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 PAGE
BASIC INSPECTION PROCEDURE ... 6 2 11. ROTATING PART WEAR OF
1. HARD STARTING ........................... 6 3 TURBOCHARGER ............................. 6 14
1-1.Starter Motor Inoperative ......... 6 3 12. OIL LEAKAGE FROM

TURBOCHRGER ............................... 6 15
1-2. Starter Motor Operates But
Engine Does Not Turn Over .......... 6 3 13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
1-3. Engine Turns Over But Does TO TURBOCHARGER ....................... 6 15
Not Start Engine ............................. 6 4
14. BATTERY CHARGING AND
2. UNSTABLE IDLING ........................ 6 5 NOISE PROBLEM.............................. 6 16
3. INSUFFICIENT POWER ................. 6 6 14-1. Battery No Charging .............. 6 16
4. EXCESSIVE FUEL 14-2. Battery Overcharging ............ 6 16
CONSUMPTION................................. 6 7
14-3. Battery Under Charging......... 6 17
5. EXCESSIVE OIL CONSUMPTION.. 6 8
14-4. Battery Unstable Charging
6. OVERHEATING............................... 6 9 Current ............................................ 6 17
7. WHITE EXHAUST SMOKE ............. 6 9 14-5. Charging System Noise......... 6 18
8. DARK EXHAUST SMOKE .............. 6 10 15. STARTER MOTOR PROBLEM..... 6 19
9. OIL PRESSURE DOES NOT RISE . 6 11 15-1. Starter Motor Pinion Engages
10. ABNORMAL ENGINE NOISE ....... 6 12 to Ring Gear But Engine Does
Not Turn Over ................................. 6 19
10-1. Engine Knocking.................... 6 12
15-2. Incorrect Pinion And Ring
10-2. Gas Leakage Noise ................ 6 12 Gear Engagement .......................... 6 19
10-3. Continuous Noise .................. 6 13 15-3. Starter Motor Continues To
10-4. Slapping Noise ....................... 6 13 Run After The Starter Switch Is
Turned Off....................................... 6 20
10-5. Excessive Turbocharger
Noise ............................................... 6 14 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 Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn Go to section
ON ? 6E On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the Was the problem found? Re-charge the
gravity battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil, Was the problem found? Return normal
vacuum and fuel piping) condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E On Board Was the problem found?
Diagnostic (OBD) System
Check Verify repair Go to Step 9
9 Go to mechanical Was the problem found?
troubleshooting chart 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 Action Value(s) Yes No
1 Check the starter switch. Repair or
Does the starter switch work? replace the
Go to Step 2 starter switch
2 Check the starter relay. Repair or
Does the starter relay work? replace the
Go to Step 3 starter relay
3 Check the magnetic switch. Repair or
Does the magnetic switch work? replace the
magnetic
Go to Step 4 switch
4 Check the pinion gear condition on the starter motor. Replace the
Was the condition normal? Go to Step 5 pinion gear
5 Check the brush wear or brush spring weakness. Repair or
Was the condition normal? Replace the replace the
starter motor brush or brush
assembly spring
1-2 Starter motor operates but engine does not turn over
1 Check the engine internal seizure. Check other
Was the engine seized? Repair or DTC by Tech
replace seized 2 and go to
parts 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
1 Check clogged, damaged the fuel piping or the
connector loosen. Repair replace
Was any problem found? problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? Repair replace
the over flow
valve Go to Step 3
3 Was the fuel filter element clogged? Replace the
fuel filter
element Go to Step 4
4 Was the fuel line air bled? Go to Step 5 Bleed the air
5 Are any DTC stored? Go to indicated
DTC Solved
Incase of the fuel is being delivered to the injection pump

1 Was the water contain in the fuel? Replace the
fuel Go to Step 2
2 Was the fuel line air bled? Go to Step 5 Bleed the air
3 Was the injection spray condition complete?
Replace the
Go to Step 4 injection nozzle
4 Was the injection nozzle injection starting pressure (See below)
OK? Replace the
5 Was the injection nozzle sticking? Replace the
injection nozzle Go to Step 6
DTC Solved
Injection nozzle opening pressure

1st = 19.5 MPa (199 kg/cm , 2828 psi)
2
TROUBLESHOOTING 6 5
2. Unstable Idling
1 Was the fuel line air bled completely? Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection (See below)
spray condition OK? Replace the
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition. Repair or
Was the idling port clogged in the throttle valve? replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valves valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa Readjust the
(31 kg/cm , valve clearance
2
441 psi) at or replace the

200rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
Go to Step 11 and valve seat
DTC Solved

1st = 19.5 MPa (199 kg/cm , 2828 psi)
2
6 6 TROUBLESHOOTING
3. Insufficient Power
1 Was the air cleaner element condition OK? (Clogged Clean or
or not) replace the air
cleaner
Go to Step 2 element.
2 Was the intake air leakage found from intake Repair or
system? replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged Clean or
or not) replace the fuel
Go to Step 4 filter element.
4 Check the fuel injection pipes. Repair or
Does the injection pipes have obstruction or any replace the fuel
damage? injection pipes. Go to Step 5
5 Was the water contained in the fuel? Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern Readjust the
normal? injection nozzle
pressure or
replace the
Go to Step 7 nozzle.
7 Was the compression pressure OK? 3.0 MPa Readjust the
(31.0 kg/cm , valve clearance
2

200 rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
8 Was the exhaust pipe clogged? Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust Repair or
system? replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or Replace the
cracked? hose. Go to Step 11
11 Was the waste gate working completely? Replace the
turbocharger
Go to Step 12 assembly.
12 Was turbocharger working completely? Replace the
turbocharger
DTC Solved
TROUBLESHOOTING 6 7
4. Excessive Fuel Consumption

1 Was the air cleaner element clogged? Clean or
replace the air
cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of Repair or
the turbocharger? replace the air
intake side of
the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? Replace the
Go to Step 4 turbocharger
4 Was there the fuel leakage? Repair or
replace the fuel
leakage part. Go to Step 5
2

gasket or
cylinder liner or
piston or piston
ring or valve
6 Was the injection nozzle pressure or spray pattern
normal?
Replace the
DTC Solved
6 8 TROUBLESHOOTING
5. Excessive Oil Consumption

1 Does the air cleaner element conditon OK? (Clogged Clean or
or not) replace the air
cleaner
Go to Step 2 element
2 Does PCV (Positive Crankcase Ventilation) Valve Repair or
has problem? replace the
relation parts. Go to Step 3
3 Was the oil pressure value more than normal value? Less than
588 kPa (6.0 Repair or
kg/cm , 85 replace the oil
2
psi) relief valve Go to Step 4

4 Inspect the front and rear crankshaft oil seal. Replace the
Was the oil leakage found? failure part. Go to Step 5
5 Was the oil leakage found from any gasket? Replace the
wrong gasket Go to Step 6
6 Inspect the valve stem seal, the valve stem and the
valve guide for worn. Replace the
Were any worn found? worn part. Go to Step 7
7 Was the oil leakage found from the turbocharger oil Replace the oil
seal? seal. Go to Step 8
8 Was the oil drain pipe of the turbocharger restricted? Repair or
replace the oil
drain pipe. Go to Step 9
9 Was the oil drain passage in the turbocharger center Clean the
housing restricted? center housing Go to Step 10
10 Does turbine wheel has any impact damage? Replace the
turbocharger Go to Step 11
DTC Solved
TROUBLESHOOTING 6 9
6. Overheating
1 Was the engine coolant level OK? Replenish the
Go to Step 2 coolant
2 Was the water leakage or the radiator restriction Repair or
found? (Include radiator cap) replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? Replace the
fan clutch
5 Was the oil leakage found from fan clutch? Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? Replace the
Go to Step 7 thermostat.
7 Was the water pump working OK? Replace the
water pump
8 Was the restriction by the foreign materials in the Clean or
cooling system found? For example, clog the water replace the
hose between the cylinder body and radiator etc.. clog part. Go to Step 9
9 Was the water leakage found from the sealing cap Replace the
on the cylinder body? sealing cap or
replace the
cylinder body. Go to Step 10
DTC. Solved
7. White Exhaust Smoke

2

gasket or
cylinder liner or
piston or piston
ring or valve
and relation
Go to Step 2 parts.
2 Was the PCV (Positive Crankcase Ventilation) valve Repair or
working completely? replace the
Go to Step 3 PCV valve.
3 Was the turbocharger working completely? Replace the
Go to Step 4 turbocharger.
DTC Solved
6 10 TROUBLESHOOTING
8. Dark Exhaust Smoke

1 Was the air cleaner element normal condition? Clean or
replace the air
cleaner
Go to Step 2 element
2 Was the EGR valve sticking? Replace the
EGR valve Go to Step 3
3 Was the injection nozzle pressure or the injection
spray pattern OK?
Replace the
4 Was the oil leakage found from the turbocharger oil Replace the oil
seal? seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted? Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the Clean the
turbocharger center housing restricted? center housing Go to Step 7
7 Does turbine wheel has any impact damage? Replace the
8 Does PCV (Positive Crankcase Ventilation) Valve Repair or
has problem? replace the
relation parts Go to Step 9
DTC Solved
TROUBLESHOOTING 6 11
9. Oil Pressure Does Not Rise

1 Was the oil pressure warning lamp working OK? Replace the oil
pressure
Go to Step 2 warning lamp
2 Does the oil filter element clog? Replace the oil
filter element Go to Step 3
3 Does the relief valve open? Repair or
replace the
relief valve Go to Step 4
4 Does the oil strainer clog? Clean or
replace the oil
strainer Go to Step 5
5 Was the oil pump working OK? (The pump related Repair or
parts worn etc.) replace the oil
Go to Step 6 pump.
6 Was the rocker arm and/or relation parts worn? Replace the
rocker arm
and/or relation
parts Go to Step 7
7 Was the camshaft and/or relation parts worn? Replace the
camshaft
and/or relation
parts Go to Step 8
8 Was the crankshaft and/or relation parts worn? Replace the
crankshaft
and/or relation
parts Go to Step 9
DTC Solved
Table of pressure unit

Pressure kPa (kg/cm ) 100 980
2
(1.0) (10.0)
Resistance ohm 81 30
Electric current A 63.5 106.7
10. Abnormal Engine Noise

101 Engine knocking
1 Was the injection nozzle pressure or injection spray
pattern OK?
Replace the
2 Was the compression pressure OK? 3.0 MPa Replace the
(31.0 kg/cm , cylinder head
2
441 psi) at gasket or

200 rpm Go to Step 3 piston ring
DTC Solved
102 Gas leakage noise

1 Was the exhaust pipe loose or broken? Retighten or
replace the
exhaust pipe Go to Step 2
2 Was the exhaust manifold loose? Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket Go to Step 3
3 Was the injection nozzle loose? Retighten or
replace the
injection nozzle
fixing bolt Go to Step 4
4 Was the cylinder head gasket broken? Replace the
cylinder head
gasket Go to Step 5
DTC Solved
103 Continuous noise

1 Was the fan belt tension OK? 9 13 mm
(0.35 0.51
in)
Adjust the fan

Go to Step 2 belt tension.
2 Was the cooling fan loose? Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? Repair or
replace the
generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? Readjust the
valve
clearance. Go to Step 6
DTC Solved
10-4 Slapping noise

1 Was noise coming from the cylinder head cover? Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in) Adjust the
both intake valve
and exhaust clearances Go to Step 3
3 Were the rocker arms damaged? Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft. Replace the
Was the crankshaft bearing and/or crankshaft worn? worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin.
Was the connecting rod bearing and/or crankpin Replace the
worn? worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or
piston pin.
Was the connecting rod small end bushing and/or Replace the
piston pin worn? worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner. Replace the
Was the piston and/or cylinder liner worn or worn or
damaged? damaged parts Go to Step 10
DTC 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.
1 Was the excessive noise coming from the
turbocharger? Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands. Tighten the
Was any problem found? loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged? Replace the
damaged
gasket. Go to Step 4
4 Inspect rotation parts condition. Replace the
Was the turbine wheel rotation rough? turbocharger. Go to Step 5
5 Inspect the turbine wheel. Replace the
Was the turbine wheel rubbing against housing? turbocharger. Go to Step 6
6 Was the turbine wheel damaged? Replace the
7 Were there carbon deposits in the turbine or Clean or
compressor housing? replace the
8 Inspect the oil supply condition. Repair or
Was the oil feed pipe clogged? replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? Replace the
DTC Solved
11. Rotating Part Wear of Turbocharger

1 Inspect engine oil. Replace the
Was it contaminated with foreign materials? engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity API CD or
being used? ISUZU
genuine/
10W30 Replace the
Go to Step 3 engine oil
3 Was the oil feed pipe restricted? Clean or
replace the oil
feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? Clean center
housing or
replace the
6 Was there oil sludge and/or coking on the turbine Replace the
shaft? turbocharger Go to Step 7
DTC Solved
12. Oil Leakage from Turbocharger

1 Inspect the oil leakage area. Tighten the eye
Was the oil feed pipe eye bolt loose or the gasket bolt or replace
broken? the gasket. Go to Step 2
2 Were the V band fixing faces tight? Tighten band
or replace the
3 Was there oil leakage from the flange of the turbine Replace the
housing? turbocharger Go to Step 4
4 Was there oil leakage from the flange of compressor Tighten the bolt
housing? and/or hose
clamp. Go to Step 5
DTC Solved
13. Insufficient Acceleration and/or Lack of Power due to turbocharger

1 Inspect the air or exhaust route. Tighten flange
Was the air and/or exhaust gas piping loose? bolts or hose
clamp. Go to Step 2
2 Inspect the work of waste gate valve control.
Was there rust on the linkage rod or pin of the waste Replace the
gate valve? turbocharger Go to Step 3
3 Was air leakage found from the actuator piping? Repair or
replace the
actuator pipe or
hose/ Go to Step 4
4 Inspect the inside of the turbocharger. Replace the
Was the turbine shaft end nut loose? turbocharger Go to Step 5
5 Were the turbine blades bent? Replace the
6 Was the turbine wheel rubbing against housing? Replace the
DTC 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
1 Was Visual/Physical Check" performed. Go to
visual/physical
Go to Step 2 check
2 Inspect the brush contact condition on the generator. Repair or
Was there poor contact between the brush and the replace the
slip ring? brush and/or
the slip ring. Go to Step 3
3 Inspect the stator coil on the generator.
Was there an open circuit or the scorching on the Replace the
stator coil? stator coil. Go to Step 4
4 Inspect the rotor coil on the generator.
Was there an open circuit or the scorching on the Replace the
rotor coil? rotor coil. Go to Step 5
5 Inspect the rectifier on the generator. Replace the
Was the rectifier defective? rectifier Go to Step 6
6 Inspect the IC regulator. Replace the IC
Was the IC regulator defective? regulator. Go to Step 7
DTC. Solved
14-2 Battery Overcharging

visual/physical
Go to Step 2 check
2 Inspect the terminal circuit. Repair the
Were the B and F terminals shorted? short circuit. Go to Step 3
3 Check the regulating voltage. Replace the IC
Was the IC regulator voltage excessive? regulator. Go to Step 4
DTC. Solved
14-3 Battery Under Charging

visual/physical
Go to Step 2 check
Was there intermittent contact between the brush replace the
and the slip ring? brush holder
assembly. Go to Step 3
3 Inspect the rotor coil on the generator. Repair or
Was there a short circuit in the rotor coil? replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator. Repair or
Was there an open circuit or the short circuit on the replace the
5 Inspect the rectifier on the generator. Replace the
Was the rectifier defective? rectifier Go to Step 6
6 Inspect the IC regulator on the generator. Replace the IC
7 Was the electrical load excessive? Replace more
higher capacity
generator. Go to Step 8
DTC. Solved
14-4 Battery Unstable Charging Current

visual/physical
Go to Step 2 check
Was there poor contact between the brush and the replace the
slip ring? brush and/or
the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator. Repair or
Was there the short circuit or an open circuit in the replace the
rotor coil? rotor coil. Go to Step 4
4 Inspect the stator coil on the generator. Repair or
Was there an open circuit or the short circuit in the replace the
5 Inspect the connection between the rectifier and
stator coil on the generator. Repair the
Was there a loose connection between the rectifier loose
and stator coil ? connection. Go to Step 6
6 Inspect the IC regulator on the generator. Replace the IC
DTC. Solved
14-5 Charging System Noise

visual/physical
Go to Step 2 check
2 Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and Replace the
decreasing engine speed? bearing. Go to Step 3
3 Was there a growling sound and does this sound Replace the
stop when the connector was disconnected? stator coil. Go to Step 4
4 Was intermittent sound heard when the generator Replace the
was running? brush and/or
slip ring. Go to Step 5
5 Was frictional sound heard when generator was Clean the slip
running? ring or replace
the brush. Go to Step 6
DTC. 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
visual/physical
Go to Step 2 check
2 Check the contact condition between the brush and Replace the
the commutator. brush or repair
Was the brush and the commutator contact the
intermittent? commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty? Clean contact
face Go to Step 4
4 Was the pinion clutch slipped? Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil. Repair or
Was there an open circuit or a short circuit in the replace the
armature field coil? armature field
coil. Go to Step 6
DTC. Solved
15-2 Incorrect pinion and ring gear engagement

visual/physical
Go to Step 2 check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or Replace the
broken? wron parts. Go to Step 3
3 Inspect the pinion gear return movement. Adjust or
Was the pinion gear return movement incorrect? replace the
movement
parts. Go to Step 4
DTC. Solved
15-3 Starter motor continues to run after the starter switch is turned off
visual/physical
Go to Step 2 check
2 Inspect the magnetic switch contact point. Repair or
Was the contact point seized? replace the
magnetic
switch. Go to Step 3
3 Inspect the starter switch. Replace the
Was the starter switch defective? starter switch. Go to Step 4
DTC. Solved
15-4 Excessive commutator sparking

visual/physical
Go to Step 2 check
2 Inspect the contact condition between the brush and Replace the
the commutator. brush or repair
Was the brush and the commutator contact the
intermittent? commutator. Go to Step 3
3 Was there the slag accumulation on the contact Clean the
face? contact face or
replace the
brush. Go to Step 4
4 Was the brush holder loose? Repair the
brush holder Go to Step 5
5 Inspect the commutator. Repair or
Was there excessive wear or pitting? replace the
commutator. Go to Step 6
6 Was there loose the solder on the commutator? Clean and
repair Go to Step 7
7 Inspect the armature shaft.
Was the run-out of armature shaft outside the Replace the
standard value due to worn bearing ? bearing Go to Step 8
DTC. Solved
ENGINE MECHANICAL 6A 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
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
4JA1T (L) 4JA1TC
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 Gear drive
No. of cylinders-bore ! stroke mm (in) 4 93 ! 92 (3.66 ! 3.62)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement cm (in ) 2,499(152.4)
3 3
Compression ratio (to 1) 18.5

Compression pressure Mpa(kg/cm /psi) 3.0 (31.0/441) 200 rpm
2
Engine weight (dry) kg (lb) Approximately 239 (527)

Fuel injection order 134-2
Fuel injection timing BTDC deg 8 -
Specified fuel type JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm 730 " 25 (A/C Off)
850 " 25 (A/C ON)
Valve clearances (At cold): Intake mm (in) 0.4 (0.016)
Exhaust mm (in) 0.4 (0.016)
Intake valves Open at (BTDC) deg 24.5
Close at (ABDC) deg 55.5
Exhaust valves Open at (BBDC) deg 54.0
Close at (ATDC) deg 26.0
Fuel system
Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed Electronically controled
type)
Injection nozzle type Hole with 5 orifices
Mpa(kg/cm /psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2
2nd (Reference) 2nd (Reference)

25.5#27.0 34.0#35.5
(260#275 / 3,702#3,920) (347#362 / 4,936#5,154)
Main fuel filter type 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)
Engine model
4JA1T (L) 4JA1TC
Item
Oil pump type Gear
Oil filter type Cartridge paper element
Oil capacity lit (US/UK gal) 6.2 (1.64/1.36)
Oil cooler type Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage ! No. of units 80D26L ! 1
95D31L ! 1 (OPT)
Generator capacity V-A 12 60
12 80
Starter motor output V-Kw 12 2.3
Turbocharger model *IHI RHF 4H
Turbine type Mixed flow type
Compressor type Backward & rake
*IHI : Ishikawajima-Harima Heavy Industries., Ltd.


Engine model
4JH1TC
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 Gear drive
No. of cylinders-bore ! stroke mm (in) 4 95.4 ! 104.9 (3.76 ! 4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter 2,999
Compression ratio (to 1) 18.3
Compression pressure MPa(kg/cm /psi) 3.0 (31.0/441) 200 rpm
2
Engine weight (dry) kg (lb) MT : Approximately 249 (549)

AT : Approximately 236 (520)
Fuel injection order 134-2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm 700 ! 25 (A/C OFF)
800 ! 25 (A/C ON)
Valve clearances (At cold): Intake mm (in) 0.4 (0.016)
Exhaust mm (in) 0.4 (0.016)
Intake valves Open at (BTDC) deg 24.5
Close at (ABDC) deg 55.5
Exhaust valves Open at (BBDC) deg 54.0
Close at (ATDC) deg 26.0
Fuel system
Injection pump type BOSCH distributor VP44 type
Injection nozzle type Hole with 5 orifices
MPa(kg/cm /psi)
2
1st 19.5 (199/2,828)
2nd (Reference) 34.3#35.8 (350#365/4,980#5,197)
Main fuel filter type 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 Gear
Oil filter type Cartridge paper element
Oil capacity lit (US/UK gal) 6.2 (1.64/1.36) (For 4 ! 2)
7.0 (1.85/1.54) (For 4 ! 4)
Oil cooler type Water cooled
Engine model
4JH1TC
Item
Cooling system
Water pump type Centrifugal
Air cleaner type Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
80D26L ! 1
Battery type/voltage ! No. of units
95D31L ! 1 (OPT)
75D26R ! 2 (OPT for EC, MT)
80D26R ! 2 (OPT for EC, AT)
12 60/12 80
Generator capacity V-A
12 2.3
Starter motor output V-Kw
*IHI RHF5
Turbocharger model
Mixed flow type Radial-inflow
Turbine type
Backward & rake type Radial-outflow
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
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 8.8
Class 4.8 (4T) (7T) 9.8 (9T)
Refined Non-Refined
Bolt
Identification
Bolt
Diameter !
Pitch (mm)
M 6 ! 1.0 5.88 1.96 7.35 2.45 -
(0.60 0.20/4.33 1.44) (0.75 0.25/5.43 1.80)
M 8 ! 1.25 12.74 ! 4.90 17.15 5.39 23.52 6.86
(1.30 0.50/9.40 3.62) (1.75 ! 0.55/12.66 ! 4.00) (2.40 0.70/17.36 5.06)
M 10 ! 1.25 27.44 6.86 36.75 9.31 49.98 12.74
(2.80 0.70/20.25 5.06) (3.75 0.95/27.12 6.87) (5.10 1.30/36.89 9.40)
M 12 ! 1.25 61.25 12.25 75.95 15.19 94.57 19.11
(6.25 1.25/45.21 9.04) (7.75 1.55/56.06 11.21) (9.65 1.95/69.80 14.10)
M 14 ! 1.5 95.55 19.11 116.13 ! 23.03 142.10 28.42
(9.75 1.95/70.52 14.10) (11.85 2.35/85.71 17.00) (14.50 2.90/104.88 21.00)
M 16 ! 1.5 130.34 26.46 169.54 34.30 199.92 40.18
(13.30 2.70/96.20 19.53) (17.30 3.50/125.13 25.32) (20.40 4.10/147.55 29.66)
M 18 ! 1.5 188.16 37.24 244.02 49.00 287.14 57.82
(19.20 3.80/138.87 27.49) (24.90 5.00/180.10 36.17) (29.30 5.90/211.93 42.67)
M 20 ! 1.5 257.74 51.94 337.12 67.62 395.92 79.38
(26.30 5.30/190.23 38.33) (34.40 6.90/248.82 49.41) (40.40 8.10/292.21 58.59)
M 22 ! 1.5 332.22 81.34 453.25 90.65 530.18 105.84
(33.90 8.30/245.20 60.03) (46.25 9.25/334.53 66.91) (54.10 10.80/391.30 78.12)
M 24 ! 2.0 448.84 90.16 570.36 140.14 691.88 138.18
(45.80 9.20/331.27 66.54) (58.20 14.30/420.96 103.43) (70.60 14.10/510.65 101.99)
* M 10 ! 1.5 26.46 6.86 36.26 8.82 48.02 11.76
(2.70 0.70/19.53 5.06) (3.70 0.90/26.76 6.50) (4.90 1.20/35.44 8.68)
* M 12 ! 1.5 56.84 11.76 70.56 13.72 89.18 17.64
(5.80 1.20/41.95 8.68) (7.20 1.40/52.08 10.13) (9.10 1.80/65.82 13.02)
* M 14 ! 2.0 89.18 17.64 109.76 21.56 133.28 26.46
(9.10 1.80/65.82 13.02) (11.20 2.20/81.01 15.91) (13.60 2.70/98.37 19.53)
* M 16 ! 2.0 124.46 24.50 161.70 32.34 191.10 38.22
(12.70 2.50/91.86 18.08) (16.50 3.30/119.34 23.87) (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 Nm (kgm/lbft)
Pipe diameter mm Pipe diameter mm

Torque Torque
(in) (in)
4.76 (0.187) 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)
6.35 (0.250) 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)
8.00 (0.315) 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)
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 Brand Name Manufacturer Remarks
RTV* ThreeBond 1207B Three Bond
Silicon Base ThreeBond 1207C Three Bond
Water Base ThreeBond 1141E Three Bond
ThreeBond 1215 Three Bond
Solvent ThreeBond 1104 Three Bond
Belco Bond 4 Isuzu
Belco Bond 401 Isuzu
Belco Bond 402 Isuzu
Anaerobic LOCTITE 515 Loctite Recommended for
LOCTITE 518 Loctite transaxle repairs
LOCTITE 262 Loctite
* 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 Application Steps
1. Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
LOCTITE 242 Blue
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
LOCTITE 262 Red
LOCTITE 270 Green
3. Tighten the bolts to the specified torque.

LOCTITE 271 Red 4. Wait at least one hour before continuing the installation procedure.
1. Completely remove lubricant and moisture from the connecting

surfaces.
The surfaces must be perfectly dry.
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.
LOCTITE 515 Violet
3. Tighten the bolts to the specified torque.

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

Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm /psi)
2
130RY00003
392 490 (4 5/57 71)
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
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
6A-6
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 MAX lit (US/UK gal)

Condition
Without oil
Engine Dry With oil filter
filter
replacement
replacement
Model
4!2 6.2 (1.64/1.36) 5.2 " 4.2 4.5 " 3.5
4!4 (1.37 " 1.11 (1.19 " 0.93
(4JA1L/TC) / 1.14 " 0.92) / 0.99 " 0.77)
4!2 6.2 (1.64/1.36) 5.2 " 4.2 4.5 " 3.5
(4JH1TC) (1.37 " 1.11 (1.19 " 0.93
/ 1.14 " 0.92) / 0.99 " 0.77)
4!4 7.0 (1.85/1.54) 6.2 " 5.2 5.3 " 4.3
(4JH1TC) (1.64 " 1.37 (1.72 " 1.14
/ 1.36 " 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. Place the drain pan under the drain plug.

2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. 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
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
Except EURO III model the glow indicator lamp turns off.
RTW46ASH002901
5. Turn the ignition switch to the "START" position and
For EURO III model 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.
RTW46ASH000501
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 9.4 (2.5 / 2.1)

M/T: 10.1 (2.7 / 2.2)
4JH1TC
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
pressure in the cooling system at 103 kPa(1.05 kg/cm ,
2
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
kPa(kg/cm /psi)
2
030LX002
90 120 (0.9 1.2/13 17)
Negative Valve (Reference) kPa(kg/cm /psi)

2
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)
82 (180)
030LX014
Oil Cooler Thermo Valve $C ($F)
76.5 (170)
EGR Cooler Thermo Valve $C ($F)
40 (104)
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature $C ($F)
95 (203)
Oil Cooler Thermo Valve $C ($F)
90 (194)
EGR Cooler Thermo Valve $C ($F)
55 (131)
Valve Lift at Fully Open position mm (in)
9.5 (0.37)
Oil Cooler Thermo Valve mm (in)
4.5 (0.18)
EGR Cooler Thermo Valve mm in)
3.5 (0.14)
Drive Belt Adjustment

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
033RY00002
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 Nm (kgm /lbft)

54 (5.5/40)
014RY00014
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.
014RY00015
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)
9. Loosen each valve clearance adjusting screw as

shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness
014RY00016 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.
014RY00017
COMPRESSION PRESSURE
MEASUREMENT
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
F06XL056 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 MPa (kg/cm /psi) at 200 rpm

2
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)
5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.
901R100003 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.
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.
RTW46ASH000601
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 mm (in)

0.5 (0.02)
RTW46ASH000701 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 When smaller than standard
value value
R 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 lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
M/T: 10.1 (2.7 / 2.2)
4JH1TC
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 11. Vacuum pump gasket
2. Head cover gasket 12. Water pump O-ring
3. Head cover cap nut gasket 13. Water outlet pipe gasket
4. Drain cock gasket 14. Intake pipe gasket
5. Crankshaft rear oil seal 15. Thermostat housing gasket
6. Gear case gasket 16. Intake manifold gasket
7. Oil pan drain plug gasket 17. Exhaust manifold gasket
8. Oil pan gasket 18. Nozzle holder O-ring
9. Oil filter gasket 19. Nozzle holder gasket
10. Joint bolt 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 15. Oil Pressure Warning Switch
2. Intake Pipe and Throttle Body 16. Fuel Leak Off Pipe
3-1. EGR Pipe 17. Oil Cooler Water Pipe
3-2. EGR cooler (EURO III model only) 18. Cooling Fan Pulley
4. EGR Valve 19. Heat Protector
5. Oil Level Gauge 20. Catalytic Converter
6. Fuel Filter Assembly (Except EURO III) 21. Turbocharger
7. Fuel Filter Bracket (Except EURO III) 22. Compressor Bracket
8. Fuel Injection Pipe with Clip 23. Vacuum Pump Oil Return Hose
9. Power Steering Oil Pump Bracket 24. Generator and Adjusting Plate
10. Intake Manifold 25. Water Inlet Pipe
11. Engine Mounting Bracket and Foot 26. Generator Bracket
12. Injection Pump Cover 27. Oil Cooler with Oil Filter
13. Injection Pump 28. Exhaust Manifold
14. Starter Motor
Removal
1. Clutch Assembly or Flex Plate
Remove the clutch assembly or the flex plate.
2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)

4JA1L
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)
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
3-1. EGR Pipe

4JA1L
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
4JA1"L
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.
RTW46ASH001001
5. Oil Level Gauge

1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level
gauge.
4JA1"TC
RTW46ASH000901
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.
8. Fuel Injection Pipe with Clip
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
4JH1"TC entry of foreign material.
RTW36ASH001201
9. Power Steering Oil Pump Bracket

10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Remove the intake manifold with gasket.
RTW36ASH000701
11. Engine Mounting Bracket and Foot

12. Injection Pump Cover
13. Injection Pump

Rrefer to secton 6C-19 (Injection Iump)
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
027R100007
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:
037RY00001
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
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
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1. Water bypass hose 5. Rocker arm shaft and rocker
2. Thermostat housing with thermo arm
switch 6. Push rod
3. Cylinder head cover 7. Cylinder head
4. Injection nozzle and bracket 8. Cylinder head gasket
RTW46ALF000101
Disassembly Steps-2
9. Crankshaft damper pulley
10. Timing gear case cove
11. Water pump
12. Idle gear "B" and shaft
13. Idle gear "A"
14. Idle gear shaft
15. Crankshaft timing gear
16. Injection pump
014R300005
Disassembly Steps-3
17. Flywheel 27. Piston and connecting rod with
18. Crank case upper bearing
19. Oil pump with oil pipe 28. Crankshaft bearing cap with
20. Camshaft timing gear lower bearing
21. Camshaft thrust plate 29. Crankshaft thrust bearing
22. Camshaft 30. Crankshaft
23. Timing gear case 31. Crankshaft upper bearing
24. Cylinder body rear plate 32. Tappet
25. Piston cooling oil jet 33. Crankshaft rear oil seal
26. Connecting rod bearing cap with 34. Cylinder body
lower bearing
Disassembly
1. Water Bypass Hose
2. Thermostat Housing with Thermo Switch
3. Cylinder Head Cover
4. Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.
011R100002
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
011RY00005
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
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
011RY00007
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
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.
020L200020
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.
020RY00019
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 mm (in)

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

Standard Limit
RTW36ASH000801
0.07 (0.0028) 0.2 (0.0079)
14. Idle Gear Shaft

4JA1T(L)
15. Crankshaft Timing Gear
040R300009
4JA1TC/4JH1TC 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
RTW36ASH001301
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
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.
Camshaft End Play mm (in)

Standard Limit
0.050 - 0.114 0.20
014RT0001
(0.002 - 0.0044) (0.008)
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.
901R100008
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
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.
052RY00001
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
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.
015LX018
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.
Crankshaft End Play mm (in)

Standard Limit
015RY00002
0.10 (0.004) 0.30 (0.012)
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
31. Crankshaft Upper Bearing

If the crankshaft upper bearings are to be reinstalled, mark
015RY00004
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.
015RY00005
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. Rocker arm shaft snap ring 5. Rocker arm shaft spring
2. Rocker arm 6. Rocker arm shaft snap ring
3. Rocker arm shaft bracket 7. Rocker arm shaft
4. Rocker arm
Disassembly
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.
011RY00010
4. Rocker Arm
5. Rocker Arm Shaft Spring
7. Rocker Arm Shaft
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1. Intake manifold 6. Intake and exhaust valve
2. Intake manifold gasket 7. Valve stem oil seal
3. Split collar 8. Valve spring lower seat
4. Valve spring upper seat 9. Cylinder head
5. Valve spring
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
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
011RY00011 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. Connecting rod bearing 4. Piston pin
2. Piston ring 5. Connecting rod
3. Piston pin snap ring 6. 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
3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.
F06MV015
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.
RTW36ASH001601
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 mm (in)

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

Standard
91.95 92.05
(3.620 3.624)
011RY00014
Positive Crankcase Ventilation (PCV) Valve
1. Remove PCV valve assembly from cylinder head cover.
2. Inspect the diaphragm for broken.
3. Inspect the spring for broken or weaken.
4. 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.
Manifold Fitting Face Warpage mm (in)

027RY00001
Maximum Grinding
Standard Limit
Allowance
0.05 0.20 0.40
(0.002) or less (0.008) (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 mm (in)

Standard Limit
0.05 (0.002) or less 0.20 (0.008)
027RY00002
Valve Stem and Valve Guide Clearance

Measuring Method-I
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.
011RY00022
Valve Stem Clearance mm (in)

Standard Limit
0.039 - 0.071 0.200
Intake Valve
(0.0015 - 0.0028) (0.008)
0.064 - 0.096 0.250
Exhaust Valve
(0.0025 - 0.0038) (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) mm (in)

12.8-13.2 (0.50-0.52)
NOTE:
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 mm (in)

Standard Limit
7.946 - 7.961 7.880
Intake Valve
(0.3128 - 0.3134) (0.3102)
011LX027
7.921 - 7.936 7.850
Exhaust Valve
(0.3119 - 0.3124) (0.3090)
Valve Thickness
Measure the valve thickness.
Intake and Exhaust Valve Thickness mm (in)

Standard Limit
4JA1T (L) 1.8 (0.07) 1.5 (0.06)
4JA1TC, Inlet 1.34 (0.054)

014RY00020
1.1 (0.045)
4JH1TC Exhaust 1.36 (0.055)
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 mm (in)

014RY00021 Standard Limit
4JA1T(L) 0.72 (0.029) 1.28 (0.050)
4JA1TC, 4JH1TC 1.17 (0.048) 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 mm (in)

Standard Limit
014RY00027 Intake 1.7 (0.067) 2.2 (0.087)
Exhaust 2.0 (0.079) 2.5 (0.078)
Valve Seat Insert Replacement

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
011LX039
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 Degree

45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
011LX037
3. Apply abrasive compound to the valve seat insert surface.

4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with
the entire circumference of the valve.
011LX038
Valve Spring Free Height

Use a vernier caliper to measure the valve spring free height.
spring must be replaced.
Spring Free Height mm (in)

Standard Limit
4JA1T (L)
4JA1TC, Single spring 48.0 (1.89) 47.1 (1.85)
011LX024 4JH1TC
Valve Spring Squareness

Use a surface plate and a square to measure the valve spring
squareness.
Spring Squareness mm (in)

Limit
4JA1T (L)
014RY00025 4JA1TC, Single spring 1.7 (0.070)
4JH1TC
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
Valve Spring Tension N (kg/lb)

Compressed
Standard Limit
Height
4JA1T (L)
Single 38.9mm 296.0 257.7
4JA1TC,
011LX026
spring (1.53in) (30.2/66.4) (26.3/57.9)
4JH1TC

Rocker Arm Shaft Run-Out
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
015LX008 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 mm (in)

Standard Limit
18.9819.00 (0.7470.748) 18.90 (0.744)
015LX009
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 mm (in)

Standard Limit
19.01019.030
19.100 (0.752)
(0.7480.749)
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 mm (in)

Standard Limit
0.010.05
0.20 (0.008)
(0.00040.0020)
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 mm (in)

Standard Limit
0.05 (0.002) or less 0.20 (0.008)
012R100001
Cylinder Body Height (H) (Reference) mm (in)

Standard
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.
Cylinder Liner Bore mm (in)

012RY00010
Standard Limit
4JA1T(L), 4JA1TC 93.00 (3.6614) 93.08 (3.6646)
4JH1TC 95.40 (3.7559) 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 mm (in)

Standard
012LX016 0-0.1 (0-0.004)
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

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.
012RY00012
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 mm (in)

Standard
-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 mm (in)
Liner
Cylinder Body Liner Outside Liner Bore
Outside Service Liner Bore Measurement
Bore Diameter Diameter Grade
Grade
95.001-95.010 95.011-95.020 AX 93.035-93.050 (3.6628-3.6634)
1
(3.7402-3.7405) (3.7406-3.7409) CX 93.051-93.066 (3.6634-3.6640)
95.011-95.020 95.021-95.030 AX 93.035-93.050 (3.6628-3.6634)
2
(3.7406-3.7409) (3.7410-3.7413) CX 93.051-93.066 (3.6634-3.6640)
95.021-95.030 95.031-95.040 AX 95.035-93.050 (3.6628-3.6634)
3
(3.7410-3.7413) (3.7414-3.7417) CX 93.051-93.066 (3.6634-3.6640)
95.031-95.040 95.041-95.050 AX 93.035-93.050 (3.6628-3.6634)
4
(3.7414-3.7417) (3.7418-3.7421) CX 93.051-93.066 (3.6634-3.6640)
4JH1TC mm (in)
Liner
Cylinder Body Liner Outside Liner Bore
Outside Service Liner Bore Measurement
Bore Diameter Diameter Grade
Grade
97.001-97.010 97.011-97.020 AX 95.435-95.450 (3.7573-3.7579)
1
(3.8189-3.8193) (3.8193-3.8197) CX 95.451-95.466 (3.7579-3.7585)
97.011-97.020 97.021-97.030 AX 95.435-95.450 (3.7573-3.7579)
2
(3.8193-3.8197) (3.8197-3.8200) CX 95.451-95.466 (3.7579-3.7585)
97.021-97.030 97.031-97.040 AX 95.435-95.450 (3.7573-3.7579)
3
(3.8197-3.8200) (3.8200-3.8205) CX 95.451-95.466 (3.7579-3.7585)
97.031-97.040 97.041-97.050 AX 95.435-95.450 (3.7573-3.7579)
4
(3.8200-3.8205) (3.8205-3.8209) CX 95.451-95.466 (3.7579-3.7585)
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:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
012RY00017
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 mm (in)

Grade Bore measurement
93.035-95.050
AX
4JA1T(L) (3.6628-3.6634)
4JA1TC 93.051-95.066
CX
(3.6634-3.6640)
95.435-95.450
AX
(3.7573-3.7579)
4JH1TC
95.451-95.466
CX
(3.7579-3.7585)
NOTE:
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 mm (in)

4JA1T(L)
78 (3.07)
4JA1TC
4JH1TC 70 (2.76)
Piston Grade (Service Part) mm (in)

92.949 - 92.964
AX
015LX021 4JA1T(L) (3.6549 - 3.6600)
4JA1TC 92.965 - 92.980
CX
(3.6600 - 3.6606)
95.359 - 95.374
AX
(3.7542 - 3.7548)
4JH1TC
95.375 - 95.390
CX
(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

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
014RY00028
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 mm (in)

Standard Limit
12.97 - 12.99
12.95 (0.510)
014RY00029 (0.510 - 0.511)
Tappet and Cylinder Body Clearance mm (in)

Standard Limit
0.01 - 0.046
0.10 (0.004)
(0.0004 - 0.0018)
012LX014
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 mm (in)
014RY00031
Limit
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 mm (in)

Standard Limit
49.945 - 49.975
49.60 (1.953)
014RY00032 (1.9663 - 1.9675)
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) mm (in)

Standard Limit
42.016 (1.6542) 41.65 (1.640)
014RY00033
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 mm (in)

Standard Limit
014LX092 0.02 (0.0008) 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 mm (in)

Standard Limit
50.00 - 50.03
50.08 (1.972)
(1.968 - 1.970)
If the clearance between the camshaft bearing inside diameter

014RY00034
and the journal exceeds the specified limit, the camshaft

bearing must be replaced.
Camshaft Bearing Clearance mm (in)

Standard Limit
0.055 (0.0022) 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
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
014RY00036
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.
Crankshaft Run-Out mm (in)

015LX061
Standard Limit
0.05 (0.002) or less 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 mm (in)

Limit
4JA1T (L),
64.5 (2.54)
Creankshaft Bearing 4JA1TC
015RY00007 4JH1TC 74.5 (2.93)
Connecting Rod Bearing 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 mm (in)
Standard Limit
4JA1T (L), 59.921-59.928
59.91 (2.3586)
4JA1TC (2.3591-2.3594)
69.917-69.932
4JH1TC 69.91(2.7524)
(2.7526-2.7532)
Crankpin Diameter mm (in)

Standard Limit
52.915 - 52.930
52.90 (2.083)
(2.0833 - 2.0839)
Crankshaft Journal and Crankpin Uneven Wear mm (in)

Standard Limit
0.05 (0.002) or less 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 mm (in)

Standard Limit
0.032 - 0.077
0.110 (0.0043)
015RY00009
(0.0013 - 0.0030)
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.
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
015RY00011 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.
Crankpin and Bearing Clearance mm (in)

Standard Limit
4JA1T (L), 0.029-0.066
0.100(0.0039)
4JA1TC (0.0011-0.0026)
0.029-0.083
4JH1TC 0.100 (0.0039)
(0.0011-0.033)
Clearance Measurements (With Plastigage)

Crankshaft Journal and Bearing Clearance
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
015RY00012
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 mm (in)

167 (17/123)
Do not allow the crankshaft to turn during bearing cap

installation and tightening.
8. Remove the bearing cap.
015RY00013
015LX129
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
015LX060 exceeds the limit, the crankshaft and/or the bearing
must be replaced.
Crankshaft Journal and Bearing Clearance mm (in)

Standard Limit
0.032 - 0.077
0.110 (0.0043)
(0.0013 - 0.0030)
Crankpin and Bearing Clearance

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.

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.
Crankpin and Bearing Clearance mm (in)

Standard Limit
4JA1T (L), 0.029-0.066
0.100 (0.0039)
4JA1TC (0.0011-0.0026)
0.029-0.083
4JH1TC 0.100 (0.0039)
(0.0011-0.0033)
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:
The crankshaft journal mark No. 4 is stamped on
015RY00016
crankshaft No. 4 journal web front side or rear side.
REFERENCE
4JA1T(L), 4JA1TC mm (in)

Crankshaft
Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Grade Grade Size Code
Diamaeter Diamaeter
Mark Mark
1 or 59.927-59.932
- (2.3593-23.595)
63.992- Brown or 4
64.000 2 or 59.922-59.927
015RY00017
1
(2.5194- -- (2.3591-2.3539)
2.5197)
3 or 59.917-59.922
Yellow or 5
--- (2.3589-2.3591)
1 or 59.927-59.932
Black or 2
- (2.3593-2.3595)
63.983-
63.992 2 or 59.922-59.927
2 Blue or 3
(2.5190- -- (2.3591-2.3593)
2.5194)
3 or 59.917-59.922
Brown or 4
--- (2.3589-2.3591)
1 or 59.927-59.932
RTW46ASH002501
Green or 1
- (2.3593-2.3595)
63.975-
63.983 2 or 59.922-59.927
3
(2.5187- -- (2.3591-2.3593)
2.5190) Black or 2
3 or 59.917-59.922
--- (2.3598-2.3591)
4JH1TC mm (in)
Crankshaft
Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Grade Grade Size Code
Diamaeter Diamaeter
Mark Mark
1 or 69.927-69.932
- (2.7530-2.7532)
73.992- 4
74.000 2 or 69.922-69.927
1
(2.9131- -- (2.7528-2.7530)
2.9134)
3 or 69.917-69.922
5
--- (2.7556-2.7528)
1 or 69.927-69.932
2
- (2.7530-2.7532)
73.983-
73.992 2 or 69.922-69.927
2 3
(2.9127- -- (2.7528-2.7530)
2.9131)
3 or 69.917-69.922
4
--- (2.7556-2.7528)
1 or 69.927-69.932
1
- (2.7530-2.7532)
73.975-
73.983 2 or 69.922-69.927
3
(2.9124- -- (2.7528-2.7530)
2.9127) 2
3 or 69.917-69.922
--- (2.7526-2.7528)
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
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.
015RY00019 flywheel must be replaced.
Flywheel Friction Surface Depth (1) mm (in)

Standard Limit
4JA1T (L),
20 (0.7874) 21 (0.8267)
4JA1TC
4JH1TC 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
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.
020LX009
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
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)
015RY00020
3. Use a feeler gauge to measure the piston ring gap.

piston ring must be replaced.
Piston Ring Gap mm (in)

4JA1T (L), 4JA1TC
Standard Limit
1st Compression Ring 0.3-0.3
2nd Compression Ring (0.0118-0.0197) 1.5
015RY00021
(0.059)
0.250-0.450
Oil Ring
(0.0098-0.0177)
4JH1TC
Standard Limit
1st Compression Ring 0.3-0.5
2nd Compression Ring (0.0118-0.0197) 1.5
(0.059)
0.250-0.450
Oil Ring
(0.0098-0.0177)
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.
Piston Ring and Piston Ring Groove Clearance mm (in)

015LX025 4JA1T (L), 4JA1TC
Standard Limit
0.09-0.125
1st Compression Ring
(0.0035-0.0049)
0.05-0.085 0.15
2nd Compression Ring
(0.0020-0.0033) (0.0059)
0.03-0.070
Oil Ring
(0.0012-0.0028)
4JH1TC
Standard Limit
0.09-0.130
1st Compression Ring
(0.0035-0.0051)
0.05-0.090 0.15
2nd Compression Ring
(0.0020-0.0035) (0.0059)
0.03-0.070
Oil Ring
(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 mm (in)

Standard Limit
015LX026 30.995-31.000 30.97
(1.2202-1.2204) (1.2193)
Piston Pin and Piston Clearance

Use and inside dial indicator to measure the piston pin hole (in
the piston).
Piston Pin Hole mm (in)

4JA1T (L) 31.002-31.010 (1.2206-1.2208)
4JA1TC, 4JH1TC 31.005-31.013 (1.2207-1.2210)
Piston Pin and Piston Pin Hole Clearance mm (in)

015RW048
4JA1T (L) 0.002-0.015 (0.00008-0.0006)

4JA1TC, 4JH1TC 0.005-0.018 (0.0002-0.0007)
CYLINDER HEAD GASKET SELECTION

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
011LX011 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 1-

2 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 mm (in)

Cylinder Head Gasket Combination
4JA1T (L), 4JA1TC mm (in)
Gasket Thickness
Gasket Grade Mark Piston Projection
(Reference)
0.718-0.773 1.6
A
(0.0283-0.0304) (0.0630)
0.773-0.819 1.65
B
(0.0304-0.0322) (0.0650)
011RY00030
0.819-0.874 1.70
C
(0.0322-0.0344) (0.0669)
4JH1TC mm (in)
Gasket Thickness
Gasket Grade Mark Piston Projection
(Reference)
0.215-0.265 1.3
A
(0.0085-0.0104) (0.5118)
0.265-0.315 1.35
B
(0.0104-0.0124) (0.5315)
0.315-0.365 1.4
C
(0.0124-0.0144) (0.5512)
NOTE:
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)
Standard Limit
Distortion 0.08 (0.003) or Less 0.20 (0.008)
Parallelism 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.
Connecting Rod Big End and Crankpin Side Face Clearance

mm (in)
011RY00029
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.
Piston Pin and Connecting Rod Small End

015LX028 Bushing Clearance mm (in)
Standard Limit
0.008-0.020
4JA1T (L) 0.050 (0.002)
(0.003-0.0008)
4JA1TC, 0.005-0.018
0.050 (0.002)
4JH1TC (0.0002-0.0007)
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.
Idler Gear "A" Shaft Outside Diameter mm (in)

Standard Limit
020RY00025
44.945-44.975
44.845 (1.755)
(1.7695-1.7707)
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 mm (in)

Standard Limit
45.0-45.03
45.10 (1.7756)
(1.7717-1.7718)
014LX022
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 mm (in)

Standard Limit
0.025-0.085
0.200 (0.0079)
(0.0010-0.0033)
TIMING GEAR CASE COVER

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

Oil Seal Removal
Use a plastic hammer and a screwdriver to tap around the oil
seal to free it from the gear case cover.
020R300004
Take care not to damage the oil seal lip surfaces.
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.
020R300005
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. Rocker arm shaft 5. Rocker arm
2. Rocker arm shaft snap ring 6. Rocker arm shaft spring
3. Rocker arm 7. Rocker arm shaft snap ring
4. Rocker arm shaft bracket
Reassembly
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
014RY00037 5. Rocker Arm
6. Rocker Arm Shaft Spring
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1. Cylinder head 6. Valve spring upper seat
2. Valve spring lower seat 7. Split collar
3. Valve stem oil seal 8. Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5. Valve spring
Reassembly
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
011RW027
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
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.
014RY00039
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 Nm(kgm/lbft)

Bolt 19 (1.9/14)
RTW46ASH002301
Nut 24 (2.4/17)
PISTON AND CONNECTING ROD
RTW46ALF000301
Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Connecting rod 6. Piston ring
3. Piston pin snap ring 7. Connecting rod bearing
4. Piston pin
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
Positive Crankcase Ventilation
1. 5. Fixing bolt
(PCV) Valve
2. Rubber space 6. Oil filler cap
3. Cylinder head insulator cover
4. Breather pipe
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
PCV Valve Bolts Torque Nm(kgm/lb in)

2 (0.2/17)
2. Rubber Spacer
010R100014
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 Nm(kgm/lb in)

19 (1.9/14)
RTW36ASH001401 6. Oil Filler Cap

MAJOR COMPONENT
014R300004
Reassembly Steps-1
1. Cylinder body 10. Camshaft timing gear
Piston and connecting rod with
2. Tappet 11.
upper bearing
Connecting rod bearing cap with
3. Crankshaft upper bearing 12.
lower bearing
4. Crankshaft 13. Piston cooling oil pipe
5. Crankshaft thrust bearing 14. Oil pump with oil pipe
Crankshaft bearing cap with
6. 15. Crankshaft rear oil seal
lower bearing
7. Camshaft 16. Crank case
8. Timing gear case 17. Cylinder body rear plate
9. Camshaft thrust plate 18. Flywheel
RTW46ALF000501
Reassembly Steps-2
19. Crankshaft timing gear 23. Injection pump
20. Idler gear shaft 24. Water pump
21. Idler gear "A" 25. Timing gear case cover
22. Idler gear "B" and shaft 26. Crankshaft damper pulley
011R300002
Reassembly Steps-3
Thermostat housing with thermo
27. Cylinder head gasket 31.
switch
28. Cylinder head 32. Water by-pass hose
29. Push rod 33. Injection nozzle and bracket
Rocker arm shaft and rocker
30. 34. Cylinder head cover with gasket
arm
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
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
015LX127
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 Nm(kgm/lbft)

167 (17/123)
5. Check to see the crankshaft turns smoothly by rotating

it manually.
015LX129
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 Nm(kgm/lbft)

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 Nm(kgm/lbft)

19 (1.9/14)
020RY00032
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 Nm(kgm/lbft)

110 (11.2/82)
RTW36ASH000901
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
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.
015R100006
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.
015LX096
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.
015R100007
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.

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!
015LX130
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)

M8 " 1.25 19 (1.9/14)
M6 " 1.00 8 (0.8/6)
052LX010
Relief Valve Torque Nm(kgm/lbft)
29 (3.0/22)
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 Nm(kgm/lbft)

19 (19/14)
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 Nm(kgm/lbft)

19 (1.9/14)
013R100001
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 Nm(kgm/lbft)

82 (8.4/61)
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 Nm(kgm/lbft)

015LX113 118 (12/87)
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
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.
020RY00035
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 Nm(kgm/lbft)
30 (3.1/22)
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 Nm(kgm/lbft)

76 (7.7/56)
020R300006
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
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
RTW31BSH000401 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 Nm(kgm/lbft)

19 (1.9/14)
RTW36AMH000101
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)

RTW46ASH002201
19 (1.9/14)
Injection pump Bracket Bolt Torque (5) Nm(kgm/lbft)

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 Nm(kgm/lbft)

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 Nm(kgm/lbft)

M8 19 (1.9/14)
M12 76 (7.7/56)
020R300004
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 Nm(kgm/lbft)

014R100014 206 (21/152)
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 Nm(kgm/lbft)

1st step 49 (5.0/36)
2nd step 60! - 75!
011LX073
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 Nm(kgm/lbft)

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 Nm(kgm/lbft)

19 (1.9/14)
031R300002
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

Nm(kgm/lbft)
Torque
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) mm(in)

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 Nm(kgm/lbft)

RTW46ASH001101 13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose

to the cylinder head cover.
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1. Exhaust Manifold 18. Engine Mounting Bracket and
2. Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5. Generator and Adjusting Plate Bracket
6. Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
Fuel Filter Bracket (Except
7. Compressor Bracket 22.
EURO III)
Fuel Filter Assembly (Except
8. Turbocharger 23.
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
EGR Cooler (EURO III model
12. Oil Cooler Water Pipe 26-2.
only)
Intake Pipe and Throttle Body
13. Fuel Leak Off Pipe 27.
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover
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.
M8!1.25 19 (1.9/14)
M10!1.25 40 (4.1/30)
042RY00003
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.
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 22 (2.25/16)
RTW46ASH001501 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.
9. Catalytic Converter
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.

10. Heat Protector
Install the heat protector and tighten the bolt to the
027R100007 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)
12. Oil Cooler Water Pipe

13. Fuel Leak Off Pipe
033R300002
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)
4JA1L, 4JH1TC 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)
Right Side M10!1.25 40 (4.1/30)
M10!1.25 40 (4.1/30)
Left Side
M14!1.50 127 (13/93)
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)
Intake Manifold Flange Nut Torque Nm(kgm/Ib ft)

RTW36ASH001001
24 (2.4/18)
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
20. Power Steering Oil Pump Bracket

Oil Pump Braket Nut and Bolt Torque Nm(kgm/Ib ft)
1 M10!1.25 37 (3.8/28)
2
M8!1.25 18 (1.8/13) (Bolt ID:8)
3
431RY00013
21. Fuel Injection Pipe with Clip

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
040R300005
Injection Pump Side (4JA1TC/4JH1TC) Nm(kgm/Ib ft)

40 (4.1/30)
Injection Pipe Sleeve Nuts Nm(kgm/Ib ft)

29 (3.0/22)
Injection Pipe Clip Nuts Nm(kgm/Ib ft)

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 19 (1.9/14)
M6 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 Nm(kgm/Ib ft)

27 (2.7/20)
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 19 (1.9/14)
Nut 24 (2.4/17)
RTW36ASH000201
28. Clutch Assembly or Flex Plate

LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
6. 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 5. Driven gear
2. Strainer 6. Relief valve assembly
3. Pump cover 7. Pinion gear
4. Driven gear with bushing 8. Oil pump body
Disassembly procedure is shown in the illustration above numerical order.

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 Limit
051RY00001 0.14 (0.0055) 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 Limit
0.06 (0.024) 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)
Standard Limit
051RY00003
0.04 (0.0016) 0.20 (0.0079)

REASSEMBLY
051R100006
Reassembly Steps
1. Oil pump body 5. Pinion gear
2. Drive gear 6. Strainer
3. Driven gear 7. Relief valve assembly
4. Pump cover 8. Oil pipe
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 Nm (1.6 kgm/12 lb ft)
OIL FILTER AND OIL COOLER

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

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.
3. Apply compressed air (200kPa (2kg/cm / 28psi)) to
2
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. Gasket
2. Regulating valve 6. Bolt
3. Oil cooler relief valve 7. Oil filter cartridge
4. Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
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 Installation Steps

1. Radiator grille 4. Inter cooler
2. Front bumper fascia 3. Front bumper inpact support assembly
3. Front bumper inpact support assembly 2. Front bumper fascia
4. Inter cooler 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

5-8840-2040-0 (4JA1L/TC)
Cylinder Liner Installer
5-8840-2313-0 (4JH1TC)
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)
Cylinder Liner Remover
5-8840-2304-0 (4JH1TC)
5-8840-2361-0 Front Oil Seal Installation

MEMO
ENGINE COOLING 6B 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B - 3
General Description .................................................................................................. 6B - 4
Coolant Flow .............................................................................................................. 6B - 4
Water Pump................................................................................................................ 6B - 5
Thermostat ................................................................................................................. 6B - 5
Radiator ...................................................................................................................... 6B - 6
Diagnosis........................................................................................................................ 6B - 7
Draining and Refilling Cooling System........................................................................ 6B - 8
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

Description
Item
M/T A/T
Cooling system Engine coolant forced circulation
Water pump type Centrifugal impeller type
Pump to crankshaft speed ratio (To 1) 1.2
Delivery volume lit (US/UK gal)/min 100 (26.3/22.2)
Pump speed at 3000 rpm
Water temperature at 30!C (86!F)
Pump bearing type Double row shaft

Valve initial opening temperature !C (!F) 82 (180)
(Oil cooler thermo valve) 76.5 (170)
(EGR cooler thermo valve) 40 (104)
Valve full opening temperature !C (!F) 95 (203)
(Oil cooler thermo valve) 90 (194)
(EGR cooler thermo valve) 55 (131)
Valve lift at fully open position mm (in) 9.5 (0.37)
(Oil cooler thermo valve) 4.5 (0.18)
(EGR cooler thermo valve) 3.5 (0.14)
Radiator Tube type corrugated
Heat radiation capacity 93.0 kw (79,980 kcal/h)
Heat radiation area !
11.63 m (1.081ft )
!
Radiator front area !

0.28m (0.026 ft )
!
Radiator dry weight 52 N (5.3 kg/11.7 lb) 53 N (5.4 kg/11.9 lb)

Radiator cap valve opening pressure 93.3 ! 122.7kpa (13.5 ! 17.8psi)
Engine coolant capacity 2.4 lit (5.1 U.S pint) 2.3 lit (4.9 U.S pint)
Engine coolant total capacity 10.1 lit (21.3 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
030RY00005
A wax pellet type thermostat is used.

The jiggle valve accelerates engine warm-up.
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
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
PTW46BSH000201
ENGINE COOLING 6B 7
DIAGNOSIS
Engine Cooling Trouble
Symptom Possible Cause Action

Engine overheating Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature Repair or replace
sensor
Clogged radiator Clean or replace
Faulty radiator cap 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
Open or shorted Throttle Position Repair or replace
sensor circuit
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warmup Faulty thermostat Replace
Thermo unit faulty 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)
2. Fan Drive Belt and Pulley

030R300002 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 mid-
portion 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 mm (in)

9.5 (0.37)
! 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
RTW36BLF000101
Legend
1. Radiator Hose 6. Reserve Tank Hose
2. Drain Plug 7. Reserve Tank
3. Fan Guide, Lower 8. Radiator Cap
4. Fan Guide 9. Radiator Assembly
5. Bracket
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the
engine.
P1010064
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.
PTW46BSH000101
7. Remove bracket(5).
RTW36BMH000101
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 ! 122.7 (13.5
!17.8)
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.
Installation
110RS005
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.
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
033R300001 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 - 3
General Description....................................................................................................... 6C - 4
Fuel Flow.................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
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 6C 3
Description
Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor Bosch distributor VP44 type
VE type
Governor type Mechanical variable Electrical controled
(Half speed oil
pressure)
Timer type Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
Injection nozzle designed operating 19.1 (195) 19.0 (194) 19.5 (199)
pressure MPa (kg/cm ) 1st
2
25.0 (255) 33.5 (328) 33.8 (331)

2nd
Main fuel filter type 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
FUEL SYSTEM 6C 7
INJECTION PUMP
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)
RTW46CMF000301
NOTE:
! Injection nozzle adjustment is possible only on the 4JA1L engine.
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 SYSTEM 6C 9
FUEL TANK
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. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7. 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 Nm (kgm / lb ft)
68 (6.9 / 50)
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 6. Fuel Tube/Quick Connector
2. Fuel Return Port 7. Retainer Ring (Fuel Gauge Unit Lock)
3. Fuel Emission Port 8. Seal; Fuel Gauge Unit
4. Fuel Gauge Unit and Sender Assembly 9. Fuel Tank Assembly
5. Connector; Fuel Gauge Unit 10. Evapo Tube/Quick Connector
FUEL SYSTEM 6C 13
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. 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
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
2
(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 6C 15
FUEL TUBE / QUICK CONNECTOR FITTINGS
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.
140R100032
Legend
(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
Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.
140R100028
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.
140R100036
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.
FUEL SYSTEM 6C 17
FILLER NECK
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.
RTW36CSH000401
Legend
(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.
FUEL SYSTEM 6C 19
INJECTION PUMP
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 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:
020L200017 If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.
RTW46CSH000201
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear B fixing hole to prevent the scissors gear from
turning.
6C-7
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)
2) Bring the piston in the No.1 cylinder to TDC on the
RTW46CSH000201 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.
020L200017
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)
RTW46CSH000101
4JA1TC/4JH1TC 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
19 (1.9 / 14)
Intake Manifold Nuts Torque Nm(kgm / lb ft)

24 (2.4 / 17)
2) Install the EGR valve to the intake manifold and EGR

pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque N!m (kg!m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)
6C 24 FUEL SYSTEM
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque Nm(kgm / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) Nm(kgm / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) Nm(kgm / lb ft)
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
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
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 Not used
With cooler
4JA1TC Not used Not used Not used (EGR cooler)
With
4JH1TC without with 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. Retaining nut 9. Collar
2. Nozzle & pin 10. Spring seat
3. Spacer & pin 11. First spring
4. Lift Piece 12. Shim (First nozzle opening
pressure adjustment)
5. Spring seat 13. Nozzle holder body
6. Push rod 14. Eye bolt
7. Shim (Second nozzle opening 15. Gasket
pressure adjustment)
8. Second spring
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 6C 27
REASSEMBLY
080L200010
Reassembly Steps
1. Nozzle holder body 9. Spring seat
2. Shim (First opening pressure 10. Lift Piece
adjustment)
3. First spring 11. Spacer & pin
4. Spring seat 12. Nozzle & pin
5. Collar 13. Retaining nut
6. Second spring 14. Gasket
7. Push rod 15. Eye bolt
8. Shim (Second opening pressure
adjustment)
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 Adjust the first nozzle opening pressure using the shim.
First nozzle opening pressure adjustment
2 Confirm the full needle valve lift in accordance with the

Full needle valve lift confirmation
closed method.
3 Confirm pre-lift in accordance with the closed method.

Pre-lift confirmation
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance
confirmation with the closed method.
5 Second nozzle opening pressure Adjust the second nozzle opening pressure using the shim.
adjustment
6 Confirm the condition of the fuel spray with the nozzle and
Final inspection nozzle holder assembled.

Nozzle needle valve full-lift 0.25 mm (0.0098 in)
Nozzle needle valve pre-lift 0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm )
2
Nozzle pressure
4JA1T(L) 1st Stage 19.1 Mpa (2759 psi, 194 kg/cm )
2
2nd Stage 25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )

2
NOTE: Only 4JA1L can perform adjustment of a nozzle.

FUEL SYSTEM 6C 29
Injection Nozzle Adjustment
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 6C 31
First nozzle opening pressure adjusting shims
Parts No. (ISUZU) Thickness (mm)
115349-0420 0.40
115349-0430 0.50
115349-0440 0.52
115349-0450 0.54
115349-0460 0.56
040LX010.tif
115349-0470 0.58
115349-0480 0.60
115349-0490 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
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
2
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)
Note:
The above operation is used to determine whether
040MV008.tif
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
1 MPa (10 kg/cm ).
2
Pre-lift mm
Pressure Mpa
(psi/ kg/cm )
2 Lift mm (in)
040H100007
4JA1T(L) 20.1 (2,858/205) 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
kg/cm ) so that the nozzles needle valve moves
2
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
Pressure Mpa
(psi/ kg/cm )
2 Lift mm (in)
4JA1T(L) 25.5-27.0 0.09 (0.0035)

(3768-3911/260-275)
040M100006
6C 36 FUEL SYSTEM
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.
040MV017.tif Use some combination of 3 adjusting shims to
adjust the pressure.
Second nozzle opening pressure adjusting shims

Part No. Thickness Part No. Thickness
(ISUZU) (mm) (ISUZU) (mm)
897116-0290 0.10 897116-0380 0.53
897116-0320 0.20 897116-0390 0.54
897116-0330 0.30 897116-0400 0.55
897116-0340 0.40 897116-0410 0.56
897116-0350 0.50 897116-0420 0.57
897116-0360 0.51 897116-0430 0.58
897116-0370 0.52 897116-0440 0.59
040LX009.tif
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.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)
040MV014-1.tif
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
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-2602-0
Remover: fuel pump retainer ring
(J-39765)
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 80A
Generator
Type AC generator with IC regulator and vacuum pump
Hitachi LR160-503E Hitachi LR180-513B
Voltage V 12
Drive and rotation V-belt, clockwise viewed from the drive pulley
Ground polarity Negative
Maximum output A 60 80
Engine speed ratio to 1 1.788
Maximum speed rpm 11,000
Weight with vacuum pump kg(lb) 5.8(12.8) 6.4(14.1)
Vacuum Pump
Delivery volume cm /rev 50
3
Exhaust Characteristic -66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000
rpm
7 seconds or less at 5,000 rpm

Maximum vacuum
-90.7 kPa (-680 mmHg) or more
Starter Motor
Type Solenoid controlled
Hitachi S13-555
Rated voltage V 12
Rated output kW 2.3
Load characteristics
Terminal voltage V 8.76
Load current A 300
Weight kg(Ib) 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.
Generator
P1010002
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 N!m (kg!m/Ib!ft)

40 (4.1/30)
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 Nm (kgm/lbft)

19 (1.9/14)
5. Reconnect the battery cable to the battery.

DISASSEMBLY
RTW46DLF000401
Disassembly Step
1. Vacuum pump
2. O-ring
3. Through bolt
4. B Terminal nut
5. Rear cover
6. Pulley
7. Rotor assembly
8. Front cover assembly
9. Rear rotor bearing
10. Rectifier assembly
11. Stator assembly
12. Rotor assembly
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
RTW46DSH000201
screwdriver tips.
RTW46DSH000601
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.
RTW46DSH002101
7. Rotor Assembly
1. Remove the rotor from front cover assembly.
Remove the front cover stator and rectifier.
RTW46DSH000301
8. Front Cover Assembly

1. Remove the front cover bearing retainer screws.
2. Remove the bearing.
RTW46DSH000701

! 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.
RTW46DSH000801
RTW46DSH000401

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 Limit
31.6 (1.245) 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) ohms
Standard 3.8
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 0.1
066RY00022
2. Check for continuity between each stator coils and the

stator core.
If there is continuity, the stator coils must be replaced.
066RY00023
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
RTW46DSH004801
25 (1.0) 6.5 (0.25)
Rectifier
RTW46DSH001201
Tester wire
E BAT
U, V, and WN " U, V, and WN "
No
----- Conductivity -----
conductivity
No
" conductivity
----- " Conductivity -----
Negative side diode check Positive side diode check
RECTIFIER ASSEMBLY
RTW46DSF000301
1. Voltmeter
2. Switch 1
3. DC regulated power supply
4. Lamp 2
5. Lamp 1
6. Switch 3
7. Switch 2
8. Pulse generator
9. 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
1 DC regulated power supply 0~20 volts variable with output of 1 ampere or more
2 Lamps (2) 12 volts, 1.4~3.4 watts
3 Switches (3) -----
4 DC voltmeter 0~30 volts, 0.5 grade
5 Pulse generator (Oscillator) 5~30 volt output at a frequency of 1kHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition
No. Remarks
1 2 3 reading Lamp 1 Lamp 2
On
1 ON OFF OFF ON Initial excitation check
(dim)
12V
On or
2 ON ON OFF Full excitation check
flashing
OFF Lamp 1 off or dimly lit when the
Off or
3 ON ON OFF 16V voltmeter shows less than 12 volts or
on (dim)
16 volts
On or
4 OFF ON OFF 12V Stator and brush separation check
flashing ON
5 ON ON ON 18V On 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.
Air Pressure kPa (kg/cm /psi)
2
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
3. Install the center plate to the rotor housing.

Be sure to use a new O-ring.
RTW46DSH002001
REASSEMBLY
RTW46DLF000501
Reassembly Step
1. Front cover
3. Rotor Assembly
4. Pulley
5. Rectifier Assembly
6. Stator Assembly
7. Rear cover
8. B Terminal nuts
9. Through bolt
10. O-ring
11. Vacuum pump
! 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
Remove the tape from the splines.
RTW46DSH006001
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
RTW460LF000201
Disassembly Step
1. Lead wire 14. Armature
2. Bolt 15. Bolt
3. Magnetic switch assembly 16. Bearing retainer
4. Torsion spring 17. Pinion assembly
5. Plunger 18. Pinion stopper clip
6. Dust cover 19. Pinion stopper
7. Magnetic switch 20. Return spring
8. Screw 21. Pinion shaft
9. Through bolt 22. Clutch
10. Rear cover 23. Dust cover
11. Motor assembly 24. Shift lever
12. Brush holder 25. Gear case
13. Yoke
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
3. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove the
switch from the shift lever.
RTW46DSH002701
Remove the torsion spring from the magnetic switch.
RTW46DSH002801
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.
RTW46DSH002901
11. Motor Assembly

Remove the four brushes from the brush holders.
RTW46DSH003001
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
12. Brush Holder

13. Yoke
14. Armature
Remove the brush holder and pull out the armature
assembly free from the yoke.
RTW46DSH003201
16. Bearing Retainer

17. Pinion Assembly
23. Dust Cover
24. Shift Lever
25. Gear Case
1. Remove the bearing retainer.
2. Remove the pinion from the gear case.
RTW46DSH003301
3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.
RTW46DSH003401

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 Limit
0.05 (0.002) 0.2 (0.008)
RTW46DSH003501
2. Check the commutator mica segments for excessive

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

more than the limit, the commutator may be reground.
065RY00025
If the mica segment depth is less than the limit, the
commutator must be replaced.
4. Measure the commutator outside diameter.

Commutator Outside Diameter mm (in)
Standard Limit
36.5 (1.44) 35.5 (1.40)
If the measured outside diameter is less than the specified

limit, the commutator must be replaced.
065RY00026
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.
RTW46DSH003601
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
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.
RTW46DSH003901
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 Limit
15 (0.59) 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. Magnetic switch assembly 14. Pinion stopper
2. Magnetic switch 15. Pinion stopper clip
3. Dust cover 16. Bearing retainer
4. Plunger 17. Bolt
5. Torsion spring 18. Motor assembly
6. Shift lever 19. Armature
7. Gear case 20. Yoke
8. Dust cover 21. Brush holder
9. Bolt 22. Rear cover
10. Pinion assembly 23. Screw
11. Clutch 24. Through bolt
12. Pinion shaft 25. Lead wire
13. Rerurn spring
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 N#m (kg#m/lb#ft)

8 (0.8/5.4)
RTW46DSH005701
10. Pinion Assembly

Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041
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.
RTW46DSH004501
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
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion should
continue to flutter.
RTW46DSH005901
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
RTW46DSH004701
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 Ohms
94 % 114
825R300046
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9
LNW21KSH001401
EGR SYSTEM 4JA1T (L)

Refer to 6F-9. (EGR system diagram)
MEMO
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E1
ENGINE
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 Outline ....................................................... 6E-70

4JA1-TC .................................................... 6E-10 Cross-section View .................................... 6E-70
4JH1-TC .................................................... 6E-11 Low Pressure Fuel Circuit .......................... 6E-71
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-14 High Pressure Fuel Circuit ......................... 6E-72
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-15 Pump Camshaft Speed Sensor ................. 6E-72
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-16 High Pressure Solenoid Valve ................... 6E-73
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-17 Timing Control Valve (TCV) ....................... 6E-74
GROUND POINT CHART GENERAL EXPORT ISUZU Strategy Based Diagnostics .............. 6E-76
(LHD) (1/4) ............................................... 6E-18 Overview .................................................... 6E-76
LOCATION ................................................ 6E-34 STRATEGY BASED DIAGNOSTICS CHART 6E-76
PARTS LOCATION ................................... 6E-39 Diagnostic Thought Process ...................... 6E-77
CONNECTOR LIST ................................... 6E-40 1. Verify the Complaint .............................. 6E-77
RELAY AND FUSE .................................... 6E-43 2. Perform Preliminary Checks .................. 6E-77
RELAY AND FUSE BOX LOCATION 3. Check Bulletins and Troubleshooting Hints 6E-78
(LHD & RHD) ........................................... 6E-43 4. Perform Service Manual Diagnostic Checks 6E-78
RELAY AND FUSE BOX LOCATION 5a and 5b. Perform Service Manual Diagnostic
(LHD & RHD) ........................................... 6E-44 Procedures .............................................. 6E-78
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45 5c. Technician Self Diagnoses .................. 6E-78
ECM WIRING DIAGRAM (1/7) .................. 6E-46 5d. Intermittent Diagnosis .......................... 6E-79
ECM WIRING DIAGRAM (2/7) .................. 6E-47 5e. Vehicle Operates as Designed ............ 6E-80
ECM WIRING DIAGRAM (3/7) .................. 6E-48 6. Re-examine the complaint ..................... 6E-81
ECM WIRING DIAGRAM (4/7) .................. 6E-49 7. Repair and Verify Fix ............................. 6E-81
ECM WIRING DIAGRAM (5/7) .................. 6E-50 GENERAL SERVICE INFORMATION ....... 6E-82
ECM WIRING DIAGRAM (6/7) .................. 6E-51 ON-BOARD DIAGNOSTIC (OBD) ............. 6E-82
ECM WIRING DIAGRAM (7/7) .................. 6E-52 TECH 2 OPERATING FLOW CART
ECM CONNECTOR PIN ASSIGNMENT & (START UP) ............................................. 6E-86
OUTPUT SIGNAL .................................... 6E-53 TYPICAL SCAN DATA & DEFINITIONS
GENERAL DESCRIPTION FOR ECM AND (ENGINE DATA) ................................... 6E-88
SENSORS ............................................... 6E-64 TYPICAL SCAN DATA & DEFINITIONS
Engine Control Module (ECM) ................... 6E-64 (ENGINE DATA) ................................... 6E-90
Pump Control Unit (PSG) & Data Exchange MISCELLANEOUS TEST .......................... 6E-92
Between Control Module ......................... 6E-64 Plotting Snapshot Graph ............................ 6E-93
Mass Air Flow (MAF) Sensor & Intake Air Plotting Graph Flow Chart (Plotting graph
Temperature (IAT) Sensor ....................... 6E-65 after obtaining vehicle information) .......... 6E-94
Throttle Position Sensor (TPS) .................. 6E-66 Flow Chart for Snapshot Replay
Crankshaft Position (CKP) Sensor ............ 6E-66 (Plotting Graph) ....................................... 6E-95
Engine Coolant Temperature (ECT) Sensor 6E-67 SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-96
Vehicle Speed Sensor (VSS) .................... 6E-67 ON-BOARD DIAGNOSTIC (OBD) SYSTEM
GENERAL DESCRIPTION FOR EGR CHECK .................................................... 6E-105
(EXHAUST GAS RE-CIRCULATION) ..... 6E-68 Circuit Description ...................................... 6E-105
GENERAL DESCRIPTION FOR Diagnostic Aids .......................................... 6E-105
INJECTION PUMP .................................. 6E-70 Test Description ......................................... 6E-105
6E2 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
On-Board Diagnostic (OBD) System Check 6E-106 VACUUM PRESSURE SENSOR VOLTAGE
NO CHECK ENGINE LAMP (MIL) ............. 6E-109 SUPPLY CIRCUIT HIGH INPUT ............. 6E-140
Circuit Description ..................................... 6E-109 DIAGNOSTIC TROUBLE CODE (DTC) P0105
Diagnostic Aids .......................................... 6E-109 (SYMPTOM CODE 9) (FLASH CODE 34)
No Check Engine Lamp (MIL) ................... 6E-110 VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT .............. 6E-140
CHECK ENGINE LAMP (MIL) ON STEADY 6E-112
Circuit description ...................................... 6E-141
Circuit description ...................................... 6E-112
Diagnostic Aids .......................................... 6E-141
Diagnostic Trouble Code (DTC) P0105
Check Engine Lamp (MIL) On Steady ....... 6E-113
(Symptom Code 1) (Flash Code 34) Vacuum
ECM Diagnostic Trouble Codes ................ 6E-114
Pressure Sensor Circuit High Input ......... 6E-142
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
Pressure Sensor Circuit Low Input ........... 6E-145
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128
Pressure Sensor Voltage Supply Circuit
MASS AIR FLOW (MAF) SENSOR
High Input ................................................. 6E-148
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128
(SYMPTOM CODE B) (FLASH CODE 65)
Pressure Sensor Voltage Supply Circuit Low
MASS AIR FLOW (MAF) SENSOR OUTPUT
Input.......................................................... 6E-150
CIRCUIT LOW INPUT ............................. 6E-128
(SYMPTOM CODE C) (FLASH CODE 65)
INTAKE AIR TEMPERATURE (IAT) SENSOR
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................ 6E-152
Circuit Description ..................................... 6E-129
Diagnostic Aids .......................................... 6E-129 INTAKE AIR TEMPERATURE (IAT) SENSOR
Diagnostic Trouble Code (DTC) P0100 CIRCUIT LOW INPUT ............................. 6E-152
(Symptom Code 7) (Flash Code 65) Mass Circuit Description ...................................... 6E-152
Air Flow (MAF) Sensor Voltage Supply
Circuit High Input ..................................... 6E-129
(Symptom Code 1) (Flash Code 23) Intake Air
(Symptom Code 9) (Flash Code 65) Mass
Temperature (IAT) Sensor Circuit High Input 6E-153
Air Flow (MAF) Sensor Voltage Supply
Circuit Low Input ...................................... 6E-132
(Symptom Code 2) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit Low Input 6E-157
(Symptom Code B) (Flash Code 65) Mass
Air Flow (MAF) Sensor Output Circuit Low
Input ......................................................... 6E-134
ENGINE COOLANT TEMPERATURE SENSOR
Diagnostic Trouble Code (DTC) P0100 (Symptom
CIRCUIT HIGHINPUT ............................. 6E-160
Code C) (Flash Code 65) Mass Air Flow (MAF)
Sensor Output Circuit High Input ............. 6E-137
ENGINE COOLANT TEMPERATURE SENSOR
VACUUM PRESSURE SENSOR CIRCUIT HIGH
Circuit Description ...................................... 6E-160
INPUT ...................................................... 6E-140
(SYMPTOM CODE 2) (FLASH CODE 34) Diagnostic Trouble Code (DTC) P0115
VACUUM PRESSURE SENSOR CIRCUIT (Symptom Code 1) (Flash Code 14) Engine
LOW INPUT ............................................. 6E-140 Coolant Temperature Sensor Circuit
HighInput ................................................. 6E-161
(Symptom Code 2) (Flash Code 14) Engine Diagnostic Trouble Code (DTC) P0216
Coolant Temperature Sensor Circuit (Symptom Code A) (Flash Code 54) Injection
LowInput .................................................. 6E-165 Timing Control Circuit Malfunction ........... 6E-180
DIAGNOSTIC TROUBLE CODE (DTC) P0180 Diagnostic Trouble Code (DTC) P0216
(SYMPTOM CODE B) (FLASH CODE 15) (Symptom Code B) (Flash Code 54) Injection
FUEL TEMPERATURE SENSOR CIRCUIT Timing Control Circuit Malfunction ........... 6E-180
RANGE/PERFORMANCE ....................... 6E-168 DIAGNOSTIC TROUBLE CODE (DTC) P0243
Circuit Description ..................................... 6E-168 (SYMPTOM CODE 3) (FLASH CODE 64)
Diagnostic Aids .......................................... 6E-168 TURBOCHARGER WASTEGATE
Diagnostic Trouble Code (DTC) P0180 SOLENOID "A" RANGE/PERFORMANCE 6E-183
(Symptom Code B) (Flash Code 15) Fuel DIAGNOSTIC TROUBLE CODE (DTC) P0243
Temperature Sensor Circuit (SYMPTOM CODE 4) (FLASH CODE 64)
Range/Performance ................................ 6E-169 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID"A" LOW ................................ 6E-183
(SYMPTOM CODE A) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
FUEL CUTOFF SOLENOID VALVE (SYMPTOM CODE 4) (FLASH CODE 64)
MALFUNCTION ....................................... 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" LOW ............................... 6E-183
(SYMPTOM CODE B) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
CIRCUIT HIGH INPUT ............................ 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" RANGE/PERFORMANCE 6E-183
(SYMPTOM CODE C) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
FUEL CUTOFF SOLENOID VALVE ALWAYS (SYMPTOM CODE 6) (FLASH CODE 64)
ACTIVE .................................................... 6E-170 TURBOCHARGER WASTEGATE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 SOLENOID "A" MALFUNCTION ............. 6E-183
(SYMPTOM CODE D) (FLASH CODE 52) DIAGNOSTIC TROUBLE CODE (DTC) P0243
MALFUNCTION ....................................... 6E-170 TURBOCHARGER WASTEGATE
Circuit Description ..................................... 6E-171 SOLENOID"A" HIGH ............................... 6E-183
Diagnostic Aids .......................................... 6E-171 Circuit description ...................................... 6E-184
Diagnostic Trouble Code (DTC) P0215 Diagnostic Aids .......................................... 6E-184
(Symptom Code A) (Flash Code 52) Fuel Diagnostic Trouble Code (DTC) P0243
Cutoff Solenoid Valve Malfunction ........... 6E-171 (Symptom Code 3) (Flash Ccode 64)
Diagnostic Trouble Code (DTC) P0215 Turbocharger Wastegate Solenoid
(Symptom Code B) (Flash Code 52) Fuel "A" Range/Performance ........................... 6E-185
Cutoff Solenoid Valve Circuit High Input . 6E-173 Diagnostic Trouble Code (DTC) P0243
Diagnostic Trouble Code (DTC) P0215 (Symptom Code 4) (Flash Code 64)
(Symptom Code C) (Flash Code 52) Fuel Turbocharger Wastegate Solenoid "A" Low 6E-187
Cutoff Solenoid Valve Always Active ....... 6E-175 Diagnostic Trouble Code (DTC) P0243
(Symptom Code D) (Flash Code 52) Fuel Turbocharger Wastegate Solenoid "A"
Cutoff Solenoid Valve Malfunction ........... 6E-177 Range/Performance ................................ 6E-190
(SYMPTOM CODE A) (FLASH CODE 54) (Symptom Code 6) (Flash Code 64)
INJECTION TIMING CONTROL CIRCUIT Turbocharger Wastegate Solenoid "A"
MALFUNCTION ....................................... 6E-178 Malfunction .............................................. 6E-192
(SYMPTOM CODE B) (FLASH CODE 54) (Symptom Code 8) (Flash Code 64)
INJECTION TIMING CONTROL CIRCUIT Turbocharger Wastegate Solenoid "A" High 6E-194
MALFUNCTION ....................................... 6E-178 DIAGNOSTIC TROUBLE CODE (DTC) P0251
Circuit Description ..................................... 6E-179 (SYMPTOM CODE 6)
Diagnostic Aids .......................................... 6E-179 (FLASH CODE 53) INJECTION PUMP
MALFUNCTION ....................................... 6E-196 RANGE/PERFORMANCE ....................... 6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Circuit Description ...................................... 6E-209
(SYMPTOM CODE 7) (FLASH CODE 53) Diagnostic Aids .......................................... 6E-209
INJECTION PUMP MALFUNCTION ....... 6E-196 Diagnostic Trouble Code (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (Symptom Code B) (Flash Code 43)
(SYMPTOM CODE 9) (FLASH CODE 53) Crankshaft Position Sensor Circuit
INJECTION PUMP MALFUNCTION ....... 6E-196 Malfunction .............................................. 6E-209
(SYMPTOM CODE A) (FLASH CODE 53) (Symptom Code D) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-196 Crankshaft Position Sensor Malfunction .. 6E-209
(SYMPTOM CODE B) (FLASH CODE 53) (Symptom Code E) (Flash Code 43) Engine
INJECTION PUMP MALFUNCTION ....... 6E-196 Speed Input Circuit Range/Performance . 6E-214
DIAGNOSTIC TROUBLE CODE (DTC) P0251 DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE D) (FLASH CODE 53) (SYMPTOM CODE 4) (FLASH CODE 66)
INJECTION PUMP MALFUNCTION ....... 6E-196 GLOW RELAY CIRCUIT VOLTAGE LOW 6E-217
(SYMPTOM CODE E) (FLASH CODE 53) (SYMPTOM CODE 8) (FLASH CODE 66)
INJECTION PUMP MALFUNCTION ....... 6E-196 GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
Circuit Description ..................................... 6E-197 Circuit Description ...................................... 6E-217
Diagnostic Aids .......................................... 6E-197 Diagnostic Aids .......................................... 6E-217
Diagnostic Trouble Code (DTC) P0251 Diagnostic Trouble Code (DTC) P0380
(Symptom Code 6) (Flash Code 53) (Symptom Code 4) (Flash Code 66)
Injection Pump Malfunction ..................... 6E-197 Glow Relay Circuit Voltage Low .............. 6E-218
(Symptom Code 7) (Flash Code 53) (Symptom Code 8) (Flash Code 66) Glow
Injection Pump Malfunction ..................... 6E-199 Relay Circuit Voltage High ....................... 6E-221
Diagnostic Trouble Code (DTC) P0251 DIAGNOSTIC TROUBLE CODE (DTC) P0381
(Symptom Code 9) (Flash Code 53) (SUB CODE 4) (FLASH CODE 67) GLOW PLUG
Injection Pump Malfunction ..................... 6E-203 INDICATOR CIRCUIT VOLTAGE LOW .. 6E-222
(Symptom Code A) (Flash Code 53) (SUB CODE 8) (FLASH CODE 67) GLOW PLUG
Injection Pump Malfunction ..................... 6E-204 INDICATOR CIRCUIT VOLTAGE HIGH . 6E-222
Diagnostic Trouble Code (DTC) P0251 Circuit Description ...................................... 6E-222
(Symptom Code B) (Flash Code 53) Diagnostic Aids .......................................... 6E-222
Injection Pump Malfunction ..................... 6E-205 Diagnostic Trouble Code (DTC) P0381
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 4) (Flash Code 67) Glow
(Symptom Code D) (Flash Code 53) Plug Indicator Circuit Voltage Low ........... 6E-222
Injection Pump Malfunction ..................... 6E-206 Diagnostic Trouble Code (DTC) P0381
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 8) (Flash Code 67) Glow
(Symptom Code E) (Flash Code 53) Plug Indicator Circuit Voltage High .......... 6E-226
Injection Pump Malfunction ..................... 6E-207 DIAGNOSTIC TROUBLE CODE (DTC) P0400
DIAGNOSTIC TROUBLE CODE (DTC) P0335 (SYMPTOM CODE 3) (FLASH CODE 32)
(SYMPTOM CODE B) (FLASH CODE 43) EXHAUST GAS RECIRCULATION FLOW
CRANKSHAFT POSITION SENSOR EXCESSIVE DETECTED ........................ 6E-227
CIRCUIT MALFUNCTION ....................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE D) (FLASH CODE 43) EXHAUST GAS RECIRCULATION CIRCUIT
CRANKSHAFT POSITION SENSOR SHORT TO GROUND OR OPEN CIRCUIT 6E-227
MALFUNCTION ....................................... 6E-208 DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE E) (FLASH CODE 43) EXHAUST GAS RECIRCULATION FLOW
ENGINE SPEED INPUT CIRCUIT INSUFFICIENT DETECTED .................... 6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Diagnostic Aids .......................................... 6E-254
EXHAUST GAS RECIRCULATION CIRCUIT (Symptom Code 1) (Flash Code 35)
SHORT TO BATTERY ............................ 6E-227 System Voltage Too High ........................ 6E-254
Circuit Description ..................................... 6E-228 Diagnostic Trouble Code (DTC) P0560
Diagnostic Aids .......................................... 6E-228 (Symptom Code 2) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Too Low ......................... 6E-256
(Symptom Code 3) (Flash Code 32) Exhaust Diagnostic Trouble Code (DTC) P0560
Gas Recirculation Flow Excessive Detected 6E-228 (Symptom Code A) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Malfunction .................... 6E-258
(Symptom Code 4) (Flash Code 32) Exhaust DIAGNOSTIC TROUBLE CODE (DTC) P0561
Gas Recirculation Circuit Short to Ground or (SYMPTOM CODE A) (FLASH CODE 18)
Open Circuit ............................................. 6E-232 IGNITION SWITCH CIRCUIT
Diagnostic Trouble Code (DTC) P0400 MALFUNCTION ....................................... 6E-260
(Symptom Code 5) (Flash Code 32) Exhaust DIAGNOSTIC TROUBLE CODE (DTC) P0561
Gas Recirculation Flow Insufficient Detected 6E-235 (SYMPTOM CODE B) (FLASH CODE 18)
Diagnostic Trouble Code (DTC) P0400 IGNITION SWITCH CIRCUIT
(Symptom Code 8) (Flash Code 32) Exhaust MALFUNCTION ....................................... 6E-260
Gas Recirculation Circuit Short to Battery 6E-238 Circuit Description ...................................... 6E-261
VEHICLE SPEED SENSOR CIRCUIT HIGH (Symptom Code A) (Flash Code 18)
INPUT ...................................................... 6E-240 Ignition Switch Circuit Malfunction ........... 6E-261
(SYMPTOM CODE A) (FLASH CODE 24) (Symptom Code B) (Flash Code 18)
VEHICLE SPEED SENSOR INPUT SIGNAL Ignition Switch Circuit Malfunction ........... 6E-261
FREQUENCY TOO HIGH ....................... 6E-240 DIAGNOSTIC TROUBLE CODE (DTC) P0602
DIAGNOSTIC TROUBLE CODE (DTC) P0500 CONTROL MODULE PROGRAMMING
(SYMPTOM CODE B) (FLASH CODE 24) ERROR .................................................... 6E-264
VEHICLE SPEED SENSOR INCORRECT Circuit Description & Diagnostic Aids ........ 6E-264
SIGNAL ................................................... 6E-240 Diagnostic Trouble Code (DTC) P0602
Circuit Description ..................................... 6E-241 Control Module Programming Error ......... 6E-264
Diagnostic Aids .......................................... 6E-241 DIAGNOSTIC TROUBLE CODE (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (SYMPTOM CODE A) (FLASH CODE 28)
(Symptom Code 1) (Flash Code 24) Vehicle ECU MALFUNCTION .............................. 6E-265
Speed Sensor Circuit High Input ............. 6E-241 DIAGNOSTIC TROUBLE CODE (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (SYMPTOM CODE B) (FLASH CODE 28)
(Symptom Code A) (Flash Code 24) ECU MALFUNCTION .............................. 6E-265
Vehicle Speed Sensor Input Signal Circuit Description & Diagnostic Aids ........ 6E-265
Frequency Too High ................................ 6E-245 Diagnostic Trouble Code (DTC) P0606
Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 28)
(Symptom Code B) (Flash Code 24) ECU Malfunction ...................................... 6E-265
VehicleSpeed Sensor Incorrect Signal .... 6E-248 Diagnostic Trouble Code (DTC) P0606
DIAGNOSTIC TROUBLE CODE (DTC) P0560 (Symptom Code B) (Flash Code 28)
(SYMPTOM CODE 1) (FLASH CODE 35) ECU Malfunction ...................................... 6E-267
SYSTEM VOLTAGE TOO HIGH ............. 6E-253 DIAGNOSTIC TROUBLE CODE (DTC) P0645
(SYMPTOM CODE 2) (FLASH CODE 35) A/C COMPRESSOR RELAY CIRCUIT
SYSTEM VOLTAGE TOO LOW .............. 6E-253 VOLTAGE LOW ...................................... 6E-268
(SYMPTOM CODE A) (FLASH CODE 35) (SYMPTOM CODE 8) (FLASH CODE 46)
SYSTEM VOLTAGE MALFUNCTION ..... 6E-253 A/C COMPRESSOR RELAY CIRCUIT
Circuit Description ..................................... 6E-253 VOLTAGE HIGH ...................................... 6E-268
Circuit Description ..................................... 6E-268 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Aids .......................................... 6E-268 VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
(Symptom Code 4) (Flash Code 46) A/C (SYMPTOM CODE 9) (FLASH CODE 21)
Compressor Relay Circuit Voltage Low ... 6E-269 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Trouble Code (DTC) P0645 VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
(Symptom Code 8) (Flash Code 46) A/C DIAGNOSTIC TROUBLE CODE (DTC) P1120
Compressor Relay Circuit Voltage High .. 6E-272 (SYMPTOM CODE D) (FLASH CODE 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0703 PEDAL/THROTTLE POSITION SENSOR
(SYMPTOM CODE A) (FLASH CODE 25) BRAKE SWITCH ERROR ....................... 6E-287
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 DIAGNOSTIC TROUBLE CODE (DTC) P1120
DIAGNOSTIC TROUBLE CODE (DTC) P0703 (SYMPTOM CODE E) (FLASH CODE 21)
(SYMPTOM CODE B) (FLASH CODE 25) PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273 IDLE POSITION SWITCH ERROR ......... 6E-287
Circuit Description ..................................... 6E-274 Circuit Description ...................................... 6E-288
Diagnostic Aids .......................................... 6E-274 Diagnostic Aids .......................................... 6E-288
(Symptom Code A) (Flash Code 25) Brake (Symptom Code 1) (Flash Code 21)
Switch Circuit Malfunction ....................... 6E-274 Pedal/Throttle Position Sensor
Diagnostic Trouble Code (DTC) P0703 Circuit High Input ..................................... 6E-288
(Symptom Code B) (Flash Code 25) Diagnostic Trouble Code (DTC) P1120
Brake Switch Circuit Malfunction ............. 6E-278 (Symptom Code 7) (Flash Code 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0704 Pedal/Throttle Position Sensor Voltage
(SYMPTOM CODE 6) (FLASH CODE 57) Supply Circuit High Input ......................... 6E-293
CLUTCH SWITCH INPUT CIRCUIT Diagnostic Trouble Code (DTC) P1120
MALFUNCTION ....................................... 6E-281 (Symptom Code 9) (Flash Code 21)
Circuit Description ..................................... 6E-281 Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input .......................... 6E-295
(Symptom Code D) (Flash Code 21)
(Symptom Code 6) (Flash Code 57)
Pedal/Throttle Position Sensor Brake
Clutch Switch Input Circuit Malfunction ... 6E-282
Switch Error ............................................. 6E-298
(Symptom Code E) (Flash Code 21)
BAROMETRIC PRESSURE SENSOR
Pedal/Throttle Position Sensor Idle
Position Switch Error ............................... 6E-300
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
BAROMETRIC PRESSURE SENSOR
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ...................................... 6E-302
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
Diagnostic Trouble Code (DTC) P1105 REDUCTION CAUSED BY HIGH FUEL
(Symptom Code 1) (Flash Code 86) Barometric TEMPERATURE ...................................... 6E-302
Pressure Sensor Circuit High Input ......... 6E-285
Diagnostic Trouble Code (DTC) P1105 (SYMPTOM CODE A) (FLASH CODE 22) FUEL
(Symptom Code 2) (Flash Code 86) Barometric REDUCTION CAUSED BY LOW FUEL
Pressure Sensor Circuit Low Input .......... 6E-285 TEMPERATURE ...................................... 6E-302
PEDAL/THROTTLE POSITION SENSOR
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant
Temperature ............................................ 6E-302 Diagnostic Trouble Code (DTC) P1605
Diagnostic Trouble Code (DTC) P1173 (Symptom Code D) (Flash Code 55)
(Symptom Code 7) (Flash Code 22) Fuel EEPROM Defect ...................................... 6E-318
Reduction Caused By High Fuel Diagnostic Trouble Code (DTC) P1605
Temperature ............................................ 6E-305 (Symptom Code E) (Flash Code 55)
Diagnostic Trouble Code (DTC) P1173 EEPROM Defect ...................................... 6E-318
(Symptom Code A) (Flash Code 22) Fuel DIAGNOSTIC TROUBLE CODE (DTC) P1610
Reduction Caused By Low Fuel (SYMPTOM CODE A) (FLASH CODE 56)
Temperature ............................................ 6E-305 SECURITY KEY AND SECURITY CODE NOT
DIAGNOSTIC TROUBLE CODE (DTC) P1335 PROGRAMMED ...................................... 6E-320
(SYMPTOM CODE A) Circuit Description ...................................... 6E-320
(FLASH CODE 43) ENGINE SPEED OUTPUT Diagnostic Aids .......................................... 6E-320
CIRCUIT MALFUNCTION ....................... 6E-306 Diagnostic Trouble Code (DTC) P1610
Circuit Description ..................................... 6E-306 (Symptom Code A) (Flash Code 56) Security
Diagnostic Aids .......................................... 6E-306 Key and Security Code Not Programmed 6E-320
(Symptom Code A) (Flash Code 43) (SYMPTOM CODE A) (FLASH CODE 56)
Engine Speed Output Circuit Malfunction 6E-307 WRONG SECURITY CODE ENTERED .. 6E-322
(SYMPTOM CODE A) (FLASH CODE 45) Diagnostic Aids .......................................... 6E-322
CAMSHAFT SPEED MALFUNCTION ..... 6E-311 Diagnostic Trouble Code (DTC) P1611
Circuit Description ..................................... 6E-311 (Symptom Code A) (Flash Code 56)
Diagnostic Aids .......................................... 6E-311 Wrong Security Code Entered ................. 6E-323
(Symptom Code A) (Flash Code 45) (SYMPTOM CODE A) (FLASH CODE 56)
Camshaft Speed Malfunction .................. 6E-312 IMMOBILIZER NO OR WRONG SIGNAL 6E-324
(SYMPTOM CODE A) (FLASH CODE 47) Diagnostic Aids .......................................... 6E-324
NEUTRAL SWITCH ON ERROR ............ 6E-313 Diagnostic Trouble Code (DTC) P1612
DIAGNOSTIC TROUBLE CODE (DTC) P1520 (Symptom Code A) (Flash Code 56)
(SYMPTOM CODE B) (FLASH CODE 47) Immobilizer No or Wrong Signal .............. 6E-325
NEUTRAL SWITCH OFF ERROR .......... 6E-313 DIAGNOSTIC TROUBLE CODE (DTC) P1613
Circuit Description ..................................... 6E-313 (SYMPTOM CODE A) (FLASH CODE 56)
Diagnostic Aids .......................................... 6E-313 IMMOBILIZER NO OR WRONG SIGNAL 6E-330
Diagnostic Trouble Code (DTC) P1520 Circuit Description ...................................... 6E-330
(Symptom Code A) (Flash Code 47) Diagnostic Aids .......................................... 6E-330
Neutral Switch ON Error .......................... 6E-314 Diagnostic Trouble Code (DTC) P1613
(Symptom Code B) (Flash Code 47) Immobilizer No or Wrong Signal .............. 6E-331
Neutral Switch OFF Error ........................ 6E-314 DIAGNOSTIC TROUBLE CODE (DTC) P1614
DIAGNOSTIC TROUBLE CODE (DTC) P1605 (SYMPTOM CODE A) (FLASH CODE 56)
(SYMPTOM CODE C) (FLASH CODE 55) WRONG TRANSPONDER KEY .............. 6E-335
SEED AND KEY FILE DESTROYED ...... 6E-318 Circuit Description ...................................... 6E-335
(SYMPTOM CODE D) (FLASH CODE 55) Diagnostic Trouble Code (DTC) P1614
EEPROM DEFECT .................................. 6E-318 (Symptom Code A) (Flash Code 56)
DIAGNOSTIC TROUBLE CODE (DTC) P1605 Wrong Transponder Key .......................... 6E-336
(SYMPTOM CODE E) (FLASH CODE 55) DIAGNOSTIC TROUBLE CODE (DTC) P1625
EEPROM DEFECT .................................. 6E-318 (SYMPTOM CODE A) (FLASH CODE 76) ECM
Circuit Description & Diagnostic Aids ........ 6E-318 MAIN RELAY SWITCHED OFF
Diagnostic Trouble Code (DTC) P1605 TOO EARLY ............................................ 6E-337
(Symptom Code C) (Flash Code 55) DIAGNOSTIC TROUBLE CODE (DTC) P1625
Seed and Key File Destroyed .................. 6E-318
(SYMPTOM CODE B) (FLASH CODE 76) ECM CAN Receives Error ................................ 6E-351
MAIN RELAY SWITCHED OFF TOO LATE 6E-337 DIAGNOSTIC TROUBLE CODE (DTC) P1690
Circuit Description ..................................... 6E-337 (SYMPTOM CODE 4) (FLASH CODE 77)
Diagnostic Aids .......................................... 6E-337 CHECK ENGINE LAMP (MIL) CIRCUIT
Diagnostic Trouble Code (DTC) P1625 VOLTAGE LOW ...................................... 6E-356
(Symptom Code A) (Flash Code 76) ECM DIAGNOSTIC TROUBLE CODE (DTC) P1690
Main Relay Switched Off Too Early ......... 6E-338 (SYMPTOM CODE 8) (FLASH CODE 77)
Diagnostic Trouble Code (DTC) P1625 CHECK ENGINE LAMP (MIL) CIRCUIT
(Symptom Code B) (Flash Code 76) ECM VOLTAGE HIGH ...................................... 6E-356
Main Relay Switched Off Too Late .......... 6E-339 Circuit Description ...................................... 6E-356
(SYMPTOM CODE A) (FLASH CODE 51) Diagnostic Trouble Code (DTC) P1690
FUEL INJECTION QUANTITY CIRCUIT (Symptom Code 4) (Flash Code 77) Check
MALFUNCTION ....................................... 6E-340 Engine Lamp (MIL) Circuit Voltage Low .. 6E-357
(SYMPTOM CODE B) (FLASH CODE 51) (Symptom Code 8) (Flash Code 77) Check
FUEL INJECTION QUANTITY CIRCUIT Engine Lamp (MIL) Circuit Voltage High . 6E-360
MALFUNCTION ....................................... 6E-340 SYMPTOM DIAGNOSIS ............................ 6E-361
Circuit Description ..................................... 6E-340 PRELIMINARY CHECKS .......................... 6E-361
Diagnostic Aids .......................................... 6E-341 VISUAL/PHYSICAL CHECK ...................... 6E-361
Diagnostic Trouble Code (DTC) P1630 INTERMITTENT ........................................ 6E-361
(Symptom Code A) (Flash Code 51) Fuel ENGINE CRANKS BUT WILL NOT RUN .. 6E-362
Injection Quantity Circuit Malfunction ...... 6E-341 HARD START SYMPTOM ......................... 6E-366
Diagnostic Trouble Code (DTC) P1630 ROUGH, UNSTABLE, OR INCORRECT
(Symptom Code B) (Flash Code 51) Fuel IDLE, STALLING SYMPTOM .................. 6E-370
Injection Quantity Circuit Malfunction ...... 6E-341
SURGES AND/OR CHUGS SYMPTOM ... 6E-377
HESITATION, SAG, STUMBLE SYMPTOM 6E-383
(SYMPTOM CODE A)
CUTS OUT, MISSES SYMPTOM .............. 6E-389
(FLASH CODE 44) CAN DEVICE OFFLINE 6E-342
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM .............................. 6E-396
CAN DEVICE HANG-UP ......................... 6E-342 POOR FUEL ECONOMY SYMPTOM ....... 6E-402
Circuit Description ..................................... 6E-342 EXCESSIVE WHITE SMOKE .................... 6E-407
Diagnostic Aids .......................................... 6E-342 EXCESSIVE BLACK SMOKE .................... 6E-413
Diagnostic Trouble Code (DTC) P1650 ON-VEHICLE SERVICE PROCEDURE .... 6E-418
(Symptom Code A) (Flash Code 44) ENGINE CONTROL MODULE (ECM) ... 6E-418
CAN Device Offline .................................. 6E-343 CRANKSHAFT POSITION (CKP) SENSOR 6E-419
Diagnostic Trouble Code (DTC) P1650 ENGINE COOLANT TEMPERATURE
(Symptom Code B) (Flash Code 44) (ECT) SENSOR ....................................... 6E-419
CAN Device Hang-up .............................. 6E-348 MASS AIR FLOW (MAF) & INTAKE AIR
DIAGNOSTIC TROUBLE CODE (DTC) P1651 TEMPERATURE (IAT) SENSOR ............ 6E-420
(SYMPTOM CODE A) (FLASH CODE 45) THROTTLE POSITION SENSOR (TPS) ... 6E-420
CAN MALFUNCTION .............................. 6E-349 EGR EVRV
DIAGNOSTIC TROUBLE CODE (DTC) P1651 (Electrical Vacuum Regulating Valve) ..... 6E-421
CAN RECEIVES ERROR ........................ 6E-349
(Symptom Code A) (Flash Code 45)
CAN Malfunction ...................................... 6E-350
(Symptom Code B) (Flash Code 45)
ABBREVIATION CHARTS
Abbreviations Appellation
A/C Air conditioner
A/T Automatic transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CAN Controller Area Network
CEL Check engine lamp
CKP Crankshaft position sensor
DLC Data link connector
DTC Diagnosis trouble code
DVM Digital voltage meter
ECM Engine control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Exhaust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VCC Voltage constunt control
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
Engine Component Locator Table
4JA1-TC
3 1 2 6 4 5
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler
(3) Air Cleaner Case
4JH1-TC
4 5
2 6 4
3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
3 2 4
(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

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

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

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

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

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

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

B-58 C-94
Black Check connector White TCM

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

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

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

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

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

C-44 C-116
White Stop lamp switch


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

C-123 E-41
Black Coolant temp sensor

C-124 E-44
Gray Vehicle speed sensor

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

E-6 E-51
Black Inhibiter switch

E-9 H-4
White Engine room ~ Mission

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

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


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

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

P-2
Silver Relay & Fuse box

P-5
Silver Battery (-)

P-6
Silver Body earth (Ground)

P-10
Silver Engine ground

X-5
Black Relay ; Glow

X-13
Black Relay ; ECM MAIN

X-14
Black Relay; A/C Compressor

X-15
Black Relay; Thermo

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

SLOW BLOW FUSE
NO.
4JA1-TC/4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2
FUSE AND RELAY LOCATION (LHD & RHD)
FUSE BOX
FUSE
No. Capacity Indication on label No. Capacity Indication on label
1 12 15A CIGER
2 10A ABS 13 15A AUDIO (+B)
3 14 20A DOOR LOCK
4 15A BACK UP 15 10A METER (+B)
5 15A METER 16 10A ROOM
6 10A TURN 17 10A ANTI THEFT
7 15A ELEC.IG 18 15A STOP
8 15A ENGINE 19 15A ACC SOCKET
9 20A FRT WIPER 20 10A STARTER
10 15A EGR 21 10A SRS
11 10A AUDIO
SLOW BLOW FUSE
No. Capacity Indication on label
SBF-10 20A RR DEF
SBF-11 30A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
4JA1-TC, 4JH1-TC REAR POWER ACC
DEFOGGER WINDOW SOCKET
ECM WIRING DIAGRAM (1/7)
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Signal or Continuity Tester Position
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
1 1 ECM Ground BLK Continuity - - - Discon- Ohm 1 GND
with nect
ground
2 2 ECM Ground BLK Continuity - - - Discon- Ohm 2 GND
with nect
ground
3 3 Battery Power Supply BLU/ Less than 10-14V Connect DC V 3 GND
RED 1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output LGN - - Approx. Approx. Connect AC V 27 GND
(To Tacho Meter) 23Hz by 67Hz by
wave form wave form
or approx. or approx.
6.3V 6.8V
28 28 No Connection - - - - - - - - -
29 29 No Connection - - - - - - - - -
30 30 Brake Switch 1 Signal GRN Less than Pedal is not stepped on: Less than 1V Connect DC V 30 GND
1V Pedal is stepped on: 10-14V
31 31 Clutch Switch Signal YEL Less than Pedal is not stepped on: 10-14V Connect DC V 31 GND
(MT Only) 1V Pedal is stepped on: Less than 1V
32 32 No Connection - - - - - - - - -
33 33 A/C ON Signal Relay GRN/ Less than A/C request switch is turned on: 10- Connect DC V 33 GND
YEL 1V 14V
A/C request switch is turned off: Less
than 1V
34 34 No Connection - - - - - - - - -
35 35 To Data Link Connec- YEL - - - - - - - -
tor No. 6 & Immobi-
lizer Control Unit (ICU
B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position Sen- GRN/ Less than Less than 1V Approx. Connect DC V 38 49
sor (TPS) Output Sig- ORG 1V 0.5V
nal
39 39 Key Switch Input Sig- WHT Less than 10-14V Connect DC V 39 GND
nal Via Engine Fuse 1V
40 40 No Connection - - - - - - - - -
tion
41 41 A/C Compressor WHT/ Less than 10-14V A/C comp. is operated: Connect DC V 41 GND
Relay GRN 1V Less than 1V
A/C comp. is not oper-
ated: 10 - 14V
42 42 Check Engine Lamp GRN/ Less than Lamp is turned on: Less than 1V Connect DC V 42 GND
YEL 1V Lamp is turned off: 10-14V
43 43 Glow Lamp ORG/ Less than Lamp is turned on: Less than 1V Connect DC V 43 GND
BLU 1V Lamp is turned off: 10-14V
44 44 No Connection - - - - - - - - -
45 45 To Data Link Connec- BLU Less than 10-14V Connect DC V 45 GND
tor No. 6 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position Sen- BLK/ Idle: - - - Discon- Ohm 38 49
sor (TPS) Ground GRN Approx. nect
0.4K ohm /
WOT:
Approx.
4.0K ohm
50 50 No Connection - - - - - - - - -
51 51 No Connection - - - - - - - - -
52 52 No Connection - - - - - - - - -
53 53 No Connection - - - - - - - - -
54 54 No Connection - - - - - - - - -
55 55 No Connection - - - - - - - - -
56 56 No Connection - - - - - - - - -
57 57 Throttle Position Sen- RED/ Less than Approx. 5V Connect DC V 57 49
sor (TPS) Power Sup- GRN 1V
ply
58 58 ECM Relay BLU/ 10-14V Less than 1V Connect DC V 58 GND
BLK
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply Less than 10-14V - DC V 63 GND
1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/ Less than Pedal is not stepped on: 10-14V Connect DC V 65 GND
BLK 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed 20km/h
69 69 Idle Switch GRN/ Less than Pedal is not stepped on: Less than 1V Connect DC V 69 GND
BLK 1V Pedal is stepped on: Approx. 5V
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
tion
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/ Less than Approx. 5V Connect DC V 83 92
Sensor Power Supply RED 1V
84 84 Intake Air Tempera- BLK/ Less than 0 deg. C: Approx. 3.6V / 20 deg. C: Connect DC V 84 92
ture (IAT) Sensor Sig- BLU 1V Approx. 2.6V / 40 deg. C: Approx.
nal 1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/ Less than In neutral: Less than 1V Connect DC V 87 GND
WHT 1V Other than neutral: 10-14V
88 88 Mass Air Flow (MAF) GRN/ Less than Approx. 1V Approx. Approx. Connect DC V 88 92
Sensor Signal RED 1V 1.8V 2.5V
89 89 Engine Coolant Tem- GRY Less than 0 deg. C: Approx. 4.4V / 20 deg. C: Connect DC V 89 93
perature (ECT) Sen- 1V Approx. 3.8V / 40 deg. C: Approx.
sor Signal 2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 134Hz by
wave form wave form
or approx.
1.1V
91 91 CKP Sensor Output PNK - - Approx. Approx. Connect AC V 91 GND
To Pump Control Unit 47Hz by 134Hz by
(PSG) No.8 wave form wave form
or approx.
0.7V
92 92 Mass Air Flow (MAF) BLK/ Continuity - - - Connect Ohm 92 GND
Sensor Ground RED with
ground
93 93 Engine Coolant Tem- BLK/ Continuity - - - Connect Ohm 93 GND
perature (ECT) Sen- PNK with
sor Ground ground
94 94 Glow Relay BLK/ Less than Glow system is operated: Less than Connect DC V 94 GND
RED 1V 1V
Glow system is not operated: 10 - 14V
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ - - Approx. 140Hz by wave - - - -
ORG form when EVRV is
operated
98 98 CKP Sensor Ground WHT Continuity - - - Connect Ohm 98 GND
with
ground
99 99 CAN (Controller Area BLU - - - - - - - -
Network) to PSG No.1
100 100 CAN (Controller Area YEL - - - - - - - -
Network) to PSG No.2
tion
101 101 CKP Sensor Shield BLK Continuity - - - Connect Ohm 101 GND
Line with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - - - - - - - -
Off (MAB) Output Sig-
nal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM & Rang (+) (-)
No. Box Color Off On Idle 2000rpm PSG Con- e
No. nection
1 99 CAN (Controller Area RED Continu- - - - Discon- Ohm 1 99

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Sensor (TPS) GRN Approx. nect
Ground 0.4K
ohm /
WOT:
Approx.
4.0K
ohm
50 50 No Connection - - - - - - - - -
51 51 No Connection - - - - - - - - -
52 52 No Connection - - - - - - - - -
53 53 No Connection - - - - - - - - -
54 54 No Connection - - - - - - - - -
55 55 No Connection - - - - - - - - -
56 56 No Connection - - - - - - - - -
57 57 Throttle Position RED/ Less Approx. 5V Connect DC V 57 49

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

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

than 1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Sig- WHT/ Less Pedal is not stepped on: 10-14V Connect DC V 65 GND
nal BLK than 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed
20km/h
69 69 Idle Switch GRN/ Less Pedal is not stepped on: Less than Connect DC V 69 GND
BLK than 1V 1V
Pedal is stepped on: Approx. 5V
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
82 82 Boost Pressure Sen- WHT/ Less Approx. 5V Connect DC V 82 93

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The analogue CKP sensor signal is converted by the
Engine Speed Fuel Temperature
Engine
Control Injection Timing
ECM into a square wave signal.

Module
Accelerator Pedal (ECM) High Pressure
The fuel cutoff solenoid valve signal is also referred to

Injection Quantity Solenoid Valve
Pump
Intake Air Temperature Control Fuel Injection
Response Signal
Unit
(PSG)
(Mechanical)
as MAB signal.
MAB in this case, refers to the German abbreviation
Mass Air Flow
Additional Signal
Others Timing Device Magnet ventil ABschaltung that stands for high pressure
Additional Operations To Timing Control Valve (TCV)
solenoid valve cut off.
The MAB signal wire is used for two purposes.
-As a reference for the engine control module (ECM) for
the pump speed (back up for the CKP sensor).
-To turn Off the engine.
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
The following signals are exchanged via the CAN-bus:
From ECM to PSG
Desired injection quantity
Desired injection timing !"#"$%&#'(%'$ )* +,- .&/()# 01&*&#&/$&0
Engine speed
233333
From PSG to ECM 23333
1&('(%"/$& @)!=C @.)D'A E'/&C

Fuel temperature
Pump speed 2333
Cylinder identifier
Control pulse (actual injection quantity + actual
233
injection timing)
PSG status
23
043 053 023 3 23 53 43 63 73 83 93 :3 ;3 233 223
+/%"<& ,'# -&=>? @A&B? C @-&$!5 1&"A'/BC
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor
The IAT sensor is a thermistor. A temperature changes

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

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

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

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

(1) Engine Coolant Temperature (ECT) Sensor
(2) Thermo Unit for Water Temperature Gauge
!"#"$%&#'(%'$ )* + , -&.()# /0&*&#&.$&/

122222
12222
0&('(%".$& ?)!=B ?-)<'@ C'.&B
1222
122
12
/32 /42 /12 2 12 42 32 52 62 72 82 92 :2 122 112 142 132
+.;'.& ))<".% ,&=> ?@&;A B ?,&$!4 0&"@'.;B
A/T 2WD
The VSS is a magnet rotated by the transmission output

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

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

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

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

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

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

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

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

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

have an effective, organized plan for your work.
As a retail service technician, you are part of the ISUZU Strategy Based Diagnostics (refer to Figure 1) provides
service team. The team goal is FIX IT RIGHT THE you with guidance as you create and follow a plan of
FIRST TIME for the satisfaction of every customer. You action for each specific diagnostic situation.
are a very important member of the team as you
diagnose and repair customer vehicles.
STRATEGY BASED DIAGNOSTICS CHART
Diagnostic Thought Process Circuit testing tools
Vehicle road tests
As you follow a diagnostic plan, every box on the
Complaint check sheet
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking Contact with the customer
optimizes your diagnosis in the following ways:
Improves your understanding and definition of the 2. Perform Preliminary Checks
customer complaint
NOTE: An estimated 10 percent of successful vehicle
Saves time by avoiding testing and/or replacing good repairs are diagnosed with this step!
parts
Allows you to look at the problem from different What you should do
perspectives
You perform preliminary checks for several reasons:
Guides you to determine what level of understanding
about system operation is needed: To detect if the cause of the complaint is VISUALLY
OBVIOUS
Owners manual level
To identify parts of the system that work correctly
Service manual level
To accumulate enough data to correctly and
In-depth (engineering) level
accurately search for a ISUZU Service Bulletin on
Owners manual level ISUZU Web site.
Service manual level The initial checks may vary depending on the
In-depth (engineering) level complexity of the system and may include the following
actions:
1. Verify the Complaint Operate the suspect system

Make a visual inspection of harness routing and
What you should do accessible/visible power and ground circuits
Check for blown fuses
To verify the customer complaint, you need to know the
Make a visual inspection for separated connectors
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the Make a visual inspection of connectors (includes
system. checking terminals for damage and tightness)
The following information will help you verify the Check for any DTCs stored by the on-board
complaint: computers
WHAT the vehicle model/options are Sense unusual noises, smells, vibrations or
WHAT aftermarket and dealer-installed accessories movements
exist Investigate the vehicle service history (call other
WHAT related system(s) operate properly dealerships, if appropriate)
WHEN the problem occurs
What resources you should use
WHERE the problem occurs
HOW the problem occurs Whenever appropriate, you should use the following
resources for assistance in performing preliminary
HOW LONG the condition has existed (and if the
checks:
system ever worked correctly)
Tech II or other technical equipment for viewing DTCs
HOW OFTEN the problem occurs
Service manual information:
Whether the severity of the problem has increased,
decreased or stayed the same Component locations
Harness routing
What resources you should use Wiring schematics
Whenever possible, you should use the following Procedures for viewing DTCs
resources to assist you in verifying the complaint: Dealership service history file
Service manual Theory or Circuit Description Vehicle road test
sections Identical vehicle or system for comparison
Service manual System Performance Check
Owner manual operational description
Technician experience
Identical vehicle for comparison
3. Check Bulletins and to the customer complaint.
Troubleshooting Hints What resources you should use
NOTE: As estimated 30 percent of successful vehicle Whenever appropriate, you should use the following
repairs are diagnosed with this step! resources to perform service manual diagnostic
procedures:
What you should do Service manual
You should have enough information gained from Technical equipment (for analyzing diagnostic data)
preliminary checks to accurately search for a bulletin Digital multimeter and circuit testing tools
and other related service information. Some service
manual sections provide troubleshooting hints that Essential and special tools
match symptoms with specific complaints.
5c. Technician Self Diagnoses
When there is no DTC stored and no matching
You should use the following resources for assistance in symptom for the condition identified in the service
checking for bulletins and troubleshooting hints: manual, you must begin with a thorough understanding
Printed bulletins of how the system(s) operates. Efficient use of the
service manual combined with you experience and a
Access ISUZU Bulletin Web site.
good process of elimination will result in accurate
Videotapes diagnosis of the condition.
Service manual
What you should do
4. Perform Service Manual
Step 1: Identify and understand the suspect
Diagnostic Checks circuit(s)
Having completed steps 1 through 4 of the Strategy
What you should do Based Diagnostics chart, you should have enough
The System Checks in most service manual sections information to identify the system(s) or sub-system(s)
and in most cells of section 8A (electrical) provide you involved. Using the service manual, you should
with: determine and investigate the following circuit
A systematic approach to narrowing down the characteristics:
possible causes of a system fault Electrical:
Direction to specific diagnostic procedures in the How is the circuit powered (power distribution
service manual charts and/or fuse block details)?
Assistance to identify what systems work correctly How is the circuit grounded (ground distribution
charts)?
What resources you should use How is the circuit controlled or sensed (theory of
Whenever possible, you should use the following operation):
resources to perform service manual checks: If it is a switched circuit, is it normally open or
Service manual normally closed?
Technical equipment (for viewing DTCs and Is the power switched or is the ground
analyzing data) switched?
Digital multimeter and circuit testing tools Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
Other tools as needed
Is it a signal generating device (MAF sensor of
VSS, for example)?
5a and 5b. Perform Service Manual Does it rely on some mechanical/vacuum
Diagnostic Procedures device to operate?
NOTE: An estimated 40 percent of successful vehicle Physical:
repairs are diagnosed with these steps! Where are the circuit components (component
locators and wire harness routing diagrams):
What you should do Are there areas where wires could be chafed
When directed by service manual diagnostic checks, or pinched (brackets or frames)?
you must then carefully and accurately perform the Are there areas subjected to extreme
steps of diagnostic procedures to locate the fault related temperatures?
Are there areas subjected to vibration or at the component
movement (engine, transmission or If a number of components do no operate, begin tests
suspension)? at the area of commonality (such as power sources,
Are there areas exposed to moisture, road salt ground circuits, switches or major connectors)
or other corrosives (battery acid, oil or other
fluids)? What resources you should use
Are there common mounting areas with other Whenever appropriate, you should use the following
systems/components? resources to assist in the diagnostic process:
Have previous repairs been performed to wiring, Service manual
connectors, components or mounting areas
Technical equipment (for data analysis)
(causing pinched wires between panels and
drivetrain or suspension components without Experience
causing and immediate problem)? Technical Assistance
Does the vehicle have aftermarket or dealer- Circuit testing tools
installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 Engine Speed rpm 730 1475 - 1975 - The engine speed is measured by ECM from the CKP
1525 2025 sensor.
2 Vehicle Speed km/h / MPH 0 0 0 This displays vehicle speed. The vehicle speed is
measured by ECM from the vehicle speed sensor.
3 Pump Speed rpm 345 - 385 725 - 775 975 - 1025 This displays injection pump speed. The injection speed is
measured by ECM from the pump cam sensor.
4 Accelerator Position % 0 4-6 6-8 Throttle position operating angle is measured by the ECM
Sensor Signal from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Active Active Inactive 0V This displays operating status of the idle switch. This
Inactive 0V should display "Active" until the accelerator position nearly
4 - 5%.
6 Mass Air Flow mg/strk 380 - 420 360 - 400 380 - 420 This displays calculated intake air volume for one cylinder
Sensor stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
7 Desired Mass Air mg/strk 350 350 350 - 370 This displays desired intake air volume for one cylinder
Flow stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
8 Barometric Pressure hpa Depends Depends Depends The barometric pressure is measured by ECM from the
on altitude on altitude on altitude sensor in the ECM. This data is changing by altitude.
9 Desired Injection mg/stk 8 - 10 6 - 10 7 - 10 This displays desired value from the ECM. The ECM
Quantity compensates for fuel rate to basic rate.
10 Injection Quantity mg/stk 8 - 10 5 - 10 5-9 This displays calculated actual fuel quantity from the PSG.
The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
11 Desired Fuel Injection deg. CA 2-4 2- 5 3-5 This displays desired injection timing from the ECM. The
Start ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12 Actual Injection Start deg. CA 2-4 2-5 3-5 This displays calculated actual injection timing based on
CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
13 Coolant Temperature deg. C / deg. 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
F voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
14 Fuel Temperature deg. C / deg. Depends Depends Depends The FT is measured by PSG from FT sensor. This data is
F on fuel on fuel on fuel changing by fuel temperature.
temp. temp. temp.
15 Intake Air deg. C / deg. Depends Depends Depends The IAT is measured by ECM from IAT sensor output
Temperature F on ambient on ambient on ambient voltage. This data is changing by intake air temperature.
temp. temp. temp.
16 Ignition Status On12V/ On 12V On 12V On 12V This displays the key switch status indicated by the ECM
Off0V with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
17 Brake Switch 1 Active/ Inactive Inactive Inactive This displays operating status of the brake switch. This
Inactive should display "Active" when the brake pedal is stepped
on.
Tech 2 Parameter Units Idle 1500rpm 2000rpm Description
on.
19 Clutch Switch Active/ Inactive Inactive Inactive This displays operating status of the clutch switch. This
Inactive should display "Active" when the clutch pedal is stepped
on.
20 Neutral Switch On/Off On On On This displays operating status of the neutral switch. This
should display "On" when the gear position is neutral.
21 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display "Active 12V" when the air conditioner switch
is switched on.
22 Diagnostic Request Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Inactive 12V 12V 12V 12V display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 14 10 - 14 10 - 14 This displays the system voltage measured by the ECM at
ignition feed.
24 Main Relay Active/ Active Active Active This displays operating status for the ECM main relay. This
Inactive should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display "Inactive 12V" when the engine is warm
upped.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This should display "On" when the glow lamp is turned on.
28 Desired Engine Idle rpm 730 730 730 The desired engine idle speed that the ECM commanding.
Speed The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor. This
Inactive 12V 12V 12V 12V should display "Active 0V" when the compressor relay is
operated.
30 Immobilizer Active/ Inactive Inactive Inactive This should display "Inactive" when the immobilizer is
Inactive correctly operated.
31 Immobilizer Signal Received/ Not Not Not This should display "Not Received" when the immobilizer is
Not Received Received Received not activated.
Received
32 Immobilizer Function Yes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
Programmed programmed.
33 EGR Pulse Ratio % 70 70 70 This displays the duty signal from the ECM to control the
(Exhaust Gas EGR flow amount.
Recirculation)
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition
1 Engine Speed rpm 675 - 725 1475 - 1975 - The engine speed is measured by ECM from the CKP
1525 2025 sensor.
2 Vehicle Speed km/h / MPH 0 0 0 This displays vehicle speed. The vehicle speed is
measured by ECM from the vehicle speed sensor.
3 Pump Speed rpm 335 - 375 725 - 775 975 - 1025 This displays injection pump speed. The injection speed is
measured by ECM from the pump cam sensor.
4 Accelerator Position % 0 3-5 5-7 Throttle position operating angle is measured by the ECM
Sensor Signal from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Active Active/ Inactive 0V This displays operating status of the idle switch. This
Inactive 0V Inactive 0V should display "Active" until the accelerator position nearly
4 - 5%.
6 Mass Air Flow mg/strk 420 - 490 380 - 460 410 - 480 This displays calculated intake air volume for one cylinder
Sensor stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
7 Desired Mass Air mg/strk 430 - 470 380 - 420 410 - 470 This displays desired intake air volume for one cylinder
Flow stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
8 Barometric Pressure hpa Depends Depends Depends The barometric pressure is measured by ECM from the
on altitude on altitude on altitude sensor in the ECM. This data is changing by altitude.
9 Desired Injection mg/stk 6 - 10 6 - 10 7 - 11 This displays desired value from the ECM. The ECM
Quantity compensates for fuel rate by throttle position and various
sensor signals.
10 Injection Quantity mg/stk 6 - 10 6 - 10 7 - 11 This displays calculated actual fuel quantity from the PSG.
The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
11 Desired Fuel Injection deg. CA 1-3 2-4 3-5 This displays desired injection timing from the ECM. The
Start ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12 Actual Injection Start deg. CA 1-3 2-4 3-5 This displays calculated actual injection timing based on
CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
13 Coolant Temperature deg. C / deg. 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
F voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
14 Fuel Temperature deg. C / deg. Depends Depends Depends The FT is measured by PSG from FT sensor. This data is
F on fuel on fuel on fuel changing by fuel temperature.
temp. temp. temp.
15 Intake Air deg. C / deg. Depends Depends Depends The IAT is measured by ECM from IAT sensor output
Temperature F on ambient on ambient on ambient voltage. This data is changing by intake air temperature.
temp. temp. temp.
16 Ignition Status On12V/ On 12V On 12V On 12V This displays the key switch status indicated by the ECM
Off0V with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
on.
Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition
on.
19 Clutch Switch (M/T Active/ Inactive Inactive Inactive This displays operating status of the clutch switch. This
Only) Inactive should display "Active" when the clutch pedal is stepped
on.
20 Neutral Switch On/Off On On On This displays operating status of the neutral switch. This
should display "On" when the gear position is neutral (M/T)
or P, N position (A/T).
21 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display "Active 12V" when the air conditioner switch
is switched on.
22 Diagnostic Request Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Inactive 12V 12V 12V 12V display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 15 10 - 15 10 - 15 This displays the system voltage measured by the ECM at
ignition feed.
24 Main Relay Active/ Active Active Active This displays operating status for the ECM main relay. This
Inactive should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display "Inactive 12V" when the engine is warm
upped.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This should display "On" when the glow lamp is turned on.
28 Desired Engine Idle rpm 700 700 700 The desired engine idle speed that the ECM commanding.
Speed The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor. This
Inactive 12V 12V 12V 12V should display "Active 0V" when the compressor relay is
operated.
30 Immobilizer Active/ Inactive Inactive Inactive This should display "Inactive" when the immobilizer is
Inactive correctly operated.
31 Immobilizer Signal Received/ Not Not Not This should display "Not Received" when the immobilizer is
Not Received Received Received not activated.
Received
32 Immobilizer Function Yes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
Programmed programmed.
33 EGR Pulse Ratio % 85 - 90 85 - 90 85 - 90 This displays the duty signal from the ECM to control the
(Exhaust Gas EGR flow amount.
Recirculation)
MISCELLANEOUS TEST F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
The state of each circuit can be tested by using increases 50rpm-by-50rpm up to 1200rpm.
miscellaneous test menus. Especially when DTC The circuit is correct if engine speed is changed in
cannot be detected, a faulty circuit can be diagnosed by accordance with this operation.
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
Engine Speed (RPM) Control
these menus could help discriminate between a
mechanical trouble and an electrical trouble. Engine Speed 850 rpm
Connect Tech 2 and select "Powertrain", "4JA1-TC Desired Idle Speed 850 rpm
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
Injection Quantity 7.5 mg/ strk
F0: Lamps
F0: Glow Time Telltale Test
Press "Increase" key.
When the Tech 2 is operated, "Glow Time Indicator
Then, Desired Idle speed is increases
Lamp" is turned on or off.
50rpm-by-50rpm up to 1200rpm. Engine speed is
The circuit is correct if the "Glow Time Indicator Lamp"
also
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
EGR Solenoid Test

Desired Mass Air Flow 470 mg/strk
Mass Air Flow 450 mg/strk
Engine Speed 700 rpm
Exhaust Gas Recirculation 95%
Press "Active" key.

Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%
Plotting Snapshot Graph
This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)
SNAPSHOT DISPLAY WITH TIS2000
Procedures for transferring and displaying Tech2 By analyzing these data in various methods, trouble
snapshot data by using TIS2000 [Snapshot Upload] conditions can be checked.
function is described below. Snapshot data is displayed by executing the three steps
Snapshot data can be displayed with [Snapshot Upload] below shown:
function included in TIS2000.
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.

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

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

Year, Vehicle Type. 1. Connect Tech-2 to P/C, turn on the power and click
7. After that. then push button and turn Ignition switch the Next button of P/C.
tuned on, off, on following Tech-2 display. Tech-2 2. Check VIN of the vehicle and choose Next.
will read information from controller after this
3. Select System Type for required control unit.
procedure.
Engine (Programming for ECM or PCM)
8. During obtaining information, Tech-2 is receiving
information from the control unit ECM and TCM (A/T Transmission (Programming for TCM)
only) at the same time. With VIN not being 4. When a lack of data is asked from among the
programmed into the new control unit at the time of following menu, enter accordingly.
shipment, "obtaining information" is not complete Select following Menu
(because the vehicle model, engine model and Model Year
model year are specified from VIN). For the
Model
procedure get additional information on vehicles,
instruction will be provided in dialog form, when Engine type
TIS2000 is in operation. Transmission type
9. Following instructions by Tech-2, push the Exit Destination code (vehicles for general export)*1
switch of Tech-2, turn off the ignition of the vehicle Immobilizer
and turn off the power of Tech-2, thereby removing Etc.
from the vehicle. * 1: How to read the destination code
Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
the figure, the destination code can be read as "RR3"
(Australia).
5. After choosing the data, click the Next button. 4. Programming of ECM
6. When all the necessary information is entered, the 1. Check to see if batteries are fully charged, while
details of software within the database that match ABS connectors shall be removed from the vehicle.
the entered data will appear for confirmation. Click 2. Connect Tech-2 to Vehicle Diagnostic Connectors.
the Program switch and then download the new
3. Turn on the power of Tech-2 and the title screen
software onto Tech-2.
comes on display.
7. Data Transfer comes on display. The progress of
4. Turn on the ignition (without allowing the engine to
downloading will be displayed on the screen in the
start)
form of bar graph.
5. On the title screen of Tech-2, push the Enter
8. Upon finishing the data transfer, turn off the power
button.
of Tech-2, removing from P/C.
6. Choose F1: Service Programming System on the
main screen and then choose Fl: Program ECU.
7. While data is being transferred, Programming in
Progress will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
Reprogramming Was Successful. Push the Exit
button to bring program to completion
9. Following Procedure 2: Demand of Data, try over
again Information Obtaining and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.
HOW TO USE BREAKER BOX
! " #
(1) Engine Control Module (ECM) (3) Breaker Box

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

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

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

and short to ground circuit.
Breaker Box Connection Type B
# $ " % !
(1) Engine Control Module (ECM) (4) Digital Voltage Meter

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

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

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

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

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

communication circuit.
2. Disconnect the ECM connector.
3. Check the circuit for open or short to ground
circuit.
C-56
!"
!
!
B-58
#
Repair faulty
harness and
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the SPS (Service Programming System).
Was the problem solved? Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 Immobilizer System-ECM replacement for
the ECM/Immobilizer linking procedure. Verify repair
NO CHECK ENGINE LAMP (MIL)
Circuit Description wire broken inside the insulation. Check for the
following items:
The check engine lamp should be illuminated and
steady for about five seconds with the ignition ON and Inspect the ECM harness and connections for
the engine stopped. Ignition feed voltage is supplied to improper mating, broken locks, improperly formed or
the check engine lamp bulb through the meter fuse. damaged terminals, poor terminal-to-wire connection,
The Engine Control Module (ECM) turns the check and damaged harness.
engine lamp ON by grounding the check engine lamp If the engine runs OK, check for a faulty light bulb, an
driver circuit. open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
Diagnostic Aids If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
An intermittent check engine lamp may be cased by a
engine ground.
poor connection, rubbed-through wire insulation, or a
No Check Engine Lamp (MIL)
1 Check the meter fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found? Verify repair Go to Step 2
2 Using the DVM and check the CHECK ENGINE
lamp circuit.
3. Ignition On.
C-56
42
V
10-14.5V Go to Step 5 Go to Step 3
3 Check the CHECK ENGINE lamp bulb.
If the bulb is burnt out, repair as necessary.
lamp circuit.
2. Disconnect the meter connector and ECM
connector.
C-56
42
B-24
17 Verify repair Go to Step 5

release?

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

The check engine lamp should always be illuminated An intermittent may be caused by a poor connection,
and steady for about five seconds with ignition ON and rubbed-through wire insulation, or a wire broken inside
the engine stopped. Ignition feed voltage is supplied the insulation. Check for the following items:
directly to the check engine lamp indicator. The Engine Poor connection or damaged harness Inspect the
Control Module (ECM) turns the check engine lamp ECM harness and connectors for improper mating,
ON by grounding the check engine lamp driver circuit. broken locks, improperly formed or damaged
The check engine lamp should not remain ON with the terminals, poor terminal-to-wire connection, and
engine running and no DTC(s) set. A steady check damaged harness.
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Check Engine Lamp (MIL) On Steady
1 1. Ignition Off, engine Off.
3. Ignition On.
Was the CHECK ENGINE lamp turned on? Go to Step 2 Go to Step 4
lamp circuit.
connector.
3. Check the circuit for short to ground circuit.
C-56
42
B-24
17
Verify repair Go to Step 3

3 Replace the meter assembly.
Is the action complete? Verify repair
release?
5 Replace the ECM.
ECM Diagnostic Trouble Codes
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% voltage is below 5.2V. circuit short to battery
Input conditions as substitute. voltage circuit. 83
2. MAFsensormalfunction.
3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V. voltage is more than 4.6V. circuit short to ground
Input circuit. 83
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is more 1. Sensor power supply
Output Circuit Low Input 600rpmand5000rpm. than -27.4mg/strk. circuit open circuit.
2. MAF sensor output is 2. Sensor signal circuit
below -33.7mg/strk. open or short to ground
circuit.
3. Sensor heater harness 83/
P0110(1)
open circuit. 88
4. Poor connector
connection.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is below 1. Sensor signal circuit
Output Circuit High Input 600rpmand5000rpm. 1378mg/strk (4JA1-TC) or shortto voltagecircuit.
2. MAF sensor output is 1784mg/strk (4JH1-TC). 2. Sensor ground circuit
more than 1378mg/strk open or short to voltage 88/
P0110(1)
(4JA1-TC) or 1784mg/ circuit. 92
strk (4JH1-TC). 3. MAFsensormalfunction.
4. ECM malfunction.
34 P0105 1 ON Vacuum Pressure Sensor Vacuum sensor output 1. Fuel injection quantity is Vacuum sensor output 1. Sensor signal circuit
Circuit High Input voltage is more than 4.4V. reduced. voltage is below 4.4V. shortto voltagecircuit.
2. ECM use 615hpa 2. Sensor ground circuit
conditions for open or short to voltage 85/
turbocharger waste gate circuit. P0115(1)
93
control. 3. Vacuum sensor
malfunction.
4. ECM malfunction.
2 ON Vacuum Pressure Sensor Vacuum sensor output Vacuum sensor output 1. Sensor power supply
Circuit Low Input voltage is below 0.5V. voltage is more than 0.5V. circuit open circuit.
2. Sensor signal circuit
open or short to ground
circuit. 82/

3. Poor connector 85
connection.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
Related Related
No. DTC
34 P0105 7 ON Vacuum Pressure Sensor Vacuum sensor power 1. Fuel injection quantity is Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit High supply voltage is more than reduced. supply voltage is below 5.2V. circuit short to battery
Input 5.2V. 2. ECM use vacuum sensor voltage circuit.
82
output voltage 5.0V 2. Vacuum sensor
condition as substitute. malfunction.
3. ECM malfunction.
9 ON Vacuum Pressure Sensor Vacuum sensor power Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit Low supply voltage is below 4.5V. supply voltage is more than circuit short to ground
Input 4.5V. circuit.
82
2. Vacuum sensor
malfunction.
3. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0 deg. C conditions IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit High Input more than 4.7V. as substitute. below 4.7V. open or short to voltage
circuit.
2. Sensor ground circuit
open or short to voltage 84/ P0100(B)/
circuit. 92 P0100(C)
3. Poor connector
connection
4. IATsensormalfunction.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit Low Input below 0.3V. more than 0.3V. shortto groundcircuit.
84
2. IATsensormalfunction.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit High more than 4.7V. temperature as below 4.7V. open or short to voltage
Input substitute. circuit.
2. ECM uses 60 deg. C 2. Sensor ground circuit
condition for injection open or short to voltage
89/
timing control. circuit. P0105(1)
93
3. ECM uses -25 deg. C 3. Poor connector
condition (4JA1-TC) or - connection
15 deg. C condition 4. ECTsensormalfunction.
(4JH1-TC) for glow time
5. ECM malfunction.
control.
2 ON Engine Coolant Temperature ECT sensor output voltage is ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit Low below 0.3V. more than 0.3V. shortto groundcircuit.
Input 89
2. ECTsensormalfunction.
3. ECM malfunction.
15 P0180 B ON Fuel Temperature Sensor FT sensor output is high The ECM use 75 deg. C FT sensor output is correct 1. ECM malfunction.
Circuit Range/Performance temperature (more than 150 conditions as substitute. temperature range between 2. PSG (pump control unit)
deg. C) or low temperature 150 deg. C and -40 deg. C. malfunction.
(below -40 deg. C).
Related Related
No. DTC
52 P0215 A ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
Malfunction 2. Engine speed is below valve) is operated. match in the next ignition key malfunction.
1500rpm. 2. Desired injection quantity cycle. 2. MAB (fuel cutoff solenoid
3. Vehicle speed is below becomes 0mg/strk. valve) malfunction.
1.5km/h.
4. PSG (pump control unit)
recognizes MAB (fuel
cutoff solenoid valve)
signal from the ECM, but
the MAB could not
operate.
B ON Fuel Cutoff Solenoid Valve ECM does not command Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid
Circuit High Input MAB (fuel cutoff solenoid valve) signal circuit short
valve) signal to the PSG to voltage circuit.
105
(pump control unit), but PSG 2. PSG (pump control unit)
detected MAB signal line malfunction.
circuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated. match in the next ignition key valve) signal circuit open
1500rpm. 2. Desired injection quantity cycle. orshorttogroundcircuit.
3. Vehicle speed is below becomes 0mg/strk. 2. PSG (pump control unit)
1.5km/h. malfunction.
105
does not recognize MAB
(fuel cutoff solenoid
valve) signal from the
ECM.
D ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction.
Malfunction 2. CAN controller does not 2. PSG (pump control unit)
operate Bus-off. malfunction.
54 P0216 A ON Injection Timing Control 1. Engine speed is more Fuel injection quantity is Deviation of actual injection 1. Timing control valve
Circuit Malfunction than 700rpm. reduced. timing and desired injection malfunction.
2. Fuel injection quantity is timing is more than +3 deg. 2. Timer piston sticking.
more than 4mg/stk. CA or -6 deg. CA for 8
3. Pump camshaft speed
seconds.
3. Deviation of actual sensor malfunction.
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8 seconds.
B ON Injection Timing Control 1. Engine speed is more 1. Engine speed is more 1. Insufficient air bleeding of
Circuit Malfunction than 2014rpm. than 2014rpm. fuel line.
2. Fluctuation of actual 2. Fluctuation of actual 2. Fuel filterclogging.
injection timing is more injection timing is more 3. Timing control valve
than +-5.2 deg. CA. than +-5.2 deg. CA. malfunction.
4. Pump camshaft speed
sensor malfunction.
Related Related
No. DTC
64 P0243 3 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum line is
temperature is between - vacuum pressure - actual obstructed.
50 deg. C and 150 deg. vacuum pressure is less 3. Vacuum is leaking.
C. than 50hpa.)
4. Vacuum pump 85/
3. Barometric pressure is malfunction.
96
between 0hpa and
5. Vacuum sensor
3500hpa.
malfunction.
4. Low vacuum pressure
6. Turbocahrger wastegate
condition. (Desired
valve malfunction.
vacuum pressure - actual
vacuum pressure is more 7. ECM malfunction.
than 50hpa.)
4 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" Low circuit open or short to reduced. circuit is correct condition. circuit open or short to
ground circuit. 2. EGR EVRV becomes ground circuit.
96
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
5 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum regulating valve
temperature is between - vacuum pressure - actual malfunction.
50 deg. C and 150 deg. vacuum pressure is more 3. Vacuum pump
C. than -50hpa.) malfunction. 85/
3. Barometric pressure is 4. Vacuum sensor
96
between 0hpa and malfunction.
3500hpa.
5. ECM malfunction.
4. High vacuum pressure
condition. (Desired
vacuum pressure - actual
vacuum pressure is less
than -50hpa.)
6 ON Turbocharger Wastegate 1. Engine coolant 1. Correct amount of mass 1. Turbocharger wastegate
Solenoid "A" Malfunction temperature is between - air flow. (= Correct boost actuator malfunction.
50 deg. C and 150 deg. pressure condition) 2. Vacuumlinemalfunction.
C. (Desired mass air flow -
3. ECM malfunction.
2. EGR control EVRV 0% actual mass air flow is
condition. more than -56mg/strk.)
3. No DTC relating to MAF
sensor, vacuum sensor &
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow -
actual mass air flow is
less than -56mg/strk.)
Related Related
No. DTC
64 P0243 8 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" High circuit short to voltage circuit. reduced. circuit is correct condition. circuit short to voltage
2. EGR EVRV becomes circuit.
96
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
speed sensor error. valve) is operated. match in the next ignition key malfunction.
2. High pressure solenoid 2. Desired injection quantity cycle. 2. Pump camshaft speed
valve control pulse width becomes 0mg/strk. sensor malfunction.
does not match with
desired fuel injection
quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft 1. No pump camshaft 1. Missing CKP sensor
speed sensor error. speed sensor error. pulses.
2. No CKP sensor error. 2. No CKP sensor error. 2. Electrical interference.
3. Difference of engine 3. Difference of engine 3. Magneticinterference.
speed and doubled pump speed and doubled pump 4. PSG (pump control unit) 91
camshaft speed is more camshaft speed is below malfunction.
than 720rpm (4JA1-TC) 800rpm (4JA1-TC) or
or 690rpm (4JH1-TC). 690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
9 ON Injection Pump Malfunction No pump map programmed No recovery until condition PSG (pump control unit)
in the PSG (pump control match in the next ignition key malfunction.
unit) or PSG malfunction. cycle.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is EEPROM or A/D converter PSG (pump control unit)
malfunction in the PSG reduced. no malfunction in the PSG malfunction.
(pump control unit). (pump control unit).
No recovery until in the next
ignition key cycle.
B ON Injection Pump Malfunction PSG (pump control unit) No fail-safe function. No recovery until condition PSG (pump control unit)
recognized high pressure match in the next ignition key malfunction.

solenoid valve drive circuit cycle.
error.
D ON Injection Pump Malfunction PSG (pump control unit) PSG (pump control unit)
could not measure the high malfunction.

pressure solenoid valve drive
voltage.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump 1. CAN high circuit open,
(pump control unit) message. valve) is operated. control unit) message. short to ground or short
2. Desired injection quantity to voltage circuit.
becomes 0mg/strk. 2. CAN low circuit open,
short to ground or short 99/ P1650(A)/
to voltage circuit. 100 P1651(B)
3. ECM malfunction.
malfunction.
Related Related
No. DTC
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more When pump camshaft speed ECM detects correct CKP 1. During engine run:
Circuit Malfunction than 665rpm. sensor is OK: pulse width. 1. CKP sensor harness
2. CKP sensor pulse width ECM uses doubled pump open circuit, short to
error. camshaft speed as substitute ground or short to
enginespeed. voltage circuit.
When pump camshaft speed 2. Poor connector
sensor is not OK: connection. 90/
1. MAB (fuel cutoff solenoid 3. CKPsensormalfunction. 98/ P1335 (A)
valve) is operated. 101
4. Pulse sensing gap
2. Desired injection quantity incorrect.
becomes 0mg/strk.
5. Pulser malfunction.
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
D ON Crankshaft Position Sensor 1. No pump camshaft When pump camshaft speed 1. Engine speed is more During engine crank:
Circuit Malfunction speed sensor error. sensor is OK: than 0rpm. 1. CKP sensor harness
2. "Crankshaft Position ECM uses doubled pump 2. Doubled pump camshaft open circuit, short to
Sensor Circuit camshaft speed as substitute speed is below 100rpm. ground or short to
Malfunction (Symptom enginespeed. voltage circuit.
CodeB)" isnotstored. Other than pump camshaft
2. Poor connector
speed sensor is OK:
3. Engine speed is 0rpm. connection. 90/
Fuel injection quantity is
4. Doubled pump camshaft 3. CKPsensormalfunction. 98/ P1135 (A)
reduced.
speed is more than 101
4. Pulse sensing gap
50rpm. incorrect.
8. ECM malfunction.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent Engine speed is below 1. Engine over-running.
Range/Performance 5700rpm. malfunction: 5700rpm. 2. CKPsensormalfunction.
1. MAB (fuel cutoff solenoid 3. Pulser malfunction.
valve) is operated.
4. ECM malfunction.
2. Desired injection quantity 90/
becomes 0mg/strk. 98/
When preliminary 101
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function. Glow relay circuit is correct 1. Glow relay circuit open or
Low short to ground circuit. condition. short to groundcircuit.
94
2. Glowrelaymalfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to ECM malfunction.
High voltage circuit.
Related Related
No. DTC
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function. Glow plug indicator circuit is 1. Glow plug indicator
Voltage Low open or short to ground correct condition. circuit open or short to
circuit. ground circuit.
43
2. Glow plug indicator lamp
malfunction.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit ECM malfunction.
Voltage High short to voltage circuit.
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Excessive Detected between 15 deg. C and reduced. 1500rpm and 3100rpm open position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGREVRVmalfunction.
2. Engine coolant and3200rpm(4JH1-TC).
3. Air intake is obstructed.
temperature is between 2. Injection quantity is
4. Airintakeisleaking.
55 deg. C and 100 deg. below 32mg/strk (4JA1-
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1- 5. MAFsensormalfunction.
and 100 deg. C (4JH1- TC). 6. ECM malfunction. 88/
TC).
3. Correct amount of mass 97
3. Barometric pressure is air flow.
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)
4 ON Exhaust Gas Recirculation EGR EVRV circuit open or Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit open
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV condition. orshorttogroundcircuit.
Open Circuit 10% conditions as substitute. 97
2. EGREVRVmalfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Insufficient Detected between 15 deg. C and reduced. 1500rpm and 3100rpm close position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGR valve operating
2. Engine coolant and3200rpm(4JH1-TC). vacuum hose is clogged
temperature is between 2. Injection quantity is or disconnected.
55 deg. C and 100 deg. below 32mg/strk (4JA1- 3. EGREVRVmalfunction.
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1-
4. MAF sensor signal circuit
and 100 deg. C (4JH1- TC). 88/
short to voltagecircuit.
TC). 3. Correct amount of mass 97
3. Barometric pressure is air flow.
between 850hpa and 6. ECM malfunction.
1100hpa.
4. Large mount of mass air
below -150 mg/strk)
8 ON Exhaust Gas Recirculation EGR EVRV circuit short to Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit short
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10% condition. to voltage circuit.
conditions as substitute. 97
2. EGREVRVmalfunction.
3. ECM malfunction.
Related Related
No. DTC
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed Vehicle speed is below 1. VSS signal circuit open,
at High Input 200km/h. 5km/h condition as 200km/h. short to ground or short
next substitute. to voltage circuit.
igniti 2. VSS malfunction.
on
3. Speed meter 68
cycle
malfunction.
4. TCM malfunction (AT
2WD).
5. ECM malfunction.
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed Correct vehicle speed signal 1. VSS malfunction.
at Signal Frequency Too High high. 5km/h condition as frequency. 2. Speed meter
next substitute. malfunction.
igniti 68
on
cycle 4. Magneticinterference.
5. ECM malfunction.
B ON Vehicle Speed Sensor 1. Engine speed is more Fuel injection quantity is Vehicle speed is more than 1. VSS open circuit, short
at Incorrect Signal than 3200rpm (4JA1-TC) reduced. 1.5km/h. to ground or short to
next or3600rpm(4JH1-TC). voltage.
igniti 2. Fuel injection quantity is 2. Poor connector
on more than 30mg/strk connection. 68
cycle (4JA1-TC) or 41mg/strk 3. VSS malfunction.
(4JH1-TC).
4. Speed meter
3. Vehicle speed is below malfunction.
1.5km/h.
5. ECM malfunction.
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as System voltage is below 20V. 1. Charge system
20V. substitute. malfunction.
3/
2. Battery jump start cable
39
misconnect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 1. Battery power feed
7V. harness open circuit or
short to ground circuit.
2. ECM ground harness
openorpoorconnection.
3. Poor connector 3/

connection. 39
4. Battery malfunction.
5. Charge system
malfunction.
6. ECM malfunction.
Related Related
No. DTC
35 P0560 A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as System voltage of PSG is 1. Battery power feed
(pump control unit) is below substitute. between 4.5V and 27V. harness open circuit or
4.5V or more than 27V. short to ground circuit.
ground harness open or
poor connection.
3. Poor connector
connection.
4. Battery malfunction.
5. Charge system
malfunction.
6. Battery jump start cable
misconnect.
malfunction.
18 P0561 A OFF Ignition Switch Circuit The ECM recognized ignition ECM stops engine. No recovery until condition 1. Ignition switch circuit
Malfunction switch turn off signal during match in the next ignition key open or short to ground
ECM is activated. cycle. circuit.
2. Poor connector
connection. 39
3. Ignition switch
malfunction.
4. ECM malfunction.
B OFF Ignition Switch Circuit Ignition switch circuit is 1. Ignition switch circuit
Malfunction malfunction. open or short to ground
circuit.
2. Poor connector
connection. 39
3. Ignition switch
malfunction.
4. ECM malfunction.
- P0602 - Control Module ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed.
Programming Error
28 P0606 A ON ECU Malfunction Gate Array communication 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction.
error. valve) is operated.

2. Desired injection quantity
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below MAB (fuel cutoff solenoid Desired injection quantity is 1. ECM malfunction.
1%. valve) is operated. below 0mg/strk. 2. PSG (pump control unit)
2. Desired injection quantity malfunction.

is more than 0mg/strk.
3. Engine speed is more
than 2000rpm.
Related Related
No. DTC
46 P0645 4 ON A/C Compressor Relay A/C compressor relay circuit No fail-safe function. A/C compressor relay circuit 1. A/C compressor relay
Circuit Voltage Low open or short to ground is correct condition. circuit open or short to
2. Poor connector
connection. 41
3. A/C compressor relay
malfunction.
4. ECM malfunction.
8 ON A/C Compressor Relay A/C compressor relay circuit ECM malfunction.
Circuit Voltage High short to voltage circuit.
25 P0703 A ON Brake Switch Circuit 1. Throttle position is more No fail-safe function. Brake switch 1 signal and 1. Brake switch 1 circuit
Malfunction than 0%. brake switch 2 signal are open, short to ground or
2. Engine speed is more correctly inputted to the short to voltage circuit.
than 693rpm (4JA1-TC) ECM. 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 1 30
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.
B ON Brake Switch Circuit 1. Throttle position is more 1. Brake switch 2 circuit
Malfunction than 0%. open or short to ground
2. Engine speed is more circuit.
than 693rpm (4JA1-TC) 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 2 65
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
ECM.
57 P0704 6 ON Clutch Switch Input Circuit Clutch signal does not No fail-safe function. Clutch signal correctly 1. Clutch switch circuit
Malfunction change between vehicle changes. open, short to ground or
speed 1.5km/h and 80km/h shorttovoltage circuit.
since ignition switch was 2. Poor connector
tuned on. connection. 31
3. Clutch switch
malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa Barometric pressure sensor ECM malfunction.
Circuit High Input output voltage is more than condition as substitute. output voltage is below 4.4V.
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor Barometric pressure sensor ECM malfunction.
Circuit Low Input output voltage is below 1.5V. output voltage is more than
1.5V.
Related Related
No. DTC
21 P1120 1 ON Pedal/Throttle Position Throttle position sensor ECM increases idle speed up Throttle position sensor 1. Sensor power supply
Sensor Circuit High Input output voltage is more than to 1400rpm. output voltage is below 4.5V. circuit short to voltage
4.5V. circuit.
2. Sensor signal circuit
short to voltagecircuit.
3. Sensor ground circuit 38/
open or short to voltage 49/
circuit. 57
4. Poor connector
connection.
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is more power supply voltage is circuit short to battery
Circuit High Input than 5.2V. below 5.2V. voltage circuit. 57
2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is power supply voltage is more circuit short to ground
Circuit Low Input below 4.6V. than 4.6V. circuit. 57
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position 1. Engine speed is more Throttle position is more than 1. Throttle sticking.
Sensor Brake Switch Error than 1700rpm. 20% or brake pedal is 2. TPSincorrectadjusting.
2. Vehicle speed is more released(switchisinactive).
3. TPS malfunction. 30/
than 1.5km/h.
4. Brake switch 38/
3. When brake pedal is malfunction. 65
depressed during
5. ECM malfunction.
accelerator pedal is
depressing.
E ON Pedal/Throttle Position 1. When idle switch is 1. When throttle position 1. TPS malfunction.
Sensor Idle Position Switch turned off, throttle sensor is 100%, idle 2. Idle switch malfunction.
Error position sensor was switch turns off.
3. ECM malfunction.
below 0.35%. 2. When throttle position
or 38/
sensor is 0%, idle switch
69
2. When idle switch is tuned turns on.
on, throttle position
sensor was more than
7.8%.
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine No fail-safe function. Engine coolant temperature 1. Engine overheat.
High Coolant Temperature coolant temperature is is normal range. 2. ECTsensormalfunction. 89
detected.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By Fuel temperature is more PSG (pump control unit) Fuel temperature is below 1. ECM malfunction.
High Fuel Temperature than 100 deg. C. controls fuel injection 100 deg. C. 2. PSG (pump control unit)
quantity based on engine malfunction.
speed and fuel temperature.
A OFF Fuel Reduction Caused By Excessive low fuel No fail-safe function. Fuel temperature is normal 1. ECM malfunction.
Low Fuel Temperature temperature is detected. range. 2. PSG (pump control unit)
malfunction.
Related Related
No. DTC
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness
Malfunction is recognized defective reduced. open circuit, short to
engine speed signal form the ground or short to
ECM. voltage.
2. CKP sensor output
harness open circuit,
short to ground or short
to voltage.
3. Poor connector 90/
connection. 91/ P0335(B)/
4. CKPsensormalfunction. 98/ P0335(D)
5. Pulse sensing gap 101
incorrect.
9. ECM malfunction.
malfunction.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed
is recognized incorrect sensor malfunction.
camshaft speed signal. 2. Pulse sensing gap
incorrect.

6. ECM malfunction.
malfunction.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is No fail-safe function. Correct neutral switch signal 1. Neutral switch circuit
inputted "On" three times is inputted two times shorttovoltage circuit.
consecutively under driving consecutively under driving 2. Neutral switch 87
conditions. conditions. malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is 1. Neutral switch circuit
inputted "Off" three times open, short to ground
consecutively under driving circuit.
conditions. 2. Poor connector
connection. 87
3. Neutral switch
malfunction.
4. ECM malfunction.
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM No fail-safe function. No recovery. ECM malfunction.
is destroyed.
D ON EEPROM Defect Write and read from the ECM uses default values Write and read from the ECM malfunction.
EEPROM are failed during from the EPROM. EEPROM are correct during
initialization of the ECM. initialization of the ECM.
Related Related
No. DTC
55 P1605 E ON EEPROM Defect EEPROM checksum does EEPROM checksum match ECM malfunction.
not match with the read with the read check sum

check sum during during initialization of the
initialization of the ECM. ECM.
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start. No recovery. ECM malfunction.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash. B****
56 P1611 A - Wrong Security Code Received security code is not 1. Engine does not start. No recovery. 1. ECM malfunction.
Entered correct. 2. Check engine lamp flash. 2. Immobilizer control unit
malfunction. B****
3. Transponder key
malfunction.
56 P1612 A - Immobilizer No or Wrong Received challenge signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1613 A - Immobilizer No or Wrong Received response signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start. No recovery. 1. ECM malfunction.
not correct from the 2. Check engine lamp flash. 2. Immobilizer control unit
transponder key. malfunction. B****
3. Transponder key
malfunction.
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function. No recovery. ECM malfunction.
Off Too Early turned off, timing of the ECM 3/

main relay turning off is too 58
early.
B OFF ECM Main Relay Switched When ignition switch was No recovery. 1. ECM main relay
Off Too Late turned off, timing of the ECM malfunction. 3/

main relay turning off is too 2. ECM malfunction. 58
late or does not off.
Related Related
No. DTC
51 P1630 A ON Fuel Injection Quantity The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) PSG (pump control unit)
Circuit Malfunction detects high pressure reduced. detects correct high pressure malfunction.
solenoid valve control circuit solenoid valve control circuit.
malfunction due to high
current.
B ON Fuel Injection Quantity The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit)
Circuit Malfunction detects high pressure valve) is operated. malfunction.
solenoid valve control circuit 2. Desired injection quantity
malfunction due to becomes 0mg/strk.
continuous current.
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid CAN controller detects 1. CAN high circuit open,
off or canceling. valve) is operated. correct Bus signal. short to ground or short
to voltage circuit.
2. CAN low circuit open,
to voltage circuit. 99/
3. Poor connector P1651(B)
100
connection.
4. Electricalinterference.
5. ECM malfunction.
malfunction.
B ON CAN Device Hang-up CAN controller does not CAN controller reacts 1. ECM malfunction.
react under engine running. correctly under engine 2. PSG (pump control unit)
running. malfunction.
45 P1651 A ON CAN Malfunction The PSG (pump control unit) 1. MAB (fuel cutoff solenoid The PSG (pump control unit) 1. ECM malfunction.
does not recognize CAN valve) is operated. recognizes CAN signal from 2. PSG (pump control unit)
signal from the CAN the CAN controller.
2. Desired injection quantity malfunction.
controller. becomes 0mg/strk.
B ON CAN Malfunction The ECM does not read CAN The ECM reads CAN signal 1. CAN high circuit open,
signal from the PSG (pump from the PSG (pump control short to ground or short
control unit). unit). to voltage circuit.
2. CAN low circuit open,
to voltage circuit. 99/
3. Poor connector P1650(A)
100
connection.
5. ECM malfunction.
malfunction.
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function. Check engine lamp circuit is 1. Check engine lamp
Circuit Voltage Low open or short to ground correct condition. circuit open or short to
42 B****
2. Check engine lamp
malfunction
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit ECM malfunction.
Circuit Voltage High short to voltage circuit.
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)

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

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

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

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

The mass air flow (MAF) sensor is part of the intake air An intermittent may be caused by the following:
system. It is fitted between the air cleaner and Poor connections.
turbocharger and measure the mass air flowing into the
Misrouted harness.
engine.
The mass air flow (MAF) sensor element measures the Rubbed through wire insulation.
partial air mass through a measurement duct on the Broken wire inside the insulation.
sensor housing. Check for the following conditions:
The ECM monitors the MAF sensor supply voltage and Poor connection at ECM-Inspect harness connectors
MAF sensor output voltage. The supply voltage is out of for backed out terminals, improper mating, broken
range, DTC P0100 (Symptom Code 7) or P0100 locks, improperly formed or damaged terminals, and
(Symptom Code 9) will be stored. The output voltage poor terminal to wire connection.
excessively high or low, DTC P0100 (Symptom Code B)
Damaged harness-Inspect the wiring harness for
or P0100 (Symptom Code C) will be stored.
damage. If the harness appears to be OK, observe
the Mass Air Flow display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
1 Was the On-Board Diagnostic (OBD) System Check Go to On Board
performed? Diagnostic
(OBD) System
Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select F0: Read DTC Infor As Stored By ECU in Refer to
F0: Diagnostic Trouble Codes. Diagnostic Aids
Is the DTC P0100 (Symptom Code 7) stored as and Go to Step
Present Failure? Go to Step 3 3

2. Select F1: Clear DTC Information in F0:
Diagnostic Trouble Codes with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the F0: Read
DTC Infor As Stored By ECU in the F0: Refer to
Diagnostic Trouble Codes. Diagnostic Aids
Was the DTC P0100 (Symptom Code 7) stored in this and Go to Step
ignition cycle? Go to Step 4 4
4 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
C-57(B) 92 C-116
2 3 4
5
88 83 Verify repair Go to Step 5

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

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

4

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

9 Repair the circuit for short to MAF sensor +12V supply
circuit.
10 Repair the short to battery voltage circuit between the
ECM and MAF sensor.
C-57(B) C-116

4
11 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? Go to Step 12 Go to Step 13
12 Replace the MAF & IAT sensor assembly.
release?
14 Replace the ECM.
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
(OBD) System
Go to Step 2 Check
C-57(B) 92 C-116
2 3 4
5

supply circuit.
C-116
4
Approximately
V

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

8 Repair the circuit for short to MAF sensor ground.
9 Repair the short to ground circuit between the ECM
and MAF sensor.
C-57(B) C-116

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


6 Using the DVM and check the MAF sensor signal
circuit.
Breaker box is available:
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
4. Check the circuit for open, short to sensor ground
or short to ground circuit.
Breaker Box C-116
88
!
!
!
Breaker box is not available:

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

8 Repair the open circuit between the ECM and MAF
sensor.
C-57(B) C-116

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


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

92
!

2. Disconnect the MAF sensor connector and ECM
connector.
C-57 C-116
Repair faulty
harness and
92 3

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

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

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT

CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH
INPUT

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

The ECM monitors altitude from the barometric An intermittent may be caused by the following:
pressure sensor. To apply specified vacuum pressure to Poor connections.
the turbocharger wastegate valve, ECM sends control
Misrouted harness.
signal to the wastegate control solenoid depending on
altitude. Rubbed through wire insulation.
Then, apply vacuum pressure to the turbocharger Broken wire inside insulation.
wastegate valve is monitored by the ECM form the Check for the following conditions:
vacuum pressure sensor output signal. The ECM Poor connection at ECM-Inspect harness connectors
controls wastegate control solenoid based on signal for backed out terminals, improper mating, broken
from vacuum pressure sensor output. locks, improperly formed or damaged terminals, and
The output voltage excessively high or low, DTC P0105 poor terminal to wire connection.
(Symptom Code 1) or P0105 (Symptom Code 2) will be
stored.
The supply voltage is out of range, DTC P0105
the DTC P0105 display on the Tech 2 while moving
connectors and wiring harnesses. A change in the
stored.
display will indicate the location of the fault.
Vacuum Pressure Sensor Circuit High Input
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
(OBD) System
- Go to Step 2 Check
2 1. 1Connect the Tech 2.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
C-57 C-124
& "
%
- Verify repair Go to Step 5

$% !# !"
5 Visually check the vacuum sensor.

Was the problem found? - Go to Step 9 Go to Step 6

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

connector and ECM connector.
C-57 C-124
$
Repair faulty
"# harness and
- verify repair Go to Step 7
!

1. Ignition "On", engine "Off".
connector.
C-124 !
V Repair faulty
harness and

sensor signal circuit.
connector.
C-124
!
V Repair faulty
harness and
9 Substitute a known good vacuum pressure sensor
and recheck.
Was the problem solved? - Go to Step 10 Go to Step 11
10 Replace the vacuum pressure sensor.
Is the action complete? - Verify repair -
release?
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 12
12 Replace the ECM.
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
Vacuum Pressure Sensor Circuit Low Input
(OBD) System
C-57 C-124
& "
%

$% !# !"
5 Visually check the vacuum pressure sensor.


connector.
Breaker Box
C-124
85 "
!
!

C-57 C-124
$
"# ! Repair faulty

harness and
!

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

pressure sensor.
C-57 C-124 !

"#

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

$% !# !"

connector.
circuit.
C-124 !
V
Approximately

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

$% !# !"

connector.
C-124 !
V
Approximately

3. Check the circuit for short to vacuum pessure
#
C-124 !

"
8 Repair the circuit for short to vacuum pressure sensor

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

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

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

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

5 Visually check the IAT sensor.

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

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

circuit.
C-116
Less than 1V:

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

84

9 Repair the short to voltage circuit between the ECM
and IAT sensor.
C-57(B) C-116
1

84
10 Using the DVM and check the IAT sensor ground
circuit.
C-116
Repair faulty
3
harness and
V

11 Using the DVM and check the IAT sensor ground
circuit.
Breaker Box C-116
92
!

ECM connector.
C-57(B) C-116
Repair faulty
harness and
92 3

and recheck.
release?
15 Replace the ECM.
Intake Air Temperature (IAT) Sensor Circuit Low Input
(OBD) System
Go to Step 2 Check
4 Check for poor/faulty connection at the IAT sensor or
C-57(B) C-116
92

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

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

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

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

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

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

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

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

5 Visually check the ECT sensor.

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

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

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


and ECT sensor.
C-57(B) E-41
89 1
10 Using the DVM and check the ECT sensor ground
circuit.
E-41
Repair faulty
2
harness and
V
11 Using the DVM and check the ECT sensor ground
circuit.
Breaker Box E-41
93
!

2. Disconnect the ECT sensor connector ECM
connector.
C-57 E-41
Repair faulty
harness and

2
93 verify repair Go to Step 14

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

5 Visually check the ECT sensor.


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

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

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

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

The fuel temperature sensor is assembled inside of the Rubbed through wire insulation.
pump control unit (PSG). The signal of fuel temperature Broken wire inside the insulation.
is sent via the CAN-bus from the PSG to ECM. Check for the following conditions:
If the fuel temperature is excessively high or low Poor connection at ECM and PSG-Inspect harness
condition, DTC P0180 will be stored. connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
Diagnostic Aids terminals, and poor terminal to wire connection.
An intermittent may be caused by the following: Damaged harness-Inspect the wiring harness for
Poor connections.
the Fuel Temperature display on the Tech2 while
sensor.
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
(OBD) System
Go to Step 2 Check
DTC Infor As Stored By ECU in the F0:
Diagnostic Trouble Codes.
Was the DTC P0180 (Symptom Code B) stored in this Refer to
ignition cycle? Go to Step 4 Diagnostic Aids
release?
5 Substitute a known good ECM and recheck.
the ECM/Immobilizer linking procedure. Go to Step 6 Go to Step 7
6 Replace the ECM.
7 Replace the injection pump assembly.
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION

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

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

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

When the ignition switch is turned Off, the fuel An intermittent may be caused by the following:
solenoid valve (MAB) signal is supplied from the ECM to Poor connections.
the PSG. This signal is the command for the PSG to turn
Misrouted harness.
Off the engine.
If the MAB signal circuit is short to voltage circuit or Rubbed through wire insulation.
short to ground circuit, DTC P0215 (Symptom Code B) Broken wire inside the insulation.
or P0215 (Symptom Code C) will be stored. Check for the following conditions:
Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
(OBD) System
Go to Step 2 Check
Is the DTC P0215 (Symptom Code A) stored as and Go to Step

Was the DTC P0215 (Symptom Code A) stored in this Refer to
Cutoff Solenoid Valve Circuit High Input
(OBD) System
Go to Step 2 Check
4 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
105 C-57 E-6

5

5 Visually check the PSG (pump control unit).

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

C-57
105
V
Less than 1V Go to Step 8 Go to Step 7
and PSG (pump control unit).
C-57 E-6
5
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
(OBD) System
Go to Step 2 Check
Is the DTC P0215 (Symptom Code C) stored as and Go to Step
Was the DTC P0215 (Symptom Code C) stored in this and Go to Step
105 C-57 E-6

5


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

connector.
circuit.
C-57 E-6
105
5
Repair faulty
harness and
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
(OBD) System
Go to Step 2 Check
Is the DTC P0215 (Symptom Code D) stored as and Go to Step
Was the DTC P0215 (Symptom Code D) stored in this Refer to
release?
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH

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

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

(OBD) System
Is the DTC P0216 (Symptom Code A) or P0216 and Go to Step
(Symptom Code B) stored as "Present Failure"? - Go to Step 3 3
3 1. 1Using the Tech 2, ignition "On" and engine "Off".
Was the DTC P0216 (Symptom Code A) or P0216 and Go to Step
(Symptom Code B) stored in this ignition cycle? - Go to Step 4 4
4 Perform the air bleeding in the fuel line sufficiently.
Air Bleeding Procedure:
1. Operate the priming pump until strong resistance
is felt.
2. Wait 1 minute, and operate the priming pump until
3. Once more wait, and operate the priming pump
until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position
and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
DTC Re-check:
1. Using the Tech 2, ignition "On" and engine "Off".
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) restored in this ignition cycle? - Go to Step 5 Verify repair

5 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 6
6 Replace the fuel filter.
7 Remove the eye bolt with gauze filter from the
injectionpumpandcheckforthefollowingconditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.
Replace the
eye bolt with
gauze filter and
release? If
not, download the latest software to the ECM using
the ECM/Immobilizer linking procedure. - Go to Step 10 Go to Step 11

10 Replace the ECM.

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

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" LOW

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

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION

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

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

8 Using the DVM and check the wastegate control
solenoid.
2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid
coil.
Does the tester indicate standard resistance?
Wastegate Solenoid
"
#
# "
Approximately
14.7 - 16.1 !
! at 20"C Go to Step 11 Go to Step 9
9 Substitute a known good wastegate control solenoid
and recheck.
10 Replace the wastegate control solenoid.
11 Using the pressure gauge and check the turbocharger
wastegate valve operation for broken diaphragm.
Was a problem found? - Go to Step 12 Go to Step 13
12 Replace the turbocharger wastegate valve .
release?
14 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Low
(OBD) System
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty
C-57 C-123
!" #
$

solenoid.
coil.
Wastegate Solenoid
"
#
# "
Approximately
14.7 - 16.1 !
at 20"C Go to Step 6 Go to Step 9
!

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

3. Remove the wastegate control solenoid
connector.
circuit.
C-57
!"
C-123
# Repair faulty
harness and
$ $

and recheck.

release?
12 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Range/Performance
(OBD) System
4 Visually check the vacuum regulating valve.
solenoid.
coil.
Wastegate Solenoid
"
#
# "
Approximately
14.7 - 16.1 !
! at 20"C Go to Step 8 Go to Step 6
and recheck.
wastegate valve operation for broken diaphragm.
9 Replace the turbocharger wastegate valve .

C-57 C-123
!" #
$

connector.
C-124
!
V Repair faulty
harness and
14 Replace the vacuum pressure sensor assembly.
release?
16 Replace the ECM.
Turbocharger Wastegate Solenoid "A" Malfunction
(OBD) System
4 Visually check the turbocharger wastegate valve and
hose.
If the hose is clogged or disconnected, repair as
necessary.
wastegate valve operation for broken diaphragm or
restrict shaft operation.
6 Replace the turbocharger wastegate valve.
C-57
!"
% C-116
$ & '

## #$


circuit.
C-116
!
V Repair faulty
harness and
and recheck.
release?
13 Replace the ECM.
Turbocharger Wastegate Solenoid "A" High
(OBD) System
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0243 (Symptom Code 8) stored in this Refer to
ignition cycle? - Go to Step 4 Diagnostic Aids
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty
solenoid.
coil.
Wastegate Solenoid
"
#
# "
Approximately
14.7- 16.1 ! at
20"C Go to Step 6 Go to Step 8
!

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

!
7 Repair the short to voltage circuit.

and recheck.
release?
11 Replace the ECM.

(FLASH CODE 53) INJECTION PUMP MALFUNCTION





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

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

The ECM is calculates an injection quantity and an An intermittent may be caused by the following:
injection timing using the various sensors. And the PSG Poor connections.
controls the high pressure solenoid valve depending on
Misrouted harness.
programmed pump map data.
Rubbed through wire insulation.
The signal of desired injection quantity and actual injec-
tion quantify are exchanged via the CAN-bus between Broken wire inside the insulation.
the PSG and ECM.
If the relation of engine speed signal and doubled pump Poor connection at ECM and PSG-Inspect harness
camshaft speed signal excessively large, DTC P0251 connectors for backed out terminals, improper
(Symptom Code 7) will be stored. mating, broken locks, improperly formed or damaged
If the CAN high or low circuit is defected, DTC P0251 terminals, and poor terminal to wire connection.
(Symptom Code E) will be stored. Damaged harness-Inspect the wiring harness for
the Injection Quantity display on the Tech2 while
sensor.
Injection Pump Malfunction
(OBD) System
Go to Step 2 Check

(OBD) System
Go to Step 2 Check
4 Was the DTC P0335 (Symptom Code B), P0335 Go to DTC
(Symptom Code D) or P1335 (Symptom Code A) Chart P0335
stored at the same time? (Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
Code A) Go to Step 5
connection is found, repair the faulty terminal.
C-57(B) 91 E-6


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
Crankshaft Position (CKP) Sensor & TDC Output Signal
Reference Wave Form
CH1
0V"
CH2
0V"
Not available:
Go to Step 7
Fixed at low:
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div
Go to Step 7
Measurement Condition: Approximately 2000rpm Fixed at High:
Go to Step 13 Go to Step 8

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

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

9 Check any accessory parts which may cause electric Remove the
interference or magnetic interference. accessory parts
Was the problem found? and verify repair Go to Step 10
release?
12 Replace the ECM.
(OBD) System
Go to Step 2 Check
(OBD) System
Go to Step 2 Check
(OBD) System
Go to Step 2 Check
(OBD) System
Go to Step 2 Check
Was the DTC P0251 (Symptom Code D) stored in this Refer to
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
(OBD) System
Go to Step 2 Check
Is the DTC P0251 (Symptom Code E) stored as and Go to Step
Was the DTC P0251 (Symptom Code E) stored in this Refer to
4 Was the DTC P1650 (Symptom Code A) or P1651 Go to DTC
(Symptom Code B) stored at the same time? Chart P1650
(Symptom
release?
7 Replace the ECM.

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION

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

The CKP sensor is located on top of the flywheel An intermittent may be caused by the following:
housing of the flywheel and fixed with a bolt. The CKP Poor connections.
sensor is of the magnet coil type. The inductive pickup
Misrouted harness.
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine Rubbed through wire insulation.
cylinder top dead center. Broken wire inside the insulation.
If the CKP sensor harness or sensor malfunction is Check for the following conditions:
detected during engine run, DTC P0335 (Symptom Poor connection at ECM-Inspect harness connectors
Code B) is stored. for backed out terminals, improper mating, broken
If the CKP sensor harness or sensor malfunction is locks, improperly formed or damaged terminals, and
detected during engine cranking, DTC P0335 poor terminal to wire connection.
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
the Engine Speed display on the Tech2 while
is stored.
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
(OBD) System
Go to Step 2 Check

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

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

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

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

4. Check the circuit for open, short to sensor wire or
Breaker Box
E-9
90 98
! "
Repair faulty
!
harness and
!
!


If the DVM indicated out of specified value, repair
faulty harness and verify repair.
E-9
1
2
V V
Less than 1V Verify repair
10 Using the DVM and check the CKP sensor signal.
1. Ignition On, engine On.
2. Measure the CKP output voltage at the sensor
and ECM.
Does the tester indicate standard voltage?
Measurement Point Voltage (V) (AC Range)

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

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

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

14 Substitute a known good CKP sensor and recheck.
15 Replace the CKP sensor.
release?
17 Replace the ECM.
Engine Speed Input Circuit Range/Performance
(OBD) System
Go to Step 2 Check
Was the DTC P0335 (Symptom Code E) stored in this and Go to Step
4 Ask to the customer whether over-speed condition Explain the
such as miss-gear shifting etc. has been experienced reason of DTC
or not. to the customer Go to Step 5
5 Check for poor/faulty connection at the CKP sensor or
C-57(B) 101 E-9

1 2 3
98
90


6 Using the DVM and check the CKP sensor signal.
1. Ignition On, engine On.
2. Measure the CKP output voltage at the sensor
and ECM.
Does the tester indicate standard voltage?
Measurement Point Voltage (V) (AC Range)

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

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

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

13 Replace the ECM.

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

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

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

5 Using the DVM and check the glow relay.
2. Remove the glow relay from the relay box.
3. Check the relay coil.
Grow Relay
# "
Replace glow
Approximately relay and verify
105! Go to Step 6 repair
!

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

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

release?
10 Replace the ECM.
Glow Relay Circuit Voltage High
(OBD) System
Go to Step 2 Check
release?
the ECM/Immobilizer linking procedure. Go to Step 6
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Code Code
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit
Circuit Description the glow plugs remain active for a certain period
depending on engine coolant temperature.
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
Diagnostic Aids
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer An intermittent may be caused by the following:
activated. Poor connections.
In the after glow phase the lamp is not illuminated but
Misrouted harness.
Rubbed through wire insulation. poor terminal to wire connection.
Broken wire inside the insulation. Damaged harness-Inspect the wiring harness for
Check for the following conditions: damage. If the harness appears to be OK, observe
Poor connection at ECM-Inspect harness connectors the DTC P0381 display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
Glow Plug Indicator Circuit Voltage Low
(OBD) System
Go to Step 2 Check
4 1. Ignition On, engine Off.
2. Check the glow plug indicator lamp.
Does the lamp turn On? Go to Step 5 Go to Step 6
2. Check the glow plug indicator lamp.
Does the lamp turn Off? Go to Step 9 Go to Step 7
6 Check the glow plug indicator lamp bulb.

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

8 Using the DVM and check the glow time telltale circuit.
3. Remove the meter connector.
circuit.
!
Breaker Box B-24
43
! !

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

release?
10 Replace the ECM.
Glow Plug Indicator Circuit Voltage High
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

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

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED

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

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

9 Substitute a known good EGR EVRV and recheck.
10 Replace the EGR EVRV.
11 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
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 Small Window
If a problem is found, repair as necessary. Verify repair or

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

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

1 2
97
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV power
supply circuit.
2. Remove the EGR EVRV connector.
C-115
V
10-14.5 V Go to Step 8 Go to Step 7
and EGR EVRV.
8 Using the DVM and check the EGR EVRV circuit.
circuit.
Breaker Box C-115
97
!
!
!

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

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

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

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

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

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

1 2
97
coil.
EGR EVRV
2 1
2 1
Approximately

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

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

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

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

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

The VSS is a magnet rotated by the transmission output Rubbed through wire insulation.
shaft. The VSS uses a hall element. It interacts with the Broken wire inside the insulation.
magnetic field treated by the rotating magnet. It outputs Check for the following conditions:
pulse signal. The 12 volts operating supply from the Poor connection at ECM-Inspect harness connectors
meter fuse. for backed out terminals, improper mating, broken
The engine control module (ECM) calculates the vehicle locks, improperly formed or damaged terminals, and
speed by VSS. poor terminal to wire connection.
An intermittent may be caused by the following: the DTC P0500 display on the Tech2 while moving
Poor connections.
Vehicle Speed Sensor Circuit High Input
(OBD) System
Go to Step 2 Check

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

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

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

4. Check the circuit for open or shot to ground circuit.
Breaker Box B-24

!"
68
! !

connector.
circuit.
C-56
68
B-24 10
Repair faulty
harness and
release?
16 Replace the ECM.
Vehicle Speed Sensor Input Signal Frequency Too High
(OBD) System
Go to Step 2 Check
Was the DTC P0500 (Symptom Code A) stored in this and Go to Step
check.

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

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

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


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

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

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

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

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

!"
68
! !

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

release?
18 Replace the ECM.

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION
Code Code
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as
20V. substitute.
2 OFF System Voltage Too Low System voltage is below 7V.
A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as
(pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
The ECM and PSG monitors the system voltage on the stored. The system voltage to the PSG excessively high
ignition feed terminal to the ECM or PSG. The system
or low, DTC P0560 (Symptom Code A) will be stored. Poor connection at ECM and PSG-Inspect harness
Diagnostic Aids mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
An intermittent may be caused by the following:
Poor connections. damage. If the harness appears to be OK, observe
Misrouted harness. the System Voltage display on the Tech2 while
Rubbed through wire insulation. moving connectors and wiring harness related to the
Broken wire inside the insulation. sensor.
System Voltage Too High
(OBD) System
Go to Step 2 Check
4 Was the battery jump start cable incorrectly Verify
connecting? procedure Go to Step 5
5 1. Using the Tech 2, ignition On and engine On.
2. Monitor the System Voltage in the data display.
3. Load the electrical system by turning on the Check the
headlights, etc.. charging
Does the Tech 2 indicate correct ignition voltage? 10 - 14.5V Go to Step 6 system
release?

7 Replace the ECM.
System Voltage Too Low
(OBD) System
Go to Step 2 Check
2. Monitor the System Voltage in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14.5V Go to Step 6 Go to Step 5
5 Using the DVM and check the battery voltage at the Check the
battery terminal. charging
Does the tester indicate enough battery voltage? system, charge
or replace the
10 - 14.5V Go to Step 6 battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
C-56
3


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

$
#
# "
" !
Replace ECM
main relay and
120-150! Go to Step 8 verify repair
!
8 Check for poor/faulty connection of the ECM ground

at the body. If a poor/faulty connection is found, repair
as necessary.
C-109

release?
10 Replace the ECM.
System Voltage Malfunction
(OBD) System
Go to Step 2 Check
4 Check for poor/faulty connection at the PSG (pump
control unit) connector. If a poor/faulty connection is
found, repair as necessary.
E-6
6

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


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


(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Code Code
18 P0561 A OFF Ignition Switch Circuit Mal- The ECM recognized ignition ECM stops engine.
function switch turn off signal during
ECM is activated.
B OFF Ignition Switch Circuit Mal- Ignition switch circuit is mal-
function function.
Circuit Description Rubbed through wire insulation.
The ECM monitors the ignition switch signal on the feed Broken wire inside the insulation.
terminal to the ECM. If the ignition switch signal with Check for the following conditions:
malfunction, DTC P0561 (Symptom Code A) or DTC Poor connection at ECM-Inspect harness connectors
P0561 (Symptom Code B) will be stored. for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Diagnostic Aids poor terminal to wire connection.
Poor connections. the Ignition Status display on the Tech2 while
Misrouted harness. moving connectors and wiring harness related to the
sensor.
Ignition Switch Circuit Malfunction
Ignition Switch Circuit Malfunction
(OBD) System
Go to Step 2 Check
(Symptom Code B) stored as Present Failure? Go to Step 3 3
(Symptom Code B)stored in this ignition cycle? Go to Step 4 4
4 Check the Engine fuse (10A).

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

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

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

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

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

(OBD) System
Go to Step 2 Check
3. Select F0: Read DTC Infor As Stored By ECU in
F0: Diagnostic Trouble Codes. Refer to
Is the DTC P0602 stored as Present Failure? Go to Step 3 Diagnostic Aids
3 Download the latest software to the ECM using the
SPS (Service Programming System).
(FLASH CODE 28) ECU MALFUNCTION

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

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
(OBD) System
Go to Step 2 Check
release?

5 Replace the ECM.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.
(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW

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

The voltage on the coil of the A/C compressor is An intermittent may be caused by the following:
supplied by the ECM main relay. The ECM switches A/C Poor connections.
compressor relay to operate A/C compressor depends
Misrouted harness.
on the A/C request signal and certain setting conditions.
Check for the following conditions: Damaged harness-Inspect the wiring harness for
Poor connection at ECM-Inspect harness connectors damage. If the harness appears to be OK, observe
for backed out terminals, improper mating, broken the DTC P0645 display on the Tech2 while moving
locks, improperly formed or damaged terminals, and connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
(OBD) System
Go to Step 2 Check
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
X-14
"
C-56 $
#

!" !
5 Using the DVM and check the A/C compressor relay.

2. Remove the A/C compressor relay from the relay
box.
A/C Compressor Relay

$
#
# "
" !
Replace A/C
compressor
relay and verify
120-150! Go to Step 6 repair
!

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

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

box.
circuit.
X-14
C-56
!" !
" " Repair faulty

harness and
release?
10 Replace the ECM.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.
(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
Code Code
25 P0703 A ON Brake Switch Circuit 1. Throttle position is more No fail-safe function.
Malfunction than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
4. Brake switch 1 signal and
ECM since the ignition
switch was turned on.
B ON Brake Switch Circuit 1. Throttle position is more
Malfunction than 0%.
693rpm (4JA1-TC) or 665
rpm (4JH1-TC).
0km/h.
4. Brake switch 1 signal and
ECM.

The ECM monitors the brake switch signal on the feed Broken wire inside the insulation.
terminal to the ECM. If brake switch 1 or 2 circuit with Check for the following conditions:
malfunction, DTC P0703 (Symptom Code A) or P0703 Poor connection at ECM-Inspect harness connectors
(Symptom Code B) will be stored. for backed out terminals, improper mating, broken
Diagnostic Aids poor terminal to wire connection.
Poor connections. the Brake Switch 1 and Brake Switch 2 display on
Misrouted harness. the Tech2 while moving connectors and wiring
harness related to the sensor.
Brake Switch Circuit Malfunction
(OBD) System
Go to Step 2 Check

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

6 Using the DVM and check the brake switch 1.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 1.
Brake Switch !
"
Pedal is not
stepped on:
Continuity
Pedal stepped Replace pedal
on: No switch and
continuity Go to Step 7 verify repair
!
7 Using the DVM and check the brake switch 1 power

supply circuit.
2. Remove the brake switch connector from the
brake switch.
C-44
V

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

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

connector and ECM.
C-56 C-44
Verify repair
30 2

release?
13 Replace the ECM.
Brake Switch Circuit Malfunction
(OBD) System
Go to Step 2 Check
4 Check for poor/faulty connection at the brake switch
C-56 C-44

3 4
5 Using the DVM and check the brake switch 2.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.
Brake Switch
" !
Pedal is not
stepped on:
No continuity Replace pedal
!
Pedal stepped switch and
on: Continuity Go to Step 6 verify repair

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

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

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

9 Repair the short to voltage circuit between the brake
switch 2 connector and ECM.
C-56 C-44

4
Verify repair
65
10 Repair the open circuit between the brake switch 2

connector and ECM.
C-56 C-44

4
Verify repair
65

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

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

5 Using the DVM and check the clutch switch.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch
Pedal is not
!
stepped on:
Continuity
"
Pedal stepped Replace pedal

!
on: No switch and

continuity Go to Step 6 verify repair

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

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

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

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

connector and ECM.
C-56 C-77
Verify repair
2
31

release?
12 Replace the ECM.
(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

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

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

5 Replace the ECM.
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH
INPUT

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

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

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

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

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

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

5 Visually check the TPS.

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

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


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

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

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


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

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


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

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

11 Replace the TPS.

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

release?
14 Replace the ECM.
Pedal/Throttle Position Sensor Idle Position Switch Error
(OBD) System
Go to Step 2 Check
Was the DTC P1120 (Symptom Code E) stored in this and Go to Step
Does the Tech 2 indicate correct Throttle Position
from 0% to 100% depending on accelerator pedal Go to Step 6Go
operation? Go to Step 7 to Step 6
3. Adjust the TPS within 0% to 100%.
2. Monitor the Idle Switch in the data display.
Does the Tech 2 indicate Inactive when the
accelerator pedal was stepped on? Go to Step 10 Go to Step 8
9 Replace the TPS.
release?

11 Replace the ECM.
(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE

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

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

The engine coolant temperature (ECT) sensor is An intermittent may be caused by the following:
installed on the coolant stream. High coolant Poor connections.
temperature produces a low resistance. The ECM
Misrouted harness.
supplies 5 volts signal to the ECT sensor through
resisters in the ECM and measures the voltage. The Rubbed through wire insulation.
signal voltage will be low when the engine temperature Broken wire inside the insulation.
is hot. Check for the following conditions:
The fuel temperature sensor is assembled inside of the Poor connection at ECM and PSG-Inspect harness
pump control unit (PSG). The signal of fuel temperature connectors for backed out terminals, improper
is sent via the CAN-bus from the PSG to ECM. mating, broken locks, improperly formed or damaged
If the engine coolant temperature is excessively high terminals, and poor terminal to wire connection.
condition, DTC P1173 (Symptom Code 3) will be stored.
If the fuel temperature is excessively high or low
condition, DTC P1173 (Symptom Code 7) or P1173
the Coolant Temperature or Fuel Temperature
(Symptom Code A) will be stored.
display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
(OBD) System
Go to Step 2 Check

4 Check the engine overheat condition. Repair the
Was the problem found? cause of
overheat and
2. Monitor the Coolant Temperature in the data
display.
Does the Tech 2 indicate correct Coolant
Temperature depending on warm up time? Go to Step 9 Go to Step 6

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

10 Replace the ECM.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Reduction Caused By Low Fuel Temperature
(OBD) System
Go to Step 2 Check
Is the DTC P1173 (Symptom Code 7) or P1173 and Go to Step
(Symptom Code A) stored as Present Failure? Go to Step 3 3
Was the DTC P1173 (Symptom Code 7) or P1173 Refer to
(Symptom Code A) stored in this ignition cycle? Go to Step 4 Diagnostic Aids
release?
6 Replace the ECM.
(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Code Code
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction is recognized defective reduced.
engine speed signal form the
ECM.

The CKP sensor is located on top of the flywheel An intermittent may be caused by the following:
housing of the flywheel and fixed with a bolt. The CKP Poor connections.
sensor is of the magnet coil type. The inductive pickup
Misrouted harness.
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine Rubbed through wire insulation.
cylinder top dead center. Broken wire inside the insulation.
The ECM converts sine wave signal to square wave Check for the following conditions:
signal. And this signal is provided from the ECM to Poor connection at ECM-Inspect harness connectors
pump control unit (PSG). for backed out terminals, improper mating, broken
Damaged harness-Inspect the wiring harness for moving connectors and wiring harness related to the
damage. If the harness appears to be OK, observe sensor.
the Engine Speed display on the Tech2 while
Engine Speed Output Circuit Malfunction
(OBD) System
Go to Step 2 Check
4 Was the DTC P0335 (Symptom Code B) or P0335 Go to DTC
(Symptom Code D) stored at the same time? Chart P0335
(Symptom
Code B)
(Symptom
Code C) Go to Step 5
C-57(B) 91 E-6


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


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

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

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

The pump camshaft sensor is a magnet with a coil. It Broken wire inside the insulation.
uses to combine with the pulser. The pulser is attached Check for the following conditions:
main shaft in the pump. It likes a gear shape. Poor connection at ECM and PSG-Inspect harness
The pump camshaft sensor is attached to the pump connectors for backed out terminals, improper
control unit (PSG). The signal of pump camshaft speed mating, broken locks, improperly formed or damaged
is sent via the CAN-bus from the PSG to ECM. terminals, and poor terminal to wire connection.
the Pump Speed display on the Tech2 while moving
Poor connections. display will indicate the location of the fault.
Misrouted harness.
Camshaft Speed Malfunction
(OBD) System
Go to Step 2 Check
2. Monitor the Pump Speed in the data display.
Does the Tech 2 indicate correct Pump Speed
depending on engine speed? Go to Step 6 Go to Step 5
release?
8 Replace the ECM.
(FLASH CODE 47) NEUTRAL SWITCH ON ERROR

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Code Code
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function.
ted On three times consecu-
tively under driving
conditions.
B ON Neutral Switch OFF Error Neutral switch signal is input-
ted Off three times consecu-
tively under driving
conditions.
Circuit Description (Symptom Code B) will be stored.
The ECM monitors the neutral switch (A/T: N or P

Diagnostic Aids
position switch in inhibitor switch) signal on the feed
terminal to the ECM. If the neutral switch with An intermittent may be caused by the following:
malfunction, DTC P1520 (Symptom Code A) or P1520 Poor connections.
Misrouted harness. poor terminal to wire connection.
Rubbed through wire insulation. Damaged harness-Inspect the wiring harness for
Broken wire inside the insulation. damage. If the harness appears to be OK, observe
Check for the following conditions: the Neutral Switch display on the Tech2 while
Poor connection at ECM-Inspect harness connectors
sensor.
for backed out terminals, improper mating, broken
Neutral Switch ON Error
Neutral Switch OFF Error
(OBD) System
Go to Step 2 Check
(Symptom Code B) stored as Present Failure? Go to Step 3 3
(Symptom Code B) stored in this ignition cycle? Go to Step 4 4

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

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

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

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

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

9 Repair the short to voltage circuit between the neutral
switch connector (inhibitor switch connector) and
ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
Verify repair
8
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 E-51
2
Verify repair
8
87
release?
12 Replace the ECM.
(FLASH CODE 55) SEED AND KEY FILE DESTROYED

(FLASH CODE 55) EEPROM DEFECT

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

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
The ECM used in this vehicle utilizes an electrically P1605 (Symptom Code C), P1605 (Symptom Code D)
erasable & programmable read only memory or P1605 (Symptom Code E) will be stored.
(EEPROM). The EEPROM contains program
information and the calibrations required for engine and
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
EEPROM Defect
EEPROM Defect
(OBD) System
Go to Step 2 Check
3. Select F0: Read DTC Infor As Stored By ECU in
F0: Diagnostic Trouble Codes. Refer to
Is the DTC P1605 (Symptom Code C), P1605 Diagnostic Aids
(Symptom Code D) or P1605 (Symptom Code E) and Go to Step
stored as Present Failure? Go to Step 3 3

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E) Refer to
stored in this ignition cycle? Go to Step 4 Diagnostic Aids
release?
5 Replace the ECM.
(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Code Code
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.

The ECM decides whether that is an abnormality in the Check for the following conditions:
immobilizer control system. DTC P1610 (Symptom Poor connection at ECM and immobilizer control unit-
Code A) is recorded when immobilizer function was not Inspect harness connectors for backed out terminals,
programmed in the ECM. improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
connectors and wiring harnesses.
Security Key and Security Code Not Programmed
(OBD) System
Go to Step 2 Check
Refer to
2. Select Immobilizer in the system selection menu Immobilizer
Body. Workshop
3. Select Read DTC Info Ordered By Priority in the Manual & Go
Diagnostic Trouble Code. to DTC Chart
Was the any DTC's B0002 or B0009 stored in this B0002 or
ignition cycle? B0009 Go to Step 5
release?
6 Replace the ECM.
(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Code Code
56 P1611 A - Wrong Security Code Entered Received security code is not 1. Engine does not start.
correct. 2. Check engine lamp flash.

Code A) is recorded when received immobilizer security Inspect harness connectors for backed out terminals,
code was not correct. improper mating, broken locks, improperly formed or
connection.
Wrong Security Code Entered
(OBD) System
Go to Step 2 Check
Refer to
Body. Workshop
Was the any DTC's B**** stored in this ignition cycle? B**** Go to Step 5
release?
6 Replace the ECM.
(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Code Code
56 P1612 A - Immobilizer No or Wrong Sig- Received challenge signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

Code A) is recorded when received immobilizer Inspect harness connectors for backed out terminals,
challenge signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobilizer No or Wrong Signal
(OBD) System
Go to Step 2 Check
Refer to
Body. Workshop
Diagnositic Trouble Code. to DTC Chart
Was the DTC B0007 stored in this ignition cycle? B0007 Go to Step 5
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68

8
7

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

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

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

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

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

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

response signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobilizer No or Wrong Signal
(OBD) System
Go to Step 2 Check
Refer to
Body. Workshop
Diagnositic Trouble Code. to DTC Chart
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68

8
7

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

lamp circuit.
circuit.
Breaker Box
42 B-68
!
!

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

circuit.
Breaker Box
35 B-68
!
!

circuit.
C-56
B-68 35
Repair faulty
harness and
release?
11 Replace the ECM.
(FLASH CODE 56) WRONG TRANSPONDER KEY
Code Code
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start.
not correct from the transpon- 2. Check engine lamp flash.
der key.

response signal was not correct from the transponder improper mating, broken locks, improperly formed or
key. damaged terminals, and poor terminal to wire
connection.
Wrong Transponder Key
(OBD) System
Go to Step 2 Check
Refer to
Body. Workshop
release?
6 Replace the ECM.
IMPORTANT: The replacement ECM must e
(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY

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

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

!
"
#
Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
release?
6 Replace the ECM.
(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION

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

The ECM is calculates an injection quantity and an
injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
Diagnostic Aids Broken wire inside the insulation.
Poor connections. connectors for backed out terminals, improper
Misrouted harness. mating, broken locks, improperly formed or damaged
Rubbed through wire insulation. terminals, and poor terminal to wire connection.
Injection Quantity Circuit Malfunction
Injection Quantity Circuit Malfunction
(OBD) System
Go to Step 2 Check
(symptom Code B) stored as Present Failure? Go to Step 3 3
Was the DTC P1630 (Symptom Code A) or P1630 Refer to
(symptom Code B) stored in this ignition cycle? Go to Step 4 Diagnostic Aids
(FLASH CODE 44) CAN DEVICE OFFLINE

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

The interchange of data between the engine control An intermittent may be caused by the following:
module (ECM) and the pump control unit (PSG) is Poor connections.
performed via a CAN-bus system. The individual CAN-
Misrouted harness.
bus systems are connected via two interfaces and can
exchange information and data. This allows control Rubbed through wire insulation.
modules that are connected to different CAN-bus Broken wire inside the insulation.
systems to communicate. Check for the following conditions:
Poor connection at ECM and PSG-Inspect harness Damaged harness-Inspect the wiring harness for
connectors for backed out terminals, improper damage. If the harness appears to be OK, observe
mating, broken locks, improperly formed or damaged the DTC P1650 display on the Tech2 while moving
terminals, and poor terminal to wire connection. connectors and wiring harnesses.
CAN Device Offline
(OBD) System
Go to Step 2 Check
C-57 E-6 2

1
100 99
6 Using the DVM and check the CAN high circuit.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 7 verify repair

connector.
circuit.
Breaker Box
100 E-6
!
!
!

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

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

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

C-57 E-6
Verify repair
100 2

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

interference. accessory parts
release?
17 Replace the ECM.
CAN Device Hang-up
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.
(FLASH CODE 45) CAN MALFUNCTION

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

Diagnostic Aids
module (ECM) and the pump control unit (PSG) is
performed via a CAN-bus system. The individual CAN- An intermittent may be caused by the following:
bus systems are connected via two interfaces and can Poor connections.
exchange information and data. This allows control
Misrouted harness.
modules that are connected to different CAN-bus
Rubbed through wire insulation. terminals, and poor terminal to wire connection.
Poor connection at ECM and PSG-Inspect harness the DTC P1651 display on the Tech2 while moving
connectors for backed out terminals, improper connectors and wiring harnesses.
CAN Malfunction
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.
CAN Receives Error
(OBD) System
Go to Step 2 Check
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
C-57 E-6 2

1
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 8 verify repair

connector.
circuit.
Breaker Box
100 E-6
!
!
!

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

connector.
circuit.
Breaker Box
99 E-6
"
!
!

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

C-57 E-6
Verify repair
100 2

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

interference. accessory parts
release?
18 Replace the ECM.
(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW

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

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


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

42
! !

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

10 Replace the ECM.
Check Engine Lamp (MIL) Circuit Voltage High
(OBD) System
Go to Step 2 Check
release?
6 Replace the ECM.
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS Road test the vehicle with a Digital Multimeter
connected to a suspected circuit. An abnormal voltage
Before using this section, perform the On-Board when the malfunction occurs is a good indication that
Diagnostic (OBD) System Check and verify all of the there is a fault in the circuit being monitored.
following items: Using Tech 2 to help detect intermittent conditions. The
The engine control module (ECM) and check engine Tech 2 have several features that can be used to
lamp (MIL=malfunction indicator lamp are operating located an intermittent condition. Use the following
correctly. features to find intermittent faults:
There are no Diagnostic Trouble Code(s) stored.
Tech 2 data is within normal operating range. Refer to To check for loss of diagnostic code memory,
Typical Scan Data Values. disconnect the MAF sensor and idle the engine until the
check engine lamp (MIL=malfunction indicator lamp)
Verify the customer complaint and locate the correct
comes on. Diagnostic Trouble Code P0100 should be
symptom in the table of contents. Perform the
stored and kept in memory when the ignition is turned
procedure included in the symptom chart.
OFF.
If not, the ECM is faulty. When this test is completed,
VISUAL/PHYSICAL CHECK make sure that you clear the Diagnostic Trouble Code
Several of the symptom procedures call for a careful P0100 from memory.
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable An intermittent check engine lamp (MIL=malfunction
time. This check should include the following items: indicator lamp) with no stored Diagnostic Trouble Code
ECM grounds for cleanliness, tightness and proper may be caused by the following:
location. Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM short to ground.
Vacuum hoses for splits, kinks, and proper
connection. Check thoroughly for any type of leak or Poor ECM grounds. Refer to the ECM wiring
restriction. diagrams.
Air intake ducts for collapsed or damaged areas.
Check for improper installation of electrical options such
Air leaks at throttle body mounting area, mass air flow as light, cellular phones, etc. Check all wires from ECM
(MAF) sensor and intake manifold sealing surfaces. to the ignition control module for poor connections.
Wiring for proper connections, pinches and cuts. Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
INTERMITTENT diagrams in Electrical Diagnosis).
Important: An intermittent problem may or may not turn
If problem has not been found, refer to ECM connector
on the check engine lamp (MIL=malfunction indicator
symptom tables.
lamp) or store a Diagnostic Trouble Code. Do NOT use
the Diagnostic Trouble Code (DTC) charts for Check the Broadcast Code of the ECM, and
intermittent problems. compare it with the latest Isuzu service bulletins and/
The fault must be present to locate the problem. or Isuzu EEPROM reprogramming equipment to
Most intermittent problems are cased by faulty electrical determine if an update to the ECM's reprogrammable
connections or wiring. Perform a careful visual/physical memory has been released.
check for the following conditions.
This identifies the contents of the reprogrammable
Poor mating of the connector halves or a terminal not
software and calibration contained in the ECM.
fully seated in the connector (backed out).
If the Broadcast Code is not the most current
Improperly formed or damaged terminal. available, it is advisable to reprogram the ECM's
All connector terminals in the problem circuit should EEPROM memory, which may either help identify a
be carefully checked for proper contact tension. hard-to find problem or may fix the problem.
Poor terminal-to-wire connection. This requires The Service Programming System (SPS) will not allow
removing the terminal form the connector body to incorrect software programming or incorrect calibration
check. changes.
Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
Poor ECM grounds. Refer to the ECM wiring
diagrams.
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.

(OBD) System
Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? Verify repair Go to Step 3
3 Was a visually/physical check performed? Go to Visual /
Go to Step 4 physical Check
4 Is the fuel amount enough?
Add fuel to the

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

11 Check the CKP sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
14 Check the exhaust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
fuel hose/pipe.
fuel.

injection pump and check for the following conditions.
fuel.
Replace the
eye bolt with
gauze filter and
18 Check the engine compression pressure for each
cylinders.
More than 2.1

Mpa (21.0 kg/
cm2) Verify repair Go to Step 19
19 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
Repair as
Go to Step 20 necessary

20 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
All electrical connections within a suspected circuit
and/or system
release?
23 Replace the ECM.
HARD START SYMPTOM
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.

(OBD) System
Go to Step 2 Check
intake system
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
8 1. Using the Tech 2, display the FT sensor value.
9 1. Using the Tech 2, ignition On.
2. Monitor the Glow Time Relay in the data display.
Does the Tech 2 indicate correct Glow Time Relay
status depending on the time from ignition switch
On?

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

fuel hose/pipe.
fuel.

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

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

Mpa Verify repair Go to Step 18

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

(In/Ex) Go to Step 19 verify repair
following:
Tech 2 data
and/or system
release?
22 Replace the ECM.
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM
DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed
may vary in RPM. Either condition may be severe
rpm
enough to stall the engine.
X
Rough Idle
Stall
time

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

9 1. Using the Tech 2, ignition On and engine Run.
2. Monitor the A/C Information Switch in the data
display.
Does the Tech 2 indicate correct A/C Information
Switch status depending on A/C switch position?
sensor value.
2. Monitor the Mass Air Flow in the data display.
Does the Tech 2 indicate correct Mass Air Flow
depending on accelerator pedal operation? Go to Step 16 Go to Step 12
Objects blocking at the MAF sensor element.
13 Check the MAF sensor harness for the following
conditions.
and recheck.
2. Monitor the Pedal/Throttle Position and Idle
Switch in the data display.
Does the Tech 2 indicate correct Pedal/Throttle
Position from 0% to 100% and correct Idle Switch
status depending on accelerator pedal operation? Go to Step 21 Go to Step 17

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

25 1. Using the Tech 2 and ignition On and engine
Run.
2. Monitor the following parameters in the data
display.
Desired Injection Quantity & Injection Quantity
Desired Injection Start & Actual Injection Start
Are the large gap or unstable parameter displayed
between Desired and Actual?
When idling or part-throttle
Desired
High
Actual
Low
Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and

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


valves.

following:
Tech 2 data
and/or system
release?
37 Replace the ECM.
SURGES AND/OR CHUGS SYMPTOM
DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time

(OBD) System
Go to Step 2 Check
intake system
display.

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

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

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

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

HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to Stumble
rpm
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Sug
Hesitation
time

(OBD) System
Go to Step 2 Check
5 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
intake system

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

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

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

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

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

(OBD) System
Go to Step 2 Check
intake system
compressor
wheel or turbine shaft sticking.

7 1. Using the Tech 2, perform test drive.
2. Monitor the Vehicle Speed in the data display.
Does the Tech 2 indicate correct Vehicle Speed
depending on driving speed?
When constant vehicle speed

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

100%.
20 Replace the TPS.
conditions.

Run.
display.
When idling or part-throttle

Desired
High
Actual
Low
Time

deposit.
Tech 2:
Vacuum Pump:
valve.

fuel hose/pipe.
fuel.

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

LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM
DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.

(OBD) System
Go to Step 2 Check
intake system
sensor value.

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

Run.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time

deposit.
Tech 2:
Vacuum Pump:
valve.


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


4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
cylinders.
More than 2.0

valves.

following:
Tech 2 data
and/or system

release?
31 Replace the ECM.
POOR FUEL ECONOMY SYMPTOM
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)

(OBD) System
Go to Step 2 Check
4 Check owner's driving habits.
Is the A/C On full time?
Are tires at the correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often? Go to Step 5 Go to Step 6
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete? System OK
6 Check for low engine coolant level.
7 Check for incorrect or faulty engine thermostat. Refer
to Engine Cooling.
8 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2? Go to Step 10 Go to Step 9
9 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis. Verify repair
10 Check for proper calibration of the fuel gauge.
11 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.

display.
intake system
sensor value.
conditions.

and recheck.
100%.
26 Replace the TPS.

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

cylinders.
More than 2.0

valves.

following:
Tech 2 data
and/or system
release?

33 Replace the ECM.
EXCESSIVE WHITE SMOKE

(OBD) System
Go to Step 2 Check
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or exhaust through the
gasket.
sensor value.
conditions.

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

conditions.

Run.
display.
Desired Desired
High High
Actual
Actu al
Low Low
Time Time

fuel hose/pipe.
fuel.

fuel.
Replace the
eye bolt with
gauze filter and

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

cylinders.
More than 20
valves.

following:
Tech 2 data
and/or system
release?

32 Replace the ECM.
EXCESSIVE BLACK SMOKE

(OBD) System
Go to Step 2 Check
intake system
sensor value.

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

deposit.
Tech 2:
Vacuum Pump:
valve.



4JA1-TC
19.0 Mpa 33.5 Mpa
4JH1-TC
cylinders.
More than 20
valves.

following:
Tech 2 data
and/or system

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

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

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

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

not stored after replacement.
Verify no engine coolant leaking from the sensor
threads after replacement.
MASS AIR FLOW (MAF) & INTAKE THROTTLE POSITION SENSOR
AIR TEMPERATURE (IAT) SENSOR (TPS)
Location Location
Installed to the intake duct housing. Installed on the throttle body.
Removal Procedure Removal Procedure

1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Disconnect a MAF & IAT sensor connector from the 2. Disconnect the TPS connector.
MAF & IAT sensor assembly. 3. Loosen two screws and remove TPS from the
3. Loosen the clips and remove the MAF & IAT sensor throttle body.
assembly from the intake duct housing.
Installation Procedure 1. Temporary tighten the TPS by two screws.
1. Install the MAF & IAT sensor assembly into intake 2. Connect a TPS connectors to the TPS.
air duct.
3. Connect the Tech2 to the vehicle.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF
5. Select Data Display with the Tech2.
& IAT sensor assembly.
6. Check the throttle position data and adjust the TPS
position.
NOTE: Verify any DTCs (diagnosis Trouble Code) are 7. Tighten two screws.
EGR EVRV (Electrical Vacuum
Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.

Verify proper connection of two hoses.
SPECIAL SERVICE TOOLS
ILLUSTRATION TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
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
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E#+$%($L& & &
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& 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 6. Front hanger rubber
2. Silencer front nut 7. Front pipe nut
3. Exhaust silencer 8. Exhaust pipe gasket
4. Silencer hanger rubber
5. Middle pipe nut
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.
43 (4.4/32)
3. Silencer Front Nut

Connect the silencer to the front or middle pipe.
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 Front Side VSV-1 ON ON ON OFF
Engine Rear Side VSV-2 ON OFF ON OFF
ON means VSV should receive signal to move EGR valve.

OFF means VSV shouldnt receive signal to move EGR valve.
6F 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and
emissions section for detail.
RTW46EMF000701
EXHAUST SYSTEM 6F 11
INSPECTION
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 Not operation

Negative Pressure 4JA1TC
Less than 100 mmHg Not operation

EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)
RTW46EMF000201
Removal Steps
1. Bolt 7. EGR Pipe Assembly
2. Gasket 8. Gasket
3. Bolt 9. Bolt
4. Gasket 10. EGR Cooler Assembly
5. Bolt 11. Gasket
6. Bolt 12. EGR Cooler Adapter
Removal
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
RTW46EMF000901
Installation steps
1. EGR Cooler Adapter 8. Bolt
2. Gasket 9. Gasket
3. EGR Cooler Assembly 10. EGR Valve Assembly
4. Gasket 11. Bolt
5. Bolt 12. EXH Manifold
6. EGR Pipe Assembly 13. Gasket
7. Bolt 14. Bolt
Installation
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Bolt
Tighten the bolts to the specified torque.
EGR adapter bolt torque N!m(kg!m/lb ft)
27(2.8/20)
5. Gasket
6. EGR Pipe Assembly
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 4JA1T(L) 4JA1TC 4JH1TC

Model IHI RHF4H IHI RHF4H IHI RHF5
Turbine type Mixed type
Compressor type Backword & rake type
Maximum permissible speed rpm 190,000 190,000 180,000
IHI : Ishikawajima Harima Heavy Industries., Ltd.
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:
Do not apply a pressure greater than 1 kg/cm to the
2
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 134.8/1011
4JA1TC 147.7/1108
150RY00032
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 Limit
0.03 - 0.06
0.09 (0.004)
(0.001 - 0.002)
150RY00034
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 Limit
0.056 - 0.127
0.127 (0.0050)
(0.0022 - 0.0050)
150RY00036
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-0075-0 Pressure Gauge
901RX00143
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 - 2
Removal...................................................................................................................... 6H - 6
Inspection................................................................................................................... 6H - 6
Installation.................................................................................................................. 6H - 6
6H 2 ACCELERATOR CONTROL

4JA1T(L)/RHD
RTW46HLF000301
4JA1T(L)/LHD
RTW46HLF000601
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
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.
Installation
RTW46HMH000201
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

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WORKSHOP MANUAL

1-1.Starter Motor Inoperative ......... 6 3 12. OIL LEAKAGE FROM

Basic Inspection Procedure

1-3 Engine turn over but does not start engine

Incase of the fuel is being delivered to the injection pump

Injection nozzle opening pressure

441 psi) at or replace the

Injection nozzle opening pressure

441 psi) at or replace the

4. Excessive Fuel Consumption

441 psi) at or replace the

5. Excessive Oil Consumption

psi) relief valve Go to Step 4

7. White Exhaust Smoke

441 psi) at or replace the

8. Dark Exhaust Smoke

9. Oil Pressure Does Not Rise

Table of pressure unit

10. Abnormal Engine Noise

441 psi) at gasket or

102 Gas leakage noise

103 Continuous noise

Adjust the fan

10-4 Slapping noise

10-5 Excessive turbocharger noise

11. Rotating Part Wear of Turbocharger

12. Oil Leakage from Turbocharger

13. Insufficient Acceleration and/or Lack of Power due to turbocharger

14. Battery Charging and Noise Problem

14-2 Battery Overcharging

14-3 Battery Under Charging

14-4 Battery Unstable Charging Current

14-5 Charging System Noise

15. Starter Motor Problem

15-2 Incorrect pinion and ring gear engagement

15-4 Excessive commutator sparking

Disassembly ............................................................................................................... 6A- 47

Lubricating Flow ........................................................................................................ 6A- 126

MAIN DATA AND SPECIFICATIONS

Compression ratio (to 1) 18.5

Engine weight (dry) kg (lb) Approximately 239 (527)

2nd (Reference) 2nd (Reference)

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

MAIN DATA AND SPECIFICATIONS

Engine weight (dry) kg (lb) MT : Approximately 249 (549)

Pipe diameter mm Pipe diameter mm

SPECIAL PARTS FIXING NUTS AND BOLTS

Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft

Cooling and Lubricating System

Intake Manifold (4JA1TC / 4JH1TC)

EGR Valve, EGR Pipe, EGR Cooler

Exhaust Manifold, and Turbocharger (4JA1L)

Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC)

Fuel Injection System (4JA1L)

Fuel Injection System (4JA1TC)

Fuel Injection System (4JH1TC)

Engine Mounting Bracket

RECOMMENDED LIQUID GASKET

* RTV : Room Temperature Vulcanizer

LOCTITE APPLICATION PROCEDURE

LOCTITE 262 Red

LOCTITE 270 Green

3. Tighten the bolts to the specified torque.