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• Page 1
  WORKSHOP MANUAL 2011MY TF SERIES ENGINE 4JA1/4JH1 MODELS SECTION 6 Isuzu Motors Limited E-Solutions & Service Marketing Dept.
• Page 3
  TROUBLESHOOTING 6 – 1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS PAGE PAGE BASIC INSPECTION PROCEDURE..6– 2 11. ROTATING PART WEAR OF TURBOCHARGER……6– 14 1. HARD STARTING……6– 3 12. OIL LEAKAGE FROM 1-1.Starter Motor Inoperative ..6– 3 TURBOCHRGER ……..6– 15 1-2. Starter Motor Operates But 13.
• Page 4
  6 – 2 TROUBLESHOOTING Basic Inspection Procedure Follow the under inspection procedure, when the problem vehicle comes workshop. Step Inspection point Inspection result Check the check engine lamp Is the check engine lamp turn Go to section ON ? 6E “On Board Diagnostic (OBD) System Check»…
• Page 5
  TROUBLESHOOTING 6 – 3 1. Hard Starting Inspect the following items before diagnosis. 1. The battery conditions. The terminal connection condition. The battery charge condition or battery power weakness. 2. The fan belt loosen or broken. 3. The main fuse condition (open or not). 4.
• Page 6
  6 – 4 TROUBLESHOOTING 1-3 Engine turn over but does not start engine Incase of the fuel not being delivered to the injection pump Step Action Value(s) Check clogged, damaged the fuel piping or the — connector loosen. Repair replace Was any problem found? problem parts.
• Page 7
  TROUBLESHOOTING 6 – 5 2. Unstable Idling Step Action Value(s) Was the fuel line air bled completely? — Go to Step 3 Bleed the air Was the fuel line leakage or blockage found? — Repair or replace relation parts. Go to Step 4 Was the water contained in the fuel? —…
• Page 8
  6 – 6 TROUBLESHOOTING 3. Insufficient Power Step Action Value(s) Was the air cleaner element condition OK? (Clogged — Clean or or not) replace the air cleaner Go to Step 2 element. Was the intake air leakage found from intake —…
• Page 9
  TROUBLESHOOTING 6 – 7 4. Excessive Fuel Consumption Step Action Value(s) Was the air cleaner element clogged? — Clean or replace the air cleaner element. Go to Step 2 Was the air leakage found from the air intake side of —…
• Page 10
  6 – 8 TROUBLESHOOTING 5. Excessive Oil Consumption Step Action Value(s) Does the air cleaner element conditon OK? (Clogged — Clean or or not) replace the air cleaner Go to Step 2 element Does PCV (Positive Crankcase Ventilation) Valve — Repair or has problem? replace the…
• Page 11
  TROUBLESHOOTING 6 – 9 6. Overheating Step Action Value(s) Was the engine coolant level OK? — Replenish the Go to Step 2 coolant Was the water leakage or the radiator restriction — Repair or found? (Include radiator cap) replace the leakage part.
• Page 12
  6 – 10 TROUBLESHOOTING 8. Dark Exhaust Smoke Step Action Value(s) Was the air cleaner element normal condition? — Clean or replace the air cleaner Go to Step 2 element Was the EGR valve sticking? — Replace the EGR valve Go to Step 3 Was the injection nozzle pressure or the injection —…
• Page 13
  TROUBLESHOOTING 6 – 11 9. Oil Pressure Does Not Rise Step Action Value(s) Was the oil pressure warning lamp working OK? — Replace the oil pressure Go to Step 2 warning lamp Does the oil filter element clog? — Replace the oil filter element Go to Step 3 Does the relief valve open?
• Page 14
  6 – 12 TROUBLESHOOTING 10. Abnormal Engine Noise 10–1 Engine knocking Step Action Value(s) Was the injection nozzle pressure or injection spray — pattern OK? Replace the Go to Step 2 injection nozzle Was the compression pressure OK? 3.0 MPa Replace the (31.0 kg/cm cylinder head…
• Page 15
  TROUBLESHOOTING 6 – 13 10–3 Continuous noise Step Action Value(s) Was the fan belt tension OK? 9 – 13 mm (0.35 – 0.51 Adjust the fan Go to Step 2 belt tension. Was the cooling fan loose? — Tighten the cooling fan Go to Step 3 Was noise coming from the generator?
• Page 16
  Was it contaminated with foreign materials? engine oil Go to Step 2 Was the recommended engine oil grade/viscosity API CD or being used? ISUZU genuine/ Replace the 10W–30 Go to Step 3 engine oil Was the oil feed pipe restricted? —…
• Page 17
  TROUBLESHOOTING 6 – 15 12. Oil Leakage from Turbocharger Step Action Value(s) Inspect the oil leakage area. — Tighten the eye Was the oil feed pipe eye bolt loose or the gasket bolt or replace broken? the gasket. Go to Step 2 Were the V band fixing faces tight? —…
• Page 18
  6 – 16 TROUBLESHOOTING 14. Battery Charging and Noise Problem Visual/physical check the following items before diagnosis. The drive belt tension. The battery terminals connection condition. The ground connection condition. The generator and the battery fastener condition. The battery fluid level and specific gravity. 14-1 Battery No Charging Step Action…
• Page 19
  TROUBLESHOOTING 6 – 17 14-3 Battery Under Charging Step Action Value(s) Was “Visual/Physical Check» performed. — Go to visual/physical Go to Step 2 check Inspect the brush contact condition on the generator. — Repair or Was there intermittent contact between the brush replace the and the slip ring? brush holder…
• Page 20
  6 – 18 TROUBLESHOOTING 14-5 Charging System Noise Step Action Value(s) Was “Visual/Physical Check» performed. — Go to visual/physical Go to Step 2 check Was there intermittent noise or continuous noise and — that could be identified clearly by increasing and Replace the decreasing engine speed? bearing.
• Page 21
  TROUBLESHOOTING 6 – 19 15. Starter Motor Problem Visual/physical check the following items before diagnosis. The battery terminals connection condition. The ground connection condition. The starter motor or the battery fastener condition. The battery fluid level and specific gravity. 15-1 Starter motor pinion engages to ring gear but engine does not turn over Step Action Value(s)
• Page 22
  6 – 20 TROUBLESHOOTING 15-3 Starter motor continues to run after the starter switch is turned off Step Action Value(s) Was “Visual/Physical Check» performed. — Go to visual/physical Go to Step 2 check Inspect the magnetic switch contact point. — Repair or Was the contact point seized? replace the…

• Page 23: Table Of Contents

  ENGINE MECHANICAL 6A – 1 SECTION 6A ENGINE MECHANICAL TABLE OF CONTENTS PAGE Main Data and Specifications………………6A — Torque Specification ………………… 6A — Standard Bolts………………….6A — Special Parts Fixing Nuts and Bolts……………. 6A — Recommended Liquid Gasket ………………6A — 22 LOCTITE Application Procedure ………………

• Page 24
  6A – 2 ENGINE MECHANICAL Disassembly………………….. 6A- 47 Internal Parts ………………….6A- 47 Major Components ………………… 6A- 47 Minor Components ………………… 6A- 56 Rocker Arm Shaft and Rocker Arm …………… 6A- 56 Cylinder Head ………………..6A- 57 Piston and Connecting Rod …………….6A- 59 Inspection and Repair ………………..
• Page 25
  ENGINE MECHANICAL 6A – 3 Lubricating Flow ………………….6A- 126 Oil Pump and Oil Filter ………………..6A- 127 Oil Pump ……………………6A- 128 Disassembly ………………….6A- 128 Inspection and Repair……………….. 6A- 129 Reassembly ………………….6A- 130 Oil Filter and Oil Cooler………………… 6A- 131 Disassembly ………………….

• Page 26: Main Data And Specifications

  2nd (Reference) 25.5∼27.0 34.0∼35.5 (260∼275 / 3,702∼3,920) (347∼362 / 4,936∼5,154) Main fuel filter type Cartridge paper element and water separator Lubricating system Lubricating method Pressure circulation Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)

• Page 27
  ENGINE MECHANICAL 6A – 5 Engine model 4JA1T (L) 4JA1TC Item Cooling system Water pump type Centrifugal Thermostat type Wax pellet with jiggle valve Air cleaner type Dry paper element Viscous paper element Battery type/voltage × No. of units 80D26L × 1 95D31L ×…
• Page 28
  Cartridge paper element and water separator Lubricating system Lubricating method Pressure circulation Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3) Oil pump type Gear Oil filter type Cartridge paper element 6.2 (1.64/1.36) (For 4 × 2)
• Page 29
  ENGINE MECHANICAL 6A – 7 Engine model 4JH1TC Item Cooling system Water pump type Centrifugal Thermostat type Wax pellet with jiggle valve Air cleaner type Dry paper element (except for Euro3 spec) Viscous paper element (for Euro3 spec) 80D26L × 1 Battery type/voltage ×…

• Page 30: Torque Specification

  6A – 8 ENGINE MECHANICAL TORQUE SPECIFICATION STANDARD BOLTS The torque values given in the following table should be applied whenever a particular torque is not specified. N·m (kg·m/lb·ft) Strength 4.8 (4T) (7T) 9.8 (9T) Class Refined Non-Refined Bolt Identification Bolt Diameter ×…

• Page 31: Special Parts Fixing Nuts And Bolts

  ENGINE MECHANICAL 6A – 9 SPECIAL PARTS FIXING NUTS AND BOLTS Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket N·m (kg·m/lb·ft) RTW86AXF000101…

• Page 32
  6A – 10 ENGINE MECHANICAL Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley, Flywheel, and Oil Pan N·m (kg·m/lb·ft) RTW86AXF000101…
• Page 33
  ENGINE MECHANICAL 6A – 11 Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft N·m (kg·m/lb·ft) RTW46AXF000601…
• Page 34
  6A – 12 ENGINE MECHANICAL Cooling and Lubricating System N·m (kg·m/lb·ft) RTW46AXF000701…
• Page 35
  ENGINE MECHANICAL 6A – 13 Intake Manifold (4JA1TC / 4JH1TC) N·m (kg·m/lb·ft) RTW36AXF000201…
• Page 36
  6A – 14 ENGINE MECHANICAL EGR Valve, EGR Pipe, EGR Cooler RTW46AXF000801…
• Page 37
  ENGINE MECHANICAL 6A – 15 Exhaust Manifold, and Turbocharger (4JA1L) RTW46AXF000901…
• Page 38
  6A – 16 ENGINE MECHANICAL Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC) N·m (kg·m/lb·ft) RTW86AXF000301…
• Page 39
  ENGINE MECHANICAL 6A – 17 Engine Electricals N·m (kg·m/lb·ft) RTW36AXF000501…
• Page 40
  6A – 18 ENGINE MECHANICAL Fuel Injection System (4JA1L) N·m (kg·m/lb·ft) RTW86AXF000201…
• Page 41
  ENGINE MECHANICAL 6A – 19 Fuel Injection System (4JA1TC) N·m (kg·m/lb·ft) RTW46AXF001201…
• Page 42
  6A – 20 ENGINE MECHANICAL Fuel Injection System (4JH1TC) N·m (kg·m/lb·ft) RTW46AXF001301…
• Page 43
  ENGINE MECHANICAL 6A – 21 Engine Mounting Bracket N·m (kg·m/lb·ft) 022R300001…

• Page 44: Recommended Liquid Gasket

  ThreeBond 1207C Three Bond Water Base ThreeBond 1141E Three Bond ThreeBond 1215 Three Bond Solvent ThreeBond 1104 Three Bond Belco Bond 4 Isuzu Belco Bond 401 Isuzu Belco Bond 402 Isuzu Anaerobic LOCTITE 515 Loctite Recommended for LOCTITE 518 Loctite…

• Page 45: Loctite Application Procedure

  ENGINE MECHANICAL 6A – 23 LOCTITE APPLICATION PROCEDURE LOCTITE Type LOCTITE Color Application Steps Completely remove all lubricant and moisture from the bolts and the female threaded surfaces of the parts to be joined. LOCTITE 242 Blue The surfaces must be perfectly dry. Apply LOCTITE to the bolts.

• Page 46: Servicing

  6A – 24 ENGINE MECHANICAL SERVICING Servicing refers to general maintenance procedures to be performed by qualified service personnel. MODEL IDENTIFICATION Engine Serial Number The engine number is stamped on the rear left hand side of the cylinder body. The engine number is stamped in the plate in front of the engine room as well.

• Page 47: Fuel System

  Filter Wrench : 5-8840-0253-0 041RY00009 6. Operate the priming pump until the air discharged completely from fuel system. 7. Start the engine and check for fuel leakage. Note: The use of an ISUZU genuine fuel filter is strongly recommended.

• Page 48
  6A – 26 ENGINE MECHANICAL Draining Procedure The indicator light will come on when the water level in the water separator exceeds the specified level. Drain the water and foreign material from the water separator (inside chassis frame) with the following procedure.

• Page 49: Cooling System

  8. Pour coolant into the reservoir tank up to “MAX” line. Engine Coolant Total Capacity Lit (U.S / UK gal) 4JA1 / TC 9.4 (2.5 / 2.1) M/T: 10.1 (2.7 / 2.2) 4JH1TC A/T: 10.0 (2.6 / 2.2)

• Page 50
  6A – 28 ENGINE MECHANICAL Cooling System Inspection Install a radiator filler cap tester to the radiator. Apply testing pressure to the cooling system to check for leakage. The testing pressure must not exceed the specified pressure. Testing Pressure kPa(kg/cm /psi) 150 (1.5/21) 030LX003…
• Page 51
  ENGINE MECHANICAL 6A – 29 Thermostat Operating Test 1. Completely submerge the thermostat in water. 2. Heat the water. Stir the water constantly to avoid direct heat being applied to the thermostat. 3. Check the thermostat initial opening temperature. °C (°F) Thermostat Initial Opening Temperature 82 (180) °C (°F)
• Page 52
  6A – 30 ENGINE MECHANICAL Cooling Fan Pulley Drive Belt Fan belt tension is adjusted by moving the generator. Depress the drive belt mid-portion with a 98N (10 kg/22 lb) force. Cooling Fan Drive Belt Deflection mm (in) New belt 4 — 7 (0.16 — 0.28) Reuse belt 6 — 9 (0.24 — 0.35) 1 Crankshaft damper pulley…

• Page 53: Valve Clearance Adjustment

  ENGINE MECHANICAL 6A – 31 VALVE CLEARANCE ADJUSTMENT 1. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft damper pulley TDC line is aligned with the timing pointer. 2.

• Page 54: Compression Pressure Measurement

  6A – 32 ENGINE MECHANICAL COMPRESSION PRESSURE MEASUREMENT 1. Start the engine and allow it to idle until the coolant temperature reaches 70 – 80 °C (158 – 176 °F). 2. Remove the following parts. • Leak off pipe • Injection nozzle holder bracket •…

• Page 55
  ENGINE MECHANICAL 6A – 33 INJECTION TIMING ADJUSTMENT (4JA1T(L) only) 1. Check that the notched line on the injection pump flange is aligned with the front plate or the timing gear case notched line. 2. Bring the piston in the No. 1 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line is aligned with the timing mark.
• Page 56
  6A – 34 ENGINE MECHANICAL 9. Turn the crankshaft clockwise and read the gauge indication when the crankshaft pulley timing mark (8°) is aligned with the pointer. Injection Timing : BTDC 8° ± 2° Standard Reading mm (in) 0.5 (0.02) If the injection timing is outside the specified range, RTW46ASH000701 continue with the following steps.
• Page 57
  ENGINE MECHANICAL 6A – 35 Idling Speed Adjustment 1. Loosen the idling set screw lock nut on the injection pump idling set bolt. 2. Adjust the idling speed to the specified range by turning the idling set bolt 3. Lock the engine set nut with the idling set bolt lock nut.

• Page 58: General Description

  6A – 36 ENGINE MECHANICAL GENERAL DESCRIPTION RTW46AMF000401 The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design provides superior fuel economy over a wide range of driving conditions. Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold.

• Page 59: Removal And Installation

  ENGINE MECHANICAL 6A – 37 REMOVAL AND INSTALLATION Read this section carefully before performing any removal and installation procedure. This section gives you important points as well as the order of operation. Be sure that you understand everything in this section before you begin.

• Page 60
  6A – 38 ENGINE MECHANICAL 6. Front propeller shaft (for 4×4 model) Remove the spline yoke flange bolt at the transfer output shaft. Do not allow the spline yoke to fall away from the front propeller shaft. If the spline yoke should fall away from the front propeller shaft, align the setting marks on the spline yoke and the propeller shaft to reassemble the two marks.
• Page 61
  ENGINE MECHANICAL 6A – 39 18. Radiator 1) Drain the engine coolant. 2) Remove the reservoir hose. 3) Remove the upper and lower hose. 4) Remove the fan guide. 5) Remove the radiator. P1010009 19. Fan 20. Air cleaner 1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.

• Page 62: Installation

  6A – 40 ENGINE MECHANICAL 26. Fuel Hose Remove the fuel hose from the fuel filter (Except EURO III). 140R300001 Remove the fuel hose from injection pump (EURO III only). RTW46ASH000501 27. Exhaust Pipe Remove the front exhaust pipe bolts and separate the exhaust manifold and the front exhaust pipe.

• Page 63: Coolant Replenishment

  7. Pour coolant into the reservoir tank up to «MAX» line. Coolant Capacity lit (US/UK gal) 4JA1 / TC 9.4 (2.5 / 2.1) M/T: 10.1 (2.7 / 2.2) 4JH1TC A/T: 10.0 (2.6 / 2.2)

• Page 64: Engine Repair Kit

  6A – 42 ENGINE MECHANICAL ENGINE REPAIR KIT RTW36ALF000601 Removal Steps 1. Cylinder head gasket 11. Vacuum pump gasket 2. Head cover gasket 12. Water pump O-ring 3. Head cover cap nut gasket 13. Water outlet pipe gasket 4. Drain cock gasket 14.

• Page 65: Engine Overhaul

  ENGINE MECHANICAL 6A – 43 ENGINE OVERHAUL REMOVAL EXTERNAL PARTS RTW36AMF000401 Removal Steps 1. Clutch Assembly or Flex Plate 15. Oil Pressure Warning Switch 2. Intake Pipe and Throttle Body 16. Fuel Leak Off Pipe 3-1. EGR Pipe 17. Oil Cooler Water Pipe 3-2.

• Page 66
  6A – 44 ENGINE MECHANICAL Removal 1. Clutch Assembly or Flex Plate Remove the clutch assembly or the flex plate. 2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) 4JA1L 1) Loosen hose clamp between turbocharger and intake duct. 2) Remove the rubber hose. 3) Remove the intake pipe and the throttle body.
• Page 67
  ENGINE MECHANICAL 6A – 45 4. EGR Valve 4JA1L 1) Remove four nuts and remove the EGR valve assembly from the intake manifold. 2) Remove four bolts and remove the adapter from the EGR valve assembly. RTW46ASH001001 5. Oil Level Gauge 1) Disconnect PCV hose.
• Page 68
  6A – 46 ENGINE MECHANICAL 13. Injection Pump Refer to section 6C-19 (Injection Pump) 14. Starter Motor 15. Oil Pressure Warning Switch 16. Fuel Leak Off Pipe 17. Oil Cooler Water Pipe 18. Cooling Fan Pulley 19. Heat Protector 20. Catalytic Converter 027R100007 21.

• Page 69: Disassembly

  ENGINE MECHANICAL 6A – 47 DISASSEMBLY INTERNAL PARTS MAJOR COMPONENTS 011R300001 Disassembly Steps-1 Water bypass hose Rocker arm shaft and rocker Thermostat housing with thermo switch Push rod Cylinder head cover Cylinder head Injection nozzle and bracket Cylinder head gasket…

• Page 70
  6A – 48 ENGINE MECHANICAL RTW46ALF000101 Disassembly Steps-2 Crankshaft damper pulley Timing gear case cove Water pump Idle gear «B» and shaft Idle gear «A» Idle gear shaft Crankshaft timing gear Injection pump…
• Page 71
  ENGINE MECHANICAL 6A – 49 014R300005 Disassembly Steps-3 Flywheel Piston and connecting rod with Crank case upper bearing Oil pump with oil pipe Crankshaft bearing cap with Camshaft timing gear lower bearing Camshaft thrust plate Crankshaft thrust bearing Camshaft Crankshaft Timing gear case Crankshaft upper bearing Cylinder body rear plate…
• Page 72
  6A – 50 ENGINE MECHANICAL Disassembly 1. Water Bypass Hose 2. Thermostat Housing with Thermo Switch 3. Cylinder Head Cover 4. Injection Nozzle and Bracket Remove the injection nozzle bracket bolts. 011R100002 2. Use the injection nozzle remover and the sliding hammer to remove the injection nozzle together.
• Page 73
  ENGINE MECHANICAL 6A – 51 10. Timing Gear Case Cover The timing gear case is tightened together with the injection pump at the 6 points indicated by the arrows in the illustration. 11. Water Pump 020L200006 12. Idle Gear B and shaft Before removing the idle gear B, install bolt (M6,L=30) to the hole marked with an arrow in the illustration to hold the scissor gear in place.
• Page 74
  6A – 52 ENGINE MECHANICAL Idler Gear «A» End Play Measurement Insert a feeler gauge between the idler gear and the thrust collar to measure the gap and determine the idler gear end play. If the measured value exceeds the specified limit, the thrust collar must be replaced.
• Page 75
  ENGINE MECHANICAL 6A – 53 20. Camshaft Timing Gear 1. Use a dial indicator to measure the camshaft end play. This must be done before removing the camshaft gear. If the camshaft end play exceeds the specified limit, the thrust plate must be replaced. Camshaft End Play mm (in) Standard…
• Page 76
  6A – 54 ENGINE MECHANICAL 26. Connecting Rod Bearing Cap with Lower Bearing If the connecting rod lower bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 014LX056 27.
• Page 77
  ENGINE MECHANICAL 6A – 55 2. Loosen the crankshaft bearing cap bolts in numerical order a little at a time. If the crankshaft bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. 29.

• Page 78: Minor Components

  6A – 56 ENGINE MECHANICAL MINOR COMPONENTS ROCKER ARM SHAFT AND ROCKER ARM 011RY00009 Disassembly Steps Rocker arm shaft snap ring Rocker arm shaft spring Rocker arm Rocker arm shaft snap ring Rocker arm shaft bracket Rocker arm shaft Rocker arm Disassembly 1.

• Page 79: Cylinder Head

  ENGINE MECHANICAL 6A – 57 CYLINDER HEAD RTW46ALF001201 Disassembly Steps Intake manifold Intake and exhaust valve Intake manifold gasket Valve stem oil seal Split collar Valve spring lower seat Valve spring upper seat Cylinder head Valve spring…

• Page 80
  6A – 58 ENGINE MECHANICAL Disassembly 1. Intake Manifold 2. Intake Manifold Gasket 3. Split Collar 1. Place the cylinder head on a flat wooden surface. 2. Use the spring compressor to remove the split collars. Do not allow the valve to fall from the cylinder head. Spring Compressor: 9-8523-1423-0 4.

• Page 81: Piston And Connecting Rod

  ENGINE MECHANICAL 6A – 59 PISTON AND CONNECTING ROD RTW46ALF000301 Disassembly Steps Connecting rod bearing Piston pin Piston ring Connecting rod Piston pin snap ring Piston…

• Page 82
  6A – 60 ENGINE MECHANICAL Disassembly 1. Connecting Rod Bearing If the connecting rod bearings are to be reinstalled, mark their fitting positions by tagging each bearing with the cylinder number from which it was removed. RTW36ASH001501 2. Piston Ring 1.

• Page 83: Inspection And Repair

  ENGINE MECHANICAL 6A – 61 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. CYLINDER HEAD Cylinder Head Lower Face Warpage 1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.

• Page 84
  6A – 62 ENGINE MECHANICAL Manifold Fitting Face Warpage Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage. Regrind the manifold cylinder head fitting surfaces if the measured values are greater than the specified limit but less than the maximum grinding allowance.
• Page 85
  ENGINE MECHANICAL 6A – 63 Measuring Method-II 1. Measure the valve stem outside diameter. Refer to the Item «Valve Stem Outside Diameter». 2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter. 011RY00023 Valve Guide Replacement Valve Guide Removal Use a hammer and the valve guide replacer to drive out the valve guide from the cylinder head lower face.
• Page 86
  6A – 64 ENGINE MECHANICAL Valve Stem Outside Diameter Measure the valve stem diameter at three points. If the measured value is less than the specified limit, the valve and the valve guide must be replaced as a set. Valve Stem Outside Diameter mm (in) Standard Limit…
• Page 87
  ENGINE MECHANICAL 6A – 65 Valve Contact Width 1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces. 2. Measure the valve contact width. If the measured value exceeds the specified limit, the valve seat insert must be replaced.
• Page 88
  6A – 66 ENGINE MECHANICAL Valve Seat Insert Installation 1. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve seat insert (2). NOTE: The smooth side of the attachment must contact the valve seat insert.
• Page 89
  ENGINE MECHANICAL 6A – 67 Valve Spring Free Height Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Spring Free Height mm (in) Standard Limit 4JA1T (L)

• Page 90: Rocker Arm Shaft And Rocker Arm

  6A – 68 ENGINE MECHANICAL ROCKER ARM SHAFT AND ROCKER ARM Rocker Arm Shaft Run-Out 1. Place the rocker arm shaft on a V-block. 2. Use a dial indicator to measure the rocker arm shaft central portion run-out. If the run-out is very slight, correct the rocker arm shaft run-out with a bench press.

• Page 91: Cylinder Body

  ENGINE MECHANICAL 6A – 69 3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm oil port. 014RY00024 Rocker Arm Correction Inspect the rocker arm valve stem contact surfaces for step wear (1) and scoring (2).

• Page 92
  6A – 70 ENGINE MECHANICAL Cylinder Liner Bore Measurement Use a cylinder indicator to measure the cylinder bore at measuring point (1) in the thrust (2-2) and axial (3-3) directions of the crankshaft. Measuring Point (1): 20 mm (0.79 in) If the measured value exceeds the specified limit, the cylinder liner must be replaced.
• Page 93
  ENGINE MECHANICAL 6A – 71 Cylinder Liner Grade Selection Subtract the average cylinder body bore from the average cylinder liner outside diameter to obtain the fitting interference. mm (in) Fitting Interference Standard -0.0010*-0.019 (-0.00004*-0.00075) * A minus (-) value indicates that the cylinder body bore is 012RY00013 smaller than the liner outside diameter.
• Page 94
  6A – 72 ENGINE MECHANICAL A mark was stamped on the upper side of the cylinder block during production to indicate the correct liner. The liner grade (i.e.1.2.3.4) is indicated in metal stamp. 012RY00022 Cylinder Liner Grade 4JA1T (L), 4JA1TC mm (in) Liner Cylinder Body…
• Page 95
  ENGINE MECHANICAL 6A – 73 Cylinder Liner Installation 1. Cylinder Liner Installation Using The Special Tool 1. Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores. 2. Use compressed air to blow-dry the cylinder liner and bore surfaces.
• Page 96
  6A – 74 ENGINE MECHANICAL Piston Grade Selection Measure the cylinder liner bore after installing the cylinder liner. Then select the appropriate piston grade for the installed cylinder liner. 1. Measure the cylinder liner bore. Refer to «Cylinder Liner Bore Measurement» Cylinder Liner Bore (Service Part) Grade mm (in) Grade…
• Page 97
  ENGINE MECHANICAL 6A – 75 2. Measure the piston diameter. mm (in) Piston Measuring Point 4JA1T(L) 78 (3.07) 4JA1TC 4JH1TC 70 (2.76) mm (in) Piston Grade (Service Part) 92.949 — 92.964 (3.6549 — 3.6600) 4JA1T(L) 015LX021 4JA1TC 92.965 — 92.980 (3.6600 — 3.6606) 95.359 — 95.374 (3.7542 — 3.7548)
• Page 98
  6A – 76 ENGINE MECHANICAL Tappet Outside Diameter Measure the tappet outside diameter with a micrometer. If the measured value is less than the specified limit, the tappet must be replaced. Tappet Outside Diameter mm (in) Standard Limit 12.97 — 12.99 12.95 (0.510) (0.510 — 0.511) 014RY00029…

• Page 99: Camshaft

  ENGINE MECHANICAL 6A – 77 CAMSHAFT Visually inspect the journals, the cams, the oil pump drive gear, and the camshaft bearings for excessive wear and damage. The camshaft and the camshaft bearings must be replaced if these conditions are discovered during inspection. Camshaft Journal Diameter Use a micrometer to measure each camshaft journal diameter in two directions (1 and 2).

• Page 100
  6A – 78 ENGINE MECHANICAL Camshaft and Camshaft Bearing Clearance Use an inside dial indicator to measure the camshaft bearing inside diameter. Crankshaft Bearing Inside Diameter mm (in) Standard Limit 50.00 — 50.03 50.08 (1.972) (1.968 — 1.970) 014RY00034 If the clearance between the camshaft bearing inside diameter and the journal exceeds the specified limit, the camshaft bearing must be replaced.

• Page 101: Crankshaft And Bearing

  ENGINE MECHANICAL 6A – 79 CRANKSHAFT AND BEARING Inspect the surface of the crankshaft journals and crankpins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. NOTE: To increase crankshaft strength, tufftriding (Nitrizing Treatment) has been applied.

• Page 102
  6A – 80 ENGINE MECHANICAL Crankshaft Journal and Crankpin Diameter 1. Use a micrometer to measure the crankshaft journal diameter across points 1 — 1 and 2 — 2. 2. Use the micrometer to measure the crankshaft journal diameter at the two points (3 and 4). 3.
• Page 103
  ENGINE MECHANICAL 6A – 81 Connecting Rod Bearing Inside Diameter 1. Install the bearing to the connecting rod big end. 2. Tighten the bearing cap to the two step of anglar tightening method. Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 78-88 (8.0/57 –…
• Page 104
  6A – 82 ENGINE MECHANICAL 015LX129 9. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the limit, perform the following additional steps. 1.

• Page 105: Crankshaft Bearing Selection

  ENGINE MECHANICAL 6A – 83 6. Remove the bearing cap. 7. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the Plastigage container. If the measured value exceeds the specified limit, perform the following additional steps.

• Page 106
  6A – 84 ENGINE MECHANICAL REFERENCE 4JA1T(L), 4JA1TC mm (in) Crankshaft Crankshaft Journal Crankshaft Bearing Housing Bearing Grade Grade Size Code Diamaeter Diamaeter Mark Mark 1 or 59.927-59.932 (2.3593-2.3595) 63.992- Brown or 4 015RY00017 64.000 2 or 59.922-59.927 (2.5194- (2.3591-2.3539) 2.5197) 3 or 59.917-59.922…

• Page 107: Crankshaft Pilot Bearing

  ENGINE MECHANICAL 6A – 85 CRANKSHAFT PILOT BEARING Check the crankshaft pilot bearing for excessive wear and damage and replace it if necessary. Crankshaft Pilot Bearing Replacement Crankshaft Pilot Bearing Removal Use the pilot bearing remover to remove the crankshaft pilot bearing.

• Page 108: Piston

  6A – 86 ENGINE MECHANICAL Ring Gear Replacement Ring Gear Removal Strike around the edges of the ring gear with a hammer and chisel to remove it. 020LX008 Ring Gear Installation 1. Heat the ring gear evenly with a gas burner to invite thermal expansion.

• Page 109
  ENGINE MECHANICAL 6A – 87 3. Use a feeler gauge to measure the piston ring gap. If the measured value exceeds the specified limit, the piston ring must be replaced. Piston Ring Gap mm (in) 4JA1T (L), 4JA1TC Standard Limit 1st Compression Ring 0.3-0.5 (0.0118-0.0197)

• Page 110: Cylinder Head Gasket Selection

  6A – 88 ENGINE MECHANICAL 4. Visually inspect the piston rings. If a piston ring groove is damaged or distorted, the piston must be replaced. Piston Pin Diameter Use a micrometer to measure the piston pin diameter at several points. If the measured value is less than the specified limit, the piston pin must be replaced.

• Page 111
  ENGINE MECHANICAL 6A – 89 Piston Head Projection Measuring Point 1. Use a dial indicator to measure the piston projection amount. 2. Refer to the illustration for the piston head projection measuring positions. All measuring positions should be as close as possible to the cylinder liner.

• Page 112: Connecting Rod

  6A – 90 ENGINE MECHANICAL CONNECTING ROD Connecting Rod Alignment Use a connecting rod aligner to measure the distortion and the parallelism between the connecting rod big end hole and the connecting rod small end hole. If either the measured distortion or parallelism exceed the specified limit, the connecting rod must be replaced.

• Page 113: Idler Gear Shaft And Idler Gear

  ENGINE MECHANICAL 6A – 91 IDLER GEAR SHAFT AND IDLER GEAR Idler Gear «A» Shaft Outside Diameter Use a micrometer to measure the idler gear shaft outside diameter. If the measured value is less than the specified limit, the idler gear shaft must be replaced.

• Page 114
  6A – 92 ENGINE MECHANICAL Oil Seal Installation Use the special tool to install the front oil seal. Front Oil Seal Installer: 5-8840-2361-0 1. With the oil seal attached to the sleeve, insert it into the front end section of the crankshaft. 2.

• Page 115: Reassembly

  ENGINE MECHANICAL 6A – 93 REASSEMBLY INTERNAL PARTS MINOR COMPONENT ROCKER ARM SHAFT AND ROCKER ARM 020RY00029 Reassembly Steps Rocker arm shaft Rocker arm Rocker arm shaft snap ring Rocker arm shaft spring Rocker arm Rocker arm shaft snap ring Rocker arm shaft bracket Reassembly 1.

• Page 116: Cylinder Head

  6A – 94 ENGINE MECHANICAL CYLINDER HEAD RTW46ALF001301 Reassembly Steps Cylinder head Valve spring upper seat Valve spring lower seat Split collar Valve stem oil seal Intake manifold gasket Intake and exhaust valve Intake manifold Valve spring…

• Page 117
  ENGINE MECHANICAL 6A – 95 Reassembly 1. Cylinder Head 2. Valve Spring Lower Seat 3. Valve Stem Oil Seal 1. Apply a coat of engine oil to the oil seal inner face. 2. Use an oil seal installer to install the oil seal to the valve guide.

• Page 118: Piston And Connecting Rod

  6A – 96 ENGINE MECHANICAL PISTON AND CONNECTING ROD RTW46ALF000301 Reassembly Steps Piston Piston pin snap ring Connecting rod Piston ring Piston pin snap ring Connecting rod bearing Piston pin…

• Page 119
  ENGINE MECHANICAL 6A – 97 Reassembly 1. Piston 2. Connecting Rod 1. Clamp the connecting rod in a vise.Take care not to damage the connecting rod. 2. Use a pair of pliers to install the piston pin snap ring to the piston.
• Page 120
  6A – 98 ENGINE MECHANICAL 6. Piston Ring 1. Use a piston ring replacer to install the three piston rings. Piston Ring Replacer Install the piston rings in the order shown in the illustration. 1. Oil ring 2. 2nd compression ring 3.

• Page 121: Positive Crankcase Ventilation (Pcv) Valve

  ENGINE MECHANICAL 6A – 99 POSITIVE CRANKCASE VENTILATION (PCV) VALVE RTW46AMF000101 Reassembly Steps Positive Crankcase Ventilation Fixing bolt (PCV) Valve Rubber space Oil filler cap Cylinder head insulator cover Breather pipe…

• Page 122
  6A – 100 ENGINE MECHANICAL Reassembly 1. PCV Valve Install the PCV valve and tighten the bolts to specified torque. PCV Valve Bolts Torque N·m(kg·m/lb in) 2 (0.2/17) 2. Rubber Spacer 010R100014 3. Cylinder Head Insulator Cover 4. Breather Hose Apply LOCTITE 262 or equivalent to the new breather pipe.

• Page 123: Major Component

  ENGINE MECHANICAL 6A – 101 MAJOR COMPONENT 014R300004 Reassembly Steps-1 Cylinder body Camshaft timing gear Piston and connecting rod with Tappet upper bearing Connecting rod bearing cap with Crankshaft upper bearing lower bearing Crankshaft Piston cooling oil pipe Crankshaft thrust bearing Oil pump with oil pipe Crankshaft bearing cap with Crankshaft rear oil seal…

• Page 124
  6A – 102 ENGINE MECHANICAL RTW46ALF000501 Reassembly Steps-2 Crankshaft timing gear Injection pump Idler gear shaft Water pump Idler gear «A» Timing gear case cover Idler gear «B» and shaft Crankshaft damper pulley…
• Page 125
  ENGINE MECHANICAL 6A – 103 011R300002 Reassembly Steps-3 Thermostat housing with thermo Cylinder head gasket switch Cylinder head Water by-pass hose Push rod Injection nozzle and bracket Rocker arm shaft and rocker Cylinder head cover with gasket…
• Page 126
  6A – 104 ENGINE MECHANICAL Reassembly 1. Cylinder Body Use compressed air to thoroughly clean the inside and outside surfaces of the cylinder body, the oil holes, and the water jackets. 015R100003 2. Tappet 1. Apply a coat of engine oil to the tappet and the cylinder body tappet insert holes.
• Page 127
  ENGINE MECHANICAL 6A – 105 5. Crankshaft Thrust Bearing Apply an ample coat of engine oil to the thrust bearings before installation. Install the thrust bearings to the crankshaft center journal. The thrust bearing oil grooves must be facing the sliding faces.
• Page 128
  6A – 106 ENGINE MECHANICAL 7. Camshaft 1. Apply a coat of engine oil to the camshaft and the camshaft bearings. 2. Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings. 014RY00019 8. Timing Gear Case Tighten the timing gear case with timing gear case gasket to the specified torque.
• Page 129
  ENGINE MECHANICAL 6A – 107 11. Piston and Connecting Rod with Upper Bearing 12. Connecting Rod Bearing Cap with Lower Bearing 1. Apply a coat of engine oil to the circumference of each piston ring and piston. 2. Position the piston ring gaps as shown in the illustration.
• Page 130
  6A – 108 ENGINE MECHANICAL 10. Apply a coat of engine oil to the threads and setting faces of each connecting rod cap bolt. 11. Tighten the connecting rod caps to the two step of anglar tigthen method. Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 78-88 (8.0/57 –…
• Page 131
  ENGINE MECHANICAL 6A – 109 16. Crank Case 1. Apply the recommended liquid gasket (Three bond 1207B) or its equivalent to arch gasket fitting surface as shown in the illustration. 2. Install the crankcase front gasket (1) to the timing gear case arches.
• Page 132
  6A – 110 ENGINE MECHANICAL 17. Cylinder Body Rear Plate 1. Align the rear plate with the cylinder body knock pins. 2. Tighten the rear plate to the specified torque. Rear Plate Torque N·m(kg·m/lbft) 82 (8.4/61) 020R100001 18. Flywheel 1. Apply a coat of engine oil to the threads of the flywheel bolts.
• Page 133
  ENGINE MECHANICAL 6A – 111 4. Align the idler gear setting mark with the crankshaft timing gear (1) setting mark. 5. Align the idler gear setting mark with the camshaft timing gear (2) setting mark. 6. Install the thrust collar and bolts to the cylinder body through the shaft.
• Page 134
  6A – 112 ENGINE MECHANICAL 4) Set the spring as shown in the illustration. RTW31BSH000101 5) Position the rear gear so that the pin is aligned with the receiving end of the spring. RTW31BSH000201 6) Install the snap ring to the main gear groove. RTW31BSH000301 7) Install suitable bolts, nuts and washers to special tool as shown in the illustration to rotate the scissors…
• Page 135
  ENGINE MECHANICAL 6A – 113 Insert the bolts of the special tool into the rear gear setting hole. Rotate the rear gear to mesh the teeth of main gear and rear gear. 9) Insert a lock bolt (M6 × 1 L=30) into scissors gear fixing hole to prevent the scissors gear from turning.
• Page 136
  6A – 114 ENGINE MECHANICAL 23. Injection Pump 1. Install the O-ring (1) to the injection pump flange (2). 2. Attach the noise insulator rubber to the cylinder body . 3. Install the injection pump to the timing gear case.Align the idler gear «B»…
• Page 137
  ENGINE MECHANICAL 6A – 115 4JA1T(L): 4. Tighten the injection pump bolts to the specified torque. 5. Install the injection pump bracket (4) and the bracket bolts (5) and (6) to the cylinder body. Temporarily tighten the bracket bolts. 6. Tighten the bracket bolts (5) to the specified torque. 7.
• Page 138
  6A – 116 ENGINE MECHANICAL 27. Cylinder Head Gasket The cylinder head gasket «TOP» mark must be facing up. NOTE: Before the gasket installation, measure the piston head projection and select the appropriate head gasket. Refer to «INSPECTION AND REPAIR», «Cylinder Head Gasket Selection».
• Page 139
  ENGINE MECHANICAL 6A – 117 33. Injection Nozzle Holder 1. Install the injection nozzle gasket and the O-ring to the injection nozzle holder. Be sure that the O-ring fits snugly in the injection nozzle groove. 2. Install the nozzle holder toghther with the nozzle holder bracket to the cylinder head.

• Page 140: Installation

  6A – 118 ENGINE MECHANICAL INSTALLATION EXTERNAL PARTS RTW36AMF000701 Installation Steps Exhaust Manifold Engine Mounting Bracket and Oil Cooler with Oil Filter Foot Generator Bracket Intake Manifold Water Inlet Pipe Power Steering Oil Pump Generator and Adjusting Plate Bracket Vacuum Pump Oil Return Hose Fuel Injection Pipe with Clip Fuel Filter Bracket (Except Compressor Bracket…

• Page 141
  ENGINE MECHANICAL 6A – 119 Installation 1. Exhaust Manifold 1) Install the exhaust manifold to the cylinder head with the manifold gasket. 2) Tighten the exhaust manifold bolts and nuts to the specified torque a little at a time. Exhaust Manifold Bolt and Nuts Torque N·m(kg·m/Ib ft) 24 (2.4/17)
• Page 142
  6A – 120 ENGINE MECHANICAL 4. Water Inlet Pipe 1) Tighten the water inlet pipe bolts to the specified torque. Suction Pipe Bolt Torque N·m(kg·m/Ib ft) 19 (1.9/14) 032R300001 5. Generator and Adjusting Plate 1) Install the generator to the bracket (1). 2) Temporarily tighten the generator bolt (2) and adjusting plate bolts (3).
• Page 143
  ENGINE MECHANICAL 6A – 121 8. Turbocharger 1) Install the turbocharger and the gasket. 2) Temporarily tighten the turbocharger nuts at this time. They will be fully tightened after the installation of the turbocharger oil pipe. Always install new nuts and new gasket. 027R100002 3) Install the oil return pipe with gasket to the turbocharger.
• Page 144
  6A – 122 ENGINE MECHANICAL 9) Install the water feed adapter (1) with the gaskets to turbocharger and tighten to the specified torque. Adapter Torque N·m(kg·m/Ib ft) 39 (4.0/29) 10) Install the water feed pipe with the gaskets and tighten to the specified torque.
• Page 145
  ENGINE MECHANICAL 6A – 123 15. Starter Motor Tighten the starter motor bolts to the specified torque. Starter Motor Bolt Torque N·m(kg·m/Ib ft) 85 (8.7/63) 16. Injection Pump 17. Injection Pump Cover (4JA1TC/4JH1TC only) 18. Engine Foot 4JA1L, 4JH1TC Install the engine foot to the cylinder body and tighten the bracket bolts to the specified torque.
• Page 146
  6A – 124 ENGINE MECHANICAL 20. Power Steering Oil Pump Bracket Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft) M10×1.25 37 (3.8/28) M8×1.25 18 (1.8/13) (Bolt ID:8) 431RY00013 21. Fuel Injection Pipe with Clip 1) Temporarily tighten the injection pipe sleeve nut. 2) Set the clip in the illustrated position.
• Page 147
  ENGINE MECHANICAL 6A – 125 25. EGR Valve Install the EGR valve assembly to the intake minifold with the two gasket. Tighten the four nuts to the specified torque. Nut Tolque N·m(kg·m/Ib ft) 31 (3.2/23) Connector the vacuum hose. 26-1. EGR Pipe Install the EGR valve adapter with the gasket to the EGR valve assembly and install the EGR pipe with the gasket.

• Page 148: Lubrication System

  6A – 126 ENGINE MECHANICAL LUBRICATION SYSTEM LUBRICATING OIL FLOW 1. Oil Pump Relief Valve Operating Pressure: 6.2 — 7.8 kg/cm (608 – 764 kPa) 2. Regulating Valve Operating Pressure: 5.7 — 6.3 kg/cm (558.6 — 617.4 kPa) 3. Oil Cooler Relief Valve Opening Pressure: 2.8 — 3.4 kg/cm (270 –…

• Page 149: Oil Pump And Oil Filter

  ENGINE MECHANICAL 6A – 127 OIL PUMP AND OIL FILTER RTW46ALF001501 The 4J series engine is equipped with a gear type oil pump. The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.

• Page 150: Oil Pump

  6A – 128 ENGINE MECHANICAL OIL PUMP DISASSEMBLY 051R100005 Disassembly Steps Oil pipe Driven gear Strainer Relief valve assembly Pump cover Pinion gear Driven gear with bushing Oil pump body Disassembly procedure is shown in the illustration above numerical order.

• Page 151: Inspection And Repair

  ENGINE MECHANICAL 6A – 129 INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Gear Teeth and Body Inner Wall Clearance Use a feeler gauge to measure the clearance between the gear teeth and the body inner wall.

• Page 152: Reassembly

  6A – 130 ENGINE MECHANICAL REASSEMBLY 051R100006 Reassembly Steps Oil pump body Pinion gear Drive gear Strainer Driven gear Relief valve assembly Pump cover Oil pipe Reassembly procedure is shown in the illustration above numerical order. Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb ft)

• Page 153: Oil Filter And Oil Cooler

  ENGINE MECHANICAL 6A – 131 OIL FILTER AND OIL COOLER DISASSEMBLY 050R300004 Disassembly Steps Oil filter cartridge Body Bolt Oil cooler relief valve Gasket Regulating valve Oil cooler Disassembly procedure is shown in the illustration above numerical order.

• Page 154: Inspection And Repair

  6A – 132 ENGINE MECHANICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Oil Cooler Water Leakage at Water Passage 1. Plug one side of the oil cooler water passage. 2.

• Page 155: Reassembly

  ENGINE MECHANICAL 6A – 133 REASSEMBLY 050R300003 Reassembly Steps Body Gasket Regulating valve Bolt Oil cooler relief valve Oil filter cartridge Oil cooler Reassembly procedure is shown in the illustration above numerical order.

• Page 156
  6A – 134 ENGINE MECHANICAL 1. Body 2. Oil Filter Safety Valve 3. Oil Cooler Safety Valve Tighten the oil filter and oil cooler relief valve to the specified torque. Regulating Valve N·m(kg·m/lb ft) 64 (6.5/48) RTW46ASH001701 4. Oil Cooler 5.

• Page 157: Inter Cooler

  ENGINE MECHANICAL 6A – 135 INTER COOLER REMOVAL AND INSTALLATION RTW46ALF001001 Removal Steps Installation Steps 4. Inter cooler 1. Radiator grille 2. Front bumper fascia 3. Front bumper inpact support assembly 3. Front bumper inpact support assembly 2. Front bumper fascia 4.

• Page 158: Removal

  6A – 136 ENGINE MECHANICAL Removal 1. Radiator Grille • Refer to removal procedure in Sheet Metal section. RTW36ASH000601 2. Front Bumper Fascia • Remove the nine clips and four screws. • Disconnect the fog light harness connectors. RTW36ASH000501 3. Front Bumper Impact Support Assembly •…

• Page 159: Special Tools

  ENGINE MECHANICAL 6A – 137 SPECIAL TOOLS Illustration Tool Number Tool Name 5-8840-0203-1 Filter Wrench 5-8840-0253-0 Filter Wrench 5-8840-2675-0 Compression Gauge 5-8531-7001-0 Adapter; Compression Gauge 5-8840-2723-0 Nozzle Holder Remover 5-8840-0019-0 Sliding Hammer 5-8521-0002-0 Universal Puller 5-8840-2360-0 Oil Seal Remover 9-8523-1423-0 Spring Compressor 9-8523-1212-0 Valve Guide Replacer…

• Page 160
  6A – 138 ENGINE MECHANICAL Illustration Tool Number Tool Name 5-8840-2040-0 (4JA1L/TC) Cylinder Liner Installer 5-8840-2313-0 (4JH1TC) 5-8840-2038-0 Bearing Replacer; Camshaft 5-8840-2000-0 Pilot Bearing Remover 5-8522-0024-0 Pilot Bearing Installer 5-8840-2033-0 Oil Seal Installer 5-8840-9018-0 Piston Ring Compressor 5-8840-2359-0 Oil Seal Installer 9-8522-0020-0 Crankshaft Timing Gear Installer 5-8840-0266-0…
• Page 161
  ENGINE MECHANICAL 6A – 139 Illustration Tool Number Tool Name 5-8840-2361-0 Front Oil Seal Installer 5-8840-0145-0 Static Timing Gauge 5-8840-2834-0 Adapter Set: Static Timing Gauge…
• Page 162
  MEMO ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
• Page 163
  ENGINE COOLING 6B – 1 SECTION 6B ENGINE COOLING TABLE OF CONTENTS PAGE Main Data and Specifications………………6B — General Description ………………..6B — Coolant Flow………………….6B — Water Pump ………………….. 6B — 5 Thermostat……………………. 6B — Radiator……………………6B — Diagnosis ……………………
• Page 164
  6B – 2 ENGINE COOLING PAGE Engine coolant change ………………… 6B — 19 Fan Clutch with Cooling Fan ………………6B — 20 Inspection and Repair………………..6B — 20 Special Tools ………………….6B — 20…

• Page 165: Main Data And Specifications

  ENGINE COOLING 6B – 3 MAIN DATA AND SPECIFICATIONS Description Item Cooling system Engine coolant forced circulation Water pump type Centrifugal impeller type Pump to crankshaft speed ratio (To 1) Delivery volume lit (US/UK gal)/min 100 (26.3/22.2) Pump speed at 3000 rpm Water temperature at 30°C (86°F) Pump bearing type Double row shaft…

• Page 166: General Description

  6B – 4 ENGINE COOLING GENERAL DESCRIPTION COOLANT FLOW RTW66ALF000101 The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump thermostat…

• Page 167: Water Pump

  ENGINE COOLING 6B – 5 WATER PUMP RTW46ASF000101 A centrifugal type water pump forcefully circulates the coolant through the cooling system. The water pump is not disassembled type. THERMOSTAT 030RY00005 A wax pellet type thermostat is used. The jiggle valve accelerates engine warm-up.

• Page 168: Radiator

  6B – 6 ENGINE COOLING RADIATOR The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a ∼ ∼ cap in which the valve is operated at 93.3 122.7 kPa (13.5 17.8 psi) pressure.

• Page 169: Diagnosis

  ENGINE COOLING 6B – 7 DIAGNOSIS Engine Cooling Trouble Symptom Possible Cause Action Engine overheating Low Engine Coolant level Replenish Thermo meter unit faulty Replace Faulty thermostat Replace Faulty Engine Coolant temperature Repair or replace sensor Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of…

• Page 170: Draining And Refilling Cooling System

  6B – 8 ENGINE COOLING Draining and Refilling Cooling System Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the “MIN»…

• Page 171
  ENGINE COOLING 6B – 9 • After tightening radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. • Check to see the thermostat has opened through the needle position of water thermometer, conduct a 5–minute idling again and stop the engine.

• Page 172: Water Pump

  6B – 10 ENGINE COOLING WATER PUMP REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

• Page 173: Inspection And Repair

  ENGINE COOLING 6B – 11 Inspection and Repair The water pump is not disassembled type. Make necessary parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced.

• Page 174
  6B – 12 ENGINE COOLING 5. Thermostat Install the thermostat to the thermostat housing. 6. Water Outlet Pipe 1) Install the water outlet pipe with new gasket to the thermostat housing. 2) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque N·m(kg·m/lb ft) 19(1.9/14)

• Page 175: Thermostat

  ENGINE COOLING 6B – 13 THERMOSTAT REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

• Page 176: Installation

  6B – 14 ENGINE COOLING Thermometer Agitating rod Wooden piece Installation 1. Thermostat Install the thermostat to the thermostat housing. 2. Water Outlet Pipe 1) Install the water outlet pipe with new gasket to the thermostat housing. 2) Tighten the outlet pipe bolt to specified torque. Outlet Pipe Bolt Torque N·m(kg·m/lb ft) 19(1.9/14)

• Page 177: Radiator

  ENGINE COOLING 6B – 15 RADIATOR REMOVAL AND INSTALLATION Radiator and Associated Parts RTW36BLF000101 Legend 1. Radiator Hose 6. Reserve Tank Hose 2. Drain Plug 7. Reserve Tank 3. Fan Guide, Lower 8. Radiator Cap 4. Fan Guide 9. Radiator Assembly 5.

• Page 178: Removal

  6B – 16 ENGINE COOLING Removal 1. Disconnect battery ground cable. 2. Loosen a drain plug to drain EC. 3. Disconnect oil cooler hose on automatic transmission (A/T). 4. Disconnect radiator inlet hose and outlet hose from the engine. P1010064 5.

• Page 179: Inspection And Repair

  ENGINE COOLING 6B – 17 Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Radiator Cap Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range.

• Page 180: Installation

  6B – 18 ENGINE COOLING • Check the rubber hoses for swelling. 110RS005 Installation 1. Install radiator assembly (9) with hose, taking care not to damage the radiator core with a fan blade. 2. Support the radiator upper tank with the bracket (5) and secure the radiator.

• Page 181
  ENGINE COOLING 6B – 19 8. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank. Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant. RTW36BSH000101 Engine coolant change Refer to 6B-8 (Draining and Refilling Cooling System).
• Page 182
  6B – 20 ENGINE COOLING FAN CLUTCH WITH COOLING FAN INSPECTION AND REPAIR Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through inspection. Visually inspect for damage, leak (sillicon grease) or other abnormal conditions.
• Page 183
  FUEL SYSTEM 6C – 1 SECTION 6C FUEL SYSTEM TABLE OF CONTENTS PAGE Main Data and Specifications………………6C — General Description …………………. 6C — Fuel Flow……………………6C — Fuel Filter and Water Separator …………….6C — Injection Pump………………….6C — Injection Nozzle ………………….

• Page 184: Main Data And Specifications

  6C – 2 FUEL SYSTEM MAIN DATA AND SPECIFICATIONS Description Item 4JA1T (L) 4JA1TC 4JH1TC Injection pump type Bosch distributor Bosch distributor VP44 type VE type Governor type Mechanical variable Electrical controled (Half speed oil pressure) Timer type Oil pressure Electrical controled Fuel feed pump type Vane with input shaft…

• Page 185: General Description

  FUEL SYSTEM 6C – 3 GENERAL DESCRIPTION FUEL FLOW RTW66CMF000101 The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection nozzle. The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other foreign material are removed from the fuel.

• Page 186: Fuel Filter And Water Separator

  6C – 4 FUEL SYSTEM FUEL FILTER AND WATER SEPARATOR As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches the injection pump.

• Page 187
  FUEL SYSTEM 6C – 5 For EURO III model RTW46AMF000201…

• Page 188: Injection Pump

  6C – 6 FUEL SYSTEM INJECTION PUMP RTW46CLF000201 4JA1T(L): A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly to the injection nozzles, regardless of the number of cylinders. The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection pump is compact, light weight, and provides reliable high-speed operation.

• Page 189: Injection Nozzle

  FUEL SYSTEM 6C – 7 INJECTION NOZZLE (4JA1L) RTW76CMF000301 NOTE: • Injection nozzle adjustment is possible only on the 4JA1L engine. A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly. The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through the nozzle body injection orifice.

• Page 190: Fuel Tank

  6C – 8 FUEL SYSTEM FUEL TANK Fuel Tank and Associated Parts RTW46CLF000801 Legend 1. Bolt; Fuel Tank 2. Fuel Tank Band 3. Fuel Tube/Quick Connector 4. Fuel Filler Hose 5. Fuel Tank 6. Under Shield Band (only specified model) 7.

• Page 191: Removal

  FUEL SYSTEM 6C – 9 Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section “Driveability and Emission». 1. Disconnect battery ground cable. 2.

• Page 192
  6C – 10 FUEL SYSTEM 5. Install the filler neck to the body with bolt. 6. Install the inner liner of the wheel house at rear left side. 7. Remove lifter from the fuel tank. 8. Lower the vehicle. 9. Tigten the filler cap until at least three clicks. 10.

• Page 193: Fuel Gauge Unit

  FUEL SYSTEM 6C – 11 FUEL GAUGE UNIT Fuel Gauge Unit and Associated Parts RTW46CLF000901 Legend 1. Fuel Feed Port 6. Fuel Tube/Quick Connector 2. Fuel Return Port 7. Retainer Ring (Fuel Gauge Unit Lock) 3. Fuel Emission Port 8. Seal; Fuel Gauge Unit 4.

• Page 194: Removal

  6C – 12 FUEL SYSTEM Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section “Driveability and Emission». 1. Remove fuel tank assembly (9). Refer to “Fuel Tank Removal»…

• Page 195
  FUEL SYSTEM 6C – 13 8. Check leak. Methed of leak check. (1) Plug end of quick connector and breather hose (Pull off the breather hose from fuel tank) and tighten fuel filler cap until at least one click are heard. (2) Apply water soap around the fuel gauge unit seal area.

• Page 196: Fuel Tube / Quick — Connector Fittings

  6C – 14 FUEL SYSTEM FUEL TUBE / QUICK – CONNECTOR FITTINGS Precautions • Do not light a match or create a flame. • Keep flames away from your work area to prevent flammable materials from catching fire. • Disconnect battery ground cable to prevent electrical shorts. •…

• Page 197
  FUEL SYSTEM 6C – 15 2. For removal of the quick connector, hold the quick connector in one hand, and pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated. NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector.

• Page 198: Filler Neck

  6C – 16 FUEL SYSTEM FILLER NECK Removal 1. Remove the fuel tank. NOTE: Refer to «Fuel Tank» in this section. 2. Put a marking the following point as the filler neck assembly is restored. • Each joint area of the hose (to restore axial direction and insertion length of the hose) •…

• Page 199: Fuel Filler Cap

  FUEL SYSTEM 6C – 17 FUEL FILLER CAP General Description A vacuum valve and pressure valve are built into the fuel filler cap which adjusts the fuel pressure in the fuel tank to prevent fuel tank damage. RTW46CSH000301 Legend 1. Seal Ring Inspection The fuel filler cap must be inspected for seal condition.

• Page 200: Injection Pump

  6C – 18 FUEL SYSTEM INJECTION PUMP REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

• Page 201
  FUEL SYSTEM 6C – 19 7. Power Steering Pump Bracket 6C-4 8. Throttle Position Sensor Harness Connector (4JA1TC/4JH1TC only) Disconnect the harness connector from the throttle position sensor. 9. Oil Level Gauge 10. Fuel Pipe 1) Disconnect the fuel hoses from the fuel filter or priming pump.
• Page 202
  6C – 20 FUEL SYSTEM 18. Timing Check Hole Cover 1) Remove the timing check hole cover. 2) For ease in reinstalling the injection pump, align the timing mark on the timing gear case cover by turning the crankshaft using wrench. And bring the piston in the No.1 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line aligned with the timing…

• Page 203: Installation

  FUEL SYSTEM 6C – 21 Installation 1. Injection Pump 1) Install the injection pump gear (When gear is removed). Injection Pump Gear Nut N⋅m (kg⋅m/lb ft) 64 (6.5 / 47) 2) Bring the piston in the No.1 cylinder to TDC on the compression stroke by turning the crankshaft until the crankshaft pulley TDC line aligned with the timing RTW46CSH000201…

• Page 204
  6C – 22 FUEL SYSTEM 4JA1T (L) RTW46CSH000101 4JA1TC/4JH1TC 2. Injection Pump Bracket 1) Install the injection pump bracket (6) and the bracket bolts (7) and (8) to the cylinder body. Temporarily tighten the bracket bolts. 2) Tighten the bracket bolts (7) to the specified torque. 3) Tighten the bracket bolts (8) to the specified torque.
• Page 205
  FUEL SYSTEM 6C – 23 6. Injection Pipe Install the injection pipe. Injection Pipe Torque N·m(kg·m / lb ft) 29 (3.0 / 22) Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft) 29 (3.0 / 22) Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft) 40 (4.1 / 30) 7.
• Page 206
  6C – 24 FUEL SYSTEM 13. Throttle Position Sensor Harness Connector (4JA1TC/4JH1TC only) Reconnect the harness connector to the throttle position sensor. 14. Power Steering Pump Bracket 15. Fan 16. Vacuum Hose Connect the vacuum hose to the EGR valve and the intake throttle.

• Page 207: Injection Nozzle (4Ja1L)

  FUEL SYSTEM 6C – 25 INJECTION NOZZLE (4JA1L) DISASSEMBLY RTW76CMF000401 Disassembly Steps Retaining nut Collar Nozzle & pin Spring seat Spacer & pin First spring Lift Piece Shim (First nozzle opening Spring seat pressure adjustment) Push rod Nozzle holder body Shim (Second nozzle opening Eye bolt pressure adjustment)

• Page 208: Reassembly

  6C – 26 FUEL SYSTEM REASSEMBLY RTW76CMF000501 Reassembly Steps Nozzle holder body Spring seat Shim (First opening pressure Lift Piece adjustment) Spacer & pin First spring Nozzle & pin Spring seat Retaining nut Collar Eye bolt Second spring Push rod Shim (Second opening pressure adjustment) Important Operations…

• Page 209
  FUEL SYSTEM 6C – 27 REASSEMBLY AND ADJUSTMENT PROCEDURE Adjust the first nozzle opening pressure using the shim. First nozzle opening pressure adjustment Confirm the full needle valve lift in accordance with the Full needle valve lift confirmation closed method. Confirm pre-lift in accordance with the closed method.
• Page 210
  6C – 28 FUEL SYSTEM Injection Nozzle Adjustment First nozzle opening pressure adjustment 1.Clamp the nozzle holder in a vise. 040MV015.tif 2. Install the shim, first spring and spring seat in the nozzle holder. 040MV016.tif 3. Install the collar, second spring, shim, spring seat and pushrod in the nozzle holder.
• Page 211
  FUEL SYSTEM 6C – 29 5. Install the pins in the spacer. 6. Install the nozzle on the spacer. 040MV019.tif 7. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder. Retaining nut: 157892-3200 (Bosch AS) Gasket: 157892-5100 (Bosch AS) (Bosch AS = Bosch Automotive Systems Corporation) 040MV010.tif…
• Page 212
  6C – 30 FUEL SYSTEM • First nozzle opening pressure adjusting shims Parts No. (ISUZU) Thickness mm (in) 115349-0420 0.40 (0.0157) 115349-0430 0.50 (0.0197) 115349-0440 0.52 (0.0205) 115349-0450 0.54 (0.0213) 115349-0460 0.56 (0.0221) 115349-0470 0.58 (0.0228) 040LX010.tif 115349-0480 0.60 (0.0236) 115349-0490 0.70 (0.0275)
• Page 213
  Pin (L=100 mm (3.9 in)): 157892-5200 (Bosch AS) Dial gauge: 157954-3800 (Bosch AS) 185317-0150 (ISUZU) 040MV029.tif 5. Secure the dial gauge to the nozzle holder using the nut so that the pin contacts the tip of the first spring seat.
• Page 214
  6C – 32 FUEL SYSTEM 8. Operate the nozzle tester and increase the in-line pressure to 34.3 — 44.1 MPa (350 — 450 kg/cm ) so that the nozzle’s needle valve moves through its full lift. Record full lift ‘L’. (Read dial gauge) Nozzle Full Lift mm (in) 0.25 ±…
• Page 215
  Service kit 105017-2990 (Bosch AS) 897302-3070 (ISUZU) 040MV031.tif Second nozzle opening pressure confirmation 1. After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3 — 44.1 MPa (350 — 450 kg/cm ) so that the nozzle’s needle valve moves…
• Page 216
  6C – 34 FUEL SYSTEM 2. Release the nozzle tester handle so that in-line pressure decreases. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little. 040MV022.tif 3. Then, read the pressure gauge indication (second nozzle opening pressure) the instant that the dial gauge indicates the specified needle valve lift (usually pre-lift + 0.05 mm).
• Page 217
  Use a micrometer to measure shim thickness. • Use some combination of 3 adjusting shims to 040MV017.tif adjust the pressure. • Second nozzle opening pressure adjusting shims Part No. Thickness Part No. Thickness (ISUZU) (mm) (ISUZU) (mm) 897116-0290 0.10 897116-0380 0.53 897116-0320 0.20 897116-0390 0.54…
• Page 218
  6C – 36 FUEL SYSTEM 4. Set the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray condition, seat oil tightness and each part for oil leaks. 5. When replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service kit.

• Page 219: Special Tools

  FUEL SYSTEM 6C – 37 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER TOOL NAME 5-8840-2602-0 Remover: fuel pump retainer ring (J-39765)

• Page 220
  MEMO ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
• Page 221
  ENGINE ELECTRICAL 6D – 1 SECTION 6D ENGINE ELECTRICAL TABLE OF CONTENTS PAGE Main Data and Specifications………………6D — 2 General Description ………………….6D — 3 Torque Specifications ………………… 6D — 5 Generator ……………………. 6D — 7 Removal and Installation ……………….. 6D — 7 Disassembly ……………………

• Page 222: Main Data And Specifications

  6D – 2 ENGINE ELECTRICAL MAIN DATA AND SPECIFICATIONS Description Item Generator Type AC generator with IC regulator and vacuum pump Hitachi LR160-503E Hitachi LR180-513B Voltage Drive and rotation V-belt, clockwise viewed from the drive pulley Ground polarity Negative Maximum output Engine speed ratio to 1 1.788…

• Page 223: General Description

  ENGINE ELECTRICAL 6D – 3 GENERAL DESCRIPTION GENERATOR STARTER MOTOR 066L300004 065L300002 The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown in charging circuit diagram. The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.

• Page 224
  6D – 4 ENGINE ELECTRICAL CHARGING CIRCUIT DIAGRAM RTW46DSH005101 STARTING CIRCUIT DIAGRAM RTW46DSH005501…

• Page 225: Torque Specifications

  ENGINE ELECTRICAL 6D – 5 TORQUE SPECIFICATIONS GENERATOR N m (kg m/Ib ft) RTW86DLF000101…

• Page 226
  6D – 6 ENGINE ELECTRICAL STARTER MOTOR N m (kg m/Ib ft) RTW86DLF000201…

• Page 227: Generator

  ENGINE ELECTRICAL 6D – 7 GENERATOR REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

• Page 228
  6D – 8 ENGINE ELECTRICAL Cooling Fan Drive Belt 1. Hold the generator toward the engine. 2. Install the fan belt to the three pulleys. Crankshaft pulley Generator pulley Cooling fan drive pulley 3. Adjust the fan belt tension 033RY00009 Fan belt tension is adjusted by moving the generator.

• Page 229: Disassembly

  ENGINE ELECTRICAL 6D – 9 DISASSEMBLY RTW46DLF000401 Disassembly Step Vacuum pump O-ring Through bolt B Terminal nut Rear cover Pulley Rotor assembly Front cover assembly Rear rotor bearing Rectifier assembly Stator assembly Rotor assembly…

• Page 230
  6D – 10 ENGINE ELECTRICAL Important Operations Vacuum Pump 1. Loosen the vacuum pump fixing screws. 2. Support the vacuum pump O-ring. 3. Carefully remove the O-ring. Cover RTW46DSH000101 Through Bolt 1. Remove the M5 through bolt. 2. Separate the front and rear sides of the vacuum pump. 3.
• Page 231
  ENGINE ELECTRICAL 6D – 11 7. Rotor Assembly 1. Remove the rotor from front cover assembly. Remove the front cover stator and rectifier. RTW46DSH000301 8. Front Cover Assembly 1. Remove the front cover bearing retainer screws. 2. Remove the bearing. RTW46DSH000701 9.

• Page 232: Inspection And Repair

  6D – 12 ENGINE ELECTRICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during inspection. ROTOR ASSEMBLY 1. Inspect the slip ring faces for dirt and pitting. Wipe away any dirt with a clean cloth soaked in alcohol.

• Page 233
  ENGINE ELECTRICAL 6D – 13 STATOR COIL ASSEMBLY 1. Check for continuity across the stator coils. If there is no continuity, the stator coils must be replaced. Resistance Between The Terminal “N” and the Coil Ends (Reference) ohms Standard 066RY00022 2.
• Page 234
  6D – 14 ENGINE ELECTRICAL RECTIFIER ASSEMBLY RTW46DSF000301 Voltmeter Switch 1 DC regulated power supply Lamp 2 Lamp 1 Switch 3 Switch 2 Pulse generator Output signal Test circuit Refer to the judgment criteria shown in the Table below. Carefully check Items 1~5. If all the items are OK, the IC regulator is normal.
• Page 235
  ENGINE ELECTRICAL 6D – 15 Oil seal The oil seal must be replaced with a new one whenever the alternator is disassembled. Oil Seal Replacement 1. Push the old oil seal from the rear bracket outside holes. 2. Use the insertion tool to press the new oil seal into place.
• Page 236
  6D – 16 ENGINE ELECTRICAL Vacuum Pump Vacuum Pump Disassembly 1. Remove the center plate from the vacuum pump housing. 2. Remove the vacuum pump rotor and the vanes from the housing. Inspection RTW46DSH000901 Vacuum Pump Housing and Center Plate Inspect the vacuum pump housing and the center plate for excessive wear, abrasion, and scoring.
• Page 237
  ENGINE ELECTRICAL 6D – 17 Vacuum Pump Reassembly 1. Install the vanes to the rotor slits. The rounded side of the vanes must be facing the rotor housing. RTW46DSH001801 2. Install the rotor with the concave side facing the center plate.

• Page 238: Reassembly

  6D – 18 ENGINE ELECTRICAL REASSEMBLY RTW46DLF000501 Reassembly Step Front cover Rear rotor bearing Rotor Assembly Pulley Rectifier Assembly Stator Assembly Rear cover B Terminal nuts Through bolt O-ring Vacuum pump…

• Page 239
  ENGINE ELECTRICAL 6D – 19 Important Operations 2. Rear rotor bearing • Re-use improper parts. RTW46DSH000401 5. Rectifier 6. Stator Use a pair of long-nose plier to connect the stator coil leads and the rectifier leads. Finish the work as quickly as possible to prevent the rectifier from heat transferred by the soldering.
• Page 240
  6D – 20 ENGINE ELECTRICAL NOTE: Be sure to attach a cooler to B terminal. RTW46DSH002201 Insert the pin from the outside of the rear cover. Press the brushes into the brush holder. Complete the assembly procedure. Remove the pin after completion of the assembly procedure.
• Page 241
  ENGINE ELECTRICAL 6D – 21 9. Through Bolt 1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover. 2. Install the through bolts and tighten them to the specified torque. Through Bolt Torque N⋅m (kg⋅m/lb⋅ft) 3.1 ∼…

• Page 242: Starter Motor

  6D – 22 ENGINE ELECTRICAL STARTER MOTOR REMOVAL AND INSTALLATION Read this Section carefully before performing any removal and installation procedure. This Section gives you important points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

• Page 243: Disassembly

  ENGINE ELECTRICAL 6D – 23 DISASSEMBLY RTW460LF000201 Disassembly Step Lead wire Armature Bolt Bolt Magnetic switch assembly Bearing retainer Torsion spring Pinion assembly Plunger Pinion stopper clip Dust cover Pinion stopper Magnetic switch Return spring Screw Pinion shaft Through bolt Clutch Rear cover Dust cover…

• Page 244
  6D – 24 ENGINE ELECTRICAL Important Operations 1. Lead Wire Disconnect the lead wire at the magnetic switch. RTW46DSH002601 3. Magnetic Switch Assembly Remove the magnetic switch bolts, then remove the switch from the shift lever. RTW46DSH002701 Remove the torsion spring from the magnetic switch. RTW46DSH002801 8.
• Page 245
  ENGINE ELECTRICAL 6D – 25 Remove the yoke along with the armature and the brush holder from the gear case. Remove the brushes and commutator carefully so as not to allow them in contact with the adjacent parts. RTW46DSH003101 12. Brush Holder 13.

• Page 246: Inspection And Repair

  6D – 26 ENGINE ELECTRICAL INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during inspection. ARMATURE 1. Measure the commutator run-out. Replace the commutator if the measured run-out exceeds the specified limit. Commutator Run-Out mm (in) Standard…

• Page 247
  ENGINE ELECTRICAL 6D – 27 6. Use the circuit tester to check the armature for continuity. Hold the circuit tester probes against two commutator segments. Repear Step 1 at different segments of the armature core. There should be continuity between all segments of the commutator.
• Page 248
  6D – 28 ENGINE ELECTRICAL BRUSH AND BRUSH HOLDER 1. Use a vernier caliper to measure the brush length (four brushes). Replace the brushes as a set if one or more of the brush lengths is less than the specified limit. Brush Length mm (in) Standard…

• Page 249: Reassembly

  ENGINE ELECTRICAL 6D – 29 REASSEMBLY RTW46DLF000601 Reassembly Steps Magnetic switch assembly Pinion stopper Magnetic switch Pinion stopper clip Dust cover Bearing retainer Plunger Bolt Torsion spring Motor assembly Shift lever Armature Gear case Yoke Dust cover Brush holder Bolt Rear cover Pinion assembly Screw…

• Page 250
  6D – 30 ENGINE ELECTRICAL Important Operations 1. Magnetic Switch Assembly 1. Attach the torsion spring to the hole in the magnetic switch as illustrated. 2. Insert the shift lever into the plunger hole of the magnetic switch. RTW46DSH005601 7. Gear Case 3,8.
• Page 251
  ENGINE ELECTRICAL 6D – 31 24. Through Bolt Install the through bolts in the rear cover and tighten them to the specified torque. Through Bolt Torque N⋅m (kg⋅m/lb⋅ft) 8.1 (0.83/6.00) 065RY00044 25. Lead Wire Connect the lead wire in the magnetic switch and tighten the terminal nut to the specified torque.
• Page 252
  6D – 32 ENGINE ELECTRICAL MAGNETIC SWITCH The following tests must be performed with the starter motor fully assembled. The yoke lead wire must be disconnected from the “M” terminal. To prevent coil burning, complete each test as quickly as possible (within three to five seconds).

• Page 253: Pre-Heating System

  ENGINE ELECTRICAL 6D – 33 PRE-HEATING SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during inspection. VISUAL CHECK Check the main fuses and glow indicator for damage. Replace the part(s) if required. GLOW RELAY The glow relay is located in the relay box the engine compartment.

• Page 254
  MEMO ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
• Page 255
  Engine Control System (4JH1) 6E-1 SECTION 6E ENGINE CONTROL SYSTEM (4JH1) TABLE OF CONTENTS Specifications …………. 6E-4 DTC P0110 (Symptom Code 2) Schematic And Routing Diagrams ….. 6E-5 (Flash Code 23) ……….6E-75 Vacuum Hose Routing Diagram…… 6E-5 DTC P0115 (Symptom Code 1) Engine Controls Schematics ……
• Page 256
  6E-2 Engine Control System (4JH1) DTC P0380 (Symptom Code DTC P1120 (Symptom Code D) (Flash Code 66) ……….6E-126 (Flash Code 21) ……….6E-184 DTC P0381 (Symptom Code 4) DTC P1120 (Symptom Code E) (Flash Code 67) ……….6E-128 (Flash Code 21) ……….6E-187 DTC P0381 (Symptom Code DTC P1173 (Symptom Code 3) (Flash Code 67) ……….6E-131…
• Page 257
  Engine Control System (4JH1) 6E-3 Rough, Unstable, or Incorrect Idle And Stalling…………6E-242 Cut Out, Misses……….6E-244 Surges/Chuggles……….6E-245 Lack of Power, Sluggishness, Sponginess ..6E-248 Hesitation, Sag, Stumble………6E-250 Fuel Knock/Combustion Noise……6E-252 Poor Fuel Economy………6E-253 Excessive Smoke (Black Smoke) ….6E-254 Excessive Smoke (White Smoke) ….6E-255 Repair Instructions ……….6E-257 Engine Control Module (ECM) Replacement ..6E-257 Service Programming System (SPS)
• Page 258
  6E-4 Engine Control System (4JH1) Specifications Temperature vs Resistance Engine Coolant Temperature vs. Resistance Altitude vs Barometric Pressure °C °F Ohms Barometric Altitude Temperature vs. Resistance Value (Approximately) Altitude Measured Pressure Measured in in Meters (m) Measured in Feet (ft) Kilopascals (kPa) Determine your altitude by contacting a local weather station or by using another reference source.
• Page 259
  Engine Control System (4JH1) 6E-5 Schematic And Routing Diagrams Vacuum Hose Routing Diagram Normal Altitude Spec RTW66EMF001001 Legend 1. Vacuum Pump 5. Intake Duct 2. Blue Stripe Vacuum Hose 6. Yellow Stripe Vacuum Hose 3. EGR Solenoid Valve 7. EGR Valve 4.
• Page 260
  6E-6 Engine Control System (4JH1) High Altitude Spec RTW66EMF001101 Legend 1. Vacuum Pump 8. Port Z 2. White Stripe Vacuum Hose 9. Blue Stripe Vacuum Hose 3. EGR Solenoid Valve 10. Turbocharger Solenoid Valve 4. EGR Valve 11. White Stripe Vacuum Hose 5.
• Page 261
  Engine Control System (4JH1) 6E-7 Engine Controls Schematics Power Distribution (1) RTW86EXF004801…
• Page 262
  6E-8 Engine Control System (4JH1) Power Distribution (2) RTW86EXF004901…
• Page 263
  Engine Control System (4JH1) 6E-9 Starting System RTW86EXF005001…
• Page 264
  6E-10 Engine Control System (4JH1) Charging System RTW86EXF005101…
• Page 265
  Engine Control System (4JH1) 6E-11 ECM Power and PCU RTW86EXF003001…
• Page 266
  6E-12 Engine Control System (4JH1) ECM Ground and DLC RTW86EXF005201…
• Page 267
  Engine Control System (4JH1) 6E-13 Gauges and Warning Lamps RTW86EXF003201…
• Page 268
  6E-14 Engine Control System (4JH1) A/C & Neutral Switch Resister, CKP Sensor, APP Sensor and Idle Switch RTW86EXF003301…
• Page 269
  Engine Control System (4JH1) 6E-15 MAF & IAT, Vacuum Pressure and ECT Sensors RTW86EXF003401…
• Page 270
  6E-16 Engine Control System (4JH1) A/C Control System, Glow Control System, Inhibitor Switch (A/T) and Neutral Switch (M/T) RTW86EXF003501…
• Page 271
  Engine Control System (4JH1) 6E-17 EGR Solenoid Valve, Turbocharger Solenoid Valve, Clutch Switch and Stop Light Switch RTW86EXF003601…
• Page 272
  6E-18 Engine Control System (4JH1) Component Locator Engine Controls Component Views Legend 1. Mass Air Flow (MAF) & Intake Air Temperature 4. Battery (IAT) Sensor Assembly 5. Relay & Fuse Box 2. Throttle Cable 6. EGR Cooler (Euro3) / EGR Pipe (Except Euro3) 3.
• Page 273
  Engine Control System (4JH1) 6E-19 Legend 1. Accelerator Pedal Position (APP) Sensor & Idle 3. Fuel Injection Pump Assembly Switch 4. Fuel Filter (Except Euro 3) 2. Fuel Iinjection Pump Control Unit (PCU) Legend 1. Mass Air Flow (MAF) & Intake Air Temperature 2.
• Page 274
  6E-20 Engine Control System (4JH1) Legend Legend 1. Engine Control Module (ECM) 1. EGR Solenoid Valve 2. To Vacuum Pump 3. To EGR Valve 4. To Intake Duct Legend 1. Engine Coolant Temperature (ECT) Sensor 2. Thermo Unit for Water Temperature Gauge Legend 1.
• Page 275
  Engine Control System (4JH1) 6E-21 Legend 1. Vehicle Speed Sensor (VSS)
• Page 276
  6E-22 Engine Control System (4JH1) Engine Control Module (ECM) Connector End Views RTW86ESF000101 Connector No. C-56 Connector No. C-56 Connector Color Black Connector Color Black Test Adapter No. J-35616-4A Test Adapter No. J-35616-4A (Pins 20, 21, 41, 61, 62) (Pins 20, 21, 41, 61, 62) J-35616-64A J-35616-64A (Pins 1-19, 22-40, 41-60, 63-81)
• Page 277
  Engine Control System (4JH1) 6E-23 Connector No. C-56 Connector Color Black Test Adapter No. J-35616-4A (Pins 20, 21, 41, 61, 62) J-35616-64A (Pins 1-19, 22-40, 41-60, 63-81) Pin No. Wire Color Pin Function Not Used Not Used RED/GRN APP Sensor Low Reference Not Used Not Used Not Used…
• Page 278
  6E-24 Engine Control System (4JH1) RTW86ESF000201 Connector No. C-57 Connector No. C-57 Connector Color Black Connector Color Black Test Adapter No. J-35616-64A Test Adapter No. J-35616-64A Pin No. Wire Color Pin Function Pin No. Wire Color Pin Function WHT/BLU Vacuum Pressure Sensor CKP Sensor Low Reference…
• Page 279
  Engine Control System (4JH1) 6E-25 Engine Control Connector End Views Connector No. C-44 Accelerator Pedal Position (APP) Sensor Connector Color White Test Adapter No. J-35616-40 (Pin 1 – 2) J35616-2A (Pin 3 – 4) Wire Color Pin Function Brake Pedal 1 Switch (Stop Lamp Pedal Switch) 12 Volts Feed Brake Pedal 1 Switch (Stop Lamp Pedal Switch) Signal…
• Page 280
  6E-26 Engine Control System (4JH1) Clutch Switch Connector No. B-58 Connector Color Black Test Adapter No. J-35616-2A Wire Color Pin Function Ground Ground Diagnostic Request Switch YEL/BLU Keyword 2000     Not Used     Not Used …
• Page 281
  Engine Control System (4JH1) 6E-27 Engine Coolant Temperature Coolant (ECT) Sensor Connector No. Connector Color Black Test Adapter No. J-35616-8 Wire Color Pin Function     Not Used Engine Shutoff (ESO) Solenoid Valve Control Signal Input Ground BLU/RED Battery voltage CKP Sensor Signal Input …
• Page 282
  6E-28 Engine Control System (4JH1) Idle Switch Connector No. C-116 Connector Color Black Test Adapter No. J-35616-4A Wire Color Pin Function BLU/RED MAF Sensor Ignition Voltage Feed BLK/RED MAF Sensor & IAT Sensor Low Reference WHT/RED MAF Sensor 5 Volts Reference GRN/RED MAF Sensor Signal Turbocharger Solenoid Valve…
• Page 283
  Engine Control System (4JH1) 6E-29 Vacuum Pressure Sensor Connector No. E-44 Connector Color Gray Test Adapter No. J-35616-33 Wire Color Pin Function VSS 12 Volts Feed LT GRN/ VSS Low Reference BLK/YEL VSS Signal RTW66ESH001001 Connector No. C-124 Connector Color Black Test Adapter No.
• Page 284
  6E-30 Engine Control System (4JH1) Diagnostic Information And Prosedures Engine Control System Check Sheet ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name Customer’s Name Model & Model Year Driver’s Name Chassis No. Date Vehicle Brought In Engine No. License No. Odometer Reading Km/miles Engine Does □…
• Page 285
  Engine Control System (4JH1) 6E-31 Diagnostic Starting Point — Engine Controls Reading Flash Diagnostic Trouble Codes Begin the system diagnosis with Diagnostic System The provision for communicating with the ECM is the Check — Engine Controls. The Diagnostic System Check Data Link Connector (DLC).
• Page 286
  6E-32 Engine Control System (4JH1) Breaker Box Breaker Box Connection Type A Breaker Box Connection Type B RTW66ESH003601 RTW66ESH003701 Legend Legend 1. Engine Control Module (ECM) 1. Engine Control Module (ECM) 2. Harness Adapter 2. Harness Adapter 3. ECM — Harness Connector 3.
• Page 287
  Engine Control System (4JH1) 6E-33 Diagnostic System Check Engine Controls 11. If there are other modules with DTCs set, refer to Description the DTC list. The DTC list directs you to the appropriate The Diagnostic System Check-Engine Controls is an diagnostic procedure.
• Page 288
  6E-34 Engine Control System (4JH1) Step Action Value(s) 1. Turn ON the ignition, with the engine OFF. 2. Attempt to establish communication with the listed control modules. • Engine control module (ECM) •  Transmission control module (TCM) (A/T Go to scan tool only) Does Not •…
• Page 289
  Engine Control System (4JH1) 6E-35 Step Action Value(s) 1. Review the following symptoms. 2. Refer to the applicable symptom diagnostic table: • Hard Start • Rough, Unstable, or Incorrect Idle and Stalling • Cuts Out, Misses • Surge/Chuggles  • Lack Power, Sluggishness,…
• Page 290
  6E-36 Engine Control System (4JH1) Scan Tool Data List The scan tool values from a properly running engine The scan tool Data List contains all engine related may be used for comparison with the engine you are parameters that are available on the scan tool. Use the diagnosing.
• Page 291
  Engine Control System (4JH1) 6E-37 Typical Data Value at Typical Data Value at 2000 Scan Tool Parameter Units Displayed Engine Idle Glow Relay Command On/Off Glow Indicator Lamp Command On/Off Malfunction Indicator Lamp (MIL) Command On/Off A/C Request Signal On/Off A/C Relay Command On/Off Scan Tool Data Definitions…
• Page 292
  6E-38 Engine Control System (4JH1) Intake Air Temperature Mass Air Flow Sensor This parameter displays the temperature of the intake This parameter displays the air flow into the engine as air based on a voltage input from the intake air calculated by the ECM based on the mass air flow temperature (IAT) sensor to the ECM.
• Page 293
  Engine Control System (4JH1) 6E-39 Brake Pedal 2 Switch A/C Relay Command This parameter displays the state of the brake pedal 2 This parameter displays the commanded state of the switch as determined by the ECM terminal (pin 65 of C- A/C compressor relay control circuit (pin 38 of C-56).
• Page 294
  6E-40 Engine Control System (4JH1) Scan Tool Output Controls scan tool Output Additional Menu Descriptions Control Selection(s) The purpose of this test is for checking whether the EGR valve is correctly moved with command. Restricted valve movement by foreign materials, EGR Solenoid Valve Solenoids excessive deposits, a faulty vacuum hose routing, a faulty EGR valve or a…
• Page 295
  Engine Control System (4JH1) 6E-41 Scan Tool Does Not Power Up • Common signal ground at terminal 5. Circuit Description The scan tool will power up with the ignition OFF. Some The data link connector (DLC) is a standardized 16- modules however, will not communicate unless the cavity connector.
• Page 296
  6E-42 Engine Control System (4JH1) Scan Tool Does Not Communicate with Keyword 2000 Device Circuit Description • A Keyword 2000 serial data circuit open. The engine control module (ECM), transmission control module (TCM) and anti-theft (keyless entry) control unit • A Keyword 2000 serial data circuit shorted to (ACU) all communicate with the scan tool over the ground.
• Page 297
  Engine Control System (4JH1) 6E-43 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the ECM C-56 and C-57 harness connectors. 3. Turn ON the ignition, with the engine OFF.  4. Attempt to communicate with the TCM and EHCU.
• Page 298
  6E-44 Engine Control System (4JH1) Lost Communication with The Engine Control Module (ECM) Circuit Description The engine control module (ECM), transmission control Lost Communication with The Engine Control module (TCM) and electronic hydraulic control unit Module (ECM) (EHCU) all communicate with the scan tool over the Schematic Reference: Engine Controls Schematics Keyword 2000 serial data link.
• Page 299
  Engine Control System (4JH1) 6E-45 Step Action Value(s) Important: An open in a ground circuit at the ECM will not cause a loss of communication.  1. Check ECM ground for corrosion and tightness. 2. Clean or tighten grounds as necessary. Did you find and correct the condition? Go to Step 17 Go to Step 9…
• Page 300
  6E-46 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Reconnect all disconnected connectors. 3. Turn the ignition ON with the engine OFF.  4. Attempt to establish scan tool communications with the ECM. Does the scan tool communicate with the ECM? System OK Go to Step 3…
• Page 301
  Engine Control System (4JH1) 6E-47 Engine Cranks but Does Not Run Diagnostic Aids Description • If an intermittent condition is suspected, refer to The Engine Cranks but Does Not Run diagnostic table Intermittent Conditions in this section. is an organized approach to identifying a condition that causes an engine to not start.
• Page 302
  6E-48 Engine Control System (4JH1) Step Action Value(s) 1. Inspect the high pressure side between the fuel injection pump and the fuel injection nozzles for fuel leakage. The following components may contain an external leak. • Fuel injection pump • Fuel injection pump control unit (PCU) •…
• Page 303
  Engine Control System (4JH1) 6E-49 Step Action Value(s) 1. Disconnect the fuel hose that connects to the fuel injection pump suction side. In order to measure the discharged fuel amount, put the hose into a bottle or a container. 2. Pump the priming pump on the fuel filter. Notice: If there is a leak on the suction side of the fuel system, the fuel from the disconnected hose will not flow out sufficiently and fuel leakage may occur.
• Page 304
  6E-50 Engine Control System (4JH1) Diagnostic Trouble Code (DTC) List Symptom Flash MIL Status DTC Description Code Code P0100 Mass Air Flow (MAF) Sensor Circuit 5V Reference High Voltage P0100 Mass Air Flow (MAF) Sensor Voltage 5V Reference Circuit Low Voltage P0100 Mass Air Flow (MAF) Sensor Circuit Low Voltage P0100…
• Page 305
  Engine Control System (4JH1) 6E-51 Symptom Flash MIL Status DTC Description Code Code P0400 Exhaust Gas Recirculation (EGR) Solenoid Circuit Low Voltage P0400 Exhaust Gas Recirculation (EGR) System Performance P0400 Exhaust Gas Recirculation (EGR) Solenoid Circuit High Voltage P0500 Vehicle Speed Sensor (VSS) Circuit P0500 Vehicle Speed Sensor (VSS) Circuit P0500…
• Page 306
  6E-52 Engine Control System (4JH1) Symptom Flash MIL Status DTC Description Code Code P1612 Immobilizer Wrong Signal P1613 Immobilizer No Signal P1614 Wrong Transponder Key P1625 ECM Main Relay Circuit P1625 ECM Main Relay Circuit P1630 Injection Pump Fuel Metering Control P1630 Injection Pump Fuel Metering Control P1650…
• Page 307
  Engine Control System (4JH1) 6E-53 DTC P0100 (Symptom Code 7) (Flash Code 65) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL when the diagnostic The mass air flow (MAF) sensor is an air flow meter that measures the amount of air that enters the engine.
• Page 308
  6E-54 Engine Control System (4JH1) Step Action Value(s) 1. Test the 5 volts reference circuit between the engine control module (ECM) (pin 2 of C-57 connector) and the MAF sensor (pin 4 of C-116 connector) for the following conditions:  •…
• Page 309
  Engine Control System (4JH1) 6E-55 DTC P0100 (Symptom Code 9) (Flash Code 65) • The ECM uses a MAF substitution of 1600 mg/strk Circuit Description for engine control. The mass air flow (MAF) sensor is an air flow meter that •…
• Page 310
  6E-56 Engine Control System (4JH1) Step Action Value(s) Replace the MAF sensor. Refer to Mass Air Flow  Sensor Replacement in this section.  Did you complete the replacement? Go to Step 7 Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.
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  Engine Control System (4JH1) 6E-57 DTC P0100 (Symptom Code B) (Flash Code 65) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL that the diagnostic The mass air flow (MAF) sensor is an air flow meter that measures the amount of air that enters the engine.
• Page 312
  6E-58 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the mass air flow (MAF) sensor harness connector. 3. Connect a test lamp between the ignition voltage  feed circuit of the MAF sensor harness (pin 2 of C-116 connector) and a known good ground.
• Page 313
  Engine Control System (4JH1) 6E-59 Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect intermittent poor connections at the harness connector of the MAF  sensor (pins 2, 4 and 5 of C-116 connector). 3. Repair the connection(s) as necessary. Did you find and correct the condition? Go to Step 17 Go to Step 15…
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  6E-60 Engine Control System (4JH1) DTC P0100 (Symptom Code C) (Flash Code 65) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL when the diagnostic The mass air flow (MAF) sensor is an air flow meter that measures the amount of air that enters the engine.
• Page 315
  Engine Control System (4JH1) 6E-61 Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a test lamp between the low reference  circuit of the MAF sensor harness (pin 3 of C-116 connector) and a battery voltage. Does the test lamp illuminate? Go to Step 7 Go to Step 6 Important: The MAF sensor may be damaged if the…
• Page 316
  6E-62 Engine Control System (4JH1) DTC P0105 (Symptom Code 1) (Flash Code 34) Circuit Description Action Taken When the DTC Sets The vacuum pressure sensor is installed to the • The ECM illuminates the malfunction indicator turbocharger wastegate control hose and it detects the lamp (MIL) when the diagnostic runs and fails.
• Page 317
  Engine Control System (4JH1) 6E-63 Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a DMM between the 5 volts reference circuit of the vacuum pressure sensor harness (pin 3 of C-124 connector) and a known good 5.5 volts ground.
• Page 318
  6E-64 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool.  3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 3 Go to Step 14…
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  Engine Control System (4JH1) 6E-65 DTC P0105 (Symptom Code 2) (Flash Code 34) Circuit Description Action Taken When the DTC Sets The vacuum pressure sensor is installed to the • The ECM illuminates the malfunction indicator turbocharger wastegate control hose and it detects the lamp (MIL) when the diagnostic runs and fails.
• Page 320
  6E-66 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a 3-amp fused jumper wire between the 5 volts reference circuit and the signal circuit of the vacuum pressure sensor harness (pins 1 and  3 of C-124 connector).
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  Engine Control System (4JH1) 6E-67 Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool.  3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 3 Go to Step 12…
• Page 322
  6E-68 Engine Control System (4JH1) DTC P0105 (Symptom Code 7) (Flash Code 34) Circuit Description Action Taken When the DTC Sets The vacuum pressure sensor is installed to the • The ECM illuminates the malfunction indicator turbocharger wastegate control hose and it detects the lamp (MIL) when the diagnostic runs and fails.
• Page 323
  Engine Control System (4JH1) 6E-69 Step Action Value(s) Observe the DTC Information with the scan tool. Go to Diagnostic  Are there any DTCs that you have not diagnosed? Trouble Code (DTC) List System OK…
• Page 324
  6E-70 Engine Control System (4JH1) DTC P0105 (Symptom Code 9) (Flash Code 34) Circuit Description Action Taken When the DTC Sets The vacuum pressure sensor is installed to the • The ECM illuminates the malfunction indicator turbocharger wastegate control hose and it detects the lamp (MIL) when the diagnostic runs and fails.
• Page 325
  Engine Control System (4JH1) 6E-71 Step Action Value(s) Replace the vacuum pressure sensor. Refer to Vacuum Pressure Sensor Replacement in this  section.  Did you complete the replacement? Go to Step 7 Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.
• Page 326
  6E-72 Engine Control System (4JH1) DTC P0110 (Symptom Code 1) (Flash Code 23) • The ECM uses an IAT substitution of 0°C (32°F) Circuit Description for engine control. The intake air temperature (IAT) sensor is fitted between the air cleaner and turbocharger internal to the Condition for Clearing the MIL/DTC mass air flow (MAF) sensor.
• Page 327
  Engine Control System (4JH1) 6E-73 Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a 3-amp fused jumper wire between the signal circuit and the low reference circuit of the IAT sensor harness (pins 1 and 3 of C-116 110°C (230°F) connector).
• Page 328
  6E-74 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool.  3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 2 Go to Step 15…
• Page 329
  Engine Control System (4JH1) 6E-75 DTC P0110 (Symptom Code 2) (Flash Code 23) • The ECM uses an IAT substitution of 0°C (32°F) Circuit Description for engine control. The intake air temperature (IAT) sensor is fitted between the air cleaner and turbocharger internal to the Condition for Clearing the MIL/DTC mass air flow (MAF) sensor.
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  6E-76 Engine Control System (4JH1) Step Action Value(s) Replace the IAT sensor. Refer to Mass Air Flow Sensor Replacement in this section. (IAT sensor is  internal to MAF sensor)  Did you complete the replacement? Go to Step 8 1.
• Page 331
  Engine Control System (4JH1) 6E-77 DTC P0115 (Symptom Code 1) (Flash Code 14) • The ECM uses an ECT substitution of 60°C Circuit Description (120°F) for injection timing control. The engine coolant temperature (ECT) sensor is • The ECM uses an ECT substitution of -15°C (5°F) installed to the thermostat housing.
• Page 332
  6E-78 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a 3-amp fused jumper wire between the signal circuit and the low reference circuit of the ECT sensor harness (pins 1 and 2 of E-41 connector).
• Page 333
  Engine Control System (4JH1) 6E-79 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 14 1. Reconnect all previously disconnected harness connector(s).
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  6E-80 Engine Control System (4JH1) DTC P0115 (Symptom Code 2) (Flash Code 14) • The ECM uses an ECT substitution of 60°C Circuit Description (120°F) for injection timing control. The engine coolant temperature (ECT) sensor is • The ECM uses an ECT substitution -15°C (5°F) for installed to the thermostat housing.
• Page 335
  Engine Control System (4JH1) 6E-81 Step Action Value(s) Replace the ECT sensor. Refer to Engine Coolant  Temperature Sensor Replacement in this section.  Did you complete the replacement? Go to Step 8 1. Turn OFF the ignition. 2. Disconnect the ECM harness connector. 3.
• Page 336
  6E-82 Engine Control System (4JH1) DTC P0180 (Symptom Code B) (Flash Code 15) • The ECM uses a default FT substitution for engine Circuit Description control. The fuel temperature (FT) sensor is internal to the fuel injection pump control unit (PCU). It detects fuel Condition for Clearing the MIL/DTC temperature in the fuel injection pump.
• Page 337
  Engine Control System (4JH1) 6E-83 DTC P0215 (Symptom Code A) (Flash Code 52) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • After the condition for running this DTC for 2 desired fuel injection quantity and timing using data sent seconds, the engine speed is higher than 200 from various sensors.
• Page 338
  6E-84 Engine Control System (4JH1) Step Action Value(s) 1. Clear the DTCs with the scan tool. 2. Turn OFF the ignition for 30 seconds. 3. Start the engine.  4. Monitor the DTC Information with the scan tool. 5. Turn OFF the engine. Does the DTC fail this ignition before the ECM turns OFF? Go to Step 3…
• Page 339
  Engine Control System (4JH1) 6E-85 DTC P0215 (Symptom Code B) (Flash Code 52) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • The PCU detects high voltage condition on the desired fuel injection quantity and timing using data sent ESO solenoid valve control circuit for longer than 1 from various sensors.
• Page 340
  6E-86 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Reconnect the PCU harness connector. 3. Disconnect the engine control module (ECM) C- 57 harness connector. Keep the C-56 harness connector with connected.  4. Connect a test lamp between the ESO solenoid valve control signal circuit (pin 29 of C-57 connector) and a known good ground.
• Page 341
  Engine Control System (4JH1) 6E-87 DTC P0215 (Symptom Code C) (Flash Code 52) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • The engine speed is higher than 200 RPM within 2 desired fuel injection quantity and timing using data sent seconds after the condition for running the DTC from various sensors.
• Page 342
  6E-88 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a DMM between the ESO solenoid valve control signal circuit (pin 5 of E-6 connector) and 10 volts a known good ground. 3. Turn ON the ignition, with the engine OFF. Is the DMM voltage more than the specified value? Go to Step 7 Go to Step 6…
• Page 343
  Engine Control System (4JH1) 6E-89 DTC P0215 (Symptom Code D) (Flash Code 52) Circuit Description Condition for Running the DTC The engine control module (ECM) calculates the • The ignition switch is OFF. desired fuel injection quantity and timing using data sent Condition for Setting the DTC from various sensors.
• Page 344
  6E-90 Engine Control System (4JH1) DTC P0216 (Symptom Code A, B) (Flash Code 54) Description Action Taken When the DTC Sets The engine control module (ECM) calculates the • The ECM illuminates the malfunction indicator desired fuel injection quantity and timing using data sent lamp (MIL) when the diagnostic runs and fails.
• Page 345
  Engine Control System (4JH1) 6E-91 Step Action Value(s) 1. Install the scan tool. 2. Turn OFF the ignition for 30 seconds. 3. Start the engine and let idle for 30 seconds. 4. Monitor the Diagnostic Trouble Code (DTC)  Information with the scan tool. Is DTC P0335 (Symptom Code B or D), P1335 (Symptom Code A) or P1345 (Symptom Code A) Go to Applicable…
• Page 346
  6E-92 Engine Control System (4JH1) Step Action Value(s) 1. Remove the fuel hose that connects to the fuel injection pump suction side. 2. Remove the fuel pipe connector that connects to the fuel injection pump suction side. 3. Inspect the eye bolt for any type of restriction or collapsed gauze filter.
• Page 347
  Engine Control System (4JH1) 6E-93 Step Action Value(s) 1. Reconnect the fuel pipe connector that connects to the fuel injection pump suction side. 2. Remove the fuel hose that connects to the fuel injection pump suction side. 3. Substitute a clear hose. Notice: A hose must be cleaned.
• Page 348
  6E-94 Engine Control System (4JH1) DTC P0243 (Symptom Code 3) (Flash Code 64) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) controls the • The ECM illuminates the malfunction indicator turbocharger wastegate valve based on the barometric lamp (MIL) when the diagnostic runs and fails.
• Page 349
  Engine Control System (4JH1) 6E-95 Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect for the following conditions: • Vacuum hoses are damaged or kinked • Misrouted vacuum hoses • A turbocharger solenoid valve is damaged • A vacuum pump is damaged •…
• Page 350
  6E-96 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the hand-held vacuum pump from the turbocharger wastegate valve. 3. Reconnect the vacuum hose to the turbocharger wastegate valve. 4. Disconnect vacuum hose from turbocharger solenoid valve that is connected to …
• Page 351
  Engine Control System (4JH1) 6E-97 Step Action Value(s) Observe the DTC Information with the scan tool. Go to Diagnostic  Are there any DTCs that you have not diagnosed? Trouble Code (DTC) List System OK…
• Page 352
  6E-98 Engine Control System (4JH1) DTC P0243 (Symptom Code 4) (Flash Code 64) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) controls the • The ECM illuminates the malfunction indicator turbocharger wastegate valve based on the barometric lamp (MIL) when the diagnostic runs and fails.
• Page 353
  Engine Control System (4JH1) 6E-99 Step Action Value(s) 1. Connect a test lamp between the control circuit of the turbocharger solenoid valve harness (pin 2  of C-123 connector) and battery voltage. 2. Turn ON the ignition, with the engine OFF. Does the test lamp continuously illuminate? Go to Step 9 Go to Step 7…
• Page 354
  6E-100 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected fuse or harness connector(s). 2. Clear the DTCs with the scan tool.  3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 3 Go to Step 16…
• Page 355
  Engine Control System (4JH1) 6E-101 DTC P0243 (Symptom Code 5) (Flash Code 64) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) controls the • The ECM illuminates the malfunction indicator turbocharger wastegate valve based on the barometric lamp (MIL) when the diagnostic runs and fails.
• Page 356
  6E-102 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect for the following conditions: • Vacuum hoses are damaged or kinked • Misrouted vacuum hoses • A turbocharger solenoid valve is damaged • A vacuum pump is damaged •…
• Page 357
  Engine Control System (4JH1) 6E-103 Step Action Value(s) 1. Turn OFF the ignition. 2. Reconnect the vacuum hose to the turbocharger wastegate valve. 3. Disconnect vacuum hose from turbocharger solenoid valve that is connected to the vacuum regulating valve “Z” port. …
• Page 358
  6E-104 Engine Control System (4JH1) Step Action Value(s) Observe the DTC Information with the scan tool. Go to Diagnostic  Are there any DTCs that you have not diagnosed? Trouble Code (DTC) List System OK…
• Page 359
  Engine Control System (4JH1) 6E-105 DTC P0243 (Symptom Code 6) (Flash Code 64) Circuit Description Action Taken When the DTC Sets • The ECM illuminates the malfunction indicator The engine control module (ECM) controls the turbocharger wastegate valve based on the barometric lamp (MIL) when the diagnostic runs and fails.
• Page 360
  6E-106 Engine Control System (4JH1) Step Action Value(s) 1. Inspect the following for possible causes of high boost pressure. • Wastegate valve stuck closed condition. Refer to the Turbocharger in  Engine Mechanical section for diagnosis. • Restricted intake or collapsed hose. 2.
• Page 361
  Engine Control System (4JH1) 6E-107 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the hand-held vacuum pump from the vacuum hose. 3. Connect the hand-held vacuum pump to the vacuum port of EGR valve.  4. Start the engine and let engine idle. 5.
• Page 362
  6E-108 Engine Control System (4JH1) DTC P0243 (Symptom Code (Flash Code 64) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) controls the • The ECM illuminates the malfunction indicator turbocharger wastegate valve based on the barometric lamp (MIL) when the diagnostic runs and fails.
• Page 363
  Engine Control System (4JH1) 6E-109 Step Action Value(s) 1. Test the control circuit between the engine control module (ECM) (pin 18 of C-57 connector) and the turbocharger solenoid valve (pin 2 of C-  123 connector) for a short to battery or ignition voltage.
• Page 364
  6E-110 Engine Control System (4JH1) DTC P0251 (Symptom Code 6) (Flash Code 53) Circuit Description Condition for Running the DTC The engine control module (ECM) calculates the • The fuel injection pump CMP sensor signal is desired fuel injection quantity and timing using data sent generated.
• Page 365
  Engine Control System (4JH1) 6E-111 Step Action Value(s) 1. Clear the DTCs with the scan tool. 2. Turn OFF the ignition for 30 seconds. 3. Start the engine and let idle for 30 seconds. 4. Accelerate the engine between idle and W.O.T. …
• Page 366
  6E-112 Engine Control System (4JH1) DTC P0251 (Symptom Code 7) (Flash Code 53) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) calculates the • The ECM illuminates the malfunction indicator desired fuel injection quantity and timing using data sent lamp (MIL) when the diagnostic runs and fails.
• Page 367
  Engine Control System (4JH1) 6E-113 Step Action Value(s) 1. Observe the Engine Speed parameter with the scan tool. 2. Accelerate the engine between idle and W.O.T.  (accelerator pedal full travel) many times while observing the scan tool. Does the Engine Speed parameter indicate correct engine speed? Go to Step 9 Go to Step 5…
• Page 368
  6E-114 Engine Control System (4JH1) DTC P0251 (Symptom Code 9, A, B, C) (Flash Code 53) Circuit Description The engine control module (ECM) calculates the • The PCU detects that the fuel injection solenoid desired fuel injection quantity and timing using data sent valve drive circuit is failed during self-test.
• Page 369
  Engine Control System (4JH1) 6E-115 Step Action Value(s) 1. Clear the DTCs with the scan tool. 2. Turn OFF the ignition for 30 seconds.  3. Turn ON the ignition, with the engine OFF. 4. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 3 Go to Step 5…
• Page 370
  6E-116 Engine Control System (4JH1) DTC P0251 (Symptom Code E) (Flash Code 53) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • The ECM detects communication message from desired fuel injection quantity and timing using data sent the PCU is not received for longer than 1 second.
• Page 371
  Engine Control System (4JH1) 6E-117 DTC P0335 (Symptom Code B, D) (Flash Code 43) Symptom Code D Circuit Description • The ECM detects that the CKP sensor signals are The crankshaft position (CKP) sensor is located on top of the flywheel housing. There are 4 slits spaced 90° not generated when doubled fuel injection pump on the flywheel circumference.
• Page 372
  6E-118 Engine Control System (4JH1) Step Action Value(s) 1. Connect a DMM across the CKP sensor terminals (measure the sensor output voltage). 2. Place the DMM on the AC volt scale. 3. Start the engine. 4. Monitor the DMM while accelerating the engine …
• Page 373
  Engine Control System (4JH1) 6E-119 Step Action Value(s) 1. Test the low reference circuit of the CKP sensor between the ECM (pin 22 of C-57 connector) and the CKP sensor (pin 1 of E-9 connector) for an  open circuit or high resistance. 2.
• Page 374
  6E-120 Engine Control System (4JH1) Step Action Value(s) 1. Inspect the CKP sensor for tightness. 2. Retest if the sensor was loose. 3. Remove the CKP sensor and check for damage,  metal particles on magnet and for flywheel circumference damage. Did you find and correct the condition? Go to Step 22 Go to Step 20…
• Page 375
  Engine Control System (4JH1) 6E-121 DTC P0335 (Symptom Code E) (Flash Code 43) Circuit Description Condition for Clearing the MIL/DTC The crankshaft position (CKP) sensor is located on top • The ECM turns OFF the MIL when the diagnostic of the flywheel housing. The engine control module runs and does not fail.
• Page 376
  6E-122 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Observe the Engine Speed parameter with the 5000 RPM scan tool.
• Page 377
  Engine Control System (4JH1) 6E-123 DTC P0380 (Symptom Code 4) (Flash Code 66) Circuit Description Condition for Clearing the MIL/DTC The engine control module (ECM) controls the glow • The ECM turns OFF the MIL when the diagnostic relay which supplies power to the glow plugs based on runs and does not fail.
• Page 378
  6E-124 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a test lamp between the control circuit of the glow relay (pin 3 of X-5 connector) and battery voltage.  3. Turn ON the ignition, with the engine OFF. Does the test lamp continuously illuminate (the test lamp blinks then goes out normally if the engine coolant temperature lower than 30°C [86°F])?
• Page 379
  Engine Control System (4JH1) 6E-125 Step Action Value(s) 1. Reconnect all previously disconnected fuse, relay or harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds.  4. Start the engine and warm up (allow engine coolant temperature to reach at least 65°C [149°F]).
• Page 380
  6E-126 Engine Control System (4JH1) DTC P0380 (Symptom Code (Flash Code 66) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL when the diagnostic The engine control module (ECM) controls the glow relay which supplies power to the glow plugs based on runs and does not fail.
• Page 381
  Engine Control System (4JH1) 6E-127 Step Action Value(s) 1. Reconnect all previously disconnected relay or harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds. 4. Cool down the engine as necessary (allow …
• Page 382
  6E-128 Engine Control System (4JH1) DTC P0381 (Symptom Code 4) (Flash Code 67) Circuit Description Action Taken When the DTC Sets The glow indicator lamp is located on the instrument • The ECM illuminates the malfunction indicator panel (IP) cluster. The glow control system is operated lamp (MIL) when the diagnostic runs and fails.
• Page 383
  Engine Control System (4JH1) 6E-129 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the engine control module (ECM) harness connector. 3. Turn ON the ignition, with the engine OFF.  4. Connect a 3-amp fused jumper wire between the glow indicator lamp control circuit of the ECM harness connector (pin 40 of C-56 connector) and a known good ground.
• Page 384
  6E-130 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect intermittent poor connections on the glow indicator lamp circuits at  the IP cluster (pin 8 of B-24 connector and pin 35 of B-23 connector). 3.
• Page 385
  Engine Control System (4JH1) 6E-131 DTC P0381 (Symptom Code (Flash Code 67) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL when the diagnostic The glow indicator lamp is located on the instrument panel (IP) cluster. The glow control system is operated runs and does not fail.
• Page 386
  6E-132 Engine Control System (4JH1) Step Action Value(s) 1. Test the control circuit of the glow indicator lamp between the engine control module (ECM) (pin 40 of C-56 connector) and the IP cluster (pin 35  of B-23 connector) for a short to battery or ignition voltage.
• Page 387
  Engine Control System (4JH1) 6E-133 DTC P0400 (Symptom Code 3) (Flash Code 32) Condition for Setting the DTC Circuit Description • The ECM detects that the MAF amount is 150 The engine control module (ECM) controls the exhaust gas recirculation (EGR) flow amount based on the mg/strk lower than the desired MAF for 60 engine speed, engine coolant temperature, intake air seconds.
• Page 388
  6E-134 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect for the following conditions: • An EGR valve control vacuum hose is damaged or kinked. • EGR solenoid valve vacuum hoses are damaged or kinked. •…
• Page 389
  Engine Control System (4JH1) 6E-135 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Inspect for an intermittent, for poor connections and corrosion at the harness connector of the MAF sensor (pins 2, 4 and 5 of C-116 connector).
• Page 390
  6E-136 Engine Control System (4JH1) DTC P0400 (Symptom Code 4) (Flash Code 32) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) controls the exhaust • The ECM illuminates the malfunction indicator gas recirculation (EGR) flow amount based on the lamp (MIL) when the diagnostic runs and fails.
• Page 391
  Engine Control System (4JH1) 6E-137 Step Action Value(s) 1. Connect a test lamp between the control circuit of the EGR solenoid valve harness (pin 2 of C- 115 connector) and battery voltage. 2. Perform the EGR Solenoid Valve test with the …
• Page 392
  6E-138 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected fuse or harness connector(s). 2. Clear the DTCs with the scan tool.  3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Monitor the DTC Information with the scan tool. Did the DTC fail this ignition? Go to Step 3 Go to Step 16…
• Page 393
  Engine Control System (4JH1) 6E-139 DTC P0400 (Symptom Code 5) (Flash Code 32) Action Taken When the DTC Sets Circuit Description • The ECM illuminates the malfunction indicator The engine control module (ECM) controls the exhaust gas recirculation (EGR) flow amount based on the lamp (MIL) when the diagnostic runs and fails.
• Page 394
  6E-140 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect for the following conditions: • An EGR valve control vacuum hose is damaged or kinked. • EGR solenoid valve vacuum hoses are damaged or kinked. •…
• Page 395
  Engine Control System (4JH1) 6E-141 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the MAF sensor harness connector. 3. Inspect for an intermittent, for a poor connection and corrosion at the harness connector of the MAF sensor (pin 3 of C-116 connector). 4.
• Page 396
  6E-142 Engine Control System (4JH1) DTC P0400 (Symptom Code (Flash Code 32) Circuit Description Condition for Clearing the MIL/DTC • The ECM turns OFF the MIL when the diagnostic The engine control module (ECM) controls the exhaust gas recirculation (EGR) flow amount based on the runs and does not fail.
• Page 397
  Engine Control System (4JH1) 6E-143 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 7 1. Reconnect all previously disconnected harness connector(s).
• Page 398
  6E-144 Engine Control System (4JH1) DTC P0500 (Symptom Code 1, A) (Flash Code 24) • The ECM detects that the vehicle speed sensor Circuit Description signal frequency is too high for 0.6 seconds. The vehicle speed sensor (VSS) is used by the engine control module (ECM)
• Page 399
  Engine Control System (4JH1) 6E-145 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the engine control module (ECM) harness connector. 3. Inspect for an intermittent and for a poor  connection on A/T VSS circuit at the harness connector of the ECM (pin 68 of C-56 connector).
• Page 400
  6E-146 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the VSS harness connector. 3. Inspect intermittent poor  connections at the harness connector of the VSS (pins 1, 2 and 3 of E-44 connector). 4.
• Page 401
  Engine Control System (4JH1) 6E-147 DTC P0500 (Symptom Code B) (Flash Code 24) Circuit Description Condition for Setting the DTC The vehicle speed sensor (VSS) is used by the engine • The ECM detects that the vehicle speed is lower control module (ECM)
• Page 402
  6E-148 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Remove the instrument panel (IP) cluster in order to disconnect the B-23 harness connector. 3. Disconnect cluster B-23 harness connector. 4. Turn ON the ignition, with the engine OFF. …
• Page 403
  Engine Control System (4JH1) 6E-149 Step Action Value(s) Replace the IP cluster (meter assembly). Refer to IP  Cluster Replacement in electrical section.  Did you complete the replacement? Go to Step 14 Important: Replacement must programmed. Replace the TCM. Refer to Transmission Control …
• Page 404
  6E-150 Engine Control System (4JH1) Step Action Value(s) 1. Remove the vehicle speed sensor (VSS). Refer to Vehicle Speed Sensor (VSS) Replacement in this section. 2. Visually inspect the VSS for the following conditions: •  Physical damage • Being loose •…
• Page 405
  Engine Control System (4JH1) 6E-151 Step Action Value(s) 1. Test the VSS signal circuit between the VSS (pin 3 of E-44 connector) and the IP cluster (pin 8 of B-23 connector) for the following conditions: • An open circuit • …
• Page 406
  6E-152 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected fuse or harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds.  4. Drive the vehicle. 5. Observe the Vehicle Speed parameter with the scan tool.
• Page 407
  Engine Control System (4JH1) 6E-153 DTC P0560 (Symptom Code 1) (Flash Code 35) Circuit Description The engine control module (ECM) monitors the system Condition for Clearing the DTC voltage on the ECM main relay load supply voltage • A history DTC clears after 40 consecutive driving terminal to make sure that the voltage stays within the cycles without a fault.
• Page 408
  6E-154 Engine Control System (4JH1) DTC P0560 (Symptom Code 2) (Flash Code 35) Circuit Description Condition for Clearing the DTC The engine control module (ECM) monitors the system • A history DTC clears after 40 consecutive driving voltage on the ECM main relay load supply voltage cycles without a fault.
• Page 409
  Engine Control System (4JH1) 6E-155 Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds. 4. Start the engine. 5. Load the electrical system by turning ON the 10 volts headlights, A/C, etc.
• Page 410
  6E-156 Engine Control System (4JH1) DTC P0560 (Symptom Code A) (Flash Code 35) Circuit Description Condition for Clearing the DTC The fuel injection pump control unit (PCU) monitors the • A history DTC clears after 40 consecutive driving system voltage on the engine control module (ECM) cycles without a fault.
• Page 411
  Engine Control System (4JH1) 6E-157 Step Action Value(s) Observe the DTC Information with the scan tool. Go to Diagnostic  Are there any DTCs that you have not diagnosed? Trouble Code (DTC) List System OK…
• Page 412
  6E-158 Engine Control System (4JH1) DTC P0561 (Symptom Code A) (Flash Code 18) Circuit Description Condition for Clearing the DTC The engine control module (ECM) main relay is • A history DTC clears after 40 consecutive driving energized when the ECM receives an ignition voltage cycles without a fault.
• Page 413
  Engine Control System (4JH1) 6E-159 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the ignition voltage feed harness connector (C-107) from the junction block (behind the cabin fuse block). 3. Inspect for an intermittent, for a poor connection and corrosion at the harness connector of the ignition voltage feed (pin 9 of C-107 connector).
• Page 414
  6E-160 Engine Control System (4JH1) DTC P0561 (Symptom Code B) (Flash Code 18) • The ECM turns OFF the ECM. Circuit Description The engine control module (ECM) main relay is Condition for Clearing the DTC energized when the ECM receives an ignition voltage •…
• Page 415
  Engine Control System (4JH1) 6E-161 DTC P0602 Diagnostic Aids Description Notice: The engine control module (ECM) has the ability to set • Production and service ECM does not require a diagnostic trouble code (DTC) if it detects that there is software programming when it is replaced except no vehicle identification (VIN) programmed.
• Page 416
  6E-162 Engine Control System (4JH1) DTC P0606 (Symptom Code A, B) (Flash Code 28) Description Action Taken When the DTC Sets This diagnostic applies to internal microprocessor • The ECM illuminates the malfunction indicator integrity conditions within the engine control module lamp (MIL) when the diagnostic runs and fails.
• Page 417
  Engine Control System (4JH1) 6E-163 DTC P0645 (Symptom Code 4) (Flash Code 46) Circuit Description Condition for Clearing the MIL/DTC The engine control module (ECM) controls the air • The ECM turns OFF the MIL when the diagnostic conditioning (A/C) compressor relay, which supplies runs and does not fail.
• Page 418
  6E-164 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Remove the A/C compressor relay. 3. Connect a test lamp between the voltage feed  circuit of the A/C compressor relay coil side (pin 3 of X-14 connector) and a known good ground. 4.
• Page 419
  Engine Control System (4JH1) 6E-165 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 16 1. Reconnect all previously disconnected fuse, relay or harness connector(s).
• Page 420
  6E-166 Engine Control System (4JH1) DTC P0645 (Symptom Code (Flash Code 46) Circuit Description Condition for Clearing the MIL/DTC The engine control module (ECM) controls the air • The ECM turns OFF the MIL when the diagnostic conditioning (A/C) compressor relay, which supplies runs and does not fail.
• Page 421
  Engine Control System (4JH1) 6E-167 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 7 1. Reconnect all previously disconnected relay or harness connector(s).
• Page 422
  6E-168 Engine Control System (4JH1) DTC P0703 (Symptom Code A, B) (Flash Code 25) Circuit Description Action Taken When the DTC Sets The brake pedal switch is installed on the brake pedal • The ECM illuminates the malfunction indicator bracket. The brake pedal 1 switch is a normally open lamp (MIL) when the diagnostic runs and fails.
• Page 423
  Engine Control System (4JH1) 6E-169 Step Action Value(s) Replace the Stop (15A) fuse (C-15). If the fuse continues to open, repair the short to ground on one of the circuits that is fed by the Stop (15A) fuse (C-  15) or replace the shorted attached component fed by the Stop (15A) fuse (C-15).
• Page 424
  6E-170 Engine Control System (4JH1) Step Action Value(s) Replace the ECM (10A) fuse (EB-4). If the fuse continues to open, repair the short to ground on one of the circuits that is fed by the ECM (10A) fuse (EB-  4) or replace the shorted attached component fed by the ECM (10A) fuse (EB-4).
• Page 425
  Engine Control System (4JH1) 6E-171 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 22 1. Reconnect all previously disconnected fuse or harness connector(s).
• Page 426
  6E-172 Engine Control System (4JH1) DTC P0704 (Symptom Code 6) (Flash Code 57) Circuit Description Action Taken When the DTC Sets The clutch pedal switch is installed on the clutch pedal • The ECM illuminates the malfunction indicator bracket. The clutch pedal switch is a normally closed lamp (MIL) when the diagnostic runs and fails.
• Page 427
  Engine Control System (4JH1) 6E-173 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the clutch pedal switch harness connector. 3. Turn ON the ignition, with the engine OFF. 4. Observe the Clutch Pedal Switch parameter with  the scan tool while momentarily jumping across the clutch pedal switch harness connector between pins 1 and 2 of C-77 connector.
• Page 428
  6E-174 Engine Control System (4JH1) Step Action Value(s) Replace the clutch pedal switch. Refer to Clutch  Pedal Switch Replacement in this section.  Did you complete the replacement? Go to Step 16 Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.
• Page 429
  Engine Control System (4JH1) 6E-175 DTC P1105 (Symptom Code 1) (Flash Code 86) Circuit Description Action Taken When the DTC Sets The barometric pressure (BARO) sensor is installed • The ECM illuminates the malfunction indicator inside of the engine control module (ECM) and converts lamp (MIL) when the diagnostic runs and fails.
• Page 430
  6E-176 Engine Control System (4JH1) DTC P1105 (Symptom Code 2) (Flash Code 86) Circuit Description Action Taken When the DTC Sets The barometric pressure (BARO) sensor is installed • The ECM illuminates the malfunction indicator inside of the engine control module (ECM) and converts lamp (MIL) when the diagnostic runs and fails.
• Page 431
  Engine Control System (4JH1) 6E-177 DTC P1120 (Symptom Code 1) (Flash Code 21) Circuit Description Condition for Setting the DTC The accelerator pedal position (APP) sensor is mounted • The ECM detects that the APP sensor signal on the intake throttle assembly. The engine control voltage is more than 4.5 volts for 0.5 seconds.
• Page 432
  6E-178 Engine Control System (4JH1) Step Action Value(s) Is the DMM voltage less than the specified value at 5.5 volts step 5? Go to Step 7 Go to Step 10 Important: The APP sensor may be damaged if the sensor signal circuit is shorted to a voltage source. 1.
• Page 433
  Engine Control System (4JH1) 6E-179 Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds.  4. Turn ON the ignition, with the engine OFF. 5.
• Page 434
  6E-180 Engine Control System (4JH1) DTC P1120 (Symptom Code 7) (Flash Code 21) Circuit Description Action Taken When the DTC Sets The accelerator pedal position (APP) sensor is mounted • The ECM illuminates the malfunction indicator on the intake throttle assembly. The engine control lamp (MIL) when the diagnostic runs and fails.
• Page 435
  Engine Control System (4JH1) 6E-181 Step Action Value(s) Observe the DTC Information with the scan tool. Go to Diagnostic  Are there any DTCs that you have not diagnosed? Trouble Code (DTC) List System OK…
• Page 436
  6E-182 Engine Control System (4JH1) DTC P1120 (Symptom Code 9) (Flash Code 21) Circuit Description Action Taken When the DTC Sets The accelerator pedal position (APP) sensor is mounted • The ECM illuminates the malfunction indicator on the intake throttle assembly. The engine control lamp (MIL) when the diagnostic runs and fails.
• Page 437
  Engine Control System (4JH1) 6E-183 Step Action Value(s) Replace the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement  in this section.  Did you complete the replacement? Go to Step 7 Important: Replacement must programmed.  Replace the ECM.
• Page 438
  6E-184 Engine Control System (4JH1) DTC P1120 (Symptom Code D) (Flash Code 21) Circuit Description Condition for Setting the DTC The accelerator pedal position (APP) sensor is mounted • The ECM detects APP sensor angle is stationary on the intake throttle assembly. The engine control more than 8.7%, then brake pedal is depressed for module (ECM) uses the APP sensors to determine the longer than 2 seconds.
• Page 439
  Engine Control System (4JH1) 6E-185 Step Action Value(s) 1. Check to ensure the brake pedal switch is adjusted correctly. The plunger should be all the way in when the pedal is released, yet should not  impede with the brake pedal full upward travel. 2.
• Page 440
  6E-186 Engine Control System (4JH1) Step Action Value(s) Replace the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement  in this section.  Did you complete the replacement? Go to Step 13 Important: Replacement must programmed.  Replace the ECM.
• Page 441
  Engine Control System (4JH1) 6E-187 DTC P1120 (Symptom Code E) (Flash Code 21) Circuit Description Condition for Setting the DTC The accelerator pedal position (APP) sensor is mounted Either of following condition is met. on the intake throttle assembly. The engine control •…
• Page 442
  6E-188 Engine Control System (4JH1) Step Action Value(s) 1. Turn ON the ignition, with the engine OFF. 2. Connect a DMM between the signal circuit of the idle switch harness (pin 2 of E-23 connector) and 4.5 volts a known good ground. Is the DMM voltage more than the specified value? Go to Step 5 Go to Step 6…
• Page 443
  Engine Control System (4JH1) 6E-189 Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a 3-amp fused jumper wire across the APP sensor connector between pins 2 and 3 of  the E-22 connector. 3. Turn ON the ignition, with the engine OFF. Does DTC P1120 (Symptom Code 1) set, but not P1120 (Symptom Code E)? Go to Step 15…
• Page 444
  6E-190 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds. 4. Turn ON the ignition, with the engine OFF. 5.
• Page 445
  Engine Control System (4JH1) 6E-191 DTC P1173 (Symptom Code 3) (Flash Code 22) Circuit Description Condition for Clearing the DTC • A history DTC clears after 40 consecutive driving The engine coolant temperature (ECT) sensor is installed to the thermostat housing. The ECT sensor is cycles without a fault.
• Page 446
  6E-192 Engine Control System (4JH1) Step Action Value(s) 1. Test the engine cooling system for the following condition. Refer to diagnosis of the engine cooling system section for testing. • Engine coolant level • Engine coolant leakage • Cooling fan belt slippage …
• Page 447
  Engine Control System (4JH1) 6E-193 DTC P1173 (Symptom Code 7, A) (Flash Code 22) Circuit Description Condition for Clearing the DTC • A history DTC clears after 40 consecutive driving The fuel temperature (FT) sensor is internal to the fuel injection pump control unit (PCU).
• Page 448
  6E-194 Engine Control System (4JH1) DTC P1335 (Symptom Code A) (Flash Code 43) Condition for Clearing the MIL/DTC Circuit Description • The ECM turns OFF the MIL when the diagnostic The crankshaft position (CKP) sensor is located on top of the flywheel housing. There are 4 slits spaced 90° runs and does not fail.
• Page 449
  Engine Control System (4JH1) 6E-195 Step Action Value(s) 1. Test the CKP sensor signal output circuit between the ECM (pin 12 of C-57 connector) and the fuel injection pump control unit (PCU) (pin 8 of E-6 connector) for a short to battery or ignition voltage.
• Page 450
  6E-196 Engine Control System (4JH1) DTC P1345 (Symptom Code A) (Flash Code 41) Circuit Description Action Taken When the DTC Sets • The ECM illuminates the malfunction indicator The engine control module (ECM) calculates the desired fuel injection quantity and timing using data sent lamp (MIL) when the diagnostic runs and fails.
• Page 451
  Engine Control System (4JH1) 6E-197 DTC P1520 (Symptom Code A) (Flash Code 47) Circuit Description Action Taken When the DTC Sets • The ECM illuminates the malfunction indicator (Manual Transmission) lamp (MIL) when the diagnostic runs and fails. The neutral switch is installed on the transmission gear Condition for Clearing the MIL/DTC control box.
• Page 452
  6E-198 Engine Control System (4JH1) Step Action Value(s) Replace the neutral switch. Refer to Neutral Switch  Replacement in Transmission Section.  Did you complete the replacement? Go to Step 7 Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.
• Page 453
  Engine Control System (4JH1) 6E-199 Step Action Value(s) 1. Check to ensure the inhibitor switch is adjusted correctly. 2. Adjust the inhibitor switch as necessary. Refer to  Inhibitor Switch Adjustment Automatic Transmission Section. Did you find and correct the condition? Go to Step 7 Go to Step 5 1.
• Page 454
  6E-200 Engine Control System (4JH1) DTC P1520 (Symptom Code B) (Flash Code 47) Circuit Description Condition for Clearing the MIL/DTC The neutral switch is installed on the transmission gear Important: control box. When the gear position is neutral, the • Following conditions must be met two consecutive switch is closed and the switch signal is provided to the driving cycles.
• Page 455
  Engine Control System (4JH1) 6E-201 Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the neutral switch harness connector. 3. Turn ON the ignition, with the engine OFF. 4. Observe the Neutral Switch parameter with the  scan tool while momentarily jumping across the neutral switch harness connectors between pin 1 of E-11 connector and pin 1 of E-12 connector.
• Page 456
  6E-202 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected harness connector(s). 2. Clear the DTCs with the scan tool. Important: Following conditions must be met two consecutive driving cycles before clear with the scan tool. (One driving cycle: Ignition switch ON > Engine run >…
• Page 457
  Engine Control System (4JH1) 6E-203 DTC P1605 (Symptom Code C, D, E) (Flash Code 55) Circuit Description Action Taken When the DTC Sets This diagnostic applies to internal microprocessor • The ECM illuminates the malfunction indicator integrity conditions within the engine control module lamp (MIL) when the diagnostic runs and fails.
• Page 458
  6E-204 Engine Control System (4JH1) DTC P1610 (Symptom Code A) (Flash Code 56) Circuit Description Action Taken When the DTC Sets The electronically erasable programmable read only • The ECM illuminates the malfunction indicator memory (EEPROM) memorize immobilizer security lamp (MIL) when the diagnostic runs and fails. code and secret key for communication with the •…
• Page 459
  Engine Control System (4JH1) 6E-205 DTC P1611 (Symptom Code A) (Flash Code 56) Circuit Description Condition for Clearing the MIL/DTC The electronically erasable programmable read only • The ECM turns OFF the MIL when the diagnostic memory (EEPROM) memorize immobilizer security runs and does not fail.
• Page 460
  6E-206 Engine Control System (4JH1) DTC P1612 (Symptom Code A) (Flash Code 56) Circuit Description Condition for Clearing the MIL/DTC The engine control module (ECM) communicates with • The ECM turns OFF the MIL when the diagnostic the immobilizer control unit (ICU) to execute immobilizer runs and does not fail.
• Page 461
  Engine Control System (4JH1) 6E-207 DTC P1613 (Symptom Code A) (Flash Code 56) Diagnostic Aids Circuit Description • Non programmed ECM may set this DTC. The engine control module (ECM) communicates with • Transponder key problem may set this DTC. the immobilizer control unit (ICU) to execute immobilizer function.
• Page 462
  6E-208 Engine Control System (4JH1) DTC P1614 (Symptom Code A) (Flash Code 56) Action Taken When the DTC Sets Circuit Description • The ECM illuminates the malfunction indicator The engine control module (ECM) communicates with lamp (MIL) when the diagnostic runs and fails. the immobilizer control unit (ICU) to execute immobilizer function.
• Page 463
  Engine Control System (4JH1) 6E-209 DTC P1625 (Symptom Code A) (Flash Code 76) Circuit Description Condition for Clearing the DTC The engine control module (ECM) main relay is • A history DTC clears after 40 consecutive driving energized when the ECM receives an ignition voltage cycles without a fault.
• Page 464
  6E-210 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected relay or harness connector(s). 2. Clear the DTCs with the scan tool. 3. Turn OFF the ignition for 30 seconds.  4. Start the engine. 5. Observe the DTC Information with the scan tool. 6.
• Page 465
  Engine Control System (4JH1) 6E-211 DTC P1625 (Symptom Code B) (Flash Code 76) Circuit Description Condition for Clearing the DTC The engine control module (ECM) main relay is • A history DTC clears after 40 consecutive driving energized when the ECM receives an ignition voltage cycles without a fault.
• Page 466
  6E-212 Engine Control System (4JH1) Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 9 1. Reconnect all previously disconnected relay or harness connector(s).
• Page 467
  Engine Control System (4JH1) 6E-213 DTC P1630 (Symptom Code A, B) (Flash Code 51) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • The ECM detects that the PCU monitored fuel desired fuel injection quantity and timing using data sent injection solenoid valve control current is too high.
• Page 468
  6E-214 Engine Control System (4JH1) DTC P1650 (Symptom Code A) (Flash Code 44) Circuit Description Action Taken When the DTC Sets The engine control module (ECM) calculates the • The ECM illuminates the malfunction indicator desired fuel injection quantity and timing using data sent lamp (MIL) when the diagnostic runs and fails.
• Page 469
  Engine Control System (4JH1) 6E-215 Step Action Value(s) 1. Turn OFF the ignition. 2. Reconnect the PCU harness connector. 3. Disconnect the engine control module (ECM) C- 57 harness connector. Keep the ECM C-56 harness connector with connected. 110-130Ω 4. Connect a DMM across the CAN harness (pins 23 and 24 of C-57 connector).
• Page 470
  6E-216 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the PCU harness connector. 3. Inspect intermittent poor  connections at the harness connector of the PCU (pins 1 and 2 of E-6 connector). 4. Repair the connection(s) as necessary. Did you find and correct the condition? Go to Step 18 Go to Step 16…
• Page 471
  Engine Control System (4JH1) 6E-217 DTC P1650 (Symptom Code B) (Flash Code 44) Circuit Description Condition for Setting the DTC The engine control module (ECM) calculates the • The ECM detects internal CAN controller does not desired fuel injection quantity and timing using data sent react.
• Page 472
  6E-218 Engine Control System (4JH1) DTC P1651 (Symptom Code A, B) (Flash Code 45) • The ECM does not receive the CAN messages Circuit Description from the PCU. (Symptom Code B) The engine control module (ECM) calculates the desired fuel injection quantity and timing using data sent Action Taken When the DTC Sets from various sensors.
• Page 473
  Engine Control System (4JH1) 6E-219 Step Action Value(s) 1. Turn OFF the ignition. 2. Reconnect the PCU harness connector. 3. Disconnect the engine control module (ECM) C- 57 harness connector. Keep the ECM C-56 harness connector with connected. 110-130Ω 4. Connect a DMM across the CAN harness pins 23 and 24 of C-57 connector).
• Page 474
  6E-220 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Disconnect the PCU harness connector. 3. Inspect intermittent poor  connections at the harness connector of the PCU (pins 1 and 2 of E-6 connector). 4. Repair the connection(s) as necessary. Did you find and correct the condition? Go to Step 17 Go to Step 15…
• Page 475
  Engine Control System (4JH1) 6E-221 DTC P1690 (Symptom Code 4) (Flash Code 77) Condition for Setting the DTC Circuit Description • The ECM detects a low voltage condition on the The malfunction indicator lamp (MIL) is located on the instrument panel (IP) cluster. The battery voltage is MIL control circuit for longer than 3 seconds when supplied to the MIL.
• Page 476
  6E-222 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Remove the instrument panel (IP) cluster. 3. Connect a test lamp between the voltage feed  circuit of the MIL (pin 8 of B-24 connector) and a known good ground.
• Page 477
  Engine Control System (4JH1) 6E-223 Step Action Value(s) Important: Replacement must programmed.  Replace the ECM. Refer to Engine Control Module (ECM) Replacement in this section.  Did you complete the replacement? Go to Step 17 1. Reconnect all previously disconnected fuse or harness connector(s).
• Page 478
  6E-224 Engine Control System (4JH1) DTC P1690 (Symptom Code (Flash Code 77) Circuit Description Action Taken When the DTC Sets • The ECM does not illuminates the MIL when the The malfunction indicator lamp (MIL) is located on the instrument panel (IP) cluster.
• Page 479
  Engine Control System (4JH1) 6E-225 Step Action Value(s) 1. Test the control circuit of the MIL between the engine control module (ECM) (pin 39 of C-56 connector) and the IP cluster (pin 38 of B-23  connector) for a short to battery or ignition voltage.
• Page 480
  6E-226 Engine Control System (4JH1) Glow Control System Check Description Glow Control Operation The glow control system consists of the engine control • The pre glow control system operates when the module (ECM), the glow relay and glow plugs. The glow engine coolant temperature is less than 30°C control system is operated when the engine coolant (86°F).
• Page 481
  Engine Control System (4JH1) 6E-227 Step Action Value(s) 1. Turn OFF the ignition. 2. Replace the glow relay with the starter relay or replace with a known good relay. 3. Turn ON the ignition, with the engine OFF. 4. Connect a test lamp between the metal bus bar (glow plug power supply E-49 connector) and a …
• Page 482
  6E-228 Engine Control System (4JH1) Step Action Value(s) Important: The glow plugs may be burnt out if the battery voltage supply circuit is shorted to a voltage source. Repair the short to battery or ignition voltage on the  switched battery voltage supply circuit between the glow relay (pin 1 of X-5 connector) and the glow plugs (E-49 terminal).
• Page 483
  Engine Control System (4JH1) 6E-229 DTC A/C Compressor System Check Condition for Running the A/C Compressor: Description • The engine is running. When air conditioning (A/C) and blower fan are • The A/C switch is ON. selected, and if the system has a sufficient refrigerant •…
• Page 484
  6E-230 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the blower motor switch. Go to Chart 2 of 2 2. Turn ON the A/C switch. with heater Step 8 Does the A/C compressor clutch keep OFF  (disengage)? Go to Chart 2 of 2 without heater Step Go to Step 8…
• Page 485
  Engine Control System (4JH1) 6E-231 Step Action Value(s) 1. Keep the ignition ON, with the engine OFF. 2. Keep 3-amp fused jumper wire with connected. 3. Disconnect A/C compressor clutch harness connector.  4. Connect a test lamp between A/C compressor voltage feed circuit (E-3) and a known good ground.
• Page 486
  6E-232 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Remove the thermo relay from the engine room relay block.  3. Turn ON the ignition, with the engine OFF. Does the A/C Request Signal parameter indicate OFF? Go to Step 3 Go to Step 4…
• Page 487
  Engine Control System (4JH1) 6E-233 Step Action Value(s) 1. Turn OFF the ignition. 2. Remove the thermo relay from the engine room relay block. 3. Connect a test lamp between the voltage feed  circuit (pins 2 and 3 of X-15 connector) and a known good ground.
• Page 488
  6E-234 Engine Control System (4JH1) Step Action Value(s) 1. Turn OFF the ignition. 2. Connect a test lamp between the electronic thermostat voltage feed circuit (pin 3 of C-55  connector) and a known good ground. 3. Turn ON the ignition, with the engine OFF. Does the test lamp illuminate? Go to Step 29 Go to Step 25…
• Page 489
  Engine Control System (4JH1) 6E-235 Step Action Value(s) 1. Turn OFF the ignition. 2. Inspect intermittent poor connections at the thermo relay terminals (pins  1, 2, 3 and 5 of X-15 connector). 3. Repair the connection(s) as necessary. Did you find and correct the condition? Go to Step 39 Go to Step 33 1.
• Page 490
  6E-236 Engine Control System (4JH1) Step Action Value(s) 1. Reconnect all previously disconnected fuse, relay or harness connector(s). 2. Turn OFF the ignition for 30 seconds. Refer to Applicable  3. Turn ON the ignition, with the engine OFF. Diagnostic Chart in 4.
• Page 491
  Engine Control System (4JH1) 6E-237 Symptoms – Engine Controls Symptoms – Engine Controls Important Preliminary Inspections Before Starting Faulty electrical connections or wiring cause most intermittent problems. Perform a careful visual and Perform Diagnostic System Check – Engine Controls physical inspection of the suspect connectors for the before using the symptom tables, and verify that all of following conditions: the following are true:…
• Page 492
  6E-238 Engine Control System (4JH1) Important: The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
• Page 493
  Engine Control System (4JH1) 6E-239 Checks Action Electrical Connections or Wiring Poor electrical connections, terminal tension or wiring problems cause most intermittent. To perform the following inspections: • Inspect for poor mating of the connector halves, or terminals improperly seated in the connector body.
• Page 494
  6E-240 Engine Control System (4JH1) Checks Action Electromagnetic Interference (EMI) Some electrical components/circuits are sensitive to EMI or other types of electrical and Electrical Noise noise. Inspect for the following conditions: • A misrouted harness that is too close to high voltage/high current devices such as injection components, motors, generator etc.
• Page 495
  Engine Control System (4JH1) 6E-241 Checks Action Inspect the engine control sensors for the following conditions. Refer to the scan tool Sensor Checks Data List in this section. • Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition.
• Page 496
  6E-242 Engine Control System (4JH1) Checks Action Inspect the engine mechanical for the following conditions. Refer to the Engine Engine Mechanical Checks Mechanical section. • Inspect for poor cylinder compression. Proper compression is more than 2100 kPa (309 psi). • Improper mechanical timing (timing gear) •…
• Page 497
  Engine Control System (4JH1) 6E-243 Checks Action Inspect the fuel system for the following conditions. Refer to the Fuel System section. Fuel System Checks • Inspect for water contamination in the fuel. • Inspect for external fuel leaks or fuel leakage into the engine oil. •…
• Page 498
  6E-244 Engine Control System (4JH1) Checks Action • Electromagnetic interference (EMI) on the reference circuit can cause an engine miss Additional Checks condition. The scan tool can usually detect EMI by monitoring the engine speed. A sudden increase in speed with little change in actual engine speed change indicates that EMI is present.
• Page 499
  Engine Control System (4JH1) 6E-245 Checks Action Inspect the fuel system for the following conditions. Refer to the Fuel System section. Fuel System Checks • Inspect for water contamination in the fuel. • Inspect for external fuel leaks or fuel leakage into the engine oil. •…
• Page 500
  6E-246 Engine Control System (4JH1) Checks Action • Diagnostic System Check — Engine Controls. Preliminary Checks • Ensure the driver understands the torque converter clutch (TCC) operation. • Ensure the driver understands the A/C compressor operation. • Use the scan tool in order to make sure the Vehicle Speed parameter reading matches the vehicle speedometer.
• Page 501
  Engine Control System (4JH1) 6E-247 Checks Action Inspect the fuel system for the following conditions. Refer to the Fuel System section. Fuel System Checks • Inspect for water contamination in the fuel. • Inspect for external fuel leaks or fuel leakage into the engine oil. •…
• Page 502
  6E-248 Engine Control System (4JH1) Lack of Power, Sluggishness, Sponginess Checks Action DEFINITION:The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. • Diagnostic System Check — Engine Controls. Preliminary Checks •…
• Page 503
  Engine Control System (4JH1) 6E-249 Checks Action Inspect the fuel system for the following conditions. Refer to the Fuel System section. Fuel System Checks • Inspect for water contamination in the fuel. • Inspect for external fuel leaks or fuel leakage into the engine oil. •…
• Page 504
  6E-250 Engine Control System (4JH1) Checks Action Inspect the engine mechanical for the following conditions. Refer to the Engine Engine Mechanical Check Mechanical section. • Inspect for poor cylinder compression. Proper compression is more than 2100 kPa (309 psi). • Improper mechanical timing •…
• Page 505
  Engine Control System (4JH1) 6E-251 Checks Action Inspect the fuel system for the following conditions. Refer to the Fuel System section. Fuel System Checks • Inspect for water contamination in the fuel. • Inspect for external fuel leaks or fuel leakage into the engine oil. •…
• Page 506
  6E-252 Engine Control System (4JH1) Checks Action Inspect the engine mechanical for the following conditions. Refer to the Engine Engine Mechanical Check Mechanical section. • Inspect for poor cylinder compression. Proper compression is more than 2100 kPa (309 psi). • Improper mechanical timing •…
• Page 507
  Engine Control System (4JH1) 6E-253 Checks Action Inspect the engine mechanical for the following conditions. Refer to the Engine Engine Mechanical Checks Mechanical section. • Inspect for poor cylinder compression. Proper compression is more than 2100 kPa (309 psi). • Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons, etc.
• Page 508
  6E-254 Engine Control System (4JH1) Checks Action Inspect the air intake system for the following conditions. Air Intake System Checks • Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks. • Inspect for a restriction or leak in the intercooler. •…
• Page 509
  Engine Control System (4JH1) 6E-255 Checks Action Inspect the air intake system for the following conditions. Air Intake System Checks • Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks. • Inspect for a restriction or leak in the intercooler. •…
• Page 510
  6E-256 Engine Control System (4JH1) Checks Action Inspect the air intake system for the following conditions. Air Intake System Checks • Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks. • Inspect for a restriction or leak in the intercooler. •…
• Page 511
  Engine Control System (4JH1) 6E-257 Repair Instructions Engine Control Module (ECM) Replacement Engine Control Module (ECM) Replacement Procedure Important: If the ECM is to be replaced the following programmed contents MUST be reprogrammed into the new ECM. • Vehicle identification number (VIN). •…
• Page 512
  6E-258 Engine Control System (4JH1) 1. Connect the scan tool to the vehicle DLC, with the Before Programming a Control Module engine and the scan tool OFF. Important: 2. Turn ON the scan tool. DO NOT program an existing ECM with the identical 3.
• Page 513
  Engine Control System (4JH1) 6E-259 • DO disturb tool harnesses while i. During obtaining information, the scan tool is programming. If an interruption occurs during the receiving information from any modules at the programming procedure, programming failure or same time. But only ECM information is ECM damage may occur.
• Page 514
  6E-260 Engine Control System (4JH1) • Destination Code Pass-Thru programming allows the scan tool to remain j. Select Next. connected to the terminal and to the vehicle throughout k. Verify your selection on the Summary screen. the programming process. The vehicle must be in close Important: proximity to the terminal while using Pass-Thru.
• Page 515
  Engine Control System (4JH1) 6E-261 2. Connect a APP sensor connectors to the APP Important: sensor. Refer to Service Bulletins before service programming is 3. Connect the Tech2 to the vehicle. performed if the bulletins are listed along with the 4.
• Page 516
  6E-262 Engine Control System (4JH1) EGR Solenoid Valve Replacement Removal Procedure 1. Disconenct the negative battery cable. 2. Disconnect solenoid valve harness connector. 3. Disconnect two hoses from the EGR solenoid valve. 4. Loosen two bolts and remove the EGR solenoid valve from the bracket.
• Page 517
  Engine Control System (4JH1) 6E-263 Legend 1. Vaccum Pressure Sensor 2. To Turbocharger 3. EGR Solenoid Valve 4. To Vacuum Regulating Valve 5. Turbocharger Solenoid Valve Installation Procedure 1. Set the turbocharger solenoid valve on the bracket and tighten a nut. 2.
• Page 518
  6E-264 Engine Control System (4JH1) Installation Procedure 1. Set the vacuum pressure sensor on the bracket and tighten a bolt. 2. Connect a harness connector to the vacuum pressure sensor. 3. Connect the negative battery cable. Vehicle Speed Sensor (VSS) Replacement Removal Procedure M/T &…
• Page 519
  Engine Control System (4JH1) 6E-265 Description And Operation Engine Control Module (ECM) Description ECM Voltage Description The ECM supplies a buffered voltage to various switches and sensors. The ECM can do this because resistance in the ECM is so high in value that a test lamp may not illuminate when connected to the circuit.
• Page 520
  6E-266 Engine Control System (4JH1) • The MIL remains illuminated after the engine is Important: started if the ECM detects a fault. A DTC is stored To prevent possible electrostatic discharge damage, any time the ECM illuminates the MIL due to an follow these guidelines: •…
• Page 521
  Engine Control System (4JH1) 6E-267 Crankshaft Position (CKP) Sensor Engine Coolant Temperature (ECT) Sensor — Amplitudes of CKP sensor signal (CH1) increase as engine speed increases. — Each waveform cycle shorten as the engine speed increases. RTW06ESH000101 Terminal: 90 (CH1), 91 (CH2) (+) / GND (-) Scale: 10V/div 2ms/div Condition: Approximately 1000RPM RTW66ESH001401…
• Page 522
  6E-268 Engine Control System (4JH1) Exhaust Gas Recirculation (EGR) Solenoid Valve The intake air temperature (IAT) sensor is fitted between the air cleaner and turbocharger internal to the mass air flow (MAF) sensor. The IAT sensor is a variable resistor. The IAT sensor measures the temperature of the air entering the engine.
• Page 523
  Engine Control System (4JH1) 6E-269 The following waveform aids to diagnose when there is Vehide Speed Sensor (VSS) an oscilloscope or equivalent. — VSS waveform cycle shorten as the vehicle speed increases. Terminal: 68 (+) / GND (-) Scale: 5V/div 50ms/div Condition: Approximately 20km/h (12MPH) RTW56EMH000301 Legend…
• Page 524
  6E-270 Engine Control System (4JH1) Fuel Injection System Description RTW66EMF000401 Legend 1. Drive Shaft 7. Fuel Injection Solenoid Valve 2. Fuel Feed Pump 8. Constran Pressure Valve (CPV) 3. Pump Camshaft Position (CMP) Sensor 9. Timing Control Valve (TCV) 4. Fuel Injection Pump Control Unit (PCU) 10.
• Page 525
  Engine Control System (4JH1) 6E-271 RTW66ESH001901 RTW66ESH002001 Legend Legend 1. Drive Shaft 1. Rotor Shaft 2. Feed Pump 2. Radial Plunger 3. Pump Camshaft Position (CMP) Sensor 3. High Pressure Passage 4. Fuel Injection Pump Control Unit (PCU) 4. Low Pressure Inlet 5.
• Page 526
  6E-272 Engine Control System (4JH1) 6. Vane Low Pressure Fuel Circuit Description 7. Driveshaft 8. Inlet 9. Fuel Suction The feed pump is driven by the drive shaft, performs suction and supply of fuel. The vanes assembled in the rotor are pressed against the inside of the casing ring by spring forces and centrifugal force during rotation to form chambers.
• Page 527
  Engine Control System (4JH1) 6E-273 Overflow Valve High Pressure Fuel Circuit Description RTW66ESH002401 Legend RTW66ESH002501 Legend 1. Valve Holder 1. Fuel Injection Pump Control Unit (PCU) 2. Port 2. Distributor Head 3. To Fuel Tank 3. Fuel Injection Solenoid Valve 4.
• Page 528
  6E-274 Engine Control System (4JH1) Radial Plunger Distributor Head RTW66ESH002601 RTW66ESH002701 Legend Legend 1. Radial Plunger 1. Rotor Shaft 2. Internal Cam 2. Valve Needle 3. Cam Ring 3. Constant Pressure Valve (CPV) Holder 4. Rotor Shaft 4. High Pressure Outlet 5.
• Page 529
  Engine Control System (4JH1) 6E-275 Fuel Injection Solenoid Valve Constant Pressure Valve (CPV) RTW66ESH002901 RTW66ESH002801 Legend Legend 1. Plug 1. Valve Seat 2. Ball 2. Valve Closing Direction 3. Seat 3. Valve Needle 4. Valve 4. Coil 5. Spacer 5. Magnet 6.
• Page 530
  6E-276 Engine Control System (4JH1) Beginning of Injection Staring Timing Control Device Description RTW66ESH003101 engine control module (ECM) contains RTW66ESH003001 Legend characteristic maps of the beginning of injection, 1. Cam Ring corresponding engine operating conditions (engine load, engine speed and engine coolant 2.
• Page 531
  Engine Control System (4JH1) 6E-277 When the drive shaft rotates, the pump camshaft The timing control valve (TCV) acts as a variable position (CMP) sensor receives signal form the sensor throttle, using the rapid opening and closing (cycling) wheel, and an electric pulse is sent through the flexible of the valve needle in the TCV.
• Page 532
  6E-278 Engine Control System (4JH1) • Momentary Cam Ring Angular Position The momentary angular position of the cam ring is input into the fuel injection PCU as a fuel injection solenoid valve control signal. From momentary input of angular position for fluctuations in running conditions, the fuel injection solenoid valve open and close intervals corresponding to the cam ring’s cam lift can be accurately determined.
• Page 533
  Engine Control System (4JH1) 6E-279 Exhaust Gas Recirculation (EGR) System Description RTW66ELF000101 Legend 1. EGR Valve 6. Injection Pump 2. ECT Sensor 7. ECM 3. MAF & IAT Sensor 8. EGR Solenoid Valve 4. Air Cleaner 9. Vacuum Pump 5. CKP Sensor The EGR system recirculates a part of exhaust gas controlling the EGR solenoid valve drive duty.
• Page 534
  6E-280 Engine Control System (4JH1) Turbocharger Description RTW66EMF000501 Legend 1. Exhaust Gas 6. Vacuum Pressure Sensor 2. Wastegate Valve 7. Engine Control Module (ECM) 3. Turbine Wheel 8. Turbocharger Solenoid Valve 4. Compressor Wheel 9. Vacuum Pump (ACG) 5. Air Cleaner 10.
• Page 535
  Engine Control System (4JH1) 6E-281 Special Tools and Equipment Special Tools and Equipment Tool Number/ Tool Number/ Illustration Illustration Description Description 5-8840-2835-0 / J-35616-C 5-8840-0279-0 / J-23738-A Connector Test Adapter Vacuum Pump (With Test Lamp) 5-8840-0285-0 / J-39200 Digital Multimeter Tech2 Kit Breaker Box Adapter Harness…
• Page 536
  MEMO ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
• Page 537
  EXHAUST SYSTEM 6F – 1 SECTION 6F EXHAUST SYSTEM TABLE OF CONTENTS PAGE Main Data and Specifications………………. 6F — 2 General Description ………………….6F — 3 Removal and Installation ………………..6F — 4 Inspection and Repair ………………….. 6F — 6 General Description ………………….

• Page 538: Main Data And Specifications

  6F – 2 EXHAUST SYSTEM MAIN DATA AND SPECIFICATIONS Front pipe Pipe outside diameter x thickness mm (in) 50.8 x 1.6 (2.0 x 0.063) For EC model, catalitic converter is combined to the front pipe. Middle pipe Pipe outside diameter x thickness mm (in) 50.8 x 1.6 (2.0 x 0.063) Silencer &…

• Page 539: General Description

  EXHAUST SYSTEM 6F – 3 GENERAL DESCRIPTION RTW86FLF000201 The exhaust pipe layout is described in the above illustration. The catalytic coverter is installed between the turbocharger and the front pipe.

• Page 540: Removal And Installation

  6F – 4 EXHAUST SYSTEM REMOVAL AND INSTALLATION RTW86FLF000101 Removal Steps 1. Rear hanger rubber 6. Front hanger rubber 2. Silencer front nut 7. Front pipe nut 3. Exhaust silencer 8. Exhaust pipe gasket 4. Silencer hanger rubber 5. Middle pipe nut…

• Page 541
  EXHAUST SYSTEM 6F – 5 Important Operations – Installation Follow the removal procedure in the reverse order to perform the installation procedure. Pay careful attention to the important points during the installation procedure. 1. Front Pipe Nut Connect the exhaust pipe to the catalytic converter. Torque N⋅m (kg⋅m/lb⋅ft) 67 (6.8/49)

• Page 542: Inspection And Repair

  6F – 6 EXHAUST SYSTEM INSPECTION AND REPAIR Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection. Front Exhaust Pipe Exhaust Silencer Check the pipes for corrosion, cracking, damage or misalignment and repair as required. Check the rubber rings for deterioration or damage and repair as required.

• Page 543: General Description

  EXHAUST SYSTEM 6F – 7 GENERAL DESCRIPTION This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber through the intake manifold. 4JA1T(L): The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to signals from various sensors.

• Page 544
  6F – 8 EXHAUST SYSTEM 4JA1TC/4JH1TC The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail. RTW46ELF001101…

• Page 545: Egr System Diagram

  EXHAUST SYSTEM 6F – 9 EGR SYSTEM DIAGRAM 4JA1T (L) RTW46AMF000301 EGR System Operation Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up. • Inspection point (Engine RPM) 900 ∼ 960 Idling 2000 3250 Engine Front Side VSV-1 Engine Rear Side VSV-2 ON means VSV should receive signal to move EGR valve.

• Page 546
  6F – 10 EXHAUST SYSTEM 4JA1TC/4JH1TC The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail. RTW46EMF000701…

• Page 547: Inspection

  EXHAUST SYSTEM 6F – 11 INSPECTION 4JA1T(L) Vacuum switch valve (VSV) Use a circuit tester to measure the V.S.V. resistance. Ω at 20°C V.S.V Resistance 37 ~ 44 If the resistance is not within specification, replace it. EGR Valve Apply vacuum to the EGR valve, check to see the valve operation.

• Page 548: Egr Cooler (4Ja1Tc/4Jh1Tc Euro-Iii Model)

  6F – 12 EXHAUST SYSTEM EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL) REMOVAL AND INSTALLATION RTW46EMF000201 Removal Steps 1. Bolt 7. EGR Pipe Assembly 2. Gasket 8. Gasket 3. Bolt 9. Bolt 4. Gasket 10. EGR Cooler Assembly 5. Bolt 11. Gasket 6.

• Page 549
  EXHAUST SYSTEM 6F – 13 RTW46EMF000901 Installation steps 1. EGR Cooler Adapter 8. Bolt 2. Gasket 9. Gasket 3. EGR Cooler Assembly 10. EGR Valve Assembly 4. Gasket 11. Bolt 5. Bolt 12. EXH Manifold 6. EGR Pipe Assembly 13. Gasket 7.
• Page 550
  6F – 14 EXHAUST SYSTEM Installation 1. EGR Cooler Adapter 2. Gasket 3. EGR Cooler Assembly 4. Bolt Tighten the bolts to the specified torque. EGR adapter bolt torque N⋅m(kg⋅m/lb ft) 27(2.8/20) 5. Gasket 6. EGR Pipe Assembly 7. Bolt Tighten bolts temporarily.

• Page 551: Turbocharger

  EXHAUST SYSTEM 6F – 15 TURBOCHARGER MAIN DATA AND SPECIFICATIONS Engine 4JA1T(L) 4JA1TC 4JH1TC Model IHI RHF4H IHI RHF4H IHI RHF5 Turbine type Mixed type Compressor type Backword & rake type Maximum permissible speed rpm 190,000 190,000 180,000 IHI : Ishikawajima Harima Heavy Industries., Ltd.

• Page 552: General Description

  6F – 16 EXHAUST SYSTEM GENERAL DESCRIPTION 036LV002 The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings. These parts are supported by the bearing housing. The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air exhaust port.

• Page 553: Inspection And Repair

  4JH1TC 134.8/1011 4JA1TC 147.7/1108 RTW86FSH000101 Contact the “ISUZU MOTORS LIMITED” Dealer service department or “IHI SERVICE FACILITY” for major repairs and maintenance. Important wheel shaft end play and bearing clearance standards and limits are included below for your reference.

• Page 554
  6F – 18 EXHAUST SYSTEM Wheel Shaft End Play Use a dial indicator to measure the wheel shaft end play. Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the compressor wheel end and the turbine wheel end. Wheel Shaft End Play mm (in) Standard Limit…

• Page 555: Special Tools

  EXHAUST SYSTEM 6F – 19 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER TOOL NAME 5-8840-0075-0 Pressure Gauge 901RX00143…

• Page 556: Ihi Service Network

  6F – 20 EXHAUST SYSTEM IHI SERVICE NETWORK For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service Facility. HEADQUARTERS ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI) General Machinery Division Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku…

• Page 557
  ACCELERATOR CONTROL 6H – 1 SECTION 6H ACCELERATOR CONTROL TABLE OF CONTENTS PAGE Removal and Installation ………………..6H — Removal ……………………6H — Inspection ……………………6H — Installation ……………………. 6H -…

• Page 558: Removal And Installation

  6H – 2 ACCELERATOR CONTROL REMOVAL AND INSTALLATION 4JA1T(L)/RHD RTW46HLF000301…

• Page 559
  ACCELERATOR CONTROL 6H – 3 4JA1T(L)/LHD RTW46HLF000601…
• Page 560
  6H – 4 ACCELERATOR CONTROL 4JA1TC, 4JH1TC/RHD RTW46HLF000201…
• Page 561
  ACCELERATOR CONTROL 6H – 5 4JA1TC, 4JH1TC/LHD PTW46BMF000101…

• Page 562: Removal

  6H – 6 ACCELERATOR CONTROL Removal 1. Disconnect the accelerator control cable from the accelerator pedal and dash panel. 2. Remove the cable clips. 3. Remove the accelerator control cable from accelerator control cable bracket. 1) Slide the lock in direction A 2) Rotate the ratchet ring in undirection an arrow 90°.

• Page 563
  This manual is applicable for vehicles in all countries except the USA and Canada. 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 E-Solutions & Service Marketing Dept.
• Page 564
  No. TF4JE-WE-1101…

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