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WORKSHOP MANUAL
TF SERIES
ENGINE DRIVEABILITY AND EMISSIONS

4JH1-TC ENGINE WITH BOSCH VP44 SYSTEM
SECTION 6E
NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section - 0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model : TFR/S 77
This manual is applicable to 2003 year model and later vehicles.

4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................ 6E-9 High Pressure Fuel Circuit ......................... 6E-46
ECM CIRCUIT DIAGRAM ......................... 6E-13 Timing Control ........................................... 6E-47
GROUND POINT CHART (1/4) ................. 6E-14 Start of Injection ......................................... 6E-47
LOCATION ................................................ 6E-18 ISUZU Strategy Based Diagnostics .............. 6E-48
ENGINE CONTROL MODULE (ECM) ....... 6E-20 Overview .................................................... 6E-48
PARTS LOCATION ................................... 6E-20 STRATEGY BASED DIAGNOSTICS
................................................................... 6E-21 CHART .................................................... 6E-48
PARTS LOCATION ................................... 6E-22 Diagnostic Thought Process ...................... 6E-49
CONNECTOR LIST ................................... 6E-23 1. Verify the Complaint .............................. 6E-49
RELAY AND FUSE .................................... 6E-26 2. Perform Preliminary Checks .................. 6E-49
RELAY AND FUSE BOX LOCATION ........ 6E-26 3. Check Bulletins and Troubleshooting
RELAY AND FUSE BOX LOCATION ........ 6E-27 Hints ........................................................ 6E-50
FUSE AND RELAY LOCATION ................ 6E-28 4. Perform Service Manual Diagnostic
ECM WIRING DIAGRAM (1/7) .................. 6E-29 Checks ..................................................... 6E-50
ECM WIRING DIAGRAM (2/7) .................. 6E-30 5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-50
ECM WIRING DIAGRAM (3/7) .................. 6E-31
5c. Technician Self Diagnoses .................. 6E-50
5d. Intermittent Diagnosis .......................... 6E-51
5e. Vehicle Operates as Designed ............ 6E-52
6. Re-examine the complaint ..................... 6E-53
7. Repair and Verify Fix ............................. 6E-53
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-36 GENERAL SERVICE INFORMATION ....... 6E-54
PSG CONNECTOR PIN ASSIGNMENT & ON-BOARD DIAGNOSTIC (OBD) ............. 6E-54
OUTPUT SIGNAL .................................... 6E-39 TECH 2 OPERATING FLOW CART
GENERAL DESCRIPTION FOR ECM AND (START UP) ............................................. 6E-58
SENSORS ............................................... 6E-40 TYPICAL SCAN DATA & DEFINITIONS
Engine Control Module (ECM) ................... 6E-40 (ENGINE DATA) ................................... 6E-60
Pump Control Unit (PSG) & Data Exchange MISCELLANEOUS TEST .......................... 6E-62
Between Control Module ......................... 6E-40 Plotting Snapshot Graph ............................ 6E-63
Mass Air Flow (MAF) Sensor & Intake Air Plotting Graph Flow Chart (Plotting graph
Temperature (IAT) Sensor ....................... 6E-41 after obtaining vehicle information) .......... 6E-64
Throttle Position Sensor (TPS) .................. 6E-41 Flow Chart for Snapshot Replay
Crankshaft Position (CKP) Sensor ............ 6E-42 (Plotting Graph) ....................................... 6E-65
Engine Coolant Temperature (ECT) Sensor 6E-42 SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-66
Vehicle Speed Sensor (VSS) .................... 6E-43 ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK .................................................... 6E-75
EGR EVRV ................................................ 6E-43
Circuit Description ...................................... 6E-75
GENERAL DESCRIPTION FOR INJECTION
PUMP ...................................................... 6E-44 Diagnostic Aids .......................................... 6E-75
Outline ....................................................... 6E-44 Test Description ......................................... 6E-75
Characteristic of VP44 Injection System ... 6E-44 On-Board Diagnostic (OBD) System Check 6E-76
Cross-section View .................................... 6E-45 NO CHECK ENGINE LAMP (MIL) ............. 6E-79
Low Pressure Fuel Circuit ......................... 6E-46 Circuit Description ...................................... 6E-79
6E–2 4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Aids .......................................... 6E-79 (Symptom Code 1) (Flash Code 23) Intake Air
No Check Engine Lamp (MIL) ................... 6E-80 Temperature (IAT) Sensor Circuit
CHECK ENGINE LAMP (MIL) “ON” High Input ................................................ 6E-108
STEADY .................................................. 6E-82 Diagnostic Trouble Code (DTC) P0110
Circuit description ...................................... 6E-82 (Symptom Code 2) (Flash Code 23) Intake Air
Diagnostic Aids .......................................... 6E-82 Temperature (IAT) Sensor Circuit
Low Input ................................................. 6E-112
Check Engine Lamp (MIL) On Steady ....... 6E-83
DIAGNOSTIC TROUBLE CODE (DTC) P0115
ECM Diagnostic Trouble Codes ................ 6E-84
(SYMPTOM CODE 1) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT HIGH INPUT ............ 6E-115
MASS AIR FLOW (MAF) SENSOR VOLTAGE
SUPPLY CIRCUIT HIGH INPUT ............. 6E-95
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT ............. 6E-115
MASS AIR FLOW (MAF) SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT .............. 6E-95
Diagnostic Aids .......................................... 6E-116
(SYMPTOM CODE B) (FLASH CODE 65) Diagnostic Trouble Code (DTC) P0115 (Symptom
MASS AIR FLOW (MAF) SENSOR OUTPUT Code 1) (Flash Code 14) Engine Coolant
CIRCUIT LOW INPUT ............................. 6E-95 Temperature Sensor Circuit High Input ... 6E-116
DIAGNOSTIC TROUBLE CODE (DTC) P0100 Diagnostic Trouble Code (DTC) P0115 (Symptom
(SYMPTOM CODE C) (FLASH CODE 65) Code 2) (Flash Code 14) Engine Coolant
MASS AIR FLOW (MAF) SENSOR OUTPUT Temperature Sensor Circuit Low Input .... 6E-120
CIRCUIT HIGH INPUT ............................ 6E-95 DIAGNOSTIC TROUBLE CODE (DTC) P0180
Circuit Description ..................................... 6E-96 (SYMPTOM CODE B) (FLASH CODE 15)
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE ....................... 6E-123
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65) Mass Air
Flow (MAF) Sensor Voltage Supply Circuit Diagnostic Aids .......................................... 6E-123
High Input ................................................ 6E-96 Diagnostic Trouble Code (DTC) P0180
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 15) Fuel
(Symptom Code 9) (Flash Code 65) Mass Air Temperature Sensor Circuit Range/
Flow (MAF) Sensor Voltage Supply Circuit Performance ............................................ 6E-124
Low Input ................................................. 6E-99 DIAGNOSTIC TROUBLE CODE (DTC) P0215
Diagnostic Trouble Code (DTC) P0100 (SYMPTOM CODE A) (FLASH CODE 52)
(Symptom Code B) (Flash Code 65) Mass Air FUEL CUTOFF SOLENOID VALVE
Flow (MAF) Sensor Output Circuit MALFUNCTION ....................................... 6E-125
Low Input ................................................. 6E-101 DIAGNOSTIC TROUBLE CODE (DTC) P0215
Diagnostic Trouble Code (DTC) P0100 (SYMPTOM CODE B) (FLASH CODE 52)
(Symptom Code C) (Flash Code 65) Mass Air FUEL CUTOFF SOLENOID VALVE
Flow (MAF) Sensor Output Circuit CIRCUIT HIGH INPUT ............................ 6E-125
High Input ................................................ 6E-104 DIAGNOSTIC TROUBLE CODE (DTC) P0215
DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE C) (FLASH CODE 52)
(SYMPTOM CODE 1) (FLASH CODE 23) FUEL CUTOFF SOLENOID VALVE ALWAYS
INTAKE AIR TEMPERATURE (IAT) SENSOR ACTIVE .................................................... 6E-125
CIRCUIT HIGH INPUT ............................ 6E-107 DIAGNOSTIC TROUBLE CODE (DTC) P0215
DIAGNOSTIC TROUBLE CODE (DTC) P0110 (SYMPTOM CODE D) (FLASH CODE 52)
(SYMPTOM CODE 2) (FLASH CODE 23) FUEL CUTOFF SOLENOID VALVE
INTAKE AIR TEMPERATURE (IAT) SENSOR MALFUNCTION ....................................... 6E-125
CIRCUIT LOW INPUT ............................. 6E-107 Circuit Description ...................................... 6E-126
Circuit Description ..................................... 6E-107 Diagnostic Aids .......................................... 6E-126
Diagnostic Aids .......................................... 6E-108 Diagnostic Trouble Code (DTC) P0215
Diagnostic Trouble Code (DTC) P0110 (Symptom Code A) (Flash Code 52)
Fuel Cutoff Solenoid Valve Malfunction ... 6E-126 (Symptom Code 6) (Flash Code 53)
Diagnostic Trouble Code (DTC) P0215 Injection Pump Malfunction ...................... 6E-138
(Symptom Code B) (Flash Code 52) Diagnostic Trouble Code (DTC) P0251
Fuel Cutoff Solenoid Valve Circuit (Symptom Code 7) (Flash Code 53)
High Input ................................................ 6E-128 Injection Pump Malfunction ...................... 6E-140
Diagnostic Trouble Code (DTC) P0215 Diagnostic Trouble Code (DTC) P0251
(Symptom Code C) (Flash Code 52) (Symptom Code 9) (Flash Code 53)
Fuel Cutoff Solenoid Valve Always Active 6E-130 Injection Pump Malfunction ...................... 6E-144
Diagnostic Trouble Code (DTC) P0215 Diagnostic Trouble Code (DTC) P0251
(Symptom Code D) (Flash Code 52) (Symptom Code A) (Flash Code 53)
Fuel Cutoff Solenoid Valve Malfunction ... 6E-132 Injection Pump Malfunction ...................... 6E-145
DIAGNOSTIC TROUBLE CODE (DTC) P0216 Diagnostic Trouble Code (DTC) P0251
(SYMPTOM CODE A) (FLASH CODE 54) (Symptom Code B) (Flash Code 53)
INJECTION TIMING CONTROL CIRCUIT Injection Pump Malfunction ...................... 6E-146
MALFUNCTION (TIMER DEVIATION) .... 6E-133 Diagnostic Trouble Code (DTC) P0251
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (Symptom Code D) (Flash Code 53)
(SYMPTOM CODE B) (FLASH CODE 54) Injection Pump Malfunction ...................... 6E-147
INJECTION TIMING CONTROL CIRCUIT Diagnostic Trouble Code (DTC) P0251
MALFUNCTION (TIMER FLUCTUATION) 6E-133 (Symptom Code E) (Flash Code 53)
Circuit Description ..................................... 6E-134 Injection Pump Malfunction ...................... 6E-148
Diagnostic Aids .......................................... 6E-134 DIAGNOSTIC TROUBLE CODE (DTC) P0335
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE B) (FLASH CODE
(Symptom Code A) (Flash Code 54) 43)CRANKSHAFT POSITION SENSOR
Injection Timing Control Circuit CIRCUIT MALFUNCTION ....................... 6E-149
Malfunction (Timer Deviation) .................. 6E-134 DIAGNOSTIC TROUBLE CODE (DTC) P0335
Diagnostic Trouble Code (DTC) P0216 (SYMPTOM CODE D) (FLASH CODE 43)
(Symptom Code B) (Flash Code 54) CRANKSHAFT POSITION SENSOR
Injection Timing Control Circuit MALFUNCTION ....................................... 6E-149
Malfunction (Timer Fluctuation) ............... 6E-135 DIAGNOSTIC TROUBLE CODE (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E) (FLASH CODE 43)
(SYMPTOM CODE 6) (FLASH CODE 53) ENGINE SPEED INPUT CIRCUIT RANGE/
INJECTION PUMP MALFUNCTION ....... 6E-137 PERFORMANCE ..................................... 6E-149
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Circuit Description ...................................... 6E-150
(SYMPTOM CODE 7) (FLASH CODE 53) Diagnostic Aids .......................................... 6E-150
INJECTION PUMP MALFUNCTION ....... 6E-137 Diagnostic Trouble Code (DTC) P0335
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (Symptom Code B) (Flash Code 43)
(SYMPTOM CODE 9) (FLASH CODE 53) Crankshaft Position Sensor Circuit
INJECTION PUMP MALFUNCTION ....... 6E-137 Malfunction .............................................. 6E-150
(SYMPTOM CODE A) (FLASH CODE 53) (Symptom Code D) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-137 Crankshaft Position Sensor Malfunction .. 6E-150
(SYMPTOM CODE B) (FLASH CODE 53) (Symptom Code E) (Flash Code 43)
INJECTION PUMP MALFUNCTION ....... 6E-137 Engine Speed Input Circuit Range/
DIAGNOSTIC TROUBLE CODE (DTC) P0251 Performance ............................................ 6E-155
(SYMPTOM CODE D) (FLASH CODE 53) DIAGNOSTIC TROUBLE CODE (DTC) P0380
INJECTION PUMP MALFUNCTION ....... 6E-137 (SYMPTOM CODE 4) (FLASH CODE 66)
DIAGNOSTIC TROUBLE CODE (DTC) P0251 GLOW RELAY CIRCUIT VOLTAGE LOW 6E-158
(SYMPTOM CODE E) (FLASH CODE 53) DIAGNOSTIC TROUBLE CODE (DTC) P0380
INJECTION PUMP MALFUNCTION ....... 6E-137 (SYMPTOM CODE 8) (FLASH CODE 66)
Circuit Description ..................................... 6E-138 GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-158
Diagnostic Aids .......................................... 6E-138 Circuit Description ...................................... 6E-158
Diagnostic Trouble Code (DTC) P0251 Diagnostic Aids .......................................... 6E-158
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 32)
(Symptom Code 4) (Flash Code 66) Exhaust Gas Recirculation Circuit Short to
Glow Relay Circuit Voltage Low .............. 6E-159 Battery ..................................................... 6E-178
Diagnostic Trouble Code (DTC) P0380 DIAGNOSTIC TROUBLE CODE (DTC) P0500
(Symptom Code 8) (Flash Code 66) (SYMPTOM CODE 1) (FLASH CODE 24)
Glow Relay Circuit Voltage High ............. 6E-162 VEHICLE SPEED SENSOR CIRCUIT
DIAGNOSTIC TROUBLE CODE (DTC) P0381 HIGH INPUT ............................................ 6E-180
(SUB CODE 4) (FLASH CODE 67) GLOW DIAGNOSTIC TROUBLE CODE (DTC) P0500
PLUG INDICATOR CIRCUIT VOLTAGE (SYMPTOM CODE A) (FLASH CODE 24)
LOW ........................................................ 6E-163 VEHICLE SPEED SENSOR INPUT SIGNAL
DIAGNOSTIC TROUBLE CODE (DTC) P0381 FREQUENCY TOO HIGH ....................... 6E-180
(SUB CODE 8) (FLASH CODE 67) GLOW DIAGNOSTIC TROUBLE CODE (DTC) P0500
PLUG INDICATOR CIRCUIT VOLTAGE (SYMPTOM CODE B) (FLASH CODE 24)
HIGH ........................................................ 6E-163 VEHICLE SPEED SENSOR INCORRECT
Circuit Description ..................................... 6E-163 SIGNAL ................................................... 6E-180
Diagnostic Aids .......................................... 6E-163 Circuit Description ...................................... 6E-181
Diagnostic Trouble Code (DTC) P0381 Diagnostic Aids .......................................... 6E-181
(Symptom Code 4) (Flash Code 67) Diagnostic Trouble Code (DTC) P0500
Glow Plug Indicator Circuit Voltage Low . 6E-164 (Symptom Code 1) (Flash Code 24) Vehicle
Diagnostic Trouble Code (DTC) P0381 Speed Sensor Circuit High Input ............. 6E-181
Glow Plug Indicator Circuit Voltage High . 6E-167 (Symptom Code A) (Flash Code 24) Vehicle
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Speed Sensor Input Signal Frequency
(SYMPTOM CODE 3) (FLASH CODE 32) Too High .................................................. 6E-186
EXHAUST GAS RECIRCULATION FLOW Diagnostic Trouble Code (DTC) P0500
EXCESSIVE DETECTED ........................ 6E-168 (Symptom Code B) (Flash Code 24) Vehicle
DIAGNOSTIC TROUBLE CODE (DTC) P0400 Speed Sensor Incorrect Signal ................ 6E-189
(SYMPTOM CODE 4) (FLASH CODE 32) DIAGNOSTIC TROUBLE CODE (DTC) P0560
EXHAUST GAS RECIRCULATION CIRCUIT (SYMPTOM CODE 1) (FLASH CODE 35)
SHORT TO GROUND OR OPEN CIRCUIT 6E-168 SYSTEM VOLTAGE TOO HIGH ............. 6E-194
DIAGNOSTIC TROUBLE CODE (DTC) P0400 DIAGNOSTIC TROUBLE CODE (DTC) P0560
(SYMPTOM CODE 5) (FLASH CODE 32) (SYMPTOM CODE 2) (FLASH CODE 35)
EXHAUST GAS RECIRCULATION FLOW SYSTEM VOLTAGE TOO LOW .............. 6E-194
INSUFFICIENT DETECTED ................... 6E-168 DIAGNOSTIC TROUBLE CODE (DTC) P0560
DIAGNOSTIC TROUBLE CODE (DTC) P0400 (SYMPTOM CODE A) (FLASH CODE 35)
(SYMPTOM CODE 8) (FLASH CODE 32) SYSTEM VOLTAGE MALFUNCTION
EXHAUST GAS RECIRCULATION CIRCUIT (PSG) ....................................................... 6E-194
SHORT TO BATTERY ............................ 6E-168 Circuit Description ...................................... 6E-194
(Symptom Code 3) (Flash Code 32) System Voltage Too High ........................ 6E-195
Exhaust Gas Recirculation Flow Excessive Diagnostic Trouble Code (DTC) P0560
Detected .................................................. 6E-169 (Symptom Code 2) (Flash Code 35)
Diagnostic Trouble Code (DTC) P0400 System Voltage Too Low ......................... 6E-197
Exhaust Gas Recirculation Circuit Short to (Symptom Code A) (Flash Code 35)
Ground or Open Circuit ........................... 6E-172 System Voltage Malfunction (PSG) ......... 6E-199
(Symptom Code 5) (Flash Code 32) (SYMPTOM CODE A) (FLASH CODE 18)
Exhaust Gas Recirculation Flow Insufficient IGNITION SWITCH CIRCUIT
Detected .................................................. 6E-175 MALFUNCTION ....................................... 6E-201
(SYMPTOM CODE B) (FLASH CODE 18) Diagnostic Trouble Code (DTC) P0703
IGNITION SWITCH CIRCUIT (Symptom Code A) (Flash Code 25)
MALFUNCTION ....................................... 6E-201 Brake Switch Malfunction ........................ 6E-215
Circuit Description ..................................... 6E-201 Diagnostic Trouble Code (DTC) P0703
Diagnostic Aids .......................................... 6E-201 (Symptom Code B) (Flash Code 25)
Diagnostic Trouble Code (DTC) P0561 Brake Switch Malfunction ........................ 6E-219
(Symptom Code A) (Flash Code 18) DIAGNOSTIC TROUBLE CODE (DTC) P0704
Ignition Switch Circuit Malfunction ........... 6E-202 (SYMPTOM CODE 6) (FLASH CODE 57)
Diagnostic Trouble Code (DTC) P0561 CLUTCH SWITCH CIRCUIT
(Symptom Code B) (Flash Code 18) MALFUNCTION ....................................... 6E-222
Ignition Switch Circuit Malfunction ........... 6E-202 Circuit Description ...................................... 6E-222
DIAGNOSTIC TROUBLE CODE (DTC) P0602 Diagnostic Aids .......................................... 6E-222
ECU PROGRAMMING ERROR .............. 6E-205 Diagnostic Trouble Code (DTC) P0704
Circuit Description & Diagnostic Aids ........ 6E-205 (Symptom Code 6) (Flash Code 57)
Diagnostic Trouble Code (DTC) P0602 Clutch Switch Circuit Malfunction ............ 6E-223
ECU Programming Error ......................... 6E-205 DIAGNOSTIC TROUBLE CODE (DTC) P1105
DIAGNOSTIC TROUBLE CODE (DTC) P0606 (SYMPTOM CODE 1) (FLASH CODE 86)
(SYMPTOM CODE A) BAROMETRIC PRESSURE SENSOR
(FLASH CODE 28) ECU MALFUNCTION 6E-206 CIRCUIT HIGH INPUT ............................ 6E-226
DIAGNOSTIC TROUBLE CODE (DTC) P0606 DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE B) (SYMPTOM CODE 2) (FLASH CODE 86)
(FLASH CODE 28) ECU MALFUNCTION 6E-206 BAROMETRIC PRESSURE SENSOR
Circuit Description & Diagnostic Aids ........ 6E-206 CIRCUIT LOW INPUT ............................. 6E-226
Diagnostic Trouble Code (DTC) P0606 Circuit Description ...................................... 6E-226
(Symptom Code A) (Flash Code 28) Diagnostic Aids .......................................... 6E-226
ECU Malfunction ...................................... 6E-206 Diagnostic Trouble Code (DTC) P1105
Diagnostic Trouble Code (DTC) P0606 (Symptom Code 1) (Flash Code 86) Barometric
(Symptom Code B) (Flash Code 28) Pressure Sensor Circuit High Input ......... 6E-226
ECU Malfunction ...................................... 6E-208 Diagnostic Trouble Code (DTC) P1105
DIAGNOSTIC TROUBLE CODE (DTC) P0645 (Symptom Code 2) (Flash Code 86) Barometric
(SYMPTOM CODE 4) (FLASH CODE 46) Pressure Sensor Circuit Low Input .......... 6E-226
A/C COMPRESSOR RELAY CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P1120
VOLTAGE LOW ...................................... 6E-209 (SYMPTOM CODE 1) (FLASH CODE 21)
DIAGNOSTIC TROUBLE CODE (DTC) P0645 PEDAL/THROTTLE POSITION SENSOR
(SYMPTOM CODE 8) (FLASH CODE 46) CIRCUIT HIGH INPUT ............................ 6E-228
A/C COMPRESSOR RELAY CIRCUIT DIAGNOSTIC TROUBLE CODE (DTC) P1120
VOLTAGE HIGH ...................................... 6E-209 (SYMPTOM CODE 7) (FLASH CODE 21)
Circuit Description ..................................... 6E-209 PEDAL/THROTTLE POSITION SENSOR
Diagnostic Aids .......................................... 6E-209 VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-228
(Symptom Code 4) (Flash Code 46) (SYMPTOM CODE 9) (FLASH CODE 21)
A/C Compressor Relay Circuit Voltage Low 6E-210 PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-228
(Symptom Code 8) (Flash Code 46) DIAGNOSTIC TROUBLE CODE (DTC) P1120
A/C Compressor Relay Circuit Voltage High 6E-213 (SYMPTOM CODE D) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH ERROR ....................... 6E-228
(SYMPTOM CODE A) (FLASH CODE 25)
BRAKE SWITCH INCORRECT SIGNAL (1) 6E-214 DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE E) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
(SYMPTOM CODE B) (FLASH CODE 25)
IDLE POSITION SWITCH ERROR ......... 6E-228
BRAKE SWITCH INCORRECT SIGNAL (2) 6E-214
Circuit Description ..................................... 6E-215
(Symptom Code 1) (Flash Code 21) Camshaft Speed Malfunction ................... 6E-253
Pedal/Throttle Position Sensor Circuit DIAGNOSTIC TROUBLE CODE (DTC) P1520
High Input ................................................ 6E-229 (SYMPTOM CODE A) (FLASH CODE 47)
Diagnostic Trouble Code (DTC) P1120 NEUTRAL SWITCH ON ERROR ............ 6E-254
(Symptom Code 7) (Flash Code 21) DIAGNOSTIC TROUBLE CODE (DTC) P1520
Pedal/Throttle Position Sensor Voltage (SYMPTOM CODE B) (FLASH CODE 47)
Supply Circuit High Input ......................... 6E-234 NEUTRAL SWITCH OFF ERROR ........... 6E-254
Diagnostic Trouble Code (DTC) P1120 Circuit Description ...................................... 6E-254
(Symptom Code 9) (Flash Code 21) Diagnostic Aids .......................................... 6E-254
Pedal/Throttle Position Sensor Voltage Diagnostic Trouble Code (DTC) P1520
Supply Circuit Low Input .......................... 6E-236 (Symptom Code A) (Flash Code 47)
Diagnostic Trouble Code (DTC) P1120 Neutral Switch ON Error .......................... 6E-255
(Symptom Code D) (Flash Code 21) Diagnostic Trouble Code (DTC) P1520
Pedal/Throttle Position Sensor Brake (Symptom Code B) (Flash Code 47)
Switch Error ............................................. 6E-239 Neutral Switch OFF Error ........................ 6E-255
(Symptom Code E) (Flash Code 21) (SYMPTOM CODE C) (FLASH CODE 55)
Pedal/Throttle Position Sensor Idle SEED AND KEY FILE DESTROYED ...... 6E-259
Position Switch Error ............................... 6E-241
DIAGNOSTIC TROUBLE CODE (DTC) P1173 (SYMPTOM CODE D) (FLASH CODE 55)
(SYMPTOM CODE 3) (FLASH CODE 22) EEPROM DEFECT .................................. 6E-259
FUEL REDUCTION CAUSED BY HIGH
COOLANT TEMPERATURE ................... 6E-243
(SYMPTOM CODE E) (FLASH CODE 55)
DIAGNOSTIC TROUBLE CODE (DTC) P1173 EEPROM DEFECT .................................. 6E-259
Circuit Description & Diagnostic Aids ........ 6E-259
FUEL REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ..................................... 6E-243
(Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed .................. 6E-259
Diagnostic Trouble Code (DTC) P1173 (Symptom Code D) (Flash Code 55)
(Symptom Code 3) (Flash Code 22) EEPROM Defect ...................................... 6E-259
Fuel Reduction Caused By High Coolant
Temperature ............................................ 6E-243
(Symptom Code E) (Flash Code 55)
Diagnostic Trouble Code (DTC) P1173 EEPROM Defect ...................................... 6E-259
(Symptom Code 7) (Flash Code 22)
Fuel Reduction Caused By High Fuel
Temperature ............................................ 6E-246
SECURITY KEY AND SECURITY CODE
DIAGNOSTIC TROUBLE CODE (DTC) P1335 NOT PROGRAMMED .............................. 6E-261
ENGINE SPEED OUTPUT CIRCUIT
MALFUNCTION ....................................... 6E-247
(Symptom Code A) (Flash Code 56) Security
Key and Security Code Not Programmed 6E-262
(Symptom Code A) (Flash Code 43)
Engine Speed Output Circuit Malfunction 6E-248
WRONG SECURITY CODE ENTERED .. 6E-263
CAMSHAFT SPEED MALFUNCTION ..... 6E-252
(Symptom Code A) (Flash Code 56)
Wrong Security Code Entered ................. 6E-264
(SYMPTOM CODE A) (FLASH CODE 56) Diagnostic Trouble Code (DTC) P1630
IMMOBILISER NO OR WRONG SIGNAL 6E-265 (Symptom Code B) (Flash Code 51) Fuel
Circuit Description ..................................... 6E-265 Injection Quantity Circuit Malfunction ...... 6E-282
Diagnostic Aids .......................................... 6E-265 DIAGNOSTIC TROUBLE CODE (DTC) P1650
Diagnostic Trouble Code (DTC) P1612 (SYMPTOM CODE A) (FLASH CODE 44)
(Symptom Code A) (Flash Code 56) CAN DEVICE OFFLINE ........................... 6E-283
Immobiliser No or Wrong Signal .............. 6E-266 DIAGNOSTIC TROUBLE CODE (DTC) P1650
DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE B) (FLASH CODE 44)
(SYMPTOM CODE A) (FLASH CODE 56) CAN DEVICE HANG-UP ......................... 6E-283
IMMOBILISER NO OR WRONG SIGNAL 6E-271 Circuit Description ...................................... 6E-283
(Symptom Code A) (Flash Code 56) CAN Device Offline .................................. 6E-284
Immobiliser No or Wrong Signal .............. 6E-272 Diagnostic Trouble Code (DTC) P1650
DIAGNOSTIC TROUBLE CODE (DTC) P1614 (Symptom Code B) (Flash Code 44)
(SYMPTOM CODE A) (FLASH CODE 56) CAN Device Hang-up .............................. 6E-289
WRONG TRANSPONDER KEY .............. 6E-276 DIAGNOSTIC TROUBLE CODE (DTC) P1651
Circuit Description ..................................... 6E-276 (SYMPTOM CODE A) (FLASH CODE 45)
Diagnostic Aids .......................................... 6E-276 CAN MALFUNCTION (PSG) ................... 6E-290
(Symptom Code A) (Flash Code 56) (SYMPTOM CODE B) (FLASH CODE 45)
Wrong Transponder Key ......................... 6E-277 CAN RECEIVES ERROR ........................ 6E-290
(SYMPTOM CODE A) (FLASH CODE 76) Diagnostic Aids .......................................... 6E-290
ECM MAIN RELAY SWITCHED OFF Diagnostic Trouble Code (DTC) P1651
TOO EARLY ............................................ 6E-278 (Symptom Code A) (Flash Code 45)
DIAGNOSTIC TROUBLE CODE (DTC) P1625 CAN Malfunction (PSG) ........................... 6E-291
ECM MAIN RELAY SWITCHED OFF (Symptom Code B) (Flash Code 45)
TOO LATE ............................................... 6E-278 CAN Receives Error ................................ 6E-292
Circuit Description ..................................... 6E-278 DIAGNOSTIC TROUBLE CODE (DTC) P1690
Diagnostic Aids .......................................... 6E-278 (SYMPTOM CODE 4) (FLASH CODE 77)
Diagnostic Trouble Code (DTC) P1625 CHECK ENGINE LAMP (MIL) CIRCUIT
(Symptom Code A) (Flash Code 76) ECM VOLTAGE LOW ...................................... 6E-297
Main Relay Switched Off Too Early ......... 6E-279 DIAGNOSTIC TROUBLE CODE (DTC) P1690
Diagnostic Trouble Code (DTC) P1625 (SYMPTOM CODE 8) (FLASH CODE 77)
(Symptom Code B) (Flash Code 76) ECM CHECK ENGINE LAMP (MIL) CIRCUIT
Main Relay Switched Off Too Late .......... 6E-280 VOLTAGE HIGH ...................................... 6E-297
(SYMPTOM CODE A) (FLASH CODE 51) Diagnostic Aids .......................................... 6E-297
FUEL INJECTION QUANTITY CIRCUIT Diagnostic Trouble Code (DTC) P1690
MALFUNCTION ....................................... 6E-281 (Symptom Code 4) (Flash Code 77) Check
DIAGNOSTIC TROUBLE CODE (DTC) P1630 Engine Lamp (MIL) Circuit Voltage Low .. 6E-298
FUEL INJECTION QUANTITY CIRCUIT (Symptom Code 8) (Flash Code 77) Check
MALFUNCTION ....................................... 6E-281 Engine Lamp (MIL) Circuit Voltage High . 6E-301
Circuit Description ..................................... 6E-281 SYMPTOM DIAGNOSIS ............................ 6E-302
Diagnostic Aids .......................................... 6E-282 PRELIMINARY CHECKS .......................... 6E-302
Diagnostic Trouble Code (DTC) P1630 VISUAL/PHYSICAL CHECK ...................... 6E-302
(Symptom Code A) (Flash Code 51) Fuel INTERMITTENT ........................................ 6E-302
Injection Quantity Circuit Malfunction ...... 6E-282 ENGINE CRANKS BUT WILL NOT RUN .. 6E-303
HARD START SYMPTOM ........................ 6E-307
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM .................. 6E-311
SURGES AND/OR CHUGS SYMPTOM ... 6E-318
HESITATION, SAG, STUMBLE
SYMPTOM .............................................. 6E-323
CUTS OUT, MISSES SYMPTOM .............. 6E-329
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM .............................................. 6E-335
POOR FUEL ECONOMY SYMPTOM ....... 6E-341
EXCESSIVE WHITE SMOKE .................... 6E-346
EXCESSIVE BLACK SMOKE ................... 6E-351
ON-VEHICLE SERVICE PROCEDURE .... 6E-355
ENGINE CONTROL MODULE (ECM) ... 6E-355
CRANKSHAFT POSITION (CKP) SENSOR 6E-356
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ................................................. 6E-356
MASS AIR FLOW (MAF) & INTAKE AIR
TEMPERATURE (IAT) SENSOR ............ 6E-357
THROTTLE POSITION SENSOR (TPS) ... 6E-357
EGR EVRV (Electrical Vacuum
Regulating Valve) .................................... 6E-358
ABBREVIATION CHARTS
Abbreviations Appellation
A/C Air conditioner
A/T Automatic transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CAN Controller Area Network
CEL Check engine lamp
CKP Crankshaft position sensor
DLC Data link connector
DTC Diagnosis trouble code
DVM Digital voltage meter
ECM Engine control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Exhaust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
COMPONENT LOCATOR
Engine Component Locator Table
3 1 2 6 4 5
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Pipe
(3) Air Cleaner Case
3 2 4
(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

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

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

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

ECM CIRCUIT DIAGRAM
GROUND POINT CHART (1/4)
LOCATION
ENGINE CONTROL MODULE (ECM)
PARTS LOCATION
PARTS LOCATION
CONNECTOR LIST
No. Connector face No. Connector face
B-24 C-56
Green Meter-B ECM-A

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

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

B-58 C-94
Black Check connector White TCM

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

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

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

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

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

C-44 C-116
White Stop lamp switch


C-118 E-44
A/C Resister & Neutral switch Gray Vehicle speed sensor

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

E-6 E-51
Black Inhibiter switch

E-9 H-4
White Engine room ~ Mission

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

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

E-23 H-33
Gray Idle SW Engine ~ Engine room

E-41 P-1
Black Coolant temp sensor Silver Battery (+)


P-2
Silver Relay & Fuse box

P-5
Silver Battery (-)

P-6
Silver Body earth (Ground)

P-10
Silver Engine ground

X-5
Black Relay ; Glow

X-13
Black Relay ; ECM MAIN

X-14
Black Relay; A/C Compressor

X-15
Black Relay; Thermo

X-16
Black DIODE
X-17
Black DIODE
RELAY AND FUSE
RELAY AND FUSE BOX LOCATION
RELAY AND FUSE BOX LOCATION
RELAY & FUSE BOX

RELAY
No. RELAY (4JH1-TC)
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; GLOW
X-6 —
X-7 RELAY; COND, FAN
X-8 RELAY; —
X-9 —
X-10 —
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; —
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
ENGINE MODEL
FUSE NO. 4JH1-TC
EB-1 10A ECM
EB-2 —
EB-3 15A FRT FOG
EB-4 10A ACG (S)
EB-5 10A ILLUMI
EB-6 10A TAIL
EB-7 10A H/LIGHT-RH
EB-8 10A H/LIGHT-LH
EB-9 —
EB-10 —
EB-11 —
EB-12 —
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD
SLOW BLOW FUSE

ENGINE MODEL
FUSE NO. 4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2
FUSE AND RELAY LOCATION
FUSE BOX
FUSE
No. Capacity Indication on label No. Capacity Indication on label
1 — — 12 15A CIGER
2 10A ABS 13 15A AUDIO (+B)
3 — — 14 20A DOOR LOCK
4 15A BACK UP 15 10A METER (+B)
5 15A METER 16 10A ROOM
6 10A TURN 17 10A ANTI THEFT
7 15A ELEC.IG 18 15A STOP
8 15A ENGINE 19 15A ACC SOCKET
9 20A FRT WIPER 20 10A STARTER
10 15A EGR 21 10A SRS
11 10A AUDIO
SLOW BLOW FUSE
No. Capacity Indication on label
22 20A RR DEF
23 30A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
4JH1-TC REAR POWER ACC
DEFOGGER WINDOW SOCKET
ECM WIRING DIAGRAM (1/7)
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
PSG(Pump Control Unit)
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLU/ BLU/ WHT RED ORG PNK 0.5
BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 Engine 4P out
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

RED/ ORG/ BRN/ BLK/ BLU/ WHT
WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay
ECM Stop Back up Engine

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
BLU/ GRN BLU/ BLU/ WHT
RED RED RED
Brake Clutch Neutral Inhibitor
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Injection Resister BLK VIO
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
BLU/ BLU/ WHT/ BLU/ 0.5 0.5 BLU/
BLK RED BLK 0.85 YEL BLK/ YEL
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
ECM Battery Heater

Main Relay Voltage Relay
ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Compressor Thermo
Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
Plug Compressor 0.5 Pressure
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

BLK/ WHT/ GRN/ BLK/ BLK/
URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
GRN/ RED WHT BLK BLK BLK BLK/ GRY WHT RED
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Engine Imnobiliser 16 15 14 13 12 11 10 9
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Signal or Continuity Tester Position

Pin B/Box Wire ECM
Pin Function Key SW Key SW Engine Engine
No. No. Color Connection Range (+) (-)
Off On Idle 2000rpm
1 1 ECM Ground BLK Continuity - - - Disconnect Ω 1 GND
with
ground
2 2 ECM Ground BLK Continuity - - - Disconnect Ω 2 GND
with
ground
3 3 Battery Power Supply BLU/RED Less than Battery voltage Connect DC V 3 GND
1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output BLU/RED - - Approx. Approx. Connect AC V 27 GND
(To Tacho Meter) 23Hz by 68Hz by
wave form wave form
or approx. or approx.
7.2V 7.5V
28 28 No Connection - - - - - - - - -
29 29 Throttle Position RED/ - Approx. 140Hz by wave form (Idle: - - - -
Signal (To TCM A16) WHT Off duty 10% WOT: Off duty 90%)
(A/T Only)
30 30 Brake Switch 1 Signal RED Less than Battery voltage when pedal is Connect DC V 30 GND
1V stepped on
31 31 Clutch Switch Signal YEL Less than Battery voltage when pedal is not Connect DC V 31 GND
(M/T Only) 1V stepped on
32 32 No Connection - - - - - - - - -
33 33 A/C Thermo Relay GRN Less than Battery voltage when A/C request Connect DC V 33 GND
1V switch is turned on
34 34 No Connection - - - - - - - - -
35 35 Immobiliser Control WHT - Wave form - - - -
Unit (ICU B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position WHT Less than Less than 1V Approx. Connect DC V 38 49
Sensor (TPS) Output 1V 1V
Signal
39 39 Key Switch Input BLU/YEL Less than Battery voltage Connect DC V 39 GND
Signal Via Engine 1V
Fuse
40 40 No Connection - - - - - - - - -
41 41 A/C Compressor BRN/RED Less than Battery Battery voltage when Connect DC V 41 GND
Relay 1V voltage A/C compressor is not
activated

Pin B/Box Wire ECM
Off On Idle 2000rpm
42 42 Check Engine Lamp RED/YEL Less than Battery voltage when lamp is turned Connect DC V 42 GND
1V off
43 43 Glow Lamp ORG/BLU Less than Battery voltage when lamp is turned Connect DC V 43 GND
1V off
44 44 No Connection - - - - - - - - -
45 45 Data Link Connector BLU Less than Battery voltage Connect DC V 45 GND
(No. 6) 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position RED/ Idle: - - - Disconnect Ω 38 49
Sensor (TPS) Ground GRN Approx.
0.4kΩ/
WOT:
Approx.
3.8kΩ
50 50 No Connection - - - - - - - - -
51 51 No Connection - - - - - - - - -
52 52 No Connection - - - - - - - - -
53 53 No Connection - - - - - - - - -
54 54 No Connection - - - - - - - - -
55 55 No Connection - - - - - - - - -
56 56 No Connection - - - - - - - - -
57 57 Throttle Position BLK/GRN Less than Approx. 5V Connect DC V 57 49
Sensor (TPS) Power 1V
Supply
58 58 ECM Main Relay BLU/BLK Battery Less than 1V Connect DC V 58 GND
voltage
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply BLU/RED Less than Battery voltage Connect DC V 63 GND
1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/BLK Less than Battery voltage when pedal is not Connect DC V 65 GND
1V stepped on
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sensor BLU/WHT - Approx. 15Hz by wave form or Connect AC V 68 GND
(VSS) Via Speed approx. 6.4V at vehicle speed
Meter 20km/h
69 69 Idle Switch GRN/BLK Less than Approx. 5V when pedal is stepped Connect DC V 69 GND
1V on
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -

Pin B/Box Wire ECM
Off On Idle 2000rpm
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/ Less than Approx. 5V Connect DC V 83 92
Sensor Power Supply RED 1V
84 84 Intake Air Temperature BLK/BLU Less than Approx. 2.5V at IAT 25°C Connect DC V 84 92
(IAT) Sensor Signal 1V
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/WHT Less than Battery voltage at other than neutral Connect DC V 87 GND
1V (M/T) / Battery voltage in
P or N (A/T)
88 88 Mass Air Flow (MAF) GRN/ Less than Approx. Approx. Approx. Connect DC V 88 92
Sensor Signal RED 1V 1V 2V 3V
89 89 Engine Coolant GRY Less than Approx. 1.3V at ECT 80°C Connect DC V 89 93
Temperature (ECT) 1V
Sensor Signal
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 133Hz by
wave form wave form
or approx. or approx.
0.7V at 1.0V
700rpm
91 91 CKP Sensor Output To PNK - - Approx. Approx. - - - -
Pump Control Unit 47Hz by 133Hz by
(PSG) No.8 wave form wave form
92 92 Mass Air Flow (MAF) BLK/RED Continuity - - - Connect Ω 92 GND
Sensor Ground with
ground
93 93 Engine Coolant BLK/PNK Continuity - - - Connect Ω 93 GND
Temperature (ECT) with
Sensor Ground ground
94 94 Glow Relay BLK/BLU Less than Battery voltage when glow system Connect DC V 94 GND
1V is not activated
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ORG - Approx. 140Hz by wave form when - - - -
EVRV is activated
98 98 CKP Sensor Ground WHT Continuity - - - Connect Ω 98 GND
with
ground
99 99 CAN (Controller Area RED - - - - - - - -
Network) to PSG No.1
100 100 CAN (Controller Area WHT - - - - - - - -
Network) to PSG No.2
101 101 CKP Sensor Shield - Continuity - - - Connect Ω 101 GND
Line with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - Wave form - - - -
Off (MAB) Output
Signal to PSG No.5
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case

Pin B/Box Wire PSG
Off On Idle 2000rpm
1 99 CAN (Controller Area RED Continuity - - - Disconnect Ω 1 99
Network) to ECM between
No.99 ECM &
PSG
2 100 CAN (Controller Area WHT Continuity - - - Disconnect Ω 2 100
Network) to ECM between
No.100 ECM &
PSG
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut ORG Continuity - - - Disconnect Ω 5 105
Off (MAB) Output between
Signal to ECM No.105 ECM &
PSG
6 - Ground BLK Continuity - - - Disconnect Ω 6 GND
with
ground
7 3 Battery Power Supply BLU/RED Continuity - - - Disconnect Ω 7 3
between
ECM &
PSG
8 91 CKP Sensor Output PNK Continuity - - - Disconnect Ω 8 91
ECM No.91 To Pump between
Control Unit (PSG) ECM &
PSG
9 - No Connection - - - - - - - - -
GENERAL DESCRIPTION FOR ECM AND management system.
SENSORS • Engine Control Module (ECM)
• Pump Control Unit (PSG) = Pumpen Steuer Great
Engine Control Module (ECM) (German)
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
The engine control module (ECM) is located flower module (ECM) and the pump control unit (PSG) is
panel just under the passenger's seat. perfumed via a CAN-bus system. The abbreviation CAN
The fuel quantity and injection timing related functions stands for Controller Area Network. By having two
are controlled by the pump control unit (PSG). separate control modules, the high pressure solenoid
The engine control module (ECM) performs the valve. This prevents the discharge of any disturbing
following functions. signals.
• Control of the exhaust gas re-circulation (EGR)
The following signals are exchanged via the CAN-bus:
• Control of the quick on start (QOS) glow control From ECM to PSG
system
• Desired injection quantity
• Control of the A/C compressor
• Desired injection timing
• Execution of the immobiliser function
• Engine speed
Pump Control Unit (PSG) & Data Exchange
Between Control Module From PSG to ECM
• Fuel temperature
• Pump speed
• Cylinder identifier
• Control pulse (actual injection quantity + actual
Self Diagnosis / Interface / Signal injection timing)
To High Pressure Solenoid
• PSG status
Cam Ring Rotational Angle
Engine Speed Fuel Temperature
Engine
Control Injection Timing
Module
Accelerator Pedal (ECM High Pressure
Injection Quantity Solenoid Valve
Pump
Intake Air Temperature Control Fuel Injection
Unit (Mechanical)
Response Signal
(PSG
Mass Air Flow
Additional Signal
Others Timing Device
Additional Operations To Timing Control Valve (TCV)
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
Mass Air Flow (MAF) Sensor & Intake Air The ECM supplies 5 volts signal to the IAT sensor
Temperature (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.
Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor is part of the intake air
system. 1 2
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine. (1) Throttle Position Sensor (TPS)
The mass air flow (MAF) sensor uses a hot film element (2) Idle Switch
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both exposed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the

partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
Characteristic of IAT Sensor

+5V Output Ground Ground +5V
Resistance ( )
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130

Temperature (oC)
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.
Engine Coolant Temperature (ECT) Sensor
Characteristic of TPS
Output Voltage (V)
Throttle Angle (%)

2 1
The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and (1) Engine Coolant Temperature (ECT) Sensor
idle switch. (2) Thermo Unit for Water Temperature Gauge
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
Characteristic of ECT Sensor
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
Resistance ( )
delivery based on throttle valve angle.
Crankshaft Position (CKP) Sensor
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Temperature (deg. C)
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 CKP sensor is located on top of the flywheel
housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
and engine cylinder top dead center (TDC).
Vehicle Speed Sensor (VSS) EGR EVRV
3 2 1
M/T & A/T 4WD

(1) EGR EVRV
(2) Connecting to Vacuum Pump
(3) Connecting to EGR Valve
7.1ms
Voltage
Time
0.7ms
Off duty 10% =EGR Pulse Ratio 10%
7.1ms
Voltage
A/T 2WD
Time
The VSS is a magnet rotated by the transmission output 6.4ms
shaft. The VSS uses a hall element. It interacts with the Off duty 70% =EGR Pulse Ratio 70%
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse. The EGR system on this engine is largely responsible
The engine control module (ECM) calculates the vehicle for a reduction of the NOx exhaust emission.
speed by VSS. The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
GENERAL DESCRIPTION FOR INJECTION dispersion and distribution (mixing with air is improved)
PUMP and results in better combustion. This contributes to
cleaner emissions.
Outline
3. Optimum Fuel Injection
High speed control of fuel injection quantity and fuel
injection timing, is performed by the control unit,
enabling lower fuel cost and high output.
4. Improved Durability
The components used in the pump are very resistant to
high pressure, ensuring improved durability.
5. Improved Engine Matching

As fuel injection is controlled by cylinder selective
adaptation, smooth running is improved.
6. Improved Reliability
As a control unit system with both an engine control
module (ECM) and a pump control unit (PSG) is used,
the control system is extremely reliable.
7. Improved Power Performance

(1) Drive Shaft As the control unit controls the optimum fuel injection
(2) Feed Pump quantify corresponding to accelerator position,
(3) Pump Camshaft Speed Sensor increased torque in low accelerator pedal positions is
(4) Pump Control Unit (PSG) possible, enabling improved power performance.
(5) Distributor Head
8. Decreased Smoke at Acceleration
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve When the amount of injected fuel is increased, to
increase engine power at acceleration, the excess fuel
(8) Constant Pressure Valve (CPV)
usually generates smoke. The VP44 fuel injection pump,
(9) Timing Control Valve (TCV)
accurately controls fuel injection quantity even in this
(10) Timer range to prevent the generation of smoke without
(11) Radial Plunger High Pressure Pump adversely affecting acceleration.
Instead of the previous face cam type, the radial plunger 9. Additional Devices are Unnecessary
distributor type injection pump utilizes a cam ring to
Such additional devices as the boost compensator and
enable fuel injection at high-pressures, marking it
the aneroid compensator are unnecessary, as the
suitable for small, high-speed direct injection diesel
control unit compensates, based on signals from each
engines. This pump was developed to provide the most
sensor. This results in less “clutter” injection pump.
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
10. Self Diagnosis Function
smoke, low noise, high output and clear exhaust
emissions. The system includes a self-diagnosis function, which
displays error codes to facilitate the diagnosis of
Characteristic of VP44 Injection System malfunctions.
1. High Pressure Injection

The radial plunger distributor type injection pump is
capable of generating pressure of 100 Mpa
(approximately 1000 Bar) demanded by small, high
speed direct injection diesel engines.
2. High Pressure Atomization of Fuel Injected from

the Nozzle
Through high pressure fuel injection, the fuel is
atomized at high pressure with a high penetrating force
(the fuel droplets penetrate further) and with greater
Cross-section View
(1) Rotor Shaft

(1) Drive Shaft (2) Radial Plunger
(2) Feed Pump (3) High Pressure Passage
(3) Pump Camshaft Speed Sensor (4) Low Pressure Inlet
(4) Pump Control Unit (PSG) (5) Distributor Slit
(5) Distributor Head (6) Valve Needle
(6) Constant Pressure Valve (CPV) Holder (7) Barrel
(7) High Pressure Solenoid Valve (8) Annular Passage
(8) Constant Pressure Valve (CPV) (9) Fuel Return
(9) Timing Control Valve (TCV) (10) High Pressure Solenoid Valve
(10) Timer (11) High Pressure Outlet
(11) Radial Plunger High Pressure Pump (12) Diaphram Chamber
(13) Accumulator Diaphram
Low Pressure Fuel Circuit High Pressure Fuel Circuit
(1) Fuel Suction (1) Pump Control Unit (PSG)

(2) Regulating Valve (2) Distributor Head
(3) Overflow Valve (3) High Pressure Solenoid Valve
(4) Feed Pump (4) Constant Pressure Valve (CPV)
(5) To Fuel Tank (5) Radial Plunger High Pressure Pump
The low pressure fuel circuit must supply sufficient fuel In addition high pressure generating device, the high
to the high pressure fuel circuit. The main components pressure circuit also consists of fuel piping, and devices
are the feed pump, the regulating valve and the overflow to set the beginning of injection and fuel injection
valve. quantity.
The main components are as follows.

• High pressure generation: Radial Plunger High
Pressure Pump
• Fuel distribution: Distributor Head
• Beginning of injection timing: Timing Device
• Prevention of secondary injection: Constant Pressure
Valve (CPV)
Timing Control Start of Injection
Engine Load
Engine Pump Timing
Engine Speed Control Control Control
Module Unit Valve
Engine Coolant
(ECM) (PSG) (TCV)
Temperature
Pump
Camshaft
Speed Sensor
(1) Cam Ring The engine control module (ECM) contains

(2) Servo Valve characteristic maps of the beginning of injection,
(3) Timer Piston corresponding to engine operating conditions (engine
(4) Outlet load, engine speed and engine coolant temperature).
(5) Feed Pump The pump control unit (PSG) is constantly comparing
(6) Inlet the set beginning of injection timing and the actual
(7) Fuel Suction beginning of injection timing.
(8) Ball Pin If there is a difference, the timing control valve (TCV) is
(9) Annular Chamber controlled by the duty ratio. (The actual beginning of
(10) Hydraulic Stopper injection timing is determined from the pump camshaft
speed sensor.)
(11) Return Passage
(12) Timing Control Valve (TCV)
The timing device determines the optimum injection

timing against variations in engine speed.
The pressure of the fuel fed from the feed pump is
adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
The timing plunger is connected to the cam ring by a
ball pin. Axial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing.
The main components are timing plunger, the timing
control valve (TCV) and pump camshaft speed sensor.
ISUZU Strategy Based Diagnostics
Overview You have maximum efficiency in diagnosis when you

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

• Vehicle road tests
As you follow a diagnostic plan, every box on the
• Complaint check sheet
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking • Contact with the customer
optimizes your diagnosis in the following ways:
• Improves your understanding and definition of the 2. Perform Preliminary Checks
customer complaint
NOTE: An estimated 10 percent of successful vehicle
• Saves time by avoiding testing and/or replacing good repairs are diagnosed with this step!
parts
• Allows you to look at the problem from different What you should do
perspectives
You perform preliminary checks for several reasons:
• Guides you to determine what level of understanding
about system operation is needed: • To detect if the cause of the complaint is VISUALLY
OBVIOUS
– Owner’s manual level
• To identify parts of the system that work correctly
– Service manual level
• To accumulate enough data to correctly and
– In-depth (engineering) level
accurately search for a ISUZU Service Bulletin on
– Owner’s manual level ISUZU Web site.
– Service manual level The initial checks may vary depending on the
– In-depth (engineering) level complexity of the system and may include the following
actions:
• Operate the suspect system
1. Verify the Complaint
• Make a visual inspection of harness routing and
What you should do accessible/visible power and ground circuits
• Check for blown fuses
To verify the customer complaint, you need to know the
• Make a visual inspection for separated connectors
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the • Make a visual inspection of connectors (includes
system. checking terminals for damage and tightness)
The following information will help you verify the • Check for any DTCs stored by the on-board
complaint: computers
• WHAT the vehicle model/options are • Sense unusual noises, smells, vibrations or
• WHAT aftermarket and dealer-installed accessories movements
exist • Investigate the vehicle service history (call other
• WHAT related system(s) operate properly dealerships, if appropriate)
• WHEN the problem occurs
What resources you should use
• WHERE the problem occurs
• HOW the problem occurs Whenever appropriate, you should use the following
resources for assistance in performing preliminary
• HOW LONG the condition has existed (and if the
checks:
system ever worked correctly)
• Tech II or other technical equipment for viewing DTCs
• HOW OFTEN the problem occurs
• Service manual information:
• Whether the severity of the problem has increased,
decreased or stayed the same – Component locations
– Harness routing
What resources you should use – Wiring schematics
Whenever possible, you should use the following – Procedures for viewing DTCs
resources to assist you in verifying the complaint: • Dealership service history file
• Service manual Theory or Circuit Description • Vehicle road test
sections • Identical vehicle or system for comparison
• Service manual “System Performance Check”
• Owner manual operational description
• Technician experience
• Identical vehicle for comparison
3. Check Bulletins and steps of diagnostic procedures to locate the fault related
to the customer complaint.
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle What resources you should use
repairs are diagnosed with this step! Whenever appropriate, you should use the following
resources to perform service manual diagnostic
What you should do procedures:
You should have enough information gained from • Service manual
preliminary checks to accurately search for a bulletin • Technical equipment (for analyzing diagnostic data)
and other related service information. Some service • Digital multimeter and circuit testing tools
manual sections provide troubleshooting hints that
match symptoms with specific complaints. • Essential and special tools
What resources you should use 5c. Technician Self Diagnoses

You should use the following resources for assistance in When there is no DTC stored and no matching
checking for bulletins and troubleshooting hints: symptom for the condition identified in the service
• Printed bulletins manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
• Access ISUZU Bulletin Web site, https://www.einet.isuzu.
service manual combined with you experience and a
co.jp//
good process of elimination will result in accurate
• Videotapes diagnosis of the condition.
• Service manual
What you should do
4. Perform Service Manual
Step 1: Identify and understand the suspect
Diagnostic Checks circuit(s)
Having completed steps 1 through 4 of the Strategy
What you should do Based Diagnostics chart, you should have enough
The “System Checks” in most service manual sections information to identify the system(s) or sub-system(s)
and in most cells of section 8A (electrical) provide you involved. Using the service manual, you should
with: determine and investigate the following circuit
• A systematic approach to narrowing down the characteristics:
possible causes of a system fault • Electrical:
• Direction to specific diagnostic procedures in the – How is the circuit powered (power distribution
service manual charts and/or fuse block details)?
• Assistance to identify what systems work correctly – How is the circuit grounded (ground distribution
charts)?
What resources you should use – How is the circuit controlled or sensed (theory of
Whenever possible, you should use the following operation):
resources to perform service manual checks: – If it is a switched circuit, is it normally open or
• Service manual normally closed?
• Technical equipment (for viewing DTCs and analyzing – Is the power switched or is the ground
data) switched?
• Digital multimeter and circuit testing tools – Is it a variable resistance circuit (ECT sensor or
TP sensor, for example)?
• Other tools as needed
– Is it a signal generating device (MAF sensor of
VSS, for example)?
5a and 5b. Perform Service Manual – Does it rely on some mechanical/vacuum
Diagnostic Procedures device to operate?
NOTE: An estimated 40 percent of successful vehicle • Physical:
repairs are diagnosed with these steps! – Where are the circuit components (component
locators and wire harness routing diagrams):
What you should do – Are there areas where wires could be chafed
When directed by service manual diagnostic checks, or pinched (brackets or frames)?
you must then carefully and accurately perform the – Are there areas subjected to extreme
temperatures? • If only one component fails to operate, begin testing
– Are there areas subjected to vibration or at the component
movement (engine, transmission or • If a number of components do no operate, begin tests
suspension)? at the area of commonality (such as power sources,
– Are there areas exposed to moisture, road salt ground circuits, switches or major connectors)
or other corrosives (battery acid, oil or other
fluids)? What resources you should use
– Are there common mounting areas with other Whenever appropriate, you should use the following
systems/components? resources to assist in the diagnostic process:
– Have previous repairs been performed to wiring, • Service manual
connectors, components or mounting areas • Technical equipment (for data analysis)
(causing pinched wires between panels and
drivetrain or suspension components without • Experience
causing and immediate problem)? • Technical Assistance
– Does the vehicle have aftermarket or dealer- • Circuit testing tools
installed equipment (radios, telephone, etc.)
5d. Intermittent Diagnosis
Step 2: Isolate the problem
At this point, you should have a good idea of what could By definition, an intermittent problem is one that does
cause the present condition, as well as could not cause not occur continuously and will occur when certain
the condition. Actions to take include the following: conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
• Divide (and separate, where possible) the system or intermittents are caused by:
circuit into smaller sections
• Faulty electrical connections and wiring
• Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing • Malfunctioning components (such as sticking relays,
panels and trim as necessary in order to eliminate solenoids, etc.)
large vehicle sections from further investigation) • EMI/RFI (Electromagnetic/radio frequency
• For two or more circuits that do not share a common interference)
power or ground, concentrate on areas where • Aftermarket equipment
harnesses are routed together or connectors are Intermittent diagnosis requires careful analysis of
shared (refer to the following hints) suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
Hints interpret customer complaints and simulating all
Though the symptoms may vary, basic electrical failures external and internal system conditions to duplicate the
are generally caused by: problem.
• Loose connections:
What you should do
– Open/high resistance in terminals, splices,
connectors or grounds Step 1: Acquire information
• Incorrect connector/harness routing (usually in new A thorough and comprehensive customer check sheet is
vehicles or after a repair has been made): critical to intermittent problem diagnosis. You should
– Open/high resistance in terminals, splices, require this, since it will dictate the diagnostic starting
connectors of grounds point. The vehicle service history file is another
• Corrosion and wire damage: source for accumulating information about the
complaint.
– Open/high resistance in terminals, splices,
connectors of grounds
Step 2: Analyze the intermittent problem
• Component failure:
Analyze the customer check sheet and service history
– Opens/short and high resistance in relays, file to determine conditions relevant to the suspect
modules, switches or loads system(s).
• Aftermarket equipment affecting normal operation of Using service manual information, you must identify,
other systems trace and locate all electrical circuits related to the
You may isolate circuits by: malfunctioning system(s). If there is more than one
• Unplugging connectors or removing a fuse to system failure, you should identify, trace and locate
separate one part of the circuit from another part areas of commonality shared by the suspect circuits.
• Operating shared circuits and eliminating those that
function normally from the suspect circuit
Step 3: Simulate the symptom and isolate the For parts and sensors, apply slight vibration to the part
problem with a light tap of the finger while monitoring the system
Simulate the symptom and isolate the system by for a malfunction.
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/ 2. Heat
systems to isolate the problem symptom. Begin with the This method is important when the complaint suggests
most logical circuit/component. that the problem occurs in a heated environment. Apply
Isolate the circuit by dividing the suspect system into moderate heat to the component with a hair drier or
simpler circuits. Next, confine the problem into a smaller similar tool while monitoring the system for a
area of the system. Begin at the most logical point (or malfunction.
point of easiest access) and thoroughly check the CAUTION: Care must be take to avoid overheating
isolated circuit for the fault, using basic circuit tests. the component.
Hints 3. Water and Moisture

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

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

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

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

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

Whenever possible, you should use the following
resources to facilitate the repair process:
• Electrical repair procedures
• Service manual information and publications
GENERAL SERVICE INFORMATION ON-BOARD DIAGNOSTIC (OBD)

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

Tech 2
The procedure for reading diagnostic trouble code(s) is
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes

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

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

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

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

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

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

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

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

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

The purpose of the “Diagnostic Trouble Codes” mode is
to display stored trouble code in the ECM.
When “Clear DTC Information” is selected, a “Clear
DTC Information”, warning screen appears.
This screen informs you that by cleaning DTC's “all
stored DTC information in the ECM will be erased”.
After clearing codes, confirm system operation by test
driving the vehicle.
Read DTC Infor As Stored By ECU
P0100 Present
(7) Mass Air Flow (MAF) Sensor
DTC No. Voltage Supply Circuit High Input
Symptom Code
Symptom Code:
This number or alphabet means identification of the
malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
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 Units Idle 1500rpm 2000rpm Description

1 Engine Speed rpm 675 - 725 1475 - 1525 1975 - 2025 The engine speed is measured by ECM from the CKP
sensor.
2 Vehicle Speed km/h 0 0 0 This displays vehicle speed. The vehicle speed is
measured by ECM from the vehicle speed sensor.
3 Pump Speed rpm 335 - 375 725 - 775 975 - 1025 This displays injection pump speed. The injection speed
is measured by ECM from the pump cam sensor.
4 Accelerator % 0 3-6 5-8 Throttle position operating angle is measured by the
Position Signal (0) (4 - 7) (8 - 11) ECM from throttle position output voltage. This should
Value of ( ) shows display 0% at idle and 99 - 100% at full throttle.
A/T model
5 Idle Switch Active/ Inactive Active Active Inactive This displays operating status of the idle switch. This
should display “Active” when the idle condition.
6 Mass Air Flow mg/strk 410 - 490 380 - 450 400 - 480 This displays intake air amount. The mass air flow is
Sensor (730 - 785) (700 - 780) (780 - 830) measured by ECM from the MAF sensor output voltage.
Value of ( ) shows
A/T model
7 Barometric hpa 990 - 1015 990 - 1015 990 - 1015 The barometric pressure is measured by ECM from the
Pressure sensor in the ECM. This data is changing by altitude.
8 Desired Injection mg/stk 5-8 5-9 6 - 10 This displays commanded value from the ECM. The ECM
Quantity (10 - 16) (8 - 12) (9 - 13) compensates for fuel rate to basic rate.
Value of ( ) shows
A/T model
9 Injection Quantity mg/stk 6-8 6-9 7 - 10 This displays actual fuel quantity. The PSG controls high
Value of ( ) shows (10 - 16) (8 - 12) (9 - 13) pressure solenoid valve to meet commanded value from
A/T model the ECM.
10 Desired Fuel °CA 1-3 2-4 3-6 This displays commanded value from the ECM. The ECM
Injection Start compensates for fuel injection timing by throttle position
and various sensor signal.
11 Actual Injection °CA 1-3 2-4 3-6 This displays actual injection timing value controlled by
Start the TCV. The TCV controls duty ratio to meet
commanded value from the PSG.
12 Coolant °C 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
Temperature voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg.
13 Fuel Temperature °C 25 - 50 25 - 50 25 - 50 The FT is measured by PSG from FT sensor. This data is
changing by fuel temperature.
14 Intake Air °C 25 - 50 25 - 50 25 - 50 The IAT is measured by ECM from IAT sensor output
Temperature voltage. This data is changing by intake air temperature.
15 Ignition Status On12V/ Off0V On 12V On 12V On 12V This displays the key switch status indicated by the ECM
with key switch signal. This should display “Off 0V” at key
OFF and “On12V” at key ON.
16 Brake Switch 1 Active/ Inactive Inactive Inactive Inactive This displays operating status of the brake switch 1. This
should display “Active” when the brake pedal is stepped
on.
17 Brake Switch 2 Active/ Inactive Inactive Inactive Inactive This displays operating status of the brake switch 2. This
should display “Active” when the brake pedal is stepped
on.
18 Clutch Switch Active/ Inactive Inactive Inactive Inactive This displays operating status of the clutch switch. This
Value of ( ) shows (-) (-) (-) should display “Active” when the clutch pedal is stepped
A/T model on.
19 Neutral Switch On/Off On On On This displays operating status of the neutral switch. This
should display “On” when the gear position is neutral.
Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

20 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display “Active 12V” when the air conditioner
switch is switched on.
21 Diagnostic Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Request Inactive 12V 12V 12V 12V display “Inactive 12V” when the Tech 2 is connected.
22 System Voltage V 10 -14 10 -14 10 -14 This displays the system voltage measured by the ECM
at ignition feed.
23 Main Relay Active/ Inactive Active Active Active This displays operating status for the ECM main relay.
This should display “Inactive” at key OFF and “Active” at
key ON.
24 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display “Inactive 12V” when the engine is warm
upped.
25 Check Engine On/Off Off Off Off This displays operating status for the Check Engine
Lamp Lamp. This should display “On” when the Check Engine
Lamp is turned on.
26 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This should display “On” when the glow lamp is turned
on.
27 Desired Engine rpm 700 700 700 The desired engine idle speed that the ECM
Idle Speed commanding. The ECM compensates for various engine
loads based on engine coolant temperature.
28 Start of Delivery °CA 18 - 22 20 - 25 22 - 26 This displays commanded value from the ECM when
engine start.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor.
Inactive 12V 12V 12V 12V This should display “Active 0V” when the compressor
relay is operated.
30 Immobiliser Active/ Inactive Inactive Inactive Inactive This should display “Inactive” when the immobiliser is
normal.
31 Immobiliser Signal Received/ Not Not Not Not This should display “Not Received” when the immobiliser
Received Received Received Received is not activated.
32 Immobiliser Yes/No Yes Yes Yes This should display “Yes” when the immobiliser is
Function programmed.
Programmed
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”, “4JH1-TC
Bosch” & “Miscellaneous Test”.
F0: Lamps
F0: Check Light
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: Glow Time Telltale Test

When the Tech 2 is operated, “Glow Indicator Lamp” is
turned on or off.
The circuit is normal if the “Glow Indicator Lamp” in the
instrument panel is turned on or off in accordance with
this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay signal turns ON
or OFF.
The circuit is normal if glow system is activated/
deactivated in accordance with this operation when key
switch is turned ON.
F2: Engine Speed (RPM) Control

When the Tech 2 is operated, “Desired Idle Speed”
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is normal if engine speed is changed in
accordance with this operation.
Engine Speed (RPM) Control

Engine Speed 850 RPM
Desired Idle Speed 850 RPM
Injection Quantity 7.5mg/strk
• Press “Increase” key.

Then, Desired Idle speed increases 50rpm-by-50rpm
up to 1200rpm. Engine speed is also changed by this
operation.
• Press “Quit” Key.
Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
Flow Chart for Snapshot Replay (Plotting Graph)
SNAPSHOT DISPLAY WITH TIS2000
Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]
function is described below.
Snapshot data can be displayed with [Snapshot Upload]
function included in TIS2000.
By analyzing these data in various methods, trouble
conditions can be checked.
Snapshot data is displayed by executing the three steps
below shown:
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.

After recording the snapshot in Tech2, transfer the data
from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen.
3. Snapshot data is displayed with TIS2000

[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
4. Select the transferred snapshot.
5. Open the snapshot, to display the data parameter
list on the screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter] 6. Graph display can be moved with the navigation
window opens. icon.
2. Click the first graph icon of the window upper part, 7. For displaying another parameter by graph, click the
and select one parameter from the list of the window parameter of the list, drug the mouse to the display
lower part. Selected parameter is displayed nest to screen while pressing the mouse button and release
the graph icon. Graph division can be selected in the mouse button. New parameter is displayed at
the field on the parameter right side. the position of the previous parameter. For
3. Repeat the same procedures with the 2nd and 3rd displaying the graph display screen in full size, move
icons. the cursor upward on the screen. When the cursor
is changed to the magnifying glass form, click the
4. After selecting all parameters to be displayed (Max.
screen. Graph screen is displayed on the whole
3 parameters), click [OK] button.
screen.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window 4. Click the [OK] button to display.
opens. 5. In this case, parameters are displayed only in graph
2. Click the graph icon, select the parameter to be form. All parameters are displayed in one graph.
displayed from the list and change divisions 6. The graph display screen can be moved with the
according to necessity. navigation icon.
3. Repeat the same procedures with the graph icons,
from the 2nd to 6th.
SERVICE PROGRAMMING SYSTEM (SPS)
The procedure to program the control unit by using the latest software release.
Service Programming System (SPS) software • The latest release of TIS2000 is loaded on the PC.
contained in TIS2000 is explained below.
• The vehicle battery is fully charged.
NOTE: • The control unit to be programmed is connected to
• If the Engine Control Module (ECM) was the vehicle.
programmed, the Immobiliser System must be linked
to the ECM: Refer to section 11 “Immobiliser System- 1. Preparations of TIS 2000
ECM replacement” for the ECM/Immobiliser linking 1. Connect Tech 2 to P/C.
procedure.
2. Check to see if Hardware Key is plugged into Port.
Important: Perform the following checks before 3. Activate TIS 2000 by P/C.
attempting to program the control unit: 4. On the activating screen of TIS2000, choose
• The Tech2 PCMCIA card is programmed with The “Service Programming System”
5. On the screen of “Diagnostic Tester and Processing

Program Selection”, choose the one that will comply
with the following.
• Diagnostic tester 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
“Continue”.
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.
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 3. Data Exchange

Year”, “Vehicle Type”, “Controller Type (Engine)”. 1. Connect Tech-2 to P/C, turn on the power and click
7. After that. then push button and turn Ignition switch the “Next” button of P/C.
tuned on, off, on following Tech-2 display. Tech-2 will 2. Check VIN of the vehicle and choose “Next”.
read information from controller after this procedure.
3. When a lack of data is asked from among the
8. During obtaining information, Tech-2 is receiving following menu, enter accordingly.
information from the control unit chosen. In Select following Menu
replacing the control unit, please be sure to
• Model Year
undertake “Obtaining Information” from the new
unit. With VIN not being programmed into the new • Model
control unit at the time of shipment, “obtaining • Engine type
information” is not complete (because the vehicle • Transmission type
model, engine model and model year are specified
• Destination code (vehicles for general export)*1
from VIN). For the procedure get additional
information on vehicles, instruction will be provided • Immobiliser
in dialog form, when TIS2000 is in operation. * 1: How to read the destination code
Destination code can be read from ID Plate affixed on
9. Following instructions by Tech-2, push the “Exit”
vehicles, while on VIN plate the destination code is
switch of Tech-2, turn off the ignition of the vehicle
described at the right-hand edge of Body Type line. In
and turn off the power of Tech-2, thereby removing
Fig.-3, the destination code can be read as “EK4
from the vehicle.
(Europe)”.
4. After choosing the data, click the “Next” button. the “Program” switch and then download the new
5. When all the necessary information is entered, the software onto Tech-2.
“details” of software within the database that match 6. “Data Transfer” comes on display. The progress of
the entered data will appear for confirmation. Click downloading will be displayed on the screen in the
form of bar graph.
7. 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 “F: Service Programming System” on the
main screen and then choose “Fl: Programming”.
7. While data is being transferred, “Downloading” will
be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
“Reprogramming Successful”. Push the “Exit” button
to bring program to completion.
9. Following “Procedure 2: Demand of Data”, try over
again “Information Obtaining” and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.
HOW TO USE BREAKER BOX
3 1
(1) Engine Control Module (ECM) (3) Breaker Box

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

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

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

and “short to ground circuit”.
Breaker Box Connection Type B
3 4 2 5 1
(1) Engine Control Module (ECM) (4) Digital Voltage Meter

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

power supply circuit” and “power, signal voltage check”
between the engine control module (ECM) and
electrical components.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
Circuit Description connection, and damaged harness.

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

Step Action Value(s) Yes No
1 1. Ignition “On”, engine “Off”. Go to No
2. Check the “CHECK ENGINE” lamp (MIL). CHECK
Does the “CHECK ENGINE” lamp turn “On”? — Go to Step 2 ENGINE Lamp
2 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Attempt to display “Data Display” with the Tech 2.
Does the Tech 2 display engine data? — Go to Step 3 Go to Step 7
2. Select the “Miscellaneous Test” and perform the
“Check Light” in “Lamps”.
3. Operate the Tech 2 in accordance with the Tech 2 Go to CHECK
instructions. ENGINE LAMP
Does the “CHECK ENGINE” lamp turn “Off”? — Go to Step 4 On Steady
4 Attempt to start the engine. Go to Engine
Does the engine start and continue to “Run”? Cranks But Will
— Go to Step 5 Not Run
2. Select the “Read DTC Infor As Stored By ECU” in
“Diagnostic Trouble Code”. Go to DTC
3. Are any DTCs stored? — Chart Go to Step 6
6 Compare typical scan data values displayed on the Refer to Refer to
Tech 2 “Data Display”. SYMPTOM TYPICAL
Are the displayed values within the range? — DIAGNOSIS SCAN DATA
7 Using the DVM and check the data link connector
power supply circuit.
1. Ignition “Off”, engine “Off”.
2. Check the circuit for open circuit.
Was the problem found?
B-58
16
Repair faulty
V harness and
— verify repair Go to Step 8

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

communication circuit.
2. Disconnect the ECM connector.
3. Check the circuit for open or short to ground
circuit.
C-56
45
B-58
6 Repair faulty
harness and
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobiliser System-ECM replacement” for
the ECM/Immobiliser linking procedure. — Verify repair —
NO CHECK ENGINE LAMP (MIL)
Butery
Voltage
Ignition
SW
Meter
10A
Meter
15A
0.5
RED/
YEL
Check
Lamp Control Unit
8 7 6 5 4 3 2 1
7 8
1.25
BLK
0.5 0.5 0.5

BRN/ WHT BLU
YEL
42 35 45
Engine
Control
Module
(ECM)
µP
IC
Circuit Description wire broken inside the insulation. Check for the
following items:
The check engine lamp should be illuminated and
steady for about five seconds with the ignition “ON” and • Inspect the ECM harness and connections for
the engine stopped. Ignition feed voltage is supplied to improper mating, broken locks, improperly formed or
the check engine lamp bulb through the meter fuse. damaged terminals, poor terminal-to-wire
The Engine Control Module (ECM) turns the check connection, and damaged harness.
engine lamp “ON” by grounding the check engine lamp • If the engine runs OK, check for a faulty light bulb, an
driver circuit. open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
Diagnostic Aids • If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
An intermittent check engine lamp may be cased by a
engine ground.
poor connection, rubbed-through wire insulation, or a
No Check Engine Lamp (MIL)

1 Check the meter fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 2
2 Using the DVM and check the “CHECK ENGINE”
lamp circuit.
3. Ignition “On”.
C-56
42
V
Battery
voltage Go to Step 5 Go to Step 3
3 Check the “CHECK ENGINE” lamp bulb.
If the bulb is burnt out, repair as necessary.
lamp circuit.
2. Disconnect the meter connector and ECM
connector.
C-56
42
B-24
17 — Verify repair Go to Step 5

release?

6 Replace the ECM.
CHECK ENGINE LAMP (MIL) “ON” STEADY
12Volt
METER (C10)
METER (C19)
10A
RED/
YEL
0.5
BLK
BLK/
GRN
Circuit description Diagnostic Aids

The check engine lamp should always be illuminated An intermittent may be caused by a poor connection,
and steady for about five seconds with ignition “ON” and rubbed-through wire insulation, or a wire broken inside
the engine stopped. Ignition feed voltage is supplied the insulation. Check for the following items:
directly to the check engine lamp indicator. The Engine • Poor connection or damaged harness – Inspect the
Control Module (ECM) turns the check engine lamp ECM harness and connectors for improper mating,
“ON” by grounding the check engine lamp driver circuit. broken locks, improperly formed or damaged
The check engine lamp should not remain “ON” with the terminals, poor terminal-to-wire connection, and
engine running and no DTC(s) set. A steady check damaged harness.
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Check Engine Lamp (MIL) On Steady

1 1. Ignition “Off”, engine “Off”.
Was the “CHECK ENGINE” lamp turned on? — Go to Step 2 Go to Step 4
lamp circuit.
connector.
3. Check the circuit for short to ground circuit.
C-56
42
B-24
17
— Verify repair Go to Step 3

3 Replace the meter assembly.
Is the action complete? — Verify repair —
release?
5 Replace the ECM.
ECM Diagnostic Trouble Codes
Related Related
Flash Symptom
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code
No. DTC
65 P0100 7 ON Mass Air Flow (MAF) Sensor Voltage MAF sensor power supply voltage ECM uses mass air flow MAF sensor power supply voltage is 1. Sensor power supply circuit short 83 -
Supply Circuit High Input is more than 5.2V. 1600mg/strk & EGR 10% condi- below 5.2V. to battery voltage circuit.
tions as substitute. 2. MAF sensor malfunction.
3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor Voltage MAF sensor power supply voltage MAF sensor power supply voltage is 1. Sensor power supply circuit short 83 -
Supply Circuit Low Input is below 4.6V. more than 4.6V. to ground circuit.
2. MAF sensor malfunction.
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor Output 1. Engine speed is between MAF sensor output is more than - 1. Sensor power supply circuit open 83/88 P0110(1)
Circuit Low Input 600rpm and 5000rpm. 27.4mg/strk. circuit.
2. MAF sensor output is below - 2. Sensor signal circuit open or short
33.7mg/strk. to ground circuit.
3. Sensor heater harness open cir-
cuit.
4. Poor connector connection.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor Output 1. Engine speed is between MAF sensor output is below 1784mg/ 1. Sensor signal circuit short to volt- 88/ 92 P0110(1)
Circuit High Input 600rpm and 5000rpm. strk. age circuit.
2. MAF sensor output is more than 2. Sensor ground circuit open or short
1784mg/strk. to voltage circuit.
4. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) Sensor IAT sensor output voltage is more ECM use 0°C conditions as sub- IAT sensor output voltage is below 4.7V. 1. Sensor signal circuit open or short 84/92 P0100(B)/
Circuit High Input than 4.7V. stitute. to voltage circuit. P0100(C)
2. Sensor ground circuit open or short
to voltage circuit.
3. Poor connector connection
4. IAT sensor malfunction.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) Sensor IAT sensor output voltage is below IAT sensor output voltage is more than 1. Sensor signal circuit short to 84 -
Circuit Low Input 0.3V. 0.3V. ground circuit.
2. IAT sensor malfunction.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature (ECT) ECT sensor output voltage is more 1. ECM uses fuel temperature as ECT sensor output voltage is below 1. Sensor signal circuit open or short 89/93 -
Sensor Circuit High Input than 4.7V. substitute. 4.7V. to voltage circuit.
2. ECM uses 60°C condition for 2. Sensor ground circuit open or short
injection timing control. to voltage circuit.
3. ECM uses -15°C condition for 3. Poor connector connection
glow time control. 4. ECT sensor malfunction.
5. ECM malfunction.
2 ON Engine Coolant Temperature (ECT) ECT sensor output voltage is ECT sensor output voltage is more than 1. Sensor signal circuit short to 89 -
Sensor Circuit Low Input below 0.3V. 0.3V. ground circuit.
2. ECT sensor malfunction.
3. ECM malfunction.
Related Related
Flash Symptom
Code Code
No. DTC
15 P0180 B ON Fuel Temperature Sensor Circuit FT sensor output is high tempera- The ECM use 75°C conditions as FT sensor output is correct temperature 1. ECM malfunction. - -
Range/Performance ture (more than 150°C) or low tem- substitute. range between 150°C and -40°C. 2. PSG (pump control unit) malfunc-
perature (below -40°C). tion.
52 P0215 A ON at Fuel Cutoff Solenoid Valve Malfunc- 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. PSG (pump control unit) malfunc- - -
next tion 2. Engine speed is below valve) is operated. next ignition key cycle. tion.
igni- 1500rpm. 2. Desired injection quantity 2. MAB (fuel cutoff solenoid valve)
tion 3. Vehicle speed is below 1.5km/h. becomes 0mg/strk. malfunction.
cycle 4. PSG (pump control unit) recog-
nizes MAB (fuel cutoff solenoid
valve) signal from the ECM, but
the MAB could not operate.
B ON Fuel Cutoff Solenoid Valve Circuit ECM does not command MAB Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid valve) 105 -
High Input (fuel cutoff solenoid valve) signal signal circuit short to voltage circuit.
to the PSG (pump control unit), but 2. PSG (pump control unit) malfunc-
PSG detected MAB signal line cir- tion.
cuit is high level.
C ON Fuel Cutoff Solenoid Valve Always 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. MAB (fuel cutoff solenoid valve) 105 -
Active 2. Engine speed is below valve) is operated. next ignition key cycle. signal circuit open or short to ground
1500rpm. 2. Desired injection quantity circuit.
3. Vehicle speed is below 1.5km/h. becomes 0mg/strk. 2. PSG (pump control unit) malfunc-
4. PSG (pump control unit) does tion.
not recognize MAB (fuel cutoff
solenoid valve) signal from the
ECM.
D ON Fuel Cutoff Solenoid Valve Malfunc- 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction. - -
tion 2. CAN controller does not operate 2. PSG (pump control unit) malfunc-
Bus-off. tion.
54 P0216 A ON Injection Timing Control Circuit Mal- 1. Engine speed is more than Fuel injection quantity is Deviation of actual injection timing and 1. Timing control valve malfunction. - -
function (Timer Deviation) 700rpm. reduced. desired injection timing is below +3°CA 2. Timer piston sticking.
2. Fuel injection quantity is more or -6°CA for 8 seconds. 3. Pump camshaft speed sensor mal-
than 4mg/stk. function.
3. Deviation of actual injection tim-
ing and desired injection timing is
more than +3°CA or -6°CA for 8
seconds.
B ON Injection Timing Control Circuit Mal- 1. Engine speed is more than 1. Engine speed is more than 2014rpm. 1. Insufficient air bleeding of fuel line. - -
function (Timer Fluctuation) 2014rpm. 2. Fluctuation of actual injection timing is 2. Fuel filter clogging.
2. Fluctuation of actual injection below ±5.2°CA. 3. Timing control valve malfunction.
timing is more than ±5.2°CA. 4. Pump camshaft speed sensor mal-
function.
Related Related
Flash Symptom
Code Code
No. DTC
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed sen- 1. MAB (fuel cutoff solenoid No recovery until condition match in the 1. PSG (pump control unit) malfunc- - -
sor error. valve) is operated. next ignition key cycle. tion.
2. High pressure solenoid valve 2. Desired injection quantity 2. Pump camshaft speed sensor mal-
control pulse width does not match becomes 0mg/strk. function.
with desired fuel injection quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed sen- 1. No pump camshaft speed sensor 1. Missing CKP sensor pulses. 91 -
sor error. error. 2. Electrical interference.
2. No CKP sensor error. 2. No CKP sensor error. 3. Magnetic interference.
3. Difference of engine speed and 3. Difference of engine speed and dou- 4. PSG (pump control unit) malfunc-
doubled pump camshaft speed is bled pump camshaft speed is below tion.
more than 690rpm. 690rpm.
No recovery until in the next ignition key
cycle.
9 ON Injection Pump Malfunction No pump map programmed in the No recovery until condition match in the PSG (pump control unit) malfunction. - -
PSG (pump control unit) or PSG next ignition key cycle.
malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter mal- Fuel injection quantity is EEPROM or A/D converter no malfunc- PSG (pump control unit) malfunction. - -
function in the PSG (pump control reduced. tion in the PSG (pump control unit).
unit). No recovery until in the next ignition key
cycle.
B ON Injection Pump Malfunction PSG (pump control unit) recog- No fail-safe function. No recovery until condition match in the PSG (pump control unit) malfunction. - -
nized high pressure solenoid valve next ignition key cycle.
drive circuit error.
D ON Injection Pump Malfunction PSG (pump control unit) could not PSG (pump control unit) malfunction. - -
measure the high pressure sole-
noid valve drive voltage.
E ON Injection Pump Malfunction ECM could not accept PSG (pump 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump control unit) 1. CAN high circuit open, short to 99/100 P1650(A)/
control unit) message. valve) is operated. message. ground or short to voltage circuit. P1651(B)
2. Desired injection quantity 2. CAN low circuit open, short to
becomes 0mg/strk. ground or short to voltage circuit.
3. ECM malfunction.
4. PSG (pump control unit) malfunc-
tion.
Related Related
Flash Symptom
Code Code
No. DTC
43 P0335 B ON Crankshaft Position Sensor Circuit 1. Engine speed is more than When pump camshaft speed ECM detects correct CKP pulse width. During engine run: 90/ 98/ P1335 (A)
Malfunction 665rpm. sensor is OK: 1. CKP sensor harness open circuit, 101
2. CKP sensor pulse width error. ECM uses doubled pump cam- short to ground or short to voltage cir-
shaft speed as substitute engine cuit.
speed. 2. Poor connector connection.
When pump camshaft speed 3. CKP sensor malfunction.
sensor is not OK: 4. Pulse sensing gap incorrect.
1. MAB (fuel cutoff solenoid 5. Pulser malfunction.
valve) is operated. 6. Electrical interference.
2. Desired injection quantity 7. Magnetic interference.
becomes 0mg/strk. 8. ECM malfunction.
D ON Crankshaft Position Sensor Circuit 1. No pump camshaft speed sen- When pump camshaft speed 1. Engine speed is more than 0rpm. During engine crank: 90/ 98/ P1135 (A)
Malfunction sor error. sensor is OK: 2. Doubled pump camshaft speed is 1. CKP sensor harness open circuit, 101
2. “Crankshaft Position Sensor Cir- ECM uses doubled pump cam- below 100rpm. short to ground or short to voltage cir-
cuit Malfunction (Symptom Code shaft speed as substitute engine cuit.
B)” is not stored. speed. 2. Poor connector connection.
3. Engine speed is 0rpm. Other than pump camshaft 3. CKP sensor malfunction.
4. Doubled pump camshaft speed speed sensor is OK: 4. Pulse sensing gap incorrect.
is more than 50rpm. Fuel injection quantity is 5. Pulser malfunction.
reduced. 6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
E ON Engine Speed Input Circuit Range/ Engine speed is more than When intermittent malfunction: Engine speed is below 5700rpm. 1. Engine over-running. 90/ 98/ -
Performance 5700rpm. 1. MAB (fuel cutoff solenoid 2. CKP sensor malfunction. 101
valve) is operated. 3. Pulser malfunction.
2. Desired injection quantity 4. ECM malfunction.
becomes 0mg/strk.
When preliminary malfunction:
ECM uses doubled pump cam-
shaft speed as substitute engine
speed.
66 P0380 4 ON Glow Relay Circuit Voltage Low Glow relay circuit open or short to No fail-safe function. Glow relay circuit is correct condition. 1. Glow relay circuit open or short to 94 -
ground circuit. ground circuit.
2. Glow relay malfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage High Glow relay circuit short to voltage ECM malfunction. - -
circuit.
67 P0381 4 ON Glow Plug Indicator Circuit Voltage Glow plug indicator circuit open or No fail-safe function. Glow plug indicator circuit is correct con- 1. Glow plug indicator circuit open or 43 -
Low short to ground circuit. dition. short to ground circuit.
2. Glow plug indicator lamp malfunc-
tion.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Voltage Glow plug indicator circuit short to ECM malfunction. - -
High voltage circuit.
Related Related
Flash Symptom
Code Code
No. DTC
32 P0400 3 ON Exhaust Gas Recirculation Flow 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1500rpm 1. EGR valve is stuck at open posi- 88/97 -
Excessive Detected between 15°C and 100°C. reduced. and 3200rpm. tion.
2. Engine coolant temperature is 2. Injection quantity is below 40mg/stk. 2. EGR EVRV malfunction.
between 35°C and 100°C. 3. Correct amount of mass air flow. 3. Air intake is obstructed.
3. Barometric pressure is between 4. Air intake is leaking.
850hpa and 1100hpa. 5. MAF sensor malfunction.
4. Small amount of mass air flow. 6. ECM malfunction.
(Desired mass air flow - mass air
flow is more than 150mg/strk)
4 ON Exhaust Gas Recirculation Circuit EGR EVRV circuit open or short to Fuel injection quantity is reduced EGR EVRV circuit is correct condition. 1. EGR EVRV circuit open or short to 97 -
Short to Ground or Open Circuit ground circuit. and EGR EVRV 10% conditions ground circuit.
as substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation Flow Insuf- 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1500rpm 1. EGR valve is stuck at close posi- 88/97 -
ficient Detected between 15°C and 100°C. reduced. and 3200rpm. tion.
2. Engine coolant temperature is 2. Injection quantity is below 40mg/stk. 2. EGR valve operating vacuum hose
between 35°C and 100°C. 3. Correct amount of mass air flow. is clogged or disconnected.
3. Barometric pressure is between 3. EGR EVRV malfunction.
850hpa and 1100hpa. 4. MAF sensor signal circuit short to
4. Large mount of mass air flow. voltage circuit.
(Desired mass air flow - mass air 5. MAF sensor malfunction.
flow is below 150 mg/strk) 6. ECM malfunction.
8 ON Exhaust Gas Recirculation Circuit EGR EVRV circuit short to voltage Fuel injection quantity is reduced EGR EVRV circuit is correct condition. 1. EGR EVRV circuit short to voltage 97 -
Short to Battery circuit. & EGR EVRV 10% conditions as circuit.
substitute. 2. EGR EVRV malfunction.
3. ECM malfunction.
24 P0500 1 ON at Vehicle Speed Sensor Circuit High Vehicle speed is more than ECM uses vehicle speed 5km/h Vehicle speed is below 200km/h. 1. VSS signal circuit open, short to 68 -
next Input 200km/h. condition as substitute. ground or short to voltage circuit.
igni- 2. VSS malfunction.
tion 3. Speed meter malfunction.
cycle 4. TCM malfunction (A/T 2WD).
5. ECM malfunction.
A ON at Vehicle Speed Sensor Input Signal Input signal frequency is too high. ECM uses vehicle speed 5km/h Correct vehicle speed signal frequency. 1. VSS malfunction. 68 -
next Frequency Too High condition as substitute. 2. Speed meter malfunction.
igni- 3. Electrical interference.
tion 4. Magnetic interference.
cycle 5. ECM malfunction.
B ON at Vehicle Speed Sensor Incorrect Sig- 1. Engine speed is more than Fuel injection quantity is Vehicle speed is more than 1.5km/h. 1. VSS open circuit, short to ground 68 -
next nal 3600rpm. reduced. or short to voltage.
igni- 2. Fuel injection quantity is more 2. Poor connector connection.
tion than 41mg/stk. 3. VSS malfunction.
cycle 3. Vehicle speed is below 1.5km/h. 4. Speed meter malfunction.
5. ECM malfunction.
Related Related
Flash Symptom
Code Code
No. DTC
35 P0560 1 OFF System Voltage Too High System voltage is more than 20V. ECM uses 9V conditions as sub- System voltage is below 20V. 1. Charge system malfunction. 3/39 -
stitute. 2. Battery jump start cable miscon-
nect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 7V. 1. Battery power feed harness open 3/39 -
circuit or short to ground circuit.
2. ECM ground harness open or poor
connection.
4. Battery malfunction.
5. Charge system malfunction.
6. ECM malfunction.
A OFF System Voltage Malfunction (PSG) System voltage of PSG (pump PSG uses default voltage as sub- System voltage of PSG is between 4.5V 1. Battery power feed harness open - -
control unit) is below 4.5V or more stitute. and 27V. circuit or short to ground circuit.
than 27V. 2. PSG (pump control unit) ground
harness open or poor connection.
4. Battery malfunction.
5. Charge system malfunction.
6. Battery jump start cable miscon-
nect.
tion.
18 P0561 A OFF Ignition Switch Circuit Malfunction The ECM recognized ignition ECM stops engine. No recovery until condition match in the 1. Ignition switch circuit open or short 39 -
switch turn off signal during ECM next ignition key cycle. to ground circuit.
is activated. 2. Poor connector connection.
3. Ignition switch malfunction.
4. ECM malfunction.
B ON Ignition Switch Circuit Malfunction Ignition switch circuit is malfunc- 1. Ignition switch circuit open or short 39 -
tion. to ground circuit.
3. Ignition switch malfunction.
4. ECM malfunction.
- P0602 - ECU Programming Error ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed. - -
28 P0606 A ON ECU Malfunction Gate Array communication error. 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction. - -
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below 1%. MAB (fuel cutoff solenoid valve) Desired injection quantity is below 0mg/ 1. ECM malfunction. - -
2. Desired injection quantity is is operated. strk. 2. PSG (pump control unit) malfunc-
more than 0mg/strk. tion.
3. Engine speed is more than
2000rpm.
Related Related
Flash Symptom
Code Code
No. DTC
46 P0645 4 ON A/C Compressor Relay Circuit Voltage A/C compressor relay circuit open No fail-safe function. A/C compressor relay circuit is correct 1. A/C compressor relay circuit open 41 -
Low or short to ground circuit. condition. or short to ground circuit.
3. A/C compressor relay malfunction.
4. ECM malfunction.
8 ON A/C Compressor Relay Circuit Voltage A/C compressor relay circuit short ECM malfunction. - -
High to voltage circuit.
25 P0703 A ON Brake Switch Malfunction 1. Throttle position is more than No fail-safe function. Brake switch 1 signal and brake switch 2 1. Brake switch 1 circuit open, short to 30 -
0%. signal are correctly inputted to the ECM. ground or short to voltage circuit.
2. Engine speed is more than 2. Poor connector connection.
665rpm. 3. Brake switch 1 malfunction.
3. Vehicle speed is more than 4. ECM malfunction.
0km/h.
4. Brake switch 1 signal and brake
switch 2 signal are differently
inputted to the ECM since the igni-
tion switch was turned on.
B ON Brake Switch Malfunction 1. Throttle position is more than 1. Brake switch 2 circuit open or short 65 -
0%. to ground circuit.
2. Engine speed is more than 2. Poor connector connection.
665rpm. 3. Brake switch 2 malfunction.
3. Vehicle speed is more than 4. ECM malfunction.
0km/h.
4. Brake switch 1 signal and brake
switch 2 signal are differently
inputted to the ECM.
57 P0704 6 ON Clutch Switch Input Circuit Malfunc- Clutch signal does not change No fail-safe function. Clutch signal correctly changes. 1. Clutch switch circuit open, short to 31 -
tion between vehicle speed 1.5km/h ground or short to voltage circuit.
and 80km/h since ignition switch 2. Poor connector connection.
was tuned on. 3. Clutch switch malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Circuit Barometric pressure sensor output ECM uses 1013hpa condition as Barometric pressure sensor output volt- ECM malfunction. - -
High Input voltage is more than 4.4V. substitute. age is below 4.4V.
2 ON Barometric Pressure Sensor Circuit Barometric pressure sensor output Barometric pressure sensor output volt- ECM malfunction. - -
Low Input voltage is below 1.5V. age is more than 1.5V.
Related Related
Flash Symptom
Code Code
No. DTC
21 P1120 1 ON Pedal/Throttle Position Sensor Circuit Throttle position sensor output ECM increases idle speed up to Throttle position sensor output voltage is 1. Sensor power supply circuit short 38/ 49/ 57 -
High Input voltage is more than 4.5V. 1400rpm. below 4.5V. to voltage circuit.
2. Sensor signal circuit short to volt-
age circuit.
3. Sensor ground circuit open or short
to voltage circuit.
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Sensor Volt- Throttle position sensor power Throttle position sensor power supply 1. Sensor power supply circuit short 57 -
age Supply Circuit High Input supply voltage is more than 5.2V. voltage is below 5.2V. to battery voltage circuit.
2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Sensor Volt- Throttle position sensor power Throttle position sensor power supply 1. Sensor power supply circuit short 57 -
age Supply Circuit Low Input supply voltage is below 4.6V. voltage is more than 4.6V. to ground circuit.
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position Sensor Brake 1. Engine speed is more than Throttle position is more than 20% or 1. Throttle sticking. 30/ 38/ 65 -
Switch Error 1700rpm. brake pedal is released (switch is inac- 2. TPS incorrect adjusting.
2. Vehicle speed is more than tive). 3. TPS malfunction.
1.5km/h. 4. Brake switch malfunction.
3. When brake pedal is depressed 5. ECM malfunction.
during accelerator pedal is
depressing.
E ON Pedal/Throttle Position Sensor Idle 1. When idle switch is turned off, 1. When throttle position sensor is 1. TPS malfunction. 38/ 69 -
Position Switch Error throttle position sensor was below 100%, idle switch turns off. 4. Idle switch malfunction.
0.35%. 2. When throttle position sensor is 0%, 5. ECM malfunction.
or idle switch turns on.
2. When idle switch is tuned on,
throttle position sensor was more
than 7.8%.
22 P1173 3 OFF Fuel Reduction Caused By High Cool- Excessive high engine coolant No fail-safe function. Engine coolant temperature is normal 1. Engine overheat. 89 -
ant Temperature temperature is detected. range. 2. ECT sensor malfunction.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By High Fuel Fuel temperature is more than PSG (pump control unit) controls Fuel temperature is below 100°C. 1. ECM malfunction. - -
Temperature 100°C. fuel injection quantity based on 2. PSG (pump control unit) malfunc-
engine speed and fuel tempera- tion.
ture.
Related Related
Flash Symptom
Code Code
No. DTC
43 P1335 A ON Engine Speed Output Circuit Malfunc- The PSG (pump control unit) is Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness open circuit, 90/91/98/ P0335(B)/
tion recognized defective engine speed reduced. short to ground or short to voltage. 101 P0335(D)
signal form the ECM. 2. CKP sensor output harness open
circuit, short to ground or short to volt-
age.
4. CKP sensor malfunction.
5. Pulse sensing gap incorrect.
6. Pulser malfunction.
7. Electrical interference.
9. ECM malfunction.
tion.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) is No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed sensor mal- - -
recognized incorrect camshaft function.
speed signal. 2. Pulse sensing gap incorrect.
3. Pulser malfunction.
5. ECM malfunction.
tion.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is inputted No fail-safe function. Correct neutral switch signal is inputted 1. Neutral switch circuit short to volt- 87 -
“On” three times consecutively two times consecutively under driving age circuit.
under driving conditions. conditions. 2. Neutral switch malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is inputted 1. Neutral switch circuit open, short to 87 -
“Off” three times consecutively ground circuit.
under driving conditions. 2. Poor connector connection.
3. Neutral switch malfunction.
4. ECM malfunction.
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM is No fail-safe function. No recovery. ECM malfunction. - -
destroyed.
D ON EEPROM Defect Write and read from the EEPROM ECM uses default values from Write and read from the EEPROM are ECM malfunction. - -
are failed during initialization of the the EPROM. correct during initialization of the ECM.
ECM.
E ON EEPROM Defect EEPROM checksum does not EEPROM checksum match with the ECM malfunction. - -
match with the read check sum read check sum during initialization of
during initialization of the ECM. the ECM.
56 P1610 A - Security Key and Security Code not Immobiliser functions are not pro- 1. Engine does not start. No recovery. ECM malfunction. - B****
Programmed grammed in the ECM. 2. Check engine lamp flash.
56 P1611 A - Wrong Security Code Entered Received security code is not cor- 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
rect. 2. Check engine lamp flash. 2. Immobiliser control unit malfunc-
tion.
3. Transponder key malfunction.
Related Related
Flash Symptom
Code Code
No. DTC
56 P1612 A - Immobiliser No or Wrong Signal Received challenge signal is not 1. Engine does not start. No recovery. 1. ECM and immobiliser control unit 27/35 B****
correct or not received. 2. Check engine lamp flash. communication circuit open circuit,
short to ground circuit or short to volt-
age circuit.
2. ECM malfunction.
3. Immobiliser control unit malfunc-
tion.
56 P1613 A - Immobiliser No or Wrong Signal Received response signal is not 1. Engine does not start. No recovery. 1. ECM and immobiliser control unit 27/35 B****
correct or not received. 2. Check engine lamp flash. communication circuit open circuit,
short to ground circuit or short to volt-
age circuit.
2. ECM malfunction.
3. Immobiliser control unit malfunc-
tion.
56 P1614 A - Wrong Transponder Key Received response signal is not 1. Engine does not start. No recovery. 1. ECM malfunction. - B****
correct from the transponder key. 2. Check engine lamp flash. 2. Immobiliser control unit malfunc-
tion.
76 P1625 A OFF ECM Main Relay Switched Off Too When ignition switch was turned No fail-safe function. No recovery. ECM malfunction. 3/58 -
Early off, timing of the ECM main relay
turning off is too early.
B OFF ECM Main Relay Switched Off Too When ignition switch was turned No recovery. 1. ECM main relay malfunction. 3/58 -
Late off, timing of the ECM main relay 2. ECM malfunction.
turning off is too late or does not
off.
51 P1630 A ON Fuel Injection Quantity Circuit Mal- The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) detects PSG (pump control unit) malfunction. - -
function detects high pressure solenoid reduced. correct high pressure solenoid valve
valve control circuit malfunction control circuit.
due to high current.
B ON Fuel Injection Quantity Circuit Mal- The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit) malfunction. - -
function detects high pressure solenoid valve) is operated.
valve control circuit malfunction 2. Desired injection quantity
due to continuous current. becomes 0mg/strk.
44 P1650 A ON CAN Device Offline CAN controller detects Bus-off or MAB (fuel cutoff solenoid valve) CAN controller detects correct Bus sig- 1. CAN high circuit open, short to 99/100 P1651(B)
canceling. is operated. nal. ground or short to voltage circuit.
2. CAN low circuit open, short to
ground or short to voltage circuit.
5. ECM malfunction.
tion.
B ON CAN Device Hang-up CAN controller does not react CAN controller reacts correctly under 1. ECM malfunction. - -
under engine running. engine running. 2. PSG (pump control unit) malfunc-
tion.
Related Related
Flash Symptom
Code Code
No. DTC
45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit) does 1. MAB (fuel cutoff solenoid The PSG (pump control unit) recognizes 1. ECM malfunction. - -
not recognize CAN signal from the valve) is operated. CAN signal from the CAN controller. 2. PSG (pump control unit) malfunc-
CAN controller. 2. Desired injection quantity tion.
becomes 0mg/strk.
B ON CAN Receives Error The ECM does not read CAN sig- The ECM reads CAN signal from the 1. CAN high circuit open, short to 99/100 P1650(A)
nal from the PSG (pump control PSG (pump control unit). ground or short to voltage circuit.
unit). 2. CAN low circuit open, short to
ground or short to voltage circuit.
5. ECM malfunction.
tion.
77 P1690 4 OFF Check Engine Lamp (MIL) Circuit Volt- Check engine lamp circuit open or No fail-safe function. Check engine lamp circuit is correct con- 1. Check engine lamp circuit open or 42 B****
age Low short to ground circuit. dition. short to ground circuit.
2. Check engine lamp malfunction.
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Circuit Volt- Check engine lamp circuit short to ECM malfunction. - -
age High voltage circuit.
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)

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

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

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

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% con-
Input ditions as substitute.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V.
Input
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit Low Input 600rpm and 5000rpm.
2. MAF sensor output is below
-33.7mg/strk.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit High Input 600rpm and 5000rpm.
2. MAF sensor output is more
than 1784mg/strk.
Circuit Description Diagnostic Aids

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

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

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

Go to Step 7
More than
V
Approximately specified value:
5.0V Go to Step 11 Go to Step 8
7 Repair the open circuit between the ECM and MAF
sensor.
Was the problem solved?
C-57(B) C-116
4

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

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

supply circuit.
C-116
4
V Approximately

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

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


6 Using the DVM and check the MAF sensor signal
circuit.
Breaker box is available:
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-73
4. Check the circuit for open, short to sensor ground
or short to ground circuit.
C-116
88
Breaker box is not available:

ECM connector.
3. Check the circuit for open, short to sensor ground
or short to ground circuit.
C-57(B) C-116
88 5
Repair faulty
harness and
supply circuit.
C-116
4
V Approximately

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


6 Using the DVM and check the MAF sensor ground
circuit.
3. Disconnect the MAF sensor connector.
C-116
92

2. Disconnect the MAF sensor connector and ECM
connector.
C-57 C-116
3 Repair faulty
92 harness and
7 Using the DVM and check the MAF sensor ground
circuit.
2. Disconnect the MAF sensor connector .
C-116
3
Repair faulty
V harness and

circuit.
C-116
5
Repair faulty
V harness and
and recheck.
release?
12 Replace the ECM.

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

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Code Code
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0°C conditions as
Sensor Circuit High Input more than 4.7V. substitute.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is
Sensor Circuit Low Input below 0.3V.
Circuit Description the resistance value. And it changes voltage. In other

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

5 Visually check the IAT sensor.

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

-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
IAT Sensor
5 4 3 2 1
Standard
3 1
resistance Go to Step 7 Go to Step 12
7 Using the DVM and check the IAT sensor signal
circuit.
C-116
Less than 1V:

Go to Step 8
1
More than
V Approximately specified value:
8 Repair the open circuit between the ECM and IAT
sensor.
C-57(B) C-116
84 1

9 Repair the short to voltage circuit between the ECM
and IAT sensor.
C-57(B) C-116
84 1
10 Using the DVM and check the IAT sensor ground
circuit.
C-116
3
Repair faulty
V harness and

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

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

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

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

-20 14210
0 5402
20 2343
40 1131
60 596
80 338
100 203
IAT Sensor
5 4 3 2 1
Standard
3 1

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

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

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

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel temperature
(ECT) Sensor Circuit High more than 4.7V. as substitute.
Input 2. ECM uses 60°C condition for
injection timing control.
2 ON Engine Coolant Temperature ECT sensor output voltage is
(ECT) Sensor Circuit Low below 0.3V. 3. ECM uses -15°C condition
Input for glow time control.
Circuit Description the coolant stream. Low coolant temperature produces

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

5 Visually check the ECT sensor.

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

-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
7 Using the DVM and check the ECT sensor signal
circuit.
2. Disconnect the ECT sensor connector.
E-41
Less than 1V:

1 Go to Step 8
More than
V
Approximately specified value:
8 Repair the open circuit between the ECM and ECT
sensor.
C-57(B) E-41
89 1

and ECT sensor.
C-57(B) E-41

10 Using the DVM and check the ECT sensor ground
circuit.
E-41
2
Repair faulty
V harness and
11 Using the DVM and check the ECT sensor ground
circuit.
E-41
93

2. Disconnect the ECT sensor connector ECM
connector.
C-57 E-41
Repair faulty
2 harness and
93 — verify repair Go to Step 14

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

5 Visually check the ECT sensor.


-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard

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

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

(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
15 P0180 B ON Fuel Temperature Sensor Cir- FT sensor output is high tem- The ECM use 75°C conditions
cuit Range/Performance perature (more than 150°C) as substitute.
or low temperature (below -
40°C).
Circuit Description • Misrouted harness.

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

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION

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

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

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
52 P0215 A ON at Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
next Malfunction 2. Engine speed is below valve) is operated.
igni- 1500rpm. 2. Desired injection quantity
tion 3. Vehicle speed is below becomes 0mg/strk.
cycle 1.5km/h.
4. PSG (pump control unit)
recognizes MAB (fuel cutoff
solenoid valve) signal from
the ECM, but the MAB
could not operate.
B ON Fuel Cutoff Solenoid Valve ECM does not command Engine does not start.
Circuit High Input MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line cir-
cuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated.
1500rpm. 2. Desired injection quantity
3. Vehicle speed is below becomes 0mg/strk.
1.5km/h.
4. PSG (pump control unit)
does not recognize MAB
(fuel cutoff solenoid valve)
signal from the ECM.
D ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. No fail-safe function.
Malfunction 2. CAN controller does not
operate Bus-off.

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

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

5

5 Visually check the PSG (pump control unit).

6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) circuit.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-73
3. Check the circuit for short to voltage circuit.
105

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

5


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

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

(FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
(TIMER DEVIATION)

(FLASH CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
(TIMER FLUCTUATION)
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
54 P0216 A ON Injection Timing Control Cir- 1. Engine speed is more than Fuel injection quantity is
cuit Malfunction (Timer Devia- 700rpm. reduced.
tion) 2. Fuel injection quantity is
more than 4mg/stk.
3. Deviation of actual injection
timing and desired injec-
tion timing is more than
+3°CA or -6°CA for 8 sec-
onds.
B ON Injection Timing Control Cir- 1. Engine speed is more than
cuit Malfunction (Timer Fluc- 2014rpm.
tuation) 2. Fluctuation of actual injec-
tion timing is more than
±5.2°CA.
The ECM is calculates an injection quantity and an An intermittent may be caused by the following:
injection timing using the various sensors (crankshaft • Poor connections.
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing • Rubbed through wire insulation.
decision. • Broken wire inside the insulation.
The TCV performs as a variable throttle, using the rapid • Insufficient air bleeding of fuel line.
opening and closing cycle of the valve needle in the Check for the following conditions:
TCV.
• Insufficient air bleeding of fuel line inside, clogged
The TCV is assembled in the injection pump. The signal
fuel filter or pinched fuel pipe/hose may cause the
of desired injection timing and actual injection timing are
DTC store or improper engine performance.
exchanged via the CAN-bus between the PSG and
ECM. • Poor connection at ECM and PSG-Inspect harness
If the timer position is out of tolerance (deviation or connectors for backed out terminals, improper
fluctuation), DTC P0216 will be stored. mating, broken locks, improperly formed or damaged
the “Actual Injection Start” display on the Tech2 while
sensor.
Injection Timing Control Circuit Malfunction (Timer Deviation)
(OBD) System
Injection Timing Control Circuit Malfunction (Timer Fluctuation)
(OBD) System
4 Perform the air bleeding in the fuel line sufficiently.
1. Using the Tech 2, ignition “On” and engine “Off”.
Was the DTC P0216 (Symptom Code B) restored in
this ignition cycle? — Go to Step 5 Verify repair
5 Visually/physically inspect for the following conditions.
• Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
• Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6
6 Replace the fuel filter.

7 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
• Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.
Replace the eye

bolt with gauze
filter and verify
— repair Go to Step 8

(FLASH CODE 53) INJECTION PUMP MALFUNCTION





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

Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft speed 1. MAB (fuel cutoff solenoid
sensor error. valve) is operated.
2. High pressure solenoid 2. Desired injection quantity
valve control pulse width becomes 0mg/strk.
does not match with
desired fuel injection quan-
tity.
7 ON Injection Pump Malfunction 1. No pump camshaft speed
sensor error.
2. No CKP sensor error.
3. Difference of engine speed
and doubled pump cam-
shaft speed is more than
690rpm.
9 ON Injection Pump Malfunction No pump map programmed in
the PSG (pump control unit)
or PSG malfunction.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is
malfunction in the PSG (pump reduced.
control unit).
B ON Injection Pump Malfunction PSG (pump control unit) rec- No fail-safe function.
ognized high pressure sole-
noid valve drive circuit error.
D ON Injection Pump Malfunction PSG (pump control unit) could
not measure the high pres-
sure solenoid valve drive volt-
age.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid
(pump control unit) message. valve) is operated.
becomes 0mg/strk.

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

Was the DTC P0251 (Symptom Code 6) stored in this Refer to
(OBD) System
4 Was the DTC P0335 (Symptom Code B), P0335 Go to DTC
(Symptom Code D) or P1335 (Symptom Code A) Chart P0335
stored at the same time? (Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
— Code A) Go to Step 5
connection is found, repair the faulty terminal.
C-57(B) 91 E-6


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
CKP Sensor Output Reference Wave Form
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Terminal: 91 (+) 1 (-) to Step 7
Measurement Scale: 5.0V/div 2.0ms/div
Measurement Condition: Engine speed at 2000rpm
Fixed at High:
— Go to Step 13 Go to Step 8

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

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

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

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION

(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more than When pump camshaft speed
Circuit Malfunction 665rpm. sensor is OK:
2. CKP sensor pulse width ECM uses doubled pump cam-
error. shaft speed as substitute
engine speed.
When pump camshaft speed
sensor is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
D ON Crankshaft Position Sensor 1. No pump camshaft speed When pump camshaft speed
Circuit Malfunction sensor error. sensor is OK:
2. “Crankshaft Position Sen- ECM uses doubled pump cam-
sor Circuit Malfunction shaft speed as substitute
(Symptom Code B)” is not engine speed.
stored. Other than pump camshaft
3. Engine speed is 0rpm. speed sensor is OK:
4. Doubled pump camshaft Fuel injection quantity is
speed is more than 50rpm. reduced.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent malfunction:
Range/Performance 5700rpm. 1. MAB (fuel cutoff solenoid
valve) is operated.
becomes 0mg/strk.
When preliminary malfunction:
ECM uses doubled pump cam-
shaft speed as substitute
engine speed.

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

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

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

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

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

4. Check the circuit for open, short to sensor wire or
short to ground circuit.
98
C-57(B) E-9
1 2
101 Repair faulty
90 harness and

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

At CKP sensor terminal 2 & 1 Approximately 1.0 V at
At ECM C57 connector 90 & 98 2000rpm
If a oscilloscope is available, monitor the CKP sensor

signal. Does the oscilloscope indicate correct wave
form?
CKP Sensor Reference Wave Form
0V→
Measurement Terminal: 90 (+) 98(-)

Measurement Scale: 20V/div 2.0ms/div
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.
12 Check the CKP sensor shield wire for open or short Repair faulty
circuit. harness and
Was the problem found? — verify repair Go to Step 13

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

1 2 3
98
90


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

At CKP sensor terminal 2 & 1 Approximately 1.0 V at
At ECM C57 connector 90 & 98 2000rpm
If a oscilloscope is available, monitor the CKP sensor

signal. Does the oscilloscope indicate correct wave
form?
CKP Sensor Reference Wave Form
0V→
Measurement Terminal: 90 (+) 98(-)

Measurement Scale: 20V/div 2.0ms/div
Go to Step 9 Go to Step 7
and visually check.
8 Check the CKP sensor shield wire for open or short Repair faulty
circuit. harness and
Was the problem found? — verify repair Go to Step 9
release?

13 Replace the ECM.

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
Code Code
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function.
Low short to ground circuit.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to volt-
High age circuit.

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

5 Using the DVM and check the glow relay.
2. Remove the glow relay from the relay box.
3. Check the relay coil.
Glow Relay
3 2
Replace glow
relay and verify
Continuity Go to Step 6 repair

6 Using the DVM and check the glow relay power supply
circuit.
circuit.
X-5
V
Battery
7 Repair the open or short to ground circuit between the
ECM main relay and glow relay.
8 Using the DVM and check the glow relay ground
circuit.
circuit.
X-5
3
94

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

release?
10 Replace the ECM.
Glow Relay Circuit Voltage High
(OBD) System
release?
the ECM/Immobiliser linking procedure. — Go to Step 6 —
6 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit
Voltage High short to voltage circuit.
Circuit Description the glow plugs remain active for a certain period
depending on engine coolant temperature.
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated. Diagnostic Aids
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer An intermittent may be caused by the following:
activated. • Poor connections.
In the after glow phase the lamp is not illuminated but
• Rubbed through wire insulation. poor terminal to wire connection.
• Broken wire inside the insulation. • Damaged harness-Inspect the wiring harness for
Check for the following conditions: damage. If the harness appears to be OK, observe
• Poor connection at ECM-Inspect harness connectors the DTC P0381 display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
Glow Plug Indicator Circuit Voltage Low
(OBD) System
4 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “On”? — Go to Step 5 Go to Step 6
2. Check the glow plug indicator lamp.
Does the lamp turn “Off”? — Go to Step 9 Go to Step 7
6 Check the glow plug indicator lamp bulb.

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

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

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

release?
10 Replace the ECM.
Glow Plug Indicator Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED

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

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED

(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
BATTERY
ECM
Main Relay
ECM
10A
0.5
BLU/
0.5 2 RED
BLU/
RED
IAT
Sensor MAF &
EGR- IAT
EVRV Sensor
4 5 3 1
0.5 0.5 0.5 0.5 0.5

URG RED RED RED BLU
97 83 88 92 84
Engine
Control
Module
(ECM) Batt
IC
CPU IC
µP
Code Code
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Excessive Detected between 15°C and 100°C. reduced.
2. Engine coolant temperature
is between 35°C and
100°C.
3. Barometric pressure is
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air flow
- mass air flow is more than
150mg/strk)
4 ON Exhaust Gas Recirculation EGR EVRV circuit open or Fuel injection quantity is
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV 10%
Open Circuit conditions as substitute.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is
Flow Insufficient Detected between 15°C and 100°C. reduced.
2. Engine coolant temperature
is between 35°C and
100°C.
3. Barometric pressure is
between 850hpa and
1100hpa.
4. Large mount of mass air
flow. (Desired mass air
flow - mass air flow is below
150 mg/strk)
8 ON Exhaust Gas Recirculation EGR EVRV circuit short to Fuel injection quantity is
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10%
conditions as substitute.

The amount of EGR is controlled by EVRV (electrical An intermittent may be caused by the following:
vacuum regulating valve) via the engine control module • Poor connections.
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature. • Rubbed through wire insulation.
The EVRV is shaped to control vacuum applied to the • Broken wire inside the insulation.
diaphragm chamber of the EGR valve based on duty • EGR valve sticking.
signal sent from the ECM.
• Faulty intake air duct connection.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored. • Poor connection at ECM-Inspect harness connectors
If the EGR EVRV circuit is open or short ground circuit, for backed out terminals, improper mating, broken
DTC P0400 (Symptom Code 4) is stored. locks, improperly formed or damaged terminals, and
If the EGR EVRV circuit is short to voltage circuit, DTC poor terminal to wire connection.
P0400 (Symptom Code 8) is stored. • Damaged harness-Inspect the wiring harness for
the DTC P0400 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
Exhaust Gas Recirculation Flow Excessive Detected
(OBD) System

4 Remove the MAF & IAT sensor assembly and check
for the following conditions.
• Objects blocking the air cleaner.
• Objects blocking the MAF sensor.
• Vacuum leaking at intake duct.
• Objects blocking the turbocharger.
5 Remove the MAF & IAT sensor assembly and visually
check.
and recheck.
8 Using the DVM and check the EGR EVRV.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
Does the tester indicate standard resistance?
EGR EVRV
2 1
2 1
Approximately
14Ω at 20°C Go to Step 11 Go to Step 9
9 Substitute a known good EGR EVRV and recheck.
10 Replace the EGR EVRV.

11 Using the vacuum pump and check the EGR valve
operation for the following condition through the small
window.
• Restrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Was a problem found?
Small Window
Verify repair or
Vacuum Pump — Go to Step 13 Go to Step 12
12 Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is
stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat. Verify repair or
13 Replace the EGR valve.
release?
15 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
(OBD) System
4 Check for poor/faulty connection at the EGR EVRV or
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

6 Using the DVM and check the EGR EVRV power
supply circuit.
2. Remove the EGR EVRV connector.
C-115
V
Battery
7 Repair the open circuit between the ECM main relay
and EGR EVRV.
8 Using the DVM and check the EGR EVRV circuit.
circuit.
C-115
2
97

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

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

8 Using the vacuum pump and check the EGR valve
operation for the following condition through the small
window.
deposit.
Small Window
Verify repair or
Vacuum Pump — Go to Step 10 Go to Step 9
9 Inspect the EGR valve.
1. Remove the EGR valve from the engine.
2. Inspect the EGR valve whether pintle valve is
stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat. Verify repair or
10 Replace the EGR valve.
Is the action complete? — Verify repair -
C-57(B) 92 C-116
2 3 4
5


circuit.
C-116
5
Repair faulty
V
harness and
and recheck.
release?
17 Replace the ECM.
Exhaust Gas Recirculation Circuit Short to Battery
(OBD) System
4 Check for poor/faulty connection at the EGR EVRV or
C-57 C-115
1 2
coil.
EGR EVRV
2 1
2 1
Approximately

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

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

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT

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

(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed 5km/
at High Input 200km/h. h condition as substitute.
next
igni-
tion
cycle
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed 5km/
at Signal Frequency Too High high. h condition as substitute.
next
igni-
tion
cycle
B ON Vehicle Speed Sensor Incor- 1. Engine speed is more than Fuel injection quantity is
at rect Signal 3600rpm. reduced.
next 2. Fuel injection quantity is
igni- more than 41mg/stk.
tion 3. Vehicle speed is below
cycle 1.5km/h.
Circuit Description • Misrouted harness.

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

4 Perform test drive and check the speed meter.
Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6
5 Perform test drive and use the Tech 2.
Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel? — Go to Step 15 Go to Step 7
6 Remove the VSS from the housing case and visually
check.

7 Using the DVM and check the VSS signal.
1. Ignition “On”, vehicle “Run (lift up)”.
2. Measure the VSS output voltage at sensor, TCM
(A/T 2WD), meter and ECM.
Does the tester indicate specified value?
Measurement Position Voltage (V) If No
(AC Range) Good
VSS terminal 3 & GND Approximately 6.5 Go to
V at 20km/h Step 8
TCM C94 connector 10 & Go to
GND (A/T 2WD) Step 9
Meter B24 connector 9 & Go to
GND Step 10
GND Step 12
ECM C56 connector 68 & Go to
GND Step 13
If a oscilloscope is available, monitor the VSS signal at

each connector connection. Does the oscilloscope
indicate correct wave form?
Vehicle Speed Sensor Reference Wave Form
0V→
Refer to
Measurement Scale: 10V/div 50ms/div Diagnostic Aids
Measurement Condition: Vehicle Speed 20km/h and Go to Step
Measurement Terminal: At Engine Control Module
15 Refer the table
8 Replace the VSS.
Is the action complete? — Verify repair
9 Replace the TCM.
IMPORTANT: The replacement TCM must be
programmed. “SPS (Service Programming System)
is necessary.” — Verify repair —

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

4. Check the circuit for open or shot to ground circuit.
B-24
68
10

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

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

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

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


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

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

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

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

connector.
B-24
10
Repair faulty
V harness and
4. Check the circuit for open or shot to ground circuit.
B-24
68
10

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

release?
18 Replace the ECM.

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH

(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW

(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION (PSG)
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as
20V. substitute.
2 OFF System Voltage Too Low System voltage is below 7V.
A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as
(PSG) (pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
(Symptom Code 1) or P0560 (Symptom Code 2) will be
The ECM and PSG monitors the system voltage on the stored. The system voltage to the PSG excessively high
ignition feed terminal to the ECM or PSG. The system
or low, DTC P0560 (Symptom Code A) will be stored. • Poor connection at ECM and PSG-Inspect harness
Diagnostic Aids mating, broken locks, improperly formed or damaged
An intermittent may be caused by the following:
• Misrouted harness. the “System Voltage” display on the Tech2 while
• Rubbed through wire insulation. moving connectors and wiring harness related to the
• Broken wire inside the insulation. sensor.
System Voltage Too High
(OBD) System
4 Was the battery jump start cable incorrectly Verify
connecting? — procedure Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the Check the
headlights, etc.. charging
Does the Tech 2 indicate correct ignition voltage? 10 - 14V Go to Step 6 system
release?

7 Replace the ECM.
System Voltage Too Low
(OBD) System
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14V Go to Step 6 Go to Step 5
5 Using the DVM and check the battery voltage at the Check the
battery terminal. charging
Does the tester indicate enough battery voltage? system, charge
or replace the
10 - 14V Go to Step 6 battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
C-56
3


7 Using the DVM and check the ECM main relay.
2. Remove the ECM main relay from the relay box.
ECM Main Relay
4 3
Replace ECM
main relay and
Continuity Go to Step 8 verify repair
8 Check for poor/faulty connection of the ECM ground at
the body. If a poor/faulty connection is found, repair as
necessary.
C-109

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

5 Using the DVM and check the PSG (pump control
unit) power supply circuit.
connector.
3. Check the PSG (pump control unit) power supply
circuit.
6 E-6
7 10 - 14V Go to Step 7 Go to Step 6


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


(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
18 P0561 A OFF Ignition Switch Circuit Mal- The ECM recognized ignition ECM stops engine.
function switch turn off signal during
ECM is activated.
B ON Ignition Switch Circuit Mal- Ignition switch circuit is mal-
function function.
Circuit Description P0561 (Symptom Code B) will be stored.

The ECM monitors the ignition switch signal on the feed
Diagnostic Aids
terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC An intermittent may be caused by the following:
• Poor connections. locks, improperly formed or damaged terminals, and
• Misrouted harness. poor terminal to wire connection.
• Rubbed through wire insulation. • Damaged harness-Inspect the wiring harness for
• Broken wire inside the insulation.
the “Ignition Status” display on the Tech2 while
• Poor connection at ECM-Inspect harness connectors sensor.
for backed out terminals, improper mating, broken
Ignition Switch Circuit Malfunction
Ignition Switch Circuit Malfunction
(OBD) System
Is the DTC P0561 (Symptom Code A) or P0561 and Go to Step
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P0561 (Symptom Code A) or P0561 and Go to Step
(Symptom Code B)stored in this ignition cycle? — Go to Step 4 4
4 Check the “Engine fuse (10A)”.

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

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

8 Replace the ECM.
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR

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

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

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

(FLASH CODE 28) ECU MALFUNCTION

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

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

5 Replace the ECM.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
ECM Battery Heater

ECM Glow A/C

10A 50A 10A
0.5 5.0 0.5 0.5 BRN 0.5

BLU/ RED/ BLU/ BLU/
RED WHT RED RED
Glow A/C A/C

Relay Relay
5.0
BLK/
RED
0.5
0.5 GRY/
BRN/ YEL
YEL Resister
Glow A/C Tripple
BLK SW
0.5 0.5 0.5

BLK/ BRN/ GRN
BLU RED
94 41 33
Engine
Control
Module
(ECM) Batt Batt
IC
µP µP
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit
Voltage High short to voltage circuit.

The voltage on the coil of the A/C compressor is An intermittent may be caused by the following:
supplied by the ECM main relay. The ECM switches A/C • Poor connections.
compressor relay to operate A/C compressor depends
on the A/C request signal and certain setting conditions.
Check for the following conditions: • Damaged harness-Inspect the wiring harness for
• Poor connection at ECM-Inspect harness connectors damage. If the harness appears to be OK, observe
for backed out terminals, improper mating, broken the DTC P0645 display on the Tech2 while moving
locks, improperly formed or damaged terminals, and connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
(OBD) System
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
C-56 1 X-14
2
3

5 Using the DVM and check the A/C compressor relay.
2. Remove the A/C compressor relay from the relay
box.
A/C Compressor Relay
X-14
3 4
Replace A/C
compressor
relay and verify
Continuity Go to Step 6 repair

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

8 Using the DVM and check the A/C compressor relay
ground circuit.
disconnected)
box.
circuit.
X-14
33

box.
circuit.
C-56 X-14
33 4
Repair faulty
harness and
release?
10 Replace the ECM.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 25) BRAKE SWITCH INCORRECT SIGNAL (1)

(FLASH CODE 25) BRAKE SWITCH INCORRECT SIGNAL (2)
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
25 P0703 A ON Brake Switch Incorrect Signal 1. Throttle position is more No fail-safe function.
(1) than 0%.
665rpm.
3. Vehicle speed is more than
0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.
B ON Brake Switch Incorrect Signal 1. Throttle position is more
(2) than 0%.
665rpm.
0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM.
Circuit Description • Rubbed through wire insulation.

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

4 Check the “Stop Lamp fuse (15A)”.
5 Check for poor/faulty connection at the brake switch or
C-56 C-44
1 2

6 Using the DVM and check the brake switch 1.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 1.
Brake Switch
4 3 Pedal is not
stepped on:
Continuity
Pedal stepped Replace pedal
on: No switch and
continuity Go to Step 7 verify repair
7 Using the DVM and check the brake switch 1 power
supply circuit.
2. Remove the brake switch connector from the
brake switch.
C-44
V
Battery

8 Repair the open circuit between the “Stop Lamp fuse
(15A)” and brake switch 1.
9 Using the DVM and check the brake switch 1 circuit.
4. Check the circuit for open or short to voltage
circuit.
30

2. Back probe the DVM to the brake switch 1 and
check the circuit for open or short to voltage
circuit.
C-44
2 Pedal is not Fixed at battery

stepped on: voltage: Go to
Less than 1V Step 10
Pedal stepped Fixed at less
V
on: Battery than 1V: Go to
voltage Go to Step 12 Step 11
10 Repair the short to voltage circuit between the brake
switch 1 connector and ECM.
C-56 C-44
30 2
11 Repair the open circuit between the brake switch 1
connector and ECM.
C-56 C-44
30 2

release?
13 Replace the ECM.
Brake Switch Malfunction
(OBD) System
4 Check for poor/faulty connection at the brake switch or
C-56 C-44
3 4
5 Using the DVM and check the brake switch 2.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.
Brake Switch
4 3
Pedal is not
stepped on:
No continuity Replace pedal
Pedal stepped switch and
on: Continuity Go to Step 6 verify repair

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

2. Back probe the DVM to the brake switch 2 and
circuit.
C-44
Pedal is not
stepped on: Fixed at battery
4 Battery voltage: Go to
voltage Step 9
Pedal stepped Fixed at less
V
on: Less than than 1V: Go to
1V Go to Step 11 Step 10

9 Repair the short to voltage circuit between the brake
switch 2 connector and ECM.
C-56 C-44
65 4
10 Repair the open circuit between the brake switch 2
connector and ECM.
C-56 C-44
65 4
release?
12 Replace the ECM.

(FLASH CODE 57) CLUTCH SWITCH CIRCUIT MALFUNCTION
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
57 P0704 6 ON Clutch Switch Circuit Malfunc- Clutch signal does not change No fail-safe function.
tion between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.

The ECM monitors the clutch switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If clutch switch circuit with Check for the following conditions:
malfunction, DTC P0704 (Symptom Code 6) will be • Poor connection at ECM-Inspect harness connectors
stored. for backed out terminals, improper mating, broken
Diagnostic Aids poor terminal to wire connection.
• Poor connections. the “Clutch Switch” display on the Tech2 while moving
• Misrouted harness. connectors and wiring harness related to the sensor.
Clutch Switch Circuit Malfunction
(OBD) System
4 Check for poor/faulty connection at the clutch switch
or ECM connector. If a poor/faulty connection is found,
31 C-56 C-77
1
2

5 Using the DVM and check the clutch switch.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch
Pedal is not
1
stepped on:
2 Continuity
Pedal stepped Replace pedal
on: No switch and
continuity Go to Step 6 verify repair

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

2. Back probe the DVM to the clutch switch and
circuit.
C-77
Pedal is not
stepped on: Fixed at battery
2 Battery voltage: Go to
voltage Step 9
V Pedal stepped Fixed at less
on: Less than than 1V: Go to

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

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT

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

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

5 Replace the ECM.

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

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

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

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

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
TPS &
Idle SW ECT CKP
Sensor Sensor
0.5
BLK
0.5 0.5 0.5 0.5 2.0 2.0 0.5 0.5 0.5 0.5
BLK PNK
69 49 38 57 1 2 93 89 98 101 90
Engine
Control
Module
(ECM)
IC IC IC
IC
Code Code
21 P1120 1 ON Pedal/Throttle Position Sen- Throttle position sensor out- ECM increases idle speed up
sor Circuit High Input put voltage is more than 4.5V. to 1400rpm.
7 ON Pedal/Throttle Position Sen- Throttle position sensor power
sor Voltage Supply Circuit supply voltage is more than
High Input 5.2V.
9 ON Pedal/Throttle Position Sen- Throttle position sensor power
sor Voltage Supply Circuit supply voltage is below 4.6V.
Low Input
D ON Pedal/Throttle Position Sen- 1. Engine speed is more than
sor Brake Switch Error 1700rpm.
1.5km/h.
3. When brake pedal is
depressed during accelera-
tor pedal is depressing.
E ON Pedal/Throttle Position Sen- 1. When idle switch is turned
sor Idle Position Switch Error off, throttle position sensor
was below 0.35%.
or
2. When idle switch is tuned
on, throttle position sensor
was more than 7.8%.

The TPS is a potentiometer connected to throttle shaft An intermittent may be caused by the following:
on the throttle body. It is installed to the main TPS and • Poor connections.
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the • Rubbed through wire insulation.
throttle valve angle is changed when accelerator pedal • Broken wire inside the insulation.
moved. The TPS signal also changed at a moved Check for the following conditions:
throttle valve. As the throttle valve opens, the output • Poor connection at ECM-Inspect harness connectors
increases so that the output voltage should be high. for backed out terminals, improper mating, broken
The ECM monitors the TPS supply voltage and TPS locks, improperly formed or damaged terminals, and
output voltage. The supply voltage is out of range, DTC poor terminal to wire connection.
P1120 (Symptom Code 7) or P0100 (Symptom Code 9)
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
the “Throttle Position”, “Idle Switch”, “Brake Switch 1”
If the brake pedal is depressed during accelerator pedal
and “Brake Switch 2” display on the Tech2 while
is depressing, DTC P1120 (Symptom Code D) will be
stored.
sensor.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.
Pedal/Throttle Position Sensor Circuit High Input
(OBD) System

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

5 Visually check the TPS.

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

Terminal
Approximately 0.5kΩ at idle position
1-2
Approximately 4.0kΩ at WOT
Approximately 4.3kΩ at idle position
2-3
Approximately 0.8kΩ at WOT
1-3 Approximately 4.6kΩ at idle position & WOT
TPS
3 2 1
3 2 1
Standard
7 Using the DVM and check the TPS power supply
circuit.
2. Disconnect the TPS connector.
E-22
3
V
Approximately
and TPS.
C-56
57
E-22


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

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

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


circuit.
E-22
3
V Approximately
7 Repair the short to battery voltage circuit between the
ECM and TPS.
C-56
57
E-22

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


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

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

11 Replace the TPS.

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

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

11 Replace the ECM.

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

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE
Code Code
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine cool- No fail-safe function.
High Coolant Temperature ant temperature is detected.
7 OFF Fuel Reduction Caused By Fuel temperature is more than PSG (pump control unit) con-
High Fuel Temperature 100Åé. trols fuel injection quantity
based on engine speed and
fuel temperature.
Circuit Description An intermittent may be caused by the following:

The engine coolant temperature (ECT) sensor is • Poor connections.
installed on the coolant stream. High coolant • Misrouted harness.
temperature produces a low resistance. The ECM • Rubbed through wire insulation.
supplies 5 volts signal to the ECT sensor through • Broken wire inside the insulation.
resisters in the ECM and measures the voltage. The Check for the following conditions:
signal voltage will be low when the engine temperature
is hot.
The fuel temperature sensor is assembled inside of the
pump control unit (PSG). The signal of fuel temperature
is sent via the CAN-bus from the PSG to ECM.
If the engine coolant temperature is excessively high • Damaged harness-Inspect the wiring harness for
condition, DTC P1173 (Symptom Code 3) will be stored. damage. If the harness appears to be OK, observe
If the fuel temperature is excessively high condition, the “Coolant Temperature” or “Fuel Temperature”
DTC P1173 (Symptom Code 7) will be stored. display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
(OBD) System

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

-30 27500
-20 16100
0 5760
20 2370
40 1080
60 537
80 290
100 161
120 95
ECT Sensor
2 1
2 1
Standard
recheck.
release?

10 Replace the ECM.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction is recognized defective reduced.
engine speed signal form the
ECM.

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


6 If a oscilloscope is available, monitor the CKP sensor
output signal. Does the oscilloscope indicate correct
wave form?
CKP Sensor Output Reference Wave Form
0V→
Not available:
Go to Step 7
Fixed at low: Go
Measurement Terminal: 91 (+) 1 (-) to Step 7
Measurement Scale: 5.0V/div 2.0ms/div Fixed at High:

circuit.
connector.
circuit.
E-6
91

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

release?
12 Replace the ECM.

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function.
is recognized incorrect cam-
shaft speed signal.

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

(FLASH CODE 47) NEUTRAL SWITCH ON ERROR

(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Battery
Voltage
Ignition
Battery SW
Voltage
ECM
Main Relay

A/T 10A 15A 15A 15A
TCM M/T
0.5 0.85 0.5 0.5 0.85 A/T
RED RED RED
SW SW SW N P SW
0.85 0.5 0.5

RED RED/ YEL/
Pump
Stop
0.5 2.0 0.5 Lamp 0.5 0.5
RED RED
WHT
58 3 65 30 63 31 87 39
Engine
Control
Module Batt Batt
(ECM)
µP
IC CPU
IC
Code Code
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function.
ted “On” three times consecu-
tively under driving conditions.
B ON Neutral Switch OFF Error Neutral switch signal is input-
ted “Off” three times consecu-
tively under driving conditions.

The ECM monitors the neutral switch (A/T: N or P An intermittent may be caused by the following:
position switch in inhibitor switch) signal on the feed • Poor connections.
terminal to the ECM. If the neutral switch with
malfunction, DTC P1520 (Symptom Code A) or P1520
(Symptom Code B) will be stored. • Rubbed through wire insulation.
for backed out terminals, improper mating, broken the “Neutral Switch” display on the Tech2 while
locks, improperly formed or damaged terminals, and moving connectors and wiring harness related to the
poor terminal to wire connection. sensor.
Neutral Switch ON Error
Neutral Switch OFF Error
(OBD) System
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1520 (Symptom Code A) or P1520 and Go to Step
(Symptom Code B) stored in this ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the neutral switch
(inhibitor switch) or ECM connector. If a poor/faulty
C-57
87
M/T
E-11 E-12
A/T
E-51
2 3


5 Using the DVM and check the neutral switch (inhibitor
switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range N range
switch).
M/T
E-11 E-12
A/T
3 2
Neutral (P or
6 5 4 3 2 1 N): Continuity
Other than Replace neutral
10 9 8 7
neutral (P or switch (inhibitor
N): No switch) and
8 continuity Go to Step 6 verify repair
switch) power supply circuit.
2. Remove the neutral switch (inhibitor switch)
connector from the switch.
M/T A/T
E-12 E-51
V 3
V
Battery
and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).

switch) circuit.
circuit.
87

2. Back probe the DVM to the neutral switch (inhibitor
switch) and check the circuit for open or short to
voltage circuit.
M/T A/T
E-11 E-51
Neutral (P or
N): Battery Fixed at battery
voltage voltage: Go to
2 8 Other than Step 9
V neutral (P or Fixed at less
V V N): Less than than 1V: Go to
9 Repair the short to voltage circuit between the neutral
switch connector (inhibitor switch connector) and
ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8

10 Repair the open circuit between the neutral switch
connector (inhibitor switch connector) and ECM.
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8
release?
12 Replace the ECM.

(FLASH CODE 55) SEED AND KEY FILE DESTROYED

(FLASH CODE 55) EEPROM DEFECT

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

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

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E) Refer to
stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
release?
5 Replace the ECM.

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1610 A - Security Key and Security Immobiliser functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.

The ECM decides whether that is an abnormality in the Check for the following conditions:
immobiliser control system. DTC P1610 (Symptom • Poor connection at ECM and immobiliser control unit-
Code A) is recorded when immobiliser function was not Inspect harness connectors for backed out terminals,
programmed in the ECM. improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
connectors and wiring harnesses.
Security Key and Security Code Not Programmed
(OBD) System
Refer to
2. Select “Immobiliser” in the system selection menu “Immobiliser
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnostic Trouble Code”. to DTC Chart
Was the any DTC's B**** stored in this ignition cycle? — B**** Go to Step 5
release?
6 Replace the ECM.

(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1611 A - Wrong Security Code Entered Received security code is not 1. Engine does not start.
correct. 2. Check engine lamp flash.

Code A) is recorded when received immobiliser security Inspect harness connectors for backed out terminals,
code was not correct. improper mating, broken locks, improperly formed or
connection.
Wrong Security Code Entered
(OBD) System
Refer to
release?
6 Replace the ECM.

(FLASH CODE 56) IMMOBILISER NO OR WRONG SIGNAL
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1612 A - Immobiliser No or Wrong Sig- Received challenge signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

Code A) is recorded when received immobiliser Inspect harness connectors for backed out terminals,
challenge signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobiliser No or Wrong Signal
(OBD) System
Refer to
“Diagnositic Trouble Code”. to DTC Chart
5 Check for poor/faulty connection at the immobiliser
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68
8

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

lamp circuit.
3. Disconnect the immobiliser control unit connector.
circuit.
B-68
42

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

8 Using the DVM and check the ECM and immobiliser
control unit communication circuit.
B-68
8
V Repair faulty
harness and
circuit.
B-68
35

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

release?
11 Replace the ECM.

(FLASH CODE 56) IMMOBILISER NO OR WRONG SIGNAL
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1613 A - Immobiliser No or Wrong Sig- Received response signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.

response signal was not correct. improper mating, broken locks, improperly formed or
connection.
Immobiliser No or Wrong Signal
(OBD) System
Refer to
“Diagnositic Trouble Code”. to DTC Chart
5 Check for poor/faulty connection at the immobiliser
control unit connector or ECM connector. If a poor/
C-56 42
35
B-68
8

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

lamp circuit.
circuit.
B-68
42

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

circuit.
B-68
35

circuit.
C-56
B-68 35
Repair faulty
harness and
release?
11 Replace the ECM.

(FLASH CODE 56) WRONG TRANSPONDER KEY
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start.
not correct from the transpon- 2. Check engine lamp flash.
der key.

response signal was not correct from the transponder improper mating, broken locks, improperly formed or
key. damaged terminals, and poor terminal to wire
connection.
Wrong Transponder Key
(OBD) System
Refer to
release?
6 Replace the ECM.
IMPORTANT: The replacement ECM must e

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function.
Off Too Early turned off, timing of the ECM
main relay turning off is too
early.
B OFF ECM Main Relay Switched When ignition switch was
Off Too Late turned off, timing of the ECM
main relay turning off is too
late or does not off.

The ECM switches ECM main relay to operate ECM and An intermittent may be caused by the following:
other sensors or controller. • Poor connections.
• Poor connection at ECM-Inspect harness connectors the “Main Relay” display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early
(OBD) System
release?
5 Replace the ECM.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late
(OBD) System
4 Using the DVM and check the ECM main relay.
2. Remove the ECM main relay from the relay box.
3. Check the relay switch.
ECM
Main Relay
1
Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
release?
6 Replace the ECM.

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
51 P1630 A ON Fuel Injection Quantity Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction detects high pressure sole- reduced.
noid valve control circuit mal-
function due to high current.
B ON Fuel Injection Quantity Circuit The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
Malfunction detects high pressure sole- valve) is operated.
noid valve control circuit mal- 2. Desired injection quantity
function due to continuous becomes 0mg/strk.
current.
Circuit Description programmed pump map data.

The ECM is calculates an injection quantity and an
injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
Diagnostic Aids • Broken wire inside the insulation.
• Poor connections. connectors for backed out terminals, improper
• Misrouted harness. mating, broken locks, improperly formed or damaged
• Rubbed through wire insulation. terminals, and poor terminal to wire connection.
Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction
Injection Quantity Circuit Malfunction
(OBD) System
(symptom Code B) stored as “Present Failure”? — Go to Step 3 3
Was the DTC P1630 (Symptom Code A) or P1630 Refer to
(symptom Code B) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids

(FLASH CODE 44) CAN DEVICE OFFLINE

(FLASH CODE 44) CAN DEVICE HANG-UP
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid
off or canceling. valve) is operated.
B ON CAN Device Hang-up CAN controller does not react
under engine running.

The interchange of data between the engine control An intermittent may be caused by the following:
module (ECM) and the pump control unit (PSG) is • Poor connections.
performed via a CAN-bus system. The individual CAN-
bus systems are connected via two interfaces and can
exchange information and data. This allows control • Rubbed through wire insulation.
modules that are connected to different CAN-bus • Broken wire inside the insulation.
systems to communicate. Check for the following conditions:
• Poor connection at ECM and PSG-Inspect harness • Damaged harness-Inspect the wiring harness for
connectors for backed out terminals, improper damage. If the harness appears to be OK, observe
mating, broken locks, improperly formed or damaged the DTC P1650 display on the Tech2 while moving
terminals, and poor terminal to wire connection. connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44) CAN
Device Offline
(OBD) System
C-57 E-6 2
1
6 Using the DVM and check the CAN high circuit.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 7 verify repair

connector.
circuit.
E-6
100

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

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

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

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
99 1 — Verify repair —
unit) ground circuit.
connector.
E-6
6
Repair faulty
harness and

interference. accessory parts
release?
17 Replace the ECM.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44) CAN
Device Hang-up
(OBD) System
release?
6 Replace the ECM.

(FLASH CODE 45) CAN MALFUNCTION (PSG)

(FLASH CODE 45) CAN RECEIVES ERROR
Battery
Voltage Battery
Voltage
ECM Meter
Main Relay 10A
ECM Fuse
0.5
RED/
A/T 2.0 YEL
BLU/
TCM RED
7 16 15 14 13 12 11 10 9
Injection 8 7 6 5 4 3 2 1
Pump
2 1 5 8 6 1.25
2.0 BLK
BLK
0.5 2.0 0.5 0.5 0.5 0.5

BLK RED BLU
58 3 100 99 105 91 45
Engine
Control
Module Batt
(ECM) CAN
Controller
µP µP
Batt
IC
µP
Code Code
45 P1651 A ON CAN Malfunction (PSG) The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
does not recognize CAN sig- valve) is operated.
nal from the CAN controller. 2. Desired injection quantity
becomes 0mg/strk.
B ON CAN Receives Error The ECM does not read CAN
signal from the PSG (pump
control unit).
Circuit Description systems to communicate.

The interchange of data between the engine control Diagnostic Aids
module (ECM) and the pump control unit (PSG) is
performed via a CAN-bus system. The individual CAN- An intermittent may be caused by the following:
bus systems are connected via two interfaces and can • Poor connections.
exchange information and data. This allows control
modules that are connected to different CAN-bus
• Rubbed through wire insulation. terminals, and poor terminal to wire connection.
• Poor connection at ECM and PSG-Inspect harness the DTC P1651 display on the Tech2 while moving
connectors for backed out terminals, improper connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45) CAN
Malfunction (PSG)
(OBD) System
release?
6 Replace the ECM.
Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45) CAN
Receives Error
(OBD) System
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
C-57 E-6 2
1
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 8 verify repair

connector.
circuit.
E-6
100

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

connector.
circuit.
E-6
99

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

C-57 E-6
100 2
connector.
approximately 5V?
E-6
1
V
C-57 E-6
99 1 — Verify repair —
unit) ground circuit.
connector.
E-6
6
Repair faulty
harness and

interference. accessory parts
release?
18 Replace the ECM.

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Battery Ignition
Voltage SW
Meter
15A
0.85 0.85
YEL YEL
A/T A1 4P out
Engine
Tacho
Check
Meter
Glow
Imnobiliser
TCM VSS
Control Unit
A16 A7 A10 7 8
0.5
BLK/
YEL
0.5
BRN/
YEL
0.5 0.5 0.5 0.5 0.5 0.5

WHT BLU YEL RED WHT
29 43 42 27 68 35
Engine
Control
Module Batt Batt
(ECM)
IC
µP µP µP µP
Code Code
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function.
Circuit Voltage Low open or short to ground cir-
cuit.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit
Circuit Voltage High short to ground circuit.

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


8 Using the DVM and check the “Check Engine” lamp
circuit.
circuit.
B-24
42
17

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

10 Replace the ECM.
Check Engine Lamp (MIL) Circuit Voltage High
(OBD) System
release?
6 Replace the ECM.
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS Road test the vehicle with a Digital Multimeter
connected to a suspected circuit. An abnormal voltage
Before using this section, perform the “On-Board when the malfunction occurs is a good indication that
Diagnostic (OBD) System Check” and verify all of the there is a fault in the circuit being monitored.
following items: Using Tech 2 to help detect intermittent conditions. The
• The engine control module (ECM) and check engine Tech 2 have several features that can be used to located
lamp (MIL=malfunction indicator lamp are operating an intermittent condition. Use the following features to
correctly. find intermittent faults:
• There are no Diagnostic Trouble Code(s) stored.
• Tech 2 data is within normal operating range. Refer to To check for loss of diagnostic code memory, disconnect
Typical Scan Data Values. the MAF sensor and idle the engine until the check
engine lamp (MIL=malfunction indicator lamp) comes
• Verify the customer complaint and locate the correct
on. Diagnostic Trouble Code P0100 should be stored
symptom in the table of contents. Perform the
and kept in memory when the ignition is turned OFF.
procedure included in the symptom chart.
If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
VISUAL/PHYSICAL CHECK P0100 from memory.
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a An intermittent check engine lamp (MIL=malfunction
problem without further checks and can save valuable indicator lamp) with no stored Diagnostic Trouble Code
time. This check should include the following items: may be caused by the following:
• ECM grounds for cleanliness, tightness and proper • Check engine lamp (MIL=malfunction indicator lamp)
location. wire to ECM short to ground.
• Vacuum hoses for splits, kinks, and proper • Poor ECM grounds. Refer to the ECM wiring
connection. Check thoroughly for any type of leak or diagrams.
restriction.
• Air intake ducts for collapsed or damaged areas. Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
• Air leaks at throttle body mounting area, mass air flow to the ignition control module for poor connections.
(MAF) sensor and intake manifold sealing surfaces. Check for an open diode across the A/C compressor
• Wiring for proper connections, pinches and cuts. clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
INTERMITTENT
If problem has not been found, refer to ECM connector
Important: An intermittent problem may or may not turn
symptom tables.
on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use • Check the “Broadcast Code” of the ECM, and
the Diagnostic Trouble Code (DTC) charts for compare it with the latest Isuzu service bulletins and/
intermittent problems. or Isuzu EEPROM reprogramming equipment to
The fault must be present to locate the problem. determine if an update to the ECM's reprogrammable
Most intermittent problems are cased by faulty electrical memory has been released.
connections or wiring. Perform a careful visual/physical
check for the following conditions. This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
• Poor mating of the connector halves or a terminal not
If the “Broadcast Code” is not the most current available,
fully seated in the connector (backed out).
it is advisable to reprogram the ECM's EEPROM
• Improperly formed or damaged terminal. memory, which may either help identify a hard-to find
• All connector terminals in the problem circuit should problem or may fix the problem.
be carefully checked for proper contact tension. The Service Programming System (SPS) will not allow
• Poor terminal-to-wire connection. This requires incorrect software programming or incorrect calibration
removing the terminal form the connector body to changes.
check.
• Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
• Poor ECM grounds. Refer to the ECM wiring
diagrams.
ENGINE CRANKS BUT WILL NOT RUN

DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobiliser system, this system may be activated. Check the immobiliser system diagnosis.

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

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

and check for the following conditions.
11 Check the CKP sensor harness for the following
conditions.
• Check for poor connector connection.
• Check for misrouted harness.
• Check for any accessory parts which may cause
electric interference.
14 Using the vacuum pump and check the exhaust
throttle valve (if equipped) operation for the following
condition.
deposit.

15 Check the exhaust system for a possible restriction.
• Damaged or collapsed pipes or catalytic converter.
• Internal muffler failure.
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
19 Check the engine compression pressure for each
cylinders.
More than 30
Mpa (31.0 kg/
cm2) Verify repair Go to Step 20
20 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
Repair as
— Go to Step 21 necessary

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
release?
24 Replace the ECM.
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.

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

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

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
16 Remove the injection nozzles from the engine and
check for the following conditions.
• Improper splay condition.
• Operating pressure is incorrect.
1st Stage 2nd Stage

Replace the
20.0 - 21.0 Mpa 34.3 - 35.8 Mpa injection nozzle
(204 - 214 kg/cm2) (350 - 365 kg/cm2)
— and verify repair Go to Step 17
cylinders.
More than 30
Mpa (31.0 kg/

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

(In/Ex) Go to Step 19 verify repair
following:
• Tech 2 data
and/or system
release?
22 Replace the ECM.
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM

DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed may
vary in RPM. Either condition may be severe enough to
rpm
stall the engine.
X
Rough Idle
Stall
time

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

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

3. Adjust the accelerator cable or TPS within 0% to
100%.
18 Check the TPS harness for the following conditions.
20 Replace the TPS.
conditions.

25 1. Using the Tech 2 and ignition “On” and engine
“Run”.
2. Monitor the following parameters in the data
display.
• “Desired Injection Quantity” & “Injection Quantity”
• “Desired Injection Start” & “Actual Injection Start”
Are the large gap or unstable parameter displayed
between “Desired” and “Actual”?
When idling or part-throttle
Desired
High
Actual
Low
Time
26 Using the vacuum pump and check the EGR valve (if
equipped) operation for the following condition through
the small window.
deposit.
Small Window
Vacuum Pump

condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage Replace the

(204 - 214 kg/cm2) (350 - 365 kg/cm2)
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
38 Replace the ECM.
SURGES AND/OR CHUGS SYMPTOM

DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time

(OBD) System
intake system
display.

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

conditions.
“Run”.
display.
When idling or part-throttle When accelerated
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window
Vacuum Pump — Verify repair Go to Step 25


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify
following:
• Tech 2 data
and/or system
release?

31 Replace the ECM.
HESITATION, SAG, STUMBLE SYMPTOM

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

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

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

conditions.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

fuel hose/pipe.
fuel.

fuel.
Replace the eye

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

CUTS OUT, MISSES SYMPTOM

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

(OBD) System
intake system
compressor
wheel or turbine shaft sticking.

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

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

100%.
20 Replace the TPS.
conditions.

“Run”.
display.
When idling or part-throttle

Desired
High
Actual
Low
Time
the small window.
deposit.
Small Window

fuel hose/pipe.
fuel.

fuel.
Replace the eye

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

LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM

DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.

(OBD) System
intake system
sensor value.

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

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window

condition.
deposit.


fuel hose/pipe.
fuel.
fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

Replace the
(204 - 214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

32 Replace the ECM.
POOR FUEL ECONOMY SYMPTOM

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

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

display.
intake system
sensor value.
conditions.

and recheck.
100%.
26 Replace the TPS.
1st Stage 2nd Stage

Replace the
(204 - 214 kg/cm2) (350 - 365 kg/cm2)

cylinders.
More than 30
Mpa (31.0 kg/
valves.

following:
• Tech 2 data
and/or system
release?

33 Replace the ECM.
EXCESSIVE WHITE SMOKE

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

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

conditions.

“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
fuel hose/pipe.
fuel.

fuel.
Replace the eye

bolt with gauze
filter and verify
1st Stage 2nd Stage

Replace the
20.0 - 21.0 Mpa 34.3 - 35.8 Mpa
(204 - 214 kg/cm2) (350 - 365 kg/cm2)
injection nozzle
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
32 Replace the ECM.
EXCESSIVE BLACK SMOKE

(OBD) System
intake system
sensor value.

conditions.
and recheck.
“Run”.
display.
Desired Desired
High High
Actual
Actual
Low Low
Time Time
the small window.
deposit.
Small Window


condition.
deposit.

1st Stage 2nd Stage Replace the

(204 - 214 kg/cm2) (350 - 365 kg/cm2) — and verify repair Go to Step 19
cylinders.
More than 30
Mpa (31.0 kg/

valves.

following:
• Tech 2 data
and/or system
release?
24 Replace the ECM.
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE tightening torque.

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

SENSOR (ECT) SENSOR
Location Location
Installed to the clutch housing. Installed to the thermostat housing.
Removal Procedure Removal Procedure

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

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

not stored after replacement.
Verify no engine coolant leaking from the sensor
threads after replacement.
MASS AIR FLOW (MAF) & INTAKE THROTTLE POSITION SENSOR (TPS)
AIR TEMPERATURE (IAT) SENSOR Location
Location Installed on the throttle body.
Installed to the intake duct housing.
Removal Procedure
Removal Procedure 1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable. 2. Disconnect the TPS connector.
2. Disconnect a MAF & IAT sensor connector from the 3. Loosen two screws and remove TPS from the
MAF & IAT sensor assembly. throttle body.
3. Loosen the clips and remove the MAF & IAT sensor
assembly from the intake duct housing.
1. Temporary tighten the TPS by two screws.
Installation Procedure 2. Connect a TPS connectors to the TPS.
1. Install the MAF & IAT sensor assembly into intake 3. Connect the Tech2 to the vehicle.
air duct. 4. Connect the negative battery cable.
2. Tighten the clips. 5. Select “Data Display” with the Tech2.
3. Connect a MAF & IAT sensor connector to the MAF 6. Check the throttle position data and adjust the TPS
& IAT sensor assembly. position.
4. Connect the negative battery cable. 7. Tighten two screws.
NOTE: Verify any DTCs (diagnosis Trouble Code) are NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement. not stored after replacement.
EGR EVRV (Electrical Vacuum

Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.
NOTE: Verify any DTCs (diagnosis Trouble Code) are

not stored after replacement.
Verify proper connection of two hoses.
SPECIAL SERVICE TOOLS

ILLUSTRATION TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
4JHED-WE-0321
You are requested to order this manual using the

manual number that is shown above.
All rights reserved, This manual may not be reproduced

in whole or in part, without the permission in writing of
ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
No.4JHED-WE-0321 PRINTED IN JAPAN

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WORKSHOP MANUAL

ENGINE DRIVEABILITY AND EMISSIONS

All material contained in this Manual is based on the latest product

Applicable Model : TFR/S 77

This manual is applicable to 2003 year model and later vehicles.

(1) Throttle Position Sensor (TPS) (3) Injection Pump Assembly

(1) Engine Control Module (ECM) (1) EGR EVRV

(1) Engine Coolant Temperature (ECT) Sensor 2 1

(1) Vehicle Speed Sensor (VSS)

Green Meter-B ECM-A

White J/B I2 ECM-B

White J/B I4 Clutch switch

Black Check connector White TCM

White Ignition switch (IGSUB : G1) White TCM

White Ignition switch (IGSUB : G2) White J/B E2

Immobiliser White J/B E1

Silver Engine room-RH ground Silver Body-LH ; ground

Silver Engine room-LH ; Ground Brown EVRV

White Stop lamp switch

No. Connector face No. Connector face

A/C Resister & Neutral switch Gray Vehicle speed sensor

Black Magnetic clutch AC COMP Gray Glow plug

Black Inhibiter switch

White Engine room ~ Mission

Silver Engine ground White Engine room ~ INST

Brown TPS 1 main White Engine ~ Engine room C

Gray Idle SW Engine ~ Engine room

Black Coolant temp sensor Silver Battery (+)

No. Connector face No. Connector face

Silver Relay & Fuse box

Silver Battery (-)

Silver Body earth (Ground)

Silver Engine ground

Black Relay ; Glow

Black Relay ; ECM MAIN

Black Relay; A/C Compressor

Black Relay; Thermo

RELAY & FUSE BOX

SLOW BLOW FUSE

0.5 2.0 0.5 0.5 0.5 0.5

A/T A1 Engine 4P out

0.5 0.5 0.5 0.5 0.5 0.5

ECM Stop Back up Engine

0.85 0.5 0.5

ECM Battery Heater

ECM Glow A/C

0.5 5.0 0.5 0.5 BRN 0.5

Glow A/C A/C

0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5

ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into ECM Case

Signal or Continuity Tester Position

Signal or Continuity Tester Position

Signal or Continuity Tester Position

PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case