Relay
GRN/
YEL
Less
than 1V
Connect
DC V
33
GND
34
34
No Connection
35
35
To Data Link Connector No. 6 & Immobilizer Control Unit

(ICU B8)
YEL
36
36
No Connection
A/C request switch is turned on: 1014V

A/C request switch is turned off:
Less than 1V

6E59
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
37
37
No Connection
38
38
Throttle Position
Sensor (TPS) Output Signal
GRN/
ORG
Less
than 1V
Approx.
0.5V
Connect
DC V
38
49
39
39
Key Switch Input Signal Via Engine Fuse
WHT
Less
than 1V
Connect
DC V
39
GND
40
40
No Connection
41
41
A/C Compressor
Relay
WHT/
GRN
Less
than 1V
10-14V
Connect
DC V
41
GND
42
42
Check Engine Lamp
GRN/
YEL
Less
than 1V

Connect
DC V
42
GND
43
43
Glow Lamp
ORG/
BLU
Less
than 1V

Connect
DC V
43
GND
44
44
No Connection
45
45
To Data Link Connector No. 6
BLU
Less
than 1V
Connect
DC V
45
GND
46
46
No Connection
47
47
No Connection
48
48
No Connection
49
49
Throttle Position
Sensor (TPS)
Ground
BLK/
GRN
Idle:
Approx.
0.4K
ohm /
WOT:
Approx.
4.0K
ohm
Disconnect
Ohm
38
49
50
50
No Connection
51
51
No Connection
52
52
No Connection
53
53
No Connection
54
54
No Connection
55
55
No Connection
56
56
No Connection
57
57
Throttle Position
Sensor (TPS) Power
Supply
RED/
GRN
Less
than 1V
Approx. 5V
Connect
DC V
57
49
58
58
ECM Relay
BLU/
BLK
10-14V
Less than 1V
Connect
DC V
58
GND
59
59
No Connection
60
60
No Connection
61
61
No Connection
62
62
No Connection
Less than 1V
10-14V
A/C comp. is operated: Less than 1V

A/C comp. is not operated: 10 - 14V
10-14V
6E60

Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
63
63
ECM Power Supply
Less
than 1V
10-14V
64
64
No Connection
65
65
WHT/
BLK
Less
than 1V
66
66
No Connection
67
67
No Connection
68
68
YEL/
GRN
69
69
Idle Switch
GRN/
BLK
Less
than 1V
70
70
No Connection
71
71
No Connection
72
72
No Connection
73
73
No Connection
74
74
No Connection
75
75
76
Tester Position
ECM
Connection
Ran
ge
(+)
(-)
DC V
63
GND
Connect
DC V
65
GND
Approx. 14.5Hz by wave form or

approx. 6.0V at vehicle speed
20km/h
Connect
AC V
68
GND
Pedal is not stepped on: Less than

1V
Pedal is stepped on: Approx. 5V
Connect
DC V
69
GND
No Connection
76
No Connection
77
77
No Connection
78
78
No Connection
79
79
No Connection
80
80
No Connection
81
81
No Connection
82
82
Boost Pressure Sensor (High Altitude

Spec. Only)
WHT/
BLU
Less
than 1V
Approx. 5V
Connect
DC V
82
93
83
83
Mass Air Flow (MAF)

Sensor Power Supply
WHT/
RED
Less
than 1V
Approx. 5V
Connect
DC V
83
92
84
84
Intake Air Temperature (IAT) Sensor

Signal
BLK/
BLU
Less
than 1V

1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
Connect
DC V
84
92
85
85
Manifold Pressure
Sensor (High Altitude Spec. Only)
RED/
BLU
Less
than 1V
Connect
DC V
85
93
86
86
No Connection
87
87
Neutral Switch
BLK/
WHT
Less
than 1V
In neutral (A/T: P or N): Less than

1V
Other than neutral (A/T: other than
P or N): 10-14V
Connect
DC V
87
GND
88
88
Mass Air Flow (MAF)

Sensor Signal
GRN/
RED
Less
than 1V
Approx.
1V
Connect
DC V
88
92
Engine
2000rpm

Approx.
1.8V
Approx.
2.5V

Engine
Idle
6E61
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
89
89
Engine Coolant Temperature (ECT) Sensor Signal
GRY
Less
than 1V

2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
Connect
DC V
89
93
90
90
CKP Sensor Signal
RED
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
1.1V
Connect
AC V
90
98
91
91
CKP Sensor Output

To Pump Control Unit
(PSG) No.8
PNK
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
0.7V
Connect
AC V
91
GND
92
92
Mass Air Flow (MAF)

Sensor Ground
BLK/
RED
Continuity with
ground
Connect
Ohm
92
GND
93
93
Engine Coolant Temperature (ECT) Sensor & Manifold

Pressure Sensor
Ground
BLK/
PNK
Continuity with
ground
Connect
Ohm
93
GND
94
94
Glow Relay
BLK/
RED
Less
than 1V
Connect
DC V
94
GND
95
95
No Connection
96
96
Turbocharger Wastegate Control EVRV
BRW/
RED
Wave form
97
97
EGR EVRV
BLK/
ORG
Approx. 140Hz by
wave form when
EVRV is operated
98
98
CKP Sensor Ground
WHT
Continuity with
ground
Connect
Ohm
98
GND
99
99

Network) to PSG
No.1
BLU
100
100

Network) to PSG
No.2
YEL
101
101
CKP Sensor Shield

Line
BLK
Continuity with
ground
Connect
Ohm
101
GND
102
102
No Connection
103
103
No Connection
104
104
No Connection
105
105
Solenoid Valve Shut

Off (MAB) Output
Signal to PSG No.5
ORG
Glow system is operated: Less than

1V
Glow system is not operated: 10 14V
-
6E62
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rp
m
ECM &
PSG Connection
Rang
e
(+)
(-)
99

Network) to ECM
No.99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(ECM
)
100

Network) to ECM
No.100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(ECM
)
No Connection
No Connection
105
Solenoid Valve Shut

Off (MAB) Output
Signal to ECM
No.105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(ECM
)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
CKP Sensor Output

ECM No.91 to Pump
Control Unit (PSG)
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(ECM
)
No Connection
10-14V

Crankshaft Position (CKP) Sensor Reference Wave Form
6E63
Crankshaft Position (CKP) Sensor & TDC Output Signal

Reference Wave Form
CH1
0V
0V
CH2
0V
Measurement Terminal: 90(+)

98(-)
Measurement Scale: 20V/div
2ms/div
Measurement Condition: Approximately 2000rpm
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)

Measurement Scale: CH1: 50V/div / CH2: 10V/div
1ms/div
Engine Speed Output Signal Reference Wave Form
Vehicle Speed Sensor (VSS) Reference Wave Form
0V
0V

GND(-)
10ms/div

GND(-)
50ms/div
Measurement Condition: Approximately 20km/h
6E64
GENERAL DESCRIPTION FOR ECM AND

SENSORS
management system.
Engine Control Module (ECM)
Engine Control Module (ECM)
Pump Control Unit (PSG) = Pumpen Steuer Great

(German)
The engine control module (ECM) is located flower

panel just under the passenger's seat.
The fuel quantity and injection timing related functions
are controlled by the pump control unit (PSG).
The engine control module (ECM) performs the
following functions.
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
module (ECM) and the pump control unit (PSG) is
perfumed via a CAN-bus system. The abbreviation CAN
stands for Controller Area Network. By having two
separate control modules, the high pressure solenoid
valve. This prevents the discharge of any disturbing
signals.
Control of the exhaust gas re-circulation (EGR)
Control of the quick on start (QOS) glow control

system
Control of the A/C compressor
Execution of the immobilizer function
Engine Speed
Accelerator Pedal
Engine
Control
Module
(ECM)
Intake Air Temperature
Injection Timing
Injection Quantity
Response Signal
Mass Air Flow
Additional Signal
Others
Additional Operations
To High Pressure Solenoid

Cam Ring Rotational Angle
Fuel Temperature
Pump
Control
Unit
(PSG)
Via analogue signal leads

Via the CAN-bus
Pump Control Unit (PSG) & Data Exchange

Between Control Module
Self Diagnosis / Interface / Signal
The information exchange between the two control

modules takes place via two means.
High Pressure
Solenoid Valve
Fuel Injection
(Mechanical)
Timing Device
To Timing Control Valve (TCV)
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
The analogue signal leads are used to exchange the

following information.
Engine speed signal (ECM terminal 91)
Pump Speed (ECM terminal 105)
Fuel Cutoff solenoid valve signal (MAB signal) (ECM

terminal 105)
The engine speed signal is sent from the ECM to PSG
based on the input from the crank shaft position (CKP)
sensor.
The analogue CKP sensor signal is converted by the
ECM into a square wave signal.
The fuel cutoff solenoid valve signal is also referred to
as MAB signal.
MAB in this case, refers to the German abbreviation
Magnet ventil ABschaltung that stands for high pressure
solenoid valve cut off.
The MAB signal wire is used for two purposes.
-As a reference for the engine control module (ECM) for
the pump speed (back up for the CKP sensor).
-To turn Off the engine.
6E65
The following signals are exchanged via the CAN-bus:

From ECM to PSG
Desired injection quantity
Desired injection timing
Engine speed
!"#"$%&#'(%'$ )* +,- .&/()# 01&*&#&/$&0
From PSG to ECM
Fuel temperature
Pump speed
Cylinder identifier
Control pulse (actual injection quantity + actual

injection timing)
PSG status
1&('(%"/$& @)!=C @.)D'A E'/&C
233333
23333
2333
233
043 053 023
Mass Air Flow (MAF) Sensor & Intake Air

Temperature (IAT) Sensor
23
23 53 43 63 73 83 93 :3
+/%"<& ,'# -&=>? @A&B? C @-&$!5 1&"A'/BC
;3
233 223
The IAT sensor is a thermistor. A temperature changes

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

(IAT) Sensor
The mass air flow (MAF) sensor is part of the intake air
system.
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine.
The mass air flow (MAF) sensor uses a hot film element
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both exposed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
6E66
Throttle Position Sensor (TPS)
Crankshaft Position (CKP) Sensor
(1) Crankshaft Position (CKP) Sensor

(2) Fly wheel with sensor slot
(1) Throttle Position Sensor (TPS)

(2) Idle Switch
The CKP sensor is located on top of the flywheel

housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
and engine cylinder top dead center (TDC).
!"#"$%&#'(%'$ )* +,- ./&*&#&0$&.
723
7
BC%DC% E)=%"A& >E@
623
6
523
5
423
4
123
1
41
43 51
53 61
63 71 73 31 33 81 83 91
,&<"= ,)('%')0 >?@ >+&$!5 /&"<'0A
93 :1
:3 ;1
;3 411
The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
delivery based on throttle valve angle.
Engine Coolant Temperature (ECT) Sensor
6E67
(1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge
M/T & A/T 4WD
!"#"$%&#'(%'$ )* + , -&.()# /0&*&#&.$&/

122222
0&('(%".$& ?)!=B ?-)<'@ C'.&B
12222
1222
122
/32 /42
/12
12
12
42 32 52 62 72 82 92 :2
+.;'.& ))<".% ,&=> ?@&;A B ?,&$!4 0&"@'.;B
122 112 142 132
A/T 2WD
The ECT sensor is a thermistor. A temperature changes
words it measures a temperature value. It is installed on
the coolant stream. Low coolant temperature produces
a high resistance.
The ECM supplies 5 volts signal to the ECT sensor
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.
The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
The 2WD model fitted with automatic transmission,
vehicle speed sensor signal is transmitted to from the
TCM to the ECM via vehicle speed meter.
6E68
GENERAL DESCRIPTION FOR EGR

(EXHAUST GAS RE-CIRCULATION)
(1) EGR Valve

(2) EGR Cooler (Euro 3) / EGR Pipe (Except Euro
3)
(3) Intercooler
(4) Intake Manifold
(5) Exhaust Manifold
(6) Waste Gate
(7) Fresh Air
(8) Exhaust Gas
(9) Turbocharger
(1)
(2)
(3)
(4)
(5)
(6)
To EGR Valve
From Vacuum Pump
EGR EVRV
EGR Cooler
Thermo Valve
EGR Valve
The 4JA1-TC & 4JH1-TC engine with Euro 3 regulation

is equipped with the EGR cooler. The EGR cooler
reduces the temperature of the air being drawn into the
engine and the combustion temperature. This results in
reducing nitrogen oxide (Nox) emissions. The 4JH1-TC
engine except Euro 3 regulation, it does not have EGR
cooler. It has steel EGR pipe instead of the cooler.
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the following
inputs.
Engine speed
Injection quantity
Mass air flow
Intake air temperature

Coolant temperature
Barometric pressure

7.1ms
0.7ms
Time
Off duty 10% =EGR Pulse Ratio 10%

7.1ms
6.4ms
Time
Off duty 90% =EGR Pulse Ratio 90%
The EVRV is shaped to control vacuum applied to the

diaphragm chamber of the EGR valve based on duty
signal sent from the ECM. The duty ratio is the time that
the EVRV is opened to one cooperate EVRV operating
cycle. A duty ratio change of 90% to 10 % is EGR
amount control.
6E69
6E70
GENERAL DESCRIPTION FOR INJECTION

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

distributor type injection pump utilizes a cam ring to
enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
smoke, low noise, high output and clear exhaust
emissions.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Drive Shaft
Feed Pump
Distributor Head
Constant Pressure Valve (CPV) Holder
Timer

Low Pressure Fuel Circuit
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Rotor Shaft
Radial Plunger
High Pressure Passage
Low Pressure Inlet
Distributor Slit
Valve Needle
Barrel
Annular Passage
Fuel Return
High Pressure Outlet
Diaphram Chamber
Accumulator Diaphram
(1)
(2)
(3)
(4)
(5)
6E71
Fuel Suction
Regulating Valve
Overflow Valve
Feed Pump
To Fuel Tank
The low pressure fuel circuit must supply sufficient fuel

to the high pressure fuel circuit. The main components
are the feed pump, the regulating valve and the
overflow valve.
6E72
High Pressure Fuel Circuit
(1)
(2)
(3)
(4)
(5)

Distributor Head
In addition high pressure generating device, the high

pressure circuit also consists of fuel piping, and devices
to set the beginning of injection and fuel injection
quantity.
The main components are as follows.
High pressure generation: Radial Plunger High

Pressure Pump
Fuel distribution: Distributor Head
Beginning of injection timing: Timing Device
Prevention of secondary injection: Constant Pressure

Valve (CPV)
(1)
(2)
(3)
(4)
(5)

Sensor Wheel
Pump Camshaft Speed Sensor Retaining Ring
Flexible Connector Harness
Drive Shaft
When the drive shaft rotates, the pump camshaft speed

sensor receives signal form the sensor wheel, and an
electric pulse is sent through the flexible connecting
harness to the pump control unit (PSG).
From these signals the pump control unit (PSG) can
determine the average pump speed and the momentary
pump speed.
The pump camshaft speed sensor is mounted to the
cam ring. Thus, the relationship between the cam ring
and the pump camshaft speed sensor signal is
constant.

The pump camshaft speed sensor signal is utilized for
the following purposes.
To determine the momentary angular position of the
cam ring.
To calculate the actual speed of the fuel injection pump.
To determine the actual timing plunger position.
+*&,-.
34**)
/0#1
/0#1
!"#,4";6
!-&6.-)
+1**2
7&%6
+*&,-.
8/+9:
6E73
!"# $%&' (&')*

/0#1 +1**2
5%#*. /-,%6%-&
(1)
(2)
(3)
(4)
The pump camshaft sensor signal has a tooth gap, and
the crankshaft position (CKP) sensor on the flywheel
housing is used as a reference signal of engine top
dead center (TDC) for the start timing of fuel delivery or
injection which is to be set.
Valve Needle
Magnet Anchor
Coil
High Pressure Passage
Fuel injection quantity control is performed from the

beginning of pressure delivery at the beginning of cam
lift until the high pressure solenoid valve opens at the
end of pressure delivery.
This interval is called the pressure delivery interval.
Accordingly, the interval that the high pressure solenoid
valve is closed determines the fuel injection quantity
(high pressure fuel supply ends when the high pressure
solenoid valve opens).
6E74
When current from the pump control unit (PSG) flows to

the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
(1) Valve Needle

(2) Coil
When the fuel injection quantity demanded by the
engine is reached, the current to the coil is cut and the
valve needle re-opens the valve seat.
As a result of this, a path is opened for the fuel in the
high pressure passage to the low pressure circuit and
the pressure decreases. With a decrease in injection
pressure the nozzle closes and injection ends.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cam Ring
Servo Valve
Timer Piston
Outlet
Feed Pump
Inlet
Fuel Suction
Ball Pin
Annular Chamber
Hydraulic Stopper
Return Passage
The pressure of the fuel fed from the feed pump is

adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
The timing plunger is connected to the cam ring by a
ball pin. Axial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing.
!"#!$ %&'(
!"#!$ )*$$(
!"#!$
+&!-0&,
2&(1,$
3 +24
51/*
+&!-0&,
6!#35)74
6E75
.#/#!"
+&!-0&,
;',<$
3.+;4
!"#!$ +&&,'!.$/*$0'-10$
51/* +'/89':)*$$( )$!8&0
(1)
(2)
(3)
(4)
(5)
Coil
From Annular Chamber
To Feed Pump
Orifice
Valve Needle
When control current flows to the timing control valve

(TCV) coil, the valve needle opens and the fuel annular
chamber flows through the orifice to the feed pump inlet.
Consequently, the pressure of the annular chamber
decreases and the hydraulic stopper is moved to the
retard side.
The timing control valve (TCV) acts as a variable
throttle, using the rapid opening and closing (cycling) of
the valve needle in the timing control valve (TCV).
At normal operation, the TCV controls the pressure
acting on the annular chamber so that the hydraulic
stopper cam move to any position, from the retard
position to the advance position. At this time, the duty
ratio is set by the pump control unit (PSG).
Duty ratio is the ratio of the time that the timing control
valve (TCV) is opened to one complete timing control
valve (TCV) operating cycle. A duty ratio change of
100% to 0% is an advance in injection timing. (The
VP44 displays an ON duty ratio.)
The engine control module (ECM) contains

characteristic maps of the start of injection,
corresponding to engine operating conditions (engine
load, engine speed and engine coolant temperature).
The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
injection timing. If there is a difference, the timing
control valve (TCV) is controlled by the duty ratio. (The
actual start of injection timing is determined from the
pump camshaft speed sensor.)
6E76
ISUZU Strategy Based Diagnostics
Overview
As a retail service technician, you are part of the ISUZU

service team. The team goal is FIX IT RIGHT THE
FIRST TIME for the satisfaction of every customer. You
are a very important member of the team as you
diagnose and repair customer vehicles.
You have maximum efficiency in diagnosis when you

have an effective, organized plan for your work.
Strategy Based Diagnostics (refer to Figure 1) provides
you with guidance as you create and follow a plan of
action for each specific diagnostic situation.
STRATEGY BASED DIAGNOSTICS CHART
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the

Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:
Improves your understanding and definition of the
customer complaint
Saves time by avoiding testing and/or replacing good

parts
Allows you to look at the problem from different
perspectives
Guides you to determine what level of understanding
about system operation is needed:
Owners manual level
Service manual level
In-depth (engineering) level

Owners manual level
Service manual level
In-depth (engineering) level
1. Verify the Complaint

What you should do
To verify the customer complaint, you need to know the

correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the
system.
The following information will help you verify the
complaint:
WHAT the vehicle model/options are
WHAT aftermarket and dealer-installed accessories

exist
WHAT related system(s) operate properly
WHEN the problem occurs
WHERE the problem occurs
HOW the problem occurs
HOW LONG the condition has existed (and if the

system ever worked correctly)
HOW OFTEN the problem occurs
Whether the severity of the problem has increased,

decreased or stayed the same
What resources you should use
Whenever possible, you should use the following

resources to assist you in verifying the complaint:
Service manual Theory or Circuit Description
sections
Service manual System Performance Check
Owner manual operational description

Technician experience
Identical vehicle for comparison
6E77
Circuit testing tools

Vehicle road tests
Complaint check sheet
Contact with the customer
2. Perform Preliminary Checks
NOTE: An estimated 10 percent of successful vehicle

repairs are diagnosed with this step!
What you should do
You perform preliminary checks for several reasons:
To detect if the cause of the complaint is VISUALLY

OBVIOUS
To identify parts of the system that work correctly
To accumulate enough data to correctly and

accurately search for a ISUZU Service Bulletin on
ISUZU Web site.
The initial checks may vary depending on the
complexity of the system and may include the following
actions:
Operate the suspect system
Make a visual inspection of harness routing and

accessible/visible power and ground circuits
Check for blown fuses
Make a visual inspection for separated connectors
Make a visual inspection of connectors (includes

checking terminals for damage and tightness)
Check for any DTCs stored by the on-board

computers
Sense unusual
movements
noises,
smells,
vibrations
or
Investigate the vehicle service history (call other

dealerships, if appropriate)
Whenever appropriate, you should use the following

resources for assistance in performing preliminary
checks:
Tech II or other technical equipment for viewing DTCs
Service manual information:
Component locations
Harness routing
Wiring schematics
Procedures for viewing DTCs
Dealership service history file

Vehicle road test
Identical vehicle or system for comparison
6E78
3. Check Bulletins and

Troubleshooting Hints
to the customer complaint.
NOTE: As estimated 30 percent of successful vehicle

repairs are diagnosed with this step!
What you should do
You should have enough information gained from

preliminary checks to accurately search for a bulletin
and other related service information. Some service
manual sections provide troubleshooting hints that
match symptoms with specific complaints.
You should use the following resources for assistance in

checking for bulletins and troubleshooting hints:
Printed bulletins
Access ISUZU Bulletin Web site.

Videotapes
Service manual
The System Checks in most service manual sections

and in most cells of section 8A (electrical) provide you
with:
A systematic approach to narrowing down the

possible causes of a system fault
Direction to specific diagnostic procedures in the
service manual
Assistance to identify what systems work correctly

resources to perform service manual checks:
and
Other tools as needed
5a and 5b. Perform Service Manual

Diagnostic Procedures
NOTE: An estimated 40 percent of successful vehicle

repairs are diagnosed with these steps!
What you should do
Service manual
Technical equipment (for analyzing diagnostic data)
Digital multimeter and circuit testing tools
Essential and special tools
5c. Technician Self Diagnoses
When there is no DTC stored and no matching

symptom for the condition identified in the service
manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
service manual combined with you experience and a
good process of elimination will result in accurate
diagnosis of the condition.
Step 1: Identify and understand the suspect

circuit(s)
What you should do
Technical equipment (for viewing DTCs

analyzing data)
Digital multimeter and circuit testing tools

resources to perform service manual diagnostic
procedures:
What you should do
4. Perform Service Manual

Diagnostic Checks
Service manual
When directed by service manual diagnostic checks,

you must then carefully and accurately perform the
steps of diagnostic procedures to locate the fault related
Having completed steps 1 through 4 of the Strategy

Based Diagnostics chart, you should have enough
information to identify the system(s) or sub-system(s)
involved. Using the service manual, you should
determine and investigate the following circuit
characteristics:
Electrical:
How is the circuit powered (power distribution

charts and/or fuse block details)?
How is the circuit grounded (ground distribution
charts)?
How is the circuit controlled or sensed (theory of

operation):
If it is a switched circuit, is it normally open or
normally closed?
Is the power switched or is the ground

switched?
Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
Is it a signal generating device (MAF sensor of

VSS, for example)?
Does it rely on some mechanical/vacuum

device to operate?
Physical:
Where are the circuit components (component
locators and wire harness routing diagrams):
Are there areas where wires could be chafed

or pinched (brackets or frames)?
Are there areas
temperatures?
subjected
to
extreme

Are there areas subjected to vibration or
movement
(engine,
transmission
or
suspension)?
Are there areas exposed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
Are there common mounting areas with other

systems/components?
Have previous repairs been performed to wiring,

connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.)
Step 2: Isolate the problem
At this point, you should have a good idea of what could

cause the present condition, as well as could not cause
the condition. Actions to take include the following:
Divide (and separate, where possible) the system or

circuit into smaller sections
Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
For two or more circuits that do not share a common

power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
Loose connections:
Open/high resistance
connectors or grounds
in
terminals,
splices,
Incorrect connector/harness routing (usually in new

vehicles or after a repair has been made):
Open/high resistance in
connectors of grounds
Corrosion and wire damage:
Open/high resistance
connectors of grounds
Component failure:
in
terminals,
splices,
terminals,
splices,
Opens/short and high resistance

modules, switches or loads
at the component
If a number of components do no operate, begin tests

at the area of commonality (such as power sources,
ground circuits, switches or major connectors)

resources to assist in the diagnostic process:
Service manual
Technical equipment (for data analysis)
Experience
Technical Assistance
Circuit testing tools
5d. Intermittent Diagnosis
By definition, an intermittent problem is one that does

not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
Faulty electrical connections and wiring
Malfunctioning components (such as sticking relays,

solenoids, etc.)
EMI/RFI
(Electromagnetic/radio
frequency
interference)
Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
external and internal system conditions to duplicate the
problem.
What you should do

Step 1: Acquire information
A thorough and comprehensive customer check sheet

is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
Step 2: Analyze the intermittent problem
in
relays,
Aftermarket equipment affecting normal operation of

other systems
You may isolate circuits by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another part
Operating shared circuits and eliminating those that
function normally from the suspect circuit
If only one component fails to operate, begin testing
6E79
Analyze the customer check sheet and service history

file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.
6E80
Step 3: Simulate the symptom and isolate the

problem
Simulate the symptom and isolate the system by

reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Next, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Unplugging connectors or removing a fuse to

separate one part of the circuit from another
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test

at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Substitute a known good part from the parts

department or the vehicle system
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.

resources to assist in the diagnostic process:
Service manual
Bulletins
connector
kits/
Experience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests

1. Vibration
This method is important when the complaint suggests

that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CAUTION: Care must be take to avoid overheating
the component.
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CAUTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the

blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system

operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
A lack of understanding by the customer
A conflict between customer expectations and

vehicle design intent
A system performance that is unacceptable to the

customer
What you should do
Digital multimeter (with a MIN/MAX feature)

Circuit testing tools (including
harnesses and jumper wires)
2. Heat
3. Water and Moisture
Hints
You can isolate a circuit by:
Tech II and Tech II upload function
For parts and sensors, apply slight vibration to the part

with a light tap of the finger while monitoring the system
for a malfunction.
This method is useful when the customer complaint

analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.
You can verify that a system is operating as designed

by:
Reviewing
checks
service
manual
functional/diagnostic
Examining bulletins and other service information for

supplementary information
Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer expectation and system
operation, you should explain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.

resources to facilitate the diagnostic process:

Vehicle service information (service manual, etc.)
ISUZU field support
Experience
Identical vehicle or system for comparison
6. Re-examine the complaint
When you do not successfully find/isolate the problem

after executing a diagnostic path, you should reexamine the complaint.
What you should do
In this case, you will need to backtrack and review

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

resources to facilitate the diagnostic process:
Service manual
Accumulated information form a previous diagnostic

path
Service information and publications
ISUZU field support
7. Repair and Verify Fix

What you should do
After you have located the cause of the problem, you

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

resources to facilitate the repair process:
Electrical repair procedures
Service manual information and publications
6E81
6E82
GENERAL SERVICE INFORMATION
Serviceability Issues
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run

with OEM parts.
Accordingly, if commercially sold
sensor or switch is installed, it makes a wrong diagnosis
and turns on the check engine lamp.
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the check
engine lamp.
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the check

engine lamp to turn on if the vehicle is not maintained
properly. Restricted oil filters, fuel filters, and crankcase
deposits due to lack of oil changes or improper oil
viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD.
Poor vehicle
maintenance can not be classified as a non-vehicle
fault, but with the sensitivity of OBD diagnostics,
vehicle maintenance schedules must be more closely
followed.
Related System Faults
Many of the OBD system diagnostics will not run if the

ECM detects a fault on a related system or component.
Visual/Physical Engine Compartment

Inspection
Perform a careful
visual and physical engine
compartment inspection when performing any
diagnostic procedure or diagnosing the cause of an
emission test failure. This can often lead to repairing a
problem without further steps.
Use the following
guidelines
when
performing
a
visual/physical
inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
Inspect all wires in the engine compartment for

proper connections, burned or chafed spots, pinched
wires, contact with sharp edges or contact with hot
exhaust manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain

when performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to
effectively use this section of the Service Manual.
ON-BOARD DIAGNOSTIC (OBD)
On-Board Diagnostic (Self Diagnosis

System) Tests
A diagnostic test is a series of steps, the result of which

is a pass or fail reported to the diagnostic executive.
When a diagnostic test reports a pass result, the
diagnostic executive records the following data:
The diagnostic test has been completed since the
last ignition cycle.
The diagnostic test has passed during the current
ignition cycle.
The fault identified by the diagnostic test is not

currently active.
When a diagnostic test reports a fail result, the
diagnostic executive records the following data:
The diagnostic test has been completed since the
last ignition cycle.
The fault identified by the diagnostic test is currently
active.
The fault has been active during this ignition cycle.
The operating conditions at the time of the failure.
The Diagnostic Executive
The Diagnostic Executive is a unique segment of

software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
Commanding the check engine lamp on and off
DTC logging and clearing
Current status information on each diagnostic

Diagnostic Information
The diagnostic charts and functional checks are

designed to locate a faulty circuit or component through
a process of logical decisions. The charts are prepared
with the requirement that the vehicle functioned
correctly at the time of assembly and that there are not
multiple faults present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented
by the diagnostic procedures contained in this manual.
The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
lamp is illuminated.
Check Engine Lamp
The check engine lamp looks the same as the check

engine lamp you are already familiar with, the Check
Engine lamp.
Basically, the check engine lamp is turned on when the

ECM detects a DTC that will impact the vehicle
emissions.
When the check engine lamp remains ON while the

engine is running, or when a malfunction is
suspected due to a driveability or emissions problem,
a Powertrain On-Board Diagnostic (OBD) System
Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
System Check. These checks will expose faults
which may not be detected if other diagnostics are
performed first.
Data Link Connector (DLC)
The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
behind the lower front instrument panel. The DLC is
used to connect to a Tech2. Some common uses of the
Tech2 are listed below:
Identifying stored Diagnostic Trouble Codes (DTCs).
Clearing DTCs.
Reading serial data.
6E83
Reading Flash Diagnostic Trouble Codes
The provision for communicating with the Engine

Control Module (ECM) is the Data Link Connector
(DLC). The DLC is located in the front console box. It is
used in the assembly plant to receive information in
checking that the engine is operating properly before it
leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECMs memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
DLC terminal 6 (diagnostic request) is pulled Low
(grounded) by jumping to DLC terminal 4 or 5, which is
a ground wire.
This will signal the ECM that you want to flash DTC(s),
if any are present. Once terminals 4 or 5 and 6 have
been connected, the ignition switch must be moved to
the ON position, with the engine not running.
The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
stored in the ECMs memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a

Tech 2
The procedure for reading diagnostic trouble code(s) is

to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes
Verifying Vehicle Repair
Verification of vehicle repair will be more

comprehensive for vehicles with OBD system
diagnostic. Following a repair, the technician should
perform the following steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the

Fail Records.
4. Monitor the DTC status information for the specific

DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps is very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
To clear Diagnostic Trouble Codes (DTCs), use the

Tech2 clear DTCs or clear information function.
When clearing DTCs follow instructions supplied by the
Tech2 manufacturer.
History DTC
History DTC can be candeled after 40 cycle driving with

no defect. Or history code can be deleted by Tech 2
Clear DTCs function.
6E84
DIAGNOSIS WITH Tech 2
If no codes are set:
Refer to F1: Data Display and identify the electrical

faults that are not indicated by trouble code.
Refer to SYMPTOM DIAGNOSIS.
6E85
Connect the SAE 16/19 adapter (3) to the DLC

cable (4).
Connect the DLC cable (4) to the Tech 2 (5).
Connect the SAE 16/19 adapter (3) to the data

link connector of the vehicle.
If codes are set:
1. Record all trouble codes displayed by Tech 2 and

check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty

status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is

intermittent. In this case, refer to DIAGNOSIS
AIDS.
6. If a code is present, refer to DTC Chart for

diagnosis.
7. Check trouble codes again using the Tech 2.
Tech 2 CONNECTION
Turn the key switch of the vehicle ON and press

the PWR key of the Tech 2.
Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied

to the Tech 2 when attaching or removing the PCMCIA
card.
Tech 2 scan tool is used to electrically diagnose the

automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Tech 2.
1. Configuration of Tech 2
Tech 2 scan tool kit (No. 7000086), Tech 2 scan

tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232

loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
Check the key switch is turn OFF.
Insert the PCMCIA card (1) into the Tech 2 (5).
6E86
TECH 2 OPERATING FLOW CART (START UP)
Press (ENTER) to Continue
Press ENTER key.
F0:
F1:
F2:
F3:
F4:
Main Menu
Diagnostic
Service Programming System (SPS)
View Capture Data
Tool Option
Download/ Upload Help
Select F0: Diagnostic.
(3) 2003
(2) 2002
(1) 2001
(Y) 2000
(X) 1999
(W) 1998
Vehicle Identification
Select (3) 2003or later.
(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Select (TF/UC).
System Selection Menu

F0: Powertrain
F1: Chassis
F3: Body
Select F0: Powertrain.
4JH1-TC Bosch
4JA1-TC Bosch
4JH1-T Denso
3.5L V6 6VE1 Hitachi
AW30-40LE
A/T JR405E
Select 4JA1-TC Bosch or 4JH1-TC Bosch.
Select 4JA1-TC Bosch or 4JH1-TC Bosch in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.

F0: Diagnostic Trouble Codes
F0: Read DTC Infor As Stored By ECU

F1: Clear DTC Information
F1: Data Display

F2: Snapshot
F3: Miscellaneous Test

F0: Lamps
F0: Glow Time Telltale Test
F1: Relays
F0: Glow Time Relay Test
F2: Solenoids
F0: EGR Solenoid Test
F3: Engine Speed (RPM) Control

F4: Programming
F0: Program VIN

F1: Lock ECU
F0: Diagnostic Trouble Code

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

malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
6E87
F1: Data Display

The purpose of the Data Display mode is to
continuously monitor data parameters.
The current actual values of all important sensors and
signals in the system are display through F1 mode.
See the Typical Scan Data section.
F2: Snapshot
Snapshot allows you to focus on making the condition
occur, rather than trying to view all of the data in
anticipation of the fault.
The snapshot will collect parameter information around
a trigger point that you select.
F3: Miscellaneous Test:
The purpose of Miscellaneous Test mode is to check
for correct operation of electronic system actuators.
F4: Programming (Factory Use Only)
The purpose of Programming is to program VIN in the
ECM and lock the programmed data.
6E88
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JA1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter
Units
Idle
1500rpm
2000rpm
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Barometric Pressure
hpa
Desired
Quantity
mg/stk
Air
730
1475 1525
1975 2025
345 - 385
725 - 775
975 - 1025
4-6
6-8
Active
Active
Inactive 0V
Flow
mg/strk
380 - 420
360 - 400
380 - 420
Air
mg/strk
350
350
350 - 370
Depends
on altitude
Depends
on altitude
Depends
on altitude
8 - 10
5 - 10
5-9
Mass
Injection
8 - 10
6 - 10
7 - 10
10
Injection Quantity
mg/stk
11
Desired Fuel Injection

Start
deg. CA
2-4
2- 5
3-5
12
Actual Injection Start
deg. CA
2-4
2-5
3-5
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg.
F
15
Intake
Temperature
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
16
Ignition Status
On12V/
Off0V
17
Brake Switch 1
Active/
Inactive
Air
deg. C / deg.
F
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.
Inactive
Inactive
Inactive
On 12V
On 12V
On 12V
Description
The engine speed is measured by ECM from the CKP

sensor.
This displays vehicle speed. The vehicle speed is

measured by ECM from the vehicle speed sensor.
This displays injection pump speed. The injection speed is

measured by ECM from the pump cam sensor.
Throttle position operating angle is measured by the ECM
from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
This displays operating status of the idle switch. This

should display "Active" until the accelerator position nearly
4 - 5%.
This displays calculated intake air volume for one cylinder

stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
This displays desired intake air volume for one cylinder

stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
The barometric pressure is measured by ECM from the
sensor in the ECM. This data is changing by altitude.
This displays desired value from the ECM. The ECM

compensates for fuel rate to basic rate.
This displays calculated actual fuel quantity from the PSG.

The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
This displays desired injection timing from the ECM. The
ECM compensates for fuel injection timing by throttle
position and various sensor signal.
This displays calculated actual injection timing based on

CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
The ECT is measured by ECM from ECT sensor output

voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
The FT is measured by PSG from FT sensor. This data is

changing by fuel temperature.
The IAT is measured by ECM from IAT sensor output

voltage. This data is changing by intake air temperature.
This displays the key switch status indicated by the ECM
with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
This displays operating status of the brake switch. This

should display "Active" when the brake pedal is stepped
on.

18
Brake Switch 2
Active/
Inactive
Inactive
Idle
1500rpm
2000rpm
19
Clutch Switch
Active/
Inactive
Inactive
Inactive
Inactive
20
Neutral Switch
On/Off
On
On
On
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V
22
Diagnostic Request
23
System Voltage
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
24
Main Relay
Active/
Inactive
Active
Active
Active
25
Glow Time Relay
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
26
Check Engine Light
On/Off
Off
Off
Off
27
Glow Time Telltale
On/Off
Off
Off
Off
28
Desired Engine Idle

Speed
rpm
730
730
730
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
30
Immobilizer
Inactive
Inactive
Inactive
31
Immobilizer Signal
Active/
Inactive
Not
Received
Not
Received
Not
Received
32
Immobilizer Function
Programmed
Yes/ No
Yes
Yes
Yes
70
70
70
33
Tech 2 Parameter
Information
EGR Pulse
(Exhaust
Recirculation)
Units
Ratio
Gas
Received/
Not
Received
10 - 14
Inactive
10 - 14
Inactive
10 - 14
6E89
Description

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

should display "Active" when the clutch pedal is stepped
on.
This displays operating status of the neutral switch. This

should display "On" when the gear position is neutral.
This displays the air conditioner request signal. This

should display "Active 12V" when the air conditioner switch
is switched on.
This displays the diagnostic request signal. This should
display "Inactive 12V" when the Tech 2 is connected.
This displays the system voltage measured by the ECM at

ignition feed.
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
This displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
upped.
This displays operating status for the Check Engine Lamp.

This should display "On" when the Check Engine Lamp is
turned on.
This displays operating status for the glow indicator lamp.
This should display "On" when the glow lamp is turned on.
The desired engine idle speed that the ECM commanding.

The ECM compensates for various engine loads based on
engine coolant temperature.
This displays operating status of the A/C compressor. This

should display "Active 0V" when the compressor relay is
operated.
This should display "Inactive" when the immobilizer is

correctly operated.
This should display "Not Received" when the immobilizer is

not activated.
This should display "Yes" when the immobilizer is correctly

programmed.
This displays the duty signal from the ECM to control the
EGR flow amount.
6E90
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter
Units
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Air
Idle
1500rpm
2000rpm
Definition
675 - 725
1475 1525
1975 2025
The engine speed is measured by ECM from the CKP

sensor.
335 - 375
725 - 775
975 - 1025
3-5
5-7
Active
Active/
Inactive 0V
Inactive 0V
Flow
mg/strk
420 - 490
380 - 460
410 - 480
Air
mg/strk
430 - 470
380 - 420
410 - 470
Barometric Pressure
hpa
Desired
Quantity
mg/stk
Depends
on altitude
Depends
on altitude
Depends
on altitude
10
Injection Quantity
mg/stk
6 - 10
6 - 10
7 - 11
11
Desired Fuel Injection

Start
deg. CA
1-3
2-4
3-5
12
Actual Injection Start
deg. CA
1-3
2-4
3-5
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg.
F
15
Intake
Temperature
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
16
Ignition Status
On12V/
Off0V
17
Brake Switch 1
Active/
Inactive
Mass
Injection
Air
deg. C / deg.
F
6 - 10
6 - 10
7 - 11
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.
Inactive
Inactive
Inactive
On 12V
On 12V
On 12V
This displays vehicle speed. The vehicle speed is

measured by ECM from the vehicle speed sensor.
This displays injection pump speed. The injection speed is

measured by ECM from the pump cam sensor.
Throttle position operating angle is measured by the ECM
from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
This displays operating status of the idle switch. This

should display "Active" until the accelerator position nearly
4 - 5%.
This displays calculated intake air volume for one cylinder

stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
This displays desired intake air volume for one cylinder

stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
The barometric pressure is measured by ECM from the
sensor in the ECM. This data is changing by altitude.
This displays desired value from the ECM. The ECM

compensates for fuel rate by throttle position and various
sensor signals.
This displays calculated actual fuel quantity from the PSG.

The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
This displays desired injection timing from the ECM. The
ECM compensates for fuel injection timing by throttle
position and various sensor signal.
This displays calculated actual injection timing based on

CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
The ECT is measured by ECM from ECT sensor output

voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
The FT is measured by PSG from FT sensor. This data is

changing by fuel temperature.
The IAT is measured by ECM from IAT sensor output

voltage. This data is changing by intake air temperature.
This displays the key switch status indicated by the ECM
with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.

on.

Tech 2 Parameter
Units
Idle
1500rpm
2000rpm
Definition
on.
18
Brake Switch 2
Active/
Inactive
Inactive
Inactive
Inactive
19
Clutch Switch (M/T

Only)
Active/
Inactive
Inactive
Inactive
Inactive
20
Neutral Switch
On/Off
On
On
On
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V
22
Diagnostic Request
23
System Voltage
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
24
Main Relay
Active/
Inactive
Active
Active
Active
25
Glow Time Relay
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
26
Check Engine Light
On/Off
Off
Off
Off
27
Glow Time Telltale
On/Off
Off
Off
Off
28
Desired Engine Idle

Speed
rpm
700
700
700
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
30
Immobilizer
Inactive
Inactive
Inactive
31
Immobilizer Signal
Active/
Inactive
Not
Received
Not
Received
Not
Received
32
Immobilizer Function
Programmed
Yes
Yes
Yes
85 - 90
85 - 90
85 - 90
33
Information
EGR Pulse
(Exhaust
Recirculation)
Ratio
Gas
Received/
Not
Received
Yes/ No
%
6E91
10 - 15
10 - 15
10 - 15
This displays operating status of the clutch switch. This

should display "Active" when the clutch pedal is stepped
on.
This displays operating status of the neutral switch. This

should display "On" when the gear position is neutral (M/T)
or P, N position (A/T).
This displays the air conditioner request signal. This

should display "Active 12V" when the air conditioner switch
is switched on.
This displays the diagnostic request signal. This should
display "Inactive 12V" when the Tech 2 is connected.
This displays the system voltage measured by the ECM at

ignition feed.
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
This displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
upped.
This displays operating status for the Check Engine Lamp.

This should display "On" when the Check Engine Lamp is
turned on.
This displays operating status for the glow indicator lamp.
This should display "On" when the glow lamp is turned on.
The desired engine idle speed that the ECM commanding.

The ECM compensates for various engine loads based on
engine coolant temperature.
This displays operating status of the A/C compressor. This

should display "Active 0V" when the compressor relay is
operated.
This should display "Inactive" when the immobilizer is

correctly operated.
This should display "Not Received" when the immobilizer is

not activated.
This should display "Yes" when the immobilizer is correctly

programmed.
This displays the duty signal from the ECM to control the
EGR flow amount.
6E92
MISCELLANEOUS TEST
The state of each circuit can be tested by using

miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
mechanical trouble and an electrical trouble.
Connect Tech 2 and select "Powertrain", "4JA1-TC
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
F0: Lamps
F0: Glow Time Telltale Test
When the Tech 2 is operated, "Glow Time Indicator
Lamp" is turned on or off.
The circuit is correct if the "Glow Time Indicator Lamp"
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
EGR Solenoid Test
Desired Mass Air Flow
470 mg/strk
Engine Speed
700 rpm
Exhaust Gas Recirculation
95%
Mass Air Flow
450 mg/strk
Press "Active" key.

Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%
F3: Engine Speed (RPM) Control

When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is correct if engine speed is changed in
Engine Speed (RPM) Control
Engine Speed
Desired Idle Speed

Injection Quantity
850 rpm
850 rpm
7.5 mg/ strk
Press "Increase" key.

Then, Desired Idle speed is increases
50rpm-by-50rpm up to 1200rpm. Engine speed is
also
Plotting Snapshot Graph
This test selects several necessary items from the data

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

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
6E93
6E94
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)
6E95
6E96
SNAPSHOT DISPLAY WITH TIS2000
Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]
function is described below.
Snapshot data can be displayed with [Snapshot Upload]
function included in TIS2000.
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.
By analyzing these data in various methods, trouble

conditions can be checked.
Snapshot data is displayed by executing the three steps
below shown:

After recording the snapshot in Tech2, transfer the data
from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start

screen.
3. Select [Upload from trouble diagnosis tool (transfer

from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot,
parameter list is displayed on the screen.
data
6E97
3.
Snapshot data is displayed with TIS2000

[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Open the existing files] or click the

corresponding icon of the tool bar.
4. Select the transferred snapshot.
5. Open the snapshot, to display the data parameter

list on the screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter]

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

and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the

parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter.
For
displaying the graph display screen in full size,
move the cursor upward on the screen. When the
cursor is changed to the magnifying glass form, click

the screen. Graph screen is displayed on the whole
screen.
6E98
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window

opens.
2. Click the graph icon, select the parameter to be
displayed from the list and change divisions
according to necessity.
3. Repeat the same procedures with the graph icons,
from the 2nd to 6th.
4. Click the [OK] button to display.
5. In this case, parameters are displayed only in graph

form. All parameters are displayed in one graph.
6. The graph display screen can be moved with the

navigation icon.
SERVICE PROGRAMMING SYSTEM (SPS)
The procedure to program the control unit by using the

Service Programming System (SPS) software contained
in TIS2000 is explained below.
NOTE:
If the Engine Control Module (ECM) was
programmed, the Immobilizer System must be
linked to the ECM: Refer to section 11
Immobilizer System-ECM replacement for the
ECM/Immobilizer linking procedure.
Should Tech2 display "SPS Procedure was not
successful", engine will not start, but no DTCs
are present, low battery voltage or poor electrical
connections should be the primary suspects.
Perform the SPS procedure again after rectifying
the fault/s.
5. On the screen of Diagnostic Tester and Processing

Program Selection, choose the one that will comply
with the following.
Tech-2 in use
New programming by the existing module or new
programming by the replaced/new module.
Fixing position of the control unit.
6E99
IMPORTANT:
Perform the following checks before attempting to
program the control unit:
The Tech2 PCMCIA card is programmed with The

latest software release.
The latest release of TIS2000 is loaded on the PC.
The vehicle battery is fully charged.
The control unit to be programmed is connected

to the vehicle.
1. Preparations of TIS 2000
1. Connect Tech 2 to P/C.
2. Check to see if Hardware Key is plugged into Port.

3. Activate TIS 2000 by P/C.
4. On the activating screen of TIS2000, choose

Service Programming System
6. Upon completion of the selection, push the button of

Next.
6E100
2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by

turning on the power of Tech-2, push the Enter
switch.
2. Turn on the ignition switch (without starting the

engine)
5. Where vehicle data has been already saved in Tech

2, the existing data come on display. In this
instance, as Tech-2 starts asking whether to keep
the data or to continue obtaining anew data from the
control unit, choose either of them
3. In the main menu of Diagnostic Tester, push F1:

Service Programming System (SPS).
4. Push F0: Request Info of Tech-2.
6. If you select continue, you have to select Model

Year, Vehicle Type.
7. After that. then push button and turn Ignition switch
tuned on, off, on following Tech-2 display. Tech-2
will read information from controller after this
procedure.
8. During obtaining information, Tech-2 is receiving

information from the control unit ECM and TCM (A/T
only) at the same time. With VIN not being
programmed into the new control unit at the time of
shipment, "obtaining information" is not complete
(because the vehicle model, engine model and
model year are specified from VIN). For the
procedure get additional information on vehicles,
instruction will be provided in dialog form, when
TIS2000 is in operation.
9. Following instructions by Tech-2, push the Exit

switch of Tech-2, turn off the ignition of the vehicle
and turn off the power of Tech-2, thereby removing
from the vehicle.
3. Data Exchange
1. Connect Tech-2 to P/C, turn on the power and click

the Next button of P/C.
2. Check VIN of the vehicle and choose Next.

3. Select System Type for required control unit.
Engine (Programming for ECM or PCM)
Transmission (Programming for TCM)
4. When a lack of data is asked from among the

following menu, enter accordingly.
Select following Menu
Model Year
Model
Engine type
Transmission type
Destination code (vehicles for general export)*1
Immobilizer
Etc.
* 1: How to read the destination code
Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
the figure, the destination code can be read as "RR3"
(Australia).
5. After choosing the data, click the Next button.
6. When all the necessary information is entered, the

details of software within the database that match
the entered data will appear for confirmation. Click
the Program switch and then download the new
software onto Tech-2.
7. Data Transfer comes on display. The progress of

downloading will be displayed on the screen in the
form of bar graph.
8. Upon finishing the data transfer, turn off the power
of Tech-2, removing from P/C.
6E101
4. Programming of ECM
1. Check to see if batteries are fully charged, while

ABS connectors shall be removed from the vehicle.
2. Connect Tech-2 to Vehicle Diagnostic Connectors.

3. Turn on the power of Tech-2 and the title screen
comes on display.
4. Turn on the ignition (without allowing the engine to

start)
5. On the title screen of Tech-2, push the Enter

button.
6. Choose F1: Service Programming System on the

main screen and then choose Fl: Program ECU.
7. While data is being transferred, Programming in

Progress will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
Reprogramming Was Successful. Push the Exit
button to bring program to completion
9. Following Procedure 2: Demand of Data, try over

again Information Obtaining and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of

the vehicle and then turn off the power of Tech-2,
removing from the vehicle.
6E102
HOW TO USE BREAKER BOX
"

(2) Harness Adapter
The engine control module (ECM) and other connectors
have water proof connector and special terminal. Water
proof terminal does not allow to use back prove. In
addition, the engine control module (ECM) special
terminal can not let regular digital voltage meter prove
to access, because terminal shape is very fin pin type.
In order to prevent damage of female terminal and
connector itself, the breaker box and adapter is the
most suitable special tool.
#
(3) Breaker Box
Breaker Box Connection Type A

(2) Harness Adapter
(3) Breaker Box
Breaker box connection type A, check for open circuit
and short to ground circuit.
(4) Digital Voltage Meter

(5) ECM - Harness Adapter Disconnection
6E103
6E104
Breaker Box Connection Type B

(2) Harness Adapter
(3) Breaker Box
Breaker box connection type B, check for short to
power supply circuit and power, signal voltage check
between the engine control module (ECM) and
electrical components.
"
(4) Digital Voltage Meter

(5) ECM - Harness Adapter Connection
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Circuit Description
The on-board diagnostic system check is the starting

point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical
check of the ECM and engine grounds for cleanliness
and tightness.
The on-board diagnostic system check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction.
Diagnostic Aids
An intermittent may be caused by a poor connection,

rubbed-through wire insulation or a wire broken inside
the insulation.
Check for poor connections or a
damaged harness. Inspect the ECM harness and
connector for improper mating, broken locks, improperly
formed or damaged terminals, poor terminal-to-wire
6E105
connection, and damaged harness.
Test Description
Number(s) below refer the step number(s) on the

Diagnostic Chart:
1. The Check Engine Lamp (MIL) should be ON steady
with the ignition On, engine Off. If not, No Check
Engine Lamp (MIL) chart should be used to isolate the
malfunction.
2. Checks the Class 2 data circuit and ensures that the
ECM is able to transmit serial data.
3. This test ensures that the ECM is capable of

controlling the Check Engine Lamp (MIL) and the Check
Engine Lamp (MIL) driver circuit is not shorted to
ground circuit.
4. If the engine will not start, Engine Cranks But Will

Not Run chart should be used to diagnose the fault.
6E106
6. The Tech2 parameters which is not within the typical

range may help to isolate the area which is causing the
problem.
12. This vehicle is equipped with ECM which utilizes an

electrically erasable programmable read only memory
(EEPROM).
On-Board Diagnostic (OBD) System Check

Step
1
2
3
4
5
6
7
Action
Value(s)
1. Ignition On, engine Off.
Yes
No
2. Check the CHECK ENGINE lamp (MIL).

Does the CHECK ENGINE lamp turn On?
Go to Step 2
Go to No
CHECK
ENGINE Lamp
2. Attempt to display Data Display with the Tech 2.

Does the Tech 2 display engine data?
Go to Step 3
Go to Step 7
Go to Step 4
Go to CHECK
ENGINE LAMP
On Steady
Go to Step 5
Go to Engine
Cranks But Will
Not Run
Go to DTC
Chart
Refer to
SYMPTOM
DIAGNOSIS
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 8
1. Using the Tech 2, ignition On and engine Off.
2. Select the Miscellaneous Test and perform the

Check Light in Lamps.
3. Operate the Tech 2 in accordance with the Tech 2
instructions.
Does the CHECK ENGINE lamp turn Off?
Attempt to start the engine.
Does the engine start and continue to Run?
2. Select the Read DTC Infor As Stored By ECU in

Diagnostic Trouble Code.
3. Are any DTCs stored?
Compare typical scan data values displayed on the

Tech 2 Data Display.
Are the displayed values within the range?
Using the DVM and check the data link connector

power supply circuit.
Refer to
TYPICAL
SCAN DATA
1. Ignition Off, engine Off.

2. Check the circuit for open circuit.
B-58

Step
8
Action

ground circuit.
6E107
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 11

B-58
4

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

Was the DVM indicated specified value?
B-58
4
V V
10

communication circuit.
Was the DVM indicated fixed battery voltage?
B-58
6
6E108
Step
11

Action

communication circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair

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

circuit.
!"
C-56
!
!
B-58
12
13
Is the ECM programmed with the latest software

release?
If not, download the latest software to the ECM using
the SPS (Service Programming System).
Was the problem solved?
Replace the ECM.

Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 Immobilizer System-ECM replacement for
the ECM/Immobilizer linking procedure.
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and

steady for about five seconds with the ignition ON and
the engine stopped. Ignition feed voltage is supplied to
the check engine lamp bulb through the meter fuse.
The Engine Control Module (ECM) turns the check
engine lamp ON by grounding the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent check engine lamp may be cased by a

poor connection, rubbed-through wire insulation, or a
wire broken inside the insulation.

following items:
6E109
Check for the
Inspect the ECM harness and connections for

improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection,
and damaged harness.
If the engine runs OK, check for a faulty light bulb, an
open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.
6E110
Step
1
No Check Engine Lamp (MIL)
Action
Check the meter fuse (15A).

If the fuse is burnt out, repair as necessary.
Using the DVM and check the CHECK ENGINE

lamp circuit.
Value(s)
Yes
No
Verify repair
Go to Step 2
10-14.5V
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6

3. Ignition On.

C-56
42
V
3
4
Check the CHECK ENGINE lamp bulb.

If the bulb is burnt out, repair as necessary.

lamp circuit.
2. Disconnect the meter connector

connector.
and
ECM
C-56
42
B-24
17

release?

Step
6
Action
Replace the ECM.

6E111
Value(s)
Yes
No
Verify repair
6E112
Circuit description
CHECK ENGINE LAMP (MIL) ON STEADY
The check engine lamp should always be illuminated

and steady for about five seconds with ignition ON and
the engine stopped. Ignition feed voltage is supplied
directly to the check engine lamp indicator. The Engine
Control Module (ECM) turns the check engine lamp
ON by grounding the check engine lamp driver circuit.
The check engine lamp should not remain ON with the
engine running and no DTC(s) set. A steady check
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection,

rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
Poor connection or damaged harness Inspect the

ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
Check Engine Lamp (MIL) On Steady

Step
1
Action

3. Ignition On.
Was the CHECK ENGINE lamp turned on?

lamp circuit.
2. Disconnect
connector.
the
meter connector
and
6E113
Value(s)
Yes
No
Go to Step 2
Go to Step 4
Verify repair
Go to Step 3
Verify repair
Verify repair
Go to Step 5
Verify repair
ECM
3. Check the circuit for short to ground circuit.

C-56
42
B-24
17
3
4
Replace the meter assembly.


release?
Replace the ECM.

Code
P0100
P0105
Flash
Code
65
34
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Vacuum Pressure Sensor

Circuit Low Input

Circuit High Input

Output Circuit High Input

Output Circuit Low Input

Voltage Supply Circuit Low
Input

Voltage Supply Circuit High
Input
DTC Name
Vacuum sensor output

voltage is below 0.5V.

voltage is more than 4.4V.
1. Engine speed is between

600rpmand5000rpm.
2. MAF sensor output is
more than 1378mg/strk
(4JA1-TC) or 1784mg/
strk (4JH1-TC).

600rpmand5000rpm.
below -33.7mg/strk.
MAF sensor power supply


DTC Setting Condition
ECM Diagnostic Trouble Codes
6E114
1. Fuel injection quantity is

reduced.
2. ECM use 615hpa
conditions for
turbocharger waste gate
control.
ECM uses mass air flow

1600mg/strk & EGR 10%
conditions as substitute.
Fail-Safe (Back Up)

1. Sensor power supply

circuit open circuit.
2. Sensor signal circuit
open or short to ground
circuit.
3. Poor connector
connection.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
82/
85
85/
93

shortto voltagecircuit.
2. Sensor ground circuit
open or short to voltage
circuit.
3. Vacuum sensor
malfunction.
4. ECM malfunction.
88/
92

shortto voltagecircuit.
circuit.
3. MAFsensormalfunction.
4. ECM malfunction.
MAF sensor output is below

1378mg/strk (4JA1-TC) or
1784mg/strk (4JH1-TC).
83/
88
83
83
Related
ECM Pin
No.

circuit open circuit.
circuit.
3. Sensor heater harness
open circuit.
4. Poor connector
connection.
6. ECM malfunction.

circuit short to ground
circuit.
3. ECM malfunction.

circuit short to battery
voltage circuit.
3. ECM malfunction.
Related Failure Parts
MAF sensor output is more

than -27.4mg/strk.


Recovery Condition
P0115(1)
P0110(1)
P0110(1)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0105
P0110
P0115
P0180
Flash
Code
34
23
14
15
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Fuel Temperature Sensor

Circuit Range/Performance
Engine Coolant Temperature

(ECT) Sensor Circuit Low
Input

(ECT) Sensor Circuit High
Input
Intake Air Temperature (IAT)

Sensor Circuit Low Input

Sensor Circuit High Input

Input

Input
DTC Name
FT sensor output is high

temperature (more than 150
deg. C) or low temperature
(below -40 deg. C).
ECT sensor output voltage is

below 0.3V.
The ECM use 75 deg. C

FT sensor output is correct

temperature range between
150 deg. C and -40 deg. C.

more than 0.3V.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.

shortto groundcircuit.
2. ECTsensormalfunction.
3. ECM malfunction.

circuit.
circuit.
3. Poor connector
connection
5. ECM malfunction.

below 4.7V.
1. ECM uses fuel

temperature as
substitute.
2. ECM uses 60 deg. C
condition for injection
timing control.
3. ECM uses -25 deg. C
condition (4JA1-TC) or 15 deg. C condition
(4JH1-TC) for glow time
control.

more than 4.7V.

circuit.
circuit.
3. Poor connector
connection
4. IATsensormalfunction.
5. ECM malfunction.

circuit.
2. Vacuum sensor
malfunction.
3. ECM malfunction.

voltage circuit.
2. Vacuum sensor
malfunction.
3. ECM malfunction.

shortto groundcircuit.
2. IATsensormalfunction.
3. ECM malfunction.
IAT sensor output voltage is

below 4.7V.
Vacuum sensor power

supply voltage is more than
4.5V.
Vacuum sensor power

supply voltage is below 5.2V.
Recovery Condition

more than 0.3V.
ECM use 0 deg. C conditions

as substitute.

reduced.
2. ECM use vacuum sensor
output voltage 5.0V
condition as substitute.
Fail-Safe (Back Up)

below 0.3V.

more than 4.7V.
Vacuum sensor power

supply voltage is below 4.5V.
Vacuum sensor power

supply voltage is more than
5.2V.
89
89/
93
84
84/
92
82
82
Related
ECM Pin
No.
P0105(1)
P0100(B)/
P0100(C)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E115
Code
P0215
P0216
52
54
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Injection Timing Control

Circuit Malfunction

Circuit Malfunction
Fuel Cutoff Solenoid Valve

Malfunction

Always Active

Circuit High Input

Malfunction
DTC Name
No fail-safe function.
1. MAB (fuel cutoff solenoid

valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
1. Engine speed is more

than 2014rpm.
2. Fluctuation of actual
injection timing is more
than +-5.2 deg. CA.

than 2014rpm.
than +-5.2 deg. CA.
Deviation of actual injection

timing and desired injection
timing is more than +3 deg.
CA or -6 deg. CA for 8
seconds.

valve) signal circuit open
orshorttogroundcircuit.
malfunction.
No recovery until condition

match in the next ignition key
cycle.
1. Insufficient air bleeding of

fuel line.
2. Fuel filterclogging.
3. Timing control valve
malfunction.
4. Pump camshaft speed
sensor malfunction.
1. Timing control valve

malfunction.
2. Timer piston sticking.
sensor malfunction.
1. ECM malfunction.
malfunction.

valve) signal circuit short
to voltage circuit.
malfunction.

malfunction.
valve) malfunction.
No recovery.

cycle.

valve) is operated.
becomes 0mg/strk.
Engine does not start.
Recovery Condition
Fail-Safe (Back Up)
Fuel injection quantity is

reduced.
than 700rpm.
more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8 seconds.
1. Ignition key switch off.

2. CAN controller does not
operate Bus-off.
1. Ignition key switchoff.

2. Engine speed is below
1500rpm.
3. Vehicle speed is below
1.5km/h.
does not recognize MAB
(fuel cutoff solenoid
valve) signal from the
ECM.
ECM does not command

MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line
circuit is high level.
1. Ignition key switchoff.

1500rpm.
1.5km/h.
recognizes MAB (fuel
cutoff solenoid valve)
signal from the ECM, but
the MAB could not
operate.
Flash
Code
6E116
105
105
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0243
Flash
Code
64
ON
ON
ON
ON
MIL
Symptom
Code
Turbocharger Wastegate
Solenoid "A" Malfunction
Solenoid "A" Range/
Performance
Solenoid "A" Low
Solenoid "A" Range/
Performance
DTC Name
1. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
2. EGR control EVRV 0%
condition.
3. No DTC relating to MAF
sensor, vacuum sensor &
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow actual mass air flow is
less than -56mg/strk.)
1. Intake air temperature is

between -50 deg. C and
200 deg. C.
2. Engine coolant
C.
3. Barometric pressure is
between 0hpa and
3500hpa.
4. High vacuum pressure
condition. (Desired
vacuum pressure - actual
vacuum pressure is less
than -50hpa.)
Wastegate control EVRV

circuit open or short to
ground circuit.

200 deg. C.
2. Engine coolant
C.
between 0hpa and
3500hpa.
4. Low vacuum pressure
condition. (Desired
vacuum pressure is more
than 50hpa.)

reduced.
2. EGR EVRV becomes
10% condition.
1. Turbocharger wastegate
control EVRV
malfunction.
2. Vacuum regulating valve
malfunction.
3. Vacuum pump
malfunction.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
actuator malfunction.
2. Vacuumlinemalfunction.
3. ECM malfunction.
1. Correct amount of mass
air flow. (= Correct boost
pressure condition)
(Desired mass air flow actual mass air flow is
more than -56mg/strk.)
1. Wastegate control EVRV

ground circuit.
malfunction.
3. ECM malfunction.
control EVRV
malfunction.
2. Vacuum line is
obstructed.
3. Vacuum is leaking.
4. Vacuum pump
malfunction.
5. Vacuum sensor
malfunction.
6. Turbocahrger wastegate
valve malfunction.
7. ECM malfunction.

500rpm and 6000rpm.
2. Correct vacuum pressure
condition. (Desired
vacuum pressure is more
than -50hpa.)

circuit is correct condition.

500rpm and 6000rpm.
2. Correct vacuum pressure
condition. (Desired
vacuum pressure is less
than 50hpa.)

reduced.
2. EGR EVRV becomes
10% condition.

reduced.
2. EGR EVRV becomes
10% condition.
becomes 32% condition.
Recovery Condition
Fail-Safe (Back Up)
85/
96
96
85/
96
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E117
Code
P0243
P0251
64
53
ON
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Injection Pump Malfunction
Solenoid "A" High
DTC Name
ECM could not accept PSG

(pump control unit) message.
PSG (pump control unit)

could not measure the high
pressure solenoid valve drive
voltage.

recognized high pressure
solenoid valve drive circuit
error.
EEPROM or A/D converter

malfunction in the PSG
(pump control unit).
No pump map programmed

in the PSG (pump control
unit) or PSG malfunction.
1. No pump camshaft
speed sensor error.
2. No CKP sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is more
than 720rpm (4JA1-TC)
or 690rpm (4JH1-TC).
1. No pump camshaft
speed sensor error.
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection
quantity.

circuit short to voltage circuit.
Flash
Code
6E118
1. Missing CKP sensor

pulses.
2. Electrical interference.
3. Magneticinterference.
malfunction.
1. No pump camshaft
speed sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is below
800rpm (4JA1-TC) or
690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
ECM accepts PSG (pump

control unit) message.

cycle.

valve) is operated.
becomes 0mg/strk.

no malfunction in the PSG
(pump control unit).
No recovery until in the next
ignition key cycle.

reduced.
1. CAN high circuit open,

short to ground or short
to voltage circuit.
2. CAN low circuit open,
to voltage circuit.
3. ECM malfunction.
malfunction.

malfunction.

malfunction.

malfunction.

malfunction.

malfunction.
sensor malfunction.

cycle.

valve) is operated.
becomes 0mg/strk.

cycle.

circuit short to voltage
circuit.
malfunction.
3. ECM malfunction.

circuit is correct condition.
Recovery Condition

reduced.
2. EGR EVRV becomes
10% condition.
Fail-Safe (Back Up)
99/
100
91
96
Related
ECM Pin
No.
P1650(A)/
P1651(B)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0335
P0380
Flash
Code
43
66
ON
ON
ON
ON
ON
MIL
Symptom
Code
Glow Relay Circuit Voltage

High

Low
Engine Speed Input Circuit

Range/Performance
Crankshaft Position Sensor

Circuit Malfunction

Circuit Malfunction
DTC Name
Glow relay circuit short to

voltage circuit.
Glow relay circuit open or

short to ground circuit.
Engine speed is more than

5700rpm.
1. No pump camshaft
speed sensor error.
2. "Crankshaft Position
Sensor Circuit
Malfunction (Symptom
CodeB)" isnotstored.
3. Engine speed is 0rpm.
4. Doubled pump camshaft
speed is more than
50rpm.

than 665rpm.
2. CKP sensor pulse width
error.
When intermittent
malfunction:
valve) is operated.
becomes 0mg/strk.
When preliminary
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
When pump camshaft speed

sensor is OK:
enginespeed.
Other than pump camshaft
speed sensor is OK:
reduced.

sensor is OK:
enginespeed.
sensor is not OK:
valve) is operated.
becomes 0mg/strk.
Fail-Safe (Back Up)
Glow relay circuit is correct

condition.
Engine speed is below

5700rpm.

than 0rpm.
speed is below 100rpm.
ECM detects correct CKP

pulse width.
Recovery Condition
ECM malfunction.
1. Glow relay circuit open or

short to groundcircuit.
2. Glowrelaymalfunction.
3. ECM malfunction.
1. Engine over-running.
2. CKPsensormalfunction.
3. Pulser malfunction.
4. ECM malfunction.
During engine crank:

1. CKP sensor harness
open circuit, short to
ground or short to
voltage circuit.
2. Poor connector
connection.
4. Pulse sensing gap
incorrect.
7. Magnetic interference.
8. ECM malfunction.
1. During engine run:

ground or short to
voltage circuit.
2. Poor connector
connection.
incorrect.
8. ECM malfunction.
94
90/
98/
101
90/
98/
101
90/
98/
101
Related
ECM Pin
No.
P1135 (A)
P1335 (A)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E119
Code
P0381
P0400
67
32
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code

Circuit Short to Battery

Flow Insufficient Detected

Circuit Short to Ground or
Open Circuit

Flow Excessive Detected
Glow Plug Indicator Circuit

Voltage High

Voltage Low
DTC Name
EGR EVRV circuit short to

voltage circuit.

between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1TC).
between 850hpa and
1100hpa.
4. Large mount of mass air
flow. (Desired mass air
flow - mass air flow is
below -150 mg/strk)
EGR EVRV circuit open or


between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1TC).
between 850hpa and
1100hpa.
4. Small amount of mass air
more than 150mg/strk)
Glow plug indicator circuit

short to voltage circuit.

circuit.
Flash
Code
6E120

reduced & EGR EVRV 10%
EGR EVRV circuit is correct

condition.
1. EGR EVRV circuit short

to voltage circuit.
2. EGREVRVmalfunction.
3. ECM malfunction.
1. EGR valve is stuck at

close position.
2. EGR valve operating
vacuum hose is clogged
or disconnected.
4. MAF sensor signal circuit
short to voltagecircuit.
6. ECM malfunction.
1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and3200rpm(4JH1-TC).
2. Injection quantity is
below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC).
air flow.

reduced.
1. EGR valve is stuck at

open position.
3. Air intake is obstructed.
4. Airintakeisleaking.
6. ECM malfunction.
ECM malfunction.
1. Glow plug indicator

ground circuit.
2. Glow plug indicator lamp
malfunction.
3. ECM malfunction.
1. EGR EVRV circuit open

orshorttogroundcircuit.
3. ECM malfunction.

1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and3200rpm(4JH1-TC).
2. Injection quantity is
below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC).
air flow.
Glow plug indicator circuit is

correct condition.
Recovery Condition

EGR EVRV circuit is correct
reduced and EGR EVRV
condition.
10% conditions as substitute.

reduced.
Fail-Safe (Back Up)
97
88/
97
97
88/
97
43
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0500
P0560
Flash
Code
24
35
OFF
OFF
System Voltage Too Low
System Voltage Too High
ON Vehicle Speed Sensor

Incorrect Signal
at
next
igniti
on
cycle
System voltage is below 7V.
System voltage is more than

20V.

or3600rpm(4JH1-TC).
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
1.5km/h.
Input signal frequency is too

high.
ON Vehicle Speed Sensor Input

at
Signal Frequency Too High
next
igniti
on
cycle
Vehicle speed is more than

200km/h.
DTC Name
ON Vehicle Speed Sensor Circuit

High Input
at
next
igniti
on
cycle
MIL
Symptom
Code

7V.

1.5km/h.

reduced.
ECM uses 9V conditions as

substitute.
Correct vehicle speed signal

frequency.
Vehicle speed is below

200km/h.
Recovery Condition
ECM uses vehicle speed

5km/h condition as
substitute.
ECM uses vehicle speed

5km/h condition as
substitute.
Fail-Safe (Back Up)
1. Battery power feed

harness open circuit or
2. ECM ground harness
openorpoorconnection.
3. Poor connector
connection.
4. Battery malfunction.
5. Charge system
malfunction.
6. ECM malfunction.
1. Charge system
malfunction.
2. Battery jump start cable
misconnect.
3. ECM malfunction.
1. VSS open circuit, short

to ground or short to
voltage.
2. Poor connector
connection.
3. VSS malfunction.
4. Speed meter
malfunction.
5. ECM malfunction.
1. VSS malfunction.
2. Speed meter
malfunction.
4. Magneticinterference.
5. ECM malfunction.
1. VSS signal circuit open,

to voltage circuit.
2. VSS malfunction.
3. Speed meter
malfunction.
4. TCM malfunction (AT
2WD).
5. ECM malfunction.
3/
39
3/
39
68
68
68
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E121
Code
P0560
P0561
P0602
P0606
35
18
28
OFF
ON
ON
OFF
OFF
MIL
Symptom
Code
ECU Malfunction
ECU Malfunction
Control Module
Programming Error
Ignition Switch Circuit

Malfunction
Ignition Switch Circuit

Malfunction
System Voltage Malfunction
DTC Name
1. Throttle position is below

1%.
is more than 0mg/strk.
than 2000rpm.
Gate Array communication

error.
ECM memory area error.
Ignition switch circuit is

malfunction.
The ECM recognized ignition

switch turn off signal during
ECM is activated.
System voltage of PSG

(pump control unit) is below
4.5V or more than 27V.
Flash
Code
6E122

valve) is operated.

valve) is operated.
becomes 0mg/strk.
Engine control disabled.
ECM stops engine.
PSG uses default voltage as

substitute.
Fail-Safe (Back Up)
Desired injection quantity is

below 0mg/strk.
No recovery.
Memory are is OK.

cycle.
System voltage of PSG is

between 4.5V and 27V.
Recovery Condition
1. ECM malfunction.
malfunction.
ECM malfunction.
ECM is not programmed.
1. Ignition switch circuit

circuit.
2. Poor connector
connection.
3. Ignition switch
malfunction.
4. ECM malfunction.
1. Ignition switch circuit

circuit.
2. Poor connector
connection.
3. Ignition switch
malfunction.
4. ECM malfunction.
1. Battery power feed

harness open circuit or
ground harness open or
poor connection.
3. Poor connector
connection.
4. Battery malfunction.
5. Charge system
malfunction.
6. Battery jump start cable
misconnect.
malfunction.
39
39
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0645
P0703
P0704
P1105
Flash
Code
46
25
57
86
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Barometric Pressure Sensor

Circuit Low Input

Circuit High Input
Clutch Switch Input Circuit

Malfunction
Brake Switch Circuit

Malfunction

Malfunction
A/C Compressor Relay

Circuit Voltage High

Circuit Voltage Low
DTC Name
Barometric pressure sensor

output voltage is below 1.5V.

output voltage is more than
4.4V.
Clutch signal does not

change between vehicle
speed 1.5km/h and 80km/h
since ignition switch was
tuned on.
1. Throttle position is more

than 0%.
or665rpm(4JH1-TC).
3. Vehicle speed is more
than 0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM.

than 0%.
or665rpm(4JH1-TC).
than 0km/h.
ECM since the ignition
switch was turned on.
A/C compressor relay circuit


circuit.
ECM uses 1013hpa

Fail-Safe (Back Up)

1.5V.

Clutch signal correctly

changes.
Brake switch 1 signal and

correctly inputted to the
ECM.

is correct condition.
Recovery Condition
ECM malfunction.
ECM malfunction.
1. Clutch switch circuit

open, short to ground or
shorttovoltage circuit.
2. Poor connector
connection.
3. Clutch switch
malfunction.
4. ECM malfunction.
1. Brake switch 2 circuit

circuit.
2. Poor connector
connection.
3. Brake switch 2
malfunction.
4. ECM malfunction.
1. Brake switch 1 circuit

open, short to ground or
2. Poor connector
connection.
3. Brake switch 1
malfunction.
4. ECM malfunction.
ECM malfunction.
1. A/C compressor relay

ground circuit.
2. Poor connector
connection.
3. A/C compressor relay
malfunction.
4. ECM malfunction.
31
65
30
41
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E123
Code
P1120
P1173
21
22
OFF
ON
OFF
ON
ON
OFF
ON
ON
MIL
Symptom
Code
Fuel Reduction Caused By

Low Fuel Temperature

High Fuel Temperature

High Coolant Temperature
Pedal/Throttle Position
Sensor Idle Position Switch
Error
Sensor Brake Switch Error
Sensor Voltage Supply
Circuit Low Input
Sensor Voltage Supply
Circuit High Input
DTC Name
Excessive low fuel

temperature is detected.
Fuel temperature is more

than 100 deg. C.
Excessive high engine

coolant temperature is
detected.
1. When idle switch is

turned off, throttle
position sensor was
below 0.35%.
or
2. When idle switch is tuned
on, throttle position
sensor was more than
7.8%.

than 1700rpm.
than 1.5km/h.
3. When brake pedal is
depressed during
accelerator pedal is
depressing.

power supply voltage is
below 4.6V.

power supply voltage is more
than 5.2V.

4.5V.
Flash
Code
6E124

controls fuel injection
quantity based on engine
speed and fuel temperature.
ECM increases idle speed up

to 1400rpm.
Fail-Safe (Back Up)
Fuel temperature is normal

range.
Fuel temperature is below

100 deg. C.
1. ECM malfunction.
malfunction.
1. ECM malfunction.
malfunction.
1. Engine overheat.
3. ECM malfunction.
1. TPS malfunction.
2. Idle switch malfunction.
3. ECM malfunction.
1. When throttle position
sensor is 100%, idle
switch turns off.
2. When throttle position
sensor is 0%, idle switch
turns on.
Engine coolant temperature

is normal range.
1. Throttle sticking.
2. TPSincorrectadjusting.
3. TPS malfunction.
4. Brake switch
malfunction.
5. ECM malfunction.

circuit.
2. TPS malfunction.
3. ECM malfunction.

voltage circuit.
2. TPS malfunction.
3. ECM malfunction.

circuit short to voltage
circuit.
short to voltagecircuit.
circuit.
4. Poor connector
connection.
5. TPS malfunction.
6. ECM malfunction.
Throttle position is more than

20% or brake pedal is
released(switchisinactive).

than 4.6V.

power supply voltage is
below 5.2V.

Recovery Condition
89
38/
69
30/
38/
65
57
57
38/
49/
57
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P1335
P1345
P1520
P1605
Flash
Code
43
45
47
55
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
The PSG (pump control unit)

is recognized defective
engine speed signal form the
ECM.
Neutral switch signal is

inputted "Off" three times
consecutively under driving
conditions.
Neutral switch signal is

inputted "On" three times
conditions.
EEPROM Defect
Write and read from the

EEPROM are failed during
initialization of the ECM.
Seed and Key File Destroyed Seed or key file in EEPROM

is destroyed.
Neutral Switch OFF Error
Neutral Switch ON Error
Camshaft Speed Malfunction The PSG (pump control unit)

is recognized incorrect
camshaft speed signal.
Engine Speed Output Circuit

Malfunction
DTC Name
ECM uses default values

from the EPROM.

EEPROM are correct during
No recovery.
Correct neutral switch signal

is inputted two times
conditions.
Correct camshaft speed.
Correct engine speed signal.
Recovery Condition

reduced.
Fail-Safe (Back Up)
87
1. Neutral switch circuit

open, short to ground
circuit.
2. Poor connector
connection.
3. Neutral switch
malfunction.
4. ECM malfunction.
ECM malfunction.
87
1. Neutral switch circuit

shorttovoltage circuit.
2. Neutral switch
malfunction.
3. ECM malfunction.
ECM malfunction.
90/
91/
98/
101
Related
ECM Pin
No.

sensor malfunction.
incorrect.
6. ECM malfunction.
malfunction.

ground or short to
voltage.
2. CKP sensor output
harness open circuit,
to voltage.
3. Poor connector
connection.
incorrect.
9. ECM malfunction.
malfunction.
P0335(B)/
P0335(D)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E125
Code
P1605
P1610
P1611
P1612
P1613
P1614
P1625
55
56
56
56
56
56
76
OFF
OFF
ON
MIL
Symptom
Code
ECM Main Relay Switched

Off Too Late

Off Too Early
Wrong Transponder Key
Immobilizer No or Wrong
Signal
Immobilizer No or Wrong
Signal
Wrong Security Code

Entered
Security Key and Security

Code not Programmed
EEPROM Defect
DTC Name
When ignition switch was

turned off, timing of the ECM
main relay turning off is too
late or does not off.

early.
Received response signal is

not correct from the
transponder key.

not correct or not received.
Received challenge signal is

Received security code is not

correct.
Immobilizer functions are not

programmed in the ECM.
EEPROM checksum does

not match with the read
check sum during
Flash
Code
6E126
1. Engine does not start.

2. Check engine lamp flash.




Fail-Safe (Back Up)
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
EEPROM checksum match

with the read check sum
during initialization of the
ECM.
Recovery Condition
1. ECM main relay

malfunction.
2. ECM malfunction.
ECM malfunction.
1. ECM malfunction.
2. Immobilizer control unit
malfunction.
3. Transponder key
malfunction.
1. ECM and immobilizer

control unit
communication circuit
ground circuit or short to
voltage circuit.
2. ECM malfunction.
malfunction.
4. Transponder key
malfunction.
1. ECM and immobilizer

control unit
communication circuit
ground circuit or short to
voltage circuit.
2. ECM malfunction.
malfunction.
4. Transponder key
malfunction.
1. ECM malfunction.
malfunction.
3. Transponder key
malfunction.
ECM malfunction.
ECM malfunction.
3/
58
3/
58
27/
35
27/
35
Related
ECM Pin
No.
B****
B****
B****
B****
B****
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P1630
P1650
P1651
P1690
Flash
Code
51
44
45
77
OFF
OFF
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Check Engine Lamp (MIL)


Circuit Voltage Low
CAN Malfunction
CAN Malfunction
CAN Device Hang-up
CAN Device Offline
Fuel Injection Quantity

Circuit Malfunction
Fuel Injection Quantity

Circuit Malfunction
DTC Name
Check engine lamp circuit


circuit.
The ECM does not read CAN

signal from the PSG (pump
control unit).

does not recognize CAN
signal from the CAN
controller.
CAN controller does not

react under engine running.
CAN controller detects Busoff or canceling.

detects high pressure
solenoid valve control circuit
malfunction due to
continuous current.

detects high pressure
solenoid valve control circuit
malfunction due to high
current.

valve) is operated.
becomes 0mg/strk.

valve) is operated.

valve) is operated.
becomes 0mg/strk.

reduced.
Fail-Safe (Back Up)
Check engine lamp circuit is

correct condition.
ECM malfunction.
1. Check engine lamp

ground circuit.
2. Check engine lamp
malfunction
3. ECM malfunction.

to voltage circuit.
to voltage circuit.
3. Poor connector
connection.
5. ECM malfunction.
malfunction.
The ECM reads CAN signal
from the PSG (pump control
unit).
42
99/
100
1. ECM malfunction.
malfunction.
1. ECM malfunction.
malfunction.
99/
100
Related
ECM Pin
No.

to voltage circuit.
to voltage circuit.
3. Poor connector
connection.
4. Electricalinterference.
5. ECM malfunction.
malfunction.

malfunction.

recognizes CAN signal from
the CAN controller.
CAN controller reacts

correctly under engine
running.
CAN controller detects

correct Bus signal.
No recovery.
The PSG (pump control unit) PSG (pump control unit)

detects correct high pressure malfunction.
solenoid valve control circuit.
Recovery Condition
B****
P1650(A)
P1651(B)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E127
6E128
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE B)
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW
INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE C)
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
Condition for setting the DTC and action taken when the DTC sets
6E129
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
65
P0100
ON

ON

Input
ECM uses mass air flow

1600mg/strk & EGR 10% conditions as substitute.
ON
ON

Input

Output Circuit Low Input

Output Circuit High Input
Circuit Description
The mass air flow (MAF) sensor is part of the intake air
system. It is fitted between the air cleaner and
turbocharger and measure the mass air flowing into the
engine.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
The ECM monitors the MAF sensor supply voltage and
MAF sensor output voltage. The supply voltage is out of
range, DTC P0100 (Symptom Code 7) or P0100
(Symptom Code 9) will be stored. The output voltage
excessively high or low, DTC P0100 (Symptom Code B)
or P0100 (Symptom Code C) will be stored.

600rpm
and
5000rpm.
below -33.7mg/strk.

600rpm
and
5000rpm.
2. MAF sensor output is more
than 1378mg/strk (4JA1-TC)
or 1784mg/strk (4JH1-TC).
Diagnostic Aids
An intermittent may be caused by the following:

Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.

Check for the following conditions:
Poor connection at ECM-Inspect harness connectors

for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for

damage. If the harness appears to be OK, observe
the Mass Air Flow display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
Step
1
Action
Was the On-Board Diagnostic (OBD) System Check

performed?
1. Connect the Tech 2.
2. Review and record the failure information.

3. Select F0: Read DTC Infor As Stored By ECU in
F0: Diagnostic Trouble Codes.
Is the DTC P0100 (Symptom Code 7) stored as
Present Failure?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
6E130
Step
3

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

Diagnostic Trouble Codes with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the F0: Read
DTC Infor As Stored By ECU in the F0:
Diagnostic Trouble Codes.
Was the DTC P0100 (Symptom Code 7) stored in this
ignition cycle?
Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,
repair as necessary.
C-57(B)
5
6
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
Approximately
5.0V
Go to Step 11
Less than 1V:

Go to Step 7
More than
specified value:
Go to Step 8
Verify repair
Go to Step 8
C-116
92
2 3
83
88
Value(s)
Visually check the MAF sensor.

Using the DVM and check the MAF sensor power

supply circuit.
2. Disconnect the MAF & IAT sensor connector.

3. Check the circuit for short to battery voltage
circuit.
C-116
4
V
7
Repair the open circuit between the ECM and MAF

sensor.
C-57(B)
C-116
4
83

Step
8
Action

supply circuit.
6E131
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 9
Verify repair
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair

2. Disconnect the MAF & IAT sensor connector and
ECM connector.
3. Check the circuit for short to MAF sensor +12V

supply circuit.
C-116
9
10
Repair the circuit for short to MAF sensor +12V supply

circuit.
Repair the short to battery voltage circuit between the

ECM and MAF sensor.
C-57(B)
C-116
4
83
11
12
13
14
Substitute a known good MAF & IAT sensor assembly

and recheck.
Replace the MAF & IAT sensor assembly.

release?
Replace the ECM.

6E132
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
Step
1
Action

performed?

Present Failure?


ignition cycle?

Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
88
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7
No
C-116
92
2 3
Yes
C-57(B)
Value(s)
83


supply circuit.

C-116
4

Step
7
Action

supply circuit.
6E133
Value(s)
Yes
No
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair

ECM connector.
3. Check the circuit for short to MAF sensor ground

circuit.
C-116
8
9
Repair the circuit for short to MAF sensor ground.

Repair the short to ground circuit between the ECM

and MAF sensor.
C-57(B)
C-116
10
11
12
13
83

and recheck.


release?
Replace the ECM.

6E134
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6

Is the DTC P0100 (Symptom Code B) stored as
Present Failure?


Was the DTC P0100 (Symptom Code B) stored in this
ignition cycle?

C-57(B)
88
83

No
C-116
92
2 3
Value(s)

Step
6
Action
Using the DVM and check the MAF sensor signal

circuit.
Breaker box is available:
6E135
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8

2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
4. Check the circuit for open, short to sensor ground

or short to ground circuit.
Breaker Box
88
C-116
!
!
!
Breaker box is not available:


ECM connector.
C-57(B)
C-116
88

supply circuit.

C-116
4
6E136
Step
8

Action
Repair the open circuit between the ECM and MAF

sensor.
C-57(B)
Yes
No
Verify repair
Go to Step 13
10-14.5V
Go to Step 11
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair
C-116
4
83
Value(s)
Using the DVM and check the MAF sensor +12V

supply circuit.

C-116
V
10
11
12
13
14
Repair the open circuit between the ECM main relay

and MAF sensor.

and recheck.

release?
Replace the ECM.

6E137
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6

Is the DTC P0100 (Symptom Code C) stored as
Present Failure?


Was the DTC P0100 (Symptom Code C) stored in this
ignition cycle?

C-57(B)
88
83

No
C-116
92
2 3
Value(s)
6E138
Step
6

Action
Using the DVM and check the MAF sensor ground

circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair

3. Disconnect the MAF sensor connector.

Breaker Box
92
C-116
!

2. Disconnect the MAF sensor connector and ECM
connector.

C-57
C-116
92
Using the DVM and check the MAF sensor ground

circuit.
2. Disconnect the MAF sensor connector .

C-116
V
Less than 1V

Step
8
Action

circuit.
Value(s)
6E139
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair


C-116
V
9
10
11
12

and recheck.

release?
Replace the ECM.

6E140
DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT
CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH
INPUT
CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW
INPUT
Flash
Code
34
Code
P0105
Symptom
Code
MIL
ON
ON
ON
ON
Circuit description
DTC Name

Circuit High Input


Circuit Low Input


Input
Vacuum sensor power supply


Input
The ECM monitors altitude from the barometric

pressure sensor. To apply specified vacuum pressure to
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude.
Then, apply vacuum pressure to the turbocharger
wastegate valve is monitored by the ECM form the
vacuum pressure sensor output signal. The ECM
controls wastegate control solenoid based on signal
from vacuum pressure sensor output.
The output voltage excessively high or low, DTC P0105
(Symptom Code 1) or P0105 (Symptom Code 2) will be
stored.
The supply voltage is out of range, DTC P0105
stored.
Vacuum sensor power supply

6E141
Fail-Safe (Back Up)

reduced.
2. ECM use 615hpa

conditions for
turbocharger waste gate
control.

reduced.
2. ECM use vacuum sensor

output voltage 5.0V
Diagnostic Aids

Poor connections.
Misrouted harness.
Broken wire inside insulation.


the DTC P0105 display on the Tech 2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
6E142
Vacuum Pressure Sensor Circuit High Input
Step
1
Action
Was the "On-Board Diagnostic (OBD) System Check"

performed?
1. 1Connect the Tech 2.
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
3. Select "F0: Read DTC Infor As Stored By ECU" in

"F0: Diagnostic Trouble Codes".
"Present Failure"?
1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
3. Operate the vehicle and monitor the "F0: Read

DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
ignition cycle?
Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
C-57
No
C-124
"
&
%
$%
!#
!"
Visually check the vacuum sensor.


Step
6
Action
Using the DVM and check the vacuum pressure

sensor ground circuit.
6E143
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
1. Ignition "Off", engine "Off".

3. Disconnect
connector.
the
vacuum
pressure
sensor

Breaker Box
93
C-124
"

2. Disconnect the vacuum pressure

connector and ECM connector.
sensor

C-57
C-124
$
"#
!

1. Ignition "On", engine "Off".
2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124
Less than 1V
6E144
Step
8

Action

sensor signal circuit.
2. Disconnect the vacuum
connector.
pressure
Value(s)
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
sensor

C-124
9
10
11
12
Substitute a known good vacuum pressure sensor

and recheck.
Replace
the
vacuum
pressure
sensor.

release?
the "SPS (Service Programming System)".
Replace the ECM.

Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
section 11 "Immobilizer System-ECM replacement" for
6E145
Vacuum Pressure Sensor Circuit Low Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6

"Present Failure"?

ignition cycle?

C-57
No
C-124
"
&
%
$%
!#
!"
Visually check the vacuum pressure sensor.

6E146
6


3. Disconnect
connector.
the
vacuum
pressure
sensor

Breaker Box
85
C-124
"
!
!


sensor

C-57
C-124
$
"#
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8
!
!

sensor power supply circuit.
2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124

8
Repair the open circuit between the ECM and vacuum

pressure sensor.
C-57
C-124
"#
9
10
11
12
6E147

assembly and recheck.
Replace the vacuum sensor assembly.


release?
Replace the ECM.

Verify repair
Go to Step 11
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
6E148
Vacuum Pressure Sensor Voltage Supply Circuit High Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
Approximately
5.0V
Go to Step 8
Go to Step 7

"Present Failure"?

ignition cycle?

C-57
No
C-124
"
&
%
!#
$%
5
6
!"


2. Disconnect
connector.
the
vacuum
pressure
sensor

circuit.
C-124

7

ECM and vacuum pressure sensor.
C-57
C-124
"#
8
9
10
11
6E149

Replace the vacuum pressure sensor assembly.

release?
Replace the ECM.

Verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
6E150
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7

"Present Failure"?

ignition cycle?

C-57
No
C-124
"
&
%
!#
$%
5
6
!"


2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124

7
6E151


sensor
3. Check the circuit for short to vacuum pessure

#
C-124
"
8
9
10
11
12
13
Repair the circuit for short to vacuum pressure sensor

ground.
Repair the short to ground circuit between the vacuum

pressure sensor.
and recheck.

release?
Replace the ECM.

No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair
6E152

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH
INPUT
(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
Flash
Code
23
Code
P0110
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name


Sensor Circuit Low Input
The IAT sensor is a thermistor. A temperature changes

more than 4.7V.

below 0.3V.
Fail-Safe (Back Up)

ECM use deg.C conditions as
substitute.

words it measures a temperature value. Low air
temperature produces a high resistance.
6E153
The ECM supplies 5 volts signal to the IAT sensor

The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is
hot.
stored.
Misrouted harness.
Diagnostic Aids

the Intake Air Temperature display on the Tech2
while moving connectors and wiring harness related
to the sensor.

Poor connections.


Intake Air Temperature (IAT) Sensor Circuit High Input
Step
1
Action

performed?

Present Failure?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
No


ignition cycle?
Check for poor/faulty connection at the IAT sensor or

C-57(B)
C-116
92
84
Visually check the IAT sensor.

6E154
Step
6

Action
Using the DVM and check the IAT sensor.
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14

2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.

Does the tester indicate standard resistance as shown
in the following table?
Temperature (C)
Resistance (!) (Approximately)
-20
13660
5430
20
2433
60
598
40
1153
80
334
100
204
IAT Sensor
1
1
Using the DVM and check the IAT sensor signal

circuit.

C-116
V
8
Repair the open circuit between the ECM and IAT

sensor.
C-57(B)
84
C-116

Step
9
Action
Repair the short to voltage circuit between the ECM

and IAT sensor.
C-57(B)
Value(s)
Yes
No
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair
C-116
84
10
6E155
Using the DVM and check the IAT sensor ground

circuit.

C-116
V
Less than 1V
6E156
Step
11

Action
Using the DVM and check the IAT sensor ground

circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair


Breaker Box
92
C-116
!


ECM connector.

C-57(B)
C-116
92
12
13
14
15

and recheck.


release?
Replace the ECM.

6E157
Intake Air Temperature (IAT) Sensor Circuit Low Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?


ignition cycle?
Check for poor/faulty connection at the IAT sensor or

C-57(B)
No
C-116
92
84
Remove the MAF & IAT sensor assembly and visually

check.
6E158
Step
6

Action
Using the DVM and check the IAT sensor.
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8

2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.

Temperature (C)
-20
13660
5430
20
2433
60
598
40
1153
80
334
100
204
IAT Sensor
4
3
1
1

Step
7
Action
Using the DVM and check the IAT sensor signal

circuit.
6E159
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair

4. Check the circuit for short to sensor ground or

ground circuit.
84
Breaker Box
92


ECM connector.
ground circuit.
C-57(B)
92
84
8
9
10
11

and recheck.

release?
Replace the ECM.

6E160

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

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
Flash
Code
14
Code
P0115
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
(ECT) Sensor Circuit High
Input

(ECT) Sensor Circuit Low
Input
The ECT sensor is a thermistor. A temperature changes
Fail-Safe (Back Up)

more than 4.7V.
1. ECM uses fuel temperature

as substitute.
2. ECM uses 60 deg.C
condition for injection timing
control.
3. ECM uses -25 deg.C
condition (4JA1-TC) or -15
deg.C condition (4JH1-TC)
for glow time control.

below 0.3V.

words it measures a temperature value. It is installed on
the coolant stream. Low coolant temperature produces

Misrouted harness.
a high resistance.
The ECM supplies 5 volts signal to the ECT sensor
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.
stored.
6E161



the Coolant Temperature display on the Tech2 while
sensor.
Diagnostic Aids

Poor connections.
Engine Coolant Temperature Sensor Circuit High Input
Step
1
Action

performed?

Present Failure?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
No


ignition cycle?
Check for poor/faulty connection at the ECT sensor or

C-57(B)
93
89
Value(s)
Visually check the ECT sensor.

E-41
6E162
Step
6

Action
Using the DVM and check the ECT sensor.
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14

2. Disconnect ECT sensor connector.
3. Measure the resistance of ECT sensor.

Temperature (C)
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2
Using the DVM and check the ECT sensor signal

circuit.
2. Disconnect the ECT sensor connector.

E-41
V
8
Repair the open circuit between the ECM and ECT

sensor.
C-57(B)
89
E-41

Step
9
Action

and ECT sensor.
C-57(B)
Value(s)
Yes
No
Verify repair
Go to Step 14
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-41
89
10
6E163
Using the DVM and check the ECT sensor ground

circuit.

E-41
V
11
Using the DVM and check the ECT sensor ground

circuit.

Breaker Box
93
E-41
!

2. Disconnect the ECT sensor connector ECM

connector.

C-57
E-41
2
93
6E164
Step
12
13
14
15

Action
Substitute a known good ECT sensor assembly and

recheck.
Replace the ECT sensor.

release?
Replace the ECM.

Value(s)
Yes
No
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair
6E165
Engine Coolant Temperature Sensor Circuit Low Input
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?


ignition cycle?
Check for poor/faulty connection at the ECT sensor or

C-57(B)
93
89
Value(s)
Visually check the ECT sensor.

E-41
No
6E166
Step
6

Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8


Temperature (C)
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2

Step
7
Action
Using the DVM and check the ECT sensor signal

circuit.
6E167
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair


ground circuit.
89
Breaker Box
93

2. Disconnect the ECT sensor connector and ECM

connector.

ground circuit.
C-57(B)
93
89
8
9
10
11

recheck.

release?
Replace the ECM.

6E168

(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Flash
Code
15
Code
P0180
Symptom
Code
B
MIL
DTC Name
ON
Fuel Temperature Sensor Circuit Range/Performance
FT sensor output is high temperature (more than

150deg.C) or low temperature
(below -40deg.C).
Fail-Safe (Back Up)

The ECM use 75deg.C conditions as substitute.
Circuit Description
Misrouted harness.
Diagnostic Aids

Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
The fuel temperature sensor is assembled inside of the

pump control unit (PSG). The signal of fuel temperature
is sent via the CAN-bus from the PSG to ECM.
If the fuel temperature is excessively high or low
condition, DTC P0180 will be stored.
Poor connections.

the Fuel Temperature display on the Tech2 while
6E169

sensor.
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair


release?
Substitute a known good ECM and recheck.

Replace the ECM.

Replace the injection pump assembly.
6E170
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D)
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Flash
Code
52
Code
P0215
Symptom
Code
MIL
DTC Name
ON

Malfunction
ON

Circuit High Input
ON

Always Active
ON

Malfunction
Circuit Description
When the ignition switch is turned Off, the fuel

solenoid valve (MAB) signal is supplied from the ECM to
the PSG. This signal is the command for the PSG to turn
Off the engine.
If the MAB signal circuit is short to voltage circuit or
short to ground circuit, DTC P0215 (Symptom Code B)
or P0215 (Symptom Code C) will be stored.
Fail-Safe (Back Up)

1500rpm.
1.5km/h.
recognizes MAB (fuel cutoff
solenoid valve) signal from
the ECM, but the MAB
could not operate.
ECM does not command

valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line circuit is high level.

1500rpm.
1.5km/h.
does not recognize MAB
(fuel cutoff solenoid valve)
signal from the ECM.

2. CAN controller does not
operate Bus-off.
6E171

valve) is operated.
becomes 0mg/strk.
Engine does not start.

valve) is operated.
becomes 0mg/strk.
Diagnostic Aids

Poor connections.
Misrouted harness.


Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Is the DTC P0215 (Symptom Code A) stored as
Present Failure?
No
6E172
Step
3

Action
Value(s)
Yes
No

Was the DTC P0215 (Symptom Code A) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair

6E173
Cutoff Solenoid Valve Circuit High Input
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?


ignition cycle?
Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty
105
Value(s)
C-57
No
E-6
Visually check the PSG (pump control unit).

6E174
Step
6

Action
Using the DVM and check the MAB (fuel cutoff

solenoid valve) circuit.
2. Install the breaker box as
connected) Ref. Page 6E-104
Value(s)
Yes
No
Less than 1V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 8
Verify repair
type B. (ECM
3. Check the circuit for short to voltage circuit.

Breaker Box
105

C-57
105
V
7

and PSG (pump control unit).
C-57
E-6
5
105

6E175
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6

Is the DTC P0215 (Symptom Code C) stored as
Present Failure?


Was the DTC P0215 (Symptom Code C) stored in this
ignition cycle?

105
Value(s)
C-57
No
E-6

6E176
Step
6

Action
Using the DVM and check the MAB (fuel cutoff

solenoid valve) circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Verify repair

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
105
E-6
!
!

2. Disconnect the PSG (pump control unit)

connector.
circuit.
C-57
105

E-6
6E177
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Is the DTC P0215 (Symptom Code D) stored as
Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P0215 (Symptom Code D) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair


release?

Replace the ECM.

6E178
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH

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

CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
Flash
Code
54
Code
P0216
Symptom
Code
A
MIL
ON
ON
DTC Name
Circuit Malfunction

Circuit Malfunction

than 700rpm.

more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8
seconds.

than 2014rpm.
than +-5.2 deg. CA.
Fail-Safe (Back Up)

reduced.
Circuit Description
The ECM is calculates an injection quantity and an

injection timing using the various sensors (crankshaft
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing
decision.
The TCV performs as a variable throttle, using the rapid
opening and closing cycle of the valve needle in the
TCV.
The TCV is assembled in the injection pump. The signal
of desired injection timing and actual injection timing are
exchanged via the CAN-bus between the PSG and
ECM.
If the timer position is out of tolerance (deviation or
fluctuation), DTC P0216 will be stored.
Diagnostic Aids

Poor connections.
Misrouted harness.
Insufficient air bleeding of fuel line.
Low fuel quantity in the fuel tank.

Insufficient air bleeding of fuel line inside, clogged
fuel filter or pinched fuel pipe/hose may cause the
DTC store or improper engine performance.
6E179
Air bleeding procedure:
1.Operate the priming pump until strong resistance is

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

3.Wait 1 minute, and operate the priming pump until
4.Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5.Turn the ignition switch to the "START" position and

crank the engine until it starts.
6.If the engine does not start, repeat Step 3 - 5.
7.Allow the engine to idle for 3 minutes to bleed air

leakage.


the "Actual Injection Start" display on the Tech2 while
sensor.
6E180
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Injection Timing Control Circuit Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Verify repair

Is the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored as "Present Failure"?
1. 1Using the Tech 2, ignition "On" and engine "Off".
No


Was the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored in this ignition cycle?
Perform the air bleeding in the fuel line sufficiently.

Air Bleeding Procedure:
1. Operate the priming pump until strong resistance

is felt.
2. Wait 1 minute, and operate the priming pump until
3. Once more wait, and operate the priming pump
until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait

until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position

and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.

7. Allow the engine to idle for 3 minutes to bleed air
leakage.
DTC Re-check:

(Symptom Code B) restored in this ignition cycle?

Step
5
6
7
6E181
Action
Value(s)
Yes
No
Restrict fuel supply system. Check for a pinched

fuel hose/pipe.
Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Visually/physically inspect for the following conditions.
Replace the fuel filter.

Remove the eye bolt with gauze filter from the

injectionpumpandcheckforthefollowingconditions.
Objects blocking at the gauze filter. Check for a

condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.

release?
If
not, download the latest software to the ECM using

6E182
Step
10
11

Action
Replace the ECM.


Value(s)
Yes
No
Verify repair
Verify repair
6E183

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

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION
CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" HIGH
6E184
Flash
Code
64
Code
P0243
Symptom
Code
3
MIL
ON
ON
ON
ON
ON
DTC Name
Fail-Safe (Back Up)
Solenoid "A" Range/
Performance

200 deg. C.

reduced.
Solenoid "A" Low

circuit open or short to ground
circuit.
Solenoid "A" Range/
Performance
Solenoid "A" Malfunction
Solenoid "A" High
2. Engine coolant
C.

200 deg. C.
2. Engine coolant
C.
2. EGR EVRV becomes 10%

condition.

reduced.

condition.

reduced.

condition.
1. Engine coolant
C.
2. EGR control EVRV 0%
condition.

circuit short to voltage circuit.

reduced.

condition.

Circuit description
The ECM monitors altitude from the barometric

pressure sensor. To apply specified vacuum pressure to
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude.
Then, apply vacuum pressure to the turbocharger
wastegate valve is monitored by the ECM form the
vacuum pressure sensor output signal. The ECM
controls wastegate control solenoid based on signal
from vacuum pressure sensor output.
If the vacuum pressure sensor detected vacuum
pressure is excessively low or high due to faulty vacuum
line, vacuum pump or turbocharger wastegate valve,
DTC P0243 (Symptom Code 3), P0243 (Symptom Code
5) or P0243 (Symptom Code 6) will be stored.
If the wastegate control solenoid circuit is open or short
to ground circuit, DTC P0243 (Symptom Code 4) will be
stored.
If the wastegate control solenoid circuit is short to
voltage circuit, DTC P0243 (Symptom Code 8) will be
stored.
Diagnostic Aids

Poor connections.
Misrouted harness.

Broken wire inside insulation.
Turbocharger wastegate valve sticking or broken.

Misrouted vacuum hose.
Faulty vacuum pump or regulating valve.


the DTC P0243 display on the Tech 2 while moving
6E185
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
Verify repair

"Present Failure"?

ignition cycle?
Remove the vacuum hose & vacuum regulating valve

and check for the following conditions.
No
Objects blocking the vacuum hose.
Objects blocking the vacuumregulating valve.

Vacuum leaking at vacuum hose or vacuum
regulating valve.
Objects blocking at the wastegate solenoidvalve.

Remove the vacuum pressure sensor and visually
check.

and recheck.
Replace the vacuum pressure sensor.
6E186
Step
8

Action
Using the DVM and check the wastegate control

solenoid.
Value(s)
Yes
No
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 11
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair

2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid

coil.
Does the tester indicate standard resistance?
Wastegate Solenoid
"
#
"
!
9
10
11
12
13
14
Substitute a known good wastegate control solenoid

and recheck.
Replace the wastegate control solenoid.
Using the pressure gauge and check the turbocharger

wastegate valve operation for broken diaphragm.
Replace the turbocharger wastegate valve .

release?
Replace the ECM.

6E187
Turbocharger Wastegate Solenoid "A" Low
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 6
Go to Step 9

"Present Failure"?

ignition cycle?
Check for poor/faulty connection at the wastegate

control solenoid or ECM connector. If a poor/faulty
!"
Value(s)
C-57
C-123
No

solenoid.

coil.
Wastegate Solenoid
"
#
"
6E188
Step
6

Action

solenoid power supply circuit.
2. Remove the wastegate
connector.
control
Value(s)
Yes
No
10 - 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 10
Go to Step 11
Verify repair
solenoid


and wastegate control solenoid.

solenoid circuit.

3. Removethewattagecontrolsolenoid connector.

circuit.
Breaker Box
96
C-123
"
!
!

3. Remove the
connector.
wastegate
control
solenoid

circuit.
C-57
!"
C-123
#
$
$
10

and recheck.

Step
11
12
Action

release?
Replace the ECM.

6E189
Value(s)
Yes
No
Verify repair
Go to Step 12
Verify repair
6E190
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Verify repair

"Present Failure"?

ignition cycle?
Visually check the vacuum regulating valve.


solenoid.
No

coil.
Wastegate Solenoid
"
#
"
!
6
7
8

and recheck.

wastegate valve operation for broken diaphragm.
Replace the turbocharger
wastegate
valve

Step
10
Action

!"
11
12
C-57
C-123

2. Disconnect
connector.
the
vacuum
pressure
Value(s)
Yes
No
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12
Less than 1V
Go to Step 15
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair
Go to Step 16
Verify repair

6E191
sensor

C-124
13
14
15
16

Replace the vacuum pressure sensor assembly.

release?
Replace the ECM.

6E192
Turbocharger Wastegate Solenoid "A" Malfunction
Step
1
6
7
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9

"Present Failure"?

ignition cycle?
Visually check the turbocharger wastegate valve and

hose.
If the hose is clogged or disconnected, repair as
necessary.

wastegate valve operation for broken diaphragm or
restrict shaft operation.
Replace the turbocharger wastegate valve.


C-57
##
#$

No
C-116
!"
Value(s)
&
'

Step
9
Action

circuit.
Value(s)
6E193
Yes
No
Less than 1V
Go to Step 12
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair


C-116
10
11
12
13

and recheck.
Replace the MAF &
IAT
sensor
assembly.

release?
Replace the ECM.

6E194
Turbocharger Wastegate Solenoid "A" High
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

"Present Failure"?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Approximately
14.7- 16.1 ! at
20"C
Go to Step 6
Go to Step 8

Check for poor/faulty connection at the wastegate

control solenoid or ECM connector. If a poor/faulty

solenoid.

coil.
Wastegate Solenoid
"
#
"

Step
6
Action

solenoid circuit.
6E195
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Verify repair
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair

2. Remove the wastegate control solenoid connector
and ECM connector.

C-123
!
7
8
9
10
11
Repair
the
short
to
voltage
circuit.

and recheck.

release?
Replace the ECM.

6E196

(FLASH CODE 53) INJECTION PUMP MALFUNCTION
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E)
Flash
Code
53
Code
P0251
Symptom
Code
MIL
DTC Name
ON
ON
ON
ON
ON
ON
ON
Circuit Description

injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
programmed pump map data.
The signal of desired injection quantity and actual injection quantify are exchanged via the CAN-bus between
the PSG and ECM.
If the relation of engine speed signal and doubled pump
camshaft speed signal excessively large, DTC P0251
(Symptom Code 7) will be stored.
If the CAN high or low circuit is defected, DTC P0251
(Symptom Code E) will be stored.
6E197
Fail-Safe (Back Up)
1. No pump camshaft speed

sensor error.
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection quantity.

valve) is operated.
becomes 0mg/strk.

sensor error.
3. Difference of engine speed
and doubled pump camshaft speed is more than
720rpm (4JA1-TC) or 690
rpm (4JH1-TC).
No pump map programmed in

the PSG (pump control unit)
or PSG malfunction.

malfunction in the PSG (pump
control unit).

reduced.
PSG (pump control unit) recognized high pressure solenoid valve drive circuit error.
ECM could not accept PSG

(pump control unit) message.

valve) is operated.
becomes 0mg/strk.
PSG (pump control unit) could

not measure the high pressure solenoid valve drive voltage.
Diagnostic Aids

Poor connections.
Misrouted harness.



the Injection Quantity display on the Tech2 while
sensor.
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
6E198
Step
2

Action

Present Failure?
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair


ignition cycle?
6E199
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Present Failure?


ignition cycle?
Was the DTC P0335 (Symptom Code B), P0335

(Symptom Code D) or P1335 (Symptom Code A)
stored at the same time?

connection is found, repair the faulty terminal.
C-57(B)
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
Code A)
Verify repair
No
Go to Step 5
E-6
91
Go to Step 6
6E200
Step
6

Action
If a oscilloscope is available, monitor the CKP sensor

output signal. Does the oscilloscope indicate correct
wave form?
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8

Reference Wave Form
CH1
0V"
CH2
0V"

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

Step
7
Action
Using the DVM and check the CKP sensor output

circuit.
6E201
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
91
E-6
!
!


3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
C-57(B)
E-6
91

circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6
V
Less than 1V
6E202
Step
9
10
11
12
13

Action
Check any accessory parts which may cause electric

interference or magnetic interference.

release?

Replace the ECM.

Value(s)
Yes
No
Remove the
accessory parts
and verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
6E203
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair


6E204
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair


6E205
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair


6E206
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53)
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair


6E207
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Is the DTC P0251 (Symptom Code E) stored as
Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P0251 (Symptom Code E) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids


(Symptom Code B) stored at the same time?
release?

Replace the ECM.

Go to DTC
Chart P1650
(Symptom
Code A)
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Go to Step 5
6E208

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION
(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION
(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
Flash
Code
43
Code
P0335
Symptom
Code
MIL
ON
DTC Name
6E209
Fail-Safe (Back Up)

Circuit Malfunction
1. Engine speed is more than

665rpm.
2. CKP sensor pulse width
error.
ON

Circuit Malfunction
ON
Engine Speed Input Circuit

Range/Performance

sensor error.
2. Crankshaft Position Sensor Circuit Malfunction
(Symptom Code B) is not
stored.
3. Engine speed is 0rpm.
speed is more than 50rpm.

sensor is OK:
ECM uses doubled pump camshaft speed as substitute
engine speed.
sensor is not OK:
valve) is operated.
becomes 0mg/strk.
Circuit Description

housing of the flywheel and fixed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine
cylinder top dead center.
If the CKP sensor harness or sensor malfunction is
detected during engine run, DTC P0335 (Symptom
Code B) is stored.
If the CKP sensor harness or sensor malfunction is
detected during engine cranking, DTC P0335
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
is stored.
Engine speed is more than

5700rpm.

sensor is OK:
engine speed.
Other than pump camshaft
speed sensor is OK:
reduced.
When intermittent malfunction:

valve) is operated.
becomes 0mg/strk.
When preliminary malfunction:
engine speed.
Diagnostic Aids

Poor connections.
Misrouted harness.



the Engine Speed display on the Tech2 while
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
6E210
Step
2

Action
Value(s)

Is the DTC P0335 (Symptom Code B) or P0335
(Symptom Code D) stored as Present Failure?
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Approximately
0.9k! at 20C
Go to Step 10
Go to Step 7


Was the DTC P0335 (Symptom Code B) or P0335
(Symptom Code D) stored in this ignition cycle?
Check for poor/faulty connection at the CKP sensor or
repair the faulty terminal.
C-57(B) 101
E-9
98
90
5
6
Visually check the CKP sensor. If a faulty installation

is found, repair as necessary.
Using the DVM and check the CKP sensor circuit.

3. Check the resistance of the CKP sensor.

90
Breaker Box
98


C-57(B)
98
90

Step
7
Action
6E211
Value(s)
Yes
No
Approximately
0.9k! at 20C
Go to Step 8
Go to Step 14
Repair faulty
harness and
verify repair
Go to Step 9

2. Disconnect the CKP sensor connector.

E-9



4. Check the circuit for open, short to sensor wire or
Breaker Box
98
90
101
!
!

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

90
Breaker Box
E-9
98
"
!
!
!
6E212
Step
9

Action
Value(s)
Yes
No
Less than 1V
Verify repair
Go to Step 13
Go to Step 11
Verify repair
Go to Step 12


If the DVM indicated out of specified value, repair
faulty harness and verify repair.
E-9
V
10
Using the DVM and check the CKP sensor signal.

1. Ignition On, engine On.
2. Measure the CKP output voltage at the sensor

and ECM.
Does the tester indicate standard voltage?
Measurement Point
At CKP sensor terminal 2 & 1
At ECM C57 connector 90 & 98
Voltage (V) (AC Range)
Approximately 1.1 V at
2000rpm

signal. Does the oscilloscope indicate correct wave
form?
0V"
Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div
11
Remove the CKP sensor from the flywheel housing

and visually check.
Check for the following conditions.
Objects sticking the CKP sensor.
12
Objects sticking the CKP sensor pulser.

Check the CKP sensor shield wire for open or short

circuit.
Repair faulty
harness and
verify repair
Go to Step 13

Step
13
14
15
16
17
Action

Substitute a known good CKP sensor and recheck.

Replace the CKP sensor.


release?
Replace the ECM.

Value(s)
Yes
6E213
No
Remove the
accessory parts
and verify repair
Go to Step 14
Go to Step 15
Go to Step 16
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
6E214
Engine Speed Input Circuit Range/Performance
Step
1
4
5
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Present Failure?


ignition cycle?
Ask to the customer whether over-speed condition

such as miss-gear shifting etc. has been experienced
or not.
Check for poor/faulty connection at the CKP sensor or
C-57(B) 101
E-9
Explain the
reason of DTC
to the customer
Verify repair
No
Go to Step 5
98
90
Go to Step 6

Step
6
Action
Using the DVM and check the CKP sensor signal.
Value(s)
6E215
Yes
No
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
1. Ignition On, engine On.

2. Measure the CKP output voltage at the sensor
and ECM.
Does the tester indicate standard voltage?
Measurement Point
At CKP sensor terminal 2 & 1
At ECM C57 connector 90 & 98
Voltage (V) (AC Range)
Approximately 1.1 V at
2000rpm

signal. Does the oscilloscope indicate correct wave
form?
0V"
Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div

and visually check.
8
9
10
11
12

Check the CKP sensor shield wire for open or short

circuit.

release?
Repair faulty
harness and
verify repair
Go to Step 9
Remove the
accessory parts
and verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
Go to Step 12
Verify repair
Go to Step 13
6E216
Step
13

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW
6E217

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Flash
Code
66
Code
P0380
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Low

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

by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
depending on engine coolant temperature.

Glow relay circuit open or
Fail-Safe (Back Up)

Glow relay circuit short to voltage circuit.
Diagnostic Aids

Poor connections.
Misrouted harness.

6E218

the DTC P0380 display on the Tech2 while moving

Glow Relay Circuit Voltage Low
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace glow
relay and verify
repair

Present Failure?


ignition cycle?
Check for poor/faulty connection at the glow relay or

C-57
X-5
94
Value(s)
Using the DVM and check the glow relay.
No
3
4
2. Remove the glow relay from the relay box.
3. Check the relay coil.

Grow Relay
"
Approximately
105!

Step
6
Action
Using the DVM and check the glow relay power

supply circuit.
6E219
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9


circuit.
X-5
2
V
7
8
Repair the open or short to ground circuit between the

ECM main relay and glow relay.
Using the DVM and check the glow relay ground

circuit.


circuit.
Breaker Box
94
X-5
!
!


circuit.
C-57
X-5
3
94
6E220
Step
9
10

Action

release?
Replace the ECM.

Value(s)
Yes
No
Verify repair
Go to Step 10
Verify repair
6E221
Glow Relay Circuit Voltage High
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair


release?

Replace the ECM.

6E222
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Flash
Code
67
Code
P0381
Symptom
Code
MIL
ON

Voltage Low
ON

Voltage High
Circuit Description
DTC Name
The function of the glow time indicator lamp is to inform

the driver whether the glow system is activated.
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer
activated.
In the after glow phase the lamp is not illuminated but

open or short to ground circuit.
Fail-Safe (Back Up)


the glow plugs remain active for a certain period

depending on engine coolant temperature.
Diagnostic Aids

Poor connections.
Misrouted harness.


6E223

Glow Plug Indicator Circuit Voltage Low
Step
1
4
5
6
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7

Present Failure?
No


ignition cycle?
2. Check the glow plug indicator lamp.
Does the lamp turn On?
2. Check the glow plug indicator lamp.

Does the lamp turn Off?
Check the glow plug indicator lamp bulb.

6E224
Step
7

Action
Check for poor/faulty connection at the meter

connector and ECM connector. If a poor/faulty
C-56
Yes
No
Verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
43
B-24
30
Value(s)
Using the DVM and check the glow time telltale circuit.

3. Remove the meter connector.

circuit.
!
Breaker Box
43
B-24
!
!


circuit.
C-56
43
6
B-24

Step
9
10
Action

release?
Replace the ECM.

6E225
Value(s)
Yes
No
Verify repair
Go to Step 10
Verify repair
6E226
Glow Plug Indicator Circuit Voltage High
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair


release?

Replace the ECM.

6E227

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
GROUND OR OPEN CIRCUIT
(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED
(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
BATTERY
6E228
Flash
Code
32
Code
P0400
Symptom
Code
MIL
ON

Flow Excessive Detected
ON
ON

Circuit Short to Ground or
Open Circuit

Flow Insufficient Detected
ON

Circuit Short to Battery
Circuit Description
DTC Name
The amount of EGR is controlled by EVRV (electrical

vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored.
If the EGR EVRV circuit is open or short ground circuit,
DTC P0400 (Symptom Code 4) is stored.
If the EGR EVRV circuit is short to voltage circuit, DTC
P0400 (Symptom Code 8) is stored.

between 15 deg.C and 100
deg.C.
2. Engine coolant temperature is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air flow
- mass air flow is more than
150mg/strk)
EGR EVRV circuit open or


between 15deg.C and 100
deg.C.
2. Engine coolant temperature is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
between 850hpa and
1100hpa.
4. Large mount of mass air
below 150 mg/strk)
EGR EVRV circuit short to

voltage circuit.
Fail-Safe (Back Up)

reduced.

reduced and EGR EVRV 10%

reduced.

reduced & EGR EVRV 10%
Diagnostic Aids

Poor connections.
Misrouted harness.

EGR valve sticking.
Faulty intake air duct connection.



6E229
Exhaust Gas Recirculation Flow Excessive Detected
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
Verify repair
Approximately
14! at 20C
Go to Step 11
Go to Step 9

Present Failure?


ignition cycle?
Remove the MAF & IAT sensor assembly and check

for the following conditions.
No
Objects blocking the air cleaner.
Objects blocking the MAF sensor.

Vacuum leaking at intake duct.
5
6
7
8
Objects blocking the turbocharger.

Remove the MAF & IAT sensor assembly and visually

check.

and recheck.
Using the DVM and check the EGR EVRV.

2. Disconnect the EGR EVRV connector.

3. Measure the resistance of EGR EVRV solenoid
coil.
EGR EVRV
2
1
2
6E230
Step
9
10
11

Action
Value(s)
Yes
No
Go to Step 10
Go to Step 11
Verify repair

Verify repair or
Go to Step 13
Go to Step 12
2. Inspect the EGR valve whether pintle valve is

stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat.
Verify repair or
Go to Step 13
Go to Step 14
Verify repair
Substitute a known good EGR EVRV and recheck.

Replace the EGR EVRV.
Using the Tech 2 or the vacuum pump and check the

EGR valve operation for the following condition
through the small window.
ERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the

"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original

vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
Vacuum Pump
12
13
Small Window
Inspect the EGR valve.

1. Remove the EGR valve from the engine.
Replace the EGR valve.


Step
14
15
Action

release?
Replace the ECM.

6E231
Value(s)
Yes
No
Verify repair
Go to Step 15
Verify repair
6E232
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 6
Go to Step 9

Present Failure?


ignition cycle?
Check for poor/faulty connection at the EGR EVRV or

C-57
No
C-115
97
Value(s)


coil.
EGR EVRV
2
1
2

Step
6
Action
Using the DVM and check the EGR EVRV power

supply circuit.
6E233
Value(s)
Yes
No
10-14.5 V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 10
Go to Step 11

2. Remove the EGR EVRV connector.

C-115
V
7
8

and EGR EVRV.
Using the DVM and check the EGR EVRV circuit.


circuit.
C-115
Breaker Box
97
!
!


circuit.
C-57
C-115
2
97

6E234
Step
10
11
12

Action


release?
Replace the ECM.

Value(s)
Yes
No
Verify repair
Verify repair
Go to Step 12
Verify repair
6E235
Exhaust Gas Recirculation Flow Insufficient Detected
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair

Present Failure?


ignition cycle?
Visually check the EGR control vacuum hose.
If the hose is clogged or disconnected, repair as
necessary.
No

coil.
EGR EVRV
2
1
2
6
7

6E236
Step
8

Action

deposit.
Value(s)
Yes
No
Verify repair or
Go to Step 10
Go to Step 9
Verify repair or
Go to Step 10
Go to Step 11
Verify repair
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
10
Small Window

Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is

stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat.
Replace the EGR valve.


Step
11
Action

C-57(B)
12
13
Value(s)
Yes
No
Verify repair
Go to Step 12
Go to Step 14
Go to Step 13
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair
Go to Step 15
Go to Step 16
Verify repair
Verify repair
Go to Step 17
Verify repair
C-116
92
2 3
88
6E237
83


circuit.

C-116
V
14
15
16
17

and recheck.


release?
Replace the ECM.

6E238
Exhaust Gas Recirculation Circuit Short to Battery
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 6
Go to Step 8

Check for poor/faulty connection at the EGR EVRV or

C-57
C-115
97
Value(s)


coil.
EGR EVRV
2
1
2

Step
6
Action
Using the DVM and check the EGR EVRV circuit.
6E239
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Verify repair
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair

2. Remove the EGR EVRV connector and ECM
connector.
3. 3. Check the circuit for short to voltage circuit.

C-115
7
8
9
10
11
Repair the short to voltage circuit.



release?
Replace the ECM.

6E240

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

(FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY
TOO HIGH
(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Flash
Code
24
Code
P0500
Symptom
Code
1
MIL
DTC Name
ON
at next
ignition
cycle
Vehicle Speed Sensor Circuit

High Input

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

h condition as substitute.
Vehicle Speed Sensor Input

Signal Frequency Too High
Input signal frequency is too

high.
ECM uses vehicle speed 5km/

h condition as substitute.
Vehicle Speed Sensor Incorrect Signal

3200rpm (4JA1-TC) or
3600rpm (4JH1-TC).
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
1.5km/h.

reduced.
ON
at next
ignition
cycle
ON
at next
ignition
cycle
6E241
Fail-Safe (Back Up)
Misrouted harness.
Circuit Description
The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
Diagnostic Aids

Poor connections.

Vehicle Speed Sensor Circuit High Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Present Failure?
No


ignition cycle?
6E242
Step
4
6
7

Action
Perform test drive and check the speed meter.

Does the speed meter indicate correct vehicle speed.
Perform test drive and use the Tech 2.

Monitor the Vehicle Speed in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel?
Remove the VSS from the housing case and visually
check.
Using the DVM and check the VSS signal.
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 15
Go to Step 7
Go to Step 8
Go to Step 7
Refer to
Diagnostic Aids
and Go to Step
15
Refer the table
1. Ignition On, vehicle Run (lift up).

2. Measure the VSS output voltage at sensor, TCM
(A/T 2WD), meter and ECM.
Does the tester indicate specified value?
Measurement Position
VSS terminal 3 & GND
TCM C94 connector 10 &
GND (A/T 2WD)
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 8
Go to
Step 9
Meter B24 connector 9 &

GND
Go to
Step 10
ECM C56 connector 68 &

GND
Go to
Step 13

GND
Go to
Step 12
If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope
indicate correct wave form?
0V"

GND(-)
50ms/div
8
9
Replace the VSS.

Replace the TCM.

IMPORTANT: The replacement TCM must be
programmed. SPS (Service Programming System)
is necessary.
Verify repair
Verify repair

Step
10
Action
Value(s)
Using the DVM and check the VSS signal circuit.
6E243
Yes
No
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Verify repair
Verify repair
Go to Step 14
Repair faulty
harness and
verify repair

2. Disconnect the meter connector.

B-24
V
11

2. Disconnect the VSS connector and meter

connector.
circuit.
If a open or short to ground circuit is found, repair the
B-24
E-44
3
12
13
Replace the speed meter.


2. Disconnect the
connector.
3. Ignition On.
meter connector
and
ECM

B-24
10
V
Less than 1V
6E244
Step
14

Action

Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair

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

B-24
Breaker Box
68
!"
!
!

2. Disconnect
connector.
the
meter connector
and
ECM

circuit.
C-56
68
B-24
15
16
10

release?
Replace the ECM.

6E245
Vehicle Speed Sensor Input Signal Frequency Too High
Step
1
4
5
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8
Go to Step 7

Present Failure?


ignition cycle?

panel?
check.
No
6E246
Step
7

Action
Value(s)
Yes
No
Refer to
Diagnostic Aids
and Go to Step
10
Refer the table

TCM terminal A10 & B5
(A/T 2WD)
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 8
Go to
Step 9

GND
Go to
Step 10

GND
Go to
Step 10

GND
Go to
Step 11

0V"

GND(-)
50ms/div
8
9
10
11
12
Replace the VSS.

Replace the TCM.

is necessary.


release?
Verify repair
Verify repair
Remove the
accessory parts
and verify repair
Go to Step 12
Verify repair
Verify repair
Go to Step 13

Step
13
Action
Replace the ECM.

6E247
Value(s)
Yes
No
Verify repair
6E248
Vehicle Speed Sensor Incorrect Signal
Step
1
4
5
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 17
Go to Step 7
Verify repair
Go to Step 8

Present Failure?


ignition cycle?

panel?
Check for poor/faulty connection at the VSS, TCM (A/
T 2WD) and meter connectors. If a poor/faulty
No
E-44
1
2
B-24
9 10
C-94(10)
10

Step
7
Action
Check for poor/faulty connection at the ECM and

other connectors. If a poor/faulty connection is found,
6E249
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 10
Go to Step 9
Refer to
Diagnostic Aids
and Go to Step
17
Refer the table
C-56
68
8
9

check.

TCM C94 connector 10 &
GND (A/T 2WD)
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 10
Go to
Step 11

GND
Go to
Step 12

GND
Go to
Step 15

GND
Go to
Step 14

0V"

GND(-)
50ms/div
10
Replace the VSS.

Verify repair
6E250
Step
11
12

Action
Replace the TCM.

is necessary.
Value(s)
Yes
No
Verify repair
Less than 1V
Go to Step 13
Repair faulty
harness and
verify repair
Verify repair
Verify repair

B-24
V
13

2. Disconnect the VSS connector
connector.
and
meter

circuit.
If a open or short to ground circuit is found, repair the
B-24
E-44
3
14


Step
15
Action
Value(s)

2. Disconnect the meter connector
connector.
and
6E251
Yes
No
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 17
ECM
3. Ignition On.

B-24
10
V
16



4. Check the circuit for open or shot to ground circuit.
B-24
Breaker Box
68
!"
!
!

2. Disconnect the meter connector and ECM

connector.
circuit.
C-56
68
B-24
10
6E252
Step
17
18

Action

release?
Replace the ECM.

Value(s)
Yes
No
Verify repair
Go to Step 18
Verify repair

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH
6E253

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW
(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION
Flash
Code
35
Code
P0560
Symptom
Code
DTC Name
OFF
OFF
Circuit Description
MIL
OFF
The ECM and PSG monitors the system voltage on the

ignition feed terminal to the ECM or PSG. The system
Fail-Safe (Back Up)

20V.
ECM uses 9V conditions as

substitute.
System voltage of PSG

(pump control unit) is below
4.5V or more than 27V.
PSG uses default voltage as

substitute.
voltage to the ECM excessively high or low, DTC P0560

stored. The system voltage to the PSG excessively high
6E254
or low, DTC P0560 (Symptom Code A) will be stored.
Diagnostic Aids

Poor connections.
Misrouted harness.



the System Voltage display on the Tech2 while
sensor.
Step
1
4
5
Action

performed?

Present Failure?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
No


ignition cycle?
Was the battery

connecting?
jump
start
cable
incorrectly
1. Using the Tech 2, ignition On and engine On.
Verify
procedure
2. Monitor the System Voltage in the data display.
3. Load the electrical system by turning on the

headlights, etc..
Does the Tech 2 indicate correct ignition voltage?

release?
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system
Verify repair
Go to Step 7

Step
7
Action
Replace the ECM.

6E255
Value(s)
Yes
No
Verify repair
6E256
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
10 - 14.5V
Go to Step 6
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system, charge
or replace the
battery
Verify repair
Go to Step 7

Present Failure?


ignition cycle?
No
2. Monitor the System Voltage in the data display.
3. Load the electrical system by turning on the

headlights, etc..
Does the Tech 2 indicate enough ignition voltage?
Using the DVM and check the battery voltage at the

battery terminal.
Does the tester indicate enough battery voltage?
Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
C-56
56

Step
7
Action
Using the DVM and check the ECM main relay.
Value(s)
6E257
Yes
No
120-150!
Go to Step 8
Replace ECM
main relay and
verify repair
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair

2. Remove the ECM main relay from the relay box.

ECM Main Relay

$
#
"
#
"
Check for poor/faulty connection of the ECM ground

at the body. If a poor/faulty connection is found, repair
as necessary.
C-109
10

release?
Replace the ECM.

6E258
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
10 - 14.5V
Go to Step 7
Go to Step 6

Present Failure?


ignition cycle?
Check for poor/faulty connection at the PSG (pump

control unit) connector. If a poor/faulty connection is
found, repair as necessary.
No
E-6
6
Using the DVM and check the PSG (pump control

unit) power supply circuit.

connector.
3. Check the PSG (pump control unit) power supply
circuit.
6
E-6
V
7

Step
6
Action
Check for poor/faulty connection of the PSG (pump

control unit) ground at the cylinder body. If a poor/
faulty connection is found, repair as necessary.
6E259
Value(s)
Yes
No
Verify repair
Go to Step 7
Verify repair
E-10

6E260

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Flash
Code
18
Code
P0561
Symptom
Code
MIL
DTC Name
OFF
Ignition Switch Circuit Malfunction
OFF

The ECM recognized ignition
switch turn off signal during
ECM is activated.
Ignition switch circuit is malfunction.
Fail-Safe (Back Up)

ECM stops engine.

Circuit Description
The ECM monitors the ignition switch signal on the feed

terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC
P0561 (Symptom Code B) will be stored.
Diagnostic Aids

Poor connections.
Misrouted harness.
6E261



the Ignition Status display on the Tech2 while
sensor.
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5

(Symptom Code B) stored as Present Failure?
No


(Symptom Code B)stored in this ignition cycle?
Check the Engine fuse (10A).
6E262
Step
5

Action
Using the DVM and check the ignition power feed

circuit.
2. Install the breaker box
disconnected)
as
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
type A. (ECM

circuit.
C-107
Breaker Box
39
!
!
!


circuit.
C-56
39
C-107
Check the ignition switch.

If a poor/faulty connection is found, repair as
necessary.

release?

Step
8
Action
Replace the ECM.

6E263
Value(s)
Yes
No
Verify repair
6E264
DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE

PROGRAMMING ERROR
Flash
Code
-
Code
P0602
Symptom
Code
MIL
DTC Name
Control Module Programming

Error
Circuit Description & Diagnostic Aids
The replacement ECM must be programmed by Service

Programming System (SPS). Because, the service

ECM memory area error.
Fail-Safe (Back Up)

Engine control disabled.
ECM does not programmed.

When the service ECM is used without SPS, DTC
P0602 will appear.
Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error

Step
1
Action

performed?

Is the DTC P0602 stored as Present Failure?
Download the latest software to the ECM using the

SPS (Service Programming System).
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
Verify repair

(FLASH CODE 28) ECU MALFUNCTION
6E265

(FLASH CODE 28) ECU MALFUNCTION
Flash
Code
28
Code
P0606
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
ON
ECM Malfunction
Gate Array communication

error.
ON
ECM Malfunction
1. Throttle position is below

1%.
2. Desired injection quantity is
more than 0mg/strk.
2000rpm.

valve) is operated.
becomes 0mg/strk.
valve) is operated.
If the ECM inside (IC, circuit, memory, etc,) failed, DTC

P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5

Present Failure?
No


ignition cycle?
release?
6E266
Step
5

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair
6E267
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair


release?

Replace the ECM.

6E268

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

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
Flash
Code
46
Code
P0645
Symptom
Code
MIL
DTC Name
ON
A/C Compressor Relay Circuit

Voltage Low
ON
A/C Compressor Relay Circuit

Voltage High
Circuit Description
The voltage on the coil of the A/C compressor is

supplied by the ECM main relay. The ECM switches A/C
compressor relay to operate A/C compressor depends
on the A/C request signal and certain setting conditions.

Fail-Safe (Back Up)


Diagnostic Aids

Poor connections.
Misrouted harness.
6E269

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace A/C
compressor
relay and verify
repair

Present Failure?
No


ignition cycle?
Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
"
C-56
X-14
$
#
!
!"
Using the DVM and check the A/C compressor relay.

2. Remove the A/C compressor relay from the relay
box.

$
#
"
#
"
120-150!
6E270
Step
6

Action
Using the DVM and check the A/C compressor relay

power supply circuit.
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair

box.

circuit.
X-14
V
7
Repair the open or short to ground circuit between the

ECM main relay and A/C compressor relay.

Step
8
Action
Using the DVM and check the A/C compressor relay

ground circuit.
disconnected)
as
6E271
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
type A. (ECM

box.

circuit.
X-14
Breaker Box
41
!
"
"


box.

circuit.
X-14
C-56
!"
"
10
"

release?
Replace the ECM.

6E272
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair


release?

Replace the ECM.


(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
6E273
6E274
Flash
Code
25
Code
P0703
Symptom
Code
MIL
DTC Name
ON

Malfunction
ON

Malfunction
Fail-Safe (Back Up)

than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
ECM since the ignition
switch was turned on.

than 0%.
693rpm (4JA1-TC) or 665
rpm (4JH1-TC).
0km/h.
ECM.
Circuit Description
The ECM monitors the brake switch signal on the feed

terminal to the ECM. If brake switch 1 or 2 circuit with
malfunction, DTC P0703 (Symptom Code A) or P0703
(Symptom Code B) will be stored.
Diagnostic Aids

Poor connections.
Misrouted harness.


the Brake Switch 1 and Brake Switch 2 display on
the Tech2 while moving connectors and wiring
harness related to the sensor.
Brake Switch Circuit Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
No

Step
3
4
5
Action
Value(s)

ignition cycle?
Check the Stop Lamp fuse (15A).
Check for poor/faulty connection at the brake switch

or ECM connector. If a poor/faulty connection is found,
C-56
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity
Go to Step 7
Replace pedal
switch and
verify repair
10-14.5V
Go to Step 9
Go to Step 8
C-44
30
6
6E275
Using the DVM and check the brake switch 1.

2. Remove the brake switch connector at the brake

pedal.
3. Check the brake switch 1.

Brake Switch
"
Using the DVM and check the brake switch 1 power

supply circuit.
2. Remove the brake switch connector from the

brake switch.

C-44
6E276
Step
8

Action
Repair the open circuit between the Stop Lamp fuse

(15A) and brake switch 1.
Using the DVM and check the brake switch 1 circuit.
Value(s)
Yes
No
Verify repair
Pedal is not
stepped on:
Less than 1V
Pedal stepped
on: 10-14.5V
Go to Step 12
Fixed at 1014.5V: Go to
Step 10
Fixed at less
than 1V: Go to
Step 11
Verify repair
Verify repair
type B. (ECM
4. Check the circuit for open or short to voltage

circuit.
Breaker Box
105

2. Back probe the DVM to the brake switch 1 and

check the circuit for open or short to voltage
circuit.
C-44
V
10
Repair the short to voltage circuit between the brake

switch 1 connector and ECM.
C-56
30
11
C-44
Repair the open circuit between the brake switch 1

connector and ECM.
C-56
30
C-44

Step
12
13
Action

release?
Replace the ECM.

6E277
Value(s)
Yes
No
Verify repair
Go to Step 13
Verify repair
6E278
Brake Switch Circuit Malfunction
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair

Present Failure?


ignition cycle?
Check for poor/faulty connection at the brake switch
C-56
No
C-44
65
5
Value(s)
Using the DVM and check the brake switch 2.

2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.

Brake Switch
!
"
Pedal is not
stepped on:
No continuity
Pedal stepped
on: Continuity

Step
6
Action
Using the DVM and check the brake switch 2 power

supply circuit.
6E279
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the brake switch connector from the
brake switch.

C-44
V
7
8
Repair the open circuit between the ECM fuse (10A)

and brake switch 2.
Using the DVM and check the brake switch 2 circuit.
connected)
as
type B. (ECM

circuit.
Breaker Box
65

2. Back probe the DVM to the brake switch 2 and

circuit.
C-44
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E280
Step
9

Action
Repair the short to voltage circuit between the brake

switch 2 connector and ECM.
C-56
10
Repair the open circuit between the brake switch 2

connector and ECM.
C-56
65
11
12
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
C-44
65
Value(s)
C-44

release?
Replace the ECM.

6E281

(FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Flash
Code
57
Code
P0704
Symptom
Code
6
MIL
ON
DTC Name
Clutch Switch Input Circuit
Malfunction
Circuit Description
The ECM monitors the clutch switch signal on the feed

terminal to the ECM. If clutch switch circuit with
malfunction, DTC P0704 (Symptom Code 6) will be
stored.
Diagnostic Aids

Poor connections.
Misrouted harness.

Clutch signal does not change
between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.
Fail-Safe (Back Up)




the Clutch Switch display on the Tech2 while
sensor.
6E282
Clutch Switch Input Circuit Malfunction
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair

Present Failure?


ignition cycle?
Check for poor/faulty connection at the clutch switch
C-56
31
Value(s)
1
2
Using the DVM and check the clutch switch.
No
C-77

2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.

Clutch Switch
"
!
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity

Step
6
Action
Using the DVM and check the clutch switch power

supply circuit.
6E283
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the clutch switch connector from the
clutch switch.

C-77
1
2
V
7
8

and clutch switch.
Using the DVM and check the clutch switch circuit.

type B. (ECM

circuit.
Breaker Box
31

2. Back probe the DVM to the clutch switch and

circuit.
C-77
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E284
Step
9

Action
Repair the short to voltage circuit between the clutch

switch connector and ECM.
C-56
10
Repair the open circuit between the clutch switch

connector and ECM.
C-56
31
11
12
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
C-77
31
Value(s)
C-77

release?
Replace the ECM.

6E285

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT
(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Flash
Code
86
Code
P1105
Symptom
Code
MIL
DTC Name
ON

Circuit High Input
ON

Circuit Low Input
Circuit Description
The ECM monitors the barometric pressure signal at

inside of the ECM. If the sensor with malfunction, DTC
P1105 (Symptom Code 1) or P1105 (Symptom Code 2)
will be stored.

4.4V.
Fail-Safe (Back Up)

ECM uses 1013hpa condition
as substitute.

Diagnostic Aids
If the DTC P1105 is stored, sensor or circuit of ECM

inside is failed.
Barometric Pressure Sensor Circuit High Input
Barometric Pressure Sensor Circuit Low Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Is the DTC P1105 (Symptom Code 1) or P1105
(Symptom Code 2) stored as Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P1105 (Symptom Code 1) or P1105
(Symptom Code 2) stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5


release?
6E286
Step
5

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair
6E287

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

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH
ERROR
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
6E288
Flash
Code
21
Code
P1120
Symptom
Code
MIL
ON
ON
ON
ON
ON
DTC Name
Pedal/Throttle Position Sensor Circuit High Input
Pedal/Throttle Position Sensor Voltage Supply Circuit

High Input
Pedal/Throttle Position Sensor Voltage Supply Circuit

Low Input
Pedal/Throttle Position Sensor Brake Switch Error
Pedal/Throttle Position Sensor Idle Position Switch Error
Circuit Description
The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The ECM monitors the TPS supply voltage and TPS
output voltage. The supply voltage is out of range, DTC
P1120 (Symptom Code 7) or P1120 (Symptom Code 9)
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
If the brake pedal is depressed during accelerator pedal
is depressing, DTC P1120 (Symptom Code D) will be
stored.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.
Fail-Safe (Back Up)
Throttle position sensor output voltage is more than 4.5V.

than 5.2V.
ECM increases idle speed up

to 1400rpm.

power supply voltage is below
4.6V.

1700rpm.
1.5km/h.
3. When brake pedal is
depressed during accelerator pedal is depressing.
1. When idle switch is turned
off, throttle position sensor
was below 0.35%.
or
2. When idle switch is tuned
on, throttle position sensor
was more than 7.8%.
Diagnostic Aids

Poor connections.
Misrouted harness.


the Throttle Position, Idle Switch, Brake Switch 1
and Brake Switch 2 display on the Tech2 while
sensor.
Pedal/Throttle Position Sensor Circuit High Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check

Step
2
Action
Value(s)

Present Failure?
6E289
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6


ignition cycle?
Check for poor/faulty connection at the TPS or ECM
as necessary.
C-56
49
39
57
Visually check the TPS.

E-22
2 3
6E290
Step
6

Action
Using the DVM and check the TPS.
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14

2. Disconnect TPS connector.
3. Measure the resistance of TPS.

Measurement
Terminal
1-2
2-3
1-3
Resistance (!)
Approximately 0.4k! at idle position
Approximately 4.0k! at WOT
Approximately 4.3k! at idle position

Approximately 0.8k! at WOT
Approximately 4.6k! at idle position &

WOT
TPS
3
2
2
Using the DVM and check the TPS power supply

circuit.
2. Disconnect the TPS connector.

E-22
V
8

and TPS.
C-56
57
E-22

Step
9
Action
Using the DVM and check the TPS signal circuit.
Value(s)
6E291
Yes
No
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair


E-22
V
10
Using the DVM and check the TPS ground circuit.
Less than 1V

2. Disconnect the TPS connector .

E-22
V
Less than 1V
6E292
Step
11

Action
Using the DVM and check the TPS ground circuit.

Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair


Breaker Box
49
E-22
!
!
!

2. Disconnect
connector.
the
TPS
connector
and
ECM

C-56
49
E-22
12
13
14
15
Substitute a known good TPS and recheck.

Replace the TPS.


release?
Replace the ECM.

6E293
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?


ignition cycle?
as necessary.
C-56
49
No
39
57

E-22
2 3
6E294
Step
6

Action

circuit.
Value(s)
Yes
No
Approximately
5.0V
Go to Step 12
Go to Step 7
Verify repair
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair


E-22
V
7

ECM and TPS.
C-56
57
E-22
8
9
10
11

Replace the TPS.

release?
Replace the ECM.

6E295
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2

Present Failure?


ignition cycle?
as necessary.
C-56
49
No
Go to On Board
Diagnostic
(OBD) System
Check
Refer to
Diagnostic Aids
Go to Step 3
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
39
57

E-22
2 3
6E296
Step
6

Action

circuit.
Value(s)
Yes
No
Approximately
5.0V
Go to Step 10
Go to Step 7
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair


circuit.
E-22
V
7

circuit.
2. Disconnect the TPS connector
connector.
and
ECM
3. Check the circuit for short to TPS ground circuit.

E-22
8
9
Repair the circuit for short to TPS ground circuit.

Repair the short to ground circuit between the ECM

and TPS.
C-56
57
E-22
10
11

Replace the TPS.

Step
12
13
Action

release?
Replace the ECM. Is the action complete?

6E297
Value(s)
Yes
No
Verify repair
Go to Step 13
Verify repair
6E298
Pedal/Throttle Position Sensor Brake Switch Error
Step
1
8
9
10
11
12
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?

No

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Accelerator pedal sticking.

Verify repair
Go to Step 5
2. Monitor the Throttle Position in the data display.

Does the Tech 2 indicate correct Throttle Position
from 0% to 100% depending on accelerator pedal
operation?
Go to Step 7
Go to Step 6
3. Adjust the TPS within 0% to 100%.

Verify repair
Go to Step 11
2. Monitor the Brake Switch 1 and Brake Switch 2

in the data display.
Does the Tech 2 indicate Inactive when the brake
pedal was not stepped on?
Go to Step 13
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 13
Verify repair
Go to Step 12
Go to Step 13
Verify repair

Adjust the brake switch.

Substitute a known good brake switch and recheck.

Replace the brake switch.


Replace the TPS.

Step
13
14
Action

release?
Replace the ECM.

6E299
Value(s)
Yes
No
Verify repair
Go to Step 14
Verify repair
6E300
Pedal/Throttle Position Sensor Idle Position Switch Error
Step
1
4
5
8
9
10
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6Go
to Step 6
3. Adjust the TPS within 0% to 100%.

Verify repair
Go to Step 8
2. Monitor the Idle Switch in the data display.

Does the Tech 2 indicate Inactive when the
accelerator pedal was stepped on?
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11

performed?

Present Failure?


ignition cycle?

Does the Tech 2 indicate correct Throttle Position
from 0% to 100% depending on accelerator pedal
operation?
No


Replace the TPS.

release?

Step
11
Action
Replace the ECM.

6E301
Value(s)
Yes
No
Verify repair
6E302

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

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE
(FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW FUEL TEMPERATURE
Flash
Code
22
Code
P1173
Symptom
Code
MIL
OFF
OFF
OFF
DTC Name

High Coolant Temperature

High Fuel Temperature
Excessive high engine coolant temperature is detected.
Fuel temperature is more than

100 deg. C.

Low Fuel Temperature
Excessive low fuel temperature is detected.
Circuit Description
The engine coolant temperature (ECT) sensor is

installed on the coolant stream. High coolant
temperature produces a low resistance. The ECM
supplies 5 volts signal to the ECT sensor through
resisters in the ECM and measures the voltage. The
signal voltage will be low when the engine temperature
is hot.
The fuel temperature sensor is assembled inside of the
pump control unit (PSG). The signal of fuel temperature
If the engine coolant temperature is excessively high
condition, DTC P1173 (Symptom Code 3) will be stored.
If the fuel temperature is excessively high or low
condition, DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) will be stored.
Fail-Safe (Back Up)
PSG (pump control unit) controls fuel injection quantity

based on engine speed and
fuel temperature.
Diagnostic Aids

Poor connections.
Misrouted harness.



the Coolant Temperature or Fuel Temperature
display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
Step
1
Action

performed?

Present Failure?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No

Step
3
Action

ignition cycle?
Check the engine overheat condition.
2. Monitor the Coolant Temperature in the data

display.
Does the Tech 2 indicate correct Coolant
Temperature depending on warm up time?
Value(s)
6E303
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Repair the
cause of
overheat and
verify repair
Go to Step 9
Go to Step 6
Standard
resistance
Go to Step 9
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Go to Step 10
Go to Step 5

Temperature (C)
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2
7
8
9

recheck.

release?
6E304
Step
10

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair
6E305
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Reduction Caused By Low Fuel Temperature
Step
1
Action

performed?

Is the DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) stored as Present Failure?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair


Was the DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) stored in this ignition cycle?
release?

Replace the ECM.

6E306

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Flash
Code
43
Code
P1335
Symptom
Code
Circuit Description
MIL
ON
DTC Name
Engine Speed Output Circuit

Malfunction

housing of the flywheel and fixed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine
cylinder top dead center.
The ECM converts sine wave signal to square wave
signal. And this signal is provided from the ECM to
pump control unit (PSG).

is recognized defective
engine speed signal form the
ECM.
Fail-Safe (Back Up)

reduced.
Diagnostic Aids

Poor connections.
Misrouted harness.


the Engine Speed display on the Tech2 while
6E307

sensor.
Engine Speed Output Circuit Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Present Failure?


ignition cycle?
Was the DTC P0335 (Symptom Code B) or P0335
(Symptom Code D) stored at the same time?

C-57(B)
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code C)
Verify repair
No
Go to Step 5
E-6
91
Go to Step 6
6E308
Step
6

Action

output signal. Does the oscilloscope indicate correct
wave form?
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8

Reference Wave Form
CH1
0V
CH2
0V

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

Step
7
Action

circuit.
6E309
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
91
E-6
!
!


3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
C-57(B)
E-6
91

circuit.

connector.
E-6
V
Less than 1V
6E310
Step
9
10
11
12
13

Action


release?

Replace the ECM.

Value(s)
Yes
No
Remove the
accessory parts
and verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
6E311
Flash
Code
45
Code
P1345
Symptom
Code
A
MIL
DTC Name
ON
Camshaft Speed Malfunction

is recognized incorrect camshaft speed signal.
Circuit Description
The pump camshaft sensor is a magnet with a coil. It

uses to combine with the pulser. The pulser is attached
main shaft in the pump. It likes a gear shape.
The pump camshaft sensor is attached to the pump
control unit (PSG). The signal of pump camshaft speed
Diagnostic Aids

Poor connections.
Misrouted harness.
Fail-Safe (Back Up)



the Pump Speed display on the Tech2 while moving
6E312
Camshaft Speed Malfunction
Step
1
5
6
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?

No

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
2. Monitor the Pump Speed in the data display.

Does the Tech 2 indicate correct Pump Speed
depending on engine speed?
Go to Step 6
Go to Step 5


release?

Replace the ECM.

Remove the
accessory parts
and verify repair
Go to Step 9
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair

(FLASH CODE 47) NEUTRAL SWITCH ON ERROR
6E313

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Flash
Code
47
Code
P1520
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
The ECM monitors the neutral switch (A/T: N or P

position switch in inhibitor switch) signal on the feed
terminal to the ECM. If the neutral switch with
malfunction, DTC P1520 (Symptom Code A) or P1520

Neutral switch signal is inputted On three times consecutively under driving
conditions.
Fail-Safe (Back Up)

Neutral switch signal is inputted Off three times consecutively under driving
conditions.
(Symptom Code B) will be stored.
Diagnostic Aids

Poor connections.
6E314
Misrouted harness.



the Neutral Switch display on the Tech2 while
sensor.
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

(Symptom Code B) stored as Present Failure?
No


(Symptom Code B) stored in this ignition cycle?

Step
4
Action
Check for poor/faulty connection at the neutral switch

(inhibitor switch) or ECM connector. If a poor/faulty
6E315
Value(s)
Yes
No
Verify repair
Go to Step 5
Go to Step 6
Replace neutral
switch (inhibitor
switch) and
verify repair
C-57
87
M/T
E-11
E-12
A/T
E-51
3
Using the DVM and check the neutral switch (inhibitor

switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range

switch).
N range
M/T
E-11
E-12
A/T
3
6
10 9
7
8
Neutral (P or
N): Continuity
Other than
neutral (P or
N): No
continuity
6E316
Step
6

Action

switch) power supply circuit.
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the neutral switch (inhibitor switch)
connector from the switch.

A/T
E-51
M/T
E-12
V
7

and neutral switch (between the Back Up fuse (15A)
and inhibitor switch).

switch) circuit.
type B. (ECM

circuit.
Breaker Box
87
E-6
!
!

2. Back probe the DVM to the neutral switch

(inhibitor switch) and check the circuit for open or
M/T
E-11
A/T
E-51
V
V
Neutral (P or
N): 10-14.5V
Other than
neutral (P or
N): Less than
1V

Step
9
Action
Repair the short to voltage circuit between the neutral

switch connector (inhibitor switch connector) and
ECM.
6E317
Value(s)
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
M/T
C-57
E-11
87
A/T
C-57
E-51
87
10
Repair the open circuit between the neutral switch

connector (inhibitor switch connector) and ECM.
M/T
C-57
E-11
87
A/T
C-57
87
11
12
E-51

release?
Replace the ECM.

6E318

(FLASH CODE 55) SEED AND KEY FILE DESTROYED
(FLASH CODE 55) EEPROM DEFECT
(FLASH CODE 55) EEPROM DEFECT
Flash
Code
55
Code
P1605
Symptom
Code
MIL
DTC Name
ON
Seed and Key File Destroyed
ON
EEPROM Defect
ON
EEPROM Defect
The ECM used in this vehicle utilizes an electrically

erasable & programmable read only memory
(EEPROM).
The
EEPROM
contains
program
information and the calibrations required for engine and
Fail-Safe (Back Up)
Seed or key file in EEPROM

is destroyed.

EEPROM are failed during initialization of the ECM.
ECM uses default values from

the EPROM.
EEPROM checksum does not

match with the read check
sum during initialization of the
ECM.
diagnostics operation.
If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P1605 (Symptom Code C), P1605 (Symptom Code D)
or P1605 (Symptom Code E) will be stored.
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
EEPROM Defect
EEPROM Defect
Step
1
Action

performed?

Is the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E)
stored as Present Failure?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No

Step
3
6E319
Action
Value(s)
Yes
No

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E)
stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Verify repair

release?
Replace the ECM.

6E320

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Flash
Code
56
Code
P1610
Symptom
Code
Circuit Description
MIL
-
DTC Name
Security Key and Security
Code not Programmed
The ECM decides whether that is an abnormality in the

immobilizer control system. DTC P1610 (Symptom
Code A) is recorded when immobilizer function was not

Immobilizer functions are not
Fail-Safe (Back Up)

Diagnostic Aids

Poor connection at ECM and immobilizer control unitInspect harness connectors for backed out terminals,
damaged terminals, and poor terminal to wire
connection.

6E321
Security Key and Security Code Not Programmed
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0002 or
B0009
Go to Step 5
Verify repair
Go to Step 6
Verify repair

Present Failure?


ignition cycle?
2. Select Immobilizer in the system selection menu

Body.
3. Select Read DTC Info Ordered By Priority in the

Was the any DTC's B0002 or B0009 stored in this
ignition cycle?

release?
Replace the ECM.

No
6E322

(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Flash
Code
56
Code
P1611
Symptom
Code
Circuit Description
MIL
DTC Name
Wrong Security Code Entered
Received security code is not

correct.

Code A) is recorded when received immobilizer security
code was not correct.
Fail-Safe (Back Up)

Diagnostic Aids

connection.

6E323
Wrong Security Code Entered
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6
Verify repair

Present Failure?


ignition cycle?

Body.

Was the any DTC's B**** stored in this ignition cycle?
release?
Replace the ECM.

No
6E324

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash
Code
56
Code
P1612
Symptom
Code
Circuit Description
MIL
DTC Name
Immobilizer No or Wrong Signal

Code A) is recorded when received immobilizer
challenge signal was not correct.

Received challenge signal is
Fail-Safe (Back Up)

Diagnostic Aids

connection.

6E325
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5
Verify repair
Go to Step 6

Present Failure?


ignition cycle?

Body.

Diagnositic Trouble Code.
Was the DTC B0007 stored in this ignition cycle?
Check for poor/faulty connection at the immobilizer

control unit connector or ECM connector. If a poor/
C-56
No
42
35
B-68
6E326
Step
6

Action

lamp circuit.
Value(s)
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair

2. Disconnect the meter connector and immobilizer
control unit connector.
3. Ignition On.

Was DVM indicated specified value?
B-68
V
Less than 1V

Step
7
Action

lamp circuit.
6E327
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8

3. Disconnect the immobilizer control unit connector.

circuit.
Breaker Box
42
B-68
!
!

2. Disconnect the the immobilizer control unit


circuit.
C-56
42
B-68
6E328
Step
8

Action
Using the DVM and check the ECM and immobilizer

control unit communication circuit.
Value(s)
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 10

3. Ignition On.

B-68
V
9


circuit.
Breaker Box
35
B-68
!
!


circuit.
C-56
B-68
35

Step
10
11
Action

release?
Replace the ECM.

6E329
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
6E330

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash
Code
56
Code
P1613
Symptom
Code
Circuit Description
MIL
DTC Name

response signal was not correct.

Fail-Safe (Back Up)

Diagnostic Aids

connection.

6E331
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6

Present Failure?


ignition cycle?

Body.

Diagnositic Trouble Code.
Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
C-56
No
42
35
B-68
6E332
Step
6

Action

lamp circuit.
Value(s)
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair

2. Disconnect the meter connector and immobilizer
control unit connector.
3. Ignition On.

Was DVM indicated specified value?
B-68
V
Less than 1V

Step
7
Action

lamp circuit.
6E333
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair


circuit.
Breaker Box
42
B-68
!
!



circuit.
C-56
42
B-68

3. Ignition On.

B-68
V
Less than 1V
6E334
Step
9

Action

Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair


circuit.
Breaker Box
35
B-68
!
!


circuit.
C-56
B-68
10
11
35

release?
Replace the ECM.


(FLASH CODE 56) WRONG TRANSPONDER KEY
6E335
Flash
Code
56
Code
P1614
Symptom
Code
Circuit Description
MIL
-
DTC Name

response signal was not correct from the transponder
key.

not correct from the transponder key.
Fail-Safe (Back Up)

Diagnostic Aids
connection.

6E336
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6
Verify repair

Present Failure?


ignition cycle?

Body.

release?
Replace the ECM.

IMPORTANT: The replacement ECM must e
No
6E337

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY
(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Flash
Code
76
Code
P1625
Symptom
Code
Circuit Description
MIL
DTC Name
OFF

Off Too Early
OFF

Off Too Late
The ECM switches ECM main relay to operate ECM

and other sensors or controller.

early.
Fail-Safe (Back Up)


late or does not off.
Diagnostic Aids

Poor connections.
Misrouted harness.
6E338



the Main Relay display on the Tech2 while moving
ECM Main Relay Switched Off Too Early
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Verify repair

Present Failure?
No


ignition cycle?
release?
Replace the ECM.

6E339
ECM Main Relay Switched Off Too Late
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
No continuitly
Go to Step 5
Replace ECM
main relay and
verify repair
Verify repair
Go to Step 6
Verify repair

Using the DVM and check the ECM main relay.

2. Remove the ECM main relay from the relay box.

3. Check the relay switch.
ECM Main Relay

!
"
#

release?
Replace the ECM.

6E340

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
Flash
Code
51
Code
P1630
Symptom
Code
MIL
DTC Name
ON
Fuel Injection Quantity Circuit

Malfunction
ON
Fuel Injection Quantity Circuit

Malfunction

detects high pressure solenoid valve control circuit malfunction due to high current.
Circuit Description

injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on

detects high pressure solenoid valve control circuit malfunction due to continuous
current.
programmed pump map data.
Fail-Safe (Back Up)

reduced.
valve) is operated.
becomes 0mg/strk.
Diagnostic Aids

Poor connections.
Misrouted harness.

6E341

Injection Quantity Circuit Malfunction
Injection Quantity Circuit Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair

(symptom Code B) stored as Present Failure?
No


(symptom Code B) stored in this ignition cycle?
6E342

(FLASH CODE 44) CAN DEVICE OFFLINE
(FLASH CODE 44) CAN DEVICE HANG-UP
Flash
Code
44
Code
P1650
Symptom
Code
MIL
ON
CAN Device Offline
ON
CAN Device Hang-up
Circuit Description
DTC Name

performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can
exchange information and data. This allows control
modules that are connected to different CAN-bus
systems to communicate.

CAN controller detects Busoff or canceling.
CAN controller does not react

under engine running.
Fail-Safe (Back Up)

valve) is operated.
Diagnostic Aids

Poor connections.
Misrouted harness.


6E343

CAN Device Offline
Step
1
Action

performed?
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 18
Go to Step 6
Go to Step 7
Repair faulty
harness and
verify repair

Present Failure?


ignition cycle?
C-57
Value(s)
E-6
100
99

Using the DVM and check the CAN high circuit.

No
2. Disconnect the ECM connector and PSG (pump

control unit) connector.
3. Check the circuit for short to CAN low circuit.

E-6
No continuity
6E344
Step
7

Action

Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
100
E-6
!
!

2. Disconnect the PSG (pump
connector.
control
unit)

circuit.
C-57
100
E-6

Step
8
Action
Using the DVM and check the CAN low circuit.

6E345
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Go to Step 10
Go to Step 11

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
99
E-6
!
!
!

connector.
control
unit)

circuit.
C-57
E-6
99

2. Disconnect
connector.
the
PSG
(pump
control
unit)

Was the DVM indicated battery voltage or
approximately 5V?
E-6
6E346
Step
10

Action

C-57
Yes
No
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-6
100
11
Value(s)

connector.
control
unit)

approximately 5V?
E-6
V
12

C-57
E-6
99
13

unit) ground circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6

Step
14
15
16
17
18
Action

interference.

release?

Replace the ECM.

Value(s)
Yes
6E347
No
Remove the
accessory parts
and verify repair
Go to Step 15
Verify repair
Go to Step 16
Go to Step 17
Go to Step 18
Verify repair
Verify repair
6E348
CAN Device Hang-up
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair


release?

Replace the ECM.


(FLASH CODE 45) CAN MALFUNCTION
6E349

(FLASH CODE 45) CAN RECEIVES ERROR
Flash
Code
45
Code
P1651
Symptom
Code
MIL
ON
CAN Malfunction
ON
CAN Malfunction
Circuit Description
DTC Name

performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can
exchange information and data. This allows control
modules that are connected to different CAN-bus

does not recognize CAN signal from the CAN controller.
The ECM does not read CAN

signal from the PSG (pump
control unit).
Fail-Safe (Back Up)

valve) is operated.
becomes 0mg/strk.
systems to communicate.
Diagnostic Aids

Poor connections.
Misrouted harness.
6E350



CAN Malfunction
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair

Present Failure?
No


ignition cycle?
release?

Replace the ECM.

6E351
CAN Receives Error
Step
1
Action

performed?

Present Failure?


ignition cycle?
Was the DTC P1650 (Symptom Code A) stored at the
same time?
E-6
100
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
C-57
Value(s)
Go to DTC
Chart P1650
(Symptom
Code A)
Verify repair
Go to Step 6
Go to Step 19
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 5
99
No


2. Disconnect the ECM connector and PSG (pump

control unit) connector.
3. Check the circuit for short to CAN low circuit.

E-6
No continuity
6E352
Step
8

Action

Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
100
E-6
!
!

connector.
control
unit)

circuit.
C-57
100
E-6

Step
9
Action

6E353
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Go to Step 12

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
Breaker Box
99
E-6
"
!
!

connector.
control
unit)

circuit.
C-57
E-6
99
10

2. Disconnect
connector.
the
PSG
(pump
control
unit)

approximately 5V?
E-6
6E354
Step
11

Action

C-57

2. Disconnect
connector.
Yes
No
Verify repair
Go to Step 13
Go to Step 14
Verify repair
Repair faulty
harness and
verify repair
Go to Step 15
E-6
100
12
Value(s)
the
PSG
(pump
control
unit)

approximately 5V?
E-6
V
13

C-57
E-6
99
14

unit) ground circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6

Step
15
16
17
18
19
Action

interference.

release?

Replace the ECM.

Value(s)
Yes
6E355
No
Remove the
accessory parts
and verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 19
Verify repair
Verify repair
6E356

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

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Flash
Code
77
Code
P1690
Symptom
Code
Circuit Description
MIL
DTC Name
OFF

Circuit Voltage Low
OFF

The Check Engine Lamp (Malfunction Indicator Lamp

=MIL) should always be illuminated and steady with
ignition On. Ignition feed voltage is supplied to the
Check Engine Lamp bulb through the meter fuse. The
ECM turns the Check Engine Lamp On by grounding
the check engine lamp driver circuit for a certain time.

Fail-Safe (Back Up)


Diagnostic Aids

Poor connections.
Misrouted harness.


6E357

the Check Engine Lamp display on the Tech2 while
moving connectors and wiring harnesses. A change
in the display will indicate the location of the fault.
Check Engine Lamp (MIL) Circuit Voltage Low
Step
1
4
5
6
7
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
No


ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
2. Check the Check Engine lamp.

Does the lamp turn On?
Go to Step 5
Go to Step 6
2. Check the Check Engine lamp.

Does the lamp turn Off?
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Check the Check Engine lamp bulb.

Check for poor/faulty connection at the meter

connector and ECM connector. If a poor/faulty
C-56
17
42
B-24
6E358
Step
8

Action
Using the DVM and check the Check Engine lamp

circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10


circuit.
Breaker Box
42
!"
B-24
!
!


circuit.
C-56
42
B-24
17

release?

Step
10
Action
Replace the ECM.

6E359
Value(s)
Yes
No
Verify repair
6E360
Check Engine Lamp (MIL) Circuit Voltage High
Step
1
Action

performed?
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No

Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair


release?

Replace the ECM.

SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the On-Board

Diagnostic (OBD) System Check and verify all of the
following items:
The engine control module (ECM) and check engine
lamp (MIL=malfunction indicator lamp are operating
correctly.
There are no Diagnostic Trouble Code(s) stored.
Tech 2 data is within normal operating range. Refer to

Typical Scan Data Values.
Verify the customer complaint and locate the correct

symptom in the table of contents. Perform the
procedure included in the symptom chart.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful

visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time. This check should include the following items:
ECM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper

connection. Check thoroughly for any type of leak or
restriction.
Air intake ducts for collapsed or damaged areas.
Air leaks at throttle body mounting area, mass air flow
(MAF) sensor and intake manifold sealing surfaces.
Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn

on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use
the Diagnostic Trouble Code (DTC) charts for
intermittent problems.
The fault must be present to locate the problem.
Most intermittent problems are cased by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions.
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should

be carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal form the connector body to
check.
Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
Poor ECM grounds. Refer to the ECM wiring

diagrams.
6E361
Road test the vehicle with a Digital Multimeter

connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Using Tech 2 to help detect intermittent conditions. The
Tech 2 have several features that can be used to
located an intermittent condition. Use the following
features to find intermittent faults:
To check for loss of diagnostic code memory,
disconnect the MAF sensor and idle the engine until the
check engine lamp (MIL=malfunction indicator lamp)
comes on. Diagnostic Trouble Code P0100 should be
stored and kept in memory when the ignition is turned
OFF.
If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
P0100 from memory.
An intermittent check engine lamp (MIL=malfunction
indicator lamp) with no stored Diagnostic Trouble Code
may be caused by the following:
Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM short to ground.
Poor ECM grounds. Refer to the ECM wiring

diagrams.
Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
to the ignition control module for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
If problem has not been found, refer to ECM connector
symptom tables.
Check the Broadcast Code of the ECM, and

compare it with the latest Isuzu service bulletins and/
or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECM's reprogrammable
memory has been released.
This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
If the Broadcast Code is not the most current
available, it is advisable to reprogram the ECM's
EEPROM memory, which may either help identify a
hard-to find problem or may fix the problem.
The Service Programming System (SPS) will not allow
incorrect software programming or incorrect calibration
changes.
6E362
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.
Step
1
Action

performed?
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?
Was a visually/physical check performed?
Is the fuel amount enough?
Is the customer using the incorrect fuel type?
Check the ECM fuse (10A) and Engine fuse (15A).

Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Go to Step 5
Add fuel to the

tank
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Go to Step 6
Restrict air intake system. Check for a restricted air

filter element, or foreign objects blocking the air
intake system
Check for objects blocking or excessive deposits in

the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
8
9
Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.

2. Monitor the Neutral Switch in the data display.
Does the Tech 2 indicate correct Neutral Switch
status depending on any shift positions?

Step
10
11
Action
6E363
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12

Go to Step 13
Go to Step 14
Verify repair
Internal muffler failure.

Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18

Check the CKP sensor harness for the following

conditions.
Check for poor connector connection.
Check for misrouted harness.
12
13
14
15
16
Check for any accessory parts which may cause

electric interference.

Check the exhaust system for a possible restriction.

Damaged or collapsed pipes or catalytic converter.

fuel hose/pipe.

fuel.

6E364
Step
17

Action

injection pump and check for the following conditions.
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 18
More than 2.1

Mpa (21.0 kg/
cm2)
Verify repair
Go to Step 19
Go to Step 20
Repair as
necessary

fuel.
18
19
Check the engine compression pressure for each

cylinders.
If the injection pump was replaced, are the timing

gears or injection pump correctly installed?

Step
20
Action
1. Review all diagnostic procedures within this table.
6E365
Value(s)
Yes
No
Verify repair
Go to Step 21
Verify repair
Go to Step 22
Go to Step 23
Go to Step 24
Verify repair
Verify repair
2. If all procedures have been completed and no

malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
21
22
23
24
All electrical connections within a suspected circuit

and/or system

release?

Replace the ECM.

6E366
HARD START SYMPTOM
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.
Step
1
Action

performed?

Value(s)
Yes
Go to Step 2
Verify repair
Go to Step 4
No
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
2. Check the displayed value.

Does the Tech 2 indicate correct temperature
depending on engine condition?
Verify repair
Go to Step 8

Go to Step 20
Go to Step 9
2. Monitor the Glow Time Relay in the data display.

Does the Tech 2 indicate correct Glow Time Relay
status depending on the time from ignition switch
On?
Go to Step 20
Go to Step 10
Go to Step 6

intake system

6
7

1. Using the Tech 2, display the ECT sensor and IAT

sensor value.
1. Using the Tech 2, display the FT sensor value.
1. Using the Tech 2, ignition On.

Step
10
11
12
13
14
Action
Yes
No
Go to Step 11
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 12

Verify repair
Go to Step 13

fuel.
Verify repair
Go to Step 14
Verify repair
Go to Step 15
1. Using the Tech 2, ignition On.
Value(s)
6E367
2. Monitor the Glow Time Relay in the data display

and then, does the supply voltage correctly supply
to the glow plug?
Check the glow plugs for continuity.


fuel hose/pipe.

6E368
Step
15

Action

Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 16
Replace the
injection nozzle
and verify repair
Go to Step 17
More than 2.1

Mpa
Verify repair
Go to Step 18

fuel.
16
Remove the injection nozzles from the engine and

Improper splay condition.
Operating pressure is incorrect.
1 st Stage
4JA1-TC
4JH1-TC
17
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

cylinders.

Step
18
19
Action
Check the inlet/exhaust valve clearance for each

valves.
Are the valve clearances within the specified value?
6E369
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 19
Adjust and
verify repair
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Verify repair

following:
Tech 2 data
20
21
22
23

and/or system

release?

Replace the ECM.

6E370
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM
DEFINITIONS: Engine runs unevenly at idle. If severe,

the engine or vehicle may shake. Engine idle speed
may vary in RPM. Either condition may be severe
enough to stall the engine.
rpm
Rough Idle
Stall
time
Step
1
Action

performed?

1. Check for incorrect idle speed. Ensure that the

following conditions are present.
Engine fully warm.
Accessories are OFF.
2. Using a Tech 2, monitor Desired Engine Idle

Speed and Engine Speed.
Is the Engine Speed within the specified values?
intake system
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Desired
Engine Idle
Speed 25
rpm
Go to Step 7
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 5




Step
8
10
11
12
13
6E371
Action
Value(s)
Yes
No

Verify repair
Go to Step 9
2. Monitor the A/C Information Switch in the data

display.
Does the Tech 2 indicate correct A/C Information
Switch status depending on A/C switch position?
Verify repair
Go to Step 10

Verify repair
Go to Step 11
2. Monitor the Mass Air Flow in the data display.

Does the Tech 2 indicate correct Mass Air Flow
depending on accelerator pedal operation?
Go to Step 16
Go to Step 12
Objects blocking at the MAF sensor element.

Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Go to Step 35
Verify repair
Go to Step 21
Go to Step 17
1. Using the Tech 2, ignition On and engine Run.

sensor value.

Check the MAF sensor harness for the following

conditions.
14
15
16


and recheck.

2. Monitor the Pedal/Throttle Position and Idle

Switch in the data display.
Does the Tech 2 indicate correct Pedal/Throttle
Position from 0% to 100% and correct Idle Switch
status depending on accelerator pedal operation?
6E372
Step
17
18

Action
Value(s)
Yes
No

3. Adjust the accelerator cable or TPS within 0% to
100%.
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Go to Step 36
Verify repair
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Go to Step 24
Go to Step 25
Verify repair
Check the TPS harness for the following conditions.

19
20
21
22


Replace the TPS.



conditions.
23
24

Substitute aknown good CKP sensorand recheck.


Step
25
Action
1. Using the Tech 2 and ignition On and engine

Run.
6E373
Value(s)
Yes
No
Go to Step 29
Go to Step 26
2. Monitor the following parameters in the data

display.
Desired Injection Quantity & Injection Quantity
Desired Injection Start & Actual Injection Start
Are the large gap or unstable parameter displayed
between Desired and Actual?
When idling or part-throttle
High
Desired
Actual
Low
Time
6E374
Step
26

Action
Value(s)
Yes
No
Verify repair
Go to Step 27

Verify repair
Go to Step 28

fuel.
Verify repair
Go to Step 29
Verify repair
Go to Step 30

deposit.
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
27
28
29
Small Window


fuel hose/pipe.


Step
30
Action

6E375
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 32
Replace the
injection nozzle
and verify repair
Go to Step 32
More than 2.1

Mpa
Verify repair
Go to Step 33

fuel.
31


1 st Stage
4JA1-TC
4JH1-TC
32
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

cylinders. Each cylinder must be evenly.
6E376
Step
33
34

Action

valves.
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 34
Adjust and
verify repair
Verify repair
Go to Step 35
Verify repair
Go to Step 36
Go to Step 37
Go to Step 38
Verify repair
Verify repair

following:
35
36
37
38
Tech 2 data
and/or system

release?

Replace the ECM.

6E377
SURGES AND/OR CHUGS SYMPTOM
DEFINITIONS: Engine power variation under steady

throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time
Step
1
Action

performed?


intake system
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7

display.
Verify repair
Go to Step 8
Go to Step 5


6
7

6E378
Step
8
10
11

Action
Value(s)
Yes
No

Verify repair
Go to Step 9

Go to Step 14
Go to Step 10

Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 29
Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 29
Verify repair

sensor value.


conditions.
12
13
14
15
16


and recheck.




100%.

17
18


Replace the TPS.


Step
19
20
Action


conditions.
6E379
Value(s)
Yes
No
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Go to Step 25
Go to Step 24

21
22
23




Run.
display.

High
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time
6E380
Step
24

Action

deposit.
Value(s)
Yes
No
Verify repair
Go to Step 25
Verify repair
Go to Step 26
Verify repair
Go to Step 27
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
25
26
Small Window


fuel hose/pipe.

fuel.


Step
27
Action

6E381
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 28
Verify repair
Go to Step 29
Verify repair
Go to Step 30
Go to Step 31
Go to Step 32
Verify repair

fuel.
28

following:
Tech 2 data
29
30
31

and/or system

release?

Replace the ECM.

6E382
Step
32

Action

Value(s)
Yes
No
Verify repair
6E383
HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the

accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Stumble
rpm
Sug
Hesitation
time
Step
1
Action

performed?

Check the torque converter clutch (TCC) for proper

operation (if A/T model). If a problem is found, repair
as necessary.
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 5

intake system



6E384
Step
8
10
11

Action
Value(s)
Yes
No

Verify repair
Go to Step 9

Go to Step 14
Go to Step 10

Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 31
Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 31
Verify repair

sensor value.


conditions.
12
13
14
15
16


and recheck.




100%.

17
18


Replace the TPS.


Step
19
20
Action


conditions.
6E385
Value(s)
Yes
No
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Go to Step 27
Go to Step 24

21
22
23




Run.
display.

High
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time
6E386
Step
24

Action
Value(s)
Yes
No
Verify repair
Go to Step 25

Verify repair
Go to Step 26

fuel.
Verify repair
Go to Step 27
Verify repair
Go to Step 28

deposit.
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
25
26
27
Small Window


fuel hose/pipe.


Step
28
Action

6E387
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 29
Verify repair
Go to Step 30
Verify repair
Go to Step 31
Go to Step 32
Go to Step 33
Verify repair

fuel.
29

following:
Tech 2 data
30
31
32

and/or system

release?

Replace the ECM.

6E388
Step
33

Action

Value(s)
Yes
No
Verify repair
CUTS OUT, MISSES SYMPTOM
DEFINITIONS: Steady pulsation or jerking that follows

engine speed; usually more pronounced as engine load
increases.
6E389
rpm
time
Step
1
Action

performed?


intake system
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 5



compressor
wheel or turbine shaft sticking.
6E390
Step
7

Action
1. Using the Tech 2, perform test drive.
Value(s)
Yes
No
Go to Step 11
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 31
Verify repair
Go to Step 16
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Go to Step 31
Verify repair
2. Monitor the Vehicle Speed in the data display.

Does the Tech 2 indicate correct Vehicle Speed
depending on driving speed?
When constant vehicle speed

High
Correct Speed
Unstable Data
Low
Time
9
10
11
12
13
Check the VSS harness for the following conditions.


Substitute a known good VSS and recheck.

Replace the VSS assembly.




conditions.
14
15


and recheck.


Step
16
17
18
6E391
Action
Value(s)
Yes
No

Go to Step 21
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Go to Step 31
Verify repair
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Go to Step 24
Go to Step 25
Verify repair


100%.

19
20
21


Replace the TPS.


22


conditions.
23
24



6E392
Step
25

Action

Run.
Value(s)
Yes
No
Go to Step 29
Go to Step 26

display.

High
Desired
Actual
Low
Time

Step
26
Action

deposit.
6E393
Value(s)
Yes
No
Verify repair
Go to Step 27
Verify repair
Go to Step 28
Verify repair
Go to Step 29
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
27
28
Small Window


fuel hose/pipe.

fuel.

6E394
Step
29

Action

Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 30
Verify repair
Go to Step 31
Verify repair
Go to Step 32
Go to Step 33
Go to Step 34
Verify repair

fuel.
30

following:
31
32
33
Tech 2 data
and/or system

release?

Replace the ECM.


Step
34
Action

6E395
Value(s)
Yes
No
Verify repair
6E396
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM
DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.
Step
1
Action

performed?

Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Verify repair
Go to Step 8

Go to Step 29
Go to Step 9

Go to Step 14
Go to Step 10
Go to Step 5

intake system

6
7


sensor value.

Step
10
11
Action
6E397
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12

Go to Step 13
Go to Step 29
Verify repair

Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 30
Verify repair


conditions.
12
13
14
15
16


and recheck.


100%.

17
18


Replace the TPS.

6E398
Step
19

Action

Run.
Value(s)
Yes
No
Go to Step 22
Go to Step 20
Verify repair
Go to Step 21

display.

Desired
High
When accelerated
Desired
High
Actual
Low
Actual
Low
Time
20
Time

deposit.
Tech 2:

Vacuum Pump:

valve.

Vacuum Pump
Small Window


Step
21
22
23
24
6E399
Action
Value(s)
Yes
No

Verify repair
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 25

fuel hose/pipe.

fuel.



fuel.
6E400
Step
25

Action

Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 26
More than 2.0

Mpa
Verify repair
Go to Step 27
0.4mm at cold
(In/Ex)
Go to Step 28
Adjust and
verify repair
Verify repair
Go to Step 29

1 st Stage
4JA1-TC
4JH1-TC
26
27
28
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

cylinders.

valves.

following:
Tech 2 data

and/or system

Step
29
30
31
32
Action

release?

Replace the ECM.

6E401
Value(s)
Yes
No
Verify repair
Go to Step 30
Go to Step 31
Go to Step 32
Verify repair
Verify repair
6E402
POOR FUEL ECONOMY SYMPTOM
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)
Step
1
Action

performed?

Check owner's driving habits.
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9
Verify repair
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Is the A/C On full time?
Are tires at the correct pressure?
Are excessively heavy loads being carried?

5
6
7
8
9
10
11
12
Is acceleration too much, too often?
Review the items in Step 4 with the customer and

advise as necessary.
Check for low engine coolant level.

Check for incorrect or faulty engine thermostat. Refer

to Engine Cooling.
Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?
Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
Check for proper calibration of the fuel gauge.

Check the torque converter clutch (TCC) for proper

operation (if A/T model). If a problem is found, repair
as necessary.


Step
13
14
6E403
Action
Value(s)
Yes
No

display.
Verify repair
Go to Step 14

Verify repair
Go to Step 15

Verify repair
Go to Step 16

Go to Step 31
Go to Step 17

Go to Step 22
Go to Step 18

Verify repair
Go to Step 19
Verify repair
Go to Step 20

intake system


15
16
17
18
19

sensor value.


conditions.

6E404
Step
20
21
22
23
24
25
26
27

Action
Value(s)
Yes
No

Go to Step 21
Go to Step 31
Verify repair

Go to Step 27
Go to Step 23

100%.
Verify repair
Go to Step 24
Verify repair
Go to Step 25
Go to Step 26
Go to Step 31
Verify repair
Replace the
injection nozzle
and verify repair
Go to Step 28

and recheck.




Replace the TPS.



1 st Stage
4JA1-TC
4JH1-TC
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

Step
28
29
30
Action

cylinders.

valves.
6E405
Value(s)
Yes
No
More than 2.0

Mpa
Verify repair
Go to Step 29
0.4mm at cold
(In/Ex)
Go to Step 30
Adjust and
verify repair
Verify repair
Go to Step 31
Verify repair
Go to Step 32
Go to Step 33
Go to Step 34

following:
Tech 2 data
31
32

and/or system

release?

6E406
Step
33
34

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair
Verify repair
EXCESSIVE WHITE SMOKE
Step
1
Action

performed?

Check the engine coolant consumption to verify that it

leaks to combustion chamber or exhaust through the
gasket.
6
7
10
11

sensor value.




conditions.
6E407
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 30
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 5


6E408
Step
12
13
14
15
16
17

Action
Value(s)
Yes
No

Go to Step 13
Go to Step 30
Verify repair
2. Monitor the Glow Time Relay in the data display.

Does the Tech 2 indicate correct Glow Time Relay
status depending on the time from engine Run?
Go to Step 30
Go to Step 15
Go to Step 16
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19

and recheck.

2. Monitor the Glow Time Relay in the data display
and then, does the supply voltage correctly supply
to the glow plug?
Check the glow plugs for continuity.


18


conditions.


Step
19
20
21
Action
6E409
Value(s)
Yes
No
Go to Step 20
Go to Step 21
Verify repair
Go to Step 23
Go to Step 22

Verify repair
Go to Step 23

fuel.
Verify repair
Go to Step 24
Verify repair
Go to Step 25



Run.
display.

High
Desired
When accelerated
High
Desired
Actual
Low
Low
Time
22
23
24
Actu al
Time

fuel hose/pipe.

6E410
Step
25

Action

Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 26
Replace the
injection nozzle
and verify repair
Go to Step 27

fuel.
26

1 st Stage
4JA1-TC
4JH1-TC
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

Step
27
28
29
Action

cylinders.

valves.
6E411
Value(s)
Yes
No
More than 20
Mpa
Verify repair
Go to Step 28
0.4mm at cold
(In/Ex)
Go to Step 29
Adjust and
verify repair
Verify repair
Go to Step 30
Verify repair
Go to Step 31
Go to Step 32
Go to Step 33

following:
Tech 2 data
30
31

and/or system

release?

6E412
Step
32
33

Action
Replace the ECM.

Value(s)
Yes
No
Verify repair
Verify repair
EXCESSIVE BLACK SMOKE
Step
1
Action

performed?

6E413
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Verify repair
Go to Step 8

Go to Step 21
Go to Step 9

Go to Step 14
Go to Step 10
Go to Step 5

intake system

6
7


sensor value.
6E414
Step
10
11

Action


conditions.
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 21
Verify repair
Go to Step 20
Go to Step 15

12
13
14


and recheck.


Run.

display.

High
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time

Step
15
Action

deposit.
6E415
Value(s)
Yes
No
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Tech 2:

Vacuum Pump:

valve.
Vacuum Pump
16
Small Window


6E416
Step
17

Action

Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 18
More than 20
Mpa
Verify repair
Go to Step 19
0.4mm at cold
(In/Ex)
Go to Step 20
Adjust and
verify repair
Verify repair
Go to Step 21

1 st Stage
4JA1-TC
4JH1-TC
18
19
20
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa

cylinders.

valves.

following:
Tech 2 data

and/or system

Step
21
22
23
24
Action

release?

Replace the ECM.

6E417
Value(s)
Yes
No
Verify repair
Go to Step 22
Go to Step 24
Go to Step 23
Verify repair
Verify repair
6E418
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE

(ECM)
Location
Under the left-hand side seat.
Removal Procedure
1. Disconnect the negative battery cable.

2. Remove the seat left-hand side.
3. Roll up the floor carpet.
4. Remove four bolts from the ECM cover.
5. Disconnect the two connectors from the ECM.
Installation Procedure
1. Connect the two connectors to the ECM.

2. Put on the ECM to the floor panel.
3. Tighten the ECM cover by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm)

4. Lay the floor carpet exactly.
5. Put on the seat to the floor panel and tighten with

specified tightening torque.
Tightening torque
Bolts: 40.0 Nm (4.1 kgfm)
6. Connect the negative battery cable.
NOTE: The replacement ECM must be programmed.

Refer to section of the Service Programming System
(SPS) in this manual.
Following ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 Immobilizer System-ECM replacement for the
ECM/Immobilizer linking procedure.
CRANKSHAFT POSITION (CKP)

SENSOR
ENGINE COOLANT TEMPERATURE

(ECT) SENSOR
Location
Installed to the clutch housing.
Location
Installed to the thermostat housing.
Removal Procedure
Removal Procedure
2. Disconnect connector from the CKP sensor.
3. Loosen a bolt and remove the CKP sensor from the

clutch housing.
6E419
2. Drain enough engine coolant so that the coolant

level will be below the ECT sensor.
3. Disconnect connector from the ECT sensor.
4. Loosen and remove the ECT sensor from the

thermostat housing.
NOTE: Cool down the engine before above procedures
are carried out.
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified

tightening torque.
Tightening Torque
Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm)
3. Connect a CKP sensor connector to the CKP

sensor.
NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.
1. Apply sealer to threads of screw at the ECT sensor.
2. Tighten the ECT sensor with specified tightening

torque.
Tightening Torque
Bolt: 13Nm (1.3kgfm)

3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.

Verify no engine coolant leaking from the sensor
threads after replacement.
6E420
MASS AIR FLOW (MAF) & INTAKE

AIR TEMPERATURE (IAT) SENSOR
THROTTLE POSITION SENSOR

(TPS)
Location
Installed to the intake duct housing.
Location
Installed on the throttle body.
Removal Procedure
Removal Procedure
2. Disconnect a MAF & IAT sensor connector from the

MAF & IAT sensor assembly.
3. Loosen the clips and remove the MAF & IAT sensor
assembly from the intake duct housing.
1. Install the MAF & IAT sensor assembly into intake

air duct.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF

& IAT sensor assembly.


3. Loosen two screws and remove TPS from the

throttle body.
1. Temporary tighten the TPS by two screws.

2. Connect a TPS connectors to the TPS.
3. Connect the Tech2 to the vehicle.

5. Select Data Display with the Tech2.
6. Check the throttle position data and adjust the TPS

position.
7. Tighten two screws.

EGR EVRV (Electrical Vacuum

Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.

3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the

bracket.
1. Tighten the purge solenoid by tow bolts.

2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.

Verify proper connection of two hoses.
6E421
6E422
ILLUSTRATION
SPECIAL SERVICE TOOLS
TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card
(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
EXHAUST SYSTEM 6F 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 6F - 2

General Description........................................................................................................... 6F - 3
Removal and Installation................................................................................................... 6F - 4
Inspection and Repair ....................................................................................................... 6F - 6

General Description........................................................................................................... 6F -7
EGR System Diagram ........................................................................................................ 6F 9

Inspection........................................................................................................................... 6F-11
EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12
Turbocharger ..................................................................................................................... 6F -15
Main Data and Specifications....................................................................................... 6F -15
General Description........................................................................................................... 6F -16

Inspection and Repair ....................................................................................................... 6F -17
Special Tools...................................................................................................................... 6F -19

IHI Service Network ........................................................................................................... 6F -20
6F 2 EXHAUST SYSTEM

!"#$%&'(')&
&
&
*(')&#+%,(-)&-(./)%)"&0&%1(23$),,&
//4($5&
&
&
&
!#"&>?&/#-)@A&2.%.@(%(2&2#$B)"%)"&(,&
&
&
&
2#/C($)-&%#&%1)&D"#$%&'(')8&
E(--@)&'(')&
&
&
//4($5&
*(')&#+%,(-)&-(./)%)"&0&%1(23$),,&
&
6789&0&:8;&4<87&0&787;=5&
&
6789&0&:8;&4<87&0&787;=5&
F(@)$2)"&G&%.(@&'(')&
&
&
&
HI')&
&
?("2+@."&,)2%(#$J,1)@@&2#$,%"+2%(#$&
&
&
&
#D&-#+C@)&,3($&.$-&)$-&'@.%),A&
&
&
&
($%)"$.@&2#$,%"+2%(#$&#D&C.DD@),&
&
&
&
.$-&')"D#".%)-&%+C),8&
&
H.(@&'(')&#+%,(-)&-(./)%)"&0&%1(23$),,&
//4($5&
6789&0&:8;&4<87&0&787;=5&
&
K)$L%1&
//4($5&
M''"#0(/.%)@I&:==6&46<8;5&
E#+$%($L&
&
&
&
N+/C)"&#D&,+,')$,(#$&'#($%,&
&
O&
&
HI')&
&
P+CC)"&
EXHAUST SYSTEM 6F 3
GENERAL DESCRIPTION
RTW46FLF000201
The exhaust pipe layout is described in the above illustration.

The catalytic coverter is installed between the turbocharger and the front pipe.
6F 4 EXHAUST SYSTEM
RTW46FLF000101
Removal Steps
1. Rear hanger rubber

2. Silencer front nut
3. Exhaust silencer
4. Silencer hanger rubber
5. Middle pipe nut
6. Front hanger rubber

7. Front pipe nut
8. Exhaust pipe gasket
EXHAUST SYSTEM 6F 5
Important Operations Installation
1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque
N!m (kg!m/lb!ft)
67 (6.8/49)
2. Middle pipe Nut (4!

!4 only)
Connect the middle pipe to the front pipe.
Torque
N!m (kg!m/lb!ft)
43 (4.4/32)
3. Silencer Front Nut

Connect the silencer to the front or middle pipe.
Torque
N!m (kg!m/lb!ft)
43 (4.4/32)
6F 6 EXHAUST SYSTEM

inspection.
Front Exhaust Pipe

Exhaust Silencer
Check the pipes for corrosion, cracking, damage or
misalignment and repair as required.
Check the rubber rings for deterioration or damage and repair
as required.
Catalytic Converter
1. Inspect outside the catalytic converter for any hitting mark.

2. Visual check inside the catalytic converter for crack or break
converter element.
3. If find any problem during the inspection, replace the
catalytic converter assembly.
EXHAUST SYSTEM 6F 7
GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
RTW46ELF001201
6F 8 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and emissions section for detail.
RTW46ELF001101
EXHAUST SYSTEM 6F 9
EGR SYSTEM DIAGRAM 4JA1T (L)
RTW46AMF000301
EGR System Operation
Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
Inspection point (Engine RPM)
RPM
Idling
900 " 960
2000
3250
Engine Rear Side VSV-2
ON
OFF
ON
OFF
Engine Front Side VSV-1
ON
ON means VSV should receive signal to move EGR valve.

OFF means VSV shouldnt receive signal to move EGR valve.
ON
ON
OFF
6F 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and
emissions section for detail.
RTW46EMF000701
INSPECTION
EXHAUST SYSTEM 6F 11
4JA1T(L)
Vacuum switch valve (VSV)

Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance
# at 20C
37 ~ 44
If the resistance is not within specification, replace it.
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure
Less then 180 mmHg
Not operation
More than 240 mmHg
Operation
4JA1TC/4JH1TC
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance
# at 20C
14
If the resistance is not within specification, replace it.
RTW46ESH000301
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure 4JH1TC
Less than 250 mmHg
More than 300 mmHg
Not operation
Operation
Negative Pressure 4JA1TC

Less than 100 mmHg
More than 170 mmHg
Not operation
Operation
EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)

RTW46EMF000201
Removal Steps
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly

8. Gasket
9. Bolt
10. EGR Cooler Assembly
11. Gasket
12. EGR Cooler Adapter
Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
8. Gasket
9. Bolt
11.Gasket
12.EGR Cooler Adapter
RTW46EMF000901
Installation steps
1. EGR Cooler Adapter

2. Gasket
4. Gasket
5. Bolt
7. Bolt
8. Bolt
9. Gasket
10. EGR Valve Assembly
11. Bolt
12. EXH Manifold
13. Gasket
14. Bolt
Installation
1.
2.
3.
4.
EGR Cooler Adapter

Gasket
EGR Cooler Assembly
Bolt
EGR adapter bolt torque
27(2.8/20)
N!m(kg!m/lb ft)
5. Gasket
7. Bolt
Tighten bolts temporarily.
8. Bolt
9. Gasket
10. Bolt
11.Gasket
12.Bolt
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing
surface.
Bolt torque (Cooler-pipe) N!m(kg!m/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) N!m (kg!m/lb ft)

24(2.4/17)
Bolt torque (Adapter-EGR valve) N!m (kg!m/lb ft)

27(2.8/20)
Bolt torque (Pipe-manifold) N!m (kg!m/lb ft)

27(2.8/20)
TURBOCHARGER

Engine
Model
Turbine type
Compressor type
Maximum permissible speed rpm

IHI : Ishikawajima Harima Heavy Industries., Ltd.
4JA1T(L)
IHI RHF4H
190,000
4JA1TC
IHI RHF4H
Mixed type
Backword & rake type

190,000
4JH1TC
IHI RHF5
180,000
GENERAL DESCRIPTION
036LV002
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.

inspection.
Turbocharger pressure check

1. Remove the hose between the master gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To compressor outlet
pipe.
3. Start the engine and gradually increase the engine
speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to
approximately 300 mmHg.
Pressure Gauge : 5-8840-0075-0
150RY00030
Waste gate operation check

1. Remove the hose between the waste gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To waste gate actuator.
3. Check to see that the rod begins to move when a
pressure of approximately 665 mmHg is applied to the
waste gate.
Note:
2
Do not apply a pressure greater than 1 kg/cm to the
wastegate during this check.
150RY00031
Unit Inspection (Remove Turbo. from engine)

Check to see the pressure required to move the control
rod 2 mm is within the limits shown below.
Kpa/mmHg
4JH1TC
4JA1TC
150RY00032
134.8/1011
147.7/1108
Contact the ISUZU MOTORS LIMITED Dealer service

department or IHI SERVICE FACILITY for major repairs
and maintenance.
Important wheel shaft end play and bearing clearance
standards and limits are included below for your reference.
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the
compressor wheel end and the turbine wheel end.
Wheel Shaft End Play
mm (in)
Standard
0.03 - 0.06
(0.001 - 0.002)
150RY00034
0.09 (0.004)
Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and
bearing clearance.
Wheel Shaft and Bearing Clearance
mm (in)
Standard
0.056 - 0.127
(0.0022 - 0.0050)
150RY00036
Limit
Limit
0.127 (0.0050)
SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
5-8840-0075-0
901RX00143
TOOL NAME
Pressure Gauge
IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL:
81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, Peoples Republic of CHINA
TEL:
86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX:
210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL:
886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX:
11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL:
66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX:
82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL:
60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX:
IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL:
62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX:
44175 IHIJKT
ACCELERATOR CONTROL
6H 1
SECTION 6H
ACCELERATOR CONTROL
TABLE OF CONTENTS
PAGE
Removal and Installation............................................................................................... 6H -
Removal...................................................................................................................... 6H -
Installation.................................................................................................................. 6H -
Inspection................................................................................................................... 6H -
6H 2 ACCELERATOR CONTROL

4JA1T(L)/RHD
RTW46HLF000301
ACCELERATOR CONTROL
6H 3
4JA1T(L)/LHD
RTW46HLF000601
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
ACCELERATOR CONTROL
6H 5
4JA1TC, 4JH1TC/LHD
PTW46BMF000101
Removal
1. Disconnect the accelerator control cable from the

accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator
control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90!.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if

any abnormality is found.
" The control cable should move smoothly.
" The control cable should not be bent or kinked.
" The control cable should not be damage or
corrosion.
RTW46HMH000201
Installation
1. Install the accelerator control cable to accelerator

control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of
engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90!
until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.
NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.
No. TF4JE-WE-0431

Isuzu Dmax Engine Service Manual

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Isuzu Dmax Engine Service Manual

Transféré par

Droits d'auteur :

Formats disponibles

WORKSHOP MANUAL

BASIC INSPECTION PROCEDURE ... 6 2

1. HARD STARTING ........................... 6 3

1-2. Starter Motor Operates But

1-3. Engine Turns Over But Does

11. ROTATING PART WEAR OF

12. OIL LEAKAGE FROM

2. UNSTABLE IDLING ........................ 6 5

14. BATTERY CHARGING AND

14-2. Battery Overcharging ............ 6 16

3. INSUFFICIENT POWER ................. 6 6

5. EXCESSIVE OIL CONSUMPTION.. 6 8

8. DARK EXHAUST SMOKE .............. 6 10

10-1. Engine Knocking.................... 6 12

10-3. Continuous Noise .................. 6 13

10-4. Slapping Noise ....................... 6 13

10-5. Excessive Turbocharger

14-1. Battery No Charging .............. 6 16

14-4. Battery Unstable Charging

14-5. Charging System Noise......... 6 18

15. STARTER MOTOR PROBLEM..... 6 19

15-1. Starter Motor Pinion Engages

15-3. Starter Motor Continues To

15-4. Excessive Commutator

Basic Inspection Procedure

Check the check engine lamp

Is the check engine lamp turn

The engine coolant capacity

Was the problem found?

The engine oil level

Was the problem found?

The air cleaner element

Was the problem found?

The piping fixing condition (oil, Was the problem found?

The drive belt tension and break

Was the problem found?

Go to section 6E On Board Was the problem found?

Inspect the following items before diagnosis.

Check the starter switch.

Check the starter relay.

Check the magnetic switch.

Check the pinion gear condition on the starter motor.

Check the engine internal seizure.

1-3 Engine turn over but does not start engine

Incase of the fuel not being delivered to the injection pump

Check clogged, damaged the fuel piping or the

Incase of the fuel is being delivered to the injection pump

Was the water contain in the fuel?

Was the fuel line air bled?

Was the injection spray condition complete?

Was the injection nozzle sticking?

Are any DTC stored?

Injection nozzle opening pressure

Bleed the air

Bleed the air

Was the fuel line air bled completely?

Was the fuel line leakage or blockage found?

Was the water contained in the fuel?

Was the fuel filter element clogged?

Was the injection starting pressure or the injection

Was the injection nozzle sticking?

Check the throttle valve condition.

Was the valve clearance improper adjusted?

Was the compression pressure OK?