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Isuzu 4ja1, Workshop Manual

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Isuzu 4ja1 Workshop Manual Download Page 241

ENGINE ELECTRICAL   6D – 21 

 

   

 

RTW06DSH000201 

 
 
 
 
 
 
 
 
 
 
 
 

9. Through 

Bolt 

1.  Place a pilot bar into the through bolt hole to align the 

front cover and the rear cover. 

2.  Install the through bolts and tighten them to the 

specified torque. 

Through Bolt Torque 

N

⋅

m (kg

⋅

m/lb

⋅

ft)

3.1 

∼

 3.9 (0.32 

∼

 0.41 / 2.6 

∼

 3.5) 

 

 

 

11. Vaccum Pump 

To install the generator - 
 
1.  Note the direction of the arrow on the vacuum pump. 
2.  Look forward from the base of the arrow to locate the 

3 generator fixing points. 

3.  Twist the fixing points down and to the left to align 

them with the middle of the center plate and the rotor.

 

 

  

 

RTW46DSH006101 

 

Install vanes into slits in rotor. 
The vanes should be installed with the chamfered side 
facing outward. 

 

  

 

RTW46DSH002401 

 

Install the vacuum pump housing. 
Make sure that the O-ring is not projecting beyond the 
slots of the center plate. 
Take care so that no scratching takes place on the vane 
resulted by contact with the housing. 

 

 

 

  

 

RTW46DSH002501 

 
 
 
 

 

 
 
 
 
 
 

 
 
 

Install the housing in the generator and fix it with the three 
bolts. 
Supply engine oil (5cc or so) from the oil port and check 
that the generator pulley can be turned smoothly with your 
hand. 
Generator Housing Bolt Torque 

N

⋅

m (kg

⋅

m/lb

⋅

ft)

5.9 

∼

 6.9 (0.6 

∼

 0.7 / 5.2 

∼

 6.1) 

 

 
 

Summary of Contents for 4ja1

Page 1: ...WORKSHOP MANUAL 2011MY TF SERIES ENGINE 4JA1 4JH1 MODELS SECTION 6 Isuzu Motors Limited E Solutions Service Marketing Dept...

Page 2: ......

Page 3: ...age Noise 6 12 10 3 Continuous Noise 6 13 10 4 Slapping Noise 6 13 10 5 Excessive Turbocharger Noise 6 14 11 ROTATING PART WEAR OF TURBOCHARGER 6 14 12 OIL LEAKAGE FROM TURBOCHRGER 6 15 13 INSUFFICIEN...

Page 4: ...lant capacity Was the problem found Replenish the engine coolant Go to Step 4 4 The engine oil level Was the problem found Replenish the engine oil Go to Step 5 5 The air cleaner element Was the probl...

Page 5: ...oes the starter relay work Go to Step 3 Repair or replace the starter relay 3 Check the magnetic switch Does the magnetic switch work Go to Step 4 Repair or replace the magnetic switch 4 Check the pin...

Page 6: ...air bled Go to Step 5 Bleed the air 5 Are any DTC stored Go to indicated DTC Solved Incase of the fuel is being delivered to the injection pump Step Action Value s Yes No 1 Was the water contain in t...

Page 7: ...zle 6 Was the injection nozzle sticking See Step 6 Replace the injection nozzle Go to Step 8 7 Check the throttle valve condition Was the idling port clogged in the throttle valve Repair or replace th...

Page 8: ...zzle pressure or spray pattern normal Go to Step 7 Readjust the injection nozzle pressure or replace the nozzle 7 Was the compression pressure OK 3 0 MPa 31 0 kg cm 2 441 psi at 200 rpm Go to Step 8 R...

Page 9: ...turbocharger working completely Go to Step 4 Replace the turbocharger 4 Was there the fuel leakage Repair or replace the fuel leakage part Go to Step 5 5 Was the compression pressure OK 3 0 MPa 31 0...

Page 10: ...age found Replace the failure part Go to Step 5 5 Was the oil leakage found from any gasket Replace the wrong gasket Go to Step 6 6 Inspect the valve stem seal the valve stem and the valve guide for w...

Page 11: ...ion by the foreign materials in the cooling system found For example clog the water hose between the cylinder body and radiator etc Clean or replace the clog part Go to Step 9 9 Was the water leakage...

Page 12: ...he oil leakage found from the turbocharger oil seal Replace the oil seal Go to Step 5 5 Was the oil drain pipe of the turbocharger restricted Repair or replace the oil drain pipe Go to Step 6 6 Was re...

Page 13: ...Go to Step 5 5 Was the oil pump working OK The pump related parts worn etc Go to Step 6 Repair or replace the oil pump 6 Was the rocker arm and or relation parts worn Replace the rocker arm and or re...

Page 14: ...any DTC stored Go to indicated DTC Solved 10 2 Gas leakage noise Step Action Value s Yes No 1 Was the exhaust pipe loose or broken Retighten or replace the exhaust pipe Go to Step 2 2 Was the exhaust...

Page 15: ...n both intake and exhaust Adjust the valve clearances Go to Step 3 3 Were the rocker arms damaged Replace the rocker arms Go to Step 4 4 Was the flywheel fixing bolt loose Tighten the fixing bolt Go t...

Page 16: ...turbine or compressor housing Clean or replace the turbocharger Go to Step 8 8 Inspect the oil supply condition Was the oil feed pipe clogged Repair or replace the oil feed pipe Go to Step 9 9 Was the...

Page 17: ...ient Acceleration and or Lack of Power due to turbocharger Step Action Value s Yes No 1 Inspect the air or exhaust route Was the air and or exhaust gas piping loose Tighten flange bolts or hose clamp...

Page 18: ...an open circuit or the scorching on the stator coil Replace the stator coil Go to Step 4 4 Inspect the rotor coil on the generator Was there an open circuit or the scorching on the rotor coil Replace...

Page 19: ...place more higher capacity generator Go to Step 8 8 Are any DTC stored Go to indicated DTC Solved 14 4 Battery Unstable Charging Current Step Action Value s Yes No 1 Was Visual Physical Check performe...

Page 20: ...and decreasing engine speed Replace the bearing Go to Step 3 3 Was there a growling sound and does this sound stop when the connector was disconnected Replace the stator coil Go to Step 4 4 Was interm...

Page 21: ...re the brush and the commutator contact faces dirty Clean contact face Go to Step 4 4 Was the pinion clutch slipped Replace the pinion clutch Go to Step 5 5 Inspect the armature field coil Was there a...

Page 22: ...d Go to Step 2 Go to visual physical check 2 Inspect the contact condition between the brush and the commutator Was the brush and the commutator contact intermittent Replace the brush or repair the co...

Page 23: ...ication Procedure 6A 23 Servicing 6A 24 Model Identification 6A 24 Air Cleaner 6A 24 Lubricating System 6A 24 Fuel System 6A 25 Cooling System 6A 27 Valve Clearance Adjustment 6A 31 Compression Pressu...

Page 24: ...Bearing 6A 79 Crankshaft Bearing Selection 6A 83 Crankshaft Pilot Bearing 6A 85 Flywheel and Ring Gear 6A 85 Piston 6A 86 Cylinder Head Gasket Selection 6A 88 Connecting Rod 6A 90 Idler Gear Shaft and...

Page 25: ...ter 6A 127 Oil Pump 6A 128 Disassembly 6A 128 Inspection and Repair 6A 129 Reassembly 6A 130 Oil Filter and Oil Cooler 6A 131 Disassembly 6A 131 Inspection and Repair 6A 132 Reassembly 6A 133 Inter Co...

Page 26: ...C OFF 850 25 A C ON 730 25 A C OFF 780 25 A C ON Specified fuel type Idling speed rpm Valve clearances At cold Intake mm in Exhaust mm in Intake valves Open at BTDC deg Close at ABDC deg Exhaust valve...

Page 27: ...h jiggle valve Air cleaner type Dry paper element Viscous paper element Battery type voltage No of units 80D26L 1 95D31L 1 OPT Generator capacity V A 12 60 12 80 Starter motor output V kW 12 2 3 Turbo...

Page 28: ...B252 1944 Diesel fuel Idling speed rpm 700 25 A C OFF 800 25 A C ON Valve clearances At cold Intake mm in Exhaust mm in Intake valves Open at BTDC deg Close at ABDC deg Exhaust valves Open at BBDC deg...

Page 29: ...output V kW Turbocharger model Turbine type Compressor type Centrifugal Wax pellet with jiggle valve Dry paper element except for Euro3 spec Viscous paper element for Euro3 spec 80D26L 1 95D31L 1 OPT...

Page 30: ...0 24 90 5 00 180 10 36 17 337 12 67 62 34 40 6 90 248 82 49 41 453 25 90 65 46 25 9 25 334 53 66 91 570 36 140 14 58 20 14 30 420 96 103 43 36 26 8 82 3 70 0 90 26 76 6 50 70 56 13 72 7 20 1 40 52 08...

Page 31: ...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: ...Temperature Vulcanizer Note 1 It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle 2 Be careful to use the specified amount of liquid gasket Follo...

Page 45: ...es must be perfectly dry 2 Apply LOCTITE to the bolts 3 Tighten the bolts to the specified torque 4 Wait at least one hour before continuing the installation procedure LOCTITE 515 Violet 1 Completely...

Page 46: ...This will blow the dust free Compressed air pressure kPa kg cm 2 psi 392 490 4 5 57 71 LUBRICATING SYSTEM Main Oil Filter Cartridge Type Paper Element Replacement Procedure 1 Drain the engine oil 2 R...

Page 47: ...ure 1 Remove the fuel filter by turning it counterclockwise with a filter wrench Filter Wrench 5 8840 0253 0 Note Be careful not to spill the fuel in the filter cartridge RTW66ASH003301 2 Clean the fu...

Page 48: ...off Except EURO III model RTW46ASH002901 For EURO III model RTW46ASH000501 Air Bleeding 1 Operate the priming pump until strong resistance is felt 2 Wait 1 minute and operate the priming pump until st...

Page 49: ...nt up to filler neck 3 Pour coolant into reservoir tank up to MAX line 4 Tighten radiator cap and start the engine After idling for 2 to 3 minutes stop the engine and reopen radiator cap If the water...

Page 50: ...adiator Cap Inspection The radiator filler cap is designed to maintain coolant pressure in the cooling system at 103 kPa 1 05 kg cm 2 15psi Check the radiator filler cap with a radiator filler cap tes...

Page 51: ...rmostat full opening temperature Thermostat Full Opening Temperature C F 95 203 Oil Cooler Thermo Valve C F 90 194 EGR Cooler Thermo Valve C F 55 131 Valve Lift at Fully Open position mm in 9 5 0 37 O...

Page 52: ...Reuse belt 6 9 0 24 0 35 1 Crankshaft damper pulley 2 Generator pulley 3 Cooling fan pulley A C Compressor Drive Belt Compressor belt tension is adjusted by moving the P S pumppulley Depress the driv...

Page 53: ...TDC on the compression stroke If the No 1 cylinder intake and exhaust valve push rods are depressed the No 4 piston is at TDC on the compression stroke 014RY00016 Adjust the No 1 or the No 4 cylinder...

Page 54: ...jection nozzle hole Injection nozzle holder bracket Injection nozzle holder bracket Bolt Torque N m kg m lb ft 37 3 8 27 Compression Gauge 5 8840 2675 0 Adapter Compression Gauge 5 8531 7001 0 4 Turn...

Page 55: ...ust valve push rods have play the No 1 piston is at TDC on the compression stroke RTW46ASH000601 3 Disconnect the injection pipe from the injection pump 4 Remove one bolt from the distributor head 5 I...

Page 56: ...ard value R A A Move the injection pump toward the engine R Move the injection pump away from the engine 12 Install the distributor head bolt Distributor head bolt torque N m kg m lb ft 29 3 0 22 ENGI...

Page 57: ...dle actuator g on the injection pump 3 Disconnect the other vacuum hose d from the vacuum switching valve e and connect it to the fast idle actuator g The vacuum line will now be connected directly fr...

Page 58: ...ise when the engine is cold Chrome plated dry type cylinder liners provide the highest durability The laminated steel sheet cylinder head gasket is very durable and to increase the head gasket reliabi...

Page 59: ...3 Remove the battery 4 Disconnect the battery cable at the starter motor and the ground cable at the cylinder body 2 Engine Hood Apply setting marks to the engine hood and the engine hood hinges befor...

Page 60: ...sion 11 Breather hose for A T model 12 Transmission shift lever for M T model Remove the shift lever from the floor 13 Transfer shift lever for 4x4 model Remove the shift lever from the floor 14 Trans...

Page 61: ...the power steering pump assembly along with piping on the body side 22 Air conditioner compressor 1 Remove air compressor magnet connector 2 Remove the air conditioner compressor Place the air conditi...

Page 62: ...27 Exhaust Pipe Remove the front exhaust pipe bolts and separate the exhaust manifold and the front exhaust pipe 28 Engine Assembly 1 Remove two right side engine foot bolts 2 Remove two left side en...

Page 63: ...Set heater adjustment to the highest temperature position and let the coolant circulate also into heater water system 5 Check to see the thermometer continuously idling 5 minutes and stop the engine...

Page 64: ...9 Oil filter gasket 10 Joint bolt gasket 11 Vacuum pump gasket 12 Water pump O ring 13 Water outlet pipe gasket 14 Intake pipe gasket 15 Thermostat housing gasket 16 Intake manifold gasket 17 Exhaust...

Page 65: ...Fuel Injection Pipe with Clip 9 Power Steering Oil Pump Bracket 10 Intake Manifold 11 Engine Mounting Bracket and Foot 12 Injection Pump Cover 13 Injection Pump 14 Starter Motor 15 Oil Pressure Warni...

Page 66: ...osen hose clamp between turbocharger and intake duct 2 Remove the rubber hose 3 Remove the intake pipe and the throttle body 4JA1TC 4JH1TC only RTW36ASH000201 4JA1L 025R100008 3 1 EGR Pipe 1 Remove tw...

Page 67: ...Bracket Except EURO III model Remove three bolts and remove the fuel filter bracket with leak pipe 4JH1TC RTW36ASH001201 8 Fuel Injection Pipe with Clip 1 Loosen the injection pipe sleeve nuts at pum...

Page 68: ...turbocharger 2 Disconnect the water hose between water inlet pipe and turbocharger 3 Remove the oil feed pipe 4 Remove the oil return pipe 5 Remove the turbocharger and the gasket NOTE Plug the turboc...

Page 69: ...TS MAJOR COMPONENTS Disassembly Steps 1 1 Water bypass hose 5 Rocker arm shaft and rocker 2 Thermostat housing with thermo arm switch 6 Push rod 3 Cylinder head cover 7 Cylinder head 4 Injection nozzl...

Page 70: ...ECHANICAL RTW46ALF000101 Disassembly Steps 2 9 Crankshaft damper pulley 10 Timing gear case cove 11 Water pump 12 Idle gear B and shaft 13 Idle gear A 14 Idle gear shaft 15 Crankshaft timing gear 16 I...

Page 71: ...28 Crankshaft bearing cap with 20 Camshaft timing gear lower bearing 21 Camshaft thrust plate 29 Crankshaft thrust bearing 22 Camshaft 30 Crankshaft 23 Timing gear case 31 Crankshaft upper bearing 24...

Page 72: ...m Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical order a little at a time Note Failure to loosen the rocker arm shaft bracket bolts in numerical order a little at a time w...

Page 73: ...re removing the idler gear 2 Measure the idler gear end play before removing the idler gear NOTE Refer to the following items for details on the backlash and end play measurement procedures Timing Gea...

Page 74: ...e Gear Shaft 15 Crankshaft Timing Gear 4JA1TC 4JH1TC RTW36ASH001301 16 Injection Pump 1 Remove the injection pump cover 4JA1TC 4JH1TC only 2 Remove the injection pump bracket 3 Pull the injection pump...

Page 75: ...turning 3 Remove the sensor rotor plate 4 Use the universal puller to pull out the camshaft timing gear Universal Puller 5 8521 0002 0 5 Remove the thrust plate 21 Camshaft Thrust Plate 22 Camshaft J...

Page 76: ...cylinder and tap it with a hammer grip or a similar object from the connecting rod lower side to drive it out RTW36ASH001501 If the connecting rod upper bearings are to be reinstalled mark their fitt...

Page 77: ...e crankshaft upper bearings are to be reinstalled mark their fitting positions by tagging each bearing with the cylinder number from which it was removed 32 Tappet If the tappets are to be reinstalled...

Page 78: ...ap Ring 2 Rocker Arm 3 Rocker Arm Shaft Bracket 1 Use a pair of pliers to remove the snap rings 2 Remove the rocker arms 3 Remove the rocker arm shaft brackets If the rocker arms and rocker arm shaft...

Page 79: ...ER HEAD RTW46ALF001201 Disassembly Steps 1 Intake manifold 6 Intake and exhaust valve 2 Intake manifold gasket 7 Valve stem oil seal 3 Split collar 8 Valve spring lower seat 4 Valve spring upper seat...

Page 80: ...der head Spring Compressor 9 8523 1423 0 4 Valve Spring Upper Seat 5 Valve Spring 6 Intake and Exhaust Valve If the intake and exhaust valves are to be reinstalled mark their installation positions by...

Page 81: ...ENGINE MECHANICAL 6A 59 PISTON AND CONNECTING ROD RTW46ALF000301 Disassembly Steps 1 Connecting rod bearing 4 Piston pin 2 Piston ring 5 Connecting rod 3 Piston pin snap ring 6 Piston...

Page 82: ...placer to remove the piston rings Piston Ring Replacer Do not attempt to use some other tool to remove the piston rings Piston ring stretching will result in reduced piston ring tension 3 Piston Pin S...

Page 83: ...ad lower surface warpage is more than the limit it should be replaced Cylinder Head Lower Face Warpage A F mm in Standard Limit 0 05 0 002 or less 0 20 0 0079 NOTE The cylinder head lower face cannot...

Page 84: ...edge and a feeler gauge to measure the manifold cylinder head fitting face warpage If the measured values exceed the specified limit the manifold must be replaced Exhaust Manifold Warpage mm in Stand...

Page 85: ...Replacer 9 8523 1212 0 Valve Guide Installation 1 Apply engine oil to the valve guide outer circumference 2 Attach the valve guide installer to the valve guide 3 Use a hammer to drive the valve guide...

Page 86: ...ss than the specified limit the valve and the valve guide must be replaced as a set Intake and Exhaust Valve Thickness mm in Standard Limit 4JA1T L 1 8 0 07 1 5 0 06 Inlet 1 34 0 053 4JA1TC 4JH1TC Exh...

Page 87: ...7 0 067 2 2 0 087 Exhaust 2 0 0 079 2 5 0 098 Valve Seat Insert Replacement Valve Seat Insert Removal 1 Arc weld the entire inside circumference 1 of the valve seat insert 2 2 Allow the valve seat in...

Page 88: ...se a valve cutter 15 45 and 75 blades to minimize scratches and other rough areas This will bring the contact width back to the standard value Remove only the scratches and rough areas Do not cut away...

Page 89: ...square to measure the valve spring squareness If the measured value exceeds the specified limit the valve spring must be replaced Spring Squareness mm in Limit 4JA1T L 4JA1TC 4JH1TC Single spring 1 7...

Page 90: ...asure the rocker arm fitting portion outside diameter If the measured value is less than the specified limit the rocker arm shaft must be replaced Rocker Arm Shaft Outside Diameter mm in Standard Limi...

Page 91: ...1 Remove the cylinder body dowel 2 Remove the cylinder liner Refer to Cylinder Liner Replacement 3 Use a straight edge 1 and a feeler gauge 2 to measure the four sides and the two diagonals of the cy...

Page 92: ...along the top edge of the cylinder liner to be measured 2 Use a feeler gauge to measure each cylinder liner projection Cylinder Liner Projection mm in Standard 0 0 1 0 0 004 The difference in the cyl...

Page 93: ...1 across positions 1 1 and 2 2 Measuring Point 1 4JA1T L 4JA1TC 13 48 83 118 153 mm 0 51 1 89 3 27 4 65 6 02 in 4JH1TC 18 53 88 123 158 mm 0 71 2 09 3 46 4 84 6 22 in Cylinder Liner Grade Selection an...

Page 94: ...6634 3 95 021 95 030 3 7410 3 7413 95 031 95 040 3 7414 3 7417 CX 93 051 93 066 3 6634 3 6640 AX 93 035 93 050 3 6628 3 6634 4 95 031 95 040 3 7414 3 7417 95 041 95 050 3 7418 3 7421 CX 93 051 93 066...

Page 95: ...top of the cylinder body 4 Set the cylinder liner installer 3 to the top of the cylinder liner Cylinder Liner Installer 5 8840 2040 0 4JA1L TC 5 8840 2313 0 4JH1TC 5 3 is directly beneath the bench pr...

Page 96: ...iner Bore Measurement Cylinder Liner Bore Service Part Grade mm in Grade Bore measurement AX 93 035 95 050 3 6628 3 6634 4JA1T L 4JA1TC CX 93 051 95 066 3 6634 3 6640 AX 95 435 95 450 3 7573 3 7579 4J...

Page 97: ...on procedure may result in slight decreases in cylinder liner clearances Always measure the cylinder liner clearance after installation to be sure that it is correct TAPPET AND PUSH ROD Visually inspe...

Page 98: ...rd Limit 0 01 0 046 0 0004 0 0018 0 10 0 004 Push Rod Curvature 1 Lay the push rod on a surface plate 2 Roll the push rod along the surface plate and measure the push rod curvature with a thickness ga...

Page 99: ...an the specified limit the camshaft must be replaced Camshaft Journal Diameter mm in Standard Limit 49 945 49 975 1 9663 1 9675 49 60 1 953 Cam Height Measure the cam height H with a micrometer If the...

Page 100: ...the specified limit the camshaft bearing must be replaced Camshaft Bearing Clearance mm in Standard Limit 0 055 0 0022 0 12 0 0047 Camshaft Bearing Replacement Camshaft Bearing Removal 1 Remove the cy...

Page 101: ...le Crankshaft Run Out 1 Set a dial indicator to the center of the crankshaft journal 2 Gently turn the crankshaft in the normal direction of rotation Read the dial indicator as you turn the crankshaft...

Page 102: ...dard Limit 4JA1T L 4JA1TC 59 921 59 928 2 3591 2 3594 59 91 2 3586 4JH1TC 69 917 69 932 2 7526 2 7532 69 91 2 7524 Crankpin Diameter mm in Standard Limit 52 915 52 930 2 0833 2 0839 52 90 2 083 Cranks...

Page 103: ...m in Standard Limit 4JA1T L 4JA1TC 0 029 0 066 0 0011 0 0026 0 100 0 0039 4JH1TC 0 029 0 083 0 0011 0 0033 0 100 0 0039 Clearance Measurements With Plastigage Crankshaft Journal and Bearing Clearance...

Page 104: ...0 032 0 077 0 0013 0 0030 0 110 0 0043 Crankpin and Bearing Clearance 1 Clean the crankshaft the connecting rod the bearing cap and the bearings 2 Install the bearing to the connecting rod and the bea...

Page 105: ...0 0 0039 CRANKSHAFT BEARING SELECTION Crankshaft bearing selection is based on the measured diameters of the crankshaft journals and the bearing inserts Match the crankshaft bearing housing grade mark...

Page 106: ...591 Brown or 4 1 or 59 927 59 932 2 3593 2 3595 Green or 1 2 or 59 922 59 927 2 3591 2 3593 3 63 975 63 983 2 5187 2 5190 3 or 59 917 59 922 2 3598 2 3591 Black or 2 4JH1TC mm in Crankshaft Bearing Ho...

Page 107: ...ring installation hole Pilot Bearing Installer 5 8522 0024 0 NOTE Strike only the crankshaft pilot bearing outer race with the hammer Do not strike the bearing inner race Bearing damage and reduced be...

Page 108: ...on and Cylinder Bore Measurement Refer to the Section Cylinder Body Item Cylinder Liner Bore Measurement for details on piston grade selection and cylinder liner bore measurement Piston Ring Gap 1 Ins...

Page 109: ...g Groove Clearance Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove at several points around the piston If the clearance between the piston ring and the p...

Page 110: ...Pin Hole mm in 4JA1T L 31 002 31 010 1 2206 1 2208 4JA1TC 4JH1TC 31 005 31 013 1 2207 1 2210 Piston Pin and Piston Pin Hole Clearance mm in 4JA1T L 0 002 0 015 0 00008 0 0006 4JA1TC 4JH1TC 0 005 0 01...

Page 111: ...ue in the four cylinders 5 Determine the gasket grade required to the maximum value described above in accordance with the following table Cylinder Head Gasket Combination 4JA1T L 4JA1TC mm in Gasket...

Page 112: ...earance between the connecting rod big end side face and the crankpin side face If the measured value exceeds the specified limit the connecting rod must be replaced Connecting Rod Big End and Crankpi...

Page 113: ...eter Idler Gear Inside Diameter mm in Standard Limit 45 0 45 03 1 7717 1 7718 45 10 1 7756 If the clearance between the idler gear shaft outside diameter and the idler gear inside diameter exceeds the...

Page 114: ...tion attached securely to the crankshaft tighten up the center bolt until the sleeve hits the front end reference plane of the crankshaft securely 3 Remove the sleeve 4 With the seal pressed in check...

Page 115: ...7 Rocker arm shaft snap ring 4 Rocker arm shaft bracket Reassembly 1 Rocker Arm Shaft 1 Position the rocker arm shaft with the large oil hole 4 facing the front of the engine 2 Install the rocker arm...

Page 116: ...ER HEAD RTW46ALF001301 Reassembly Steps 1 Cylinder head 6 Valve spring upper seat 2 Valve spring lower seat 7 Split collar 3 Valve stem oil seal 8 Intake manifold gasket 4 Intake and exhaust valve 9 I...

Page 117: ...Spring Install the valve spring with their fine pitched end painted facing down 6 Valve Spring Upper Seat 7 Split Collar 1 Use the spring compressor to compress the valve spring into position Spring C...

Page 118: ...96 ENGINE MECHANICAL PISTON AND CONNECTING ROD RTW46ALF000301 Reassembly Steps 1 Piston 5 Piston pin snap ring 2 Connecting rod 6 Piston ring 3 Piston pin snap ring 7 Connecting rod bearing 4 Piston p...

Page 119: ...front mark 1 and the connecting rod mark 2 are facing in the same direction 3 Piston Pin Snap Ring RTW36ASH001901 4 Piston Pin 1 Apply a coat of engine oil to the piston pin and the piston pin hole 2...

Page 120: ...ession rings with the stamped side facing up Insert the expander coil into the oil ring groove so that there is no gap on either side of the expander coil before installing the oil ring 2 Apply engine...

Page 121: ...6A 99 POSITIVE CRANKCASE VENTILATION PCV VALVE RTW46AMF000101 Reassembly Steps 1 Positive Crankcase Ventilation PCV Valve 5 Fixing bolt 2 Rubber space 6 Oil filler cap 3 Cylinder head insulator cover...

Page 122: ...orque PCV Valve Bolts Torque N m kg m lb in 2 0 2 17 2 Rubber Spacer 3 Cylinder Head Insulator Cover RTW36ASH001401 4 Breather Hose Apply LOCTITE 262 or equivalent to the new breather pipe Do not reus...

Page 123: ...Crankshaft upper bearing 12 Connecting rod bearing cap with lower bearing 4 Crankshaft 13 Piston cooling oil pipe 5 Crankshaft thrust bearing 14 Oil pump with oil pipe 6 Crankshaft bearing cap with lo...

Page 124: ...CHANICAL RTW46ALF000501 Reassembly Steps 2 19 Crankshaft timing gear 23 Injection pump 20 Idler gear shaft 24 Water pump 21 Idler gear A 25 Timing gear case cover 22 Idler gear B and shaft 26 Cranksha...

Page 125: ...Steps 3 27 Cylinder head gasket 31 Thermostat housing with thermo switch 28 Cylinder head 32 Water by pass hose 29 Push rod 33 Injection nozzle and bracket 30 Rocker arm shaft and rocker arm 34 Cylind...

Page 126: ...ore the camshaft installation 3 Crankshaft Upper Bearing The crankshaft upper bearings have an oil hole and an oil groove The lower bearings do not 1 Carefully wipe any foreign material from the upper...

Page 127: ...illustration NOTE Be sure that the bearing cap fitting surface is completely free of oil before applying the liquid gasket Three bond 1207B Do not allow the liquid gasket to obstruct the cylinder thre...

Page 128: ...Timing Gear Case Bolt Torque N m kg m lbft 19 1 9 14 9 Camshaft Thrust Plate Install the thrust plate to the cylinder body and tighten the thrust plate bolts to the specified torque Thrust Plate Bolt...

Page 129: ...arted after reassembly 4 Apply a coat of engine oil to the upper bearing surfaces 5 Apply a coat of engine oil to the cylinder wall 6 Position the piston head front mark so that it is facing the front...

Page 130: ...Jet Bolt Torque N m kg m lb ft M8 1 25 19 1 9 14 M6 1 00 8 0 8 6 Relief Valve Torque N m kg m lb ft 29 3 0 22 NOTE Check that there is no interference between the piston and the oiling jet by slowly...

Page 131: ...h gasket into the bearing cap groove Take care not to scratch the arch gasket outer surface Also apply the recommended liquid gasket 1207C or its equivalent to arch gasket fitting area as indicated in...

Page 132: ...8840 0214 0 Flywheel Bolt Torque N m kg m lbft 118 12 87 19 Crankshaft Timing Gear Use the crankshaft timing gear installer 1 to install the crankshaft timing gear 2 The crankshaft timing gear settin...

Page 133: ...r Gear B and Shaft 1 Apply engine oil to the idler gear and the idler gear shaft 2 Align the idler gear B 3 setting mark with the idler gear A 4 setting mark 3 Tighten the idler gear bolt to the speci...

Page 134: ...ition the rear gear so that the pin is aligned with the receiving end of the spring RTW31BSH000301 6 Install the snap ring to the main gear groove RTW31BSH000501 7 Install suitable bolts nuts and wash...

Page 135: ...ar and rear gear 9 Insert a lock bolt M6 1 L 30 into scissors gear fixing hole to prevent the scissors gear from turning 10 Place the main gear in a vise with copper plate so that the front side of th...

Page 136: ...W36AMH000101 4JA1TC 4JH1TC 4 Tighten the injection pump bolts 5 to the specified torque Injection Pump Bolt Torque N m kg m lbft 19 1 9 14 5 Install the injection pump bracket 6 and the bracket bolts...

Page 137: ...in the illustration Do not apply an excessive amount of liquid gasket 2 Tighten the water pump bolts to the specified torque Water Pump Bolt Torque N m kg m lbft 20 2 0 14 25 Timing Gear Case Cover 1...

Page 138: ...cylinder head bolt threads and setting faces 3 Tighten the cylinder head bolts in three steps of anglar tightening methed Follow the numerical sequence shown in the illustration Cylinder Head Bolt Tor...

Page 139: ...ce Adjustment Valve clearances must be adjusted before the cylinder head cover is reinstalled Refer to Valve Clearance Adjustment in the Servicing Section of this manual Valve Clearance At Cold mm in...

Page 140: ...Hose 21 Fuel Injection Pipe with Clip 7 Compressor Bracket 22 Fuel Filter Bracket Except EURO III 8 Turbocharger 23 Fuel Filter Assembly Except EURO III 9 Catalytic Converter 24 Oil Level Gauge 10 He...

Page 141: ...d the cylinder body Manifold Bracket Bolt Torque N m kg m Ib ft 19 1 9 14 RTW46ASH001301 2 Oil Cooler with Oil Filter 1 Install the O ring to the oil filter body flange groove 2 Install the oil filter...

Page 142: ...lts will be finally tightened after installation of the cooling fan drive belt 3 Connect the vacuum pump rubber hose 4 to the vacuum pump 5 and the oil pan 6 6 Vacuum Pump Oil Return Hose Connect the...

Page 143: ...ed torque Bracket Bolt Torque N m kg m Ib ft 8 0 8 6 5 Before installing the oil feed pipe supply 10 20 cc of clean engine oil to the turbocharger center housing through the oil feed opening 6 Turn th...

Page 144: ...Bolt 3 Torque N m kg m Ib ft 8 0 8 6 13 Install the hoses for the water feed and return 9 Catalytic Converter Install the catalytic converter with gasket and tighten the nut to the specified torque C...

Page 145: ...25 40 4 1 30 M10 1 25 40 4 1 30 Left Side M14 1 50 127 13 93 4JA1L 4JH1TC 022R300003 4JA1TC RTW46ASH002601 RTW36ASH001001 19 Intake Manifold 1 Install the manifold gasket to the intake manifold 2 Conn...

Page 146: ...torque Torque Injection Pump Side 4JA1TC 4JH1TC N m kg m Ib ft 40 4 1 30 Injection Pipe Sleeve Nuts N m kg m Ib ft 29 3 0 22 Injection Pipe Clip Nuts N m kg m Ib ft 8 0 8 6 22 Fuel Filter Bracket Exce...

Page 147: ...d Nuts N m kg m Ib ft 27 2 8 20 RTW48ASH001801 26 2 EGR Cooler EURO III model only Install the EGR valve adapter with the gasket to the EGR valve assembly and install the EGR pipe with the gasket Tigh...

Page 148: ...2 78 4 117 6 kPa 5 Oil Pressure Switch Operating Pressure 0 3 0 5 kg cm 2 29 4 49 0 kPa 6 Regulating Valve 1 8 2 2 kg cm 2 176 216 kPa The 4J series engine has a full flow type lubricating system Lubr...

Page 149: ...ICAL 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 co...

Page 150: ...SEMBLY Disassembly Steps 1 Oil pipe 5 Driven gear 2 Strainer 6 Relief valve assembly 3 Pump cover 7 Pinion gear 4 Driven gear with bushing 8 Oil pump body Disassembly procedure is shown in the illustr...

Page 151: ...01 0 14 0 0055 0 20 0 0079 Gear and Body Clearance Use a feeler gauge to measure the clearance between the body and the gear If the clearance between the gear and the body exceeds the specified limit...

Page 152: ...Oil pump body 5 Pinion gear 2 Drive gear 6 Strainer 3 Driven gear 7 Relief valve assembly 4 Pump cover 8 Oil pipe Reassembly procedure is shown in the illustration above numerical order Pump cover fi...

Page 153: ...R AND OIL COOLER DISASSEMBLY Disassembly Steps 1 Oil filter cartridge 5 Body 2 Bolt 6 Oil cooler relief valve 3 Gasket 7 Regulating valve 4 Oil cooler Disassembly procedure is shown in the illustratio...

Page 154: ...d during inspection Oil Cooler Water Leakage at Water Passage 1 Plug one side of the oil cooler water passage 2 Submerge the oil cooler in water 3 Apply compressed air 200kPa 2kg cm 2 28psi to the oth...

Page 155: ...133 REASSEMBLY Reassembly Steps 1 Body 5 Gasket 2 Regulating valve 6 Bolt 3 Oil cooler relief valve 7 Oil filter cartridge 4 Oil cooler Reassembly procedure is shown in the illustration above numeric...

Page 156: ...ting Valve N m kg m lb ft A 64 6 5 48 4 Oil Cooler 5 Gasket 6 Bolt Tighten bolt with gasket and oil cooler to the specified torque Bolt Torque N m kg m lb ft 40 4 1 30 7 Oil Filter Cartridge 1 Apply e...

Page 157: ...INSTALLATION RTW46ALF001001 Removal Steps 1 Radiator grille 2 Front bumper fascia 3 Front bumper inpact support assembly 4 Inter cooler Installation Steps 4 Inter cooler 3 Front bumper inpact support...

Page 158: ...02101 3 Front Bumper Impact Support Assembly Remove the nut and two bolts 4 Inter Cooler Remove the nut and two bolts Disconnect the air hose Installation 4 Inter Cooler Tighten the nut and two bolts...

Page 159: ...nch 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...

Page 160: ...cer 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 002...

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: ...7 Draining and Refilling Cooling System 6B 8 Water Pump 6B 10 Removal and Installation 6B 10 Removal 6B 10 Inspection and Repair 6B 11 Installation 6B 11 Thermostat 6B 13 Removal and Installation 6B 1...

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: ...in Oil cooler thermo valve EGR cooler thermo valve Engine coolant forced circulation Centrifugal impeller type 1 2 100 26 3 22 2 Double row shaft Wax pellet with jiggle valve 82 180 76 5 170 40 104 9...

Page 166: ...the water pump and thermostat through the bypass hose and back to the cylinder body The coolant does not circulate through the radiator When the coolant temperature reaches specified value the thermos...

Page 167: ...00101 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...

Page 168: ...e No oil cooler provided for M T F06RW005 Antifreeze Solution NOTE Antifreeze solution Water Total cooling system capacity Total Cooling System Capacity Lit US UK gal 9 4 2 5 2 1 4JA1L TC M T 10 1 2 7...

Page 169: ...ty radiator cap Replace Low engine oil level or use of improper engine oil Replenish or change oil Clogged exhaust system Clean exhaust system or replace faulty parts Faulty Throttle Position sensor R...

Page 170: ...Scalding fluid and steam can be blown out under pressure 3 Disconnect all hoses from the EC reserve tank Scrub and clean the inside of the reserve tank with soap and water Flush it well with clean wat...

Page 171: ...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 When the engine has been cooled check filler neck fo...

Page 172: ...r Outlet Pipe 1 Disconnect the turbocharger cooling pipe from outlet pipe 2 Loosen the fixing bolt and remove the water outlet bolt 3 Thermostat Remove the thermostat from the thermostat housing Take...

Page 173: ...sion in the impeller Installation 1 Water Pump 1 Install the water pump with new gasket 2 Tighten bolts and nuts to specified torque Water Pump Bolt Nut Torque N m kg m lb ft 20 2 0 14 2 Fan Drive Bel...

Page 174: ...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 3 Connect the turbocharger cooling pipe to outlet pipe 7 Radiator U...

Page 175: ...the water outlet bolt 3 Thermostat Remove the thermostat from the thermostat housing Take care not to damage the thermostat 031R300003 Inspection and Repair Make the necessary adjustments repairs and...

Page 176: ...let 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 3 Connect the turbocharger cooling pipe to outlet...

Page 177: ...DIATOR REMOVAL AND INSTALLATION Radiator and Associated Parts RTW36BLF000101 Legend 1 Radiator Hose 2 Drain Plug 3 Fan Guide Lower 4 Fan Guide 5 Bracket 6 Reserve Tank Hose 7 Reserve Tank 8 Radiator C...

Page 178: ...radiator inlet hose and outlet hose from the engine PTW46BSH000101 5 Remove fan guide 1 clips 2 on both sides and the bottom lock then remove lower fan guide 3 with fan shroud 4 RTW36BMH000101 6 Disc...

Page 179: ...ve seat cannot be moved by hand clean or replace the cap 110RS006 Valve opening vacuum kPa psi 1 96 4 91 0 28 0 71 Radiator Core 1 A bent fin may result in reduced ventilation and overheating may occu...

Page 180: ...damage the radiator core with a fan blade 2 Support the radiator upper tank with the bracket 5 and secure the radiator 3 Connect reserve tank hose 6 4 Install lower fan guide 3 5 Connect radiator inl...

Page 181: ...e 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 Engine coolant change Refe...

Page 182: ...ngine and confirm that the fan clutch can be turned with considerable effort clutch torque when turned by hand If the fan clutch rotates more readily however this indicates that the silicone grease is...

Page 183: ...ion Nozzle 6C 7 Fuel Tank 6C 8 Removal 6C 9 Installation 6C 9 Fuel Gauge Unit 6C 11 Removal 6C 12 Installation 6C 12 Fuel Tube Quick Connector Fittings 6C 14 Filler Neck 6C 16 Removal 6C 16 Installati...

Page 184: ...8 33 8 331 Main fuel filter type Disposable cartridge paper element Precautions When working on the fuel system there are several things to keep in mind Any time the fuel system is being worked on dis...

Page 185: ...e water separator and the fuel filter where water particles and other foreign material are removed from the fuel Fuel fed by the injection pump plunger is delivered to the injection nozzle in the meas...

Page 186: ...er particles and other foreign material from the fuel before it reaches the injection pump The water separator has an internal float When the float reaches the specified level a warning light comes on...

Page 187: ...FUEL SYSTEM 6C 5 For EURO III model RTW46AMF000201...

Page 188: ...r increases the engine idling speed to provide the additional power required to operate the air conditioner Fast idler diaphragm movement is caused by changes in the negative pressure created by the e...

Page 189: ...s 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...

Page 190: ...d 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 Under Shield only specified model...

Page 191: ...n when performing any repairs 8 Remove fixing bolt 1 of the tank band and remove the tank band 2 9 Disconnect the pump and sender connector on the fuel pump and remove the harness from weld clip on th...

Page 192: ...er 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...

Page 193: ...LF000901 Legend 1 Fuel Feed Port 2 Fuel Return Port 3 Fuel Emission Port 4 Fuel Gauge Unit and Sender Assembly 5 Connector Fuel Gauge Unit 6 Fuel Tube Quick Connector 7 Retainer Ring Fuel Gauge Unit L...

Page 194: ...entering 6 Discard fuel gauge unit seal 8 because it cannot be reusable Installation 1 Clean the seal surface of the fuel tank and the fuel gauge unit NOTE If there is dust on the seal surface it bec...

Page 195: ...uel filler cap until at least one click are heard 2 Apply water soap around the fuel gauge unit seal area 3 Pressure air into the fuel tank from end of breather pipe at 5psi 34 5 kPa 0 35kgf cm 2 over...

Page 196: ...ttery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electrolyte Piping that has been splattered with battery electrolyte or battery electrolyte soaked cloth that...

Page 197: ...nd Remove any dirt build up on the port when installing the connector Replace the connector if there is any forms of rust dent scratch After cleaning the port insert it straight into the connector unt...

Page 198: ...lip to restore position and fasten length of the band clip NOTE Cover end of each hose and pipe to prevent any dust entering Installation 1 Align each marking and restore the following point Each join...

Page 199: ...n the fuel tank to prevent fuel tank damage Inspection The fuel filler cap must be inspected for seal condition The fuel filler cap must be replaced if found defective CAUTION A replacement fuel fille...

Page 200: ...everything in this Section before you begin Removal 1 Battery Remove the battery from the battery tray Battery Battery tray P1010011 2 Drive Belt 1 Loosen the adjust bolt of the power steering pump pu...

Page 201: ...del 13 Leak Off Hose Disconnect the leak off hose at the injection pump 14 Injection Pipe Clip 15 Injection Pipe 1 Loosen the injection pipe sleeve nuts at the delivery valve side and the injection no...

Page 202: ...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 mark Note If the check hole cover is r...

Page 203: ...crankshaft pulley TDC line aligned with the timing mark 020L200017 3 Install the injection pump to the timing gear case with align the timing mark on the pump gear to the arrow mark on the timing gear...

Page 204: ...que N m kg m lb ft 8 19 1 9 14 7 40 4 1 30 3 Timing Check Hole Cover Install the timing check hole cover and tighten bolts to the specified torque Timing Check Hole Cover Bolts Torque N m kg m lb in 8...

Page 205: ...ff hose to the injection pump 9 Fuel Filter Bracket Except EURO III model Install the fuel filter bracket and tighten bolts to the specified torque Fuel Filter Bracket Bolts Torque N m kg m lb ft 21 2...

Page 206: ...R valve and the intake throttle Euro under Euro I Euro II Euro III 4JA1L without with with Not used 4JA1TC Not used Not used Not used With cooler EGR cooler 4JH1TC without with with With EGR cooler 17...

Page 207: ...Nozzle holder body 14 Eye bolt Important Operations Injection nozzle adjustment is possible only on the 4JA1L engine The two spring nozzle holder has been developed to reduce NOx Nitrogen Oxides and...

Page 208: ...cond opening pressure adjustment 9 Spring seat 10 Lift Piece 11 Spacer pin 12 Nozzle pin 13 Retaining nut 14 Eye bolt Important Operations The nozzle holder is adjusted as the components are reassembl...

Page 209: ...nd nozzle opening pressure confirmation Confirm the second nozzle opening pressure in accordance with the closed method 5 Second nozzle opening pressure adjustment Adjust the second nozzle opening pre...

Page 210: ...the nozzle holder in a vise 2 Install the shim first spring and spring seat in the nozzle holder 3 Install the collar second spring shim spring seat and pushrod in the nozzle holder 4 Install the pins...

Page 211: ...poration 8 Tighten the adjustment retaining nut to the specified torque Torque 50 N m 5 1 kg m 36 9 Ib ft 9 Set the nozzle holder to the nozzle tester 10 Operate the nozzle tester and measure the firs...

Page 212: ...5349 0490 0 70 0 0275 Full needle valve lift confirmation 1 Install the gasket and plug on the adjustment retaining nut Gasket 026508 1140 Bosch AS 8 9422 7602 0 ISUZU Plug 157892 1600 Bosch AS 2 Posi...

Page 213: ...at the pin contacts the tip of the first spring seat CAUTION Secure the dial gauge so that a stroke of 2 mm can be measured Do not over tighten the nut as the dial gauge shaft may jam Confirm from the...

Page 214: ...ll Lift mm in 0 25 0 02 0 0098 0 0008 Note The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition Pre lift confirmation 1 With th...

Page 215: ...016 Note This point can be found while the pressure is decreasing 3 Confirm that pre lift is as specified 4 If pre lift is not as specified replace the pins lift piece spacer and nozzle assembly as a...

Page 216: ...ed on the dial gauge will also decrease a little 3 Then read the pressure gauge indication second nozzle opening pressure the instant that the dial gauge indicates the specified needle valve lift usua...

Page 217: ...ning pressure adjusting shims Part No ISUZU Thickness mm Part No ISUZU Thickness mm 897116 0290 0 10 897116 0380 0 53 897116 0320 0 20 897116 0390 0 54 897116 0330 0 30 897116 0400 0 55 897116 0340 0...

Page 218: ...zzle 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 CAUT...

Page 219: ...FUEL SYSTEM 6C 37 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER TOOL NAME 5 8840 2602 0 J 39765 Remover fuel pump retainer ring...

Page 220: ...MEMO...

Page 221: ...pecifications 6D 5 Generator 6D 7 Removal and Installation 6D 7 Disassembly 6D 9 Inspection and Repair 6D 12 Reassembly 6D 18 Starter Motor 6D 22 Removal and Installation 6D 22 Disassembly 6D 23 Inspe...

Page 222: ...ut A 60 80 Engine speed ratio to 1 1 788 Maximum speed rpm 11 000 Weight with vacuum pump kg lb 5 8 12 8 6 4 14 1 Vacuum Pump Delivery volume cm 3 rev Exhaust Characteristic Maximum vacuum 50 66 7 kPa...

Page 223: ...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...

Page 224: ...6D 4 ENGINE ELECTRICAL CHARGING CIRCUIT DIAGRAM RTW46DSH005101 STARTING CIRCUIT DIAGRAM RTW46DSH005501...

Page 225: ...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: ...als 2 Loosen and remove the fan belt adjusting plate bolts 3 Remove the fan belt from the generator drive pulley Generator 1 Remove the vacuum pump hose 2 Remove the generator bolt and the generator f...

Page 228: ...ve pulley 3 Adjust the fan belt tension Fan belt tension is adjusted by moving the generator Depress the drive belt mid portion with a 98N 10 kg 22 Ib force Cooling Fan Drive Belt Deflection mm in New...

Page 229: ...LY RTW46DLF000401 Disassembly Step 1 Vacuum pump 2 O ring 3 Through bolt 4 B Terminal nut 5 Rear cover 6 Pulley 7 Rotor assembly 8 Front cover assembly 9 Rear rotor bearing 10 Rectifier assembly 11 St...

Page 230: ...ween the front cover and the stator core Remove the front cover and rotor together with the rear cover and stator If removal is difficult push the rear cover to the side and lightly tap the end of the...

Page 231: ...e front cover bearing retainer screws 2 Remove the bearing RTW46DSH000801 9 Rear rotor bearing Re use improper parts 10 Rectifier 1 Disconnect the stator coil leads between each rectifier by melting t...

Page 232: ...ked in alcohol 2 Measure the slip ring diameter Slip Ring Diameter mm in Standard Limit 31 6 1 245 30 6 1 205 RTW06DSH000101 If the slip ring diameter is less than the specified limit the slip rings m...

Page 233: ...ity the stator coils must be replaced 066RY00023 RTW46DSH004801 BRUSH Measure the length of the brush If abrasion has reduced the brush length to less than 6 5 mm the brush must be replaced with a new...

Page 234: ...tput of 1 ampere or more 2 Lamps 2 12 volts 1 4 3 4 watts 3 Switches 3 4 DC voltmeter 1 0 30 volts 0 5 grade 5 Pulse generator Oscillator 5 30 volt output at a frequency of 1kHz Judgment criteria Lamp...

Page 235: ...at the E1 and E2 surfaces fit into the cradle Take care not to damage the E1 and E2 surfaces After completing the procedure carefully check the oil seal seating Be absolutely sure that the seal is eve...

Page 236: ...vanes if either of these conditions are present Never replace only one vane Rotor 1 Inspect the rotor for excessive wear abrasion and scoring Pay particular attention to the internal spline Replace t...

Page 237: ...all the vanes to the rotor slits The rounded side of the vanes must be facing the rotor housing RTW46DSH001901 2 Install the rotor with the concave side facing the center plate RTW46DSH002001 3 Instal...

Page 238: ...RICAL REASSEMBLY RTW46DLF000501 Reassembly Step 1 Front cover 2 Rear rotor bearing 3 Rotor Assembly 4 Pulley 5 Rectifier Assembly 6 Stator Assembly 7 Rear cover 8 B Terminal nuts 9 Through bolt 10 O r...

Page 239: ...the soldering RTW46DSH002101 3 Rotor Assembly 4 Pulley Assembly Clamp the rotor in a vise and install the pulley nut Pulley Nut Torque N m kg m lb ft 83 3 98 0 8 5 10 0 61 72 RTW46DSH006001 Remove th...

Page 240: ...OTE Be sure to attach a cooler to B terminal RTW46DSH005301 Insert the pin from the outside of the rear cover Press the brushes into the brush holder Complete the assembly procedure Remove the pin aft...

Page 241: ...o the left to align them with the middle of the center plate and the rotor RTW46DSH006101 Install vanes into slits in rotor The vanes should be installed with the chamfered side facing outward RTW46DS...

Page 242: ...Disconnect the battery cable at the starter motor and the ground cable at the cylinder body 4 Remove the starter motor from the engine Important Operations Installation Follow the removal procedure i...

Page 243: ...switch assembly 16 Bearing retainer 4 Torsion spring 17 Pinion assembly 5 Plunger 18 Pinion stopper clip 6 Dust cover 19 Pinion stopper 7 Magnetic switch 20 Return spring 8 Screw 21 Pinion shaft 9 Thr...

Page 244: ...c Switch Assembly Remove the magnetic switch bolts then remove the switch from the shift lever RTW46DSH002801 Remove the torsion spring from the magnetic switch RTW46DSH002901 8 Through Bolt 9 Screw 1...

Page 245: ...adjacent parts RTW46DSH003201 12 Brush Holder 13 Yoke 14 Armature Remove the brush holder and pull out the armature assembly free from the yoke RTW46DSH003301 16 Bearing Retainer 17 Pinion Assembly 23...

Page 246: ...RY00025 If the mica segment depth is less than the standard but more than the limit the commutator may be reground If the mica segment depth is less than the limit the commutator must be replaced 4 Me...

Page 247: ...o check the field winding ground 1 Hold one circuit tester probe against the field winding end or brush 2 Hold the other circuit tester probe against the bare surface of the yoke body There should be...

Page 248: ...der There should be no continuity 3 Inspect the brushes for excessive wear If the negative brushes have excessive wear the entire brush holder assembly must be replaced If the positive brushes have ex...

Page 249: ...netic switch 15 Pinion stopper clip 3 Dust cover 16 Bearing retainer 4 Plunger 17 Bolt 5 Torsion spring 18 Motor assembly 6 Shift lever 19 Armature 7 Gear case 20 Yoke 8 Dust cover 21 Brush holder 9 B...

Page 250: ...tic switch assembly in the gear case 2 Install the dust cover Dust Cover Bolt Torque N m kg m lb ft 8 0 8 5 4 10 Pinion Assembly Apply a coat of grease to the reduction gear and install the pinion ass...

Page 251: ...Wire Connect the lead wire in the magnetic switch and tighten the terminal nut to the specified torque Lead Wire Terminal Nut Torque N m kg m lb ft 8 6 0 88 6 40 RTW46DSH005801 Inspection After Assem...

Page 252: ...and the housing and run the following test Complete each test within three to five seconds 1 Pull in Test Connect the battery negative terminal with the solenoid switch body and the M terminal When c...

Page 253: ...ired GLOW RELAY The glow relay is located in the relay box the engine compartment 825R300046 Use an ohmmeter to measure the resistance between terminals No 2 and No 3 If the measured value is outside...

Page 254: ...MEMO...

Page 255: ...0 Symptom Code C Flash Code 65 6E 60 DTC P0105 Symptom Code 1 Flash Code 34 6E 62 DTC P0105 Symptom Code 2 Flash Code 34 6E 65 DTC P0105 Symptom Code 7 Flash Code 34 6E 68 DTC P0105 Symptom Code 9 Fla...

Page 256: ...tom Code 7 Flash Code 21 6E 180 DTC P1120 Symptom Code 9 Flash Code 21 6E 182 DTC P1120 Symptom Code D Flash Code 21 6E 184 DTC P1120 Symptom Code E Flash Code 21 6E 187 DTC P1173 Symptom Code 3 Flash...

Page 257: ...haft Position CKP Sensor Replacement 6E 261 EGR Solenoid Valve Replacement 6E 262 Engine Coolant Temperature ECT Sensor Replacement 6E 262 Mass Air Flow MAF Intake Air Temperature IAT Sensor Replaceme...

Page 258: ...190 90 194 240 80 176 320 70 158 430 60 140 590 50 122 810 40 104 1150 30 86 1650 25 77 2000 20 68 2430 10 50 3660 0 32 5650 10 14 8970 20 4 14700 Altitude vs Barometric Pressure Altitude Measured in...

Page 259: ...tic And Routing Diagrams Vacuum Hose Routing Diagram Normal Altitude Spec RTW66EMF001001 Legend 1 Vacuum Pump 2 Blue Stripe Vacuum Hose 3 EGR Solenoid Valve 4 White Stripe Vacuum Hose 5 Intake Duct 6...

Page 260: ...2 White Stripe Vacuum Hose 3 EGR Solenoid Valve 4 EGR Valve 5 White Stripe Vacuum Hose 6 Vacuum Regulating Valve 7 Port S 8 Port Z 9 Blue Stripe Vacuum Hose 10 Turbocharger Solenoid Valve 11 White Str...

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: ...mponent Locator Engine Controls Component Views 3 4 1 2 6 4 5 Legend 1 Mass Air Flow MAF Intake Air Temperature IAT Sensor Assembly 2 Throttle Cable 3 Air Cleaner Case 4 Battery 5 Relay Fuse Box 6 EGR...

Page 273: ...elerator Pedal Position APP Sensor Idle Switch 2 Fuel Iinjection Pump Control Unit PCU 3 Fuel Injection Pump Assembly 4 Fuel Filter Except Euro 3 3 2 1 Legend 1 Mass Air Flow MAF Intake Air Temperatur...

Page 274: ...trol Module ECM 2 1 Legend 1 Engine Coolant Temperature ECT Sensor 2 Thermo Unit for Water Temperature Gauge 2 3 1 4 Legend 1 EGR Solenoid Valve 2 To Vacuum Pump 3 To EGR Valve 4 To Intake Duct 2 1 Le...

Page 275: ...Engine Control System 4JH1 6E 21 1 Legend 1 Vehicle Speed Sensor VSS...

Page 276: ...or 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 24 BLK RED Engine Speed Signal Output to Tachomet...

Page 277: ...Not Used 53 Not Used 54 Not Used 55 BLK GRN APP Sensor 5 Volts reference 56 BLU BLK ECM Main Relay Control 57 Not Used 58 Not Used 59 Not Used 60 Not Used 61 BLK ECM Ground 62 BLK ECM Ground 63 BLU RE...

Page 278: ...nsor Signal 13 PNK CKP Sensor Signal Output 14 BLK RED MAF Sensor IAT Sensor Low Reference 15 BLK PNK ECT Sensor Vacuum Pressure Sensor High Altitude Only Low Reference 16 BLK BLU Glow Relay Control 1...

Page 279: ...ector No C 44 Connector Color White Test Adapter No J 35616 40 Pin 1 2 J35616 2A Pin 3 4 Pin Wire Color Pin Function 1 GRN Brake Pedal 1 Switch Stop Lamp Pedal Switch 12 Volts Feed 2 RED Brake Pedal 1...

Page 280: ...t Used 2 GRN J1850 Class 2 3 Not Used Connector No B 58 Connector Color Black Test Adapter No J 35616 2A Pin Wire Color Pin Function 4 BLK Ground 5 BLK Ground 6 BLU Diagnostic Request Switch 7 YEL BLU...

Page 281: ...ctor No E 6 Connector Color Black Test Adapter No J 35616 8 Pin Wire Color Pin Function 1 RED CAN Low Signal 2 YEL CAN High Signal 3 Not Used Connector No E 6 Connector Color Black Test Adapter No J 3...

Page 282: ...No J 35616 4A Pin Wire Color Pin Function 1 BLK BLU IAT Sensor Signal Connector No C 116 Connector Color Black Test Adapter No J 35616 4A Pin Wire Color Pin Function 2 BLU RED MAF Sensor Ignition Vol...

Page 283: ...Function 1 RED BLU Vacuum Pressure Sensor Signal 2 BLK PNK Vacuum Pressure Sensor Low Reference 3 WHT BLU Vacuum Pressure Sensor 5 Volts Reference Vehicle Speed Sensor VSS LNW46ESH001401 Connector No...

Page 284: ...her Black smoke White smoke Poor fuel economy Fuel knock combustion noise Problem Symptoms Others Other Dates problem occurred Constant Intermittently times per day month Once only Problem frequency O...

Page 285: ...at the customer complaint is a valid failure of the system Reading Flash Diagnostic Trouble Codes The provision for communicating with the ECM is the Data Link Connector DLC The DTCs stored in the ECM...

Page 286: ...to the engine control module ECM harness connector is possible by Test Adapter Breaker Box Connection Type A is suitable usage to prevent misprobe and damage of female terminals when test open circui...

Page 287: ...uch as sensor DTCs solenoid DTCs actuator DTCs and relay DTCs Diagnose the multiple DTCs within this category in numerical order Begin with the lowest numbered DTC unless the diagnostic table directs...

Page 288: ...ool Did you complete the action Go to Step 6 6 Does the scan tool display ECM DTC P0602 Go to Applicable DTC Go to Step 7 7 Does the scan tool display ECM DTC P0251 Symptom Code 9 or A P0606 Symptom C...

Page 289: ...table Hard Start Rough Unstable or Incorrect Idle and Stalling Cuts Out Misses Surge Chuggles Lack of Power Sluggishness or Sponginess Hesitation Sag Stumble Fuel Knock Combustion Noise Poor Fuel Eco...

Page 290: ...e Speed RPM 650 750 1950 2050 Desired Idle Speed RPM 700 700 Injection Pump Speed RPM 325 375 975 1025 Accelerator Pedal Position 0 0 5 0 7 0 Idle Switch On Off On Off Intake Air Temperature C F 20 40...

Page 291: ...circuits of the ECM Off indicates the main relay is not being commanded On by the ECM Engine Speed This parameter displays the speed of the crankshaft as calculated by the ECM based on input from the...

Page 292: ...ion volume and various sensor inputs When a small duty ratio the EGR valve is controlled to close When a large duty ratio the EGR valve is controlled to open Mass Air Flow Sensor This parameter displa...

Page 293: ...plug relay is not being commanded On by the ECM Glow Indicator Lamp Command This parameter displays the commanded state of the glow indicator lamp control circuit pin 40 of C 56 The glow indicator lam...

Page 294: ...ing whether the actual engine idle speed can change to match the commanded RPM Glow Indicator Lamps The purpose of this test is for checking whether the glow indicator lamp is operating when commanded...

Page 295: ...o to Step 3 2 Replace the Meter B 10A fuse C 19 If the fuse continues to open repair the short to ground on one of the circuits that is fed by the Meter B 10A fuse C 19 or replace the shorted attached...

Page 296: ...ew Reference Engine Controls Connector End Views or Engine Control Module ECM Connector End Views Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2...

Page 297: ...with the engine OFF 5 Attempt to communicate with the ECM and TCM Does the scan tool communicate with the ECM and TCM Go to Step 14 Go to Step 11 11 Repair the short to ground or short to voltage on...

Page 298: ...n Go to Step 17 Go to Step 4 4 Check the electronic hydraulic control unit EHCU C 67 connector for poor connection Did you find and correct the condition Go to Step 17 Go to Step 5 5 1 Turn ON the ign...

Page 299: ...and OFF while listening or feeling for the ECM main relay click Wait 2 seconds between transitions Does the ECM main relay click when the ignition is turned ON or OFF Go to Step 13 Go to Step 12 12 R...

Page 300: ...e s Yes No 17 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...

Page 301: ...r to Intermittent Conditions in this section 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 Ins...

Page 302: ...ghtness and all fuel hoses for cuts cracks and for the use of proper clamps 3 Pump the priming pump on the fuel filter until it becomes firm If there is a leak on the suction side of the fuel system b...

Page 303: ...ir any fuel system leaks and restrictions as necessary Did you find and correct the condition Go to Step 10 Go to Step 8 8 1 Other possible causes for the no start condition Fuel injection pump mechan...

Page 304: ...oid Control Circuit P0215 D 52 ON Engine Shutoff ESO Solenoid Control Circuit P0216 A 54 ON Injection Timing Control Circuit P0216 B 54 ON Injection Timing Control Circuit P0243 3 64 ON Turbocharger W...

Page 305: ...04 6 57 ON Clutch Switch Input Circuit P1105 1 86 ON Barometric Pressure BARO Sensor Circuit High Voltage P1105 2 86 ON Barometric Pressure BARO Sensor Circuit Low Voltage P1120 1 21 ON Accelerator Pe...

Page 306: ...Relay Circuit P1625 B 76 OFF ECM Main Relay Circuit P1630 A 51 ON Injection Pump Fuel Metering Control P1630 B 51 ON Injection Pump Fuel Metering Control P1650 A 44 ON CAN Device Offline P1650 B 44 O...

Page 307: ...10 Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the sc...

Page 308: ...Sensor Replacement in this section Did you complete the replacement Go to Step 7 6 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this...

Page 309: ...thout a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Notice The MAF Sensor parameter on the scan tool wi...

Page 310: ...CM Replacement in this section Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with the scan tool 3 Turn OFF the ignition f...

Page 311: ...f an intermittent condition is suspected refer to Intermittent Conditions in this section Notice Wrong direction of MAF sensor installation will cause this DTC to set Contaminated or restricted MAF se...

Page 312: ...ith connected 2 Start the engine and let idle for 30 seconds Does DTC P0100 Symptom Code C set but not DTC P0100 Symptom Code B Go to Step 13 Go to Step 12 9 Repair the open circuit or high resistance...

Page 313: ...Go to Step 16 15 Replace the MAF sensor Refer to Mass Air Flow Sensor Replacement in this section Did you complete the replacement Go to Step 17 16 Important Replacement ECM must be programmed Replac...

Page 314: ...of 10 Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with th...

Page 315: ...r of the MAF sensor pin 3 of C 116 connector 3 Repair the connection s as necessary Did you find and correct the condition Go to Step 11 Go to Step 9 8 1 Turn OFF the ignition 2 Disconnect the ECM har...

Page 316: ...CM limits fuel injection quantity The ECM uses a barometric pressure of 615 hPa for turbocharger wastegate valve control Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnosti...

Page 317: ...rrect the condition Go to Step 13 Go to Step 10 8 1 Test the 5 volts reference circuit between the ECM pin 1 of C 57 connector and the vacuum pressure sensor pin 3 of C 124 connector for a short to ba...

Page 318: ...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 14 Observe...

Page 319: ...function indicator lamp MIL when the diagnostic runs and fails The ECM limits fuel injection quantity The ECM uses a barometric pressure of 615 hPa for turbocharger wastegate valve control Condition f...

Page 320: ...r for the following conditions An open 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 S...

Page 321: ...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 12 Observe...

Page 322: ...after 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P0105 Sym...

Page 323: ...gine Control System 4JH1 6E 69 Step Action Value s Yes No 6 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List System...

Page 324: ...ith the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Test Description The number below refers to the step number on the diagnost...

Page 325: ...odule ECM Replacement in this section Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with the scan tool 3 Turn OFF the ign...

Page 326: ...ermittent Conditions in this section Use the Temperature vs Resistance table to test the IAT sensor at various temperature levels to evaluate the possibility of a skewed sensor A skewed sensor could r...

Page 327: ...for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 14 Go to Step 11 9 1 Test the signal circuit between the ECM pin 3 of C 57...

Page 328: ...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 15 Observe...

Page 329: ...tic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Use the Temperature vs Resistance table to test the IAT sensor at various temperature levels to eval...

Page 330: ...ecessary Did you find and correct the condition Go to Step 8 Go to Step 7 7 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section...

Page 331: ...ith the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section After starting the engine the ECT should rise steadily to about 80 C 85 C 1...

Page 332: ...ference circuit between the ECM pin 15 of C 57 connector and the ECT sensor pin 2 of E 41 connector for an open circuit or high resistance 2 Repair the circuit s as necessary Did you find and correct...

Page 333: ...to Step 14 14 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 w...

Page 334: ...consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section After starting the eng...

Page 335: ...you find and correct the condition Go to Step 8 Go to Step 7 7 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section Did you comp...

Page 336: ...ion is suspected refer to Intermittent Conditions in this section Notice FT sensor is internal to the PCU and it is part of the fuel injection pump assembly DTC P0180 Symptom Code B Flash Code 15 Step...

Page 337: ...DTC The ignition switch is OFF The engine speed is lower than 1500 RPM The vehicle speed is lower than 1 5 km h 1 MPH Condition for Setting the DTC After the condition for running this DTC for 2 seco...

Page 338: ...0 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 Go to Step 5 5 Observe the DTC...

Page 339: ...The ignition switch is ON Condition for Setting the DTC The PCU detects high voltage condition on the ESO solenoid valve control circuit for longer than 1 second when the ECM does not command shutoff...

Page 340: ...s necessary Did you find and correct the condition Go to Step 8 Go to Step 7 6 Important The fuel injection pump must be timed to the engine Replace the fuel injection pump Refer to Fuel Injection Pum...

Page 341: ...wer than 1 5 km h 1 MPH Condition for Setting the DTC The engine speed is higher than 200 RPM within 2 seconds after the condition for running the DTC are met This indicates the PCU does not react to...

Page 342: ...onnection s as necessary Did you find and correct the condition Go to Step 11 Go to Step 9 8 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for a poor...

Page 343: ...lamp MIL when the diagnostic runs and fails Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving c...

Page 344: ...etarded more than desired by 6 CA for longer than 12 seconds Symptom Code B The PCU monitored actual fuel injection timing is oscillated higher than desired by 5 2 CA Action Taken When the DTC Sets Th...

Page 345: ...the scan tool Does the Actual Injection Timing parameter follow the Desired Injection Timing within 2 CA on each engine speed Go to Diagnostic Aids Go to Step 4 4 1 Turn OFF the ignition 2 Check the...

Page 346: ...n 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...

Page 347: ...8 Important The fuel injection pump must be timed to the engine Replace the fuel injection pump Refer to Fuel Injection Pump Replacement in engine mechanical section Did you complete the replacement G...

Page 348: ...the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM limits fuel injection quantity The ECM uses an EGR solenoid valve control substitution o...

Page 349: ...ep 6 Go to Step 14 6 1 Turn OFF the ignition 2 Disconnect the vacuum pressure sensor harness connector 3 Inspect for an intermittent and for poor connections at the vacuum pressure sensor harness conn...

Page 350: ...re sensor harness connector in order to active turbocharger solenoid valve 7 Start the engine and let engine idle Does the needle of hand held vacuum pump shake between 0 and 20 cmHg 8 inHg Go to Step...

Page 351: ...ine Control System 4JH1 6E 97 Step Action Value s Yes No 16 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List System...

Page 352: ...substitution of 10 Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or c...

Page 353: ...est the control circuit between the ECM pin 18 of C 57 connector and the turbocharger solenoid valve pin 2 of C 123 connector for an open circuit or high resistance 2 Repair the circuit s as necessary...

Page 354: ...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 16 Obs...

Page 355: ...ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM limits fuel injection quantity The ECM uses an EGR solenoid valve control substitution of 10 Condition fo...

Page 356: ...ric pressure table Refer to Altitude vs Barometric Pressure Is the BARO parameter within the range specified Go to Step 6 Go to Step 14 6 1 Turn OFF the ignition 2 Disconnect the vacuum pressure senso...

Page 357: ...active turbocharger solenoid valve 7 Start the engine and let engine idle Does the needle of hand held vacuum pump shake between 0 and 20 cmHg 8 inHg Go to Step 10 Go to Step 11 10 Replace the vacuum...

Page 358: ...104 Engine Control System 4JH1 Step Action Value s Yes No 16 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List System...

Page 359: ...MAF for 3 seconds This indicates an excessive high boost pressure Action Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM limit...

Page 360: ...for the following conditions An EGR valve control vacuum hose is damaged or kinked EGR solenoid valve vacuum hoses are damaged or kinked EGR solenoid valve ventilation is damaged An EGR valve is stuc...

Page 361: ...at the harness connector of the ECM pin 14 of C 57 connector 6 Test for high resistance on each MAF sensor circuit 7 Repair the circuit s as necessary Did you find and correct the condition Go to Step...

Page 362: ...y The ECM uses a turbocharger solenoid valve control substitution of 32 The ECM uses an EGR solenoid valve control substitution of 10 Condition for Clearing the MIL DTC The ECM turns OFF the MIL when...

Page 363: ...ent in this section Did you complete the replacement Go to Step 7 6 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section Did you...

Page 364: ...sired injection quantity from the ECM is 0 mg strk this DTC will set Condition for Running the DTC The fuel injection pump CMP sensor signal is generated The CAN communication between the ECM and PCU...

Page 365: ...idle for 30 seconds 4 Accelerate the engine between idle and W O T accelerator pedal full travel many times while observing the DTC Information with the scan tool Did the DTC fail this ignition Go to...

Page 366: ...longer than 0 2 seconds Action Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM cuts fuel injection Condition for Clearing the...

Page 367: ...sensor signal input at the harness connector of the PCU pin 8 of E 6 connector 4 Repair the connection s as necessary Did you find and correct the condition Go to Step 10 Go to Step 8 8 1 Turn OFF the...

Page 368: ...nternal fuel injection pump control maps are not programmed during self test Symptom Code 9 The PCU detects internal EEPROM or A D converter is failed during self test Symptom Code A The PCU detects t...

Page 369: ...nition 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 5 Observe the DTC Information...

Page 370: ...injection Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with...

Page 371: ...RPM Action Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM uses an engine speed substitution of doubled fuel injection pump s...

Page 372: ...d circuit of the CKP sensor harness pin 3 of E 9 connector and a known good ground Does the test lamp illuminate Go to Step 13 Go to Step 8 8 1 Keep the ignition switch ON with the engine OFF 2 Connec...

Page 373: ...ctor and the CKP sensor pin 2 of E 9 connector for the following conditions A short to ground A short to the low reference circuit A short to the shield ground 2 Repair the circuit s as necessary Did...

Page 374: ...te the replacement Go to Step 22 21 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section Did you complete the replacement Go to S...

Page 375: ...damage Excessive engine over speed may damage internal engine components DTC P0335 Symptom Code E Flash Code 43 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls...

Page 376: ...5 Observe the Engine Speed parameter with the scan tool 6 Accelerate the engine between idle and W O T accelerator pedal full travel many times while observing the scan tool Does the Engine Speed para...

Page 377: ...Schematics Connector End View Reference Engine Controls Connector End Views or Engine Control Module ECM Connector End Views Step Action Value s Yes No 1 Did you perform the Diagnostic System Check E...

Page 378: ...s as necessary Did you find and correct the condition Go to Step 16 Go to Step 15 11 1 Test the control circuit of the glow relay between the ECM pin 16 of C 57 connector and the glow relay pin 3 of...

Page 379: ...n 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 5 Monitor the DTC Information with the scan tool Did the DTC fail this ig...

Page 380: ...DTC P0380 Symptom Code 8 Flash Code 66 Schematic Reference Engine Controls Schematics Connector End View Reference Engine Controls Connector End Views or Engine Control Module ECM Connector End Views...

Page 381: ...on for 30 seconds 4 Cool down the engine as necessary allow engine coolant temperature to cool down at least 50 C 122 F 5 Start the engine 6 Monitor the DTC Information with the scan tool Did the DTC...

Page 382: ...fter 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Notice The glo...

Page 383: ...ol 6 Command the Glow Indicator ON with the scan tool Does the test lamp turn ON when commanded ON with the scan tool Go to Step 13 Go to Step 12 9 1 Test the control circuit of the glow indicator lam...

Page 384: ...with the engine OFF 3 Monitor the DTC Information with the scan tool Does the DTC fail this ignition Go to Step 16 Go to Diagnostic Aids 16 Important Replacement ECM must be programmed Replace the ECM...

Page 385: ...scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section Notice The glow indicator lamp is commanded OFF with the ignition ON and engine OF...

Page 386: ...t ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness...

Page 387: ...tic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Inter...

Page 388: ...turbocharger needs to be wipe off Contaminated skewed or slow MAF sensor 3 Repair or replace as necessary Did you find and correct the condition Go to Step 10 Go to Step 5 5 1 Turn OFF the ignition 2...

Page 389: ...you find and correct the condition Go to Step 10 Go to Step 8 8 Replace the EGR valve Refer to EGR Valve Replacement in engine mechanical section Did you complete the replacement Go to Step 10 9 Repl...

Page 390: ...ool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P0400 Symptom Code 4 Flash Code 32 Schematic Reference Engine Controls Schematics Con...

Page 391: ...ou find and correct the condition Go to Step 15 Go to Step 12 10 1 Test the control circuit between the ECM pin 19 of C 57 connector and the EGR solenoid valve pin 2 of C 115 connector for a short to...

Page 392: ...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 16 Obs...

Page 393: ...fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in...

Page 394: ...o Step 10 Go to Step 5 5 1 Turn OFF the ignition 2 Disconnect the EGR valve control vacuum hose from the EGR valve 3 Connect a hand held vacuum pump 5 8840 0279 0 J 23738 A to the disconnected vacuum...

Page 395: ...Go to Step 8 8 Replace the EGR valve Refer to EGR Valve Replacement in engine mechanical section Did you complete the replacement Go to Step 10 9 Replace the EGR solenoid valve Refer to EGR Solenoid V...

Page 396: ...n The number below refers to the step number on the diagnostic table 3 If the control circuit of the EGR solenoid valve between the ECM and the solenoid valve is normal the control circuit voltage low...

Page 397: ...usly disconnected 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 60 C...

Page 398: ...h 3 MPH for engine control Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a f...

Page 399: ...sion section Did you complete the replacement Go to Step 7 7 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 Dr...

Page 400: ...Sensor VSS Replacement in this section 2 Visually inspect the VSS for the following conditions Physical damage Being loose Improper installation 3 The following conditions may cause this DTC to set El...

Page 401: ...iagnostic Aids Electrical or magnetic interference may affect intermittent condition If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P0500 Symptom Code B...

Page 402: ...M pin 68 of C 56 connector and the IP cluster pin 8 of B 23 connector for the following conditions An open circuit A short to ground A short to battery or ignition voltage High resistance 2 Repair the...

Page 403: ...ed parameter indicate correct vehicle speed Go to Step 15 Go to Step 2 15 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DT...

Page 404: ...the signal circuit of the VSS pin 3 of E 44 connector with a test lamp that is connected to a known good ground while monitoring the Vehicle Speed parameter with the scan tool Does the scan tool indic...

Page 405: ...pair the connection s as necessary Did you find and correct the condition Go to Step 20 Go to Step 17 15 1 Turn OFF the ignition 2 Disconnect the IP cluster B 23 harness connector 3 Inspect for an int...

Page 406: ...an tool 3 Turn OFF the ignition for 30 seconds 4 Drive the vehicle 5 Observe the Vehicle Speed parameter with the scan tool Does the Vehicle Speed parameter indicate correct vehicle speed Go to Step 2...

Page 407: ...ngine 4 Monitor the Diagnostic Trouble Code DTC Information with the scan tool Does the DTC fail this ignition Go to Step 3 Go to Diagnostic Aids 3 Was the vehicle recently jump started from 24 volts...

Page 408: ...o Diagnostic System Check Engine Controls 2 1 Install the scan tool 2 Turn OFF the ignition for 30 seconds 3 Start the engine 4 Monitor the Diagnostic Trouble Code DTC Information with the scan tool D...

Page 409: ...econds 4 Start the engine 5 Load the electrical system by turning ON the headlights A C etc 6 Observe the System Voltage parameter with the scan tool Is the System Voltage parameter more than the spec...

Page 410: ...alue 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 the scan tool 2 Turn OFF the ignition for 30 seconds...

Page 411: ...ine Control System 4JH1 6E 157 Step Action Value s Yes No 7 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List System...

Page 412: ...switch may set this DTC Test Description The numbers below refer to the step number on the diagnostic table 2 If DTC P1625 Symptom Code A is present scan tool can communicate with the ECM when the ig...

Page 413: ...ECM pin 36 of C 56 connector 6 Test for high resistance on ignition voltage feed circuit 7 Repair the connection s or circuit s as necessary Did you find and correct the condition Go to Step 6 Go to S...

Page 414: ...Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P0561 Symptom Code B Flash Code 18 Step Action Value s Yes No 1 Did you perform the Diagnostic Syst...

Page 415: ...ail this ignition Go to Step 3 Go to Step 6 3 Important Blank engine control module ECM must be programmed Program the ECM Refer to Engine Control Module ECM Replacement in this section Did you comple...

Page 416: ...consecutive driving cycles without a fault Or clear with the scan tool DTC P0606 Symptom Code A B Flash Code 28 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls...

Page 417: ...1 F and it commanded ON again below 100 C 212 F DTC P0645 Symptom Code 4 Flash Code 46 Schematic Reference Engine Controls Schematics Connector End View Reference Engine Controls Connector End Views o...

Page 418: ...rol circuit of the A C compressor relay between the ECM pin 38 of C 56 connector and the A C compressor relay pin 5 of X 14 connector for a short to ground 2 Repair the circuit s as necessary Did you...

Page 419: ...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 Turn ON the blower motor switch and the A C compressor switc...

Page 420: ...mperature is reached around 105 C 221 F and it commanded ON again below 100 C 212 F DTC P0645 Symptom Code 8 Flash Code 46 Schematic Reference Engine Controls Schematics Connector End View Reference E...

Page 421: ...ay 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 Turn ON the blower motor switch and the A C compressor switch 6 Monitor the DT...

Page 422: ...ic runs and fails Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or cl...

Page 423: ...sistance on the voltage feed circuit between the Stop 15A fuse C 15 and the brake pedal 1 switch pin 1 of C 44 connector Did you complete the repair Go to Step 22 9 1 Test the brake pedal 1 switch sig...

Page 424: ...e on the voltage feed circuit between the ECM 10A fuse EB 4 and the brake pedal 2 switch pin 3 of C 44 connector Did you complete the repair Go to Step 22 17 1 Test the brake pedal 2 switch signal cir...

Page 425: ...s 2 Clear the DTCs with the scan tool 3 Turn ON the ignition with the engine OFF 4 Observe the Brake Pedal 1 Switch and the Brake Pedal 2 Switch with the scan tool while fully depressing and releasing...

Page 426: ...is section Misadjusted clutch pedal switch will cause this DTC to set DTC P0704 Symptom Code 6 Flash Code 57 Schematic Reference Engine Controls Schematics Connector End View Reference Engine Controls...

Page 427: ...B 4 and the clutch pedal switch pin 1 of C 77 connector Did you complete the repair Go to Step 16 10 1 Test the clutch pedal switch signal circuit between the engine control module ECM pin 28 of C 56...

Page 428: ...Step 16 16 1 Reconnect all previously disconnected fuse or harness connector s 2 Clear the DTCs with the scan tool 3 Turn ON the ignition with the engine OFF 4 Observe the Clutch Pedal Switch paramet...

Page 429: ...tic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool DTC P1105 Symptom Code 1 Flash Code 86 Step Action Value s Yes No 1 Did...

Page 430: ...ic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool DTC P1105 Symptom Code 2 Flash Code 86 Step Action Value s Yes No 1 Did y...

Page 431: ...DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section D...

Page 432: ...t 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 15 Go to Step 14 10 1 Test the 5 volts reference circuit between the ECM pin 55 of C 56 connector and the APP se...

Page 433: ...ition for 30 seconds 4 Turn ON the ignition with the engine OFF 5 Fully depress and release the accelerator pedal many times 6 Monitor the DTC Information with the scan tool Did the DTC fail this igni...

Page 434: ...If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P1120 Symptom Code 7 Flash Code 21 Schematic Reference Engine Controls Schematics Connector End View Ref...

Page 435: ...ine Control System 4JH1 6E 181 Step Action Value s Yes No 6 Observe the DTC Information with the scan tool Are there any DTCs that you have not diagnosed Go to Diagnostic Trouble Code DTC List System...

Page 436: ...uspected refer to Intermittent Conditions in this section Test Description The number below refers to the step number on the diagnostic table 3 If the APP sensor 5 volts reference circuit between the...

Page 437: ...ection Did you complete the replacement Go to Step 7 7 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...

Page 438: ...l is depressed for longer than 2 seconds Action Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM uses an engine speed substitut...

Page 439: ...High resistance 2 Repair the circuit s as necessary Did you find and correct the condition Go to Step 13 Go to Step 7 7 1 Turn OFF the ignition 2 Disconnect the ECM harness connector 3 Inspect for an...

Page 440: ...n for 30 seconds 4 Turn ON the ignition with the engine OFF 5 Observe the APP parameter while fully depressing and releasing the accelerator pedal many times Also observe the Brake Pedal 1 Switch para...

Page 441: ...witch is ON for longer than 0 6 seconds Action Taken When the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM uses an engine speed substituti...

Page 442: ...you find and correct the condition Go to Step 21 Go to Step 20 8 Repair the open circuit or high resistance on the idle switch ground circuit between the idle switch pin 1 of E 23 connector and engine...

Page 443: ...ition Go to Step 21 Go to Step 16 16 1 Test the low reference circuit between the ECM pin 47 of C 56 connector and the APP sensor pin 1 of E 22 connector for high resistance 2 Repair the circuit s as...

Page 444: ...pressing and releasing the accelerator pedal many times Does the scan tool indicate the APP parameter smoothly changed within 0 to 100 when the accelerator pedal is depressed and released then scan to...

Page 445: ...ected refer to Intermittent Conditions in this section After starting the engine the ECT should rise steadily to about 80 C 85 C 176 F 185 F then stabilize when the thermostat opens Use the Temperatur...

Page 446: ...s necessary Did you find and correct the condition Go to Step 6 Go to Diagnostic Aids 6 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with the scan tool 3 Turn OFF the i...

Page 447: ...tice FT sensor is internal to the PCU and it is part of the fuel injection pump assembly DTC P1173 Symptom Code 7 A Flash Code 22 Step Action Value s Yes No 1 Did you perform the Diagnostic System Che...

Page 448: ...ns in this section Notice PCU is part of the fuel injection pump assembly DTC P1335 Symptom Code A Flash Code 43 Schematic Reference Engine Controls Schematics Connector End View Reference Engine Cont...

Page 449: ...nition 2 Disconnect the ECM harness connector 3 Inspect for an intermittent and for a poor connection on the CKP sensor signal output circuit at the harness connector of the ECM pin 12 of C 57 connect...

Page 450: ...and fails The ECM limits fuel injection quantity Condition for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive drivi...

Page 451: ...ition switch OFF for 10 seconds The engine speed is higher than 1500 RPM The vehicle speed is higher than 63 km h 39 MPH M T or 78 km h 49 MPH A T The clutch pedal is released M T Other than neutral o...

Page 452: ...ther positions Does the scan tool indicate ON when the position is neutral and OFF when other than the neutral Go to Step 8 Go to Step 3 8 Observe the DTC Information with the scan tool Are there any...

Page 453: ...Replacement in this section Did you complete the replacement Go to Step 7 7 1 Reconnect all previously disconnected harness connector s 2 Clear the DTCs with the scan tool Important Following conditi...

Page 454: ...speed is lower than 2 km h 1 2 MPH The clutch pedal is released after once depressed Neutral position After the above procedure is done a history DTC clears after 40 consecutive driving cycles withou...

Page 455: ...rcuit between the engine control module ECM pin 6 of C 57 connector and the neutral switch pin 1 of E 11 connector for an open circuit or high resistance 2 Repair the circuit s as necessary Did you fi...

Page 456: ...e speed is higher than 665 RPM The vehicle speed is lower than 2 km h 1 2 MPH The clutch pedal is released after once depressed Neutral position 3 Turn ON the ignition with the engine OFF 4 Observe th...

Page 457: ...n for Clearing the MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool DTC...

Page 458: ...m Code A Flash Code 56 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 the scan tool 2 T...

Page 459: ...Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install the scan tool 2 Turn OFF the ignition for 30 seconds 3 Turn ON the ignition with the engine OFF 4 Select the Immobilizer in the system...

Page 460: ...000 Device in this section ECM with wrong specification may set this DTC DTC P1612 Symptom Code A Flash Code 56 Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls...

Page 461: ...an tool Does Not Communicate with Keyword 2000 Device in this section ECM with wrong specification may set this DTC DTC P1613 Symptom Code A Flash Code 56 Step Action Value s Yes No 1 Did you perform...

Page 462: ...erform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic System Check Engine Controls 2 1 Install the scan tool 2 Turn OFF the ignition for 30 seconds 3 Turn ON the ignition wi...

Page 463: ...ontrols Connector End Views or Engine Control Module ECM Connector End Views Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Controls Go to Step 2 Go to Diagnostic Syst...

Page 464: ...rn OFF the ignition for 30 seconds 4 Start the engine 5 Observe the DTC Information with the scan tool 6 Turn OFF the ignition 7 Turn ON the ignition with the engine OFF Does the DTC fail this ignitio...

Page 465: ...Connector End View Reference Engine Controls Connector End Views or Engine Control Module ECM Connector End Views Step Action Value s Yes No 1 Did you perform the Diagnostic System Check Engine Contro...

Page 466: ...o to Step 9 9 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 Monitor the DTC Information with the sca...

Page 467: ...solenoid valve control current is too high Symptom Code A The ECM detects that the PCU continuously flow the control current to the fuel injection solenoid valve Symptom Code B Action Taken When the...

Page 468: ...riving cycles without a fault Or clear with the scan tool Diagnostic Aids If an intermittent condition is suspected refer to Intermittent Conditions in this section DTC P1650 Symptom Code A Flash Code...

Page 469: ...nd High circuit between the ECM pins 23 and 24 of C 57 connector and the PCU pins 1 and 2 of E 6 connector for the following conditions An open circuit A short each other High resistance 2 Repair the...

Page 470: ...18 Go to Step 17 16 Important The fuel injection pump must be timed to the engine Replace the fuel injection pump Refer to Fuel Injection Pump Replacement in engine mechanical section PCU is part of...

Page 471: ...the DTC Sets The ECM illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The ECM cuts the fuel injection Condition for Clearing the MIL DTC The ECM turns OFF the MIL whe...

Page 472: ...e MIL DTC The ECM turns OFF the MIL when the diagnostic runs and does not fail A history DTC clears after 40 consecutive driving cycles without a fault Or clear with the scan tool Diagnostic Aids If a...

Page 473: ...nd High circuit between the ECM pins 23 and 24 of C 57 connector and the PCU pins 1 and 2 of E 6 connector for the following conditions An open circuit A short each other High resistance 2 Repair the...

Page 474: ...17 Go to Step 16 15 Important The fuel injection pump must be timed to the engine Replace the fuel injection pump Refer to Fuel Injection Pump Replacement in engine mechanical section PCU is part of...

Page 475: ...to Intermittent Conditions in this section DTC P1690 Symptom Code 4 Flash Code 77 Schematic Reference Engine Controls Schematics Connector End View Reference Engine Controls Connector End Views or Eng...

Page 476: ...ctor 3 Inspect for an intermittent and for a poor connection on the MIL control circuit at the harness connector of the ECM pin 39 of C 56 connector 4 Repair the connection s as necessary Did you find...

Page 477: ...Step 17 17 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 Informat...

Page 478: ...tion is suspected refer to Intermittent Conditions in this section Test Description The number below refers to the step number on the diagnostic table 3 If the control circuit of the MIL between the E...

Page 479: ...air or replacement Go to Step 7 6 Important Replacement ECM must be programmed Replace the ECM Refer to Engine Control Module ECM Replacement in this section Did you complete the replacement Go to Ste...

Page 480: ...30 seconds 3 Turn ON the ignition with the engine OFF 4 Monitor the Diagnostic Trouble Code DTC Information of the engine control system with the scan tool and check whether following DTC s is set P01...

Page 481: ...Step 8 Go to Step 11 8 1 Turn ON the ignition with the engine OFF 2 Connect a test lamp between the power supply circuit of glow plugs pin 1 of X 5 connector and a known good ground Does the test lam...

Page 482: ...complete the replacement Go to Step 16 15 Replace the appropriate glow plug Did you complete the replacement Go to Step 16 16 1 Reconnect all previously disconnected components relay fuse or harness...

Page 483: ...s or Engine Control Module ECM Connector End Views Chart 1 of 2 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 Engi...

Page 484: ...1 Turn OFF the ignition 2 Remove the A C compressor relay from the engine room relay block 3 Connect a test lamp between the A C compressor clutch voltage supply circuit pin 2 of X 14 connector and a...

Page 485: ...as necessary Did you find and correct the condition Go to Step 23 Go to Step 21 20 1 Turn OFF the ignition 2 Inspect for an intermittent and for a poor connection at the harness connector of the A C...

Page 486: ...h pin 1 of C 24 connector Did you complete the repair Go to Step 39 6 Repair the short to ground between the pressure switch pin 2 of C 24 connector and the electronic thermostat pin 2 of C 55 connect...

Page 487: ...30 of C 56 connector and a known good ground 5 Turn ON the ignition with the engine OFF DO NOT START the engine Does the test lamp illuminate Go to Step 32 Go to Step 21 15 1 Turn OFF the ignition 2...

Page 488: ...the repair Go to Step 39 22 Repair the open circuit or high resistance on the pressure switch voltage feed circuit between the thermo relay pin 5 of X 15 connector and pressure switch pin 1 of C 24 c...

Page 489: ...Go to Step 39 Go to Step 36 31 1 Turn OFF the ignition 2 Inspect for an intermittent and for a poor connection at the harness connector of the blower motor switch pin 1 of B 13 connector 3 Repair the...

Page 490: ...d fuse relay or harness connector s 2 Turn OFF the ignition for 30 seconds 3 Turn ON the ignition with the engine OFF 4 Turn ON the blower motor switch Does the blower motor turn ON and operate correc...

Page 491: ...may cause the condition Important The problem may or may not turn ON the MIL or store a DTC Faulty electrical connections or wiring cause most intermittent problems Perform a careful visual and physi...

Page 492: ...TION The problem is not currently present but is indicated in DTC History OR There is a customer complaint but the symptom cannot currently be duplicated if the problem is not DTC related Preliminary...

Page 493: ...ate connections between the power source and the module component A test lamp or a DMM may indicate that voltage is present but neither tests the ability of the circuit to carry sufficient current Ens...

Page 494: ...alibration files have been released for this vehicle Verify that the ECM contains the correct software calibration If incorrect programming is found reprogram the ECM with the most current software ca...

Page 495: ...nnects to the fuel injection pump suction side b Substitute a clear hose Notice A hose must be cleaned c Connect the clear hose to the fuel injection pump d Bleed the fuel system e Let the engine run...

Page 496: ...that the harness connectors are correctly connected Inspect the fuel type and quality Inspect the scan tool Data List in this section Inspect the Service Bulletins for ECM software updates Sensor Chec...

Page 497: ...fuel tank as possible going to the fuel pickup tube to verify a clean stream of fuel comes out use the hand held vacuum pump 5 8840 0279 0 J 23738 A with a clear hose or equivalent This will ensure t...

Page 498: ...s the engine speed usually more pronounced as the engine load increase The exhaust has a steady spitting sound at idle low speed or hard acceleration for the fuel starvation that can cause the engine...

Page 499: ...ossible going to the fuel pickup tube to verify a clean stream of fuel comes out use the hand held vacuum pump 5 8840 0279 0 J 23738 A with a clear hose or equivalent This will ensure the fuel pickup...

Page 500: ...following conditions Refer to the scan tool Data List in this section Use the scan tool to compare the Mass Air Flow MAF Sensor parameter with the Desired MAF parameter Start the engine and warm up al...

Page 501: ...up tube to verify a clean stream of fuel comes out use the hand held vacuum pump 5 8840 0279 0 J 23738 A with a clear hose or equivalent This will ensure the fuel pickup tube is not cracked drawing ai...

Page 502: ...are updates Sensor Checks Inspect the engine control sensors for the following conditions Refer to the scan tool Data List in this section Use the scan tool to compare the Engine Coolant Temperature E...

Page 503: ...t This will ensure the fuel pickup tube is not cracked drawing air into the fuel line Inspect the fuel injection pump operation Notice The fuel injection pump must be timed to the engine Inspect the e...

Page 504: ...he engine oil level and quality Inspect the scan tool Data List in this section Inspect the engine control module ECM and fuel injection pump control unit PCU grounds for being clean tight and in thei...

Page 505: ...t This will ensure the fuel pickup tube is not cracked drawing air into the fuel line Inspect the fuel injection pump operation Notice The fuel injection pump must be timed to the engine Inspect the e...

Page 506: ...ce on the low reference circuit and signal circuit or for a skewed sensor Notice The mass air flow MAF sensor is heated and as a result the IAT sensor may indicate a higher than normal intake air temp...

Page 507: ...t pattern and down shift operation A T only Inspect the fuel quality cetane index Inspect the engine oil level and quality Suggest to the owner to fill the fuel tank and recheck the fuel economy Sugge...

Page 508: ...ompare the Engine Coolant Temperature ECT with the Intake Air Temperature IAT and Fuel Temperature FT on a cold engine condition If the difference among temperature reading is more than 5 C 9 F on a c...

Page 509: ...inary Check Ensure the vehicle has an actual problem Inspect the engine control module ECM and fuel injection pump control unit PCU grounds for being clean tight and in their proper locations Inspect...

Page 510: ...ger inspection in the Engine Mechanical section Engine Mechanical Checks Inspect the engine mechanical for the following conditions Refer to the Engine Mechanical section Inspect for poor cylinder com...

Page 511: ...floor panel 3 Tighten the ECM cover by four bolts with specified tightening torque Tightening torque Bolts 8 0 12 0 N m 0 8 1 2 kgf m 4 Lay the floor carpet exactly 5 Put on the seat to the floor pan...

Page 512: ...using one of the methods listed above refer to Service Programming System SPS Remote Procedure or Service Programming System SPS Pass Thru Procedure Before Programming a Control Module Important DO N...

Page 513: ...ehicle identification h Enter the vehicle description by following the on screen instructions based on stamped VIN or affixed VIN plate on the vehicle i During obtaining information the scan tool is r...

Page 514: ...rom the vehicle Service Programming System SPS Pass Thru Procedure Pass Thru programming allows the scan tool to remain connected to the terminal and to the vehicle throughout the programming process...

Page 515: ...erator Pedal Position APP Sensor Replacement Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the APP sensor connector 3 Loosen two screws and remove APP sensor from the throttle...

Page 516: ...l will be below the ECT sensor 4 Disconnect connector from the ECT sensor 5 Loosen and remove the ECT sensor from the thermostat housing Notice Cool down the engine before above procedures are carried...

Page 517: ...1 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...

Page 518: ...connector from the vehicle speed sensor VSS 3 Remove the VSS from the transmission A T 2WD 1 Disconnect the negative battery cable 2 Disconnect a harness connector from the vehicle speed sensor VSS 3...

Page 519: ...accurate voltage readings The input and or output devices in the ECM include analog to digital converters signal buffers counters and special drivers The ECM controls most components with electronic s...

Page 520: ...when commanded ON RTW76ESH004001 The MIL indicates that an emission or performance related fault has occurred and vehicle service is required The following is a list of the modes of operation for the...

Page 521: ...CKP sensor signal CH1 increase as engine speed increases Each waveform cycle shorten as the engine speed increases Terminal 90 CH1 91 CH2 GND Scale 10V div 2ms div Condition Approximately 1000RPM CH1...

Page 522: ...ECM supplies 5 volts to the IAT signal circuit and a ground for the IAT low reference circuit When the IAT sensor is cold the sensor resistance is high When the air temperature increases the sensor re...

Page 523: ...rates a speed signal from the transmission output shaft The VSS uses a hall effect element It interacts with the magnetic field created by the rotating magnet and outputs square wave pulse signal The...

Page 524: ...arious sensors These desired data are sent to the fuel injection pump control unit PCU via a controller area network CAN communication bus The PCU also receives signals from the internal inputs pump c...

Page 525: ...PV Holder 7 Fuel Injection Solenoid Valve 8 Constant Pressure Valve CPV 9 Timing Control Valve TCV 10 Timer 11 Radial Plunger RTW66ESH002001 Legend 1 Rotor Shaft 2 Radial Plunger 3 High Pressure Passa...

Page 526: ...he volume of these chambers increase when they reach recesses the casing ring connected to the inlet port Pressure then decreases and fuel is drawn in When the chambers have passed the inlets and rece...

Page 527: ...ing of the fuel pump during operation Also the orifice port is installed to assist in automatic air bleeding High Pressure Fuel Circuit Description RTW66ESH002501 Legend 1 Fuel Injection Pump Control...

Page 528: ...uced reciprocating movement to suck in and compress the fuel in the plunger chamber Distributor Head RTW66ESH002701 Legend 1 Rotor Shaft 2 Valve Needle 3 Constant Pressure Valve CPV Holder 4 High Pres...

Page 529: ...pressure pump and injected into the engine cylinder through the nozzle holder assembly When the required injection quantity is reached the current to the coil is cut the valve seat opens and injectio...

Page 530: ...timing plunger is transferred to the cam ring in the form of rotational movement Movement to the right of the timing plunger to the spring side advances injection timing The main components are timin...

Page 531: ...Flexible Connecting Harness 3 Drive Shaft 4 Pump Camshaft Position CMP Sensor Retaining Ring 5 Sensor Wheel When the drive shaft rotates the pump camshaft position CMP sensor receives signal form the...

Page 532: ...ons the fuel injection solenoid valve open and close intervals corresponding to the cam ring s cam lift can be accurately determined Actual Injection Pump Speed When the crankshaft position CKP sensor...

Page 533: ...ntrol system uses an electronic control system solenoid valve and vacuum control EGR valve to ensure both driveability and low emission The engine control module ECM controls the EGR flow amount based...

Page 534: ...e air is compressed and delivered through a crossover pipe to the engine air intake manifold then into the cylinders The amount of air pressure rise and air volume delivered to the engine from the com...

Page 535: ...ols and Equipment Illustration Tool Number Description Illustration Tool Number Description 5 8840 2835 0 J 35616 C Connector Test Adapter Kit With Test Lamp 5 8840 0279 0 J 23738 A Vacuum Pump 5 8840...

Page 536: ...MEMO...

Page 537: ...3 Removal and Installation 6F 4 Inspection and Repair 6F 6 General Description 6F 7 EGR System Diagram 6F 9 Inspection 6F 11 EGR Cooler 4JA1TC 4JH1TC Euro III model 6F 12 Turbocharger 6F 15 Main Data...

Page 538: ...pipe Middle pipe Pipe outside diameter x thickness mm in 50 8 x 1 6 2 0 x 0 063 Silencer tail pipe Type Circular section shell construction of double skin and end plates internal construction of baff...

Page 539: ...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 RTW86FLF000101 Removal Steps 1 Rear hanger rubber 2 Silencer front nut 3 Exhaust silencer 4 Silencer hanger rubber 5 Middle pipe nut 6 Front hanger rubber 7 Front pipe nut 8...

Page 541: ...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 2 Middle pipe Nut 4 4 only Connect the m...

Page 542: ...the pipes for corrosion cracking damage or misalignment and repair as required Check the rubber rings for deterioration or damage and repair as required Catalytic Converter 1 Inspect outside the cata...

Page 543: ...t 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...

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: ...ally while changing engine RPM under no load condition after warming up Inspection point Engine RPM RPM Idling 900 960 2000 3250 Engine Front Side VSV 1 ON ON ON OFF Engine Rear Side VSV 2 ON OFF ON O...

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: ...Pressure 4JA1TC 4JH1TC RTW46ESH000301 EVRV Use a circuit tester to measure the EVRV resistance EVRV Resistance at 20 C 14 If the resistance is not within specification replace it EGR Valve Apply vacuu...

Page 548: ...01 Removal Steps 1 Bolt 2 Gasket 3 Bolt 4 Gasket 5 Bolt 6 Bolt 7 EGR Pipe Assembly 8 Gasket 9 Bolt 10 EGR Cooler Assembly 11 Gasket 12 EGR Cooler Adapter Removal 1 Bolt 2 Gasket 3 Bolt 4 Gasket 5 Bolt...

Page 549: ...6F 13 RTW46EMF000901 Installation steps 1 EGR Cooler Adapter 2 Gasket 3 EGR Cooler Assembly 4 Gasket 5 Bolt 6 EGR Pipe Assembly 7 Bolt 8 Bolt 9 Gasket 10 EGR Valve Assembly 11 Bolt 12 EXH Manifold 13...

Page 550: ...ily 8 Bolt Tighten bolts temporarily 9 Gasket 10 Bolt Tighten bolts temporarily 11 Gasket 12 Bolt Tighten bolts temporarily Finally tighten all bolts to the specified torque Confirm that there is no m...

Page 551: ...A 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 IH...

Page 552: ...g air exhaust port The turbocharger increases air intake efficiency This results in increased engine power reduced fuel consumption and minimal engine noise The turbocharger operates at very high spee...

Page 553: ...on check 1 Remove the hose between the waste gate and the compressor outlet pipe 2 Connect the pressure gauge To waste gate actuator 3 Check to see that the rod begins to move when a pressure of appro...

Page 554: ...to the compressor wheel end and the turbine wheel end Wheel Shaft End Play mm in Standard Limit 0 03 0 06 0 001 0 002 0 09 0 004 150RY00034 Wheel Shaft and Bearing Clearance Use a dial indicator to me...

Page 555: ...EXHAUST SYSTEM 6F 19 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER TOOL NAME 901RX00143 5 8840 0075 0 Pressure Gauge...

Page 556: ...6 1 505 4997 0408 FAX 86 1 505 4350 TLX 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202 Chia Hsin Building No 96 Chung Shan North Road Section 2 Taipei TAIWAN TEL 886 2 542 5520 5521 5523 FAX 886 2...

Page 557: ...ACCELERATOR CONTROL 6H 1 SECTION 6H ACCELERATOR CONTROL TABLE OF CONTENTS PAGE Removal and Installation 6H 2 Removal 6H 6 Inspection 6H 6 Installation 6H 6...

Page 558: ...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: ...ontrol cable should not be bent or kinked The control cable should not be damage or corrosion Installation 1 Install the accelerator control cable to accelerator control pedal dash panel 2 Install the...

Page 563: ...s 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...

Page 564: ...No TF4JE WE 1101...

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