06 - Tfheo We 0431

WORKSHOP MANUAL
TF SERIES
ENGINE
C24SE
SECTION 6
ENGINE DIAGNOSIS (C24SE) 6-1
SECTION 6
ENGINE DIAGNOSIS
CONTENTS
PAGE Engine Diagnosis............................................................................................................... 6- 2 Hard Starting ................................................................................................................. 6- 2 Engine Compression Test Procedure ......................................................................... 6- 3 Rough Engine Idling or Engine Stalling...................................................................... 6- 4 Rough Engine Running ................................................................................................ 6- 5 Hesitation....................................................................................................................... 6- 6 Engine Lacks Power ..................................................................................................... 6- 7 Engine Noisy ................................................................................................................. 6- 8 Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9 Troubleshooting Procedure ......................................................................................... 6- 9 Abnormal Combustion.................................................................................................. 6-11 Engine Oil Consumption Excessive ............................................................................ 6-12 Fuel Consumption Excessive ...................................................................................... 6-13 Oil Problems.................................................................................................................. 6-13 Engine Oil Pressure Check .......................................................................................... 6-13 Malfunction Indicator Lamp ......................................................................................... 6-14
6-2 ENGINE DIAGNOSIS (C24SE)
Engine Diagnosis
Hard Starting
1.Starting Motor Does Not Turn Over Trouble Shooting Procedure Turn on headlights and starter switch. Condition Headlights go out or dim considerably Possible cause Battery run down or under charged Terminals poorly connected Starting motor coil circuit shorted Starting motor defective 2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start Spark Test Disconnect a high tension cable from any spark plug. Connect the spark plug tester (use commercially available tool), crank the engine, and check if a spark is generated in the spark plug tester. Before cranking the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the high tension cable while the engine is running. Condition Spark jumps across gap Possible cause Spark plug defective Spark plug wire in correct Ignition timing incorrect Fuel not reaching fuel injector(s) or engine Valve timing incorrect Engine lacks compression Ignition coil disconnected or broken Electronic Ignition System with module Poor connections in engine harness Engine Control Module cable disconnected or defective Correction Clean, adjust spark gap or replace Connect properly or replace Refer to Ignition System Refer to item 3 (Trouble in fuel system) Adjust Refer to item 4 (Engine lacks compression) Connect properly or replace Replace Correct Correct or replace Correction Recharge or replace battery Clean battery posts and terminals and connect properly Overhaul or replace Overhaul or replace
No sparking takes place
ENGINE DIAGNOSIS (C24SE) 6-3 3.Trouble in Fuel System Condition Starting motor turns over and spark occurs but engine does not start. Possible cause Fuel tank empty Correction Fill
Water in fuel system Fuel filter clogged Fuel pipe clogged Fuel pump defective Fuel pump circuit open Evaporative Emission Control system circuit clogged Multiport Fuel Injection System faulty 4.Engine Lacks Compression Condition Engine lacks compression Possible cause Spark plug loosely fitted or spark plug gasket defective Spark plug wire incorrect Valve timing incorrect Cylinder head gasket defective Valve incorrectly seated Valve stem seized Valve spring weakened Cylinder or piston rings worn Piston ring seized 6. 7. 8.
Clean Replace filter Clean or replace Replace Correct or replace Correct or replace Refer to "Electronic Fuel Injection" section
Correction Tighten to specified torque or replace gasket Connect properly or replace Adjust Replace gasket Lap valve Replace valve and valve guide Replace Overhaul engine Overhaul engine.
Engine Compression Test Procedure

1. 2. 3. 4. 5. Start and run the engine until the engine reaches normal operating temperature. Turn the engine off. Remove all the spark plugs. Remove ignition coil fuse (15A) and disable the ignition system. Remove the fuel pump relay from the relay and fuse box.
Engage the starter and check that the cranking speed is approximately 300 rpm. Install cylinder compression gauge into spark plug hole. With the throttle valve opened fully, keep the starter engaged until the compression gauge needle reaches the maximum level. Note the reading. Repeat the test with each cylinder. The pressure difference between the individual cylinders should not exceed 100kPa (14.5 psi).
9.
Rough Engine Idling or Engine Stalling

Condition Trouble in fuel injection system Possible cause Idle air control valve defective Throttle shutting off incomplete Throttle position sensor circuit open or shorted Fuel injector circuits open or shorted Fuel injectors damaged Fuel pump relay defective Manifold Absolute Pressure Sensor cable disconnected or broken Manifold Absolute Pressure Sensor defective Engine Coolant Temperature Sensor cable disconnected or broken Engine Coolant Temperature Sensor defective Intake Air Temperature sensor cable disconnected or broken Intake Air Temperature sensor defective Knock Sensor (KS) circuits open or shorted KS defective KS Module circuits open or ground KS Module defective Vehicle Speed Sensor circuit open or shorted Vehicle Speed Sensor defective Engine Control Module defective Canister purge solenoid circuit open Canister purge solenoid defective Evaporative Emission Canister Purge control valve defective Trouble in ignition system Others Engine lacks compression Valve incorrectly seated Air Cleaner Filter clogged Valve timing incorrect Idle air control valve broken Correction Replace Correct or replace Correct or replace Correct or replace Replace Replace Correct or replace
Replace Correct or replace
Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Replace Correct Replace Replace Refer to Hard Start Troubleshooting Guide Refer to Hard Start Troubleshooting Guide Lap valve Replace filter element Readjust Replace
Trouble in emission control system
Rough Engine Running

Condition Engine misfires regularly Possible cause Ignition coil layer shorted Spark plugs fouling Spark plug(s) insulator nose leaking Spark plug wire incorrect Fuel injector(s) defective Engine control module faulty Spark plugs running too hot Powertrain control module faulty Spark plugs fouled Spark plug wire incorrect Fuel injectors defective Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective Engine Control Module faulty Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective Throttle Position Sensor or Throttle Position Sensor circuit defective Knock Sensor or Knock Sensor circuits defective Knock Sensor Module or Knock Sensor Module circuits defective Correction Replace Clean or install hotter type plug Replace Connect properly or replace Replace Replace Install colder type spark plugs Replace Clean Connect properly or replace Replace Correct or replace
Engine knocks regularly Engine lacks power
Correct or replace
Replace Correct or replace
Correct or replace
Correct or replace Correct or replace
Hesitation
Condition Hesitation on acceleration Possible cause Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Excessive play in accelerator linkage Manifold Absolute Pressure (MAP) Sensor circuit open or shorted MAP Sensor defective Intake Air Temperature (IAT) Sensor circuit open or shorted Knock Sensor (KS) Circuit open or shorted KS defective KS Module circuits open or shorted KS Module defective IAT Sensor defective Fuel tank strainer clogged Fuel pipe clogged Fuel filter clogged Defective fuel pump system Fuel Pressure Control Valve leaking Power supply or ground circuit for Multiport Fuel Injection System shorted or open Cable of Multiport Fuel Injection System disconnected or defective Engine Control Module defective Throttle Position Sensor circuit open or shorted Throttle Position Sensor defective Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective MAP Sensor cable open or shorted MAP Sensor defective IAT Sensor circuit open or shorted IAT Sensor defective KS Circuit open or shorted KS defective KS Module circuit open or shorted KS Module defective Throttle valve not wide opened Air Cleaner Filter clogged Power supply voltage too low Correction Replace throttle valve assembly Correct or replace Adjust or replace Correct or replace
Replace Correct or replace Correct or replace Replace Correct or replace Replace Replace Clean or replace Clean or replace Replace Check and replace Replace Check and correct or replace
Hesitation at high speeds (Fuel pressure too low)
Hesitation at high speeds (Fuel injector not working normally)
Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Check and correct or replace Replace filter element Check and correct or replace
Hesitation at high speeds
Engine Lacks Power

Condition Trouble in fuel system Possible cause Fuel Pressure Control Valve not working normally Fuel injector clogged Fuel pipe clogged Fuel filter clogged or fouled Fuel pump drive circuit not working normally Fuel tank not sufficiently breathing due to clogged Evaporative Emission Control System circuit Water in fuel system Inferior quality fuel in fuel system Engine Control Module supplied poor voltage Throttle Position Sensor cable disconnected or broken Throttle Position Sensor defective Manifold Absolute Pressure Sensor not working normally Intake Air Temperature sensor not working normally Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Engine Control Module defective Air Cleaner Filter clogged Air duct kicked or flattened Ignition failure Heat range of spark plug inadequate Electronic Ignition System with module Correction Replace Clean or replace Clean Replace Correct or replace Clean or replace
Clean Use fuel of specified octane rating Correct circuit Correct or replace Replace Replace Replace Correct or replace Replace Replace Replace filter element Correct or replace Refer to Hard Start Troubleshooting Guide Install spark plugs of adequate heat range Replace
Trouble in intake or exhaust system
6-8 ENGINE DIAGNOSIS (C24SE) Condition Engine overheating Possible cause Level of Engine Coolant too low Thermo switch or fan motor defective Thermostat defective Engine Coolant pump defective Radiator clogged Radiator filter cap defective Level of oil in engine crankcase too low or wrong oil in engine Resistance in exhaust system increased Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Cylinder head gasket damaged Cooling Fan clutch defective Fan belt slipping Thermostat defective Tire inflation pressure abnormal Brake drag Clutch slipping Level of oil in engine crankcase too high Correction Replenish Replace Replace Correct or replace Clean or replace Replace Change or replenish Clean exhaust system or replace defective parts Adjust Wide Open Throttle switch setting Correct or replace Replace Replace Adjust tension of V-belt or replace V-belt Replace (Use a thermostat set to open at 92 C (197.6 F)) Refer to Hard Start Adjust to recommend pressures Adjust Adjust or replace Correct level of engine oil
Engine overcooling Engine lacks compression Others
Engine Noisy
Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically. Condition Noise from crank journals or from crank bearings (Faulty crank journals and crank bearings usually make dull noise that becomes more evident when accelerating) Possible cause Oil clearance increased due to worn crank journals or crank bearings Correction Replace crank bearings and crankshaft or regrind crankshaft and install the over size bearing
Crankshaft out of round
Crank bearing seized
Replace crank bearings and crankshaft or regrind crankshaft and install the over size bearing Replace crank bearings and crankshaft or regrind crankshaft and install the over size bearing
Abnormal Noise Due to Hydraulic Lash Adjuster

Should abnormal noise due to the hydraulic lash adjuster trouble be heard immediately after the engine is started, inspect as follows: Condition Abnormal noise is heard HLA is spongy Possible cause Air contaminated Check ball valve broken Safety valve in cylinder head broken HLA inside stick Correction Bleed Repair Replace Replace HLA assembly
Valve clearance is not zero
Troubleshooting Procedure
Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated) Possible cause Bearing or crankshaft pin worn Correction Replace connecting rod bearings and crankshaft or regrind crankshaft and install the under size bearing
Crankpin out of round
Connecting rod bent Connecting rod bearing seized
Replace connecting rod bearings and crankshaft or regrind crankshaft and install the under size bearing Correct or replace Replace connecting rod bearings and crankshaft or regrind crankshaft and install the under size bearing
Abnormal noise stops when the spark plug on the cylinder with defective parts is shorted out. Condition Piston and cylinder (Faulty piston or cylinder usually makes a combined mechanical thumping noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up) Possible cause Piston clearance increased due to cylinder wear Correction Replace piston and cylinder body
Piston seized Piston ring broken Piston defective
Replace piston and cylinder body Replace piston and cylinder body Replace pistons and others
Condition Piston pin noise (Piston makes noise each time it goes up and down)
Possible cause Piston pin or piston pin hole worn
Correction Replace piston, piston pin and connecting rod assy
The slapping sound stops when spark plug on bad cylinder is shorted out. Condition Timing belt noise Possible cause Timing belt tension is incorrect Correction Replace pusher or adjust the tension pulley or replace timing belt Replace Replace Replace Replace timing belt and timing cover Replace valve and valve guide Replace Correct Replace thrust bearing
Valve noise
Crankshaft noise
Engine knocking
Others
Tensioner bearing defective Timing belt defective Timing wheels defective Timing belt comes in contact with timing cover Valve and valve guide seized Valve spring broken Valve seat off-positioned Crankshaft end play excessive (noise occurs when clutch is engaged) Preignition due to use of spark plugs of inadequate heat range Fuel too low in octane rating Wide Open Throttle enrichment system failure Selection of transmission gear incorrect Engine overheating Water pump defective V-belt slipping
Install Spark Plugs of adequate heat range Replace fuel Refer to Section 6E Caution operator or incorrect gear selection Refer to "Engine Lacks Power" Replace Adjust tension of V-belt or replace V-belt
Abnormal Combustion
Condition Trouble in fuel injection system Possible cause Fuel pressure control valve defective Fuel filter clogged Fuel pump clogged Fuel tank or fuel pipe clogged Fuel injector clogged Fuel pump relay defective Power supply cable for fuel pump loosely connected or defective Manifold Absolute Pressure Sensor circuit open or shorted Manifold Absolute Pressure Sensor defective Engine Coolant Temperature (ECT) Sensor circuit open or shorted ECT Sensor defective Throttle Position Sensor adjustment incorrect Throttle Position Sensor defective Throttle Position Sensor connector loosely connected Vehicle Speed Sensor cable loosely connected or defective Vehicle Speed Sensor loosely fixed Vehicle Speed Sensor in wrong contact or defective Engine Control Module cable loosely connected or defective Heated Oxygen Sensor circuit open (If applicable) Heated Oxygen Sensor defective (If applicable) Signal vacuum hose loosely fitted or defective ECT Sensor circuit open or shorted ECT Sensor defective Evaporative Emission Control system (If applicable) Carbon deposits in combustion chamber Carbon deposit on valve, valve seat and valve guide Correction Replace Replace Clean or replace Clean or replace Clean or replace Replace Reconnect, correct or replace Correct or replace Replace Correct or replace
Replace Reconnect Replace Reconnect Correct or replace Fix tightly Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Refer to Section 6E Refer to "Engine Lacks Power" Remove carbon Remove carbon
Trouble in emission control system
Trouble in ignition system Trouble in cylinder head parts
Engine Oil Consumption Excessive

Condition Oil leaking Possible cause Oil pan drain plug loose Oil pan setting bolds loosened Oil pan gasket broken Front cover retaining bolts loose or gasket broken Head cover retaining bolts loose or gasket broken Oil filter adapter cracked Oil filter attaching bolt loose or rubber gasket broken Crankshaft front or rear oil seal defective Oil pressure unit loose or broken Blow-by gas hose broken Engine/Transmission coupling area Valve stem oil seal defective Correction Retighten or replace gasket Retighten Replace gasket Retighten or replace gasket Retighten or replace gasket Replace Retighten or replace oil filter Replace oil seal Retighten or replace Replace hose Replace oil seal Replace
Oil leaking into combustion chambers due to poor seal in valve system Oil leaking into combustion chambers due to poor seal in cylinder parts
Valve stem or valve guide worn Cylinders and pistons worn excessively Piston ring gaps incorrectly positioned Piston rings set with wrong side up Piston rings sticking Piston ring and ring groove worn Return ports in oil rings clogged Positive Crankcase Ventilation Hose clogged Improper oil viscosity Continuous high speed driving and or severe usage such as trailer towing
Replace valve and valve guide Rebore cylinder and replace pistons and others Correct Correct Rebore cylinder and replace pistons and others Replace pistons and others Clean piston and replace rings Clean
Crank case ventilation, Positive Crankcase Ventilation System malfunctioning Others
Use oil of recommended S.A.E. viscosity Continuous high speed operation and or severe usage will normally cause increased oil consumption
Fuel Consumption Excessive

Condition Trouble in fuel system Possible cause Mixture too rich or too lean due to trouble in fuel injection system Fuel cut function does not act Misfiring or abnormal combustion due to trouble in ignition system Engine idle speed too high Returning of accelerator control sluggish Fuel system leakage Clutch slipping Brake drag Selection of transmission gear incorrect Correction Refer to "Abnormal Combustion" Refer to "Abnormal Combustion" Refer to Hard Start or Abnormal Combustion Troubleshooting Guide Reset Idle Air Control Valve Correct Correct or replace Correct Correct Caution operator of incorrect gear selection
Trouble in ignition system
Others
Oil Problems
Condition Oil pressure too low Possible cause Wrong oil in use Relief valve sticking Oil pump not operating properly Oil pump strainer clogged Oil pump worn Oil pressure gauge defective Crankshaft bearing or connecting rod bearing worn Wrong oil in use Oil filter clogged Cylinder head gasket damage Burned gases leaking Oil passage in cylinder head or cylinder body clogged 3. 4. 5. 6. Correction Replace with correct engine oil Replace Correct or replace Clean or replace strainer Replace Correct or replace Replace Replace with new engine oil Replace oil filter Replace gasket Replace piston and piston rings or rebore cylinders Clean or correct
Oil contamination
Oil not reaching valve system
Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Change the oil if the viscosity is outside the specified standard. c. Refer to the "Maintenance and Lubrication" section of this manual. 2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.
Remove the oil pressure unit. Install an oil pressure gauge. Start the engine and allow the engine to reach normal operating temperature (About 80 C). Measure the oil pressure. Oil pressure should be: 150 kPa(21.8 psi) at idle speed. Stop the engine. Remove the oil pressure gauge Install the oil pressure unit. Start the engine and check for leaks.
7. 8. 9. 10.
Malfunction Indicator Lamp

The instrument panel "CHECK ENGINE" Malfunction Indicator lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition "CHECK ENGINE" MIL does not illuminate at the starting of engine Possible cause Bulb defective MIL circuit open Command signal circuit to operate self diagnostic system shorted Engine Control Module (ECM) cable loosely connected, disconnected or defective ECM defective Deterioration heated oxygen sensor of internal element Heated oxygen sensor connector terminal improper contact (If applicable) Heated oxygen sensor lead wire shorted (If applicable) Heated oxygen sensor circuit open (If applicable) Deterioration engine coolant temperature sensor of internal element Engine coolant temperature sensor connector terminal improper contact Engine coolant temperature sensor lead wire shorted Engine coolant temperature sensor circuit open Throttle position sensor open or shorted circuits Deterioration of crankshaft position sensor Crankshaft position sensor circuit open or shorted Vehicle speed sensor circuit open Manifold absolute pressure sensor circuit open or shorted Intake air temperature sensor circuit open or shorted Fuel injector circuit open or shorted ECM driver transistor defective Malfunctioning of ECM RAM (Random Access Memory) or Malfunctioning of ECM PROM (Programmed Read Only Memory) Correction Replace Correct or replace Correct or replace Correct or replace
CHECK ENGINE MIL illuminates, and stays on
Replace Replace Reconnect properly
Correct Correct or replace Replace
Reconnect properly
Correct Correct or replace Correct or replace Replace Correct or replace Correct or replace Correct or replace Correct or replace Correct or replace Replace EPROM or ECM Replace EPROM or ECM
ENGINE MECHANICAL (C24SE) 6A-1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE General Description......................................................................................................... 6A- 4 ENGINE PICTORIAL .................................................................................................... 6A- 6 Main Data and Specification ........................................................................................... 6A-11 CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16 ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17 OPERATIONS ON ENGINE AGGREGATES.................................................................... 6A-18 Engine Damping Blocks(Engine without Transmission)......................................... 6A-18 Toothed Belt and Timing Check ............................................................................... 6A-21 Toothed Belt Tension, Adjust .................................................................................... 6A-23 Toothed Belt, Replace ................................................................................................ 6A-24 OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26 Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26 Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26 Seal Ring, Camshaft Housing, Timing Side.............................................................. 6A-27 Seal Ring, Thermostat Housing, Cylinder Head ....................................................... 6A-27 Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28 Toother Belt Rear Cover ............................................................................................. 6A-30 Toother Belt Tension Roller ....................................................................................... 6A-31 COMPONENT PARTS ...................................................................................................... 6A-32 Cylinder Head .............................................................................................................. 6A-32 Hydraulic Valve Lifter.................................................................................................. 6A-33 OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34 Camshaft...................................................................................................................... 6A-34 Camshaft Housing Removal and Installation ........................................................... 6A-35 Cylinder Head .............................................................................................................. 6A-35 Hydraulic Valve Lifers, Replace ................................................................................. 6A-37 Camshaft Housing, Replace....................................................................................... 6A-37
6A-2 ENGINE MECHANICAL (C24SE)
PAGE Camshaft Housing, Check for Plance Surface ......................................................... 6A-39 Cylinder Head, Removal and Installation .................................................................. 6A-39 Cylinder Head, Disassemble and Assemble ............................................................. 6A-42 Valve, Grind ................................................................................................................. 6A-44 Valve Guide, Ream ..................................................................................................... 6A-44 Valve Seating, Mill....................................................................................................... 6A-45 Cylinder Head, Overhaul............................................................................................. 6A-45 Flywheel ....................................................................................................................... 6A-46 Starter Ring Gear(Manual Transmission) ................................................................. 6A-47 Seal Ring, Crankshaft ................................................................................................. 6A-48 Seal Ring, Crankshaft Rear ........................................................................................ 6A-48 Oil Pan and Bearing Bridge........................................................................................ 6A-49 OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51 Con-Rod Bearing......................................................................................................... 6A-51 Piston with Con-Rod................................................................................................... 6A-51 Con-Rod ....................................................................................................................... 6A-52 Pistion Rings ............................................................................................................... 6A-53 OPERATIONS ON REMOVED ENGINE ........................................................................... 6A-55 Crankshaft ................................................................................................................... 6A-55 Bearing Free Play Measurement................................................................................ 6A-57 Plastigage Method ...................................................................................................... 6A-57 Micrometer and gauge method .................................................................................. 6A-58 Bypass Valve ............................................................................................................... 6A-59 Oil Filter ....................................................................................................................... 6A-59 Oil Pump ...................................................................................................................... 6A-59 Oil Pump Safety Valve ................................................................................................ 6A-60 Oil Pump(Overhaul) .................................................................................................... 6A-60 OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61 Cylinder Head Safety Valve ........................................................................................ 6A-61 OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63 Cooling System, Check for Leakes ........................................................................... 6A-63 Cooling System, Fill Up and Bleed ............................................................................ 6A-63 Refill Coolant ............................................................................................................... 6A-64 Ignition Timing, Check................................................................................................ 6A-64
PAGE ENGINE EXTERNAL PARTS............................................................................................ 6A-65 Radiator ....................................................................................................................... 6A-65 Thermostat................................................................................................................... 6A-66 Water Pump ................................................................................................................. 6A-66 Coating sealing surfaces with Silicone Grease ....................................................... 6A-67 Alternator ..................................................................................................................... 6A-67 Starter .......................................................................................................................... 6A-67 V-belt Tension of Alternator ....................................................................................... 6A-68 FUEL INJECTION SYSTEM.............................................................................................. 6A-69 Map Sensor.................................................................................................................. 6A-69 Pressure Regulator ..................................................................................................... 6A-69 ECM (Engine Control Module).................................................................................... 6A-69 ECT............................................................................................................................... 6A-70 Idle Air Control(IAC) Valve.......................................................................................... 6A-70 Ignition Coil ................................................................................................................. 6A-70 Crank Position Sensor................................................................................................ 6A-71 FUEL INJECTOR .............................................................................................................. 6A-72 Knock Sensor .............................................................................................................. 6A-72 Oxygen Sensor............................................................................................................ 6A-73 Throttle Valve Position Sensor .................................................................................. 6A-73 Acclelerator Pedal and Cable..................................................................................... 6A-73 Air Cleaner Filter ......................................................................................................... 6A-74 Spark Plug Thread ...................................................................................................... 6A-75 TECHNICAL DATA ........................................................................................................... 6A-76 Recommended Troque Values................................................................................... 6A-87 SPECIAL SERVICE TOOL................................................................................................ 6A-88
GENERAL DESCRIPTION
Engine Cleanliness And Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaced as when removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft pulley.
General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and
ENGINE MECHANICAL (C24SE) 6A-5 contributing to reliable engine performance: When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick up unit. The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery. Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.
Cylinder Block
The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of nodular cast iron.
Cylinder Head
The cylinder head is made of aluminum alloy casting with a spark plug in the center.
Valve Train
Valve system is a single over head camshaft. The valves clearance adjustment are hydraulic. Hydraulic valve lifter adjustment, no adjustment necessary.
Intake Manifold
The intake manifold is made of aluminum alloy.
Exhaust Manifold
The exhaust manifold is made of high Si-Mo nodular iron.
Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.
Crankshaft and Bearings

The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.
ENGINE PICTORIAL
Front View
4WD OIL PAN
Inlet Side View
4WD OIL PAN
Rear View
4WD OIL PAN
Exhaust Side View
4WD OIL PAN
Top View
Main Data and Specifications

Engine - General Engine type C24SE Four-cycle, water cooled cross-flow with single over head camshaft Micro-computer control, fuel injection 3 Hemispherical (43.3cm ) Belt drive 4-87.5 100.0 (3.44 3.93) 93.0 mm (3.66 in) 1-3-4-2 87.5 100.0 (3.44 3.93) 2,405(146.80) 3 43.3cm Compression ring: 2, Oil ring: 1 12.2-16.3 (174-232/1200-1600) No adjustment 825 0 (0) (Hydraulic valve lash adjustment) 0 (0) ( " ) 17 30 76 30 58 30 35 30 Fully transistorized battery ignition Not applicable, Electronic Spark Timing control Not applicable, Electronic Spark Timing control RN9YC4 1.0--1.1 (0.039--0.043) Fully flow pressure circulation SE, SF, SG or SH grade 4-4.6 (56.9-65.4/400-450) Gear Cartridge full flow 4.25 Corrugated fin with reserve tank 2.3 (0.66/0.55) Centrifugal Wax pellet with jiggle hole
Combustion chamber type (Volume) Timing train system No. of cylinders-bore stroke mm (in) Bore Spacing(C/L to C/L) Firing Order Bore Stroke mm (in) 3 3 Total piston displacement cm (in ) Combustion Chamber Volume No. of piston ring 2 Compression pressure kg/cm (psi/pa) Ignition timing (BTDC) Idling speed: rpm(WO/AC,W/AC) A/C off Valve clearances (At cold) Intake mm (in) Exhaust mm (in) Open at (BTDC) deg Close at (ABDC) deg Exhaust valves Open at (BBDC) deg Close at (ATDC) deg Ignition system Distributor type Distributor advance type Spark plug type Spark plug gap mm (in) Lubrication system Lubricating method Special engine oil (API grade) 2 Oil pressure kg/cm (psi/Pa) rpm Oil pump type Oil filter type Oil capacity lit. (US/UK gal.) Cooling system Radiator type Coolant capacity lit. (US/UK gal.) Water pump type Thermostat
6A-12 ENGINE MECHANICAL (C24SE) Engine - General Fuel system Fuel pump type 2 Fuel pressure kg/cm (psi/Pa) Fuel filter type Air cleaner type Battery Type/V-Ax No. of units Alternator Capacity V-A(W) Starter Output V-kW Exhaust system CO Adjustment Compression Ratio (with Tolerance) Cylinder Head Material Cylinder Block Material No. of Mounting Points (including trans.) Engine Installation Angles -Longitudinal -Lateral Overall Dimensions (L W H): - TF (2.4Litre/2WD) - TF (2.4Litre/4WD) Engine Weight Engine Weight - TF (2.4Liter/Man) Camshaft Type No. of Valves per Cylinder - Inlet - Exhaust Spark Plug Location Port Arrangement Working Principle C24SE Electronically controlled Multi Port Fuel Injection System Electric 3.4 (48.4/334) Cartridge paper element Dry paper element 34B19L/50D20L 12-90 (1080), 12-100 (1200) 1.4 (1) Applicable to Open Loop System (Not equipped H2OS) (2) Not applicable to Closed Loop System (Equipped H2OS) 9.6:1 0.25 Aluminum Alloy (gravity cast) Cast Iron 3 4 60' 7 50' (towards exhaust side) 610 564 708mm 610 564 746mm 140kg SOHC 1 1 Side Cross Flow Spark Ignition 4-stroke
ENGINE MECHANICAL (C24SE) 6A-13 Valve System Actuation Type Valve Clearance Adjustment Valve Rotor Type Inlet-Valve Material -Seat Insert Material Exhaust-Valve Material -Seat Insert Material Valve Spring Material Valve Guide Material Valve Seal Type Water Pump Type Drive-Material &Type Bearing Type Shaft Seal Type Thermostat-Coolant Type Oil Pump & Filter Type Location Drive Filter Type Oil & Oil Reservoir Reservoir-Description & Location Reservoir Material Replacement Oil Fill Volume -With Filter change -Without Filter change Recommended Oil-Run-in -Service (above-18 C) -Service (below-18 C) Oil Classification Ignition Components Spark Plugs Type No. of Coils &Type Coil Location Ignition Lead Type C24SE Direct-acting Inverted Bucked Tappet Hydraulic None Chromium Alloyed Steel Sintered Iron Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated Sintered Iron GME 06 100-C1 QS 13 MR 00 Lip C24SE Centrifugal HNBR Toothed-belt Double Row Ball Mechanical Ceramic C24SE Bypass C24SE Gear Pump Front of Engine Direct Crankshaft Driven Full Flow with Bypass for blocked filter C24SE 1-piece below Engine Aluminum Alloy (pressure cast) 4.25liters 4.00liters 10W/30SG 10W/40SG 5W/30SG API&CCMC C24SE Conventional Electronic Spark Control 2 Solid State Engine-mounted Inductive (hi-resistance)
6A-14 ENGINE MECHANICAL (C24SE) Crankshaft Material Bearing subjected to End Thrust Main Bearing-Material &Type Front Seal-Diameter &Type Rear seal-Diameter &Type Crankshaft Balancing No. of Counterweights Camshaft Location Material Bearing Material No. of Bearings Camshaft Drive-Material &Type C24SE Nodular Cast Iron Guide Bearing NO.3 Steel Backed Tri-metal Babbitt 35.0mm Lip Seal 90.0mm Micro-lip Seal Individually Balanced 8 C24SE Overhead (Cylinder Head) Grey Cast Iron Aluminum 200-250 HB5/750
(Camshaft drive type: toothed belt Camshaft drive material: rubber composite GD380)
Pistons Material Finish & Type Piston Rings Function (top to bottom) -Ring 1 -Ring 2 -Ring 3 Description -Ring 1 -Ring 2 -Ring 3 Material -Ring 1 -Ring 2 -Ring 3 Material Retention Bearing Connecting Rod Material Bearing-Material &Type Inlet Manifold Material Exhaust Manifold Description Material
C24SE Aluminum Alloy Tin-coated Strutless Compression Ring Compression Ring Oil Ring Rectangular Taper Face 3-piece (2 Scrapers&1 Expander) Molybdenum Inlay Nodular Cast Iron Cast Iron (individually cast) Steel Case Hardened Steel Locked in Rod Machined in Piston Pin Boss C24SE Nodular Cast Iron Steel Backed Tri-metal Babbitt C24SE Aluminum Alloy C24SE Dual Take-down High Si-Mo Nodular Iron
Engine Specification Matrix for destination

04 HEO FOR TF MODEL:
VEHICLE MODEL TFR/S
2.4L AUSTRALIA, CHILE, GULF, NEW ZEALAND, SAUDI ARABIA, SOUTH AFRICA 4 2 TX C24SE CLOSE LOOP 9.6:1 91RON UN-LEADED YES YES YES YES YES 85RON UN-LEADED YES YES YES YES YES YES YES YES YES YES 80RON LEADED NO YES YES YES YES CLOSED LOOP OPEN LOOP 4x4 TY COLOMBIA, COSTA RICA, EQUADOR, GUATEMALA BOLIVIA, GENERAL EXPORT, PERU, VENEZUELA
Major Description
VEHICLE TYPE VEHICLE IDENT. CODE ENGINE TYPE FUEL CONTROL SYSYTEM COMPRESSION RATIO FUEL OCTANE(ROD) FUEL TYPE HO2 EVAP CANISTER PURGE CONTROL SOLENOID CHECK & RELIEF VALVE ECM EXHAUST SYSTEM FRONT PIPE SILENCER TWC CO ADJUSTMENT
4 2 TX
4 4 TY
4 2 TX
YES NO Refer to 6A-77
YES
YES
NO YES Refer to 6A-77
NO NO Refer to 6A-77
CRANKCASE VENTILATION SYSTEM
The Engine Ventilation System passes crankcase vapours, via the Engine Vent Pipe, to the Cam Support Cover, where separation of oil and exhaust gases occur. The oil drains into the Cylinder Head, via the Camshaft Support. The gases pass through the Primary and Secondary Vent Hoses to the intake system, and are consumed during the combustion process.
ENGINE ASSEMBLY & LOOSE PARTS
Loose Parts
1 2 3 4 5 6 7 8 9 Alternator P/S Pivot Spacer P/S Adjusting Screw P/S Adjusting Plate P/S Adjusting Nut Alternator & Fan Drive Belt A/C Compressor Drive Belt P/S Pump Drive Belt Tensioner Bolt
10 11 12 13 14 15 16
Tensioner Pulley Pulley Dust Shield Cover Pulley Spacer A/C Compressor Bracket Pulley Bolt Fan Pulley Cooling Fan
Engine Assembly
20 C24SE
OPERATIONS ON ENGINE AGGREGATES

Engine Damping Blocks (Engine Without Transmission)
Removal
1. 2. 3. 4. Remove bonnet. Remove radiator. Remove air inlet hose. Remove power steering pump drive belt and power steering pump from engine. Remove all cable connections, hoses and lines from engine. Remove accelerator cable from inlet pipe.
5. 6.
7.
Remove exhaust pipe from manifold.
8. 9. 10.
Remove lower nine bolts and transmission from engine block. Remove clutch slave cylinder and allow to hang free. Remove starter from engine block.
11. 12. 13. 14.
Remove upper bolts of left and right engine mounting from damping blocks. Raise engine slightly. Remove lower bolts of left and right damping blocks. Remove damping blocks.
ENGINE MECHANICAL (C24SE) 6A-19 Attach engine to cable, support transmission with car jack and remove upper transmission fastening bolt. Press off engine from transmission and lift out of engine compartment.
Installation
Lower engine into engine compartment and insert guide bushings on cylinder block into transmission.
Tighten (Torque)
Transmission to cylinder block (M10) Transmission to cylinder block (M12) -45 N m (4.6 kgf m) -60 N m (6.1 kgf m)
Installation
1. 2. Install engine to vehicle and transmission. Install clutch slave cylinder.
Tighten (Torque)
Transmission to engine block bolts - 76 N m (7.6 kgf m)
3. 4.
Install left engine damping block to sidemember. Install left and right engine damping blocks to engine brackets.
Tighten (Torque)
Engine damper block to sidememebr - 50 N m (5.1 kgf m) Engine damper block to engine bracket - 85 N m (8.6 kgf m)
RTW46ASH000401
5.
Install exhaust pipe to manifold.
6A-20 ENGINE MECHANICAL (C24SE) 6. Install power steering pump and V-belt.
Adjust
Adjust power steering pump V-belt tension according to the corresponding operation.
Installation
7. 8. 9. 10. 11. Install radiator according to the corresponding operation. Install air inlet hose. Install all electrical cable connections, hoses and lines to engine. Install accelerator cable from inlet pipe. Install bonnet.
Inspection
1. 2. Check engine oil level. Fill up cooling system and bleed according to the corresponding operation.
Toothed Belt and Timing Check Removal

1. 2. 3. 4. 5. 6. Remove the belts on the bracket for alternator. Remove the fan. Remove the V-belt for power steering. Remove the V-belt for A/C. Remove the fan belt. Remove the fan shroud.
7. 8.
Remove the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear. Remove the toothed belt from cover.
Inspection
1. Turn the crankshaft in the engine rotational direction mark(2) so that the notch (1) on the camshaft gear aligns with the mark on toothed belt rear cover. Check the timing belt for worn, cracks or oil adhesion.
2.
3. 4.
Check that the cast on the water pump aligns with the counterpart on cylinder block (arrowed). The tension of a toothed belt is correctly adjusted when the pointer and the center of the notch are aligned(I). The tension of a run-in toothed belt (regardless of mileage covered) is correctly adjusted when the pointer is positioned approx. 4mm (0.16 in.) to the left of the center of the notch(II). Check the condition of the run-in toothed belt for suitability for reuse. Only toothed belts of the toothed belt tension rollers must be replaced and the source of oil contamination must be eliminated.
Installation
1. 2. 3. Install the toothed belt to the cover. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear. Install the fan shroud.
Tighten(Torque)
Crankshaft pulley bolts - 20 N m (2.1 kgf m) 4. 5. 6. 7. 8. Install the fan belt Install the V-belt for A/C. Install the V-belt for power steering. Install the fan. Install the belts on the bracket for alternator.
Toothed Belt Tension, Adjust (Engines with toothed belt tension roller)
Removal
Refer to 6A-21. Toothed Belt and Timing check and removal steps.
Adjust
1. 2. Loosen the fastening bolt of the toothed belt tension roller. Turn the toothed belt tension roller at adjustment eccentric (1) in the direction of arrow (counterclockwise), until pointer (2) comes to the right stop. If necessary tighten the fastening bolt of toothed belt tension roller.
3.
4.
Rotate the crankshaft twice (720 ) in the engine rotational direction until marks (2) and (1) align again.
5.
Turn the eccentric in the direction of arrow (clockwise) until pointer (1) and notch (2) are positioned to suit age of toothed belt. Rotate the crankshaft twice (720 ) in the engine rotational direction again and correct adjustment if necessary.
6.
Installation
Refer to 6A-21. Toothed Belt and Timing check and installation steps.
Toothed Belt, Replace (Engine with toothed belt tension roller)

Removal
1. 2. 3. 4. 5. 6. Remove the belts on the bracket for alternator. Remove the fan. Remove the V-belt for power steering. Remove the V-belt for A/C. Remove the fan belt. Remove the fan shroud.
7. 8.
Remove the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear. Remove the toothed belt from cover.
Adjust
Turn the crankshaft in the engine rotational direction to mark(2). Align markings on toothed belt and on toothed belt rear cover. Simultaneously, notch (1) on camshaft gear must align with the mark on toothed belt rear cover. Turn the crankshaft slowly and smoothly.
Adjust
Loosen the fastening bolt of the toothed belt tension roller and turn the adjustment eccentric in the direction of arrow (clockwise) until pointer (1) comes to the left stop. Remove the toothed belt.
Installation
1. Install a new toothed belt while keeping tension side taut.
Adjust
Toothed belt tension - see operation " Toothed Belt Tension". 2. 3. 4. 5. 6. 7. 8. 9. Install the toothed belt to the cover. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear. Install the fan shroud. Install the fan belt. Install the V-belt for A/C. Install the V-belt for power steering. Install the fan. Install the belts to the bracket for alternator.
OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS
Gasket, Exhaust Manifold, Cylinder Head
Removal
1. 2. 3. 4. Remove front exhaust pipe from exhaust manifold. Remove exhaust manifold heat shield. Remove exhaust manifold retaining nut. Remove exhaust manifold from cylinder head.
Clean
Sealing surfaces.
Tighten (Torque)
Exhaust manifold to cylinder head - 22 N m (2.2 kgf m) Front exhaust pipe to exhaust manifold - 25 N m (2.6 kgf m)
Gasket, Intake Manifold, Cylinder Head
Removal
1. 2. 3. 4. Remove air intake hose. Remove drive belt for alternator. Remove bolt clamping bracket for alternator from intake manifold. Remove intake manifold from cylinder head.
Clean
Sealing surfaces
Tighten (Torque)
Intake manifold to cylinder head - 22 N m (2.2 kgf m) Clamping bracket for alternator to intake manifold - 25 N m (2.5 kgf m)
Installation
1. 2. Install V-belt according to the corresponding operation. Install air intake hose.
Seal Ring, Camshaft Housing, Timing Side
Removal
1. Remove front toothed belt cover toothed belt from camshaft timing gear according to the corresponding operation. Remove camshaft housing cover and camshaft timing gear. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.
2. 3.
Installation
1. 2. Install sealing ring by using 5-8840-0451-0 with camshaft sprocket bolt and washer. Install coat seal lips of shaft seal ring slightly.
Seal Ring, Thermostat Housing, Cylinder Head
Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. Open radiator drain tap and collect coolant. Remove toothed belt rear cover and toothed belt according to the corresponding operation. Remove camshaft housing cover. Remove camshaft timing gear by counterholding camshaft with a flat spanner. Remove cable from temperature sensor. Remove upper inner hex bolts of rear toothed belt cover. Turn rear toothed belt cover to one side. Remove thermostat housing. Remove sealing ring from cylinder head.
Clean
Sealing surfaces in cylinder head and thermostat housing.
Installation
1. Install sealing ring in recess of cylinder head.
6A-28 ENGINE MECHANICAL (C24SE) 2. 3. 4. 5. 6. 7. Install cable to temperature sensor. Install upper bolts of rear toothed belt rear cover. Install camshaft timing gear then check timing according to the corresponding operation. Install camshaft housing cover. Install toothed belt and front cover. Fill up and bleed cooling system according to the corresponding operation.
Tighten (Torque)
Thermostat housing to cylinder head - 15 N m/1.5 kgf m.
Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt. Remove toothed belt-see operation Toothed Belt, Replace. Camshaft housing cover, camshaft pulley-counterhold on hex of camshaft.
Removal
Screw self-tapping screw into seal ring. Edge out seal ring.
Installation
Lightly coat sealing lip of seal ring with protective grease. Install seal ring with 5-8840-0451-0 into camshaft housing-use screw and washer of camshaft pulley.
Installation
Camshaft pulley-counterhold at hex head of camshaft, camshaft housing cover. Toothed belt-see operation Toothed Belt, Replace. Note operating erection of toothed belt.
Tighten (Torque)
Camshaft pulley to cammshaft-45 N m (3.7 kgf m)
Tighten (Torque)
Camshaft housing cover to cover to housing-8 N m (0.8 kgf m)
Toothed Belt Rear Cover (Engine with toothed belt tension roller)
Removal
1. 2. 3. Mark operating direction of toothed belt. Remove toothed belt according to the operation "Toothed Belt". Remove toothed belt tension roller according to the operation "Toothed Belt Tension Roller ".
4.
Remove fastening bolt while counterholding with 5-88402598-0 (Holding wrench).
5. 6. 7.
Remove toothed belt drive gear while counterholding with 5-8840-2598-0 (Holding wrench). Remove camshaft housing cover. Remove camshaft pulley while counterholding at hex head of camshaft.
8.
Remove toothed belt rear cover (arrows) from oil pump and camshaft housing.
Installation
1. 2. 3. Install toothed belt rear cover. Install camshaft pulley while counterholding at camshaft hex head. Install camshaft housing cover.
Tighten (Torque)
Toothed belt rear cover to oil pump and camshaft housing - 6 N m/4 lbf ft. Camshaft housing cover to housing - 6 N m (0.6 kgf m). Camshaft pulley to camshaft - 45 N m (4.6 kgf m). 4. 5. Install toothed belt drive gear to crankshaft - 130 N m (13.3 kgf m). Install toothed belt according to the operation "Toothed Belt".
Toothed Belt Tension Roller
Removal
1. 2. 3. Mark operating direction of toothed belt. Remove toothed belt according to the operation "Toothed Belt. Remove toothed belt tension roller (1) from oil pump.
Installation
1. Install toothed belt tension roller and make sure that the locking lever (1) engages in the guide lugs (arrowed) on the oil pump housing. Install toothed belt according to the operation "Toothed Belt" with paying attention to the operating direction of toothed belt.
2.
Tighten (Torque)
Toothed belt tension roller to oil pump - 25 N m (2.5 kgf m)
COMPONENT PARTS
CYLINDER HEAD
(A)
1. 2. 3. 4.
Camshaft Housing Cover Camshaft Housing Camshaft Cylinder Head
(A)
Valve Drive
HYDRAULIC VALVE LIFTER
1.
Hydraulic Valve Lifter
1. 2. 3. 4. 5. 6.
Oil reservoir Piston with ball head (moving) Pressure cylinder (fixed) Check ball Pressure chamber Oil feed
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING

Camshaft
Removal
1. 2. 3. 4. Remove cylinder head according to the corresponding operation. Remove camshaft housing from cylinder head and lay housing on base provided Remove rear sealing gasket and plate camshaft housing with taking care not to damage housing. Remove thrust plate.
5. 6.
Remove camshaft. Remove front sealing gasket and plate from camshaft housing with taking care not to damage housing.
Inspection
All parts.
Installation
1. 2. Install camshaft. Coat sliding surfaces with molybdenum disulphate paste.
Tighten (Torque)
Thrust plate for camshaft housing - 8 N m (0.8 kgf m)
Camshaft Housing, Removal and Installation
Cylinder Head
Important!
Remove cylinder head only from cold engine (room temperature).
Removal
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove ground cable from battery. Open radiator drain tap and collect coolant. Remove air intake hose. Remove all cable connections, hoses and lines to the cylinder head. Remove accelerator cable on the throttle valve. Remove V-belt for alternator. Remove front toothed belt cover according to the corresponding operation. Bring piston of 1st cylinder to TDC and mark the position. Remove camshaft housing cover. Remove camshaft timing gear after releasing tension on toothed belt.
11. 12. 13.
Remove upper bolts of rear toothed belt cover. Remove exhaust pipe from exhaust manifold. Remove cylinder head after loosening bolts from outside inwards (at first quarter turn then half turn) in a spiral pattern. Remove camshaft housing from cylinder head. Remove rocker arm, pressure parts and hydraulic valve lifter adjuster.
14. 15.
Clean
All sealing surfaces, drill holes in cylinder head bolts. Check cylinder block and cylinder head for plane surface according to the corresponding operations.
Installation
1. 2. 3. 4. Install cylinder head sealing with marking "OBEN/TOP" facing upwards and to right side of engine. Install cylinder head on cylinder block. Install hydraulic valve lash adjuster, pressure parts and rocker arm - molybdenum disulphate paste. Install camshaft housing-Sealing Compound TB-1207C or equivalent.
Important!
Use new cylinder head bolts. Screw in bolts until they rest on cover.
Torque - Angle Method

Cylinder head to cylinder block - 25 N m (2.5 kgf m) Further turn angle 90 +90 + 90 . Tighten cylinder head bolts from inside outwards. In four stages in a spiral pattern.
5. 6.
Install rear toothed belt cover onto camshaft housing. Install toothed belt and apply tension according to the corresponding operation.
Tighten (Torque)
Camshaft timing gear to camshaft - 45 N m (4.6 kgf m)
7. 8. 9. 10. 11. 12. 13. 14.
Install camshaft housing cover and front toothed belt cover. Install cable connections, all hoses and lines onto cylinder head. Adjust accelerator cable for free of play. Install V-belt according to the corresponding operation. Install air intake hose. Install front exhaust pipe. Install ground cable onto battery. Fill up cooling system and bleed according to the corresponding operation.
Hydraulic Valve Lifters, Replace
Removal
1. 2. Remove the spark plug connectors and spark plugs. Remove the camshaft housing cover.
Removal
3. Turn the crankshaft at fastening bolt of toothed belt drive gear in the direction of the engine rotation until the cam of hydraulic valve lifter being replaced stands vertically.
Removal
4. Apply 5-8840-0457-0 to the camshaft housing, valve spring cap and tension valve spring.
Removal
5. 6. Remove the cam follower from camshaft housing. Note thrust pieces. Remove hydraulic valve lifter from camshaft housing.
Camshaft Housing, Replace
Removal
Cylinder head-see operation Cylinder Head. Remove and Install.
Inspection
All parts, if necessary replace. When replacing camshaft, always replace all cam followers.
Installation
Insert hydraulic valve lifter (1) in camshaft housing. Coat sliding surfaces of rocker arm with Mcs, Paste and insert in camshaft housing.
Adjust
Adjustment of the hydraulic valve liters is not required. Pretension is provided by the design.
Installation
1. 2. Remove 5-8840-0457-0 and install the camshaft housing cover. Insert the spark plug connectors.
Tighten (Torque)
Guide plate to camshaft housing. Insert camshaft with MoS2 paste.
Installation
1. 2. 3. Install the front seal ring in camshaft housing with 5-8840-0451-0. Install the camshaft housing rear cover. Install the cylinder head.
Camshaft Housing, Check for Plane Surface
Clean
Sealing surfaces.
Inspection
Check length and width of sealing surface for deformation and diagnosis for warpage and use straight edge feeler gauge.
Measure
Height of camshaft housing (sealing surface to sealing surface). Dimension I: (74.0 mm)
Cylinder Head, Removal and Installation
Important
Only remove cylinder head with engine cold (room temperature).
Removal
1. Remove the alternator, power steering and V-belts.
Removal
2. 3. Loosen the fastening bolts from alternator. Loosen the lower alternator fastening bolt by swinging the alternator to the rear.
Removal
4. 5. Remove the front toothed belt cover. Remove the toothed belt from camshaft pulley. See operation "Timing Check and Adjust".
Removal
6. Remove the camshaft housing cover and camshaft pulley by counter-holding at the hex head of camshaft.
Removal
7. Remove the fastening bolts from camshaft housing.
Removal
8. 9. Remove the exhaust pipe from exhaust manifold. Loosen the cylinder head bolts spirally from the outside inwards (first 1/4, then 1/2 revolution).
Removal
1. 2. Remove the camshaft housing from cylinder head. Remove the cam followers, thrust pieces and hydraulic valve lifters. Note the allocation. 3. Remove the cylinder head.
Clean
Sealing surfaces, bores and threads of cylinder head bolts.
Inspection
Check cylinder head and cylinder block for plane surfface-see operations Cylinder Head, Check for Plane Surface and Cylinder Block, Check for Plane Surface.
Installation
1. Install the cylinder head gasket. Mark "OBEN/TOP" on top and turn it towards timing side of engine. 2. Place cylinder head on cylinder block.
1 2 3
Installation
1. Insert the hydraulic valve lifters (3), thrust pieces (2) and cam followers (1) with MoS2 paste. Note allocation. 2. 3. Apply a bead of Sealing Compound TB1207C to sealing surface of cylinder head. Install the camshaft housing on cylinder head.
Torque-Angle Method
Cylinder head and camshaft housing with new cylinder head bolts to cylinder block. Cylinder head bolts in sequence shown.
Installation
1. 2. 3. Install the rear toothed belt cover to camshaft housing. Install the camshaft pulley to camshaft. Install the camshaft housing cover to housing.
Installation
1. 2. Install the toothed belt on camshaft pulley. See operation "Timing Adjust". Install the front toothed belt cover.
Installation
1. 2. 3. Install the fastening bolts. Loosen the lower alternator fastening bolt. Install the alternator, power steering and V-belts.
Cylinder Head, Disassemble and Assemble
Removal
1. 2. Remove the hydraulic valve lifters. Lay aside in installation positions. Remove the spark plugs, exhaust manifold and intake manifold from cylinder head.
Removal
1. 2. 3. Mark valves. Remove the tension valve springs with 5-8840-2594-0 (1). Remove valve keepers, valve spring cap and valve spring.
Removal
1. 2. 3. Remove the valve and valve stem seal. Remove the valve spacer ring (1-exhaust) and valve spring seat (2-intake). Remove valve from cylinder head.
Clean
Sealing surfaces.
Inspection
Sealing surfaces for plane surface, guides, sliding and bearing points for wear-see operation Cylinder Head. Overhaul.
Installation
1. 2. 3. 4. 5. Coat the valves with engine oil and insert in cylinder head. Install the valve spacer ring or valve rotator(exhaust) and valve spring seal(intake). Push the accompanying assembly sleeve onto valve stem and coat with engine oil. Insert a new valve stem seal with 5-8840-2601-0 (1). Drive the valve stem seal carefully in to stop with light hammer blow.
Installation
1. 2. Install the valve springs and valve spring caps. Install the tension valve springs with 5-8840-2594-0 (1), valve keeper.
Important!
Note markings made on valves.
Tighten (Torque)
Exhaust manifold and intake manifold with new gaskets to cylinder head. Thermostat housing with new seal ring to cylinder head:
Tighten (Torque)
Spark plugs with spark plug wrench to cylinder head.
Installation
1. 2. Coat hydraulic valves lifters (1) with oil. Insert them in cylinder head. Note installation position.
Valve, Grind
Valves can be reused once or twice after regrinding-only if there are no crater-like burns on the valve cone. Excessive grinding can cause the upper valve head edge to become too thin.
Important!
Valve stem protection must not exceed dimension A-use 58840-2596-0. Do not regrind valve stem ends. For all valve reworking note that angle of valve head is 44 and the valve seat 45 -see also Technical Data.
Valve, Grind In
Grind-In the valve to improve valve seating. Grind-In by rhythmically lifting valves and turning uniformly. Use commercially available grinding tool.
Important!
Use only fine-grained pastes for grinding. Lubricate valve stem before grinding in.
Clean
After grinding, carefully clean valve and valve soat.
Valve Guide, Ream
Measure
Diameter of valve guide-dial gauge and internal measuring instrument.
Important!
Valve oversizes are available ex-works. Oversize identification, on the valve guide and on the valve stem end with the following specified identificaton flgures/letters-see also Technical Data. Identification Mark Production Customer Service none 1 2 K K1 K2
Size
Reamer
Normal 0.075 mm 0.150mm
Ream valve guide from the upper side of the cylinder head to the next oversize (use 5-8840-2599-0). After reaming, cross out identification mark and stamp in new identification mark.
Valve Seating, Mill

Place cylinder head on block of wood. Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-88402593-0. Valve seat-45 , side face, upper correction-30 , side face (arrows on cutter). Valve seat width: Inlet-1.0 to 1.5 mm/0.04 to 0.06 in. Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.
Inspection
Valve stem projection-use 5-8840-2596-0.
Important!
If dimension A is exceeded, use new valves. Check valve stem projection again. If dimension A is exceeded, replace cylinder head.
Cylinder Head, Overhaul

Cylinder head disassembled.
Valve, Grind
Important!
Ensure that there are no crater-like burns on the valve cone. Regrinding possible once or twice. Grinding of valve stem end is not permitted. Angle at valve head-44
Inspection
Check valve stem projection as shown 5-8840-2596-0.
Valve, Grind in
Lubricate valve stem, use fine-graining grinding paste. Lift up valve from seat rythmically using valve grinding tool (1) for distribution of grinding paste.
Inspection
Check contact pattern (I) on valve seat and in cylinder head.
Clean
Valves, valve guides, cylinder head.
Flywheel
Removal
1. 2. Remove transmission and clutch. Remove flywheel while locking with 5-88400-446-0.

Flywheel to crankshaft - 65 Nm/6.5 kgf m.+30 to 45
Important!
Use new bolts. Do not apply grease to the thread.
Installation
1. Install clutch and transmission.
Component Parts
Flywheel and Ring gear. (Manual Transmission)
Starter Ring Gear (Manual Transmission)
Removal
1. 2. Remove flywheel according to the corresponding operation. Drill starter ring gear underneath tooth gap approx. 8mm/0.30in. deep with 8mm/0.25in. diameter drill.
3.
Separate starter ring gear with chisel on the drilling point.
Installation
1. 2. 3. Install starter ring gear with inner chamfered edge to flywheel. Heat starter ring gear evenly to 180 C /356 F to 230 C /446 F (yellow paint mark) Install flywheel according to the corresponding operation.
Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.
Seal Ring, Crankshaft (Oil Pump Housing)

Removal
1. 2. Remove toothed belt rear cover according to the corresponding operation. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.
Installation
1 2. 3. 4. 5. 6. 7. Install the protective sleeve to the crankshaft. Coat the sealing lip with protective grease. Install the sealing ring. Install the sealing ring using 5-8840-0455-0. Install the rear toothed belt cover and toothed belt according to the corresponding operations. Replace the sealing ring with a new one. Tighten the belt to the crankshaft.
Seal Ring, Crankshaft Rear
Removal
1. 2. 3. Remove transmission and clutch. Remove flywheel or flex plate according to the corresponding operations. Make hole in middle of sealing ring, turn in self-tapping screw and edge out.
Installation
1. 2. 3. 4. Install protective sleeve. Coat sealing lip with Protective Grease. Install sealing ring using 5-8840-0459-0 and 5-88402597-0. Install flywheel, clutch and transmission.
Reassembly
Reassemble clutch assembly.
Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0
Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf m.
Oil Pan and Bearing Bridge
Removal
1. 2. 3. 4. 5.
RTW46ASH002801
Remove the crossmember. Shift downward the power steering unit (and front axle [4 4 model only]). Loosen fixing bolts. Remove oil pan from oil pump and cylinder block. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate. Remove the bearing bridge.
6.
Clean
Sealing surfaces.
Installation
1. 2. 3. 4. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration. Install the bearing bridge. Install baffle plate, or reuse baffle plate.
013RW004
Caution
Baffle plates can be retrofitted without difficulty - replace baffle plate. 5. 6. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347). Maximum assembly time including torque check is 10 min. Return the power steering unit (and front axle [4 4 model only]). Install the crossmember.
7. 8.
Tighten (Torque)
Oil intake pipe to oil pump -8N m (0.8 kgf m) Oil intake pipe bracket to cylinder block - 6 N m (0.6 kgf m) Oil pan to cylinder block - 8 N m (0.8 kgf m) Bearing bridge to cylinder block 8 N m (0.8 kgf m)
OPERATIONS ON CRANK DRIVE

Con-Rod Bearing
Removal
1. 2. Remove oil pan and bearing bridge according to the corresponding operation. Remove con-rod bearing cap and con-rod bearing after marking both sides.
Clean
Con-rod journal, con-rod bearing cap
Installation
1. 2. Install new bearing shafts lightly coated with engine oil. Install con-rod bearing cap.
Torque-Angle Method
Con-rod bearing cap to con-rod - 35N m (3.5 kgf m) +45 to 60
Important!
Use new bolts. 3. Install oil pan and bearing bridge according to the corresponding operation.
Piston with Con-Rod
Removal
1. 2. Remove cylinder head and oil pan according to the corresponding operations. Remove piston with con-rod after marking con-rod bearing cap.
Inspection
Remove and install all parts, if applicable.
Important!
Ring gap offset: Piston rings - 180 . Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of intermediate ring to the left and to the right.
Installation
1. 2. Install piston with con-rod by inserting with engine oil. Coat piston rings with engine oil and compress with piston ring compressor.
Important!
Installation position: Arrow / notch on piston head on timing side of engine Beads on con-rod on clutch side
Torque-Angle Method
Piston to cylinder block. Con-rod bearing cap to con-rod-35N m (3.5 kgf m) +45 to 60
Important!
Use new bolts.
Installation
1. 2. 3. 4. Install oil pan and cylinder head according to the corresponding operations. Install sealing Gasket or replace if damaged. Install camshaft housing to cylinder head. Install cylinder head according to the corresponding operation.
Con-Rod
Removal
1. 2. Remove piston with con-rod according to the corresponding operation. Disassemble con-rod piston assembly by pressing out piston pin, using 5-8840-0468-0.
Installation
1. 2. 3. Slide guide drift (5-8840-0468-0) in horizontal position through piston and con-rod as far as side plate stops. Tighten bolts evenly so that the piston rests flush on the rear plate. Remove centre piece from guide drift and insert piston bolts (lubricated) into guide drift.
ENGINE MECHANICAL (C24SE) 6A-53 4. 5. Heat a new con-rod to 280 C in the oil bath. Install the con-rod to the piston and insert the piston pin.
Important!
Since the con-rods have no weight balancing studs, re-working is not possible. Exchange con-rods in sets only. Installation position, beads on con-rod point to the flattening on the piston pin eye. Firmly seated piston pin cannot be pushed in. Carry out installation quickly.
Piston Rings
Removal
1. 2. Remove piston with con-rod according to the corresponding operation. Remove piston rings using commercially available ring installer or piston ring clamp pliers.
Clean
Piston ring grooves - ground piece of old piston ring
Inspection
Piston ring gap For piston ring sizes, permissible piston ring gaps - see "Technical Data"
Installation
1. 2. 3. 4. 5. 6. Install oil scraper ring. Offset ring gaps of steel band rings each 25 to 50 mm/1 to 2in. to the left or right of the intermediate ring gap. Install piston rings. Offset ring gaps by approx. 180 . Install second piston ring with identification mark "TOP" facing upwards. Install piston with con-rod according to the corresponding operation.
RTW46ASH002401
OPERATIONS ON REMOVED ENGINE

Crankshaft
Removal
1. 2. Mount the engine on an engine overhaul stand with appropriate adapters. Remove the aggregates, flywheel/drive disc, oil pan, bearing bridge and oil pump according to the corresponding operation. Mark the con-rod bearing cover. Remove the crankshaft bearing cover. Remove the crankshaft from cylinder block.
3. 4. 5.
Inspection
Remove and install all parts if necessary. Crankshaft pulse pickup sensor rotor inspection and repair. Inspect the crankshaft pulse pickup sensor rotor for excessive wear and damage. Replace the crankshaft pulse pickup rotor if the inspection results exceed wear and damage limits.
Installation
1. 2. 3. 4. Install the crankshaft pulse pickup sensor. Torque: 13N m (1.3 kgf m) Install new bearing shells into the cylinder block and bearing cover. Coat the bearing shafts with engine oil. For oversizes-see Technical Data Install a new crankshaft into the cylinder block.
Note
The sealing of the crankshaft can be corrected with light blows with a rubber hammer on the crank arm (arrowed).
6A-56 ENGINE MECHANICAL (C24SE) 5. Apply a bead of sealant (TB-1207C or equivalent) in the grooves of both bearing shells.
Important!
After installation of bearing cover, press in sealing compound again from above, until compound emerges at the joints.

Bearing cover to cylinder block - 50 N m (5.1 kgf m) +40 to 50 Con-rod bearing cover to con-rod - 35 N m (3.5 kgf m) +45 to 60 . Use new bolts.
6.
Install oil pump, oil pan, bearing bridge rear crankshaft sealing, flywheel/drive plate, and aggregates according to the corresponding operations.
Inspection
Bearing play - bearing cover removed
Measure
With "Plastigage" (ductile plastic threads) Cut threads to length of bearing width and lay axiaity between crankshaft journal and bearing shell (arrowed). Install bearing cover with correct torque.
Important!
Grease crankshaft journal and lubricate bearing shell slightly so that the thread does not tear when the bearing cover is moved.
Crankshaft
Inspection
End play when bearing shells are installed. Front end contact surfaces of flywheel/flexible plate. Permissible end play - see "Technical Data "
Inspection
Out-of-round (run-out)-middle bearing shell removed when mounting on front and rear bearing. Permissible out-of-round - see "Technical Data"
Bearing Free Play Measurement

Two methods for measuring bearing free play are described 1. Plastigage method and 2. micrometer and gauge method. The two procedures are suitable for measuring both con-rod and main bearing free play. For both methods ensure con-rod and main bearing caps are identified (1) prior to removal as they are machine matched.
1.Plastigage Method Removal

1. 2. Remove bearing cap and shell. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.
Installation
1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.
Important!
Do not allow crankshaft to rotate.

Main bearing cap bolt - 60 N m (6.1 kgf m) +40 + to 50 . Con-rod bearing cap bolts - 35 N m (3.6 kgf m) +45 .
Removal
1. Remove bearing cap and shell.
Measure
Width of Plastigage -use scale supplied with Plastigage. If con-rod bearing clearance exceeds 0.031mm/0.001in or main journal bearing clearance exceeds 0.04mm/0.02in. check crankshaft journal diameters - see corresponding operation. Replace bearing if crankshaft is within specification - see "Technical Data"
Clean
Plastigage from journals. Lightly coat journals and bearings with engine oil.
Installation
Install bearing cap and shell using new bolts.

Main bearing cap bolt - 60 N m (6.1 kgf m) +40 to 50 . Con-rod bearing cap bolts - 35 N m (3.9 kgf m) +45 .
2.Micrometer and gauge method.

Crankshaft removed.
Installation
1. Install caps and bearing shells to con-rods and cylinder block.
Measure
Con-rod and main bearing diameters at three points I, II, III (arrowed). Divide the sum of the three measurements by three to obtain a mean diameter. The top illustration shows con-rod measuring points. The second illustration shows main bearing measuring points.
Measure
Crankshaft main and con-rod bearing journals at points I and II. Divide the sum of both measurements to obtain a mean diameter. Crankshaft must be replaced if mean diameter of main or conrod journals is below specified limit - see "Technical Data". If crankshaft is serviceable subtract crankshaft mean journal diameters from corresponding shell bearing mean diameters to determine bearing clearance. Permissible main bearing clearance - 0.015 to 0.04mm/0.0006 to 0.002in. Permissible con-rod bearing clearance - 0.006 to 0.031mm/0.002 to 0.001in.
Bypass Valve
Removal
1. 2. Remove oil filter. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking out bypass valve from seating. Install bypass valve using drift (diameter approx. 15mm/0.6in.).
Installation
1.
Oil Filter
Removal
1. Remove oil filter using commercially available tool.
Installation
1. 2. Install oil filter by hand and oil seal ring. Fill up engine oil while preventing overflow.
Oil Pump
Removal
1. 2. Remove rear toothed belt cover, and oil pan according to the corresponding operations. Remove oil filter, wiring plug from oil pressure switch, oil pump from cylinder block, and oil pressure switch from oil pump.
Clean
Sealing surfaces
Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder block, oil pan, bearing bridge wiring plug, oil filter and toothed belt cover.
Tighten (Torque)
Oil pressure switch to oil pump - 30 N m (3.2 kgf m) Oil pump to cylinder block - 6 N m (0.6 kgf m) Oil intake pipe to oil pump - 8 N m (0.8 kgf m) Intake pipe bracket to cylinder block - 8 N m (0.8 kgf m) *Insert bolts with Locktite (Refer to General Description Recommended Liguid Gasket)
Oil Pump Safety Valve
Removal
1. 2. 3. 4. Remove closure plug. Remove seal ring. Remove spring. Remove piston.
Installation
1. 2. 3. 4. Install piston (observe installation position). Install spring. Install seal ring. Install closure plug.
Tighten (Torque)
Closure plug - 30 N m (3.0 kgf m)
Oil Pump (Overhaul)
Removal
1. 2. Remove oil pump according to the corresponding operation. Remove oil cover and pressure control valve.
Inspect
Clearance between gear pair and housing upper edge - see Technical Data. Check housing, cover and pressure control valve.
Installation
1. 2. 3. Install pump cover with Sealing Compound 15 03 166 (90 094 714). Install oil pump safety valve according to the corresponding operation. Install oil pump according to the corresponding operation.
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1. 2. Remove cylinder head according to the corresponding operation. Make hole in core plugs with pointed drift, turn in self tapping screw and edge out.
Important!
Cover oil duct in cylinder head with piece of cloth. 3. 4. 5. 6. Pull out valve retainer, using commercially available tool. Remove ball and spring. Cut three threads in the ball seating with M 10 tap (3rd stage). Coat tap with grease.
7.
Remove ball seating from cylinder head with commercially available tool. Do not damage cylinder head.
Installation
1. Install new pressure valve into cylinder head - with suitable pipe until stop.
2.
Install core hole plugs into cylinder head - with suitable pipe to end of chamfer.
OPERATIONS ON COOLING SYSTEM

Caution!
Before working with the cooling system, be sure to confirm that the temperature of the engine is cooled down. Failure to observe this may cause burn.
Cooling System, Check for Leaks
Installation
1. Install commercially available coolant checking instrument onto compensation tank (Refer to section 6B; Engine cooling). Check coolant level.
2.
Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.
Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium. To avoid corrosion, use only anti-freeze with corrosion protection.
Replace Coolant
1. 2. 3. 4. 5. Confirm the engine is cold enough. Open the radiator cap, pour coolant to the filler neck level and close the cap. Pour coolant into the reservoir until MAX line is reached. Start the engine, run 2 switch off the engine. 3 minutes at idling speed and
Refill coolant if the coolant level is lowered.
Important!
Do not loosen or open the radiator cap when coolant is hot. Doing so may cause hot water or steam to splash out, resulting in burn. When opening the radiator cap, be sure to confirm the coolant is cold. Cover a thick cloth over the cap and loosen it slowly to reduce pressure, then open the cap. 6. Close the radiator cap firmly and run the engine at approx. 2000 rpm. In addition, set the heater temperature adjuster to the max position to circulate coolant in the heater conduit system. 7. Confirm that the temperature gauge reads half or more of full scale and that the thermostat is activated. Then continue idling 5 minutes more and switch off the engine, and allow it to cool. After the engine cools down, check the coolant level and refill it if necessary. When the level is lowered extremely, check the coolant conduit system and reservoir hose for leak. Pour coolant into the reservoir to MAX level.
8.
9.
Refill Coolant
Important!
After closing the cooling system, let engine run warm until thermostat opens (coolant approx. 92 C/197.6F)
Inspection
Coolant level Allow engine to cool. If necessary, refill coolant. Check that cooling system self-bleeds during engine warmingup phase.
Ignition Timing, Check
No Adjustment
ENGINE EXTERNAL PARTS

Radiator
Removal
1. 2. 3. Disconnect battery ground cable. Loosen a drain plug to drain EC. Disconnect radiator inlet hose and outlet hose from the engine.
4.
Remove fan guide(1), clips(2) on both sides and the bottom lock, then remove lower fan guide(3) with fan shroud(4). Disconnect the reserve tank hose(6) from radiator.
5.
RTW46BSH000101
6.
Remove bracket(5).
RTW36BMH000101
7.
Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade.
Installation
Follow the removal procedure in the reverse order to install the radiator.
Thermostat
Removal
1. 2. Remove water outlet nozzles with thermostat from thermostat housing. Remove coolant hose and collect coolant.
Important!
Remove and Install thermostat only together with water outlet nozzles.
Tighten (Torque)
Water outlet nozzles to thermostat housing - 8 N m (0.8 kgf m)
Installation
1. 2. Install coolant hose. Fill cooling system and bleed according to the corresponding operation.
Water Pump
Removal
1. 2. 3. Remove lower hose band from pipe band and collect coolant. Remove front toothed belt cover according to the corresponding operation. Remove water pump from cylinder block after releasing tension on toothed belt.
Clean
Sealing surfaces
Coating sealing surfaces with Silicone Grease
Installation
1. 2. 3. 4. Install water pump to cylinder block with new rubber Oring. Apply tension to toothed belt according to the corresponding operation. Install coolant hoses. Fill cooling system and bleed according to the corresponding operation.
Alternator
Removal
1. 2. 3. Remove ground cable from battery. Remove cable connection from alternator and V-belt. Remove alternator from retaining strap and lower fastening.
Installation
1. 2. 3. 4. Install alternator by tightening firmly by hand. Install V-belt and apply tension according to the corresponding operation. Install cable connections to alternator. Install ground cable to battery.
Starter
Removeal
1. 2. 3. Remove cable connections from starter. Remove upper bolt of transmission side. Remove lower bolt of engine side.
Tighten (Torque)
Starter to cylinder block: Engine side - 51 N m (5.2 kgf m) Transmission side - 75 N m (7.6 kgf m) Starter support to cylinder block - 25 N m (2.5 kgf m) Re-connect cables.
V-belt Tension of Alternator

Measure
Measure V-belt tension of alternator. Permitted values for new V-belt are approx. 311-489N (31-50 kgf). Note: V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bracket and lower alternator bracket and moving alternator.
Tighten (Torque)
Clamping bracket to alternator - 35 N m (3.6 kgf m) Lower alternator bracket - 25 N m (2.6 kgf m)
V-Belt Tension of Power Steering Pump
Measure
Measure V-belt tension of power steering pump. Permitted values for new belt are approx. 578-712N (59-73 kgf) and 534667N (54-68 kgf) for used belt. Note: V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bolt, lower pump bracket, and adjusting nuts and moving steering pump.
Tighten (Torque)
Adjusting nuts - 18 N m (1.8 kgf m) Clamping bolt - 25 N m (2.6 kgf m) Lower pump bracket - 26 N m (2.6 kgf m)
FUEL INJECTION SYSTEM

MAP SENSOR
Removal
1. 2. 3. 4. Disconnect the battery cable. Disconnect the electrical connector from the sensor. Remove the mounting bolts securing the sensor to the manifold. Remove the sensor from the intake manifold.
Installation
1. 2. 3. 4. Push MAP sensor into the manifold. Install the mounting bolts and tighten them. Connect electrical connector. Connect the battery cable.
Pressure Regulator
Removal
1. 2. 3. Remove vacuum hose. Remove fuel hoses. Remove pressure regulator.
Installation
1. 2. 3. Install pressure regulator. Install fuel hoses. Install vacuum hoses.
ECM (Engine Control Module)
Removal
(2.4L) 1. 2. 3. Disconnect the ECM connector. Remove the four hex bolts and nuts. Remove the ECM from the ECM bracket on engine.
Installation
(2.4L) 1. 2. 3. Install the ECM to the ECM bracket on engine. Tighten the four screws to the bracket. Connect the connector.
ECT
Removal
1. Remove wiring harness plug and coolant temperature sensor.
Tighten (Torque)
Temperature sensor to intake pipe - 10 N m (1.0 kgf m) Wiring harness plug to temperature sensor
Inspection
Coolant level
Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle speed adjuster.
Installation
1. Install idle speed adjuster, hose clamps and wiring harness plug.
Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.
Installation
1. Install ignition coil, plug and bolts.
Crank Position Sensor
Removal
1. Remove crank position sensor.
Installation
1. Install crank position sensor.
FUEL INJECTOR
Removal
Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components. Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fitting with a shop towel before disconnecting the fittings. The towel will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container. 1. 2. 3. 4. 5. Depressurize the fuel system. Disconnect the fuel inlet. Disconnect the fuel return line. Remove the fuel rail from the intake manifold. Remove the fuel injector from the fuel rail by disengaging claws.
Installation
1. 2. 3. 4. Install the fuel injector to the fuel rail by engaging claws. Install the fuel rail to the intake manifold. Connect the fuel return line firmly. Connect the fuel supply line firmly.
Knock sensor
Removal
1. 2. Remove fixing bolts. Disconnect the connector at the other side.
Tighten (Torque)
Oxygen sensor in exhaust pipe - 30N m (3.2 kgf m) When re-using, insert oxygen sensor.
Oxygen Sensor (If applicable)
Removal
1. 2. Remove wiring harness plug. Remove oxygen sensor from the front exhaust pipe.
Tighten (Torque)
Oxygen sensor in exhaust pipe - 30 N m (3.1 kgf m)
Throttle Valve Position Sensor
Removal
1. 2. Remove wiring harness connector. Remove throttle valve position sensor.
Installation
1. 2. Install throttle valve position sensor. Install wiring harness connector.
Accelerator Pedal and Cable
Removal
1. Remove pad stopper from pedal stop bolt.
Installation
1. Install pad stopper.
Inspection
Ensure that accelerator pedal is fully in idle position and accelerator level at engine is in closed position. Pull outer sleeve of accelerator cable towards pedal and check that clip on sleeve is in slot nearest to grommet. Reposition clip if necessary, and check that full throttle and idle positions are obtained at engine lever.
Air Cleaner Filter

NOTE: The air cleaner filter is not damaged with the edge of the air cleaner housing.
Removal
(2.4L) 1. 2.
RTW46JSH000101
Remove air cleaner cover and air cleaner element. Remove air intake nose. Remove lower air cleaner. Remove mud guard. Remove front fender cover. Remove outside air intake duct.
3. 4. 5. 6.
Inspection
Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty.
Installation
(2.4L) 1.
130RW002
Install outside air intake duct. Install front fender cover. Install mud guard. Install lower air cleaner. Install air intake hose. Install air cleaner element and air cleaner cover.
2. 3. 4. 5. 6.
Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark plug thread drill (observe manufacturer's instructions).
Removal
Remove thread bush on spark plug. (dimensions (A) = 17mm/0.67in.)
Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N m (2.5 kgf m) - use.
TECHNICAL DATA
SOHC Gasoline Engine C24SE
Engine Oil Viscosity
The following engine oils can be used: A = single-grade oils B = multigrade oils C = easy run oils depending on the outside temperature.
Engine Oil Quality

It is important that the following API and CCMC classes are used:
Engines Petrol
Single and multigrade oils API-SF/CC, SF/CD, SG/CC, SG/CD, CCMC/G4
Easy run oils API-SF/CC, SF/CD, SG/CD CCMC-G5/PD2
Important!
CD engine oils designed by manufacturers specially for diesel engines are not suitable for petrol engines, unless a sufficient performance class for petrol engines (e.g. API-SF/CCMC-G4) is also indicated.
Disposal.
Observe the relevant national regulations when disposing of used oil.
Engine Oil Filling Quantities

Engine Model Initial filling Filling quantity (litres) with filter change* (litres) MIN to MAX (litres)
2.4L
4.80
4.25
1.00
*Up to mark "MAX" on oil dipstick
Oil Pump
Backlash Gaps in gears opposite housing Oil pressure at idle speed 0.1 to 0.2mm 0.03 to 0.1mm Engine at operating temperature (>70 C oil and approx. 80 C coolant) 450 - 500 kpa
Oil drain plug
M14
1.5
Cooling System
Radiator Type: Radiator core surface in cm : Cooling system capacity (in litres):
2
Cross-flow 2000 7.2
Anti-freeze Mixture
Anti-freeze Mixture
Required Quantity (in litres) Up to-10 C Quantity in litres Water (80%) 5.7 AntiFreeze (20%) 1.5 Up to-20 C Quantity in litres Water (66%) 4.7 AntiFreeze (34%) 2.5 Up to-30 C Quantity in litres Water (56%) 4.0 AntiFreeze (44%) 3.2 Up to-40 C Quantity of litres Water (48%) 3.4 AntiFreeze (52%) 3.8
7.2
Cooling System (continued)

Fan
Type Number of blades Distribution of blades Diameter mm Visco Clutch Fan 5 asymmetric
Radiator cap
Boiling point 123 C Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)
Thermostat
Start of opening Fully opened Type 92 C 107 C Bypassed
Idle Speeds, CO Content, Ignition Adjustment

Applicable System Idle speed in min-1 (rpm) Manual CO content in vol. % Ignition timing in CA BTDC (adjustment ensues at able speed, ignition marks must align) with TDC sensor measuring instrument: *** 8 to 12 *** 8 to 12
Closed Loop System Open Loop System
825 825
*<0.4 **1.0+0.2 -0.5
Note) * CO content adjustment not applicable. ** CO content adjustment refer to Section 6E1 (W/O catalytic converter system) *** Ignition timing adjustment not possible.
Adjustment Values/Checking Values

Valve clearance Inlet Outlet Spark plugs - electrode gap Compression Hydraulic valve lash adjustment No adjustment necessary 1.0 1.1mm
The difference in compression between the individual cylinders in the engine must not exceed 100 kPa (1 bar). The pressure loss of an engine in perfect condition per cylinder is not more than max. 25%
Pressure loss
Cylinder Head
Cylinder Head Gasket Thickness - installed Valve seat width at cylinder head inlet outlet Valve stem play inlet outlet mm 1.2
mm mm mm mm
1.0 to 1.5 1.7 to 2.2 0.018 to 0.052 0.038 to 0.072
Permissible valve stem to cone runout inlet mm outlet mm Overall height of cylinder head (Sealing surface to sealing surface) mm Installation height inlet and outlet valves dimension "A"
0.03 0.33
95.5
0.25
mm
17.85 to 18.25 Distance Gauge 5-8840-2596-0 83.50 to 83.80 max. 0.025
Installation height valve guide
mm
Sealing surface peak-to-valley height mm
Cylinder Head (continued)

Valve System Valve lifter valve play compensator (hydraulic)
Valve rotators (inlet or outlet) Valve play (warm or cold) inlet outlet
outlet
mm mm
0 0 mm mm 280.3 0.075 0.05
Cylinder head height Cylinder head bottom, face parallelism Valve Dimensions A in mm 1) Inlet valve Outlet valve 104.2 104.0 2) 103.8 103.6 41.8 36.5 B in mm
C24SE C(diameter in mm) and identification mark Normal K 7.012 6.998 6.992 6.978 7.050 7.030 Oversize K1 0.075 7.087 7.073 7.087 7.053 7.125 7.105 Oversize K2 0.150 7.162 7.148 7.142 7.128 7.200 7.180 Oversize A 0.250 7.262 7.248 7.242 7.228 7.300 7.280
44 44
Valve stem bore 1) Production 2) Customer service The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve) only
Camshaft
Identification letter Colour code Normal size 0.1mm undersize mm mm Inlet and outlet valve mm 2.4L K violet 0.03 0.09 to 0.21 6.67
Radial runout End play Cam lift
6A-80 ENGINE MECHANICAL (C24SE) Grinding Dimension for Camshaft Bearing Position Bearing Bearing journal diameter in mm normal -0.1mm 1 42.470 42.370 42.455 42.355 2 42.720 42.705 42.970 42.955 43.220 43.205 43.470 43.455 42.620 42.605 42.870 42.855 43.120 43.105 43.370 43.355
Diameter in housing normal 42.525 42.425 42.775 42.750 43.025 43.000 43.275 43.250 43.525 43.500 -0.1mm 42.500 42.400 42.675 42.650 42.925 42.900 43.175 43.150 43.425 43.400
Crankshaft, Cylinder Block

Cylinder Grinding and Piston Dimensions Size Cylinder bore dia. in mm
over to Production 1 87.48 87.49 (2.4L) 87.49 87.50 Customer 87.99 88.00 service (2.4L) Piston diameter must be measured at the position "D". *inclusive
Cylinder to Related piston dia. in mm Crankshaft housing co-efficient over to 99 87.46 87.47 00 87.47 87.48 0+0.5 87.97 87.98
Piston head coefficient
99 00 7+0.5
Cylinder Bore
Rebore cylinder Permissible oversize to 0.5mm (see parts microfiche) After reboring, invalidate original crankcase housing coefficient and drive in new oversize coefficient Permissible out-of-round: 0.013mm Permissible taper: 0.013mm Measure out-of-round in bore at 4 different heights Piston projection above upper edge of cylinder block 0.40mm Piston Type Clearance
Recessed pistons For short-blocks and cylinder blocks with complete pistons, the clearance is 0.02 to 0.04mm For replacement (oversize), depending on available pistons, a clearance of 0.02 to 0.04mm is permissible
Crankshaft, Cylinder Block (continued)

Piston Rings
Square ring Height mm mm mm 2.4L 1.2 1.5 2.5 180
Tapered ring Height Oil scraper Height
Ring gap offset
Note that the upper steel band ring gap is offset 25 to 50mm to the left and the lower 25 to 50mm to the right opposite the intermediate ring gap. Piston Pin Length Diameter Type Play in piston in con-rod Installation mm mm mm 61.5 21 Shrunk into con-rod 2.4L 0.010-0.015 none When installing piston pins, heat con-rods to approx. 280 C in oil bath. This temperature should under no circumstances be exceeded.

The permissible weight variation of con-rods without piston and bearing shell inside an engine is 8 g. As the con-rods do not have balancing studs, reworking is not possible. Con-rods can only be replaced in sets.

Crankshaft jounal I, II, IV, V Diameter mm Guide bearing III Widtht mm Con-rod journal 1 to 4 Diameter mm Normal size Bearing journal and colour code from to > to 57.9820 green 57.9885 57.9885 brown 57.9950 25.900 25.850 48.988 48.970 26.580 26.460 26.390 26.338 Width mm Con-rod width
mm
Bearing shell identification mark Colour code and embossed Identification mark
Crankshaft bearing I, II, IV, V brown-662N green-663N Crankshaft jounal I, II, IV, V Diameter mm
Guide bearing III brown-655N green-658N Guide bearing III Widtht mm
Con-rod bearing 1 to 4
Con-rod journal 1 to 4 Diameter mm Width mm
Con-rod width
mm
0.25mm Undersize for Production and Customer Service Bearing journal and colour code from to > to 57.7320 green/ 57.7385 blue 57.7385 brown/ 57.7450 blue 26.100 26.050 48.738 48.720 26.580 26.460
Crankshaft bearing I, II, IV, V brown/blue-664 A green/blue-655 A
Guide bearing III brown/blue-657 A green/blue-658 A
Crankshaft jounal I, II, IV, V Diameter mm
Guide bearing III Widtht mm
Con-rod journal 1 to 4 Diameter mm Width mm
Con-rod width
mm
0.50mm Undersize Customer Service Bearing journal and colour code from to > to 57.4820 green/ 57.4885 blue 57.4885 brown/ 57.4950 blue 26.300 26.250 48.488 48.470 26.580 26.460
Crankshaft bearing I, II, IV, V brown/white-666 B green/white-667 B
Guide bearing III brown/blue-659 B green/blue-660 B
Piston Pins
Dimensions Length Diameter Type Clearance In piston In con-rod Installation mm mm 61.5 21 Shank-fit in con-rod 2.4L 0.010 to 0.015 0 See operation Con-rod, Replace
mm mm
Con-rod
Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g. As the con-rods have no counterweights, re-working is not possible. Con-rods must be replaced only as a set.
Crankshaft Grinding Dimensions Crankshaft bearing journals I, II, III, IV, V Guide bearings III Con-Rod bearing journals 1 to 4 Con-rod
diameter in mm/colour code
width in mm
diameter in mm
width in mm
width in mm
Standard Size for Production and Service from 57.974 to white 57.981 26.002 25.950 48.988 48.970 26.580 26.450 26.390 26.338
over 57.981 green to 57.988 over 57.988 brown to 57.995

Crankshaft and con-rod journal Permissible out-of-round: 0.04mm Out-of-round Permissible variation of middle crankshaft bearing journal when seating shaft into cylinder block: 0.03mm 0.05 to 0.152mm Bearing I to V0.015 to 0.04mm 0.006 to 0.031mm 0.07 to 0.24mm
Permissible end play Permissible main bearing play
Permissible con-rod play Permissible con-rod and play

Flywheel Starter ring gear Before fitting, heat ring gear to 180 C 230 C Permissible lateral run-out of installed starter ring gear to flywheel: 0.5mm Permissible removal of material in clutch disc lining surface area: 0.3mm In order to achieve the functional relationship again after removal of material, the same removal of material must take place on the fore part of the flywheel (contact for clutch assembly) Dimension A: 2.1 to 2.2mm Cylinder block Top deck flatness mm Cylinder block height mm
Lateral run-out
Precision turning
0.05 271 0.075
Recommended Torque Values

N m (kgf m) Bearing cover to cylinder block ....................................................................................... Bracket for alternator to cylinder block ............................................................................ Bracket for engine damping block to transmission ......................................................... Bracket for engine damping block to engine block ......................................................... Bracket for pump/compressor to engine block ............................................................... Camshaft housing cover to housing ................................................................................ Camshaft timing gear to camshaft .................................................................................. Clamping bracket for alternator to intake manifold ......................................................... Clamping bracket to alternator ........................................................................................ Con-rod bearing cap to con-rod ...................................................................................... Crankshaft pulley bolts .................................................................................................... Cylinder head to cylinder block ........................................................................................ 60 40 2) 60 60 35 8 50 25 25 1) 35 20 1)2) 25 +90 Engine damping block to engine bracket ........................................................................ 8.5 1) Engine damping block to side member ........................................................................... 52 Exhaust manifold to cylinder head .................................................................................. 22 1) Use new bolts 2) Use new locking plates
1)
6.1 4.1 6.1 6.1 3.6 0.8 5.1 2.5 2.5 3.5 2.0 2.5 8.7 5.3 2.2
+40 to 50
+45 to 60 +90 +90
Recommended Torque Values

N m (kgf m) Flywheel to crankshaft ..................................................................................................... 65 Front exhaust pipe to exhaust manifold .......................................................................... 25 Guide sleeve for pressure bearing to transmission ......................................................... 22 Intake manifold to cylinder head ...................................................................................... 22 Lower alternator bracket ................................................................................................. 25 Oil drain plug to oil pan .................................................................................................... 45 2) Oil intake pipe bracket to cylinder block .......................................................................... 6 Oil intake pipe to oil pump ............................................................................................... 8 2)3) Oil pan to cylinder block .................................................................................................. 8 2)3) Bearing bridge to cylinder block ...................................................................................... 8 Oil pressure switch to oil pump ....................................................................................... 30 Pump for power steering (ribbed V-belt) to engine block ................................................ 30 Spark plugs in cylinder head ........................................................................................... 20 Starter support to cylinder block ...................................................................................... 25 Starter to cylinder block - engine side ............................................................................. 45 Starter to cylinder block - transmission side .................................................................... 75 Thermostat housing to cylinder head .............................................................................. 15 1) Toothed belt drive gear to crankshaft .............................................................................. 130 Toothed belt front cover .................................................................................................. 4 Toothed belt rear cover ................................................................................................... 6 Toothed belt tension roller to oil pump ............................................................................ 20 (M10) ............................................................................ 45 Transmission to engine block ......................................................................................... 76 (M12) ............................................................................ 60 Water pump to cylinder block .......................................................................................... 17 1) Use new bolts 2) Use Locking Compound 3) Maximum installation time - 10 minutes
1)
6.6 +30 to 45 2.5 2.2 2.2 2.5 4.6 0.6 0.8 0.8 0.8 3.2 3.2 2.3 2.5 4.6 7.6 1.5 13.3 0.4 0.6 2.3 4.6 7.7 6.1 1.7
SPECIAL SERVICE TOOLS

ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-2634-0
Aligner
5-8840-2593-0
Cutter set
5-8840-2594-0
Spring Compressor
5-8840-0451-0
Installer
5-8840-0452-0
Remover / Installer
5-8840-2596-0
Distance Gauge
5-8840-0455-0
Assembly Sleeves
5-8840-2597-0
Installer
5-8840-0457-0
Remover / Installer
5-8840-0468-0
Remover / Installer
ENGINE MECHANICAL (C24SE) 6A-89 ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-0459-0
Installer
5-8840-0460-0
Installer
5-8840-0446-0
Flywheel Holder
5-8840-2598-0
Holding Wrench
5-8840-2599-0
Reamer Set
5-8840-2600-0
Socket Wrench
5-8840-2601-0
Installer
MEMO
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE General Description........................................................................................................ 6B- 2 Service Precaution ......................................................................................................... 6B- 3 Diagnosis......................................................................................................................... 6B- 5 Draining and Refilling Cooling System......................................................................... 6B- 6 Water Pump..................................................................................................................... 6B- 7 Water Pump and Associated Parts........................................................................... 6B- 7 Removal ...................................................................................................................... 6B- 7 Inspection ................................................................................................................... 6B- 7 Installation .................................................................................................................. 6B- 8 Thermostat ...................................................................................................................... 6B- 9 Removal ...................................................................................................................... 6B- 9 Inspection ................................................................................................................... 6B- 9 Installation .................................................................................................................. 6B- 9 Fan clutch with Cooling Fan .......................................................................................... 6B- 9 Inspection and Repair................................................................................................ 6B- 9 Radiator ........................................................................................................................... 6B-11 Radiator and Associated Parts ................................................................................. 6B-11 Removal ...................................................................................................................... 6B-11 Inspection ................................................................................................................... 6B-12 Installation .................................................................................................................. 6B-13 Main Data and Specifications ........................................................................................ 6B-13 Special Service Tool....................................................................................................... 6B-14
6B-2 ENGINE COOLING
General Description
Legend
1 Water Pump 2 Thermostat 3 Radiator 4 Reserve Tank 5 Coolant Distributor 6 Cylinder Block and Head 7 Throttle Body 8 Heater
The Cooling System is a pressurized type, where the water pump, which is cambelt driven, forces the circulation of the coolant through the cylinder block and head. The thermostat regulates the flow of coolant between the radiator and the bypass circuit. The heater is part of the bypass circuit. The throttle body pre-heat is a separate circuit which is not regulated by the thermostat. An oil cooler may be fitted as part of this circuit.
ENGINE COOLING 6B-3
Service Precaution
CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
Water pump
The water pump is centrifugal type and is driven by timing belt.
Thermostat
The thermostat is a bypass type and is a wax pellet type with a air hole.
Radiator
The radiator is a flow type with corrugated fins.
110RS001
6B-4 ENGINE COOLING
Antifreeze Solution
Calculating mixing ratio Mixing ratio = Antifreeze solution (Lit/gal.) Antifreeze solution (Lit/gal.) + Water (Lit/gal.)
NOTE: Antifreeze solution + Water = Total cooling system capacity. Total Cooling System Capacity 5.7Lit Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0 C to 50 C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. NOTE: The LLC is 50% at all environment in order to prevent the corrosion of cooling system parts.
ENGINE COOLING 6B-5
Diagnosis Engine Cooling Trouble

Condition Engine overheating Possible cause Low Engine Coolant level Thermo mater unit faulty Faulty thermostat Faulty Engine Coolant temperature sensor Clogged radiator Faulty radiator cap Low engine oil level or use of improper engine oil Clogged exhaust system Faulty Throttle Position sensor Open or shorted Throttle Position sensor circuit Damaged cylinder head gasket Loosen V-belt tension Collapsed hoses Faulty Fan clutch Faulty thermostat Faulty thermostat Thermo unit faulty Correction Replenish Replace Replace Repair or replace Clean or replace Replace Replenish or change oil Clean exhaust system or replace faulty parts Replace throttle valve assembly Repair or replace Replace Adjust belt tension or replace. Replace Replace Replace Replace Replace
Engine overcooling Engine slow to warm-up
6B-6 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. 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. 5. Fill the radiator to the base of the filler neck. Fill the EC reserve tank to "MAX" line when the engine is cold. 6. Block the drive wheels and firmly apply the parking brake. Shift an automatic transmission to "P" (Park) or a manual transmission to neutral. 7. Remove the radiator cap. Start the engine and warm it up at 2,500 - 3,000 rpm for about 30 minutes. 8. When the air comes out from the radiator filler neck and the EC level has gone down, replenish with the EC. Repeat this procedure until the EC level does not go down. Then stop the engine and install the radiator cap. Let the engine cool down. 9. After the engine has cooled, replenish with EC up to the "MAX" line of the reserve tank. 10. Start the engine. With the engine running at 3,000 rpm, make sure there is no running water sound from the heater core (behind the center console). 11. If the running water sound is heard, repeat steps 8 to 10.
ENGINE COOLING 6B-7
Water Pump
Water Pump and Associated Parts
Legend
1 Water Pump Assembly
2 O-Ring 3 Bolt
Removal
1. 2. 3. 4. 5. Disconnect battery ground cable. Drain coolant. Disconnect radiator hose (on inlet pipe side). Remove timing belt, refer to "Timing Belt" in this manual. Remove water pump assembly.
Inspection
Make necessary repair and 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:
6B-8 ENGINE COOLING Crack in the water pump body EC leakage from the seal unit Play or abnormal noise in the bearing Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with silicon grease. 2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 N m (2.5 kgf m) 3. Timing belt Install timing belt, refer to timing belt installation step in "Timing Belt" in this manual. 4. Connect radiator hose and replenish EC. 5. Connect battery ground cable.
ENGINE COOLING 6B-9
Thermostat
Removal
1. 2. 3. 4. 5. Disconnect battery ground cable. Drain engine coolant from the radiator and engine. Disconnect radiator hose from the inlet pipe. Remove thermostat housing. Remove thermostat from thermostat housing.
Inspection
Suspend the thermostat in a water-filled container using thin wire. Place a thermometer next to the thermostat. Do not directly heat the thermostat. Gradually increase the water temperature. Stir the water so that the entire water is same temperature. Confirm the temperature when the valve first begins to open. Valve opening temperature 92 C (197.6 F) Confirm the temperature when the valve is fully opened. Valve full open temperature 107 C(224.6 F) Make necessary repair and parts replacement if extreme wear or damage is found during inspection.
Installation
1. Before installing thermostat, coat sealing surface with silicon grease. 2. Install O-ring. 3. Install thermostat housing and tighten bolts to the specified torque. Torque: 15 N m (1.5 kgf m) 4. Installation rubber hose. 5. Replenish engine coolant (EC). 6. Start engine and check for EC leakage.
Fan Clutch with Cooling Fan

Inspection and Repair
Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection. Visually inspect for damage, leak (silicon grease) or other abnormal conditions. 1. Inspection (on-vehicle) 1) Turn the fan clutch by hand when in a low temperature condition before starting the engine, and confirm that it can be turned readily. 2) Start the engine to warm it up until the temperature at the fan clutch portion gets to around 80 C. Then stop the engine and confirm that the fan clutch can be turned with considerable effort (clutch torque) when turned by hand.
6B-10 ENGINE COOLING If the fan clutch rotates more readily, however, this indicates that the silicon 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 silicon grease is leaking internally. Replace the fan clutch with a new one.
ENGINE COOLING 6B-11
Radiator
Radiator and Associated Parts
Legend
1 Radiator Hose 2 Drain Plug 3 Fan Guide, Lower 4 Fan Guide 5 Bracket 6 Reserve Tank Hose 7 Reserve Tank 8 Radiator Cap 9 Radiator Assembly
Removal
1. 2. 3. 4. 5. Disconnect battery ground cable. Loosen a drain plug to drain engine coolant (EC). Disconnect radiator inlet hose and outlet hose. Disconnect the reserve tank hose from radiator. Lift out the radiator assembly, taking care not to damage the radiator core.
6B-12 ENGINE COOLING
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) 88.3 103.0 (13.5 15.7) Cap tester: 5-8840-0277-0 Adapter: 5-8840-2603-0 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) 1.9 - 4.9 (0.28 - 0.71)
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 sign 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. Cap tester: 5-8840-0277-0 Adapter: 5-8840-2603-0
ENGINE COOLING 6B-13
Installation
1. Install radiator assembly, taking care not to damage the radiator core. 2. Install the radiator assembly. 3. Connect reserve tank hose. 4. Connect radiator inlet hose and outlet hose. 5. 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. Remove radiator cap. Fill with engine coolant (EC) to the radiator filler neck. Fill with EC to the "MAX" line on the reservoir tank. Start the engine with the radiator cap removed and bring to operating temperature by running engine at 2,500 - 3,000 rpm for 30 minutes. By EC temperature gauge reading make sure that the thermostat is open. If air bubbles come up to the radiator filler neck, replenish with EC. Repeat until the EC level does not drop any further. Install the radiator cap and stop the engine. Replenish EC to the "MAX" line on the reservoir tank and leave as it is until the engine gets cool. After the engine gets cool, start the engine and make sure there is no water running noise heard from the heater core while the engine runs at 3000 rpm. Should water running noise be heard, repeat the same procedure from the beginning.
Main Data and Specifications General Specifications

Cooling system Radiator Heat radiation capacity Heat radiation area Radiator front area Radiator dry (weight) Radiator cap valve opening pressure Engine coolant capacity Engine coolant pump Thermostat Engine coolant total capacity Engine Coolant forced circulation Tube type corrugated (2 tube in row) 66.3 kcal/h 2 7.08 m 2 028 m 3.1 kg 93.3 122.7 kpa 2.0L Centrifugal type Bypass type 5.7lit
6B-14 ENGINE COOLING
SPECIAL SERVICE TOOL

ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-0277-0
Tester; radiator cap
5-8840-2603-0
Adapter; radiator cap
ENGINE FUEL (C24SE) 6C-1
ENGINE
ENGINE FUEL (C24SE)
CONTENTS
General Description............................................. 6C-2 Service Precaution............................................... 6C-3 Fuel Metering ........................................................ 6C-4 Fuel Filter ............................................................... 6C-5 Removal .............................................................. 6C-5 Inspection ........................................................... 6C-6 Installation .......................................................... 6C-6 Inspection ........................................................... 6C-6 In-Tank Fuel Filter ............................................. 6C-6 Fuel Pump Flow Test ....................................... 6C-7 Fuel Pump .............................................................. 6C-8 Fuel Pump and Associated Parts ................. 6C-8 Removal .............................................................. 6C-8 Installation .......................................................... 6C-9 Fuel Tube / Quick - Connector Fittings .......... 6C-10 Precautions ........................................................ 6C-10 Cautions During Work ..................................... 6C-10 Removal ............................................................... Reuse of Quick-Connector ............................. Assembling Advice ........................................... Fuel Pump Relay ................................................... General Description .......................................... Fuel Tank ................................................................ Fuel Tank and Associated Parts .................... Removal ............................................................... Installation .......................................................... Filler Neck ............................................................... Removal ............................................................... Installation .......................................................... Fuel Gauge Unit .................................................... Removal and Installation ................................. Fuel Filler Cap........................................................ General Description .......................................... Inspection............................................................ Main Data and Specifications ............................ Special Tool ........................................................ 6C-10 6C-11 6C-11 6C-12 6C-12 6C-13 6C-13 6C-14 6C-14 6C-15 6C-15 6C-15 6C-15 6C-15 6C-16 6C-16 6C-16 6C-17 6C-18
6C-2 ENGINE FUEL (C24SE)
General Description
* * *
* Applicable to EVAP Emission Control System ** Not applicable to EVAP Emission Control System
ENGINE FUEL (C24SE) 6C-3 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. All gasoline engines are designed to use only unleaded gasoline. Unleaded gasoline must be used for proper emission control system operation. Its use will also minimize spark plug fouling and extend engine oil life. Using leaded gasoline can damage the emission control system and could result in loss of emission warranty coverage. All cars are equipped with an Evaporative Emission Control System. The purpose of the system is to minimize the escape of fuel vapors to the atmosphere.
Service Precaution
Fuel Metering
Engine Control Module (ECM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, which the MAP sensor converts to a voltage output. This sensor generates the voltage to change corresponding to the flow of the air drawn into the engine. The changing voltage is transformed into an electric signal and provided to the ECM. With receipt of the signals sent from the MAP sensor, Intake Air Temperature sensor and others, the ECM determines an appropriate fuel injection pulse width feeding such information to the fuel injector valves to effect an appropriate air/fuel ratio. The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution. The ECM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions. Two interchangeable "O" rings are used on the injector that must be replaced when the injectors are removed. The fuel rail is attached to the top of the intake manifold and supplies fuel to all the injectors. Fuel is recirculated through the rail continually while the engine is running. This removes air and vapors from the fuel as well as keeping the fuel cool during hot weather operation. The fuel pressure control valve that is mounted on the fuel rail maintains a pressure differential across the injectors under all operating conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. See Section "Driveability and Emission" for more information and diagnosis.
Fuel Filter
Fuel Filter and Associated Parts
Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connections or leakage. For the fuel system diagnosis, see Section "Driveability and Emissions". (2.4L) 1. Disconnect battery ground cable. 2. Disconnect the quick connector from the fuel filter. 3. Pull off fuel filter from the holder to side member side. 4. Remove the fuel filter.
Fuel Filter
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter body or if the fuel filter body itself is damaged. 2. Replace the filter if it is clogged with dirt or sediment. NOTE: Verify to hang holder hook to fuel filter.
Installation
1. Install the filter to holder from side member side. NOTE: Attend direction of fuel filter. (1) to engine side (2) to fuel tank side. NOTE: Verify to hang holder hook to fuel filter.
RTW36CSH000301
2. Connect the quick connector from the fuel tube to the fuel filter. NOTE: Pull of the left checker into the fuel pipe. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs. 3. Tighten fuel filler cap until at least one click are heard. 4. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel leakage.
InTank Fuel Filter

The filter is located on the lower end of fuel pickup tube in the fuel tank. It prevents dirt from entering the fuel pipe and also stops water unless the filter is completely submerged in the water. It is a selfcleaning type, not requiring scheduled maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stoppage. In such a case, the tank must be cleaned thoroughly.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the following checks. 1. Make sure that there is fuel in the tank. 2. With the engine running, check the fuel feed pipe and hose from fuel tank to injector for evidence of leakage. Retighten, if pipe or hose connection is loose. Also, check pipes and hoses for squashing or clogging. 3. Insert the hose from fuel feed pipe into a clean container, and check for fuel pump flow rate. 4. Connect the pump relay terminals (2) with a jumper wire (1) as shown and start the fuel pump to measure delivery.
RTW36CSH000201
CAUTION: Never generate sparks when connecting a jumper wire. Delivery 15 seconds Delivery 0.38 liters minimum
If the measure value is out of standard, conduct the pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E Fuel Control System".
Fuel Pump
Fuel Pump and Associated Parts
RTW46FMF000401
Legend (1) Fuel Feed Port (2) Fuel Return Port (3) Fuel Emission Port (4) Fuel Pump and Sender Assembly (5) Connector; Fuel Feed Pump & Sender
(6) Fuel Tube/Quick Connector (7) Retainer Ring (Fuel Pump Lock) (8) Seal; Fuel Pump (9) Fuel Tank Assembly (10) Evapo Tube/Quick Connector
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) into the fuel tube from fuel pump. 3. Disconnect the quick connector (10) into the evapo tube from fuel pump.
ENGINE FUEL (C24SE) 6C-9 3. Remove the retainer ring (7) from the fuel tank with the removal tool 5-8840-2602-0. 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 pump seal area. (3) Pressure air into the fuel tank from end of 2 breather pipe at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds. (4) Verify no bubbles around the fuel pump seal area. 8. Install the fuel tank assembly (9). NOTE: Refer to Install the fuel tank in this section.
140R100035
4. Remove slowly the fuel pump (4) from the fuel tank as no bend float arm. NOTE: Cover opening for the fuel pump on fuel tank to prevent any dust enthering. 5. Discard fuel pump seal (8) because it cannot be reusable.
Installation
1. Clean the seal surface of the fuel tank and the fuel pump. NOTE: If there is dust on the seal surface, it becomes cause of fuel leak. 2. Install the new fuel pump seal (8) to opening of the fuel tank as along the groove. 3. Install slowly the fuel pump (4) into the fuel tank as no bend float arm. 4. Set flange of the fuel pump on fuel pump seal as mating convexity of the fuel pump 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. Connector the quick conector (10) into the evapo tube to fuel pump. 7. Connect the quick connector (6) into the fuel tube to fuel pump. NOTE: Pull off the left ckecker into the fuel pipe. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs.
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 electrical shorts. ground cable to prevent
Pre-treat piping system or associated parts from thermal damage or from spattering when welding or similar heat-generating work.
Cautions During Work
141R100002
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. 2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connentor with the other hand while pressing the square relieve button of the connector, as illustrated.
140R100032
Legend (1) O-ring (2) Port (3) Connector (4) Plastic Tube Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electorolyte. Piping that has been splattered with battery electrolyte or battery electrolyte soaked cloth that was wiped on the piping cannot be used.
140R100037
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.
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. Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering.
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. Turn the ignition key to the ON" position and listen for pump start-up sound. Inspect for leaks, the fuel pressure will increase as the fuel pump is actuated. 3. Perform leak inspection (step 2) several times.
140R100028
4. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel injection system.
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
Fuel Pump Relay

General Description
In order to control the fuel pump and sender assembly (FPAS) operation, the FPAS relay is provided. When the starter switch is turned to ON" position, the FPAS relay operates the FPAS for 2 seconds. When it is turned to START" position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPAS to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
RTW46FLF000301
Legend (1) Bolt; Fuel Tank (2) Fuel Tank Band (3) Rear Side Shield (4) Side Shield (5) Retainer (6) Fuel Tank
(7) Fuel Filler Hose (8) Fuel Tube/Quick Connector (9) Fuel Filter (10) Band; Under Shield (11) Under Shield (12) Evapo Tube / Quick Connector Only Specified Model
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: To prevent spouting out fuel to 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 on rear left side. 6. Remove fasten bolt to the filler neck from the body. 7. Disconnect the quick connector (8) into the fuel tube from the fuel pipe and the evapo tube from evapo joint connector. NOTE: Cover the quick connector to prevent any dust entering and fuel leaking. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs. 8. Remove fasten bolt (1) to the tank band and 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 (6). NOTE: When the fuel tank is lowered from the vehicle, dont scratch each hose and tube by around other pars.
Installation
1. Rise the fuel tank into position. NOTE: Ensure hoses and tubes do not foul on other component. 2. Connect the pump and sender connector to the fuel pump and install harness to into the plastic clip welded to the top of the fuel tank.. NOTE: The connector must be certainly connected against stopper. Ensure tank band anchor mates with guide hole on frame. 3. Install the tank band to fasten bolt. Torque: 68 N m (6.9kg m/50 lb ft) NOTE: The anchor of the tank band must be certainly installed to guide hole on frame. 4. Connect the quick connector from the fuel tube to the fuel pipe and the evapo tube from evapo joint connector. NOTE: Pull off the left checker into the fuel pipe. NOTE: Refer to Fuel Tube/Quick Connector Fittings in this section when performing any repairs. 5. Install the filler neck to the body by bolt. 6. Install the inner liner of the wheel house on rear side. 7. Remove lifter to support underneath of the fuel tank. 8. Put back the vehicle. 9. Tigten the filler cap until at least three clicks are heard. 10. Connect the battery ground cable.
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: 2.5 N m (0.25 kg m / 2 lb ft) 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.
Fuel Gauge Unit

Removal and Installation
As for removal and installation of the Fuel Gauge Unit, refer to Fuel Tank" of this section 6C as the fuel gauge unit is combined with the fuel pump and sender assembly.
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.

Torque Specification
N m (kg m/ lb ft)
RTW46CLF000601
Special Tools
ILLUSTRATION PART NO. PART NAME
5884026020 (J39765) Remover; fuel pump retainer
ENGINE ELECTRICAL 6D1-1
SECTION 6D1
ENGINE ELECTRICAL
CONTENTS
PAGE Battery ............................................................................................................................. 6D1- 2 General Description ................................................................................................... 6D1- 2 Service Precaution..................................................................................................... 6D1- 2 Diagnosis.................................................................................................................... 6D1- 3 Battery Charging ........................................................................................................ 6D1- 4 Jump Starting ............................................................................................................. 6D1- 4 Removal ...................................................................................................................... 6D1- 6 Installation .................................................................................................................. 6D1- 6 Main Data and Specifications ................................................................................... 6D1- 6
6D1-2 ENGINE ELECTRICAL
Battery
General Description
There are six battery fluid caps on top of the battery. These are covered by a paper label. The battery is completely sealed except for the six small vent holes on the side. These vent holes permit the escape of small amounts of gas generated by the battery. This type of battery has the following advantages over conventional batteries: 1. There is no need to add water during the entire service life of the battery. 2. The battery protects itself against overcharging. The battery will refuse to accept an extensive charge. (A conventional battery will accept an excessive charge, resulting in gassing and loss of battery fluid.) 3. The battery is much less vulnerable to self discharge than a conventional type battery.
Service Precaution
ENGINE ELECTRICAL 6D1-3
Diagnosis 1. Visual Inspection

Inspect the battery for obvious physical damage, such as a cracked or broken case, which would permit electrolyte loss. Replace the battery if obvious physical damage is discovered during inspection. Check for any other physical damage and correct it as necessary.
2. Hydrometer Check
3. Fluid Level Check

The fluid level should be between the upper level line (2) and lower lever line (3) on side of battery. a. CORRECT FLUID LEVEL - Charge the battery. b. BELOW LOWER LEVEL - Replace battery.
4. Voltage Check
1. Put voltmeter test leads to battery terminals. a. VOLTAGE IS 12.4V OR ABOVE - Go to Step 5. b. VOLTAGE IS UNDER 12.4V - Go to procedure (2) below. 2. Determine fast charge amperage from specification. (See Main Data and Specifications in this section). Fast charge battery for 30 minutes at amperage rate no higher than specified value. Take voltage and amperage readings after charge. a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF AMPERAGE RATE - Replace battery. b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF AMPERAGE RATE - Drop charging voltage to 15V and charge for 10 - 15 hours. Then go to Step 5. c. VOLTAGE IS BETWEEN 12V AND 16V - Continue charging at the same rate for an additional 3-1/2 hours. Then go to Step 5. d. VOLTAGE BELOW 12V - Replace Battery.
Battery Charging
Observe the following safety precautions when charging the battery: 1. Never attempt to charge the battery when the fluid level is below the lower level line on the side of the battery. In this case, the battery must be replaced. 2. Pay close attention to the battery during charging procedure. Battery charging should be discontinued or the rate of charge reduced if the battery feels hot to the touch. Battery charging should be discontinued or the rate of charge reduced if the battery begins to gas or spew electrolyte from the vent holes. 3. In order to more easily view the hydrometer blue dot or ring, it may be necessary to jiggle or tilt the battery. 4. Battery temperature can have a great effect on battery charging capacity. 5. The sealed battery used on this vehicle may be either quick charged or slow charged in the same manner as other batteries. Whichever method you decide to use, be sure that you completely charge the battery. Never partially charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster) Battery
CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces.
ENGINE ELECTRICAL 6D1-5 Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vahicle. This will protect against a short circuit. Always keep batteries out of reach of young children.
Jump Starting Procedure

1. Set the vehicle parking brake. If the vahicle is equipped with an automatic transmission, place the selector level in the "PARK" position. If the vehicle is equipped with a manual transmission, place the shift lever in the "NEUTRAL" position. Turn "OFF" the ignition. Turn "OFF" all lights and any other accessory requiring electrical power. 2. Look at the built-in hydrometer. If the indication area of the built-in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned "OFF". 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery.

2
Removal
1. 2. 3. 4. 5. Remove negative cable (1). Remove positive cable (2). Remove retainer screw and rods (3). Remove retainer (4). Remove battery (5).
1 4
Installation
1. Install battery. 2. Install retainer. 3. Instal retainer screw and rods. NOTE: Make sure that the rod is hooked on the body side. 4. Install positive cable. 5. Install negative cable.

Model (JIS) Voltage (V) Cold Cranking Performance (Amp) Reserve Capacity (Min) 34B19L 12 272 49 50D20L 12 306 78
IGNITION SYSTEM 6D2-1
SECTION 6D2
IGNITION SYSTEM
CONTENTS
PAGE General Description........................................................................................................ 6D2- 2 Service Precaution ......................................................................................................... 6D2- 2 Diagnosis......................................................................................................................... 6D2- 2 Ignition Coil ..................................................................................................................... 6D2- 2 Removal ...................................................................................................................... 6D2- 2 Installation .................................................................................................................. 6D2- 2 Spark Plug ....................................................................................................................... 6D2- 3 Removal ...................................................................................................................... 6D2- 3 Inspection and Repair................................................................................................ 6D2- 3 Installation .................................................................................................................. 6D2- 4 Crankshaft Angle Sensor ............................................................................................... 6D2- 4 Removal ...................................................................................................................... 6D2- 4 Installation .................................................................................................................. 6D2- 4 Main Data and Specifications ........................................................................................ 6D2- 5
6D2-2 IGNITION SYSTEM
General Description
Ignition is done by the Ignition Module that fires. Since the cylinder on exhaust stroke requires less energy to fire its spark plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. A notch in the timing disc on the crankshaft activates the crank angle sensor which then sends information such as firing order and starting timing of ignition coil to the ECM. By receiving signals such as crank position, engine speed, water temperature and Manifold Absolute Pressure (MAP), the ECM controls the ignition timing.
Service Precaution
Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to electronic ignition system (El system).
Ignition Coil
Removal
1. Disconnect battery ground cable. 2. Disconnect the Ignition coil connector. 3. Remove the ignition coil.
Installation
1. Install the ignition coil. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque: 20 N m (2.0 kgf m) 2. Connect battery ground cable.
Spark Plug
Removal
1. Remove spark plugs.

The spark plug affects entire engine performance and therefore its inspection is very important. Check electrode and insulator for presence of cracks, and replace if any. Check electrode for wear, and replace if necessary. Check gasket for damage, and replace if necessary. Measure insulation resistance with an ohmmeter, and replace if faulty. Adjust spark plug gap to 1.0 - 1.1 mm (0.027 in) - 0.8 mm (0.031 in). Check fuel and electrical systems if spark plug is extremely dirty. Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned.
Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: Too rich mixture Presence of oil in combustion chamber Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: Too lean mixture Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt megaohm meter. Replace spark plugs if measured value is out of standard. Insulation resistance: 50 M9 or more
Cleaning Spark Plugs

Clean spark plugs with a spark plug cleaner. Raise the ground electrode to an angle of 45 to 60 degrees. if electrode is wet, dry it gefore cleaning. After spark plug is thoroughly cleaned, check insulator for presence of cracks.
Clean threads and metal body with a wire brush. File the electrode tip if electrode is extremely worn. Bend the ground electrode to adjust the spark plug gap.
Installation
1. Spark plugs Tighten spark plugs to the specified torque. Torque: 25 N m (2.5 kgf m)
Crankshaft Angle Sensor

Removal
1. Disconnect battery ground cable 2. Disconnect the wiring connector from crankshaft angle sensor. 3. Remove crankshaft angle sensor from cylinder block.
Installation
1. Install crankshaft angle sensor into the cylinder block. Before installation, apply small amount of engine oil to the O-ring. Torque: 6 N m (0.6 kgf m) 2. Reconnect wiring connector to crankshaft angle sensor.

Ignition System Ignition Form Spark Plug Type No. of Coils and Type Coil Location Torque
Electronic Ignition System (El system) with Crankshaft angle Sensor Electronic Spark Control 2 Solid State Engine-mounted 20 N m (2.0 kgf m)
MEMO
STARTING AND CHARGING SYSTEM 6D3-1
SECTION 6D3
STARTING AND CHARGING SYSTEM

CONTENTS
PAGE Starting System .............................................................................................................. 6D3- 2 General Description........................................................................................................ 6D3- 2 Service Precaution ......................................................................................................... 6D3- 2 Diagnosis......................................................................................................................... 6D3- 2 Starter .............................................................................................................................. 6D3- 3 Removal ...................................................................................................................... 6D3- 3 Installation .................................................................................................................. 6D3- 3 Disassembled View.................................................................................................... 6D3- 4 Inspection and Repair................................................................................................ 6D3- 5 Characteristic Test..................................................................................................... 6D3- 6 Charging System ............................................................................................................ 6D3- 7 General Description........................................................................................................ 6D3- 7 General On-Vehicle Inspection...................................................................................... 6D3- 8 Generator......................................................................................................................... 6D3- 8 Removal ...................................................................................................................... 6D3- 8 Inspection ................................................................................................................... 6D3- 8 Installation .................................................................................................................. 6D3- 9 Diagnosis......................................................................................................................... 6D3-12 Disassembly ............................................................................................................... 6D3-13 Clean ........................................................................................................................... 6D3-14 Inspection ................................................................................................................... 6D3-14 Reassembly ................................................................................................................ 6D3-18 Inspection ................................................................................................................... 6D3-19 Technical Data ................................................................................................................ 6D3-21
6D3-2 STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected.
Starter
The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with the ring gear. Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger returns, the pinion is disengaged from the ring gear, and the armature stops rotation. When the engine speed is higher than the pinion, the pinion idles, so that the armature is not driven.
Service Precaution
Diagnosis
Condition Starter does not run Possible cause Charging failure Battery Failure Terminal connection failure Starter switch failure Starter failure Correction Repair charging system Replace Battery Repair or replace terminal connector and/or wiring harness Repair or replace starter switch Repair or replace starter
Starter
Removal
1. Remove the battery ground cable. 2. Remove harness connectors (1) and (2).
3. Remove bolts from starter.
Installation
1. Install starter assembly. 2. Install mounting bolts and tighten bolts to specified torque. Torque: 51 N m (5.2 kgf m) 3. Connect harness. 4. Reconnect the battery ground cable.
Disassembled View
Legend
1 Bolt 2 Magnetic Switch 3 Gear Case 4 Piston 5 Piston Shaft 6 Center Bracket 7 Armature 8 Yoke Assembly 9 Brush and Brush Holder 10 Washer 11 Rear Cover 12 Through Bolt

Repair or replace necessary parts if extreme wear or damage is found during inspection.
Armature
Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected).
Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core, armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded).
Brush
Measure the length of brush. Replace with a new one, if it is below the limit.
Brush Holder
Check for continuity between brush holder (+) (4) and base (-). Replace, if there is continuity (i.e., insulation is broken).
Magnetic Switch
Check for continuity of shunt coil between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).
Continuity of Series Coil

Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).
Continuity of Contacts
With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty).
Pinion
Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse. If not, replace the pinion.
Characteristic Test
For easily confirming the characteristics, conduct the noload test as follows: Rating as short as 30 seconds requires rapid testing. Fix the starter on the test bench, and wire as shown in illustration. When the switch is closed, the current flows and the starter runs under no load. At this time, measure current, voltage and speed to check if they satisfy the standard.
Legend
1 Volt Meter 2 Revolution Indicator 3 Battery 4 Ammeter 5 Switch
Charging System
General Description
The charging system is an IC integral regulator charging system and its main components are connected as shown in illustration. The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover. The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the stator coil has eight diodes to transform AC voltage into DC voltage. This DC voltage is connected to the output terminal of generator.
10 11 6 7 11 1
12 9 8 2
Legend
1 Startor assembly 2 Housing 3 Slipring 4 Screws (2) 5 Regulator 6.Bolt (4)
7 Rectifier assembly 8 Retaining assembly 9 B+ terminal nut and washer 10 Pulley 11 Rotor assembly 12 Ball bearing
General On-Vehicle Inspection

The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on when the starter switch is turned to "ON" position. The charging system operates normally if the lamp goes off when the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected, perform diagnosis by checking the charging system as follows: 1. Check visually the belt and wiring connector. 2. With the engine stopped, turn the stator switch to "ON" position and observe the warning lamp. If lamp does not come on: Disconnect wiring connector from generator, and ground the terminal "L" on connector side. If lamp comes on: Repair or replace the generator.
Generator
Removal
1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt. 3. Disconnect terminal "B" wiring connector and connector. 4. Remove generator assembly.
Generator Power and Circuit Diagram
Inspection
Legend
1 Load resistor, set parallel to battery 2 Battery 3 Voltmeter 4 Ammeter 5 Ignition Lock 6 Charge Telltale 7 Generator 1. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect battery. Close off connecting cable from alternator terminal "B+". Set ammeter (measuring range 100A) in disconnected line. Connect controllable load resistor to battery terminal. Set resistor in front of connection to "O"; connect first to battery, then to resistor. Connect tachometer. Connect oscilloscope according to manufacturer's instructions. Connect battery. Start engine and read off resulting current at various engine speeds.
Generator Power
1. Adjust load resistor, if the required load currents are not attained. 2. The shape of the voltage curves on oscilloscope curve should be regular. 3. Test value: 5 to 7A. 4. If the required minimum current intensity is not attained, or if the oscilloscope picture shows variations, the alternator should be overhauled.
Regulated Voltage Circuit Diagram
Legend
1 Battery 2 Ignition Lock 3 Charge Telltale 4 Resistor, for attainment of load current with the battery set in series 5 Voltmeter 6 Ammeter 7 Generator
Installation
1. Install generator assembly and bring generator assembly to the position to be installed. 2. Install generator assembly and tighten to the specified torque. Torque: Long bolt: 35 N m (3.6 kgf m) Short bolt: 20 N m (2.0 kgf m) 3. Connect wiring harness connector. 4. Move drive belt tensioner to loose side using a wrench, then install drive belt to normal position. 5. Reconnect battery ground cable.
6D3-10 STARTING AND CHARGING SYSTEM The generator has four external connections; the "B+" lead to battery positive, "L" lead to the warning lamp circuit(max. 2 watts), "S" lead to battery positive terminal for battery sensing and an earth connection.
Explanation of type inscripiton

Example:KC-A--> 14V 50-90A. K = Code for Stator OD(126mm OD). C = Compact Generator. A = Ausland (countries other than Germany) > = Direction of rotation(clockwise). 14V = Generator Operating Voltage. 50A = Stabilised output at 25 C at 1800 RPM./13.5 Volts. 90A = Stabilised output at 25 C at 1800 RPM./13.5 Volts.
Generator Connetions.
B+ : Battery Main Connection (battery positive) S : Battery Sense Connection(battery positive) L : Waring lamp(via warning lamp to Ignition switch)
8+
SUPPRESSOR CAPACITOR 0.5 f
ALTERNATOR ASSEMBLY
BATT.SENSE
1GN.SW.
WARN.LAMP 1.2 WATT
S L HYBR10
12V BATT.
300a*
REGULATOR ASSEMBLY
NOTE: * RESISTOR IS RECOMMENDED TO ENSURE THAT THE GENERATOR REMAINS FUNCTIONAL IN CASE OF WARNING LAMP FAILURE
Warning
Do not reverse S and L connections as this will destroy the warning lamp circuit of the regulator. Ensure good electrical contact beween generator earth and battery negative,
Operation
With the Iginiton switch turnded "ON", current is supplied via the warning lamp to the "L" terminal of the regulator. Base current is fed to T15 causing it to turn on, current then flows from B+ through the rotor winding via the regulator brushes and the collector emitter junction of T15 to earth completing the circuit. The current in the rotor causes a magnetic field between adjacent poles to be created, this field is rotated and cuts the windings of the stator at right angles inducing a voltage into them. As the speed is increased this induced voltage increases and results in curent being rectified in the 3 phase diode bridge and supplied as DC to the B+ output and hence to the battery. When the voltage at the B+ terminal of the battery reaches around 14.2 volts, this voltage is monitored by the "S" lead and turns the regulator Hybrid base current to T15 OFF removing rotor current, resulting in a decrease in output voltage to below the regulating voltage, T15 base current turns ON and the whole cycle is repeated very rapidly. D38 protects T15 and the regulator against the back voltage developed across the rotor winding when T15 turns OFF. The new generated EP regulators incorporate current limiting in the warning lamp circuit.
Backup Regulation
The EP regulator will limit the output voltage to a safe level should either the main B+ cable or the battery sense wire become decoupled, the output voltage will be slightly above the normal setting(1-3 volts).
Start up phase
When the Iginition switch is turned on and the engine is not running, the current to the rotor is reduced by switching it on and off at a 50% duty cycle, the frequency is approximately 4 KHz and may be audible at times. This is quite normal, once the engine is started normal regulation commences.
Warning lamp failure

Should the warning lamp fail, the generator will self excite by deriving a small current from the phase connecion allowing the voltage to build up to regulating level. Note: no filed current will flow when the engine is cranking.
Diagnosis
The EP regulator incorporates diagnostics which will illuminate the warning lamp as a result of fault conditions in the generator and external circuitry. These conditions include: 1. An open circuit in the regulator battery sensing wire (S Terninal) 2. An open circuit or excessive voltage drop in the B+ cable. 3. An open circuit in the generator phase connection. 4. Overcharging of the battery. 5. Regulator output stage short circuit. 6. Open circuit rotor. The regulator compares the voltage at B+ with the voltage at the "S" terminal connceted to battery positive. If the voltage differential exceeds a predetermined threshold, the regulator will operate in backup mode to limit the output voltage to a safe level. The warning lamp; will remain illuminated as along as these conditions prevail. Sources of high resistance which will trigger the warning lamp are: a. Poor contact in wiring harness connectors. b. Poor contact between rectifier and regulator. c. High resistance in fusible link assembly. Caution: When bench testing the generator it is important that the warning lamp wattage of 2 watts is not exceeded. Reversal of the "S" and "L" on the regulator will damage the regulator. The correct plug for the regulator is a 9 122 067 011 for the Bosch tye and for the Shinagawa connector the number is X02FW. See appendix 1 for daignostic matrix. Before testing or disassembling the generator please observe the following points. 1. When testing the diodes with AC type testers the RMS. Vlotage output must not exceed 12.0 volts, it is recommended that the stator should be disconnected during this test. 2. Where zener power diodes are used, the breakdown voltage should be tested to ensure all diodes have the same zener voltage. 3. Insulation tests on the rotor and stator should use a voltage not exceeding 110v for a series test lamp. The rectifier must be disconnected from the stator prior to testing. 4. When carrying out repairs to the charging system always disconnected the battery negative first, and reconnect it last.
STARTING AND CHARGING SYSTEM 6D3-13 5. During current output tests please make sure that the ammeter is securely connceted into the charge circuit. 6. Some battery powered timing lights can produce high transient voltages when connected or disconnected. Only disconnect or connect timing lights when the engine is switched off. 7. Make sure the warning lamp circuit is functioning normally before commencing tests. 8. Battery isolation switches must only be operated when the engine is stopped. 9. To protect the charging system when using 240 volt chargers it is recommeneded that the battery is disconnected whilst charging. 10.Due to the very low resistance value of the stator winding it may not be possible to obtain accurate readings without special equipment. 11.12 volts must never be connected to the "L" terminal of the regulator as this will damage the lamp driver circuit. 12.No loads apart from the warning lamp can be connected to the "L" termainal. The "W" terminal is provided for this purpose.
Disassembly
1. Mark the relative positions of the end housings in relation to the stator assembly to aid reassembly. Use a permanent marking pen do not use centre punched as this can cause misalignmnet of the housings. 2. Remove the EP regulator from the slipring end housing by removing the two screws. Tilt the regulator slightly from the plug connection until the regulator clears the housing, then lift clear. 3. Remove the four through bolts. 4. Carefully remove the stator assembly along with the slipring end housing taking care not to put strain on the stator wires. 5. To disconnect the stator from the rectifier assembly, grasp the stator wires close to the wire loop with a pair of long nosed pliers, heat the joint with a soldering iron, when the point becomes plastic apply a slight twisting motion to the wires, then pull upwards to release the wires. Remove the stator. This procedure opens the wire loop to release the stator connections easily. 6. To remove the rectifier remove the three retaining screw and the B+ terminal nut and washers. Note: the B+ bolt and the positive heatsink retaining screw are fitted with mica insulating washers. These must be discarded and replaced with new washers and heatsink compound.
6D3-14 STARTING AND CHARGING SYSTEM 7. To remove the pulley, mount an 8mm Allen key in the vice with the short end upwards, place a 24mm ring spanner on the puley nut, position the internal hexagon of the rotor shaft onto the Allen ken, loosen the nut and remove the pulley. Note: the pulley has an integral boss which locks up against the bearing, therefore no thrust collar is provided. 8. Removing the rotor assembly. Remove the four retaining screws from the drive end housing, withdraw the rotor complete with the bearing. Note: the rotor must not be pressed from the drive end housing using a press as the bearing retaining plate and drive end housing will be damaged or distorted. Parts removed in this way must be replaced if the integrity of the generator is to be maintained. 9. Remove the drive end bearing from the rotor shaft using a chuck type puler, take care not to distort the fan assembly during this process. 10.Remove the slipring end bearing using the same meghod as in 9.
Clean
Thoroughly clean all components except the rotor and stator with an approved cleaning agent. Ensure that all traced of oil and dirt are removed. If an abrasive cleaner is used to remove scale and paint from the housings take care not to abrade the bearing and mounting spigot surfaces. The rotor and stator must be cleaned with compressed air only, the use of solvents could cause damage to the insulating materials.
Inspection
1. Rectifier assembly The following test equipment is required. The recitifier assembly is not repairable and must be replaced if a faulty diode is detected during inspection. (a) Adiode tester where the DC output at the test probes does not exceed 14 volts or in the case of AC testers 12 volts RMS. This is to ensue that when inspection rectifiers fitted with zener power diodes the forward and reverse checks are completer and are not masked by the diode turning on due to the zener breakdown voltage. (b) A zenere diode tester with a DC output in excess of 30 volts, the tester should also incorporate internal current limiting set to 5 Ma. to prevent high currents during inspection. (c) Diodes can be destroyed during service due to high temperature and overload, open circuits are usually a result of excessive voltage.
6 diode
Diode connections Stator connection D
8 diode
B+Bolt H
Negative heatsink A Starpoint F
Positive heatsink
1.1
Power Diodes.
Apply the negative test probe of the diode tester or a multimeter with a diode test feature to the positive heatsink and the positive probe alternatevely to A,B,C, a low resistance reading, or the forward voltage drop across the diode shoud be obtained. Reverse the test probes, a high resistance reading or a higher reverse voltage should be obtained. Now connect the positive test probe to the negative heatsink and the negative alternatively to D,E,F, a low resistance or forward voltage drop across the diode should be obtained. Reverse the test probes, a high resistance reading or a higher reverse voltage should be obtained. For 8 diode rectifier plates tests for G and H should be included. When the reverse voltage test is done the applied voltage should be less than 14 volts DC or 12 volts RMS for AC testers. 1.2 Zener Diode
The basic tests in 1.1 should be undertaken first before the diode zener voltage is tested. Diodes are grouped together according to their zener voltag i.e. all diodes within a rectifier must have the same zener voltage. Connect the test probes as for the reverese test listed above i.e. reverse biased apply the test voltage form the zener diode tester (current limited to 5ma) and read to zener breakdown voltage this should be a steady reading and not increase with increased voltage from the tester.
Readings for Zener diode groups 011 to 042

Zener voltage at 5Ma. 17.8v-19.2v 18.8v-20.2v 19.8v-21.2v 20.8v-22.2v 21.8v-23.2v 22.8v-24.2v 17.8v-19.2v 18.8v-20.2v 19.8v-21.2v 20.8v-22.2v 21.8v-23.2v 22.8v-24.2v Positive diode 011 013 015 017 019 021 031 033 035 037 039 041 Negative diode 012 014 016 018 020 022 032 034 036 038 040 042 Fordward current Rating 25A 25A 25A 25A 25A 25A 35A 35A 35A 35A 35A 35A
Note: Diode number is stamped on the rear of the diode. 2. Stator Inspect the stator insulation resistance to ground with an insuation tester or a series test lamp up to 110 volts. The insulation resistance must be greater than 1 megohm. The winding reisistance is measured between phases using a low reading ohmmeter designed for this purpose, the values are given at the rear of this instruction. 3. Rotor Inspect the rotor for insulation resistance to ground using an insulation tester or a series test lamp up to 110 volts. The insulation resistance must be grater than 1 megohm. Measure the rotor resistance between the sliprings using an ohmmeter or apply 12 volts across the sliprings and measure the rotor current flow, then divide 12 by the measured current, the results is the rotor resistance in ohms. values are given at the rear of this instruction. If the sliprings are worn or out of round they must be remachined to a minimum diameter or 26.7 mm and should have a runout not exceeding 0.060mm. If the slipring is below these limits it must be replaced with a new one. Warning; extreme care must be exercised when machining the slipring as it is possible for the turning tool to foul the
STARTING AND CHARGING SYSTEM 6D3-17 fan. 4. Replacing the brushes (inbuilt regulator) Check the brushes for length, this is measured from the brush holder to the end of the brush along it's centre line. Also inspect for any sideways wear. If worn replace both brushes. The minimum length is 3.8mm. Inspect the brush springs for signs of corrosion or loss of tension or uneven tension. Replacing the brushes, using a soldering iron apply heat to the soldered joints on the rear of the brush holder of the regulator, using a small lever prise up the retaining tabs to release the brush lead and spring. Thread the new brush lead up the brush holder along with the spring, pull the lead through the tabs until the brush is protruding 12mm from the holder. Bend down the tabs and solder the brush lead taking care not to allow the solder to run up the lead which will reduce flexibility. Use 60/40 resin cored solder. 5. Ball bearing Please note the bearings used in this KCA generator are a high tolerance type, only fully sealed bearings of the same specification are to be used as replacements. It is recommended that the bearings be replaced during the reconditioning process to restore the unit to original specification. 6. Regulator The regulator can only be tested when fitted into an altenator. Warning: do not reverse"S" and "L" connections or put 12 volt supply to "L" terminal, this connection must not be used as a supply source other than to supply the requirements of the warning lamp 2(watts). Such action will destroy the regulator warning lamp circuit. For test voltages refer to Generator output testing section. See also additional information on regulator function earlier in this instruction.
Reassembly Generator
(a) Press new bearing onto slipring end of the rotor taking care to aplly the force to the bearing inner race only, otherwise the bearing will be noisy and it's life will be shortened. (b) Fit a new bearing to the drive end housing, fit the bearing plate, and four retaining screws, press the rotor into the bearing, using a support tool to take the thrust against the bearing inner. The support is fitted from the pulley side of the bearing. In this way the thrust is not taken by the drive end housing. (c) To fit pulley, mount an 8mm Allen key in the vice with the short end upwards, place a 24mm ring spanner on the shaft nut, position the internal hexagon of the rotor shaft onto the Allen key, tighten the nut to the required torque(See torque chart) (d) Inspect the bearing support ring for signs of damage, if in doubt replace the ring by pressing it into the housing by hand, do not use excessive force. (e) To refit the rectifier, fit new mica washers to the positive heatsink B+ bolt and retaining screw each washer must have heatsink compound applied to both surfaces before fitting. Fit the three retaining screws to the rectifier then install into slipring end housing. Tighten the B+ bolt to the reuired torque. (f) To refit the stator, make sure the spigot surface are clean and free from damage, fit the stator into the slipring end housing noting the correct lead connection positioning. Fit the stator leads into the wire loops in the recrifier. Using a pair of pliers squeeze the loop to retain the stator lead prior to soldering. Repeat for each lead in turn, solder the leads into position using 60/40 resin cored solder. Make sure the leads will be clear of the internal fan when the rotor is assmebled into the stator. (g) Carefully install the rotor into the stator/slipring end housing assembly, noting the alignment of the housings and through bolt holes. Fit the through bolts making sure the stator is seated correctly, tighten the through bolts to the correct torque setting (uneven torque can produce magnetic noise levels above normal). (h) Fitting the regulator. Compress the brushes into the brush holder by hand, slip the regulator through the opening in the rear of the slipring end housing until the brushes come in contact with the slipring. Press the regulator towards the slipring until the holes are aligned then fit the retaining screws and tighten.
Inspection Generator
Before any in field testing can be undertaken it is important that the battery's conditions is established and the terminals are clean and tight. Check the condition of the generator drive belt and ensure that it is adjusted in accordance with the engine manufacturer's recommnedations. Battery conditions: Note: This assessment may be difficult with maintenance free assemblies. Test the specific gravity of the individual cells the readings should be within 10 points of each other, it is recommended that the average SG should be 1.260 or higher. A load test should be carried out to determine the ability of the battery to supply and accept current. This is a good indicator as to the general condition of the battery. A load equal to the normal starting current should be placed across the battery, the duration of this load test should not exceed 10 seconds, during this time the terminal voltage across the battery should not drop below 9.6 volts. Observe each cell for signs of excessive gas liberation, usuall an indication of cell failure. If the battery test is clear proceed with the Generator tests as follows. Care should be taken when making the following connections. It is recommended that the battery negative terminal be disconnected before the test meters are connected, and reconnecting the negative terminal when the meters are inserted into the circuit under test. The warning lamp in the D+ circuit should not exceed 2 watts.
Regulating voltage test on the vehicle.

Connect a voltmeter to the generator, the positive lead to the B+ terminal and the nagative lead to the generator casing. Select the voltage range to suit the system, i.e. 20v for 12 volt sysytems or 40v for 24 volt systems. Connect an ammeter in series with the main output cable from the B+ terminal on the generator, the range selected must be capable of reading the maximum output from the generator. Note the voltmeter reading before starting the engine. This reading should increase when the engine is running indicating generator output, start the engine and increase the engine speed until the generator is running at 4000 rpm, switch on vehicle loads of 5-10 A is indcated on the ammeter, the voltmeter shoud read 14.0-14.2 v for a 12 volt system, for a 24 volt system the readings should be 5-10 A and 27.7-28.5 volts.
Load regulation test

Increase the engine speed until the generator is running at 6000 rpm, increase the load to 90% of full output a decrease in the regulating voltage should not exceed 0.50 volts for 12 v and 0.70 v for 24 v regulators of the readings obtained in the previous test. If so, the regulator is defective.
Generator output test at full load

Increase engine speed until the altenator is running at 6000 rpm, switch on electrical loads until the generator voltage drops to 13.5 volts for 12 v systems and 26 volts for 24 v systems, full outut should be obtained under these conditions. It may be necessary to adjust engine speed to maintain altenator speed. If sufficient electrical loads are not available a carbon pile resistance can be connected across the battery and adjusted until maximum output is obtained. Keep the time for this test to a minimum to avoid undue heating and high engine speeds.
Technical Data
(mm) Brush wear Sliprings Sliprings Pole claws Torque N.m(kgf m) Pulley retaining nut Capacitor retaining screw Capacitor whiz nut B+ terminal nut M8 B+ terminal rectifier nut Regulator retaining screw Rectifier retaining screw Bearing retaining plate screw Through bolt 54-68(5.5-6.9) 2.7-3.8(0.3-0.4) 1.5-2.2(0.1-0.2) 7.5-8.5(0.8-0.9) 6.0-7.5(0.6-0.8) 1.6-2.3(0.1-0.2) 1.6-2.3(0.1-0.2) 2.1-3.0(0.2-0.3) 3.8-5.5(0.4-0.6) (9) 70 Amp generator 85 Amp generator 90 Amp generator Stator 0.086+10% 2.6 0.13 0.058+10% 2.6 0.13 0.056+10% 2.6 0.13 Rotor Minimum Length 3.8 Minimum Diameter 26.7 Trueness <0.06 Trueness <0.05(93.25 0.05)
Winding resistance(between phases)
Warning lamp fault indication
Fault running
Generator not running Ignition ON ON ON ON OFF ON ON ON ON ON OFF
Generator Iginiton ON ON ON ON ON ON OFF OFF ON ON OFF
Generator out cable O/C Battery "S" cable O/C Battery overcharged Positive diode short Negative diode short Positive diode open Negative diode open Phase voltage sensing cable open circuit Power transistor shorted Warnign lamp driver O/C
6D3-22 STARTING AND CHARGING SYSTEM Output wave forms for phase and startpoint connections. Note; the average of these two waveforms are identical from no load to 100% output of rated load. Voltage phase = Voltage startpoint 6.9v@ rated output
7.2v@ Zero output
Note: The phase frequency is one third of the startpoint frequency.
ENGINE DRIVEABILITY AND EMISSIONS
6E1
ENGINE
C24SE ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATIONS CHARTS ......................... ECM Circuit Diagram (1/2) ............................ ECM Circuit Diagram (2/2) ............................ GROUND POINT CHART - LHD G.EXP (1/4) GROUND POINT CHART - RHD G.EXP (1/4) LOCATION ................................................... CABLE HARNESS & CONNECTOR LOCATION .............................................. CABLE HARNESS & CONNECTOR LOCATION LHD ................................... CABLE HARNESS & CONNECTOR LOCATION RHD ................................... CONNECTOR LIST ...................................... RELAY AND FUSE ....................................... RELAY AND FUSE BOX LOCATION (LHD & RHD) ........................................... FUSE AND RELAY LOCATION (LHD & RHD) ECM WIRING DIAGRAM (1/9) ..................... ECM WIRING DIAGRAM (2/9) ..................... ECM WIRING DIAGRAM (3/9) ..................... ECM WIRING DIAGRAM (4/9) ..................... ECM WIRING DIAGRAM (5/9) ..................... ECM WIRING DIAGRAM (6/9) ..................... ECM WIRING DIAGRAM (7/9) ..................... ECM WIRING DIAGRAM (8/9) ..................... ECM WIRING DIAGRAM (9/9) ..................... ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL .................................... GENERAL DESCRIPTION FOR ECM AND SENSORS ............................................... Engine Control Module (ECM) ................... Manifold Absolute Pressure (MAP) Sensor Throttle Position Sensor (TPS) .................. Idle Air Control (IAC) Valve ....................... Crankshaft Position (CKP) Sensor ............ Knock Sensor (KS) .................................... Engine Coolant Temperature (ECT) Sensor Intake Air Temperature (IAT) Sensor ........ Vehicle Speed Sensor (VSS) .................... Heated Oxygen (O2) Sensor ..................... GENERAL DESCRIPTION FOR FUEL METERING .............................................. 6E-6 6E-11 6E-12 6E-13 6E-17 6E-21 6E-23 6E-24 6E-25 6E-28 6E-30 6E-30 6E-32 6E-33 6E-34 6E-35 6E-36 6E-37 6E-38 6E-39 6E-40 6E-41 6E-42 6E-48 6E-48 6E-48 6E-49 6E-49 6E-50 6E-50 6E-50 6E-51 6E-51 6E-51 6E-52 Battery Voltage Correction Mode ............... Clear Flood Mode ...................................... Deceleration Fuel Cutoff (DFCO) Mode .... Engine Speed/ Vehicle Speed/ Fuel Disable Mode ........................................................ Acceleration Mode ..................................... Fuel Cutoff Mode ....................................... Starting Mode ............................................ Run Mode .................................................. Fuel Metering System Components .......... Fuel Injector ............................................... Fuel Pressure Regulator ............................ Fuel Rail ..................................................... Fuel Pump Electrical Circuit ....................... Thottle Body Unit ....................................... GENERAL DESCRIPTION FOR ELECTRIC IGNITION SYSTEM ................................. Spark Plug ................................................. GENERAL DESCRIPTION FOR EVAPORATIVE EMISSION SYSTEM ............................... EVAP Emission Control System Purpose .. EVAP Emission Control System Operation System Fault Detection .............................. POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM .................................................. Crankcase Ventilation System Purpose .... A/C CLUTCH DIAGNOSIS ........................ A/C Clutch Circuit Operation ...................... A/C Clutch Circuit Purpose ........................ A/C Request Signal ................................... ISUZU STRATEGY BASED DIAGNOSTICS Overview .................................................... STRATEGY BASED DIAGNOSTICS CHART Diagnostic Thought Process ...................... 1. Verify the Complaint .............................. 2. Perform Preliminary Checks .................. 3. Check Bulletins and Troubleshooting Hints 4. Perform Service Manual Diagnostic Checks 5a and 5b. Perform Service Manual Diagnostic Procedures .............................................. 5c. Technician Self Diagnoses .................. 5d. Intermittent Diagnosis .......................... 6E-52 6E-52 6E-52 6E-52 6E-52 6E-52 6E-52 6E-52 6E-53 6E-53 6E-53 6E-53 6E-53 6E-53 6E-54 6E-54 6E-57 6E-57 6E-57 6E-57 6E-59 6E-59 6E-60 6E-60 6E-60 6E-60 6E-61 6E-61 6E-61 6E-62 6E-62 6E-62 6E-63 6E-63 6E-63 6E-63 6E-64
6E2

Fuel Pressure Relief Procedure ................. 6E-104 Fuel Pressure Gauge Installation .............. 6E-104 Fuel System Electrical Test ....................... 6E-104 FUEL SYSTEM DIAGNOSIS ........................ 6E-108 Circuit Description ...................................... 6E-108 Test Description ......................................... 6E-108 Fuel Pressure Relief Procedure ................. 6E-109 Fuel Pressure Gauge Installation .............. 6E-109 Fuel System Diagnosis .............................. 6E-110 ECM DIAGNOSTIC TROUBLE CODES (DTC) 6E-113 DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE CIRCUIT LOW INPUT ................................ 6E-119 Circuit Description ...................................... 6E-119 Diagnostic Aids .......................................... 6E-119 Diagnostic Trouble Code (DTC) P0107 Manifold Absolute Pressure Circuit Low Input ......................................................... 6E-120 DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE CIRCUIT HIGH INPUT ............................... 6E-123 Circuit Description ...................................... 6E-123 Diagnostic Aids .......................................... 6E-124 Diagnostic Trouble Code (DTC) P0108 Manifold Absolute Pressure Circuit High Input ......................................................... 6E-124 DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE SENSOR LOW INPUT ......................................................... 6E-127 Circuit Description ...................................... 6E-127 Diagnostic Aids .......................................... 6E-127 Diagnostic Trouble Code (DTC) P0112 Intake Air Temperature Sensor Low Input 6E-128 DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE SENSOR HIGH INPUT ......................................................... 6E-131 Circuit Description ...................................... 6E-131 Diagnostic Aids .......................................... 6E-131 Diagnostic Trouble Code (DTC) P0113 Intake Air Temperature Sensor High Input 6E-132 DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE SENSOR LOW INPUT ................................ 6E-136 Circuit Description ...................................... 6E-136 Diagnostic Aids .......................................... 6E-136 Diagnostic Trouble Code (DTC) P0117 Engine Coolant Temperature Sensor Low Input ......................................................... 6E-137 DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE SENSOR HIGH INPUT ............................... 6E-139 Circuit Description ...................................... 6E-139
5e. Vehicle Operates as Designed ............ 6E-65 6. Re-examine the complaint ..................... 6E-66 7. Repair and Verify Fix ............................. 6E-66 GENERAL SERVICE INFORMATION .......... 6E-67 On-Board Diagnostic (OBD) ...................... 6E-68 On-Board Diagnostic Tests ....................... 6E-68 The Diagnostic Executive .......................... 6E-68 Diagnostic Information ............................... 6E-68 Check Engine Lamp .................................. 6E-68 Data Link Connector (DLC) ....................... 6E-68 Tech 2 Operating Flow Cart (Start Up) ...... 6E-70 TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA) ......................................... 6E-72 TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA) .................................. 6E-74 MISCELLANEOUS TEST ............................. 6E-76 PLOTTING SNAPSHOT GRAPH ................. 6E-78 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) .................. 6E-79 Flow Chart for Snapshot Replay (Plotting Graph) ....................................... 6E-80 SNAPSHOT DISPLAY WITH TIS2000 ......... 6E-81 ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK 6E-98 Circuit Description ......................................... 6E-90 Diagnostic Aids ............................................. 6E-90 Test Description ............................................ 6E-90 ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK .................................................... 6E-91 NO CHECK ENGINE LAMP (MIL) ................ 6E-94 Circuit Description ..................................... 6E-94 Diagnostic Aids .......................................... 6E-94 No Check Engine Lamp (MIL) ................... 6E-94 CHECK ENGINE LAMP (MIL) ON STEADY 6E-96 Circuit description ...................................... 6E-96 Diagnostic Aids .......................................... 6E-96 Check Engine Lamp (MIL) ON Steady .... 6E-96 FUEL METERING SYSTEM CHECK ........... 6E-98 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE ............................................. 6E-98 Test Description ......................................... 6E-98 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) ............................................. 6E-99 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) ............................................. 6E-100 FUEL SYSTEM ELECTRICAL TEST ........... 6E-103 Circuit Description ..................................... 6E-103 Diagnostic Aids .......................................... 6E-104

Diagnostic Aids .......................................... 6E-139 Diagnostic Trouble Code (DTC) P0118 Engine Coolant Temperature Sensor High Input ......................................................... 6E-140 DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION SENSOR LOW INPUT ......................................................... 6E-143 Circuit Description ..................................... 6E-143 Diagnostic Aids .......................................... 6E-143 Diagnostic Trouble Code (DTC) P0122 Throttle Position Sensor Low Input ....................... 6E-144 DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION SENSOR HIGH INPUT ...................................................... 6E-147 Circuit Description ..................................... 6E-147 Diagnostic Aids .......................................... 6E-147 Diagnostic Trouble Code (DTC) P0123 Throttle Position Sensor High Input ...................... 6E-148 DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) ................................. 6E-150 Circuit Description ..................................... 6E-150 Diagnostic Aids .......................................... 6E-150 Diagnostic Trouble Code (DTC) P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) 6E-160 DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) ................................................ 6E-155 Circuit Description ..................................... 6E-155 Diagnostic Aids .......................................... 6E-155 Diagnostic Trouble Code (DTC) P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) .................................... 6E-156 DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR NO ACTIVITY DEFECTED (BANK 1 SENSOR 1) ................................. 6E-159 Circuit Description ..................................... 6E-159 Diagnostic Aids .......................................... 6E-160 Diagnostic Trouble Code (DTC) P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) .................................... 6E-160 DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT (BANK 1 SENSOR 1) ................................. 6E-163 Circuit Description ..................................... 6E-163 Diagnostic Aids .......................................... 6E-164 Diagnostic Trouble Code (DTC) P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) 6E-164 DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR 1 CONTROL CIRCUIT ............. 6E-167 DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR 2 CONTROL CIRCUIT ............. DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR 3 CONTROL CIRCUIT ............. DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR 4 CONTROL CIRCUIT ............. Circuit Description ...................................... Diagnostic Aids .......................................... Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit .......................... Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit .......................... Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit .......................... Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit .......................... DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) MODULE CIRCUIT Circuit Description ...................................... Diagnostic Aids .......................................... Diagnostic Trouble Code (DTC) P0325 Knock Sensor Module Circuit ............................. DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT ............... Circuit Description ...................................... Diagnostic Aids .......................................... Diagnostic Trouble Code (DTC) P0327 Knock Sensor Circuit ............................... DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE (58X) . DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT (58X) ...................... Circuit Description ...................................... Diagnostic Aids .......................................... Diagnostic Trouble Code (DTC) P0336 Crankshaft Position Sensor Circuit Range/performance (58x) ........................ Diagnostic Trouble Code (DTC) P0337 Crankshaft Position Sensor Circuit Low Input (58x) ............................................... DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION 1 CONTROL CIRCUIT ............... DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION 2 CONTROL CIRCUIT ............... Circuit Description ...................................... Diagnostic Aids .......................................... Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit .......................... Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit ..........................
6E3
6E-167 6E-167 6E-167 6E-167 6E-168 6E-168 6E-168 6E-168 6E-168 6E-174 6E-174 6E-174
6E-174 6E-177 6E-177 6E-177 6E-178
6E-180
6E-180 6E-180 6E-181
6E-181
6E-181 6E-186 6E-186 6E-186 6E-186 6E-187 6E-187
6E4

Fuel Supply System Rich During Deceleration Fuel Cutoff .......................... 6E-212 DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SUPPLY SYSTEM LEAN DURING POWER ENRICHMENT ............................. 6E-214 Circuit Description ...................................... 6E-214 Diagnostic Aids .......................................... 6E-215 Diagnostic Trouble Code (DTC) P1171 Fuel Supply System Lean During Power Enrichment .............................................. 6E-215 DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM SYSTEM RESET ............................... 6E-217 Circuit Description ...................................... 6E-217 Diagnostic Aids .......................................... 6E-217 Diagnostic Trouble Code (DTC) P1625 ECM System Reset .......................................... 6E-217 DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILIZER NO SIGNAL ........................ 6E-218 Circuit Description ...................................... 6E-218 Diagnostic Aids .......................................... 6E-218 Diagnostic Trouble Code (DTC) P1626 Immobilizer No Signal .............................. 6E-219 DIAGNOSTIC TROUBLE CODE (DTC) P1631 IMMOBILIZER WRONG SIGNAL ............... 6E-222 Circuit Description ...................................... 6E-222 Diagnostic Aids .......................................... 6E-222 Diagnostic Trouble Code (DTC) P1631 Immobilizer Wrong Signal ........................ 6E-223 DIAGNOSTIC TROUBLE CODE (DTC) P1648 WRONG SECURITY CODE ENTERED .. 6E-224 Circuit Description ...................................... 6E-224 Diagnostic Aids .......................................... 6E-224 Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered ............................ 6E-225 DIAGNOSTIC TROUBLE CODE (DTC) P1649 IMMOBILIZER FUNCTION NOT PROGRAMMED ......................................... 6E-226 Circuit Description ...................................... 6E-226 Diagnostic Aids .......................................... 6E-226 Diagnostic Trouble Code (DTC) P1649 Immobilizer Function Not Programmed ... 6E-227 DIAGNOSTIC TROUBLE CODE (DTC) P1693 TACHOMETER OUTPUT LOW VOLTAGE 6E-228 Circuit Description ...................................... 6E-228 Diagnostic Aids .......................................... 6E-228 Diagnostic Trouble Code (DTC) P1693 Tachometer Output Low Voltage ............. 6E-229 SYMPTOM DIAGNOSIS ............................... 6E-232 PRELIMINARY CHECKS ............................. 6E-232 VISUAL/PHYSICAL CHECK ......................... 6E-232 INTERMITTENT ........................................... 6E-232
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM PURGE CONTROL CIRCUIT ..... 6E-191 Circuit Description ..................................... 6E-191 Diagnostic Aids .......................................... 6E-191 Diagnostic Trouble Code (DTC) P0443 EVAP Emission Control System Purge Control Circuit .......................................... 6E-192 DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT ................................................ 6E-195 Circuit Description ..................................... 6E-195 Diagnostic Aids .......................................... 6E-195 Diagnostic Trouble Code (DTC) P0502 Vehicle Speed Sensor Circuit Low Input . 6E-196 DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW .......................... 6E-202 Circuit Description ..................................... 6E-202 Diagnostic Aids .......................................... 6E-202 Diagnostic Trouble Code (DTC) P0562 System Voltage Low ............................................. 6E-202 DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH ......................... 6E-204 Circuit Description ..................................... 6E-204 Diagnostic Aids .......................................... 6E-204 Diagnostic Trouble Code (DTC) P0563 System Voltage High ............................................ 6E-204 DIAGNOSTIC TROUBLE CODE (DTC) P0601 ECM MEMORY CHECKSUM ..................... 6E-206 Circuit Description ..................................... 6E-206 Diagnostic Aids .......................................... 6E-206 Diagnostic Trouble Code (DTC) P0601 ECM Memory Checksum .................................. 6E-206 DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR ................. 6E-207 Circuit Description ..................................... 6E-207 Diagnostic Aids .......................................... 6E-207 Diagnostic Trouble Code (DTC) P0602 ECU Programming Error .................................. 6E-207 DTC P0650 MALFUNCTION INDICATOR LAMP (MIL) CONTOROL CIRCUIT MALFUNCTION 6E-208 Circuit Description ..................................... 6E-208 Diagnostic Aids .......................................... 6E-208 Diagnostic Trouble Code (DTC) P0650 Malfunction Indicator Lamp (MIL) Control Circuit Malfunction ................................... 6E-209 DIAGNOSTIC TROUBLE CODE (DTC) P1167 FUEL SUPPLY SYSTEM RICH DURING DECELERATION FUEL CUT OFF ............. 6E-211 Circuit Description ..................................... 6E-211 Diagnostic Aids .......................................... 6E-211 Diagnostic Trouble Code (DTC) P1167

ENGINE CRANKS BUT WILL NOT RUN ..... HARD START SYMPTOM ............................ ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM ............................... SURGES AND/OR CHUGS SYMPTOM ...... HESITATION, SAG, STUMBLE SYMPTOM CUTS OUT, MISSES SYMPTOM ................. LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM ................................................. DETONATION/SPARK KNOCK SYMPTOM POOR FUEL ECONOMY SYMPTOM .......... EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM ................................... DIESELING, RUN-ON SYMPTOM ............... BACKFIRE SYMPTOM ................................. ON-VEHICLE SERVICE PROCEDURE ....... ENGINE CONTROL MODULE (ECM) .......... CRANKSHAFT POSITION (CKP) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR .................................................... INTAKE AIR TEMPERATURE (IAT) SENSOR MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR .................................................... THROTTLE POSITION SENSOR (TPS) ...... IDLE AIR CONTROL (IAC) VALVE .............. KNOCK SENSOR ......................................... POWER STEERING PRESSURE (PSP) SWITCH ..................................................... HEATED OXYGEN SENSOR (HO2S) ......... EVAP CANISTER PURGE VALVE SOLENOID FUEL PRESSURE RELIEF .......................... FUEL RAIL ASSEMBLY ............................... FUEL INJECTOR .......................................... FUEL PRESSURE REGULATOR ................ IGNITION COIL ............................................ SPARK PLUGS ............................................ SPARK PLUG CABLES ................................ EMISSION CONTROL ; CO ADJUSTER (W/O CATALYSTIC CONVERTER) .................. SPECIAL SERVICE TOOLS ......................... 6E-233 6E-236 6E-239 6E-242 6E-245 6E-248 6E-251 6E-254 6E-256 6E-258 6E-261 6E-262 6E-264 6E-264 6E-264 6E-265 6E-265 6E-266 6E-266 6E-267 6E-268 6E-268 6E-269 6E-269 6E-270 6E-270 6E-271 6E-273 6E-275 6E-275 6E-277 6E-277 6E-279
6E5
6E6
ABBREVIATIONS CHARTS
Abbreviations A/C A/T ACC BLK BLU BRN CEL CKP DLC DTC DVM ECM ECT EEPROM EVAP EVRV EXH FT GND GRY HOS2 IAC IAT IG ITP KS M/T MAP MIL OBD ORN OT PNK RED SW TB TEMP TP VCC VSS WHT YEL Air Conditioner Automatic Transmission Accessory Black Blue Brown Check Engine Lamp Crankshaft Position Data Link Connector Diagnostic Trouble Code Digital Volt Meter Engine Control Module Engine Coolant Temperature Electrically Erasable & Programmable Read Only Memory Evaporative Emission Electric Vacuum Regulating Valve Exhaust Fuel Temperature Ground Gray Heated Oxygen Sensor Idel Air Control Intake Air Temperature Ignition Intake Throttle Position Knock Sensor Manual Transmission Manifold Absolute Pressure Malfunction Indicator Lamp On-Board Diagnostic Orange Oil Temperature Pink Red Switch Throttle Body Temperature Throttle Position Voltage Constant Control Vehicle Speed Sensor White Yellow Appellation
6E7
COMPONENT LOCATORt
2 4
(1) Air Cleaner (2) Idle Air Control (IAC) Valve
(3) Engine Coolant Temperature (ECT) Sensor (4) Engine Control Module (ECM)
(1) Intake Air Temperature (IAT) Sensor (2) Idle Air Control (IAC) Valve (3) Throttle Position Sensor (TPS)
6E8
(1) Injector #1 Cylinder (2) Injector #2 Cylinder
(3) Injector #3 Cylinder (4) Injector #4 Cylinder (Under the ECM)
(1) Ignition Coil Module Assembly
(1) Heated Oxygen Sensor (HO2S)
6E9
(1) Crankshaft Position (CKP) Sensor
(1) Knock Sensor (KS)
(1) Engine Coolant Temperature (ECT) Sensor (2) Thermo Meter Sensor
(1) Manifold Absolute Pressure (MAP) Sensor
(1) Throttle Position Sensor (2) Idle Air Control (IAC) Valve
(1) EVAP Purge Solenoid
6E10
(1) Canister
(1) Fuel Tank (2) Fuel Pump
(1) Vehicle Speed Sensor (VSS) (2) Transmission Assembly
(1) Power Steering Pressure Switch (2) Power Steering Oil Pump Assembly
6E11
ECM Circuit Diagram (1/2)
6E12
ECM Circuit Diagram (2/2)
ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART - LHD GENERAL EXPORT (1/4)
6E13
6E14
GROUND POINT CHART - LHD GENERAL EXPORT (2/4)
ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART - LHD GENERAL EXPORT (3/4)
6E15
6E16
GROUND POINT CHART - LHD GENERAL EXPORT (4/4)
ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART - RHD GENERAL EXPORT (1/4)
6E17
6E18
GROUND POINT CHART - RHD GENERAL EXPORT (2/4)
ENGINE DRIVEABILITY AND EMISSIONS GROUND POINT CHART - RHD GENERAL EXPORT (3/4)
6E19
6E20
GROUND POINT CHART - RHD GENERAL EXPORT (4/4)
ENGINE DRIVEABILITY AND EMISSIONS LOCATION
6E21
6E22
ENGINE DRIVEABILITY AND EMISSIONS CABLE HARNESS & CONNECTOR LOCATION
6E23
6E24
ENGINE DRIVEABILITY AND EMISSIONS CABLE HARNESS & CONNECTOR LOCATION LHD
ENGINE DRIVEABILITY AND EMISSIONS CABLE HARNESS & CONNECTOR LOCATION RHD
6E25
6E26
6E27
6E28
CONNECTOR LIST
No. B-24 Connector face No. C-122 Connector face
Green B-58
Meter-B E-6
CO Adjuster
Black B-62
Check connector E-7
Fuel injector
White B-63
Ignition switch (IGSUB : G1) E-8
Fuel injector
White B-68
Ignition switch (IGSUB : G2) E-9
Fuel injector
Immobilizer C-2 E-18
Fuel injector
Silver C-56
Engine room-RH ground E-60
Ignition coil
ECM C-107 E-72
ECM
White C-108
J/B E2 E-74
Engine earth-A
White C-121
J/B E1 E-77
Engine earth-B
IAT sensor
O2 sensor
6E29
No. E-84
Connector face
No. P-1
Connector face
Knock sensor E-85
Silver P-2
Battery (+)
MAP sensor F-2
Silver P-5
Relay & Fuse box
White H-4
Fuel pump & sensor
Silver P-6
Battery (-)
White H-6
Engine room ~ Mission
Silver P-10
Body earth (Ground)
White H-7
Engine room ~ INST
Silver X-2
Engine ground
White H-9
Engine room ~ INST
Black X-11
Relay; Fuel pump
Blue H-18
Engine room ~ Chassis
Black X-14
Relay; Heater
White H-31
Engine room ~ INST
Black
Relay; A/C Compressor
Engine room ~ Mission H-34
Engine ~ Engine room
6E30
ENGINE DRIVEABILITY AND EMISSIONS RELAY AND FUSE
RELAY AND FUSE BOX LOCATION (LHD & RHD)
LHD
RHD

RELAY AND FUSE BOX LOCATION (LHD & RHD) RELAY & FUSE BOX RELAY No. X-1 X-2 X-3 X-4 X-5 X-6 X-7 X-8 X-9 X-10 X-11 X-12 X-13 X-14 X-15 FUSE NO. EB-1 EB-2 EB-3 EB-4 EB-5 EB-6 EB-7 EB-8
6E31
Relay Name RELAY; TAIL LIGHT RELAY; FUEL PUMP RELAY; HORN RELAY; DIMMER RELAY; FRT FOG LIGHT (LHD only) RELAY; STARTER RELAY; COND, FAN RELAY; HEATER RELAY; HEAD LIGHT RELAY; A/C COMP RELAY; THERMO Fuse Name 15A ECM 15A FRT FOG 15A ACG (S) 10A ILLUMI 10A TAIL 10A H/LIGHT-RH 10A H/LIGHT-RH-LOW 10A H/LIGHT-LH 10A H/LIGHT-LH-LOW (LHD only) 20A FUEL PUMP 10A O2 SENSOR 10A H/LIGHT-RHHIGH (LHD only) 10A H/LIGHT-LHHIGH (LHD only) 10A A/C 10A HORN 10A HAZARD
EB-9 EB-10 EB-11 EB-12 EB-13 EB-14 EB-15 EB-16 SLOW BLOW FUSE NO. SBF-1 SBF-2 SBF-3 SBF-4 SBF-5 40A IG 1 Slow Blow Fuse Name 100A MAIN 20A COND, FAN FUSE NO. SBF-6 SBF-7 SBF-8 SBF-9
Slow Blow Fuse Name 30A BLOWER 50A IG 2
6E32
FUSE AND RELAY LOCATION (LHD & RHD) FUSE BOX
FUSE No. 1 2 3 4 5 6 7 8 9 10 11
Capacity 10A 10A 15A 15A 10A 15A 15A 20A 15A 10A
Indication on label ABS TRAILER BACK UP METER TURN ELEC.IG ENGINE FRT WIPER EGR AUDIO Indication on label RR DEF POWER WINDOW
No. 12 13 14 15 16 17 18 19 20 21
Capacity 15A 15A 20A 10A 10A 10A 15A 15A 10A 10A
Indication on label CIGER AUDIO (+B) DOOR LOCK METER (+B) ROOM ANTI THEFT STOP ACC SOCKET STARTER SRS
SLOW BLOW FUSE No. Capacity 22 20A 23 30A RELAY Connector No. C24SE
B-7 REAR DEFOGGER
B-8 POWER WINDOW
B-40 ACC SOCKET
ENGINE DRIVEABILITY AND EMISSIONS ECM WIRING DIAGRAM (1/9)
6E33
6E34
ECM WIRING DIAGRAM (2/9)
6E35
6E36
6E37
6E38
6E39
6E40
6E41
6E42
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

Connector J1 Port: View Looking Into ECM Case
PIN1 PIN16
1 17
16 32
PIN32
PIN17
Pin No. J1-1
B/ Box No. J1-1
Pin Function Ground
Wire Color BLK/ WHT BLK/ WHT YEL RED/ YEL RED BLU
Signal or Continuity Key SW Off Continuity with ground Continuity with ground Less than 1V Less than 1V Approx. 0.58k Less than 1V Less than 1V Less than 1V Less than 1V Less than 1V Less than 1V Continuity with ground Continuity with ground Approx 0.7V Key SW On Engine Idle Engine 2000rpm -
ECM Connection Disconnect
Tester Position Range 9 (+) J1-1 (-) GND
J1-2
J1-2
Ground
Disconnect
J1-2
GND
J1-3 J1-4 J1-5 J1-6 J1-7
J1-3 J1-4 J1-5 J1-6 J1-7
Knock Sensor Signal No Connection Canister Purge Solenoid Valve Crankshaft Position (CKP) Sensor (Ground) Throttle Position Sensor (TPS) Output Signal No. 3 Injector No. 1 Injector No Connection No. 4 Injector No Connection Idle Air Control Valve (IACV) Coil B High No Connection Throttle Position Sensor (TPS) Power Supply MAP Sensor Ground
Wave form G or 12-14V -
Connect
DC V 9 DC V
J1-5 J1-6 J1-7
GND J1-21 J1-32
Approx 0.8V
Disconnect Connect
J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15
J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15
GRN/ BLK GRN/ WHT GRN BLU/ RED RED
Wave form E or 12-14V Wave form E or 12-14V Wave form E or 12-14V Less than 1V / 10-14V Approx. 5V -
Connect Connect Connect Connect Connect
DC V DC V DC V DC V DC V
J1-8 J1-9 J1-11 J1-13 J1-15
GND GND GND GND J1-32
J1-16
J1-16
GRN
Connect
J1-16
GND
J1-17
J1-17
Ground
BLK/ WHT BLU GRN -
Connect
J1-17
GND
J1-18 J1-19 J1-20
J1-18 J1-19 J1-20
Coil Module 2 (No. 2 & 3 Cylinder) Coil Module 1 (No. 1 & 4 Cylinder) No Connection
Wave form F Wave form F -

Pin No. J1-21 B/ Box No. J1-21 Pin Function Crankshaft Position (CKP) Sensor Signal Wire Color WHT Signal or Continuity Key SW Off Key SW On Engine Idle Wave form or approx. 3.7V Engine 2000rpm Wave form A or approx. 7.8V ECM Connection Connect
6E43
Tester Position Range AC V (+) J1-21 (-) J1-6
J1-22 J1-23 J1-24 J1-25 J1-26 J1-27
J1-22 J1-23 J1-24 J1-25 J1-26 J1-27
No.2 Injector No Connection MAP Sensor Signal No Connection No Connection Engine Coolant Temp. (ECT) Sensor Signal Idle Air Control Valve (IACV) Coil A High Idle Air Control Valve (IACV) Coil B Low Idle Air Control Valve (IACV) Coil A Low MAP Sensor Power Supply ECT Sensor, Knock Sensor, Throttle Position Sensor Ground
GRN/ WHT GRY GRY
Less than 1V Less than 1V Less than 1V Less than 1V Less than 1V Less than 1V Less than 1V Continuity with ground -
Wave form E or 12-14V Approx. 1.3V Approx. 0.9V -
Connect Connect Connect
DC V DC V DC V
J1-22 J1-24 J1-26 J1-27
GND J1-16 J1-32
Approx. 4.8V -
20 : Approx. 2.4V / 40 : Approx. 1.4V or 4.1V / 60 : Approx. 3.3V / 80 : Approx. 2.5V
J1-28 J1-29 J1-30 J1-31 J1-32
J1-28 J1-29 J1-30 J1-31 J1-32
BLU BLU/ BLK BLU/ WHT RED GRN
Less than 1V / 10-14V Less than 1V / 10-14V Less than 1V / 10-14V Approx.. 5V -
Connect Connect Connect Connect Connect
DC V DC V DC V DC V 9
J1-28 J1-29 J1-30 J1-31 J1-32
GND GND GND J1-16 GND
6E44
Connector J2 Port: View Looking Into ECM Case

PIN32 PIN17
PIN16
Pin No. J2-1
B/ Box No. J2-1
Pin Function Intake Air Temp. (IAT) Sensor Ground Battery Power Supply Ignition Power Supply To Data Link Connector No. 6 No Connection Oxygen Sensor (Ground) No Connection No Connection No Connection CO Adjust Signal (W/O Catalystic Converter) Fuel Pump Relay
Wire Color GRN
Signal or Continuity Key SW Off Continuity with ground Key SW On Engine Idle Engine 2000rpm -
J2-2 J2-3 J2-4 J2-5 J2-6
J2-2 J2-3 J2-4 J2-5 J2-6
RED/ WHT BLU/ YEL BLU PNK Less than 1V Continuity with ground -
10-14V 10-14V -
J2-7 J2-8 J2-9 J2-10
J2-7 J2-8 J2-9 J2-10
YEL
J2-11
J2-11
GRN/ WHT
10-14V
While relay is activated; 10-14V Relay is not activated; Less than 1V
10-14V
J2-12 J2-13 J2-14 J2-15 J2-16 J2-17 J2-18 J2-19 J2-20 J2-21 J2-22
J2-12 J2-13 J2-14 J2-15 J2-16 J2-17 J2-18 J2-19 J2-20 J2-21 J2-22
No Connection A/C Compressor Relay No Connection No Connection No Connection CO Adjust (W/O Catalystic Converter) Battery Power Supply No Connection Power Steering Pressure Switch Oxygen Sensor Intake Air Temp. (IAT) Sensor (Signal)
GRY/ RED RED RED/ WHT GRN/ YEL BLU YEL/ GRN
Less than 1V -
A/C comp. is operated: Less than 1V A/C comp. is not operated: 10-14V 10-14V -
Less than 1V Less than 1V Less than 1V
Pressure switch is turned on: Less than 1V Pressure switch is turned off: 10-14V
Approx. 0.4V
Wave form D or 0.1 0.9V
20 : Approx. 2.9V / 40 : Approx. 1.8V V / 60 : Approx. 1.1V / 80 : Approx. 0.6V
1 17
PIN1
ECM Connection Disconnect Tester Position Range 9 (+) J2-1 (-) GND Connect Connect Connect DC V DC V 9 J2-2 J2-3 J2-6 GND GND GND Connect DC V J2-11 GND Connect Connect Connect Connect Connect DC V DC V DC V DC V DC V J2-13 J2-18 J2-20 J2-21 J2-22 GND GND GND J2-6 33
16 32

Pin No. J2-23 B/ Box No. J2-23 Pin Function Vehicle Speed Sensor (VSS) Signal (Immobilizer Control Unit Terminal B8) No Connection Tachometer Output Signal Wire Color WHT Signal or Continuity Key SW Off Key SW On Engine Idle Engine 2000rpm ECM Connection Connect
6E45
Tester Position Range AC V (+) J2-23 (-) GND
Wave form C or Approx. 6.5V at 20km/h
J2-24 J2-25
J2-24 J2-25
BLK/ RED
Wave form
Wave form B or Approx. 4.5V
Connect
AC V
J2-25
GND
J2-26 J2-27 J2-28 J2-29 J2-30 J2-31
J2-26 J2-27 J2-28 J2-29 J2-30 J2-31
Thermo Relay No Connection No Connection No Connection To Data Link Connector No. 2 Oxygen Sensor Heater
GRN/ BLK GRN BLU/ WHT BRN/ YEL
Less than 1V Continuity with ground Less than 1V
A/C request is activated: 10-14V A/C request is not activated: Less than 1V
Connect Connect
DC V 9
J2-26 J2-31
GND GND
Wave Form
Wave Form D
J2-32
J2-32
Check Engine Lamp (Immobilizer Control Unit Terminal B7)
Less than 1V
Lamp is turned on: Less than 1V Lamp is turned off: 1014V
Connect
DC V
J2-32
GND
6E46
Reference Wave Form

Crankshaft Position (CKP) Sensor Reference Wave Form
Crankshaft Position (CKP) Sensor & Tacho Output Signal Reference Wave Form
CH1 0V
0V
CH2 0V
Measurement Terminal: J1-21(+) J1-6(-) Measurement Scale: 10V/div 5ms/div Measurement Condition: Approximately 2000rpm
Measurement Terminal: CH1: J1-21(+) / CH2: J2-25(+) GND(-) Measurement Scale: CH1: 2V/div / CH2: 10V/div 5ms/div Measurement Condition: Approximately 2000rpm
Ve h ic le S p e e d S e n s or (V S S ) R e fe re n c e W a ve F o rm
Heated Oxygen Sensor (HO2S) Reference Wave Form
C H1 0V
0V
C H2 0V
Measurement Term inal: CH1: ECM J2-23(+) / CH2: VSS 3(+) GND(-) Measurem ent Scale: CH1: 10V/div / CH2: 10V/div 50m s/div Measurem ent Condition: A pproximately 20km /h Note: The vehicle is without im mobilizer system, CH1 signal is same as CH2.
Measurement Terminal: J2-21(+) GND(-) Measurement Scale: 500mV/div 500ms/div Measurement Condition: Approximately 2000rpm in Closed Loop
Injector Control Signal Reference Wave Form
Ignition Coil Control Signal Reference Wave Form
0V
CH1 0V CH2 0V
Measurement Terminal: J1-9(+) (No.1 Cylinder) GND(-) Measurement Scale: 20V/div 5ms/div Measurement Condition: Approximately 2000rpm
Measurement Terminal: CH1: J1-19(+) / CH2: J1-18(+) Measurement Scale: CH1: 20V/div / CH2: 20V/div Measurement Condition: Approximately 2000rpm
GND(-) 10ms
6E47
EVAP Canister Purge Solenoid Reference Wave Form
0V
Measurement Terminal: J1-5(+) GND(-) Measurement Scale: 20V/div 20ms/div Frequency: Approximately 16Hz
6E48

Knock signal Throttle position Vehicle speed Power steering pressure Air conditioning request on or off Outputs (Systems controlled): Ignition control Fuel control Idle air control Fuel pump EVAP canister purge Air conditioning Diagnostics functions
GENERAL DESCRIPTION FOR ECM AND SENSORS Engine Control Module (ECM)
Manifold Absolute Pressure (MAP) Sensor
(1) J1 Port (2) J2 Port The engine control module (ECM) is located on the intake manifold. The ECM controls the following. Fuel metering system Ignition timing On-board diagnostics for electrical functions. The ECM constantly observes the information from various sensors. The ECM controls the systems that affect vehicle performance. And it performs the diagnostic function of the system. The function can recognize operational problems, and warn to the driver through the check engine lamp, and store diagnostic trouble code (DTC). DTCs identify the problem areas to aid the technician in marking repairs.
Output Voltage (V)
C h arac teris tic of MA P S ens or -R ef erenc e5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105
The input / output devices in the ECM include analog to digital converts, signal buffers, counters and drivers. The ECM controls most components with electronic switches which complete a ground circuit when turned on. Inputs (Operating condition read): Battery voltage Electrical ignition Exhaust oxygen content Intake manifold pressure Intake air temperature Engine coolant temperature Crankshaft position
Mani fold A bs olute P res s ure (K P a) (T ec h2 Reading)
The MAP sensor is a strain gage. A pressure strains the resistance on the silicon base. At that time the resistance value changes. And it changes voltage. In other words it measures a pressure value. It is installed to the intake manifold. Output voltage of the MAP sensor is low as pressure is low.
ENGINE DRIVEABILITY AND EMISSIONS Throttle Position Sensor (TPS) Idle Air Control (IAC) Valve
Coil Coil (EC M Coil (EC M Coil (EC M Coil (EC M Step A High J1-28) A Low J1-30) B High J1-13) B Low J1-29) A On On On On On On On B C D On
6E49
(IAC Va lve Close Direction)
(IAC Valve Open Direction)
(1) Throttle Position Sensor (2) Idle Air Control (IAC) Valve
C haract erist ic of TPS -R ef erenc e5 4. 5 4 3. 5 Output Voltage (V) 3 2. 5 2 1. 5 1 0. 5 0 0 10 20 30 40 50 60 70 80 90 100
The idle air control valve (IAC) valve is two directional and gives 2-way control. With power supply to the coils controlled steps by the engine control module (ECM), the IAC valve's pintle is moved to adjust idle speed, raising it for fast idle when cold or there is extra load from the air conditioning or power steering. By moving the pintle in (to decrease air flow) or out (to increase air flow), a controlled amount of the air can move around the throttle plate. If the engine speed is too low, the engine control module (ECM) will retract the IAC pintle, resulting in more air moving past the throttle plate to increase the engine speed. If the engine speed is too high, the engine control module (ECM) will extend the IAC pintle, allowing less air to move past the throttle plate, decreasing the engine speed. The IAC pintle valve moves in small step called counts. During idle, the proper position of the IAC pintle is calculated by the engine control module (ECM) based on battery voltage, coolant temperature, engine load, and engine speed. If the engine speed drops below a specified value, and the throttle plate is closed, the engine control module (ECM) senses a near-stall condition. The engine control module (ECM) will then calculate a new IAC pintle valve position to prevent stalls. If the IAC valve is disconnected and reconnected with the engine running, the idle speed will be wrong. In this case, the IAC must be reset. The IAC resets when the key is cycled On then Off. When servicing the IAC, it should only be disconnected or connected with the ignition Off. The position of the IAC pintle valve affects engine startup and the idle characteristic of the vehicle. If the IAC pintle is fully open, too much air will be allowed into the manifold. This results in high idle speed, along with possible hard starting and lean air/ fuel ratio.
Th rot t le An gle (%) (Tech2 R eading)
The TPS is a potentiometer connected to throttle shaft on the throttle body. 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 throttle body has a throttle plate to control the amount of the air delivered to the engine. Engine coolant is directed through a coolant cavity in the throttle body to warm the throttle valve and to prevent icing.
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ENGINE DRIVEABILITY AND EMISSIONS Engine Coolant Temperature (ECT) Sensor
Crankshaft Position (CKP) Sensor
Characteristic of ECT Sensor -Reference100000
The crankshaft position (CKP) sensor, which sends a signal necessary for deciding on injection timing to the ECM, is mounted on the left-hand side of the cylinder block just back of the A/C compressor. The crankshaft has a 58 teeth press-fit timing disc, from which the CKP sensor reads the position of the crankshaft at all the times. It converts this to an electrical signal, which it sends to the ECM. Using the 58 X signals per rotation and the timing-mark signal sent by the CKP sensor, the ECM is able to accurately calculate engine speed and crank position. The ECM converts the 58 X signals into square signals. This converted signal is sent from the ECM terminal J225 to the tachometer.
Resistance (ohm) (Solid Line)
10000
1000
100
10 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 Coolant Temp. (deg. C) (Tech2 Reading)
Knock Sensor (KS)
The ECT sensor is a thermistor. A temperature changes the resistance value. And it changes voltage. In other words it measures a temperature value. It is installed on the coolant stream. Low coolant temperature produces a high resistance. The ECM supplies 5 volts signal to the ECT sensor through resisters in the ECM and measures the voltage. The signal voltage will be high when the engine temperature is cold, and it will be low when the engine temperature is hot.
The knock sensor (KS) contains an element that converts detection of knock into an electrical signal, and is mounted on cylinder block wall. When the ECM receives a signal that indicates knock, the ECM orders ignition timing to be adjusted to compensate.
ENGINE DRIVEABILITY AND EMISSIONS Intake Air Temperature (IAT) Sensor
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The VSS is a magnet rotated by the transmission output shaft. The VSS uses a hall element. It interacts with the magnetic field treated by the rotating magnet. It outputs pulse signal. The 12 volts operating supply from the meter fuse.
Heated Oxygen (O2) Sensor
Characteristic of IAT Sensor -Ref erence100000
10000 Resistance (ohm) (Solid Line)
1000
100
10 -20 -10 0 10 20 30 40 50 60 70 80 Intake Air Temp. (deg. C) (Tech2 Reading) 90 100 110 120
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.
Vehicle Speed Sensor (VSS)
The heated oxygen sensor consists of a 4-wire low temperature activated zirconia oxygen analyzer element with heater for operating temperature of 315C, and there is one mounted on each exhaust pipe. A constant 450millivolt is supplied by the ECM between the two supply terminals, and oxygen concentration in the exhaust gas is reported to the ECM as returned signal voltage. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100mV to 1000mV and the ECM calculates the pulse width commanded for the injectors to produce the proper combustion chamber mixture. Low oxygen sensor output voltage is a lean mixture which will result in a rich commanded to compensate. High oxygen sensor output voltage is a rich mixture which result in a lean commanded to compensate. When the engine is first started the system is in Open Loop operation. In Open Loop, the ECM ignores the signal from the oxygen sensors. When various conditions (ECT, time from start, engine speed & oxygen sensor output) are met, the system enters Closed Loop operation. In Closed Loop, the ECM calculates the air fuel ratio based on the signal from the oxygen sensors. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control to begin operation and allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors to become active. Oxygen sensor heaters are required by catalyst monitor and sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further away from the engine.
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ENGINE DRIVEABILITY AND EMISSIONS Engine Speed/ Vehicle Speed/ Fuel Disable Mode
The ECM monitors engine speed. It turns off the fuel injectors when the engine speed increases above 6000 RPM. The fuel injectors are turned back on when engine speed decreases below 3500 RPM.
GENERAL DESCRIPTION FOR FUEL METERING

The fuel metering system starts with the fuel in the fuel tank. An electric fuel pump, located in the fuel tank, pumps fuel to the fuel rail through an in-line fuel filter. The pump is designed to provide fuel at a pressure above the pressure needed by the injectors. A fuel pressure regulator in the fuel rail keeps fuel available to the fuel injectors at a constant pressure. A return line delivers unused fuel back to the fuel tank. The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold. The main control sensor is the heated oxygen sensor located in the exhaust system. The heated oxygen sensor reports to the ECM how much oxygen is in the exhaust gas. The ECM changes the air/fuel ratio to the engine by controlling the amount of time that fuel injector is On. The best mixture to minimize exhaust emissions is 14.7 parts of air to 1 part of gasoline by weight, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a closed loop system. The ECM monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is delivered under one of several conditions called mode. All modes are controlled by the ECM.
Acceleration Mode
The ECM provides extra fuel when it detects a rapid increase in the throttle position and the air flow.
Fuel Cutoff Mode

No fuel is delivered by the fuel injectors when the ignition is OFF. This prevents engine run-on. In addition, the ECM suspends fuel delivery if no reference pulses are detected (engine not running) to prevent engine flooding.
Starting Mode
When the ignition is first turned ON, the ECM energizes the fuel pump relay for two seconds to allow the fuel pump to build up pressure. The ECM then checks the engine coolant temperature (ECT) sensor and the throttle position sensor to determine the proper air/fuel ratio for starting. The ECM controls the amount of fuel delivered in the starting mode by adjusting how long the fuel injectors are energized by pulsing the injectors for very short times.
Run Mode
The run mode has the following two conditions: Open loop Closed loop When the engine is first started, the system is in open loop operation. In Open Loop, the ECM ignores the signal from the heated oxygen sensor (HO2S). It calculates the air/fuel ratio based on inputs from the TP, ECT, and MAP sensors. The system remains in Open Loop until the following conditions are met: The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature). The ECT has reached a specified temperature. A specific amount of time has elapsed since starting the engine. Engine speed has been greater than a specified RPM since start-up. The specific values for the above conditions vary with different engines and are stored in the programmable read only memory (PROM). When these conditions are met, the system enters closed loop operation. In closed loop, the ECM calculates the air/fuel ratio (injector on-time) based on the signal from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.
Battery Voltage Correction Mode

When battery voltage is low, the ECM will compensate for the weak spark by increasing the following: The amount of fuel delivered. The idle RPM.
Clear Flood Mode

Clear a flooded engine by pushing the accelerator pedal down all the way. The ECM then de-energizes the fuel injectors. The ECM holds the fuel injectors de-energized as long as the throttle remains above 75% and the engine speed is below 800 RPM. If the throttle position becomes less than 75%, the ECM again begins to pulse the injectors ON and OFF, allowing fuel into the cylinders.
Deceleration Fuel Cutoff (DFCO) Mode

The ECM reduces the amount of fuel injected when it detects a decrease in the throttle position and the air flow. When deceleration is very fast, the ECM may cut off fuel completely. Until enable conditions meet the engine revolution less 1000 rpm or manifold absolute pressure less than 10 kPa.
ENGINE DRIVEABILITY AND EMISSIONS Fuel Metering System Components

The fuel metering system is made up of the following parts. Fuel injector Throttle body Fuel rail Fuel pressure regulator ECM Crankshaft position (CKP) sensor Idle air control (IAC) valve Fuel pump pressure will result in poor performance.
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Thottle Body Unit

The throttle body has a throttle plate to control the amount of air delivered to the engine. The Thottle position sensor and IAC valve are also mounted on the throttle body. Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components. Engine coolant is directed through a coolant cavity in the throttle body to warm the throttle valve and to prevent icing.
Fuel Injector
The group fuel injection fuel injector is a solenoid operated device controlled by the ECM. The ECM energizes the solenoid, which opens a valve to allow fuel delivery. The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank.
Fuel Pressure Regulator

The fuel pressure regulator is a diaphragm-operated relief valve mounted on the fuel rail with fuel pump pressure on one side and manifold pressure on the other side. The fuel pressure regulator maintains the fuel pressure available to the injector at three times barometric pressure adjusted for engine load. It may be serviced separately. If the pressure is too low or poor performance, DTC P0131 or P1171 will be the result. If the pressure is too high, DTC P0132 or P1167 will be the result. Refer to Fuel System Diagnosis for information on diagnosing fuel pressure conditions.
Fuel Rail
The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors. Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines. The fuel goes through the fuel rail to the fuel pressure regulator. The fuel pressure regulator maintains a constant fuel pressure at the injectors. Remaining fuel is then returned to the fuel tank.
Fuel Pump Electrical Circuit

When the key is first turned ON, the ECM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly. If the engine is not started within two seconds, the ECM shuts the fuel pump off and waits until the engine is cranked. When the engine is cranked and the 58X crankshaft position signal has been detected by the ECM, the ECM supplies 12 volts to the fuel pump relay to energize the electric in-tank fuel pump. An inoperative fuel pump will cause a no-start condition. A fuel pump which does not provide enough
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before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P1167. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve.
GENERAL DESCRIPTION FOR ELECTRIC IGNITION SYSTEM

The engine use two ignition coils, one per two cylinders. A two wire connector provides a battery voltage primary supply through the ignition fuse. The ignition control spark timing is the ECM s method of controlling the spark advance and the ignition dwell. The ignition control spark advance and the ignition dwell are calculated by the ECM using the following inputs. Engine speed Crankshaft position (CKP) sensor Engine coolant temperature (ECT) sensor Throttle position sensor Vehicle speed sensor ECM and ignition system supply voltage Ignition coil works to generate only the secondary voltage be receiving the primary voltage from ECM. The primary voltage is generated at the coil driver located in the ECM. The coil driver generate the primary voltage based on the crankshaft position signal. In accordance with the crankshaft position signal, ignition coil driver determines the adequate ignition timing and also cylinder number to ignite. Ignition timing is determined the coolant temperature, intake air temperature, engine speed, engine load, knock sensor signal, etc.
Spark Plug
Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequently fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as misfiring. This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as pre-ignition. Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs
Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture.
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Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Over tightening may cause the spark plug shell to be stretched and will result in poor contact between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later.
A broken or cracked lower insulator tip (around the center electrode) may result from damage during regapping or from heat shock (spark plug suddenly operating too hot). Damage during re-gapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to crack. When re-gapping a spark plug, make the adjustment by bending only the ground side terminal, keeping the tool clear of other parts.
Heat shock breakage in the lower insulator tip generally occurs during several engine operating conditions (high speeds or heavy loading) and may be caused by over-advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material to crack. Spark plugs with less than the recommended amount of service can sometimes be cleaned and re-gapped, then
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returned to service. However, if there is any doubt about the serviceability of a spark plug, replace it. Spark plugs with cracked or broken insulators should always be replaced.
ENGINE DRIVEABILITY AND EMISSIONS GENERAL DESCRIPTION FOR EVAPORATIVE EMISSION SYSTEM
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EVAP Emission Control System Operation

The EVAP canister purge is controlled by a solenoid valve that allows the manifold vacuum to purge the canister. The engine control module (ECM) supplies a ground to energize the solenoid valve (purge on). The EVAP purge solenoid control is pulse-width modulated (PWM) (turned on and off several times a second). The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the ECM. the output is commanded when the appropriate conditions have been met. These conditions are: The engine is fully warmed up. The engine has been running for a specified time. The IAT reading is above 10C (50F). Purge/Vacuum Hoses. Made of rubber compounds, these hoses route the gasoline fumes from their sources to the canister and from the canister to the intake air flow. EVAP Canister. Mounted on a bracket ahead of the fuel tank, the canister stores fuel vapors until the ECM determined that engine conditions are right for them to be removed and burned. Poor idle, stalling and Poor driveability can be caused by: A malfunctioning purge solenoid. A damaged canister. Hoses that are split, cracked, or not connected properly.
(1) Purge Solenoid Valve (2) From Canistor to Purge Solenoid (3) From Purge Solenoid to Intake
System Fault Detection

The EVAP leak detection strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. At an appropriate time, the EVAP purge solenoid is turned ON, allowing the engine vacuum to draw a small vacuum on the entire evaporative emission system. After the desired vacuum level has been achieved, the EVAP purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. If the desired vacuum level cannot be achieved in the test described above, a large leak or a faulty EVAP purge control solenoid valve is indicated. Leaks can be caused by the following conditions: Missing or faulty fuel cap Disconnected, damaged, pinched, or blocked EVAP purge line Disconnected, damaged, pinched, or blocked fuel tank vapor line Disconnected or faulty EVAP purge control solenoid valve Open ignition feed circuit to the purge solenoid
(1) Canistor (2) Air Separator
EVAP Emission Control System Purpose

The basic evaporative emission control system used on the charcoal canister storage method. The method transfers fuel vapor from the fuel tank to an activated carbon (charcoal) storage devise to hold the vapors when the vehicle is not operating. The canister is located on the rear axle housing by the frame cross-member. When the engine is running, the fuel vapor is purged from the carbon element by intake air flow and consumed in the normal combustion process.
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Damaged EVAP canister Leaking fuel sender assembly O-ring Leaking fuel tank or fuel filler neck The ECM supplies a ground to energize the purge control solenoid valve (purge ON ). The EVAP purge control is turned ON and OFF, several times a second. The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the ECM and the output is commanded when the appropriate conditions have been met. The system checks for conditions that cause the EVAP system to purge continuously by commanding the EVAP purge solenoid OFF, EVAP purge solenoid duty ratio 0%. If fuel tank vacuum level increases during the test, a continuous purge flow condition is indicated. This can be caused by the following conditions: EVAP purge solenoid leaking EVAP purge and engine vacuum lines switched at the EVAP purge control solenoid valve EVAP purge control solenoid valve driver circuit grounded
ENGINE DRIVEABILITY AND EMISSIONS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
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Crankcase Ventilation System Purpose

The crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to the atmosphere. Fresh air from the throttle body is supplied to the crankcase and mixed with blow-by gases. This mixture is then passed through the positive crankcase ventilation (PCV) port into the intake manifold. While the engine is running, exhaust gases and small amounts of the fuel/air mixture escape past the piston rings and enter the crankcase. these gases are mixed with clean air entering through a tube from the air intake duct. During normal, part-throttle operation, the system is designed to allow crankcase gases to flow through the PCV hose into the intake manifold to be consumed by normal combustion. A plugged positive crankcase ventilation port or PCV hose may cause the following conditions: Rough idle. Stalling or slow idle speed. Oil leaks. Sludge in the engine. A leaking PCV hose would cause: Rough idle. Stalling. High idle speed.
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A/C CLUTCH DIAGNOSIS A/C Clutch Circuit Operation

A 12-volt signal is supplied to the A/C request input of the ECM when the A/C is selected through the A/C control switch. The A/C compressor clutch relay is controlled through the ECM. This allows the ECM to modify the idle air control position prior to the A/C clutch engagement for better idle quality. If the engine operating conditions are within their specified calibrated acceptable ranges, the ECM will enable the A/C compressor relay. This is done by providing a ground path for the A/C relay coil within the ECM. When the A/C compressor relay is enabled, battery voltage is supplied to the compressor relay is enabled, battery voltage is supplied to the compressor clutch coil. The ECM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested. The ECM will not enable the A/C compressor clutch if any of the following conditions are met: The engine speed is greater than 6000 RPM. The ECT is greater than 122C (251F). The throttle is more than 95% open.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the engine control module (ECM) for the following reasons: It improves idle quality during compressor clutch engagement. It improves wide open throttle (WOT) performance. It provides A/C compressor protection from operation with incorrect refrigerant pressures. The A/C electrical system consists of the following components: The A/C control switch. The A/C refrigerant pressure switches. The A/C compressor clutch. The A/C compressor clutch relay. The ECM.
A/C Request Signal

This signal tells the ECM when the A/C mode is selected at the A/C control switch. The ECM uses this input to adjust the idle speed before turning on the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the ECM. Refer to A/C Clutch Circuit Diagnosis for A/C wiring diagrams and diagnosis for the A/C electrical system.
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ISUZU STRATEGY BASED DIAGNOSTICS Overview

As a retail service technician, you are part of the ISUZU service team. The team goal is FIX IT RIGHT THE FIRST TIME for the satisfaction of every customer. You are a very important member of the team as you diagnose and repair customer vehicles. You have maximum efficiency in diagnosis when you have an effective, organized plan for your work. Strategy Based Diagnostics (refer to Figure 1) provides you with guidance as you create and follow a plan of action for each specific diagnostic situation.
STRATEGY BASED DIAGNOSTICS CHART
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Circuit testing tools Vehicle road tests Complaint check sheet Contact with the customer
Diagnostic Thought Process

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

NOTE: An estimated 10 percent of successful vehicle repairs are diagnosed with this step!
What you should do

You perform preliminary checks for several reasons: To detect if the cause of the complaint is VISUALLY OBVIOUS To identify parts of the system that work correctly To accumulate enough data to correctly and accurately search for a ISUZU Service Bulletin on ISUZU Web site. The initial checks may vary depending on the complexity of the system and may include the following actions: Operate the suspect system Make a visual inspection of harness routing and accessible/visible power and ground circuits Check for blown fuses Make a visual inspection for separated connectors Make a visual inspection of connectors (includes checking terminals for damage and tightness) Check for any DTCs stored by the on-board computers Sense unusual movements noises, smells, vibrations or
1. Verify the Complaint

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

Whenever appropriate, you should use the following resources for assistance in performing preliminary checks: Tech II or other technical equipment for viewing DTCs Service manual information: Component locations Harness routing Wiring schematics Procedures for viewing DTCs Dealership service history file Vehicle road test Identical vehicle or system for comparison

Whenever possible, you should use the following resources to assist you in verifying the complaint: Service manual Theory or Circuit Description sections Service manual System Performance Check Owner manual operational description Technician experience Identical vehicle for comparison
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3. Check Bulletins and Troubleshooting Hints

NOTE: As estimated 30 percent of successful vehicle repairs are diagnosed with this step!
to the customer complaint.

Whenever appropriate, you should use the following resources to perform service manual diagnostic procedures: Service manual Technical equipment (for analyzing diagnostic data) Digital multimeter and circuit testing tools Essential and special tools
What you should do

You should have enough information gained from preliminary checks to accurately search for a bulletin and other related service information. Some service manual sections provide troubleshooting hints that match symptoms with specific complaints.
5c. Technician Self Diagnoses

You should use the following resources for assistance in checking for bulletins and troubleshooting hints: Printed bulletins Access ISUZU Bulletin Web site. Videotapes Service manual When there is no DTC stored and no matching symptom for the condition identified in the service manual, you must begin with a thorough understanding of how the system(s) operates. Efficient use of the service manual combined with you experience and a good process of elimination will result in accurate diagnosis of the condition.
What you should do
4. Perform Service Manual Diagnostic Checks

What you should do
The System Checks in most service manual sections and in most cells of section 8A (electrical) provide you with: A systematic approach to narrowing down the possible causes of a system fault Direction to specific diagnostic procedures in the service manual Assistance to identify what systems work correctly
Step 1: Identify and understand the suspect circuit(s) Having completed steps 1 through 4 of the Strategy Based Diagnostics chart, you should have enough information to identify the system(s) or sub-system(s) involved. Using the service manual, you should determine and investigate the following circuit characteristics: Electrical: How is the circuit powered (power distribution charts and/or fuse block details)? How is the circuit grounded (ground distribution charts)? How is the circuit controlled or sensed (theory of operation): If it is a switched circuit, is it normally open or normally closed? Is the power switched or is the ground switched? Is it a variable resistance circuit (ECT sensor or TP sensor, for example)? Is it a signal generating device (MAF sensor of VSS, for example)? Does it rely on some mechanical/vacuum device to operate? Physical: Where are the circuit components (component locators and wire harness routing diagrams): Are there areas where wires could be chafed or pinched (brackets or frames)? Are there areas temperatures? subjected to extreme

Whenever possible, you should use the following resources to perform service manual checks: Service manual Technical equipment (for viewing DTCs analyzing data) Digital multimeter and circuit testing tools Other tools as needed and
5a and 5b. Perform Service Manual Diagnostic Procedures

NOTE: An estimated 40 percent of successful vehicle repairs are diagnosed with these steps!
What you should do

When directed by service manual diagnostic checks, you must then carefully and accurately perform the steps of diagnostic procedures to locate the fault related
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at the component If a number of components do no operate, begin tests at the area of commonality (such as power sources, ground circuits, switches or major connectors)
Are there areas subjected to vibration or movement (engine, transmission or suspension)? Are there areas exposed to moisture, road salt or other corrosives (battery acid, oil or other fluids)? Are there common mounting areas with other systems/components? Have previous repairs been performed to wiring, connectors, components or mounting areas (causing pinched wires between panels and drivetrain or suspension components without causing and immediate problem)? Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.) Step 2: Isolate the problem At this point, you should have a good idea of what could cause the present condition, as well as could not cause the condition. Actions to take include the following: Divide (and separate, where possible) the system or circuit into smaller sections Confine the problem to a smaller area of the vehicle (start with main harness connections while removing panels and trim as necessary in order to eliminate large vehicle sections from further investigation) For two or more circuits that do not share a common power or ground, concentrate on areas where harnesses are routed together or connectors are shared (refer to the following hints) Hints Though the symptoms may vary, basic electrical failures are generally caused by: Loose connections: Open/high resistance connectors or grounds in terminals, splices,

Whenever appropriate, you should use the following resources to assist in the diagnostic process: Service manual Technical equipment (for data analysis) Experience Technical Assistance Circuit testing tools
5d. Intermittent Diagnosis

By definition, an intermittent problem is one that does not occur continuously and will occur when certain conditions are met. All these conditions, however, may not be obvious or currently known. Generally, intermittents are caused by: Faulty electrical connections and wiring Malfunctioning components (such as sticking relays, solenoids, etc.) EMI/RFI (Electromagnetic/radio frequency interference) Aftermarket equipment Intermittent diagnosis requires careful analysis of suspected systems to help prevent replacing good parts. This may involve using creativity and ingenuity to interpret customer complaints and simulating all external and internal system conditions to duplicate the problem.
What you should do

Step 1: Acquire information A thorough and comprehensive customer check sheet is critical to intermittent problem diagnosis. You should require this, since it will dictate the diagnostic starting point. The vehicle service history file is another source for accumulating information about the complaint. Step 2: Analyze the intermittent problem
Incorrect connector/harness routing (usually in new vehicles or after a repair has been made): Open/high resistance in connectors of grounds Corrosion and wire damage: Open/high resistance connectors of grounds Component failure: Opens/short and high resistance modules, switches or loads in relays, in terminals, splices,
terminals,
splices,
Aftermarket equipment affecting normal operation of other systems You may isolate circuits by: Unplugging connectors or removing a fuse to separate one part of the circuit from another part Operating shared circuits and eliminating those that function normally from the suspect circuit If only one component fails to operate, begin testing
Analyze the customer check sheet and service history file to determine conditions relevant to the suspect system(s). Using service manual information, you must identify, trace and locate all electrical circuits related to the malfunctioning system(s). If there is more than one system failure, you should identify, trace and locate areas of commonality shared by the suspect circuits.

Step 3: Simulate the symptom and isolate the problem Simulate the symptom and isolate the system by reproducing all possible conditions suggested in Step 1 while monitoring suspected circuits/components/ systems to isolate the problem symptom. Begin with the most logical circuit/component. Isolate the circuit by dividing the suspect system into simpler circuits. Next, confine the problem into a smaller area of the system. Begin at the most logical point (or point of easiest access) and thoroughly check the isolated circuit for the fault, using basic circuit tests. Hints You can isolate a circuit by: Unplugging connectors or removing a fuse to separate one part of the circuit from another If only component fails to operate, begin testing the component If a number of components do not operate, begin test at areas of commonality (such as power sources, ground circuits, switches, main connectors or major components) Substitute a known good part from the parts department or the vehicle system Try the suspect part in a known good vehicle See Symptom Simulation Tests on the next page for problem simulation procedures. Refer to service manual sections 6E and 8A for information about intermittent diagnosis. Follow procedures for basic circuit testing in service manual section 8A.
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For parts and sensors, apply slight vibration to the part with a light tap of the finger while monitoring the system for a malfunction. 2. Heat This method is important when the complaint suggests that the problem occurs in a heated environment. Apply moderate heat to the component with a hair drier or similar tool while monitoring the system for a malfunction. CAUTION: Care must be take to avoid overheating the component. 3. Water and Moisture This method may be used when the complaint suggests that the malfunction occurs on a rainy day or under conditions of high humidity. In this case, apply water in a light spray on the vehicle to duplicate the problem. CAUTION: Care must be take to avoid directly exposing electrical connections to water. 4. Electrical loads This method involves turning systems ON (such as the blower, lights or rear window defogger) to create a load on the vehicle electrical system at the same time you are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed

This condition refers to instances where a system operating as designed is perceived to be unsatisfactory or undesirable. In general, this is due to: A lack of understanding by the customer A conflict between customer expectations and vehicle design intent A system performance that is unacceptable to the customer

Whenever appropriate, you should use the following resources to assist in the diagnostic process: Service manual Bulletins Digital multimeter (with a MIN/MAX feature) Tech II and Tech II upload function Circuit testing tools (including harnesses and jumper wires) connector kits/
What you should do

You can verify that a system is operating as designed by: Reviewing checks service manual functional/diagnostic
Experience Intermittent problem solving simulation methods Customer complaint check sheet
Symptom Simulation Tests

1. Vibration This method is useful when the customer complaint analysis indicates that the problem occurs when the vehicle/system undergoes some form of vibration. For connectors and wire harness, slightly shake vertically and horizontally. Inspect the connector joint and body for damage. Also, tapping lightly along a suspected circuit may be helpful.
Examining bulletins and other service information for supplementary information Compare system operation to an identical vehicle If the condition is due to a customer misunderstanding or a conflict between customer expectation and system operation, you should explain the system operation to the customer. If the complaint is due to a case of unsatisfactory system performance, you should contact Technical Assistance for the latest information.

Whenever possible, you should use the following resources to facilitate the diagnostic process:
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Vehicle service information (service manual, etc.) ISUZU field support Experience Identical vehicle or system for comparison
6. Re-examine the complaint

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

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

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
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GENERAL SERVICE INFORMATION

Aftermarket Electrical and Vacuum Equipment
Aftermarket (add-on) electrical and vacuum equipment is defined as any equipment which connects to the vehicle's electrical or vacuum systems that is installed on a vehicle after it leaves the factory. No allowances have been made in the vehicle design for this type of equipment. NOTE: No add-on vacuum equipment should be added to this vehicle. NOTE: Add-on electrical equipment must only be connected to the vehicle's electrical system at the battery (power and ground). Add-on electrical equipment, even when installed to these guidelines, may still cause the electric system to malfunction. This may also include equipment not connected to the vehicle electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any electric problem is to eliminate all aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, it may be diagnosed in the normal manner.
Non-OEM Parts All of the OBD diagnostics have been calibrated to run with OEM parts. Accordingly, if commercially sold sensor or switch is installed, it makes a wrong diagnosis and turns on the check engine lamp. Aftermarket electronics, such as cellular phones, stereos, and anti-theft devices, may radiate EMI into the control system if they are improperly installed. This may cause a false sensor reading and turn on the check engine lamp. Poor Vehicle Maintenance The sensitivity of OBD diagnostics will cause the check engine lamp to turn on if the vehicle is not maintained properly. Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD. Poor vehicle maintenance can not be classified as a non-vehicle fault, but with the sensitivity of OBD diagnostics, vehicle maintenance schedules must be more closely followed. Related System Faults Many of the OBD system diagnostics will not run if the ECM detects a fault on a related system or component.
Electrostatic Discharge Damage
Visual/Physical Engine Compartment Inspection

Perform a careful visual and physical engine compartment inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual/physical inspection: Electronic components used in the ECM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. An example of charging by friction is a person sliding across a vehicle seat. Charge by induction occurs when a person with wellinsulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components. Inspect all vacuum hoses for punches, disconnects, and correct routing. cuts,
Inspect hoses that are difficult to see behind other components. Inspect all wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, contact with sharp edges or contact with hot exhaust manifolds or pipes.
Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in an incorrect diagnosis or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.
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suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first. Data Link Connector (DLC) The provision for communication with the contorl module is the Data Link Connector (DLC). It is located behind the lower front instrument panel. The DLC is used to connect to a Tech2. Some common uses of the Tech2 are listed below: Identifying stored Diagnostic Trouble Codes (DTCs). Clearing DTCs. Reading serial data.
On-Board Diagnostic (OBD)

On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data: The diagnostic test has been completed since the last ignition cycle. The diagnostic test has passed during the current ignition cycle. The fault identified by the diagnostic test is not currently active. When a diagnostic test reports a fail result, the diagnostic executive records the following data: The diagnostic test has been completed since the last ignition cycle. The fault identified by the diagnostic test is currently active. The fault has been active during this ignition cycle. The operating conditions at the time of the failure.
The Diagnostic Executive

The Diagnostic Executive is a unique segment of software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The main responsibilities of the Diagnostic Executive are listed as follows: Commanding the check engine lamp on and off DTC logging and clearing Current status information on each diagnostic Diagnostic Information The diagnostic charts and functional checks are designed to locate a faulty circuit or component through a process of logical decisions. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are not multiple faults present. There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code is set and the check engine lamp is illuminated. Check Engine Lamp The check engine lamp looks the same as the check engine lamp you are already familiar with, the Check Engine lamp. Basically, the check engine lamp is turned on when the ECM detects a DTC that will impact the vehicle emissions. When the check engine lamp remains ON while the engine is running, or when a malfunction is
Verifying Vehicle Repair

Verification of vehicle repair will be more comprehensive for vehicles with OBD system diagnostic. Following a repair, the technician should perform the following steps: 1. Review and record the Fail Records for the DTC which has been diagnosed. 2. Clear DTC(s). 3. Operate the vehicle within conditions noted in the Fail Records. 4. Monitor the DTC status information for the specific DTC which has been diagnosed until the diagnostic test associated with that DTC runs. Following these steps is very important in verifying repairs on OBD systems. Failure to follow these steps could result in unnecessary repairs.
ENGINE DRIVEABILITY AND EMISSIONS 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. 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. 1. Configuration of Tech 2
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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). Connect the SAE 16/19 adapter (3) to the DLC cable (4). Connect the DLC cable (4) to the Tech 2 (5). Connect the SAE 16/19 adapter (3) to the data link connector of the vehicle.
Diagnosis With Tech 2

If no codes are set: Refer to F1: Data Display and identify the electrical faults that are not indicated by trouble code. Refer to SYMPTOM DIAGNOSIS. 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.
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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.

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

Vehicle Identification (3) 2003 (2) 2002 (1) 2001 (Y) 2000 (X) 1999 (W) 1998
Select F0: Powertrain.

Vehicle Identification 4JH1-TC Bosch 4JH1-T Denso 2.XL L4 HV240 3.5L V6 6VE1 Hitachi AW30-40LE AT JR405E
Select (3) 2003 or later.
Select 2.XL L4 HV240.
Select 2.XL L4 HV240 in Vehicle Identification menu and the following table is shown in the Tech 2 screen.

F0: Diagnostic Trouble Code F0: Read DTC Infor By Priority F1: Clear DTC Information F2: DTC Information F0: History F1: MIL SVS or Message Requested F2: Last Test Failed F3: Test Failed Since Code Cleared F4: Not Run Since Code Cleared F5: Failed This Ignition
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Lamp). It will display all type A and B DTCs that requested the MIL and have failed within the last 40 warm-up cycles. In addition, it will display all type C and D DTCs that have failed within the last 40 warm-up cycles. MIL SVC or Message Request This selection will display only DTCs that are requesting the MIL. Type C and Type D DTCs cannot be displayed using the MIL. Type C and D DTCs cannot be displayed using this option. This selection will report type B DTCs only after the MIL has been requested. Last Test Failed This selection will display only DTCs that have failed the last time the test run. The last test may have run during a previous ignition cycle of a type A or type B DTC is displayed. For type C and type D DTCs, the last failure must have occurred during the current ignition cycle to appear as last test fail. Test Failed Since Code Cleared The selection will display all active and history DTCs that have reported a test failure since the last time DTCs were cleared. DTCs that last failed more that 40 warm-up cycles before this option is selected will not be displayed. No Run Since Code Cleared This selection will display up to DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition (passing or failing) is unknown. Failed This Ignition This selection will display all DTCs during the present ignition cycle.
F1: Data Display F0: Engine Data F1: O2 Sensor Data F2: Snapshot
F3: Miscellaneous Test F0: Lamps F0: Malfunction Indicator Lamps F1: Relays F0: Fuel Pump Relay F1: A/C Clutch Relay F2: EVAP F0: Purge Solenoid F3: IAC System F0: IAC Control F1: IAC Reset F4: Injector Balance Test 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. Use the DTC Information mode to search for a specific type of stored DTC information. History This selection will display only DTCs that are stored in the ECM's history memory. It will not display Type B DTCs that have not requested the MIL (Check Engine
that have failed
F1: Data Display The purpose of the Data Display mode is to continuously monitor data parameters. The current actual values of all important sensors and signals in the system are display through F1 mode. See the Typical Scan Data section. F2: Snapshot Snapshot allows you to focus on making the condition occur, rather than trying to view all of the data in anticipation of the fault. The snapshot will collect parameter information around a trigger point that you select. F3: Miscellaneous Test: The purpose of Miscellaneous Test mode is to check for correct operation of electronic system actuators.
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ENGINE DRIVEABILITY AND EMISSIONS TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 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.)
Tech 2 Parameter 1 2 Engine Speed Desired Idle Speed Units rpm rpm Idle 775 - 875 825 2000rpm 1950 - 2050 800 - 850 Description The actual engine speed is measured by ECM from the CKP sensor 58X signal. The desired engine idle speed that the ECM commanding. The ECM compensates for various engine loads. The ECT is measured by ECM from ECT sensor output voltage. When the engine is normally warm upped, this data displays approximately 80 C or more. Start-up ECT is measured by ECM from ECT sensor output voltage when engine is started. The IAT is measured by ECM from IAT sensor output voltage. This data is changing by intake air temperature. Start-up IAT is measured by ECM from IAT sensor output voltage when engine is started. The MAP (kPa) is measured by ECM from MAP output voltage. This data is changing by inlet manifold pressure. The barometric pressure is measured by ECM from the MAP sensor output voltage monitored during key up and wide open throttle. This data is changing by altitude. Throttle position operating angle is measured by the ECM from throttle position output voltage. This should display 0% at idle and 99 - 100% at full throttle. This displays calculated air mount from MAP sensor output. This data is changing by inlet manifold pressure. This displays the ECM commanded value. In closed loop, this should normally be displayed around 14.2:1 - 14.7:1. This displays the amount of spark advance being commanded by the ECM. This displays is calculated by the ECM form engine speed and MAF sensor reading. Engine load should increase with an increase in engine speed or air flow amount. This displays the amount of time the ECM is commanding each injector On during each engine cycle. A longer injector pulse width will cause more fuel to be delivered. Injector pulse width should increase with increased engine load. When the engine is first started the system is in Open Loop operation. In Open Loop, the ECM ignores the signal from the oxygen sensors. When various conditions (ECT, time from start, engine speed & oxygen sensor output) are met, the system enters Closed Loop operation. In Closed Loop, the ECM calculates the air fuel ratio based on the signal from the oxygen sensors. This displays knock sensor detection status. When engine knock is occurred, displays "Yes". This displays the number of knock during a ignition cycle. This displays the commanded ignition spark timing retard timing based on the signal from the knock sensor. This displays whether the ECM has commanded the A/C compressor clutch On or Off.
Engine Coolant Temperature Start Up ECT (Engine Coolant Temperature) Intake Air Temperature Start Up IAT (Intake Air Temperature) Manifold Absolute Pressure Barometric Pressure
C or F
80 - 90
80 - 90
4 5 6 7 8
C or F C or F C or F kPa kPa
Depends on ECT at start-up Depends on ambient temp Depends on IAT at start-up 31 - 36 Depends on altitude 0
Depends on ECT at start-up Depends on ambient temp Depends on IAT at start-up 25 - 30 Depends on altitude 2-4
Throttle Position
10 11 12 13
Calculated Air Flow Air Fuel Ratio Spark Advance Engine Load
g/s
3.5 -4.50 14.6:1
8.0 - 10.0 14.6:1 25 - 32 5 - 10
CA %
8 - 15 2-5
14
Injection Pulse Width
ms
1.0 - 3.0
3.0 - 4.0
15
Fuel System Status
Open Loop/ Close Loop
Close Loop
Close Loop
16 17 18 19
Knock Present Knock Counter Knock Retard A/C Clutch Relay
Yes/No
No -
No 0 Off
CA On/Off
0 Off

Tech 2 Parameter 20 A/C Request Units Yes/No Idle Off 2000rpm Off Description
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This displays the air conditioner request signal. This should display On when the air conditioner switch is switched on. This displays the duty signal from the ECM to control the canister purge solenoid valve. This displays operating status for the fuel pump main relay. This should display On when the key switch is turned on and while engine is running. This displays the ECM commanded position of the idle air control valve pintle. A larger number means that more air is being commanded through the idle air passage. This displays variation of actual engine speed & desired idle speed. This displays vehicle speed. The vehicle speed is measured by ECM from the vehicle speed sensor. This displays the system voltage measured by the ECM at ignition feed.
21
EVAP Purge Solenoid (Evaporative Emission) Fuel Pump
0 - 10
0 - 10
22
On/Off
On
On
23
Idle Air Control
Steps
20 - 30
65 - 75
24 25 26 27 28
Idle Speed Variation Vehicle Speed Ignition Voltage Reference Voltage Malfunction Indicator Lamp Time From Start
rpm km/h or mph V V On/Off
-25 - 0 0 10.0 - 14.5 5.00 Off
1125 - 1225 0 10.0 - 14.5 5.00 Off
This displays operating status for the Check Engine Lamp. This should display On when the Check Engine Lamp is turned on. This displays the engine time elapsed since the engine was started. If the engine is stopped, engine run time will be reset to 00:00:00
29
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ENGINE DRIVEABILITY AND EMISSIONS TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA)
Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 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.)
Tech 2 Parameter 1 2 Engine Speed Desired Idle Speed Units rpm rpm Idle 710 - 875 825 2000rpm 1950 - 2050 800 - 850 Description The actual engine speed is measured by ECM from the CKP sensor 58X signal. The desired engine idle speed that the ECM commanding. The ECM compensates for various engine loads. The ECT is measured by ECM from ECT sensor output voltage. When the engine is normally warm upped, this data displays approximately 80 C or more. Start-up ECT is measured by ECM from ECT sensor output voltage when engine is started. The IAT is measured by ECM from IAT sensor output voltage. This data is changing by intake air temperature. Start-up IAT is measured by ECM from IAT sensor output voltage when engine is started. The MAP (kPa) is measured by ECM from MAP output voltage. This data is changing by inlet manifold pressure. The barometric pressure is measured by ECM from the MAP sensor output voltage monitored during key up and wide open throttle. This data is changing by altitude. Throttle position operating angle is measured by the ECM from throttle position output voltage. This should display 0% at idle and 99 - 100% at full throttle. This displays intake air amount. The mass air flow is measured by ECM from the MAF sensor output voltage. This displays the ECM commanded value. In closed loop, this should normally be displayed around 14.2:1 14.7:1. When the engine is first started the system is in Open Loop operation. In Open Loop , the ECM ignores the signal from the oxygen sensors. When various conditions (ECT, time from start, engine speed & oxygen sensor output) are met, the system enters Closed Loop operation. In Closed Loop , the ECM calculates the air fuel ratio based on the signal from the oxygen sensors. This displays is calculated by the ECM form engine speed and MAF sensor reading. Engine load should increase with an increase in engine speed or air flow amount. This displays the status of the exhaust oxygen sensor. This display will indicate Yes when the ECM detects a fluctuating oxygen sensor output voltage sufficient to allow closed loop operation. This will not occur unless the oxygen sensor is warmed up. This displays dependent on the exhaust oxygen sensor output voltage. Should fluctuate constantly Rich and Lean in closed loop. When conditions are appropriate for enabling long term fuel trim corrections, fuel trim learn will display Yes. This indicates that the long term fuel trim is responding to the short term fuel trim. If the fuel trim lean displays No , then long term fuel trim will not respond to changes in short term fuel trim.
Engine Coolant Temperature Start Up ECT (Engine Coolant Temperature) Intake Air Temperature Start Up IAT (Intake Air Temperature) Manifold Absolute Pressure Barometric Pressure
C or F
80 - 90
80 - 90
4 5 6 7 8
C or F C or F C or F kPa kPa
Depends on ECT at start-up Depends on ambient temp Depends on IAT at start-up 31 - 36 Depends on altitude 0
Depends on ECT at start-up Depends on ambient temp Depends on IAT at start-up 25 - 30 Depends on altitude 2-4
Throttle Position
10 11
Calculated Air Flow Air Fuel Ratio
g/s
3.5 -4.50 14.6:1
8.0 - 10.0 14.6:1
12
Fuel System Status
Open Loop/ Close Loop
Close Loop
Close Loop
13
Engine Load
2-5
5 - 10
14
B1 O2 Sensor Ready (Bank 1)
Yes/No
Yes
Yes
15
B1S1 Status (Bank 1 Sensor 1) Fuel Trim Learned
Rich / Lean
Rich / Lean
Rich / Lean
16
Yes/No
Yes
Yes

Tech 2 Parameter 17 Fuel Trim Cell Units Idle 15 - 20 2000rpm 1-2 Description
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This displays dependent on engine speed and calculated intake air flow reading. A plot of engine speed versus intake air flow amount is divided into the cells. Fuel trim cell indicates which cell is currently active. This displays the exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10mV (lean exhaust) and 1000mV (rich exhaust) while operating in closed loop. The short term fuel trim to a bank represents a short term correction to the bank fuel delivery by the ECM in response to the amount of time the bank fuel control oxygen sensor voltage spends above or below the 450mV threshold. If the oxygen sensor voltage has mainly remained less than 450mV, indicating a lean air/ fuel, short term fuel trim will increase into the positive range above 0% and the ECM will pass fuel. If the oxygen sensor voltage stays mainly above the threshold, short term fuel trim will decrease below 0% into the negative range while the ECM reduces fuel delivery to compensate for the indicated rich condition. Under certain conditions such as extended idle and high ambient temperatures, canister purge may cause short term fuel trim to read in the negative range during normal operation. Fuel trim values at maximum authority may indicate an excessively rich or lean system. The long term fuel trim is delivered from the short term fuel term values and represents a long term correction of fuel delivery for bank in question. A value of 0% indicates that fuel delivery requires no compensation to maintain the ECM commanded air fuel ratio. A negative value indicates that the fuel system is rich and fuel delivery is being reduced (decreased injector pulse width). A positive value indicates that a lean condition exists and the ECM is compensating by add fuel (increased injector pulse width). Because long term fuel trim tends to follow short term fuel trim, a value in the negative range due to canister purge at idle should not be considered unusual. Fuel trim values at maximum authority may indicate an excessively rich or lean system. This displays the amount of time the ECM is commanding each injector On during each engine cycle. A longer injector pulse width will cause more fuel to be delivered. Injector pulse width should increase with increased engine load. The ECM provides the extra amount of fuel when it detects a rapid increase in the throttle position and air flow (Power Enrichment). Under this condition the ECM should detect a rich condition (high oxygen sensor voltage). The ECM reduces the amount of fuel injected when it detects a decrease in the throttle position and the air flow. When deceleration is very fast, the ECM may cut off fuel completely. Until enable conditions meet the engine revolution less than 1000rpm or MAP less than 10kPa. This displays the engine time elapsed since the engine was started. If the engine is stopped, engine run time will be reset to 00:00:00
18
B1S1 O2 Sensor (Bank1 Sensor 1)
mV
50 - 950
50 -950
19
B1 Short Term Fuel Trim (Bank 1)
-6 - 0
-6 - 0
20
B1 Long Term Fuel Trim (Bank 1)
-10 - 0
-5 - 0
21
Injection Pulse Width
ms
3.0 - 1.0
3.0 - 4.0
22
Power Enrichment
Yes/No
No
No
23
Deceleration Cutoff
Fuel
Active/ Inactive
Inactive
Inactive
24
Time From Start
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F3: IAC System F0: IAC Control When the Tech 2 is operated, Idle Air Control increases or decreases 5steps-by-5steps up to 150steps. The circuit is normal if idle engine speed is changed in accordance with this operation. IAC Control Engine Speed Desired Idle Speed Engine Coolant Temperature Start Up ECT Intake Air Temperature Start Up IAT Manifold Absolute Pressure Idle Air Control 800 RPM 762 RPM 80 C 50 C 30 C 25 C 35kPa 30 Steps
MISCELLANEOUS TEST
The state of each circuit can be tested by using miscellaneous test menus. Especially when DTC cannot be detected, a faulty circuit can be diagnosed by testing each circuit by means of these menus. Even DTC has been detected, the circuit tests using these menus could help discriminate between a mechanical trouble and an electrical trouble. Connect Tech 2 and select Powertrain, 2.XL L4 HV240 & Miscellaneous Test. F0: Lamps F0: Malfunction Indicator Lamp When the Tech 2 is operated, Malfunction Indicator Lamp (Check Engine Lamp) is turned on or off. The circuit is normal if the Malfunction Indicator Lamp (Check Engine Lamp) in the instrument panel is turned on or off in accordance with this operation. F1: Relays F0: Fuel Pump Relay When the Tech 2 is operated, fuel pump relay signal turns ON or OFF. The circuit is normal if fuel pump sound is generated in accordance with this operation when key switch is turned ON. F1: A/C Clutch Relay When the Tech 2 is operated, A/C clutch relay signal turns ON or OFF. The circuit is normal if A/C compressor clutch is energized in accordance with this operation when the engine is running. F2: EVAP F0: Purge Solenoid When the Tech 2 is operated, duty ratio of EVAP purge solenoid is changed 10%-by-10%. Purge Solenoid Engine Speed Desired Idle Speed Engine Coolant Temperature Start Up ECT Intake Air Temperature Start Up IAT Manifold Absolute Pressure EVAP Purge Solenoid 800 RPM 762 RPM 80 C 50 C 30 C 25 C 35kPa 30%
Press Increase key. Then, Idle Air Control is increases 1osteps-by10steps up to 160steps. Engine speed is also changed by this operation. Press Quit Key. F1: IAC Reset When the Tech 2 is operated, Idle Air Control resets. The circuit is normal if idle engine speed is droped in accordance with this operation. IAC Reset Engine Speed Desired Idle Speed Engine Coolant Temperature Start Up ECT Intake Air Temperature Start Up IAT Manifold Absolute Pressure Idle Air Control 800 RPM 762 RPM 80 C 50 C 30 C 25 C 35kPa 30 Steps
Press Increase key. Then, Desired Idle speed is increases 50rpm-by50rpm up to 1550rpm. Engine speed is also changed by this operation. Press Quit Key.
Press Increase key. Then, EVAP Purge Solenoid is increases 10%-by10%. Press Quit Key.

F4: Injector Balance Test When the Tech 2 is operated, selected injector turns ON or OFF. The circuit is normal if engine vibration is changed at selected cylinder in accordance with this operation when engine is idling. Injector Balance Test Engine Speed Desired Idle Speed Engine Coolant Temperature Start Up ECT Intake Air Temperature Start Up IAT Manifold Absolute Pressure Injector 1 800 RPM 762 RPM 80 50 30 25 35kPa On
6E77
Press Injector Off key. Then, engine speed drops and vibration occurs when a cylinder is selected. Press Quit Key.
6E78
PLOTTING SNAPSHOT GRAPH

This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis. It is an effective test particularly in emission related evaluations.
060RX037
For trouble diagnosis, you can collect graphic data (snap shot) directly from the vehicle. You can replay the snapshot data as needed. Therefore, accurate diagnosis is possible, even though the vehicle is not available.
ENGINE DRIVEABILITY AND EMISSIONS Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
6E79
D06RY00167
6E80
Flow Chart for Snapshot Replay (Plotting Graph)
060RX0-40
ENGINE DRIVEABILITY AND EMISSIONS SNAPSHOT DISPLAY WITH TIS2000
6E81
Procedures for transferring and displaying Tech2 snapshot data by using TIS2000 [Snapshot Upload] function is described below. Snapshot data can be displayed with [Snapshot Upload] function included in TIS2000. 1. Record the snapshot data, in Tech2. 2. Transfer the snapshot data to PC.
By analyzing these data in various methods, trouble conditions can be checked. Snapshot data is displayed by executing the three steps below shown:
After recording the snapshot in Tech2, transfer the data from Tech2 to PC by the below procedures. 1. Start TIS2000. 2. Select [Snapshot Upload] on the TIS2000 start screen. 3. Select [Upload from trouble diagnosis tool (transfer from diagnosis tester)] or click the corresponding icon of the tool bar. 4. Select Tech2, and transfer the recorded snapshot information.
5. Select the transferred snapshot. 6. After ending transfer of the snapshot, parameter list is displayed on the screen. data
6E82
3.

3. Select [Open the existing files] or click the corresponding icon of the tool bar. 4. Select the transferred snapshot. 5. Open the snapshot, to display the data parameter list on the screen.
Snapshot data is displayed with TIS2000 [Snapshot Upload] function. Snapshot is stored in the PC hard disk or floppy disk, and can be displayed any time. Stored snapshot can be displayed by the below procedures. 1. Start TIS2000. 2. Select [Snapshot Upload] on the TIS2000 start screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter] window opens. 2. Click the first graph icon of the window upper part, and select one parameter from the list of the window lower part. Selected parameter is displayed nest to the graph icon. Graph division can be selected in the field on the parameter right side. 3. Repeat the same procedures with the 2nd and 3rd icons. 4. After selecting all parameters to be displayed (Max. 3 parameters), click [OK] button. 5. Parameter selected is displayed in graph form on the right of the data parameter on the screen.
6. Graph display can be moved with the navigation icon. 7. For displaying another parameter by graph, click the parameter of the list, drug the mouse to the display screen while pressing the mouse button and release the mouse button. New parameter is displayed at the position of the previous parameter. For displaying the graph display screen in full size, move the cursor upward on the screen. When the cursor is changed to the magnifying glass form, click the screen. Graph screen is displayed on the whole screen.
ENGINE DRIVEABILITY AND EMISSIONS Display of graphs on one screen (Max. 6 graphs):
6E83
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.
6E84

IMPORTANT: Perform the following checks before attempting to program the control unit: The Tech2 PCMCIA card is programmed with The latest software release. The latest release of TIS2000 is loaded on the PC. The vehicle battery is fully charged. The control unit to be programmed is connected to the vehicle. 1. Preparations of TIS 2000 1. Connect Tech 2 to P/C. 2. Check to see if Hardware Key is plugged into Port. 3. Activate TIS 2000 by P/C. 4. On the activating screen of TIS2000, choose Service Programming System
SERVICE PROGRAMMING SYSTEM (SPS)

The procedure to program the control unit by using the Service Programming System (SPS) software contained in TIS2000 is explained below. NOTE: If the Engine Control Module (ECM) was programmed, the Immobilizer System must be linked to the ECM: Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Should Tech2 display "SPS Procedure was not successful", engine will not start, but no DTCs are present, low battery voltage or poor electrical connections should be the primary suspects. Perform the SPS procedure again after rectifying the fault/s.
5. On the screen of Diagnostic Tester and Processing Program Selection, choose the one that will comply with the following. Tech-2 in use New programming by the existing module or new programming by the replaced/new module. Fixing position of the control unit.
6. Upon completion of the selection, push the button of Next.

2. Demand of Data 1. Connect Tech-2 to the vehicle. When activated by turning on the power of Tech-2, push the Enter switch. 2. Turn on the ignition switch (without starting the engine) 3. In the main menu of Diagnostic Tester, push F1: Service Programming System (SPS). 4. Push F0: Request Info of Tech-2.
6E85
5. Where vehicle data has been already saved in Tech 2, the existing data come on display. In this instance, as Tech-2 starts asking whether to keep the data or to continue obtaining anew data from the control unit, choose either of them
6. If you select continue, you have to select Model Year, Vehicle Type. 7. After that. then push button and turn Ignition switch tuned on, off, on following Tech-2 display. Tech-2 will read information from controller after this procedure. 8. During obtaining information, Tech-2 is receiving information from the control unit ECM and TCM (A/T only) at the same time. With VIN not being programmed into the new control unit at the time of shipment, "obtaining information" is not complete (because the vehicle model, engine model and model year are specified from VIN). For the procedure get additional information on vehicles, instruction will be provided in dialog form, when TIS2000 is in operation. 9. Following instructions by Tech-2, push the Exit switch of Tech-2, turn off the ignition of the vehicle and turn off the power of Tech-2, thereby removing from the vehicle.
3. Data Exchange 1. Connect Tech-2 to P/C, turn on the power and click the Next button of P/C. 2. Check VIN of the vehicle and choose Next. 3. Select System Type for required control unit. Engine (Programming for ECM or PCM) Transmission (Programming for TCM) 4. When a lack of data is asked from among the following menu, enter accordingly. Select following Menu Model Year Model Engine type Transmission type Destination code (vehicles for general export)*1 Immobilizer Etc. * 1: How to read the destination code Destination code can be read from ID Plate affixed on vehicles, while on VIN plate the destination code is described at the right-hand edge of Body Type line. In the figure, the destination code can be read as "RR3" (Australia).
6E86
5. After choosing the data, click the Next button. 6. When all the necessary information is entered, the details of software within the database that match the entered data will appear for confirmation. Click the Program switch and then download the new software onto Tech-2. 7. Data Transfer comes on display. The progress of downloading will be displayed on the screen in the form of bar graph. 8. Upon finishing the data transfer, turn off the power of Tech-2, removing from P/C.
4. Programming of ECM 1. Check to see if batteries are fully charged, while ABS connectors shall be removed from the vehicle. 2. Connect Tech-2 to Vehicle Diagnostic Connectors. 3. Turn on the power of Tech-2 and the title screen comes on display. 4. Turn on the ignition (without allowing the engine to start) 5. On the title screen of Tech-2, push the Enter button. 6. Choose F1: Service Programming System on the main screen and then choose Fl: Program ECU. 7. While data is being transferred, Programming in Progress will be displayed on the Tech-2 screen. 8. Upon finishing the data transfer, Tech-2 will display Reprogramming Was Successful. Push the Exit button to bring program to completion 9. Following Procedure 2: Demand of Data, try over again Information Obtaining and check to confirm if the data has been correctly re-loaded. 10. Upon finishing confirmation, turn off the ignition of the vehicle and then turn off the power of Tech-2, removing from the vehicle.
ENGINE DRIVEABILITY AND EMISSIONS HOW TO USE BREAKER BOX
6E87
3 2
1
(1) Engine Control Module (ECM) (2) Harness Adapter The engine control module (ECM) and other connectors have water proof connector and special terminal. Water proof terminal does not allow to use back prove. In addition, the engine control module (ECM) special terminal can not let regular digital voltage meter prove to access, because terminal shape is very fin pin type. In order to prevent damage of female terminal and connector itself, the breaker box and adapter is the most suitable special tool. (3) Breaker Box
6E88
Breaker Box Connection Type A
2 (4) Digital Voltage Meter (5) ECM - Harness Adapter Disconnection
(1) Engine Control Module (ECM) (2) Harness Adapter (3) Breaker Box Breaker box connection type A, check for open circuit and short to ground circuit.
ENGINE DRIVEABILITY AND EMISSIONS Breaker Box Connection Type B
6E89
5 (1) Engine Control Module (ECM) (2) Harness Adapter (3) Breaker Box
(4) Digital Voltage Meter (5) ECM - Harness Adapter Connection
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.
6E90
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Circuit Description
The on-board diagnostic system check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical check of the ECM and engine grounds for cleanliness and tightness. The on-board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction.
Test Description
Number(s) below refer the step number(s) on the Diagnostic Chart: 1. The Check Engine Lamp (MIL) should be ON steady with the ignition On, engine Off. If not, No Check Engine Lamp (MIL) chart should be used to isolate the malfunction. 2. Checks the Class 2 data circuit and ensures that the ECM is able to transmit serial data. 3. This test ensures that the ECM is capable of controlling the Check Engine Lamp (MIL) and the Check Engine Lamp (MIL) driver circuit is not shorted to ground circuit. 4. If the engine will not start, Engine Cranks But Will Not Run chart should be used to diagnose the fault. 6. The Tech2 parameters which is not within the typical range may help to isolate the area which is causing the problem. 12. This vehicle is equipped with ECM which utilizes an electrically erasable programmable read only memory (EEPROM).
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the ECM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
6E91
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

Step 1 Action 1. Ignition On, engine Off. 2. Check the CHECK ENGINE lamp (MIL). Does the CHECK ENGINE lamp turn On? 2 1. Using the Tech 2, ignition On and engine Off. 2. Attempt to display Engine Datawith the Tech 2. Does the Tech 2 display Engine Data and O2 Sensor Data? 3 1. Using the Tech 2, ignition On and engine Off. 2. Select the Miscellaneous Test and perform the Malfunction Indicator Lamp in Lamps. 3. Operate the Tech 2 in accordance with the Tech 2 instructions. Does the CHECK ENGINE lamp turn Off? 4 Attempt to start the engine. Does the engine start and continue to Run? 5 1. Using the Tech 2, ignition On and engine Off. 2. Select the Read DTC Infor By Priority in Diagnostic Trouble Code. 3. Are any DTCs stored? 6 Compare typical scan data values displayed on the Tech 2 Engine Data and O2 Sensor Data. Are the displayed values within the range? 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?
B58 16
Value(s)
Yes
No Go to No CHECK ENGINE Lamp
Go to Step 2
Go to Step 3
Go to Step 7
Go to Step 4
Go to CHECK ENGINE LAMP On Steady Go to Engine Cranks But Will Not Run
Go to Step 5
Go to DTC Chart Refer to SYMPTOM DIAGNOSIS
Go to Step 6 Refer to TYPICAL SCAN DATA
V
8 Using the DVM and check the data link connector ground circuit. 1. Ignition Off, engine Off. 2. Check the circuit for open circuit. Was the problem found?
4 B58 5
Repair faulty harness and verify repair
Go to Step 8
Go to Step 9
6E92
Step 9

Action Using the DVM and check the data link connector ground circuit. 1. Ignition On, engine Off. 2. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
4 B58 5
Value(s)
Yes
No
V
10
V
Less than 1V Go to Step 10
Using the DVM and check the data link connector communication circuit. 1. Ignition On, engine Off. 2. Check the circuit for short to power supply circuit. Was the DVM indicated battery voltage?
B-58
11 Using the DVM and check the data link connector communication circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
Go to Step 11
C-56(J2)
B-58
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?
Go to Step 12
Verify repair
Go to Step 13

Step 13 Action 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. Value(s) Yes
6E93
No
Verify repair
6E94
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and steady for about five seconds with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the check engine lamp bulb through the meter fuse. The Engine Control Module (ECM) turns the check engine lamp ON by grounding the check engine lamp driver circuit.
wire broken inside the insulation. following items:
Check for the
Inspect the ECM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. If the engine runs OK, check for a faulty light bulb, an open in the check engine lamp driver circuit, or an open in the instrument cluster ignition feed. If the engine cranks but will not run, check for an open ECM ignition or battery feed, or a poor ECM to engine ground.
Diagnostic Aids
An intermittent check engine lamp may be cased by a poor connection, rubbed-through wire insulation, or a
No Check Engine Lamp (MIL)

Step 1 Action Check the Meter fuse (15A). If the fuse is burnt out, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
Go to Step 2

Step 2 Action Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Ignition On. 4. Check the circuit for open circuit. Was the DVM indicated specified value?
32 C56(J2)
6E95
No
Value(s)
Yes
V
10 - 14.5V 3 Check the CHECK ENGINE lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found? Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect connector. the meter connector and ECM Go to Step 5 Go to Step 3
Verify repair
Go to Step 4
3. Check the circuit for open circuit. Was the problem found?
32 C56(J2) 17 B24
5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E96
CHECK ENGINE LAMP (MIL) ON STEADY
Circuit description
The check engine lamp should always be illuminated and steady for about five seconds with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the check engine lamp indicator. The Engine Control Module (ECM) turns the check engine lamp ON by grounding the check engine lamp driver circuit. The check engine lamp should not remain ON with the engine running and no DTC(s) set. A steady check engine lamp with the engine running and no DTC(s) suggests a short to ground in the check engine lamp driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: Poor connection or damaged harness - Inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
Check Engine Lamp (MIL) ON Steady

Step 1 Action 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Ignition On. Was the CHECK ENGINE lamp turned on? Go to Step 2 Go to Step 4 Value(s) Yes No

Step 2 Action Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector connector. and ECM Value(s) Yes
6E97
No
3. Check the circuit for short to ground circuit. Was the problem found?
32 C56(J2)
3 4 Replace the meter assembly. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair Verify repair
Go to Step 3
Verify repair
Go to Step 5
Verify repair
6E98
ENGINE DRIVEABILITY AND EMISSIONS FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE
FUEL METERING SYSTEM CHECK

Some failures of the fuel metering system will result in an Engine Cranks But Will Not Run symptom. If this condition exists, refer to the Cranks But Will Not Run chart. This chart will determine if the problem is caused by the ignition system, the ECM, or the fuel pump electrical circuit. Refer to Fuel System Electrical Test for the fuel system wiring schematic. If there is a fuel delivery problem, refer to Fuel System Diagnosis, which diagnoses the fuel injectors, the fuel pressure regulator, and the fuel pump. Followings are applicable to the vehicles with closed Loop System: If a malfunction occurs in the fuel metering system, it usually results in either a rich HO2S signal or a lean HO2S signal. This condition is indicated by the HO2S voltage, which causes the ECM to change the fuel calculation (fuel injector pulse width) based on the HO2S reading. Changes made to the fuel calculation will be indicated by a change in the long term fuel trim values which can be monitored with a Scan Tool. Ideal long term fuel trim values are around 0%; for a lean HO2S signal, the ECM will add fuel, resulting in a fuel trim value above 0%. Some variations in fuel trim values are normal because all engines are not exactly the same. If the evaporative emission canister purge is 02 status may be rich condition. 02 status indicates the lean condition, refer to DTC P1171 for items which can cause a lean HO2S signal.
Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting 5-88400378-0 T-Joint to the fuel pressure connection on the fuel rail. Caution: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Place the fuel pressure gauge bleed hose in an approved gasoline container. With the ignition switch OFF open the valve on the fuel pressure gauge. 3. Record the lowest voltage displayed by the DVM after the first second of the test. (During the first second, voltage displayed by the DVM may be inaccurate due to the initial current surge.) Injector Specifications: Resistance Ohms 11.8-12.6 Voltage Specification at 10C-35C (50F-95F) 5.7-6.6
The voltage displayed by the DVM should be within the specified range. The voltage displayed by the DVM may increase throughout the test as the fuel injector windings warm and the resistance of the fuel injector windings changes.

An erratic voltage reading (large fluctuations in voltage that do not stabilize) indicates an intermittent connection within the fuel injector. 5. Injector Specifications: Highest Acceptable Voltage Reading Above/Below 35C/10C (95F/50F) 9.5Volts Acceptable Subtracted Value 0.6Volt
6E99
7. The Fuel Injector Balance Test portion of this chart (Step 7 through Step 11) checks the mechanical (fuel delivery) portion of the fuel injector. An engine cooldown period of 10 minutes is necessary in order to avoid irregular fuel pressure readings due to Hot Soak fuel boiling.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
CYLINDER 1 1st Reading (1) 2nd Reading (2) Amount of Drop (1st Reading-2nd Reading) Av. Drop = 166kPa/24psi 10kPa/1.5psi = 156 - 176kPa or 22.5 - 25.5psi NOTE: These figures are examples only. 296kPa (43psi) 205kPa (29psi) 91kPa (14psi) Faulty, Lean (Too Little Fuel Drop) 2 296kPa (43psi) 205kPa (29psi) 91kPa (14psi) Faulty, Lean (Too Little Fuel Drop) 3 296kPa (43psi) 196kPa (28psi) 100kPa (15psi) Faulty, Lean (Too Little Fuel Drop) 4 296kPa (43psi) 274kPa (39psi) 22kPa (4psi) Faulty, Lean (Too Little Fuel Drop)
6E100
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the engine OFF. NOTE: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure. 2. Relieve the fuel pressure. Description Number 2. Refer to Test Value(s) Yes Go to Step 2 No Go to OBD System Check
3. Connect the 5-8840-2618-0 Fuel Injector Tester to B+ and ground, and to the 5-8840-2589-0 Injector Adapter Cable. 4. Remove the harness connector of the Fuel Injector and connect the 5-8840-2589-0 Injector Adapter Cable for F/I check. 5. Set the amperage supply selector switch on the fuel injector tester to the Coil Test 0.5 amp position. 6. Connect the leads from the 5-8840-2392-0 Digital Voltmeter (DVM) to the fuel injector tester. Refer to the illustrations associated with the test description. 7. Set the DVM to the tenths scale (0.0). 8. Observe the engine coolant temperature. Is the engine coolant temperature within the specified values? 3 1. Set the injector adapter cable to injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. Important: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector adapter cable to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading outside of the specified values? 4 Replace the faulty fuel injector(S). Refer to Fuel Injector. Is the action complete? 10C (50F) to 35C (95F)
Go to Step 3
Go to Step 5
5.7-6.6V
Go to Step 4
Go to Step 7
Go to Step 7

Step 5 Action 1. Set the Injector Adapter Cable to injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. Important: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the Injector Adapter Cable to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading above the specified value? 6 1. Identify the highest voltage reading recorded (other than those above 9.5V). 2. Subtract the voltage reading of each injector from the highest voltage selected in step 1. Repeat until you have a subtracted value for each injector. For any injector, is the subtracted value in step 2 greater than the specified value? 7 Caution: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the Towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Connect the 5-8840-0378-0 Fuel Pressure Gauge to the fuel pressure test port. 2. Energize the fuel pump using the Scan Tool. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Bleed the air out of the fuel pressure gauge. 5. With the fuel pump running, observe the reading on the fuel pressure gauge. Is the fuel pressure within the specified values? 8 Turn the fuel pump OFF. Does the fuel pressure remain constant? Go to Step 9 296kPa376kPa (43-55psi) Value(s) Yes
6E101
No
9.5V
Go to Step 4
Go to Step 6
0.6V
Go to Step 4
Go to Step 7
Go to Step 8
Go to Fuel System Diagnosis Go to Fuel System Diagnosis
6E102
Step 9

Action 1. Connect the 5-8840-0378-0 Fuel Injector Tester and 5-8840-2589-0 Injector Adapter Cable to the fuel injector harness connector. 2. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amp position. 3. Using the Scan Tool turn the fuel pump ON then OFF in order to pressurize the fuel system. 4. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure stabilizes. This is the first pressure reading. 5. Energize the fuel injector by depressing the Push to Start Test button on the fuel injector tester. 6. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure gauge needle has stopped moving. This is the second pressure reading. 7. Repeat steps 1 through 6 for each fuel injector. 8. Subtract the second pressure reading from the first pressure reading for one fuel injector. The result is the pressure drop value. 9. Obtain a pressure drop value for each fuel injector. 10. Add all of the individual pressure drop values. This is the total pressure drop. 11. Divide the total pressure drop by the number of fuel injectors. This is the average pressure drop. Does any fuel injector have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value? Value(s) Yes No
10kPa (1.5psi)
Go to Step 10
Go to OBD System Check
10
Re-test any fuel injector that does not meet the specification. Refer to the procedure in Step 11. NOTE: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding. Does any fuel injector still have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value? 1. Replace the faulty fuel injector(s). Refer to Fuel Injector. 2. Disconnect the 5-8840-2589-0 Injector Adapter Cable for F/I check and re-connect the original F/I check connector. Is the action complete?
10kPa (1.5psi)
Go to Step 11
Go to Symptoms
11
Verify repair
6E103
FUEL SYSTEM ELECTRICAL TEST
Circuit Description
When the ignition switch is first turned ON, the engine control module (ECM) energizes the fuel pump relay which applies power to the in-tank fuel pump. The fuel pump relay will remain ON as long as the engine is running or cranking and the ECM is receiving 58X crankshaft position pulses. If no 58X crankshaft position pulses are present, the ECM de-energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped. The fuel pump delivers fuel to the fuel rail and injectors, then to the fuel pressure regulator. The fuel pressure regulator controls fuel pressure by allowing excess fuel to be returned to the fuel tank. With the engine stopped and ignition ON, the fuel pump can be turned ON by using a command by the scan tool.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: Poor connection or damaged harness - Inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. Caution: To reduce the risk of fire and personal injury: It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the disconnect is completed.
6E104
ENGINE DRIVEABILITY AND EMISSIONS Fuel Pressure Gauge Installation

1. Remove the fuel pressure fitting cap. 2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located in front of and above the right side valve cover. 3. Reinstall the fuel pump relay.
Fuel Pressure Relief Procedure

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and alow it to stall. 4. Crank the engine for an additional 3 seconds.
Fuel System Electrical Test

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Using the Tech 2, ignition On and engine On. 2. Select the Miscellaneous Test and perform the Fuel Pump Relay in the Relays. 3. Operate the Tech 2 in accordance with procedure. Was the fuel pump operated, when the Tech 2 is operated? 3 Check the Fuel Pump fuse (20A). If the fuse is burnt out, repair as necessary. Was the problem found? Check for poor/faulty connection at the fuel pump, fuel pump relay or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
11 C56(J2)
Value(s)
Yes
No Go to On Board Diagnostic (OBD) System Check
Go to Step 2
Go to Fuel System Diagnosis
Go to Step 3
Verify repair
Go to Step 4
X2
F2
5 Using the DVM and check the fuel pump relay. 1. Ignition Off, engine Off. 2. Remove the fuel pump relay from the relay box. 3. Check the relay coil. Was the DVM indicated specified value?
Verify repair
Go to Step 5
Fuel Pump Relay

120 - 150
Go to Step 6
Replace fuel pump relay and verify repair

Step 6 Action Using the DVM and check the fuel pump relay power supply circuit. 1. Ignition On, engine Off. 2. Remove the fuel pump relay from the relay box. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
X2 3
6E105
No
Value(s)
Yes
V
10 - 14.5V 7 Repair the open or short to ground circuit between the ECM fuse (15A) and fuel pump relay. Is the action complete? Using the DVM and check the fuel pump relay ground circuit. 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the fuel pump relay from the relay box. 4. Check the circuit for open or short to ground circuit. Was the problem found?
11 C56(J2) X2 4
Go to Step 8
Go to Step 7
Verify repair
9 Using the DVM and check the fuel pump relay power supply circuit. 1. Ignition Off, engine Off. 2. Remove the fuel pump relay from the relay box. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
1 X2
Go to Step 9
V
10 - 14.5V Go to Step 11 Go to Step 10
6E106
Step 10

Action Repair the open circuit between the fuel pump relay and battery. Is the action complete? Using the DVM and check the fuel pump power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the fuel pump connector. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
F2 1
Value(s)
Yes
No
Verify repair
11
V
10 - 14.5V 12 Repair the open or short to ground circuit between the fuel pump relay and fuel pump. Is the action complete? Using the DVM and check the fuel pump ground circuit. 1. Ignition Off, engine Off. 2. Disconnect the fuel pump connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
F-2
Go to Step 13
Go to Step 12
Verify repair
13
Continuity 14 Repair the open circuit between the fuel pump and body ground. Is the action complete? Replace the fuel pump. Was the problem solved? 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?
Go to Step 15
Go to Step 14
Go to Step 16
15 16
Verify repair
Go to Step 17

6E107
No
Verify repair
6E108
FUEL SYSTEM DIAGNOSIS
Circuit Description
When the ignition switch is turned ON, the engine control module (ECM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the ECM is receiving 58X crankshaft position pulses. If there are no 58X crankshaft position pulses, the ECM will turn the intank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return line.
Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Connect the fuel pressure gauge to the fuel feed line as shown in the fuel system illustration. Wrap a shop towel around the fuel pressure connection in order to absorb any duel leakage that may occur when installing the fuel pressure gauge. With the ignition switch ON and the fuel pump running, the fuel pressure indicated by the fuel pressure gauge should be 283-376 kPa (41-55 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that cannot maintain a constant fuel pressure has a leak in one or more of the following areas: The fuel pump check valve. The fuel pump flex line. The valve or valve seat within the fuel pressure regulator.

The fuel injector(s). 4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a Tech 2 Scan Tool. Following are applicable to the vehicle with closed Loop System: If an extremely lean condition occurs, the oxygen sensor(s) will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. Important: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside the fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in step 2 with the engine OFF. 16.Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. If checking the spark plug associated with a particular fuel injector for fouling or saturation does not determine that a particular fuel injector is leaking, use the following procedure: Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel Rail Assembly in On-Vehicle Service. Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports. Caution: In order to reduce the risk of fire and personal injury that may result from fuel spraying on the engine, verify that the fuel rail is positioned over the fuel injector ports and verify that the fuel injector retaining clips are intact. Pressurize the fuel system by connecting a 20 amp fused jumper between B+ and the fuel pump relay connector. Visually and physically inspect the fuel injector nozzles for leaks. 17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may cause a 45 to set. Driveability conditions associated
6E109
with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator. 21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a 44 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold), hesitation, poor driveability, lack of power, surging, and misfiring. 22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure. Command the fuel pump ON with the scan tool. The fuel pressure should rise above 376 kPa (55 psi) as the fuel return line becomes partially closed. NOTE: Do not allow the fuel pressure to exceed 414 kPa (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may damage the fuel pressure regulator. Caution: To reduce the risk of fire and personal injury: It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the disconnect is completed.
Fuel Pressure Relief Procedure

1. Remove the fuel cap. 2. Located on the intake manifold which is at the top right part of the engine. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.
Fuel Pressure Gauge Installation

1. Remove the fuel pressure fitting cap. 2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located on the upper right side of the engine. 3. Reinstall the fuel pump relay.
6E110
Fuel System Diagnosis

Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Turn the ignition OFF. 2. Turn the air conditioning system OFF. 3. Relieve fuel system pressure and install the fuel pressure gauge. 4. Turn the ignition ON. NOTE: The fuel pump will run for approximately 2 seconds. Use the Scan Tool to command the fuel pump ON. 5. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? 3 Does the fuel pressure indicated by the fuel pressure gauge remain constant? NOTE: The fuel pressure will drop when the fuel pump stops running, then it should stabilize and remain constant. 4 1. When the vehicle is at normal operating temperature, turn the ignition ON to build fuel pressure and observe the measurement on the gauge. 2. Start the engine and observe the fuel pressure gauge. Did the reading drop by the amount specified after the engine was started? 5 6 Is fuel pressure dropping off during acceleration, cruise, or hard cornering? Visually and physically inspect the following items for a restriction: The in-line fuel filter. The fuel feed line. Was a restriction found? 7 Remove the fuel tank and visually and physically inspect the following items: The fuel pump strainer for a restriction. The fuel line for a leak. Verify that the correct fuel pump is in the vehicle. Was a problem found in any of these areas? 8 9 Replace the fuel pump. Is the action complete? 1. Disconnect the vacuum hose from the fuel pressure regulator. 2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator. Does the fuel pressure indicated by the fuel pressure gauge drop by the amount specified? Verify repair Verify repair Go to Step 8 Verify repair Go to Step 7 283-376 kPa (41-55 psi) Value(s) Yes Go to Step 2 No Go to OBD System Check
Go to Step 3
Go to Step 17
Go to Step 4
Go to Step 12
21-105 kPa (3-15 psi)
Go to Step 5 Go to Step 6
Go to Step 9 Check for improper fuel
21-105 kPa (3-15 psi)
Go to Step 10
Go to Step 11

Step 10 Action Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete? Replace the fuel pressure regulator. Is the action complete? 1. Run the fuel pump with the Scan Tool. 2. After pressure has built up, turn off the pump and clamp the supply hose shut with suitable locking pliers. Does the fuel pressure indicated by the fuel pressure gauge remain constant? 13 Visually inspect the fuel supply line and repair any leaks. Was a problem found? Remove the fuel tank and inspect for leaky hose or intank fuel line. Was a problem found? 1. If the pliers are still clamped to the fuel supply hose, remove the locking pliers. 2. With suitable locking pliers, clamp the fuel return line to prevent fuel from returning to the fuel tank. 3. Run the fuel pump with the Scan Tool. 4. After pressure has built up, remove power to the pump. Does the fuel pressure indicated by the fuel pressure gauge remain constant? 16 17 18 Locate and replace any leaking fuel injector(s). Is the action complete? Is the fuel pressure indicated by the fuel pressure gauge above the specified limit? 1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief. 2. Disconnect the fuel return line from the fuel rail. 3. Attach a length of flexible hose to the fuel rail return outlet passage. 4. Place the open end of the flexible hose into an approved gasoline container. 5. Run the fuel pump with the Scan Tool. 6. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? 19 Locate and correct the restriction in the fuel return line. Is the action complete? Visually and physically inspect the fuel rail outlet passages for a restriction. Was a restriction found? Is the fuel pressure indicated by the fuel pressure gauge above the specified value? 290-376 kPa (42-55 psi) Value(s) Yes
6E111
No
11 12
Go to Step 13
Go to Step 15
Verify repair
Go to Step 14
14
Verify repair
Go to Step 8
15
376 kPa (55 psi)
Go to Step 11 Verify repair Go to Step 18
Go to Step 19
Go to Step 20
Verify repair
20
0 kPa (0 psi)
Verify repair Go to Step 22
21
6E112
Step 22

Action 1. Command the fuel pump ON with the Scan Tool. 2. Using suitable pliers which will not damage the fuel hose, gradually apply pressure with the pliers to pinch the flexible fuel return hose closed. Does the fuel pressure indicated by the fuel pressure gauge rise above the first specified value? Caution: Do not let the fuel pressure exceed the second specified value. 376 kPa (55 psi) Value(s) Yes No
414 kPa (60 psi)
Go to Step 11
Go to Step 7
23
1. Command the fuel pump ON with the Scan Tool. 2. Remove the fuel filler cap and listen for the sound of the fuel pump running. 3. Turn the pump off. Was the fuel pump running? Go to Step 7 Go to Fuel System Electrical Test Chart

Type A Emission related.
6E113
ECM DIAGNOSTIC TROUBLE CODES (DTC)
Requests illumination of the MIL (Malfunction Indicator Lamp = Check Engine Lamp) of the first trip with a fail. Stores a history DTC on the first trip. Stores a freeze frame (If empty). Stores a fail record. Updates the fail record each time the diagnostic test fails. Type B Emission related. Armed after one trip with fail. Disarmed after one trip with a pass. Requests illumination of the MIL on the second consecutive trip with a fail. Store a history DTC on the second consecutive trip with a fail. (The DTC will be armed after the first fail.) Stores a freeze frame on the second consecutive trip with a fail (If empty). Stores a fail record when the first test fails (not dependent on consecutive trip). Updates the fail record each time the diagnostic test fails. Type D Non emission related. Does not request illumination of any lamp. Stores a history DTC on the first trip. Does not store a freeze frame. Stores fail record when test fails. Updates the fail record each time the diagnostic test fails.
6E114
Code

Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related ECM Pin No. J1-24/ J1-31
P0107
Manifold Absolute Pressure Circuit Low Input
MAP sensor output is more than 12kPa. The ECM uses default manifold 1. No DTC relating to TPS. absolute pressure value based on 2. Throttle position is more than 0% if engine engine speed and throttle position. speed is below 1000rpm, or throttle position more than 5% if engine speed is more than 1000rpm. 3. MAP sensor output is below 12kPa.
1. Sensor power supply circuit open or short to ground circuit. 2. Sensor signal circuit open or short to ground circuit. 3. Poor connector connection. 4. MAP sensor malfunction. 5. ECM malfunction. 1. Sensor power supply circuit short to voltage circuit. 2. Sensor signal circuit short to voltage circuit. 3. Sensor ground circuit open or short to voltage circuit. 4. Poor connector connection. 5. MAP sensor malfunction. 6. ECM malfunction. 1. Sensor signal circuit short to ground circuit. 2. IAT sensor malfunction. 3. ECM malfunction.
P0108
Manifold Absolute Pressure Circuit High Input
1. No DTC relating to TPS. 2. Throttle position is below 15% if engine speed is below 2500rpm, or throttle position is below 35% if engine speed is more than 2500rpm. 3. Engine run time is longer than 10 seconds. 4. MAP sensor output is more than 103kPa.
MAP sensor output is below 103kPa.
J1-16/ J1-24/ J1-31
P0112
Intake Air Temperature Sensor Low Input
1. No DTC relating to VSS. 2. Vehicle speed is more than 25km/h. 3. Engine run time is longer than 120 seconds. 4. IAT sensor output is more than 149 deg. C. 1. No DTC relating to VSS & ECT sensor. 2. Vehicle speed is below 70km/h. 3. 3Engine coolant temperature is more than -8 deg. C. 4. Engine run time is longer than 120 seconds. 5. Mass air flow is below 30g/s. 6. IAT sensor output is below -38 deg. C. 1. Engine run time is longer than 120 seconds. 2. ECT sensor output is more than 149 deg. C. 1. Engine run time is longer than 120 seconds. 2. ECT sensor output is below -38 deg. C.
The ECM uses 20 deg. C condition IAT sensor output is below 149 deg. C. as substitute.
J2-22
P0113
Intake Air Temperature Sensor High Input
IAT sensor output is more than -38 deg. C.
1. Sensor signal circuit open or short to voltage circuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Poor connector connection 4. IAT sensor malfunction. 5. ECM malfunction.
J2-1/ J2-22
P0117
Engine Coolant Temperature Sensor Low Input
The ECM uses default engine coolant temperature value based on intake air temperature and engine run time.
ECT sensor output is below 149 deg. C.
1. Sensor signal circuit short to ground circuit. 2. ECT sensor malfunction. 3. ECM malfunction. 1. Sensor signal circuit open or short to voltage circuit. 2. Sensor ground circuit open or short to voltage circuit. 3. Poor connector connection 4. ECT sensor malfunction. 5. ECM malfunction.
J1-27
P0118
Engine Coolant Temperature Sensor High Input
ECT sensor output is more than -38 deg. C.
J1-27/ J1-32

Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts
6E115
Related ECM Pin No. J1-7/ J1-15/
P0122
Throttle Position Sensor Low Input
TPS output voltage is below 0.14V.
The ECM uses 0% condition as substitute.
TPS output voltage is more than 0.14V.
1. Sensor power supply circuit open or short to ground circuit. 2. Sensor signal circuit open or short to ground circuit. 3. Poor connector connection. 4. TPS malfunction. 5. ECM malfunction. 1. Sensor power supply circuit short to voltage circuit. 2. Sensor signal circuit short to voltage circuit. 3. Sensor ground circuit open or short to voltage circuit. 4. Poor connector connection. 5. TPS malfunction. 6. ECM malfunction. 1. Sensor harness short to ground circuit. 2. O2 sensor malfunction. 3. ECM malfunction.
P0123
Throttle Position Sensor High Input
TPS output voltage is more than 4.9V.
TPS output voltage is below 4.9V.
J1-7/ J1-15/ J1-32
P0131
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
Open Loop fuel control. 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. O2 sensor bank 1 output voltage is below 50mV in Closed Loop condition. 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. O2 sensor bank 1 output voltage is more than 952mV in Closed Loop condition. 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. Engine run time is longer than 40 seconds. 4. Mass air flow is more than 7g/s. 5. O2 sensor bank 1 output voltage is between 300mV and 600mV.
O2 sensor bank 1 output voltage is more than 50mV.
J2-6/ J2-21
P0132
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
O2 sensor bank 1 output voltage is below 952mV.
1. Sensor harness short to voltage circuit. 2. O2 sensor malfunction. 3. MAF sensor output is incorrect. 4. Air intake line malfunction. 5. IAC valve malfunction. 6. Incorrect fuel pressure. 7. Injector malfunction. 8. ECM malfunction. 1. Sensor harness open circuit. 2. O2 sensor malfunction. 3. MAF sensor output is incorrect. 4. Air intake line malfunction. 5. IAC valve malfunction. 6. Incorrect fuel pressure. 7. Injector malfunction. 8. ECM malfunction.
J2-6/ J2-21
P0134
O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
O2 sensor bank 1 output voltage is below 300mV consecutively. OR O2 sensor bank 1 output voltage is more than 600mV consecutively.
J2-6/ J2-21
6E116
Code

Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related ECM Pin No. J2-31
P0135
O2 Sensor Heater Circuit (Bank 1 Sensor 1)
1. No DTC relating to MAP sensor and ECT No fail-safe function. sensor. 2. Engine coolant temperature is more than 60 deg. C. 3. Engine run time is longer than 20 seconds. 4. MAP sensor output is more than 70kPa. 5. O2 sensor bank 1 heater current more than 10mA. 1. Engine is running. 2. Engine speed is more than 1000rpm. 3. Injector voltage does not meet to the battery voltage when the injector is commanded Off or does not meet to the 0V when the injector is commanded On. 1. No DTC relating to MAP sensor. 2. Engine coolant temperature is more than 50 deg. C. 3. Engine speed is more than 1600rpm. 4. Knock sensor filter module integrated circuit malfunction. 1. No DTC relating to MAP sensor. 2. Engine coolant temperature is more than 50 deg. C. 3. Engine speed is more than 1600rpm. 4. Knock sensor harness short to ground or short to voltage circuit. 1. Engine is running. 2. Extra or missing pulse is detected consecutively. No fail-safe function. ECM retards ignition timing 4 deg. C.
O2 sensor bank 1 heater circuit is correct condition.
1. Heater harness open, short to ground or short to voltage circuit. 2. O2 sensor heater malfunction. 3. ECM malfunction.
P0201 P0202 P0203 P0204 P0325
A A A A B
Injector 1 Control Circuit Injector 2 Control Circuit Injector 3 Control Circuit Injector 4 Control Circuit Knock Sensor Module Circuit
Injector circuit is correct condition.
1. Injector harness open circuit, short to ground or short to voltage circuit. 2. Injector malfunction. 3. ECM malfunction.
J1-9 J1-22 J1-8 J1-11
Knock sensor is correct condition.
1. KS harness open circuit. 2. Poor connector connection. 3. KS sensor malfunction. 4. ECM malfunction.
J1-3/ J1-32
P0327
Knock Sensor Circuit
1. KS harness short to ground or short to voltage circuit. 2. Poor connector connection. 3. KS sensor malfunction. 4. ECM malfunction. Correct pulse is detected consecutively. 1. CKP sensor harness open circuit, short to ground or short to voltage circuit. 2. Poor connector connection. 3. CKP sensor malfunction. 4. Pulse sensing gap incorrect. 5. Pluser malfunction. 6. Electrical interference. 7. Magnetic interference. 8. ECM malfunction. 1. CKP sensor harness open circuit, short to ground or short to voltage. 2. Poor connector connection. 3. CKP sensor malfunction. 4. Pulse sensing gap incorrect. 5. Pluser malfunction. 6. Electrical interference. 7. Magnetic interference. 8. ECM malfunction.
J1-3/ J1-32
P0336
Crankshaft Position Sensor Circuit Range/ Performance (58X)
J1-6/ J1-21
P0337
Crankshaft Position Sensor Circuit Low Input (58X)
No pulse is detected during engine cranking.
J1-6/ J1-21

Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts
6E117
Related ECM Pin No. J1-19
P0351
Ignition 1 Control Circuit
#1 or #4cylinder ignition signals are not detected consecutively.
No fail-safe function.
Consecutive ignition signals are detected.
1. Ignition coil module 1 harness open circuit, short to ground or short to voltage circuit. 2. Ignition coil module malfunction. 3. ECM malfunction. 1. Ignition coil module 2 harness open circuit, short to ground or short to voltage circuit. 2. Ignition coil module malfunction. 3. ECM malfunction.
P0352
Ignition 2 Control Circuit
#2 or #3 cylinder ignition signals are not detected consecutively.
J1-18
P0443
EVAP Emission Control System Purge Control Circuit
EVAP purge solenoid circuit open, short to ground or short to voltage circuit.
EVAP purge solenoid circuit is correct condition.
1. Solenoid harness open circuit, short to ground or short to voltage circuit. 2. Solenoid malfunction. 3. ECM malfunction. 1. Sensor harness open circuit, short to ground circuit or short to voltage circuit. 2. Poor connector connection. 3. VSS malfunction. 4. ECM malfunction.
J1-5
P0502
Vehicle Speed Sensor Circuit Low Input
1. No DTC relating to MAP sensor, TPS, ECT sensor, injector control circuit and ignition control circuit. 2. Engine is running. 3. Vehicle speed is below 3km/h in power condition or 2km/h in deceleration condition. Battery voltage is below 11V.
ECM uses 0km/h condition as substitute.
VSS circuit correct condition.
J2-23
P0562
System Voltage Low
Battery voltage is between 11V and 16V.
1. Battery power feed harness open circuit or short to ground circuit. 2. ECM ground harness open or poor connection. 3. Poor connector connection. 4. Battery malfunction. 5. Charge system malfunction. 6. ECM malfunction. 1. Charge system malfunction. 2. Battery jump start cable misconnect. 3. ECM malfunction.
P0563
System Voltage High
Battery voltage is above 16V.
P0601 P0602 P0650
A A
ECM Memory Checksum ECU Programming Error Malfunction Indicator Lamp (MIL) Control Circuit Malfunction
ECM memory area error. ECM memory area error. Check engine lamp circuit open, short to ground or short to voltage circuit.
Engine control disabled. Engine control disabled. No fail-safe function.
Memory are is OK. Memory are is OK. Check engine lamp circuit is correct condition.
ECM malfunction. ECM is not programmed. 1. Solenoid harness open circuit, short to ground or short to voltage circuit. 2. Solenoid malfunction. 3. ECM malfunction.
J2-32
6E118
Code

Type DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts Related ECM Pin No. J2-6/ J2-21
P1167
Fuel Supply System Rich During Deceleration Fuel Cutoff
1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. O2 sensor bank 1 output voltage is more than 550mV in deceleration fuel cutoff mode.
O2 sensor output voltage is below 550mV.
1. Sensor harness open or short to ground circuit. 2. O2 sensor malfunction. 3. MAF sensor output is incorrect. 4. Air intake line malfunction. 5. IAC valve malfunction. 6. Low fuel pressure. 7. Injector malfunction. 8. EVAP purge solenoid valve malfunction. 9. Ignition system malfunction. 10. Spark plug malfunction. 11. ECM malfunction. 1. Sensor harness open or short to ground circuit. 2. O2 sensor malfunction. 3. MAF sensor output is incorrect. 4. Air intake line malfunction. 5. IAC valve malfunction. 6. Low fuel pressure. 7. Injector malfunction. 8. ECM malfunction. 1. Electrical interference. 2. Magnetic interference. 3. ECM malfunction. 1. ECM and immobilizer control unit communication circuit open circuit, short to ground circuit or short to voltage circuit. 2. ECM malfunction. 3. Immobilizer control unit malfunction. 4. Transponder key malfunction. 1. ECM malfunction. 2. Immobilizer control unit malfunction. 3. Transponder key malfunction. 1. ECM malfunction. 2. Immobilizer control unit malfunction. 3. Transponder key malfunction. ECM malfunction.
P1171
Fuel Supply System Lean During Power Enrichment
No fail-safe function. 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60deg. C. 3. Mass air flow is below 13.5m/s. 4. O2 sensor bank 1 output voltage is below 350mV in power enrichment mode. ECM reset has occurred other than On. Engine control disabled.
O2 sensor output voltage is more than 350mV.
J2-6/ J2-21
P1625
ECM System Reset
Memory are is OK.
P1626
Immobilizer No Signal
No response from immobilizer control unit.
1. Engine does not start. 2. Check engine lamp flash.
No recovery.
J2-23/ J2-32
P1631
Immobilizer Wrong Signal
Received response is not correct.
P1648
Wrong Security Code Entered
Received incorrect security code.
P1649 P1693
Immobilizer Function Not Programmed Tachometer Output Low Voltage
Immobilizer function is not programmed in the ECM. Tacho output circuit short to ground circuit. No fail-safe function. Tacho output circuit is correct condition.
J2-25
1. Tacho output circuit short to ground circuit. 2. Poor connector connection. 3. ECM malfunction.
6E119
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE CIRCUIT LOW INPUT
Condition for setting the DTC and action taken when the DTC sets
Code P0107 Type A DTC Name Manifold Absolute Pressure Circuit Low Input DTC Setting Condition 1. No DTC relating to TPS. 2. Throttle position is more than 0% if engine speed is below 1000rpm, or throttle position more than 5% if engine speed is more than 1000rpm. 3. MAP sensor output is below 12kPa. Fail-Safe (Back Up) The ECM uses default manifold absolute pressure value based on engine speed and throttle position.
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure. The MAP sensor signal voltage to the engine control module (ECM) varies from below 2 volts at idle (low manifold pressure) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (high manifold pressure). A speed density method of determining engine load is used on the 2.4L engine. This is calculated using inputs from the MAP sensor, the CKP Sensor, and the Intake
Air Temperature (IAT) sensor. The MAP sensor is the main sensor used in this calculation, and measuring engine load is its main function. The ECM monitors the MAP signals for voltages outside the normal range (10-104 kPa) of the MAP sensor. If the ECM detects a MAP signal voltage that is excessively low, Diagnostic Trouble Code P0107 will be set.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM Inspect harness
6E120

damage, short to ground, short to battery positive, and open circuit. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.
connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. Damaged harness - Inspect the wiring harness for
Diagnostic Trouble Code (DTC) P0107 Manifold Absolute Pressure Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0107 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0107 stored in this ignition cycle? 4 Check for poor/faulty connection at the MAP sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
16 E60(J1) E85
Value(s)
Yes
Go to Step 2
Go to Step 3
Refer to Diagnostic Aids and Go to Step 3
Go to Step 4
31
24
5 6
Visually check the MAP. Was the problem found? Using the DVM and check the MAP sensor power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAP sensor connector. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
E85 3
Approximately 5.0V
Go to Step 8
Go to Step 7

Step 7 Action Repair the open or short to ground circuit between the ECM and MAP sensor Was the problem solved?
31 E60(J1) E85 3
6E121
No
Value(s)
Yes
8 Using the DVM and check the MAP sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect MAP sensor connector. 4. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
Breaker Box J1-16 J1-24 E-85
Verify repair
Go to Step 11
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAP sensor connector and ECM connector. 3. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
16 E60(J1) 24 E85 2
9 10 11 Substitute a known good MAP sensor and recheck. Was the problem solved? Replace the MAP sensor. Is the action complete? 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?
Repair faulty harness and verify repair Go to Step 10 Verify repair
Verify repair
Go to Step 12
6E122
Step 12

Action 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. Value(s) Yes No
Verify repair
6E123
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE CIRCUIT HIGH INPUT
Code P0108 Type A DTC Name Manifold Absolute Pressure Circuit High Input DTC Setting Condition Fail-Safe (Back Up)
The ECM uses default manifold absolute 1. No DTC relating to TPS. pressure value based on engine speed 2. Throttle position is below 15% if engine and throttle position. speed is below 2500rpm, or throttle position is below 35% if engine speed is more than 2500rpm. 3. Engine run time is longer than 10 seconds. 4. MAP sensor output is more than 103kPa.
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure. The MAP sensor signal voltage to the engine control module (ECM) varies from below 2 volts at idle (low manifold pressure) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (high manifold pressure). A speed density method of determining engine load is used on the 2.4L engine. This is calculated using inputs
from the MAP sensor, RPM, CKP Sensor, and the Intake Air Temperature (IAT) sensor. The MAP sensor is the main sensor used in this calculation, and measuring engine load is its main function. The ECM monitors the MAP signals for voltages outside the normal range (10-104 kPa) of the MAP sensor. If the ECM detects a MAP signal voltage that is excessively high, Diagnostic Trouble Code P0108 will be set.
6E124

problem with the 5 Volt reference circuit. Damaged harness - Inspect the wiring harness for damage; an open circuit, a short to ground, or a short to voltage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. If these codes are also set, it could indicate a
Diagnostic Trouble Code (DTC) P0108 Manifold Absolute Pressure Circuit High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0108 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0108 stored in this ignition cycle? 4 Check for poor/faulty connection at the MAP sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
16 E60(J1) E85
Value(s)
Yes
No Go to On Board Diagnostic (OBD) System Check Refer to Diagnostic Aids and Go to Step 3
Go to Step 2
Go to Step 3
Go to Step 4
31
24
Visually check the MAP sensor. Was the problem found?

Step 6 Action Using the DVM and check the MAP sensor power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the MAP sensor connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
E85 3
6E125
No
Value(s)
Yes
V
7 Repair the short to voltage circuit between the ECM and MAP sensor. Was the problem solved?
31 E60(J1) E85 3
Approximately 5.0V
Go to Step 8
Go to Step 7
8 Using the DVM and check the MAP sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the MAP sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E85 2
Verify repair
Go to Step 13
V
Less than 1V 9 Using the DVM and check the MAP sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the MAP sensor connector . 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E85 1
Go to Step 9
V
6E126
Step 10

Action Using the DVM and check the MAP sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the MAP sensor connector. 4. Check the circuit for open circuit. Was the problem found?
Breaker Box J1-16 E-85
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the MAP sensor connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found?
16 E60(J1) 1 E85
11 12 13 Substitute a known good MAP sensor and recheck. Was the problem solved? Replace the MAP sensor. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 14
14
Verify repair
6E127
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE SENSOR LOW INPUT
Code P0112 Type A DTC Name Intake Air Temperature Sensor Low Input DTC Setting Condition Fail-Safe (Back Up)
The ECM uses 20 deg. C condition as 1. No DTC relating to VSS. substitute. 2. Vehicle speed is more than 25km/h. 3. Engine run time is longer than 120 seconds. 4. IAT sensor output is more than 149 deg. C.
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The engine control module (ECM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the ECM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower, causing the ECM to monitor a lower voltage. Diagnostic Trouble Code P0112 will set when the ECM detects an excessively low signal voltage
(short to ground) on the intake air temperature sensor signal circuit.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery and open
6E128

change in the IAT display will indicate the location of the fault.
circuit. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A
Diagnostic Trouble Code (DTC) P0112 Intake Air Temperature Sensor Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0112 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0112 stored in this ignition cycle? 4 Check for poor/faulty connection at the IAT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C56(J2) 1 C121
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
22
Remove the IAT sensor and visually check. Was the problem found?

Step 6 Action Using the DVM and check the IAT sensor. 1. Ignition Off, engine Off. 2. Disconnect IAT sensor connector. 3. Measure the resistance of IAT sensor. Does the tester indicate standard resistance as shown in the following table?
Temperature (C) -20 0 20 40 60 80 100 120 Resistance ( 9) (Approximately) 32500 9910 3400 1509 670 329 182 101
6E129
No
Value(s)
Yes
IAT Sensor
Standard resistance 7 Using the DVM and check the IAT sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the IAT sensor connector. (ECM
Go to Step 7
Go to Step 8
4. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
Breaker Box J2-1 J2-22
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the IAT sensor connector. 3. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
C56(J2) 22 1
Go to Step 10
6E130
Step 8

Action Substitute a known good IAT sensor assembly and recheck. Was the problem solved? Replace the IAT sensor assembly. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Go to Step 9 Verify repair
Go to Step 10
9 10
Verify repair
Go to Step 11
11
Verify repair
6E131
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE SENSOR HIGH INPUT
Code P0113 Type A DTC Name Intake Air Temperature Sensor High Input DTC Setting Condition Fail-Safe (Back Up)
The ECM uses 20 deg. C condition as 1. No DTC relating to VSS & ECT sensor. substitute. 2. Vehicle speed is below 70km/h. 3. 3Engine coolant temperature is more than 8 deg. C. 4. Engine run time is longer than 120 seconds. 5. Mass air flow is below 30g/s. 6. IAT sensor output is below -38 deg. C.
Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The engine control module (ECM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the ECM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the ECM to monitor a lower
voltage. Diagnostic Trouble Code P0113 will set when the ECM detects an excessively high signal voltage on the intake air temperature sensor signal circuit.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged
6E132

observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault.
terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery positive, and open circuit. If the harness appears to be OK,
Diagnostic Trouble Code (DTC) P0113 Intake Air Temperature Sensor High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0113 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0113 stored in this ignition cycle? 4 Check for poor/faulty connection at the IAT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C56(J2) 1 C121
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
22
Visually check the IAT sensor. Was the problem found?

Step 6 Action Using the DVM and check the IAT sensor. 1. Ignition Off, engine Off. 2. Disconnect IAT sensor connector. 3. Measure the resistance of IAT sensor. Does the tester indicate standard resistance as shown in the following table?
Temperature ( C) -20 0 20 40 60 80 100 120 Resistance ( 9) (Approximately) 32500 9910 3400 1509 670 329 182 101
6E133
No
Value(s)
Yes
IAT Sensor
Standard resistance 7 Using the DVM and check the IAT sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the IAT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
1 C121
Go to Step 7
Go to Step 12
V
8 Repair the open circuit between the ECM and IAT sensor. Was the problem solved?
C56(J2) 22 1 C121
Approximately 5.0V
Go to Step 10
Less than 1V: Go to Step 8 More than specified value: Go to Step 9
9 Repair the short to voltage circuit between the ECM and IAT sensor. Was the problem solved?
C56(J2) 22 1 C121
Verify repair
Go to Step 14
Verify repair
Go to Step 14
6E134
Step 10

Action Using the DVM and check the IAT sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the IAT sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C121 2
Value(s)
Yes
No
V
Less than 1V 11 Using the DVM and check the IAT sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the IAT sensor connector. 4. Check the circuit for open circuit. Was the problem found?
Breaker Box J2-1 C-121
Go to Step 11
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the IAT sensor connector. 3. Check the circuit for open circuit. Was the problem found?
C56(J2) 1 C121 2
12 Substitute a known good IAT sensor assembly and recheck. Was the problem solved? Replace the IAT sensor assembly. Is the action complete? 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?
Go to Step 14
Go to Step 14
13 14
Verify repair
Go to Step 15

6E135
No
Verify repair
6E136
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE SENSOR LOW INPUT
Code P0117 Type A DTC Name Engine Coolant Temperature Sensor Low Input DTC Setting Condition 1. Engine run time is longer than 120 seconds. 2. ECT sensor output is more than 149 deg. C. Fail-Safe (Back Up) The ECM uses default engine coolant temperature value based on intake air temperature and engine run time.
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The engine control module (ECM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the ECM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes lower, and the ECT signal voltage measured at the ECM drops. Diagnostic Trouble code P0117 set when the ECM detects an excessively low signal voltage on the engine coolant temperature sensor signal circuit.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery positive, and open circuit. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault.
6E137
Diagnostic Trouble Code (DTC) P0117 Engine Coolant Temperature Sensor Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0117 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0117 stored in this ignition cycle? 4 Check for poor/faulty connection at the ECT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E60(J1) E69
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
32
27
5 6
Visually check the ECT sensor. Was the problem found? Using the DVM and check the ECT sensor. 1. Ignition Off, engine Off. 2. Disconnect ECT sensor connector. 3. Measure the resistance of ECT sensor. Does the tester indicate standard resistance as shown in the following table?
ECT Sensor
Standard resistance
Go to Step 7
Go to Step 8
6E138
Step 7

Action Using the DVM and check the ECT sensor signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the ECT sensor connector. 4. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
32 27 E60(J1)
8 Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 10
Go to Step 10
9 10
Verify repair
Go to Step 11
11
Verify repair
6E139
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE SENSOR HIGH INPUT
Code P0118 Type A DTC Name Engine Coolant Temperature Sensor High Input DTC Setting Condition 1. Engine run time is longer than 120 seconds. 2. ECT sensor output is below -38 deg.C. Fail-Safe (Back Up) The ECM uses default engine coolant temperature value based on intake air temperature and engine run time.
Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The engine control module (ECM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the ECM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the ECM drops. Diagnostic Trouble code P0118 set when the ECM detects an excessively high signal voltage on the engine coolant temperature sensor signal circuit.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery positive, and open circuit. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault.
6E140
Diagnostic Trouble Code (DTC) P0118 Engine Coolant Temperature Sensor High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0118 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0118 stored in this ignition cycle? 4 Check for poor/faulty connection at the ECT sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E60(J1) E69
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
32
27
5 6
Visually check the ECT sensor. Was the problem found? Using the DVM and check the ECT sensor. 1. Ignition Off, engine Off. 2. Disconnect ECT sensor connector. 3. Measure the resistance of ECT sensor. Does the tester indicate standard resistance as shown in the following table?
ECT Sensor
Standard resistance
Go to Step 7
Go to Step 12

Step 7 Action Using the DVM and check the ECT sensor signal circuit. 1. Ignition On, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E69 1
6E141
No
Value(s)
Yes
V
8 Repair the open circuit between the ECM and ECT sensor. Was the problem solved?
27 E60(J1) 1 E69
Approximately 5.0V
Go to Step 10
Less than 1V: Go to Step 8 More than specified value: Go to Step 9
9 Repair the short to voltage circuit between the ECM and ECT sensor. Was the problem solved?
27 E60(J1) 1 E69
Verify repair
Go to Step 14
10 Using the DVM and check the ECT sensor ground circuit. 1. Ignition On, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E69 2
Verify repair
Go to Step 14
V
6E142
Step 11

Action Using the DVM and check the ECT sensor ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the ECT sensor connector. 4. Check the circuit for open circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECT sensor connector. 3. Check the circuit for open circuit. Was the problem found?
32 E60(J1) E69 2
12 Substitute a known good ECT sensor assembly and recheck. Was the problem solved? Replace the ECT sensor. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 14
Go to Step 14
13 14
Verify repair
Go to Step 15
15
Verify repair
6E143
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION SENSOR LOW INPUT
Code P0122 Type A DTC Name Throttle Position Sensor Low Input DTC Setting Condition TPS output voltage is below 0.14V. Fail-Safe (Back Up) The ECM uses 0% condition as substitute.
Circuit Description
The throttle position sensor circuit provides a signal voltage that changes relative to throttle blade angle. The signal voltage will vary from below 1 volt at closed throttle to about 4 volts at wide open throttle (WOT). The TPS signal is used by the engine control module (ECM) for fuel control and most of the ECM-controlled outputs. If the ECM detect a continuous short to ground in the TPS or circuit, then a code P0122 will set.
Diagnostic Aids
Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery positive, and open circuit. If the harness appears to be OK, observe the throttle position display on the Tech 2 while moving connectors and wiring harnesses related to the TPS. A change in the display will indicate the location of the fault.
6E144
Diagnostic Trouble Code (DTC) P0122 Throttle Position Sensor Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0122 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0122 stored in this ignition cycle? 4 Check for poor/faulty connection at the TPS or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E60(J1) E68
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
32
15 7
5 6
Visually check the TPS. Was the problem found? Using the DVM and check the TPS. 1. Ignition Off, engine Off. 2. Disconnect TPS connector. 3. Measure the resistance of TPS. Does the tester indicate standard resistance as shown in the following table?
Measurement Terminal 1-2 2-3 1-3 Resistance (9) Approximately 5.6k9 at idle position & WOT Approximately 6.0k9 at idle position Approximately 1.7k9 at WOT Approximately 2.3k9 at idle position & WOT Approximately 6.6k9 at WOT
TPS
2 3
Standard resistance
Go to Step 7
Go to Step 10

Step 7 Action Using the DVM and check the TPS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
E68 2
6E145
No
Value(s)
Yes
V
8 Repair the open or short to ground circuit between the ECM and TPS. Was the problem solved?
15 E60(J1) E68 2
Approximately 5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 12
6E146
Step 9

Action Using the DVM and check the TPS signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect TPS connector. 4. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the TPS connector and ECM connector. 3. Check the circuit for open, short to sensor ground or short to ground circuit. Was the problem found?
32 E60(J1)7 E68 3
10 11 12 Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 12 Go to Step 12 -
Verify repair
Go to Step 12
13
Verify repair
6E147
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION SENSOR HIGH INPUT
Code P0123 Type A DTC Name Throttle Position Sensor High Input DTC Setting Condition TPS output voltage is more than 4.9V. Fail-Safe (Back Up) The ECM uses 0% condition as substitute.
Circuit Description
The throttle position sensor circuit provides a voltage signal that changes relative to throttle blade angle. The signal voltage will vary from below 1 volt at closed throttle to about 4 volts at wide open throttle (WOT). The TPS is used by the engine control module (ECM) for fuel control and most of the ECM-controlled outputs. If the ECM detect a continuous short voltage in the TPS or circuit, then a code P0123 will set.
connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit or components itself. Damaged harness - Inspect the wiring harness for damage, short to ground, short to battery positive and open circuit. If the harness appears to be OK, observe the Throttle Position sensor display on the Tech 2 while moving connectors and wiring harnesses related to the TP sensor. A change in the display will indicate the location of the fault.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM Inspect harness
6E148
Diagnostic Trouble Code (DTC) P0123 Throttle Position Sensor High Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0123 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0123 stored in this ignition cycle? 4 Check for poor/faulty connection at the TPS or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E60(J1) E68
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
32
15 7
5 6
Visually check the TPS. Was the problem found? Using the DVM and check the TPS. 1. Ignition Off, engine Off. 2. Disconnect TPS connector. 3. Measure the resistance of TPS. Does the tester indicate standard resistance as shown in the following table?
Measurement Terminal 1-2 2-3 1-3 Resistance (9) Approximately 5.6k9 at idle position & WOT Approximately 6.0k9 at idle position Approximately 1.7k9 at WOT Approximately 2.3k9 at idle position & WOT Approximately 6.6k9 at WOT
TPS
2 3
Standard resistance
Go to Step 7
Go to Step 12

Step 7 Action Using the DVM and check the TPS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated specified value?
E68 2
6E149
No
Value(s)
Yes
V
8 Repair the short to voltage circuit between the ECM and TPS. Was the problem solved?
15 E60(J1) E68 2
Approximately 5.0V
Go to Step 9
Go to Step 8
9 Using the DVM and check the TPS signal circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E68 3
Verify repair
Go to Step 14
V
Less than 1V 10 Using the DVM and check the TPS ground circuit. 1. Ignition On, engine Off. 2. Disconnect the TPS connector . 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E68 1
Go to Step 10
V
6E150
Step 11

Action Using the DVM and check the TPS ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the TPS connector. 4. Check the circuit for open circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect connector. the TPS connector and ECM
3. Check the circuit for open circuit. Was the problem found?
32 E60(J1) 1 E68
12 13 14 Substitute a known good TPS and recheck. Was the problem solved? Replace the TPS. Is the action complete? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 14
15
Verify repair
6E151
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
Code P0131 Type A DTC Name O2 SensorCircuit Low Voltage (Bank 1 Sensor 1) DTC Setting Condition 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. O2 sensor bank 1 output voltage is below 50mV in Closed Loop condition. Fail-Safe (Back Up) Open Loop fuel control.
Circuit Description
The engine control module (ECM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal and low circuits. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The ECM constantly monitors the HO2S signal during Closed Loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the
Bank 1 HO2S 1 voltage remains excessively low for an extended period of time, Diagnostic Trouble Code P0131 will be set.
Diagnostic Aids
Check for the following conditions: Heated oxygen sensor wiring - The sensor pigtail may be routed incorrectly and/or contacting the exhaust system. Also, check for shorts to ground, shorts to battery positive and open circuits.
6E152

Exhaust leaks - An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. Fuel contamination - Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. For the procedure to check for fuel contamination, Refer to Fuel System Diagnosis.
Poor ECM to engine block grounds. Fuel pressure - The system will go lean if pressure is too low. The ECM can compensate for some decrease. However, if fuel pressure is too low, a Diagnostic Trouble Code P0131 may be set. Refer to Fuel System Diagnosis. Lean injector(s) - Perform Injector Balance Test. Vacuum leaks - Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.
Diagnostic Trouble Code (DTC) P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0131 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0131 stored in this ignition cycle? 4 Check for poor/faulty connection at the O2 sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C56(J2) 6 E77
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
31
21
Verify repair
Go to Step 5
Using the DVM and check the O2 sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the O2 sensor connector. 3. Check the circuit for short to heater ground or ground circuit. Was the DVM indicated specified value?
E77 1 2
Approximatly 450mV
Go to Step 7
Go to Step 6

Step 6 Action Using the DVM and check the O2 sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the O2 sensor. 4. Check the circuit for short to heater ground or short to ground circuit. Was the problem found?
J2-6 Breaker Box J2-21
6E153
No
Value(s)
Yes
(ECM
J2-31
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the O2 sensor connector and ECM connector. 3. Check the circuit for short to heater ground or short to ground circuit. Was the problem found?
C-56(J2)
C-56(J2)
7 Using the DVM and check the O2 sensor circuit. 1. Ignition Off, engine Off. 2. Disconnect the the O2 sensor connector. 3. Check the circuit for short to heater ground circuit. Was the DVM indicated specified value?
O 2 Sensor
Go to Step 15
No continuity 8 Repair the short to heater ground circuit. Was the problem found?
6E154
Step 9

Action 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Manifold Absolute Pressure in the data display. Does the Tech 2 indicate correct Manifold Absolute Pressure in accordance with engine speed or acceleration? Value(s) Yes No
Go to Step 11
Go to Step 10
10
Remove the MAP sensor and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAP sensor. Objects blocking the throttle valve. Vacuum leaking at intake duct. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 11
11
1. Using the Tech 2, ignition On and engine On. 2. Select the Miscellaneous Test and perform the IAC Control in the IAC System. 3. Operate the Tech 2 in accordance with procedure. Was the engine speed changed, when the IAC valve is operating step by step?
Go to Step 13
Go to Step 12
12
Check for the following conditions. Objects blocking the IAC valve. Objects blocking the throttle valve. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 13 Refer to Injector Coil Test & Injector Balance Test Procedure Refer to Fuel System Diagnosis Go to Step 16
13
Check for injector for the affected bank. Refer to Injector Coil Test & Injector Balance Test Procedure 6E-98 page. Was the injector operation correct? Go to Step 14 Check for fuel pressure. Refer to Fuel System Diagnosis 6E-108 page. Was the fuel pressure correct? Replace the O2 sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
14
15 16
Verify repair
Go to Step 17
17
Verify repair
6E155
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
Code P0132 Type A DTC Name DTC Setting Condition Fail-Safe (Back Up) Open Loop fuel control.
O2 Sensor Circuit High Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS, Sensor 1) EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. O2 sensor bank 1 output voltage is more than 952mV in Closed Loop condition.
Circuit Description
The engine control module (ECM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal and low circuits. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The ECM constantly monitors the HO2S signal during Closed Loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the
Bank 1 HO2S 1 voltage remains excessively high for an extended period of time, Diagnostic Trouble Code P0132 will be set.
Diagnostic Aids
Check the following items: Fuel pressure - The system will go rich if pressure is too high. The ECM can compensate for some increase. However, if fuel pressure is too high, a Diagnostic Trouble Code P0132 may be set. Refer to
6E156

An intermittent TPS output will cause the system to go rich due to a false indication of the engine accelerating. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery white deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S.
Fuel System Diagnosis. Perform Injector Balance Test - Refer to Fuel System Diagnosis. Check the EVAP canister for fuel saturation - If full of fuel, check canister control and hoses. Refer to Evaporative (EVAP) Emission Control System. Check for a leak in the fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel.
Diagnostic Trouble Code (DTC) P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
C56(J2) 6 E77
Value(S)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
31
21
Verify repair
Go to Step 5
Using the DVM and check the O2 sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the the O2 sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E77 1 2
Approximatly 450mV
Go to Step 7
Go to Step 6

Step 6 Action Using the DVM and check the O2 sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the O2 sensor connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specifed value?
E77 1 2
6E157
No
Value(S)
Yes
V V
Less than 1V 7 Using the DVM and check the O2 sensor circuit. 1. Ignition Off, engine Off. 2. Disconnect the the O2 sensor connector. 3. Check the circuit for short to heater power supply circuit. Was the DVM indicated specified value?
4 4 O2 Sensor 2 3 2 1 1
Go to Step 15
No continuity 8 9 Repair the short to heater power supply circuit. Was the problem found? 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Manifold Absolute Pressure in the data display. Does the Tech 2 indicate correct Manifold Absolute Pressure in accordance with engine speed or acceleration? 10 Remove the MAP sensor and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAP sensor. Objects blocking the throttle valve. Vacuum leaking at intake duct. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? 11 1. Using the Tech 2, ignition On and engine On. 2. Select the Miscellaneous Test and perform the IAC Control in the IAC System. 3. Operate the Tech 2 in accordance with procedure. Was the engine speed changed, when the IAC valve is operating step by step?
Go to Step 11
Go to Step 10
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12
6E158
Step 12

Action Check for the following conditions. Objects blocking the IAC valve. Objects blocking the throttle valve. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? Value(S) Yes No
Verify repair
13
14
15 16
Verify repair
Go to Step 17
17
Verify repair
6E159
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR NO ACTIVITY DEFECTED (BANK 1 SENSOR 1)
Code P0134 Type A DTC Name DTC Setting Condition Fail-Safe (Back Up)
O2 Sensor Circuit No Activity Detected 1. No DTC relating to MAP sensor, TPS, Open Loop fuel control. (Bank 1 Sensor 1) EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg.C. 3. Engine run time is longer than 40 seconds. 4. Mass air flow is more than 7g/s. 5. O2 sensor bank 1 output voltage is between 300mV and 600mV.
Circuit Description
The engine control module (ECM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The ECM constantly monitors the HO2S signal during Closed Loop operation and
compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, Diagnostic Trouble Code P0134 will be set, indicating an open sensor signal or sensor low circuit.
6E160

harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
Diagnostic Aids
Check for the following conditions: Poor connection or damaged harness - Inspect the
Diagnostic Trouble Code (DTC) P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
C56(J2) 6 E77
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
31
21
Verify repair
Go to Step 5
Using the DVM and check the O2 sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the O2 sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E77 1 2
Approximatly 450mV
Go to Step 7
Go to Step 6

Step 6 Action Using the DVM and check the O2 sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the O2 sensor. 4. Check the circuit for open circuit. Was the problem found?
E-77 Breaker Box J2-6 J2-21
6E161
No
Value(s)
Yes
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the O2 sensor connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found?
6 C56(J2) 1 E77
21
Go to Step 13
1. Using the Tech 2, ignition On and engine On. 2. Monitor the Manifold Absolute Pressure in the data display. Does the Tech 2 indicate correct Manifold Absolute Pressure in accordance with engine speed or acceleration?
Go to Step 9
Go to Step 8
Remove the MAP sensor and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAP sensor. Objects blocking the throttle valve. Vacuum leaking at intake duct. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 9
Go to Step 11
Go to Step 10
6E162
Step 10

Action Check for the following conditions. Objects blocking the IAC valve. Objects blocking the throttle valve. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
11
12
13 14
Verify repair
Go to Step 15
15
Verify repair
6E163
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT (BANK 1 SENSOR 1)
Code P0135 Type A DTC Name O2 SensorHeater Circuit (Bank 1 Sensor 1) DTC Setting Condition Fail-Safe (Back Up)
1. No DTC relating to MAP sensor and ECT No fail-safe function. sensor. 2. Engine coolant temperature is more than 60 deg. C. 3. Engine run time is longer than 20 seconds. 4. MAP sensor output is more than 70kPa. 5. O2 sensor bank 1 heater current more than 10mA.
Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for Closed Loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 1 to become active. Oxygen sensor heaters are required by catalyst monitor sensors Bank 1 HO2S 2 to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the
engine. The engine control module (ECM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the ECM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the ECM looks at how much time has elapsed since start-up. If the ECM determines that too much time was required for the Bank 1 HO2S 1 to become active, a Diagnostic Trouble Code P0135 will set.
6E164

terminals, and poor terminal-to-wire connection. Damaged harness - Inspect the wiring harness for damage; shorts to ground, shorts to battery positive and open circuits.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM - Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged
Diagnostic Trouble Code (DTC) P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1)
C56(J2) E77
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
31
3 4
5 6
Visually check the O2 sensor. Was the problem found? Using the DVM and check the O2 sensor. 1. Ignition Off, engine Off. 2. Disconnect O2 sensor connector 3. Measure the resistance of heater. Was the tester indicated specified value?
O2 Sensor 3 4 3 2 1
Approximately 12.59 at 20C
Go to Step 7
Go to Step 11

Step 7 Action Using the DVM and check the heater power supply circuit for the affected cylinder. 1. Ignition On, engine Off. 2. Disconnect the O2 sensor connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E77 4
6E165
No
Value(s)
Yes
V
10 - 14.5V 8 Repair the open or short to ground circuit between the O2 Sensor fuse (10A) and O2 sensor. Is the action complete? Using the DVM and check the heater ground circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the O2 sensor connector. (ECM Go to Step 9 Go to Step 8
Verify repair
4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the O2 sensor connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
31 E56(J2) E77 3
Go to Step 10
6E166
Step 10

Action Using the DVM and check the heater ground circuit. 1. Ignition On, engine Off. 2. Disconnect the O2 sensor connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated voltage?
E77 3
Value(s)
Yes
No
V
11 12 Replace the O2 sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Repair faulty harness and verify repair Verify repair
Verify repair
Go to Step 13
13
Verify repair
6E167
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR 1 CONTROL CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR 2 CONTROL CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR 3 CONTROL CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR 4 CONTROL CIRCUIT
Code P0201 P0202 P0203 P0204 Type A A A A DTC Name Injector 1 Control Circuit Injector 2 Control Circuit Injector 3 Control Circuit Injector 4 Control Circuit DTC Setting Condition 1. Engine is running. 2. Engine speed is more than 1000rpm. 3. Injector voltage does not meet to the battery voltage when the injector is commanded Off or does not meet to the 0V when the injector is commanded On. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The engine control module (ECM) has four individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the ECM, the injector is
activated. The ECM monitors the current in each driver circuit. The ECM measures a voltage drop through a fixed resistor and controls it. The voltage on each driver is monitored to detect a fault. If the voltage is not what the ECM expects to monitor on the circuit, a Diagnostic
6E168

injector. A misfire Diagnostic Trouble Code will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.
Trouble Code is set. This Diagnostic Trouble Code is also set if an injector driver is shorted to voltage.
Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a Diagnostic Trouble Code P0201 to set. It will also cause a misfire due to an inoperative
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0201, P0202, P0203 or P0204 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0201, P0202, P0203 or P0204 stored in this ignition cycle? 4 Check for poor/faulty connection at the injector or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
11 98 E-60(J1) 22
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
E-6/E-7/E-8/E-9
5 Visually check the injector for the affected cylinder. Was the problem found?

Step 6 Action Using the DVM and check the injector coil for the affected cylinder. 1. Ignition Off, engine Off. 2. Disconnect injector connector for the affected cylinder. 3. Measure the resistance of injector coil. Was the tester indicated specified value?
Injector
6E169
No
Value(s)
Yes
Approximately 12.59 at 20C
Go to Step 7
Go to Step 11
6E170
Step 7

Action Using the DVM and check the injector power supply circuit for the affected cylinder. 1. Ignition On, engine Off. 2. Disconnect the injector connector for the affected cylinder. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
No.1 Cylinder E-6 1
Value(s)
Yes
No
No.2 Cylinder E-7 1
No.3 Cylinder E-8 1
No.4 Cylinder E-9 1
V
10 - 14.5V 8 Repair the open or short to ground circuit between the IGN fuse (15A) and injector for the affected cylinder. Is the action complete? Go to Step 9 Go to Step 8
Verify repair

Step 9 Action Using the DVM and check the injector signal circuit for the affected cylinder. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Value(s) Yes
6E171
No
3. Disconnect the injector connector for the affected cylinder. 4. Check the circuit for open or short to ground circuit. Was the problem found?
No. 1 Cylinder Breaker Box J1-9 E-6
Go to Step 10
6E172
Step 9

Action Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the injector connector for the affected cylinder and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
No.1 Cylinder E-60(J1) E-6 2
Value(s)
Yes
No
22
11
Go to Step 10

Step 10 Action Using the DVM and check the injector signal circuit. 1. Ignition On, engine Off. 2. Disconnect the injector connector for the affected cylinder. 3. Check the circuit for short to voltage circuit. Was the DVM indicated voltage?
No.1 CylinderE-6 2
6E173
No
Value(s)
Yes
V
No.2 CylinderE-7 2
V
No.3 CylinderE-8 2
V
No.4 CylinderE-9 2
V
11 12 Replace the injector for the affected cylinder. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Repair faulty harness and verify repair Verify repair
Verify repair
Go to Step 13
13
Verify repair
6E174
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) MODULE CIRCUIT
Code P0325 Type B DTC Name Knock Sensor Module Circuit DTC Setting Condition 1. No DTC relating to MAP sensor. 2. Engine coolant temperature is more than 50 deg. C. 3. Engine speed is more than 1600rpm. 4. Knock sensor filter module integrated circuit malfunction. Fail-Safe (Back Up) ECM retards ignition timing 4 deg. C.
Circuit Description
The knock sensor (KS) system is used to detect engine detonation. The knock sensor produced an AC voltage signal. The knock sensor sends this signal to the ECM. The amplitude and the frequency of the AC voltage signal depends upon the knock level being detected. The ECM will then retard the spark timing based on the
signals from the Knock Sensor.
Diagnostic Aids
Correct any abnormal engine noise before using the diagnostic table. Check for an open circuit.
Diagnostic Trouble Code (DTC) P0325 Knock Sensor Module Circuit

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check

Step 2 Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0325 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0325 stored in this ignition cycle? 4 Check for poor/faulty connection at the knock sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-60(J1) 3 E-84
6E175
No
Value(s)
Yes
Go to Step 3
Go to Step 4
32
5 6
Visually check the knock sensor. Was the problem found? Listen to the engine noise while raising and lowering the engine speed. Is a knock or audible noise present? Repair the mechanical engine problem or a loose bracket or component. Is the action complete?
Go to Step 7
Go to Step 8
Verify repair
6E176
Step 8

Action Using the DVM and check the knock sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the knock sensor. 4. Check the circuit for open circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the knock sensor connector and ECM connector. 3. Check the circuit for open circuit. Was the problem found?
E-60(J1) 3 1 E-84 2
32
9 10 11 Substitute a known good knock sensor and recheck. Was the problem solved? Replace the knock sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 9 Go to Step 11 Go to Step 11
Verify repair
Go to Step 12
12
Verify repair
6E177
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT
Code P0327 Type A DTC Name Knock Sensor Circuit DTC Setting Condition 1. No DTC relating to MAP sensor. 2. Engine coolant temperature is more than 50 deg. C. 3. Engine speed is more than 1600rpm. 4. Knock sensor harness short to ground or short to voltage circuit. Fail-Safe (Back Up) ECM retards ignition timing 4 deg. C.
Circuit Description
The ECM uses the Knock Sensor (KS) in order to detect engine detonation. This allows the ECM to retard the Ignition Control (IC) spark timing based on the KS signal the ECM receives. The knock sensors produce an AC signal that rides on the 1.3 volts DC. The signals amplitude and frequency are dependent upon the amount of the knock being experienced. The ECM determines whether the knock is occurring by comparing the signal level on the KS circuit with a voltage level on the noise channel. The normal engine noise varies depending on the engine speed and load. Then the ECM determines that an abnormally high noise channel voltage level is being experienced, a Diagnostic Trouble Code P0327 sets.
Diagnostic Aids
Check for the following conditions: A poor connection at the ECM. Inspect the knock sensor and the ECM connectors for: , broken locks, improperly formed or damaged terminals. Backed out terminals Broken locks Improperly formed or damaged terminals Also, check the wiring harness for: shorts to ground, shorts to battery positive, and open circuits. A misrouted harness. Inspect the knock sensor harness in order to ensure that it is not routed too close to high voltage wires such as spark plug leads.
6E178
Diagnostic Trouble Code (DTC) P0327 Knock Sensor Circuit

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0327 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0327 stored in this ignition cycle? 4 Check for poor/faulty connection at the knock sensor or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-60(J1) 3 E-84
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
32
5 6
Visually check the knock sensor. Was the problem found? Using the DVM and check the knock sensor circuit. 1. Ignition Off, engine Off. 2. Disconnect the knock sensor connector and ECM connector. 3. Check the circuit for short to sensor ground or ground circuit. Was the problem found?
E-84 1 2
Go to Step 7

Step 7 Action Using the DVM and check the knock sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the knock sensor connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated voltage?
E-84 1 2
6E179
No
Value(s)
Yes
8 9 10 Substitute a known good knock sensor and recheck. Was the problem solved? Replace the knock sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 11
11
Verify repair
6E180
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE (58X) DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT (58X)
Code P0336 Type B DTC Name Crankshaft Position Sensor Circuit Range/Performance (58X) DTC Setting Condition Fail-Safe (Back Up)
1. Engine is running. No fail-safe function. 2. Extra or missing pulse is detected consecutively.
P0337
Crankshaft Position Sensor Circuit Low No pulse is detected during engine cranking. Input (58X)
Circuit Description
The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The engine control module (ECM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The ECM constantly monitors the number of pulses on
the 58X reference circuit. If the ECM receives an incorrect number of pulses on the 58X reference circuit, Diagnostic Trouble Code P0336 will set. If the ECM does not receive pluses on the 58X reference circuit, Diagnostic Trouble Code P0337 will set.
ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Aids

An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: Poor connection - Inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection.
6E181
Damaged harness - Inspect the wiring harness for damage; shorts to ground, shorts to battery positive and open circuits. If the harness appears to be OK, disconnect the ECM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the ECM harness connector while moving connectors and wiring harnesses related to the ECM. A change in voltage will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0336 Crankshaft Position Sensor Circuit Range/performance (58x) Diagnostic Trouble Code (DTC) P0337 Crankshaft Position Sensor Circuit Low Input (58x)
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0336 or P0337 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0336 or P0337 stored in this ignition cycle? 4 Check for poor/faulty connection at the CKP sensor or ECM connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
E-60(J1) 6 1 E-59
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
21
Verify repair
Go to Step 5
Visually check the CKP sensor. If a faulty installation is found, repair as necessary. Was the problem found?
Verify repair
Go to Step 6
6E182
Step 6

Action Using the DVM and check the CKP sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
6 E-60(J1)
21
Approximately 0.58k9 at 20C
Go to Step 10
Go to Step 7
Using the DVM and check the CKP sensor circuit. 1. Ignition Off, engine Off. 2. Disconnect the CKP sensor connector. 3. Check the resistance of the CKP sensor. Was the DVM indicated specified value?
CKP Sensor
Approximately 0.58k9 at 20C
Go to Step 8
Go to Step 14

Step 8 Action Using the DVM and check the CKP sensor circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the CKP sensor connector. 4. Check the circuit for open, short to sensor wire or short to ground circuit. Was the problem found?
E-59
6E183
No
Value(s)
Yes
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Disconnect the CKP sensor connector. 4. Check the circuit for open, short to sensor wire or short to ground circuit. Was the problem found?
6 E-60(J1)
21
E-60(J1) 6 1
E-59 2
21
Go to Step 9
6E184
Step 9

Action Using the DVM and check the CKP sensor circuit. 1. Ignition On, engine Off. 2. Disconnect the CKP sensor connector. 3. Check the circuit for short to power supply circuit. If the DVM indicated out of specified value, repair faulty harness and verify repair. Is the action complete?
1 E-59 2
Value(s)
Yes
No
V
10
V
Less than 1V Verify repair
Using the DVM and check the CKP sensor signal. 1. Ignition On, engine On. 2. Measure the CKP output voltage at the sensor and ECM. Does the tester indicate standard voltage?
Measurement Point At CKP sensor terminal 1 & 2 At ECM E60 (J1) connector 21 & 6 Voltage (V) (AC Range) Approx. 3.7V in engine idle Approx. 7.8V at 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
Measurement Terminal: J1-21(+) J1-6(-) Measurement Scale: 10V/div 5ms/div Measurement Condition: Approximately 2000rpm
Go to Step 13
Go to Step 11
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. If a problem is found, repair as necessary. Was the problem found?
Verify repair Repair faulty harness and verify repair
Go to Step 12
12
Check the CKP sensor shield wire for open or short circuit. Was the problem found?
Go to Step 13

Step 13 Action Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? Substitute a known good CKP sensor and recheck. Was the problem solved? Replace the CKP sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Remove the accessory parts and verify repair Go to Step 15 Verify repair
6E185
No
14 15 16
Verify repair
Go to Step 17
17
Verify repair
6E186
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION 1 CONTROL CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION 2 CONTROL CIRCUIT
Code P0351 P0352 Type A A DTC Name Ignition 1 Control Circuit Ignition 2 Control Circuit DTC Setting Condition #1 or #4cylinder ignition signals are not detected consecutively. #2 or #3 cylinder ignition signals are not detected consecutively. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The ignition control circuit provides a zero volt or a 5 volt signal to the ignition control module. The normal circuit voltage is zero volts. When the module receives the 5 volt signal from the ECM, it provides a ground path for the B+ voltage supplied to the ignition primary coil. When the ECM turns off the 5 volts to the module, the module will remove the ground path of the ignition primary coils; causing the magnetic field produces a voltage in the secondary coils which fires the spark plug.
The circuit between the ECM and the ignition control module is monitored for an open circuit, short to voltage, and short to ground. When the ECM detects a problem in the ignition control circuit, it will set DTC P0351 or P0352.
Diagnostic Aids
Check for the following conditions: Poor connection at the ECM - Inspect the harness connectors for backed-out terminals, improper

mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. Damaged harness - Inspect the wiring harness for damage; Open circuits, shorts to ground, or shorts to Voltage. If the harness appears to be OK, observe
6E187
the Tech 2 display related to DTC P0351 or P0352 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0351 or P0352 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0351 or P0352 stored in this ignition cycle? 4 Check for poor/faulty connection at the ignition coil module or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-60(J1) E-18
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
19
18
Visually check the ignition coil module. Was the problem found?
6E188
Step 6

Action Using the DVM and check the ignition coil module signal circuit for the affected coil. 1. Ignition On, engine Off. 2. Disconnect the ignition coil module connector. 3. Check the circuit for short to battery voltage circuit for the affected coil. Was the DVM indicated battery voltage?
Coil 1 E-18
Value(s)
Yes
No
Coil 2 E-18
Go to Step 7

Step 7 Action Using the DVM and check the ignition coil signal circuit for the affected coil. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Value(s) Yes
6E189
No
3. Disconnect the ignition coil module connector. 4. Check the circuit for open or short to ground circuit for the affected coil. Was the problem found?
Coil 2 Breaker Box J1-18
E-18
Coil 1 Breaker Box J1-19

E-18
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ignition coil module connector and ECM connector. 3. Check the circuit for open or short to ground circuit for the affected coil. Was the problem found?
Coil 1 E-60(J1)
E-18
Coil 2 E-60(J1)
E-18
Go to Step 8
6E190
Step 8

Action Using the DVM and check the ignition coil module power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the ignition coil module connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E-18 2
Value(s)
Yes
No
V
10 - 14.5V 9 Repair the open or short to ground circuit between the IGN. Coil fuse (15A) and ignition coil module. Is the action complete? Replace the ignition coil module. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 10 Go to Step 9
Go to Step 11
10 11
Verify repair
Go to Step 12
12
Verify repair
6E191
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM PURGE CONTROL CIRCUIT
Code P0443 Type B DTC Name EVAP Emission Control System Purge Control Circuit DTC Setting Condition EVAP purge solenoid circuit open, short to ground or short to voltage circuit. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The Engine Control Module (ECM) controls the Evaporative Emission (EVAP) Canister Purge Solenoid Valve through the use of a control (ground) circuit. If the ECM commands the Purge solenoid to maximum duty cycle (100%) but the voltage remains High (12 Volts); or, if the ECM commands the Purge solenoid to minimum duty cycle (0%) but the voltage remains Low (0 volts), then DTC P0443 will set.
Diagnostic Aids
Poor connections, or a damaged harness - Inspect the harness connectors for: backed-out terminals, improper mating or damaged terminals. Also check for open circuits, shorts to ground, and shorts to voltage.
6E192
Diagnostic Trouble Code (DTC) P0443 EVAP Emission Control System Purge Control Circuit
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0443 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0443 stored in this ignition cycle? 4 Check for poor/faulty connection at the purge solenoid valve or ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-60(J1) 5 E-66
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
5 Using the DVM and check the purge solenoid valve. 1. Ignition Off, engine Off. 2. Disconnect purge solenoid valve connector. 3. Measure the resistance of purge solenoid valve coil. Does the tester indicate standard resistance?
EVAP Purge Solenoid
Verify repair
Go to Step 5
25 - 309at 20C
Go to Step 6
Go to Step 9

Step 6 Action Using the DVM and check the purge solenoid valve power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the purge solenoid valve connector. 3. Check the circuit for open circuit. Was the DVM indicated specified value?
E-66 2
6E193
No
Value(s)
Yes
V
10 - 14.5V 7 Repair the open or short to ground circuit between the Engine fuse (15A) and purge solenoid valve. Is the action complete? Using the DVM and check the purge solenoid valve solenoid signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Go to Step 8 Go to Step 7
Verify repair
3. Disconnect the purge solenoid valve connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the purge solenoid valve connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
E-60(J1) 1 5 E-66
Go to Step 9
6E194
Step 9

Action Using the DVM and check the purge solenoid valve signal circuit. 1. Ignition On, engine Off. 2. Disconnect the purge solenoid valve connector. 3. Check the circuit for short to voltage circuit. Was the DVM indicated voltage?
E-66 1
Value(s)
Yes
No
V
10 Substitute a known good purge solenoid valve and recheck. Was the problem solved? Replace the purge solenoid valve. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Go to Step 10
11 12
Verify repair
Go to Step 13
13
Verify repair
6E195
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT
Code P0502 Type B DTC Name Vehicle Speed Sensor Circuit Low Input DTC Setting Condition Fail-Safe (Back Up)
1. No DTC relating to MAP sensor, TPS, ECT ECM uses 0km/h condition as substitute. sensor, injector control circuit and ignition control circuit. 2. Engine is running. 3. Vehicle speed is below 3km/h in power condition or 2km/h in deceleration condition.
Circuit Description
The vehicle speed sensor has a magnet rotated by the transmission output shaft. Attached to the sensor is a hall effect circuit that interacts with the magnetic field created by the rotating magnet. A 12-volt operating supply for the speed sensor hall circuit is supplied from the meter fuse.
Diagnostic Aids
Poor connection at ECM: Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.
6E196
Diagnostic Trouble Code (DTC) P0502 Vehicle Speed Sensor Circuit Low Input
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0502 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0502 stored in this ignition cycle? 4 Check for poor/faulty connection at the VSS, meter, immobilizer control unit (if equipped), ECM and other connectors. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-56(J2) 23
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
B-68 8 6 B-24 9 10
E-44
27
5 Remove the VSS from the housing case and visually check. Was the problem found?
Verify repair
Go to Step 5
Go to Step 19
Go to Step 6

Step 6 Action Using the DVM and check the VSS signal. 1. Ignition On, vehicle Run (lift up). 2. Measure the VSS output voltage at sensor, meter, immobilizer control unit (if equipped) and ECM. Does the tester indicate specified value?
Measurement Position VSS terminal 3 & GND Meter B24 connector 9 & GND Meter B24 connector 10 & GND Immobilizer control unit B68 connector 6 & GND Immobilizer control unit B68 connector 8 & GND ECM C56 (J2) connector 23 & GND Approximately 6.5V at 20km/h Voltage (V) (AC Range) Approximately 7.0 V at 20km/h If No Good Go to Step 7 Go to Step 11 Go to Step 13 Go to Step 14 Go to Step 16 Go to Step 17
6E197
No
Value(s)
Yes
If a oscilloscope is available, monitor the VSS signal. Does the oscilloscope indicate correct wave form?
Vehicle Speed Sensor (V SS) Reference Wave Form
CH1 0V
CH2 0V
Measurement Terminal: CH1: ECM J2-23(+) / CH2: VSS 3(+) GND(-) Measurement Scale: CH1: 10V/div / CH2: 10V /div 50ms/div Measurement Condition: A pproxim ately 20km/h Note: The vehicle is without immobilizer syste m, CH1 signal is sam e as CH2.
Refer the table
Using the DVM and check the VSS power supply circuit. 1. Ignition On, engine Off. 2. Disconnect the VSS connector. 3. Check the circuit for open or short to ground circuit. Was the DVM indicated specified value?
1 E-44
V
10 - 14.5V 8 Repair the open circuit between the VSS and meter fuse. Is the action complete? Go to Step 9 Go to Step 8
Verify repair
6E198
Step 9

Action Using the DVM and check the VSS ground circuit. 1. Ignition On, engine Off. 2. Disconnect the VSS connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
E-44 2
Value(s)
Yes
No
V
Less than 1V 10 Using the DVM and check the VSS ground circuit. 1. Ignition Off, engine Off. 2. Disconnect the VSS connector. 3. Check the circuit for open circuit. Was the problem found?
E-44 2
Go to Step 10
11 Using the DVM and check the VSS signal circuit. 1. Ignition On, engine Off. 2. Disconnect connector. the VSS connector and meter
Go to Step 19
3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-24 9
V

Step 12 Action Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the VSS connector connector. and meter Value(s) Yes
6E199
No
3. Check the circuit for open or short to ground circuit. If a open or short to ground circuit is found, repair the faulty harness and verify repair. Is the action complete?
B-24 9 E-44 3
13 14 Replace the speed meter. Is the action complete? Using the DVM and check the VSS signal circuit. 1. Ignition On, engine Off. 2. Disconnect the meter connector and immobilizer control unit connector (if equipped). 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-68
V
Less than 1V 15 Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector and immobilizer control unit connector (if equipped). 3. Check the circuit for open or short to ground circuit. If a open or short to ground circuit is found, repair the faulty harness and verify repair. Is the action complete?
B-24 10 B-68
Go to Step 15
Verify repair
6E200
Step 16 17

Action Replace the immobilizer control unit (if equipped). Is the action complete? Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector (if equipped) and ECM connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
C-56(J2) 23
Value(s)
Yes Verify repair
No
V
Less than 1V 18 Using the DVM and check the VSS signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Go to Step 18
3. Disconnect the immobilizer control unit connector (if equipped). 4. Check the circuit for open or shot to ground circuit. Was the problem found?
Breaker Box J2-32 B-68
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector (if equipped) and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-56(J2) 23 B-68 8
19 Substitute a known good VSS and recheck. Was the problem solved?
Repair faulty harness and verify repair Go to Step 20

Step 20 21 Action Replace the VSS. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Verify repair
6E201
No
Go to Step 21
Verify repair
Go to Step 22
22
Verify repair
6E202
DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW
Code P0562 Type D DTC Name System Voltage Low DTC Setting Condition Battery voltage is below 11V. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The engine control module (ECM) monitors the system voltage on the ignition feed terminal to the ECM. A system voltage Diagnostic Trouble Code will set whenever the voltage is below a calibrated value.
Diagnostic Aids
If the Diagnostic Trouble Code sets when an accessory is operated, check for a poor connection or excessive current draw. Check for open circuits or shorts to ground on the ECM s battery or ignition inputs.
Diagnostic Trouble Code (DTC) P0562 System Voltage Low


Step 2 Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0562 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0562 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Ignition Voltage in the data display. 3. Load the electrical system by turning on the headlights, etc.. Does the Tech 2 indicate enough ignition voltage? 5 Using the DVM and check the battery voltage at the battery terminal. Does the tester indicate enough battery voltage? 10 - 14.5V 6 Check for poor/faulty connection at the ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56(J2) 2 E-60(J1) 2 1
6E203
No
Value(s)
Yes
Go to Step 3
Go to Step 4
10 - 14.5V
Go to Step 6
Go to Step 5 Check the charging system, charge or replace the battery
Go to Step 6
16
17
Verify repair
Go to Step 7
Check for poor/faulty connection of the ECM ground at the inlet manifold. If a poor/faulty connection is found, repair as necessary. Was the problem found?
E-72
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
6E204
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Code P0563 Type A DTC Name System Voltage High DTC Setting Condition Battery voltage is above 16V. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The engine control module (ECM) monitors the system voltage on the ignition feed terminals to the ECM. A system voltage Diagnostic Trouble Code will set
whenever the voltage is above a calibrated value.
Diagnostic Aids
Check for a faulty charging system components.
Diagnostic Trouble Code (DTC) P0563 System Voltage High


Step 2 Action 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0563 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0563 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Ignition Voltage in the data display. 3. Load the electrical system by turning on the headlights, etc.. Does the Tech 2 indicate correct ignition voltage? Less than 16V 5 6 Is the battery jamp start cable incorrectly connecting? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E205
No
Go to Step 3
Go to Step 4
Refer to Diagnostic Aids and Go to Step 4 Check the charging system and Go to Step 5 Go to Step 6
Go to Step 5 Verify procedure
Verify repair
Go to Step 7
Verify repair
6E206
DIAGNOSTIC TROUBLE CODE (DTC) P0601 ECM MEMORY CHECKSUM

Code P0601 Type A DTC Name ECM Memory Checksum DTC Setting Condition ECM memory area error. Fail-Safe (Back Up) Engine control disabled.
Circuit Description
The engine control module (ECM) used in this vehicle utilizes an electrically erasable programmable read-only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine, transmission, and powertrain diagnostics operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. When the ECM is replaced or a calibration update is required, the ECM
must be programmed using a Tech 2.
Diagnostic Aids
Diagnostic Trouble Code P0601 indicates that the contents of the EEPROM have changed since the ECM was programmed. The only possible repair is ECM reprogramming or replacement. Check service bulletins to program the replacement ECM with the correct software and calibration for the vehicle.
Diagnostic Trouble Code (DTC) P0601 ECM Memory Checksum

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0601 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0601 stored in this ignition cycle? 4 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Refer to Diagnostic Aids
Verify repair
Go to Step 5
Verify repair
6E207
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR

Code P0602 Type DTC Name ECU Programming Error DTC Setting Condition ECM memory area error. Fail-Safe (Back Up) Engine control disabled.
Circuit Description
The engine control module (ECM) used in this vehicle utilizes an electrically erasable programmable read-only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine, transmission, and powertrain diagnostics operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. When the ECM is
replaced or a calibration update is required, the ECM must be programmed using a Tech 2.
Diagnostic Aids
Diagnostic Trouble Code P0602 indicates when non programmed ECM is used without service programming system (SPS). The replacement ECM must be programmed.
Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0602 stored as Present Failure? 3 Download the latest software to the ECM using the SPS (Service Programming System). Is the action complete? Refer to Diagnostic Aids Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Verify repair
6E208
DTC P0650 MALFUNCTION INDICATOR LAMP (MIL) CONTOROL CIRCUIT MALFUNCTION
Code P0650 Type A DTC Name DTC Setting Condition Fail-Safe (Back Up) No fail-safe function.
Malfunction Indicator Lamp (MIL) Con- Check engine lamp circuit open, short to trol Circuit Malfunction ground or short to voltage circuit.
Circuit Description
The check engine lamp should always be illuminated and steady with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the check engine lamp indicator. The Engine Control Module (ECM) turns the check engine lamp ON by grounding the check engine lamp driver circuit. The check engine lamp should not remain ON with the engine running and no DTC(s) set. A steady check engine lamp with the engine running and no DTC(s) suggests a short to ground in the check engine lamp driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: Poor connection or damaged harness - Inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.
6E209
Diagnostic Trouble Code (DTC) P0650 Malfunction Indicator Lamp (MIL) Control Circuit Malfunction
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P0650 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P0650 stored in this ignition cycle? 4 1. Ignition On, engine Off. 2. Check the Check Engine lamp. Does the lamp turn On? 5 1. Ignition On, engine Off. 2. Check the Check Engine lamp. Does the lamp turn Off? 6 Check the Check Engine lamp bulb. If the bulb is burnt out, repair as necessary. Was the problem found? Check for poor/faulty connection at the meter connector and ECM connector. If a poor/faulty connection is found, repair as necessary. Was the problem found?
C-56(J2) B-24
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7
32
17
Verify repair
Go to Step 8
6E210
Step 8

Action Using the DVM and check the Check Engine lamp circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Remove the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Remove the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
32 C-56(J2) 17 B-24
Go to Step 9
Verify repair
Go to Step 10
10
Verify repair
6E211
DIAGNOSTIC TROUBLE CODE (DTC) P1167 FUEL SUPPLY SYSTEM RICH DURING DECELERATION FUEL CUT OFF
Code P1167 Type D DTC Name Fuel Supply System Rich During Deceleration Fuel Cutoff DTC Setting Condition 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. O2 sensor bank 1 output voltage is more than 550mV in deceleration fuel cutoff mode. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The engine control module (ECM) internal circuitry can identify if the vehicle fuel system is capable of supplying adequate amounts of fuel during deceleration (fuel cut off). The ECM monitors the voltage of the oxygen sensor during fuel cut off. When a fuel cut off mode of operation is requested during Closed Loop operation (by deceleration), the ECM will provide more fuel to the engine. Under these conditions the ECM should detect a lean condition (low oxygen sensor voltage). If this
lean exhaust is not detected at this time, a Diagnostic Trouble Code P1167 will set.
Diagnostic Aids
Check the following items: Fuel pressure - The system will go rich if pressure is too high. The ECM can compensate for some increase. However, if fuel pressure is too high, a Diagnostic Trouble Code P1167 may be set. Refer to Fuel System Diagnosis.
6E212

An intermittent TP sensor output will cause the system to go rich due to a false indication of the engine accelerating. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery white deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S.
Perform Injector Balance Test - Refer to Fuel System Diagnosis. Check the EVAP canister for fuel saturation - If full of fuel, check canister control and hoses. Refer to Evaporative (EVAP) Emission Control System . Check for a leak in the fuel pressure regulator diaphragm by checking the vacuum line to toe regulator for the presence of fuel.
Diagnostic Trouble Code (DTC) P1167 Fuel Supply System Rich During Deceleration Fuel Cutoff
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1167 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1167 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. Does the Tech 2 indicate correct Throttle Position in accordance with accelerator pedal operation? Check for the following conditions. Objects blocking the throttle valve. Incorrectly installed. If a problem is found, repair as necessary. Was the problem found? 6 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Manifold Absolute Pressure in the data display. Does the Tech 2 indicate correct Manifold Absolute Pressure in accordance with engine speed or acceleration? 7 Remove the MAP sensor and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAP sensor. Objects blocking the throttle valve. Vacuum leaking at intake duct. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 8
Go to Step 7
Verify repair
Go to Step 13

Step 8 Action 1. Using the Tech 2, ignition On and engine On. 2. Select the Miscellaneous Test and perform the IAC Control in the IAC System. 3. Operate the Tech 2 in accordance with procedure. Was the engine speed changed, when the IAC valve is operating step by step? 9 Check for the following conditions. Objects blocking the IAC valve. Objects blocking the throttle valve. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? 10 Check for injector for the affected bank. Refer to Injector Coil Test & Injector Balance Test Procedure 6E-98 page. Was the injector operation correct? 11 Check for fuel pressure. Refer to Fuel System Diagnosis 6E-108 page. Was the fuel pressure correct? Replace the TPS. Is the action complete? Replace the MAP sensor. Is the action complete? Replace the IAC valve. Is the action complete? Replace the O2 sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 11 Value(s) Yes
6E213
No
Go to Step 10
Go to Step 9
Verify repair
Go to Step 15 Verify repair Verify repair Verify repair Verify repair
12 13 14 15 16
Verify repair
Go to Step 17
17
Verify repair
6E214
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SUPPLY SYSTEM LEAN DURING POWER ENRICHMENT
Code P1171 Type D DTC Name Fuel Supply System Lean During Power Enrichment DTC Setting Condition 1. No DTC relating to MAP sensor, TPS, EVAP purge, ECT sensor, CKP sensor, VSS, injector control circuit and ignition control circuit. 2. Engine coolant temperature is more than 60 deg. C. 3. Mass air flow is below 13.5m/s. 4. O2 sensor bank 1 output voltage is below 350mV in power enrichment mode. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
The engine control module (ECM) internal circuitry can identify if the vehicle fuel system is capable of supplying adequate amounts of fuel during heavy acceleration (power enrichment). The ECM monitors the voltage of the oxygen sensor during power enrichment. When a power enrichment mode of operation is requested during Closed Loop operation (by heavy acceleration),
the ECM will provide more fuel to the engine. Under these conditions the ECM should detect a rich condition (high oxygen sensor voltage). If this rich exhaust is not detected at this time, a Diagnostic Trouble Code P1171 will set. A plugged fuel filter or restricted fuel line can prevent adequate amounts of fuel from being supplied during power enrichment mode.
ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Aids

Check for the following conditions: Heated oxygen sensor wiring - The sensor pigtail may be routed incorrectly and contacting the exhaust system. Poor ECM to engine block ground. Fuel pressure - The system will go lean if pressure is too low. The ECM can compensate for some decrease. However, if fuel pressure is too low, a diagnostic Trouble Code P1171 may be set. Refer to Fuel System Diagnosis. Lean injector(s) - Perform Injector Balance Test.
6E215
Vacuum leaks - Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, and PCV system. Exhaust leaks - An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. Fuel contamination - Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated, Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.
Diagnostic Trouble Code (DTC) P1171 Fuel Supply System Lean During Power Enrichment
Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1171 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1171 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Monitor the Throttle Position in the data display. Does the Tech 2 indicate correct Throttle Position in accordance with accelerator pedal operation? Check for the following conditions. Objects blocking the throttle valve. Incorrectly installed. If a problem is found, repair as necessary. Was the problem found? 6 1. Using the Tech 2, ignition On and engine On. 2. Monitor the Manifold Absolute Pressure in the data display. Does the Tech 2 indicate correct Manifold Absolute Pressure in accordance with engine speed or acceleration? Refer to Diagnostic Aids and Go to Step 4 Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 8
Go to Step 7
6E216
Step 7

Action Remove the MAP sensor and check for the following conditions. Objects blocking the air cleaner. Objects blocking the MAP sensor. Objects blocking the throttle valve. Vacuum leaking at intake duct. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found? Value(s) Yes No
Verify repair
Go to Step 13
Go to Step 10
Go to Step 9
Check for the following conditions. Objects blocking the IAC valve. Objects blocking the throttle valve. Vacuum leaking at throttle body. If a problem is found, repair as necessary. Was the problem found?
Verify repair
10
Check for injector for the affected bank. Refer to Injector Coil Test & Injector Balance Test Procedure 6E-98 page. Was the injector operation correct? Go to Step 11 Check for fuel pressure. Refer to Fuel System Diagnosis 6E-108 page. Was the fuel pressure correct? Replace the TPS. Is the action complete? Replace the MAP sensor. Is the action complete? Replace the IAC valve. Is the action complete? Replace the O2 sensor. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
11
Go to Step 15 Verify repair Verify repair Verify repair Verify repair
12 13 14 15 16
Verify repair
Go to Step 17
17
Verify repair
6E217
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM SYSTEM RESET

Code P1625 Type B DTC Name ECM System Reset DTC Setting Condition ECM reset has occurred other than On. Fail-Safe (Back Up) Engine control disabled.
Circuit Description
The engine control module (ECM) monitors unexpected ECM reset. This will not turn on MIL light on, only records code DTC P1625.
Diagnostic Aids
Check for the follwing conditions: P1625 alone stored does not need diagnosis. Clear DTC code. NOTE: DTC P1625 is a DTC to record a ECM reset history. If DTC P1625 is not reset and no engine abnormality occurs after learing the DTC, no farther diagnostic procedures are required.
Diagnostic Trouble Code (DTC) P1625 ECM System Reset

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1625 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1625 stored in this ignition cycle? 4 5 Is the Immobilizer function programmed in the ECM? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 3 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check
Go to Step 3
Refer to Diagnostic Aids and Go to Step 4 Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E218
DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILIZER NO SIGNAL
Code P1626 Type DTC Name Immobilizer No Signal DTC Setting Condition No response from immobilizer control unit. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnomality in the immobilizer control system. DTC P1626 is recorded by the ECM when no response from immobiliser.
damaged terminals, and poor terminal to wire connection. Damaged harness Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the ECM and Immobilizer, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the ECM and Immobilizer harnass connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM and Immobilizer-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or
6E219
Diagnostic Trouble Code (DTC) P1626 Immobilizer No Signal

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1626 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1626 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body . 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Was the DTC B0007 stored in this ignition cycle? 5 Check for poor/faulty connection at the immobilizer control unit connector or ECM connector. If a poor/ faulty connection is found, repair as necessary. Was the problem found?
C-56(J2) B-68
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4 Refer to Immobilizer Workshop Manual & Go to DTC Chart B0007
Go to Step 5
32
23
Verify repair
Go to Step 6
Using the DVM and check the CHECK ENGINE lamp circuit. 1. Ignition Off, engine Off. 2. Disconnect the meter connector and immobilizer control unit connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the problem found?
B-68 B-24
17
Go to Step 7
6E220
Step 7

Action Using the DVM and check the CHECK ENGINE lamp circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Value(s) Yes No
3. Disconnect the immobilizer control unit connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the the immobilizer control unit connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
32 C-56(J2) B-68 7
8 Using the DVM and check the VSS signal circuit. 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector and ECM connector. 3. Ignition On. 4. Check the circuit for short to power supply circuit. Was the problem found?
C-56(J2) B-68 7
Go to Step 8
23
Go to Step 9

Step 9 Action Using the DVM and check the VSS signal circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. (ECM Value(s) Yes
6E221
No
3. Disconnect the immobilizer control unit connector. 4. Checkthecircuitforopenorshot togroundcircuit. Was the problem found?
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the immobilizer control unit connector and ECM connector. 3. Check the circuit for open or short to ground circuit. Was the problem found?
C-56(J2) 23 B-68 8
Go to Srtep 10
Verify repair
Go to Step 11
11
Verify repair
6E222
DIAGNOSTIC TROUBLE CODE (DTC) P1631 IMMOBILIZER WRONG SIGNAL
Code P1631 Type DTC Name Immobilizer Wrong Signal DTC Setting Condition Received response is not correct. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnomality in the immobilizer control system. DTC P1631 is recorded by the ECM when received response was not correct.
damaged terminals, and poor terminal to wire connection. Damaged harness-Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the ECM and Immobilizer, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the ECM and Immobilizer harnass connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault.
Diagnostic Aids
6E223
Diagnostic Trouble Code (DTC) P1631 Immobilizer Wrong Signal

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1631 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1631 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body . 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Was the DTC B0007 stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check Refer to Diagnostic Aids and Go to Step 3
Go to Step 3
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E224
DIAGNOSTIC TROUBLE CODE (DTC) P1648 WRONG SECURITY CODE ENTERED
Code P1648 Type DTC Name Wrong Security Code Entered DTC Setting Condition Received incorrect security code. Fail-Safe (Back Up) 1. Engine does not start. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnomality in the immobilizer control system. DTC P1648 is recorded by the ECM when received incorrect security code.
damaged terminals, and poor terminal to wire connection. Damaged harness Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the ECM and Immobilizer, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the ECM and Immobilizer harnass connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault.
Diagnostic Aids
6E225
Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1648 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1648 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body . 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Was the DTC B0007 stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check Refer to Diagnostic Aids and Go to Step 3
Go to Step 3
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E226
DIAGNOSTIC TROUBLE CODE (DTC) P1649 IMMOBILIZER FUNCTION NOT PROGRAMMED
Code P1649 Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
Immobilizer Function Not Programmed Immobilizer function is not programmed in the 1. Engine does not start. ECM. 2. Check engine lamp flash.
Circuit Description
The ECM decides whether that is an abnomality in the immobilizer control system. DTC P1649 is recorded by the ECM when security code & secret key not programmed.
improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. Damaged harness Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the ECM and Immobilizer, turn the ignition ON and observe a voltmeter connected to the suspect driver circuit at the ECM and Immobilizer harnass connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault.
Diagnostic Aids
Check for the following conditions: Poor connection at ECM and Immobilizer-Inspect harness connectors for backed out terminals,
6E227
Diagnostic Trouble Code (DTC) P1649 Immobilizer Function Not Programmed

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1649 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1649 stored in this ignition cycle? 4 1. Using the Tech 2, ignition On and engine Off. 2. Select Immobilizer in the system selection menu Body . 3. Select Read DTC Info Ordered By Priority in the Diagnositic Trouble Code. Were the any DTC's B0002 or B0009 stored in this ignition cycle? 5 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Refer to Diagnostic Aids and Go to Step 4 Go to Step 2 Value(s) Yes No Go to On Board Diagnostic (OBD) System Check Refer to Diagnostic Aids and Go to Step 3
Go to Step 3
Go to Step 4 Refer to Immobilizer Workshop Manual & Go to DTC Chart B0002 or B0009
Go to Step 5
Verify repair
Go to Step 6
Verify repair
6E228
DIAGNOSTIC TROUBLE CODE (DTC) P1693 TACHOMETER OUTPUT LOW VOLTAGE
Code P1693 Type B DTC Name Tachometer Output Low Voltage DTC Setting Condition Tacho output circuit short to ground circuit. Fail-Safe (Back Up) No fail-safe function.
Circuit Description
Based on the information from the Crank Position Sensor (CKP), X58 reference signal is generated at each rotation of the crankshaft. Engine Control Module (ECM) converts X58 reference signal into the square wave signal which is used to drive the pulse generator of the tachometer. When the wave length of the output signal is long, the tacho meter indicates the engine speed is low, and vise versa. This malfunction detects a low impedance short to
ground or open contact on the Tacho output, the Diagnostic Trouble Code P1693 will be set.
Diagnostic Aids
Poor connections or a damaged harness - Inspect the harness connections for: backed out terminals, imprope, mating or damaged terminals. Also check for open circuit, short to ground, and short to voltage. This malfunction detects a low impedance short to ground or open contact on the ECM out put circuit.
6E229
Diagnostic Trouble Code (DTC) P1693 Tachometer Output Low Voltage

Step 1 Action Was the On-Board Diagnostic (OBD) System Check performed? 2 1. Connect the Tech 2. 2. Review and record the failure information. 3. Select F0: Read DTC Infor By Priority in F0: Diagnostic Trouble Code. Is the DTC P1693 stored as Present Failure? 3 1. Using the Tech2, ignition On and engine Off. 2. Select Clear DTC Information with the Tech2 and clear the DTC information. 3. Operate the vehicle and monitor the F5: Failed This Ignition in F2: DTC Information. Was the DTC P1693 stored in this ignition cycle? 4 Check for poor/faulty connection at the ECM or meter connector. If a poor/faulty connection is found, repair the faulty terminal. Was the problem found?
C-56(J2) B-24 11
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
25
Verify repair
Go to Step 5
If a oscilloscope is available, monitor the Tachometer output signal. Does the oscilloscope indicate correct wave form?
Crankshaft Position (CKP) Sensor & Tacho Output Signal Reference Wave Form
CH1 0V
CH2 0V
Measurement Terminal: CH1: J1-21(+) / CH2: J2-25(+) GND(-) Measurement Scale: CH1: 2V/div / CH2: 10V/div 5ms/div Measurement Condition: Approximately 2000rpm
Go to Step 10
Not available: Go to Step 6 Fixed at low: Go to Step 6 Fixed at High: Go to Step 7
6E230
Step 6

Action Using the DVM and check the Tacho output circuit. Breaker box is available: 1. Ignition Off, engine Off. 2. Install the breaker box as type A. disconnected) Refer to 6E-88 page. 3. Disconnect the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
Value(s)
Yes
No
(ECM
Breaker box is not available: 1. Ignition Off, engine Off. 2. Disconnect the ECM connector. 3. Disconnect the meter connector. 4. Check the circuit for open or short to ground circuit. Was the problem found?
25 C-56(J2) B-24 11
7 Using the DVM and check the Tacho output circuit. 1. Ignition On, engine Off. 2. Disconnect the meter connector. 3. Check the circuit for short to power supply circuit. Was the DVM indicated specified value?
B-24 11
Go to Step 7
V
Less than 1V 8 Check any accessory parts which may cause electric interference or magnetic interference. Was the problem found? Go to Step 8 Remove the accessory parts and verify repair
Go to Step 9

Step 9 10 Action Replace the Tacho meter. Was the problem solved? Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Verify repair
6E231
No
Go to Step 10
Verify repair
Go to Step 11
11
Verify repair
6E232
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the On-Board Diagnostic (OBD) System Check and verify all of the following items: The engine control module (ECM) and malfunction indicator lamp (MIL = Check Engine Lamp) are operating correctly. There are no Diagnostic Trouble Code(s) stored. Tech 2 data is within normal operating range. Refer to Typical Scan Data Values. Verify the customer complaint and locate the correct symptom in the table of contents. Perform the procedure included in the symptom chart. MIL (Check Engine Lamp) wire to ECM shorted to ground. Poor ECM grounds. Refer to the ECM wiring diagrams. Road test the vehicle with a Digital Multimeter connected to a suspected circuit. An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored. Using Tech 2 to help detect intermittent conditions. The Tech 2 has several features that can be used to located an intermittent condition. An intermittent MIL (Check Engine Lamp) with no stored Diagnostic Trouble Code may be caused by the following: Ignition coil shorted to ground and arcing at ignition wires or plugs. MIL (Check Engine Lamp) wire to ECM short to ground. Poor ECM grounds. Refer to the ECM wiring diagrams. Check for improper installation of electrical options such as light, cellular phones, etc. Check all wires from ECM to the ignition control module for poor connections. Check for an open diode across the A/C compressor clutch and check for other open diodes (refer to wiring diagrams in Electrical Diagnosis). If problem has not been found, refer to ECM connector symptom tables. Check the Broadcast Code of the ECM, and compare it with the latest Isuzu service bulletins and/ or Isuzu EEPROM reprogramming equipment to determine if an update to the ECMs reprogrammable memory has been released. To check the Broadcast Code, connect the Tech 2, then look for ID info. then select Broadcast Code. This should display a 4 character code, such as XBYA (example only). This identifies the contents of the reprogrammable software and calibration contained in the ECM. If the Broadcast Code is not the most current available, it is advisable to reprogram the ECM s EEPROM memory, which may either help identify a hard-to find problem or may fix the problem. The Service Programming System (SPS) will not allow incorrect software programming or incorrect calibration changes.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful visual/physical check. This can lead to correcting a problem without further checks and can save valuable time. This check should include the following items: ECM grounds for cleanliness, tightness and proper location. Vacuum hoses for splits, kinks, and proper connection, shown on the Emission Control System Schematics. Check thoroughly for any type of leak or restriction. Air intake ducts for collapsed or damaged areas. Air leaks at throttle body mounting area, manifold absolute pressure (MAP) sensor and intake manifold sealing surfaces. Ignition wires for cracking, harness, and carbon tracking. Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn on the malfunction indicator lamp (MIL) or store a Diagnostic Trouble Code. Do NOT use the Diagnostic Trouble Code (DTC) charts for intermittent problems. The fault must be present to locate the problem. Most intermittent problems are cased by faulty electrical connections or wiring. Perform a careful visual/physical check for the following conditions. Poor mating of the connector halves or a terminal not fully seated in the connector (backed out). Improperly formed or damaged terminal. All connector terminals in the problem circuit should be carefully checked for proper contact tension. Poor terminal-to-wire connection. This requires removing the terminal form the connector body to check. Ignition coils shorted to ground and arcing at ignition wires or plugs.
6E233
ENGINE CRANKS BUT WILL NOT RUN

DEFINITIONS: Engine cranks, but will not run. (The engine never start.) NOTE: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagosis. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? Was a visually/physical check performed? 4 Check the Ignition coil fuse (15A) and ECM fuse (15A). Was a fuse blown? 1. Ignition ON 2. Use a DVM to verify that battery voltage at the ignition coil fuse, and the ECM fuse. Was battery voltage presented at the fuses? 6 1. Visually/physically conditions: inspect for the following Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Go to Step 3 Go to Visual / physical Check.
Verify repair
Go to Step 5
Go to Step 6
Verify & repair
Restriction of air intake system. Check for a restricted air filter element, or foreign objects blocking the air intake system. Check for objects blocking the IAC passage or throttle bore, 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/brake booster hose. Was a problem found? 7 1. Using a Tech 2, display the IAC value. 2. Check for a faulty, plugged, or sticking IAC operation. Was the problem found? 8 1. Using a Tech 2, display the MAP sensor value. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? If oscilloscope is available, check the wave form of the CKP signal. Was the correct wave form found? Check the CKP sensor wire for open or short circuit. Was a problem found? Replace CKP sensor. Is there still problem?
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 12 Verify repair Replace pulsar ring.
Go to Step 10 Go to Step 11 Verify repair
10 11
6E234
Step 12

Action Visually/physically inspect the secondary ignition wires. Check for the following conditions: Verify that all ignition wire resistance are less than the specified value. Verify that ignition wires are correctly routed to eliminate cross-fitting. Verify that ignition wires are not arcing to ground. Spraying the secondary ignition wires with a light mist of water may help locate an intermittent problem. Was a problem found? #1 cyl. 4.4k9 #2 cyl. 3.6k9 #3 cyl. 3.1k9 #4 cyl. 2.8k9 Value(s) Yes No
Verify repair
Go to Step 13
13
1. Disconnect the spark plug high tension cable from No.1 spark plug. 2. Install a spark tester at disconnected ignition coil. the end of the
3. Clip the spark tester to a good ground. 4. Observe the spark tester while the engine is cranking. Was a crisp blue spark observed? (Only one or two sparks followed by no result is considered the same as No Spark.) 14 1. Disconnect the ignition coil harness connector. 2. Check for an open or short circuit between the ignition coil and the ECM. Was a problem found? 15 1. Ignition On. 2. Using a Digital Voltmeter (DVM) check the ignition wire coil at the ignition coil harness connector. Was the voltage equal to the specified value? 1. Ignition Off. 2. With DVM, check for an open in the ground wire at the ignition coil harness connector. Was the ground wire OK? 17 Replace the ignition coil, verify the repair. Attempt to start the engine. Is there still a problem? Use an ohmmeter to check the ignition coil primary winding resistance. Was the primary winding resistance approximately equal to the specified value? Use an ohmmeter to check the ignition coil secondary winding resistance. Was the primary winding resistance hear around the to the specified value? Replace the ignition coil. 1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes. 3. Replace any spark plugs with loose or missing electrodes or cracked insulators. Did your inspection reveal any spark plugs exhibiting excessive fouling?
Go to Step 21
Go to Step 14
Verify repair
Go to Step 15
Battery voltage
Go to Step 16
Verify repair
16
Go to Step 17
Verify repair
Go to Step 18
Verify repair
18
0.8-18k9
Go to Step 19
Go to Step 20
19
2.5k9
Go to Step 20
20 21
Correct the fouling condition
Go to Step 22

Step 22 Action Perform the procedure in Fuel System Pressure Test (Refer to 6E-108 Fuel System Diagnosis) to determine if there is a problem with fuel delivery. Was a problem found? Refer to 6E-108 page Fuel System Diagnosisto determine if there is a problem with fuel delivery. Was a problem found? Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Camshaft drive belt slipped or stripped Was a problem found? 25 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 Was a problem found? 26 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E235
No
Verify repair
Go to Step 23
23
Verify repair
Go to Step 24
24
Verify repair
Go to Step 25
Verify repair
Go to Step 26
Verify repair
Go to Step 27
27
Verify Repair
6E236
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, of may start and then immediately stall. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visually/physical check performed? 1. Visually/physically conditions: inspect for the following Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Restriction of air intake system. Check for a restricted air filter element, or foreign objects blocking the air intake system Check for objects blocking the IAC passage or throttle bore, 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/brake booster hose. Was a problem found? 5 1. Using a Tech 2, display the IAC value. 2. Check for a faulty, plugged, or sticking IAC operation. Was the problem found? 6 Check engine coolant temperature (ECT) sensor for shift in value. 1. After 8 hours with hood up and the engine not running, connect the Tech 2. 2. Ignition On, engine not running. 3. Using Tech 2, compare Engine Coolant Temperature to Intake Air Temperature. Are ECT and IAT within the specified value of each other?
Verify repair
Go to Step 5
Verify repair
Go to Step 6
5C
Go to Step 8
Go to Step 7

Step 7 Action 1. Using a Tech 2, display the engine coolant temperature and note the value. 2. Check the resistance of the engine coolant temperature sensor. Is the actual resistance near the resistance value in the chart for the temperature that was noted?
Temperature (C) -20 0 20 40 60 80 100 120 Resistance ( 9) (Approximately) 26740 9120 3500 1464 664 333 175 102
6E237
No
Value(s)
Yes
Go to Step 8
Replace the ECT sensor. Verify repair
1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? Visually/physically inspect all spark plug high-tension cables. Check for the following conditions: Verify that the resistance of all spark plug hightension cables are less than the specified value. Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting. Verify that the all spark plug high-tension cables are not arcing to ground. Spraying the spark plug high-tension cables with a light mist of water may help locate an intermittent problem. Was a problem found?
Verify repair
Go to Step 9
#1 cyl. 4.4k9 #2 cyl. 3.6k9 #3 cyl. 3.1k9 #4 cyl. 2.8k9
Verify repair
Go to Step 10
10
Check for proper ignition voltage output with a spark tester. Was the problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found?
Verify repair
Go to Step 11
11
12 13
Check for a loose ignition control module ground. Was a problem found? 1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specified resistance. Did the coil require replacement?
2.5k9
Verify repair
Go to Step 14
6E238
Step 14

Action Drain sample fuel, visual inspection. Any suspecion about the fuel, such as discoloration, particle, contamination, water, unusual smell, then drain the fuel from fuel tank. Replace the fuel from know vehicle source. If any suspicion of alcohol contamination, completely drain the fuel, replace by fuel from known vehicle source. Perform the procedure in Fuel System Pressure Test (Refer to 6E-108 Fuel System Diagnosis) to determine if there is a problem with fuel delivery. Was a problem found? 1. Check the injector connectors. 2. If any of the connectors are connected at an improper cylinder, connect as necessary. Was a problem found? Value(s) Yes No
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
16
Verify repair
Go to Step 17
17
Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Camshaft drive belt slipped or stripped Was a problem found? Verify repair Go to Step 18
18
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 Was a problem found?
Verify repair
Go to Step 19
19
Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
Verify repair
Go to Step 20
20
Verify Repair
6E239
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM

DEFINITIONS: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
Step 1 2
Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?
Value(s)
Yes Go to Step 2
No Go to OBD System Check
3 4
Was a visual/physical check performed? 1. Check for faulty, plugged or incorrectly installed PCV valve. 2. Verify that the PCV system is not plugged. Was a problem found? Verify repair
Go to Step 5
1. Check for incorrect idle speed. Ensure that the following conditions are present. Engine fully warm Accessories are Off 2. Using a Tech 2, monitor IAC position. Is the IAC position within the specified values? 20-30 Steps Go to Step 7 Go to Step 6
1. Visually/physically conditions:
inspect
for
the
following
Restriction of the air intake system. Check for a restricted air filter element, or foreign objects blocking the air intake system. Check for objects blocking the IAC passage or throttle bore, 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/brake booster hose. Was a problem found?
Verify repair
Go to Step 7
6E240
Step 7

Action 1. Using a Tech 2, display the engine coolant temperature and note the value. 2. Check the resistance of the engine coolant temperature sensor. Is the actual resistance near the resistance value in the chart for the temperature that was noted?
Temperature (C) -20 0 20 40 60 80 100 120 Resistance (9) (Approximately) 26740 9120 3500 1464 664 333 175 102
Value(s)
Yes
No
Go to Step 8
Replace the ECT sensor. Verify repair
1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found?
Verify repair
Go to Step 9 Refer to Diagnostic Trouble Code P0123 for further diagnosis
Using Tech 2, monitor throttle position with the engine idling. Is the throttle position at the specified value and steady? 0% Go to Step 10
10
Check for proper ignition voltage output with the spark tester. Was a problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found? Check for a loose ignition control module ground. Was a problem found? Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? Check the injector connectors, if any of the injectors are connected any incorrect cylinder, correct as necessary. Was a problem found? 1. Check for faulty engine mounts. 2. If a problem is found, repair as necessary. Was a problem found?
Verify repair
Go to Step 11
11
12 13
Verify repair
Go to Step 14
14
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
16
Verify repair
Go to Step 17

Step 17 Action Perform the procedure in Fuel System Pressure Test (Refer to 6E-108 Fuel System Diagnosis) to determine if there is a problem with fuel delivery. Was a problem found? Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Camshaft drive belt slipped or stripped Was a problem found? 19 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 Was a problem found? 20 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Verify repair Value(s) Yes
6E241
No
Verify repair
Go to Step 18
18
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
21
Verify Repair
6E242
SURGES AND/OR CHUGS SYMPTOM

DEFINITIONS: See the illustration below. Feels like the vehicle speeds up and slows down with no charge in the accelerator pedal.
Step 1 2
Value(s)
Yes Go to Step 2
3 4
Was a visual/physical check performed? Be sure that the driver understands A/C compressor operation as explained in the owners manual. Inform the customer how the A/C clutch operate. Is the customer experiencing a normal condition? 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? Observe the throttle position display on the Tech 2 while slowly increasing throttle pedal. Is the throttle position at the specified value and steady in any position? Go to Step 7
System OK
Go to Step 5
Verify repair
Check the knock sensor wire, shield wire, or installation condition. Was a problem found? Run Engine. Check the fuel control Heated Oxygen Sensor (HO2S). When monitored on the Tech 2, the HO2S should respond quickly to different throttle positions. If it doesnt check for silicon or other contaminates from fuel or use of improper sealant. The sensors may have a white powdery coating. Silicon contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air/fuel mixture. Was a problem found?
Verify repair
Go to Step 8
Verify repair
Go to Step 9

Step 9 Action Check the fuel pressure. Refer to 6E-108 pageFuel System Diagnosis. Was a problem found? Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition? Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? Check for proper ignition voltage output with the spark tester. Was a problem found? Check for a loose ignition control module ground. Was a problem found? Visually/physically inspect all spark plug high-tension cables. Check for the following conditions: Verify that the resistance of all spark plug hightension cables are less than the specified value. Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting. Verify that the all spark plug high-tension cables are not arcing to ground. Spraying the spark plug high-tension cables with a light mist of water may help locate an intermittent problem. Was a problem found? 16 1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specified resistance. Did the coil require replacement? 17 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found? 18 1. Check the injector connectors. 2. If any of the connectors are connected at an improper cylinder, connect as necessary. Was a problem found? 19 Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? Visually/physically check the vacuum hose for splits, kinks and proper connections and routing. Was a problem found? Value(s) Yes
6E243
No
Verify repair
Go to Step 10
10
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12
12
Verify repair
Go to Step 13
13
14 15
Verify repair
Go to Step 16
2.5k9
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
20
Verify repair
Go to Step 21
6E244
Step 21

Action Check the exhaust system for a possible restriction: Damaged or collapsed pipes Internal muffler failure Was a problem found? Value(s) Yes No
Verify repair
Go to Step 22
22
Verify repair
Go to Step 23
23
Verify repair
Go to Step 24
24
Verify Repair
6E245
HESITATION, SAG, STUMBLE SYMPTOM

DEFINITIONS: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually most pronounced when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough.
Step 1 2
Value(s)
Yes Go to Step 2
Verify repair Go to Step 4 Replace fuel
Go to Step 3 Go to Visual / physical Check. Go to Step 5
3 4 5
Was a visual/physical check performed? Check the fuel quality. Is the customer using improper fuel or degraded fuel? 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? Observe the throttle position display on the Tech 2 while slowly increasing throttle pedal. Does the throttle position increase steady with increasing smoothly? Go to Step 7
Verify repair
Check the knock sensor wire, shield wire, or installation condition. Was a problem found? Run Engine. Check the fuel control Heated Oxygen Sensor (HO2S). When monitored on the Tech 2, the HO2S should respond quickly to different throttle positions. If it doesnt check for silicon or other contaminates from fuel or use of improper sealant. The sensors may have a white powdery coating. Silicon contamination sends a rich exhaust signal which causes the ECM to command and excessively lean air/fuel mixture. Was a problem found? Check the fuel pressure. Refer to 6E-108 Fuel System Diagnosis. Was a problem found?
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
6E246
Step 10

Action Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition? Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? Check for proper ignition voltage output with the spark tester. Was a problem found? Check for a loose ignition control module ground. Was a problem found? Visually/physically inspect all spark plug high-tension cables. Check for the following conditions: Verify that the resistance of all spark plug hightension cables are less than the specified value. Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting. Verify that the all spark plug high-tension cables are not arcing to ground. Spraying the spark plug high-tension cables with a light mist of water may help locate an intermittent problem. Was a problem found? Value(s) Yes No
Go to Step 11
Go to Step 12
11
Verify repair
Go to Step 12
12
Verify repair
Go to Step 13
13
14 15
Verify repair
Go to Step 16
16
1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specified resistance. Did the coil require replacement?
2.5k9
Verify repair
Go to Step 17
17
1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found?
Verify repair
Go to Step 18
18
Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? Visually/physically check the vacuum hose for splits, kinks and proper connections and routing. Was a problem found?
Verify repair
Go to Step 19
19
Verify repair
Go to Step 20

Step 20 Action 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 Was a problem found? 21 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E247
No
Verify repair
Go to Step 21
Verify repair
Go to Step 22
22
Verify Repair
6E248
CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases.
Step 1 2
Value(s)
Yes Go to Step 2
3 4
Was a visual/physical check performed? Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams in Electrical Diagnosis. Was a problem found? Check for a loose or short circuit of ignition coil module voltage feed. Was a problem found? Check for a loose or short circuit of ignition coil module ground. Was a problem found? Visually/physically inspect all spark plug high-tension cables. Check for the following conditions: Verify that the resistance of all spark plug hightension cables are less than the specified value. Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting. Verify that the all spark plug high-tension cables are not arcing to ground. Spraying the spark plug high-tension cables with a light mist of water may help locate an intermittent problem. Was a problem found?
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 7
Check the CKP sensor wire, shield wire, or installation condition. Was a problem found? Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition?
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11

Step 10 Action Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the lean condition? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? 1. Visually/physically conditions: inspect for the following Value(s) Yes
6E249
No
Verify repair
Go to Step 11
11
Go to Step 12
Go to Step 13
12
Verify repair
Go to Step 13
13
Restriction of air intake system. Check for a restricted air filter element, or foreign objects blocking the air intake system. Check for objects blocking the IAC passage or throttle bore, 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/brake booster hose. Was a problem found? 14 Check the injector connectors, if any of the injectors are connected an incorrect cylinder, correct as necessary. Was a problem found? Perform the Injector Coil/Balance Test (Refer to 6E98 page). Was a problem found. 1. Check for fuel in the pressure regulator vacuum hose. 2. If fuel is present, replace the fuel pressure regulator assembly. Was a problem found? 17 Check for proper ignition voltage output with the spark tester. Was a problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found?
Verify repair
Go to Step 14
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
18
Verify repair
Go to Step 19
6E250
Step 19

Action Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Camshaft drive belt slipped or stripped Was a problem found? Verify repair Go to Step 20 Value(s) Yes No
20
1. Check for faulty engine mounts. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 21
21
Verify repair
Go to Step 22
22
Verify repair
Go to Step 23
23
Verify Repair
6E251
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM

DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no increase in vehicle speed. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visual/physical check performed? 1. Remove and check the air filter element for dirt or restrictions. 2. Replace the air filter element if necessary. Was a repair required? 5 Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams. Was a problem found? 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? 1. Using a Tech 2, display the ECT sensor and IAT sensor value and warm up condition compared with the typical data. 2. Check the specified value or wire. Was the problem found? 8 Observe the throttle position display on the Tech 2 while slowly increasing throttle pedal. Does the throttle position increase steady with increasing smoothly? 9 Check the knock sensor wire, shield wire, or installation condition. Was a problem found? Run Engine. Check the fuel control Heated Oxygen Sensor (HO2S). When monitored on the Tech 2, the HO2S should respond quickly to different throttle positions. If it doesnt check for silicon or other contaminates from fuel or use of improper sealant. The sensors may have a white powdery coating. Silicon contamination sends a rich exhaust signal which causes the ECM to command and excessively lean air/fuel mixture. Was a problem found? Check the fuel pressure. Refer to Fuel System Diagnosis 6E-108. Was a problem found? Go to Step 9 Verify repair Go to Step 8 Refer to Diagnostic Trouble Code P0123 for further diagnosis Verify repair Go to Step 5 Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 10
10
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12
6E252
Step 12

Action Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition? Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? Check for proper ignition voltage output with a spark tester. Was the problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found? Drain sample fuel, visual inspection. Any suspecion about the fuel, such as discoloration, particle, contamination, water, unusual smell, then drain the fuel from fuel tank. Replace the fuel from know vehicle source. If any suspencion of alcohol contamination, completely drain the fuel, replace by fuel from known vehicle source. Check the exhaust system for a possible restriction: Damaged or collapsed pipes Internal muffler failure Was a problem found? Value(s) Yes No
Verify repair
Go to Step 13
13
Verify repair
Go to Step 14
14
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
16
Verify repair
Go to Step 17
17
Verify repair
Go to Step 18
18
Verify repair
Go to Step 19
19
Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Loose timing belt Was a problem found? Verify repair Go to Step 20
20
Verify repair
Go to Step 21

Step 21 Action Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes
6E253
No
Verify repair
Go to Step 22
22
Verify Repair
6E254
DETONATION/SPARK KNOCK SYMPTOM

DEFINITIONS: A mild to severe ping, usually worse under acceleration. The engine makes a sharp metallic knocking sound that changes with throttle opening. Prolonged detonation may lead to complete engine tailure. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visual/physical check performed? 1. If Tech 2 readings are normal (refer to Typical Scan Data Values) and there are no engine mechanical faults, fill the fuel tank with a known quality gasoline. 2. Re-evaluate the vehicle performance. Is detonation present? 5 1. Check for obvious overheating problems: Low engine coolant Restricted air flow to radiator Incorrect coolant solution 2. If a problem is found, repair as necessary. Was a problem found? 6 Check the fuel pressure. Refer to 6E-108 page Fuel System Diagnosis . Was a problem found? 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? 1. Using a Tech 2, display the ECT sensor and IAT sensor value and warm up condition compared with the typical data. 2. Check the specified value or wire. Was the problem found? 9 Observe the throttle position display on the Tech 2 while slowly increasing throttle pedal. Does the throttle position increase steady with increasing smoothly? 10 Check the knock sensor wire, shield wire, or installation condition. Was a problem found? Check items that can cause the engine to run lean. Refer to DTC P1171 Fuel Supply System Lean During Power Enrichment. Was a problem found? Go to Step 10 Verify repair Go to Step 9 Refer to Diagnostic Trouble Code P0123 for further diagnosis Verify repair Go to Step 6 Go to Step 5 Verify repair Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 11
11
Verify repair
Go to Step 12

Step 12 13 Action Check spark plugs for proper heat range. Were incorrect spark plugs installed? 1. Remove excessive carbon buildup with a top engine cleaner. 2. Re-evaluate vehicle performance. Is detonation still present? Check for an engine mechanical problem. Perform a cylinder compression check. Refer to Engine Mechanical. Was a problem found? 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 Was a problem found? 16 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes Verify repair
6E255
No
Go to Step 13
Verify repair
Go to Step 14
14
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
17
Verify Repair
6E256
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. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visual/physical check performed? Check owner s driving habits. Is the A/C On full time (defroster mode On)? Are tires at the correct pressure? Are excessively heavy loads being carried? Is acceleration too much, too often? 5 Review the items in Step 4 with the customer and advise as necessary. Is the action complete? Visually/physically check: Vacuum hoses for splits, kinks, and improper connections and routing as shown on the Emission Control System Schematics. Was a problem found? Check for low engine coolant level. Was a problem found? Check for incorrect or faulty engine thermostat. Refer to Engine Cooling. Was a problem found? Remove and check the air filter element for dirt or for restrictions. Was a problem found? 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature. 2. Check for a faulty, plugged, or incorrectly installed MAP sensor. Was the problem found? 11 1. Using a Tech 2, display the ECT sensor and IAT sensor value and warm up condition compared with the typical data. 2. Check the specified value or wire. Was the problem found? 12 Check the knock sensor wire, shield wire, or installation condition. Was a problem found? Check the fuel pressure. Refer to 6E-108 pageFuel System Diagnosis. Was a problem found? Verify repair Go to Step 12 Go to Step 5 Go to Step 6 Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
System OK
7 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
10
Verify repair
Go to Step 11
Verify repair
Go to Step 13
13
Verify repair
Go to Step 14

Step 14 Action Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition? Check items that can cause the engine to run rich. Refer to DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Was a problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found? 17 Check for proper calibration of the speedometer. Does the speed indicated on the speed meter closely match the vehicle speed displayed on the Tech 2? Diagnose and repair the inaccurate speedometer condition as necessary. Refer to Vehicle Speed Sensor in Electrical Diagnosis. Check for proper calibration of the fuel gauge. Was a problem found? Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Worn camshaft Sticking or leaking valves Valve timing Was a problem found? 21 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 Was a problem found? 22 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Verify repair Value(s) Yes
6E257
No
Verify repair
Go to Step 15
15
Verify repair
Go to Step 16
16
Verify repair
Go to Step 17
Go to Step 19
Go to Step 18
18
Verify Repair Verify repair
Go to Step 20
19 20
Go to Step 21
Verify repair
Go to Step 22
Verify repair
Go to Step 23
23
Verify Repair
6E258
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITIONS: Vehicle fails an emission test. There is excessive rotten egg smell. (Excessive odors do not necessarily indicate excessive emissions.) Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 5 6 Was a visual/physical check performed? Does the customer continual accelerate On/Off during cold condition? Is the customer using the incorrect fuel type? Check for vacuum leaks (vacuum lines, intake manifold, throttle body, etc.) Were any vacuum leaks found? 1. Check fuel cap for proper installation. 2. Secure the fuel cap if necessary. Was a problem found? 8 Check the fuel pressure. Refer to 6E-108 page Fuel System Diagnosis . Was a problem found? 1. Check for faulty, plugged or incorrectly installed PCV valve. 2. Verify that the PCV system is not plugged. Was a problem found? Check the injector connectors, if any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found? Perform theInjector Coil/Balance Test (Refer to 6E98 page). Was a problem found. Check for a problem with the engine cooling system. Was a problem found? Check EVAP canister for fuel loading. Refer to Evaporative Emission Control System. Was a problem found? Check the EVAP purge solenoid valve operation. Is the valve operated normally? Check the exhaust system for a possible restriction: Damaged or collapsed pipes Internal catalytic converter failure Was a problem found? Verify repair & Go to Step 16 Go to Step 17 Go to Step 17 Go to Step 8 Go to Step 4 System OK Replace with unleaded fuel Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Go to Step 3 Go to Visual / physical Check. Go to Step 5 Go to Step 6
Go to Step 17
Go to Step 7
Go to Step 17
Go to Step 9
Go to Step 17
Go to Step 10
10
Go to Step 17
Go to Step 11
11
12 13
Go to Step 14 Verify repair & Go to Step 15
14 15

Step 16 Action 1. Remove excessive carbon buildup with a top engine cleaner. Refer to the instructions on the top engine cleaner can. 2. Perform the exhaust emission test. Does the vehicle pass the test? 17 18 Perform the exhaust emission test. Does the vehicle pass the test? Run Engine. Check the fuel control Heated Oxygen Sensor (HO2S). When monitored on the Tech 2, the HO2S should respond quickly to different throttle positions. If it doesnt check for silicon or other contaminates from fuel or use of improper sealant. The sensors may have a white powdery coating. Silicon contamination sends a rich exhaust signal which causes the ECM to command and excessively lean air/fuel mixture. Was a problem found? Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech 2. Is the B1S1 (Bank 1 Sensor 1) Status in the rich condition? 1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P1167 Fuel Supply System Rich During Deceleration Fuel Cut Off. Make any necessary repairs. 2. Perform the exhaust emission test. Does the vehicle pass the test? 21 1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P1171 Fuel Supply System Lean During Power Enrichment. Make any necessary repairs. 2. Perform the exhaust emission test. Does the vehicle pass the test? 22 Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Was a problem found? 23 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 Was a problem found? Verify repair System OK System OK System OK System OK Value(s) Yes
6E259
No
Verify repair
Go to Step 19
19
Go to Step 20
Go to Step 21
20
Go to Step 22
Go to Step 22
Go to Step 23
Verify repair
Go to Step 24
6E260
Step 24

Action Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Value(s) Yes No
Verify repair
Go to Step 25
25
Verify Repair
6E261
DIESELING, RUN-ON SYMPTOM

DEFINITIONS: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check the ignition switch and adjustment. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visual/physical check performed? Check for a short between battery voltage and the ignition feed circuit. Was a problem found? Check the fuel leaking from injector. Refer to Fuel System Diagnostic. Was the problem found? 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 Was a problem found? 7 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
6E262
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Step 1 2 Action Was the On-Board Diagnostic (OBD) System Check performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom? 3 4 Was a visual/physical check performed? Check for proper ignition voltage output with the spark tester. Was a problem found? 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs. Was a problem found? 6 Visually/physically inspect all spark plug high-tension cables. Check for the following conditions: Verify that the resistance of all spark plug hightension cables are less than the specified value. Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting. Verify that the all spark plug high-tension cables are not arcing to ground. Spraying the spark plug high-tension cables with a light mist of water may help locate an intermittent problem. Was a problem found? 7 Check the fuel pressure. Refer to 6E-108 page Fuel System Diagnosis . Was a problem found? Check for an intermittent ignition system malfunction: Intermittent CKP 58X signal Intermittent ignition feed circuit or sensor ground circuit to the crankshaft position sensor. Was a problem found? 9 Refer to 6E-108 page Fuel System Diagnosis to determine if there is a problem with fuel delivery. Was a problem found? Go to Step 4 Value(s) Yes Go to Step 2 No Go to OBD System Check
Verify repair
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

Step 10 Action Check for the following engine mechanical problems (refer to Engine Mechanical): Low compression Leaking cylinder head gaskets Worn camshaft Sticking or leaking valves Valve timing Broken valve springs Camshaft drive belt slipped or stripped Was a problem found? 11 Check leakage at exhaust system. Check the intake and exhaust manifold for casting flash. Refer to Engine Mechanical. Was a problem found? 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 Was a problem found? 13 Is the ECM programmed with the latest software release? If not, download the latest software to the ECM using the SPS (Service Programming System). Was the problem solved? Replace the ECM. Is the action complete? IMPORTANT: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM. Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure. Verify repair Value(s) Yes
6E263
No
Go to Step 11
Verify repair
Go to Step 12
12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
14
Verify repair
6E264
ON-VEHICLE SERVICE PROCEDURE

ENGINE CONTROL MODULE (ECM)
Location On the intake manifold. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the two connectors from the ECM. 3. Remove four bolts. 4. Remove the ECM from bracket. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the drive belt. Refer to Engine Mechanical Section. 3. Remove the A/C compressor from engine. Refer to Engine Mechanical Section. 4. Disconnect connector from the CKP sensor. 5. Loosen a bolt and remove the CKP sensor from the cylinder block. NOTE: Use caution to avoid any hot oil that might drip out.
CRANKSHAFT POSITION (CKP) SENSOR

Location Left-hand side of the cylinder block. (Back of the A/C compressor)
Installation Procedure 1. Put on the ECM to the bracket. 2. Tighten the ECM by four bolts with specified tightening torque. Tightening torque Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm) 3. Connect the two connectors to the ECM. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Installation Procedure 1. Install the CKP sensor to the cylinder block. 2. Tighten CKP sensor by a bolt with specified tightening torque. Tightening Torque Bolt: 6Nm (0.6kgfm) 3. Reinstall the A/C compressor to the engine. 4. Reinstall the accessory drive belt. 5. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
ENGINE DRIVEABILITY AND EMISSIONS ENGINE COOLANT TEMPERATURE (ECT) SENSOR

Location Installed to the thermostat housing. Removal Procedure 1. Disconnect the negative battery cable. 2. Drain enough engine coolant so that the coolant level will be below the ECT sensor. 3. Disconnect connector from the ECT sensor. 4. Loosen and remove the ECT sensor from the thermostat housing. NOTE: Cool down the engine before above procedures are carried out.
6E265
INTAKE AIR TEMPERATURE (IAT) SENSOR

Location Installed to the intake duct housing. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect a IAT sensor connector from the IAT sensor. 3. Remove the IAT sensor from the intake duct.
Installation Procedure 1. Install the IAT sensor into intake air duct. 2. Connect a IAT sensor connector to the IAT sensor. 3. Connect the negative battery cable. Installation Procedure 1. Apply sealer to threads of screw at the ECT sensor. 2. Tighten the ECT sensor with specified tightening torque. Tightening Torque Bolt: 13Nm (1.3kgfm) 3. Connect a ECT sensor connector to the ECT sensor. 4. Fill the engine coolant. 5. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify no engine coolant leaking from the sensor threads after replacement. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
6E266
ENGINE DRIVEABILITY AND EMISSIONS THROTTLE POSITION SENSOR (TPS)

Location Installed on the throttle body. Removal Procedure
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Location Installed on the intake manifold. Removal Procedure 1. Disconenct the negative battery cable. 2. Disconnect a MAP sensor connector from the MAP sensor. 3. Loosen a bolt and remove the MAP sensor from the intake manifold. 4. Remove the MAP sensor from the bracket.
1. Disconnect the negative battery cable. 2. Disconnect the TPS connector. 3. Loosen two screws and remove TPS from the throttle body.
Installation Procedure 1. Temporary tighten the TPS by two screws. 2. Connect a TPS connectors to the TPS. Installation Procedure 1. Tighten the MAP sensor by a bolt with specified tightening torque. Tightening Torque Bolt: 8Nm (0.8kgfm) 2. Connect a MAP sensor connector to the MAP sensor. 3. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. 3. Connect the Tech2 to the vehicle. 4. Connect the negative battery cable. 5. Select "Data Display" with the Tech2. 6. Check the throttle position data and adjust the TPS position. 7. Tighten two screws. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
ENGINE DRIVEABILITY AND EMISSIONS IDLE AIR CONTROL (IAC) VALVE

Location Installed on the throttle body. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Loosen two screws and remove IAC valve from the throttle body.
6E267
Installation Procedure 1. Tighten the IAC valve by two screws. 2. Connect a IAC valve connector to the MAP sensor. 3. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement.
Cleaning and Inspection 1. Clean the IAC valve O-ring sealing surface, pintle valve seat and air passage. 2. Use carburetor cleaner and a parts cleaning brush to remove carbon deposit. Do not use a cleaner that contain methyl ethyl ketone. This is an extremely strong solvent and not necessary for this type of deposit. 3. Shiny spots on the pintle are normal and do not indicate misalignment or a bent pintle shaft. 4. Inspect the IAC valve O-ring for cuts, cracks or distortion. Measurement Clean the IAC valve O-ring sealing surface, pintle valve seat and air passage. Use carburetor cleaner and a parts cleaning brush to remove carbon deposit. Do not use a cleaner that contain methyl ethyl ketone. This is an extremely strong solvent and not necessary for this type of deposit. Shiny spots on the pintle are normal and do not indicate misalignment or a bent pintle shaft. Inspect the IAC valve O-ring for cuts, cracks or distortion. Replace the O-ring if damaged.
6E268
ENGINE DRIVEABILITY AND EMISSIONS POWER SWITCH STEERING PRESSURE (PSP)
KNOCK SENSOR
Location Right-hand side of the cylinder block. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the knock sensor connector. 3. Loosen a bolt and remove knock sensor from the cylinder block.
Location Installed on the power steering pump assembly. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the power steering pressure switch connector. 3. Loosen and remove the power steering pressure switch from the power steering pump.
Installation Procedure 1. Tighten the knock sensor by a bolt with specified tightening torque. Tightening Torque Bolt: 20Nm (2.0kgfm) 2. Connect a knock sensor connector to the knock sensor. 3. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Installation Procedure 1. Install the power steering pressure switch to the power steering pump. 2. Tighten the power steering pressure switch. 3. Connect a connector to the power steering pressure switch. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify no power steering fluid leaking from the sensor threads after replacement.
ENGINE DRIVEABILITY AND EMISSIONS HEATED OXYGEN SENSOR (HO2S)

Location Installed on the exhaust pipe. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the O2 sensor connector. 3. Loosen and remove the O2 sensor from the exhaust pipe. Removal Procedure
6E269 VALVE
EVAP CANISTER SOLENOID

Location On the intake manifold.
PURGE
1. Disconenct the negative battery cable. 2. Disconnect a purge solenoid connector from the purge solenoid. 3. Disconnect two hoses from the purge solenoid valve. 4. Slide from the bracket and remove the purge solenoid.
Inspection Inspect the louvered end of the sensor for grease, dirt, excessive carbon build up or other contamination. Installation Procedure 1. Install the O2 sensor to the exhaust pipe. 2. Tighten the O2 sensor with specified tightening torque. Tightening Torque Bolt: 42Nm (4.3kgfm) 3. Connect a O2 sensor connector to the O2 sensor. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify no exhaust gas leaking from the sensor threads after replacement. Installation Procedure 1. Insert EVAP purge solenoid valve onto the bracket. 2. Connect two hoses to the purge solenoid valve. 3. Connect a purge solenoid connector to the purge solenoid. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify proper connection of two hoses.
6E270
ENGINE DRIVEABILITY AND EMISSIONS FUEL RAIL ASSEMBLY

Removal Procedure NOTE: Use care when removing the fuel rail assembly in order to prevent damage to the injector al connector terminal and the injector spray tips. Fitting should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passage. Important: An eight-digit identification number is stamped on side of the fuel injector. Refer to this number when you service the fuel rail or when a replacement part is required. 1. Disconnect 4 injector connectors. 2. Lift side-clip up on the fuel rail. 3. Disconnect fuel pressure regulator hose. 4. Disconnect wiring harness from the bands on the fuel rail. 5. Remove the intake pipe. 6. Loosen flare nut. A. Lift up the injectors carefully to separate them from intake manifold. B. Lift up the fuel rail with injectors as assembly. Do not separate the fuel injectors from fuel rail. C. If an injector become separated from fuel rail, injector backup O-ring and injector retainer clip must be replaced. D. Drain residual fuel from fuel rail into an approved container.
FUEL PRESSURE RELIEF

Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components. Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fitting with a short towel before disconnecting the fittings. The towel will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container. 1. Remove the fuel filler cap. 2. Remove the fuel pump relay from the underhood relay box. 3. Start the engine and allow it to stall. 4. Crank the engine for about 30 seconds. 5. Disconnect the negative battery cable.
7. If removal of fuel pressure regulator is necessary, Refer to Fuel Pressure Regulator Removal Procedure.

8. If removal of fuel injector is necessary, Refer to Fuel Injectors Removal Procedure.
6E271
8. Connect the fuel return line securely. Do not over tighten. 9. Connect the negative battery cable. 10. Crank the engine until it starts. Cranking the engine may take longer than usual due to trapped air in the fuel system. Check for leak. If fuel leak is observed, stop engine immediately. Before correcting fuel leak, be sure to depressurize system again.
Installation Procedure 1. Install the fuel injectors if necessary. Refer to Fuel Injector Installation Procedure. 2. Install the fuel pressure regulator if necessary. Refer to Fuel Pressure Regulator Installation Procedure. 3. Place the fuel injector rail assembly on the manifold and insert the injectors into each port by pushing fuel rail.
4. Install two fuel rail retaining bolts. Tighten fuel rail retaining bolt to 19 Nm (1.9kgfm) 5. Place wiring harness in its place and secure it with two nuts. 6. Connect all connector to each fuel injector. 7. Connect the fuel supply line securely. Do not over tighten.
6E272
FUEL INJECTOR
Removal Procedure NOTE: If the fuel injectors are leaking, the engine oil may be contaminated with fuel. Check the oil for signs of contamination and change the oil and filter if necessary. NOTE: Use care in removing the fuel injector in order to prevent damage to the fuel injector al connector pins or fuel injector nozzles. The fuel injector is an al component and should not be immersed in any type of cleaner as this may damage the fuel injector.
Inspection 1. Inspect O-ring for crack, damage or leaks. 2. Replace worn or damaged O-ring. 3. Lubricate the new O-rings with engine oil before installation. Installation Procedure 1. Lubricate the new O-ring with engine oil. 2. Install the O-ring backup on the fuel injector. 3. Install new O-ring on the fuel injector. 4. Install all four injector on the fuel rail. 5. Use new injector retainer clip to retain the injetor to the fuel rail. 6. Coat the end of the fuel injector with engine oil.
Important: Fuel injectors are serviced as complete assembly only. 1. Disconnect the negative battery cable. 2. Disconnect al connector from fuel injector. 3. Remove the fuel rail. Refer to Fuel Rail Removal Procedure. 4. Remove the fuel injector retainer clip. 5. Remove the fuel injector assembly from fuel rail. 6. Remove O-ring from the fuel injector. 7. Remove O-ring backup from fuel injector.

7. Install fuel rail assembly. Tighten the nuts to 19 Nm (1.9 kgfm). Refer to Fuel Rail Installation Procedure. Tighten the flare nut to 27 - 33 Nm (2.8 - 3.4 kgfm). 8. Connect the negative battery cable.
6E273
FUEL PRESSURE REGULATOR

Removal Procedure Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components. Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fitting with a shop towel before disconnecting the fittings. The towel will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container. NOTE: Compressed air must never be used to test or clean a fuel pressure regulator, as damage to the fuel pressure regulator may occur. NOTE: To prevent damage to the fuel pressure regulator, do not immerse the pressure regulator in solvent.
Removal Procedure 1. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the negative battery cable. 3. Remove the fuel pump relay. 4. Disconnect the vacuum line form fuel pressure regulator.
6E274
5. Remove the fuel pressure regulator retaining screw. 6. Remove the fuel pressure regulator from fuel rail.
2. Install the fuel pressure regulator retaining bracket and tighten with a screw. 3. Connect vacuum line onto the fuel pressure regulator.
Installation Procedure 1. Insert the fuel pressure regulator into the fuel rail. 4. Install the fuel pump relay. 5. Connect the negative battery cable. 6. Crank the engine until it starts. Cranking the engine may take longer than usual due to trapped air in the fuel line. 7. Tighten the flare nut to 27 - 33 Nm (2.8 - 3.4 kgfm).
ENGINE DRIVEABILITY AND EMISSIONS IGNITION COIL

Location Back of the engine right-hand side. Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the ignition coil connector. 3. Disconnect four spark plug cables from the ignition coil. 4. Loosen three bolts and remove ignition coil from the bracket.
6E275
SPARK PLUGS
Location Installed on the left-hand side of cylinder head. Removal Procedure 1. Disconnect the negative battery cable 2. Remove the spark plug cable. 3. Remove the spark plug.
Inspection 1. Check the insulator for cracks. Replace the spark plug if cracks are present. Installation Procedure 1. Tighten the ignition coil by three bolts. 2. Connect four spark plug cables to the ignition coil. 3. Connect a ignition coil connector to the ignition coil. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify proper connection of spark plug cables for each cylinders. 2. Check the electrode condition and replace the spark plug if necessary.
If the spark plug electrodes and insulators are fouled with carbon or oil, the engine will not operate efficiently. There are a number of possible causes: Fuel mixture is too rich.
6E276
Oil in the combustion chamber. The spark plug gap is not set correctly. If spark plug fouling is excessive, check the fuel and al system for possible causes of trouble. If fuel and al system are normal, install spark plugs of a higher heat range which have the same physical dimensions as the original equipment spark plugs. The following symptoms are characteristics of spark plugs that are running too hot: Fuel mixture is too lean. Heat range is incorrect.
Installation 1. Tighten the spark plug to the 25Nm (2.5kgfm). 2. Push the spark plug cable in until it snaps in.
If vehicle usage does not conform to normal driving conditions, a more suitable spark plug may be substituted. If fuel and al system are normal, in most cases of this sort, the problem can be corrected by using a colder type spark plug with the same physical dimensions as the original equipment spark plug. 3. Check the gaskets for damage and replace if necessary. 4. Measure the spark plug gap. The specification is 1.0 to 1.1mm (0.039 to 0.043"). 5. Adjust the spark gap by bending the grounded electrode. Installation Procedure 1. Install the spark plug to the cylinder head. 2. Tighten the spark plug with specified tightening torque. Tightening Torque Bolt: 25Nm (2.5kgfm) 3. Connect the spark plug cable to the spark plug. 4. Connect the negative battery cable. NOTE: Verify any DTCs (diagnosis Trouble Code) are not stored after replacement. Verify proper connection of spark plug cables for each cylinders.
ENGINE DRIVEABILITY AND EMISSIONS SPARK PLUG CABLES

The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil. The original equipment cables and the ignition coil are marked to show correct location of the cables. If spark plug cables or the ignition coil are replaced previously, before cables are removed from the ignition coil, mark the cables and the coil so they can be reconnected in the same position. Inspection NOTE: Never puncture the spark plug cables insulation with a needle or the pointed end of a probe into the cable. An increase in resistance would be created which would cause the cable to become defective. 1. If the cable has broken or cracked insulation, it must be replaced. 2. If the terminals are corroded or loose, the cable must be replaced. 3. Check that the cable resistance does not exceed specified value. #1 cylinder: 3.50k9 - 5.24k9 #2 cylinder: 2.89k9 - 4.33k9 #3 cylinder: 2.49k9 - 3.73k9 #4 cylinder: 2.22k9 - 3.32k9
6E277
EMISSION CONTROL ; CO ADJUSTER (W/ O CATALYSTIC CONVERTER)

CO : Carbon monoxide Location Under the leht-hand side of the front sheet. Removal Procedure 1. Remove the left-hand side of the front sheet. Refer to Sec.10 CAB Front Sheet. 2. Disconnect the CO adjuster connector.
3. Remove the CO adjuster. Installation Procedure 1. Connect the CO adjuster connector. 2. Install the left-hand side of the front sheet. Refer to Sec.10 CAB Front Sheet. 3. Check and adjust CO concentration. Checking procedure 1. Operate the engine at normal temperature. 2. Turn all accessories switch OFF. 3. Place the select lever in the N range. 4. Start the engine at idle.
6E278

Adjustment Procedure 1. Warm-up the engine. 2. Turn OFF switches of all electrical equipment. 3. Open the CO adjuster cap. 4. Turn the CO adjuster screw checking the CO concentration .
5. Measure the CO concentration for 1-3 minutes, after idlling the engine to allow the CO concentration to stabilize. 6. Check the CO concentration. 7. If the value is not within specification, adjust the CO concentration. 5. Adjust the CO concentration within specification. Specification: CO concentration : 0.6 ' 1.0 % NOTE: Apply the liquid gasket to the CO adjuster screw after the adjustment.
6E279
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
5-8840-0378-0 (J34730-E) Port Fuel Injection Diagnostic Kit
Breaker Box
5-8840-2589-0 Injector Adapter Cable
MEMO
ENGINE EXHAUST 6F-1
SECTION 6F
ENGINE EXHAUST
CONTENTS
PAGE General Description........................................................................................................ 6F- 2 Service Precaution ......................................................................................................... 6F- 4 Exhaust Pipe ................................................................................................................... 6F- 5 Exhaust pipe and Associated parts.......................................................................... 6F- 5 Removal ...................................................................................................................... 6F- 5 Installation .................................................................................................................. 6F- 6 Inspection ................................................................................................................... 6F- 6 Front Exhaust Pipe ......................................................................................................... 6F- 7 Front Exhaust Pipe and Associated Parts ............................................................... 6F- 7 Removal ...................................................................................................................... 6F- 7 Installation .................................................................................................................. 6F- 7 Mid Pipe ........................................................................................................................... 6F- 8 Mid Pipe and associated Parts ................................................................................. 6F- 8 Removal ...................................................................................................................... 6F- 8 Installation .................................................................................................................. 6F- 8 Catalytic Converter (If applicable) ................................................................................. 6F- 9 Catalytic Converter and Associated Parts ............................................................... 6F- 9 Removal ...................................................................................................................... 6F- 9 Installation .................................................................................................................. 6F- 9 3 way Catalytic Converter System ............................................................................ 6F- 10 Exhaust Silencer............................................................................................................. 6F- 12 Exhaust Silencer and Associated Parts................................................................... 6F- 12 Removal ...................................................................................................................... 6F- 12 Installation .................................................................................................................. 6F- 13 Main Data and Specifications ........................................................................................ 6F- 14 Torque Specification.................................................................................................. 6F- 15
6F-2 ENGINE EXHAUST
General Description
RTW46AMF000501
ENGINE EXHAUST 6F-3 When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating the floor pan and possible damage to the passenger compartment insulation and trim materials. Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an indication of a problem in one of these areas. Any faulty areas should be corrected immediately.
Hangers
Various types of hangers are used to support exhaust system(s). These include conventional rubber straps, rubber rings, and rubber blocks. The installation of exhaust system supports is very important, as improperly installed supports can cause annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter (If applicable)

The three way catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust gas stream. CAUTION: The catalytic converter requires the use of unleaded fuel only. Periodic maintenance of the exhaust system is not required. If the vehicle is raised for other service, it is advisable to check the condition of the complete exhaust system. A dual bed monolith catalytic converter is used in combination with three way catalytic converter. Catalytic Types: Three way (Reduction/Oxidation) catalyst The catalyst coating on the three way (reduction) converter contains platinum and rhodium which lowers the levels of nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust pipe, muffler or catalytic converter is installed.
6F-4 ENGINE EXHAUST
Service Precaution
ENGINE EXHAUST 6F-5
Exhaust Pipe
Exhaust Pipe and Associated parts
RTW46FLF000401
Removal
(2.4L) CAUTION When you remove or install the front exhaust pipe, make sure not to damage the fuel evaporative pipe. 1. 2. 3. 4. 5. 6. 7. Damper rubber Exhaust silencer Mid pipe Damper rubber Front exhaust pipe fixing nut Catalytic converter (If applicable) Front exhaust pipe
6F-6 ENGINE EXHAUST
Installation
To install, follow the removal steps in the reverse order.
Important - Installation
1. Front Exhaust Pipe Flange Nut Connect the exhaust pipe to the exhaust manifold. Front exhaust pipe to manifold nut. Torque N m (kgf m) 28 (2.9)
Inspection
Make the necessary adjustments, and part replacements if excessive wear or damage is discover during inspection. 1. 2. 3. 4. Front Exhaust Pipe Center Exhaust Pipe and Catalytic Converter Flange Nut Exhaust Pipe Damper Rubber Exhaust Silencer with Rear Exhaust Pipe
Check the pipes for for corrosion, cracking , damage or misalignment and repair if required. Check the damper rubber for deterioration or damage and repair if required.
ENGINE EXHAUST 6F-7
Front Exhaust Pipe (W/O Catalytic Converter)

Front Exhaust Pipe and Associated Parts
RTW46F000101
Legend
1. Front Exhaust Pipe Fixing Nuts 2. Front Exhaust Pipe 3. Mid Exhaust Pipe Fixing Nuts
Removal
(2.4L) 1. 2. 3. 4. 5. Disconnect battery ground cable. Raise the vehicle and support with suitable safety stands. Remove the front exhaust pipe fixing nuts (1). Remove mid pipe fixing nuts (3). Remove front exhaust pipe (2).
Installation
1. Install front exhaust pipe (2) and tighten four nuts (1). Torque: Nuts: 28 N m (2.9 kgf m) 2. Tighten two nuts (3). Torque: 43 N m (4.4 kgf m)
6F-8 ENGINE EXHAUST
Mid Pipe
Mid Pipe and Associated Parts
RTW46FSF000201
Legend
1. Mid Exhaust Pipe 2. Mid Exhaust Pipe Fixing Nuts 3. Exhaust Silencer Fixing Nuts
Removal
(2.4L) 1. 2. 3. 4. 5. Disconnect battery ground cable. Raise the vehicle and support with suitable safety stands. Remove mid pipe fixing nuts (2). Remove exhaust silencer fixing nuts (3). Remove the pipe.
Installation
1. Install mid exhaust pipe (1) and tighten four fixing nuts (2)(3) to the specified torque: Torque: Fixing nuts: 43 N m (4.4 kgf m)
ENGINE EXHAUST 6F-9
Catalytic Converter (If applicable)

Catalytic Converter and Associated Parts
RTW46FSF000301
Legend
1. Catalytic Converter 2. O2 Sensor Converter 3. Front Pipe Fixing Nuts 4. Mid Pipe Fixing Nuts
Removal
(2.4L) 1. 2. 3. 4. 5. 6. Disconnect battery ground cable. Raise the vehicle and support with suitable safety stands. Remove front pipe fixing nuts (3). Remove mid pipe fixing nuts (4). Remove the O2 sensor connector (2). Remove the front exhaust pipe with catalytic converter (1).
Installation
1. Install Catalytic Converter (1) and tighten four to the specified torque: Torque: Fixing nuts: 28 N m (2.9 kgf m) 2. Tight two nuts (4) Torque: Nuts: 43 N m (4.4 kgf m) 3. Connect the O2 sensor connector (2).
6F-10 ENGINE EXHAUST
3 WAY CATALYTIC CONVERTER SYSTEM (If applicable)
N2
Inspection
Make the necessary adjustments, and part replacements if excessive or damage is discovered during inspection.
Exhaust Pipe Assembly

1. Check connections for looseness or damage. 2. Check clamps for weakness, crack, or damage.
Catalytic Converter
Check for dents or damage. If any part of the converter is damaged or dented, repair or replace it.
Removal
1. 2. 3. 4. Jack up the vehicle. Check that the converter is cool. Remove the bolts at the front and rear of the converter. Remove the converter and gaskets.
ENGINE EXHAUST 6F-11

(2.4L model)
Installation
1. Place new gaskets on the converter front and rear pipes, and connect the converter to the exhaust pipes. 2. Tighten the bolts with the specified torque. 3. Reinstall the bracket bolts and tighten them.
Exhaust Silencer
Exhaust Silencer and Associated Parts
RTW46FMF000701
Legend
1. Exhaust Silencer 2. Exhaust Silencer Fixing Nuts 3. Rubber
Removal
(2.4L) 1. 2. 3. 4. Disconnect battery ground cable. Raise the vehicle and support with suitable safety stands. Remove the damper rubber and nut (2)(3). Remove exhaust silencer (1).
Installation
(2.4L) 1. Install the exhaust silencer and tighten two nuts and the damper rubbers. Torque: Bolts: 43 N m (4.4 kgf m)

Exhaust system Pipe outside diameter thickness Front pipe Middle pipe Rear pipe Silencer Type
mm(in) mm(in) mm(in)
44.5 1.5 (1.750.059) 50.8 1.5 (2.00 0.059) 50.8 1.5 (2.0 0.059)
Circular section-shell construction of triple; double skin and end plates, internal construction of baffles and perforated tubes. 4 Rubber Three way Catalytic Converter
Number of suspension points Type Catalytic converter type (If applicable)

Torque Specification
N m (kgf m)
43Nm (4.4 kgfm)
43Nm (4.4 kgfm)
MEMO
ENGINE LUBRICATION 6G-1
SECTION 6G
ENGINE LUBRICATION
CONTENTS
PAGE General Description........................................................................................................ 6G- 2 Service Precaution ......................................................................................................... 6G- 3 Oil Pump .......................................................................................................................... 6G- 4 Oil Pump and Associated Parts ................................................................................ 6G- 4 Disassembly ............................................................................................................... 6G- 4 Inspection and Repair................................................................................................ 6G- 5 Reassembly ................................................................................................................ 6G- 5 Oil Pan ............................................................................................................................. 6G- 6 Oil Pan and Associated Parts ................................................................................... 6G- 6 Disassembly ............................................................................................................... 6G- 6 Inspection and Repair................................................................................................ 6G- 7 Reassembly ................................................................................................................ 6G- 7
6G-2 ENGINE LUBRICATION
General Description
Legend
1 Oil Strainer 2 Oil Pump 3 Relief Valve 4 Oil Filter 5 Safety Valve 6 Oil Gallery 7 Crankshaft Bearing 8 Crankshaft
9 Connecting Rod Bearing 10 Connecting Rod 11 Piston 12 Oil Gallery; Cylinder Head 13 Camshaft 14 Camshaft Journal 15 HLV 16 Check relief valve 17 Oil Pan
A gear-type oil pump is directly driven by the crankshaft and draws oil from the oil pan, via the suction pipe. If then passes the pressured oil through a full-flow disposable oil filter, to the main oil gallery in the cylinder Block. An oil pump pressure relief valve and oil filter bypass valve are incorporated in the system. From the main oil gallery in the cylinder block, the cylinder head and crankshaft main bearings are supplied with oil. The camshaft bearings and hydraulic tappets are supplied through the main feed galleries in the cylinder head. Vent valves allow air to be expelled from the oil galleries in the cylinder head. The balance shaft journals are directly fed from the crankshaft main bearings. The connecting rod bearings are fed via passages in the crankshaft. The oil returns to the oil pan via passages in the cylinder block.
Service Precaution
Oil Pump
Oil Pump and Associated Parts
Legend
1 Oil Pump Assembly 2 Oil Pressure Switch 3 Gasket 4 Sleeve
Disassembly
1. 2. 3. 4. 5. 6. 7. Remove crankshaft timing pulley. Remove oil pan. Remove oil strainer. Remove oil pump assembly. Remove oil pressure switch. Remove gasket. Remove sleeve.

CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.
Body and Gears

The pump assembly must be replaced if one or more of the conditions below is discovered during inspection: Indentation of gear pair - Use feeler strip and straight edge. Dimension: 0.03 mm to 0.10 mm (0.0012 to 0.0039 in)
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking and scoring are found, the oil strainer must be replaced.
Reassembly
1. Install oil pressure switch to the oil pump. Torque: 40 N m (4.1 kgf m) 2. Install the oil pump with the sleeve and the gasket. Torque: 6 N m (0.6 kgf m) 3. Install oil strainer. Torque: 8 N m (0.8 kgf m) 4. Install the oil pan. Tighten the bolts: 15 N m (1.5 kgf m) 5. Install crankshaft timing pulley. Tighten the bolts: 20 N m (2.0 kgf m)
Oil Pan
Oil Pan and Associated Parts
(2.4L 44 Model)
(2.4L 42 Model)
Important Disassembly
1. 2. 3. 4. 5. 6. Loosen a drain plug to drain oil. Remove engine hood. Remove engine rear mounting. Remove transmission assembly. Remove engine front mounting. Raise the vehicle and support with switch stands, and then remove engine. 7. Remove oil pan.

CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection.
Reassembly
To install, follows the disassembly steps in the reverse order. Important Sealer - Apply silicon into groove in oil pan lugs prior to fitment of oil pan to block, remove excess sealer after oil pan is bolted to block.
(2.4L 44 Model)
4
Torque
Bolts - Tighten bolts to the specified torque. Torque : 20 N m (2.0 kgf m) Engine oil - Refill engine oil to the oil pan. (Lit)
3 1
Replacement Oil Fill Volume Without filter change With filter change
2.4L 4.00 4.25
(2.4L 42 Model)
4
3 1 2
MEMO
ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (C24SE)
CONTENTS
Service Precaution............................................... Accelerator Pedal Control Cable ...................... Removal .............................................................. Inspection ........................................................... Installation .......................................................... 6H-1 6H-2 6H-2 6H-3 6H-3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
6H-2 ENGINE SPEED CONTROL SYSTEM (C24SE)
Accelerator Pedal Control Cable
RHD MODEL
RTW46HLF000501
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 indirection an arrow 90 .
ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-3 4. Remove the accelerator control cable from the throttle. LHD MODEL
RTW46AMH000101
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
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.
6H-4 ENGINE SPEED CONTROL SYSTEM (C24SE)
MEMO
INDUCTION 6J-1
SECTION 6J
INDUCTION
CONTENTS
PAGE Service Precaution ......................................................................................................... 6J- 2 Air Cleaner Filter............................................................................................................. 6J- 2 Removal ...................................................................................................................... 6J- 2 Inspection ................................................................................................................... 6J- 2 Installation .................................................................................................................. 6J- 3
6J-2 INDUCTION
Service Precaution
Air Cleaner Filter

NOTE: The air cleaner filter is not damaged with the edge of the air cleaner housing.
Removal
1. 2. 3. 4. 5. Remove positive ventilation hose connector. Remove intake air temperature sensor. Remove mass air flow sensor. Remove air cleaner duct assembly. Remove air cleaner element.
RTW46JSH000101
Inspection
Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty.
INDUCTION 6J-3
Installation
1. Install air cleaner element. 2. Attach the air cleaner duct cover to the body completely, then clamp it with the clip. 3. Install mass air flow sensor. 4. Install mass air temperature sensor. 5. Install positive crankcase ventilation hose connector.
6J-4 INDUCTION
MEMO
No. TFHEO-WE-0431

06 - Tfheo We 0431

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WORKSHOP MANUAL

ENGINE DIAGNOSIS (C24SE) 6-1

6-2 ENGINE DIAGNOSIS (C24SE)

No sparking takes place

Engine Compression Test Procedure

6-4 ENGINE DIAGNOSIS (C24SE)

Rough Engine Idling or Engine Stalling

Replace Correct or replace

Trouble in emission control system

ENGINE DIAGNOSIS (C24SE) 6-5

Rough Engine Running

Engine knocks regularly Engine lacks power

Replace Correct or replace

Correct or replace Correct or replace

6-6 ENGINE DIAGNOSIS (C24SE)

Hesitation at high speeds (Fuel pressure too low)

Hesitation at high speeds (Fuel injector not working normally)

Hesitation at high speeds

ENGINE DIAGNOSIS (C24SE) 6-7

Engine Lacks Power

Trouble in intake or exhaust system

Engine overcooling Engine lacks compression Others

Crankshaft out of round

Crank bearing seized

ENGINE DIAGNOSIS (C24SE) 6-9

Abnormal Noise Due to Hydraulic Lash Adjuster

Valve clearance is not zero

Crankpin out of round

Connecting rod bent Connecting rod bearing seized

Piston seized Piston ring broken Piston defective

6-10 ENGINE DIAGNOSIS (C24SE)

Possible cause Piston pin or piston pin hole worn

Correction Replace piston, piston pin and connecting rod assy

ENGINE DIAGNOSIS (C24SE) 6-11

Trouble in emission control system

Trouble in ignition system Trouble in cylinder head parts

6-12 ENGINE DIAGNOSIS (C24SE)

Engine Oil Consumption Excessive

Crank case ventilation, Positive Crankcase Ventilation System malfunctioning Others

ENGINE DIAGNOSIS (C24SE) 6-13

Fuel Consumption Excessive

Trouble in ignition system

Oil not reaching valve system

Engine Oil Pressure Check

6-14 ENGINE DIAGNOSIS (C24SE)

Malfunction Indicator Lamp

CHECK ENGINE MIL illuminates, and stays on

Replace Replace Reconnect properly

Correct Correct or replace Replace

ENGINE MECHANICAL (C24SE) 6A-1

6A-2 ENGINE MECHANICAL (C24SE)

ENGINE MECHANICAL (C24SE) 6A-3

6A-4 ENGINE MECHANICAL (C24SE)

Engine Cleanliness And Care

General Information on Engine Service

Pistons and Connecting Rods

Crankshaft and Bearings

6A-6 ENGINE MECHANICAL (C24SE)

4WD OIL PAN