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1A-372 Engine Control System (4HK1)

Repair Instructions

Engine Control Module (ECM)
Replacement

Description

The following A - E steps provide an overview
procedure to replace and reprogram an ECM. Each A -
E steps is explained further in this section.

A-1. Uploading Fuel Injector ID Code (Except Euro
4 Specification)

The current fuel injector ID code data can be uploaded
with a scan tool. If the old ECM cannot be
communicated with a scan tool, go to Retrieving the
Fuel Injector ID Code Data with a Non-communicating
ECM.

1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle

identification > 4HK1 > Programming > Injector ID
Code < Upload ID Code.

4. After compete the uploading, turn OFF the scan

tool.

5. Turn OFF the ignition.

A-2. Recoding Fuel Injector ID Code

Each fuel injector is designated with 24 hexadecimal
characters (0 - 9 or A - F) that MUST be programmed
into the ECM for correct engine fueling for each specific
cylinder. These characters can be retrieved in one of
following places:

Retrieving the Fuel Injector ID Code Data from the
ECM

The current fuel injector ID code data can be
determined with a scan tool. If the ECM does not
communicate with a scan tool, go to the next
procedure.

1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle

identification > 4HK1 > Additional Functions >
Display Injector Codes.

4. Record 24 digits of each fuel injector ID code.
5. After complete the recording, turn OFF the scan

tool.

6. Turn OFF the ignition.

Retrieving the Fuel Injector ID Code Data with a
Non-communicating ECM

If a scan tool does not communicate, the fuel injector ID
codes must be recorded from the factory affixed label
on the cylinder head cover or each fuel injector ID
plate.

Recording from the label on cylinder head cover
Notice:

Only perform this procedure if the fuel injectors

are not being replaced in the past.

1. Record all numbers of each cylinder on the label.

Legend

1. Cylinder #1 fuel injector ID code
2. Cylinder #2 fuel injector ID code
3. Cylinder #3 fuel injector ID code
4. Cylinder #4 fuel injector ID code
5. Injector ID code label

A-1. Upload the fuel injector ID codes from the old

ECM (Except Euro 4 specification).

A-2. Record the fuel injector ID codes manually from

the old ECM.

B.

Replace the old ECM with the new ECM.

C.

Program the latest software and calibrations
into the new ECM using the Service
Programming System (SPS).

D-1. Program the uploaded fuel injector ID codes

and program the vehicle identification number
(VIN) into the ECM (Except Euro 4
specification).

D-2. Program the recorded fuel injector ID codes

and the VIN into the ECM using a scan tool
programming function.

E.

Perform the fuel supply pump relearn
procedure by allowing the engine to idle in Park
or Neutral until normal operating temperature is
achieved.

LNW81ASH000101

1
2

3
4

5

4HK1

64
64
64
64

FB
0B

CB

21

00
08

1A

17

00
10
00
16

0A
2B
2F
2B

00
28

3C
3A

04

1E

29

2D

F4
26

3D
4A

F0
17
FF
14

00
16
27
25

01
31

5A

65

94

7C

F0
66

SAMPLE

LG4HKED-WE-0871.book 372

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２００７年１１月２９日　木曜日　午後６時２９分

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Содержание 2008MY N Series

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

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

Страница 3: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 100: ...Go to Step 3 3 1 Turn OFF the ignition 2 Disconnect the MAF sensor harness connector 3 Inspect for an intermittent for poor connections and corrosion at the harness connector of the MAF sensor pins 1...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 403: ......

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

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