4JVP44 We 0112 PDF

WORKSHOP MANUAL
TF SERIES, NKR
ENGINE DRIVEABILITY AND EMISSIONS

ENGINE with TF 4JA1-TC/TF 4JH1-TC/
NKR 4JH1-TC Bosch VP44 System
SECTION 6E
NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section - 0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model : TFR/S 54, TFR/S 77, NKR 77
This manual is applicable to 2001 year model and later vehicles.

INDEX
ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE with TF 4JA1-TC/TF

4JH1-TC/NKR 4JH1-TC Bosch VP44 system
CONTENTS
ISUZU Strategy Based Diagnostics .............. 6E-4 TF 4JA1-TC/4JH1-TC TDC Sensor

Overview .................................................... 6E-4 Location ................................................... 6E-25
STRATEGY BASED DIAGNOSTICS TF 4JA1-TC, 4JH1-TC with Bosch VP44
CHART .................................................... 6E-4 System Component Locator .................... 6E-26
Diagnostic Thought Process ...................... 6E-5 TF 4JH1-TC with Bosch VP44
1. Verify the Complaint .............................. 6E-5 System Component Locator .................... 6E-27
2. Perform Preliminary Checks .................. 6E-5 TF 4JH1-TC with Bosch VP44
3. Check Bulletins and Troubleshooting System Component Locator .................... 6E-28
Hints ........................................................ 6E-6 N*R 4JH1-TC with Bosch VP44
4. Perform Service Manual Diagnostic System Component Locator .................... 6E-29
Checks ..................................................... 6E-6 N*R 4JH1-TC with Bosch System
5a and 5b. Perform Service Manual Component Locator ................................. 6E-30
Diagnostic Procedures ............................ 6E-6 N*R 4JH1-TC with Bosch System
5c. Technician Self Diagnoses .................. 6E-6 Component Locator ................................. 6E-31
5d. Intermittent Diagnosis .......................... 6E-7 N*R 4JH1-TC with Bosch VP44
System Component Locator .................... 6E-32
5e. Vehicle Operates as Designed ............ 6E-8
N*R 4JH1-TC with Bosch VP44
6. Re-examine the complaint ..................... 6E-9
7. Repair and Verify Fix ............................. 6E-9
NKR 4JH1-TC with Bosch VP44
Specification difference ............................. 6E-10
TF 4JA1-TC with Bosch VP44
TF 4JA1-TC Fuse Box ............................... 6E-35
System ECM Wiring Scheme
TF 4JH1-TC Fuse Box ............................... 6E-36
(Manual Transmission) ............................ 6E-11
N*R 4JH1-TC Fuse Box ............................. 6E-37
TF 4JH1-TC with Bosch VP44
System ECM Wiring Scheme N*R 4JH1-TC Fuse and Relay Panel ........ 6E-38
(Automatic Transmission) ........................ 6E-12 N*R 4JH1-TC Relay Panel ........................ 6E-39
TF 4JH1-TC with Bosch VP44 Abbreviations Charts ................................. 6E-40
System ECM Wiring Scheme Injection pump Control System .................. 6E-41
(Manual Transmission) ............................ 6E-13 TDC Sensor ............................................... 6E-42
N*R 4JH1-TC with Bosch VP44 Engine Coolant Temperature (ECT)
System ECM Wiring Diagram .................. 6E-14 Sensor ..................................................... 6E-42
TF 4JA1-TC/4JH1-TC ECM Pinouts .......... 6E-15 Vehicle Speed Sensor (VSS) ..................... 6E-42
N*R 4JH1-TC ECM Pinouts ....................... 6E-18 TDC (Engine Speed) Sensor ..................... 6E-42
NKR (4JH1-TC) TF (4JA1-TC, 4JH1-TC) ECM System Diagram – No.1 .................... 6E-43
PCU Pinouts ............................................ 6E-21 ECM System Diagram – No.2 .................... 6E-44
TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC, MAF/IAT Sensor Circuit ............................. 6E-45
Specifications ................................................ 6E-22 ECM System Diagram – No.3 .................... 6E-46
Tightening Specifications ........................... 6E-22 ECM System Diagram – No.4 .................... 6E-47
TF 4JA1-TC with Bosch VP44 ECM System Diagram – No.5 .................... 6E-48
System Component Locator .................... 6E-23 General Service Information ...................... 6E-49
TF 4JA1-TC with Bosch VP44 Serviceability Issues .................................. 6E-49
Non-OEM Parts ......................................... 6E-49
6E–2 ENGINE DRIVEABILITY AND EMISSIONS
Poor Vehicle Maintenance ......................... 6E-49 Check ...................................................... 6E-84
Related System Faults ............................... 6E-49 No Check Engine Lamp ............................. 6E-85
On-Board Diagnostic (OBD) ...................... 6E-49 Diagnostic Aids .......................................... 6E-85
On-Board Diagnostic Test Description ......................................... 6E-85
(Self Diagnosis System) Tests ................ 6E-49 No Check Engine Lamp ............................. 6E-86
The Diagnostic Executive .......................... 6E-49 Check Engine Lamp “ON” Steady ............. 6E-88
Diagnostic Information ............................... 6E-49 Circuit description ...................................... 6E-88
Check Engine Lamp .................................. 6E-49 Diagnostic Aids .......................................... 6E-88
Data Link Connector (DLC) ....................... 6E-49 Test Description ......................................... 6E-88
Reading Flash Diagnostic Trouble Codes . 6E-51 Check Engine Lamp “ON” Steady ............. 6E-89
Reading Diagnostic Trouble Codes Using DTC P0100
a TECH 2 ................................................. 6E-51 MAF SENSOR MALFUNCTION .............. 6E-90
Clearing Diagnostic Trouble Codes ........... 6E-51 DTC P0110
History DTC ............................................... 6E-51 IAT Sensor Maifunction ........................... 6E-98
Tech2 ........................................................ 6E-52 DTC P0115
Tech2 Features ......................................... 6E-52 Engine Coolant Temperature
Getting Started .......................................... 6E-53 Sensor Malfunction .................................. 6E-102
Operating Procedure (For Example) ......... 6E-53 DTC P0180 SUB CODE 1011
DTC ........................................................... 6E-54 FUEL TEMPARETURE SENSOR
CIRCUIT RANGE/PERFORMANCE ....... 6E-106
DTC Information Mode .............................. 6E-54
DTC P0215
Engine ....................................................... 6E-54
FUEL CUTOFF SOLENOID
History ....................................................... 6E-54
VALVE MALFUNCTION .......................... 6E-108
Clear DTC Information ............................... 6E-54
DTC P0216
Tech2 Data Display ................................... 6E-54 TIMING DEVICE DEVIATION ................. 6E-114
Plotting Snapshot Graph ........................... 6E-55 DTC P0216
Plotting Graph Flow Chart TIMING DEVICE FLUCTUATION ............ 6E-115
(Plotting graph after obtaining DTC P0251
vehicle information) ................................. 6E-56 INJECTION MALFUNCTION ................... 6E-116
Flow Chart for Snapshot Replay DTC P0335
(Plotting Graph) ....................................... 6E-57 TDC MALFUNCTION .............................. 6E-119
How To Use Breaker Box .......................... 6E-58 DTC P0380
Breaker Box Connection Type A for Open GLOW DEVICE MALFUNCTION ............ 6E-126
Circuit Check, Short to Ground Check DTC P0381
and Short to Battery Check ..................... 6E-59 GLOW TIME TELLTALE
Breaker Box Connection Type B for Power, CIRCUIT MALFUNCTION ....................... 6E-131
Signal Voltage Check between ECM DTC P0400
and Sensors ............................................ 6E-60 EGR SYSTEM MALFUNCTION .............. 6E-134
How To Use TIS2000 Snapshot Analysis .. 6E-61 DTC P0500
Snapshot Display ....................................... 6E-61 VSS MALFUNCTION ............................... 6E-141
Typical Scan Data Values ......................... 6E-65 DTC P0560
TF 4JA1-TC .......................................... 6E-65 SYSTEM VOLTAGE MALFUNCTION ..... 6E-144
TF 4JH1-TC (MT) ................................. 6E-66 Circuit Description ...................................... 6E-144
TF 4JH1-TC (AT) .................................. 6E-67 DTC P0561
NKR 4JH1-TC ....................................... 6E-68 SWITCHED SYSTEM VOLTAGE
Engine Data Definitions ............................. 6E-70 (IGNITION ON) CIRCUIT MALFUNCTION 6E-148
On-Board Diagnostic (OBD) System DTC P0606
Check ...................................................... 6E-83 ECM Malfunction1 ................................... 6E-150
Circuit Description ..................................... 6E-83 DTC P0606
Diagnostic Aids .......................................... 6E-83 ECM Malfunction2 ................................... 6E-150
Test Description ......................................... 6E-83 DTC P0645
On Board Diagnostic (OBD) System A/C COMPRESSOR CUTOFF
RELAY MALFUNCTION .......................... 6E-151 DTC P1651
DTC P0703 INJECTION PUMP:
BRAKE-LIGHT SWITCH CIRCUIT CAN MALFUNCTION .............................. 6E-192
MAIFUNCTION ........................................ 6E-157 DTC P1651 SUB CODE 1010
DTC P0704 INJECTION PUMP:
CLUTCH SWITCH INPUT CIRCUIT CAN MALFUNCTION .............................. 6E-192
MALFUNCTION ....................................... 6E-160 DTC P1651 SUB CODE 1011
DTC P1105 CAN RECEIVEDS ERROR ..................... 6E-194
BAROMETRIC PRESSURE SENSOR DTC P1690
(BP) MALFUNCTION .............................. 6E-162 MALFUNCTION INDICATION LAMP
DTC P1110 (MIL) CIRCUIT MALFUNCTION .............. 6E-195
INTAKE SHUTTER VSV (DIESEL)
MALFUNCTION (NKR 4JH1-TC only) ..... 6E-163 Symptom chart & perform procedure ....... 6E-198
DTC P1120 1-1. No cranking happens. ......................... 6E-199
AP SENSOR MAIFUNCTION .................. 6E-167
1-2. Starter can crank engine,
DTC P1173 but seems to be lower than usual. ........... 6E-199
FUEL REDUCTION CAUSED BY
1-3. Cranking speed seems to be OK,
HIGH COOLANT TEMPERATURE ......... 6E-173
but no combustion sounds can be heard. 6E-200
Fuel Reduction adjustment ........................ 6E-173
1-4. Engine run as idle speed,
NKR 4JH1-TC ............................................ 6E-173 but can not raise engine speed to
TF 4JH1-TC, 4JH1-TC .............................. 6E-173 usual engine speed zone. ........................ 6E-203
DTC P1173 1-5. Engine stall after engine speed reach
FUEL REDUCTION CAUSED BY more than 2000 rpm. ............................... 6E-206
HIGH FUEL TEMPERATURE 1 .............. 6E-175 2. Engine stall ............................................ 6E-208
DTC P1173 2-1 Engine stall at idling. ............................ 6E-208
FUEL REDUCTION CAUSED BY
2-2 Engine stall after engine revolution
HIGH FUEL TEMPERATURE 2 .............. 6E-175
becomes more than idling speed.
DTC P1345 Undershoot stall. ...................................... 6E-212
INJECTION PUMP:CAMSHAFT
3. Rough idle .............................................. 6E-214
SPEED MALFUNCTION ......................... 6E-176
4. Excessive white smoke. ......................... 6E-217
DTC P1520
5. Excessive black smoke .......................... 6E-223
NEUTRAL SWITCH ................................. 6E-177
6. Hesitation 7. Surge/Sag ...................... 6E-227
DTC P1576
EXHAUST BRAKE VALVE1 8. Lack of power ........................................ 6E-233
CIRCUIT MALFUNCTION ....................... 6E-180 9. Poor fuel consumption ........................... 6E-236
DTC P1605 SPECIAL SERVICE TOOLS ...................... 6E-240
EEPROM DEFECT .................................. 6E-186
DTC P1610
SEEDS AND KEY FILE DESTROYED .... 6E-187
DTC P1611
WRONG SECURITY CODE ENTERED .. 6E-187
DTC P1612/P1613
IMMOBILIZER NO OR WRONG
SIGNAL ................................................... 6E-187
DTC P1614
Wrong transponder key ........................... 6E-187
DTC P1625
Power supply relay malfunction ............... 6E-188
DTC P1630
FUEL-INJECTION QUANTITY
CIRCUIT MALFUNCTION ....................... 6E-189
DTC P1650
CAN: DEVICE MALFUNCTION ............... 6E-190
ISUZU Strategy Based Diagnostics
Overview You have maximum efficiency in diagnosis when you

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

• Vehicle road tests
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use • Complaint check sheet
the diagnostic thought process. This method of thinking • Contact with the customer
optimizes your diagnosis in the following ways:
• Improves your understanding and definition of the 2. Perform Preliminary Checks
customer complaint
NOTE: An estimated 10 percent of successful vehicle
• Saves time by avoiding testing and/or replacing good repairs are diagnosed with this step!
parts
• Allows you to look at the problem from different What you should do
perspectives
You perform preliminary checks for several reasons:
• Guides you to determine what level of understanding
about system operation is needed: • To detect if the cause of the complaint is VISUALLY
OBVIOUS
– Owner’s manual level
• To identify parts of the system that work correctly
– Service manual level
• To accumulate enough data to correctly and
– In-depth (engineering) level
accurately search for a ISUZU Service Bulletin on
– Owner’s manual level ISUZU Web site. http://www.isuzu.co.jp/IDoc/ISB/
– Service manual level 2000/
– In-depth (engineering) level The initial checks may vary depending on the
complexity of the system and may include the following
actions:
1. Verify the Complaint • Operate the suspect system
What you should do • Make a visual inspection of harness routing and
accessible/visible power and ground circuits
To verify the customer complaint, you need to know the • Check for blown fuses
correct (normal) operating behavior of the system and
• Make a visual inspection for separated connectors
verify that the customer complaint is a valid failure of the
system. • Make a visual inspection of connectors (includes
The following information will help you verify the checking terminals for damage and tightness)
complaint: • Check for any DTCs stored by the on-board
• WHAT the vehicle model/options are computers
• WHAT aftermarket and dealer-installed accessories • Sense unusual noises, smells, vibrations or
exist movements
• WHAT related system(s) operate properly • Investigate the vehicle service history (call other
• WHEN the problem occurs dealerships, if appropriate)
• WHERE the problem occurs What resources you should use
• HOW the problem occurs
Whenever appropriate, you should use the following
• HOW LONG the condition has existed (and if the
resources for assistance in performing preliminary
system ever worked correctly)
checks:
• HOW OFTEN the problem occurs
• Tech II or other technical equipment for viewing DTCs
• Whether the severity of the problem has increased,
• Service manual information:
decreased or stayed the same
– Component locations
What resources you should use – Harness routing
Whenever possible, you should use the following – Wiring schematics
resources to assist you in verifying the complaint: – Procedures for viewing DTCs
• Service manual Theory or Circuit Description • Dealership service history file
sections • Vehicle road test
• Service manual “System Performance Check” • Identical vehicle or system for comparison
• Owner manual operational description
• Technician experience
• Identical vehicle for comparison
3. Check Bulletins and steps of diagnostic procedures to locate the fault related
to the customer complaint.
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle What resources you should use
repairs are diagnosed with this step! Whenever appropriate, you should use the following
resources to perform service manual diagnostic
What you should do procedures:
You should have enough information gained from • Service manual
preliminary checks to accurately search for a bulletin • Technical equipment (for analyzing diagnostic data)
and other related service information. Some service • Digital multimeter and circuit testing tools
manual sections provide troubleshooting hints that
match symptoms with specific complaints. • Essential and special tools
What resources you should use 5c. Technician Self Diagnoses

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

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

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

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

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

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

Whenever possible, you should use the following
resources to facilitate the repair process:
• Electrical repair procedures
• Service manual information and publications
Specification difference
Vehicle Model TF NKR
Engine 4JA1-TC 4JH1-TC 4JH1-TC
Engine desplacemert 2.5L 3.0L 3.0L
Intake shutter N/A N/A standard
Exhaust Brake N/A N/A standard
Idle 730rpm± 700rpm± 700rpm±
25rpm 25rpm 25rpm
at 80°C MT, AT at 80°C
at 80°C
Transmission MT MT AT MT
Immobilizer standard standard standard not available
EGR EGR with EGR cooler no EGR no EGR EGR with
EGR cooler
Catalitic Floor type catatic converter not available not available assembled in silencer
converter
QWS option not available not available EC HK Taiwan
stand- not not
ard available available
ABS not available not available not available EC HK Taiwan
option not not
available available
TF 4JA1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission)
BATT
RELAY ; ECM MAIN
PA01
8B/R
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
IC03
2B/Y
IC01
2L/R
A41(3)
A63(63) IC05
MAIN
IG.1
50A
80A
0.5Y A-2
ECM
0.5L/B
25A
2 B24(100) A56(58)
IC31 IC04 VSV ; EXT 1
INJ.PUMP
0.5R A-3
3 B23(99)
GLOW
PA28
50A
40A
IG2
IC32 0.5W/B 0.5L/R
8W
PA28
A37(40)
3B
0.5O A-4 IC22 IC17
4 B29(105)
IC33 VSV ; EXT 2
0.5P A-5
1 B13(91) 0.5W/R 0.5L/R
IC34 A59(61)
0.5L/R
J/C ; B
IZ03
IC23 IC18
HB01
5R/W
3W/B B1
PA02
PA03
PA13
PA16
0.5
IC11
3W B2
3W
3W
EVRV ; EGR
0.5B/O 0.5L/R
SW ;IGNITION
B19(97)
IZ04
0.5
IC26 IC16
ACG(B)
STOP
10A
EB
B2(83) 0.5W/R IC27
4
OFF
0.5G/R IC28 0.5L/R
ACC
B7(88)
MAF
5 2
(THROTTLE VALVE)
IG1 3B/R
IG2
ST
0.5B/R IC30 IC15
T.P.S.&SW ; IDLE
0.5G/B A-6 B14(92) 3

A69(69) B3(84) 0.5B/L IC39
SW ; THERMO
IC35 1
0.5R/G A-7
RELAY ;
A47(49)
GLOW
SW ; ENG WARMING
IC36
CA01
JOINT 0.5B 0.5G/R
PA17
JOINT
3B/R
0.5G
0.5G/O A-8 TO MX01 BX16 BA26 TO BA15
A35(38)
IC37 0.5BR/R
A44(46)
ENGINE
IC14
METER
0.5B/G A-9
BACK
A55(57)
10A
15A
15A
IC38 0.5B JOINT
HY05 TO SX01
0.5B/L HB06
IZ07
IZ06
B16(94)
0.5L/Y IC06
0.85W
MA01
0.85Y
KA01
A36(39)
SW ; BRAKE
0.5R IC12
A27(30)
(ON)
0.5B/R
0.5W/B IC13
IC50
0.5B/P B-7
ECT sensor
B15(93) A65(65)
IC43 RESISTER ; CLUTCH SW (OFF)
(YZK NO ; 7321-9900)
0.5B 0.5Y SW ; CLUTCH
0.5GR B-1
B8(89) IZ08 510 IC57 0.5G
IC44 A28(31)
0.5Y IC08 (OFF) IC07
CA02
0.5G
0.5R
IC48
GLOW PULG x4
1 0.5W B-2
B22(98) A-16 5B/R
IC45
TDC
3 HB03
2 0.5G/R B-3
B12(90) FUEL
IC46
HEATER
B-10 SW ; NEUTRAL 0.5B
IZ05 0.5B/W B-10 0.5L/R
B25(101) B6(87) IZ05
IC10 IC09
SW ; BACK UP
0.5B/W
RESISTER ; NEUTRAL SW
IC58
A-1 0.85Y
KA01
B-11 0.85R/Y
(IDLE SW)
KA02
2B A-11 0.85Y
A61(2)
IZ01 MA02
VEHICLE SPEED
SENSOR A-12 0.5L/B
0.5B
IZ10
2B 0.85B
A62(1) MX05 MA03 METER
IZ02
THERMO UNIT ENG COOLANT
B-14 0.5Y/B B6
CONT ; 0.5R/L MA06
IMMOBILIZER(B8) A32(35)
MB11 OIL PSESSURE UNIT OIL GAGE
0.5Y/G
MA09
4WD
0.5B 4WD SW B-6 0.5W/R B15
ECM IZ06 MA11
SW ; OIL
OIL
B-5 0.5L A10
MA10
GLOW
0.5O/L B8 B2
BACK UP LAMP
A40(43)
BRAKE LAMP
MA28
CHECK ENG
CONT ; IMMOBILIZER(B5)
0.5BR/Y A6
A39(42)
IC29
TACHO METER
0.5B/R B3
A24(27)
JOINT TO EX12
MA05
0.5O/L
MB01
SPEED METER
0.5L/W A8 A9
A68(68)
IC21 RELAY ; A/C COMPRESSOR
; ENG.HARN.-ENGROOM HARN.
; ENGINE
CONNECTION
0.5BR/W HA20 1 0.5BR HA19

A38(41) CONT ; IMMOBILIZER(B1)
B-5 0.5G 4 2 0.5BR HA17
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
HA18
0.5O/B
0.5B/L
MB04
EX02
MAG.CLUTCH
(COMPRESSOR)
0.5B
EX03 0.5G 0.5BR
HA22 HA23
0.5L
A43(45) 0.5G/R 1 0.5L/W HA14
IC47 ELEC.THERMO FUSE ; BLOOR
HA13 4 2 0.5G/W HA16
0.5G HA21
A30(33)
RESISTER ; IDLE UP
0.5B 0.5G
HX03 270 HA24 RELAY ; A/C THERMO 0.5G
SW ; PRESSURE IC30
ECM
REV
060RY00393
TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Automatic Transmission)
RELAY ; ECM MAIN
BATT
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
PA01
8B/R
IC03
2B/Y
IC01
0.5L/R
IC62
0.5L/R IC11
0.5L/W HB04
2L/R IC05 0.5L/R HA15
A63(63)
MAIN
A41(3)
IG.1
50A
80A
0.5L/R IC15
ECM
0.5Y A-2
25A
2 B24(100) 0.5L/B IC04 0.5L/R HA19
IC31 A56(58)
INJ.PUMP
0.5R A-3 0.5W/R IC27

3 B23(99)
GLOW
B2(83)
PA28
4
50A
40A
PA28
IG2
IC32
8W
3B
0.5G/R IC28 0.5L/R
0.5O A-4 B7(88) 5 2
4 B29(105) 0.5B/R IC30 IC15
IC33 B14(92) 3 MAF
0.5P A-5 0.5B/L IC39
1 B13(91) B3(84) 1
IC34
0.5L/R
0.5BR
0.5BR
J/C ; B
HA19
HA15
HB01
5R/W
3W/B
PA02
PA03
PA13
PA16
IZ03
IC11
RELAY ;
0.5
3W
3W
3W
A/C COMPRESSOR
SW ;IGNITION
B1
B2
0.5BR/W HA20 1
A38(41)
ACG(B)
STOP
0.5L/W
B-1 0.5G 4 2 0.5BR FUSE ;
10A
HB04
EB
HA18 HA17 A/C
OFF
MAG.CLUTCH
ACC
IG1 3B/R
IG2
ST
(COMPRESSOR)
SW ; THERMO
0.5B 0.5G RELAY ;
RELAY ;
GLOW
A/C THERMO
HX22 HA23
CA01
PA17
3B/R
0.5G
1 0.5L/W
ELEC.THERMO 0.5G/R FUSE ;
HA13 4 2 HA14 BLOOR
0.5B/P B-5 0.5G HA21
ECT sensor
B15(93) A30(33)
IC43 0.5G/W HA16
ENGINE
RESISTER ; IDLE UP
METER
BACK
10A
15A
15A
(YZK NO ; 7321-9430)
0.5O B-6 0.5B 0.5G
B8(89) HX03 HA24
IC44
270
0.5B/L HB06
B16(94)
0.85W
MA01
0.85Y
KA01
0.5L/Y IC06
1 0.5W A-7 A36(39)
B22(98) SW ; BRAKE
IC45
TDC
3 0.5R
A27(30)
IC12 (ON)
2 0.5G/R A-8
B12(90) A65(65) 0.5W/B
IC46 IC13 (OFF)
A-9
IZ05
B25(101)
GLOW PULG x4
A-16 5B/R
HB03
CA02
0.5G
0.5R
IC48
IZ04
0.5 B
B6(87) 0.5R/B
IC60 0.5R/B
E
IC61
P C-15 0.5R/G
10
(THROTTLE VALVE)
OA10
T.P.S.&SW ; IDLE
F 0.5G/B R A-10 0.85R/Y 0.5R/Y

A69(69) 11
IC35 KA02 OA11
A 0.5R/G N C-10 0.5W/R 0.5W/R
A47(49) 31
IC36 OA57 OA31
C-3 0.5Y/R TCM
C D 32
0.5G/O
A35(38) OA32
IC37 C-4 0.5Y/L
2 47
B 0.5B/G OA58
IC38 A55(57) 1 C-2 0.5Y/V 48
OA59
IZ07
B N B-4 0.5B/W
FUSE ; STARTER
LA06
ECM C-14 0.5B/G
RELAY ; STARTER
LA09
A-1
2B
A61(2)
IZ01 SW ; MODE A-11 0.85Y
MA02
VEHICLE SPEED
2B SENSOR
A62(1) 0.85B A-12 0.5L/B
IZ02
0.85R/Y
MX05 MA03
KA02

CONT ; 0.5R/L B-3 0.5Y/B B6
MB11 MA06
OIL PSESSURE UNIT OIL GAGE
0.5Y/G
MA09
4WD
0.5B 4WD SW B-2 0.5W/R B15
IZ06 MA11(W/SOF)
SW ; OIL TB07(W/O SOF)
OIL
JOINT TO EX12
A-6 0.5L A10

MA10
GLOW
0.5O/L B8 B2
A40(43)
MA18
CHECK ENG
BACK UP LAMP
; ENGINE
0.5BR/R A6
CONNECTION
A39(42)
BRAKE LAMP
IC29
TACHO METER
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
0.5O/B
0.5B/R B3
0.5B/L
MB04
EX02
A24(27)
MA05
OA25
0.5B SPEED METER

EX03 0.5L/W A8 A9
A68(68)
IC21 25
0.5L 37 5 OA05
A43(45) 0.5R/Y
IC47 A46(48) METER
OA60
0.5B/R 6
A26(28) TCM 0.5O/L
OA06 CONT ; IMMOBILIZER(B1)
MB01
ENG 0.5B
EARTH OX01
0.5G
IC48
060RY00394
TF 4JH1-TC with Bosch VP44 System ECM Wiring Scheme (Manual Transmission)
RELAY ; ECM MAIN
BATT
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
IC03
PA01
8B/R
2B/Y
IC01
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
MAIN
2L/R
IG.1
50A
80A
2L/R
ECM
25A
A41(63) A41(3) IC05 0.5L/R IC15
IC05
0.5Y A-2 2L/B 0.5L/R HA19
2 B24(100) A56(58)
IC31 IC04
GLOW
PA28
50A
40A
PA28
IG2
INJ.PUMP
8W
0.5R A-3
3B
3 B23(99) B2(83) 0.5W/R IC27
IC32 4
0.5G/R IC28 0.5L/R
0.5O A-4 B7(88) 5 2
4 B29(105) 0.5B/R IC30 IC15
IC33 B14(92) 3 MAF
0.5P A-5 0.5B/L IC39
1 B13(91) B3(84) 1
J/C ; B
IC34
0.5L/R
0.5L/R
HA15
HB01
5R/W
3W/B
PA02
PA03
PA13
PA16
IC11
IZ03
3W
3W
3W
RELAY ;
0.5
A/C COMPRESSOR
SW ;IGNITION
B1
B2
0.5BR/W HA20 1
A38(41)
ACG(B)
STOP
B-1 0.5G 4 2 0.5BR
0.5L/R
FUSE ;
10A
HB04
B-5
EB
0.5B/P
ECT sensor
B15(93) HA18 HA17 A/C

IC43
OFF
MAG.CLUTCH
ACC
IG1 3B/R
IG2
ST
(COMPRESSOR)
0.5O B-6
B8(89)
IC44
SW ; THERMO
0.5B 0.5G
RELAY ;
RELAY ;
HX22 HA23
GLOW
A/C THERMO
CA01
PA17
3B/R
0.5G
0.5G/R 1 0.5L/W FUSE ;
0.5W A-7 ELEC.THERMO
1 HA13 0.5G BLOOR
B22(98) 4 2 HA14
ENGINE
METER
IC45 A30(33)
BACK
TDC
3 HA21 0.5G/W HA16
10A
15A
15A
2 0.5G/R A-8 RESISTER ; IDLE UP
B12(90) 0.5B 0.5G
IC46
A-9 HX03 HA24
0.5B/L 270
IZ05
0.85W
B16(94)
MA01
0.85Y
KA01
B25(101) HB06
SW ; NEWTRAL 0.5L/Y
A36(39)
0.5L/R 0.5B/W A-9 IC06 SW ; BRAKE
IC09 IC10
A27(30) 0.5R
IC12 (ON)
0.5W/B
A65(65)
IC13 (OFF)
RESISTER ; NEWTRAL SW RESISTER ; CLUTCH SW
0.5B 0.5B/W (YZK NO ; 7321-9900)
IZ10 IC58 0.5B 0.5Y SW ; CLUTCH
270 IZ08 IC57
IZ04
0.5 B
510 0.5G
(IDLE SW) A28(31)
CA02
0.5G
0.5R
IC48
E
GLOW PULG x4
(THROTTLE VALVE)
T.P.S.&SW ; IDLE
F 0.5G/B
A69(69) A-16 5B/R
IC35
A 0.5R/G HB03
A47(49)
IC36
C 0.5G/O
A35(38)
IC37 SW ; BACK UP
B A-1 0.85Y
0.5B/G
IC38 A55(57) KA01
A-10 0.85R/Y
IZ07
KA02
ECM A-11 0.85Y
MA02
VEHICLE SPEED
2B SENSOR
A61(2) 0.85B A-12 0.5L/B
IZ01
MX05 MA03
2B B-3 0.5Y/B B6
A62(1)
IZ02 MA06
CONT ; 0.5R/L 0.5Y/G
IMMOBILIZER(B8) A32(35) MA09
MB11
4WD
0.5B 4WD SW B-2 0.5W/R B15
IZ06 MA11(W/SOF)

OIL
A-6 0.5L A10
MA10
JOINT TO EX12
GLOW
0.5O/L B8 B2
A40(43)
MA18
CHECK ENG
0.5BR/R A6
A39(42)
BACK UP LAMP
; ENGINE
IC29
CONNECTION
BRAKE LAMP
TACHO METER
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
0.5B/R B3
A24(27)
0.5O/B
0.5B/L
MB04
EX02
MA05
SPEED METER
0.5B
0.5L/W A8 A9
EX03 A68(68)
IC21
0.5L
A43(45) METER
IC47
0.5O/L
MB01
0.5G
IC48
060RY00363
060RY00329
0.5W
5B/L IC60 5B/Y
HB01 1.25L/R HB02
GLOW
60A STOP LAMP HB03
0.5G
TO CONT UNIT ; ABS
BB09
TO RELAY ; CHARGE (STOP
SIGNAL )
LAMP
CONT UNIT ; ENGINE RELAY ;
G/PULG
RELAY ; ECU
#20
MAIN ECU 1.25B/Y 0.5L/B A-56 MAIN RELAY GLOW RELAY B-16 0.5B/R
80A 25A (58) (94) GLOW PULG
IC05 IC03 HB04
RESISTER ;
5W 3B/Y (4 x4)
PA07 2L/R A-41 BAT(+)
GENERATOR
FTX
IDLE SW
IC01 (3) ACCEL SENSOR A-55 0.5R/G 3 TPS
IC02
(510 )
2L
N*R 4JH1-TC with Bosch VP44 System ECM Wiring Diagram
(+5V)(57) IC42
TURN
ACCEL SENSOR A-35 0.5G/O 2

10A
15A
#19
#18
SW ; (SIG.)(38) IC43
0.85W STOP LAMP 0.5W A-36 IG
0.5G/B
IC62
PA10 IC04 (39) A-47 1
(BRAKE PEDAL ; ON) ACCEL SENSOR 0.5B/G
LEVELINGA
TO SW ; BACK UP LAMP
BATT 0.5G/Y (GND.)(49) IC44

0.5G 0.5G A-27 BARAKE ON SW ; IDEL
CA01 CA02 IC10 (30)
#17 ACCEL SENSOR A-69 0.5G/B
10A
#15
H/L
STOP LAMP 1.25L/R 0.5L/R 0.5W/B A-65 BARAKE OFF (IDEL)(69) IC45
10A IC59 IC09 IC11 (65)
KEY SW
J/C
(BRAKE PEDAL ; OFF) GND. A-61 2B

0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
OFF (2) JOINT

IZ02
GAUGE,
BACK
KEY SW ACC SW ; CLUTCH A-62

10A
2B 0.5B
#12
50A B GND.
ON (CLUTCH PEDAL ; OFF) 0.5Y A-28 CLUTCH (1) IZ01 IZ11
(31) METER
IZ03
IC12 THERMO UNIT
5B
ST
TO RELAY ; CORNEING
(WATER TEMP)
WASHER
SW ; EXH.BRAKE THERMO
WIPER,
FRAME D-4 0.5Y/B

0.5LG/L A-64 SW;EXH.BRAKE
15A
MA08
#11
IC13 (64) EARTH POINT

EXH.BRAKE 14V, METER IND TACHO
0.5LG/L 2.0W 0.5G/R A-58 (EXH.BRAKE) ENG.SPEED A-24 B-8 B-9
0.5LG 0.3V
IC14 IC64 (60)(KEY ON;ENABLE) (OUTPUT-1) VEHICLE
CHECK ENG. 14V, (27) MA07 MX04

METER IND SPEED
0.5B/Y 1.4W 0.5G/Y A-39 0.5B/Y
(CHECK ENG.) +
MA01 IC17 (42) SPEED MA32
SW ;
TO RELAY ; TAIL
GLOW 14V,
AIR CON
RELAY ; ENG.WARM 1.4W 0.5O/L A-40 METER IND

RELAY ; B-9 0.5Y/G SIG.
TO ELECTRO THERMO
THERMO A/C IC18 (GLOW)

HEATER&A/C 0.5LG/R 0.3B (43) MA33
10A
METER
#2
IC21 IZ09 0.5B

0.5BR 0.85B GND.
0.5BR/R A-44 QWS SW
3L/R IC34
HA09 (46) MX01 MX11
IC19
0.85B
MX06
TO RELAY ; VEHICLE SPEED A-68 0.5Y/G
0.5BR/R A-57 METER IND (68)
CHARGE
#1
HEATER
25A
14V, IC20 (QWS) IC46

60mA (59)(KEY ON;ENABLE)
0.5BR 0.5W/R B-2 MAF +5V
4 (83)
IC65 IC23 WITH ; ABS
TO BLOWER
0.85G/W
MOTOR 0.5L/R MAF 0.5G/R B-7 MAF SIG. CONT.UNIT ; ABS

HA10
2 5 (88)
IC22 IC24
0.5G/O ABS A-60 0.5LG/B 7 EXH.B/CUT
IC48 EVRV ; EGR B-14 MAF GND (OUT) 29 0.3W/B
1 3 0.5B/R (62) BB07 IN
(92) J1850
RELAY ; IC25 BB21
A/C COMP. ABS A-29 0.5LG/W 8 EXH.B/CUT
0.5L/R 0.5L/R 0.5B/O B-19 EGR (IN)
0.5L/R (97) BB06 OUT 4 0.3W/G
PDS IC33 IC26 IC27 (32) FRASH
IC39 MAG.VALVE ; EXH.BRAKE BB20
0.85G/O 0.5B/L B-3 MAT SIG.
(84)
A/C ON SIGNAL
HA11 IC56
MAG.VALVE TDC
0.5B 0.5LG A-37 (EXH.BRAKE)
TDC (+) B-12 0.5R 2
IC15 IC16 (40) (90)
RELAY ;
VSV ; INT.THROTTLE IC49
B-17 INT.SLOTTLE 3
(95) B-22 0.5W IC50 1
TDC (-)
0.5L/R 0.5LG/W B-6 SW;NEUTRAL (98)
(87) IZ10
IC28 IC29 TWIST LINE
TDC B-25 (SHIELD)
0.5Y B-24 INJ.PUMP 0.5B
0.85Y/G
SW ; NEUTRAL
A/C ON SIGNAL(270 )
(SHIELDED)
0.5Y/G
2
HA19
(CAN-H)
0.5B
IZ12
IC47
(NEUTRAL;ON) IC35 (101) IZ07 ALDL
(100) ECT sensor CONNECTOR
2L/R 0.5B/W INJ.PUMP WATER TEMP
0.5R B-23 INJ.PUMP B-8 0.5GR
IC30 IC31 1 (CAN-L) (ECU)
IC36 (89) IC51 16 15 14 13 12 11 10 9
7 (99)
RESISTER ;
RESISTER ;
0.5B/W
0.5O B-29 INJ.PUMP
IC32
NEUTRAL SW GND. B-15 0.5B/P 8 7 6 5 4 3 2 1
5 (MAB)
(510 ) IC37 (93) IC52
6 (105)
0.3B
0.5B
IZ08
IZ04
B-13 INJ.PUMP
2B
IZ06 8 0.5P ISO-K A-32 0.5Y
MAGNET CLUTCH
ZZ06
(DZG)
0.5B
IC38 (35) IC57
(COMPRESSOR) (91)
A-30 A/C SW A-43
DIAG 0.5L
ZZ05
0.5G/Y IC41 FRAME EARTH POINT (33)
0.5B
(45) IC58
6E–14 0.5W/G IC40 A-38 A/C RELAY
(41)
1.25B/Y IC63
TF 4JA1-TC/4JH1-TC ECM Pinouts
43 25 98 105
3
62 44 90 97
1 2
81 63 82 89
060RY00234
Pin No. Connected car component Note

1 Battery minus —
2 Battery minus —
3 Battery plus —
25 No Connect —
26 No Connect —
27 Engine speed output signal —
28 No Connect —
29 Accel position output siganl —
30 Brake switch signal —
31 Clutch switch signal Manual
Transmis-
sion only
32 —
33 Air-conditioning request switch input signal —
34 No Connect —
35 ISO K-line —
36 No Connect —
37 No Connect —
38 Accelerator pedal sensor signal —
39 ignition SW input signal —
40 —
41 Air conditioning cut request switch signal —
42 Check engine lamp —
43 Glow lamp —
44 No Connect —
45 Diag request signal —
46 QWS request switch signal TF 4JA1-
TC only

47 No Connect —
48 Water temperature output signal TF 4JH1
AT only
49 Accelerator pedal sensor qround —
50 No Connect —
51 No Connect —
52 No Connect —
53 No Connect —
54 No Connect —
55 No Connect —
56 No Connect —
57 Accelerator pedal sensor supply —
58 System power relay —
59 —
60 EGR Actuator2 4JA1-TC
only
61 VSV EXH.2 4JA1-TC
only
62 —
63 Vehicle Select Signal —
64 —
65 Redundant Brake switch signal —
66 No Connect —
67 No Connect —
68 Vehicle speed sensor siganl —
69 Lowidle position switch signal —
70 No Connect —
71 No Connect —
72 No Connect —
73 No Connect —
74 No Connect —
75 No Connect —
76 No Connect —
77 No Connect —
78 No Connect —
79 No Connect —
80 No Connect —
81 No Connect —
82 No Connect —
83 MAF Hot-film air mass sensor supply —
84 IAT Air temperature sensor signal —
85 No Connect —
86 No Connect —
87 Neutral switch signal —

88 MAF Hot-film air mass sensor signal —
89 ECT sensor signal —
90 TDC (Engine speed sensor) signal —
91 TDC (Engine speed sensor) output signal —
92 MAF Hot-film air mass sensor ground —
93 Analog common ground (LDF, LTF, WTF) —
94 Glow relay —
95 —
96 No Connect —
97 EVRV:EGR 4JA1-TC
only
98 TDC (Engine speed sensor) ground —
99 CAN1-L (Controller Area Network) —
100 CAN1-H (Controller Area Network) —
101 TDC(Engine speed) sensor, shield connection —
102 No Connect —
103 No Connect —
104 No Connect —
105 Solenoid valve shut-off (MAB) output signal —
N*R 4JH1-TC ECM Pinouts
43 25 98 105
3
62 44 90 97
1 2
81 63 82 89
060RY00234

1 Battery minus —
2 Battery minus —
3 Battery plus —
25 No Connect —
26 No Connect —
27 Engine speed output signal —
28 No Connect —
29 —
30 Brake switch signal —
31 Clutch switch signal —
32 ABS input signal —
33 Air-conditioning request switch input signal —
34 No Connect —
35 ISO K-line —
36 No Connect —
37 No Connect —
38 Accelerator pedal sensor signal —
39 Ignition SW input signal —
40 Exhaust VSV1 —
41 Air conditioning cut request switch signal —
42 Check engine lamp —
43 Glow lamp —
44 No Connect —
45 Diag request signal —
46 QWS request switch signal —

47 No Connect —
48 —
49 Accelerator pedal sensor qround —
50 No Connect —
51 No Connect —
52 No Connect —
53 No Connect —
54 No Connect —
55 No Connect —
56 No Connect —
57 Accelerator pedal sensor supply —
58 System power relay —
59 QWS Lamp —
60 EXH.Brake Lamp —
61 —
62 ABS Out —
63 —
64 EXH.Brake switch signal —
65 Redundant Brake switch signal —
66 No Connect —
67 No Connect —
68 Vehicle speed sensor siganl —
69 Lowidle position switch signal —
70 No Connect —
71 No Connect —
72 No Connect —
73 No Connect —
74 No Connect —
75 No Connect —
76 No Connect —
77 No Connect —
78 No Connect —
79 No Connect —
80 No Connect —
81 No Connect —
82 No Connect —
83 MAF Hot-film air mass sensor supply —
84 IAT Air temperature sensor signal —
85 No Connect —
86 No Connect —
87 Neutral switch signal —
88 MAF Hot-film air mass sensor signal —
89 ECT sensor signal —
90 TDC (Engine speed) sensor signal —

91 TDC (Engine speed) sensor output signal —
92 MAF Hot-film air mass sensor ground —
93 Analog common ground (LDF, LTF, WTF) —
94 Glow relay —
95 Intake VSV —
96 —
97 EGR actuator 1 —
98 Engine speed sensor ground —
99 CAN1-L (Controler Area Network) —
100 CAN1-H (Controler Area Network) —
101 TDC (Engine speed) sensor, shield connection —
102 Needle movement sensor ground —
103 No Connect —
104 No Connect —
105 Solenoid valve shut-off (MAB) output signal —
NKR (4JH1-TC) TF (4JA1-TC, 4JH1-TC) PCU Pinouts
2 4 5 6
3
1 9 8 7

1 CAN1_L (Controler Area Network) —
2 CAN1_H (Controler Area Network) —
3 No connect —
4 No connect —
5 Solenoid valve shut-off (MAB) output —
6 Battery minus —
7 Battery plus —
8 Camsensor output signal —
9 No connect —
TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC, Specifications

Tightening Specifications
Application Location N·m Kg·m
ECM(Engine Control Modul) Bolt On the ECM bracket 8 0.8
CKP(Crankshaft Position) Sensor Bolt Gear case cover 8 0.8
MAF(Mass Air Flow) Sensor Mounted the intake pipe 3 0.3
ECT(Engine Coolant Temperature) Sensor Mounted the thermostat housing 13 1.3
Component Locator
TF 4JA1-TC with Bosch VP44 System Component Locator
2 1 3
Legend (3) Injection pump

(1) Manifold Air Flow (MAF) sensor
(2) Engine Coolant Temperature (ECT) sensor
EndOFCallout
TF 4JA1-TC with Bosch VP44 System Component Locator
4 1 2 3
Legend (3) Fuel Filter

(1) Mass Air Flow (MAF) sensor (4) Inter Cooler
(2) EVRV:EGR
TF 4JA1-TC/4JH1-TC TDC Sensor Location
3 1 2
Legend (3) Wiper Motor

(1) Top Dead Center (TDC) sensor
(2) Inter Cooler
EndOFCallout
TF 4JA1-TC, 4JH1-TC with Bosch VP44 System Component Locator
1 2
Legend (2) SRS Control Module

(1) Engine Control Module
EndOFCallout
TF 4JH1-TC with Bosch VP44 System Component Locator
2 1
Legend
(1) Manifold Air Flow (MAF) Sensor
(2) Engine Coolant Temperature (ECT) Sensor
EndOFCallout
TF 4JH1-TC with Bosch VP44 System Component Locator
2 1 3 4
Legend (3) Fuel Filter

(1) MAF sensor (4) Inter Cooler
(2) ECT sensor
EndOFCallout
N*R 4JH1-TC with Bosch VP44 System Component Locator
4 5 3 2 1
Legend (4) Injection pump

(1) Mass Air Flow (MAF) Sensor (5) EGR Valve
(2) Engine Coolant Temperature (ECT) Sensor
(3) EGR cooler
EndOFCallout
N*R 4JH1-TC with Bosch System Component Locator
2 1
Legend
(1) MAF sensor
(2) Fuel filter/Fuel sedimerter
N*R 4JH1-TC with Bosch System Component Locator
1 2 3 4
Legend (3) TDC sensor

(1) EGR valve (4) Turbo waste gate actuator
(2) EGR cooler
1 2 3
Legend (3) EGR Valve

(1) Intake Shutter VSV
(2) EGR EVRV
EndOFCallout
Legend
(1) Engine Control Module .
NKR 4JH1-TC with Bosch VP44 System Component Locator
Legend
(1) Vehicle Speed sensor
TF 4JA1-TC Fuse Box
40A 30A 40A TAIL

STARTER 10A 10A CHARGE
C IGN. H/LAMP IGN. LH
BAT ALT TAIL RR
CONN B1 WASHER B2 10A 10A
RH FOG
10A ECM 10A A/C

100A
J/C:B J/C:A H/LIGHT
MAIN 10A
LH(LO)
20A BLOWER
30A
H/LIGHT STOP
ECM 10A 10A
RH(LO) LIGHT
STARTER H/LIGHT
A/C A/C 10A 10A HORN
RR FOG ( THERMO ) ( COMP.
) LH(HI)
H/LIGHT
10A 15A HAZARD
ECM RH(HI)
IMMOBILIZER
MAIN
STARTER
DIMMER HEAD TAIL
HORN CUT
LIGHT LIGHT
(DIODE)
CAUTION ( )···IF EQUIPPED. HEATER
· USE SPECIFIED FUSES ONLY
UNSPECIFIED FUSES CAN CAUSE FIRE AND
MALFUNCTION OF EQUIPMENTS.
· SPARE FUSES & PULLER ARE LOCATED AT
FUSE BOX IN THE CABIN. 897300 9020
· DROPPING BRAKE OIL, ETC ON THE COVER,
WIPE WITH A CLOTH.
7154-8127 Y
TF 4JH1-TC Fuse Box
40A 60A 40A

STARTER 10A ECM 10A CHARGE
C BAT IGN. IGN. ALT
GIOW RR
CONN B1 B2 10A
FOG
10A TAIL
100A
J/C:B J/C:A STOP
MAIN 10A
LIGHT
20A BLOWER
H/LIGHT
10A
LH(LO)
STARTER H/LIGHT
A/C A/C 10A 10A HORN
RR FOG ( THERMO ) COMP.
RH(HI)
H/LIGHT
10A 15A HAZARD
ECM LH(HI)
IMMOBILIZER
MAIN
STARTER
HEAD TAIL
HORN CUT
LIGHT LIGHT
(DIODE)
CAUTION ( )···IF EQUIPPED. HEATER
· USE SPECIFIED FUSES ONLY
UNSPECIFIED FUSES CAN CAUSE FIRE AND
MALFUNCTION OF EQUIPMENTS.
· SPARE FUSES & PULLER ARE LOCATED AT
FUSE BOX IN THE CABIN. 897300 9020
· DROPPING BRAKE OIL, ETC ON THE COVER,
WIPE WITH A CLOTH.
7154-8127 Y
ECM
TURN S/LIGHT
GENERATOR
STOP LIGHT
POWER WINDOW
HDLP LEVELING
FUEL HEATER
REAR HEATER
GAVGE, BACK
WATER, WASHER
FOG LIGHT
TAIL LIGHT
HAZARD, HORN
N*R 4JH1-TC Fuse Box
AUDIO, DOOR LOCK
HEAD LIGHT (LH)
HEAD LIGHT (RH)
CIGAR LIGHTER
STARTER
AIR CON
HEATER
25A 10A 15A 10A 25A 10A 15A 15A 10A 15A 10A 15A 15A 15A 10A 10A 15A 10A 10A 25A
6E–37
N*R 4JH1-TC Fuse and Relay Panel
A E B F G H C D
E S/B FUSE;MAIN 80A

NO NAME TYPE
60A
A RELAY;STARTER MRB
F S/B FUSE;KEY 50A
---
50A
B RELAY;GLCN(1) MRB
G S/B FUSE;GLOW 60A
RELAY;GLCN MRB
50A
C RELAY;4WD LND LAMP ISO
H S/B FUSE;ABS IND. 60A
RELAY;REAR FOG ISO
40A
D RELAY;MARKER LAMP ISO
N*R 4JH1-TC Relay Panel
I A B H C G D E F
F RELAY;HDRN ISO
NO NAME TYPE
G RELAY;P/WINDOW ISO
A RELAY;CHG, WARING ISO
H RELAY;ABS IND ISO
B RELAY;LIGHT ISO
RELAY;CORNERING LAMP ISO
C RELAY;HEATER & A/C ISO
I RELAY;BUZZER CANSEL ISO
D RELAY;TALE ISO
RELAY;ECU ISO
E RELAY;Dimmer ISO
Abbreviations Charts
List of abbreviations which may be used in this section.
Abbreviations Term
A/C Air Conditioner
A/T Automatic Transmission
ACC Accessory
AP Accel Position
CKP Crank Shaft Position
CMP Pump Camshaft Position
DLC Data Link Connector
DTC Diagnosis Trouble Code
DVM Digital Volt Meter
ECM Engine Control Module
ECT Engine Coolant Temperature
EGR Exhaust Gas Recirculation
EVRV Electric Vacuum Regulating Valve
EXH Exhaust
FT Fuel Temperature
IAT Intake Air Temperature
IG Ignition
ITP Intake Throttle Position
M/T Manual Transmission
OBD On-Board Diagnostic (Self Diagnosis System)
OT Oil Temperature
SW Switch
TCV Timing Control Valve
TEMP Temperature
TP Throttle Position
VSS Vehicle Speed Sensor
VSV Vacuum Switching Valve
MAB Solenoido Valve Switch Off
PCU Ing. Pump Control Unit
MAF Manifold Air Flow
Injection pump Control System
2
3
1
11 6 5
10
9
8 7
Legend (7) TCV

(1) Cam angle sensor (8) Timer
(2) Pump control unit (PCU) (9) Radial pluger high pressure pump
(3) Distributor head (10) Feed pump
(4) High pressure solenoid valve (11) Drive shaft
(5) Delivery holder
(6) CPV
TDC Sensor
The TDC Sensor is located at bell housing of flywheel.
TDC sensor is magnet coil type.
TDC sensor is used for deferming top read center of
cylinder.
Flywheel has 4 teeth of excifering.
Engine Coolant Temperature (ECT) Sensor

The ECT Sensor is a thermistor. A temperature
changes the resistance value. And it changes voltage.
In other words it measures a temperature value. It is
installed on the coolant stream. Low coolant
temperature produces a high resistance.
The ECM supplies a 5 volts signal to the ECT Sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot. The ECM uses to this value, and
calculates, a fuel injection timing, a main injection TDC (Engine Speed) Sensor
volume and an EGR VSVs switching.
The TDC sensor is magnet type sensor.
Vehicle Speed Sensor (VSS)

The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall effect. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The ECM calculates the speed of the vehicle by it. The
ECM uses this signal to operate the speedometer, too
and The TCM (Transmission Control Module) monitors
it.
IG
#12 Cause / Back fuse NKR onry
ON Meter fuse TF 4JA1-TC,4JH1-TC
ECM Stop lamp

15A
25A 10A
Relay EW
SW:Exh Brake
Stop lamp SW SW:clutch
Glow (NKR 4JH1-TC only)
Clutch pedal:OFF Meter
plug
relay Exh
Brake
coil (NKR Check
Glow
NKR 4JH1-TC 4JH1-TC Engine
ABS only only)
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
NKR 4JH1-TC
only
Batt Batt
ECM System Diagram – No.1
µP IC 08 µP µP µP µP
IC 035 IC 035
µP : Microproccesor
6E–43
6E–44
ECM
25A
EVRV: VSV : Ext 2 MAG valve VSV:

SW:Neutral 6 7
2 EGR (QWS) Exh Brake INT. Throttle
(MT only)
TF 4JA1-TC (NKR 4JH1-TC only)
MAF only VSV : Ext 1 (QWS)
(TF 4JA1-TC only) PCU
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 97 40 95 87 91 105 CAN-L CAN-H
Batt Batt Batt Batt Batt Batt
CF 150
US
Batt
CPU µP µP µP µP µP
IC 08
IC 08 µP
MAF/IAT Sensor Circuit
NTC IAT sensor
+5V
4
Heater
MAF sensor
5
Main fuse
ECM ECM
relay A/C on relay
signal
HVAC
relay
ECM
relay
A/C Fuse
AC
Thermo
relay NKR 4JH1-TC only
TF 4JA1-TC /
4JH1-TC only
Electrical
thermo
PDS
(NKR 4JH1-TC)
only
A/C
Comp relay A/C
Comp relay
Compressor Compressor
clutch clutch
41 41 33
Batt Batt
µP µP IC 08
Glow ECU
60A Relay Register : idle SW
Relay APS
G/plug
Glow
plug
+5V
94 57 38 49 69 2 1
GND GND
Balt
IC 08
µP
6E–47
6E–48
VSS 16 15 14 13 12 11 10 9
meter fuse
(TF 4JA1-TC/ (NKR 4JH1-TC only) 8 7 6 5 4 3 2 1
4JH1-TC only)
29 4
VSS ABS
TDC ECT
7 8
Speed meter Speed meter

68 27 68 62 32 90 98 89 93 35 45
Balt Balt Balt

Us
IC 08 IC 08
IC 08
µP IC 08 IC 03
General Service Information The Diagnostic Executive

Serviceability Issues The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
Non-OEM Parts the diagnostic procedures as well as define the protocol
All of the OBD diagnostics have been calibrated to run for recording and displaying their results. The main
with OEM parts. Accordingly, if commercially sold responsibilities of the Diagnostic Executive are listed as
sensor or switch is installed, it makes a wrong diagnosis follows:
and turns on the check engine lamp. • Commanding the check engine lamp on and off
Aftermarket electronics, such as cellular phones,
• DTC logging and clearing
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may • Current status information on each diagnostic
cause a false sensor reading and turn on the check Diagnostic Information
engine lamp. The diagnostic charts and functional checks are
Poor Vehicle Maintenance designed to locate a faulty circuit or component through
The sensitivity of OBD diagnostics will cause the check a process of logical decisions. The charts are prepared
engine lamp to turn on if the vehicle is not maintained with the requirement that the vehicle functioned
properly. Restricted oil filters, fuel filters, and crankcase correctly at the time of assembly and that there are not
deposits due to lack of oil changes or improper oil multiple faults present.
viscosity can trigger actual vehicle faults that were not There is a continuous self-diagnosis on certain control
previously monitored prior to OBD. Poor vehicle functions. This diagnostic capability is complemented
maintenance can not be classified as a “non-vehicle by the diagnostic procedures contained in this manual.
fault”, but with the sensitivity of OBD diagnostics, The language of communicating the source of the
vehicle maintenance schedules must be more closely malfunction is a system of diagnostic trouble codes.
followed. When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
Related System Faults lamp is illuminated.
Many of the OBD system diagnostics will not run if the
ECM detects a fault on a related system or component. Check Engine Lamp
The check engine lamp looks the same as the check
engine lamp you are already familiar with, the “Check
On-Board Diagnostic (OBD) Engine” lamp.
On-Board Diagnostic (Self Diagnosis Basically, the check engine lamp is turned on when the
System) Tests ECM detects a DTC that will impact the vehicle
emissions.
A diagnostic test is a series of steps, the result of which
• When the check engine lamp remains “ON” while the
is a pass or fail reported to the diagnostic executive.
engine is running, or when a malfunction is
When a diagnostic test reports a pass result, the suspected due to a driveability or emissions problem,
diagnostic executive records the following data: a Powertrain On-Board Diagnostic (OBD) System
• The diagnostic test has been completed since the Check must be performed. The procedures for these
last ignition cycle. checks are given in On-Board Diagnostic (OBD)
• The diagnostic test has passed during the current System Check. These checks will expose faults which
ignition cycle. may not be detected if other diagnostics are
performed first.
• The fault identified by the diagnostic test is not
currently active. Data Link Connector (DLC)
When a diagnostic test reports a fail result, the
diagnostic executive records the following data: The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
• The diagnostic test has been completed since the
last ignition cycle. behind the lower front instrument panel. The DLC is
used to connect to a Tech2. Some common uses of the
• The fault identified by the diagnostic test is currently
Tech2 are listed below:
active.
• The fault has been active during this ignition cycle. • Identifying stored Diagnostic Trouble Codes (DTCs).
• The operating conditions at the time of the failure. • Clearing DTCs.
• Reading serial data.
Reading Flash Diagnostic Trouble Codes Reading Diagnostic Trouble Codes Using a
The provision for communicating with the Engine TECH 2
Control Module (ECM) is the Data Link Connector The procedure for reading diagnostic trouble code(s) is
(DLC). The DLC is located in the front console box. It is to used a diagnostic Tech2. When reading DTC(s),
used in the assembly plant to receive information in follow instructions supplied by Tech2 manufacturer.
checking that the engine is operating properly before it For model year, Isuzu dealer service departments will
leaves the plant. continue to use Tech2.
The diagnostic trouble code(s) (DTCs) stored in the
ECM's memory can be read either through a hand-held Clearing Diagnostic Trouble Codes
diagnostic scanner plugged into the DLC or by counting To clear Diagnostic Trouble Codes (DTCs), use the
the number of flashes of the check engine lamp when Tech2 “clear DTCs” or “clear information” function.
the diagnostic test terminal of the DLC is grounded. When clearing DTCs follow instructions supplied by the
When diagnostic switch (dimDIG) is ON, the Cell Tech2 manufacturer.
flashing function will start blinking by blink codes
(fbwS...BCO) of each error codes. History DTC
The blink codes are flashed in turn, and repeated until
dimDIG is changed to OFF. History DTC can be canceled after 40 cycle driving with
When the key switch is turned on, flash once, after no defect. Or history code can be deleted by Tech2
3,250mm second later and twice after 1,250mm second “Clear DTCs” function.
later and then, flash the stored error codes three times
in sequence of the storing.
(example)
Two Digit Unique Code Number=32
ON
(1250msec)
Diagnostic
SW (500msec)
ON
Lamp OFF
1 2 3 2 3 2 3 2
(500msec)
(3250msec) (3250msec)
After all the stored error codes are flashed, the same flashing patterns are repeated again.
Tech2
From 98 MY, Isuzu dealer service departments are
recommended to use the Tech2 Scan Tool. Please refer
to the Tech2 user guide.
901RW180
Legend (3) SAE 16/19 Adaptor

(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech2
EndOFCallout
Tech2 Features 4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the
1. Tech2 is a 12 volt system. Do not apply 24 volts. Tech 1 Mass Storage Cartridge.
2. After connecting and/or installing the Vehicle
5. The Tech2 has the capability of two snapshots.
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech2, connect the 6. The PCMCIA card is sensitive to magnetism and
tool to the vehicle DLC. static electricity, so care should be taken in the
handling of the card.
3. Make sure the Tech2 is powered OFF when
removing or installing the PCMCIA card. 7. The Tech2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the
EXIT key several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open Operating Procedure (For Example)
Application Menu and press “F1: Clear DTC Info”.
The power up screen is displayed when you power up
Getting Started the tester with the Isuzu systems PCMCIA card. Follow
the operating procedure below.
• Before operating the Isuzu PCMCIA card with the
Tech2, the following steps must be performed:
1. The Isuzu System PCMCIA card (1) inserts into the
Tech2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech2 (5)
4. Make sure the vehicle ignition is off.
5. Connect the Tech2 SAE 16/19 adapter to the
vehicle DLC.
826RY00058
6. Turn on the vehicle ignition.

7. Power the Tech2 ON and verify the Tech2 power up
display.
060RY027
060RW009
NOTE: The RS232 Loop back connector is only to use

for diagnosis of Tech2. Refer to user guide of the Tech2.
Menu
• The following table shows, which functions are used
the available equipment versions.
F0: Diagnostic Trouble Codes

F0: DTC Information
F0: Engine
F1: History
F0: Clear DTC Information
F1: Data Display
F2: Snapshot
F3: ID Information
DTC
On OBD has two options available in Tech2 DTC mode
to display the enhanced information available. A
description of the new modes, DTC info and Clear DTC
Information. After selecting DTC, the following menu
appears:
• DTC Info
• Clear DTC Infomation
DTC Information Mode

Use the DTC info mode to search for store DTC
information. There are two choices. The service manual
may instruct the technician to test for DTCs is a certain
manner. Always follow published service procedures.
To get a complete description of any status, press the
“Enter” key befor pressing the desired F-key. For
example, ptessing “Enter” then an F-key will display a
definition of the abbreviated scan tool status.
Engine
This selection will display all DTCs that have failed
060RY00275
during the present ignition cycle.
History
This selection will display only DTCs that are stored in
the ECM's history memory.
Clear DTC Information

To clear Diagnostic Trouble Code (DTCs), use the
daiagnostic scan tool “clear DTC information” function.
Tech2 Data Display

Use the tech2 Data Values only after the On-Board
Diagnostic System Check has been completed, no
DTC(s) were noted, and you have determined that the
on-board diagnostics are functioning properly. Tech2
values form a properly-running engine may be used for
comparison with the engine you are diagnosting. The
Tech2 data values represent values that would be seen
on a mormally-running engine.
Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
060RX037
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
D06RY00167
Flow Chart for Snapshot Replay (Plotting Graph)
060RX040
How To Use Breaker Box
3 1 2
Legend (2) Harness adaptor

(1) ECM (3) Breaker box
Each breaker box terminal has pin No., which is assigned as same an ECM pin
assignment.
When need to check ECM pin No or ECM harness pin refected ECM pin No, you can use
same ECM pin No as breaker box terminal No.
Wiring harness connection on the vehicle
Engine harness
Engine harness
ECM
Breaker
ECM
box
Insert breaker box
Harness
adaptor
Breaker Box Connection Type A for Open Circuit Check, Short to Ground
Check and Short to Battery Check
3 1 5 4 2
Legend (3) Breaker box

(1) ECM (4) Digital volt meter
(2) Harness adaptor (5) ECM – harness adaptor connector disconnected
Breaker box connection type A.
ENG. harness
Breaker
ECM
box
Harness
adaptor
or
DVM
Connect to ground
Breaker Box Connection Type B for Power, Signal Voltage Check between ECM
and Sensors
3 1 2 4
Legend (3) Breaker box

(1) ECM (4) Digital volt meter
(2) Harness adaptor
Breaker box connection type B.

ENG. harness
Breaker
ECM
box
Harness
adaptor
or
DVM
Connect to ground
How To Use TIS2000 Snapshot Analysis

Snapshot Display
Fig. 1: [Snapshot Upload] icon Fig. 2: Data display
Procedures for transferring and displaying Tech2 C. Snapshot data is displayed with TIS2000
snapshot data by using TIS2000 [Snapshot Upload] [Snapshot Upload] function.
function is described below.
Snapshot data can be displayed with [Snapshot Upload] Snapshot is stored in the PC hard disk or floppy disk,
function included in TIS2000. and can be displayed any time.
By analyzing these data in various methods, trouble Stored snapshot can be displayed by the below
conditions can be checked. procedures.
Snapshot data is displayed by executing the three steps 1. Start TIS2000.
below shown: 2. Select [Snapshot Upload] on the TIS2000 start
screen.
A. Record the snapshot data, in Tech2.
3. Select [Open the existing files] or click the
(Refer to Repair Manual or Tech2 Instruction
corresponding icon of the tool bar.
Manual)
B. Transfer the snapshot data to PC. 4. Select the transferred snapshot.
C. Display the snapshot data with TIS2000 5. Open the snapshot, to display the data parameter
[Snapshot Upload] function. list on the screen.
B. Transfer of snapshot data to PC:

After recording the snapshot in Tech2, transfer the
data from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen.
Displayed icons Regeneration of snapshot
With the below icons, data display can be controlled: Snapshot can be regenerated with the icons on the
screen lower side.
Transfer of snapshot from Tech2 to PC.
1st record: The 1st record of the snapshot
is displayed.
Load of snapshot from floppy disk or hard
disk. Previous record: Changed to the just
previous record of the present one.
Store of snapshot to floppy disk or hard
disk. Regeneration in reverse direction:
Displayed by returning in the reverse
Display of data parameters on one screen. direction.
Trigger of record: Display by moving to the
set trigger position.
Display of data parameters on 2 screens
Regeneration in forward direction: The
whole snapshot is regenerated in the
Change of units. forward direction.
Next record: Changed to the next record of
the present one.
Display of data parameters by graph and
list (in graph, Max. 3 parameters ). Last record: The last record of the
snapshot is displayed.
Display of data parameters by graph and
list (in graph, Max. 3 parameters). End of regeneration: Record regeneration
end at the point clicking the snapshot.
Display of data parameters by graph (only
in graph, Max. 6 parameters).
Graph display
Print (printing data parameters). Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter]
window opens.
2. Click the first graph icon of the window upper part,
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
Fig. 3: Snapshot regeneration control
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
Display of graphs on one screen (Max. 6
graphs):
1. Click the 6 graph icon. [Graph Parameter] window
opens.
Fig. 4: [Graph Parameter] window
Fig. 6: [Graph Parameter] Window
Fig. 5: Graph display screen (values and graphs)

5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon. Fig. 7: Graph Display screen (6 graphs)
7. For displaying another parameter by graph, click the 2. Click the graph icon, select the parameter to be
parameter of the list, drug the mouse to the display displayed from the list and change divisions
screen while pressing the mouse button and release according to necessity.
the mouse button. New parameter is displayed at 3. Repeat the same procedures with the graph icons,
the position of the previous parameter. For from the 2nd to 6th.
displaying the graph display screen in full size, move
4. Click the [OK] button to display.
the cursor upward on the screen. When the cursor
is changed to the magnifying glass form, click the 5. In this case, parameters are displayed only in graph
screen. Graph screen is displayed on the whole form. All parameters are displayed in one graph.
screen. 6. The graph display screen can be moved with the
navigation icon.
Parameter lock/unlock TIS2000 navigation
With parameter lock/unlock function, certain parameters With the below icons, all TIS2000 applications can be
can be selected from the wide list and the selected used.
parameters can be displayed at once. At first, click the
parameter to be selected to put marking, then click With [TIS2000 end], all TIS2000
[Parameter lock/unlock]. Selected parameter is applications are ended, and Windows desk
displayed at the upper part of the [Lock line] of the data top is returned.
list upper part. Other parameters can be added in the
same way. By parameter [Lock], continuous display is With [Select page], TIS2000 start page is
possible for comparing data values. For removing returned without ending the application
parameters from the list, click the parameter to put being used. The application being used is
marking, then, click the [Parameter Lock/Unlock] button. opened in the background.
For ending application of [Snapshot Display], question
whether the file is stored or not is automatically With [Vehicle data], [Vehicle data display]
displayed. Here, storing the file in the PC hard disk or in function is opened. This function display all
floppy disk can be selected. vehicle technical data.
With [Executed applications end],

applications being used is ended, and
TIS2000 start page is returned.
With [Session], user information is

registered and displayed.
With [Help], TIS2000 integration help

function is started.
With [Print], copy of the screen can be

printed out.
Fig. 8: Locked parameters
Location of stored data

Usually, data is stored in the folder of C:\Program
Files\cosids\DATA\SNAPSHOT\. In case folder is
changed in installing, refer to the changed destination.
Stored data is already stored in installing by 2
(“10000000SUR”, “10000001.SUR”) as samples.
Typical Scan Data Values

Use the Typical Values Table only after the On-Board seen on a normally-running engine.
Diagnostic System Check has been completed, no
A Scan tool that displays faulty data should not be
DTC(s) were noted, and you have determined that the
used, and the problem should be reported to the Scan
on-board diagnostics are functioning properly. Scan tool
tool manufacturer. Use of a faulty Scan tool can result
values from a properly-running engine may be used for
in misdiagnosis and unnecessary replacement of parts.
comparison with the engine you are diagnosing. The
typical scan data values represent values that would be
TF 4JA1-TC
Tech 2 Display
Typical Data values Idling Typical Data values
after the engine warm up 2000rpm after the engine
Item Tech 2 parameter Unit Displayed and A/C “Off” warm up and A/C “Off”
(The engine coolant (The engine coolant
temperature is about 80°C) temperature is about 80°C)
1 Engine Speed rpm 730±25 1952~2026
2 Vehicle Speed rpm 0 0
3 Pump Speed rpm 362~367 975~1014
4 Acceletor Position % 0 6.3~7.75
5 Manifold Air Flow mg/strk 379.5~431.5 334.6~383.3
6 Barometric Pressure hPa Sea level Sea level
7 Desired Injection Quantity mg/strk 7.19~8.36 5.54~7.81
8 Injection quantity mg/strk 6.96~8.64 7.38~9.81
9 Desired Injection Start °CA -1.00 -2.00~-1.77
10 Actual Injection Start °CA -1.00 -2.00~-1.77
11 Coolant Temperature °C 83.86~84.66 84.86~86.26
12 Fuel Temperature °C 49.96~50.26 50.46~51.26
13 Intake Temperature °C 49.06~49.86 50.96~55.96
14 Ignition Status On/Off (V) ON12V ON12V
15 Idle Switch Active/Inactive Active Active
16 Brake Switch 1 Active/Inactive Inactive Inactive
18 Clutch Switch Active/Inactive Active Active
19 Neutral Switch Active/Inactive Active Active
20 A/C Information Switch Active/Inactive Inactive Inactive
21 Diagnostic Request Active/Inactive(V) Inactive Inactive
22 System Voltage mVolts 13690.3~13873.6 13832.9~13975.5
23 Main Relay Active/Inactive Active Active
24 Glow Time Relay On/Off Off Off
25 Check Engine Light On/Off Off Off
26 Glow Time Telltale On/Off Off Off
27 ABS Input Signal On/Off Off Off
28 ABS Output Signal On/Off ON ON
29 EGR Pulse Ratio % 70.0 52~53.5
30 EGR command mg/strk – –
31 Intake Manifold valve Active/Inactive Inactive Inactive
32 Exhaust Brake valve 1 Active/Inactive Inactive Inactive
Tech 2 Display
34 Desired Engine Idle Speed rpm 730 730
35 Start of Dlivery °CA 19.45~19.46 21.91~22.07
36 A/C Request Active/Inactive(V) Inactive12V Inactive12V
37 Immobilizer Active/Inactive Inactive Inactive
38 Immobilizer signal Not received Not received
39 Immobilizer Function Yes Yes
program
TF 4JH1-TC (MT)
Tech 2 Display
3 Pump Speed rpm 347~352 942~1022
5 Manifold Air Flow mg/strk 691~800 691.7~767.4
7 Desired Injection Quantity mg/strk 7.087.85 5.96~9.26
8 Injection quantity mg/strk 6.87~8.22 6.33~10.89
9 Desired Injection Start °CA 1.00 1.13~1.51
10 Actual Injection Start °CA 1.00 1.13~1.51
11 Coolant Temperature °C 81.46~86.26 83.26~86.26
12 Fuel Temperature °C 28.26~28.56 32.06~34.06
13 Intake Temperature °C 24.06~28.86 47.46~53.56
14 Ignition Status On/Off (V) ON 12V ON 12V
15 Idle Switch Active/Inactive Active Inactive
21 Exhaust Brake Switch On/Off – –
22 Diagnostic Request Active/Inactive(V) Inactive 12V Inactive 12V
23 QWS Switch On/Off – –
24 System Voltage mVolts 13894~14097.7 13853.3~13995.9
Tech 2 Display
29 ABS Input Signal On/Off – –
30 ABS Output Signal On/Off – –
31 EGR Pulse Ratio % – –
33 Intake Manifold valve Active/Inactive – –
34 Exhaust Brake valve 1 Active/Inactive – –
36 Start of Dlivery °CA 19.09~19.11 23.13~23.62
37 A/C Request Active/Inactive(V) Inactive Inactive
TF 4JH1-TC (AT)
Tech 2 Display
3 Pump Speed rpm 340~360 978~1010
5 Manifold Air Flow mg/strk 750~795 790~830
7 Desired Injection Quantity mg/strk 11~15 12~13
8 Injection quantity mg/strk 11~13.5 10~11
9 Desired Injection Start °CA 1.6 3.8~4.0
10 Actual Injection Start °CA 1.5~1.7 3.8~4.0
11 Coolant Temperature °C 80~85 80~85
12 Fuel Temperature °C 32~34 32~34
13 Intake Temperature °C 25~30 25~30
14 Ignition Status On/Off (V) ON 12V ON 12V
18 Clutch Switch Active/Inactive – –
Tech 2 Display
21 Exhaust Brake Switch On/Off – –
23 QWS Switch On/Off – –
24 System Voltage mVolts 13600~13800 1380013900
29 ABS Input Signal On/Off – –
30 ABS Output Signal On/Off – –
31 EGR Pulse Ratio % – –
33 Intake Manifold valve Active/Inactive – –
34 Exhaust Brake valve 1 Active/Inactive – –
36 Start of Dlivery °CA 19.10 23.0~24.0
37 A/C Request Active/Inactive(V) Inactive Inactive
NKR 4JH1-TC
Tech 2 Display
1 Engine Speed rpm 700±25 1979∼2058
3 Pump Speed rpm 348∼351 988∼1001
4 Acceletor Position % 0 21.07∼21.84%
5 Manifold Air Flow mg/strk 495.7∼536.4 845.3∼893.2
7 Desired Injection Quantity mg/strk 9.25∼10.17 5.75∼10
8 Injection quantity mg/strk 8.08∼11.85 12.14∼7.47
9 Desired Injection Start °CA 5∼5.18 6
10 Actual Injection Start °CA 5∼5.18 6
11 Coolant Temperature °C 83.06∼83.86 84∼88
12 Fuel Temperature °C 33.76∼34.96 38.76∼39.26
13 Intake Temperature °C 27.76∼29.76 26.16∼27.46
14 Ignition Status On/Off (V) ON12V ON12V
Tech 2 Display
21 Exhaust Brake Switch On/Off Off Off
23 QWS Switch On/Off Off Off
24 System Voltage mVolts 13710.6∼13894 13853.3∼13975.5
28 Glow Time Telltale On/Off OFF OFF
29 ABS Input Signal On/Off Off Off
30 ABS Output Signal On/Off ON ON
31 EGR Pulse Ratio % 69.95∼70 30
32 EGR command mg/strk 500 1600
33 Intake Manifold valve Active/Inactive Inactive Inactive
36 Start of Dlivery °CA 23.28∼23.6 28.04∼28.24
37 A/C Request Active/Inactive(V) Inactive 12Volts Inactive 12Volts
Engine Data Definitions

Data Display Engine
1 Engine Speed(RPM) Engine speed is computed by the ECM from the TDC sensor.
2 Vehicle Speed This displays vehicle speed.
3 Pump Speed(RPM) This displays operating correlation status for the CKP sensor signal
and the pump cam signal.
This displays jug pump revolution. Jug pump revolution is measured by
jug pump cam IAT senser. Jug pump PCU sends signal of ECM.
4 Accelerator Position Sensor Signal Throttle position sensor is computed by the ECM from TP sensor
voltages.This should display about 0% at idle and about 100% at wide
open throttle.
5 Mass Air Flow This indicates measurement value of Mass Air flow senser.
6 Barometric Pressure(HDS)
7 Desined Injection Quantity
8 Injection Quantity(mg/strk) This is displayed current fuel rate (Fuel quantity). The ECM will
compensate for fuel rate to basic fuel rate.
9 Desired Injection Start(°CA)
10 Actual Injection Start(°CA)
11 Coolant Temperature(°C) Engine Coolant temperature is computed by the ECM with ECT sensor
voltages. The ECM appies 5 volts to the ECT circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the ECM monitors a high
signal voltage and interprets that as a cold engine.
12 Fuel Temperature(°C) The fuel temperature is meassured at jug pump. PCU sends signal of
fuel temperature through SAC of ECM.
13 Intake Air Temperature(°C) Intake air temperature is computed by the ECM with MAF sensor
voltages. The ECM appies 5 volts to the MAF circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the ECM monitors a high
signal voltage and interprets that as a cold intake air.
14 Ignition Status Ignition status is indicated by the ECM with Ignition SW signal .This
should display Off at Key “OFF” and ON at Key “ON”.
15 Idle Switch This indicates idle switch is ON or OFF. Idle switch ON means accel
pedal is at idling condition.
16 Brake Switch 1 This
17 Brake Switch 2
18 Clutch Switch
19 Neutral Switch
20 A/C Information SW
21 Diagnostic Request
22 System Voltage This represents the system voltage measured by the ECM at ignition
feed.
23 Main Relay Main relay is indicated by the ECM to main relay signal .
24 Glow Time Relay This indicates glow timer relay ON or OFF.
25 Check Engine Lamp This displays operating status for the Check engine Light.
26 Glow Time Telltale This indicates glow lamp ON or OFF.
27 ABS Input Signal
28 ABS Output Signal
29 EGR Pulse Ratio %
30 EGR 2 Pulse Ratio %

31 Intake Manifold Value
(Intake Throttle)
32 Exh. Brake Valve 1
33 Exh. Brake Valve 2
34 Desired Engine Idle Speed The desired engine idle speed that the ECM is commanding. The
ECM will compensate for various engine loads based on engine
coolant temperature, to keep the engine at the desired idle speed.
35 Start of Delivery
36 A/C Request(Air Conditioning) This displays the A/C request signal.
37 Immobilizer
38 Immobilizer Signal
39 Immobilizer Function Programmed
Sub
DTC F/Code DTC Name Setting condition Back-up mode History code Cancel condition Cancel Mode MIL light N*R 4JH1-TC TF 4JA1-TC TF 4JH1-TC
code
P0100 1001 65 Mass Air Flow Sensor Voltage MAF < 4.589V more than N*R 4JH1/TF 4JA1.4JH1--- Default=5V Yes MAF >= 4.589V more During same ignition ON X X X
Supply Circuit Low Input 500msec Air flow defaut=1600mg/hub, N*R 4JH1/ than 500msec cycle
TF 4JA1(Excluding TF 4JH1)---, EGR
default=10% ( usually 30-40%)
0111 Mass Air Flow Sensor Voltage MAF >5.20V more than Default=5V Air flow defaut=1600mg/ Yes MAF <= 5.20V more During same ignition ON X X X
Supply Circuit High Input 500msec hub, EGR default=10% than 500msec cycle
1011 Mass Air Flow Sensor Circuit 600RPM<Eng Default=freezed value of immidiate Yes MAF output>= -18.6kg/h During same ignition ON X X X
High Input RPM<5000RPM and MAF previous value Air flow defaut=1600mg/ more than 600msec cycle
output<-18.6kg/h more than hub, EGR default=10%
5 sec
1100 Mass Air Flow Sensor Circuit 600RPM<Eng Default=freezed value of immidiate Yes MAF output<=806.4kg/h During same ignition ON X X X
Low Input RPM<5000RPM and MAF previous value Air flow defaut=1600mg/ more than 600msec cycle
output>806.4kg/h(N*R 4JH1- hub, EGR default=10%
TC/TF 4JA1-TC) or 825kg/
h(TF 4JH1-TC) more than 10
sec
P0110 0010 23 IAT Signal Volatage Low IAT(Intake Air Temp--different Default = -50 deg C Yes IAT volt > 0.32V more During same ignition ON X X X
from Pump IAT) <= 0.318V than 3 Sec cycle
more than 3 sec
0001 IAT Signal Volatage High IAT(Intake Air Temp--different Default = -50 deg C Yes IAT volt < 4.7V more During same ignition ON X X X
from Pump IAT) >= 4.7V than 3 sec cycle
more than 3 sec
P0115 0010 14 ECT Sensor Circuit Low Input ECT volt < 0.32V more than ECT uses fuel pump temp, Injection Yes ECT volt > 0.32V more During same ignition ON X X X
3 sec beginning governing use 50deg C, Glow than 600msec cycle
timer use -25 deg C
0001 ECT Sensor Circuit High Input ECT volt > 5.7V more than ECT uses fuel pump temp, Injection Yes ECT volt < 4.7V more During same ignition ON X X X
3 sec beginning governing use 50deg C, Glow than 600msec cycle
timer use -25 deg C
P0180 1011 15 Fuel Temperature Sensor Pump temperature > 150 Fuel temp = default 75deg C Yes No more failure is During same ignition ON X X X
Circuit Range/Performance deg C or < -40 deg C more regognized more than 3 cycle
than 3 sec. sec.
P0215 1011 52 Fuel cutoff solenoid valve No ECM requests Engine Engine stops, can not start engine. Yes No more failure is Ignition Key off, no ON X X X
(MAB) circuit high input stop, but PCU recognises MAB shut off recognized. condition matches
High level on MAB line then canceled.
during Initilization.
1100 Fuel cutoff solenoid valve During afterrun, Ign OFF, Engine stop, MAB shut off Yes No more failure is Ignition Key off, no OFF X X X
(MAB) always active Engine speed <1500 RPM, recognized. condition matches during
VSS<5km/h, 2 sec after, still then canceled. DTC set,
engine rpm.200rpm MIL ON at
immidiate action. next Ign
cycle.
1010 Fuel cutoff solenoid valve Ign OFF, Engine speed Engine stop, MAB shut off, MIL turn on Yes No more failure is Ignition Key off, no OFF X X X
(MAB) malfunction 1 <1500 RPM, VSS<5km/h, 2 after starts engine. recognized. condition matches during
sec after, still engine then canceled. DTC set,
rpm.200rpm, immidiate MIL ON at
action next Ign
cycle.
6E– 74 ENGINE DRIVEABILITY AND EMISSIONS
Sub
code
1101 Fuel cutoff solenoid valve During afterrun period, CAN None Yes No more failure is Ignition Key off, at OFF X X X
(MAB) malfunction 2 --- Gate controller can not be bus off recognized. next Ign cycle no during
Array error mode. Immidiate action. condition matches DTC set,
then canceled. MIL ON at
next Ign
cycle.
P0216 1010 54 Persistant governer deviaton Conditions: Eng rpm > 700 Limit Q is employed. Yes No more failure is During the same ON X X X
RPM, Q> 4mg/hub and recognized. Return to ignition cycle
Judgement :Actual timing normal mode
and target timing deviation > immidiately.
+3 CA or < -6 CA , more than
12sec.
1011 Timing device fluctuation Engine RPM > 2014RPM, Limit Q is employed. Yes No more failure is During the same ON X X X
timing fluctuation becomes recognized. Return to ignition cycle
more than +-5.2CA and more normal mode
than for 1 sec. immidiately.
P0251 0110 53 Injection Pump Malfunction PCU detects control pulse Engine stops. Yes No more failure is Ignition Key off, at OFF X X X
width. recognized. next Ign cycle no during
condition matches DTC set,
then canceled. MIL ON at
next Ign
cycle.
0111 TDC and CAM speed TDC sensor Engine speed - Engine stops. Yes TDC Engine speed - Ignition Key off, at ON X X X
comparison error 2* Cam speed sensor> 2*Cam speed sensorI<= next Ign cycle no
800RPM(N*R 4JH1-TC) or 800RPM(N*R 4JH1-TC) condition matches
720RPM(TF 4JA1-TC) or or 720RPM(TF 4JA1- then canceled.
690RPM(TF 4JH1-TC) more TC) or 690RPM(TF
than 200msec 4JH1-TC).
1001 Injection Pump Malfunction No pump map programmed Engine stops. MAB shut off. Yes No more failure is Ignition Key off, at ON X X X
or pump control unit(PCU) recognized. next Ign cycle no
RAM defect condition matches
then canceled.
1010 Injection Pump Malfunction PCU-EEPROM defect or A/D Limit Q is employed. Yes No more failure is Ignition Key off, at ON X X X
converter defect recognized. next Ign cycle no
condition matches
then canceled.
1011 Injection Pump Malfunction PCU selftest finds None Yes No more failure is Ignition Key off, at ON X X X
powerstage hardware error. recognized. next Ign cycle no
condition matches
then canceled.
1101 Injection Pump Malfunction PCU selftest finds internal None Yes No more failure is Ignition Key off, at ON X X X
voltage check is OK or not. recognized. next Ign cycle no
condition matches
then canceled.
1110 Injection Pump Malfunction ECM does not accept PCU Engine stops. MAB shut off. Yes No more failure is Ignition Key off, at ON X X X
message more than 1sec recognized. next Ign cycle no
condition matches
then canceled.
ENGINE DRIVEABILITY AND EMISSIONS 6E– 75
Sub
code
P0335 1110 43 Engine Speed Sensor Input RPM > 5100 RPM more Set rpm backup Yes RPM <= 5100RPM for > During same ignition ON X
Circuit Signal Range/ than 20 m sec(sampling 1. If Injection Cam sensor is OK, Engine 50 m sec cycle
Performance(Over Speed) time) Speed becomes Injection Pump Cam
Signal X 2.
(TDC=DZG-Crank angle
sensor detects this error)
1011 Dynamic plausibility The immidiate previous Set rpm backup Yes If OK condition During same ignition ON X X X
engine speed should be 1. If Injection Cam sensor is OK, Engine continues more than cycle
more than 665 RPM and Speed becomes Injection Pump Cam times, become normal .
then the period btwn pulses Signal X 2.
is fluctuated by the thresh 2. If Injection Cam sensor (IAT)fails,
hold more than 16 times Set default 0 rpm
during same ignition cycle. MAB qty becomes 0, and retard
Injection. Engine stops.
Set Q backup
1101 Static Plausibility Conditions to required: IAT Set rpm backup Yes If OK condition During same ignition ON X X X
should be OK, CAN 1. If Injection Cam sensor is OK, Engine continues more than cycle
communication should Speed becomes Injection Pump Cam times, become normal .
OK,Dynamic plausibility Signal X 2.
should be OK. Judgment: 2. If Injection Cam sensor (IAT)fails,
TDC(DZG) is 0 RPM and IAT Set default 0 rpm
is more than 100 RPM for 10 MAB qty becomes 0, and retard
msec. Injection. Engine stops.
Set Q backup
P0380 1000 66 Glow Device Voltage High After Key ON, glow lamp None Yes Detective circuit During same ignition ON X X X
stays on, Glow Relay circuit recognized as normal cycle
is short circuit more than 3 more than 1 sec
sec
0100 Glow Device Voltage Low After Key ON, glow lamp None Yes Detective circuit During same ignition ON X X X
stays on, Glow Relay circuit recognized as normal cycle
is open circuit more than 3 more than 1 sec
sec
P0381 1000 67 Glow Time Telltale Circuit Lamp circuit power on, IC None Yes IC recognizes no more During same ignition ON X X X
Voltage High recognizes short circuit more short circuit more than cycle
than 3 sec 1sec
0100 Glow Time Telltale Circuit Lamp circuit power off, IC None Yes IC recognizes no more During same ignition ON X X X
Voltage Low recognizes short circuit more open circuit more than cycle
than 3 sec 3sec
P0400 1000 32 EGR short to Batt Powerstage ON, ECM LimitQ is employed. EGR becomes 10% Yes IC recgnizes no more During same ignition ON X X
initialized, IC recognises ratio. short circuit more than cycle
short to batt more than 3sec 3sec
0100 EGR short to grand or open Powerstage ON, ECM LimitQ is employed. EGR becomes 10% Yes IC recgnizes no more During same ignition ON X X
circuit initialized, IC recognises ratio. failure more than 3sec cycle
short to ground and open
circuit more than 3sec
Sub
code
0011 EGR Flow Excessive N*R 4JH1--70deg LimitQ is employed. but EGR operation Yes Target MAF-Actual During same ignition ON X
Detected C<ECT<100, TF 4JA1-- is normal. MAF<=150mg/hub, cycle
55degC<ECT<100degC,N*R more than 600msec
4JH1--16 deg C<IAT<34,TF
4JA1--
15degC<IAT<100degC,N*R
4JH1--880 hpa<
Baro<1100hpa,TF 4JA1--
850hpa<Baro<1100hpa, 7
sec after start mode, and
Target MAF - Actual MAF >
150 mg/huv more than 60
sec.
N*R 4JH1--judgement is
made between 2165 and
3160RPM, and between 15-
35mg/huv. TF 4JA1--
judgement is made between
1500-3100RPM, and
between 8 - 32mg/huv.
0101 EGR Flow Insufficient N*R 4JH1--70deg LimitQ is employed. but EGR operation Yes Target MAF-Actual During same ignition ON X
Detected C<ECT<100, TF 4JA1-- is normal. MAF>=150mg/hub, cycle
55degC<ECT<100degC,N*R more than 600msec
4JH1--16 deg C<IAT<34,TF
4JA1--
15degC<IAT<100degC,N*R
4JH1--880 hpa<
Baro<1100hpa,TF 4JA1--
850hpa<Baro<1100hpa, 7
sec after start mode, and
Target MAF - Actual MAF < -
150 mg/huv more than 60
sec.
N*R 4JH1--judgement is
made between 2165 and
3160RPM, and between 15-
35mg/huv. TF 4JA1--
judgement is made between
1500-3100RPM, and
between 8 - 32mg/huv.
P0500 0001 24 VSS Circuit High Input VSS out put > 190 km/h(N*R VSS default=5km/h Yes VSS <= 190 km/h(N*R During same ignition N*R 4JH1- X X
4JH1-TC) or 200km/h(TF 4JH1-TC) or 200km/ cycle TC-- OFF
4JA1-TC,4JH1-TC) more h(TF 4JA1-TC,TF 4JH1- TF 4JA1-
than 5 sec TC) more than 5 sec TC,4JH1-
TC--ON
1010 VSS input signal frequency VSS signal frequency is too VSS default=5km/h Yes VSS signal frequency < During same ignition N*R 4JH1- X X X
too high high, CPU can not recognise CPU eligible frequency cycle TC-- OFF
more than 600msec more than600m sec TF 4JA1-
TC,4JH1-
TC--ON
Sub
code
1011 VSS plausibility Q >= 30 mg / hub, Engine Brake light becomes ON Yes VSS>=5km/h more than During same ignition N*R 4JH1- X X
speed>=2500RPM, VSS < 600msec cycle TC-- OFF
5km/h more than 30 sec TF 4JA1-
TC,4JH1-
TC--ON
P0560 0010 35 System Voltage Too Low System Volatage < 7 Volt, Back up volate figure 9 Volt is used. Yes When system volage During same ignition OFF X X X
more than 100 m sec becomes more than 7 cycle
volt for 100 m sec.
0001 System Voltage Too High System Volatage > 20 Volt, Back up volate figure 9 Volt is used. Yes When system volage During same ignition OFF X X X
more than 600 m sec becomes less than 20 cycle
volt for 600 m sec.
1010 Extrem voltage input System voltage < 4.5 V, or > PSG uses default value. Yes 4.5V, System volatage < During same ignition OFF X X X
27 V for 0 m sec 27 V for 0 m sec cycle
P0561 1011 18 Switched System CPU recognises IC circuit Engine stops N*R4JH1- No return to normal During same ignition OFF X X X
Voltage(Ignition ON) Circuit error of main relay control. TC-- Yes mode during this driving cycle
Malfunction TF4JA1- cycle.
TC,4JH1-TC--
NO
1010 Switched System During initialization, quick If condition continue more than 1 sec N*R4JH1- No return to normal During same ignition OFF X X X
Voltage(Ignition ON) Circuit motion of ignition ON of after DTC set, ECM goes into afterrun TC-- Yes mode during this driving cycle
Malfunction ignition OFF triggers this mode. TF4JA1- cycle.
DTC TC,4JH1-TC--
NO
P0606 1011 28 ECU Malfunction 2 APS <1%, Q > 0 mg/strk, Engine stops, MAB shut off Yes Target Q <= 0 (mg/hub) During same ignition ON X X X
then RPM >2000RPM more than 200m sec , cycle
or restart
1010 ECU Malfunction 1 Gate array counter reach 5 Engine stops, MAB shut off Yes No failure happens During same ignition ON X X X
counts more than 20 sec. cycle
P0645 1000 46 A/C Comp Cutoff Relay AC Power ON at least one None Yes IC recognises no more During same ignition ON X X X
Primary Circuit High Input time after Ign ON, IC short circuit more than 3 cycle
recognises short circuit more sec
than 3 sec.
0100 A/C Comp Cutoff Relay AC Power OFF at least one None Yes IC recognises no more During same ignition ON X X X
Primary Circuit Open time after Ign ON, IC open circuit more than 3 cycle
recognises Open circuit sec
more than 3 sec.
P0703 1010 25 During Brake SW on, Brake- N*R 4JH1-TC--After start None Yes BRK SW1 = BRK SW2 During same ignition ON X X
Light SW Circuit Incorrect engine, Engine more than 300sec cycle
Signal(Ignition On) RPM>=1500RPM,
APS>=10%, VSS>=15km/h
TF4JA1-TC--
RPM>=693RPM,APS>=0%,
VSS>=0km/h.TF4JH1-TC--
VSS>=0km/h and Brk SW1 /
Brk Sw2 indicate different
more than 300sec.
Sub
code
1011 During Brake SW off, Brake- N*R 4JH1-TC--After start None Yes BRK SW1 = BRK SW2 During same ignition ON X X
Light SW Circuit Incorrect engine, Engine more than 300sec cycle
Signal RPM>=1500RPM,
APS>=10%, VSS>=15km/h
TF4JA1-TC--
VSS>=0km/h.TF4JH1-TC--
VSS>=0km/h and Brk SW1 /
Brk Sw2 indicate different
more than 300sec.
P0704 0110 57 Clutch SW Input Circuit N*R 4JH1-TC--This check is Cut off Auto cruise control Yes Clutch signal change is During same ignition ON X X X
Malfunction measured by only one time made more than cycle
per 1 Ign ON, after 500msec
initialization, clutch signal
measured upto 5km/h and
no clutch signal change upto
80km/h more than 60 sec.
TF4JA1-TC/4JH1-TC--
1.5km/h upto 80km/h.
P1105 0010 86 Baro sensor Circuit Low Input Baro V< Default =1013hpa Yes Baro>=1.48V more than During same ignition ON X X X
1.48V(1.4794V=6000M) 1 sec cycle
more than1 sec
0001 Baro sensor Circuit High Input Baro V>4.42V(4.42V=- Default =1013hpa Yes Baro<=4.42V more than During same ignition ON X X X
1000M) more than1 sec 1 sec cycle
P1110 1000 72 Intake VSV High Input Powerstage ON, ECM None Yes IC recognises no more During same ignition ON X X
initialized, IC recognises failure , more than 3sec cycle
short to batt more than 3sec
0100 Intake VSV Open Circuit Powerstage ON, ECM None Yes IC recognises no more During same ignition ON X
initialized, IC recognises failure , more than 3sec cycle
short to batt open circuit or
short to ground more than
3sec
P1120 0010 21 Pedal Position Sensor Circuit APS signal volage < 320 mV Use Idle SW position = 0%, Yes APS signal volage > 320 During same ignition ON X
Low Input more than 500 m sec acceleration, decceleration becomes m V more than 500 m cycle
limmitted performance. Idle speed sec
becomes 1400 RPM.
0001 Pedal Position Sensor Circuit APS signal volage > 4.9 Use Idle SW position = 100%, Yes APS signal volage < 4.9 Need to check ON X X X
High Input V(N*R 4JH1-TC) or acceleration, decceleration becomes V(N*R 4JH1-TC) or
4.5V(TF4JA1-TC,4JH1-TC) limmitted performance. Idle speed 4.5V(TF 4JA1-TC/4JH1-
more than 500 m sec becomes 1400 RPM. TC) more than 500 m
sec
1001 Pedal Position Sensor Voltage APS signal voltage < 4.6 V System volatge is used as 4.9Volt. Idling Yes APS signal volage > 4.6 During same ignition ON X X X
Supply Circuit Low Input more than 500 m sec speed becomes 1400 RPM. APS uses V more than 500 m sec cycle
default 0%.
0111 Pedal Position Sensor Voltage APS signal voltage > 5.2 V System volatge is used as 4.9Volt. Idling Yes APS signal volage < 5.2 During same ignition ON X X X
Supply Circuit High Input more than 500 m sec speed becomes 1400 RPM. V more than 500 m sec cycle
Sub
code
1101 Pedal Position Sensor Brake No brake error DTC indicates APS value becomes “0%”. Yes Brake OFF, ACC OFF or During same ignition ON X X X
Error Brake pedal(sw is ON) and Idle speed becomes “1400 rpm”. ACC acceleration 20%/ cycle
accel pedal (more than APS value, idle speed are controlled to Sec or brake error
18%(N*R 4JH1-TC) or reach the above value smoothly. happens.
8.7%(TF 4JA1/4JH1-
TC)accel)are depressed at
same time and Engine
Speed is more than
1700RPM and more than 2
sec. If accel input fluctuates
more than 20% within 1 sec,
it is cancelled.
1110 Pedal Position Sensor N*R4JH1-TC--Idle SW ON Set to APS value = 0% and idle speed Yes Idle SW OFF and APS Ignition Key off, no ON X X X
General Error and APS value > 18% , more 1400RPM. 100%, or Idle SW ON condition matches
than 600msec TF 4JA1/ and APS 0%. But N*R then canceled.
4JH1-TC--Idle SW OFF and can not cance.
APS value<0.35% or Idle SW
ON and APS valu>8.7%,
more than 600msec
P1173 0011 22 Fuel Reduction caused by Fuel quantity is not normal None Yes No more failure is During same ignition OFF X X X
High Coolant Temp condition because ECT recognized. It returns to cycle
indicates more than 100deg normal condition
C and more than for 30sec. immiditely.
0111 Fuel Reduction caused by PSG detects fuel temp PCU reduced Q-map is employed. Yes No more failure is During same ignition OFF X X X
High fuel Temp 1 output becomes more than recognized. It returns to cycle
100deg C more than 30sec. normal condition
immiditely.
1010 Fuel Reduction caused by ECM detects fuel ECM reduced Q-map is employed Yes No more failure is During same ignition OFF X X X
High fuel Temp 2 temperature is more than recognized. It returns to cycle
80degC and last more than normal condition
for 30sec. immiditely.
P1335 1010 43 Engine Speed Output Circuit PCU detects Limit Q is employed. Yes PCU accepts no more During same ignition ON X X X
Malfunction DZG(TDC)pulse error erro of TDC. Counter cycle
immidiately. becomes 0 from 120.
P1345 1010 41 Injection Pump:Camshaft PCU recognises cam speed None Yes No more failure is During same ignition ON X X X
Speed Malfunction sensor(increment angle time recognized. Return to cycle
system) error more than 1 normal mode by counter
sec. reduction, almost
immidiately.
(Inrement angle time system-

IAT)
P1520 1010 47 Neutral Switch ON During driving condition*1, None Yes Two no failure The ignition cycle ON X X X
Neutral SW on error signals consequetive driving after two consecutive
are recognized more than cycle no failure igniton
three times and more than cycle makes MIL
60 sec. light off.
Sub
code
1011 Neutral Switch OFF During no driving condition*1, None Yes Two no failure The ignition cycle ON X X X
Neutral SW off error signals consequetive driving after two consecutive MT Only
are recognized more than cycle no failure igniton
three times and more than cycle makes MIL
60 sec. light off.
P1576 1000 71 Exh Brake and QWS Valve Powerstage ON, ECM ECM sends reverse phase signal, Yes IC recognises no more During same ignition ON X
1(N*R 4JH1-TC--Exhaust initialized, IC recognises results to turn on ABS light ON. failure, more than cycle Exh.Brake
Brake and QWS, TF 4JH1- short to batt more than 1sec 1.5sec
TC--QWS system only) Circuit
Short to Battery
0100 Exh Brake and QWS Valve Powerstage ON, ECM ECM sends reverse phase signal, Yes IC recognises no more During same ignition ON X NKR X NKR
1(N*R 4JH1-TC--Exh Brake initialized, IC recognises results to turn on ABS light ON. failure, more than cycle 4JH1-TC-- 4JH1-TC--
and QWS ,TF4JA1-TC--QWS short to ground or open 600msec Exh.Brake Exh.Brake
only) Circuit Short to Ground circuit more than 600msec and QWS TF and QWS
or Open Circuit 4JA1-TC-- TF 4JA2-
QWS TC--QWS
P1577 1000 Ext VSV 2(TF 4JA1-TC-- Powerstage ON, ECM ECM sends reverse phase signal, Yes IC recognises no more During same ignition ON X TF
QWS) Circuit short to Battery initialized, IC recognises results to turn on ABS light ON. failure, more than cycle 4JA1-TC--
short to batt more than 1sec 1.5sec QWS
P1577 0100 Ext VSV 2 (TF 4JA1-TC-- Powerstage ON, ECM ECM sends reverse phase signal, Yes IC recognises no more During same ignition ON X TF
QWS) Circuit short to Ground initialized, IC recognises results to turn on ABS light ON. failure, more than cycle 4JA1-TC--
or Open Circuit short to ground or open 600msec QWS
circuit more than 600msec
P1605 1110 55 EEPROM Defect EEPROM check sum does Engine does not start, idle target Q=0. Yes Right after EEPROM During same ignition ON X X X
not match with the check checksum value cycle
sum during initialization. matches with initial
Becomes back-up values.
immidiately.
1101 EEPROM Defect Fail of read or write Engine does not start, idle target Q=1. Yes Right after EEPROM During same ignition ON X X X
EEPROM data as checksum value cycle
initialization. matches with initial
values.
1100 Seeds and key file destroyed When either sees or keys None Yes None During same ignition ON X X X
data is or are destoryed. cycle
P1610 1010 56 Seeds and Key file destroyed The engine control unit is in Can not start Engine, ECM must be Yes No more failure is During same ignition ON X X
the as-delivered condition reprogrammed. recognized. cycle
P1611 1010 56 Wrong Security Code Entered Incorrect security code was The injection qty is immidiately stopped. Yes The engine can first be During same ignition ON X X
input with Tech-II started when the correct cycle
security code is input or
the ignition is switched
OFF/ON.
P1612 1010 56 Immobiliser No Or Wrong The immo ICU-ECM The injection qty is immidiately stopped. Yes No more failure is During same ignition ON X X
Signal communication could not be The engine can not start. recognized. cycle
correctly completed.
P1613 1010 56 Immobiliser No Or Wrong The Immo-MSG Q stopped, can not start engine. Yes No more failure is During same ignition ON X X
Signal communication could not be recognized. cycle
correctedly completed.
Sub
code
P1614 1010 56 Wrong Transponder Key The compare response The injection qty is immidiately stopped. Yes No more failure is During same ignition ON X X
calculated in the ECM does The engine can not start. recognized. cycle
not agree with the response
in immo.
P1625 1011 76 Power Supply Relay Switched During after-run , Main relay ECM command to shut main relay. Yes Engine can not restart Ignition Key off, no OFF X X X
Off too late shut off more than 2 sec failure condition
matches then
canceled.
1010 Power Supply Relay Switched By thia monitoring function a None Yes Engine can not restart Ignition Key off, no ON X X X
Off too Early main relay or control unit failure condition
defect is recognized which matches then
causes a MSG shut off canceled.
before the Microprocessor
has given the shut demand.
P1630 1010 51 Fuel-Injection Quality Circuit Solenoid valve has Limit Q is employed. Yes No failure recognised During same ignition ON X X X
High Input overcurrent. cycle
1011 Fuel-Injection Quality Circuit Solenoid valve has continous Engine stops, MAB operated, Yes No return to normal Ignition Key off, no ON X X X
High Input energized. mode during this driving failure condition
cycle. matches then
canceled.
P1650 1010 44 CAN: Device Offline CAN communication is cut Engine stops, MAB operated, Yes No more failure more During same ignition ON X X X
more than 200msec than 100msec cycle
1011 CAN: Device Hangup During driving, CAN lin hang Engine stops, MAB operated, Yes No more failure more During same ignition ON X X X
up. than 100msec cycle
P1651 1010 45 Inj Pump:CAN Malfunction PSG can not receive ECM Engine stops, MAB operated, Yes No more failure During same ignition ON X X X
message or time out. cycle
1011 CAN Receiver Error Can not read out PSG Engine stops, MAB operated, Yes No more failure During same ignition ON X X X
message during afterrun cycle
P1690 1000 77 MIL Circuit Open Lamp circuit power on, IC None Yes IC recgnises no more During sameignition OFF X X X
recognises short circuit more short circuit more than cycle
than 1 sec 600msec
0100 MIL Circuit High Input Lamp circuit power off, IC None Yes IC recgnises no more During sameignition OFF X X X
recognises open circuit more open circuit more than 3 cycle
than 3 sec sec
*1
Driving condition No driving condition
TF 4JA1-TC VS>62.9km/h V/N>0.00412 1st gear VS<1.5km/h Eng rpm>693rpm V/N<0.00412
585
TF 4JH1-TC MT VS>62.4km/h V/N>0.0041602 VS<1.5km/h Eng>665 V/N<0.0041602
587 AT VS>65.0km/h V/N>0.0043359 VS<0km/h Eng>6000rpm V/N<0.0043359
N*R 4JH1-TC VS>64.0km/h V/N>0.003398 VS<2km/h Eng rpm>665rpm V/N<0.003338
134
On-Board Diagnostic (OBD) System Check
1GN
Fuse ECU
25A
DLC Ignition Feed Circuit

ABS
NKR 4JH1-TC
only
Check
Diagnostic
Engine 16 15 14 13 12 11 10 9 Connector
Lamp(CEL)
8 7 6 5 4 3 2 1
ABS
NKR 4JH1-TC
Serial only
Data
BRN/ Circuit YEL/ ORN/
YEL GRN BLU
42 35 45
Keyword 2000 Diag Engine
(Serial Data) Switch Control
Module
(ECM)
µP
µP : Microproccesor 1,2
ECM Ground
060RY00330
Circuit Description connection, and damaged harness.

The on-board diagnostic system check is the starting
Test Description
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical Number(s) below refer to the step number(s) on the
check of the ECM and engine grounds for cleanliness Diagnostic Chart:
and tightness. 1. The check engine lamp should be “ON” steady with
The on-board diagnostic system check is an organized the ignition “ON” engine “OFF.” If not, the “No Check
approach to identifying a problem created by an Engine Lamp” chart should be used to isolate the
electronic engine control system malfunction. malfunction.
2. Checks the serial data circuit and ensures that the
Diagnostic Aids ECM is able to transmit serial data.
4. If the Tech 2 isn't used, perform “Reading Flash
An intermittent may be caused by a poor connection, Diagnostic Trouble Codes”.
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness. Inspect the ECM harness and
connector for improper mating, broken locks, improperly
formed or damaged terminals, poor terminal-to-wire
On Board Diagnostic (OBD) System Check

Step Action Value(s) Yes No
1 1. Ignition “On”, engine “Off”. Go to “No
2. Check CHECK ENGINE lamp. Check Engine
Did the check engine lamp turn on? — Go to Step 2 Lamp”
2 1. Ignition “Off”, engine “Off”.
2. Install the Tech 2.
3. Ignition “On”, engine “Off”.
4. Attempt to display ECM engine data with it.
Did it display ECM data? — Go to Step 3 Go to Step 6
3 1. Ignition “On”, engine “On”. Go to “Engine
Did the engine start and continue to run? Cranking But
— Go to Step 4 Won't Run”
4 1. Select “Display DTCs” with the Tech 2. Go to DTC
Are any DTCs stored? — Chart Go to Step 5
5 1. Compare ECM data values displayed on the Refer to
Tech2 to typical values. Indicated
Refer to the typical scan data values. Component
Are the display values normal or close to it? — Go to Symptom System Checks
6 1. Ignition “Off”, engine “Off”.
2. Disconnect ECM
4. Check serial data circuit for an open, short to
ground or short to voltage.
5. Check DLC ignition feed circuit for an open, short
to ground or short to voltage.
6. If the problem is found, repair circuit as necessary.
Was the problem found? — Go to Step 2 Go to Step 7
7 1. Check ECM ground circuit for open or short to
voltage.
2. If the problem is found, repair as necessary.
Was the problem found? — Go to Step 2 Go to Step 8
8 1. Replace ECM.
Is the action complete? — Go to Step 2 —
No Check Engine Lamp

Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or a
wire broken inside the insulation. Check for the
following items:
• Inspect the ECM harness and connections for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire
connection, and damaged harness.
• If the engine runs OK, check for a faulty light bulb, an
open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
• If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. A “No Check Engine Lamp” condition accompanied
by a no-start condition suggests a faulty ECM
ignition feed or battery feed circuit.
9. Using a test light connected to B+, probe each of the
ECM ground terminals to ensure that a good ground
is present. Refer to ECM Terminal End Viewfor
terminal locations of the ECM ground circuits.
No Check Engine Lamp

1 Was the “On-Board Diagnostic (OBD) System Check” Go to “On
performed? Board
Diagnostic
(OBD) System
— Go to Step 2 Check”
2 1. Ignition “On”, engine “On”
Did the engine start? — Go to Step 3 Go to Step 7
3 1. Check the meter fuse for the instrument cluster
ignition feed circuit.
2. If the problem is found, replace as necessary.
Was a ploblem found? — Verify repair Go to Step 4
4 1. Ignition “On”, engine “Off”
2. Probe the ignition feed circuit at the cluster
connector with the test light to ground.
Did it turn on? — Go to Step 5 Go to Step 8
5 1. Check the lamp bulb at check engine lamp .
2. If a ploblem is found, replace as necessary.
Was a ploblem found? — Verify repair Go to Step 6
6 1. Ignition “Off”, engine “Off”
2. Disconnect Harness connector from ECM.
3. Jumper the check engine lamp driver circuit at the
ECM connector to ground.
Was the light turn on? — Go to Step 11 Go to Step 8
7 1. Check following fuse.
•Main(80A) •Key SW(50A) •ECM •Meter(15A)
If the problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 10
3. Jumper the ignition circuit at the ECM connector to
ground.
Was the light turn on? — Go to Step 9 Go to Step 13
9 1. Ignition “On”, engine “Off”
3. Probe the battery circuit at the cluster connector
with the test light to ground.
10 1. Check ECM ground circuit for an open or short to
voltage.

11 1. Check ECM connector for condition.
12 1. Check check engine lamp driver circuit for an open
or short to ground.
CHECK POINT: Open wire, Coming off connector
13 1. Check ECM relay for a condition.
14 1. Check ignition circuit for an open or short to
voltage.
2. Check ignition switch for a condition.
Was the problem found? — Verify repair —
15 1. Check ECM battery circuit for an open.
16 1. Check ECM ignition feed circuit and ECM battery
feed circuit.
17 1. Probe the ignition feed circuit at the cluster
connector for open or short to ground.
Did it turn on? — Verify repair —
18 1. Replace ECM.
Is the action complete? — Verify repair —
19 1. Probe the cluster connector for a coming off.
Did it turn on?
Check Engine Lamp “ON” Steady

Circuit description
The check engine lamp should always be illuminated
and steady for about five seconds with ignition “ON” and
the engine stopped. Ignition feed voltage is supplied
directly to the check engine lamp indicator. The Engine
Control Module (ECM) turns the check engine lamp
“ON” by grounding the check engine lamp driver circuit.
The check engine lamp should not remain “ON” with the
engine running and no DTC(s) set. A steady check
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
• Poor connection or damaged harness – Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. If the check engine lamp does not remain “ON”
when the ECM is disconnected, the check engine
lamp driver wiring is not faulty.
3. If the check engine lamp driver circuit is OK, the
instrument panel cluster is faulty.
Check Engine Lamp “ON” Steady

1 Was the “On-Board Diagnostic (OBD) System Check” Go to “On
performed? Board
Diagnostic
(OBD) System
— Go to Step 2 Check”
2. Disconnect ECM.
3. Ignistion “On”, observe the check engine lamp.
2. Disconnect the instrument panel cluster.
3. Check check engine lamp driver circuit between
ECM to the instrument panel cluster for short to
voltage.
4. If the problem is found, repair circuit as necessary.
4 1. Replace instrument panel cluster.
Was the malfunction fixed? — Verify repair
5 1. Check ECM ground circuit for an open or short to
voltage.
6 Replace ECM.
Is the action complete? — Verify repair —
6E–90
ECM
25A
EVRV: MAG valve VSV:

SW:Neutral 6 7
2 EGR Exh Brake INT. Throttle
(MT only)
(NKR 4JH1-TC only)
MAF VSV : Ext 1 (QWS)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H

DTC P0100
Batt Batt Batt Batt Batt
CF 150
US
MAF SENSOR MALFUNCTION
Batt
CPU µP µP µP µP
IC 08
IC 08 µP
MAF Circuit
NTC IAT sensor
+5V
4
Heater
MAF sensor
Temperature Sensor
Power Supply
Power Ground
Suppliment Voltage
Voltage Output
Top view of mode on page 6E-92.

HOTFLM-MASS AIR SENSOR
MTC CILY IN PAST ACC. POS. MO. 2 MCLSED
CYLINDER HOUSING
BUSH
SCREEN FILTER WITH FAN
FLOW GRID
Circuit Description
The mass air flow meter uses a platinum hot wire. The
hot wire air flow meter consists of a platinum hot wire,
thermistor and a control circuit installed in a plastic
housing. The hot wire air flow meter works on the
principle that the hot wire and thermistor located in the
intake air bypass of the housing detect any changes in
the intake air temperature.
The hot wire is maintained at the set temperature by
controlling the current flow through the hot wire. This
current flow is ten measured as the output voltage of the
air mass flow meter.
The circuit is constructed so that the platinum hot wire
and thermistor provide a bridge circuit, with the power
transistor controlled so that the potential of A and B
remains equal to maintain the set temperature.
DTC P0100 SUB CODE 1100

MAF SENSOR CIRCUIT HIGH INPUT

1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? — Go to Step 2 system check
2 1. Clear the DTC. Refer to
2. Observe the DTC. Intermittent
Was the DTC P0100 stored? Go to Step 3 Diagnosis
3 Breaker box is available
Ignition off
Install breaker box as type B, see page 6E-58.
Disconnect MAF sensor.
Measure voltage between ECM pin 88 and pin 92.
Breaker box is not available
Ignition off
Disconnect ECM from ECM harness.
Measure voltage at ECM pin 88 and pin 92.
If voltage indicates "0"V, go to step 4.
If voltage indicates more than "0"V, disconnect MAF
sensor. Measure voltage between ECM pin 88 and pin
92. If voltage indicates 0 volt, go to yes column at this
step. If voltage indicates more than 0 volt, repair Replace MAF
Engine harness. 0V and verify Go to Step 4
Ignition off
Replace the ECM to the another ECM known as OK.
Measure voltage between ECM pin 88 and pin 92.
Ignition off Repair engine
Replace the ECM by the ECM know as OK. Replace ECM harness and
Check DTC turn ON or not. 0V and verify verify

MAF SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT

2 1. Clear the DTC P0100. Refer to
2. Observe the DTCs. Intermittent
Was the DTC P0100 stored? — Go to Step 3 Diagnosis
Ignition off
Disconnect MAF sensor from engine harness.
Measure voltage at ECM pin 83 and ground. Replace MAF
Measure the resistance between ECM pin 83 and sensor and
ground. 5V verify Go to Step 4
Ignition off
Disconnect engine harness at ECM side and MAF
side both.
Measure resistance between engine harness
connector pin 83 and ground.
ECM harness connector
83
More than Repair engine

10MΩ Go to Step 5 harness
Ignition off
Replace the ECM to the another ECM known as OK. More than Repair Engine
Measure voltage at ECM pin 83 and ground. 4.6V Replace ECM harness
5 Breaker box is not available
Ignition off
Keep disconnected MAF condition.
Measure resistance between MAF side connector pin
3 and ground.
1 2 3 4 5
MAF sensor connector Replace ECM Replace MAF

13.70kΩ and verify and verify

MAF SENSOR CIRCUIT LOW INPUT

Ignition off
Install breaker box as type A, see page 6E-58.
Make jump wire between MAF 3 pin and MAF 4 pin at
engine harness connector.
Check continuity between 83 and 92.
1 2 3 4 5
Continuity
Make jump wire between MAF 3 and MAF 5 pin at
Check continuity between ECM pin 88 and pin 92.
1 2 3 4 5
Continuity
Remove jump wire, MAF sensor should disconnected.
Check isolation resistance between ECM pin 88 and More than
ECM pin 92. 1MΩ
Ignition off
Disconnect engine harness from ECM and MAF.
Make jump wire between MAF 3 pin and MAF 4 pin at
1 2 3 4 5
Continuity
Make jump wire between MAF 3 and MAF 5 pin at
Check continuity between ECM pin 88 and pin 92.
1 2 3 4 5
Continuity
Remove jump wire, MAF sensor should disconnected.
Check isolation resistance between ECM pin 88 and
ECM pin 92.
88
92
Repair or
More than Replace
1MΩ Go to Step 4 harness

Ignition off
Check MAF sensor resistance between MAF pin 5 Less than
and 3. 13.7KΩ Replace ECM Replace MAF

MAF SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT

Ignition off
Disconnect MAF connector from engine harness.
Measure voltage between ECM pin 83 and ground. 5V
Ignition off
Disconnect engine harness at ECM side.
Measure isolation resistance between ECM pin 83 at
engine harness side and ground.
83
More than
1MΩ Go to Step 4 Go to Step 5
4 Measure voltage at MAF connector.
1 2 3 4 5
Go to
Intermittent
0V Diagnosis. (I/D) Replace MAF
Ignition off
Replace to the another ECM known as OK. Replace ECM Repair engine
Measure voltage between ECM pin 83 and ground 5V and verify harness
Ignition off No DTC DTC ON
Replace to the another ECM know as OK. Replace ECM Repair engine
Check DTC turn ON. No DTC and veirfy harness
DTC P0110
IAT Sensor Maifunction
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

IAT Sensor Low Voltage


Ignition off
Measure resistance between 84 and ground.
Ignition off
Disconnect ECM harness and MAF sensor.
84
More than
1MΩ Go to Step 4 Repair wiring
Ignition off
Connect MAF sensor.
Measure resistance between 84 and 92.
Ignition off
Keep MAF connector disconnected.
Measure resistance between MAF 1 and MAF 3. No short
circuit
Appx 2.0KΩ
1 2 3 4 5
at 20°C room
temperature Replace ECM Replace MAF

IAT High Voltage (Open Circuit)

Ignition off
Make jump wire between MAF 1 and MAF 3 at MAF
connector side.
1 2 3 4 5
Check continuity between 84 and 92. Continuity

Ignition off
Disconnect ECM, MAF sensor.
Make jump wire between MAF 1 and MAF 3 at MAF
connector side.
1 2 3 4 5
Repair engine
harness and
Continuity Go to Step 4 verify
Ignition off 2.0KΩ at
Disconnect MAF sensor. 20°C room
Measure resistance between MAF pin 1 and pin 3. temperature
Measure any voltage at pin 1 or 3. 0V
Ignition off 2.0KΩ at
Disconnect MAF sensor. 20°C room Replace MAF
Measure resistance between MAF pin 1 and pin 3. temperature sensor and
Measure any voltage at pin 1 or 3. 0V Go to Step 5 verify

Ignition off
Replace to the another ECM know as OK.
Check DTC ON or not.
Ignition off
Replace to the another ECM know as OK.
Check DTC ON or not. No DTC ON Replace ECM —
1 23 4 5
DTC P0115
Engine Coolant Temperature Sensor Malfunction
16 15 14 13 12 11 10 9
VSS
8 7 6 5 4 3 2 1
Balt
29 4
ABS
TDC ECT
7 8
27 68 62 32 90 98 89 93 35 45
Balt Balt
Us
IC 08 IC 08
IC 08
µP IC 08 IC 03
Circuit Description Engine Coolant Temperature Sensor

The ECT Sensor is a thermistor. A temperature
changes the resistance value. And it changes voltage. °C OHMS
In other words it measures a temperature value. It is
Temperature vs. Resistance Values (approximate)
installed on the coolant stream. Low coolant
temperature produces a high resistance. 100 177
The ECM supplies a 5 volts signal to the ECT Sensor 80 332
through resisters in the ECM and measure the voltage.
60 667
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine 45 1188
temperature is hot. The ECM uses to this value, and 35 1802
calculates a SPV switching, a fuel injection timing, a
25 2796
main injection volume and an EGR VSVs switching.
The Scan Tool displays ECT in degrees. After engine 15 4450
start up, the temperature should rise steadily to about 5 7280
80°C.
−5 12300
If the engine has not been run for several hours, the
ECT and intake air temperature displays should be −15 21450
close to each other. An ECT failure with the short to −30 52700
voltage or ground will set a DTC P0115.
−40 100700
DTC P0115 SUB CODE: 0001

ECT SENSOR CIRCUIT HIGH INPUT

3 Check water temp metor.
Does it indicate very low temperature? Go to Step 4
4 Check atomosphere temperature? Less than
-36°C Go to Step 5 Go to Step 7
5 Warm up engine. Lamp goes off No repair
Check lamp goes off or not. after warm up necessary Go to Step 6
6 Does water temperature meter indicate still low Coolant system Peplace ECT
temperature? and lamp still stay. check sensor
Ignition off
Install a breaker box as type A, see page 6E-58.
Disconnect ECT sensor.
Make jump wire between ECT connector pins.
Check continuity between ECM pin 93 and 89.
Ignition off
Disconnect ECM connector and ECT sensor.
Make jump wire between ECT connector pins.
105
Continuity Go to Step 8 Repair wire

8 Check ECT resistance. Compare with
ECT sensor Replace ECT
table. Go to Step 9 sensor
Ignition off
Measure voltage between ECM connector pin 89 and
ground.
Ignition off
ground.
99
0V Replace ECM Repair harness

DTC P0115 SUB CODE: 0010

ECT SENSOR CIRCUIT LOW INPUT

3 Check water temp meter.
Does it indicate very high temperature? or indicate
more than max condition. Go to Step 4 Go to Step 8
4 Check engine has over heat condition. More than Follow
136°C DTC mechanical
turns ON section Go to Step 5
5 LLC consentration is too high, check reserver tank. LLC : Water =
50 : 50 Go to Step 6 Change LLC
6 Check radiator cap setting pressure. See the
mechanical
section Go to Step 7
7 Check water temp meter indicator. See the
electrical
section —
Ignition off
Disconnect ECT sensor.
Make jump wire between ECT sensor connector.
Check short to ground between ECM connector pin 89
and ground.
Ignition off
Disconnect ECM connector and ECT sensor.
Make jump wire between ECT sensor terminal.
Check ECT circuit short to ground.
105
No short to
ground Go to Step 9 Repair wiring

9 Check ECT sensor not short to ground.
No short to Short to ground

ground Go to Step 10 replace ECT
10 Check ECT sensor performance.
Does it indicate within the engine coolant temperature
sensor resistance table? See the table Replace ECM Replace ECT

FUEL TEMPARETURE SENSOR CIRCUIT RANGE/PERFORMANCE
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP
Circuit Description
Fuel temperature sensor is located in injection pump.
Fuel temperature sensor malfunction message is sent
by DSG through CAN communication.
CAN communication failure is indicated by other DTC.

3 Ignition on and run engine. Out of
Check Tech-II data within 3 sec right after engine run. specification
* After 3 sec, fuel temperature becomes back up -40°C<fuel Replace
default figure, therefore data can not defect. temp<150°C Go to Step 4 injection pump

Ignition off
Disconnect PCU connector.
Make jump wire between PCU connector pin 1 and 2.
Check continuity between ECM connector 99 and
100.

Ignition off
Disconnect ECM connector.
Make jump wire between PCU connector pin 1 and 2.
Check continuity between ECM connector 99 and Replace
100. Continuity injection pump Repair wiring
DTC P0215
FUEL CUTOFF SOLENOID VALVE MALFUNCTION
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
TDC MAB
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP
Conditions for Clearing the MIL/DTC

• Diagnostic Trouble Code P0215 can be cleared by
using the Scan Tool’s “Clear Info” function.

FUEL CUTOFF SOLENOID VALVE (MAB) CIRCUIT HIGH INPUT

2 1. Clear the DTC P0215. Go to
Was the DTC P0215 restored? — Go to Step 3 Diagnosis

Ignition off
Check short circuit between ECM pin 105 and power
source points, see “reference” on page 6E-110.
Sample shows only 4JA1-TC, but other 4JH1-TC
system should be same points.
Ignition off
Disconnect ECM and PCU connector.
source points, see page 6E-110.
105
see No short
page 6E-110 circuit Go to Step 4 Repair wiring
Ignition off
Make jump wire between PCU connector 1 and 2.
Check continuity between ECM connector pin 99 and
connector pin 100.

Ignition off
connector pin 100.
99
Continuity Repair wiring

reference
BATT
RELAY ; ECM MAIN
PA01
8B/R
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
IC03
2B/Y
IC01
2L/R
A41(3)
A63(63) IC05
MAIN
IG.1
50A
80A
0.5Y A-2
ECM
0.5L/B
25A
2 B24(100) A56(58)
IC31 IC04 VSV ; EXT 1
INJ.PUMP
0.5R A-3
3 B23(99)
GLOW
PA28
50A
40A
IG2
IC32 0.5W/B 0.5L/R
8W
PA28
A37(40)
3B
0.5O A-4 IC22 IC17
4 B29(105)
IC33 VSV ; EXT 2
0.5P A-5
1 B13(91) 0.5W/R 0.5L/R
IC34 A59(61)
0.5L/R
J/C ; B
IZ03
IC23 IC18
HB01
5R/W
3W/B B1
PA02
PA03
PA13
PA16
0.5
IC11
3W B2
3W
3W
EVRV ; EGR
0.5B/O 0.5L/R
SW ;IGNITION
B19(97)
IZ04
0.5
IC26 IC16
ACG(B)
STOP
10A
EB
B2(83) 0.5W/R IC27
4
OFF
0.5G/R IC28 0.5L/R
ACC
B7(88)
MAF
5 2
(THROTTLE VALVE)
IG1 3B/R
IG2
ST
0.5B/R IC30 IC15
T.P.S.&SW ; IDLE
0.5G/B A-6 B14(92) 3

A69(69) B3(84) 0.5B/L IC39
1
SW ;THERMO
IC35
0.5R/G A-7
RELAY ;
A47(49)
GLOW
SW ; ENG WARMING
IC36
CA01
JOINT 0.5B 0.5G/R
PA17
JOINT
3B/R
0.5G
0.5G/O A-8 TO MX01 BX16 BA26 TO BA15
A35(38)
IC37 0.5BR/R
A44(46)
ENGINE
IC14
METER
0.5B/G A-9
BACK
A55(57)
10A
15A
15A
IC38 0.5B JOINT
HY05 TO SX01
0.5B/L HB06
IZ07
IZ06
B16(94)
0.5L/Y IC06
0.85W
MA01
0.85Y
KA01
A36(39)
SW ; BRAKE
0.5R IC12
A27(30)
(ON)
0.5B/R
0.5W/B IC13
IC50
0.5B/P B-7 A65(65)
SENSOR
B15(93) (OFF)
IC43 RESISTER ; CLUTCH SW
ECT
(YZK NO ; 7321-9900)
0.5B 0.5Y SW ; CLUTCH
0.5GR B-1
B8(89) IZ08 510 IC57 0.5G
IC44 A28(31)
CA02
0.5G
0.5R
IC48
GLOW PULG x4
1 0.5W B-2
B22(98) A-16 5B/R
IC45
TDC
3 HB03
2 0.5G/R B-3
B12(90) FUEL
IC46
HEATER
B-10 SW ; NEUTRAL 0.5B
IZ05 0.5B/W B-10 0.5L/R
B25(101) B6(87) IZ05
IC10 IC09
SW ; BACK UP
0.5B/W
RESISTER ; NEUTRAL SW
IC58
A-1 0.85Y
KA01
B-11 0.85R/Y
(IDLE SW)
KA02
2B A-11 0.85Y
A61(2)
IZ01 MA02
VEHICLE SPEED
SENSOR A-12 0.5L/B
0.5B
IZ10
2B 0.85B
A62(1) MX05 MA03 METER
IZ02
B-14 0.5Y/B B6
CONT ; 0.5R/L MA06
MB11 OIL PSESSURE UNIT OIL GAGE
0.5Y/G
MA09
4WD
0.5B 4WD SW B-6 0.5W/R B15
ECM IZ06 MA11
SW ; OIL
OIL
B-5 0.5L A10
MA10
GLOW
0.5O/L B8 B2
BACK UP LAMP
A40(43)
BRAKE LAMP
MA28
CHECK ENG
0.5BR/Y A6
A39(42)
IC29
TACHO METER
0.5B/R B3
A24(27)
JOINT TO EX12
MA05
0.5O/L
MB01
SPEED METER
0.5L/W A8 A9
A68(68)
IC21 RELAY ; A/C COMPRESSOR
; ENGINE
CONNECTION
0.5BR/W HA20 1 0.5BR HA19

A38(41) CONT ; IMMOBILIZER(B1)
B-5 0.5G 4 2 0.5BR HA17
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
HA18
0.5O/B
0.5B/L
MB04
EX02
MAG.CLUTCH
(COMPRESSOR)
0.5B
EX03 0.5G 0.5BR
HA22 HA23
0.5L
A43(45) 0.5G/R 1 0.5L/W HA14
IC47 ELEC.THERMO FUSE ; BLOOR
HA13 4 2 0.5G/W HA16
0.5G HA21
A30(33)
RESISTER ; IDLE UP
0.5B 0.5G
HX03 270 HA24 RELAY ; A/C THERMO 0.5G
SW ; PRESSURE IC30
ECM
REV

FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE

Ignition off
source points, see “reference” on page 6E-110.
Ignition off
Disconnect ECM and PCU connector.
source points, see 6E-110.
105
see No short
page 6E-110 circuit Go to Step 4 Repair wiring

Ignition off
connector pin 100.

Ignition off
connector pin 100.
99
100
Continuity Go to Step 5 Repair wiring

5 Replace to ok ECM run engine for more than 5 sec, if
no DTC occures, goes to ‘NO’ column if DTC occures, Replace
goes to ‘YES’ column. injection pump Replace ECM


2. Observe the DTCs. Replace Intermittent
Was the DTC P0215 restored? — injection pump Diagnosis


Was the DTC P0215 restored? — Replace ECM Diagnosis
DTC P0216
TIMING DEVICE DEVIATION
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
TDC MAB
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

PERSISTANT GOVERNER DEVIATION

3 Check timing gear positions align between cam and
injection pump. See the timing gear check procedure
in the mechanical engine section. Go to Step 4 Adjust
4 Check TDC sensor with any damage or exciter ring Replace or
teeth damage. Repair
Replace TDC sensor or
injection pump exciter ring
DTC P0216
TIMING DEVICE FLUCTUATION

3 Bleed air in fuel. Verify still DTC
See the procedure of air bleed in fuel section. Verify appears
4 Replace injection pump. Verify —
DTC P0251
INJECTION MALFUNCTION
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
TDC MAB
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

INJECTION PUMP MALFUNCTION 1

3 Replace injection pump Verify

TDC AND CAM SPEED COMPARSION ERROR

3 Check TDC sensor with any damage and exciter ring Replace or
with any damage. Repair TDC
sensor or
Go to Step 4 exciter ring
Ignition off
Measure resistance between 91 and 105.

Ignition off
Disconnect ECU and PCU harness.
Make junping between 8 and 5.
91
105
Replace ECM
and verify if still
DTC appears. Repair wiring
Measure resistance between 91 and 105. 0Ω Go to Step 5 harness
5 Replace injection pump. Verify —


DTC P0251 SUB CODE 1010, 1011, 1101

INJECTION PUMP MALFUNCTION 3, 4, 5



Ignition off
Check continuity between ECM connector 99 and
100.
Replace ECM
Breaker box is not available ↓
Ignition off Verify
Disconnect ECM, PCU connectors. ↓
Make jump wire between PCU connector 1 and 2. NG
Check continuity between ECM connector 99 and Replace
100. Continuity injection pump Repair wiring
DTC P0335
TDC MALFUNCTION

TDC INPUT CIRCUIT SIGNAL RANGE/PERFORMANCE (OVER SPEED)
16 15 14 13 12 11 10 9
VSS
8 7 6 5 4 3 2 1
Balt
29 4
ABS
TDC
7 8
27 68 62 32 90 98 89 93 35 45
Balt Balt
Us
IC 08 IC 08
IC 08
µP IC 08 IC 03
TDC sensor Excitor ring


1 Ask the customer whether or not he experience over Explain
speed condition such as long down slope driving, mis customer why
gear shift etc. DTC turns on Go to Step 2
Ignition off
Measure resistance between ECM pin 90 and 98.
Ignition off
Measure resistance between ECM connector 90 and
98.
98
90
0.9KΩ
at 20°C room
temp Go to Step 6 Go to Step 5
Ignition off
Disconnect TDC sensor connector.
Make jump wire between TDC connector pins.
Ignition off
Disconnect TDC sensor.
98.
98
90
Replace TDC
Continuity sensor Repair wire
6 Check shield wire and ground.
Check any damage of wire related shield wire. Go to Step 7 Repair
7 Check any accessary which may cause electric or Remove
magnetic interference. accessary and
Go to Step 8 verify

Ignition off
Connect TDC sensor.
Connect ECM to breaker box as type B.
Run engine.
Measure voltage at ECM pin 90 and 98 by digital volt
meter AC range.
98
90

Ignition off
Skip this step.
Go to next step 9. 18V Replace ECM Go to Step 9
9 Check TDC sensor. No damage Replace TDC
Remove TDC sensor. No foreign sensor and
Check any damage or foreign materials on TDC. material Go to Step 10 verify
10 Check exciter ring whether or not any damage. Replace or
Repair excitor
Replace ECM ring

TDC DYNAMIC PLAUSIBILITY

Ignition off
Ignition off
98.
98
90
0.9KΩ at
20°C room

Ignition off
Ignition off
98.
98
90
Replace TDC
Continuity sensor Repair wire
Go to Step 7 verify
Ignition off
Connect TDC sensor.
Connect ECM to breaker box as type B.
Measure voltage at ECM pin 90 and 98 by digital volt
meter AC range.
98
90

Ignition off
Skip this step.
Go to next step 9. Replace ECM Go to Step 9
8 Check TDC sensor. NO damage Replace TDC
Remove TDC sensor. NO foreign sensor and
Repair excitor
Replace ECM ring

ENGINE SPEED INPUT STATIC PLAUSIBILITY

Ignition off
Ignition off
98.
98
90
0.9KΩ at
20°C room

Ignition off
Ignition off
Check continuity between ECM connector pin 90 and Replace TDC
98. Continuity sensor Repair wire
Go to Step 7 verify
Ignition off
Connect TDC sensor.
Disconnect ECM from breaker box.
Measure voltage at ECM pin 90 and ground or
between ECM pin 98 and ground. 0V
8 Check TDC sensor. NO damage Replace TDC
Remove TDC sensor. NO foreign sensor and
Repair excitor
Replace ECM ring
DTC P0380
GLOW DEVICE MALFUNCTION
Glow ECU
60A Relay Register idle SW
Relay APS
G/plug
Glow
plug
+5V
94 57 38 49 69 2 1
GND GND
Balt
IC 08
µP
System Description
Pre glow system calibration Example
sec.
8 Pre glow
7 After glow
glow current
glow relay on setting curve After run
6
5
Time
4
3
Lg ON Cranking Vehicle Log
2 run
1
0
-30 -10 10 30 50 70 90
Water temperature (°C)
After glow system calibration
sec.
30
glow relay on setting curve

24
Time
18
-10 0 10 30 35
After run glow
sec.
100
glow relay on setting curve
45
Time
40
35
0 10 20 30

GLOW DEVICE VOLTAGE HIGH

Ignition off
Check short circuit between ECM pin 94 and pour
souce line see “reference” on page 6E-129.
Ignition off
Disconnect ECM connector and ECM relay.
Check short circuit between ECM pin 94 and pour No short Repair wiring or
souce line see “reference” on page 6E-129. circuit Replace ECM G/plug relay
reference
RELAY ; ECM MAIN
BATT
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
PA01
8B/R
IC03
2B/Y
IC01
0.5L/R
IC62
0.5L/R IC11
0.5L/W HB04
2L/R IC05 0.5L/R HA15
A63(63)
MAIN
A41(3)
IG.1
50A
80A
0.5L/R IC15
ECM
0.5Y A-2
25A
2 B24(100) 0.5L/B IC04 0.5L/R HA19
IC31 A56(58)
INJ.PUMP
0.5R A-3 0.5W/R IC27

3 B23(99)
GLOW
B2(83)
PA28
4
50A
40A
PA28
IG2
IC32
8W
3B
0.5G/R IC28 0.5L/R
0.5O A-4 B7(88) 5 2
4 B29(105) 0.5B/R IC30 IC15
IC33 B14(92) 3 MAF
0.5P A-5 0.5B/L IC39
1 B13(91) B3(84) 1
IC34
0.5L/R
0.5BR
0.5BR
J/C ; B
HA19
HA15
HB01
5R/W
3W/B
PA02
PA03
PA13
PA16
IZ03
IC11
RELAY ;
0.5
3W
3W
3W
A/C COMPRESSOR
SW ;IGNITION
B1
B2
0.5BR/W HA20 1
A38(41)
ACG(B)
STOP
0.5L/W
B-1 0.5G 4 2 0.5BR FUSE ;
10A
HB04
EB
HA18 HA17 A/C
OFF
MAG.CLUTCH
ACC
IG1 3B/R
IG2
ST
(COMPRESSOR)
SW ; PRESSURE
0.5B 0.5G RELAY ;
RELAY ;
GLOW
A/C THERMO
HX22 HA23
CA01
PA17
3B/R
0.5G
1 0.5L/W
ELEC.THERMO 0.5G/R FUSE ;
HA13 4 2 HA14 BLOOR
0.5B/P B-5 0.5G HA21
A30(33)
SENSOR
B15(93)
IC43 0.5G/W HA16
ENGINE
RESISTER ; IDLE UP
METER
ECT
BACK
10A
15A
15A
(YZK NO ; 7321-9430)
0.5O B-6 0.5B 0.5G
B8(89) HX03 HA24
IC44
270
0.5B/L HB06
B16(94)
0.85W
MA01
0.85Y
KA01
0.5L/Y IC06
1 0.5W A-7 A36(39)
B22(98) SW ; BRAKE
IC45
TDC
3 0.5R
A27(30)
IC12 (ON)
2 0.5G/R A-8
B12(90) 0.5W/B
IC46 A65(65)
IC13 (OFF)
A-9
IZ05
B25(101)
GLOW PULG x4
A-16 5B/R
HB03
CA02
0.5G
0.5R
IC48
IZ04
0.5 B
B6(87) 0.5R/B
IC60 0.5R/B
E
IC61
P C-15 0.5R/G
10
(THROTTLE VALVE)
OA10
T.P.S.&SW ; IDLE
F 0.5G/B R A-10 0.85R/Y 0.5R/Y

A69(69) 11
IC35 KA02 OA11
A 0.5R/G N C-10 0.5W/R 0.5W/R
A47(49) 31
IC36 OA57 OA31
C-3 0.5Y/R TCM
C D 32
0.5G/O
A35(38) OA32
IC37 C-4 0.5Y/L
2 47
B 0.5B/G OA58
IC38 A55(57) 1 C-2 0.5Y/V 48
OA59
IZ07
B N B-4 0.5B/W
FUSE ; STARTER
LA06
ECM C-14 0.5B/G
RELAY ; STARTER
LA09
A-1
2B
A61(2)
IZ01 SW ; MODE A-11 0.85Y
MA02
VEHICLE SPEED
2B SENSOR
A62(1) 0.85B A-12 0.5L/B
IZ02
0.85R/Y
MX05 MA03
KA02

CONT ; 0.5R/L B-3 0.5Y/B B6
MB11 MA06
0.5Y/G
MA09
4WD
0.5B 4WD SW B-2 0.5W/R B15
IZ06 MA11(W/SOF)
OIL
JOINT TO EX12
A-6 0.5L A10

MA10
GLOW
0.5O/L B8 B2
A40(43)
MA18
CHECK ENG
BACK UP LAMP
; ENGINE
0.5BR/R A6
CONNECTION
A39(42)
BRAKE LAMP
IC29
TACHO METER
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
0.5O/B
0.5B/R B3
0.5B/L
MB04
EX02
A24(27)
MA05
OA25
0.5B SPEED METER

EX03 0.5L/W A8 A9
A68(68)
IC21 25
0.5L 37 5 OA05
A43(45) 0.5R/Y
IC47 A46(48) METER
OA60
0.5B/R 6
A26(28) TCM 0.5O/L
OA06 CONT ; IMMOBILIZER(B1)
MB01
ENG 0.5B
EARTH OX01
0.5G
IC48
DTC P0380
GLOW DEVICE VOLTAGE LOW (Short to ground or internal ECM to ground)

Ignition off
Install breaker box.
Disconnect ECM relay.
Check continuity between ECM relay socket 87a (NKR
4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) pin and ECM
94 pin. Continuity
Check short to ground between ECM 94 pin and
ground. No short to
87 85 ground
87a
86 85
87 30
30 86
ECM relay ECM relay

(N∗R) (TF4JA1-TC,4JH1-TC)

Ignition off
Disconnect ECM connector and ECM relay.
4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) pin and ECM
94 pin. Continuity
Check short to gruons between ECM 94 pin and
ground.
94
87
87a
86 85
30
ECM relay
85
86
87 30 No short to
ground Replace ECM Repair wiring
DTC P0381
GLOW TIME TELLTALE CIRCUIT MALFUNCTION
1G
ECM Stop lamp

15A
25A 10A
Relay EW
Stop lamp SW SW:clutch SW:ExG Brake

Glow Clutch pedal:OFF Meter
plug
relay
coil ExG Check
Glow
Brake Engine
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
IC 035 IC 035

GLOW TIME TELLTALE CIRCUIT SHORT TO BATTERY VOLTAGE

3 Check glow lamp bulb is burnt out. Go to Step 4 Replace bulb

Ignition off
Remove #12 fuse (NKR), meter fuse (TF).
Disconnect ECM connector from the breaker box.
Measure voltage between ECM pin 43 and ground.
Ignition off
Disconnect ECM connector and #12 fuse (NKR) or
meter fuse (TF).
ground.
43
0V Replace ECM Repair wiry


GLOW TIME TELLTALE CIRCUIT (Open circuit or short to ground)

3 There are two DTC P0381, P1690 ON? See the P1690
wiring check Go to Step 4
Ignition off
Remove #12 fuse (NKR) or meter fuse (TF).
Check resistance between ECM pin 42 and 43 or
continuity.
Ignition off
Disconnect ECM connector, and #12 fuse (NKR) or
meter fuse (TF).
Check resistance between ECM connector pin 42 and
43 or continuity.
Lamp value
NKR 140Ω/
12V
43 42
460Ω/
24V
TF 140Ω/
12V Repair wiring
Continuity Go to Step 35 for open circuit
Ignition off
Check resistance between ECM pin 43 and ground.
Ignition off
Check resistance between ECM connector pin 43 and
ground.
43
Repair wiring
More than for short to
10MΩ Replace ECM ground
DTC P0400
EGR SYSTEM MALFUNCTION
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

EGR CIRCUIT OPEN

Ignition off
Remove ECM relay.
4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) and ECM pin
97.
87 85
87a
86 85
87 30
30 86
ECM relay ECM relay

(N∗R) (TF4JA1-TC,4JH1-TC)

Ignition off
Disconnect ECM connector, ECM relay.
4JH1-TC), 30 (TF 4JA1-TC, 4JH1-TC) and ECM pin
97.
97
87
87a
86 85
30
ECM relay
85
Repair wiring or
86
87 30 Repair EVRV of
Continuity Replace ECM EGR

EGR CIRCUIT HIGH INPUT

Ignition off
Disconnect EVRV:EGR from wiring harness.
Ignition ON, no engine run.
Check voltage between ECM pin 97 and ground.
Ignition off
Disconnect ECM harness and EGR EVRV.
Ignition ON, no engine run.
Check voltage between ECM pin 97 and ground.
Breaker
EVRV:EGR box
ECM
Replace EVRV
check
0V Go to Step 4 Repair wiring
4 Verify
Still DTC ON. Replace ECM

EGR FLOW EXCESSIVE DETECTED
A0 (Air mass mcasured by MAF)

Intake shutter Aircleaner
Compressor
MAF Output A0
MAF Airduct
EGR
ENG A1 If A0≠A2,
(Leakage) need of cheak leakage A1,
because A2=A0+A1
Turbo
Silencer Exh. valve

A2 (Air mass goes to cylinders)

3 Check inlet pipe disconnected or loose or hole or
detorted.
A0 (Air mass mcasured by MAF)
MAF Output A0
A1 If A0≠A2,
(Leakage) need of cheak leakage A1,
because A2=A0+A1
A2 (Air mass goes to cylinders)

Repair Go to Step 4
4 Check intake shutter stack closed with engine Repair intake
running. shutter Go to Step 5
5 Check MAF is within typical data. Check turbo
Go to Step 6 system
6 Check exhaust pipe, silensor detorted, or deformed. Replace
It may cauese exhaust pressure extremely high. exhaust related
brake Go to Step 7

7 Check exhaust brake stuck close, if exhaust breake is
required.(NKR 4JH1-TC only)
mighty vac
Picture Exh. Brake
Open
Apply vacuum by mighty vac. Replace

See the valve operation. exhaust brake Go to Step 8
8 Check EGR value stuck open.(NKR 4JH1-TC, TF
4JA1-TC only)
check
window
Apply vacuum by mighty vac.

Check valve operation through window. See page 6E-
140. Go to Step 9
9 Check MAF data within typical data. Go to Step 10 Replace MAF
10 Replace ECM Verify

EGR FLOW INSUFFICIENT DETECTED
Intake shutter Aircleaner

Compressor
MAF Airduct
EGR
ENG
Turbo
Silencer Exh. valve

3 Check exhaust system such exhaust pipe, silensor
etc. disconnected. Repair Go to Step 4
4 Check wastegete setting pressure.
Is it in specification? — Go to Step 5 Repair
5 Check EGR pipe disconnected or any leak from EGR
pipe, EGR valve. Repair Go to Step 6
6 Check EGR cooler has coolant circulation operation.
No circulation or no water? Repair Go to Step 7
7 Check EGR valve stuck closed. Replace EGR
valve Go to Step 8
8 Cehck MAF with typical data. See the
Is it within typical data? typical data
table Replace ECM Replace MAF
reference
DTC P0500
VSS MALFUNCTION
VSS 16 15 14 13 12 11 10 9
meter fuse
(TF 4JA1-TC/ (NKR 4JH1-TC only) 8 7 6 5 4 3 2 1
4JH1-TC only)
29 4
VSS ABS
TDC ECT
7 8
Speed meter Speed meter
68 27 68 62 32 90 98 89 93 35 45
Balt Balt Balt

Us
IC 08 IC 08
IC 08
µP IC 08 IC 03

VSS CIRCUIT HIGH INPUT

3 Check speed meter, whether meter indicate incorrect Indicate Indicate correct
speed. incorrect speed speed
Go to Step 4 Go to Step 7
4 Check the speed meter. (TF 4JA1-TC/4JH1-TC only)
See the electrical section. Go to Step 5 Repair
5 Check the vehicle speed sensor wiring.
6 Check the vehicle speed sensor, exciter ring.
Remove the vehicle speed sensor.
Inspect any damage of sensor, exciter ring and foreign
material on the sensor, or on the exciter ring. Go to Step 7 Repair

Ignition off
Install a breaker box as type B, see page 6E-58.
Remove the connector from the meter.
Measure any voltage between ECM pin 68 and
ground at breaker box. No voltage
Ignition off No damage at
Check the wiring between speed meter output and wiring Replace ECM
ECM. harness and verify Repair wiring

VSS INCORRECT SIGNAL

3 Check speed meter indication.
Is the meter indication OK? Go to Step 4
4 Check the speed meter.
5 Check the vehicle speed sensor wiring.
6 Check the vehicle speed sensor, exciter ring.
Remove the vehicle speed sensor.
Inspect any damage of sensor, exciter ring and foreign
material on the sensor, or on the exciter ring. Go to Step 7 Repair
Ignition off
Install a breaker box as type B, see page 6E-58.
Remove the connector from the meter.
Measure any voltage between ECM pin 68 and
ground at breaker box. No voltage
Ignition off No damage at
Check the wiring between speed meter output and wiring Replace ECM
ECM. harness and verify Repair wiring
8 Check the meter output.
See the electrical section. Go to Step 9
9 Replace ECM. Verify

VSS PLAUSIBILITY

3 Check whether the speed meter is operated correctly.
(NKR 4JH1-TC only)
If not, inspect signal line of VSS.
And inspect VSS sensor, exciter ring.
(TF 4JA1-TC, 4JH-TC) The speed
If not, inspect signal line of VSS. meter is Repair wiring
And inspect VSS sensor, exciting ring. operating harness or VSS
Check speed meter out put. correctly Go to Step 4 or exciter ring
4 Check the wiring between signal of speed sensor and No open Repair wiring
ECM. circuit Replace ECM harness
DTC P0560
SYSTEM VOLTAGE MALFUNCTION
1G
ECM Stop lamp

15A
25A 10A
Relay EW

plug
relay
coil ExG Check
Glow
Brake Engine
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
IC 035 IC 035
Circuit Description
Battery voltage condition is detected at ECM terminal
NO 3 by ECM internal IC.

SYSTEM VOLTAGE TOO LOW

3 Check battery voltage. Battery
voltage ≥ 7V Go to Step 4 Replace battery

Ignition off
Remove ECM fuse 1.
Check resistance of ECM 58 ˜ ECM fuse1.
Remove relay.
Check continuity between ECM 3 and relay socket B.
Check continuity between relay socket A and fuse 1. Continuity
Ignition off
Disconnect engine harness at ECM.
Remove ECM fuse1.
Check resistance of ECM 58 ˜ ECM fuse1.
Remove relay.
Check continuity between ECM 3 and relay socket B.
Check continuity between relay socket A and fuse 1.
58 Fuse1
B A
3
Repair wiring
58
Continuity Go to Step 4 harness
5 Remove relay.
Check relay function.
1. Apply 12 V at solenoid terminals.
2. Check continuity between 87 and 30 (TF 4JA1-TC,
4JH1-TC) after applied 12V.
Check continuity between 87 and 87a after
applied 12V.
3. No continuity means malfunction of relay.
87
87a 86 85
86 85 87
30 30
ECM relay ECM relay Replace ECM

(NKR only) (TF4JA1-TC,4JH1-TC)
0 and verify Replace relay

SYSTEM VOLTAGE TOO HIGH

1 Ask the customer whether 24V batterry is used?
Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
2 1. Clear the DTC P0560. Ask the
2. Observe the DTCs. customer
Was the DTC P0560 stored? whether 24V
batterry was
installed or
used.
Refer to
Intermittent
— Go to Step 3 Diagnosis
Ignition off
Install breaker box as type B.
Install Tech-II.
Ignition ON
Compare system voltage by Tech-II and system
voltage by DVM at ECM pin 3, pin 58 and ground.
If DVM shows less than 20V and Tech-II shows more
than 20V, go to Yes - replace ECM.
If DVM shows more than 20V and Tech-II shows more
than 20V, go to No step 4.
Ignition off
Install OK ECM.
Check DTC, if DTC does not appear, go to Yes -
replace ECM.
If DTC appear, go to No step 4.
58 Fuse1
B A
3
Less than
58
20 V Replace ECM Go to Step 4
Ignition off
Remove ECM relay.
Measure voltage at ECM pin 3 and ground, ECM pin Replace ECM
58 and ground. relay and repair
Breaker box is not available any shortage or
Ignition off extra power
Remove ECM relay. source between Repair engine
Disconnect Engine harness at ECM. relay and harness
Measure voltage at ECM pin 3 and ground, ECM pin Less than ignition sw, between ECM
58 and ground. 20V battery. relay and ECM.

PCU SYSTEM VOLTAGE TOO HIGH OR TOO LOW
ECM
25A

SW:Newtral 6 7
(MT only)
(NKR 4JH1-TC only)
PCU
(TF 4JA1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

3 Disconnect PCU connector.
Measure voltage at terminal 7 of PCU connector.
27 V ≥ voltage Replace
≥ 4.5 V Injection pump Repair wiring
DTC P0561
SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION
IG
ECM Stop lamp

15A
25A 10A
Relay EW

plug
relay
coil ExG Check
Glow
Brake Engine
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
IC 035 IC 035

2 1. Clear the DTC P0561.
2. Ignition ON. Wait for .
Does the DTC P0561 still appear? — Go to Step 3 Verify
Ignition off
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
Ignition off
Disconnect ECM from Engine harness.
Check the continuity or poor connection along the OK Repair wiring or
wiring between ECM pin 39 and ignition ON fuse line. Replace ECM main relay
DTC P0561
SWITCHED SYSTEM VOLTAGE (IGNITION ON) CIRCUIT MALFUNCTION
DURING INITIALIZATION

2. Ignition ON. Wait for see.
Does the DTC P0561 still appear? — Go to Step 3 Verify
Ignition off
Check the continuity or poor connection along the
wiring between ECM pin 39 and ignition ON fuse line.
Ignition off
Disconnect ECM from Engine harness.
Check the continuity or poor connection along the OK Repair wiring or
wiring between ECM pin 39 and ignition ON fuse line. Replace ECM main relay
DTC P0606
ECM Malfunction1

DTC P0606
ECM Malfunction2

DTC P0645
A/C COMPRESSOR CUTOFF RELAY MALFUNCTION
Main fuse
ECM ECM
relay A/C on relay
signal
HVAC
relay
ECM
relay
A/C Fuse
AC
Thermo
relay NKR 4JH1-TC only
TF 4JA1-TC /
4JH1-TC only
Electrical
thermo
PDS
(NKR 4JH1-TC)
only
A/C
Comp relay A/C
Comp relay
Compressor Compressor
clutch clutch
41 41 33
Batt Batt
µP µP IC 08

A/C COMPRESSOR CUTOFF RELAY PRIMARY CIRCUIT OPEN
(Short to ground)

Ignition off
Disconnect breaker box harness adapter from ECM.
Disconnect ECM relay.
Measure a resistance between ECM relay connector
pin 30 and ECM pin 41.
ground.
Ignition off
Remove ECM relay.
Measure resistance between ECM relay connector pin
30 and ECM connector pin 41.
ground.
41
Resistance
_Ω
87
87a
ECM relay
86 85
connector Isolation Go to
or
30 resistance intermittent
> 1MΩ Diagnosis Go to Step 4
4 Check continuity A/C relay. Replace A/C
Continuity Go to Step 5 relay and verify
5 Check continuity between relay : A/C pin 85 and Repair wiring
engine harness connector pin 30 at ECM relay. Continuity Go to Step 6 and verify

Ignition off
Remove A/C relay.
Check continuity between A/C relay connector pin 87
and ECM pin 41.
Ignition off
Remove A/C relay.
Check continuity between A/C relay connector pin 87
and ECM connector pin 41.
41
87
87a
A/C relay
86 85
connector
30 Repair wiring
0Ω Intermittent and verify

A/C COMPRESSOR CUTOFF RELAY PRIMARY CIRCUIT HIGH INPUT
(Short to battery)

Ignition off
Disconnect ECM relay, AC compressor relay.
Check short circuit between ECM pin 41 and, ECM
relay socket 30, ignition ON, battery plus. See the
attached circuit.
See the attached circuit on page 6E-156.
87
87a
86 85
30

Ignition off
Disconnect ECM relay, AC compressor relay.
Check short circuit between ECM pin 41 and, ECM
relay socket 30, ignition ON, battery plus. See the
attached circuit.
See the attached circuit on page 6E-156.
41
87
87a
86 85
30 Repair wiring
0V Go to Step 4 and verify
4 Check resistance A/C relay. Replace A/C
260 - 310Ω Go to Step 5 relay and verify

Ignition off
Remove A/C relay.
Measure voltage between ECM pin 41 and A/C relay
connector pin 87.
Ignition off
Remove ECM relay.
Measure voltage between ECM pin 41 and A/C relay
connector pin 87.
41
87
87a
86 85 Go to
30
Intermittent Repair wiring
0V Diagnosis and verify
reference
RELAY ; ECM MAIN
BATT
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
IC03
PA01
8B/R
2B/Y
IC01
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
MAIN
2L/R
IG.1
50A
80A
2L/R
ECM
25A
A41(63) A41(3) IC05 0.5L/R IC15
IC05
0.5Y A-2 2L/B 0.5L/R HA19
2 B24(100) A56(58)
IC31 IC04
GLOW
PA28
50A
40A
PA28
IG2
INJ.PUMP
8W
0.5R A-3
3B
3 B23(99) B2(83) 0.5W/R IC27
IC32 4
0.5G/R IC28 0.5L/R
0.5O A-4 B7(88) 5 2
4 B29(105) 0.5B/R IC30 IC15
IC33 B14(92) 3 MAF
0.5P A-5 0.5B/L IC39
1 B13(91) B3(84) 1
J/C ; B
IC34
0.5L/R
0.5L/R
HA15
HB01
5R/W
3W/B
PA02
PA03
PA13
PA16
IC11
IZ03
3W
3W
3W
RELAY ;
0.5
A/C COMPRESSOR
SW ;IGNITION
B1
B2
0.5BR/W HA20 1
A38(41)
ACG(B)
STOP
B-1 0.5G 4 2 0.5BR
0.5L/R
FUSE ;
10A
HB04
B-5
EB
0.5B/P
SENSOR
B15(93) HA18 HA17 A/C

IC43
OFF
MAG.CLUTCH
ECT
ACC
IG1 3B/R
IG2
ST
(COMPRESSOR)
0.5O B-6
B8(89)
IC44
SW ; THERMO
0.5B 0.5G
RELAY ;
RELAY ;
HX22 HA23
GLOW
A/C THERMO
CA01
PA17
3B/R
0.5G
0.5G/R 1 0.5L/W FUSE ;
1 HA13 0.5G BLOOR
B22(98) 4 2 HA14
ENGINE
METER
IC45 A30(33)
BACK
TDC
3 HA21 0.5G/W HA16
10A
15A
15A
B12(90) 0.5B 0.5G
IC46
A-9 HX03 HA24
0.5B/L 270
IZ05
0.85W
B16(94)
MA01
0.85Y
KA01
B25(101) HB06
SW ; NEWTRAL 0.5L/Y
A36(39)
IC09 IC10
A27(30) 0.5R
IC12 (ON)
0.5W/B
A65(65)
IC13 (OFF)
0.5B 0.5B/W (YZK NO ; 7321-9900)
270 IZ08 IC57
IZ04
0.5 B
510 0.5G
(IDLE SW) A28(31)
CA02
0.5G
0.5R
IC48
E
GLOW PULG x4
(THROTTLE VALVE)
T.P.S.&SW ; IDLE
F 0.5G/B
A69(69) A-16 5B/R
IC35
A 0.5R/G HB03
A47(49)
IC36
C 0.5G/O
A35(38)
IC37 SW ; BACK UP
B A-1 0.85Y
0.5B/G
IC38 A55(57) KA01
A-10 0.85R/Y
IZ07
KA02
ECM A-11 0.85Y
MA02
VEHICLE SPEED
2B SENSOR
A61(2) 0.85B A-12 0.5L/B
IZ01
MX05 MA03
2B B-3 0.5Y/B B6
A62(1)
IZ02 MA06
MB11
4WD
0.5B 4WD SW B-2 0.5W/R B15
IZ06 MA11(W/SOF)

OIL
A-6 0.5L A10
MA10
JOINT TO EX12
GLOW
0.5O/L B8 B2
A40(43)
MA18
CHECK ENG
0.5BR/R A6
A39(42)
BACK UP LAMP
; ENGINE
IC29
CONNECTION
BRAKE LAMP
TACHO METER
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
0.5B/R B3
A24(27)
0.5O/B
0.5B/L
MB04
EX02
MA05
SPEED METER
0.5B
0.5L/W A8 A9
EX03 A68(68)
IC21
0.5L
A43(45) METER
IC47
0.5O/L
MB01
0.5G
IC48
DTC P0703
BRAKE-LIGHT SWITCH CIRCUIT MAIFUNCTION
1G
ECM Stop lamp

15A
25A 10A
Relay EW
SW:ExG Brake
plug
relay Exh
Brake
coil (NKR Check
Glow
ABS only only)
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
NKR 4JH1-TC
only
Batt Batt
IC 035 IC 035
DTC P0703
BRAKE-LIGHT SWITCH CIRCUIT INCORRECT SIGNAL (IGNITION ON)
(Short to battery, short to ground, open circuit)

3 In case of TF with Automatic transmission, brake light
bulb burn out triggers DTC P0703. TF with
Before going to further step, check brake light bulb. Automatic Bulb burn out
Other than TF with Automatic transmission, go to step transmission Bulb is OK replace bulb,
4. only Go to Step 4 and verify
4 Check two brake switch condition by Tech-II. Two brake
When apply brake pedal, and release brake pedal, switch
check Tech-II indication. condition
Change ON or OFF, two brake switch indicates ON/ should be
OFF. ON/OFF OK Replace brake
same Go to Step 5 switch

Ignition off
Check any open circuit between ECM pin 30 and ECM No open
relay, and between ECM pin 65 and ECM relay. circuit
ECM relay at brake switch NO (Normal open) open
condition, and between ECM pin 65 and ECM relay at
brake switch NC (Normal close) open condition.
Ignition off install a breaker box as type B, see More than
page 6E-58. 1MΩ
Without applying brake switch ON (NO switch
becomes close) Check no voltage to appear between
ECM pin 30 and ground. No voltage
By applying brake switch ON (NO switch becomes
close)
Check no voltage to appear between ECM pin 65 and
ground. No voltage
Ignition off
ECM relay at brake switch NO open condition, and
between ECM pin 65 and ECM relay at brake switch
NC open condition.
30
65
ECM relay
or All check is OK
↓
More than Replace ECM Repair wiring or
1MΩ and verify relay

BRAKE-LIGHT SWITCH CIRCUIT INCORRECT SIGNAL (During Brake SW off)

Ignition off
ECM relay at brake switch NO (Normal open) open
condition, and between ECM pin 65 and ECM relay at
brake switch NC (Normal close) open condition.
Ignition off install a breaker box as type B, see More than
page 6E-58. 1MΩ
Without applying brake switch ON (NO switch
becomes close) Check no voltage to appear between
ECM pin 30 and ground. No voltage
By applying brake switch ON (NO switch becomes
close)
ground. No voltage
Ignition off
ECM relay at brake switch NO open condition, and
between ECM pin 65 and ECM relay at brake switch
NC open condition.
By applying brake switch OFF (NO switch becomes
open)
ground.
30
65
ECM relay TF with

or Automatic Bulb burn out
transmission Bulb is OK replace bulb,
only Go to Step 4 and verify
4 Check two brake switch condition by Tech-II. Two brake
When apply brake pedal, and release brake pedal, switch
check Tech-II indication. condition
Change ON or OFF, two brake switch indicates ON/ should be
OFF. ON/OFF OK Repalce brake
different Go to Step 5 switch
DTC P0704
CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
1G
ECM Stop lamp

15A
25A 10A
ECM relay
SW:ExG Brake
plug
relay Exh
Brake
coil (NKR Check
Glow
ABS only only)
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
NKR 4JH1-TC
only
Batt Batt
IC 035 IC 035

CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION

3 Check clutch switch and clutch pedal adjustment.
See section. Go to Step 4 Replace
4 Check clutch switch electrical function. Go to Step 5 Replace

Ignition off
Check continuity between ECM pin 31 and clutch SW.
Check continuity between clutch SW and ECM relay.
Ignition off
Check continuity between ECM pin 31 and ground.
Check continuity between clutch SW and ECM relar.
0Ω
(Clutch OFF)
∞
(Clutch ON) Replace ECM Repaire wiring
DTC P1105
BAROMETRIC PRESSURE SENSOR (BP) MALFUNCTION

BAROMETRIC PRESSURE SENSOR (BP) CIRCUIT LOW INPUT

1 Was the “On-Board Diagnostic (OBD) System check” Go to OBD
Was the DTC P1105 restored? Replace ECM Diagnosis

BAROMETRIC PRESSURE SENSOR (BP) CIRCUIT HIGH OUTPUT

Was the DTC P1105 restored? Replace ECM Diagnosis
DTC P1110
INTAKE SHUTTER VSV (DIESEL) MALFUNCTION (NKR 4JH1-TC only)
ECM
25A

SW:Neutral 6 7
(MT only)
(NKR 4JH1-TC only)
(TF 4JA1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

INTAKE VSV HIGH INPUT (Short to battery)


Ignition off
Check isolation resistance between battery position
and ECM pin 95 by ignition off, ignition ON power
source and ECM pin 95 by ignition off.
See the attached schematic.
Ignition off
Check isolation resistance between battery position
and ECM pin 95 by ignition off, ignition ON power
source and ECM pin 95 by ignition off.
See the attached schematic.
95
see page More than

6E-165 1MΩ Replace ECM Repair wiring
6E–165
0.5W
5B/L IC60 5B/Y
HB01 1.25L/R HB02
GLOW
60A STOP LAMP HB03
0.5G
TO CONT UNIT ; ABS
BB09
SIGNAL )
LAMP
G/PULG
RELAY ; ECU
#20
80A 25A (58) (94) GLOW PULG
IC05 IC03 HB04
RESISTER ;
5W 3B/Y (4 x4)
PA07 2L/R A-41 BAT(+)
GENERATOR
FTX
IDLE SW
IC02
(510 )
2L (+5V)(57) IC42
TURN

10A
15A
#19
#18
SW ; (SIG.)(38) IC43
0.5G/B
IC62
PA10 IC04 (39) A-47 1
LEVELINGA

CA01 CA02 IC10 (30)
10A
#15
H/L
10A IC59 IC09 IC11 (65)
KEY SW
J/C

0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
OFF (2) JOINT

IZ02
GAUGE,
BACK

10A
2B 0.5B
#12
50A B GND.
(31) METER
IZ03
IC12 THERMO UNIT
5B
ST
TO RELAY ; CORNEING
(WATER TEMP)
WASHER
WIPER,
FRAME D-4 0.5Y/B

15A
MA08
#11

0.5LG 0.3V
METER IND SPEED
0.5B/Y 1.4W 0.5G/Y A-39 0.5B/Y
(CHECK ENG.) +
SW ;
TO RELAY ; TAIL
GLOW 14V,
AIR CON

TO ELECTRO THERMO

10A
METER
#2
IC21 IZ09 0.5B

0.5BR 0.85B GND.
0.5BR/R A-44 QWS SW
HA09 3L/R IC34 IC19 (46) MX01 MX11
0.85B
MX06
CHARGE
#1
HEATER
25A

0.5BR 0.5W/R B-2 MAF +5V
4 (83)
TO BLOWER
0.85G/W

HA10
2 5 (88)
IC22 IC24
1 3 0.5B/R (62) BB07 IN
(92) J1850
RELAY ; IC25 BB21
0.5L/R 0.5L/R 0.5B/O B-19 EGR (IN)
0.5L/R (97) BB06 OUT 4 0.3W/G
(84)
A/C ON SIGNAL
HA11 IC56
MAG.VALVE TDC
TDC (+) B-12 0.5R 2
IC15 IC16 (40) (90)
RELAY ;
B-17 INT.SLOTTLE 3
(95) B-22 0.5W IC50 1
TDC (-)
(87) IZ10
TDC B-25 (SHIELD)
0.85Y/G
SW ; NEUTRAL
A/C ON SIGNAL(270 )
(SHIELDED)
0.5Y/G
2
HA19
(CAN-H)
0.5B
IZ12
IC47
(100) WATER TEMP CONNECTOR
IC36 (89) IC51 16 15 14 13 12 11 10 9
7 (99)
RESISTER ;
RESISTER ;
0.5B/W
0.5O B-29 INJ.PUMP
IC32
5 (MAB)
(510 ) IC37 (93) IC52
6 (105)
0.3B
0.5B
IZ08
IZ04
B-13 INJ.PUMP
2B
IZ06 8 0.5P ISO-K A-32 0.5Y
MAGNET CLUTCH
ZZ06
(DZG)
0.5B
IC38 (35) IC57
(COMPRESSOR) (91)
A-30 A/C SW
referance
DIAG A-43 0.5L
ZZ05
0.5B
(45) IC58
0.5W/G IC40 A-38 A/C RELAY
(41)
1.25B/Y IC63
DTC P1110 SUBCODE 0100

(DIESEL) CIRCUIT OPEN (Short to ground)

Ignition off
• Install a breaker box as type A, see page 6E-58.
• Disconnect VSV. Repair the
Check continuity between ECM pin 95 and 0Ω Go to Step 4 harness
4 Check the resistance of harness between the relay of
ECM and Exh. Brake. Repair the
Did the DVM indicate at the specified value. 0Ω Replace ECM harness
DTC P1120
AP SENSOR MAIFUNCTION
Glow ECU
60A Relay Register : idle SW
Relay APS
G/plug
Glow
plug
+5V
94 57 38 49 69 2 1
GND GND
Balt
IC 08
µP
Circuit Description APS caractalistic

The APS is a potentio meter connected to the
accelerator pedal. The ECM monitors the voltage on the
signal line and caliculate accel pedal position. 5.0V +5V 3
Output voltage
Signal 2
2.5V
GND 1
0.0
-45 0 +45
Aps Avn Turning
angle
2 1
3
Connector view of APS

AP SENSOR CIRCUIT LOW INPUT

3 1. Ignition “On”, engine “Off”. Idle position
2. Check pedal position % on Tech-II for pedal sensor 0.5–
posiotn sensor within the value or not. 0.9V WOT
Was a problem found? TP1 Between
4.0V and 4.7V Go to Step 7 Go to Step 4
4 • Disconnect APS and ECM from harness.
• Check the signal line open circuit on the harness
between ECM and APS.
• Check the power feed line open circuit on the Repair harness
harness between ECM and APS. and verify Go to Step 5
5 • Check APS sensor open circuit between power Repair harness
feed line and signal line. and verify Go to Step 6
6 Replace ECM. Repair harness
and verify

AP SENSOR CIRCUIT HIGH INPUT

3 1. Ignition “ON” engine “OFF” .
2. Check pedal position % on Tech-II for pedal See the
position sensor within the value or not. typical data Go to Step 8 Go to Step 4
Ignition off
Check open circuit of ground line between APS and
ECM pin 49.
Ignition off
Disconnect engine harness.
Check open circuit of ground line between APS and No open Repair wiring or
ECM pin 49. circuit Go to Step 5 Replace APS
5 Breaker box is available Check short to
Ignition off battery on the
Connect ECM to engine harness. APS wiring
Ignition ON including APS
Measure voltage at signal line at APS, and +5V power ↓
supply, whether the voltage is more than values. Repair
Breaker box is not available including APS
Ignition off ↓
Disconnect Engine harness. NKR 4JH1- Verify
Check short circuit between 38 and power sources by TC ≤ 4.9V ↓
ignition ON/OFF. NG
See the attachment on 6E-170. TF 4JH1/ ↓
4JA1 ≤ 4.5V Replace ECM Replace ECM

AP SENSOR VOLTAGE SUPPLY CIRCUIT HIGH INPUT (Short to battery)

1 Was the “On-Board Diagnostic (OBD) System Check”
performed? Go to Step 2 OBD
2 1. Clear code. Refer to
2. Observe DTCs. Intermittent
Was the DTC P1120 stored? Go to Step 3 Diagnosis
Ignition off
Check voltage at power feed pin 57.
Ignition off No more than
Skip to step 4. 5.2V Replace ECM Go to Step 4
Ignition off
Disconnect ECM harness.
sources, see the attachment on page 6E-171.
Ignition off
Check short circuit between ECM pin 57 and power No short to Repair wiring,
sources, see the attachment on page 6E-171. battery Replace ECM APS
5 Disconnect APS.
Check voltage at power feed voltage pin of ECM
connector. 0V Go to Step 6 Repari wiring
6 Check voltage at APS. 0V Go to Step 4 Replace APS
6E–171
0.5W
5B/L IC60 5B/Y
HB01 1.25L/R HB02
GLOW
60A STOP LAMP HB03
0.5G
TO CONT UNIT ; ABS
BB09
SIGNAL )
LAMP
G/PULG
RELAY ; ECU
#20
80A 25A (58) (94) GLOW PULG
IC05 IC03 HB04
RESISTER ;
5W 3B/Y (4 x4)
PA07 2L/R A-41 BAT(+)
GENERATOR
FTX
IDLE SW
IC02
(510 )
2L (+5V)(57) IC42
TURN

10A
15A
#19
#18
SW ; (SIG.)(38) IC43
0.5G/B
IC62
PA10 IC04 (39) A-47 1
LEVELINGA

CA01 CA02 IC10 (30)
10A
#15
H/L
10A IC59 IC09 IC11 (65)
KEY SW
J/C

0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
OFF (2) JOINT

IZ02
GAUGE,
BACK

10A
2B 0.5B
#12
50A B GND.
(31) METER
IZ03
IC12 THERMO UNIT
5B
ST
TO RELAY ; CORNEING
(WATER TEMP)
WASHER
WIPER,
FRAME D-4 0.5Y/B

15A
MA08
#11

0.5LG 0.3V
METER IND SPEED
0.5B/Y 1.4W 0.5G/Y A-39 0.5B/Y
(CHECK ENG.) +
SW ;
TO RELAY ; TAIL
GLOW 14V,
AIR CON

TO ELECTRO THERMO

10A
METER
#2
IC21 IZ09 0.5B

0.5BR 0.85B GND.
0.5BR/R A-44 QWS SW
HA09 3L/R IC34 IC19 (46) MX01 MX11
0.85B
MX06
CHARGE
#1
HEATER
25A

0.5BR 0.5W/R B-2 MAF +5V
4 (83)
TO BLOWER
0.85G/W

HA10
2 5 (88)
IC22 IC24
1 3 0.5B/R (62) BB07 IN
(92) J1850
RELAY ; IC25 BB21
0.5L/R 0.5L/R 0.5B/O B-19 EGR (IN)
0.5L/R (97) BB06 OUT 4 0.3W/G
(84)
A/C ON SIGNAL
HA11 IC56
MAG.VALVE TDC
TDC (+) B-12 0.5R 2
IC15 IC16 (40) (90)
RELAY ;
B-17 INT.SLOTTLE 3
(95) B-22 0.5W IC50 1
TDC (-)
(87) IZ10
TDC B-25 (SHIELD)
0.85Y/G
SW ; NEUTRAL
A/C ON SIGNAL(270 )
(SHIELDED)
0.5Y/G
2
HA19
(CAN-H)
0.5B
IZ12
IC47
IC36 (89) IC51 16 15 14 13 12 11 10 9
7 (99)
RESISTER ;
RESISTER ;
0.5B/W
0.5O B-29 INJ.PUMP
IC32
5 (MAB)
(510 ) IC37 (93) IC52
6 (105)
0.3B
0.5B
IZ08
IZ04
B-13 INJ.PUMP
2B
IZ06 8 0.5P ISO-K A-32 0.5Y
MAGNET CLUTCH
ZZ06
(DZG)
0.5B
IC38 (35) IC57
(COMPRESSOR) (91)
A-30 A/C SW
reference
DIAG A-43 0.5L
ZZ05
0.5B
(45) IC58
(41)
1.25B/Y IC63

AP SENSOR VOLTAGE SUPPLY CIRCUIT LOW INPUT

Ignition off
Ignition ON
Check voltage at ECM pin 57.
Ignition off
Skip to step 4. 5V Replace ECM Go to Step 4
Ignition off
Install breaker box as type A.
Disconnect APS sensor.
Make jump wire between ECM pin 57 and 35.
Check short to ground between ECM pin 57 and
ground.
Ignition off
Disconnect APS sensor.
Make jump wire between ECM pin 57 and 35.
Check short to ground between ECM pin 57 and No short to
ground.šNo short to ground ground Go to Step 5 Repair wiring
5 Disconnect APS. No short to
Check short to ground at APS sensor. ground Replace ECM Replace APS
6 Check continuity ECM wiring of power feed. Go to Step 4 Replace wiring
DTC P1173
FUEL REDUCTION CAUSED BY HIGH COOLANT TEMPERATURE

1 Inspect coolant temp gauge whether needle indicates
high temp.
or
Ask the customer whether experience of overheat? — Go to Step 3 Go to Step 2
2 Inspect coolant temp sensor. Check coolant
Meet temp sensor Replace
standard poor connection coolant temp
resistance and repair sensor
3 Find out the cause of overheat. See the. Go to Step 4 Repair
4 Replace ECM. Verify —
Fuel Reduction adjustment

NKR 4JH1-TC
Q
5%
15%
80°C 90°C 100°C 110°C
TF 4JH1-TC, 4JH1-TC
15%
Q
80°C 90°C 100°C 110°C


FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE

1 Was the “On-Board Diagnostic (OBD) System Check” Explain
performed? customer and
No MIL light report
on representative Go to Step 2
2 Clear DTC P1173. Ask the
Observe the DTC. customer,
Was the DTC P0645 stored? whether fuel
Go to Step 3 level was low?
3 Check fuel level. Explain to the
If it is low, add fuel to the half of tank. customer
Drive a few minutes, and stay at idling. No DTC extremely low
comes on fuel caused Go to Step 4
4 Measure fuel temp by Tech-II. Replace ECM.
Verify. If still
DTC ON,
Less than replace Inj.
100°C pump Go to Step 5
5 Check fuel leakage at fuel routine.
Air in pump may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
6 Replace fuel filter. Replace inj
Drive a few min, and stay at idling. No DTC ON — pump
DTC P1173
FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 1

No MIL light report
3 Measure fuel temp by Tech-II. Less than Replace
100°C injection pump Go to Step 4
4 Check fuel leakage at fuel routine, pump.
Air may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
DTC P1173
FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE 2

No MIL light report
3 Check fuel level. Explain to the
If it is low, add fuel to the half of tank. customer
Drive a few minutes, and stay at idling. No DTC extremely low
comes on fuel caused Go to Step 4
4 Measure fuel temp by Tech-II. Replace ECM.
NKR 4JH1-TC reduce Q (fuel quantity). Verify. If still
TF 4JH1-TC, 4JA1-TC do not reduce. DTC ON,
Less than replace Inj.
80°C pump Go to Step 5
5 Check fuel leakage at fuel routine, pump.
Air may cause high temp at inj.pump. No leakage Go to Step 6 Repair leakage
DTC P1345
INJECTION PUMP:CAMSHAFT SPEED MALFUNCTION

3 Replace Injection Pump. Verify
DTC P1520
NEUTRAL SWITCH
ECM
25A

SW:Neutral 6 7
(MT only)
(NKR 4JH1-TC only)
(TF 4JA1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

NEUTRAL SWITCH ON (Short to battery)

3 Are there any other DTC on such as P0704, P1576? Check the bold
circuit Go to Step 4
4 Check the neutral switch. Function is Replace neutral
OK Go to Step 5 switch
Ignition off
Check short circuit to battery by ignition on, off. See No short to
the see page 6E-178. battery Replace ECM Repair wiring
Ignition off
Disconnect engine harness at ECM connector.
Check short circuit to battery by ignition ON, OFF. See
the page 6E-178. Replace ECM Repair wiring
reference
RELAY ; ECM MAIN

Ω
BATT
2L/R A-15 2L/R
IC02 IC02 0.5B/Y
IC03
PA01
8B/R
2B/Y
IC01
0.5L/R IC11
0.5L/R HB04
0.5L/R HA15
0.5G IC07
MAIN
2L/R
IG.1
50A
80A
2L/R
ECM
25A
A41(63) A41(3) IC05 0.5L/R IC15
IC05
0.5Y A-2 2L/B 0.5L/R HA19
2 B24(100) A56(58)
IC31 IC04
GLOW
PA28
50A
40A
PA28
IG2
INJ.PUMP
8W
0.5R A-3
3B
3 B23(99) B2(83) 0.5W/R IC27
IC32 4
0.5G/R IC28 0.5L/R
0.5O A-4 B7(88) 5 2
4 B29(105) 0.5B/R IC30 IC15
IC33 B14(92) 3 MAF
0.5P A-5 0.5B/L IC39
1 B13(91) B3(84) 1
J/C ; B
IC34
0.5L/R
0.5L/R
HA15
HB01
5R/W
3W/B
PA02
PA03
PA13
PA16
IC11
IZ03
3W
3W
3W
RELAY ;
0.5
A/C COMPRESSOR
SW ;IGNITION
B1
B2
0.5BR/W HA20 1
A38(41)
ACG(B)
STOP
B-1 0.5G 4 2 0.5BR
0.5L/R
FUSE ;
10A
HB04
B-5
EB
0.5B/P
SENSOR
B15(93) HA18 HA17 A/C

IC43
OFF
MAG.CLUTCH
ECT
ACC
IG1 3B/R
IG2
ST
(COMPRESSOR)
0.5O B-6
B8(89)
IC44
SW ; THERMO
0.5B 0.5G
RELAY ;
RELAY ;
HX22 HA23
GLOW
A/C THERMO
CA01
PA17
3B/R
0.5G
0.5G/R 1 0.5L/W FUSE ;
1 HA13 0.5G BLOOR
B22(98) 4 2 HA14
ENGINE
METER
IC45 A30(33)
BACK
TDC
3 HA21 0.5G/W HA16
10A
15A
15A
B12(90) 0.5B 0.5G
IC46
A-9 HX03 HA24
0.5B/L 270
IZ05
0.85W
B16(94)
MA01
0.85Y
KA01
B25(101) HB06
SW ; NEWTRAL 0.5L/Y
A36(39)
IC09 IC10
A27(30) 0.5R
IC12 (ON)
0.5W/B
A65(65)
IC13 (OFF)
0.5B 0.5B/W (YZK NO ; 7321-9900)
270 IZ08 IC57
IZ04
0.5 B
510 0.5G
(IDLE SW) A28(31)
CA02
0.5G
0.5R
IC48
E
GLOW PULG x4
(THROTTLE VALVE)
T.P.S.&SW ; IDLE
F 0.5G/B
A69(69) A-16 5B/R
IC35
A 0.5R/G HB03
A47(49)
IC36
C 0.5G/O
A35(38)
IC37 SW ; BACK UP
B A-1 0.85Y
0.5B/G
IC38 A55(57) KA01
A-10 0.85R/Y
IZ07
KA02
ECM A-11 0.85Y
MA02
VEHICLE SPEED
2B SENSOR
A61(2) 0.85B A-12 0.5L/B
IZ01
MX05 MA03
2B B-3 0.5Y/B B6
A62(1)
IZ02 MA06
MB11
4WD
0.5B 4WD SW B-2 0.5W/R B15
IZ06 MA11(W/SOF)

OIL
A-6 0.5L A10
MA10
JOINT TO EX12
GLOW
0.5O/L B8 B2
A40(43)
MA18
CHECK ENG
0.5BR/R A6
A39(42)
BACK UP LAMP
; ENGINE
IC29
CONNECTION
BRAKE LAMP
TACHO METER
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
0.5B/R B3
A24(27)
0.5O/B
0.5B/L
MB04
EX02
MA05
SPEED METER
0.5B
0.5L/W A8 A9
EX03 A68(68)
IC21
0.5L
A43(45) METER
IC47
0.5O/L
MB01
0.5G
IC48

NEUTRAL SWITCH OFF (Open circuit)

3 Are there any other DTC on such as P0704, P1576? Check the bold
circuit
Open circuit Go to Step 4
4 Check Neutral switch. Function is
OK not Replace Neutral
always ON Go to Step 5 switch
Ignition off
Check continuity between ECM pin 87 and Neutral sw.
Ignition off
Check continuity between ECM pin 87 and Neutral sw. Continuity Replace ECM Repair wiring
DTC P1576
EXHAUST BRAKE VALVE1 CIRCUIT MALFUNCTION
ECM
25A

SW:Neutral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP
System Description Signal follow
5V
ABS ECM
ABS
ECM control unit
5V
ECM ABS
ABS Exh. Brake cut
OUT IN If ECM recognizes any
failure, ECM sends 180
deg different phase signal.
ABS Exh. Brake cut
This reverse phase signal reverse
IN OUT
triggers to turn ON ABS light. phase
signal
Operation
ABS activate signal command to cancel Exh. Brake.
TF 4JA1-TC QWS QWS operation reguirement
vss < 2km/h

+Battery
QWS Idle switch = ON
request switch
APS ≤ 2%
ECM Ext vsv1
ECT requires ON
Atomasphone Ext vsv2
temp switch ON 80ºc
70ºc OFF
IAT requires ON
ON 150ºc
10ºc OFF
IAT ECT APS Engine
speed
NKR 4JHI-TC Exh. Brake + Intake shutter +

QWS
+Battery
Mag valve
Exh. Brake
request sw ECM
VSV : Int
QWS
regnest sw
VSS
Idle sw
IAT ECT APS
Exh. Brake and Intake shutter operate at same time.

QWS operate condition.

EXH. BRAKE AND QWS VALUE 1 CIRCUIT SHORT TO BATTERY

Ignition off
Check short to battery, see on page 6E-183, 6E-184
(NKR 4JH1-TC only).
Ignition off
Disconnect engine harness.
Check short to battery, see on page 6E-183, 6E-184 No short to
(NKR 4JH1-TC only). battery Go to Step 4 Repair wiring
4 Check Exhaust brake valve circuit, intake shutter Replace Exh.
circuit. brake valve or
Replace ECM intake shutter
6E–183
0.5W
5B/L IC60 5B/Y
HB01 1.25L/R HB02
GLOW
60A STOP LAMP HB03
0.5G
TO CONT UNIT ; ABS
BB09
SIGNAL )
LAMP
G/PULG
RELAY ; ECU
#20
80A 25A (58) (94) GLOW PULG
IC05 IC03 HB04
RESISTER ;
5W 3B/Y (4 x4)
PA07 2L/R A-41 BAT(+)
GENERATOR
FTX
IDLE SW
IC02
(510 )
2L (+5V)(57) IC42
TURN

10A
15A
#19
#18
SW ; (SIG.)(38) IC43
0.5G/B
IC62
PA10 IC04 (39) A-47 1
LEVELINGA

CA01 CA02 IC10 (30)
10A
#15
H/L
10A IC59 IC09 IC11 (65)
KEY SW
J/C

0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
OFF (2) JOINT

IZ02
GAUGE,
BACK

10A
2B 0.5B
#12
50A B GND.
(31) METER
IZ03
IC12 THERMO UNIT
5B
ST
TO RELAY ; CORNEING
(WATER TEMP)
WASHER
WIPER,
FRAME D-4 0.5Y/B

15A
MA08
#11

0.5LG 0.3V
METER IND SPEED
0.5B/Y 1.4W 0.5G/Y A-39 0.5B/Y
(CHECK ENG.) +
SW ;
TO RELAY ; TAIL
GLOW 14V,
AIR CON

TO ELECTRO THERMO

10A
METER
#2
IC21 IZ09 0.5B

0.5BR 0.85B GND.
3L/R IC34 0.5BR/R A-44 QWS SW
HA09 (46) MX01 MX11
IC19
0.85B
MX06
CHARGE
#1
HEATER
25A

0.5BR 0.5W/R B-2 MAF +5V
4 (83)
TO BLOWER
0.85G/W

HA10
2 5 (88)
IC22 IC24
1 3 0.5B/R (62) BB07 IN
(92) J1850
RELAY ; IC25 BB21
0.5L/R 0.5L/R 0.5B/O B-19 EGR (IN)
0.5L/R (97) BB06 OUT 4 0.3W/G
(84)
A/C ON SIGNAL
HA11 IC56
MAG.VALVE TDC
TDC (+) B-12 0.5R 2
IC15 IC16 (40) (90)
RELAY ;
B-17 INT.SLOTTLE 3
(95) B-22 0.5W IC50 1
TDC (-)
(87) IZ10
TDC B-25 (SHIELD)
0.85Y/G
SW ; NEUTRAL
A/C ON SIGNAL(270 )
(SHIELDED)
0.5Y/G
2
HA19
(CAN-H)
0.5B
IZ12
IC47
IC36 (89) IC51 16 15 14 13 12 11 10 9
7 (99)
RESISTER ;
RESISTER ;
0.5B/W
0.5O B-29 INJ.PUMP
IC32
5 (MAB)
(510 ) IC37 (93) IC52
6 (105)
0.3B
0.5B
IZ08
IZ04
B-13 INJ.PUMP
2B
IZ06 8 0.5P ISO-K A-32 0.5Y
MAGNET CLUTCH
ZZ06
(DZG)
0.5B
IC38 (35) IC57
reference (COMPRESSOR) (91)
A-30 A/C SW A-43
DIAG 0.5L
ZZ05
0.5B
(45) IC58
(41)
1.25B/Y IC63
0.5W
5B/L IC60 5B/Y
HB01 1.25L/R HB02
GLOW
60A STOP LAMP HB03
0.5G
TO CONT UNIT ; ABS
BB09
SIGNAL )
LAMP
G/PULG
RELAY ; ECU
#20
80A 25A (58) (94) GLOW PULG
IC05 IC03 HB04
RESISTER ;
5W 3B/Y (4 x4)
PA07 2L/R A-41 BAT(+)
GENERATOR
FTX
IDLE SW
IC02
(510 )
2L (+5V)(57) IC42
TURN

10A
15A
#19
#18
SW ; (SIG.)(38) IC43
0.5G/B
IC62
PA10 IC04 (39) A-47 1
LEVELINGA

CA01 CA02 IC10 (30)
10A
#15
H/L
10A IC59 IC09 IC11 (65)
KEY SW
J/C

0.5L/R IC06
0.5L/R IC07
0.5L/R IC08
OFF (2) JOINT

IZ02
GAUGE,
BACK

10A
2B 0.5B
#12
50A B GND.
(31) METER
IZ03
IC12 THERMO UNIT
5B
ST
TO RELAY ; CORNEING
(WATER TEMP)
WASHER
WIPER,
FRAME D-4 0.5Y/B

15A
MA08
#11

0.5LG/L 2.0W 0.5G/R A-58 (EXH.BRAKE) ENG.SPEED
A-24 0.5LG B-8 B-9 0.3V

METER IND SPEED
0.5B/Y 1.4W 0.5G/Y A-39 0.5B/Y
(CHECK ENG.) +
SW ;
TO RELAY ; TAIL
GLOW 14V,
AIR CON

TO ELECTRO THERMO

10A
METER
#2
IC21 IZ09 0.5B

0.5BR 0.85B GND.
3L/R IC34 0.5BR/R A-44 QWS SW
HA09 (46) MX01 MX11
IC19
0.85B
MX06
CHARGE
#1
HEATER
25A

0.5BR 0.5W/R B-2 MAF +5V
4 (83)
TO BLOWER
0.85G/W

HA10
2 5 (88)
IC22 IC24
1 3 0.5B/R (62) BB07 IN
(92) J1850
RELAY ; IC25 BB21
0.5L/R 0.5L/R 0.5B/O B-19 EGR (IN)
0.5L/R (97) BB06 OUT 4 0.3W/G
(84)
A/C ON SIGNAL
HA11 IC56
MAG.VALVE TDC
TDC (+) B-12 0.5R 2
IC15 IC16 (40) (90)
RELAY ;
B-17 INT.SLOTTLE 3
(95) B-22 0.5W IC50 1
TDC (-)
(87) IZ10
TDC B-25 (SHIELD)
0.85Y/G
SW ; NEUTRAL
ONLY NKR
A/C ON SIGNAL(270 )
(SHIELDED)
0.5Y/G
2
HA19
(CAN-H)
0.5B
IZ12
IC47
INJ.PUMP
4JH1-TC
2L/R 0.5B/W 0.5R B-23 INJ.PUMP WATER TEMP B-8 0.5GR
IC36 (89) IC51 16 15 14 13 12 11 10 9
7 (99)
RESISTER ;
RESISTER ;
0.5B/W
0.5O B-29 INJ.PUMP
IC32
5 (MAB)
(510 ) IC37 (93) IC52
6 (105)
0.3B
0.5B
IZ08
IZ04
B-13 INJ.PUMP
2B
IZ06 8 0.5P ISO-K A-32 0.5Y
MAGNET CLUTCH
ZZ06
(DZG)
0.5B
IC38 (35) IC57
reference (COMPRESSOR) (91)
A-30 A/C SW A-43
6E–184
DIAG 0.5L
ZZ05
0.5B
(45) IC58
(41)
1.25B/Y IC63

EXHAUST BRAKE VALVE1 CIRCUIT SHORT

Ignition off
Install a breaker box.
Disconnect a breaker box adapter harness.
Measure voltage between ECM pin 40 and ground.
Ignition off
ground.
40
12V Replace ECM Go to Step 4

4 Check the Exhaust Brake circuit.
Was the problem found? Verify repair —

EXHAUST BRAKE VALVE1 CIRCUIT OPEN (Short to ground)

Ignition off
Check continuity between ECM relay and ECM pin 40.
• Check no short to ground between ground and
ECM pin 40. Continuity
Ignition off
• Disconnect ECM connector.
• Check continuity between ECM relay and ECM pin
40.
• Check no short to ground between ground and No short to Repair the
ECM pin 40. ground Replace ECM harness
DTC P1605
EEPROM DEFECT
DTC P1605 SUB CODE 1110&1101

EEPROM DEFECT

2. Observe the DTCs. Go to
Was the DTC P1605 restored? — Replace ECM Intermittent
DTC P1610
SEEDS AND KEY FILE DESTROYED

1 Clear the DTC P1610.
Observe the DTCs.
Was the DTC P1610 stored? No DTC Verify Go to Step 2
2 Reprogram ECM by SPS and verify no more DTC. No DTC — Replace ECM
DTC P1611
WRONG SECURITY CODE ENTERED

1 Clear DTC P1611.
Observe the DTCs.
Was DTC P1610 stored? No DTC Verify Go to Step 2
2 Write proper security code.
See the immobilizer procedure. No DTC Verify Replace ECM
DTC P1612/P1613
IMMOBILIZER NO OR WRONG SIGNAL

Observe the DTCs.
2 Check open circuit of wire between ECM - Immobilizer Check
ICU. No open immobilizer
circuit section of WSM Repair wire
DTC P1614
Wrong transponder key

Observe the DTCs.
2 Check immobilizer section of WSM.
DTC P1625
Power supply relay malfunction
IGN
ON
OFF
2sec
ECM relay
OFF

POWER SUPPLY RELAY SWITCHED OFF TOO LATE

3 Check ECM relay function. ECM relay
function is OK Replace ECM Replace relay

POWER SUPPLY RELAY SWITCHED OFF TOO EARLY

3 Check ECM relay function. Replace ECM Replace felay
DTC P1630
FUEL-INJECTION QUANTITY CIRCUIT MALFUNCTION

FUEL-INJECTION QUANTITY CIRCUIT HIGH INPUT

2 1. Clear the DTC P1630. DTC stored Go to
2. Observe the DTCs. Replace Intermittent
Was the DTC P1630 restored? — injection pump Diagnosis

FUEL-INJECTION QUANTITY CIRCUIT HIGH INPUT

1 Was the “On-Board Diagnostic (OBD) System Check”
performed? Go to Step 2
Ignition off and wait for 3 sec. Ignition on.
Run engine.
Raise engine speed. DTC stored Go to
Observe the DTCs. Replace intermittent
Was the DTC P1630 stored? injection pump diagnosis
DTC P1650
CAN: DEVICE MALFUNCTION

CAN: DEVICE OFF LINE

Ignition off
• Disconnect PCU connector.
• Make jumping at PCM pin 1 and pin 2.
• Check continuity between ECM pin 99&100.
Ignition off
• Disconnect ECU and PCU connector.
• Make jumping at PCM pin 1 and pin 2.
• Check continuity between ECM pin 99&100.
and and
0Ω
and
0V Go to Step 4 Repair harness
4 Replace ECU. DTC stored
Was the DTC P1650 restored? Replace
injection pump
and verify —

CAN: DEVICE HANGUP

Ignition off
• Check continuity between ECM pin 99&100 and
ground.
Ignition off
• Disconnect ECU and PCU connector.
• Check continuity between ECM pin 99&100 and
ground.
and and
0Ω
and
0V Go to Step 4 Repair harness
injection pump
and verify
DTC P1651
INJECTION PUMP: CAN MALFUNCTION
ECM
25A

SW:Neutral 6 7
(MT only)
(NKR 4JH1-TC only)
1
3 5 4 8 5 1 2
99 100
84 92 88 83 97 40 95 87 91 105 CAN-L CAN-H
CF 150
US
Batt
CPU µP µP µP µP
IC 08
IC 08 µP

INJECTION PUMP: CAN MALFUNCTION


Ignition off
• Make jumping at PCU pin 1 and PCU pin 2.
• Check continuity between ECM pin 99 and 100.
Ignition off
• Disconnect ECM and PCU connector.
Continuity Go to Step 4 Repair harness

injection pump
and verify —

CAN RECEIVEDS ERROR

Ignition off
Ignition off
• Disconnect ECM and PCU connector.
0Ω Go to Step 4 Repair harness

4 Replace ECM. Verify
DTC P1690
MALFUNCTION INDICATION LAMP (MIL) CIRCUIT MALFUNCTION
IG
ECM Stop lamp

15A
25A 10A
Relay EW

plug
relay
coil ExG Check
Glow
Brake Engine
ABS
control
unit
3 58 39 30 65 31 64 60 42 43 59 46
Batt Batt
IC 035 IC 035
Circuit Description engine lamp bulb. The ECM (Engine Control Module)
turns the check engine lamp “On” by grounding the
The check engine lamp should always be illuminated check engine lamp driver circuit.
and steady with the ignition “On” and the engine
stopped. Ignition feed voltage is supplied to the check
DTC P1690 SUB CODE1000

MALFUNCTION INDICATION LAMP (MIL) CIRCUIT HIGH INPUT


Ignition off
• Remove the No.12 fuse (NKR only), meter fuse (TF
4JH1-TC, 4JA1-TC).
• Measure voltage between ECM pin 42 and ground.
Ignition off
• Remove the No.12 fuse (NKR only), meter fuse (TF
4JH1-TC, 4JA1-TC).
• Measure voltage between ECM pin 42 and ground.
0V Replace ECM Go to Step 4

4 Disconnect the connector of instrument panel.
Check the voltage between the connector of Repair engine
instrument panel and the ECM. 0V Go to Step 5 harness
5 Check the voltage between the fuse and the lump Check the
bulb. ground the Repair harness
0V lump verify

MALFUNCTION INDICATION LAMP (MIL) CIRCUIT OPEN

3 • Ignition key “ON”.
• Does the “Glow” lamp flash? Go to Step 4 Go to Step 5
Ignition off
• Remove the No.12 fuse (NKR only), mater fuse (TF
4JA1-TC, 4JH1-TC).
• Check continuity between ECM pin 42 and
instrument panel side.
Ignition off
• Remove the No.12 (NKR only), meter fuse (TF
4JA1-TC, 4JH1-TC).
• Check continuity between ECM pin 42 and
instrument panel side.
Instrument panel Replace engine

Continuity Go to Step 5 harness
5 Check the No.12 fuse (NKR only), meter fuse (TF Fuse blown
4JA1-TC, 4JH1-TC) is not blown. Replace the
No blown Go to Step 6 fuse
6 Check the “Check Eng” lamp and “Glow” lamp bulbs. Bulb should Replace the
Are the bulbs available? be OK Go to Step 7 bulbs
7 Check continuity between the meter panel and No.12 Repair or
fuse (NKR only), meter fuse (TF 4JA1-TC, 4JH1-TC). replace body
Continuity Replace ECM harness
Symptom chart & perform procedure

1. No start or hard start.
1-1. No cranking happens.
1-2. Starter can crank engine, but seems to lower than usual.
1-3. Cranking speed seems to be OK, but no combustion sounds can be heard.
1-4. Engine run as idling speed, but can raise engine speed to usual engine
speed zone.
1-5. Engine can reach high engine speed, after release accel pedal engine stalls.
2. Engine stall.
2-1. Engine stalls at idling.
2-2. Engine stalls after engine revolution becomes more than idling speed—
Under shoot stall.
3. Rough idle.
4. Excessive white smoke.
5. Excessive black smoke.
6. Hesifation.
7. Surge/sag.
8. Lack of power.
9. Poor fuel consumption.
1-1. No cranking happens.

Check starter circuit, following section
1-2. Starter can crank engine, but seems to be lower than usual.

1 Ask the customer whether or not they use proper low-30 Replace oil and
viscosity oil. low-40 Go to Step 2 flash well
2 Check the manual transmission position. Clutch system
Should be Neutral. should not Clutch is
Run the engine. drug clutch drugged check
If cranking speed is lower, check the clutch system. plate Go to Step 3 clutch system
3 Measure cranking speed.
Does cranking speed meet standard?
Cranking speed
Oil temperature Cranking speed is OK
-20°C 100-150rpm or more Go to 1-3.
+20°C 200-250rpm or more “Cranking
speed seems to
If oil temperature can not be measured, water be OK, but no
temperature can be used. combustion
If water temperature can not be measured, See the left sounds can be
atmosphere temp can be used as reference. box heard” Go to Step 4
4 Check battery voltage and battery specific gravity. More than Recharge and
12V Go to Step 5 follow section
5 Check the starter circuit. Repair starter
See the electrical section. Go to Step 6 circuit
6 Check any accessory including Air conditioner
installed.
Remove or disconnect all accessory which make load Repair
to cranking. No accessory Go to Step 7 accessory
7 Check value gap. Valve gap
If valve gap is close to “zero”, need to be adjusted. value can be
Crank engine. seen on
engine
mechanical Adjust valve
section Go to Step 8 gap
8 Check engine whether any part has excessive friction.
See the overhaul procedure. Verify —
1-3. Cranking speed seems to be OK, but no combustion sounds can be heard.

1 Ask the customer whether use proper fuel. Replace and
Go to Step 2 flash well
2 Check cranking speed with following table.
Oil temperature Cranking speed

-20°C 100-150rpm or more
+20°C 200-250rpm or more Go to “1-2.
Starter can
If oil temperature can not be measured, water crank engine,
temperature can be used. but seems to be
If water temperature can not be measured, See the left lower than
atmosphere temp can be used as reference. box Go to Step 3 usual”
3 Ignition off, check the fuses.
ECU fuse 25A
Generator fuse 15A
Check any poor ground of ECM.
Check ECM engine harness poor cnnector pin. No fuse blown Go to Step 4 Repair
4 Check the fuel level. Add fuel and
Go to Step 5 bleed air
5 Check fuel feed pipe pinched, deformed or fuel No pinched
leakage. No deformed
No fuel
leakage Go to Step 6 Repair
6 Check sedimentary light on or not
If sedimentary light stays on, frozen water may cause
plugged fuel line at fuel filter. No light on Go to Step 7 Brain water
7 Check Air in fuel.
See the procedure in section No air Go to Step 8 Bleed air
8 Ask customer whether this happens at only around
0°C or less temperature.
Waxing might cause plugged fuel flow at fuel filter and
sedimenter.
If yes, change fuel to winter type fuel.
If no, see the No column.
No waxing
waxing
causes
plugging fuel Change to
Fuel feed line Fuel sedimenter/fuel filter flow Go to Step 9 winter type fuel

9 Check any deformation, plugged at inlet air passage.
Repair and
No plugged Go to Step 10 verify
10 Check Air cleaner element. Clean or
Is the element clean? replace
Air cleaner
Clean Go to Step 11 element
11 Operate the intake shutter by hand.
Check the position by no vacuum if intake shutter
position is not wide open position need to replace
intake shutter.
Intake shutter Replace intake

operate shutter and
smoothly Go to Step 12 verify
12 Check whether exhaust system is deformed, plugged. Exhaust
system is not
deformed
plugged.
Exhaust
system Repair or
should be ok Go to Step 13 Replace
13 • Operate exhaust valve by mighty vac if that does
not more smoothly, remove and check exhaust
Valve.
• Check the position by no vacuum if exhaust valve
position is not wide open position, need to replace
exhaust Valve.
Exhaust valve
moves
smoothly,
wide open Repair or
position by no Replace
Exhaust valve vacuum Go to Step 14 exhaust valve

14 Check catalytic converter is plugged or not. Replace
catalytic
No plugged Go to Step 15 converter
15 Check whether the turbine of turbo isn’t damaged. Go to Step 16 Repalce turbo
16 Check whether after market Air conditioner
compressor is in stalled.
If so, check whether Air conditioner compressor is Replace
seized by hand. Go to Step 17 compressure
17 Remove injection nozzle and confirm injection nozzle
1) Confirm the valve stick by hand tester
2) Confirm nozzle injection pressure Go to Step 18 Repair
18 Measure compression
• Engine coolant temperature 50°C. Compression
• Crank 200 to 250 rpm 28 kg/cm3 Go to Step 19 Repair engine
19 Remove coolant tempereture sensor and check See the ECT Replace
relation between the water temperature and sensor Table coolant
resistance value. on page 6E- temperature
203 Go to Step 20 sensor
20 Check injection valve, over flow valve. Go to Step 21 Replace valve
21 Replace ECM. Verify Replace pump
1-4. Engine run as idle speed, but can not raise engine speed to usual engine
speed zone.
1 Ask the customer whether the customer uses proper
fuel. — Go to Step 2 Change fuel
2 Check the fuel level.
If fuel level at tank is low, air can be contained. Add fuel and
Engine can not raise speed. — Go to Step 3 bleed air
No fuel
4 Check sedimenter light on or not. If sedimenter light
stays on, frozen water may cause plugged fuel line at
fuel filter. No light on Go to Step 5 Drain water
5 Check Air in fuel. See the procedure in section. No air Go to Step 6 Bleed air
0°C or less temperature. Waxing might cause plugged
fuel flow. If yes, change fuel to winter type fuel. If no, Change to
see the No column. — winter type fuel. Go to Step 7
7 Remove injecter. No problem
1. Check injection patter is OK. See the
engine
2. Check injection opening pressure is in
mechanical
specification.
section Go to Step 8 Repair & verify
8 Check ECT sensor resistance. See ECT sensor look
up table.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
See the left Replace ECT
-40 100700
table Go to Step 9 and verify
9 Inspect if overflow valve is kept open. No problem Go to Step 10 Repair

10 Check TPS position by Tech-II. Is data within typical Raise engine
data? speed two or
three times and
check again.
If condition still
continues,
Within replace
specification Go to Step 11 injection pump
11 Check TPS position becomes within typical data. Replace or
Typical data Go to Step 12 adjust
12 Remove MAF, check whether IAT works in 2.0KΩ at
specification. 20°C room
temperature Go to Step 13 Replace MAF
13 Check air cleaner element plugged, to use genuine No imitation
parts, intake pipe deformation or plugged. no
deformation
or plugged Go to Step 14 Correct them
14 Check intake shutter operation.
1. Should operate smoothly.
2. Should return to stopper bolt position.
3. Stopper bolt position should be proper.
4. No vacuum stays.
See the left

1-4 items Go to Step 15 Correct it
15 Check the compressor of turbo charger operation.
1. Remove inlet pipe.
2. Turn compressor fins manually.
3. Check oil deposit. Operate Correct it and
4. Clean them smoothly Go to Step 16 verify

16 Check any deformation, plugged at exhaust system.
No
deformation Correct it and
or plugged Go to Step 17 verify
17 Check turbine of turbo charger. — Go to Step 18 Correct it
18 Repalce ECM and verify. Still does not
run well,
replace
— — injection pump
1-5. Engine stall after engine speed reach more than 2000 rpm.
1 Foreign materials sometimes cause MAB valve stuck.
Stop engine, and raise engine speed more than 2000
rpm. Release accelerator pedal, check the engine
stalls or not. No stall Verify Go to Step 2
2 Even engine run at 1st hand, waxing at fuel filter Engine run Replace to
causes no engine raise, or stall. more than proper fuel and
2000 rpm Go to Step 3 flash it
3 Check fuel level or any air mixing to fuel line. Repair it and
— Go to Step 4 verify.
4 Check air cleaner element plugged, to use genuine No imitation
parts, intake pipe deformation or plugged. no
deformation
or no plugged Go to Step 14 Correct them
4. No vacuum stays.
See left 1-4

items Go to Step 15 Correct it
4. Clean them. smoothly Go to Step 16 verify
See the procedure.
No
deformation Correct it and
or plugged Go to Step 17 verify

8 Check turbine of turbo charger. See the procedure on
engine mechanical section.
It any damage,
replace turbo
— Go to Step 18 charger
9 If engine reaches more than 2500 rpm and stall,
check any after market accessory is installed for
engine load. Possible A/C compressor is on after No after Replace to
engine run. If no signal goes to ECM, change after market genuine parts
marked A/C compressor. accessory Go to Step 10 or remove it
10 After glow may not work properly because ECM does
not recognize after glow is required. See the DTC
P380 as reference.
Check ECT resistance up is in specification.
See the table.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
Within Repalce ECT
-40 100700
specification Replace ECM sensor
2. Engine stall
2-1 Engine stall at idling.

1 Did engine stall happen at lower than 10°C or more Lower than
than 10°C Lower than 10°C
10°C Go to Step 2 Go to Step 14
2 Check the fuel level in tank. Add fuel and
Fuel is bleed air &
sufficient Go to Step 3 verify
3 Ask the customer what kind of fuel the customer use.
Cetane index more than specified on owner’s manual.
No gasoline
No kevocin Replace and
No bio chemical fuel Proper fuel Go to Step 4 flash fuel
4 It may be caused by waxing or air mixture in the fuel.
1. Ask the customer what kind of temperature make
this failure. If that happen only around 0°C or a
Replace and
little more, waxing of fuel may cause. Request to
flash fuel
customer to change the fuel to winter type fuel.
Drain water
2. Check the sedimentary light is on or not. If it is on, from
ice may plug fuel flow. sedimenter
3. If this is intermittent, ask the customer how is the Proper fuel Ask customer to
level of car at parking. If road or parking lot has and no air in put more fuel
slope, it maybe caused by air mixing in the fuel. the fuel Go to Step 5 regularity
5 Check APS position is within typical data. See the
typical data Go to Step 9 Go to Step 6
6 Check any fuel leakage at fuel pipe, injection pipe. Correct it and
Check any damage of fuel pipe or injection pipe. — Go to Step 7 verify.
7 Replace fuel filter, because it maybe caused by fuel Verify, still
filter plugged or resistance fuel flow through fuel filter. simpton exist,
Does it fix the problem? Verify
— Go to Step 9 Go to Step 9
8 Check the over flow valve stuck open. No stuck OK
open Go to Step 10 Repair
9 Check any installation of after market accessory No
especially A/C compressor. installation. Go to Step 11 Remove

11 Inspect ECT is within specification.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
Within Replace it and
-40 100700
specification Go to Step 12 Verify
12 Replace injection pump. Verify
but still
condition
continues, Go
— to Step 13
13 Replace ECM — Verify —
Fuel is bleed air &
sufficient Go to Step 15 verify
15 Ask the customer what kind of fuel the customer use.
Cetane index more than specified on owner’s manual.
No gasoline
No Kevocin
No bio chemical fuel Proper fuel Go to Step 16 Replace it.
16 It maybe caused by air mixing in the fuel.
1. Check the sedimenter light is on. If so, drain water.
2. If this is intermittent, ask the customer how is the Drain water ask
level of the car at parking. If road or parking lot the customer to
has grade, it may be caused by air mixing in the put more fuel
fuel. — Go to Step 17 regnlary
17 Check any fuel leakage at fuel pipe, injection pipe. Correct it and
Check any damage of fuel pipe or injection pipe. — Go to Step 18 verify
18 Check air cleaner element plugged, to use genuine
parts, intake pipe deformation or plugged. — Go to Step 19 Correct them

4. No vacuum stays.
See the left

1-4 items Go to Step 20 Correct it
Correct it and
— Go to Step 22 verify
engine mechanical section.
— Go to Step 23 Correct it

23 Check any installation of after market accessory No
especially A/C compressor. installation. Go to Step 24 Remove
24 Inspect ECT is within specification.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
Within Replace it and
-40 100700
specification Go to Step 25 verify
25 Run engine again. Foreign material at MAB may If no more stall,
cause High pressure soloenoid valve stuck. No foreign verify one more
material time Go to Step 26
26 Check injection nozzle spray pattern and opening Opening
pressure. pressure
1st 19.5kpa/
199kg/cm2
2ns 33.8kpa/
345kg/cm2 Go to Step 27 Change nozzle
27 Check the compression. Follow the
procedure at
engine
mechanical
See the left Go to Step 28 section
28 Replace injection pump. — Verify Go to Step 29
2-2 Engine stall after engine revolution becomes more than idling speed.
Undershoot stall.

1 Ask the customer, does it happen always or Always Go to Sometimes Go
sometimes. — Step 2 to Step 9
2 Check intake throttle operation. Should be operated
smoothly.
4. No vacuum stays.
(Intake throttle is available only NKR 4JH1-TC, Within Replace and

operation should be smooth.) specification Go to Step 3 verify.
3 Check exhaust valve operation. Operation
should be
smooth Go to Step 4 Replace it
4 Ask the customer what kind of oil he or she uses. 10w-30 or
10w-40 Go to Step 5 —
5 Record data of Q–final, rpm, APS, MAF output (Air
weight) by Tech-II. Continuous record from idling to
stall condition is necessary for further engineering
study. Send this record to ISUZU representative. — Go to Step 6 —
6 Check PTO system or accessory. How? — Go to Step 7 —
7 Inspect any mechanical friction increased.
1. Clutch
2. A/C compressor
3. Generator
4. P/S pump
5. Injection system See the
mechanical
6. Lubrication system
section of
7. Valve train system workshop If any problem,
8. Crank shaft manual Go to Step 8 repair and verify
8 Replace ECM — — —

9 Check intake throttle operation. Should be operated
smoothly.
4. No vacuum stays.
(Intake throttle is available only NKR 4JH1-TC, Correct it and

operation should be smooth.) — — verify
10 Check exhaust valve operation — Go to Step 11 Replace it
11 Ask the customer what kind of oil he or she uses. 10w-30
10w-40 Go to Step 12 —
12 Check whether ECM connector, ECT connector PCU No poor
connector, glow plug connector have poor connection connection Go to Step 13 Repair
13 Record data of Q-final, rpm, APS, MAF output(Air
weight) by Tech-II. Continuous record from idling to
study. Send this record to ISUZU representative. — Go to Step 13 —
14 Check PTO system or accessory.
How? — Go to Step 14 —
15 Replace ECM — — —
3. Rough idle
1 Use Tech-II to confirm. Compare actual idling speed Repace to OK
and target idling speed. ECM
If rough idle is
Actual idle fixed, replace
speed = ECM
target idle If not, go to
speed Go to Step 2 Step 2
2 Check accessory belt tension. 98 - 118 (V) Adjust and
10 - 12 (kg) Go to Step 3 verify
3 Check any after market accessory, which ECM does No accesay Go to Step 4 Remove after
not recognize additional engine load of A/C with ECM happens only market
compressor or wrong wring. recogaition during night accessory
4 Ask the customer when it happen. If happens only If happens only
during night, ACG load fluctuation causes rough idle. during night,
ask ISUZU
— representative Go to Step 5
5 Check air cleaner element plugged, to use genuine No imitation,
parts, intake pipe deformation or plugged. no plugged,
no
deformation Go to Step 6 Correct them.
6 Check intake shutter operation. (NKR 4JH1-TC only)
4. No vacuum stays.
See the left Replace and

1-4 items Go to Step 7 verify
7 Check fuel level. Add fuel and
— Go to Step 8 bleed air
8 Check fuel feed pipe pinched, deformed, damaged or
fuel leakage. — Go to Step 9 Repair
9 Ask the customer what kind of fuel the customer use. Proper fuel
see the
owners Replace to
manual Go to Step 10 proper one
10 Check APS sensor return to 0% by Tech-II and by
DVM. — Go to Step 11 Repair

No
deformation, Correct it and
plugged Go to Step 13 verify
13 Check turbine of turbo charger. See the procedure or
engine mechanical see section.
No damage Go to Step 14 Correct it

14 Check over flow valve stuck or not. — Go to Step 15 —
15 Check EGR valve operation. Apply vacuum by mighty
vac.
See the valve movement through EGR valve window.
Oporate Replace and

smoothly Go to Step 16 verify
16 Replace fuel filter cartridge. Run engine, check rough No more
idle is fixed or not. rough idle Verify Go to Step 17

17 Check injection nozzle spray pattern and injection Opening
opening pressure. pressure
1st 19.5kpa/
199kg/cm2
2ns 33.8kpa/
345kg/cm2 Go to Step 18 Replace nozzle
18 Inspect delivery valve leaking or any damage around
seal area. No leakoge Go to Step 19 Repair
19 Check the compression. Compression is
not in
specification.
Check the
cause based on
engine
mechanical
More than section of work
28 kg/cm2 Go to Step 20 shop manual
20 Inspect ECT sensor with specification table below.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
Repalce ECT
-40 100700
— Go to Step 21 sensor
21 Check glow plug. Replace glow
Ω Go to Step 22 plug
22 Check IAT sensor. 2.0KΩ at
20°C room
temp Go to Step 23 Replace MAF
23 Replace injection pump. — Verify —
4. Excessive white smoke.

Step Action Valve(s) Yes No
1 Ask the customer when excessive white smoke
happen.
1) When start engine
2) During driving the vehicle 1-1)→2
a) Low elevation 1-2)a)→21
b) High elevation — 1-2)b)→41 —
2 Ask the customer whether he or she use proper fuel.
1. Diesel fuel cetane index.
2. No gasoline.
3. No kelosin.
4. Bio chemical fuel.
5. No high sulfur fuel consult with ISUZU Replace fuel
representative. Proper fuel Go to Step 3 and flash
3 Ask the customer whether this white smoke happen No long hours
just one time after soak the vehicle for long hours Explain to parking
under cold weather. It is normal. — customer Go to Step 4
4 Check air cleaner element plugged, to use genuine No immitation
no
deformation Go to Step 5 Correct them
1. Should operate smoothly
4. No vacuum stays.
See the left

1-4
Smooth
operation Go to Step 6 Correct it

Correct it and
No damage Go to Step 8 verify
engine mechanical sectin.
9 Check over flow valve stuck open by foreign material. Remove foreign
— Go to Step 12 material
10 Check injection pipe, fuel feed pipe damaged. No damage Go to Step 10 —
11 Check any fuel leakage. No leakage Go to Step 11 Repair leakage
12 Check TPS timer position by Tech-II. Compare actual
position and target position. If both are same, go to Replace
yes. If both are not same, go to no. — Go to Step 13 injection pump

13 Check ECT valve by Tech-II with actual condition.
If nearly equal, check ECT sensor in specification.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450 Within
-30 52700 specification
see the left
-40 100700
table Go to Step 14 Replace ECT
14 Check glow plug resistance. Within Replace glow
specification Go to Step 15 plug
15 Check poor connection of glow plug, ECT sensor
ECM connector, PCU connector. Go to Step 16 Repair wiring
16 Check IAT sensor — Go to Step 17 Replace IAT
17 Check valve timing. See the procedure on the engine
mechanical. Within spec Go to Step 18 Adjust
18 Inspect injection nozzle spray pattern, opening Opening
pressure. pressure
1st 19.5kpa/
199kg/cm2
2ns 33.8kpa/
weight) by TechII. Continuous record from idling to
study. Send this record to ISE representative. Go to Step 20 —
21 Ask the customer whether excessive white smoke
occurs during download slope.
Record download or flat slope. — Go to Step 22 —
22 Compare the particular vehicle with standard vehicle, Explain to the
if excessive white smoke is confirmed, go to yes. If not customer it is
go to no. — Go to Step 25 within standard
23 Ask the customer whether he or she use proper fuel.
1. Diesel fuel cetane index.
2. No gasoline.
3. No kelosin.
4. Bio chemical fuel.
5. No high sulfur fuel consult with ISUZU Replace fuel
representative. Proper fuel Go to Step 24 and flash

24 Check air cleaner element plugged, to use genuine No immitation
no
1. Should operate smoothly
4. No vacuum stays.
See the left

1-4
Smooth
operation Go to Step 26 Correct it
Correct it and
No damage Go to Step 28 verify

engine mechanical sectin.
29 Check over flow valve stuck open by foreign material. Remove foreign
— Go to Step 30 material
30 Check injection pipe, fuel feed pipe damaged. No damage Go to Step 31 —
31 Check any fuel leakage. No leakage Go to Step 32 Repair leakage
32 Check TPS timer position by Tech-II. Compare actual
position and target position. If both are same, go to Replace
yes. If both are not same, go to no. — Go to Step 33 injection pump
33 Check ECT valve by Tech-II with actual condition.
If nearly egnal, check ECT sensor in specification.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450 Within
see the left
-40 100700
34 Does customer drive after run glow period? During after run Not during after
See the system description on page of DTC P0380 period, Go to run period, Go
glow device Malfunction. step 35 to step 39
35 Check glow plug resistance. Within Replace glow
specification Go to Step 36 plug
36 Check poor connection of glow plug, ECT sensor,
ECM connector, PCU connector. Go to Step 37 Repair wiring
37 Check IAT sensor — Go to Step 38 Replace IAT
38 Check valve timing. See the procedure on the engine
mechanical. Within spec Go to Step 39 Adjust

39 Inspect injection nozzle spray pattern, opening Opening
pressure. pressure
1st 19.5kpa/
199kg/cm2
2ns 33.8kpa/
weight) by TechII. Continuous record from idling to
study. Send this record to ISE representative. Go to Step 41 —
42 Ask the customer whether excessive white smoke Go to Step
occurs during down road slope or flat. Go to Step 23-34
Record the condition. 22-41 37-41
5. Excessive black smoke

1 Ask the customer what condition make excessive 1-1)-2-2)
black smoke. step 2
1. Elevation 1-1)-2-3)
1) Sea level. step 16
2) High elevation more than 2500 m. 1-1)-2-4)
step 21
2. Engine condition
1-1)-2-1)
1) Starting
step 25
2) Idling
1-2)-2)
3) Part load (Part throttle)
step 29
4) full load (WOT)
1-2)-3)
3. Does not pass FA smoke test? step 29
1-2)-4)
step 29
3
— step 30 —
2 Compare the claimed vehicle with any other vehicle. If smoke level is
Smoke level is same or not. same, explain
— to the customer Go to Step 3
2. Should return to stopper bolt position
4. No vacuum stays.
4. Clean them. smoothly Go to Step 6 verify.

See the procedure.
Correct it and
engine mechanical section of work shop manual.
Engine speed is
not proper
Repair speed
sensor
↓
Still NG
↓
Repalce ECM
— Go to Step 8 Coorect it
8 Check engine mode is in cranking mode or normal
mode.
Even engine speed seems to be high enough for
normal mode, Tech-II may show cranking model.
Check engine speed is OK between Tech-II reading
and revolution meter.
If ECM does not have or recognize right engine
speed, crank mode can continue. Crank mode
Crank mode requests much more fuel quantity. threshold Go to Step 9 —
9 Compare desire timer piston position (Desired Raise engine
injection start) and actual timer piston position. (Actual speed to more
injection start) than 3000 rpm
two or three
times and
check again. If
condition still
continue
Within replace
tolerance Go to Step 10 injection pump.

10 Check the EGR valve stuck or not.
Procedure
• Remove vacuum hose
• Check valve return “0” position.
• Apply vacuum by mighty VAC.
• Check operation is smooth.
• Remove EGR valve.
• Check any foreign material at valve seat or stem
area.
NG
Replace EGR
— Go to Step 11 valve
11 Check ECT sensor resistance.
Compare it with the table below.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450 Within
See the left OK NG
-40 100700
12 Check injection nozzle spray pattern and opening Opening
pressure. pressure
If opening pressure is low than standard, it may cause 1st 19.5kpa/
excessive black smoke. 199kg/cm2 NG
2ns 33.8kpa/ OK Replace
345kg/cm2 Go to Step 13 injection nozzle
13 Check whether excessive PCV oil pass through inlet
manifold. OK Replace PCV
If a lot of PCV oil appears, check PCV system. — Go to Step 14 system

14 Check compression. See the procedure on the page OK
of engine mechanical section. — Go to Step 15 Repair
15 Check any damage at combustion room, piston, any Repair and Repair and
combustion related area. — verify verify
16 Go to 2, 3, 4, 5, 6, 7, 10, 11 — Go to Step 17 —
17 Check MAF sensor.
If MAT indicates much high than actual, it may cause Compare with
excessive black smoke. typical data Go to Step 18 Replace MAF
18 Check injection nozzle spray pattern, 1st/2nd stage
opening pressure.
If 1st stage opening pressure is lower than standard, it Opening
may cause excessive black smoke. pressure
Adjust and check again. 1st 19.5kpa/
If 2nd stage opening pressure is high than standard, it 199kg/cm2
may cause excessive black smoke. 2ns 33.8kpa/
Adjust and check again. 345kg/cm2 Verify Go to Step 19
19 Compare fuel temperature on Tech-II.
If fuel temperature exhibit extremely low temperature, Replace
it may cause excessive black. — Go to Step 20 injection pump.
20 Go to 13, 14, 15 — Verify Verify
21 Go to 2, 3, 4, 5, 6, 7, 10, 11, 17, 19 — Go to Step 22 —
22 Check injection nozzle spray pattern, 1st/2nd stage Opening
opening pressure. pressure
Lower opening pressure may cause excessive black 1st 19.5kpa/
smoke. 199kg/cm2
Adjust and check again. 2ns 33.8kpa/
345kg/cm2 Verify Go to Step 23
23 MAB may stuck, wave form may be œ.
Replace and check again. — Verify Go to Step 24
24 Go to 14, 15 — — —
25 Check any fuel leakage which cause air in fuel at fuel Repair and
supply, injection line. — Go to Step 26 verify
26 If DTC of ECT appears, back up valve becomes
–30°C, black smoke may exhaust. — Repair Go to Step 27
27 If DTC of Timer piston appears, excessive black
smoke may exhaust. — See DTC. Go to Step 28
28 Go to 19, 17 — Verify Verify
29 Atmosphere sensor may indicate wrong data in Follow same as
comparison with actual condition. 1-1)-2-2)
Compare atmosphere data by Tech-II with real 2
atmosphere. or
If compare result shows different, replace ECM. 1-1)-2-3)
16
or
1-1)-2-4)
— Verify 21
30 Most of case deposit smoke in the exhaust system NG
cause temporary excessive smoke. Raise engine Go to 1-1)-2-3)
speed to close to no load max. Check it again. — OK Verify procedure
6. Hesitation 7. Surge/Sag
1 Verify the customer complain
Is the complain hesitation/flatness or sug/surge?
rpm
Definifion of engine performance
Expectation
Surge
Sug
Hesitation/
flatness
Hesitation
Go to Step 2
Flatness
Time Sug/Surge
— Go to Step 21 —
2 Check the tire specification Within Replace to the
NKR tire spec. specification Go to Step 3 specified tire
3 Check the load on the vehicle. Are those exceeded to Within Adjust to the
the standard? standard Go to Step 4 standard weight
4 Ask the customer whether he or she uses proper fuel. Proper fuel Go to Step 5 Change fuel
5 Check the fuel level in the fuel tank. Sufficient
level of, fuel in Add fuel and
the fuel tank Go to Step 6 bleed air
leakage No deformed
No fuel
7 Check sedimenter light on or not. If sedimenter light
fuel filter. No light on Go to Step 8 Drain water
8 Check Air in fuel. See the procedure in engine
mechanical section. No air Go to Step 9 Bleed air
0°C or less temperature. Waxing might cause Change to
plugged fuel flow. — winter type fuel Go to Step 10
10 Check vehicle speed with another vehicle. Possible
different type speed sensor is installed. Gear NKR and
speed sensor NPR. — Go to Step 11 Replace it
11 Check APS sensor opening angle and Tech-II data. If
different, replace it. — Go to Step 12 Replace it
12 Check ETC sensor data by Tech-II, compare with ECT sensor
actual engine coolant temperature. ECT sensor shows different
indicates same valve from
as actual actual data
Go to Step 14 Go to Step 13

13 Check ECT sensor with the following table.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
Within Replace and
-40 100700
specification Go to Step 14 verify
14 Check air cleaner element plugged, to use genuine No after
parts, intake pipe deformation or plugged. marked
No plugged,
No
3. Stopper bolt position should be proper
4. No vacuum stays.
Go to Step 16 Correct it

See the procedure.
Correct it and
18 Check turbine of turbo charger.
See the procedure.
19 Check MAF actual data with typical data. Within typical
data Go to Step 20 Repair

Procedure
• Remove vacuum hose.
• Check any foreign material at valve seat or stem
area.
NG
Replace EGR
— Go to Step 21 valve.
21 Check turbo waste gate. — Go to Step 22 Repair
22 Compare MAF valve with typical data.
If MAF is not typical data, boost control and EGR
becomes poor. — Go to Step 23 Repair
23 Compare engine revolution by Tech-II and engine
revolution meter.
If different,
1. Check speed sensor,
2. Check ECM.
Repair or replace malfunction parts. — Go to Step 24 Repair
24 Check EVRV function. Replace or
— Go to Step 25 repair
25 Check injection nozzle spray pattern, 1st/2nd opening Opening
pressure. pressure
1st
2nd Go to Step 26 Repair

26 Check timer piston movement.
Plot graph by SOL, LST.
Record engine speed, timer piston SOL IST, ECT
sensor, IAT sensor, MAF.
SOL
Timer advance
IST
Replace
rpm — Go to Step 27 injection pump
27 Raise engine speed up to max two or three times. Injection pump
Check it again. — replace verify —
28 Go to 2, 3. — Go to Step 29 —
29 Check A/C compressor wiring harness. If A/C on
request signal harness is cut off, ECM does not
recognize ECM input. It may cause surge or sug. — Go to Step 30 —
30 Check any accessory, additional load such as
compressor, ITO loads. — Go to Step 31 Remove it
31 Go to 4, 5, 6-27. — Verify —
EGR control logic
• Engine Revolution
OFF
• APS Input
+ Atomasphere
temp ON
+5°C 10°C
OFF
+ Atomasphere
pressure
ON
1500rpm
TF 4JA1
EGR lift control
+ Water
temp
10°C 20°C 80°C

Water temp [°C]
NKR 4JH1-TC
EGR lift control
+ Water
temp
60°C 65°C
Water temp [°C]
8. Lack of power
1 Ask the customer the following condition. 1. Go to Step
1. During the acceleration 2
2. During the climbing 2. Go to Step
— 25 —
2 Check the vehicle performance. In the
0-400m sec specification
40-60km/h sec Explain to the
— customer Go to Step 3
3 Check the tire size. spec Go to Step 5 Replace tires
4 Check APS whether APS moves smoothly or
excessive free play. — Go to Step 13 —
5 Compare the complained vehicle with another vehicle
about the vehicle speed. — Go to Step 6 Repair
6 Check the load on the vehicle. If overload, remove
exceeded part of load. Check the power performance. — OK Go to Step 6
7 Ask the customer whether he or she proper fuel — Go to Step 8 Change fuel
— Go to Step 9 bleed air
No fuel
10 Check sedimentary light on or not. If sedimentary light
fuel filter.
Fuel feed line Fuel sedimenter/fuel filter No light on Go to Step 11 Drain water
11 Check Air in fuel. See the procedure in section. No air Go to Step 12 Bleed air
12 Remove injection nozzle.
1. Check injection patter is OK.
2. Check injection opening pressure. No problem Go to Step 13 Repair & verify

13 Check ECT sensor resistance. See ECT sensor look
up table.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
ECT sensor
-15 21450 within
See the left Replace &
-40 100700
table Go to Step 14 verify
14 Check TPS position by Tech II. Is data within typical Raise engine
data? speed two or
three times and
check œ
condition still
continue
Within Replace
specification Go to Step 15 injection pump
15 Replace fuel sedimenter filter. Check TPS position
becomes within typical data. — verify Go to Step 16
16 Remove MAF, check whether MAF works in
specification. — Go to Step 17 Replay MAF
parts, intake pipe deformation or plugged. — Go to Step 18 correct them
2. Should reform to stop bolt position.
4. No vacuum stays.

19 Check the compressor of turbo changer operation.
2. Turn compressor fins manually
See the procedure.
Correct it and
21 Check turbine of tanks changer. See the procedure. — Go to Step 22 Correct it
22 Check waste gate operation. If waste gate stuck open,
power loss may happen. — Go to Step 23 NG Repair
23 Replace injection pump
SPV valve may have foreign materials. — Verify —
Procedure
• Check any freign material at valve seat or stem
area.
Replace EGR
25 Check the vehicle performance. — — Go to Step 26
26 Go to Step 3 ~ 24 — — —
9. Poor fuel consumption

1 Ask the customer how many km/l is recorded.
Compare the standard data with claim fuel
consumption. If data indicates difference between
them, drive the following condition. within explain to the
Note: Set driving course for fuel consumption test. specification customer 2
2 Check the vehicle condition.
1. Tire
2. Accessory installation after market Air
conditioning
Change to the
3. Towing or not standard
4. PTO — Go to Step 3 condition
3 Ask the customer what kind of fuel he or she uses.
DIESEL FUELS
DIESEL FUEL/APPLICABLE STANDARD
JIS Based on K2204 GAS
(JAPANESE INDUSTRIAL STANDARD) OIL
DIN Based on EN590: 1997
(DEUTSCHE INDUSTRIE NORMEN)
SAE Based on SAE J-313C
(SOCIETY OF AUTOMOTIVE ENGI-
NEERS)
BS Based on BS EN590:
(BRITISH STANDARD) 1997
Use the applicable standard or equivalent for diesel fuels.
If possible, measure the specific gravity, check the

measured specific gravity meet to the standard. proper fuel Go to Step 4 Replace
4 Ask the customer what kind of engine oil he or she
uses.
oil viscosity 10w–40
10w–30
Ask the customer when change the interval.
Refer to the owner’s manual.
Check oil viscosity by hand. 10w–40
If oil viscosity is high, replace it. 10w–30 Go to Step 5
5 Check any fuel leakage at fuel system. OK Go to Step
Go to Step 6
6 Measure timer piston movement by Tech-II.
SOL
Timer advance
IST
Raise engine
speed and
verify it NG.
rpm Replace
— Go to Step 7 injection pump.

2. Should reform to stop bolt position.
4. No vacuum stays.
Operate
smoothly
See item 1-4
on the left Go to Step 9 Correct it
1. Return inlet pipe.
3. Check oil deposit. operate Correct it and
No
deformation, Correct it and
no plugged Go to Step 11 verify
11 Check turbine of turbo charger see the procedure. — Go to Step 12 Correct it

Procedure
• Remove EGK valve.
• Check any foreign material at valve seat or stew
area.
Replace EGK
13 Check turbo waste gate. — Go to Step 14 Repair
14 Compare MAF valve with typical data.
If MAF is not typical data, boost control and EGK
becomes poor. — Go to Step 15 Repair
revolution meter. If different,
1. Check speed sensor,
2. Check ECM. Repair or Replace malfunction parts. — Go to Step 16 Repair
16 Check EVRV function Replace or
17 Inspect APS sensor operation. — Go to Step 18 —
18 Inspect MAT sensor output, comparing with
atmosphere temperature. Use T-II. — Go to Step 19

19 Inspect ECT sensor, compare with the following table.
°C OHMS
100 177
80 332
60 667
45 1188
35 1802
25 2796
15 4450
5 7280
-5 12300
-15 21450
-30 52700
-40 100700
— Go to Step 20
20 Inspect atmosphere sensor with actual atmosphere.
Nearly equal is OK. — Go to Step 21 —
21 Check the EGK valve stuck or not.
Procedure
• Remove EGK valve.
• Check any foreign material at valve seat or stew Replace EGK
area. — Go to Step 22 valve
22 Check turbo waste gate. — Go to Step 23 Replace
23 Compare MAF valve with typical data. If MAF is not
typical data, boost control and EGK becomes poor. — Go to Step 24 Repair
revolution meter.
If different,
1. Check speed sensor.
2. Check ECM.
Repair or replace malfunction parts. — Go to Step 25 Repair
25 Check EVRV function. Replace or
26 Check injection nozzle spray pattern, 1st/2nd opening opening
pressure. pressure
1st
2nd — Repair
SPECIAL SERVICE TOOLS
ILLUSTRATION PART NO. PART NAME REMARKS

Connector Test Adapter Kit
KM 609 Electronic Kits
Electronic kit
5-8840-2392-0 High Impedance Multimeter

(Digital Voltmeter -DVM)
Tech-II Refer to the ISUZU service

Bulletin
5-8840-0378-0 Pressure Gauge
5-8840-0279-0 Vacuum Pump with Gauge

4JVP44-WE-0112
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA, Canada.
All rights reserved, This manual may not be reproduced

in whole or in part, without the permission in writing of
ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
Second edition OCT., 2001

No.4JVP44-WE-0112 PRINTED IN JAPAN

4JVP44 We 0112 PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

4JVP44 We 0112 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

WORKSHOP MANUAL

ENGINE DRIVEABILITY AND EMISSIONS

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

Applicable Model : TFR/S 54, TFR/S 77, NKR 77

This manual is applicable to 2001 year model and later vehicles.

ENGINE DRIVEABILITY AND EMISSIONS 6E–1

ENGINE with TF 4JA1-TC/TF

ISUZU Strategy Based Diagnostics .............. 6E-4 TF 4JA1-TC/4JH1-TC TDC Sensor

ISUZU Strategy Based Diagnostics

Overview You have maximum efficiency in diagnosis when you

Diagnostic Thought Process • Circuit testing tools

What resources you should use 5c. Technician Self Diagnoses

Hints 3. Water and Moisture

6. Re-examine the complaint

What you should do

What resources you should use

7. Repair and Verify Fix

What resources you should use

0.5G/B A-6 B14(92) 3

0.5BR/W HA20 1 0.5BR HA19

RELAY ; ECM MAIN

0.5R A-3 0.5W/R IC27

F 0.5G/B R A-10 0.85R/Y 0.5R/Y

THERMO UNIT ENG COOLANT

A-6 0.5L A10

0.5B SPEED METER

RELAY ; ECM MAIN

B15(93) HA18 HA17 A/C

3 HA21 0.5G/W HA16

SW ; OIL TB07(W/O SOF)

ACCEL SENSOR A-35 0.5G/O 2

BATT 0.5G/Y (GND.)(49) IC44

(BRAKE PEDAL ; OFF) GND. A-61 2B

OFF (2) JOINT

KEY SW ACC SW ; CLUTCH A-62

FRAME D-4 0.5Y/B

IC13 (64) EARTH POINT

CHECK ENG. 14V, (27) MA07 MX04

RELAY ; ENG.WARM 1.4W 0.5O/L A-40 METER IND

THERMO A/C IC18 (GLOW)

IC21 IZ09 0.5B

14V, IC20 (QWS) IC46

MOTOR 0.5L/R MAF 0.5G/R B-7 MAF SIG. CONT.UNIT ; ABS

Pin No. Connected car component Note

Pin No. Connected car component Note

Pin No. Connected car component Note

N*R 4JH1-TC ECM Pinouts

Pin No. Connected car component Note

Pin No. Connected car component Note

Pin No. Connected car component Note

NKR (4JH1-TC) TF (4JA1-TC, 4JH1-TC) PCU Pinouts

Pin No. Connected car component Note

TF 4JA1-TC/4JH1-TC, N*R 4JH1-TC, Specifications

Legend (3) Injection pump

TF 4JA1-TC with Bosch VP44 System Component Locator

Legend (3) Fuel Filter

TF 4JA1-TC/4JH1-TC TDC Sensor Location

Legend (3) Wiper Motor

TF 4JA1-TC, 4JH1-TC with Bosch VP44 System Component Locator

Legend (2) SRS Control Module

TF 4JH1-TC with Bosch VP44 System Component Locator

TF 4JH1-TC with Bosch VP44 System Component Locator

Legend (3) Fuel Filter