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    Lg4jjed-We - 4jj1 Euro 5 With DPD

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    Lg4jjed-We - 4jj1 Euro 5 With DPD

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    vik_md
    288 views379 pages

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    06. Lg4jjed-We - 4jj1 Euro 5 With Dpd

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    Lg4jjed-We - 4jj1 Euro 5 With DPD

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    vik_md

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    ISU2U 2009/2010MY Ni SERIES WORKSHOP MANUAL ENGINE CONTROL SYSTEM (4JJ1 model) ‘This Workshop Manual deals only with the screen toned section(s) in the table below. Section, ‘Sub Section 0 | GENERAL INFORMATION SUSPENSION General Information’ Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Emission Control Engine Exhaust Engine Lubrication Engine Speed Control System Induction Pre-Heating System Front Suspension Rear Suspension ‘Wheel and Tire System DRIVELINE/AXLE Front Differential Rear Differential Propeller Shaft Front Axle Rear Axle 7 “Transfer Case (Part Time) 4 | BRAKES Brake ‘Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR) Parking Brake Hill Start Aid (HSA) 5 | TRANSMISSION/TRANSAXLE, “Transmission Control System ‘Automatic Transmission Manual Transmission Clutch Side Power Take-Off STEERING Power Steering HVAC Heating and Ventilation fanual Air Conditioning Automatic Air Conditioning 8 | RESTRAINTS: Seat Belt ‘Supplemental Restraint System (SRS) ‘SRS Control System ‘9 | BODY, CAB AND ACCESSORIES Lighting System \Wiper/Washer System Entertainment Wiring System. Instrumentation/Driver Info. Body Structure Cab IH_| Seats Security and Lock Exterior/Interior Trim Cab Mounting [10| CONTROL SYSTEMS Vehicle Control 11] FRAME Frame Engine Control System (4JJ1) 14-1 Engine Control System (4JJ1) TABLE OF CONTENTS Spectications 1A3 DIC PORS (Flash Code 15). 10196 “Temperature vs Resistance. 1A3 DTC P0326 (Flash Code 15), 1139, Alitude vs Baromotc Pressure 14 DIC POGHO (Flash Cod 14), ern Diagnoste Trouble Code (OTC) Type DTC P0341 (Fiash Code 14) sania Definitions . 1A5 DTC P0380 (Flash Code 66). . 1A-146, Diagnostic Trouble: Code (ore) List|. 1A6 DTC P0381 (Flash Code 67). 10-148 Overview Wings 1&9 DIC PO4O! (Flash Code 93). 1161 Overviow Wings EINEUTiae pre po«0s (Fash Code 45). Taatsa Routing Diagrams = TESTA —— pr6 posos (Fash Code 44) taas7 Fucl Systom Routing Diagram 1AM DTC P0426 (Flash Code 143) 14-160 ‘Vacuum Hose Routing Diagram . 1A DTC P0427 or P0428 (Flash Code 48). .... 14-162 Component Locator... . 1A12 DTC P0428 (Flash Code 145) 1A-167, Engine Controls Component Views T1A12 DTC PO4ZC or POAZD (Flash Code 49) |... 14-169 Engine Contro! Module (ECM) Connector DTC P0477 or P0478 (Flash Code 46). 1At74 End Views 1A18 —_DTE.POSOO (Fiash Code 25) iat77 Engine Contiol Connecior End Views.....1. 14-20 DTC POSO2 or POSUS (Flash Code 26)... 4A-180 Diagnoste information and Procecures 1832 DTC POS60 (Fiash Code 155) 10-105 Engine Control System Check Sheet 14-32 DTC P0563 (Flash Code 35), 1A-189 Diagnostic Starting Point - Engine Controls . . 14-33. DTC P0601 (Flash Code 53). 1A-190 Dag Syst Gheck-EngineContls -1ASH_ DTC R602 ash Coe 14) ato Scan Tool Data List... 1A37 DTC P0604, POGUE oF POG Scan Tool Data Defntions - ttt (Flash Code 183, 51 or 36) 1as93 Scan Tool Output Controls AAT DTC PBS (Flash Code 176) sat94 Scan Tool Does Not Power Up LU 4m49 DTC 06GB (Flash Code 61)... 8195 Scan Tool Does Not Communicate with DTC POSH (Flash Code 55) sA-198 CAN Device : s1A50 DTC P0650 (Fiash Code 7)... Saa201 Engine Cranks but Does Not Run. 153 DTC POESI (Flash Code 56) 1208 DTC P0016 (Flash Cod 16) 155 DTC .PO685 oF POEGT (Flash Code 416)... 1A-207 DTC P0045 (Flash Code 33).........-.... 1A-57 DTC P0697 (Flash Code 57)... «10-210 DTC PO07S or PODBO (Flasn Code 38)... || 18-60 ‘DTC POTOO (Flash Cade 185) sans DTC P0087 (Flash Code 225). 14-63 DTC P1093 (Flash Code 227). 1A-215 DTC P0088 (Flash Code 118). 14-68 DTC P1261 or P1262 (Flash Code 34). 1A-220 DTC P0089 (Flash Code 151). 1473 DTC P1404 (Flash Code 48), 10-221 DIC P0081 or PODS? (Flash Code 247)... 1876 DIC P1456 (Flash Code 132) 1a223 DTC P0093 (Flash Code 227). 1&73 DTC P1471 (Flasn Code 149). 1a.225 DTC PO101 (Flash Code £2) 1A85 DTC P164B (Fiash Coco 179) sa228 DTC P0102 or P0103 (Flash Code 91)...... 14-88 DTC P1621 (Flash Code 54). . . «1-229 DTC P0112 or P0113 (Flash Code 22) . 1-82 DTC P1664 (Flash Code 76). 18-230 DTC P0116 (Flash Code 23). 14-96 DTC P1669 (Flash Code 75). 18-233 DTC P0117 or P0118 (Flash Code 23) 1098 DTC P2002 (Flash Code 127) 4A-238 DTC P0122 or P0123 (Flash Code 43). 1A-102 DTC P2122 or P2123 (Flash Code 121)... 10-241, DTC P0162 or PO18S (Flash Code 211)... 1A-108. DTC P2127 or P2128 (Flash Code 122)... 4A-245 DIC P0192 or P0183 (Flasn Code 245)... 1A-110-—«dDTC P2438 (Flash Code 124) 1a249 DTC P0201, P0202, P0203 or P0204 DTG P2146 or P2149 (Flash Code 271, 272, 273 or 274). 1A-114 (Flash Code 158 or 159). 1A-251 DTC P0217 (Flash Code 542). 1A-122, DTC P215A (Flash Code 25) ...... 10-256 DTC P0219 (Flash Code 543). 1124 DTC P2227 (Flash Code 71). 18-258 DTC P0234 (Flash Code 42) 1A126 DTC P2726 or P2229 (Flash Code 71)... 18-264 DTC P0237 or P0238 (Flash Code 92)... | 1A-120 DTC P242F (Flash Code 131) 18265 DTC P0299 (Flash Code 65). 18-133 DTC P2453 (Flash Code 141)...... «14-267 1A-2 Engine Control System (4JJ1) DTC P2454 or P2485 (Flash Code 47) DTC P2456 (Flash Code 47) DIC P2458 (Flash Code 199). ........ DIC P2527 or P2528 (Flash Code 233) DIG P253A (Flash Code 28) DTC P256A (Flash Code 31) DTC U0073 (Flash Code 84) |... DIC W001 (Flash Code 85)... DIC U0167 (Flash Code 177) EGR Control System Check Glow Control System Check. Engine Warm Up Control System Check Exhaust Brake Control System Check Diese! Particulate Defuser (DPD) Control System Check... oF ‘Symptoms - Engine Controls . ‘Symptoms - Engine Controls Intermittent Conditions Hard Start Rough, Unstable, or Incorrect Idle and Staling - High Idle Speed... Cuts Out Surges. Lack of Power, Sluggishness or Sponginess Hesitation, Sag or Stumble - ‘Abnormal Combustion Noise Poor Fusl Economy...» Excessive Smoke (Biack Smoke). Excessive Smoke (White Smoke)... DPD System Manual Regeneration Frequently DPD System Regeneration Long Time. . Repair Instructions Engine Contro! Module (ECM) Replacement Service Programming System (SPS) Description Service Programming System (SPS) (Remote Procedure)... . Service Programming System (SPS) (Pass-Thru Procedure) . . Description and Operation... Engine Gontrol Module (ECM) Description Engine Control Component Descristion Fuel System Description Fuel System Component Description . Fuel injection System Description. Exhaust Gas Recirculation (EGR) System Description Turbocharger Description .. 2.2... Diesel Particulate Defuser (DPD) ‘System Description Special Too's and Equipment ‘Special Tools and Equioment .......-. 10270 18275 10.277 14-280 10-285 1A288 1-292 14-295 14-297 14-208 14302 14-305 14-308 10314 14-320 14-320 10-322 14325 10.327 14-330 14-331 14333 14-335 14-337 10.339 14-340 14-342 14-344 10.346 10-348 14-350 14-350 14.352 14-353 14-354 14-356 14-356 14359 14.363 14-364 14-368 14-369 14-370 14.372 10.375 14.375 Engine Control System (4JJ1)_1A-3 Specifications ‘Temperature vs Resistance c * ‘Ohms Engine Coolant Temperature vs. Resistance Temperature vs. Resistance Value (Approximately) °c °F ores. (250 482 4300 “Temperature vs. Resistance Value (Approximately) 200 392 6500 120 248 15 150, 302 13900 110 230 150 100 212 33600 100 ea, 190 50, 122 106000 0 194 250 30 176 330 poe Tempersturn ee Recicianes 70 158 450 ea F ‘Onn 1 am = Temperature va. Resistance Value (Approximately) = iz a 70 230 740 a a mo 100 212 180 30 86 1730, 80 194 240 a = am 3 776 310 7 = 7 7 188 220 a 2 eno 80 140 50 = 7 e200 50 122 310 20 4 18700 40 ‘104 1150 30 -22 26500 5 88 ‘1880. 20 8 2450 Exhaust Temperature vs. Resistance 70 50 3700 *6 F Ohms 7 % 5740 ‘Temperature vs. Resistance Value (Approximately) 10 14 9160 7000 1832 720 20 = 15000 950 1742 735 “30 2 25400 900 652 755 a aaa aa Intake Air Temperature vs. Resistance ‘800 1472 205 a F Obes a a oa “Temperature vs. Resistance Vale (Approximately) = a = 100 212 90 650 1202 345 80 ite aa 600 qn12 426 80 176 320 ‘550 1022 530 fo 188 4a 500 932 675 £0 140 580 w as 288 50 72 B10 400 752 1200 a tos leo 350 662, 1710 30 86 ‘1650 300 572 (2580 20 bd ae 1A-4 Engine Control System (4JJ1) C F ‘Ohms: “Temperature vs, Resistance Value (Approximately) 10 50 3660 0 32 5550 “10 14 8970 -20 4 14700 Altitude vs Barometric Pressure Barometric Atituce Altitude Pressure. Measured in | Measured in | Measured in Meters (m) Feet (ft) Kilopascals (kPa) Determine your alttude by contacting a local weather station or by using another reference source, 4267 14000 56-84 3962 73000 56-06 3668 12000 61-69 3368 11000 4-72 3048 10000 66-74 2743 9000 69-77 2436 8000 778 2194 7000 74-82 7628 ‘6000 77-85 1524 5000 80-88 7218 4000 33-91 918 3000 87-95 610 2000 90-98 305 1000 84-102 0 0 Sea Level ‘96-104 “305 “1000 101-105 Engine Control System (4JJ1)_1A-5 Diagnostic Trouble Code (DTC) Type Definitions Emission Related DTC Action Taken When the DTC Sets - Type A + The ECM illuminates the maifunction indicator amp (MIL) when the diagnostic runs and fails. + The ECM records the operating conditions at the time the diagnostic fails. Tho ECM stores this information in the Freeze Frame/ Failure Records. Action Taken When the DTC Sots - Type B + The ECM iluminates the MIL on the second consecutive driving cycle when the diagnostic runs and fails + The ECM records the operating conditions at the time the diagnostic fails. The first time the ciagnostic falls, the ECM stores this information in the Fallure Records. If the diagnostic reports a failure on the second consecutive driving cycle, the ECM records the operating conditions at the time of failure and stores this information in the Freeze Frame and updates the Failure Records. Conditions for Clearing the MIL/ DTC - Type A or Type B + The ECM tums OFF the MIL after 3 consecutive ciriving cycles when the diagnostic runs and does rt fal + Acurrent DTC clears when the diagnostic runs and passes. + Ahistory DTC clears after 40 consecutive warm-up cycles, ifno failures are reported. + Use a scan too! to clear the MIL and the DTC. Non-Emissions Related DTCs Action Taken When the DTC Sets - Type C + The ECM illuminates the Service Vehicle Soon (SVS) lamp when the diagnostic runs and fails + The ECM records the operating conditions at the time the diagnostic fails. The ECM stores this information in the Failure Records. Conditions for Clearing the SVS Lamp/ DTC - Type c + The ECM turns OFF the SVS lamp after 1 driving cycle when the diagnostic runs and does not fail. + Acurrent DTC clears when the diagnostic runs and asses. + Ahistory DTC clears after 40 consecutive warm-up eycies, ifn failures are reported. + Use a scan tool to clear the SVS lamp and the pre. Action Taken When the DTC Sets - Type D + The ECM will not illuminate the MIL or SVS lamp. + The ECM records the operating conditions at the: time the diagnostic fails. The ECM stores this information in the Failure Records. Conditions for Clearing the DTC - Type D + Acurrent DTC clears when the diagnostic runs and passes. + Ahistory OTC clears after 40 consecutive warm-up, cycles, if no fallures are reported. + Use a scan tool to clear the DTC. 1-6 Engine Control System (4JJ1) Diagnostic Trouble Code (DTC) List DIC | Flash Gode | DTC Type DIC Descriptor Poo | 16 ‘A__ | Crankshaft Position - Camshaft Position Correlation Po0as | a8 ‘A__| Turbocharger Boost Control Solenoid Circuit P0079 | 38 ‘A | Exhaust Valve Control Solenoid Circuit Low Pooeo | 38 ‘A | Exhaust Valve Control Solenoid Gireuit High poo? | 225 B | Fuel Rail System Pressure Too Low Pooss | 118 ‘| Fuel Rail System Pressure Too High P0089 | 151 B | Fuel Pressure Regulator Performance poost | 247 ‘A | Fuel Pressure Regulator Control Circuit Low o0a2 | __287 ‘A | Fuel Pressure Regulator Control Giroult High PO08S | _227 B | Fuel System Leak Detected Pott] 92 B | Mass Air Flow Sensor Circuit Rangel Performance Pot2| 91 ‘A___ | Mass Air Flow Sensor Circuit Low Input Pots | 7 A__ | Mass Air Flow Sensor Circuit High Input Pou] 22 ‘A_| Intake Air Temperature Sensor Circuit Low Poms | 22 ‘A_| Intake Air Temperature Sensor Circuit High Poe) 2 B _ | Engine Coolant Temperature Sensor Circuit Rangel Performance Pot? | 23 ‘A___ | Engine Coolant Temperature Sensor Circuit Low Poms | 23 ‘A [Engine Coolant Temperature Sensor Gircult High Poi | 43, ‘A__| Thwottie Position Sensor Gircult Low pois | 43 ‘A__| Throttle Position Sensor Circuit High pote2 | 217 ‘A ___ | Fuel Temperature Sensor Circuit Low potas | 211 ‘A___ | Fuel Temperature Sensor Circuit High pois? | 245 ‘A___ | Fuel Rail Pressure Sensor Circuit Low Pots | 245 ‘| Fuel Rail Pressure Sensor Circult High Po2ot | 271 ‘A | Injector Circuit Open - Cylinder 1 P0202 | 272 ‘A___| Injector Circuit Open - Cylinder 2 Po203 | 273 ‘A__ | Injactor Circuit Open - Cylinder 3 Po204 | 274 ‘A___ | Injactor Circuit Open - Cylinder 4 Po2i7 | 542 D___ | Engine Coolant Over Temperature Condition Po219 | 543 D__ | Engine Overspeed Condition o2ae | 42, ‘A | Turbocharger Overbaost Condition p27 | 32 ‘A__ | Turbo Charger Boost Sensor Circuit Low P0238 | a2 ‘| Turbo Charger Boost Sensor Circuit High P0209 | 68 B_| Turbocharger Underboost P0335 | 15 ‘A__| Crankshaft Position Sensor Circuit P0336 | 15 ‘A___| Crankshaft Position Sensor Circuit Range! Performance oso | 14 ‘A | Camshait Position Sensor Circuit Engine Control System (4JJ1)_1A-7 DTG | Flash Gode | DTC Type DTC Descriptor Posdt | 14 ‘A | Gamshait Position Sensor Cirouit Range! Performance P0380 | 66 Glow Plug Circuit poset | 67 C [Glow Plug Indicator Cirouit Poaot | 93 ‘A [EGR Flow Insufficient Detected P0404 | 45 ‘A___ [EGR Control Circuit Range! Performance Poaog| 44 ‘A | EGR Position Sensor Circuit P0426 | 143 | Catalyst Temperature Sensor Gircult Range! Performance Sensor 1 oar) 48 ‘A | Catalyst Temperature Sensor Circuit Low Sensor 1 P0428) 48 ‘A | Catalyst Temperature Sensor Gircuit High Sensor 1 Pow2e | 145 C__| Catalyst Temperature Sensor Circuit Rangei Performance Sensor 2 poazc| 49 C | Catalyst Temperature Sensor Circuit Low Sensor 2 poaad| 49 C | Catalyst Temperature Sensor Circuit High Sensor 2 Poa? | 46 ‘A___| Exhaust Pressure Control Valve Low Poa7a| 46 ‘A___ | Exhaust Pressure Control Valve High P0500 | 25 ‘A | Vehicle Speed Sensor Pos02 | 25 ‘A | Vehicle Speed Sensor Circuit Low Input Osos | 28 ‘A__| Vehicle Speed Sensor Circuit High input POs60 | _155 | System vonage P0563 | 35 © | System Voltage High Posot | 63 ‘A___|Inteinal Control Module Memory Check Sum Error PO602 | 154 © __| Control Module Programming Error Pos | 153 ‘A | Intemal Control Module RAM Error Po606 | 87 ‘A | ECM Processor Po60B | 96 ‘A__| Internal Control Module A/D Processing Performance P0633 | _176 D__| Immobilizer Not Programmed Po6as | __67 A_| Throitle Actuator Control Ranga/ Performance Poeat | 55 ‘A___ | Sensor Reference Voltage 1 Circut P0650 | 77 ‘A___| Malfunction Indicator Lamp (MIL) Control Circuit Post | 88 ‘A__|Sensor Reference Voltage 2 Circuit POsaS | 416 C__ [ECM Power Relay Control Circuit Open Poss? | _416 © __ | ECM Power Relay Control Gircult High Poe? | a7 ‘A | Sensor Reference Voltage 3 Circult po700 | 185 ‘A__| Transmission Control System Emissions Related Malfunction P1083 | __227 B | Fuel Rail Pressure Too Low Pizet| 34 ‘A | Injoctor Positive Voltage Control Circuit Group 1 Pi262| 34 ‘A | Injector Positive Voltage Control Circuit Group 2 140s | 45 ‘A__ [EGR Postion Fault (Closed Position Error) pias] 45 ‘A__ [EGR Postion Fault (Learned Position Eror) es A___|PM Over Accumulation 1A-8 Engine Control System (4JJ1) DTG | Flash Code | OTC Type DTG Descriptor Pia7t| 149 ‘A [DPD Insufficient Regeneration Pieia| 179 Immobilizer Wrong Response Pie2i| 54 ‘A | Control Module Long Term Memory Performance Pies4 | 76 C___| Service Vehicle Soon Lamp Control Circuit Pies | 75 ©__ [DPD Lamp Control Circuit P2002 [127 ‘A__ | Partioulate Trap Efficiency Below Threshold P2122 | 124 ‘A__ | Pedal Position Sensor 1 Circuit Low Input P2123 | 124 ‘A__ | Pedal Position Sensor + Gircult High Input Paia7 | 122 ‘A | Pedal Position Sensor 2 Gircuil Low Input P2128 | 122 ‘A__ | Pedal Position Sensor 2 Circuit High Input P2ise | 126 ‘A__ | Pedal Position Sensor 1-2 Voltage Correlation p2ia6 | 158 ‘A__ | Fuel Injector Group 1 Supply Voltage Circuit P23 | 159 ‘A_ | Fuel Injector Group 2 Supply Voltage Circuit Poa] 2 ‘A___ | Vehicle Speed - Wheel Speed Correlation Por | Ti 'B | Barometric Pressure Sensor Circuit Range’ Performance P2228 | 71 ‘A__ | Barometric Pressure Sensor Circuit Low Pama] 71 ‘A__ | Barometric Pressure Sensor Circuit High P2a2F | 13h ‘A__ [DPD Restriction P2ag3 | 144 ‘A__| DPD Differential Pressure Sensor Circuit Range’ Performance Poise | AT ‘A___ [DPD Differential Pressure Sensor Circuit Low p2ass | 47 ‘__ [DPD Differential Pressure Sensor Circuit High P2456 | 47 ‘A___ [DPD Differential Pressure Sensor Leamed Position P2458 | 139 ‘A [DPD Regeneration Duration P2527 | 233 ‘A_| Vacuum Pressure Sensor Circuit Low P2528 | 233 ‘_| Vacuum Pressure Sensor Circuit High P25aA| 28 © __ [PTO Sensor Circuit P25GA| at ©_ [Engine Idle Speed Selector Sensor woos | _s B__ | Control Module Communication Bus OF voit | 85 ‘A__ [Lost Communication with TEM uo? | 177 D___ | Lost Gommunication With Vehicle Immobilizer Control Module Engine Control System (4JJ1) _1A-9 Overview Wirings Overview Wirings 42 towsdomeene Bb Eom hana z @ a} Gas e Wren . g a i Spel ca Toa] [Paar | Eno] aes lo [-——___ 1A-10 Engine Control System (4JJ1) 212 990 ©O 2EO To © @© 11 senanatsemsion CAC L ai SS Engine Control System (4JJ1)_1A-11 Legend 1. Fuel rail 8. Fuel tank 2. Pressure limiter valve 8. Vent valve 3. Leak off pipe 410. Pre-fue iter with sedimenter 4. Fuel injector 44. Priming pump: 5. Fuel cooler 42. Fuel fiter with water separator 8. Fuol retum pipe 48, Return fue! low back valve 7. Fuel feed pipe 14, Fuel supply pump Vacuum Hose Routing Diagram 2 r 3 ‘Vacuum pressure sensor 5. 2. Turbocharger nozzle control solenoid valve 6 3. Vacuum pipe 7 4. Brake booster Vacuum pump ‘Actuator control vacuum hose “Turoacharger nozzle cantrol actuator 1A-12_Engine Control System (4JJ1) Component Locator Engine Controls Component Views Legend ‘1. Barometric pressure (BARO) sensor 2. Accelerator pedal position (APP) sensor Legend 1. Fuel injector No.1 cylinder 2. Fuel injector No.2 cylinder 3. Fuel injector No.3 cylinder 4. Fuel injector No.4 cylinder Exhaust gas recirculation (EGR) valve Intake throttle vaive . Turbocharger nozzle control solenoid valve Boost pressure sensor Engine Control System (4JJ1)_1A-13 id 1 Variable nozzle turbocharger (VNT) vacuum 2. Engine coolant temperature (ECT) sensor pressure sensor 3. Camshaft position (CMP) sensor Legend 1. Fuel ral pressure (FRP) regulator 2. Fuel temperature (FT) sensor 3. Pressure limiter valve 4, Fuel rail pressure (FRP) sensor 5. Engine oil pressure switch 6. Crankshaft postion (CKP) sensor 7. Engine oil level switch 1A-14 Engine Control System (4JJ1) Legend 1. Exhaust brake valve 4. Exhaust diferential pressure sensor 2. Exhaust temperature sensor 2 (in front of oxygen 5. Exhaust throtte valve catalyst) 6. DPD assembly 3. Exhaust temperature sensor 1 (in front of fiter) Legend 1. Mass air flow (MAF) sensor! intake air temperature (IAT) sensor Engine Control System (4JJ1) 14-15 Legend 1. Vehicle speed sensor (VSS) (without ABS model) Legend 1. CAN resistor (LHD) (with immobilizer model) 2. CAN resistor (RHD) (with immobilizer model) 44-16 _Engine Control System (4JJ1) NLR, NMR model id 11. Engine control module (ECM) 2. Dropping resistor NNR, NPR mode! id 1. Engine control module (ECM) 2. Dropping resistor Engine Control System (4JJ1) 14-17 NLS model id 1. Engine control module (ECM) 41-18 Engine Control System (4JJ1) Engine Control Module (ECM) Connector ‘Connector No. 4 End Views; ‘Connector color Black Engine Contra Modul (ECM) Tost depo o 738616 8 Pin No [Wee cobr | Pinfinaon 77 _| BAN’ GRAN [SVS lp cons 78] LUT WT | GAN fig signa VSS signal {without ABS) or 10 | yeu oR | encle ona sonal fom EHCU (with ABS) APP sensor, up sear 20 [aux war |ond P70 thot sursr ad ground 24 | BLUPYEL | ECM main ray cond 22 | BLK |WAF senoriow reference 28 | RED’ BLU WAF sensor 1 vos reference 24 BOTBLU |nionvotage 2} —|htused Conner No a 2 [wir euic| Out pode oni sina Genrer cor Bick >t+—_ Test aap TISSI6SIR a Pin No. | Wire color Pin function| 22) | cae | Meier Seosieior swat etinel 7 | BUR [EGR ponor gun 2} ~~ |Retusee a 30 | Rete ot BRN’ | water separator lamp control 3 BLK ECM power ground WHT - a 7 [BIR] EGHT poner ground a] [Reed co 38 BLUTBLK | Retigeraarsvich oar 34 [BRN YEL [AC signal BEL BLK: | Mit control 35 GRN__| Dropping resistor 7 BRN! | Exhaust brake lamp control 36 Not used BRA Leave bak amp conto = 8 | _LTGRN [Engine speed signal output Sr | BLU [GAM ewelonel 3] |e 3 OPO antoriomp conta ue se eux waar | APP snsar Band BARO a sons sl rove 0 iow iy cone oan TO] BLUTYET | ECHT manny cont 3 [ORE [So 1 | p1urneD | ond p10 mot arcor ow rere 8 = Lacie APP sensor 1, idle up sensor 14 [BLKIRED | Saree oy cone a2 | aw |Srspromaie sence Sts 15 WHT! | Exhaust brake solenoid valve seterence, ED | cone! S| BK [ec signal rear 6 BLU VEC |i i oval ap con | OTT | PTO ach ira Engine Control System (4JJ1) 14-19 ‘Connector No 4 Connector No. a Connector color Black Connector color Black Test adapior No. 535616648 “Test adaptor No. F356 16-644, Pin No. | Wire color Pin function Pin No, | Wire color Pin function 45 | ULGRN' | echaust brake switch signal a = _|Notused 76 =_[Netused 45 | BLK/WHT | ignition switch signal a — tose 47 | BLU/ war | BED regeneration ewich 78 | GRN | CAN low signal [VEL |Parng bre sch agral Exhaust diferenal resure 49 = | Not usec 72 | BLK | sensor 1 and exhaust | BERTGRN | Noa awich sonal temperature sensor ow 51 | BRN/RED | Engine warm up switch signal co | WAT | Exhaust dirt wessire 52 BLK/WHT [Diagnostic request ewitch ORN | sensor 5 volts reference 52 _| VIOVVEL [Engine olllevel switch signal ai | BLK [ECM case ground 54 = [Not usec % = [Netusea 3 =__ | Notused a = __ | Netused 58 | Giny |CAN high signal % = | Notused Bas co | Re dint once onrtronce oa er | ern [APP sensor2 and BARO sensor 5 volts reference | BLK _[ECMaignal ground @3_ [BLU WHT [APP sensor 1 signal | WHT [APP sensor 2 signal ee es = | Notused 6 _| VEL GRN | lle up sensor signal Connector No. 2 or | rex [Exhaust ire esse Connector color Black “Tost adaptor No. T3561 64A o | BLK {Ground Pin No, | Wire color Pin function Ge" || WHE _|MAReensor shane! 32 _ | BLU/WHT | FRP sencor signal 70 | YEL | PTO tvatlle sensor signal i 71 | WHT! aaR0 sensor signal WHT ° @4_| GRNIYEL | ECT sonsor signal 72,_| BLUIBUK IAT sensor signal a5 | ior war | intake throte postion sensor 73 | veu nen [Fausto sre sensor signal a6 = |[Netusea 7 | we [Exheetenporse sensor? 414-20 _Engine Control System (4JJ1) ‘Connector No E72 Connector No. E72 Connector color Black Connector color Black Test adapier No. 535616648 “Test adaptor No. F356 16-644, Pin No. | Wire color Pin function Pin No, | Wire color Pin function GMP sensor, FRP sensor and (GKP sensor, intake throtte 87 | LTGRN [EGR postion sensor 5 vols position sensor, FT sensor, reference 109 | BLK | VNT vacuum pressure sensor, ECT sensor and boost 86 = _|Notused pressure sensor low reference 89! [GR RED | FAP remilelor ow side 710 | WHT _ | EGR solenoid control 3 PWM) BO) BULLET, | FRP\seneor.signel 777 BLK ORN [EGR solenoid contra 1 (PWN) 31 _| RED _ | Boost pressure sensor signal 2 Ie Intake trotie solenoid drive LK! GRN a2 | GRN | VNT vacuum pressure sensor voltage sional 4a. | WHT) [ERP regulator contol high 93 | LTBLU [EGR positon sensor signal 2 RED _ | side (PWM) a4 | WHT! TeGR postion sensor signal 1 tt = _|Netieed 115 =__[Netused ‘GKP sensor, intake throtle Sa postonsensor viTvacium | | 6 | Rep | Conmon2 (ander Rand 95 | VEL | pressure sensor and boost ) fuel ine ge voltage pressure sensor 5 volts 417 | WHT YEL | Gylinder #4 fuel injector control saterence, Te BLK | Cylinder #2 fuel injector contrl g8 | WHT) _| Turbocharger nozzle contol GANT GRN _ | solenoid valve control (PWM) 119 | Qi | Cylinder #1 tuet injector control B7’_| SRN/ RED [PRP regulator tow side 720__| BLKIBLU | Oyiinder #3 fuel injector control 3 [BLU/WHT | GMP sensor signal carina 1 GRE aR UT GRNT Tt | WHT | 44) fuel injector charge volta 99 EGR position sensor signal 3 fuel injector charge voltage BLK 100 Bik) | GME senserand ERP ssneot Engine Control Connector End Views shield ground 101 | YELBLK CMP sensor, FRP sensor and EGR position sensor low reference ta | SRN [Exacta stenic vate 103_| _ORN | EGRsolenoid control 2 (PWM) 104 | can | she rote senod iow 105. | WHT! [FRP regulator contro! high RED {side (PWM) 108 = _ [Not used 107 | RED/BLU (CKP sensor signal 108 | BLK (CKP sensor and boost pressure sensor shield ground Accelerator Pedal Position (APP) Sensor Engine Control System (4JJ1) 14-21 Connector No 85 Tonnecor color Gay Test adaptor Tas6T3E Piano | Wire cor Pin funcon ee Z_ [VEL [APP sensor? signal 3_ [BLU [APP sensor 2 fw eforonce 4 | Ue [veto retoroce 3 [RED [APP sensor signal &_|_wHt [APP sensor ow eference Barometric Pressure (BARO) Sensor Boost Pressure Sensor Conner No ea Garner cor Blak Test adoro fo od Fin No. | Wre or | Bn fnction 1 [BLU | Sensortoweterenco 2 | WET | sensor sina 3 [ea [ Sensor oi tres ‘Connector No. E24 ‘Connector color Black “Test adapter No, ¥36616-33 Pin No. | Wire color Pin function i RED _| Sensor signal BLK | Sensor low reference YEL__ | Sensor 5 volts reference Cluteh Switeh 1A-22 _Engine Control System (4JJ1) ‘Connector No. Bret Connector color White Test adapter No. F3561642 Pin No. | Wire color Pin function 7 | BLK/ORN | Ignition voltage feed 2 _ | WHT/BLK | Switch signal Camshaft Position (CMP) Sensor Connector No. E18 Connector color Black Test adapter No. 3561633 Pin No. | Wire color Pin function 1 | BLU/WHT | Sensor signal 2 | YEL/BLK | Sensor low reference LTGRN | Sensor 5 volts reference Crankshaft Position (CKP) Sensor Connector No. E20 ‘Connector color Black Test adapter No. 3561633 Pin No, | Wire color Pin function 1 | RED/BLU | Sensor signal 2 BLK _ | Sensor low reference 3 YEL _ | Sensor 5 volts reference Data Link Connector (DLC) Del) ees] Engine Control System (4JJ1) 14-23 DPD Regonoration Switch ‘Connector No. Bat Connector color Blue ‘Test adapter No. 53561628 Pin No. | Wire color Pin function 7 = [Not used 2 | ETGRNT | Class 2 serial data (EHOU RED _ | [ABS module)) 3 = _ [Not used 4 BLK | Ground 3 BLK | Ground 6 | SRN Tan high Keyword serial data (HSA 7 | tT BLU | contro! unit, SRS control unit, ICU and BCM) 8 = [Not used 8 = [Not used 70 = __ [Not used 7 = _ [Not used 12 | BLK WHT. Diagnostic request switch (ECM, TCM, SRS control unit, and IP cluster) 13 | BLK/ WHT Diagnostic request switch (EHCU [ABS module}) GRNI WHT 14 (RHD) | CAN tow RN (LHD) 15 = | Notused 16 | RED [Battery voltage Conner We we Comair cobr Be Tost depo He oad Pine [Wie cor | Pintinaon 7 BLKF GR | Sch votags food 2] LUT WT Sen signa a] = [Net usee a] Raed 3] Rese 7] BUR] rinasonTamp aud 3 | ESR |insraraion amp vata oo eo [|e 1A-24 Engine Control System (4JJ1) EGR Valve Engino Coolant Temporaturo (ECT) Sensor onnacor No Be Gemnetor No: a Genrer cobr Blak Comair cobr Sey Test fap Wo, TI 6IR Tost depo He od Pia No, Wire wor | Pa fnation Pine [Wie cor | Pir finaon |) rerw | Psion sensor 8 vats 7 [RNY | Sonsar sal sofeleoce: BLK ‘Sensor low reference: 2 | ESR |pcsin sensor signals = [Ret sed 3 | Er LO | Pein soon signal? engine Warm Up Sitch @ | WET |pstin senor signa 3 | YELT@UK | Postion soror ow reference 3} WaT | Scienid eontats 7} ORNS eontal2 Engine Control System (4JJ1) 14-25 Exhaust Differential Prossure Sensor Connector No 3168 Connector color Black Test adapter No FI8676 33 Pin No, | Wire color Pin function Engine warmup Switch votege 1 | euxrorn [Ene 2 [BRN/RED | Engine warm up switch signal 3 = [Net used a = _ [Net used 3 = [Not used 3 = [Notused 7_|__BUK __|iiumination famp sround TTGRNT romeo 8 | “SRN | itumination lamp votage food 9 = __[Notuses Connector No. 35 0 = [Notused Tomecior color Black 7 ra50Te Exhaust Brake Solenoid Valve leatndapten No: SBS Pin No. | Wire color Pin function 7 | BLK | Sensor low reference 2_ | GRNIYEL | Sensor signal wat? 3 | WHT | sensor 6 volts reference Exhaust Temperature Sensor 1 y Connector No 125 Connector color Black Test adapter No F866 3S in No, | Wire color Pin function 7 _| GRN’BLK | ignition voltage feed snes WaT? 2 | WHT | solenoid valve convel 414-26 Engine Control System (4JJ1) Exhaust Throttle Solenoid Valve Connector Na wa Connector color Tahtorey Test adapior No T3561 Pin No | Wire color Pia fanation 7 _[__BtK _ | SensorTow reference 4 2 YEL/ RED | Sensor signal -_ we Connector No. Connector color Bue “est adapler No F355TE33 Pin No. | Wie color Pin funeton 7_|__BtK [Solenoid vave conta 2 | RED _|gniton voltage fees Fuel injector #1 to #4 Cylinder Connector No 5 Connector lor Dark aay Test adap No 73561633 Pin No, | Wire calor Pin function 1 | __BtK _ | Sonsorfow reference 2 | RED | Sensor signal Engine Control System (4JJ1) 14-27 Commecor No [6S FSET ond eB Gennaio coor Say Test aap T8 FF RNTWT 1 HEB | et nec cone fe wre 7 fat ana wie [Fan je eres Bone s6.ne [wore Fuel Rail Pressure (FRP) Regulator Fuol Rall Pressure (FRP) Sensor ‘Connector No. E19 ‘Connector color Black “Test adapter No. 735616-33 Pin No. | Wire color Pin function 1_| YEL/BLK | Sensor low reference BLU/ WHT | Sensor signal LTGRN_ | Sensor 5 volts reference ‘Connestor No, EW Connector color White Test adapter No. -35616-33 Pin No. | Wire color Pin function| 1 WHT) | Regulator control high side RED |(PwM) 2 GRN/RED | Regulator low side Fuel Temperature (FT) Sensor 414-28 Engine Control System (4JJ1) Mass Air Flow (MAF) Intake Air Tomperature (IAT) Sensor 2S [err slow \8)(+(60) Connector No E14 Connector color = Pin No. | Wire color Pin function 7 _| BLKIYEL [Power Supply ‘Connector No. 8 ‘Connector color Black ‘Test adapter No, 735616648 Pin No. | Wire color Pin function 1_| RED/ BLU | MAF sensor 12 volts reference 2 BLK _ | MAF sensor low reference 3 WHT _ | MAF sensor signal 4 | BLU/BLK [IAT sensor signal 5 RED _ | IAT sensor low reference Intake Throttle Valve Engine Control System (4JJ1) 14-29 PTO Switch ‘Connector No. E16 Connector corer Black Test adapter No, J35616-64A Pin No. | Wire color Pin function’ 7 crn [Sie enrol iow sie 2 _ | BLK/GRN | Solenoid drive voltage 3 BLK _ | Position sensor low reference 4 = | Not used 5 _ | VIO/WHT | Position sensor signal a vex [Postion sensor vas Idle Up Sensor peuaiene ‘Connector No. B168 ‘Connector color Black “Test adapter No, ¥36616-33 Pin No. | Wire color Pin function 1 _| VIO WHT | PTO switch signal 2 BLK [PTO switch ground PTO Throttle Sensor ‘Connector No. B87 Connector color White Test adaptor No. 35616-33 Pin No. | Wire color Pin function| 1 | BLU/RED | Sensor low reference 2 _ | YEL/GRN | Sensor signal 3 BLU [Sensor 5 volts reference (Connector No. a8 ‘Connector color Black Test adapter No. -35616-33 Pin No. | Wire color Pin function| 1 | BLU/ RED | Sensor low reference 14-30 _Engine Control System (4JJ1) NT Vacuum Prossure Sonsor ‘Connector No 89 Connector color Black Test adapter No. -35616-33 Pin No. | Wire color Pin function| 2 YEL _ [Sensor signal 3 BLU _ [Sensor vols reference ‘Turbocharger Nozzle Control Solenoid Valve Conner We Bi Comair cobr Tack Tost depo He ed Pino [Wie cor | Pin tinaon 7 | BLK | arsorow erence ewrecsrcuoio GRN | Sensor signal YEL | Senor 6 vat eeence Conner No Fa ‘Connector color White Vehicle Speed Sensor (VSS) Test aap J3561635 Bi No, Wre wor | Pa fncton 7 EToRW [non votage fed 2 | WET scents conta pwn ‘Connector No vB Connector color Gray ‘Test adapter No. ¥35616-33 Pin No. | Wire color Pin function 7_| GRNV EL [lonition vonage Teed 2 BLK _ | Sensor low reference 3__ | YEL/GRN | Sensor signal Engine Control System (4JJ1) 14-31 1A-32__Engine Control System (4JJ1) Diagnostic Information and Procedures Engine Control System Check Sheet ENGINE CONTROL SYSTEM CHECK SREET Inspec Nae users Name edo & od Yoo Dive’ Name casi No ae Veil rowan Eng Ne Lins dome Roda eines o & em 1 Engine does not crank No intial combustion No complete combustion aint |. Ene cons doy U onere 1 . Rae ig red Tieng eee RP a ig eed £1 mcoroxise [2 noanions & Other ( | Ele a to em Tae Tata © |D bevenbaty |S Lack of power, sgaieters, sponginess i 3 oe i 5 Son sag 7 race peed Bearman |Z teventopecen B atereccevresfealeamse’ ©. Shing Wi 0 2 om | Saran Twemaz Fearn ey 2 ores |G Amanat contusion rose OPO seen Fey 5 DSropmorton tga 2 Onmt , eed 3 ca 7a Tas aaa) Foy Proven Fey overt A Seamer fe ooaiy Trans Taw 5 oscar [ess tater Fam aa Tea apa Fem [5 toy epee 8 Noe faa a Bas Taye oT ¢ 3 Deal Reh! Bonet ‘ | Boros io Bho os E [tonscontton | 5 acannon, ton) i lem res Tama Tiere Tenet ee eo | ; oS at ar sng Wy Tag E lemw pemon {2 Pech, owe 1 Comartepesd Aeon § [fro op aton | Deeteen © Aoncr onion 3 Om , Foaaront — |e ra Thon iz Coon Terao Fo ra aa aa 2 Rena On irs On Doe alton aru cote rear ate ne 8 Diagnostic Trouble " Nod )| eaters san ce Noting a Rarucode 5 SPD ams or near [Bd oer oeD sikh orate 1 et at ph ccoseun —[OPPasanain ana? a aa uA af pe0 sine ss [ors 2 3 ce OPO hoops aero es ze a aa BPD rash gw i ae a a2 Ems dees presse al sha tins eo rad HAF Win ris err pss nS os Engine Control System (4JJ1) 14-33 Diagnostic Starting Point - Engine Controls Begin the system diagnosis with Diagnostic System Check - Engine Controls. The Diagnostic System Check - Engine Controls will provide the following information| + The Ientiication of the control modules which ‘command the system + The ability of the contral modules to communicate through tne serial data circuit + The identification of any stored diagnostic trouble codes (DTCs) and the their statuses. ‘The use of the Diagnostic System Check - Engine Controis will Identify the correct procedure for diagnosing the system and where the procedure is located. Important: Engine Control System Check Sheet must be used to verify the customer complaint, you need to know the correct (normal) operating behavior of the systom and verify that the customer complaint isa valid failure of the system, Reading Flash Diagnostic Trouble Codes (DTC) ‘The provision for communicating with the ECM is the Data Link Connector (DLC). The DTC{s) stored in the ECM memory can be read either through a hand-held diagnostic scanner such as Tech 2 plugged into the DLC ot by counting the number of flashes of the malfunction indicator lamp (MIL) or the service vehicle soon (SVS) lamp when the diagnostic test terminal of the DLC is grounded. The DLC terminal "12" (diagnostic request) is pulled "Low" (grounded) by Jumped to DLC terminal "4", which is @ ground wire. ‘Once terminals "12" and "4" have been connected, turn the ignition switch ON, with the engine OFF. The SVS lamp will indicate a DTC three times is a DTC is present and history. If more than one DTC has been stored in the ECM's memory, the DTCs will be output numerical order with each DTC being displayed three times. The flash DTC display will continue as long as, the DLC is shorted, os edhe Ea eels 1A-34 _ Engine Control System (4JJ1) Diagnostic System Check - Engine Con- trols Description “The Diagnostic System Check - Engine Controls is an organized approach to identifying a condition that is created by a malfunction in the electronic engine control system. The Diagnostic System Check must be the starting point for any criveabilty concer. The Diagnostic System Check directs the service technician to the next logical step in order to diagnose the concem. Understanding and corectly using the diagnostic table reduces diagnostic time, and prevents the replacement of good parts. Test Description ‘The numbers below refer to the step numbers on the diagnostic table, 2. Lack of communication may be because of a partial fr a total malfunction of the serial data circu. 7. The presence of DTCs which begin with U, indicate that some other module is not communicating, 10. If there are other modules with DTCs set, refer to the DTC list. The DTC list directs you to the appropriate diegnostic procedure, If the control module stores multiple DTCs, diagnose the DTCs in the following order: + Component level DTCs, such as sensor DTCs, solenoid DTCs, actuator DTCs, and relay DTCs. Diagnose the multiple DTCs within this category in numerical order. Begin with the lowest numbered DTC, unless the diagnostic table directs you otherwise, Diagnostic System Check Engine Controls Important: Diagnostic System Check - Engine Controls + DO NOT perform this diagnostic if there is not a criveability concern, unless another procedure directs you to this ciagnosti. + Before you proceed with diagnosis, search for applicable service bulletins. + Unless a diagnostic procedure instructs you, DO NOT clear the DTCs, + Ifthere is a condition withthe starting system, refer to the Starting System in Section 1E Engine Electrical + Ensure the battery has a full charge, + Engure the battery cables (+) (-) are clean and tight + Ensure the ECM grounds are clean, tight, and in the correct location. + Ensure the ECM hamess connectors are clean ‘and correctly connected. DO NOT attempt to crank the engine with ECM hamess connectors disconnect. + Ensure the ECM terminals are clean and correctly mating, + Ensure the fuel injector ID code data is correctly programmed in to the ECM. + Ensure the Immobilizer security information is conrectly programmed into the ECM and Immobilizer control unit (ICU), + If there are fuel system DTC's (P0087, PODS, P0059, P0093 or P1093), diagnose sensor DTCs, solenoid DTCs, actuator DTCs and relay DTCs first + If thore are DPD system DTC's (P1495, P1471, P242F, P2453 or P2458), diagnose sensor DTCs, solenoid DTCs, actuator DTCs and relay OTCs first. Sep) ‘ation Value(s) Yes Ne Tnstalla sean tool 1 = Go to Scan Too! Does the scan tool tum ON? Goto step? _| Does Not Power Up 7. Turn ON the ignition, withthe engine OFF 2. Attempt to establish communication with the {Go to Scan Too! 2 ECHL - oes Not ‘Communicate with Does the sean tool communicate with the ECM? Goto Stop 3 CAN Devico Notice: If en immobilizer system is actve the ECM \will disable the fuel injection causing the engine to stall immediately after staring and energze the 3 | starter cut relay to disable cranking. Attempt to > ‘rank the engine. Doos the engin crank? Goto Stop 4 Goto Step 5 ‘Allempt to star the engine (Go 10 Engine a — Cranks but Does Does the engine start and ide? Goto Sep 6 Rat Engine Control System (4JJ1) 14-35 Sep ‘Actor Value(s) Yes No Does the scan tool display ECM DTCs P0633, Problem fs relating P1618 or 0167? ta starting systom, 5 = Refer to Starting Goto Appicablo | _systom in Section ore AE Engine Electrical Selact the DTC cisplay funciion for the folowing ‘control modules: ECM + Transmission control module (TCM) (Smoother only) 6 = * Electronic hydraulic control unit (EHCU) (it so equipped) ‘Immobilizer control unt {ICU) (so equipped) oes the scan tool display any DTCs? Goto Step7 Goto Step 11 Does the scan tool display DTCs which begin with 7 | U-or other control module communication fault = Go to Applicable Dros? pre Goto Sep 8 'g | Does the scan tool display ECM DTCs POEOT, _ Go to Applicable P0602, P0604, POBOS, POGUE or P1621? pie Goto Stop 9 ‘| Does the scan tol display ECM DTC POSES? _ Go to Applicable ore Goto Stop 10. 40. | | there any other code in any controler that has: _ (Go to Applicable not been diagnosed? pre Goto Step 11 Te the customers concer withthe Wansmission? Goto Diagnostic ‘System Check " Transmission - CContrels in Section 5A Transmission Control System Goto Step 12 Ts the customers concern with the antilock brake Go to Diagnostic system? ‘System Check - R = ABS Contos in ‘Section 4C1 ABS! ASR Goto Stop 13, Is the customers concem with the immobilizer Go to Diagnostic system? ‘System Check - 8 = Immobilizer Controls in Section 81 Secunty and Lock | Goto Step 14 1A-36 _Engine Control System (4JJ1) Sep Aston Value(s) Yes No 14 7. Review the following symptoms. 2, Refer to the sppiicable symptom diagnostic table + Hard Start + Rough, Unstable, or Incorrect ile and Stalling + High idle Speed + Cuts Out + Surges + Lack of Sponginess: Power, Siuggishness or + Hesitation, Sag or Stumble + Abnormal Comaustion Noise + Poor Fuel Economy + Excessive Smoke (Black Smoke) + Excessive Smoke (White Smoke) + DPD. System Manual Regeneration Frequently + DPD System Regeneration Long Time Did you find and correct the coneltion? System OK Go to Intermittent Conettions Engine Control System (4JJ1) 14-37 Scan Tool Data List The Engine Scan Tool Data List contains all engine related parameters that are available on the scan tool ‘A given parameter may appear in any one of the data lists, and in some cases may appear more than once, fr in more than one data list in order to group certain related parameters together. Use the Engine Scan Too! Data List only after the following is determines: + Tho Engine Controls - Diagnostic Systom Chock is completed + On-board diagnostics are functioning propery ‘Scan tool values from a properly running engine may be used for comparison with the engine you are. diagnosing, The Engine Scan Tool Data List represents values that would be seen on a normal running engine. COnly the parameters listed bolow are referenced in this service manual for use in diagnosis ‘Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Data Value at 1700 Idle RPM Operating Conditions: Engine idling or 1700 RPM Engine coolant temperature is between 75 to 85°C (167 to 185°F/ Accelerator pedal is constanU Neutral or Park’ Accessories OFF! Vehicle located at sea level! DPD is not under regeneration Engine Speed RPM Nearly 600 RPM Nearly 1700 RPM Desired Idle Speed RPM 600 RPM 600 RPM Calculated Engine Load % Less than 25% Less than 15% Coolant Temperature °CrF 75 to 85 °C) 167 to 185°F | 75 to 85 °C/ 167 to 185 °F Engine Coolant Temperature Valls 04 06 volis 0410 0.6 vols Sensor Intake Alr Temperature “Orr 201040 °C/6Bt0 104°F | 201040 °C/68 to 104 °F Intake Air Temperature Valts 1.4123 volis 14 102.3 volls Sensor Fuel Temperature “Orr 2010 60°C 15010 140°F | 20t060°0/ 5010 40°F Fuel Temperature Sensor Volts 08 102.3 volts 081025 vols MAF (Mass Air Flow) gov! More than 0.2 g/ cylatsea | More than 0.2 gi eylat sea level level ‘Averaged MAF (Mass Air as More than 5 g/s at sea level | More than 25 g/s at sea level Flow) MAF Sensor (Mass Air Flow) Valls Morethan 1.2 vols atsea_| More than 2.0 volts at sea level level Barometric Pressure kPal psi Nearly 100 kPa/ 14.5 psiat | Nearly 100 kPa/ 14.5 psiat sea level sea level Barometric Pressure Sensor Vos Nearly 2.3 volts at sea level | Nearly 2.3 volts at sea level Dasired Turbocharger % 7010 20% 25 t0 35% Position Desired Boost Pressure kPal psi Neatly 100 kPai 14.5 psiat | Less than 175 KPal 16.7 psi at sea level sea level ‘Boast Pressure KPal psi Nearly 100 kPai 14.5 psiat | Less than 175 kPal 16.7 pal at sea level sea level Boost Pressure Sensor Volts Nearly 7.0 voltat sea level | Less than 1.3 volts at sea level Desired Fuel Rail Pressure MPai psi Nearly 30 MPa/ 4,300 psi_| More than 60 MPa’ 8,700 psi Fuel Rail Pressure MPal psi ‘27 to 33 MPa] 3,900 psito | More than 60 MPaf 8,700 psi 4,800 psi Fuel Rail Pressure Sensor Volts 7A to 1.5 volts More than 2.0 volts 1A-38 Engine Control System (4JJ1) Scan Tool Parameter | Units Displayed | Typical Data Value al Engine | Typical Dala Value at 1700 tale RPM FRP Regulator Command % 3010 48% 3010 40% (Fuel Rail Pressure) FRP Regulator Commanded | mm/sec | More than 650 mm® sec | More than 1600 mm sec Fuel Flow FRP Regulator Feedback mA 800 1100 mA 300 1 1000 mA Current (Fuel Rail Pressure) ‘Accelerator Pedal Position % O% 126 20% ‘APP Sensor 1 (Accelerator Volts Nearly 0.5 vols 0810 1.4 volts Pedal Position) ‘APP Sensor 2 (Accelerator Volts Nearly 45 volts 3714.3 volts Pedal Postion) Desired EGR Postion % Less than 95% Less than 55% EGR Position 1 % Less than 95% Less than 55% EGR Position 7 Tow High Tow oF High Tow or High EGR Position 2 Tow High Tow or High Tow or High EGR Position 3 Lowi High Low or High Low or High Intake Throtle Solenoid % 0% 0% Command Desired intake Throlle % Mare than 80% Wore than 80% Position Intake Throtle Postion % Mare than 100% More than 100% Intake Throtle Position Vaits More than 3.9 vols More than 3.9 volts Sensor Tale Up Sensor Valls 03106 volts 031006 vals Fuel Gompensation Oy. 1 mane BO to 5.0 mm®(varios) 0.0 mm Fuel Compensation Cyl. 2 min -6.010 5.0 mim(varies) 0.0 mam? Fuel Compensation Owl 3 ia “BO 10 5.0 mar varies) 0mm Fuel Compensation Ov 4 a “50 10 5.0 ma (varies) 0mm Fuel Supply Pump Status | Not Learned? Teamed Teamed Learned Rall Pressure Feedback Mode | Shutoff Mode? Feedback Mode Feedback Mode Slart Mode! Wait Mode! Wait to Restart Feedback Mode Engine Running Salus | Of Ignition Onl Running Running Cranking? Running Engine Runtime Time (hour Varies Varies minute: second) Vehicle Speed keh MPH OkmhvOMPH ‘Oki OPH Siarter Switoh ‘On of oF of igalion Switch ‘On Of on On Engine Control System (4JJ1) 14-39 Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Data Value at 1700 alo RPM igniion Volage Vols 22.01 30.0 vols 010 50.0 vals Batiory Voltage Volts 22.0 1030.0 vols 22010 30.0 vols Clutch Pedal Switch ‘Applied? ‘Applied oF Released ‘Applied or Released Released Neutral Switeh Neutral In Gear Neutral Neutral Park Brake Switch Applied? ‘Anpled or Released ‘Applied oF Released Released Exhaust Brake Switch ‘On Of OF Off Exhaust Brake Valve ‘On/Off oF of ‘Command Exhaust Brake Gul Request | Inactive! Active inactive inactive from ABS Module Exhaust Brake Gul Request | Inactive! Aatve Tnectve inactive from TCM ‘ASR Commanded APP % 700% 700% (Accelerator Pedal Position) PTO Switch ‘Onl OF OF Off PTO Remote Throtie % o% % PTO Remote Throtie Sensor | Valls Tess than 04 vals Tess than 04 vals Engine Warm Up Switch On! Off Of Off AIC Signal ‘Onl Of OF OF Refrigerator Switch ‘Ono Of Of Oi Level Tow Neral Normal Worm Glow Plug Relay Command | __ On Of OFF OFF Malfunction indicator Lamp | ont OW oF Of (ity Distance Wie MILs Ten Bios Ok’ O Wiles Ow O Wiles Activated Engine Runtime Win MIL | minutes 0 3 ‘active Total Engine Overspeed Counter Varies Varies Event Total Engine Coolant Counter Varies Vanes Overtemperature Event Total Fuel Temperature Counter Varies Vares Overtemperature Event Total Intake Air Temperature | Counter Varies Vanes Overtemperature Event DPD Regeneration Switch | __ On OW oF of DPD Mode Varies 3 30 DPD Accumulation Status | 01/2416 0.7.2,S0r4 D2 30rd DPD Distance Status wae 01,208 01, 2erd 14-40 _Engine Control System (4JJ1) ‘Scan Tool Parameter | Units Displayed | Typical Data Value at Engine | Typical Dala Value at 1700 Idle RPM DPD Incomplete orn Oort ort Regeneration Status DPD Insufficient Regeneration one Oort ort ‘Status DPD LLIR Condition On Varies Varies Varies Particulate Matter DPD Trip km Varies Varies DPD DIL Tip km Varies Varies Exhaust Differential Pressure | __kPal psi Varies Varies Exhaust Differential Pressure Valts Varies Varies Sensor Exhaust Temperature 1 “Or Varies Varies Exhaust Temperature Sensor Vals Varies Varies 1 Exhaust Temperature 2 °OrF Varies Varies: Exhaust Temperature Sensor Volts: Varies Varies 2 Exhaust Thratie Status ‘Onl Off Of Of Immobilizer Signal Yesi No Yes Yes Wrong Immobilizer Signal Yesi No No No Immobilizer Function Yesi No Yes Yes Programmed Security Walt Time Inactive Time Inactive Tnactive (hour: minute: second) Engine Control System (4JJ1) 14-41 Scan Tool Data Definitions This information wil assist in emission or driveability problems. The displays can be viewed while the vehicle is being driven, Always perform the Diagnostic System Check = Engine Controls first. The Diagnostic System Check will confirm proper system operation. Engine Speed ‘This parameter displays the rotational speed of the crankshaft as calculated by the ECM based on inputs from the crankshaft position (CKP) sensor or camshaft position (CMP) sensor. Desired Idle Speed ‘This parameter displays the idle speed requested by the ECM. The ECM will change desired idle speed based on engine coolant temperature and ather inputs. Calculated Engine Load This parameter displays the engine load in percent based on inputs to the ECM from various engine sensors. The scan tool will display a lower percentage when the engine is at idle with lite or no load. The scan tool will display a higher percentage when the engine is cunning at high engine speed under @ heavy loa, Coolant Temperature This parameter displays the temperature of the engine coolant as calculated by the ECM using the signal from the engine coolant temperature (ECT) sensor. The scan tool will display a low temperature when the ECT sensor signal voltage is high, and a high temperature when the ECT sensor signal voltage is low. Engine Coolant Temperature Sensor This parameter displays the voltage signal sent to the ECM from the engine coolant temperature (ECT) sensor. ECT sensor is a range of value incicating a law voltage when the temperature is high, and a high voltage whan the temperature is low. Intake Air Tomporaturo ‘This parameter displays the temperature of the intake air as calculated by the ECM using the signal from the intake air temperature (IAT) sensor. The scan too! will display a low temperature when the IAT sensor signal voltage is high, and a high temperature when the IAT ‘sensor signal voltage is low. Intake Air Temperature Sensor ‘This parameter displays the voltage signal sent to the ECM from the intake air temperature (IAT) sensor. |AT sensor is a range of value indicating a low voltage when the temperature is high, and a high voltage when the temperature is low. Fuel Temperature This parameter displays the temperature of the fuel as calculated by the ECM using the signal from the fuel temperature (FT) sensor. The scan tool will display 2 low temperature when the FT sensor signal voltage is high, and a high temperature when the FT sensor signal voltage is low, Fuel Temperature Sensor This parameter displays the voltage signal sent to the ECM from the fuel temperature (FT) sensor. FT sensor is a range of value indicating low voltage when the temperature is high, and a high voltage when the temperature is low. MAF (Mass Air Flow) This parameter displays the air flow into the engine as. calculated by the ECM based on the mass air flow (MAF) sensor input. The scan tool will display a high value at higher engine speeds, and a low valve at lower engine speed. ‘Averaged MAF (Mass Air Flow) This parameter displays the alr low averaged a second 2s calculated by the ECM based on the mass air flow (MAF) sensor input. The scan tool will display @ high value at higher engine speeds, and a low value at lower engine spec. MAF Sonsor (Mass Air Flow) This parameter displays the voltage signal sent to the ECM from the mass air flow (MAF) sensor, MAF sensor is 8 range of value indicating a low voltage at lower engine speed, and a high vollage at a higher engine speeds. Barometric Pressure This parameter displays the barometric pressure (ARO) 2s calculated by the ECM using the signal fram the BARO sensor. The scan tool will display @ low barometric pressure in high altitude area, Barometric Pressure Sensor This parameter displays the voltage signal sent to the ECM from the barometric pressure (BARO) sensor. BARO sensor is a range of value indicating a low voltage in high altitude area, and a middle voltage in sea level Desired Turbocharger Position This parameter displays turbocharger nozzle position dosired by the ECM based on current boost pressure. Desired Boost Pressure This parameter displays boost pressure desired by the ECM based on current driving conditions. This can be compared to the actual boost pressure to determine, sensor accuracy or turbocharger control problems, Boost Pressure This parameter displays the boost pressure in the: intake duct as calculated by the ECM using the signal from the boost pressure sensor. The scan tool will

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