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TF SERIES
ENGINE
4JA1/4JH1-TC
SECTION 6
TROUBLESHOOTING 6 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE
PAGE
4. EXCESSIVE FUEL
CONSUMPTION................................. 6 7
6. OVERHEATING............................... 6 9
7. WHITE EXHAUST SMOKE ............. 6 9
6 2 TROUBLESHOOTING
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step
1
Inspection point
Inspection result
The battery fluid level and the Was the problem found?
gravity
7
8
9
Go
to
mechanical Was the problem found?
troubleshooting chart
YES
Go to section
6E On Board
Diagnostic
(OBD) System
Check"
Re-charge the
battery or
replace the
battery
Replenish the
engine coolant
Replenish the
engine oil
Clean or
replace
Return normal
condition
NO
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Re-adjust the
tension or
replace
Go to Step 8
Verify repair
Go to Step 9
Verify repair
TROUBLESHOOTING 6 3
1. Hard Starting
4
5
Action
1-2 Starter motor operates but engine does not turn over
Step
Value(s)
Action
Value(s)
Yes
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
No
Repair or
replace the
starter switch
Repair or
replace the
starter relay
Repair or
replace the
magnetic
switch
Replace the
pinion gear
Replace the
starter motor
assembly
Repair or
replace the
brush or brush
spring
Yes
No
Repair or
replace seized
parts
Check other
DTC by Tech
2 and go to
indicated DTC
6 4 TROUBLESHOOTING
Action
Action
3
4
Value(s)
No
Repair replace
problem parts.
Go to Step 2
Repair replace
the over flow
valve
Go to Step 3
Replace the
fuel filter
element
Go to Step 4
Go to indicated
DTC
Solved
Value(s)
Yes
(See below)
Yes
Go to Step 5
No
Replace the
fuel
Go to Step 2
Go to Step 4
Replace the
injection nozzle
Go to Step 5
Replace the
injection nozzle
Go to Step 5
Replace the
injection nozzle
Go to indicated
DTC
Go to Step 6
Solved
TROUBLESHOOTING 6 5
2. Unstable Idling
Step
1
2
Action
Value(s)
(See below)
See Step 6
10
0.4 mm
(0.016 in)
both intake
and exhaust
valves
3,040 kPa
2
(31 kg/cm ,
441 psi) at
200rpm
Yes
Go to Step 3
Repair or
replace relation
parts.
Replace the
fuel
No
Replace the
fuel filter
element
Go to Step 6
Go to Step 7
Replace the
injection nozzle
Replace the
injection nozzle
Go to Step 8
Repair or
replace the
throttle valve
Go to Step 9
Adjust the
valve clearance
Go to Step 10
Go to Step 11
Go to indicated
DTC
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Solved
6 6 TROUBLESHOOTING
3. Insufficient Power
Step
1
3
4
5
6
8
9
10
11
12
13
Action
Value(s)
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
Go to Step 2
Repair or
replace the
intake air
system.
Go to Step 4
Repair or
replace the fuel
injection pipes.
Replace the
fuel
Go to Step 7
Go to Step 8
Repair or
replace the
exhaust pipe.
Repair or
replace the
exhaust
system.
Replace the
hose.
Go to Step 12
Go to Step 13
Go to indicated
DTC
No
Clean or
replace the air
cleaner
element.
Go to Step 3
Clean or
replace the fuel
filter element.
Go to Step 5
Go to Step 6
Readjust the
injection nozzle
pressure or
replace the
nozzle.
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to Step 9
Go to Step 10
Go to Step 11
Replace the
turbocharger
assembly.
Replace the
turbocharger
assembly.
Solved
TROUBLESHOOTING 6 7
Action
Was the air leakage found from the air intake side of
the turbocharger?
Value(s)
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
Clean or
replace the air
cleaner
element.
Repair or
replace the air
intake side of
the
turbocharger.
Go to Step 4
Repair or
replace the fuel
leakage part.
No
Go to Step 2
Go to Step 3
Replace the
turbocharger
Go to Step 5
Go to Step 6
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to Step 7
Replace the
injection nozzle
Go to indicated
DTC
Solved
6 8 TROUBLESHOOTING
2
3
Action
Value(s)
Less than
588 kPa (6.0
2
kg/cm , 85
psi)
Inspect the valve stem seal, the valve stem and the
valve guide for worn.
Were any worn found?
7
8
9
10
11
Yes
Go to Step 2
Repair or
replace the
relation parts.
No
Clean or
replace the air
cleaner
element
Go to Step 3
Repair or
replace the oil
relief valve
Go to Step 4
Replace the
failure part.
Go to Step 5
Replace the
wrong gasket
Replace the
worn part.
Clean the
center housing
Replace the
turbocharger
Go to indicated
DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 11
Solved
TROUBLESHOOTING 6 9
6. Overheating
Step
Action
Value(s)
3
4
5
8
9
10
Yes
Go to Step 2
Repair or
replace the
leakage part.
Tension or
replace the fan
belt.
Go to Step 5
Replace the
fan clutch
assembly
Go to Step 7
Go to Step 8
Clean or
replace the
clog part.
Replace the
sealing cap or
replace the
cylinder body.
Go to indicated
DTC.
Value(s)
Yes
No
Replenish the
coolant
Go to Step 3
Go to Step 4
Replace the
fan clutch
assembly.
Go to Step 6
Replace the
thermostat.
Replace the
water pump
assembly.
Go to Step 9
Go to Step 10
Solved
Action
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Go to Step 2
Go to Step 3
Go to Step 4
Go to indicated
DTC
No
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
Repair or
replace the
PCV valve.
Replace the
turbocharger.
Solved
6 10 TROUBLESHOOTING
Action
Value(s)
4
5
6
7
8
9
Yes
Go to Step 2
Replace the
EGR valve
Go to Step 4
Clean the
center housing
Replace the
turbocharger
Repair or
replace the
relation parts
Go to indicated
DTC
No
Clean or
replace the air
cleaner
element
Go to Step 3
Replace the
injection nozzle
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Solved
TROUBLESHOOTING 6 11
Action
Value(s)
4
5
6
Resistance
Electric current
kPa (kg/cm )
2
ohm
A
100
(1.0)
980
(10.0)
63.5
106.7
81
30
Yes
Go to Step 2
Clean or
replace the oil
strainer
Go to Step 6
Replace the
rocker arm
and/or relation
parts
Replace the
camshaft
and/or relation
parts
Replace the
crankshaft
and/or relation
parts
Go to indicated
DTC
No
Repair or
replace the oil
pump.
Go to Step 7
Go to Step 8
Go to Step 9
Solved
6 12 TROUBLESHOOTING
4
5
Action
Action
Value(s)
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Yes
No
Go to Step 2
Replace the
injection nozzle
Go to Step 3
Go to indicated
DTC
Value(s)
Yes
Retighten or
replace the
exhaust pipe
Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket
Retighten or
replace the
injection nozzle
fixing bolt
Replace the
cylinder head
gasket
Go to indicated
DTC
Replace the
cylinder head
gasket or
piston ring
Solved
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Solved
TROUBLESHOOTING 6 13
103 Continuous noise
Step
1
Action
Value(s)
9 13 mm
(0.35 0.51
in)
Action
0.4 mm
(0.016 in)
both intake
and exhaust
9
10
Tighten the
cooling fan
Repair or
replace the
generator
and/or the
vacuum pump
Replace the
water pump
Readjust the
valve
clearance.
Yes
Value(s)
Go to Step 2
Go to indicated
DTC
No
Yes
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Solved
No
Go to Step 2
Go to Step 4
Adjust the
valve
clearances
Go to Step 3
Replace the
rocker arms
Tighten the
fixing bolt.
Go to Step 6
Replace the
worn parts
Go to Step 4
Go to Step 5
Go to Step 10
Go to Step 7
Replace the
worn parts
Go to Step 8
Replace the
worn parts
Go to Step 9
Replace the
worn or
damaged parts
Go to indicated
DTC
Go to Step 10
Solved
6 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step
1
2
3
4
5
6
Action
noise
coming
from
the
Value(s)
Yes
No
Go to Step 2
Go to Step 10
Tighten the
loose parts
Replace the
damaged
gasket.
Replace the
turbocharger.
Replace the
turbocharger.
10
Go to indicated
DTC
Value(s)
Yes
7
8
Action
API CD or
ISUZU
genuine/
10W30
6
7
Replace the
turbocharger.
Clean or
replace the
turbocharger.
Repair or
replace the oil
feed pipe.
Replace the
turbocharger.
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 10
Solved
No
Replace the
engine oil
Go to Step 2
Go to Step 3
Replace the
engine oil
Clean or
replace the oil
feed pipe
Go to indicated
DTC
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
TROUBLESHOOTING 6 15
Action
Value(s)
Yes
4
5
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Solved
No
Tighten flange
bolts or hose
clamp.
Go to Step 2
Replace the
turbocharger
Go to Step 3
Repair or
replace the
actuator pipe or
hose/
Replace the
turbocharger
Replace the
turbocharger
Replace the
turbocharger
Go to indicated
DTC
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
6 16 TROUBLESHOOTING
3
4
5
6
7
Action
1
2
3
4
Value(s)
Action
Yes
Go to Step 2
Repair or
replace the
brush and/or
the slip ring.
Replace the
rotor coil.
Go to Step 5
Replace the
rectifier
Replace the IC
regulator.
Value(s)
Yes
Go to Step 3
Go to Step 4
Go to indicated
DTC.
Go to
visual/physical
check
Replace the
stator coil.
No
Go to Step 2
Repair the
short circuit.
Replace the IC
regulator.
Go to indicated
DTC.
Go to Step 6
Go to Step 7
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Solved
TROUBLESHOOTING 6 17
14-3 Battery Under Charging
Step
1
2
3
4
5
6
7
8
Action
1
2
3
4
5
6
7
Value(s)
Action
Repair or
replace the
stator coil.
Replace the
rectifier
Replace the IC
regulator.
Replace more
higher capacity
generator.
Yes
Repair or
replace the
rotor coil.
Value(s)
Repair or
replace the
brush holder
assembly.
Go to indicated
DTC.
Go to Step 2
Yes
Go to Step 2
Repair or
replace the
brush and/or
the slip ring.
Repair or
replace the
rotor coil.
Repair or
replace the
stator coil.
Repair the
loose
connection.
Replace the IC
regulator.
Go to indicated
DTC.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Solved
6 18 TROUBLESHOOTING
14-5 Charging System Noise
Step
1
2
3
4
5
6
Action
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
bearing.
Go to Step 3
Replace the
stator coil.
Replace the
brush and/or
slip ring.
Go to indicated
DTC.
Go to Step 4
Go to Step 5
Go to Step 6
Solved
TROUBLESHOOTING 6 19
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step
1
2
Action
Value(s)
Yes
Go to Step 2
Replace the
brush or repair
the
commutator.
Go to indicated
DTC.
Value(s)
Yes
Action
Clean contact
face
Replace the
pinion clutch
Repair or
replace the
armature field
coil.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Solved
No
Go to Step 2
Go to
visual/physical
check
Replace the
wron parts.
Go to Step 3
Adjust or
replace the
movement
parts.
Go to indicated
DTC.
Go to Step 4
Solved
6 20 TROUBLESHOOTING
15-3 Starter motor continues to run after the starter switch is turned off
Step
1
2
3
4
Action
Action
Value(s)
Repair or
replace the
magnetic
switch.
Replace the
starter switch.
Go to indicated
DTC.
Value(s)
Yes
Go to Step 2
Yes
Go to Step 2
Replace the
brush or repair
the
commutator.
Clean the
contact face or
replace the
brush.
Repair the
brush holder
Repair or
replace the
commutator.
Clean and
repair
Replace the
bearing
Go to indicated
DTC.
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Solved
No
Go to
visual/physical
check
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
Solved
ENGINE MECHANICAL 6A 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Torque Specifications ................................................................................................... 6A Special Parts Fixing Nuts and Bolts ........................................................................ 6A -
6A 2 ENGINE MECHANICAL
ENGINE MECHANICAL 6A 3
6A 4 ENGINE MECHANICAL
Item
Engine type
4JA1T (L)
Direct injection
mm (in)
cm (in )
3
4 93 ! 92 (3.66 ! 3.62)
Mpa(kg/cm /psi)
kg (lb)
deg
Idling speed
rpm
Exhaust
Intake valves
Open at (BTDC)
Exhaust valves
Open at (BBDC)
mm (in)
mm (in)
deg
Close at (ABDC)
134-2
deg
54.0
deg
26.0
BOSCH distributor VE type
Governor type
Lubricating system
Mpa(kg/cm /psi)
deg
Close at (ATDC)
Lubricating method
Gear drive
Fuel system
4JA1TC
2nd (Reference)
25.5#27.0
(260#275 / 3,702#3,920)
2nd (Reference)
34.0#35.5
(347#362 / 4,936#5,154)
ENGINE MECHANICAL 6A 5
Item
Engine model
Oil capacity
4JA1TC
Gear
4JA1T (L)
Cooling system
Centrifugal
Thermostat type
Turbocharger model
V-A
V-Kw
Turbine type
Compressor type
*IHI : Ishikawajima-Harima Heavy Industries., Ltd.
80D26L ! 1
95D31L ! 1 (OPT)
12 60
12 80
12 2.3
*IHI RHF 4H
6A 6 ENGINE MECHANICAL
Item
Engine type
Direct injection
mm (in)
liter
MPa(kg/cm /psi)
2
kg (lb)
rpm
Exhaust
Intake valves
Open at (BTDC)
Exhaust valves
Open at (BBDC)
mm (in)
mm (in)
deg
Close at (ABDC)
deg
deg
Close at (ATDC)
deg
2,999
18.3
Lubricating system
Lubricating method
Pressure circulation
MPa(kg/cm /psi)
Oil capacity
Gear drive
134-2
Fuel system
4JH1TC
Gear
ENGINE MECHANICAL 6A 7
Item
Engine model
Cooling system
4JH1TC
Centrifugal
Thermostat type
80D26L ! 1
95D31L ! 1 (OPT)
Generator capacity
Turbocharger model
V-A
V-Kw
Turbine type
Compressor type
12 60/12 80
12 2.3
*IHI RHF5
6A 8 ENGINE MECHANICAL
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
Nm (kgm/lbft)
Strength
Class
4.8 (4T)
(7T)
Bolt
Identification
Refined
8.8
Non-Refined
9.8 (9T)
Bolt
Diameter !
Pitch (mm)
M 6 ! 1.0
M 8 ! 1.25
M 10 ! 1.25
M 12 ! 1.25
M 14 ! 1.5
M 16 ! 1.5
M 18 ! 1.5
M 20 ! 1.5
M 22 ! 1.5
M 24 ! 2.0
* M 10 ! 1.5
* M 12 ! 1.5
* M 14 ! 2.0
* M 16 ! 2.0
5.88 1.96
(0.60 0.20/4.33 1.44)
7.35 2.45
(0.75 0.25/5.43 1.80)
12.74 ! 4.90
(1.30 0.50/9.40 3.62)
17.15 5.39
(1.75 ! 0.55/12.66 ! 4.00)
23.52 6.86
(2.40 0.70/17.36 5.06)
61.25 12.25
(6.25 1.25/45.21 9.04)
75.95 15.19
(7.75 1.55/56.06 11.21)
94.57 19.11
(9.65 1.95/69.80 14.10)
27.44 6.86
(2.80 0.70/20.25 5.06)
95.55 19.11
(9.75 1.95/70.52 14.10)
116.13 ! 23.03
(11.85 2.35/85.71 17.00)
142.10 28.42
(14.50 2.90/104.88 21.00)
244.02 49.00
(24.90 5.00/180.10 36.17)
287.14 57.82
(29.30 5.90/211.93 42.67)
130.34 26.46
(13.30 2.70/96.20 19.53)
169.54 34.30
(17.30 3.50/125.13 25.32)
257.74 51.94
(26.30 5.30/190.23 38.33)
337.12 67.62
(34.40 6.90/248.82 49.41)
188.16 37.24
(19.20 3.80/138.87 27.49)
332.22 81.34
(33.90 8.30/245.20 60.03)
49.98 12.74
(5.10 1.30/36.89 9.40)
36.75 9.31
(3.75 0.95/27.12 6.87)
199.92 40.18
(20.40 4.10/147.55 29.66)
395.92 79.38
(40.40 8.10/292.21 58.59)
453.25 90.65
(46.25 9.25/334.53 66.91)
530.18 105.84
(54.10 10.80/391.30 78.12)
36.26 8.82
(3.70 0.90/26.76 6.50)
48.02 11.76
(4.90 1.20/35.44 8.68)
448.84 90.16
(45.80 9.20/331.27 66.54)
570.36 140.14
(58.20 14.30/420.96 103.43)
56.84 11.76
(5.80 1.20/41.95 8.68)
70.56 13.72
(7.20 1.40/52.08 10.13)
26.46 6.86
(2.70 0.70/19.53 5.06)
89.18 17.64
(9.10 1.80/65.82 13.02)
124.46 24.50
(12.70 2.50/91.86 18.08)
109.76 21.56
(11.20 2.20/81.01 15.91)
161.70 32.34
(16.50 3.30/119.34 23.87)
691.88 138.18
(70.60 14.10/510.65 101.99)
89.18 17.64
(9.10 1.80/65.82 13.02)
133.28 26.46
(13.60 2.70/98.37 19.53)
191.10 38.22
(19.50 3.90/141.04 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS
Pipe diameter mm
(in)
4.76 (0.187)
6.35 (0.250)
8.00 (0.315)
Nm (kgm/lbft)
Torque
Pipe diameter mm
(in)
Torque
10.00 (0.394)
15.00 (0.591)
12.00 (0.472)
ENGINE MECHANICAL 6A 9
Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
Nm (kgm/lbft)
RTW46AXF000501
6A 10 ENGINE MECHANICAL
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
Nm (kgm/lbft)
RTW36AXF000101
ENGINE MECHANICAL 6A 11
RTW46AXF000601
6A 12 ENGINE MECHANICAL
RTW46AXF000701
ENGINE MECHANICAL 6A 13
RTW36AXF000201
6A 14 ENGINE MECHANICAL
RTW46AXF000801
ENGINE MECHANICAL 6A 15
RTW46AXF000901
6A 16 ENGINE MECHANICAL
RTW46AXF001001
ENGINE MECHANICAL 6A 17
Engine Electricals
Nm (kgm/lbft)
RTW36AXF000501
6A 18 ENGINE MECHANICAL
Nm (kgm/lbft)
RTW46AXF001101
ENGINE MECHANICAL 6A 19
RTW46AXF001201
6A 20 ENGINE MECHANICAL
RTW46AXF001301
ENGINE MECHANICAL 6A 21
Nm (kgm/lbft)
022R300001
6A 22 ENGINE MECHANICAL
RTV*
Silicon Base
Water Base
Solvent
Anaerobic
Brand Name
Manufacturer
ThreeBond 1141E
ThreeBond 1215
Three Bond
Three Bond
LOCTITE 515
LOCTITE 518
LOCTITE 262
Loctite
Loctite
Loctite
ThreeBond 1207B
ThreeBond 1207C
ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Three Bond
Three Bond
Isuzu
Isuzu
Isuzu
Remarks
Recommended for
transaxle repairs
ENGINE MECHANICAL 6A 23
LOCTITE Color
LOCTITE 242
Blue
1.
2.
LOCTITE 262
Red
LOCTITE 270
Green
LOCTITE 271
LOCTITE 515
Red
Application Steps
Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
Apply LOCTITE to the bolts.
3.
1.
4.
2.
3.
Violet
4.
6A 24 ENGINE MECHANICAL
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
130RY00003
LUBRICATING SYSTEM
6A-6
RTW36ASH000101
ENGINE MECHANICAL 6A 25
Replenished Engine Oil
Condition
Engine Dry
4!2
4!4
(4JA1L/TC)
4!2
(4JH1TC)
Without oil
filter
replacement
6.2 (1.64/1.36)
4!4
(4JH1TC)
7.0 (1.85/1.54)
Model
6.2 (1.64/1.36)
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
RTW46ASH000501
041RY00009
6A 26 ENGINE MECHANICAL
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.
041RY00011
1.
2.
3.
4.
Air Bleeding
RTW46ASH000501
ENGINE MECHANICAL 6A 27
COOLING SYSTEM
Coolant Level
6A 28 ENGINE MECHANICAL
kPa(kg/cm /psi)
2
150 (1.5/21)
030LX003
kPa(kg/cm /psi)
ENGINE MECHANICAL 6A 29
82 (180)
76.5 (170)
40 (104)
$C ($F)
$C ($F)
95 (203)
90 (194)
55 (131)
$C ($F)
$C ($F)
mm (in)
mm (in)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
mm in)
033RY00002
6A 30 ENGINE MECHANICAL
033RY00003
033RY00004
ENGINE MECHANICAL 6A 31
014RY00014
014RY00015
Nm (kgm /lbft)
014RY00016
014RY00017
6A 32 ENGINE MECHANICAL
COMPRESSION PRESSURE
MEASUREMENT
F06XL056
3.0 (31.0/441)
901R100003
Limit
2.1 (21.7/309)
ENGINE MECHANICAL 6A 33
RTW46ASH000601
6A 34 ENGINE MECHANICAL
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8$)
is aligned with the pointer.
Injection Timing : BTDC 8$ " 2$
Standard Reading
RTW46ASH000701
mm (in)
0.5 (0.02)
3. Lock the engine set nut ! with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.
ENGINE MECHANICAL 6A 35
6A 36 ENGINE MECHANICAL
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.
ENGINE MECHANICAL 6A 37
Removal
1. Battery
1) Disconnect the battery cable and the grounding cable
from the battery terminals.
2) Remove the battery clamp. Take care not to
accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
P1010011
2. Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.
P1010002
F06R300006
6A 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.
P1010025
F06R300007
ENGINE MECHANICAL 6A 39
18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.
P1010009
19. Fan
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC)
from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box
from engine room.
3) Remove the two air ducts from inter cooler
(4JA1TC/4JH1TC).
P1010034
6A 40 ENGINE MECHANICAL
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).
140R300001
RTW46ASH000501
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse
order.
ENGINE MECHANICAL 6A 41
Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity
4JA1 / TC
4JH1TC
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.
6A 42 ENGINE MECHANICAL
RTW36ALF000601
Removal Steps
NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.
ENGINE MECHANICAL 6A 43
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
RTW36AMF000401
Removal Steps
6A 44 ENGINE MECHANICAL
Removal
1. Clutch Assembly or Flex Plate
Remove the clutch assembly or the flex plate.
2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
1) Loosen hose clamp between turbocharger and intake
duct.
2) Remove the rubber hose.
3) Remove the intake pipe and the throttle body.
(4JA1TC/4JH1TC only)
4JA1L
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
4JA1L
025R100008
4JH1TC
RTW36ASH000301
ENGINE MECHANICAL 6A 45
4. EGR Valve
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.
4JA1"L
RTW46ASH001001
4JA1"TC
RTW46ASH000901
4JH1"TC
RTW36ASH001201
RTW36ASH000701
6A 46 ENGINE MECHANICAL
13. Injection Pump
14.
15.
16.
17.
18.
19.
027R100007
037RY00001
21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
22.
23.
24.
25.
26.
27.
28.
Compressor Bracket
Vacuum Pump Oil Return Hose
Generator and Adjusting Plate
Water Inlet Pipe
Generator Bracket
Oil Cooler with Oil Filter
Exhaust Manifold
ENGINE MECHANICAL 6A 47
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1.
2.
3.
4.
5.
6.
7.
8.
6A 48 ENGINE MECHANICAL
RTW46ALF000101
Disassembly Steps-2
9.
10.
11.
12.
13.
14.
15.
16.
ENGINE MECHANICAL 6A 49
014R300005
Disassembly Steps-3
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Flywheel
Crank case
Oil pump with oil pipe
Camshaft timing gear
Camshaft thrust plate
Camshaft
Timing gear case
Cylinder body rear plate
Piston cooling oil jet
Connecting rod bearing cap with
lower bearing
27.
28.
29.
30.
31.
32.
33.
34.
6A 50 ENGINE MECHANICAL
Disassembly
1.
2.
3.
4.
011R100002
011RY00005
011RY00006
011RY00007
7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
8. Cylinder Head Gasket
9. Crankshaft Damper Pulley
ENGINE MECHANICAL 6A 51
10. Timing Gear Case Cover
The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.
11. Water Pump
020L200006
020L200020
020RY00019
Limit
0.30 (0.012)
mm (in)
6A 52 ENGINE MECHANICAL
RTW36ASH000801
4JA1T(L)
040R300009
4JA1TC/4JH1TC
RTW36ASH001301
mm (in)
015RY00001
Limit
0.2 (0.0079)
ENGINE MECHANICAL 6A 53
20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
014RT0001
901R100008
Limit
0.20
(0.008)
mm (in)
052RY00001
6A 54 ENGINE MECHANICAL
26. Connecting Rod Bearing Cap with Lower Bearing
If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
014LX056
015LX018
RTW36ASH001501
015RY00002
Limit
0.30 (0.012)
mm (in)
ENGINE MECHANICAL 6A 55
2. Loosen the crankshaft bearing cap bolts in numerical
order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
29. Crankshaft Thrust Bearing
30.Crankshaft
015RY00003
015RY00004
015RY00005
32. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.
6A 56 ENGINE MECHANICAL
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1.
2.
3.
4.
5.
6.
7.
Disassembly
011RY00010
ENGINE MECHANICAL 6A 57
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1.
2.
3.
4.
5.
Intake manifold
Intake manifold gasket
Split collar
Valve spring upper seat
Valve spring
6.
7.
8.
9.
6A 58 ENGINE MECHANICAL
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
011RY00011
011LX022
ENGINE MECHANICAL 6A 59
RTW46ALF000301
Disassembly Steps
1.
2.
3.
4.
5.
6.
Piston pin
Connecting rod
Piston
6A 60 ENGINE MECHANICAL
Disassembly
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
RTW36ASH001501
2. Piston Ring
1. Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2. Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
015RW041
F06MV015
RTW36ASH001601
4. Piston Pin
5. Connecting Rod
6. Piston
Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled, mark
their installation positions by tagging each piston and piston
pin with the cylinder number from which it was removed.
ENGINE MECHANICAL 6A 61
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the
limit, it should be replaced.
011RY00012
0.05
(0.002) or less
Limit
mm (in)
0.20
(0.0079)
NOTE:
011RY00013
mm (in)
91.95 92.05
(3.620 3.624)
011RY00014
6A 62 ENGINE MECHANICAL
Limit
0.05
(0.002) or less
0.20
(0.008)
mm (in)
Maximum Grinding
Allowance
0.40
(0.016)
027RY00002
Limit
mm (in)
0.20 (0.008)
011RY00022
1. With the valve stem inserted in the valve guide, set the dial
indicator needle to "0".
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the valve
and the valve guide must be replaced as a set.
Valve Stem Clearance
Intake Valve
Exhaust Valve
Standard
0.039 - 0.071
(0.0015 - 0.0028)
0.064 - 0.096
(0.0025 - 0.0038)
mm (in)
Limit
0.200
(0.008)
0.250
(0.0098)
ENGINE MECHANICAL 6A 63
Measuring Method-II
011RY00023
011LX029
011RY00024
4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference)
12.8-13.2 (0.50-0.52)
NOTE:
mm (in)
6A 64 ENGINE MECHANICAL
Exhaust Valve
7.946 - 7.961
(0.3128 - 0.3134)
7.921 - 7.936
(0.3119 - 0.3124)
mm (in)
Limit
7.880
(0.3102)
7.850
(0.3090)
Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the valve
and the valve guide must be replaced as a set.
Intake and Exhaust Valve Thickness
Standard
4JA1T (L)
014RY00020
Inlet
4JA1TC,
4JH1TC Exhaust
1.8 (0.07)
1.34 (0.054)
1.36 (0.055)
mm (in)
Limit
1.5 (0.06)
1.1 (0.045)
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head lower
surface.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.
Valve Depression
014RY00021
4JA1T(L)
4JA1TC, 4JH1TC
Standard
0.72 (0.029)
1.17 (0.048)
mm (in)
Limit
1.28 (0.050)
1.67 (0.068)
ENGINE MECHANICAL 6A 65
Intake
Exhaust
Standard
1.7 (0.067)
2.0 (0.079)
mm (in)
Limit
2.2 (0.087)
2.5 (0.078)
011LX039
6A 66 ENGINE MECHANICAL
Valve Seat Insert Installation
45
Degree
NOTE:
011LX037
011LX038
3.
4.
5.
6.
7.
ENGINE MECHANICAL 6A 67
011LX024
4JA1T (L)
4JA1TC,
4JH1TC
Single spring
mm (in)
Standard
Limit
48.0 (1.89)
47.1 (1.85)
014RY00025
4JA1T (L)
4JA1TC,
4JH1TC
Limit
Single spring
mm (in)
1.7 (0.070)
011LX026
4JA1T (L)
4JA1TC,
4JH1TC
Single
spring
N (kg/lb)
Compressed
Height
Standard
Limit
38.9mm
(1.53in)
296.0
(30.2/66.4)
257.7
(26.3/57.9)
6A 68 ENGINE MECHANICAL
015LX008
mm (in)
Limit
0.3 (0.012)
015LX009
18.9819.00 (0.7470.748)
Limit
mm (in)
18.90 (0.744)
19.01019.030
(0.7480.749)
Limit
mm (in)
19.100 (0.752)
014RY00024
0.010.05
(0.00040.0020)
Limit
0.20 (0.008)
mm (in)
ENGINE MECHANICAL 6A 69
3. Check that the rocker arm oil port is free of obstructions.
If necessary, use compressed air to clean the rocker arm
oil port.
014RY00024
014RY00023
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to "Cylinder Liner Replacement".
3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.
Cylinder Body Upper Face Warpage
Standard
012R100001
Limit
mm (in)
0.20 (0.008)
mm (in)
6A 70 ENGINE MECHANICAL
Standard
93.00 (3.6614)
95.40 (3.7559)
mm (in)
Limit
93.08 (3.6646)
95.48 (3.7590)
NOTE:
Standard
mm (in)
0-0.1 (0-0.004)
012LX016
012RY00012
ENGINE MECHANICAL 6A 71
Standard
mm (in)
-0.0010*-0.019 (-0.00004*-0.0007)
012RY00013
012R300001
6A 72 ENGINE MECHANICAL
A mark was stamped on the upper side of the cylinder block
during production to indicate the correct liner.
The liner grade (i.e.1.2.3.4) is indicated in metal stamp.
012RY00022
Liner Outside
Diameter
Liner Bore
Grade
AX
93.035-93.050 (3.6628-3.6634)
95.001-95.010
(3.7402-3.7405)
95.011-95.020
(3.7406-3.7409)
95.011-95.020
(3.7406-3.7409)
95.021-95.030
(3.7410-3.7413)
95.021-95.030
(3.7410-3.7413)
95.031-95.040
(3.7414-3.7417)
95.031-95.040
(3.7414-3.7417)
95.041-95.050
(3.7418-3.7421)
4JH1TC
Liner
Outside
Grade
mm (in)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
CX
93.051-93.066 (3.6634-3.6640)
AX
AX
AX
93.035-93.050 (3.6628-3.6634)
95.035-93.050 (3.6628-3.6634)
93.035-93.050 (3.6628-3.6634)
mm (in)
Cylinder Body
Bore Diameter
Liner Outside
Diameter
Liner Bore
Grade
97.001-97.010
(3.8189-3.8193)
97.011-97.020
(3.8193-3.8197)
AX
95.435-95.450 (3.7573-3.7579)
97.011-97.020
(3.8193-3.8197)
97.021-97.030
(3.8197-3.8200)
97.021-97.030
(3.8197-3.8200)
97.031-97.040
(3.8200-3.8205)
97.031-97.040
(3.8200-3.8205)
97.041-97.050
(3.8205-3.8209)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
CX
95.451-95.466 (3.7579-3.7585)
AX
AX
AX
95.435-95.450 (3.7573-3.7579)
95.435-95.450 (3.7573-3.7579)
95.435-95.450 (3.7573-3.7579)
ENGINE MECHANICAL 6A 73
6A 74 ENGINE MECHANICAL
4JA1T(L)
4JA1TC
4JH1TC
NOTE:
AX
CX
AX
CX
mm (in)
Bore measurement
93.035-95.050
(3.6628-3.6634)
93.051-95.066
(3.6634-3.6640)
95.435-95.450
(3.7573-3.7579)
95.451-95.466
(3.7579-3.7585)
ENGINE MECHANICAL 6A 75
2. Measure the piston diameter.
Piston Measuring Point
4JA1T(L)
4JA1TC
4JH1TC
78 (3.07)
70 (2.76)
4JA1T(L)
4JA1TC
4JH1TC
mm (in)
AX
CX
AX
CX
mm (in)
92.949 - 92.964
(3.6549 - 3.6600)
92.965 - 92.980
(3.6600 - 3.6606)
95.359 - 95.374
(3.7542 - 3.7548)
95.375 - 95.390
(3.7548 - 3.7555)
014RY00028
6A 76 ENGINE MECHANICAL
014RY00029
Limit
12.97 - 12.99
(0.510 - 0.511)
12.95 (0.510)
0.01 - 0.046
(0.0004 - 0.0018)
012LX014
mm (in)
Limit
mm (in)
0.10 (0.004)
014RY00031
Limit
mm (in)
0.3 (0.012)
3. Visually inspect both ends of the push rod for excessive
wear and damage. The push rod must be replaced if these
conditions are discovered during inspection.
ENGINE MECHANICAL 6A 77
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.
014RY00032
49.945 - 49.975
(1.9663 - 1.9675)
Limit
mm (in)
49.60 (1.953)
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.
Cam Height (H)
Standard
42.016 (1.6542)
014RY00033
Limit
mm (in)
41.65 (1.640)
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit, the
camshaft must be replaced.
Camshaft Run-Out
Standard
014LX092
0.02 (0.0008)
Limit
mm (in)
0.10 (0.004)
6A 78 ENGINE MECHANICAL
50.00 - 50.03
(1.968 - 1.970)
014RY00034
Limit
mm (in)
50.08 (1.972)
0.055 (0.0022)
Limit
mm (in)
0.12 (0.005)
014RY00035
014RY00036
ENGINE MECHANICAL 6A 79
Crankshaft Run-Out
Crankshaft Run-Out
Standard
Limit
mm (in)
0.08 (0.003)
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
Bearing Spread
015RY00007
Creankshaft Bearing
Connecting Rod Bearing
4JA1T (L),
4JA1TC
4JH1TC
mm (in)
Limit
64.5 (2.54)
74.5 (2.93)
56.5 (2.22)
6A 80 ENGINE MECHANICAL
Standard
59.921-59.928
(2.3591-2.3594)
69.917-69.932
(2.7526-2.7532)
Limit
59.91 (2.3586)
69.91(2.7524)
Crankpin Diameter
Standard
52.915 - 52.930
(2.0833 - 2.0839)
mm (in)
Limit
mm (in)
52.90 (2.083)
Limit
mm (in)
0.08 (0.003)
015RY00009
0.032 - 0.077
(0.0013 - 0.0030)
Limit
mm (in)
0.110 (0.0043)
ENGINE MECHANICAL 6A 81
015RY00011
Standard
0.029-0.066
(0.0011-0.0026)
0.029-0.083
(0.0011-0.033)
Limit
mm (in)
0.100(0.0039)
0.100 (0.0039)
015RY00012
167 (17/123)
mm (in)
6A 82 ENGINE MECHANICAL
015LX129
015LX060
0.032 - 0.077
(0.0013 - 0.0030)
Limit
mm (in)
0.110 (0.0043)
ENGINE MECHANICAL 6A 83
6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the specified limit, perform
the following additional steps.
1. Use a micrometer to measure the crankpin outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing must
be replaced.
Crankpin and Bearing Clearance
4JA1T (L),
4JA1TC
4JH1TC
Standard
0.029-0.066
(0.0011-0.0026)
0.029-0.083
(0.0011-0.0033)
Limit
mm (in)
0.100 (0.0039)
0.100 (0.0039)
015LX060
015RY00016
6A 84 ENGINE MECHANICAL
REFERENCE
4JA1T(L), 4JA1TC
Crankshaft
Bearing Housing
015RY00017
Grade
Mark
Diamaeter
63.99264.000
(2.51942.5197)
63.98363.992
(2.51902.5194)
RTW46ASH002501
63.97563.983
(2.51872.5190)
mm (in)
Crankshaft Journal
Grade
Mark
Diamaeter
1 or
-
59.927-59.932
(2.3593-23.595)
3 or
---
59.917-59.922
Yellow or 5
(2.3589-2.3591)
2 or
--
1 or
2 or
--
3 or
---
59.922-59.927
(2.3591-2.3539)
59.927-59.932
(2.3593-2.3595)
59.922-59.927
(2.3591-2.3593)
Grade
Mark
Diamaeter
73.99274.000
(2.91312.9134)
73.98373.992
(2.91272.9131)
73.97573.983
(2.91242.9127)
Brown or 4
Black or 2
Blue or 3
59.917-59.922
Brown or 4
(2.3589-2.3591)
1 or
-
59.927-59.932
Green or 1
(2.3593-2.3595)
3 or
---
59.917-59.922
(2.3598-2.3591)
2 or
--
59.922-59.927
(2.3591-2.3593)
4JH1TC
Crankshaft
Bearing Housing
Crankshaft
Bearing
Size Code
Black or 2
mm (in)
Crankshaft Journal
Grade
Mark
Diamaeter
1 or
-
69.927-69.932
(2.7530-2.7532)
3 or
---
69.917-69.922
(2.7556-2.7528)
2 or
--
1 or
2 or
--
3 or
---
69.922-69.927
(2.7528-2.7530)
69.927-69.932
(2.7530-2.7532)
69.922-69.927
(2.7528-2.7530)
69.917-69.922
(2.7556-2.7528)
1 or
-
69.927-69.932
(2.7530-2.7532)
3 or
---
69.917-69.922
(2.7526-2.7528)
2 or
--
69.922-69.927
(2.7528-2.7530)
Crankshaft
Bearing
Size Code
4
5
2
3
4
1
2
ENGINE MECHANICAL 6A 85
015RY00018
015RY00010
015RY00019
mm (in)
Standard
Limit
20 (0.7874)
21 (0.8267)
18 (0.7087)
19 (0.7480)
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
6A 86 ENGINE MECHANICAL
020LX008
020LX009
PISTON
Piston Grade Selection and Cylinder Bore
Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore
Measurement" for details on piston grade selection and
cylinder liner bore measurement.
015LX023
015RY00020
2. Push the piston ring into the cylinder bore until it reaches
the measuring point 1 or 2 where the cylinder liner bore is
the smallest.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in)
ENGINE MECHANICAL 6A 87
3. Use a feeler gauge to measure the piston ring gap.
If the measured value exceeds the specified limit, the
piston ring must be replaced.
Piston Ring Gap
4JA1T (L), 4JA1TC
1st Compression Ring
015RY00021
mm (in)
Standard
0.3-0.3
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Standard
0.3-0.5
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Limit
1.5
(0.059)
Limit
1.5
(0.059)
015LX025
mm (in)
Standard
Limit
0.05-0.085
(0.0020-0.0033)
0.15
(0.0059)
Standard
Limit
0.05-0.090
(0.0020-0.0035)
0.15
(0.0059)
0.09-0.125
(0.0035-0.0049)
0.03-0.070
(0.0012-0.0028)
0.09-0.130
(0.0035-0.0051)
0.03-0.070
(0.0012-0.0028)
6A 88 ENGINE MECHANICAL
4. Visually inspect the piston rings.
If a piston ring groove is damaged or distorted, the piston
must be replaced.
Standard
015LX026
Limit
30.995-31.000
(1.2202-1.2204)
mm (in)
30.97
(1.2193)
4JA1T (L)
4JA1TC, 4JH1TC
015RW048
mm (in)
31.002-31.010 (1.2206-1.2208)
31.005-31.013 (1.2207-1.2210)
4JA1TC, 4JH1TC
mm (in)
0.002-0.015 (0.00008-0.0006)
0.005-0.018 (0.0002-0.0007)
011LX011
ENGINE MECHANICAL 6A 89
3. Measure the points 1, 2, 3, 4 and obtain two differences 12 and 3-4 on each cylinder.
Calculate the average value of the piston head projection
on each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum
value described above in accordance with the following
table.
011RY00027
011RY00030
0.718-0.773
(0.0283-0.0304)
0.773-0.819
(0.0304-0.0322)
0.819-0.874
(0.0322-0.0344)
4JH1TC
B
C
NOTE:
mm (in)
Gasket Thickness
(Reference)
1.6
(0.0630)
1.65
(0.0650)
1.70
(0.0669)
mm (in)
mm (in)
0.215-0.265
(0.0085-0.0104)
0.265-0.315
(0.0104-0.0124)
0.315-0.365
(0.0124-0.0144)
Gasket Thickness
(Reference)
1.3
(0.5118)
1.35
(0.5315)
1.4
(0.5512)
6A 90 ENGINE MECHANICAL
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.
015LX034
Parallelism
Standard
Limit
0.20 (0.008)
0.15 (0.006)
Limit
0.23 (0.009)
0.35 (0.014)
015LX028
4JA1T (L)
4JA1TC,
4JH1TC
0.008-0.020
(0.003-0.0008)
0.005-0.018
(0.0002-0.0007)
Limit
mm (in)
0.050 (0.002)
0.050 (0.002)
ENGINE MECHANICAL 6A 91
020RY00025
44.945-44.975
(1.7695-1.7707)
Limit
mm (in)
44.845 (1.755)
45.0-45.03
(1.7717-1.7718)
014LX022
Limit
mm (in)
45.10 (1.7756)
0.025-0.085
(0.0010-0.0033)
Limit
mm (in)
0.200 (0.0079)
020R300004
6A 92 ENGINE MECHANICAL
020R300005
ENGINE MECHANICAL 6A 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
020RY00029
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
Rocker arm
Rocker arm shaft spring
Rocker arm shaft snap ring
Reassembly
014RY00037
6A 94 ENGINE MECHANICAL
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1.
2.
3.
4.
5.
Cylinder head
Valve spring lower seat
Valve stem oil seal
Intake and exhaust valve
Valve spring
6.
7.
8.
9.
ENGINE MECHANICAL 6A 95
Reassembly
011RW027
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
6. Valve Spring Upper Seat
011LX055
014RY00039
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
RTW46ASH002301
Bolt
Nut
19 (1.9/14)
24 (2.4/17)
Nm(kgm/lbft)
6A 96 ENGINE MECHANICAL
RTW46ALF000301
Reassembly Steps
1.
2.
3.
4.
Piston
Connecting rod
Piston pin snap ring
Piston pin
5.
6.
7.
ENGINE MECHANICAL 6A 97
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
F06MV015
RTW36ASH001801
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
RTW36ASH001901
015R100001
6A 98 ENGINE MECHANICAL
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
NOTE:
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the
piston ring grooves
015R100006
ENGINE MECHANICAL 6A 99
RTW46AMF000101
Reassembly Steps
1.
2.
3.
4.
5.
6.
Fixing bolt
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
PCV Valve Bolts Torque
010R100014
2 (0.2/17)
Nm(kgm/lb in)
2. Rubber Spacer
3. Cylinder Head Insulator Cover
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
Fixing Bolt Torque
RTW36ASH001401
19 (1.9/14)
Nm(kgm/lb in)
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1.
Cylinder body
10.
2.
Tappet
11.
3.
12.
4.
5.
6.
7.
8.
9.
Crankshaft
Crankshaft thrust bearing
Crankshaft bearing cap with
lower bearing
Camshaft
Timing gear case
Camshaft thrust plate
13.
14.
15.
16.
17.
18.
Crank case
Cylinder body rear plate
Flywheel
RTW46ALF000501
Reassembly Steps-2
19.
20.
21.
22.
23.
24.
25.
26.
Injection pump
Water pump
Timing gear case cover
Crankshaft damper pulley
011R300002
Reassembly Steps-3
27.
28.
29.
30.
Cylinder head
Push rod
Rocker arm shaft and rocker
arm
31.
32.
33.
34.
Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
015R100003
2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).
NOTE:
015R100004
015LX115
015LX127
015LX128
167 (17/123)
015LX129
Nm(kgm/lbft)
014RY00019
19 (1.9/14)
020R300003
020RY00032
Nm(kgm/lbft)
19 (1.9/14)
Nm(kgm/lbft)
110 (11.2/82)
RTW36ASH000901
Nm(kgm/lbft)
015R100006
015LX096
015R100007
015LX130
Nm(kgm/lbft)
19 (1.9/14)
M8 " 1.25
8 (0.8/6)
M6 " 1.00
052LX010
29 (3.0/22)
Nm(kgm/lbft)
NOTE:
19 (19/14)
Nm(kgm/lbft)
NOTE:
051R100004
015LX112
013RW012
013RW011
013R100001
19 (1.9/14)
Nm(kgm/lbft)
020R100001
18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0
Flywheel Bolt Torque
015LX113
82 (8.4/61)
Nm(kgm/lbft)
118 (12/87)
Nm(kgm/lbft)
020RY00034
020RY00035
30 (3.1/22)
Nm(kgm/lbft)
1. Apply engine oil to the idler gear and the idler gear shaft.
2. Align the idler gear "B" (3) setting mark with the idler
gear "A" (4) setting mark.
3. Tighten the idler gear bolt to the specified torque.
4. Be sure to remove the lock bolt (5) from idle gear B.
76 (7.7/56)
Nm(kgm/lbft)
020L200019
020L200007
RTW31BSH000101
RTW31BSH000201
RTW31BSH000301
RTW31BSH000501
RTW31BSH000401
8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6 " 1 L=30) into scissors gear
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gear
with lock bolt (inserted at Step 8).
020RY00039
4JA1TC/4JH1TC:
19 (1.9/14)
RTW36AMH000101
Nm(kgm/lbft)
Nm(kgm/lbft)
Nm(kgm/lbft)
19 (1.9/14)
RTW46ASH002201
40 (4.1/30)
20 (2.0/14)
030RY00007
020R300004
Nm(kgm/lbft)
M12
Nm(kgm/lbft)
19 (1.9/14)
76 (7.7/56)
206 (21/152)
Nm(kgm/lbft)
2nd step
011LX073
Nm(kgm/lbft)
49 (5.0/36)
60! - 75!
3rd step
60! - 75!
014LX083
19 (1.9/14)
031R300002
Nm(kgm/lbft)
Nm(kgm/lbft)
RTW46ASH001201
Nm(kgm/lbft)
37 (3.8/28)
0.4 (0.0157)
014RY00015
RTW46ASH001101
mm(in)
13 (1.3/9.4)
Nm(kgm/lbft)
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1.
2.
3.
4.
5.
6.
Exhaust Manifold
Oil Cooler with Oil Filter
Generator Bracket
Water Inlet Pipe
Generator and Adjusting Plate
Vacuum Pump Oil Return Hose
19.
20.
8.
Turbocharger
23.
7.
Compressor Bracket
18.
21.
22.
9.
10.
11.
Catalytic Converter
Heat Protector
Cooling Fan Pulley
24.
25.
26-1.
13.
27.
12.
14.
15.
16.
17.
26-2.
28.
Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque
Nm(kgm/Ib ft)
027R100003
27 (2.7/20)
027R100004
RTW46ASH001301
3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
40 (4.1/30)
066RY00001
032R300001
066RY00002
052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
M8!1.25
M10!1.25
042RY00003
19 (1.9/14)
40 (4.1/30)
027R100002
036R100001
RTW46ASH001501
22 (2.25/16)
M14!1.5
54 (5.5/40)
027R100005
10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque
Nm(kgm/Ib ft)
39 (4.0/29)
11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque
Nm(kgm/Ib ft)
39 (4.0/29)
12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque
Nm(kgm/Ib ft)
8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return.
9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque
Nm(kgm/Ib ft)
27 (2.7/20)
027R100007
033R300002
4JA1L, 4JH1TC
Right Side
Left Side
M10!1.25
40 (4.1/30)
M14!1.50
127 (13/93)
M10!1.25
40 (4.1/30)
022R300003
4JA1TC
RTW46ASH002601
RTW36ASH001001
24 (2.4/18)
Nm(kgm/Ib ft)
Nm(kgm/Ib ft)
M10!1.25
2
3
37 (3.8/28)
M8!1.25
431RY00013
040R300005
Nm(kgm/Ib ft)
Nm(kgm/Ib ft)
29 (3.0/22)
8 (0.8/6)
M6
19 (1.9/14)
8 (0.8/6)
27 (2.7/20)
Nm(kgm/Ib ft)
025R100008
RTW36ASH000301
RTW48ASH001801
RTW36ASH000201
19 (1.9/14)
24 (2.4/17)
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1.
2.
3.
4.
5.
6.
Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
RTW46ALF001501
OIL PUMP
DISASSEMBLY
051R100005
Disassembly Steps
1.
Oil pipe
2.
Strainer
3.
Pump cover
4.
Driven gear with bushing
Disassembly procedure is shown in the illustration above numerical order.
5.
6.
7.
8.
Driven gear
Relief valve assembly
Pinion gear
Oil pump body
051RY00001
0.14 (0.0055)
Limit
0.20 (0.0079)
0.06 (0.024)
Limit
0.15 (0.0059)
RTW46ASH002701
Standard
0.04 (0.0016)
Limit
0.20 (0.0079)
REASSEMBLY
051R100006
Reassembly Steps
1.
Oil pump body
2.
Drive gear
3.
Driven gear
4.
Pump cover
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 Nm (1.6 kgm/12 lb ft)
5.
6.
7.
8.
Pinion gear
Strainer
Relief valve assembly
Oil pipe
050R300004
Disassembly Steps
1.
Oil filter cartridge
5.
2.
Bolt
6.
3.
Gasket
7.
4.
Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
Body
Oil cooler relief valve
Regulating valve
Oil Cooler
REASSEMBLY
050R300003
Reassembly Steps
1.
Body
5.
2.
Regulating valve
6.
3.
Oil cooler relief valve
7.
4.
Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
Gasket
Bolt
Oil filter cartridge
64 (6.5/48)
RTW46ASH001701
4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque
Nm(kgm/lb ft)
40 (4.1/30)
050R300006
050RY00004
INTER COOLER
REMOVAL AND INSTALLATION
RTW46ALF001001
Removal Steps
1. Radiator grille
2. Front bumper fascia
3. Front bumper inpact support assembly
4. Inter cooler
Installation Steps
4. Inter cooler
3. Front bumper inpact support assembly
2. Front bumper fascia
1. Radiator grille
Removal
1. Radiator Grille
! Refer to removal procedure in Sheet Metal section.
RTW36ASH000601
RTW36ASH000501
RTW46ASH002101
4. Inter Cooler
! Remove the nut and two bolts.
! Disconnect the air hose.
Installation
4. Inter Cooler
! Tighten the nut and two bolts.
3. Front Bumper Impact Support Assembly
! Tighten the nut and two bolts.
1. Radiator grille
! Refer to installation procedure in Sheet Metal section.
SPECIAL TOOLS
Illustration
Tool Number
Tool Name
5-8840-0201-0
Filter Wrench
5-8840-0253-0
Filter Wrench
5-8840-2675-0
Compression Gauge
5-8531-7001-0
5-8840-2723-0
5-8840-0019-0
Sliding Hammer
5-8521-0002-0
Universal Puller
5-8840-2360-0
9-8523-1423-0
Spring Compressor
9-8523-1212-0
Illustration
Tool Number
5-8840-2040-0 (4JA1L/TC)
5-8840-2313-0 (4JH1TC)
Tool Name
Cylinder Liner Installer
5-8840-2038-0
5-8840-2000-0
5-8522-0024-0
5-8840-2033-0
5-8840-9018-0
5-8840-2359-0
9-8522-0020-0
5-8840-0266-0
Angle Gauge
5-8840-0214-0
Gear Stopper
5-8840-2039-0 (4JA1L/TC)
5-8840-2304-0 (4JH1TC)
Illustration
Tool Number
5-8840-2361-0
Tool Name
Front Oil Seal Installation
MEMO
ENGINE COOLING 6B 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Water Pump................................................................................................................ 6B -
Radiator ...................................................................................................................... 6B -
Thermostat ................................................................................................................. 6B -
Diagnosis........................................................................................................................ 6B -
Water Pump.................................................................................................................... 6B - 10
Installation.................................................................................................................. 6B - 11
Thermostat ..................................................................................................................... 6B - 13
Installation.................................................................................................................. 6B - 14
Radiator .......................................................................................................................... 6B - 15
Installation.................................................................................................................. 6B - 18
6B 2 ENGINE COOLING
PAGE
ENGINE COOLING 6B 3
M/T
Delivery volume
(To 1)
Thermostat type
!C (!F)
!C (!F)
mm (in)
Radiator
100 (26.3/22.2)
A/T
Cooling system
Description
76.5 (170)
40 (104)
95 (203)
90 (194)
55 (131)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
11.63 m (1.081ft )
!
0.28m (0.026 ft )
6B 4 ENGINE COOLING
GENERAL DESCRIPTION
COOLANT FLOW
RTW46ALF001101
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and thermostat through the bypass hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing
amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now
circulating through the radiator for effective engine cooling.
ENGINE COOLING 6B 5
WATER PUMP
RTW46ASF000101
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.
THERMOSTAT
030RY00005
6B 6 ENGINE COOLING
RADIATOR
110RS001
Antifreeze Solution
PTW46BSH000201
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE
ENGINE COOLING 6B 7
DIAGNOSIS
Engine Cooling Trouble
Symptom
Engine overheating
Possible Cause
Replenish
Faulty thermostat
Replace
Action
Replace
Clean or replace
Replace
Replace
Engine overcooling
Faulty thermostat
Replace
Replace
Faulty thermostat
Replace
6B 8 ENGINE COOLING
P1010064
ENGINE COOLING 6B 9
" After tightening radiator cap, warm up the engine at about
2000 rpm. Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heater water
system.
" Check to see the thermostat has opened through the
needle position of water thermometer, conduct a 5minute
idling again and stop the engine.
" When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the cooling system and
reservoir tank hose for leakage.
" Pour coolant into the reservoir tank up to MAX" line.
6B 10 ENGINE COOLING
WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
030R300001
7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.
030R300002
ENGINE COOLING 6B 11
Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque
Nm(kgm/lb ft)
20 (2.0/14)
030R300002
030R300001
6B 12 ENGINE COOLING
5. Thermostat
Install the thermostat to the thermostat housing.
6. Water Outlet Pipe
1) Install the water outlet pipe with new gasket to the
thermostat housing.
2) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
19(1.9/14)
031R300003
ENGINE COOLING 6B 13
THERMOSTAT
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
031RY00005
9.5 (0.37)
mm (in)
6B 14 ENGINE COOLING
! Thermometer
" Agitating rod
# Wooden piece
Installation
1. Thermostat
Install the thermostat to the thermostat housing.
2. Water Outlet Pipe
3) Install the water outlet pipe with new gasket to the
thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
031R300003
19(1.9/14)
ENGINE COOLING 6B 15
RADIATOR
REMOVAL AND INSTALLATION
Legend
1. Radiator Hose
2. Drain Plug
3. Fan Guide, Lower
4. Fan Guide
5. Bracket
RTW36BLF000101
6B 16 ENGINE COOLING
Removal
1.
2.
3.
4.
P1010064
PTW46BSH000101
RTW36BMH000101
7. Remove bracket(5).
ENGINE COOLING 6B 17
Radiator Cap
!17.8)
! 122.7 (13.5
110RS006
Radiator Core
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
" Leakage from the radiator
" Leakage from the coolant pump
" Leakage from the water hoses
6B 18 ENGINE COOLING
" Check the rubber hoses for swelling.
110RS005
Installation
RTW36BMH000101
ENGINE COOLING 6B 19
8. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
RTW36BSH000101
6B 20 ENGINE COOLING
033R300001
033RY00011
FUEL SYSTEM
6C 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Fuel Flow.................................................................................................................... 6C -
General Description....................................................................................................... 6C -
Injection Pump........................................................................................................... 6C -
Removal ..................................................................................................................... 6C -
Installation ................................................................................................................. 6C - 10
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
6C 2 FUEL SYSTEM
PAGE
Injection Nozzle.............................................................................................................. 6C - 25
Inspection................................................................................................................... 6C - 25
Special Tools.................................................................................................................. 6C - 36
FUEL SYSTEM
Item
4JA1T (L)
Bosch distributor
VE type
Governor type
Oil pressure
4JH1TC
4JA1TC
Mechanical variable
(Half speed oil
pressure)
Timer type
6C 3
mm (in)
1st
2nd
0.19 (0.0075)
0.17 (0.0067)
0.21 (0.0083)
25.0 (255)
33.5 (328)
33.8 (331)
19.1 (195)
19.0 (194)
19.5 (199)
Precautions
When working on the fuel system, there are several things
to keep in mind:
NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.
6C 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
RTW46CMF000201
The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.
FUEL SYSTEM
6C 5
RTW36CLF000701
6C 6 FUEL SYSTEM
For EURO III model
RTW46AMF000201
INJECTION PUMP
FUEL SYSTEM
6C 7
RTW46CLF000201
4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engines vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.
4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C 8 FUEL SYSTEM
NOTE:
! Injection nozzle adjustment is possible only on the 4JA1L engine.
RTW46CMF000301
A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through
the nozzle body injection orifice.
FUEL TANK
FUEL SYSTEM
6C 9
RTW46CLF000401
Legend
6C 10 FUEL SYSTEM
Removal
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, dont scratch
each hose and tube by around other parts.
Installation
NOTE: When raise the fuel tank to the vehicle, dont scratch
each hose and tube by around other parts.
Nm (kgm / lb ft)
FUEL SYSTEM
6C 11
6C 12 FUEL SYSTEM
RTW46CLF000501
Legend
Removal
FUEL SYSTEM
6C 13
Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
6C 14 FUEL SYSTEM
8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose (Pull off
the breather hose from fuel tank) and tighten fuel filler
cap until at least one click are heard.
(2) Apply water soap around the fuel gauge unit seal area.
(3) Pressure air into the fuel tank from end of breather pipe
2
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
(4) Verify no bubbles around the fuel gauge unit seal area.
9. Install the fuel tank assembly (9).
NOTE: Refer to Install the fuel tank in this section.
FUEL SYSTEM
6C 15
Precautions
Legend
140R100032
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the
fuel pipe may
still have some pressure in it.
141R100002
6C 16 FUEL SYSTEM
140R100037
140R100028
140R100036
Reuse of QuickConnector
Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.
FILLER NECK
FUEL SYSTEM
6C 17
Removal
Installation
6C 18 FUEL SYSTEM
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.
Legend
RTW36CSH000401
Inspection
INJECTION PUMP
FUEL SYSTEM
6C 19
Removal
1. Battery
Remove the battery from the battery tray.
6C-1
2. Drive Belt
1) Loosen the adjust bolt of the power steering pump
pulley.
2) Remove the drive belt.
P1010003
5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the
intake throttle.
6. Fan
6C 20 FUEL SYSTEM
6C-4
8. Throttle
Position
Sensor
Harness
Connector
(4JA1TC/4JH1TC only)
Disconnect the harness connector from the throttle
position sensor.
9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.
11. Fuel Filter Assembly (Except EURO III model)
6C-5
FUEL SYSTEM
020L200017
RTW46CSH000201
6C-7
6C 21
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear B fixing hole to prevent the scissors gear from
turning.
6C 22 FUEL SYSTEM
Installation!!
1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut
N"m (kg"m/lb ft)
64 (6.5 / 47)
RTW46CSH000201
020L200017
6C-7
FUEL SYSTEM
6C 23
4JA1T (L)
4JA1TC/4JH1TC
RTW46CSH000101
RTW36AMH000101
24 (2.4 / 17)
Nm(kgm / lb ft)
Torque
Nuts
Bolts
24 (2.4/17)
27 (2.8/20)
6C 24 FUEL SYSTEM
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque
29 (3.0 / 22)
Nm(kgm / lb ft)
Nm(kgm / lb ft)
Nm(kgm / lb ft)
29 (3.0 / 22)
40 (4.1 / 30)
FUEL SYSTEM
6C 25
Euro I
Euro II
Euro III
4JA1L
without
with
with
4JA1TC
Not used
Not used
Not used
4JH1TC
without
with
with
Not used
With cooler
(EGR cooler)
With
(EGR cooler)
6C 26 FUEL SYSTEM
080L200009
Disassembly Steps
1.
2.
3.
4.
Retaining nut
Nozzle & pin
Spacer & pin
Lift Piece
9.
10.
11.
12.
5.
6.
7.
Spring seat
Push rod
Shim (Second nozzle opening
pressure adjustment)
Second spring
13.
14.
15.
8.
Collar
Spring seat
First spring
Shim (First nozzle
pressure adjustment)
Nozzle holder body
Eye bolt
Gasket
opening
Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
FUEL SYSTEM
REASSEMBLY
6C 27
080L200010
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Spring seat
Lift Piece
11.
12.
13.
14.
15.
Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
6C 28 FUEL SYSTEM
Pre-lift confirmation
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
Final inspection
1st Stage
2nd Stage
Confirm the condition of the fuel spray with the nozzle and
nozzle holder assembled.
FUEL SYSTEM
6C 29
040MV015.tif
040MV016.tif
040MV017.tif
040MV018.tif
6C 30 FUEL SYSTEM
040MV019.tif
040MV010.tif
040MV014-1.tif
FUEL SYSTEM
Thickness (mm)
115349-0430
0.50
115349-0420
115349-0440
115349-0450
115349-0460
040LX010.tif
6C 31
115349-0470
115349-0480
115349-0490
0.40
0.52
0.54
0.56
0.58
0.60
0.70
040MV013.tif
040MV012.tif
040MV011.tif
6C 32 FUEL SYSTEM
040MV009.tif
040MV030.tif
FUEL SYSTEM
6C 33
040MV008.tif
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040R300008
6C 34 FUEL SYSTEM
4JA1T(L)
Pressure Mpa
2
(psi/ kg/cm )
20.1 (2,858/205)
Lift mm (in)
0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.
3. Confirm that pre-lift is as specified.
040MV005.tif
040MV031.tif
040MV030.tif
FUEL SYSTEM
6C 35
040MV022.tif
4JA1T(L)
040M100006
Pressure Mpa
2
(psi/ kg/cm )
25.5-27.0
(3768-3911/260-275)
Lift mm (in)
0.09 (0.0035)
6C 36 FUEL SYSTEM
040MV017.tif
040LX009.tif
897116-0290
897116-0320
897116-0330
897116-0340
897116-0350
897116-0360
897116-0370
Thickness
(mm)
0.10
0.20
0.30
0.40
0.50
0.51
0.52
Part No.
(ISUZU)
897116-0380
897116-0390
897116-0400
897116-0410
897116-0420
897116-0430
897116-0440
Thickness
(mm)
0.53
0.54
0.55
0.56
0.57
0.58
0.59
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
040MV014-1.tif
FUEL SYSTEM
6C 37
6C 38 FUEL SYSTEM
ILLUSTRATION
SPECIAL TOOLS
TOOL NUMBER
5-8840-2602-0
(J-39765)
TOOL NAME
ENGINE ELECTRICAL 6D 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE
Generator.......................................................................................................................... 6D - 7
Reassembly.................................................................................................................. 6D - 18
Disassembly................................................................................................................. 6D - 23
Reassembly.................................................................................................................. 6D - 29
6D 2 ENGINE ELECTRICAL
Item
60A
Generator
Type
Voltage
Drive and rotation
Ground polarity
Maximum output
Engine speed ratio
Maximum speed
Vacuum Pump
Delivery volume
Exhaust Characteristic
V
A
to 1
rpm
kg(lb)
cm /rev
3
Starter Motor
Type
Weight
Hitachi LR160-503E
Hitachi LR180-513B
12
V-belt, clockwise viewed from the drive pulley
Negative
60
5.8(12.8)
1.788
11,000
80
6.4(14.1)
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000
rpm
7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Maximum vacuum
Rated voltage
Rated output
Load characteristics
Terminal voltage
Load current
80A
Solenoid controlled
V
kW
V
A
kg(Ib)
Hitachi S13-555
12
2.3
8.76
300
4.7 (10.4)
ENGINE ELECTRICAL 6D 3
GENERAL DESCRIPTION
GENERATOR
STARTER MOTOR
066L300004
065L300002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.
6D 4 ENGINE ELECTRICAL
RTW46DSH005101
RTW46DSH005501
ENGINE ELECTRICAL 6D 5
TORQUE SPECIFICATIONS
GENERATOR
N!m (kg!m/Ib!ft)
RTW46DLF000201
6D 6 ENGINE ELECTRICAL
STARTER MOTOR
N!m (kg!m/Ib!ft)
RTW46DLF000301
GENERATOR
ENGINE ELECTRICAL 6D 7
Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.
P1010002
Generator
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the
bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque
40 (4.1/30)
N!m (kg!m/Ib!ft)
6D 8 ENGINE ELECTRICAL
Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys.
1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley
033RY00009
19 (1.9/14)
Nm (kgm/lbft)
ENGINE ELECTRICAL 6D 9
DISASSEMBLY
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Vacuum pump
O-ring
Through bolt
B Terminal nut
Rear cover
Pulley
Rotor assembly
Front cover assembly
Rear rotor bearing
Rectifier assembly
Stator assembly
Rotor assembly
RTW46DLF000401
6D 10 ENGINE ELECTRICAL
Important Operations
1.
Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover
RTW46DSH000101
3.
Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space
between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
! The front cover oil seal must be replaced with a new
one when the front cover is removed.
! Take care not to damage the stator core with the
screwdriver tips.
4.
Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.
RTW46DSH000201
RTW46DSH000601
RTW46DSH002101
ENGINE ELECTRICAL 6D 11
7. Rotor Assembly
1. Remove the rotor from front cover assembly.
Remove the front cover stator and rectifier.
RTW46DSH000301
RTW46DSH000701
RTW46DSH000801
RTW46DSH000401
6D 12 ENGINE ELECTRICAL
ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting.
Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter
mm (in)
Standard
31.6 (1.245)
Limit
30.6 (1.183)
RTW06DSH000101
If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.
3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20"C (68"F)
Standard
3.8
ohms
RTW46DSH001001
RTW46DSH001101
ENGINE ELECTRICAL 6D 13
066RY00022
066RY00023
0.1
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference)
mm (in)
Standard
Limit
25 (1.0)
RTW46DSH004801
6.5 (0.25)
Rectifier
RTW46DSH001201
E
U, V, and WN
"
Tester wire
"
-----
Conductivity
No
----conductivity
Negative side diode check
BAT
U, V, and WN
"
----Conductivity
"
No
conductivity
-----
6D 14 ENGINE ELECTRICAL
RECTIFIER ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
RTW46DSF000301
Voltmeter
Switch 1
DC regulated power supply
Lamp 2
Lamp 1
Switch 3
Switch 2
Pulse generator
Output signal
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.
Circuit components
DC regulated power supply
1
Lamps (2)
2
Switches (3)
3
DC voltmeter
4
Pulse generator (Oscillator)
5
Judgment criteria
No.
Switch
1
Switch
2
Switch
3
ON
OFF
OFF
ON
ON
OFF
ON
ON
OFF
16V
OFF
ON
OFF
12V
ON
ON
ON
Voltmeter
reading
12V
18V
Lamp condition
Lamp 1 Lamp 2
On
ON
(dim)
On or
flashing
OFF
Off or
on (dim)
On or
flashing
On
ON
Remarks
Initial excitation check
Full excitation check
ENGINE ELECTRICAL 6D 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.
RTW46DSF000101
6D 16 ENGINE ELECTRICAL
Vacuum Pump
Vacuum Pump Disassembly
RTW46DSH000901
Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and
scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash.
Replace the rotor if backlash is present.
Check Value
RTW46DSH005201
ENGINE ELECTRICAL 6D 17
Vacuum Pump Reassembly
RTW46DSH001801
2. Install the rotor with the concave side facing the center
plate.
RTW46DSH001901
RTW46DSH002001
6D 18 ENGINE ELECTRICAL
REASSEMBLY
RTW46DLF000501
Reassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Front cover
Rear rotor bearing
Rotor Assembly
Pulley
Rectifier Assembly
Stator Assembly
Rear cover
B Terminal nuts
Through bolt
O-ring
Vacuum pump
ENGINE ELECTRICAL 6D 19
Important Operations
2. Rear rotor bearing
! Re-use improper parts.
RTW46DSH000401
5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.
3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque
N#m (kg#m/lb#ft)
83.3 $ 98.0 (8.5 $ 10.0 / 61 $ 72)
RTW46DSH002101
RTW46DSH006001
RTW46DSH004901
6D 20 ENGINE ELECTRICAL
NOTE: Be sure to attach a cooler to B terminal.
RTW46DSH002201
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.
Remove the pin after completion of the assembly
procedure.
RTW46DSH005301
ENGINE ELECTRICAL 6D 21
9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque
N#m (kg#m/lb#ft)
3.1 $ 3.9 (0.32 $ 0.41 / 2.6 $ 3.5)
RTW06DSH000201
RTW46DSH006101
RTW46DSH002401
Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque
N#m (kg#m/lb#ft)
5.9 $ 6.9 (0.6 $ 0.7 / 5.2 $ 6.1)
RTW46DSH002501
6D 22 ENGINE ELECTRICAL
STARTER MOTOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
ENGINE ELECTRICAL 6D 23
DISASSEMBLY
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lead wire
Bolt
Magnetic switch assembly
Torsion spring
Plunger
Dust cover
Magnetic switch
Screw
Through bolt
Rear cover
Motor assembly
Brush holder
Yoke
RTW460LF000201
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Armature
Bolt
Bearing retainer
Pinion assembly
Pinion stopper clip
Pinion stopper
Return spring
Pinion shaft
Clutch
Dust cover
Shift lever
Gear case
6D 24 ENGINE ELECTRICAL
Important Operations
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
RTW46DSH002701
RTW46DSH002801
RTW46DSH002901
RTW46DSH003001
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.
ENGINE ELECTRICAL 6D 25
Remove the yoke along with the armature and the brush
holder from the gear case.
Remove the brushes and commutator carefully so as not
to allow them in contact with the adjacent parts.
RTW46DSH003101
RTW46DSH003201
RTW46DSH003301
RTW46DSH003401
16.
17.
23.
24.
25.
Bearing Retainer
Pinion Assembly
Dust Cover
Shift Lever
Gear Case
1. Remove the bearing retainer.
2. Remove the pinion from the gear case.
6D 26 ENGINE ELECTRICAL
ARMATURE
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out
mm (in)
Standard
0.05 (0.002)
RTW46DSH003501
0.2 (0.008)
065RY00025
Limit
Limit
0.2 (0.008)
36.5 (1.44)
Limit
mm (in)
35.5 (1.40)
065RY00026
RTW46DSH003601
ENGINE ELECTRICAL 6D 27
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two
commutator segments.
2 Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the commutator.
If there is not, the armature must be replaced.
RTW46DSH003701
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.
RTW46DSH003801
RTW46DSH003901
6D 28 ENGINE ELECTRICAL
Limit
12 (0.47)
RTW46DSH004001
RTW46DSH004101
OVERRUNNING CLUTCH
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
RTW46DSH004401
ENGINE ELECTRICAL 6D 29
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Pinion stopper
Pinion stopper clip
Bearing retainer
Bolt
Motor assembly
Armature
Yoke
Brush holder
Rear cover
Screw
Through bolt
Lead wire
6D 30 ENGINE ELECTRICAL
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.
RTW46DSH005601
7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
Dust Cover Bolt Torque
RTW46DSH005701
065RY00041
RTW46DSH004501
8 (0.8/5.4)
N#m (kg#m/lb#ft)
ENGINE ELECTRICAL 6D 31
24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque
N#m (kg#m/lb#ft)
8.1 (0.83/6.00)
065RY00044
RTW46DSH002601
RTW46DSH005801
6D 32 ENGINE ELECTRICAL
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the M
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.
RTW46DSH004601
RTW46DSH005901
RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
ENGINE ELECTRICAL 6D 33
PRE-HEATING SYSTEM
VISUAL CHECK
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance
825R300046
94 % 114
Ohms
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference)
Approximately 0.9
LNW21KSH001401
Ohms
6D 34 ENGINE ELECTRICAL
MEMO
6E1
ENGINE
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ........................
6E-9
4JA1-TC ....................................................
6E-10
4JH1-TC ....................................................
6E-11
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-14
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-15
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-16
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-17
GROUND POINT CHART GENERAL EXPORT
(LHD) (1/4) ...............................................
6E-18
LOCATION ................................................
6E-34
PARTS LOCATION ...................................
6E-39
CONNECTOR LIST ...................................
6E-40
RELAY AND FUSE ....................................
6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ...........................................
6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ...........................................
6E-44
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45
ECM WIRING DIAGRAM (1/7) ..................
6E-46
ECM WIRING DIAGRAM (2/7) ..................
6E-47
ECM WIRING DIAGRAM (3/7) ..................
6E-48
ECM WIRING DIAGRAM (4/7) ..................
6E-49
ECM WIRING DIAGRAM (5/7) ..................
6E-50
ECM WIRING DIAGRAM (6/7) ..................
6E-51
ECM WIRING DIAGRAM (7/7) ..................
6E-52
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL ....................................
6E-53
GENERAL DESCRIPTION FOR ECM AND
SENSORS ...............................................
6E-64
Engine Control Module (ECM) ...................
6E-64
Pump Control Unit (PSG) & Data Exchange
Between Control Module .........................
6E-64
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor .......................
6E-65
Throttle Position Sensor (TPS) ..................
6E-66
Crankshaft Position (CKP) Sensor ............
6E-66
Engine Coolant Temperature (ECT) Sensor
6E-67
Vehicle Speed Sensor (VSS) ....................
6E-67
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION) .....
6E-68
GENERAL DESCRIPTION FOR
INJECTION PUMP ..................................
6E-70
Outline .......................................................
6E-70
Cross-section View ....................................
6E-70
Low Pressure Fuel Circuit ..........................
6E-71
High Pressure Fuel Circuit .........................
6E-72
Pump Camshaft Speed Sensor .................
6E-72
High Pressure Solenoid Valve ...................
6E-73
Timing Control Valve (TCV) .......................
6E-74
ISUZU Strategy Based Diagnostics ..............
6E-76
Overview ....................................................
6E-76
STRATEGY BASED DIAGNOSTICS CHART 6E-76
Diagnostic Thought Process ......................
6E-77
1. Verify the Complaint ..............................
6E-77
2. Perform Preliminary Checks ..................
6E-77
3. Check Bulletins and Troubleshooting Hints 6E-78
4. Perform Service Manual Diagnostic Checks 6E-78
5a and 5b. Perform Service Manual Diagnostic
Procedures ..............................................
6E-78
5c. Technician Self Diagnoses ..................
6E-78
5d. Intermittent Diagnosis ..........................
6E-79
5e. Vehicle Operates as Designed ............
6E-80
6. Re-examine the complaint .....................
6E-81
7. Repair and Verify Fix .............................
6E-81
GENERAL SERVICE INFORMATION .......
6E-82
ON-BOARD DIAGNOSTIC (OBD) .............
6E-82
TECH 2 OPERATING FLOW CART
(START UP) .............................................
6E-86
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ...................................
6E-88
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ...................................
6E-90
MISCELLANEOUS TEST ..........................
6E-92
Plotting Snapshot Graph ............................
6E-93
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) ..........
6E-94
Flow Chart for Snapshot Replay
(Plotting Graph) .......................................
6E-95
SNAPSHOT DISPLAY WITH TIS2000 ......
6E-96
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK ....................................................
6E-105
Circuit Description ......................................
6E-105
Diagnostic Aids ..........................................
6E-105
Test Description .........................................
6E-105
6E2
6E3
6E4
MALFUNCTION .......................................
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE 7) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE 9) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE A) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE B) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE D) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE E) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION .......
6E-196
Circuit Description .....................................
6E-197
Diagnostic Aids ..........................................
6E-197
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 6) (Flash Code 53)
Injection Pump Malfunction .....................
6E-197
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 7) (Flash Code 53)
Injection Pump Malfunction .....................
6E-199
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 9) (Flash Code 53)
Injection Pump Malfunction .....................
6E-203
Diagnostic Trouble Code (DTC) P0251
(Symptom Code A) (Flash Code 53)
Injection Pump Malfunction .....................
6E-204
Diagnostic Trouble Code (DTC) P0251
(Symptom Code B) (Flash Code 53)
Injection Pump Malfunction .....................
6E-205
Diagnostic Trouble Code (DTC) P0251
(Symptom Code D) (Flash Code 53)
Injection Pump Malfunction .....................
6E-206
Diagnostic Trouble Code (DTC) P0251
(Symptom Code E) (Flash Code 53)
Injection Pump Malfunction .....................
6E-207
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE B) (FLASH CODE 43)
CRANKSHAFT POSITION SENSOR
CIRCUIT MALFUNCTION .......................
6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE D) (FLASH CODE 43)
CRANKSHAFT POSITION SENSOR
MALFUNCTION .......................................
6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE E) (FLASH CODE 43)
ENGINE SPEED INPUT CIRCUIT
RANGE/PERFORMANCE .......................
6E-208
Circuit Description ......................................
6E-209
Diagnostic Aids ..........................................
6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit
Malfunction ..............................................
6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction ..
6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code E) (Flash Code 43) Engine
Speed Input Circuit Range/Performance .
6E-214
DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE 4) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE LOW
6E-217
DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE 8) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
Circuit Description ......................................
6E-217
Diagnostic Aids ..........................................
6E-217
Diagnostic Trouble Code (DTC) P0380
(Symptom Code 4) (Flash Code 66)
Glow Relay Circuit Voltage Low ..............
6E-218
Diagnostic Trouble Code (DTC) P0380
(Symptom Code 8) (Flash Code 66) Glow
Relay Circuit Voltage High .......................
6E-221
DIAGNOSTIC TROUBLE CODE (DTC) P0381
(SUB CODE 4) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE LOW ..
6E-222
DIAGNOSTIC TROUBLE CODE (DTC) P0381
(SUB CODE 8) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE HIGH .
6E-222
Circuit Description ......................................
6E-222
Diagnostic Aids ..........................................
6E-222
Diagnostic Trouble Code (DTC) P0381
(Symptom Code 4) (Flash Code 67) Glow
Plug Indicator Circuit Voltage Low ...........
6E-222
Diagnostic Trouble Code (DTC) P0381
(Symptom Code 8) (Flash Code 67) Glow
Plug Indicator Circuit Voltage High ..........
6E-226
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 3) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION FLOW
EXCESSIVE DETECTED ........................
6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 4) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO GROUND OR OPEN CIRCUIT 6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 5) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION FLOW
INSUFFICIENT DETECTED ....................
6E-227
6E5
6E6
6E7
6E8
ABBREVIATION CHARTS
Abbreviations
A/C
Air conditioner
A/T
Automatic transmission
BLK
Black
ACC
Accessory
BLU
Blue
CAN
BRN
Brown
CEL
DLC
CKP
DTC
ECM
DVM
ECT
EGR
GND
Ground
EEPROM
EVRV
Appellation
GRY
Gray
IG
Ignition
MAB
IAT
M/T
MAF
MIL
OBD
On-board diagnostic
ORN
Orange
RED
Red
PNK
Pink
PSG
TCM
TDC
VCC
SW
TCV
TPS
Switch
VIO
Violet
WHT
White
VSS
YEL
Yellow
6E9
6E10
COMPONENT LOCATOR
(4) Battery
(5) Relay & Fuse Box
(6) EGR Cooler
4JH1-TC
6E11
(4) Battery
(5) Relay & Fuse Box
(6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
6E12
6E13
6E14
6E15
6E16
6E17
6E18
6E19
6E20
6E21
6E22
6E23
6E24
6E25
6E26
6E27
6E28
6E29
6E30
6E31
6E32
6E33
6E34
LOCATION
6E35
6E36
6E37
6E38
PARTS LOCATION
6E39
6E40
CONNECTOR LIST
No.
Connector face
Green
Meter-B
White
J/B I2
White
J/B I4
Black
Check connector
White
TCM
White
White
TCM
White
White
J/B E2
White
J/B E1
Silver
Body-LH ; ground
Brown
EVRV
B-24
B-54
B-56
B-58
B-62
B-63
B-68
C-2
Immobilizer
Silver
Silver
White
C-36
C-44
No.
C-56
C-57
C-77
C-94
C-95
C-107
C-108
C-109
C-115
C-116
Connector face
ECM-A
ECM-B
Clutch switch
C-118
C-123
Connector face
C-124
E-6
Connector face
Gray
Idle SW
Black
Gray
Gray
Glow plug
Black
Inhibiter switch
White
E-23
E-41
E-44
E-3
Black
No.
E-49
E-9
E-51
H-4
E-10
H-6
Silver
Engine ground
White
Natural
green
Neutral switch
White
Natural
green
Neutral switch
White
Brown
TPS 1 main
White
E-11
E-12
E-22
H-7
H-18
H-22
6E41
6E42
No.
Connector face
Black
DIODE
Silver
Battery (+)
Black
DIODE
Silver
Silver
Battery (-)
Silver
Silver
Engine ground
Black
Relay ; Glow
Black
Black
Black
Relay; Thermo
H-33
P-1
P-2
P-5
P-6
P-10
X-5
X-13
X-14
X-15
Connector face
X-16
X-17
LHD
RHD
6E43
6E44
RELAY
(4JA1-TC/4JH1-TC)
RELAY; TAIL LIGHT
RELAY; FRT FOG LIGHT
RELAY; HORN
RELAY; DIMMER
RELAY; GLOW
RELAY; COND, FAN
RELAY; RR FOG
RELAY; STARTER
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-RH (RHD)
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-LH (RHD)
RELAY; HEATER
RELAY; HEAD LIGHT
RELAY; ECM MAIN
RELAY; A/C COMP
RELAY; THERMO
FUSE
FUSE
(4JA1-TC/4JH1-TC)
NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
EB-7
EB-8
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
10A ECM
10A RR FOG
15A FRT FOG
80A MAIN
20A COND, FAN
50A GLOW
30A ECM
40A IG 1
40A ABS-1
30A ABS-2
30A BLOWER
50A IG 2
FUSE
No.
1
2
3
4
5
6
7
8
9
10
11
Capacity
10A
15A
15A
10A
15A
15A
20A
15A
10A
4JA1-TC, 4JH1-TC
Indication on label
ABS
BACK UP
METER
TURN
ELEC.IG
ENGINE
FRT WIPER
EGR
AUDIO
No.
12
13
14
15
16
17
18
19
20
21
Capacity
15A
15A
20A
10A
10A
10A
15A
15A
10A
10A
Indication on label
RR DEF
POWER WINDOW
B-7
B-8
REAR
POWER
DEFOGGER WINDOW
B-40
ACC
SOCKET
Indication on label
CIGER
AUDIO (+B)
DOOR LOCK
METER (+B)
ROOM
ANTI THEFT
STOP
ACC SOCKET
STARTER
SRS
6E45
6E46
6E47
6E48
6E49
6E50
6E51
6E52
6E53
Signal or Continuity
Tester Position
ECM
Connection
Range
(+)
(-)
Disconnect
Ohm
GND
Disconnect
Ohm
GND
Connect
DC V
GND
Approx.
23Hz by
wave form
or approx.
6.3V
Approx.
67Hz by
wave form
or approx.
6.8V
Connect
AC V
27
GND
Connect
DC V
30
GND
Connect
DC V
31
GND
Connect
DC V
33
GND
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM Ground
BLK
ECM Ground
BLK
Continuity
with
ground
25
25
No Connection
BLU/
RED
Continuity
with
ground
27
27
LGN
28
28
No Connection
30
30
GRN
31
31
YEL
32
32
Less than
1V
33
GRN/
YEL
Less than
1V
34
34
No Connection
No Connection
GRN/
ORG
Less than
1V
WHT
No Connection
Less than
1V
26
29
33
26
29
35
35
36
36
38
38
39
39
40
40
37
37
No Connection
No Connection
No Connection
YEL
Less than
1V
-
Less than
1V
-
10-14V
Approx.
0.5V
Connect
DC V
38
49
Connect
DC V
39
GND
Less than 1V
10-14V
-
6E54
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
41
41
A/C Compressor
Relay
WHT/
GRN
Less than
1V
10-14V
42
42
43
43
Glow Lamp
GRN/
YEL
Less than
1V
44
44
45
45
46
46
48
48
47
47
ORG/
BLU
Less than
1V
BLU
Less than
1V
No Connection
No Connection
No Connection
No Connection
49
49
BLK/
GRN
50
50
No Connection
52
52
No Connection
51
53
54
55
56
51
53
54
55
56
No Connection
No Connection
No Connection
65
66
66
No Connection
68
68
67
No Connection
Idle:
Approx.
0.4K ohm /
WOT:
Approx.
4.0K ohm
69
69
70
70
No Connection
72
72
No Connection
71
73
74
Idle Switch
No Connection
No Connection
No Connection
GND
-
Disconnect
Ohm
38
49
Less than
1V
-
Less than
1V
45
GRN/
BLK
DC V
Connect
GND
Less than
1V
YEL/
GRN
43
WHT/
BLK
-
DC V
65
Connect
GND
No Connection
42
64
DC V
No Connection
64
Connect
61
GND
63
41
63
DC V
Connect
No Connection
(-)
62
(+)
No Connection
Range
No Connection
60
ECM Relay
ECM
Connection
59
61
74
10-14V
10-14V
59
73
BLU/
BLK
58
71
Less than
1V
58
67
RED/
GRN
57
62
No Connection
Engine
2000rpm
57
60
No Connection
Engine
Idle
Tester Position
Approx. 5V
10-14V
57
49
Connect
DC V
58
GND
DC V
Connect
Less than 1V
DC V
63
GND
Connect
DC V
65
GND
Connect
AC V
68
GND
Connect
DC V
69
GND
Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
75
75
No Connection
77
77
No Connection
76
78
79
80
81
82
76
78
79
80
81
82
83
83
84
84
85
No Connection
No Connection
No Connection
No Connection
No Connection
No Connection
WHT/
RED
BLK/
BLU
Less than
1V
85
No Connection
87
87
Neutral Switch
88
88
BLK/
WHT
Less than
1V
89
89
90
86
86
No Connection
GRN/
RED
90
91
Less than
1V
DC V
84
92
Connect
DC V
87
GND
91
PNK
92
92
BLK/
RED
93
93
BLK/
PNK
94
94
95
Approx.
1.8V
Approx.
2.5V
Connect
DC V
88
92
Connect
DC V
89
93
Approx.
47Hz by
wave form
Connect
AC V
90
98
Approx.
47Hz by
wave form
Approx.
134Hz by
wave form
or approx.
1.1V
Connect
AC V
91
GND
Continuity
with
ground
Connect
Ohm
92
GND
Connect
Ohm
93
GND
Connect
DC V
94
GND
Continuity
with
ground
Glow Relay
BLK/
RED
95
No Connection
97
97
EGR EVRV
BLK/
ORG
98
98
WHT
99
99
BLU
100
100
YEL
Approx. 5V
Connect
RED
(-)
92
Less than
1V
No Connection
(+)
83
GRY
96
Range
DC V
Approx. 1V
96
ECM
Connection
Connect
Less than
1V
6E55
Less than
1V
Continuity
with
ground
Approx.
134Hz by
wave form
or approx.
0.7V
Connect
Ohm
98
GND
6E56
Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
101
101
BLK
102
102
No Connection
Continuity
with
ground
-
103
104
105
103
104
105
No Connection
No Connection
ORG
ECM
Connection
Range
(+)
(-)
Connect
Ohm
101
GND
6E57
Signal or Continuity
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM &
PSG Connection
Rang
e
(+)
(-)
99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(EC
M)
100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(EC
M)
No Connection
No Connection
105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(EC
M)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(EC
M)
No Connection
10-14V
6E58
Signal or Continuity
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Connect
DC V
GND
25
25
No Connection
26
26
No Connection
27
27
LGN
Approx.
23Hz by
wave
form or
approx.
6.3V
Approx.
67Hz by
wave
form or
approx.
6.8V
Connect
AC V
27
GND
28
28
No Connection
29
29
30
30
31
31
32
10-14V
GRN
Less
than 1V
Connect
DC V
30
GND
YEL
Less
than 1V
Connect
DC V
31
GND
32
No Connection
33
33
GRN/
YEL
Less
than 1V
Connect
DC V
33
GND
34
34
No Connection
35
35
YEL
36
36
No Connection
6E59
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
37
37
No Connection
38
38
Throttle Position
Sensor (TPS) Output Signal
GRN/
ORG
Less
than 1V
Approx.
0.5V
Connect
DC V
38
49
39
39
WHT
Less
than 1V
Connect
DC V
39
GND
40
40
No Connection
41
41
A/C Compressor
Relay
WHT/
GRN
Less
than 1V
10-14V
Connect
DC V
41
GND
42
42
GRN/
YEL
Less
than 1V
Connect
DC V
42
GND
43
43
Glow Lamp
ORG/
BLU
Less
than 1V
Connect
DC V
43
GND
44
44
No Connection
45
45
BLU
Less
than 1V
Connect
DC V
45
GND
46
46
No Connection
47
47
No Connection
48
48
No Connection
49
49
Throttle Position
Sensor (TPS)
Ground
BLK/
GRN
Idle:
Approx.
0.4K
ohm /
WOT:
Approx.
4.0K
ohm
Disconnect
Ohm
38
49
50
50
No Connection
51
51
No Connection
52
52
No Connection
53
53
No Connection
54
54
No Connection
55
55
No Connection
56
56
No Connection
57
57
Throttle Position
Sensor (TPS) Power
Supply
RED/
GRN
Less
than 1V
Approx. 5V
Connect
DC V
57
49
58
58
ECM Relay
BLU/
BLK
10-14V
Less than 1V
Connect
DC V
58
GND
59
59
No Connection
60
60
No Connection
61
61
No Connection
62
62
No Connection
Less than 1V
10-14V
10-14V
6E60
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
63
63
Less
than 1V
10-14V
64
64
No Connection
65
65
WHT/
BLK
Less
than 1V
66
66
No Connection
67
67
No Connection
68
68
YEL/
GRN
69
69
Idle Switch
GRN/
BLK
Less
than 1V
70
70
No Connection
71
71
No Connection
72
72
No Connection
73
73
No Connection
74
74
No Connection
75
75
76
Tester Position
ECM
Connection
Ran
ge
(+)
(-)
DC V
63
GND
Connect
DC V
65
GND
Connect
AC V
68
GND
Connect
DC V
69
GND
No Connection
76
No Connection
77
77
No Connection
78
78
No Connection
79
79
No Connection
80
80
No Connection
81
81
No Connection
82
82
WHT/
BLU
Less
than 1V
Approx. 5V
Connect
DC V
82
93
83
83
WHT/
RED
Less
than 1V
Approx. 5V
Connect
DC V
83
92
84
84
BLK/
BLU
Less
than 1V
Connect
DC V
84
92
85
85
Manifold Pressure
Sensor (High Altitude Spec. Only)
RED/
BLU
Less
than 1V
Connect
DC V
85
93
86
86
No Connection
87
87
Neutral Switch
BLK/
WHT
Less
than 1V
Connect
DC V
87
GND
88
88
GRN/
RED
Less
than 1V
Approx.
1V
Connect
DC V
88
92
Engine
2000rpm
Approx.
1.8V
Approx.
2.5V
6E61
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
89
89
GRY
Less
than 1V
Connect
DC V
89
93
90
90
RED
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
1.1V
Connect
AC V
90
98
91
91
PNK
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
0.7V
Connect
AC V
91
GND
92
92
BLK/
RED
Continuity with
ground
Connect
Ohm
92
GND
93
93
BLK/
PNK
Continuity with
ground
Connect
Ohm
93
GND
94
94
Glow Relay
BLK/
RED
Less
than 1V
Connect
DC V
94
GND
95
95
No Connection
96
96
BRW/
RED
Wave form
97
97
EGR EVRV
BLK/
ORG
Approx. 140Hz by
wave form when
EVRV is operated
98
98
WHT
Continuity with
ground
Connect
Ohm
98
GND
99
99
BLU
100
100
YEL
101
101
BLK
Continuity with
ground
Connect
Ohm
101
GND
102
102
No Connection
103
103
No Connection
104
104
No Connection
105
105
ORG
6E62
Signal or Continuity
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rp
m
ECM &
PSG Connection
Rang
e
(+)
(-)
99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(ECM
)
100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(ECM
)
No Connection
No Connection
105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(ECM
)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(ECM
)
No Connection
10-14V
6E63
CH1
0V
0V
CH2
0V
0V
0V
6E64
management system.
Engine Speed
Accelerator Pedal
Engine
Control
Module
(ECM)
Injection Timing
Injection Quantity
Response Signal
Additional Signal
Others
Additional Operations
Pump
Control
Unit
(PSG)
High Pressure
Solenoid Valve
Fuel Injection
(Mechanical)
Timing Device
To Timing Control Valve (TCV)
6E65
Fuel temperature
Pump speed
Cylinder identifier
233333
23333
2333
233
23
23 53 43 63 73 83 93 :3
+/%"<& ,'# -&=>? @A&B? C @-&$!5 1&"A'/BC
;3
233 223
6E66
723
7
623
6
523
5
423
4
123
1
41
43 51
53 61
63 71 73 31 33 81 83 91
,&<"= ,)('%')0 >?@ >+&$!5 /&"<'0A
93 :1
:3 ;1
;3 411
6E67
12222
1222
122
/32 /42
/12
12
12
42 32 52 62 72 82 92 :2
+.;'.& ))<".% ,&=> ?@&;A B ?,&$!4 0&"@'.;B
A/T 2WD
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 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.
6E68
(1)
(2)
(3)
(4)
(5)
(6)
To EGR Valve
From Vacuum Pump
EGR EVRV
EGR Cooler
Thermo Valve
EGR Valve
Injection quantity
Mass air flow
0.7ms
Time
6.4ms
Time
6E69
6E70
Cross-section View
Outline
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Drive Shaft
Feed Pump
Pump Camshaft Speed Sensor
Pump Control Unit (PSG)
Distributor Head
Constant Pressure Valve (CPV) Holder
High Pressure Solenoid Valve
Constant Pressure Valve (CPV)
Timing Control Valve (TCV)
Timer
Radial Plunger High Pressure Pump
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Drive Shaft
Feed Pump
Pump Camshaft Speed Sensor
Pump Control Unit (PSG)
Distributor Head
Constant Pressure Valve (CPV) Holder
High Pressure Solenoid Valve
Constant Pressure Valve (CPV)
Timing Control Valve (TCV)
Timer
Radial Plunger High Pressure Pump
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Rotor Shaft
Radial Plunger
High Pressure Passage
Low Pressure Inlet
Distributor Slit
Valve Needle
Barrel
Annular Passage
Fuel Return
High Pressure Solenoid Valve
High Pressure Outlet
Diaphram Chamber
Accumulator Diaphram
(1)
(2)
(3)
(4)
(5)
6E71
Fuel Suction
Regulating Valve
Overflow Valve
Feed Pump
To Fuel Tank
6E72
(1)
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(4)
(5)
+*&,-.
34**)
/0#1
/0#1
!"#,4";6
!-&6.-)
+1**2
7&%6
+*&,-.
8/+9:
6E73
(1)
(2)
(3)
(4)
The pump camshaft sensor signal has a tooth gap, and
the crankshaft position (CKP) sensor on the flywheel
housing is used as a reference signal of engine top
dead center (TDC) for the start timing of fuel delivery or
injection which is to be set.
Valve Needle
Magnet Anchor
Coil
High Pressure Passage
6E74
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cam Ring
Servo Valve
Timer Piston
Outlet
Feed Pump
Inlet
Fuel Suction
Ball Pin
Annular Chamber
Hydraulic Stopper
Return Passage
Timing Control Valve (TCV)
!"#!$ %&'(
!"#!$ )*$$(
!"#!$
+&!-0&,
2&(1,$
3 +24
51/*
+&!-0&,
6!#35)74
6E75
.#/#!"
+&!-0&,
;',<$
3.+;4
!"#!$ +&&,'!.$/*$0'-10$
(1)
(2)
(3)
(4)
(5)
Coil
From Annular Chamber
To Feed Pump
Orifice
Valve Needle
6E76
Overview
6E77
noises,
smells,
vibrations
or
Wiring schematics
6E78
Service manual
Technical equipment (for analyzing diagnostic data)
Digital multimeter and circuit testing tools
Essential and special tools
Service manual
subjected
to
extreme
Open/high resistance
connectors or grounds
in
terminals,
splices,
Open/high resistance in
connectors of grounds
Corrosion and wire damage:
Open/high resistance
connectors of grounds
Component failure:
in
terminals,
splices,
terminals,
splices,
at the component
Technical Assistance
Circuit testing tools
EMI/RFI
(Electromagnetic/radio
frequency
interference)
Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
external and internal system conditions to duplicate the
problem.
in
relays,
6E79
6E80
connector
kits/
Experience
Intermittent problem solving simulation methods
Customer complaint check sheet
2. Heat
Hints
You can isolate a circuit by:
service
manual
functional/diagnostic
6E81
6E82
Serviceability Issues
Non-OEM Parts
Perform a careful
visual and physical engine
compartment inspection when performing any
diagnostic procedure or diagnosing the cause of an
emission test failure. This can often lead to repairing a
problem without further steps.
Use the following
guidelines
when
performing
a
visual/physical
inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
6E83
History DTC
6E84
6E85
2. Tech 2 Connection
Check the key switch is turn OFF.
6E86
F0:
F1:
F2:
F3:
F4:
Main Menu
Diagnostic
Service Programming System (SPS)
View Capture Data
Tool Option
Download/ Upload Help
(3) 2003
(2) 2002
(1) 2001
(Y) 2000
(X) 1999
(W) 1998
Vehicle Identification
Vehicle Identification
(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Select (TF/UC).
Vehicle Identification
4JH1-TC Bosch
4JA1-TC Bosch
4JH1-T Denso
3.5L V6 6VE1 Hitachi
AW30-40LE
A/T JR405E
Select 4JA1-TC Bosch or 4JH1-TC Bosch in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.
F1: Relays
F2: Solenoids
DTC No.
P0100 Present
(7)
Mass Air Flow (MAF) Sensor
Voltage Supply Circuit High Input
Symptom Code
6E87
6E88
4JA1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter
Units
Idle
1500rpm
2000rpm
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Barometric Pressure
hpa
Desired
Quantity
mg/stk
Air
730
1475 1525
1975 2025
345 - 385
725 - 775
975 - 1025
4-6
6-8
Active
Active
Inactive 0V
Flow
mg/strk
380 - 420
360 - 400
380 - 420
Air
mg/strk
350
350
350 - 370
Depends
on altitude
Depends
on altitude
Depends
on altitude
8 - 10
5 - 10
5-9
Mass
Injection
8 - 10
6 - 10
7 - 10
10
Injection Quantity
mg/stk
11
deg. CA
2-4
2- 5
3-5
12
deg. CA
2-4
2-5
3-5
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg.
F
15
Intake
Temperature
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
16
Ignition Status
On12V/
Off0V
17
Brake Switch 1
Active/
Inactive
Air
deg. C / deg.
F
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.
Inactive
Inactive
Inactive
On 12V
On 12V
On 12V
Description
Brake Switch 2
Active/
Inactive
Inactive
Idle
1500rpm
2000rpm
19
Clutch Switch
Active/
Inactive
Inactive
Inactive
Inactive
20
Neutral Switch
On/Off
On
On
On
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V
22
Diagnostic Request
23
System Voltage
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
24
Main Relay
Active/
Inactive
Active
Active
Active
25
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
26
On/Off
Off
Off
Off
27
On/Off
Off
Off
Off
28
rpm
730
730
730
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
30
Immobilizer
Inactive
Inactive
Inactive
31
Immobilizer Signal
Active/
Inactive
Not
Received
Not
Received
Not
Received
32
Immobilizer Function
Programmed
Yes/ No
Yes
Yes
Yes
70
70
70
33
Tech 2 Parameter
Information
EGR Pulse
(Exhaust
Recirculation)
Units
Ratio
Gas
Received/
Not
Received
10 - 14
Inactive
10 - 14
Inactive
10 - 14
6E89
Description
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
This displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
upped.
This displays the duty signal from the ECM to control the
EGR flow amount.
6E90
4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter
Units
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Air
Idle
1500rpm
2000rpm
Definition
675 - 725
1475 1525
1975 2025
335 - 375
725 - 775
975 - 1025
3-5
5-7
Active
Active/
Inactive 0V
Inactive 0V
Flow
mg/strk
420 - 490
380 - 460
410 - 480
Air
mg/strk
430 - 470
380 - 420
410 - 470
Barometric Pressure
hpa
Desired
Quantity
mg/stk
Depends
on altitude
Depends
on altitude
Depends
on altitude
10
Injection Quantity
mg/stk
6 - 10
6 - 10
7 - 11
11
deg. CA
1-3
2-4
3-5
12
deg. CA
1-3
2-4
3-5
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85
14
Fuel Temperature
deg. C / deg.
F
15
Intake
Temperature
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
16
Ignition Status
On12V/
Off0V
17
Brake Switch 1
Active/
Inactive
Mass
Injection
Air
deg. C / deg.
F
6 - 10
6 - 10
7 - 11
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.
Inactive
Inactive
Inactive
On 12V
On 12V
On 12V
Units
Idle
1500rpm
2000rpm
Definition
This displays operating status of the brake switch. This
should display "Active" when the brake pedal is stepped
on.
18
Brake Switch 2
Active/
Inactive
Inactive
Inactive
Inactive
19
Active/
Inactive
Inactive
Inactive
Inactive
20
Neutral Switch
On/Off
On
On
On
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V
22
Diagnostic Request
23
System Voltage
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
24
Main Relay
Active/
Inactive
Active
Active
Active
25
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
26
On/Off
Off
Off
Off
27
On/Off
Off
Off
Off
28
rpm
700
700
700
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
30
Immobilizer
Inactive
Inactive
Inactive
31
Immobilizer Signal
Active/
Inactive
Not
Received
Not
Received
Not
Received
32
Immobilizer Function
Programmed
Yes
Yes
Yes
85 - 90
85 - 90
85 - 90
33
Information
EGR Pulse
(Exhaust
Recirculation)
Ratio
Gas
Received/
Not
Received
Yes/ No
%
6E91
10 - 15
10 - 15
10 - 15
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
This displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
upped.
This displays the duty signal from the ECM to control the
EGR flow amount.
6E92
MISCELLANEOUS TEST
470 mg/strk
Engine Speed
700 rpm
95%
450 mg/strk
Engine Speed
850 rpm
850 rpm
6E93
6E94
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
6E95
6E96
data
6E97
3.
6E98
6E99
IMPORTANT:
Perform the following checks before attempting to
program the control unit:
6E100
2. Demand of Data
3. Data Exchange
Model
Engine type
Transmission type
Immobilizer
Etc.
* 1: How to read the destination code
Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
the figure, the destination code can be read as "RR3"
(Australia).
6E101
4. Programming of ECM
6E102
"
#
(3) Breaker Box
6E103
6E104
"
Circuit Description
Diagnostic Aids
6E105
Test Description
6E106
2
3
4
5
6
7
Action
Value(s)
Yes
No
Go to Step 2
Go to No
CHECK
ENGINE Lamp
Go to Step 3
Go to Step 7
Go to Step 4
Go to CHECK
ENGINE LAMP
On Steady
Go to Step 5
Go to Engine
Cranks But Will
Not Run
Go to DTC
Chart
Refer to
SYMPTOM
DIAGNOSIS
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 8
Refer to
TYPICAL
SCAN DATA
B-58
Action
6E107
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 11
V V
10
6E108
Step
11
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
!"
C-56
!
!
B-58
12
13
Circuit Description
Diagnostic Aids
6E109
6E110
Step
1
Action
Value(s)
Yes
No
Verify repair
Go to Step 2
10-14.5V
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
42
V
3
4
and
ECM
C-56
42
B-24
17
Action
6E111
Value(s)
Yes
No
Verify repair
6E112
Circuit description
Diagnostic Aids
Action
the
meter connector
and
6E113
Value(s)
Yes
No
Go to Step 2
Go to Step 4
Verify repair
Go to Step 3
Verify repair
Verify repair
Go to Step 5
Verify repair
ECM
42
B-24
17
3
4
Code
P0100
P0105
Flash
Code
65
34
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
6E114
82/
85
85/
93
88/
92
83/
88
83
83
Related
ECM Pin
No.
Recovery Condition
P0115(1)
P0110(1)
P0110(1)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0105
P0110
P0115
P0180
Flash
Code
34
23
14
15
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
Recovery Condition
89
89/
93
84
84/
92
82
82
Related
ECM Pin
No.
P0105(1)
P0100(B)/
P0100(C)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E115
Code
P0215
P0216
52
54
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
No fail-safe function.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
No recovery.
Recovery Condition
Flash
Code
6E116
105
105
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0243
Flash
Code
64
ON
ON
ON
ON
MIL
Symptom
Code
Turbocharger Wastegate
Solenoid "A" Malfunction
Turbocharger Wastegate
Solenoid "A" Range/
Performance
Turbocharger Wastegate
Solenoid "A" Low
Turbocharger Wastegate
Solenoid "A" Range/
Performance
DTC Name
1. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
2. EGR control EVRV 0%
condition.
3. No DTC relating to MAF
sensor, vacuum sensor &
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow actual mass air flow is
less than -56mg/strk.)
1. Turbocharger wastegate
control EVRV
malfunction.
2. Vacuum regulating valve
malfunction.
3. Vacuum pump
malfunction.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
1. Turbocharger wastegate
actuator malfunction.
2. Vacuumlinemalfunction.
3. ECM malfunction.
1. Correct amount of mass
air flow. (= Correct boost
pressure condition)
(Desired mass air flow actual mass air flow is
more than -56mg/strk.)
1. Turbocharger wastegate
control EVRV
malfunction.
2. Vacuum line is
obstructed.
3. Vacuum is leaking.
4. Vacuum pump
malfunction.
5. Vacuum sensor
malfunction.
6. Turbocahrger wastegate
valve malfunction.
7. ECM malfunction.
Recovery Condition
85/
96
96
85/
96
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E117
Code
P0243
P0251
64
53
ON
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
Turbocharger Wastegate
Solenoid "A" High
DTC Name
1. No pump camshaft
speed sensor error.
2. No CKP sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is more
than 720rpm (4JA1-TC)
or 690rpm (4JH1-TC).
1. No pump camshaft
speed sensor error.
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection
quantity.
Flash
Code
6E118
1. No pump camshaft
speed sensor error.
2. No CKP sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is below
800rpm (4JA1-TC) or
690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
No fail-safe function.
Recovery Condition
99/
100
91
96
Related
ECM Pin
No.
P1650(A)/
P1651(B)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0335
P0380
Flash
Code
43
66
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
1. No pump camshaft
speed sensor error.
2. "Crankshaft Position
Sensor Circuit
Malfunction (Symptom
CodeB)" isnotstored.
3. Engine speed is 0rpm.
4. Doubled pump camshaft
speed is more than
50rpm.
No fail-safe function.
When intermittent
malfunction:
1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
When preliminary
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
Recovery Condition
ECM malfunction.
1. Engine over-running.
2. CKPsensormalfunction.
3. Pulser malfunction.
4. ECM malfunction.
94
90/
98/
101
90/
98/
101
90/
98/
101
Related
ECM Pin
No.
P1135 (A)
P1335 (A)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E119
Code
P0381
P0400
67
32
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
Flash
Code
6E120
ECM malfunction.
Recovery Condition
No fail-safe function.
97
88/
97
97
88/
97
43
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0500
P0560
Flash
Code
24
35
OFF
OFF
DTC Name
MIL
Symptom
Code
Recovery Condition
1. Charge system
malfunction.
2. Battery jump start cable
misconnect.
3. ECM malfunction.
1. VSS malfunction.
2. Speed meter
malfunction.
3. Electrical interference.
4. Magneticinterference.
5. ECM malfunction.
3/
39
3/
39
68
68
68
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E121
Code
P0560
P0561
P0602
P0606
35
18
28
OFF
ON
ON
OFF
OFF
MIL
Symptom
Code
ECU Malfunction
ECU Malfunction
Control Module
Programming Error
DTC Name
Flash
Code
6E122
No recovery.
Recovery Condition
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
ECM malfunction.
39
39
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P0645
P0703
P0704
P1105
Flash
Code
46
25
57
86
ON
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
DTC Name
No fail-safe function.
No fail-safe function.
No fail-safe function.
Recovery Condition
ECM malfunction.
ECM malfunction.
ECM malfunction.
31
65
30
41
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E123
Code
P1120
P1173
21
22
OFF
ON
OFF
ON
ON
OFF
ON
ON
MIL
Symptom
Code
Pedal/Throttle Position
Sensor Idle Position Switch
Error
Pedal/Throttle Position
Sensor Brake Switch Error
Pedal/Throttle Position
Sensor Voltage Supply
Circuit Low Input
Pedal/Throttle Position
Sensor Voltage Supply
Circuit High Input
Pedal/Throttle Position
Sensor Circuit High Input
DTC Name
Flash
Code
6E124
No fail-safe function.
No fail-safe function.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
1. Engine overheat.
2. ECTsensormalfunction.
3. ECM malfunction.
1. TPS malfunction.
2. Idle switch malfunction.
3. ECM malfunction.
1. When throttle position
sensor is 100%, idle
switch turns off.
2. When throttle position
sensor is 0%, idle switch
turns on.
1. Throttle sticking.
2. TPSincorrectadjusting.
3. TPS malfunction.
4. Brake switch
malfunction.
5. ECM malfunction.
Recovery Condition
89
38/
69
30/
38/
65
57
57
38/
49/
57
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P1335
P1345
P1520
P1605
Flash
Code
43
45
47
55
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
EEPROM Defect
DTC Name
No recovery.
No fail-safe function.
No fail-safe function.
Recovery Condition
No fail-safe function.
87
ECM malfunction.
87
ECM malfunction.
90/
91/
98/
101
Related
ECM Pin
No.
P0335(B)/
P0335(D)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E125
Code
P1605
P1610
P1611
P1612
P1613
P1614
P1625
55
56
56
56
56
56
76
OFF
OFF
ON
MIL
Symptom
Code
Immobilizer No or Wrong
Signal
Immobilizer No or Wrong
Signal
EEPROM Defect
DTC Name
Flash
Code
6E126
No fail-safe function.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
Recovery Condition
ECM malfunction.
1. ECM malfunction.
2. Immobilizer control unit
malfunction.
3. Transponder key
malfunction.
1. ECM malfunction.
2. Immobilizer control unit
malfunction.
3. Transponder key
malfunction.
ECM malfunction.
ECM malfunction.
3/
58
3/
58
27/
35
27/
35
Related
ECM Pin
No.
B****
B****
B****
B****
B****
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
Code
P1630
P1650
P1651
P1690
Flash
Code
51
44
45
77
OFF
OFF
ON
ON
ON
ON
ON
ON
MIL
Symptom
Code
CAN Malfunction
CAN Malfunction
DTC Name
No fail-safe function.
ECM malfunction.
42
99/
100
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
99/
100
Related
ECM Pin
No.
No recovery.
Recovery Condition
B****
P1650(A)
P1651(B)
Related
Multiple
DTC
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)
6E127
6E128
Condition for setting the DTC and action taken when the DTC sets
6E129
Flash
Code
Code
Symptom
Code
MIL
DTC Name
65
P0100
ON
ON
ON
ON
Circuit Description
The mass air flow (MAF) sensor is part of the intake air
system. It is fitted between the air cleaner and
turbocharger and measure the mass air flowing into the
engine.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
The ECM monitors the MAF sensor supply voltage and
MAF sensor output voltage. The supply voltage is out of
range, DTC P0100 (Symptom Code 7) or P0100
(Symptom Code 9) will be stored. The output voltage
excessively high or low, DTC P0100 (Symptom Code B)
or P0100 (Symptom Code C) will be stored.
Diagnostic Aids
Misrouted harness.
Rubbed through wire insulation.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
6E130
Step
3
5
6
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
Approximately
5.0V
Go to Step 11
Verify repair
Go to Step 8
C-116
92
2 3
83
88
Value(s)
V
7
C-116
4
83
Action
6E131
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 9
Verify repair
Verify repair
Go to Step 13
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair
9
10
C-116
4
83
11
12
13
14
6E132
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
Step
1
Action
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
88
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7
No
C-116
92
2 3
Yes
C-57(B)
Value(s)
83
Action
6E133
Value(s)
Yes
No
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair
8
9
C-116
10
11
12
13
83
6E134
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
88
83
No
C-116
92
2 3
Value(s)
Action
6E135
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8
C-116
!
!
!
C-116
88
6E136
Step
8
Yes
No
Verify repair
Go to Step 13
10-14.5V
Go to Step 11
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair
C-116
4
83
Value(s)
V
10
11
12
13
14
6E137
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
88
83
No
C-116
92
2 3
Value(s)
6E138
Step
6
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
C-116
!
C-116
92
V
Less than 1V
Action
Value(s)
6E139
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
V
9
10
11
12
6E140
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
34
Code
P0105
Symptom
Code
MIL
ON
ON
ON
ON
Circuit description
DTC Name
6E141
Diagnostic Aids
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside insulation.
Check for the following conditions:
6E142
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34)
Vacuum Pressure Sensor Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
C-57
No
C-124
"
&
%
$%
!#
!"
Action
6E143
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
the
vacuum
pressure
sensor
Breaker Box
93
C-124
"
sensor
C-57
C-124
$
"#
!
the
vacuum
pressure
sensor
C-124
Less than 1V
6E144
Step
8
pressure
Value(s)
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
sensor
C-124
9
10
11
12
pressure
sensor.
6E145
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34)
Vacuum Pressure Sensor Circuit Low Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
C-57
No
C-124
"
&
%
$%
!#
!"
6E146
6
the
vacuum
pressure
sensor
Breaker Box
85
C-124
"
!
!
sensor
C-57
C-124
$
"#
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8
!
!
the
vacuum
pressure
sensor
C-124
C-57
C-124
"#
9
10
11
12
6E147
Verify repair
Go to Step 11
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
6E148
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34)
Vacuum Pressure Sensor Voltage Supply Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
Approximately
5.0V
Go to Step 8
Go to Step 7
C-57
No
C-124
"
&
%
!#
$%
5
6
!"
the
vacuum
pressure
sensor
C-124
C-57
C-124
"#
8
9
10
11
6E149
Verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
6E150
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34)
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7
C-57
No
C-124
"
&
%
!#
$%
5
6
!"
the
vacuum
pressure
sensor
C-124
6E151
sensor
C-124
"
8
9
10
11
12
13
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair
6E152
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
23
Code
P0110
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
6E153
Misrouted harness.
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23)
Intake Air Temperature (IAT) Sensor Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
No
C-116
92
84
6E154
Step
6
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Verify repair
Go to Step 14
-20
13660
5430
20
2433
60
598
40
1153
80
334
100
204
IAT Sensor
1
1
V
8
84
C-116
Action
Value(s)
Yes
No
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair
C-116
84
10
6E155
V
Less than 1V
6E156
Step
11
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair
C-116
!
C-116
92
12
13
14
15
6E157
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23)
Intake Air Temperature (IAT) Sensor Circuit Low Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
No
C-116
92
84
6E158
Step
6
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8
-20
13660
5430
20
2433
60
598
40
1153
80
334
100
204
IAT Sensor
4
3
1
1
Action
6E159
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
Breaker Box
92
92
84
8
9
10
11
6E160
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
14
Code
P0115
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Engine Coolant Temperature
(ECT) Sensor Circuit High
Input
a high resistance.
The ECM supplies 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 output voltage excessively high or low, DTC P0115
(Symptom Code 1) or P0115 (Symptom Code 2) will be
stored.
6E161
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 1) (Flash Code 14)
Engine Coolant Temperature Sensor Circuit High Input
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
No
89
Value(s)
E-41
6E162
Step
6
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Verify repair
Go to Step 14
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2
V
8
89
E-41
Action
Value(s)
Yes
No
Verify repair
Go to Step 14
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-41
89
10
6E163
V
11
E-41
!
E-41
2
93
6E164
Step
12
13
14
15
Value(s)
Yes
No
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair
6E165
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 2) (Flash Code 14)
Engine Coolant Temperature Sensor Circuit Low Input
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
89
Value(s)
E-41
No
6E166
Step
6
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2
Action
6E167
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
Breaker Box
93
93
89
8
9
10
11
6E168
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
15
Code
P0180
Symptom
Code
B
MIL
DTC Name
ON
Circuit Description
Misrouted harness.
Diagnostic Aids
6E169
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
6E170
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
52
Code
P0215
Symptom
Code
MIL
DTC Name
ON
ON
ON
ON
Circuit Description
6E171
No fail-safe function.
Diagnostic Aids
Misrouted harness.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
6E172
Step
3
Value(s)
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E173
Diagnostic Trouble Code (DTC) P0215 (Symptom Code B) (Flash Code 52) Fuel
Cutoff Solenoid Valve Circuit High Input
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
Value(s)
C-57
No
E-6
6E174
Step
6
Value(s)
Yes
No
Less than 1V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 8
Verify repair
type B. (ECM
105
V
7
E-6
5
105
6E175
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6
Value(s)
C-57
No
E-6
6E176
Step
6
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Verify repair
the
PSG
(pump
control
unit)
E-6
!
!
105
E-6
6E177
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
6E178
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
54
Code
P0216
Symptom
Code
A
MIL
ON
ON
DTC Name
Injection Timing Control
Circuit Malfunction
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8
seconds.
2. Fluctuation of actual
injection timing is more
than +-5.2 deg. CA.
Circuit Description
Diagnostic Aids
6E179
6E180
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Verify repair
No
6
7
6E181
Action
Value(s)
Yes
No
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 11
6E182
Step
10
11
Value(s)
Yes
No
Verify repair
Verify repair
6E183
6E184
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
64
Code
P0243
Symptom
Code
3
MIL
ON
ON
ON
ON
ON
DTC Name
Turbocharger Wastegate
Solenoid "A" Range/
Performance
Turbocharger Wastegate
Solenoid "A" Low
Turbocharger Wastegate
Solenoid "A" Range/
Performance
Turbocharger Wastegate
Solenoid "A" Malfunction
Turbocharger Wastegate
Solenoid "A" High
2. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
2. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
1. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
2. EGR control EVRV 0%
condition.
Circuit description
Diagnostic Aids
6E185
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
Verify repair
No
6E186
Step
8
Value(s)
Yes
No
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 11
Go to Step 9
Go to Step 10
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair
Wastegate Solenoid
"
#
"
!
9
10
11
12
13
14
6E187
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Low
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 6
Go to Step 9
Value(s)
C-57
C-123
No
Wastegate Solenoid
"
#
"
6E188
Step
6
control
Value(s)
Yes
No
10 - 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 10
Go to Step 11
Verify repair
solenoid
Breaker Box
96
C-123
"
!
!
wastegate
control
solenoid
C-57
!"
C-123
#
$
$
10
12
Action
6E189
Value(s)
Yes
No
Verify repair
Go to Step 12
Verify repair
6E190
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14.7 - 16.1 !
at 20"C
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Verify repair
No
Wastegate Solenoid
"
#
"
!
6
7
8
wastegate
valve
Action
11
12
C-57
C-123
the
vacuum
pressure
Value(s)
Yes
No
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12
Less than 1V
Go to Step 15
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 15
Verify repair
Verify repair
Go to Step 16
Verify repair
6E191
sensor
C-124
13
14
15
16
6E192
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Malfunction
Step
1
6
7
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9
C-57
##
#$
No
C-116
!"
Value(s)
&
'
Action
Value(s)
6E193
Yes
No
Less than 1V
Go to Step 12
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Verify repair
C-116
10
11
12
13
IAT
sensor
assembly.
6E194
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" High
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Approximately
14.7- 16.1 ! at
20"C
Go to Step 6
Go to Step 8
Wastegate Solenoid
"
#
"
Action
6E195
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Verify repair
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
C-123
!
7
8
9
10
11
Repair
the
short
Is the action complete?
to
voltage
circuit.
6E196
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
53
Code
P0251
Symptom
Code
MIL
DTC Name
ON
ON
ON
ON
ON
ON
ON
Circuit Description
6E197
PSG (pump control unit) recognized high pressure solenoid valve drive circuit error.
No fail-safe function.
Diagnostic Aids
Misrouted harness.
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 6) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
6E198
Step
2
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E199
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 7) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
Code A)
Verify repair
No
Go to Step 5
E-6
91
Go to Step 6
6E200
Step
6
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8
CH1
0V"
CH2
0V"
Action
6E201
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
the
PSG
(pump
control
unit)
E-6
!
!
the
PSG
(pump
control
unit)
E-6
91
the
PSG
(pump
control
unit)
V
Less than 1V
6E202
Step
9
10
11
12
13
Value(s)
Yes
No
Remove the
accessory parts
and verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
6E203
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 9) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E204
Diagnostic Trouble Code (DTC) P0251 (Symptom Code A) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E205
Diagnostic Trouble Code (DTC) P0251 (Symptom Code B) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E206
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
6E207
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
Injection Pump Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Go to DTC
Chart P1650
(Symptom
Code A)
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Go to Step 5
6E208
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
43
Code
P0335
Symptom
Code
MIL
ON
DTC Name
6E209
ON
ON
Circuit Description
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit Malfunction
Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
6E210
Step
2
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Approximately
0.9k! at 20C
Go to Step 10
Go to Step 7
E-9
98
90
5
6
Breaker Box
98
98
90
Action
6E211
Value(s)
Yes
No
Approximately
0.9k! at 20C
Go to Step 8
Go to Step 14
Repair faulty
harness and
verify repair
Go to Step 9
Breaker Box
98
90
101
!
!
Breaker Box
E-9
98
"
!
!
!
6E212
Step
9
Value(s)
Yes
No
Less than 1V
Verify repair
Go to Step 13
Go to Step 11
Verify repair
Go to Step 12
V
10
Approximately 1.1 V at
2000rpm
0V"
11
12
Repair faulty
harness and
verify repair
Go to Step 13
14
15
16
17
Action
Value(s)
Yes
6E213
No
Remove the
accessory parts
and verify repair
Go to Step 14
Go to Step 15
Go to Step 16
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
6E214
Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43)
Engine Speed Input Circuit Range/Performance
Step
1
4
5
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
E-9
Explain the
reason of DTC
to the customer
Verify repair
No
Go to Step 5
98
90
Go to Step 6
Action
Value(s)
6E215
Yes
No
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Approximately 1.1 V at
2000rpm
0V"
8
9
10
11
12
Repair faulty
harness and
verify repair
Go to Step 9
Remove the
accessory parts
and verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
Go to Step 12
Verify repair
Go to Step 13
6E216
Step
13
Value(s)
Yes
No
Verify repair
6E217
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
66
Code
P0380
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Glow Relay Circuit Voltage
Low
Diagnostic Aids
Misrouted harness.
6E218
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66)
Glow Relay Circuit Voltage Low
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace glow
relay and verify
repair
X-5
94
Value(s)
No
3
4
Grow Relay
"
Approximately
105!
Action
6E219
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9
V
7
8
X-5
!
!
X-5
3
94
6E220
Step
9
10
Value(s)
Yes
No
Verify repair
Go to Step 10
Verify repair
6E221
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66)
Glow Relay Circuit Voltage High
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E222
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
67
Code
P0381
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Diagnostic Aids
Misrouted harness.
6E223
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67)
Glow Plug Indicator Circuit Voltage Low
Step
1
4
5
6
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7
No
6E224
Step
7
Yes
No
Verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
43
B-24
30
Value(s)
Using the DVM and check the glow time telltale circuit.
Breaker box is available:
1. Ignition Off, engine Off.
Breaker Box
43
B-24
!
!
43
6
B-24
10
Action
6E225
Value(s)
Yes
No
Verify repair
Go to Step 10
Verify repair
6E226
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67)
Glow Plug Indicator Circuit Voltage High
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E227
6E228
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
32
Code
P0400
Symptom
Code
MIL
ON
ON
ON
ON
Circuit Description
DTC Name
Diagnostic Aids
Misrouted harness.
Rubbed through wire insulation.
6E229
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32)
Exhaust Gas Recirculation Flow Excessive Detected
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
Verify repair
Approximately
14! at 20C
Go to Step 11
Go to Step 9
No
5
6
7
8
1
2
6E230
Step
9
10
11
Value(s)
Yes
No
Go to Step 10
Go to Step 11
Verify repair
Verify repair or
Go to Step 13
Go to Step 12
Verify repair or
Go to Step 13
Go to Step 14
Verify repair
Vacuum Pump:
Vacuum Pump
12
13
Small Window
15
Action
6E231
Value(s)
Yes
No
Verify repair
Go to Step 15
Verify repair
6E232
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32)
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 6
Go to Step 9
No
C-115
97
Value(s)
1
2
Action
6E233
Value(s)
Yes
No
10-14.5 V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 10
Go to Step 11
V
7
8
Breaker Box
97
!
!
C-115
2
97
6E234
Step
10
11
12
Value(s)
Yes
No
Verify repair
Verify repair
Go to Step 12
Verify repair
6E235
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32)
Exhaust Gas Recirculation Flow Insufficient Detected
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
No
1
2
6
7
6E236
Step
8
Value(s)
Yes
No
Verify repair or
Go to Step 10
Go to Step 9
Verify repair or
Go to Step 10
Go to Step 11
Verify repair
Tech 2:
Vacuum Pump:
Vacuum Pump
10
Small Window
Action
12
13
Value(s)
Yes
No
Verify repair
Go to Step 12
Go to Step 14
Go to Step 13
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair
Go to Step 15
Go to Step 16
Verify repair
Verify repair
Go to Step 17
Verify repair
C-116
92
2 3
88
6E237
83
V
14
15
16
17
6E238
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32)
Exhaust Gas Recirculation Circuit Short to Battery
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Approximately
14! at 20C
Go to Step 6
Go to Step 8
C-115
97
Value(s)
1
2
Action
6E239
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Verify repair
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
7
8
9
10
11
6E240
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
24
Code
P0500
Symptom
Code
1
MIL
DTC Name
ON
at next
ignition
cycle
ON
at next
ignition
cycle
ON
at next
ignition
cycle
6E241
Misrouted harness.
Circuit Description
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24)
Vehicle Speed Sensor Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
No
6E242
Step
4
6
7
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 15
Go to Step 7
Go to Step 8
Go to Step 7
Refer to
Diagnostic Aids
and Go to Step
15
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 8
Go to
Step 9
Go to
Step 10
Go to
Step 13
Go to
Step 12
0V"
8
9
Verify repair
Verify repair
Action
Value(s)
6E243
Yes
No
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Verify repair
Verify repair
Go to Step 14
Repair faulty
harness and
verify repair
V
11
E-44
3
12
13
meter connector
and
ECM
10
V
Less than 1V
6E244
Step
14
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Breaker Box
68
!"
!
!
the
meter connector
and
ECM
68
B-24
15
16
10
6E245
Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24)
Vehicle Speed Sensor Input Signal Frequency Too High
Step
1
4
5
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8
Go to Step 7
No
6E246
Step
7
Value(s)
Yes
No
Refer to
Diagnostic Aids
and Go to Step
10
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 8
Go to
Step 9
Go to
Step 10
Go to
Step 10
Go to
Step 11
0V"
8
9
10
11
12
Verify repair
Verify repair
Remove the
accessory parts
and verify repair
Go to Step 12
Verify repair
Verify repair
Go to Step 13
Action
6E247
Value(s)
Yes
No
Verify repair
6E248
Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24)
Vehicle Speed Sensor Incorrect Signal
Step
1
4
5
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 17
Go to Step 7
Verify repair
Go to Step 8
No
E-44
1
2
B-24
9 10
C-94(10)
10
Action
6E249
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 10
Go to Step 9
Refer to
Diagnostic Aids
and Go to Step
17
C-56
68
8
9
Voltage (V)
(AC Range)
Approximately 6.0
V at 20km/h
If No
Good
Go to
Step 10
Go to
Step 11
Go to
Step 12
Go to
Step 15
Go to
Step 14
0V"
10
Verify repair
6E250
Step
11
12
Value(s)
Yes
No
Verify repair
Less than 1V
Go to Step 13
Repair faulty
harness and
verify repair
Verify repair
Verify repair
V
13
and
meter
E-44
3
14
Action
Value(s)
and
6E251
Yes
No
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 17
ECM
3. Ignition On.
10
V
16
Breaker Box
68
!"
!
!
68
B-24
10
6E252
Step
17
18
Value(s)
Yes
No
Verify repair
Go to Step 18
Verify repair
6E253
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
35
Code
P0560
Symptom
Code
DTC Name
OFF
OFF
Circuit Description
MIL
OFF
6E254
Diagnostic Aids
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35)
System Voltage Too High
Step
1
4
5
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
No
jump
start
cable
incorrectly
Verify
procedure
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system
Verify repair
Go to Step 7
Action
6E255
Value(s)
Yes
No
Verify repair
6E256
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35)
System Voltage Too Low
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
10 - 14.5V
Go to Step 6
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system, charge
or replace the
battery
Verify repair
Go to Step 7
No
56
Action
Value(s)
6E257
Yes
No
120-150!
Go to Step 8
Replace ECM
main relay and
verify repair
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
"
#
"
10
6E258
Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35)
System Voltage Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
10 - 14.5V
Go to Step 7
Go to Step 6
No
E-6
6
E-6
V
7
Action
6E259
Value(s)
Yes
No
Verify repair
Go to Step 7
Verify repair
E-10
6E260
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
18
Code
P0561
Symptom
Code
MIL
DTC Name
OFF
OFF
Circuit Description
Diagnostic Aids
6E261
Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18)
Ignition Switch Circuit Malfunction
Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18)
Ignition Switch Circuit Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
No
6E262
Step
5
as
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
type A. (ECM
Breaker Box
39
!
!
!
39
C-107
Action
6E263
Value(s)
Yes
No
Verify repair
6E264
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
-
Code
P0602
Symptom
Code
MIL
DTC Name
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
Verify repair
6E265
Code
P0606
Symptom
Code
MIL
DTC Name
ON
ECM Malfunction
ON
ECM Malfunction
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
No
6E266
Step
5
Value(s)
Yes
No
Verify repair
6E267
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
6E268
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
46
Code
P0645
Symptom
Code
MIL
DTC Name
ON
ON
Circuit Description
Diagnostic Aids
6E269
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace A/C
compressor
relay and verify
repair
No
X-14
$
#
!
!"
"
#
"
120-150!
6E270
Step
6
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
V
7
Action
as
6E271
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
type A. (ECM
Breaker Box
41
!
"
"
C-56
!"
"
10
"
6E272
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair
6E273
6E274
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
25
Code
P0703
Symptom
Code
MIL
DTC Name
ON
ON
No fail-safe function.
Circuit Description
Diagnostic Aids
Misrouted harness.
Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25)
Brake Switch Circuit Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
4
5
Action
Value(s)
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity
Go to Step 7
Replace pedal
switch and
verify repair
10-14.5V
Go to Step 9
Go to Step 8
C-44
30
6
6E275
6E276
Step
8
Value(s)
Yes
No
Verify repair
Pedal is not
stepped on:
Less than 1V
Pedal stepped
on: 10-14.5V
Go to Step 12
Fixed at 1014.5V: Go to
Step 10
Fixed at less
than 1V: Go to
Step 11
Verify repair
Verify repair
type B. (ECM
V
10
30
11
C-44
30
C-44
13
Action
6E277
Value(s)
Yes
No
Verify repair
Go to Step 13
Verify repair
6E278
Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25)
Brake Switch Circuit Malfunction
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair
No
C-44
65
5
Value(s)
"
Pedal is not
stepped on:
No continuity
Pedal stepped
on: Continuity
Action
6E279
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Fixed at 1014.5V: Go to
Step 9
Fixed at less
than 1V: Go to
Step 10
V
7
8
as
type B. (ECM
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E280
Step
9
10
65
11
12
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
C-44
65
Value(s)
C-44
6E281
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
57
Code
P0704
Symptom
Code
6
MIL
ON
DTC Name
Clutch Switch Input Circuit
Malfunction
Circuit Description
Diagnostic Aids
6E282
Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57)
Clutch Switch Input Circuit Malfunction
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair
31
Value(s)
1
2
No
C-77
"
!
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity
Action
6E283
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Fixed at 1014.5V: Go to
Step 9
Fixed at less
than 1V: Go to
Step 10
V
7
8
type B. (ECM
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E284
Step
9
10
31
11
12
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
C-77
31
Value(s)
C-77
6E285
Code
P1105
Symptom
Code
MIL
DTC Name
ON
ON
Circuit Description
Diagnostic Aids
Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86)
Barometric Pressure Sensor Circuit High Input
Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86)
Barometric Pressure Sensor Circuit Low Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
6E286
Step
5
Value(s)
Yes
No
Verify repair
6E287
6E288
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
21
Code
P1120
Symptom
Code
MIL
ON
ON
ON
ON
ON
DTC Name
Circuit Description
Diagnostic Aids
Misrouted harness.
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 1) (Flash Code 21)
Pedal/Throttle Position Sensor Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
Action
Value(s)
6E289
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
49
39
57
E-22
2 3
6E290
Step
6
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14
Resistance (!)
Approximately 0.4k! at idle position
Approximately 4.0k! at WOT
TPS
3
2
2
V
8
57
E-22
Action
Value(s)
6E291
Yes
No
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair
V
10
Less than 1V
V
Less than 1V
6E292
Step
11
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair
E-22
!
!
!
the
TPS
connector
and
ECM
49
E-22
12
13
14
15
6E293
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
49
No
39
57
E-22
2 3
6E294
Step
6
Value(s)
Yes
No
Approximately
5.0V
Go to Step 12
Go to Step 7
Verify repair
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
Verify repair
V
7
57
E-22
8
9
10
11
6E295
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Step
1
Action
Value(s)
Yes
Go to Step 2
49
No
Go to On Board
Diagnostic
(OBD) System
Check
Refer to
Diagnostic Aids
Go to Step 3
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
39
57
E-22
2 3
6E296
Step
6
Value(s)
Yes
No
Approximately
5.0V
Go to Step 10
Go to Step 7
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
V
7
and
ECM
8
9
57
E-22
10
11
13
Action
6E297
Value(s)
Yes
No
Verify repair
Go to Step 13
Verify repair
6E298
Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake Switch Error
Step
1
8
9
10
11
12
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6
Verify repair
Go to Step 11
Go to Step 13
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 13
Verify repair
Go to Step 12
Go to Step 13
Verify repair
14
Action
6E299
Value(s)
Yes
No
Verify repair
Go to Step 14
Verify repair
6E300
Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21)
Pedal/Throttle Position Sensor Idle Position Switch Error
Step
1
4
5
8
9
10
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 8
Go to Step 5
Go to Step 7
Go to Step 6Go
to Step 6
Verify repair
Go to Step 8
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11
No
Action
6E301
Value(s)
Yes
No
Verify repair
6E302
Code
P1173
Symptom
Code
MIL
OFF
OFF
OFF
DTC Name
No fail-safe function.
No fail-safe function.
Circuit Description
Diagnostic Aids
Misrouted harness.
Rubbed through wire insulation.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
Action
Value(s)
6E303
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Repair the
cause of
overheat and
verify repair
Go to Step 9
Go to Step 6
Standard
resistance
Go to Step 9
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
Go to Step 10
Go to Step 5
-20
16100
5760
20
2370
60
537
40
1080
80
290
100
161
120
95
ECT Sensor
2
1
2
7
8
9
6E304
Step
10
Value(s)
Yes
No
Verify repair
6E305
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Diagnostic Trouble Code (DTC) P1173 (Symptom Code A) (Flash Code 22) Fuel
Reduction Caused By Low Fuel Temperature
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
6E306
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
43
Code
P1335
Symptom
Code
Circuit Description
MIL
ON
DTC Name
Diagnostic Aids
Misrouted harness.
6E307
Diagnostic Trouble Code (DTC) P1335 (Symptom Code A) (Flash Code 43)
Engine Speed Output Circuit Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code C)
Verify repair
No
Go to Step 5
E-6
91
Go to Step 6
6E308
Step
6
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8
CH1
0V
CH2
0V
Action
6E309
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
the
PSG
(pump
control
unit)
E-6
!
!
the
PSG
(pump
control
unit)
E-6
91
V
Less than 1V
6E310
Step
9
10
11
12
13
Value(s)
Yes
No
Remove the
accessory parts
and verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
6E311
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
45
Code
P1345
Symptom
Code
A
MIL
DTC Name
ON
Circuit Description
Diagnostic Aids
Misrouted harness.
6E312
Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45)
Camshaft Speed Malfunction
Step
1
5
6
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 6
Go to Step 5
Remove the
accessory parts
and verify repair
Go to Step 9
Verify repair
Go to Step 7
Go to Step 8
Go to Step 9
Verify repair
Verify repair
6E313
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
47
Code
P1520
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Neutral switch signal is inputted Off three times consecutively under driving
conditions.
Diagnostic Aids
6E314
Misrouted harness.
Diagnostic Trouble Code (DTC) P1520 (Symptom Code A) (Flash Code 47)
Neutral Switch ON Error
Diagnostic Trouble Code (DTC) P1520 (Symptom Code B) (Flash Code 47)
Neutral Switch OFF Error
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
No
Action
6E315
Value(s)
Yes
No
Verify repair
Go to Step 5
Go to Step 6
Replace neutral
switch (inhibitor
switch) and
verify repair
C-57
87
M/T
E-11
E-12
A/T
E-51
3
N range
M/T
E-11
E-12
A/T
3
6
10 9
7
8
Neutral (P or
N): Continuity
Other than
neutral (P or
N): No
continuity
6E316
Step
6
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Fixed at 1014.5V: Go to
Step 9
Fixed at less
than 1V: Go to
Step 10
A/T
E-51
M/T
E-12
V
7
type B. (ECM
E-6
!
!
A/T
E-51
V
V
Neutral (P or
N): 10-14.5V
Other than
neutral (P or
N): Less than
1V
Action
6E317
Value(s)
Yes
No
Verify repair
Verify repair
Verify repair
Go to Step 12
Verify repair
M/T
C-57
E-11
87
A/T
C-57
E-51
87
10
E-11
87
A/T
C-57
87
11
12
E-51
6E318
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
55
Code
P1605
Symptom
Code
MIL
DTC Name
ON
ON
EEPROM Defect
ON
EEPROM Defect
No fail-safe function.
diagnostics operation.
If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P1605 (Symptom Code C), P1605 (Symptom Code D)
or P1605 (Symptom Code E) will be stored.
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55)
EEPROM Defect
Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55)
EEPROM Defect
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
6E319
Action
Value(s)
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Verify repair
6E320
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
56
Code
P1610
Symptom
Code
Circuit Description
MIL
-
DTC Name
Security Key and Security
Code not Programmed
Diagnostic Aids
6E321
Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56)
Security Key and Security Code Not Programmed
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0002 or
B0009
Go to Step 5
Verify repair
Go to Step 6
Verify repair
No
6E322
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
56
Code
P1611
Symptom
Code
Circuit Description
MIL
DTC Name
Diagnostic Aids
6E323
Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56)
Wrong Security Code Entered
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6
Verify repair
No
6E324
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
56
Code
P1612
Symptom
Code
Circuit Description
MIL
DTC Name
Diagnostic Aids
6E325
Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5
Verify repair
Go to Step 6
No
42
35
B-68
6E326
Step
6
Value(s)
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair
V
Less than 1V
Action
6E327
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
B-68
!
!
42
B-68
6E328
Step
8
Value(s)
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 10
V
9
B-68
!
!
B-68
35
11
Action
6E329
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
6E330
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
56
Code
P1613
Symptom
Code
Circuit Description
MIL
DTC Name
Diagnostic Aids
6E331
Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6
No
42
35
B-68
6E332
Step
6
Value(s)
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair
V
Less than 1V
Action
6E333
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
B-68
!
!
42
B-68
V
Less than 1V
6E334
Step
9
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
B-68
!
!
B-68
10
11
35
6E335
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
56
Code
P1614
Symptom
Code
Circuit Description
MIL
-
DTC Name
Wrong Transponder Key
Diagnostic Aids
Poor connection at ECM and immobilizer control unitInspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
6E336
Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56)
Wrong Transponder Key
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6
Verify repair
No
6E337
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
76
Code
P1625
Symptom
Code
Circuit Description
MIL
DTC Name
OFF
OFF
Diagnostic Aids
Misrouted harness.
6E338
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76)
ECM Main Relay Switched Off Too Early
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Verify repair
No
6E339
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76)
ECM Main Relay Switched Off Too Late
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
No continuitly
Go to Step 5
Replace ECM
main relay and
verify repair
Verify repair
Go to Step 6
Verify repair
6E340
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
51
Code
P1630
Symptom
Code
MIL
DTC Name
ON
ON
Circuit Description
Diagnostic Aids
Misrouted harness.
6E341
Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction
Diagnostic Trouble Code (DTC) P1630 (Symptom Code B) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
No
6E342
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
44
Code
P1650
Symptom
Code
MIL
ON
ON
Circuit Description
DTC Name
Diagnostic Aids
Misrouted harness.
6E343
Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44)
CAN Device Offline
Step
1
Action
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 18
Go to Step 6
Go to Step 7
Repair faulty
harness and
verify repair
Value(s)
E-6
100
99
No
No continuity
6E344
Step
7
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
the
PSG
(pump
control
unit)
E-6
!
!
control
unit)
100
E-6
Action
6E345
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Go to Step 10
Go to Step 11
the
PSG
(pump
control
unit)
E-6
!
!
!
control
unit)
E-6
99
the
PSG
(pump
control
unit)
6E346
Step
10
Yes
No
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-6
100
11
Value(s)
control
unit)
V
12
E-6
99
13
the
PSG
(pump
control
unit)
15
16
17
18
Action
Value(s)
Yes
6E347
No
Remove the
accessory parts
and verify repair
Go to Step 15
Verify repair
Go to Step 16
Go to Step 17
Go to Step 18
Verify repair
Verify repair
6E348
Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44)
CAN Device Hang-up
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
6E349
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
45
Code
P1651
Symptom
Code
MIL
ON
CAN Malfunction
ON
CAN Malfunction
Circuit Description
DTC Name
systems to communicate.
Diagnostic Aids
6E350
Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45)
CAN Malfunction
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
No
6E351
Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45)
CAN Receives Error
Step
1
Action
100
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
C-57
Value(s)
Go to DTC
Chart P1650
(Symptom
Code A)
Verify repair
Go to Step 6
Go to Step 19
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 5
99
No
No continuity
6E352
Step
8
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
the
PSG
(pump
control
unit)
E-6
!
!
control
unit)
100
E-6
Action
6E353
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Go to Step 12
the
PSG
(pump
control
unit)
E-6
"
!
!
control
unit)
E-6
99
10
the
PSG
(pump
control
unit)
6E354
Step
11
Yes
No
Verify repair
Go to Step 13
Go to Step 14
Verify repair
Repair faulty
harness and
verify repair
Go to Step 15
E-6
100
12
Value(s)
the
PSG
(pump
control
unit)
V
13
E-6
99
14
the
PSG
(pump
control
unit)
16
17
18
19
Action
Value(s)
Yes
6E355
No
Remove the
accessory parts
and verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 19
Verify repair
Verify repair
6E356
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
77
Code
P1690
Symptom
Code
Circuit Description
MIL
DTC Name
OFF
OFF
Diagnostic Aids
6E357
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 4) (Flash Code 77)
Check Engine Lamp (MIL) Circuit Voltage Low
Step
1
4
5
6
7
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 7
Verify repair
Go to Step 7
Verify repair
Go to Step 8
17
42
B-24
6E358
Step
8
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10
!"
B-24
!
!
42
B-24
17
Action
6E359
Value(s)
Yes
No
Verify repair
6E360
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77)
Check Engine Lamp (MIL) Circuit Voltage High
Step
1
Action
Value(s)
Yes
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Go to Step 6
Verify repair
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
VISUAL/PHYSICAL CHECK
INTERMITTENT
6E361
6E362
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Go to Step 5
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Go to Step 6
8
9
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
11
Action
6E363
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
12
13
14
15
16
6E364
Step
17
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Repair as
necessary
18
19
Action
6E365
Value(s)
Yes
No
Verify repair
Go to Step 21
Verify repair
Go to Step 22
Go to Step 23
Go to Step 24
Verify repair
Verify repair
21
22
23
24
6E366
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.
Step
1
Action
Value(s)
Yes
Go to Step 2
Verify repair
Go to Step 4
No
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 20
Go to Step 9
Go to Step 20
Go to Step 10
Go to Step 6
6
7
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
11
12
13
14
Action
Yes
No
Go to Step 11
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Value(s)
6E367
6E368
Step
15
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 16
Replace the
injection nozzle
and verify repair
Go to Step 17
Verify repair
Go to Step 18
16
1 st Stage
4JA1-TC
4JH1-TC
17
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
19
Action
6E369
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 19
Adjust and
verify repair
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Verify repair
Visual/physical inspection
Tech 2 data
20
21
22
23
6E370
rpm
Rough Idle
Stall
time
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Desired
Engine Idle
Speed 25
rpm
Go to Step 7
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 5
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
10
11
12
13
6E371
Action
Value(s)
Yes
No
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 16
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Go to Step 35
Verify repair
Go to Step 21
Go to Step 17
14
15
16
6E372
Step
17
18
Value(s)
Yes
No
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Go to Step 36
Verify repair
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Go to Step 24
Go to Step 25
Verify repair
19
20
21
22
23
24
Action
6E373
Value(s)
Yes
No
Go to Step 29
Go to Step 26
High
Desired
Actual
Low
Time
6E374
Step
26
Value(s)
Yes
No
Verify repair
Go to Step 27
Verify repair
Go to Step 28
Verify repair
Go to Step 29
Verify repair
Go to Step 30
Vacuum Pump:
Vacuum Pump
27
28
29
Small Window
Action
6E375
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 32
Replace the
injection nozzle
and verify repair
Go to Step 32
Verify repair
Go to Step 33
31
1 st Stage
4JA1-TC
4JH1-TC
32
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
6E376
Step
33
34
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 34
Adjust and
verify repair
Verify repair
Go to Step 35
Verify repair
Go to Step 36
Go to Step 37
Go to Step 38
Verify repair
Verify repair
Visual/physical inspection
35
36
37
38
Tech 2 data
All electrical connections within a suspected circuit
and/or system
Was a problem found?
6E377
rpm
Surge
time
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 5
6
7
6E378
Step
8
10
11
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 29
Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 29
Verify repair
12
13
14
15
16
17
18
20
Action
6E379
Value(s)
Yes
No
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Go to Step 25
Go to Step 24
21
22
23
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time
6E380
Step
24
Value(s)
Yes
No
Verify repair
Go to Step 25
Verify repair
Go to Step 26
Verify repair
Go to Step 27
Tech 2:
Vacuum Pump:
Vacuum Pump
25
26
Small Window
Action
6E381
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 28
Verify repair
Go to Step 29
Verify repair
Go to Step 30
Go to Step 31
Go to Step 32
Verify repair
28
29
30
31
6E382
Step
32
Value(s)
Yes
No
Verify repair
6E383
Stumble
rpm
Sug
Hesitation
time
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 5
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
6E384
Step
8
10
11
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 31
Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 31
Verify repair
12
13
14
15
16
17
18
20
Action
6E385
Value(s)
Yes
No
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Go to Step 22
Go to Step 23
Verify repair
Go to Step 27
Go to Step 24
21
22
23
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time
6E386
Step
24
Value(s)
Yes
No
Verify repair
Go to Step 25
Verify repair
Go to Step 26
Verify repair
Go to Step 27
Verify repair
Go to Step 28
Vacuum Pump:
Vacuum Pump
25
26
27
Small Window
Action
6E387
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 29
Verify repair
Go to Step 30
Verify repair
Go to Step 31
Go to Step 32
Go to Step 33
Verify repair
29
30
31
32
6E388
Step
33
Value(s)
Yes
No
Verify repair
6E389
rpm
time
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 5
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
6E390
Step
7
Value(s)
Yes
No
Go to Step 11
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Go to Step 31
Verify repair
Go to Step 16
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Go to Step 15
Go to Step 31
Verify repair
Correct Speed
Unstable Data
Low
Time
9
10
11
12
13
14
15
17
18
6E391
Action
Value(s)
Yes
No
Go to Step 21
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Go to Step 31
Verify repair
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Go to Step 24
Go to Step 25
Verify repair
19
20
21
22
23
24
6E392
Step
25
Value(s)
Yes
No
Go to Step 29
Go to Step 26
Desired
Actual
Low
Time
Action
6E393
Value(s)
Yes
No
Verify repair
Go to Step 27
Verify repair
Go to Step 28
Verify repair
Go to Step 29
Tech 2:
Vacuum Pump:
Vacuum Pump
27
28
Small Window
6E394
Step
29
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 30
Verify repair
Go to Step 31
Verify repair
Go to Step 32
Go to Step 33
Go to Step 34
Verify repair
30
Visual/physical inspection
31
32
33
Tech 2 data
All electrical connections within a suspected circuit
and/or system
Was a problem found?
Action
6E395
Value(s)
Yes
No
Verify repair
6E396
DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 29
Go to Step 9
Go to Step 14
Go to Step 10
Go to Step 5
6
7
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
11
Action
6E397
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 29
Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Go to Step 18
Go to Step 30
Verify repair
12
13
14
15
16
17
18
6E398
Step
19
Value(s)
Yes
No
Go to Step 22
Go to Step 20
Verify repair
Go to Step 21
High
When accelerated
Desired
High
Actual
Low
Actual
Low
Time
20
Time
Vacuum Pump
Small Window
22
23
24
6E399
Action
Value(s)
Yes
No
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 25
6E400
Step
25
Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 26
Verify repair
Go to Step 27
0.4mm at cold
(In/Ex)
Go to Step 28
Adjust and
verify repair
Verify repair
Go to Step 29
1 st Stage
4JA1-TC
4JH1-TC
26
27
28
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
Visual/physical inspection
Tech 2 data
30
31
32
Action
6E401
Value(s)
Yes
No
Verify repair
Go to Step 30
Go to Step 31
Go to Step 32
Verify repair
Verify repair
6E402
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9
Verify repair
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
12
14
6E403
Action
Value(s)
Yes
No
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Go to Step 31
Go to Step 17
Go to Step 22
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
15
16
17
18
19
6E404
Step
20
21
22
23
24
25
26
27
Value(s)
Yes
No
Go to Step 21
Go to Step 31
Verify repair
Go to Step 27
Go to Step 23
Verify repair
Go to Step 24
Verify repair
Go to Step 25
Go to Step 26
Go to Step 31
Verify repair
Replace the
injection nozzle
and verify repair
Go to Step 28
1 st Stage
4JA1-TC
4JH1-TC
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
29
30
Action
6E405
Value(s)
Yes
No
Verify repair
Go to Step 29
0.4mm at cold
(In/Ex)
Go to Step 30
Adjust and
verify repair
Verify repair
Go to Step 31
Verify repair
Go to Step 32
Go to Step 33
Go to Step 34
Visual/physical inspection
Tech 2 data
31
32
6E406
Step
33
34
Value(s)
Yes
No
Verify repair
Verify repair
Step
1
Action
6
7
10
11
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?
6E407
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 30
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 5
6E408
Step
12
13
14
15
16
17
Value(s)
Yes
No
Go to Step 13
Go to Step 30
Verify repair
Go to Step 30
Go to Step 15
Go to Step 16
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
18
Action
6E409
Value(s)
Yes
No
Go to Step 20
Go to Step 21
Verify repair
Go to Step 23
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Verify repair
Go to Step 25
Desired
When accelerated
High
Desired
Actual
Low
Low
Time
22
23
24
Actu al
Time
6E410
Step
25
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 26
Replace the
injection nozzle
and verify repair
Go to Step 27
26
1 st Stage
4JA1-TC
4JH1-TC
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
28
29
Action
6E411
Value(s)
Yes
No
More than 20
Mpa
Verify repair
Go to Step 28
0.4mm at cold
(In/Ex)
Go to Step 29
Adjust and
verify repair
Verify repair
Go to Step 30
Verify repair
Go to Step 31
Go to Step 32
Go to Step 33
Visual/physical inspection
Tech 2 data
30
31
6E412
Step
32
33
Value(s)
Yes
No
Verify repair
Verify repair
Step
1
Action
6E413
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 21
Go to Step 9
Go to Step 14
Go to Step 10
Go to Step 5
6
7
6E414
Step
10
11
Value(s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 21
Verify repair
Go to Step 20
Go to Step 15
12
13
14
Desired
When accelerated
High
Actual
Low
Low
Time
Desired
Actual
Time
Action
6E415
Value(s)
Yes
No
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Tech 2:
Vacuum Pump:
Vacuum Pump
16
Small Window
6E416
Step
17
Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 18
More than 20
Mpa
Verify repair
Go to Step 19
0.4mm at cold
(In/Ex)
Go to Step 20
Adjust and
verify repair
Verify repair
Go to Step 21
1 st Stage
4JA1-TC
4JH1-TC
18
19
20
Approximatly
19.0 Mpa
Approximatly
19.5 Mpa
2nd Stage
Approximatly
33.5 Mpa
Approximatly
33.8 Mpa
Visual/physical inspection
Tech 2 data
22
23
24
Action
6E417
Value(s)
Yes
No
Verify repair
Go to Step 22
Go to Step 24
Go to Step 23
Verify repair
Verify repair
6E418
Location
Under the left-hand side seat.
Removal Procedure
Installation Procedure
tightening torque.
Tightening torque
Location
Installed to the clutch housing.
Location
Installed to the thermostat housing.
Removal Procedure
Removal Procedure
6E419
Installation Procedure
Installation Procedure
6E420
Location
Installed to the intake duct housing.
Location
Installed on the throttle body.
Removal Procedure
Removal Procedure
3. Loosen the clips and remove the MAF & IAT sensor
assembly from the intake duct housing.
Installation Procedure
Installation Procedure
Location
Back of the air cleaner case.
Removal Procedure
Installation Procedure
6E421
6E422
ILLUSTRATION
TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card
(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
EXHAUST SYSTEM 6F 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
6F 2 EXHAUST SYSTEM
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EXHAUST SYSTEM 6F 3
GENERAL DESCRIPTION
RTW46FLF000201
6F 4 EXHAUST SYSTEM
RTW46FLF000101
Removal Steps
EXHAUST SYSTEM 6F 5
Important Operations Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque
N!m (kg!m/lb!ft)
67 (6.8/49)
6F 6 EXHAUST SYSTEM
Catalytic Converter
EXHAUST SYSTEM 6F 7
GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
RTW46ELF001201
6F 8 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and emissions section for detail.
RTW46ELF001101
EXHAUST SYSTEM 6F 9
RTW46AMF000301
Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
Inspection point (Engine RPM)
RPM
Idling
2000
3250
ON
OFF
ON
OFF
ON
ON
ON
OFF
6F 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and
emissions section for detail.
RTW46EMF000701
INSPECTION
EXHAUST SYSTEM 6F 11
4JA1T(L)
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure
Less then 180 mmHg
Not operation
Operation
4JA1TC/4JH1TC
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance
# at 20C
14
RTW46ESH000301
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure 4JH1TC
Less than 250 mmHg
Not operation
Operation
Not operation
Operation
6F 12 EXHAUST SYSTEM
RTW46EMF000201
Removal Steps
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11.Gasket
12.EGR Cooler Adapter
EXHAUST SYSTEM 6F 13
RTW46EMF000901
Installation steps
8. Bolt
9. Gasket
10. EGR Valve Assembly
11. Bolt
12. EXH Manifold
13. Gasket
14. Bolt
6F 14 EXHAUST SYSTEM
Installation
1.
2.
3.
4.
N!m(kg!m/lb ft)
5. Gasket
6. EGR Pipe Assembly
7. Bolt
Tighten bolts temporarily.
8. Bolt
Tighten bolts temporarily.
9. Gasket
10. Bolt
Tighten bolts temporarily.
11.Gasket
12.Bolt
Tighten bolts temporarily.
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing
surface.
Bolt torque (Cooler-pipe) N!m(kg!m/lb ft)
27(2.8/20)
TURBOCHARGER
EXHAUST SYSTEM 6F 15
Model
Turbine type
Compressor type
4JA1T(L)
IHI RHF4H
190,000
4JA1TC
IHI RHF4H
Mixed type
4JH1TC
IHI RHF5
180,000
6F 16 EXHAUST SYSTEM
GENERAL DESCRIPTION
036LV002
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.
EXHAUST SYSTEM 6F 17
150RY00031
150RY00032
134.8/1011
147.7/1108
6F 18 EXHAUST SYSTEM
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the
compressor wheel end and the turbine wheel end.
Wheel Shaft End Play
mm (in)
Standard
0.03 - 0.06
(0.001 - 0.002)
150RY00034
0.09 (0.004)
0.056 - 0.127
(0.0022 - 0.0050)
150RY00036
Limit
Limit
0.127 (0.0050)
EXHAUST SYSTEM 6F 19
SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
5-8840-0075-0
901RX00143
TOOL NAME
Pressure Gauge
6F 20 EXHAUST SYSTEM
ACCELERATOR CONTROL
6H 1
SECTION 6H
ACCELERATOR CONTROL
TABLE OF CONTENTS
PAGE
Removal...................................................................................................................... 6H -
Installation.................................................................................................................. 6H -
Inspection................................................................................................................... 6H -
6H 2 ACCELERATOR CONTROL
RTW46HLF000301
ACCELERATOR CONTROL
6H 3
4JA1T(L)/LHD
RTW46HLF000601
6H 4 ACCELERATOR CONTROL
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
ACCELERATOR CONTROL
6H 5
4JA1TC, 4JH1TC/LHD
PTW46BMF000101
6H 6 ACCELERATOR CONTROL
Removal
Inspection
RTW46HMH000201
Installation
No. TF4JE-WE-0431