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Isuzu 2008MY N Series, Workshop Manual

The Isuzu 2008MY N Series Workshop Manual is a must-have for anyone looking to maintain or repair their vehicle. This comprehensive manual covers everything you need to know about your Isuzu N Series truck, and it's available for free download from manualshive.com. Get your manual today and keep your truck running smoothly.

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WORKSHOP MANUAL

ENGINE CONTROL SYSTEM

(4HK1 model)

No.LG4HKED-WE-0871

WORKSHOP MANUAL

 

ENGINE CONTROL SYSTEM (4HK1 model)

Summary of Contents for 2008MY N Series

Page 1: ...WORKSHOP MANUAL ENGINE CONTROL SYSTEM 4HK1 model No LG4HKED WE 0871 WORKSHOP MANUAL ENGINE CONTROL SYSTEM 4HK1 model...

Page 2: ...ase Part Time 4 BRAKES 4B Brake 4C1 Anti Lock Brake ABS Anti Slip Regulator ASR 4D Parking Brake 4E Hill Start Aid HSA 5 TRANSMISSION TRANSAXLE 5A Transmission Control System 5B Automatic Transmission...

Page 3: ......

Page 4: ...C P0182 or P0183 Flash Code 211 1A 124 DTC P0192 or P0193 Flash Code 245 1A 128 DTC P0201 P0202 P0203 or P0204 Flash Code 271 272 273 or 274 1A 132 DTC P0217 Flash Code 542 1A 142 DTC P0219 Flash Code...

Page 5: ...r Sluggishness or Sponginess 1A 357 Hesitation Sag or Stumble 1A 359 Abnormal Combustion Noise 1A 361 Poor Fuel Economy 1A 362 Excessive Smoke Black Smoke 1A 364 Excessive Smoke White Smoke 1A 366 DPD...

Page 6: ...10 14 9810 20 4 16000 30 22 27000 C F Ohms Temperature vs Resistance Value Approximately 90 194 240 80 176 320 70 158 430 60 140 590 50 122 810 40 104 1150 30 86 1650 20 68 2430 10 50 3660 0 32 5650...

Page 7: ...300 572 2360 2830 200 392 6230 7830 150 302 11900 16300 100 212 27600 41200 50 122 82000 137000 Altitude Measured in Meters m Altitude Measured in Feet ft Barometric Pressure Measured in Kilopascals...

Page 8: ...DTC clears after 40 consecutive warm up cycles if no failures are reported Euro 4 specification A history DTC clears after 20 consecutive driving cycles if no failures are reported Except Euro 4 speci...

Page 9: ...A A Manifold Absolute Pressure Sensor Circuit Low Input P0108 32 A A A Manifold Absolute Pressure Sensor Circuit High Input P0112 22 A A A Intake Air Temperature Sensor Circuit Low P0113 22 A A A Int...

Page 10: ...w P0478 46 A A Exhaust Pressure Control Valve High P0500 25 B A A Vehicle Speed Sensor P0502 25 A A A Vehicle Speed Sensor Circuit Low Input P0503 25 A A A Vehicle Speed Sensor Circuit High Input P056...

Page 11: ...ector Group 1 Supply Voltage Circuit P2149 159 A A A Fuel Injector Group 2 Supply Voltage Circuit P2227 71 B Barometric Pressure Sensor Circuit Range Performance P2228 71 A A A Barometric Pressure Sen...

Page 12: ...1 Fuel rail 2 Pressure limiter valve 3 Leak off pipe 4 Fuel injector 5 Fuel return pipe 6 Fuel feed pipe 7 Fuel tank 8 Vent valve 9 Priming pump 10 Fuel filter with water separator 11 Return fuel flo...

Page 13: ...d Signal ground Signal ground Power ground Power ground Power ground Key position Battery 24V MIL Glow lamp DPD lamp Oil pressure lamp Glow relay Glow plug Starter cut relay Exhaust brake solenoid val...

Page 14: ...sensor Camshaft position sensor Fuel injector 1 Intake throttle solenoid Fuel injector 3 Fuel injector 2 Fuel injector 4 Fuel rail pressure regulator Exhaust throttle solenoid valve ECM 121 119 118 11...

Page 15: ...4HK1 Component Locator Engine Controls Component Views Legend 1 Barometric pressure BARO sensor 2 Accelerator pedal position APP sensor Legend 1 Boost pressure sensor LNW81ASF000901 1 2 LNW76ESF00120...

Page 16: ...sensor 2 Camshaft position CMP sensor 3 Variable nozzle turbocharger VNT actuator sensor Legend 1 Engine coolant temperature ECT sensor 2 Exhaust gas recirculation EGR valve 3 Intake throttle valve L...

Page 17: ...essure FRP sensor 3 Fuel temperature FT sensor 4 Fuel rail pressure FRP regulator Legend 1 Fuel injector No 1 cylinder 2 Fuel injector No 2 cylinder 3 Fuel injector No 3 cylinder 4 Fuel injector No 4...

Page 18: ...in front of oxygen catalyst 3 Exhaust temperature sensor 1 in front of filter 4 Exhaust differential pressure sensor 5 Exhaust throttle valve 6 DPD assembly Legend 1 Mass air flow MAF sensor intake ai...

Page 19: ...1A 16 Engine Control System 4HK1 Legend 1 Vehicle speed sensor VSS without ABS Legend 1 CAN resistor RHD LNW76ESF001101 1 LNW81ASF001101 1 LG4HKED WE 0871 book 16...

Page 20: ...Engine Control System 4HK1 1A 17 Legend 1 ECM 2 Dropping resistor Legend 1 VNT control module LNW81ASF000101 1 2 LNW81ASF000201 1 LG4HKED WE 0871 book 17...

Page 21: ...0 25 26 27 31 32 33 34 35 54 73 2 1 3 17 BLU BLK SVS lamp control Euro 4 specification 18 BLU WHT CAN high signal 19 YEL GRN VSS signal or EHCU 20 BLK APP sensor 1 shield ground 21 BLU BLK ECM main re...

Page 22: ...uro 4 specification 70 BRN PTO throttle sensor signal 71 BRN GRN BARO sensor signal 72 RED GRN IAT sensor signal Connector No J 14 Connector Color Black Test Adapter No J 35616 64A Pin No Wire Color P...

Page 23: ...tle solenoid control Euro 4 specification 103 ORN EGR motor control 2 104 GRN Intake throttle solenoid low side 105 WHT RED FRP regulator control high side 106 Not used 107 RED BLU CKP sensor signal 1...

Page 24: ...eference 5 BLU WHT APP sensor 1 signal 6 BLU RED APP sensor 1 low reference Connector No B 121 Connector Color Gray Test Adapter No J 35616 33 Pin No Wire Color Pin Function 1 ORN Sensor low reference...

Page 25: ...gnal Connector No E 18 Connector Color Black Test Adapter No J 35616 33 Pin No Wire Color Pin Function 1 WHT Sensor signal 2 BLK Sensor low reference 3 RED Sensor 5 volts reference RTW76ESH000701 1 2...

Page 26: ...Not used 2 WHT BLK Class 2 serial data EHCU ABS module 3 Not used 4 BLK Ground LNW36ESH015801 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 5 BLK Ground 6 BLU WHT CAN high Euro 4 specification 7 LT BLU Keyw...

Page 27: ...pter No J 35616 64A Pin No Wire Color Pin Function 1 LT GRN Position sensor 5 volts reference 2 LT GRN BLK Position sensor signal 3 3 LT BLU Position sensor signal 2 4 WHT ORN Position sensor signal 1...

Page 28: ...Not used 5 Not used 6 Not used 7 BLK Illumination lamp ground 8 LT GRN RED Illumination lamp voltage feed 9 Not used 10 Not used LNW76ESH004201 5 6 1 2 9 8 10 4 3 7 Connector No J 26 Connector Color B...

Page 29: ...low reference 2 YEL RED Sensor signal Connector No J 33 Connector Color Black Test Adapter No J 35616 33 Pin No Wire Color Pin Function RTW76ESH001601 1 2 Connector No J 35 Connector Color Dark gray...

Page 30: ...Solenoid control Connector No J 59 Connector Color Black Test Adapter No J 35616 33 Pin No Wire Color Pin Function LNW46ESH001001 1 2 3 LNW46ESH001001 1 2 3 Connector No E 37 Pin No Wire Color Pin Fu...

Page 31: ...K Solenoid control Connector No E 17 Connector Color Gray Test Adapter No J 35616 33 Pin No Wire Color Pin Function 1 WHT RED Control high side PWM 2 GRN RED Low side LNW46ESH001101 1 2 Connector No E...

Page 32: ...K Sensor low reference 2 LT GRN WHT Sensor signal Connector No E 14 Connector Color Silver Pin No Wire Color Pin Function 1 BLK RED Power Supply LNW46ESH000701 Connector No J 38 Connector Color Black...

Page 33: ...64A Pin No Wire Color Pin Function 1 GRN Solenoid control low side PWM 2 BLK GRN Solenoid drive voltage 3 Not used 4 BLK Position sensor low reference 5 VIO WHT Position sensor signal 6 YEL Position s...

Page 34: ...e RTW76ESH001801 1 2 3 Connector No E 4 Connector Color Black Test Adapter No J 35616 64A Pin No Wire Color Pin Function 1 BLU WHT Position sensor signal 1 2 BRN Position sensor signal 2 3 BLU Positio...

Page 35: ...ion sensor signal 3 3 BRN Position sensor signal 2 4 BLU WHT Position sensor signal 1 5 BLK Position sensor low reference 6 BLU RED Motor control 2 7 YEL RED Motor control 3 8 GRN RED Motor control 1...

Page 36: ...her Fine Cloudy Rainy Snow Weather Various Other Hot approx Warm Cool Cold approx Outside Temperature Any temperature Highway Suburbs City area Uphill Place Downhill Rough road Other Over approx tons...

Page 37: ...ped to DLC terminal 4 which is a ground wire Once terminals 12 and 4 have been connected turn the ignition switch ON with the engine OFF The MIL Except Euro 4 specification or the SVS lamp Euro 4 spec...

Page 38: ...nosis search for applicable service bulletins Unless a diagnostic procedure instructs you DO NOT clear the DTCs If there is a condition with the starting system refer to the Starting System in Section...

Page 39: ...Step 10 10 Is there any other code in any controller that has not been diagnosed Go to Applicable DTC Go to Step 11 11 Is the customer s concern with the transmission Go to Diagnostic System Check Tr...

Page 40: ...t the engine Does the engine start and idle Go to Step 6 Go to Engine Cranks but Does Not Run 5 Does the scan tool display ECM DTCs P0633 P161B or U0167 Go to Applicable DTC Problem is relating to sta...

Page 41: ...to Diagnostic System Check SRS Controls in Section 8C SRS Control System Go to Step 15 15 1 Review the following symptoms 2 Refer to the applicable symptom diagnostic table Hard Start Rough Unstable...

Page 42: ...han 25 Less than 20 Coolant Temperature C F 75 to 85 C 167 to 185 F 75 to 85 C 167 to 185 F Engine Coolant Temperature Sensor Volts 0 4 to 0 6 volts 0 4 to 0 6 volts Intake Air Temperature C F 20 to 4...

Page 43: ...an 90 Intake Throttle Position More than 100 More than 100 Intake Throttle Position Sensor Volts More than 3 9 volts More than 3 9 volts Idle Up Sensor Volts 0 3 to 0 6 volts 0 3 to 0 6 volts Fuel Com...

Page 44: ...Sensor Volts Less than 0 4 volts Less than 0 4 volts Engine Warm Up Switch On Off Off Off A C Signal On Off Off Off Refrigerator Switch On Off Off Off Oil Level Normal Low Normal Normal Glow plug Rela...

Page 45: ...essure kPa psi Varies Varies Exhaust Differential Pressure Sensor Volts Varies Varies Exhaust Temperature 1 C F Varies Varies Exhaust Temperature Sensor 1 Volts Varies Varies Exhaust Temperature 2 C F...

Page 46: ...d by the ECM using the signal from the fuel temperature FT sensor The scan tool will display a low temperature when the FT sensor signal voltage is high and a high temperature when the FT sensor signa...

Page 47: ...tage when the accelerator pedal is not depressed and a low voltage when the accelerator pedal is fully depressed Desired EGR Position This parameter displays EGR position desired by the ECM based on c...

Page 48: ...f the starter switch to the ECM When the ignition switch is turned at START position the scan tool displays On Ignition Switch This parameter displays the input status of the ignition switch to the EC...

Page 49: ...ameter displays the commanded state of the glow relay control circuit On indicates the glow relay control circuit is being grounded by the ECM allowing voltage to the glow plugs Malfunction Indicator...

Page 50: ...a high differential pressure such as large PM accumulation Exhaust Temperature 1 This parameter displays the temperature of the exhaust gas in front of filter as calculated by the ECM using the signal...

Page 51: ...me indicates under security wait time This wait time stage will prevent any further attempts to enter the security code until the wait time has elapsed Note that this parameter is not count downed It...

Page 52: ...The purpose of this test is for checking whether the EGR valve is correctly moved with command Restricted valve movement by foreign materials excessive deposits or a faulty valve could be considered i...

Page 53: ...AUDIO 15A fuse open Go to Step 2 Go to Step 3 2 Replace the ROOM LAMP AUDIO 15A fuse If the fuse continues to open repair the short to ground on one of the circuits that is fed by the ROOM LAMP AUDIO...

Page 54: ...tem Check Engine Controls 2 Important Make sure the CANdi module is not malfunctioning When functioning properly the CANdi module LED will be flashing In the event of a problem the LED will be continu...

Page 55: ...ata circuits between the ECM pins 58 and 78 of J 14 and the DLC pins 6 and 14 of B 31 for the following conditions An open circuit A short circuit each other High resistance 5 Repair the connection s...

Page 56: ...conds between transitions Does the ECM main relay click when the ignition switch is turned ON or OFF Go to Step 15 Go to Step 14 14 Repair the ECM main relay ground circuit between the ECM main relay...

Page 57: ...all previously disconnected fuse relay or harness connector s 3 Turn ON the ignition with the engine OFF 4 Attempt to establish communication with the ECM Does the scan tool communicate with the ECM S...

Page 58: ...rence Engine Controls Schematics Connector End View Reference Engine Controls Connector End Views or ECM Connector End Views Circuit System Testing Scan Tool Does Not Communicate with Keyword Device E...

Page 59: ...oor connection and for corrosion at the data link connector DLC pin 7 of B 31 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 21 Go to Step 10 10 1 Turn OFF th...

Page 60: ...e ECM TCM and HSA control unit Does the scan tool communicate with the ECM TCM ICU and HSA control unit Go to Step 19 Go to Step 14 14 Notice If no immobilizer system installed skip to Step 15 1 Turn...

Page 61: ...HSA Control Unit in Section 4E Hill Start Aid HSA Did you complete the replacement Go to Step 21 19 Replace the SRS control unit Refer to SRS Control Unit in Section 8B Supplemental Restraint System S...

Page 62: ...Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 Attempt to establish communication with the ECM Does t...

Page 63: ...elay 4 Turn ON the ignition with the engine OFF 5 Attempt to establish communication with the ECM Does the scan tool communicate with the ECM Go to Step 13 Go to Step 9 9 1 Turn OFF the ignition 2 Rem...

Page 64: ...14 13 Replace the ECM main relay Did you complete the replacement Go to Step 15 14 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete t...

Page 65: ...m Testing Engine Cranks but Does Not Run Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install...

Page 66: ...and the FRP regulator pin 2 of E 17 Did you compete the repair Go to Step 11 9 1 Check for normal readings at key up for the following sensor inputs Use the Scan Tool Data List or a known good vehicl...

Page 67: ...OFF the ignition for 30 seconds 3 Attempt to start the engine Does the engine start and continue to run Go to Step 12 Go to Step 2 12 Observe the DTC Information with a scan tool Are there any DTCs t...

Page 68: ...The CKP sensor signal pulse is detected The CMP sensor signal pulse is detected Condition for Setting the DTC The ECM detects that the CKP sensor signals and CMP sensor signals are out of synchroniza...

Page 69: ...the flywheel is incorrectly installed this DTC may set 3 Repair or replace as necessary Did you complete the repair Go to Step 4 4 1 Reconnect all previously disconnected harness connector s if discon...

Page 70: ...und or short to voltage circuit on the solenoid circuit The VNT control module detects solenoid or nozzle control is stuck condition Action Taken When the DTC Sets The ECM illuminates the MIL when the...

Page 71: ...Test the solenoid circuit between the VNT control module pins 10 11 and 12 of E 4 and the actuator sensor pins 6 7 and 8 of E 2 for a short circuit each other 2 Repair the circuit s as necessary Did y...

Page 72: ...e following conditions An open circuit A short to ground A short to the low reference circuit A short to battery or ignition voltage High resistance 2 Repair the circuit s as necessary Did you find an...

Page 73: ...lace the turbocharger Refer to Turbocharger Assembly in Section 1J Induction Did you complete the replacement Go to Step 20 19 Replace the VNT control module Refer to VNT Control Module Replacement in...

Page 74: ...ondition is suspected refer to Intermittent Conditions in this section Test Description The number below refers to the step number on the Circuit System Testing DTC P0080 3 If the exhaust throttle sol...

Page 75: ...2 of J 59 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 13 Go to Step 11 10 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an i...

Page 76: ...of E 12 and the solenoid valve pin 1 of J 59 for a short to battery or ignition voltage 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 7 Go to Step 6 5 Replace t...

Page 77: ...o DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids An intermittently sticking FRP regulator may have allowed the fuel pressure to become high enough to open the press...

Page 78: ...Step 6 6 1 Inspect the fuel system line connections between the fuel tank and the fuel supply pump for tightness and all fuel hoses for cuts cracks and for the use of proper clamps Notice The fuel sys...

Page 79: ...minimum of 1 minute Does the fuel pressure vacuum gauge ever indicate a larger vacuum than the specified amount during the test 5 inHg Go to Step 9 Go to Step 8 8 1 Fully clamp off a fuel hose as clo...

Page 80: ...tion 2 Disconnect the FRP sensor harness connector 3 Inspect for an intermittent for poor connections and corrosion at the harness connector of the FRP sensor pins 1 2 and 3 of E 19 4 Disconnect the E...

Page 81: ...cement Go to Step 17 17 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Start the engine 5 Operate the vehicle wi...

Page 82: ...Sets Type A Except Euro 4 specification The ECM limits fuel injection quantity The ECM inhibits pilot injection Second Stage The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC...

Page 83: ...exceed the specified value 180 MPa 26 000 psi Go to Step 4 An intermittent problem by foreign material in the fuel system is suspected Go to Step 13 4 1 Turn OFF the ignition 2 Wait 1 minute for the...

Page 84: ...r any fuel system leaks as necessary Did you find and correct the condition Go to Step 17 Go to Step 7 7 1 Turn OFF the ignition 2 Remove the rubber fuel hose from the fuel filter housing fuel supply...

Page 85: ...rawn into the fuel line pickup causing a blocked condition 4 Repair or replace as necessary Did you find and correct the condition Go to Step 17 Go to Step 13 10 1 Inspect the fuel system line connect...

Page 86: ...the appropriate fuel injector that does not change engine speed when commanded OFF Refer to Injector in Section 1D Engine Fuel Did you complete the replacement Go to Step 17 16 Important The fuel supp...

Page 87: ...bits EGR control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids An intermittently sticking FRP regulator may have allowed th...

Page 88: ...n at the harness connector of the ECM pins 82 87 90 and 101 of E 12 6 Test for high resistance on each circuit 7 Repair the connection s or circuit s as necessary Did you find and correct the conditio...

Page 89: ...cement Go to Step 10 10 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Start the engine 5 Operate the vehicle wi...

Page 90: ...the DTC Sets Type A The ECM limits fuel injection quantity The ECM inhibits pilot injection The ECM inhibits EGR control Condition for Clearing the MIL DTC Refer to DTC Type Definitions for Condition...

Page 91: ...ircuit s as necessary Did you find and correct the condition Go to Step 15 Go to Step 14 9 1 Test the high side circuits between the ECM pins 105 and 113 of E 12 and the FRP regulator pin 1 of E 17 fo...

Page 92: ...ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 15 15 1 Reconnect all previously disconnected harness connector s 2 Clear the D...

Page 93: ...ntermittently sticking FRP regulator may have allowed the fuel pressure to become low enough to set this DTC Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at i...

Page 94: ...tion pipe when foreign material was in contact 2 Repair any fuel system leaks as necessary Did you find and correct the condition Go to Step 19 Go to Step 3 3 1 Remove each glow plug from the cylinder...

Page 95: ...he fuel supply pump is under a slight vacuum with the engine running As a result air can enter the fuel system if these connections are not tight Air in the fuel system will cause fuel rail pressure f...

Page 96: ...minimum of 1 minute Does the fuel pressure vacuum gauge ever indicate a larger vacuum than the specified amount during the test 5 inHg Go to Step 10 Go to Step 9 9 1 Fully clamp off a fuel hose as clo...

Page 97: ...or harness connector 3 Inspect for an intermittent for poor connections and corrosion at the harness connector of the FRP sensor pins 1 2 and 3 of E 19 4 Disconnect the ECM harness connector 5 Inspect...

Page 98: ...el filter element Refer to Fuel Supply Pump and Fuel Filter Element in Section 1D Engine Fuel Did you complete the replacement Go to Step 19 19 1 Reconnect all previously disconnected harness connecto...

Page 99: ...500 to 2800 RPM The EGR control is commanded OFF The intake throttle control is commanded OFF The DPD filter regeneration is inactive The engine run time is longer than 5 seconds Condition for Setting...

Page 100: ...Go to Step 3 3 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 1...

Page 101: ...te the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition G...

Page 102: ...he DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM uses a MAF substitution of default value The...

Page 103: ...d 3 of J 38 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 12 Go to Step 10 9 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an...

Page 104: ...ness connector 3 Turn ON the ignition with the engine OFF Is the MAF Sensor parameter less than the specified value 0 1 volts Go to DTC P0560 Go to Step 7 5 1 Turn OFF the ignition 2 Disconnect the MA...

Page 105: ...ssary Did you find and correct the condition Go to Step 13 Go to Step 12 11 Replace the MAF sensor Refer to MAF IAT Sensor in Section 1J Induction Did you complete the replacement Go to Step 13 12 Imp...

Page 106: ...luminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM uses a boost pressure substitution of default value The ECM inhibit...

Page 107: ...ircuit A short to ground A short to the low reference circuit High resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 12 Go to Step 9 8 1 Inspect for an i...

Page 108: ...ool 2 Turn OFF the ignition for 30 seconds 3 Start the engine 4 Observe the Boost Pressure Sensor parameter with a scan tool Is the Boost Pressure Sensor parameter more than the specified value 4 9 vo...

Page 109: ...ector of the boost pressure sensor pin 2 of E 24 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 13 Go to Step 11 10 1 Turn OFF the ignition 2 Disconnect the E...

Page 110: ...ine Control System 4HK1 1A 107 14 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 111: ...DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM uses an IAT substitution of default value The ECM inhibits EGR control Condition for Clearing the DTC Refer to DTC Type Definitio...

Page 112: ...rtant Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 9 9 1 Reconnect all previously disconnected harness connector...

Page 113: ...Euro 4 specification for the following conditions A short to battery or ignition voltage A short to the 12 volts reference 2 Repair the circuit s as necessary Did you find and correct the condition Go...

Page 114: ...ns 1 and 2 of J 217 Expect Euro 4 specification 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 15 Go to Step 13 12 1 Turn OFF the ignition 2 Disconnect the EC...

Page 115: ...112 Engine Control System 4HK1 16 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 116: ...1 to 15 C 1 8 to 27 F Action Taken When the DTC Sets The ECM illuminates the MIL on the second consecutive driving cycle when the diagnostic runs and fails Refer to DTC Type Definitions for Action Tak...

Page 117: ...ition Go to Step 6 Go to Step 5 5 Replace the ECT sensor Refer to ECT Sensor in Section 1C Engine Cooling Did you complete the replacement Go to Step 6 6 1 Reconnect all previously disconnected harnes...

Page 118: ...runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM uses an ECT substitution of default value The ECM inhibits EGR control Condition for Clearing the DTC Ref...

Page 119: ...and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 9 9 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Tur...

Page 120: ...he specified value 0 1 volts Go to Step 10 Go to Step 7 7 Connect a 3 amp fused jumper wire between the signal circuit pin 1 of E 25 and a known good ground Is the ECT Sensor parameter less than the s...

Page 121: ...ensor in Section 1C Engine Cooling Did you complete the replacement Go to Step 15 14 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete...

Page 122: ...nostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM inhibits EGR control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition fo...

Page 123: ...n circuit A short to ground A short to the low reference circuit High resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 12 Go to Step 9 8 1 Inspect for a...

Page 124: ...gnition for 30 seconds 3 Start the engine 4 Observe the Intake Throttle Position Sensor parameter with a scan tool Is the Intake Throttle Position Sensor parameter more than the specified value 4 9 vo...

Page 125: ...s connector of the intake throttle valve pin 4 of E 16 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 13 Go to Step 11 10 1 Turn OFF the ignition 2 Disconnect...

Page 126: ...ine Control System 4HK1 1A 123 14 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 127: ...r Action Taken When the DTC Sets Type A The ECM uses a FT substitution of default value Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagn...

Page 128: ...learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 9 9 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn O...

Page 129: ...e 0 1 volts Go to Step 10 Go to Step 7 7 Connect a 3 amp fused jumper wire between the signal circuit of the sensor harness pin 2 of E 22 and a known good ground Is the FT Sensor parameter less than t...

Page 130: ...ensor in Section 1D Engine Fuel Did you complete the replacement Go to Step 15 14 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete the...

Page 131: ...Type A The ECM uses a FRP substitution of default value The ECM limits fuel injection quantity The ECM inhibits pilot injection The ECM inhibits EGR control Condition for Clearing the DTC Refer to DT...

Page 132: ...on Go to Step 12 Go to Step 10 9 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for a poor connection at the harness connector of the ECM pin 87 of E...

Page 133: ...n 2 of E 19 and a known good ground 2 Connect a DMM between the probe of the test lamp and a known good ground Is the DMM voltage more than the specified value 4 5 volts Go to Step 9 Go to Step 6 6 Co...

Page 134: ...onnect the ECM harness connector 3 Inspect for an intermittent and for poor connections at the harness connector of the ECM pins 82 90 and 87 of E 12 4 Repair the connection s as necessary Did you fin...

Page 135: ...rcuit Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injectio...

Page 136: ...ent and for poor connections at the in line harness connector 4 Repair the connection s as necessary Did you find and correct the condition Go to Step 17 Go to Step 13 9 Repair the open circuit or hig...

Page 137: ...el injector Refer to Injector in Section 1D Engine Fuel Did you complete the replacement Go to Step 17 16 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacem...

Page 138: ...olenoid control circuit and a known good ground Is the DMM voltage less than the specified value 16 0 volts Go to Step 6 Go to Step 11 6 Is the DMM voltage more than the specified value at Step 5 12 0...

Page 139: ...circuits between the fuel injector terminals and the in line harness connector for the following conditions An open circuit A short circuit each other High resistance 2 Repair the circuit s or replac...

Page 140: ...DTC Information with a scan tool Does the DTC fail this ignition Go to Step 3 Go to Diagnostic Aids 3 1 Turn OFF the ignition 2 Disconnect the in line harness connector from the cylinder head cover ca...

Page 141: ...the circuit s as necessary Did you find and correct the condition Go to Step 17 Go to Step 15 11 1 Test the control circuit between the ECM and the in line harness connector for a short to battery or...

Page 142: ...Step 3 Go to Step 18 18 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No Step Action Value s Yes No 1 Did...

Page 143: ...ent and for poor connections at the in line harness connector 4 Repair the connection s as necessary Did you find and correct the condition Go to Step 17 Go to Step 13 9 Repair the open circuit or hig...

Page 144: ...fuel injector must be programmed Replace the cylinder 4 fuel injector Refer to Injector in Section 1D Engine Fuel Did you complete the replacement Go to Step 17 16 Important Replacement ECM must be pr...

Page 145: ...bilize when the thermostat opens Use the Temperature vs Resistance table to test the ECT sensor at various temperature levels to evaluate the possibility of a skewed sensor A skewed sensor could resul...

Page 146: ...arious temperature levels to evaluate the possibility of a skewed sensor 2 Replace the ECT sensor as necessary Did you find and correct the condition Go to Step 7 Go to Diagnostic Aids 7 1 Reconnect a...

Page 147: ...rotor teeth are not damaged Electromagnetic interference in the CKP sensor circuits may set this DTC The Total Engine Overspeed Events parameter on the scan tool indicates number of overrun events No...

Page 148: ...CKP Sensor in Section 1B Engine Mechanical Did you complete the replacement Go to Step 5 6 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the...

Page 149: ...alue The fuel with which gasoline was mixed may set this DTC Test Description The numbers below refer to the step number on the Circuit System Testing 3 A skewed boost pressure sensor value shifted to...

Page 150: ...ent for a poor connection and corrosion at the harness connector of the ECM pin 109 of E 12 6 Test for high resistance of the low reference circuit 7 Repair the connection s or circuit s as necessary...

Page 151: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 152: ...B Euro 4 specification Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Except Euro 4 specification Diagnostic Aids Induction air leakage can cause a low boost pressure cond...

Page 153: ...ir or replace as necessary Did you find and correct the condition Go to Step 10 Go to Step 4 4 1 Turn ON the ignition with the engine OFF 2 Observe the Boost Pressure and Barometric Pressure BARO with...

Page 154: ...re sensor Refer to Boost Pressure Sensor in Section 1J Induction Did you complete the replacement Go to Step 10 9 Replace the BARO sensor Refer to BARO Sensor Replacement Did you complete the replacem...

Page 155: ...the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Electrom...

Page 156: ...set DTCs on sensors that share this circuit 1 Test the 5 volts reference circuit between the ECM pin 95 of E 12 and the CKP sensor pin 3 of E 20 for an open circuit or high resistance 2 Repair the cir...

Page 157: ...to Step 16 15 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for poor connections at the harness connector of the ECM pins 95 107 108 and 109 of E 12...

Page 158: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 159: ...f an intermittent condition is suspected refer to Intermittent Conditions in this section Electromagnetic interference in the CKP sensor circuits may set this DTC An intermittent CKP sensor signal pul...

Page 160: ...ing between sensor and sensor rotor Physical damage of sensor rotor Loose or improper installation of sensor rotor 2 Repair or replace as necessary Did you find and correct the condition Go to Step 7...

Page 161: ...ion for Clearing the MIL DTC Type A Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Electromagnetic interference in the CMP sensor circuits m...

Page 162: ...may set DTCs on sensors that share this circuit 1 Test the 5 volts reference circuit between the ECM pin 87 of E 12 and the CMP sensor pin 3 of E 18 for an open circuit or high resistance 2 Repair th...

Page 163: ...Step 16 15 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for poor connections at the harness connector of the ECM pins 87 98 100 and 101 of E 12 4 R...

Page 164: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 165: ...n intermittent condition is suspected refer to Intermittent Conditions in this section Electromagnetic interference in the CMP sensor circuits may set this DTC An intermittent CMP sensor signal pulse...

Page 166: ...g between sensor and camshaft gear Physical damage of camshaft gear Loose or improper installation of camshaft gear 2 Repair or replace as necessary Did you find and correct the condition Go to Step 7...

Page 167: ...fication Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp DTC Type C Euro 4 specification Refer to DTC Type Definitions for Condition for Clearing t...

Page 168: ...sary Did you find and correct the condition Go to Step 12 Go to Step 9 7 Repair the open circuit or high resistance between the ECM 10A fuse and the glow relay coil side pin 3 of X 19 Check the ECM 10...

Page 169: ...e ECT sensor harness connector in order to gain glow ON time long enough 5 Turn ON the ignition for 30 seconds while observing the DTC information with a scan tool Did the DTC P0380 fail this ignition...

Page 170: ...en the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type C Euro 4 specification The ECM illuminates the MIL when the diagnostic runs and fails Refer to DT...

Page 171: ...the ignition with the engine OFF Does the test lamp illuminate Go to Step 9 Go to Step 14 9 1 Test the control circuit between the ECM pin 11 of J 14 and the IP cluster pin 5 of B 106 for an open circ...

Page 172: ...acement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 17 17 1 Reconnect all previously disconnected fuse or harness connector...

Page 173: ...R flow Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injecti...

Page 174: ...uct if connected 2 Repair or replace as necessary Did you find and correct the condition Go to Step 7 Go to Step 5 5 1 Perform the EGR Solenoid Control with a scan tool several times 2 Command the Des...

Page 175: ...172 Engine Control System 4HK1 8 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 176: ...s EGR control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Notice A history DTC remains 9 600 hours accumulated engine runtime and will no...

Page 177: ...d corrosion at the harness connector of the ECM pins 87 93 94 99 101 103 110 and 111 of E 12 6 Test for an open circuit or high resistance on each circuit 7 Repair the connection s or circuit s as nec...

Page 178: ...med and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 10 10 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool...

Page 179: ...ions for Action Taken When the DTC Sets Type A The ECM inhibits EGR control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Notice A history...

Page 180: ...E 15 for the following conditions A short to battery or ignition voltage A short to any 5 volts reference 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 16 Go to...

Page 181: ...o to Step 16 Go to Step 14 13 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for poor connections at the harness connector of the ECM pins 87 93 94 99...

Page 182: ...ine Control System 4HK1 1A 179 17 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 183: ...temperature condition which was most likely caused by uncontrolled burning while regeneration process of DPD filter Excessive high exhaust gas temperature may damage DPD filter or oxygen catalyst Sch...

Page 184: ...Operate the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Failure Records Did the DTC fail this ignition Go to St...

Page 185: ...to 10 minutes DTC P0428 Condition for Setting the DTC The ECM detects that the exhaust temperature sensor 1 signal voltage is less than 0 2 volts for 3 seconds DTC P0427 The ECM detects that the exha...

Page 186: ...2 Disconnect the ECM harness connector 3 Inspect connections at the harness connector of the ECM pins 73 and 79 of J 14 for corrosion 4 Repair or clean the connection s as necessary Did you find and...

Page 187: ...s connector 3 Connect a DMM between the signal circuit pin 1 of J 34 and a known good ground 4 Turn ON the ignition with the engine OFF Is the DMM voltage more than the specified value 5 5 volts Go to...

Page 188: ...34 for a short to any 5 volts reference circuit 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 15 Go to Step 11 11 1 Inspect for an intermittent and for poor co...

Page 189: ...0 C 176 F 5 Accelerate the engine between idle and W O T accelerator pedal full travel many times while observing the Exhaust Temperature Sensor 1 parameter with a scan tool Is the Exhaust Temperature...

Page 190: ...dition which was most likely caused by uncontrolled burning while regeneration process of DPD filter Excessive high exhaust gas temperature may damage DPD filter Schematic Reference Engine Controls Sc...

Page 191: ...Operate the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Failure Records Did the DTC fail this ignition Go to St...

Page 192: ...s longer than 5 to 10 minutes DTC P042D Condition for Setting the DTC The ECM detects that the exhaust temperature sensor 2 signal voltage is less than 0 2 volts for 3 seconds DTC P042C The ECM detect...

Page 193: ...onnections at the harness connector of the ECM pins 74 and 79 of J 14 for corrosion 4 Repair or clean the connection s as necessary Did you find and correct the condition Go to Step 9 Go to Step 8 8 I...

Page 194: ...nt The exhaust temperature sensor 2 may be damaged if the sensor signal circuit is shorted to a voltage source 1 Test the signal circuit between the ECM pin 74 of J 14 and the exhaust temperature sens...

Page 195: ...5 Go to Step 13 12 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for poor connections at the harness connector of the ECM pins 74 and 79 of J 14 4 Re...

Page 196: ...ine Control System 4HK1 1A 193 16 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 1...

Page 197: ...runs and fails The ECM inhibits exhaust brake control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids If an intermittent cond...

Page 198: ...find and correct the condition Go to Step 13 Go to Step 12 9 1 Inspect for an intermittent and for poor connections at the harness connector of the solenoid valve pins 1 and 2 of J 26 2 Repair the con...

Page 199: ...ut not P0478 Go to Step 5 Go to Step 4 4 1 Test the control circuit between the ECM pin 15 of J 14 and the solenoid valve pin 2 of J 26 for a short to battery or ignition voltage 2 Repair the circuit...

Page 200: ...n Taken When the DTC Sets Type B Euro 4 specification The ECM illuminates MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A Except Euro 4 s...

Page 201: ...ace the VSS Refer to Vehicle Speed Sensor in Section 9E Instrumentation Driver Info Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness connector s 2 Clear...

Page 202: ...n 19 of J 14 6 Repair the connection s as necessary Did you find and correct the condition Go to Step 7 Go to Step 6 6 Important Replacement EHCU must be programmed Replace the EHCU Refer to EHCU in S...

Page 203: ...fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injection quantity Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clea...

Page 204: ...and the VSS pin 3 of J 48 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 10 9 1 Inspect for an intermittent...

Page 205: ...scan tool Does the DTC fail this ignition Go to Step 3 Go to Diagnostic Aids 3 Observe the ABS DTCs information with a scan tool Is DTC C0251 C0252 C0253 C0254 C0261 C0262 C0263 or C0264 set Go to Ap...

Page 206: ...11 10 Important Replacement EHCU must be programmed Replace the EHCU Refer to EHCU in Section 4C1 ABS ASR Did you complete the replacement Go to Step 12 11 Important Replacement ECM must be programme...

Page 207: ...ground as necessary Did you complete the repair Go to Step 10 7 1 Inspect for an intermittent and for a poor connection at the harness connector of the VSS pin 2 of J 48 2 Repair the connection s as n...

Page 208: ...battery or ignition voltage 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 9 Go to Step 8 6 1 Inspect for an intermittent and for a poor connection at the harnes...

Page 209: ...206 Engine Control System 4HK1 10 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 2...

Page 210: ...the MIL DTC Type A Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Schematic Reference Engine Controls Schematics Connector End View Referenc...

Page 211: ...p 14 10 1 Test the voltage supply circuit between the ECM pin 35 of J 14 and the dropping resistor pin 2 of J 30 for the following conditions A short to ground A short to battery or ignition voltage 2...

Page 212: ...Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 18 18 1 Reconnect all previously disconnected fuse or harness connec...

Page 213: ...charging system problem may set this DTC Schematic Reference Engine Controls Schematics Connector End View Reference Engine Controls Connector End Views or ECM Connector End Views Circuit System Test...

Page 214: ...gine Control System 4HK1 1A 211 7 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 2...

Page 215: ...it System Testing DTC P0601 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install a scan tool...

Page 216: ...SVS Lamp DTC Type C Euro 4 specification Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Except Euro 4 specification Notice Clear the DTC with a scan tool after programming...

Page 217: ...itions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go to Step 3 Go to Step 6 6 Obs...

Page 218: ...OFF for longer than 10 seconds DTC P0604 Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Circuit System Testing DTC P0604 P0606 or P060B Ste...

Page 219: ...on programmed ECM sets this DTC Circuit System Testing DTC P0633 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Eng...

Page 220: ...DTC Sets Type A Except Euro 4 specification Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type B Euro 4 specification Refer to DTC Type Definitio...

Page 221: ...an intermittent for poor connections and corrosion on each intake throttle valve circuit at the harness connector of the ECM pins 85 95 104 109 and 112 of E 12 6 Test for an open circuit or high resis...

Page 222: ...med and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 10 10 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool...

Page 223: ...The ECM blinks the exhaust brake indicator lamp when the diagnostic runs and fails The ECM limits fuel injection quantity The ECM inhibits exhaust brake control Condition for Clearing the DTC Refer t...

Page 224: ...PTO throttle sensor pin 1 of J 39 Idle up sensor pin 3 of B 87 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 12 8 1 Test the 5 volts reference cir...

Page 225: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 226: ...Euro 4 specification Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Euro 4 specification Refer to DTC Type Definitions for Condition for Cl...

Page 227: ...u find and correct the condition Go to Step 17 Go to Step 10 10 1 Inspect for an intermittent and for poor connections at the harness connector of the IP cluster pins 2 and 31 of B 105 2 Repair the co...

Page 228: ...or harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Turn ON the ignition for 10 seconds 5 Start the engine 6 Monitor the DTC Information with a scan tool...

Page 229: ...uns and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM blinks the exhaust brake indicator lamp when the diagnostic runs and fails The ECM limits fuel injection q...

Page 230: ...oes the DMM voltage change to more than the specified value 4 5 volts Go to Step 14 Go to Step 8 8 1 Leave the DMM connected to the EGR valve harness connector 2 Turn OFF the ignition 3 Disconnect the...

Page 231: ...fer to CMP Sensor in Section 1B Engine Mechanical Did you complete the replacement Go to Step 17 14 Replace the BARO sensor Refer to BARO Sensor Replacement Did you complete the replacement Go to Step...

Page 232: ...Taken When the DTC Sets Type C Euro 4 specification The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A Except Euro...

Page 233: ...n pins 2 and 5 of J 14 and pin 2 of X 18 Between pins 21 and 40 of J 14 and pin 3 of X 18 Between ECM 40A slow blow fuse and pin 1 of X 18 Between pin 5 of X 18 and chassis ground J 13 5 Repair the co...

Page 234: ...od relay 3 Turn ON the ignition with the engine OFF Does the DTC fail Go to Step 6 Go to Step 7 5 Repair the short to battery on the battery voltage feed circuits between the ECM pins 2 and 5 of J 14...

Page 235: ...3 or 4 voltage is more than 5 5 volts Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Ty...

Page 236: ...ep 8 8 1 Test the 5 volts reference circuit 3 between the ECM pin 80 of J 14 and the exhaust differential pressure sensor pin 3 of J 33 for a short to ground or short to the low reference circuit 2 Te...

Page 237: ...Pressure Sensor in Section 1G Engine Exhaust Did you complete the replacement Go to Step 15 14 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM Replacement Did yo...

Page 238: ...become low enough to set this DTC Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at idle is around 27 to 33 MPa 3 900 to 4 800 psi after warm up A skewed FRP s...

Page 239: ...nter the fuel system if these connections are not tight Air in the fuel system will cause fuel rail pressure fluctuations especially at high engine speed and load which may set this DTC 2 Pump the pri...

Page 240: ...a minimum of 1 minute Does the fuel pressure vacuum gauge ever indicate a larger vacuum than the specified amount during the test 5 inHg Go to Step 7 Go to Step 6 6 1 Fully clamp off a fuel hose as cl...

Page 241: ...f the FRP regulator pins 1 and 2 of E 17 4 Disconnect the ECM harness connector 5 Inspect for an intermittent for poor connections and corrosion at the harness connector of the ECM pins 89 97 105 and...

Page 242: ...er Element in Section 1D Engine Fuel Did you complete the replacement Go to Step 17 16 Notice There is a possibility that the pressure limiter valve stuck open or operating pressure has fallen Replace...

Page 243: ...EGR control Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids If an intermittent condition is suspected refer to Intermittent C...

Page 244: ...inates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injection quantity The ECM inhibits EGR control Condition...

Page 245: ...the EGR position sensor circuit s 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 7 Go to Step 6 6 Replace the EGR valve Refer to EGR Valve and EGR Cooler in Sect...

Page 246: ...Taken When the DTC Sets Type A The ECM limits fuel injection quantity Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type A Diagnostic Aids If man...

Page 247: ...scan tool if set 3 Turn OFF the ignition for 30 seconds Important Engine oil must be replaced after DPD slow regeneration is completed 4 Perform the DPD Slow Regeneration with a scan tool Did you comp...

Page 248: ...s ON The exhaust gas temperature 1 in front of filter is more than 100 C 212 F The engine speed is more than 1000RPM The EGR position is less than 95 The intake throttle position is more than 22 The D...

Page 249: ...ted air cleaner element restricted or collapsed air tubing between the air cleaner and the intake manifold Modified air induction system Any air induction leak Any contamination or objects that block...

Page 250: ...the Exhaust Temperature 1 parameter with a scan tool Make sure the temperature is less than 150 C 302 F If more than 150 C 302 F let increase 1500 RPM without load Turn the idle up control knob clock...

Page 251: ...s If an intermittent condition is suspected refer to Intermittent Conditions in this section Electromagnetic interference may affect intermittent condition Circuit System Testing DTC P161B Step Action...

Page 252: ...te the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition G...

Page 253: ...ols Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Ensure that all tool connections are secure 2 Ensure that programming equipment is operating correctly 3 Install a scan tool 4 Turn O...

Page 254: ...r Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp DTC Type C Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this s...

Page 255: ...you find and correct the condition Go to Step 17 Go to Step 10 10 1 Inspect for an intermittent and for poor connections at the harness connector of the IP cluster pins 2 of B 105 and pin 4 of B 106 2...

Page 256: ...or harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Turn ON the ignition for 10 seconds 5 Start the engine 6 Monitor the DTC Information with a scan tool...

Page 257: ...pe C Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp DTC Type C Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Con...

Page 258: ...J 14 and the IP cluster pin 35 of B 105 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 17 Go to Step 10 10 1 Inspect for a...

Page 259: ...d you complete the replacement Go to Step 17 17 1 Reconnect all previously disconnected fuse or harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Turn ON t...

Page 260: ...The ECM illuminates MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A Except Euro 4 specification The ECM blinks the exhaust brake indicato...

Page 261: ...ary Did you find and correct the condition Go to Step 12 Go to Step 9 7 1 Test the signal circuit between the ECM pin 63 of J 14 and the APP sensor pin 5 of B 5 for the following conditions An open ci...

Page 262: ...the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install a scan tool 2 Turn OFF the ignition for 30 seconds 3 Start the engine 4 Fully depress...

Page 263: ...the APP sensor pin 6 of B 5 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 10 9 1 Inspect for an intermitten...

Page 264: ...and release the accelerator pedal while observing the APP Sensor 1 parameter with the scan tool Does the scan tool indicate more than the specified value during depressing or releasing the pedal 4 9...

Page 265: ...The ECM illuminates MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A Except Euro 4 specification The ECM blinks the exhaust brake indicato...

Page 266: ...ary Did you find and correct the condition Go to Step 12 Go to Step 9 7 1 Test the signal circuit between the ECM pin 64 of J 14 and the APP sensor pin 2 of B 5 for the following conditions An open ci...

Page 267: ...the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install a scan tool 2 Turn OFF the ignition for 30 seconds 3 Start the engine 4 Fully depress...

Page 268: ...the APP sensor pin 3 of B 5 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 10 9 1 Inspect for an intermitten...

Page 269: ...and release the accelerator pedal while observing the APP Sensor 1 parameter with the scan tool Does the scan tool indicate more than the specified value during depressing or releasing the pedal 4 9...

Page 270: ...other Action Taken When the DTC Sets The ECM illuminates the MIL on the second consecutive driving cycle when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC...

Page 271: ...r Refer to Accelerator Pedal Sensor in Section 1I Engine Speed Control System Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness connector s 2 Clear the DT...

Page 272: ...ltage circuit or cylinder 2 or 3 fuel injector solenoid coil control circuit is shorted to ground DTC P2149 Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fail...

Page 273: ...nder 1 Between pin 121 of E 12 and 1 of H 70 Cylinder 4 Between pin 121 of E 12 and 4 of H 70 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 15 Go to Step 14 9 1...

Page 274: ...he replacement Go to Step 15 15 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Start the engine Operate the vehi...

Page 275: ...a short to ground Cylinder 2 Between pin 118 of E 12 and 6 of H 70 Cylinder 3 Between pin 120 of E 12 and 7 of H 70 2 Repair the circuit s as necessary Did you find and correct the condition Go to St...

Page 276: ...ation resistance of the cylinder 2 and 3 fuel injector between each fuel injector terminal and a known good ground Is the resistance more than the specified value 1M Go to Step 12 Go to Step 13 12 Rep...

Page 277: ...274 Engine Control System 4HK1 16 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 2...

Page 278: ...er to DTC Type Definitions for Action Taken When the DTC Sets Type B Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type B Diagnostic Aids If an in...

Page 279: ...ignition 2 Disconnect the BARO sensor harness connector 3 Inspect for an intermittent for poor connections and corrosion at the harness connector of the BARO sensor pins 1 2 and 3 of B 121 4 Disconnec...

Page 280: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 281: ...conds DTC P2229 Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM uses a BAR...

Page 282: ...circuit A short to ground A short to the low reference circuit High resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 12 Go to Step 9 8 1 Inspect for an...

Page 283: ...2 1 Install a scan tool 2 Turn OFF the ignition for 30 seconds 3 Start the engine 4 Observe the Barometric Pressure BARO Sensor parameter with a scan tool Is the BARO Sensor parameter more than the sp...

Page 284: ...nnector of the BARO sensor pin 1 of B 121 2 Repair the connection s as necessary Did you find and correct the condition Go to Step 13 Go to Step 11 10 1 Turn OFF the ignition 2 Disconnect the ECM harn...

Page 285: ...282 Engine Control System 4HK1 14 Observe the DTC Information with a scan tool Are there any DTCs that you have not diagnosed Go to DTC List System OK Step Action Value s Yes No LG4HKED WE 0871 book 2...

Page 286: ...ken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injection quantity Cond...

Page 287: ...scan tool if set 3 Turn OFF the ignition for 30 seconds Important Engine oil must be replaced after DPD slow regeneration is completed 4 Perform the DPD Slow Regeneration with a scan tool Did you comp...

Page 288: ...r 1 0 to 3 5 kPa high output for longer than 30 seconds Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken Whe...

Page 289: ...asket that is missing or damaged Exhaust gas leakage from the exhaust pipe gasket DPD assembly exhaust temperature sensor s or exhaust differential pressure hoses or pipes Modified exhaust system Exha...

Page 290: ...connected harness connector s or components 2 Turn ON the ignition for 30 seconds DO NOT start the engine This is to relearn exhaust differential pressure sensor 3 Clear the DTC and reset the DPD Stat...

Page 291: ...and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injection quantity Condition for Clearing the DTC Refer to DTC Type Definitions for Condition for...

Page 292: ...find and correct the condition Go to Step 6 Go to Step 4 4 1 Turn OFF the ignition 2 Disconnect the exhaust differential pressure sensor harness connector 3 Inspect for an intermittent for poor connec...

Page 293: ...re is less than 150 C 302 F If more than 150 C 302 F let increase 1500 RPM without load Turn the idle up control knob clockwise 2 Accelerate the engine to W O T accelerator pedal full travel and read...

Page 294: ...nal voltage is more than 4 9 volts DTC P2455 Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC S...

Page 295: ...rect the condition Go to Step 12 Go to Step 9 8 1 Inspect for an intermittent and for poor connections at the harness connector of the exhaust differential pressure sensor pins 2 and 3 of J 33 2 Repai...

Page 296: ...Start the engine 4 Observe the Exhaust Differential Pressure Sensor parameter with a scan tool Is the Exhaust Differential Pressure Sensor parameter more than the specified value 4 9 volts Go to Step...

Page 297: ...it s as necessary Did you find and correct the condition Go to Step 13 Go to Step 10 9 1 Inspect for an intermittent and for a poor connection at the harness connector of the exhaust differential pres...

Page 298: ...e the vehicle within the Conditions for Running the DTC You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records Did the DTC fail this ignition Go...

Page 299: ...ns and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A The ECM limits fuel injection quantity The ECM inhibits pilot injection Condition for Clearing the DTC Refer to DTC...

Page 300: ...ressure sensor pins 1 2 and 3 of J 33 for high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 7 Go to Step 6 6 Important Replacement exhaust different...

Page 301: ...rocess is continuously over a predetermined time Action Taken When the DTC Sets The ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the D...

Page 302: ...as necessary 4 Reconnect all previously disconnected harness connector s or components Did you find and correct the condition Go to Step 6 Go to Step 4 4 1 Turn ON the ignition for 30 seconds DO NOT s...

Page 303: ...thout load Turn the idle up control knob clockwise 2 Accelerate the engine to W O T accelerator pedal full travel and read the Exhaust Differential Pressure parameter when the Exhaust Temperature 1 pa...

Page 304: ...Type Definitions for Action Taken When the DTC Sets Type A Except Euro 4 specification The ECM disables PTO throttle sensor control Condition for Clearing the DTC Refer to DTC Type Definitions for Con...

Page 305: ...ir the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 12 8 Notice The PTO throttle sensor shares the low reference circuit with other sensors A fault condition...

Page 306: ...an tool 3 Turn OFF the ignition for 30 seconds 4 Start the engine 5 Observe the PTO Remote Throttle Sensor parameter with a scan tool while operating the PTO throttle sensor Does the scan tool indicat...

Page 307: ...e ECM illuminates the MIL when the diagnostic runs and fails Refer to DTC Type Definitions for Action Taken When the DTC Sets Type A Except Euro 4 specification The ECM disables idle up sensor control...

Page 308: ...r 3 Turn ON the ignition with the engine OFF Is the Idle Up Sensor parameter less than the specified value 0 1 volts Go to DTC P0641 Go to Step 13 9 1 Turn OFF the ignition 2 Disconnect the idle up se...

Page 309: ...circuit 1 Test the low reference circuit between the ECM pin 41 of J 14 and the idle up sensor pin 1 of B 87 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find an...

Page 310: ...ion full counterclockwise direction and highest position full clockwise direction while observing the Idle Up Sensor parameter with a scan tool Does the scan tool indicate within the specified value d...

Page 311: ...ondition for Clearing the DTC Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type B Euro 4 specification Refer to DTC Type Definitions for Condition for Clearing the MIL DTC Type...

Page 312: ...ct the electric hydraulic control unit EHCU harness connector Is the resistance within the specified value 50 to 70 Go to Step 20 Go to Step 8 8 1 Leave the DMM connected to the IP cluster 2 Disconnec...

Page 313: ...onnectors 3 Turn ON the ignition with the engine OFF 4 Connect a DMM between the CAN Low circuit pin 14 of B 105 and a known good ground 5 Connect a DMM between the CAN High circuit pin 13 of B 105 an...

Page 314: ...o BCM in Section 10B Vehicle Control Did you complete the replacement Go to Step 23 22 Important Replacement TCM must be programmed and learned Replace the TCM Refer to TCM in Section 5A Transmission...

Page 315: ...TC Type Definitions for Condition for Clearing the MIL DTC Type A Except Euro 4 specification Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section...

Page 316: ...4 of B 105 and the joint connection for an open circuit or high resistance 2 Inspect for an intermittent for poor connections and corrosion at the harness connector of the IP cluster pins 13 and 14 of...

Page 317: ...cement Go to Step 14 14 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with a scan tool 3 Turn OFF the ignition for 30 seconds 4 Start the engine 5 Operate the vehicle wi...

Page 318: ...MIL DTC Type A Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Schematic Reference Engine Controls Schematics Connector End View Reference En...

Page 319: ...joint connection for an open circuit or high resistance 2 Inspect for an intermittent for poor connections and corrosion at the harness connector of the IP cluster pins 13 and 14 of B 105 3 Repair th...

Page 320: ...ument Panel IP Cluster in Section 9E Instrumentation Driver Info Did you complete the replacement Go to Step 17 15 Important Replacement ECM must be programmed and learned Replace the ECM Refer to ECM...

Page 321: ...on fault with the ICU may set this DTC Circuit System Testing DTC U0167 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Ch...

Page 322: ...lenoid is determined and the valve is driven accordingly The intake throttle valve is provided to adequate intake manifold depression to ensure EGR gas flow EGR Control Operation The engine coolant te...

Page 323: ...O sensor Determine the outside barometric pressure from you location specified in the altitude vs barometric pressure table Refer to Altitude vs Barometric Pressure A sticking intake throttle valve 2...

Page 324: ...tent for poor connections and corrosion at the harness connector of the EGR valve pins 1 2 3 4 5 6 7 and 8 of E 15 4 Disconnect the ECM harness connector 5 Inspect for an intermittent for poor connect...

Page 325: ...112 of E 12 6 Test for high resistance on each circuit 7 Repair the connection s or circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 12 11 Replace the EGR valve...

Page 326: ...Views or ECM Connector End Views Circuit System Testing Glow Control System Check Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnosti...

Page 327: ...emove the glow relay 3 Probe the battery voltage feed circuit of the relay pin 1 of X 19 with a test lamp that is connected to a known good ground Does the test lamp illuminate Go to Step 9 Go to Step...

Page 328: ...Did you complete the replacement Go to Step 16 16 1 Reconnect all previously disconnected components relay fuse or harness connector s 2 Turn OFF the ignition for 30 seconds 3 Turn ON the ignition wi...

Page 329: ...tics Connector End View Reference Engine Controls Connector End Views or ECM Connector End Views Circuit System Testing Engine Warm Up Control System Check Step Action Value s Yes No 1 Did you perform...

Page 330: ...the Engine Warm Up Switch parameter with a scan tool while momentarily jumping 3 amp fused jumper wire across the switch harness connector between pins 1 and 2 of B 168 Does the scan tool indicate ON...

Page 331: ...B 168 for a short to battery or ignition voltage 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 20 Go to Step 19 18 Repair or replace the engine warm up switch...

Page 332: ...Controls Schematics Connector End View Reference Engine Controls Connector End Views or ECM Connector End Views Circuit System Testing Exhaust Brake Control System Check 1 of 2 Step Action Value s Yes...

Page 333: ...not allowing exhaust brake control Refer to Exhaust Brake Control Operation 9 1 Install a scan tool 2 Turn ON the ignition with the engine OFF 3 Observe the Clutch Pedal Switch parameter with a scan t...

Page 334: ...tion s as necessary Did you find and correct the condition Go to Step 29 Go to Step 17 16 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for a poor co...

Page 335: ...ECM pin 15 of J 14 and the solenoid valve pin 2 of J 26 for a short to ground 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 29 25 1 Inspect for an intermittent...

Page 336: ...the scan tool indicate ON when the circuit is jumpered and OFF when the circuit is not jumpered Go to Step 7 Go to Step 6 5 Repair the open circuit or high resistance between the ECM 10A fuse and the...

Page 337: ...n the ECM pin 7 of J 14 and the IP cluster pin 13 of B 106 for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 20 Go to Step 14...

Page 338: ...and learned Replace the ECM Refer to ECM Replacement Did you complete the replacement Go to Step 20 20 Reconnect all previously disconnected components fuse or harness connector s Did you complete th...

Page 339: ...he DPD Distance Status parameter To use this table observe both parameters with a scan tool and plot both readings on the DPD status table The intersected range indicates A B C or D e g DPD Accumulati...

Page 340: ...to Step 3 Refer to P1669 for DPD lamp circuit diagnosis or Refer to IP cluster diagnosis in Section 9E Instrumentation Driver Info 3 1 Inspect engine oil level Make sure the oil amount is within a ra...

Page 341: ...ust throttle valve or exhaust brake valve for stuck condition Refer to Exhaust System in Section 1G Engine Exhaust Skewed or slow exhaust temperature sensors Restricted air cleaner element restricted...

Page 342: ...eter is reached to 200 C 392 F Is the Exhaust Differential Pressure parameter less than the specified value 5 9 kPa low output 2 5 kPa higt output Go to Step 12 Ash cleaning must be performed Refer to...

Page 343: ...o Step 23 18 1 Test the signal circuit between the ECM pin 47 of J 14 and the switch pin 2 of B 165 for the following conditions An open circuit A short to battery or ignition voltage High resistance...

Page 344: ...sconnected components fuse or harness connector s 2 Start the engine 3 Observe the DPD Switch parameter with a scan tool Does the scan tool indicate ON and OFF with each switch transition Go to Step 4...

Page 345: ...e with the DMM connected to the suspected circuit An abnormal reading that occurs when the malfunction occurs is a good indication that there is a malfunction in the circuit being monitored Use the sc...

Page 346: ...ol readings do not indicate the problems then proceed in a logical order easiest to check or most likely to cause first In order to determine if a specific vehicle is using a particular system or comp...

Page 347: ...ver insulation This requires removing the terminal from the connector body Corrosion water intrusion Pierced or damaged insulation can allow moisture to enter the wiring The conductor can corrode insi...

Page 348: ...igh voltage high current devices such as injection components motors generator etc These components may induce electrical noise on a circuit that could interfere with normal circuit operation Electric...

Page 349: ...ia serial data The Snapshot function records live data over a period of time The recorded data can be played back and analyzed The scan tool can also graph parameters singly or in combinations of para...

Page 350: ...st in this section Compare the Coolant Temperature with the Intake Air Temperature IAT and Fuel Temperature FT parameters on a cold engine condition If the difference among temperature reading is more...

Page 351: ...r Force Drive with a scan tool Observe the FRP Regulator Feedback current on the scan tool Air Intake System Checks Inspect the air intake system for the following conditions Air cleaner air intake du...

Page 352: ...ction Compare the Coolant Temperature with the Intake Air Temperature IAT and Fuel Temperature FT parameters on a cold engine condition If the difference among temperature reading is more than 5 C 9 F...

Page 353: ...er Balance Test with a scan tool Perform the Injector Force Drive with a scan tool Observe the Fuel Compensation for each cylinder at idle on the scan tool Observe the FRP Regulator Feedback current o...

Page 354: ...with little change in actual engine speed change indicates that EMI is present If a problem exists check routing of high voltage components such as fuel injector solenoid valve wiring near the sensor...

Page 355: ...mal intake air temperature if the ignition switch is being ON Observe the Fuel Rail Pressure FRP Sensor parameter with the engine OFF The FRP Sensor should read 0 9 to 1 0 volt with the ignition switc...

Page 356: ...pedal full travel in Neutral Fuel Rail Pressure parameter should follow within 5 MPa 725 psi quick enough Observe the Accelerator Pedal Position APP APP parameter should change linearly from 0 to 100...

Page 357: ...e EMI on the reference circuit can cause an engine miss condition The scan tool can usually detect EMI by monitoring the engine speed A sudden increase in speed with little change in actual engine spe...

Page 358: ...ngine has stopped running for a minimum of 1 minute If not check for high resistance in each circuit or for a skewed sensor Observe the Fuel Rail Pressure and Desired Fuel Rail Pressure parameter betw...

Page 359: ...ocharger nozzle control solenoid for a stuck condition Refer to Turbocharger Assembly in Section 1J Induction Exhaust System Checks Inspect the exhaust system for a possible restriction Refer to Exhau...

Page 360: ...lowing conditions Refer to the Scan Tool Data List in this section Compare the Coolant Temperature with the Intake Air Temperature IAT and Fuel Temperature FT parameters on a cold engine condition If...

Page 361: ...hecks Inspect the air intake system for the following conditions Air cleaner air intake ducts and charge air cooler for a restriction holes or leaks A restriction in the turbocharger inlet duct Intake...

Page 362: ...e Air Temperature IAT and Fuel Temperature FT parameters on a cold engine condition If the difference among temperature reading is more than 5 C 9 F on a cold engine check for high resistance in each...

Page 363: ...hecks Inspect the air intake system for the following conditions Air cleaner air intake ducts and charge air cooler for a restriction holes or leaks A restriction in the turbocharger inlet duct Intake...

Page 364: ...with the engine OFF The FRP Sensor should read 0 9 to 1 0 volt with the ignition switch ON and engine OFF after the engine has stopped running for a minimum of 1 minute If not check for high resistanc...

Page 365: ...k the fuel economy Inspect the odometer is correctly operated Inspect the Scan Tool Data List in this section Inspect the Service Bulletin Sensor Checks Inspect the engine control sensors for the foll...

Page 366: ...haft or compressor wheel Refer to Turbocharger Assembly in Section 1J Induction Turbocharger nozzle control solenoid for a stuck condition Refer to Turbocharger Assembly in Section 1J Induction Exhaus...

Page 367: ...MAF sensor is heated and as a result the IAT may indicate a higher than normal intake air temperature if the ignition switch is being ON Observe the MAF parameter for a skewed or slow MAF sensor Obser...

Page 368: ...Turbocharger Assembly in Section 1J Induction Exhaust System Checks Inspect the exhaust system for a possible restriction Refer to Exhaust System in Section 1G Engine Exhaust Engine Mechanical Checks...

Page 369: ...sure FRP Sensor parameter with the engine OFF The FRP Sensor should read 0 9 to 1 0 volt with the ignition switch ON and engine OFF after the engine has stopped running for a minimum of 1 minute If no...

Page 370: ...arger Assembly in Section 1J Induction Exhaust System Checks If an excessive white smoke is present while DPD filter regeneration process a deteriorated or damaged oxygen catalyst is suspected Engine...

Page 371: ...ong time Is the engine runtime short Is the vehicle runtime short Is the accelerator pedal ON and OFF too often Sensor Checks Inspect the engine control sensors relating to the DPD system control for...

Page 372: ...heel Refer to Turbocharger Assembly in Section 1J Induction Exhaust System Checks Inspect the exhaust system for the following conditions Refer to Exhaust System in Section 1G Engine Exhaust An exhaus...

Page 373: ...ionality in the exhaust differential pressure hoses Refer to Exhaust System in Section 1G Engine Exhaust Plugged crushed or kinked exhaust differential pressure hoses or pipes Dislocated or inclined e...

Page 374: ...the following conditions Refer to Exhaust System in Section 1G Engine Exhaust An exhaust system gasket that is missing or damaged Exhaust gas leakage from the exhaust pipe gasket DPD assembly exhaust...

Page 375: ...ts of each fuel injector ID code 5 After complete the recording turn OFF the scan tool 6 Turn OFF the ignition Retrieving the Fuel Injector ID Code Data with a Non communicating ECM If a scan tool doe...

Page 376: ...ropping resistor harness connector 6 Reconnect the negative battery cable C Programming Software and Calibrations Program latest software calibrations if released Refer to Service Programming System S...

Page 377: ...nning condition and for no DTC s Refer to the Diagnostic System Check Engine Controls if needed E Supply Pump Relearn 1 Install a scan tool 2 Start the engine and let idle until engine coolant tempera...

Page 378: ...thru procedure The Remote SPS method is a three step process that involves the following procedures 1 Connecting the scan tool to the vehicle and obtaining the information from the ECM 2 Connecting t...

Page 379: ...e Programming in Process will appear until the progress bar reaches 100 Notice Some warning lamp may turn ON or blink while programming the ECM since communication between the ECM and other modules ar...

Page 380: ...selected is already the current calibration in the ECM and reprogramming with the same download is not allowed 10 Click Reprog 11 The Transfer Data screen will appear until the progress bar reaches 10...

Page 381: ...e side cover on the left via mounting bracket The ECM mainly controls the following The fuel system control The exhaust gas recirculation EGR system control The turbocharger system control The diesel...

Page 382: ...refore the first step in diagnosing any powertrain fault is to eliminate all aftermarket electrical equipment from the vehicle After this is done if the fault still exists the fault may be diagnosed i...

Page 383: ...located in the instrument panel cluster The MIL will display the following symbols when commanded ON The MIL indicates that an emission related fault Type A or B has occurred Euro 4 specification or...

Page 384: ...d after the engine is started if the ECM detects a fault A DTC is stored any time the ECM illuminates the SVS lamp due to a non emission related fault Engine Control Component Description Accelerator...

Page 385: ...n tubing The boost pressure sensor is a transducer that varies voltage according to changes in the air pressure inside the air tubing The boost pressure sensor provides a signal to the ECM on the sign...

Page 386: ...ylinder 1 compression TDC to ensure they correlate with each other Engine Coolant Temperature ECT Sensor Legend 1 Engine coolant temperature ECT sensor The ECT sensor is installed to the thermostat ho...

Page 387: ...entering the engine When the IAT sensor is cold the sensor resistance is high When the air temperature increases the sensor resistance decreases With high sensor resistance the ECM detects a high vol...

Page 388: ...cle starting or acceleration can be reduced dramatically As a result exhaust gas emissions are clear and reduced and higher output is achieved 1 High Pressure Control Enables high pressure injection f...

Page 389: ...m 4HK1 Fuel System Component Description Injector Legend 1 Terminal stud 2 Fuel leak off port 3 O ring 4 Fuel inlet port 5 Injector parts number marking 6 QR plate LNW76EMH000101 4 3 2 1 5 6 64 0000 0...

Page 390: ...by means of a spring force when no current is supplied from the ECM to the solenoid At this time the fuel pressure applied to the nozzle leading end is equal to the fuel pressure applied to the contr...

Page 391: ...the fuel tank via the fuel supply pump by the use of an internal feed pump trochoid type This feed pump pumps fuel into a 2 plunger chamber also internal to the fuel supply pump Fuel into this chambe...

Page 392: ...fuel rail and it detects the fuel pressure in the fuel rail converts the pressure into a voltage signal and sends the signal to the ECM The ECM monitors the FRP sensor signal voltage Higher fuel rail...

Page 393: ...ine speed Combined with high pressure injection of atomized fuel this control improves exhaust gas and ensures proper fuel consumption Compared with conventional mechanical governors an electronic con...

Page 394: ...ed based on pulse width modulation PWM signal sent from the ECM The EGR valve position is detected by the position sensor and relayed to the ECM The position sensor is made up three individual sensors...

Page 395: ...g effect helps extend engine life Heat energy and pressures in the engine exhaust gas are utilized to drive the turbine Exhaust gas is directed to the turbine housing The turbine housing acts as a noz...

Page 396: ...harger nozzles B thus increasing the boost The ECM will vary the boost dependant upon the load requirements of the engine The charge air cooler also helps the performance of the diesel Intake air is d...

Page 397: ...rential pressure sensor 9 Oxygen catalyst 10 DPD filter 11 Exhaust throttle valve 12 Exhaust throttle solenoid 13 Exhaust silencer 14 ECM 15 Other inputs 16 DPD switch 17 DPD lamp or MID indicators LN...

Page 398: ...sors and then raises the temperature by controlling fuel injections the exhaust brake valve and exhaust throttle valve to burn off the accumulated PM Once the regeneration starts it must be finished w...

Page 399: ...rake Valve Legend 1 Exhaust throttle valve exhaust brake valve Legend 1 Vacuum inlet 2 Vacuum outlet 3 Vacuum exhaust 4 Solenoid valve The exhaust throttle valve is installed in rear of the DPD housin...

Page 400: ...Lamp 5 8840 0285 0 J 39200 Digital Multimeter Tech2 Kit Tech2 DC24 Volt Adapter II CAN di Module Breaker Box 5884028350 5884002850 AAW0Z0SH015701 ADAPTER2 CANDI BREAKER A B C Adapter Harness 5 8840 28...

Page 401: ...MEMO LG4HKED WE 0871 book 1...

Page 402: ...blished Dec 2007 First Edition Issued by ISUZU MOTORS LIMITED SERVICE MARKETING DEPARTMENT Shinagawa ku Tokyo 140 8722 Japan All rights reserved 0 XXXKI WORKSHOP MANUAL ENGINE CONTROL SYSTEM 4HK1 mode...

Page 403: ......

Page 404: ...WORKSHOP MANUAL ENGINE CONTROL SYSTEM 4HK1 model No LG4HKED WE 0871 WORKSHOP MANUAL ENGINE CONTROL SYSTEM 4HK1 model...

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