LG4HVED WE 0981 - 5th

No.LG4HVED-WE-0981
61167_Maegaki 2009.7.21 1:07 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
61167_Maegaki 2009.7.21 1:07 PM ページ 2
LG4HVED-WE-0981.book 1 ページ２０１２年４月９日　月曜日　午後４時５６分
Engine Control System (4HV1-CNG) 1A-1
ENGINE
Engine Control System
(4HV1-CNG)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 DTC P0353 (Flash Code 35). . . . . . . . . . . . . 1A-128
Temperature vs Resistance. . . . . . . . . . . . . . . . 1A-3 DTC P0354 (Flash Code 35). . . . . . . . . . . . . 1A-131
Altitude vs Barometric Pressure . . . . . . . . . . . . 1A-3 DTC P0452 (Flash Code 37). . . . . . . . . . . . . 1A-134
Diagnostic Trouble Code (DTC) Type DTC P0453 (Flash Code 37). . . . . . . . . . . . . 1A-137
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 DTC P0475 (Flash Code 64). . . . . . . . . . . . . 1A-140
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6 DTC P0502 (Flash Code 24). . . . . . . . . . . . . 1A-144
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . . 1A-8 DTC P0506 (Flash Code 53). . . . . . . . . . . . . 1A-147
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . 1A-8 DTC P0507 (Flash Code 53). . . . . . . . . . . . . 1A-149
Routing Diagrams . . . . . . . . . . . . . . . . . . . . . . . 1A-10 DTC P0560 (Flash Code 36). . . . . . . . . . . . . 1A-151
Fuel System Routing Diagram . . . . . . . . . . . . 1A-10 DTC P0562 (Flash Code 66). . . . . . . . . . . . . 1A-159
Component Locator . . . . . . . . . . . . . . . . . . . . . . 1A-12 DTC P0563 (Flash Code 66). . . . . . . . . . . . . 1A-162
Engine Controls Component Views . . . . . . . . 1A-12 DTC P0606 (Flash Code 51). . . . . . . . . . . . . 1A-164
Engine Control Module (ECM) Connector DTC P1120 (Flash Code 21) . . . . . . . . . . . . . 1A-166
End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-21 DTC P1125 (Flash Code 52) . . . . . . . . . . . . . 1A-170
Engine Control Connector End Views. . . . . . . 1A-23 DTC P1150 (Flash Code 13) . . . . . . . . . . . . . 1A-172
Diagnostic Information and Procedures . . . . . . . 1A-36 DTC P1151 (Flash Code 13) . . . . . . . . . . . . . 1A-174
Engine Control System Check Sheet . . . . . . . 1A-36 DTC P1152 (Flash Code 13) . . . . . . . . . . . . . 1A-176
Diagnostic Starting Point - Engine Controls . . 1A-37 DTC P1155 (Flash Code 13) . . . . . . . . . . . . . 1A-178
Diagnostic System Check - Engine Controls . 1A-40 DTC P1156 (Flash Code 13) . . . . . . . . . . . . . 1A-182
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-42 DTC P1157 (Flash Code 13) . . . . . . . . . . . . . 1A-184
Scan Tool Data Definitions . . . . . . . . . . . . . . . 1A-45 DTC P1158 (Flash Code 13) . . . . . . . . . . . . . 1A-186
Scan Tool Output Controls . . . . . . . . . . . . . . . 1A-48 DTC P1220 (Flash Code 21). . . . . . . . . . . . . 1A-188
Scan Tool Does Not Power Up . . . . . . . . . . . . 1A-49 DTC P1221 (Flash Code 21). . . . . . . . . . . . . 1A-192
Scan Tool Does Not Communicate with the DTC P1271 (Flash Code 22). . . . . . . . . . . . . 1A-194
Engine Control Module (ECM) . . . . . . . . . . . . 1A-50 DTC P1275 (Flash Code 22). . . . . . . . . . . . . 1A-197
DTC P0105 (Flash Code 71). . . . . . . . . . . . . . 1A-53 DTC P1280 (Flash Code 22). . . . . . . . . . . . . 1A-201
DTC P0112 (Flash Code 23) . . . . . . . . . . . . . . 1A-60 DTC P1299 (Flash Code 21). . . . . . . . . . . . . 1A-209
DTC P0182 (Flash Code 34). . . . . . . . . . . . . . 1A-83 Check Engine Warning Light Illumination
DTC P0183 (Flash Code 34). . . . . . . . . . . . . . 1A-86 Circuit System Check . . . . . . . . . . . . . . . . . . 1A-235
DTC P0192 (Flash Code 32). . . . . . . . . . . . . . 1A-91 Check Engine Warning Light Blinking
DTC P0193 (Flash Code 32). . . . . . . . . . . . . . 1A-95 Circuit System Check . . . . . . . . . . . . . . . . . . 1A-237
DTC P0201 (Flash Code 31). . . . . . . . . . . . . 1A-100 Starting System Check . . . . . . . . . . . . . . . . . 1A-239
DTC P0202 (Flash Code 31). . . . . . . . . . . . . 1A-103 Fuel System Check . . . . . . . . . . . . . . . . . . . . 1A-241
DTC P0203 (Flash Code 31). . . . . . . . . . . . . 1A-106 Ignition System Check . . . . . . . . . . . . . . . . . 1A-250
DTC P0204 (Flash Code 31). . . . . . . . . . . . . 1A-109 Exhaust System Check . . . . . . . . . . . . . . . . . 1A-252
DTC P0327 (Flash Code 16). . . . . . . . . . . . . 1A-112 Symptoms - Engine Controls . . . . . . . . . . . . . . 1A-254
DTC P0328 (Flash Code 16). . . . . . . . . . . . . 1A-114 Diagnosis By Symptom . . . . . . . . . . . . . . . . . 1A-254
DTC P0335 (Flash Code 41). . . . . . . . . . . . . 1A-116 Intermittent Conditions . . . . . . . . . . . . . . . . . 1A-256
DTC P0340 (Flash Code 43). . . . . . . . . . . . . 1A-119 Abnormal Combustion Noise . . . . . . . . . . . . 1A-259
DTC P0351 (Flash Code 35). . . . . . . . . . . . . 1A-122 Poor Fuel Economy. . . . . . . . . . . . . . . . . . . . 1A-261
DTC P0352 (Flash Code 35). . . . . . . . . . . . . 1A-125 Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-264
1A-2 Engine Control System (4HV1-CNG)

Rough, Unstable, or Incorrect Idle and
Stalling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-267
High Idle Speed. . . . . . . . . . . . . . . . . . . . . . . 1A-270
Pulsing in Engine Speed . . . . . . . . . . . . . . . . 1A-273
Surges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-276
Lack of Power, Sluggishness or Sponginess 1A-279
Abnormal Sound/ Abnormal Smell . . . . . . . . 1A-282
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-285
Engine Control Module (ECM) Replacement 1A-285
Fuel Compensation Rate Learn . . . . . . . . . . 1A-286
Engine Driver Unit (EDU) Replacement . . . . 1A-286
Description and Operation . . . . . . . . . . . . . . . . 1A-288
Engine Control Module (ECM) Description . . 1A-288
Engine Control Component Description . . . . 1A-292
Air/ Fuel Ratio Control System Description. . 1A-298
Fuel Injection System Description. . . . . . . . . 1A-299
Fuel Injection System Component
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-302
Ignition System Description. . . . . . . . . . . . . . 1A-309
Throttle Valve Control Description. . . . . . . . . 1A-313
Exhaust Brake Control Description . . . . . . . . 1A-314
Special Tools and Equipment . . . . . . . . . . . . . . 1A-315
Special Tools and Equipment . . . . . . . . . . . . 1A-315
Specifications
Temperature vs Resistance °C °F Ohms
Engine Coolant Temperature vs. Resistance Temperature vs. Resistance Value (Approximately)
°C °F Ohms -30 -22 26108
Temperature vs. Resistance Value (Approximately)
Intake Air Temperature vs. Resistance
120 248 115
°C °F Ohms
110 230 150
Temperature vs. Resistance Value (Approximately)
100 212 190
90 194 240
90 194 240
80 176 320
80 176 320
70 158 450
70 158 430
60 140 660
60 140 590
50 122 960
50 122 810
40 104 1440
40 104 1150
30 86 2300
30 86 1660
20 68 3430
20 68 2450
10 50 5410
10 50 3700
0 32 9770
0 32 5800
-10 14 16410
-10 14 9300
-20 -4 28560
-20 -4 15480
-30 -22 26700
Altitude vs Barometric Pressure
Fuel Temperature vs. Resistance
°C °F Ohms Barometric
Temperature vs. Resistance Value (Approximately) Altitude Altitude Pressure
Measured in Measured in Measured in
120 248 112 Meters (m) Feet (ft) Kilopascals
110 230 144 (kPa)
100 212 186 Determine your altitude by contacting a local weather

station or by using another reference source.
90 194 243
4267 14000 56-64
80 176 322
3962 13000 58-66
70 158 435
3658 12000 61-69
60 140 595
3353 11000 64-72
50 122 833
3048 10000 66-74
40 104 1174
2743 9000 69-77
30 86 1706
2438 8000 71-79
20 68 2499
2134 7000 74-82
10 50 3791
1829 6000 77-85
0 32 5895
1524 5000 80-88
-10 14 9395
1219 4000 83-91
-20 -4 15458
914 3000 87-95
Barometric
Altitude Altitude Pressure
Measured in Measured in Measured in
Meters (m) Feet (ft) Kilopascals
(kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105

Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC
Action Taken When the DTC Sets - Type A
• The ECM illuminates the malfunction indicator
lamp (MIL) 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 Freeze Frame.
Action Taken When the DTC Sets - Type B

• The ECM illuminates 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. 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.
Conditions for Clearing the MIL/DTC - Type A or

Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail.
• A current DTC clear when the diagnostic runs and
passes.
• A history DTC and the Freeze Frame clears after
40 consecutive warm-up cycles, if no failures are
reported.
• Use a scan tool or memory clear switch function to
clear the MIL and the DTC.
Non-Emissions Related DTCs

Action Taken When the DTC Sets - Type D
• The ECM will not illuminate the MIL.
Conditions for Clearing the DTC - Type D

• A current DTC clear when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported.
• Use a scan tool or memory clear switch function to
clear the DTC.

Diagnostic Trouble Code (DTC) List
Flash DTC
DTC DTC Descriptor
Code Type
P0105 71 A Barometric Pressure Sensor Circuit Error
P0107 33 A Intake Air Pressure Sensor Circuit Low Voltage
P0108 33 A Intake Air Pressure Sensor Circuit High Voltage
P0112 23 A Intake Air Temperature (IAT) Sensor Circuit Low Voltage
P0113 23 A Intake Air Temperature (IAT) Sensor Circuit High Voltage
P0117 14 A Engine Coolant Temperature Circuit Low Input
P0118 14 A Engine Coolant Temperature Circuit High Input
P0136 46 B O2 Sensor 2 Circuit No Activity Detected
P0141 55 B O2 Sensor Heater Circuit Open Or Short To Ground
P0171 44 B Exhaust System Parts Lean
P0172 45 B Exhaust System Parts Rich
P0182 34 A Fuel Temperature (FT) Sensor Circuit Low Voltage
P0183 34 A Fuel Temperature (FT) Sensor Circuit High Voltage
P0192 32 A Fuel Pressure Sensor Circuit Low Voltage
P0193 32 A Fuel Pressure Sensor Circuit High Voltage
P0201 31 A Injector #1 Load Open Circuit or Short Circuit to Ground
P0327 16 D Knock Sensor 1 Circuit Low Input (Bank 1 Or Single Sensor)
P0328 16 D Knock Sensor 1 Circuit High Input (Bank 1 Or Single Sensor)
P0335 41 A Crankshaft Position Sensor Circuit
P0340 43 A Camshaft Position Sensor Circuit Malfunction
P0351 35 A Ignition 1 Control Circuit
P0452 37 A Fuel Tank Pressure Sensor Circuit Low Voltage
P0453 37 A Fuel Tank Pressure Sensor Circuit High Voltage
P0475 64 A Exhaust Brake VSV Open Circuit or Short Circuit
P0502 24 B Vehicle Speed Sensor
P0506 53 D Idle Speed Control RPM Too Low
P0507 53 D Idle Speed Control RPM too High
P0560 36 A Ignition Power Source Error
P0562 66 D System Voltage Low
P0563 66 B System Voltage High
Flash DTC
DTC DTC Descriptor
Code Type
P0606 51 A Control Module Internal Performance
P1120 21 A Throttle Position Sensor 1 Circuit
P1125 52 A Electronic Throttle Control Limited Performance Mode
P1150 13 A Air Fuel Ratio Sensor AFC(Base Voltage) Or AFV(Supply Voltage) Open
P1151 13 A Air Fuel Ratio Sensor AFV(Supply Voltage) Circuit Shorted
P1152 13 A Air Fuel Ratio Sensor AFC(Base Voltage) Circuit Shorted
P1155 13 A Air Fuel Ratio Sensor, Release of Heater Output
P1156 13 A Air Fuel Ratio Sensor, Short Circuit of Heater Output
P1157 13 A Air Fuel Ratio Sensor Heater Error
P1158 13 A Air Fuel Ratio Sensor Protection Circuit Operation
P1220 21 A Throttle Position Sensor 2 Circuit
P1221 21 D TPS1 and TPS2 Comparison Error
P1271 22 A APS1 and APS2 Comparison Error
P1275 22 A Accelerator Pedal Position Sensor 1 Circuit
P1280 22 A Accelerator Pedal Position Sensor 2 Circuit
P1290 21 A Electronic Throttle Control Forced Idle Mode
P1295 21 A Electronic Throttle Control Power Management Mode
P1299 21 A Electronic Throttle Control Forced Engine Shutdown Mode
P1514 21 A TPS and MAF Comparison Error
P1515 21 A Direction Of ECU and TPS Comparison Error 1
P1516 21 A Direction Of ECU and TPS Comparison Error 2
P1523 21 D Throttle Actuator Control Return Performance
P1635 21 D 5V Reference #1 Circuit
P1639 22 D 5V Reference #2 Circuit
P2125 25 D PTO Accelerator Sensor Error
Overview Wirings
Overview Wirings
1/2
Engine Control Module (ECM)

DC-DC Power Supply Monitor Ignition Coil #1
56 6
Exhaust Brake Solenoid Valve
13
Fan Relay Ignition Coil #2
9
EDU
31
Starter Cut Relay
21 Ignition Coil #3
7
Gas Valve Relay
15
Gas Cut Valve Relay
Ignition Relay (Except Australia)
Ignition Coil #4
Converter Relay (For Australia)
8
14
A/C Compressor Relay
EDU Relay
121 Heater (+)

18 120 Heater (-)
Signal (AFV)
119
118 Signal (AFC)
Exhaust Brake Indicator Light
20 Air/Fuel Ratio
Check Engine Warning Light (A/F) Sensor
19 12 Heater
DC-DC Converter
Signal
Battery (24V) 3 50 GND
Battery (24V) 4 69
O2 Sensor
16 Intake Air
Signal
51 Temperature
ECM 70 GND (IAT) Sensor
Relay
Ignition SW (Except Australia)
5
Power Supply
110
Signal CNG Pressure/
103
Parking Brake SW
33 84 GND Temperature
Ignition Exhaust Brake SW Signal Sensor
Converter 34 102
Relay (For Relay (Except Neutral SW 40
Australia) Clutch SW
Australia) 39 (For Australia)
Refrigerator SW
36
A/C SW 37 102 Signal CNG Temperature
Ignition SW 83 GND Sensor
41
Diag. SW 110 Power Supply
Ignition 30 Signal CNG Pressure
103
SW Memory Clear SW 84 GND Sensor
29
PTO SW 35
Power Supply
113 Camshaft Position
97 Signal (CMP) Sensor
Power Supply
CAN (H) 89 Crankshaft Position
DRM CAN (L) 60 96 Signal (CKP) Sensor
Batt. 59 88 GND
IP Cluster Data Link Connector

24
Case GND 77
78
ECM GND 75
76
Power GND 1
2
ECM GND
79
Fuel Tank (CNG Container)
Pressure Sensor
Power Supply
81
Signal
55
GND
74
Vehicle Speed Sensor

57
LNW91AXF002001

2/2
Engine Driver Unit (EDU)
Gas Injector #1 (H)

27
Gas Injector #1 (L) Throttle (L)2
26 41 114 111 Power Supply Manifold Absolute
Throttle (H)2 Signal
20 94 Pressure (MAP)
116
Gas Injector #3 (H) 86 GND Sensor
29
Engine Coolant
Gas Injector #3 (L) 105 Signal Temperature (ECT)
28
85 GND Sensor
Throttle (L)1
42 115 GND
Gas Injector #4 (H) Throttle (H)1 87
31 19 117 104 Signal 1 Intake Throttle
Gas Injector #4 (L) 30 112 Power Supply Position Sensor
95 Signal 2
Gas Injector Circuit Monitor #2
40 90
Gas Injector #2 (H) Gas Injector #2 (L) Power Supply 1
33 38 98 43
Gas Injector #2 (L) Gas Injector #2 (H) 52 Signal 1
32 16 106 GND 1 Accelerator Pedal
Gas Injector Circuit Monitor #4 71
39 91 42 Power Supply 2 Position (APP)
Motor (-) Gas Injector #4 (L) 53 Signal 2 Sensor
24 37 99 GND 2
Motor (+) Gas Injector #4 (H) 72
25 15 107
Gas Injector Circuit Monitor #3 62 Power Supply PTO Throttle
Throttle Motor 18 92 Signal
Battery (24V) Gas Injector #3 (L) 54 GND Sensor
21 36 100 73
Battery (24V) Gas Injector #3 (H)
43 14 108 (Except Australia)
System GND Gas Injector Circuit Monitor #1 Sensor Signal
22 17 93 48
System GND Gas Injector #1 (L) Knock Sensor
35 101
44
Power GND 1 Gas Injector #1 (H) 67 Sensor GND
13 109
Power GND
23
EDU Relay
LNW91AXF002101
Routing Diagrams
Fuel System Routing Diagram
Except Australia
4
2 3
13 12
11 5
10
8
LNW91DMF000401
Legend
1. Spark plug 8. Filling unit
2. Gas injector 9. Automatic valve (at tank) and manual cylinder
3. Gas filter valves
4. Pressure regulator 10. CNG container (CNG cylinder)
5. Fuel gauge 11. Throttle valve
6. Engine control module (ECM) 12. Intake pipe
7. Automatic valve (before regulator) 13. Exhaust pipe

For Australia
3
2
12 11
10 4
9
8 7
LNW71DMF001601
Legend
1. Spark plug 7. Filling unit
2. Gas injector 8. Automatic valve (at tank)
3. Pressure regulator 9. CNG container (CNG cylinder)
4. Fuel gauge 10. Throttle valve
5. Engine control module (ECM) 11. Intake pipe
6. Automatic valve (before regulator) 12. Exhaust pipe
Component Locator
Engine Controls Component Views
LNW91ASF001201
Legend
1. Accelerator pedal position (APP) sensor
RHD
LNW91ASF001401
Legend
1. DC-DC converter

LHD
LNW91ASF002501
Legend
1. DC-DC converter
Except Australia
6 5
LNW91AMF000801
Legend
1. CNG pressure/ temperature sensor 4. Intake air temperature (IAT) sensor
2. Throttle valve 5. Manifold absolute pressure (MAP) sensor
3. Crankshaft position (CKP) sensor 6. Knock sensor

For Australia
1 2
LNW91AMF001401
Legend
1. CNG pressure sensor 4. Crankshaft position (CKP) sensor
2. CNG temperature sensor 5. Intake air temperature (IAT) sensor
3. Throttle valve 6. Manifold absolute pressure (MAP) sensor

Except Australia
1 2 3 4
10 9 8 7
LNW91AMF001301
Legend
1. Ignition coil No.1 cylinder 6. PCV valve
2. Ignition coil No.2 cylinder 7. Gas injector No.4 cylinder
5. Camshaft position (CMP) sensor 10. Gas injector No.1 cylinder

For Australia
1 2 3 4 5
10 9 8 7
LNW91AMF000901
Legend
1. Ignition coil No.1 cylinder 6. PCV valve
5. Camshaft position (CMP) sensor 10. Gas injector No.1 cylinder

Except Australia
2 1
3
LNW91ASF001501
Legend
1. Automatic valve (at tank) 3. Pressure regulator
2. Fuel tank (CNG container) pressure sensor 4. Automatic valve (before regulator)
For Australia
1
2
3
LNW91ASF002201
Legend
1. Automatic valve (at tank) 3. Pressure regulator
2. Fuel tank (CNG container) pressure sensor 4. Automatic valve (before regulator)

Except Australia
LNW91ASF001601
Legend
1. Exhaust brake solenoid valve (NMR) 2. Exhaust brake solenoid valve (NPR)
For Australia
1
LNW91ASF002301
Legend
1. Exhaust brake solenoid valve (NLR) 2. Exhaust brake solenoid valve (NPR)
1 2
3 4
LNW91ASF002101
Legend
1. Air-fuel ratio (A/F) sensor 3. O2 sensor
2. Exhaust brake assembly 4. 3-way catalyst integrated silencer
1 LNW76ESF001101
Legend
1. Vehicle speed sensor (VSS)

NMR (Except Australia)/ NLR (for Australia)
1
LNW91ASF001001
Legend
1. Engine control module (ECM) 2. Engine driver unit (EDU)
NPR
LNW91ASF001101
Legend
1. Engine control module (ECM) 2. Engine driver unit (EDU)

Engine Control Module (ECM) Connector Connector No. J95
End Views
Connector color Black
Test adapter No. J-35616-64B
Pin No. Wire color Pin function
18 PNK A/C compressor relay control
Check engine warning light
19 YEL/ BLK
control
BRN/ Exhaust brake indicator light
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4
WHT control (Except Australia)
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
20
3 Exhaust brake indicator light
GRN/ RED
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 2 1
control (for Australia)
Starter cut relay control
BLK/ GRN
(Except Australia)
21
Starter cut relay control
BLK/ BLU
(for Australia)
22 – Not used
LNW76ESH001501
23 – Not used
Keyword 2000 serial data
LT BLU
Connector No. J95 (Except Australia)
24
Connector color Black Keyword 2000 serial data
BLK/ WHT
(for Australia)
25 – Not used
26 – Not used
1 BLK ECM power ground
27 – Not used
2 BLK ECM power ground
28 – Not used
WHT/
3 Battery voltage
GRN 29 YEL/ GRN Memory clear request switch
WHT/ 30 YEL Diagnostic request switch
4 Battery voltage
GRN
31 BLK/ PNK Fan relay control
5 BLK/ ORN Ignition voltage
32 – Not used
6 RED/ BLU Cylinder #1 ignition coil
33 YEL Parking brake switch signal
7 RED Cylinder #3 ignition coil
LT GRN/
34 Exhaust brake switch signal
8 RED/ YEL Cylinder #4 ignition coil RED
9 RED/ BLK Cylinder #2 ignition coil 35 VIO/ WHT PTO switch signal
10 – Not used 36 BLU/ WHT Refrigerator switch signal
11 – Not used 37 BRN/ YEL A/C switch signal
RED/ 38 – Not used
12 O2 sensor heater control
WHT
Clutch switch signal
39 WHT/ BLK
Exhaust brake solenoid valve (Except Australia)
13 BLK
control
40 BLK/ GRN Neutral switch signal
14 ORN Gas cut valve relay control
41 BLK/ ORN Ignition switch signal
15 BLK/ RED Gas valve relay control
APP sensor 2
42 GRN
16 BLU/ WHT ECM relay control 5 volts reference
17 – Not used
Connector No. J95 Connector No. J95

Connector color Black Connector color Black
Test adapter No. J-35616-64B Test adapter No. J-35616-64B
Pin No. Wire color Pin function Pin No. Wire color Pin function
APP sensor 1 Fuel tank (CNG container)
43 BLK 74 BLK/ RED
5 volts reference pressure sensor low reference
44 – Not used 75 BLK ECM system low reference
45 – Not used 76 BLK ECM system low reference
46 – Not used 77 BLK ECM case low reference
47 – Not used 78 BLK ECM case low reference
Knock sensor signal 79 BLK ECM system low reference
48 WHT
(Except Australia)
80 – Not used
49 – Not used
Fuel tank (CNG container)
50 YEL O2 sensor signal 81 BLK/ YEL pressure sensor 5 volts
reference
51 YEL/ GRN IAT sensor signal
52 WHT APP sensor 1 signal
53 YEL APP sensor 2 signal
54 BLU/ WHT PTO throttle sensor signal
Fuel tank (CNG container)
55 BLK/ PNK
pressure sensor signal
RED/ DC-DC converter power
56 121 120 119 113 112 111 110 109 108 107 106
WHT supply voltage monitor 105 104 103 102 101 100 99 98
118 117
57 YEL/ GRN VSS signal 97 96 95 94 93 92 91 90
116 115 114 89 88 87 86 85 84 83 82
58 – Not used
59 BLU CAN low signal
60 BLU/ WHT CAN high signal
61 – Not used
PTO throttle sensor 5 volts
62 BLU LNW76ESH001601
reference
63 – Not used
Connector No. E125
64 – Not used
65 – Not used
66 – Not used
Knock sensor low reference
67 BLK
(Except Australia) 82 – Not used
68 – Not used CNG temperature sensor low
83 YEL/ RED
reference (for Australia)
69 VIO/ WHT O2 sensor low reference
CNG pressure/ temperature
70 GRN IAT sensor low reference
sensor low reference
71 RED APP sensor 1 low reference 84 BLK/ RED (Except Australia)
72 BLU APP sensor 2 low reference CNG pressure sensor low
reference (for Australia)
PTO throttle sensor low
73 BLU/ RED
reference 85 BLK/ RED ECT sensor low reference
Connector No. E125 Connector No. E125

Connector color Black Connector color Black
Test adapter No. J-35616-64B Test adapter No. J-35616-64B
Pin No. Wire color Pin function Pin No. Wire color Pin function
86 BLK MAP sensor low reference RED/ CNG pressure sensor 5 volts
110
WHT reference
Intake throttle position sensor
87 BLU
low reference 111 RED MAP sensor 5 volts reference
88 BLK CKP sensor low reference Intake throttle position sensor
112 RED
5 volts reference
89 BLU CKP sensor 5 volts reference
113 RED CMP sensor 14 volts reference
ORN/ Cylinder #2 gas injector circuit
90
GRN monitor 114 RED Intake throttle motor (LOW) 2
LT GRN/ Cylinder #4 gas injector circuit 115 YEL Intake throttle motor (LOW) 1
91
RED monitor
116 GRN Intake throttle motor (HIGH) 2
Cylinder #3 gas injector circuit
92 YEL 117 BRN Intake throttle motor (HIGH) 1
monitor
118 GRN A/F sensor signal (AFC)
93 PNK/ WHT
monitor 119 RED A/F sensor signal (AFV)
94 WHT MAP sensor signal 120 RED/ YEL A/F sensor heater (-)
Intake throttle position sensor RED/
95 WHT 121 A/F sensor heater (+)
2 signal WHT
96 WHT CKP sensor signal
97 WHT CMP sensor signal Engine Control Connector End Views
Cylinder #2 gas injector control Accelerator Pedal Position (APP) Sensor
98 RED
low side
Cylinder #4 gas injector control
99 GRN
low side
100 BLK/ BLU
low side
101 BLK/ WHT
low side
CNG temperature sensor 1 2 3
102 BLU/ RED
signal
4 5 6
WHT/
103 CNG pressure sensor signal
RED
Intake throttle position sensor
104 GRN
1 signal
105 RED/ BLK ECT sensor signal
Cylinder #2 gas injector control RTW76ESH001201
106 WHT
high side
107 GRY
high side
108 WHT/ BLU
high side
109 BRN
high side

Automatic Valve (at tank) (LH)
Connector No. B5 Except Australia
Connector color Gray

Test adapter No. J-35616-33
APP sensor 2
1 GRN
5 volts reference
2 YEL APP sensor 2 signal
3 BLU APP sensor 2 low reference 1 2
APP sensor 1
4 BLK
5 volts reference
5 WHT APP sensor 1 signal
6 RED APP sensor 1 low reference
Air/ Fuel Ratio (A/F) Sensor LNW46ESH003901
Connector No. J92

1 BLK Ground
1 2
GRN/
3 4 2 Valve control
WHT
Automatic Valve (at tank) (LH)

For Australia
LNW91ASH001201
Connector No. E120

1 2 3
1 RED/ YEL Sensor heater control (-)
RED/
2 Sensor heater control (+)
WHT
3 GRN Sensor signal (AFC)
4 RED Sensor signal (AFV) LNW91ASH001801

Automatic Valve (at tank) (RH)
Connector No. J92 For Australia

1 BLK Ground
2 PNK/ WHT Valve control
3 WHT Retention coil control
1 2 3
Automatic Valve (at tank) (RH)

Except Australia
LNW91ASH001801
Connector No. J94
1 2 Connector color Black

1 BLK Ground
2 BLK/ RED Valve control
LNW46ESH003901
Automatic Valve (before regulator)

Connector No. J94
1 BLK Ground
2 WHT Valve control
1 2 3
LNW91ASH001801

CNG Pressure/ Temperature Sensor
Connector No. J199 Except Australia

1 BLK Ground
2 BLK/ RED Suction coil control
1 2 3 4
Camshaft Position (CMP) Sensor
LNW91ASH001301
Connector No. E136

1 2 3
1 BLK/ RED Sensor low reference
CNG temperature sensor
2 BLU/ RED
signal
LNW91ASH001501
RED/ CNG pressure sensor 5 volts
3
WHT reference
Connector No. E121
WHT/
4 CNG pressure sensor signal
Connector color Black RED
CNG Pressure Sensor
For Australia
1 BLK Shield ground
2 WHT Sensor signal
3 RED Sensor 14 volts reference
1 2 3
MFW91ASH000501

Crankshaft Position (CKP) Sensor
Connector No. E136
RED/
1 Sensor 5 volts reference
WHT
WHT/
2 Sensor signal 1 2 3
RED
CNG Temperature Sensor

For Australia
LNW91ASH001401
Connector No. E122

1 2 Pin No. Wire color Pin function
1 WHT Sensor signal
2 BLK Sensor low reference
3 BLU Sensor 5 volts reference
Engine Coolant Temperature (ECT) Sensor

MFW91ASH000401
Connector No. E127

1 YEL/ RED Sensor low reference
2 BLU/ RED Sensor signal 1 2
LNW46ESH001201
Connector No. E126

Connector No. E138 Connector color White
Connector color Black Pin No. Wire color Pin function
Test adapter No. J-35616-33 Cylinder #4 gas injector (High)
15 GRY
Pin No. Wire color Pin function (Input from ECM)
1 BLK/ RED Sensor low reference Cylinder #2 gas injector (High)

16 WHT
(Input from ECM)
2 RED/ BLK Sensor signal
17 PNK/ WHT
monitor (Output to ECM)
Engine Driver Unit (EDU)
18 YEL
Throttle motor (High) 1
19 BRN
(Input from ECM)
Throttle motor (High) 2
20 GRN
(Input from ECM)
21 GRN/ RED Battery voltage
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
22 BLK EDU system ground
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
23 BLK EDU power ground
Throttle motor (-)
24 GRN
(Output to throttle valve)
Throttle motor (+)
25 RED
(Output to throttle valve)
WHT/ Cylinder #1 gas injector (Low)
26
LNW91ASH000901 RED (Output to gas injector)
Cylinder #1 gas injector (High)
27 BLK/ RED
Connector No. E126 (Output to gas injector)
Connector color White Cylinder #3 gas injector (Low)

28 RED
(Output to gas injector)
1 BLK EDU power ground 29 WHT
2 – Not used Cylinder #4 gas injector (Low)
30 LT GRN
3 – Not used (Output to gas injector)
4 – Not used Cylinder #4 gas injector (High)

31 BLU
5 – Not used
GRY/ Cylinder #2 gas injector (Low)
6 – Not used 32
GRN (Output to gas injector)
7 – Not used Cylinder #2 gas injector (High)
33 YEL/ RED
8 – Not used (Output to gas injector)
9 – Not used 34 – Not used
10 – Not used Cylinder #1 gas injector (Low)

35 BLK/ WHT
(Input from ECM)
11 – Not used
Cylinder #3 gas injector (Low)
12 – Not used 36 BLK/ BLU
(Input from ECM)
Cylinder #1 gas injector (High) Cylinder #4 gas injector (Low)
13 BRN 37 GRN
(Input from ECM) (Input from ECM)
14 WHT/ BLU
(Input from ECM)
Connector No. E126 Fuel Tank (CNG Container) Pressure Sensor
Connector color White

Cylinder #2 gas injector (Low)
38 RED
(Input from ECM)
LT GRN/ Cylinder #4 gas injector circuit
39
RED monitor (Output to ECM)
40
ORN/
GRN
123
Throttle motor (Low) 2
41 RED
(Input from ECM)
Throttle motor (Low) 1
42 YEL
(Input from ECM)
43 GRN/ RED Battery voltage
44 BLK EDU system ground LNW46ESH001501
Exhaust Brake Solenoid Valve

Connector No. J200
2 BLK/ PNK Sensor signal
3 BLK/ YEL Sensor 5 volts reference
1 2
Gas Injector #1 Cylinder
LNW66ESH001101
Connector No. J96 1 2

1 BLK/ RED Ignition voltage feed
2 BLK Solenoid valve control
LNW91ASH001001

Connector No. E139
WHT/
1 Gas injector control low side
RED
2 BLK/ RED Gas injector control high side 1 2
LNW91ASH001001
Connector No. E141

1 2
1 RED Gas injector control low side
2 WHT Gas injector control high side
LNW91ASH001001
Connector No. E140

GRY/
1 Gas injector control low side
GRN 1 2
2 YEL/ RED Gas injector control high side
LNW91ASH001001
Connector No. E142

1 LT GRN Gas injector control low side
Connector No. E142 Ignition Coil Cylinder #2

2 BLU Gas injector control high side
Ignition Coil Cylinder #1
1 2 3
LNW91ASH001101
1 2 3
Connector No. E129

LNW91ASH001101
RED/
1 Power supply
WHT
Connector No. E130 2 BLK Ground
Connector color Black 3 RED/ BLK Ignition coil control
RED/
1 Power supply
WHT
2 BLK Ground
3 RED/ BLU Ignition coil control
1 2 3
LNW91ASH001101

Intake Air Temperature (IAT) Sensor
Connector No. E128
RED/
1 Power supply
WHT
2 BLK Ground
3 RED Ignition coil control 1 2
LNW76ESH006101
Connector No. E134

Connector color Yellow
1 2 3
1 YEL/ GRN Sensor signal
2 GRN Sensor low reference
Knock Sensor (Except Australia)

LNW91ASH001101
Connector No. E131

RED/
1
WHT
Power supply 1 2
2 BLK Ground
3 RED/ YEL Ignition coil control
LNW46ESH003901
Connector No. E145

1 WHT Sensor signal
Connector No. E145 O2 Sensor

Manifold Absolute Pressure (MAP) Sensor

1 2
3 4
LNW91ASH001201
1 2 3
Connector No. J97

LNW91ASH001601
BRN/
1 Sensor heater control (+)
WHT
Connector No. E133 2 YEL Sensor signal
Connector color Brown 3 VIO/ WHT Sensor low reference
Test adapter No. J-35616-33 RED/
4 Sensor heater control (-)
WHT
1 BLK Sensor low reference PI Monitor Connector
2 WHT Sensor signal
3 RED Sensor 5 volts reference
1 2 3 4
5 6 7 8 9
LNW91ASH002201

Throttle Valve
Connector No. B283
1 YEL/ GRN Memory clear request switch
2 YEL Diagnostic request switch
1 2 3
3 – Not used
4 5 6
4 GRN 12 volts feed
5 BLK Ground
Pull-in coil of automatic valve
6 BLK/ WHT
turn ON request switch
RED/
7 Battery voltage feed
WHT LNW91ASH001701
Hold-in coil of automatic valve

8 GRY/ RED
turn ON request switch
Connector No. E137
9 BLK Ground
PTO Throttle Sensor Test adapter No. J-35616-33
Position sensor 5 volts
1 RED
reference
2 RED Motor control (+)
3 GRN Motor control (-)
4 WHT Position sensor 2 signal
5 GRN Position sensor 1 signal
1 2 3
6 BLU Position sensor low reference
Vehicle Speed Sensor (VSS)
LNW81ASH001601
Connector No. J99

Test adapter No. J-35616-33 1 2 3
1 BLU/ RED Sensor low reference
2 BLU/ WHT Sensor signal
3 BLU Sensor 5 volts reference
RTW76ESH000701
Connector No. J48

Connector color Light Gray
1 RED/ BLK Ignition voltage feed
3 YEL/ GRN Sensor signal
Diagnostic Information and Procedures

Engine Control System Check Sheet
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name

Customers Name Model & Model Year
Drivers Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km/miles
Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms
Incorrect Idle Rough idling

Other ( )
Hesitation, sag, stumble Surge Cut out
Poor Lack of power, sluggishness, sponginess
Driveability
Other ( )
Soon after starting After accelerator pedal depressed
Engine Stall During A/C operation After accelerator pedal released Shifting from N to D
Other ( )
Black smoke White smoke Poor fuel economy
Others Abnormal combustion noise DPF system emergency regeneration frequently
DPF system regeneration long time
Other ( )
Dates problem occurred

Problem frequency Constant Intermittently ( times per day/month) Once only
Other ( )
Weather Fine Cloudy Rainy Snow
Various/Other ( )
Outside Hot (approx. ) Warm Cool Cold (approx. )
Condition When Problem Occurs
Temperature Any temperature

Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland
Condition of MIL Remains On Intermittently turns On Does not turn On
Present Code Nothing P or U Code

No. ( )
Diagnostic Trouble
Code (DTC)
History Code Nothing P or U Code
No. ( )
Other Additional
Condition
LNW91AXF000801

Diagnostic Starting Point - Engine Controls
Begin the system diagnosis with Diagnostic System Battery
Check - Engine Controls. The Diagnostic System

Check - Engine Controls will provide the following
information: Check
• The identification of the control modules which Engine
command the system. Warning
Light
• The ability of the control modules to communicate

through the serial data circuit.
• The identification of any stored diagnostic trouble Diag. Switch
ECM
codes (DTCs) and the their statuses.
The use of the Diagnostic System Check - Engine
Controls will identify the correct procedure for Memory Clear Switch
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 LNW91ASH000701
know the correct (normal) operating behavior of the

system and verify that the customer complaint is a valid
Self-diagnosis control modes
failure of the system.
You can switch to the self-diagnosis modes by
Self-diagnosing function switching the diagnostic switch function and memory
clear switch function. However, the ignition switch
If there is a malfunction of a sensor or actuator, etc., a
should be left "ON" during each mode.
trouble code will be stored in the ECM memory, the
check engine warning light will illuminate (continually
illuminate), and the system may enter the backup Memory
Diagnosis
process, depending on the trouble code. clear Engine
switch Control mode
The check engine warning light turns off when the switch revolution
function
problem is resolved, but the trouble code will remain function
recorded until you connect pins 1 and 5 of the PI
Light check
monitor connector and turn the memory clear switch (1) OFF OFF Stopped
mode
function to "ON" or clear the code using the scan tool.
(2) OFF OFF Running Normal mode
Trouble code
(3) OFF ON Stopped
clear mode
Trouble code
(4) ON OFF Stopped
display mode
Stopped/ Backup data
(5) ON ON
running clear mode
Light check mode

1. When the ignition switch is turned "ON", the check
engine warning light illuminates.
LNW91ASH002101

2. If no trouble is detected, the check engine warning Trouble code clear mode
light turns off 4 seconds after starting the engine. If you connect pins 1 and 5 of the PI monitor connector
If any failure is detected, the check engine warning and the memory clear switch function stays "ON" for 3
light remains illuminated after starting the engine. consecutive seconds, or if a scan tool is used for
clearing, all of the trouble codes recorded in the ECM
will be cleared.
1 2 3 4
ST 5 6 7 8 9
ON
Ignition Switch OFF
Start
Engine Start Stop
Continue to ON
Determination (When there is a problem)
ON
Check Engine OFF OFF (When there is no problem)
Warning Light
4 Sec.
LNW91ASH000801
Normal mode LNW91ASH001901
1. If an emission related (DTC type A or B) code is

detected, the DTC will be recorded, and the check Trouble code display mode
engine warning light remains illuminated. (For DTC 1. If you connect pins 2 and 5 of the PI monitor
type D, only the DTC is recorded) connector with the ignition switch turned "ON" (but
2. If after detecting a failure, the vehicle becomes the engine stopped), the system will enter the
normal, and the ignition cycle has been cleared trouble code display mode while the diagnostic
three times, the check engine warning light will turn switch function is turned "ON".
off.
However, the trouble code will remain recorded.
3. If the same failure does not occur once after 40
warm up cycles, that trouble code will be cleared.
1 2 3 4
5 6 7 8 9
LNW91ASH002001

2. If no trouble codes are recorded, code "12" will be
repeatedly displayed three times.
If trouble codes are recorded, code "12" and the
recorded trouble codes will be repeatedly
displayed three times.
Example Display of Codes 23,44
Normal Code Trouble Code Trouble Code
12 12 12 23 23 23 44 44 44 12
Display of Normal Code 12
10 1 2
ON
OFF
0.4 0.4 1.2 0.4 0.4 0.4 3.2 Time (Sec.)
1Cycle
Display 2nd Cycle
Starts Starts
Example Display of Code 23
10
ON
OFF
0.4 0.4 0.4 0.4 1.2 0.4 0.4 0.4 0.4 0.4 3.2 Time (Sec.)
1Cycle
Display 2nd Cycle
Starts Starts
LNW91AMF000701
Backup data clear mode

1. The system will enter the backup data clear mode
when you connect pins 1 and 5 of the PI monitor
connector with the ignition switch turned "ON", turn
the memory clear switch function "ON", connect
pins 2 and 5 of the PI monitor connector, and turn
the diagnostic switch function "ON".
2. After 3 seconds have elapsed, the following values
are returned to their initial values.
• A/F sensor threshold value
• Air-fuel ratio learning value
• Coefficient corrected by fuel of different kind
• Throttle idling position learning value
• Learning value for the throttle fully closed
position
• Learning value for the accelerator pedal
position (APP) sensor fully closed position

Diagnostic System Check - Engine Con- Diagnostic System Check Engine Controls
trols Important:
Description • DO NOT perform this diagnostic if there is not a
driveability concern, unless another procedure
The Diagnostic System Check - Engine Controls is an
directs you to this diagnostic.
organized approach to identifying a condition that is
created by a malfunction in the electronic engine • Before you proceed with diagnosis, search for
control system. The Diagnostic System Check must be applicable service bulletins.
the starting point for any driveability concern. The • Unless a diagnostic procedure instructs you, DO
Diagnostic System Check directs the service technician NOT clear the DTCs.
to the next logical step in order to diagnose the • If there is a condition with the starting system, refer
concern. Understanding and correctly using the to the Starting System in Section 1E Engine
diagnostic table reduces diagnostic time, and prevents Electrical (4HV1-CNG).
the replacement of good parts.
• Ensure the battery has a full charge.
Test Description • Ensure the battery cables (+) (-) are clean and
tight.
The numbers below refer to the step numbers on the
diagnostic table. • Ensure the ECM grounds are clean, tight, and in
2. Lack of communication may be because of a partial the correct location.
or a total malfunction of the serial data circuit. • Ensure the ECM harness connectors are clean
6. The DTC list directs you to the appropriate and correctly connected. DO NOT attempt to crank
diagnostic procedure. If the control module stores the engine with ECM harness connectors
multiple DTCs, diagnose the DTCs in the following disconnect.
order: • Ensure the ECM terminals are clean and correctly
• Component level DTCs, such as sensor DTCs, mating.
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.
Step Action Value(s) Yes No

Install a scan tool.
1 — Go to Scan Tool
Does the scan tool turn ON? Go to Step 2 Does Not Power Up
1. Turn ON the ignition, with the engine OFF.
2. Attempt to establish communication with the Go to Scan Tool
2 ECM. — Does Not
Communicate with
Does the scan tool communicate with the ECM? Go to Step 3 the ECM
1. Turn ON the ignition, with the engine OFF. Go to Check Engine
2. Check the check engine warning light. Warning Light
3 —
Illumination Circuit
Did the check engine warning light illuminate? Go to Step 4 System Check
1. Connect pins 2 and 5 of the PI monitor
connector. Go to Check Engine
4 2. Check the check engine warning light. — Warning Light
Blinking Circuit
Did the check engine warning light blink? Go to Step 5 System Check
Attempt to start the engine.
5 — Go to Starting
Does the engine start and idle? Go to Step 6 System Check
Does the scan tool display ECM DTCs? Go to Applicable
6 —
DTC Go to Step 7

1. Review the following symptoms.
2. Refer to the applicable symptom diagnostic
table:
• Abnormal Combustion Noise
• Poor Fuel Economy
• Hard Start
• Rough, Unstable, or Incorrect Idle and
7 Stalling —
• High Idle Speed
• Pulsing in Engine Speed
• Surges
• Lack of Power, Sluggishness or
Sponginess
• Abnormal Sound/ Abnormal Smell
Go to Intermittent
Did you find and correct the condition? System OK Conditions

Scan Tool Data List • The Engine Controls - Diagnostic System Check is
completed.
The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool. • On-board diagnostics are functioning properly.
A given parameter may appear in any one of the data Scan tool values from a properly running engine may
lists, and in some cases may appear more than once, be used for comparison with the engine you are
or in more than one data list in order to group certain diagnosing. The Engine Scan Tool Data List represents
related parameters together. Use the Engine Scan Tool values that would be seen on a normal running engine.
Data List only after the following is determined: Only the parameters listed below are referenced in this
service manual for use in diagnosis.
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle
Operating Conditions: Engine idling/ Engine coolant temperature is higher than 80°C (176°C)/ Accelerator pedal
is not depressed/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level.
Vehicle Speed km/h / MPH 0
Desired Idling Speed RPM 650
Engine Speed RPM 663
Desired Throttle Position ° 2
TPS Signal (Throttle Position ° 2
Sensor)
APS Signal (Acceleration Pedal ° 0
Sensor)
MAP Sensor (Manifold Absolute kPa 26
Pressure)
Fuel Pressure Sensor kPa 361
Engine Coolant Temperature °C / °F 87
IAT Sensor (Intake Air Temperature) °C / °F 38
Fuel Temperature Sensor °C / °F 67
Air Fuel Ratio Sensor — 0.97
O2 Sensor 2 mV 810
Barometric Pressure kPa 98
PTO Accelerator Sensor ° 0
Ignition Voltage V 13.6
System Voltage V 27.2
Injection Pulse Width ms 4.96
Air Fuel Ratio Sensor Threshold — 0.98
Ignition Timing ° 8
Dwell Angle ° 12
Acceleration Pedal Sensor #1 ° 0
Acceleration Pedal Sensor #2 ° 0.12
Throttle Position Sensor #1 ° 3.46
Throttle Position Sensor #2 ° 2.96
Basic of Jetting Pulse Width (Tp) ms 5
F/B (Feed Back) Correction % 100
Coefficient to correction Open Loop % 78
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle
Coefficient in which studied mixture % 100
ratio is revised
Map of Coefficient in which studied % 100
mixture ratio is revised
Coefficient corrected by fuel of % 100
different kind
Timing to finish jetting ° 50
Throttle Position Sensor Learning ° 3
Value
Electronic Control Throttle Default ° 11
Position
Commanded Air Fuel Ratio — 0.98
Injection Control Phase Refer to Table 1 Close Loop (Idle)
Electronic Throttle Control Phase Refer to Table 2 Idle
Exhaust Brake Switch ON/OFF OFF
Parking Switch ON/OFF ON
PTO Idle Switch ON/OFF ON
Accelerator Idle Switch ON/OFF ON
Idle Switch ON/OFF ON
Clutch Switch ON/OFF ON
Memory Clear Switch ON/OFF OFF
Diagnostic Switch ON/OFF OFF
PTO Switch ON/OFF OFF
Freezer Switch ON/OFF OFF
A/C Switch (Air Conditioning) ON/OFF OFF
Accelerator Pedal Switch ON/OFF ON
Neutral Switch ON/OFF ON
Starter Switch ON/OFF OFF
Ignition Switch Status ON/OFF ON
Exhaust Brake VSV (Vacuum ON/OFF OFF
Switching Valve)
O2 Sensor Heater ON/OFF ON
Warning Lamp ON/OFF OFF
F/C (Fuel Cut) Solenoid ON/OFF OFF
F/C 2 (Fuel Cut 2) Solenoid ON/OFF ON
ECM Relay ON/OFF ON
Fuel Tank Pressure Sensor MPa 9
Table 1 Deceleration
Open Loop High Load Increase
Fuel Cut A/F Sensor Error
Power Management
Closed Loop
Close Loop(Idle)
Table 2
Engine Stopped/Crank
NEES Roll Req
PTO
Speed Limiter
Engine Stop Saver
Decelerate Fuel Cut
Deceleration
Idle(Running)
Idle
Off Idle Control

Scan Tool Data Definitions IAT Sensor (Intake Air Temperature)
This parameter displays the temperature of the intake
This information will assist in emission or driveability
air as calculated by the ECM using the signal from the
problems. The displays can be viewed while the vehicle
intake air temperature (IAT) sensor. The scan tool will
is being driven. Always perform the Diagnostic System
display a low temperature when the IAT sensor signal
Check - Engine Controls first. The Diagnostic System
voltage is high, and a high temperature when the IAT
Check will confirm proper system operation.
sensor signal voltage is low.
Vehicle Speed
Fuel Temperature Sensor
This parameter indicates the vehicle speed calculated
This parameter displays the temperature of the fuel as
by the ECM using the signal from the vehicle speed
calculated by the ECM using the signal from the CNG
sensor (VSS). The scan tool will display a low value at
temperature sensor. The scan tool will display a low
lower vehicle speeds, and a high value at higher
temperature when the CNG temperature sensor signal
vehicle speeds.
voltage is high, and a high temperature when the CNG
Desired Idling Speed temperature sensor signal voltage is low.
This parameter displays the idle speed requested by
Air Fuel Ratio Sensor
the ECM. The ECM will change desired idle speed
This parameter displays the current air-fuel ratio
based on engine coolant temperature and other inputs.
calculated by the ECM based on input signals from the
Engine Speed A/F sensor.
This parameter displays the rotational speed of the
O2 Sensor 2
crankshaft as calculated by the ECM based on inputs
This parameter displays the output voltage value of the
from the crankshaft position (CKP) sensor or camshaft
O2 sensor.
position (CMP) sensor.
Barometric Pressure
Desired Throttle Position
This parameter displays the barometric pressure
This parameter displays throttle valve position desired
(BARO) as calculated by the ECM using the signal from
by the ECM based on current driving conditions. This
the BARO sensor. The scan tool will display a low
can be compared to the actual throttle valve position to
barometric pressure in high altitude area.
determine sensor accuracy or valve control problems.
PTO Accelerator Sensor
TPS Signal (Throttle Position Sensor)
This parameter displays the angle of the PTO throttle
This parameter displays the angle of the throttle valve
sensor as calculated by the ECM using the signal from
position calculated by the ECM using the signal from
the PTO throttle sensor. The PTO throttle angle is a
intake throttle position sensor. The scan tool will display
range of values indicating a small angle when the
a small angle when the throttle valve is closed, and a
throttle sensor is not operated to a large angle when
large angle when the throttle valve is opened.
the throttle sensor is operated.
APS Signal (Acceleration Pedal Sensor)
Ignition Voltage
This parameter displays the angle of the accelerator
This parameter displays the ignition voltage measured
pedal as calculated by the ECM using the signals from
at the ignition feed circuit of the ECM. Voltage is
the accelerator pedal position (APP) sensors. The scan
applied to the ECM when the ignition switch is ON
tool will display linearly from 0 to 36° according to the
position.
pedal operation.
System Voltage
MAP Sensor (Manifold Absolute Pressure)
This parameter displays the battery voltage measured
This parameter displays the current manifold absolute
at the ECM main relay switched voltage feed circuit of
pressure detected by the MAP sensor.
the ECM. Voltage is applied to the ECM when the ECM
Fuel Pressure Sensor main relay is energized.
This parameter displays the current fuel pressure
Injection Pulse Width
detected by the CNG pressure sensor.
This parameter displays the fuel injection time that the
Engine Coolant Temperature ECM is outputting to the gas injector.
This parameter displays the temperature of the engine
Air Fuel Ratio Sensor Threshold
coolant as calculated by the ECM using the signal from
This parameter displays the air-fuel ratio threshold
the engine coolant temperature (ECT) sensor. The
value set in the ECM in advance.
scan tool will display a low temperature when the ECT
sensor signal voltage is high, and a high temperature Ignition Timing
when the ECT sensor signal voltage is low. This parameter displays the ignition timing that the
ECM is outputting to the ignition coil.

Dwell Angle Commanded Air Fuel Ratio
This parameter displays the dwell angle (angle before This parameter displays the desired air-fuel ratio
the top dead center) for starting fuel injection calculated calculated by the ECM.
by the ECM.
Injection Control Phase
Acceleration Pedal Sensor #1 This parameter displays the current status of fuel
This parameter displays the current accelerator injection control.
opening angle detected by the APP sensor 1.
Electronic Throttle Control Phase
Acceleration Pedal Sensor #2 This parameter displays the current status of throttle
This parameter displays the current accelerator control.
opening angle detected by the APP sensor 2.
Exhaust Brake Switch
Throttle Position Sensor #1 This parameter displays the input status of the exhaust
This parameter displays the current throttle position brake switch.
detected by the intake throttle position sensor 1.
Parking Switch
Throttle Position Sensor #2 This parameter displays the input status of the parking
This parameter displays the current throttle position brake switch.
detected by the intake throttle position sensor 2.
PTO Idle Switch
Basic of Jetting Pulse Width (Tp) This parameter displays the status of the PTO
This parameter displays the basic fuel injection time accelerator. Displays "ON" when the ECM detects a
calculated by the ECM. PTO accelerator position of 0%.
F/B (Feed Back) Correction Accelerator Idle Switch
This parameter displays the correction value for the fuel This parameter displays the status of the accelerator
injection amount calculated by the ECM based on input idle switch that the ECM has detected internally.
signals from the O2 sensor. (After starting feedback
Idle Switch
control)
This parameter displays the status of the idle switch
Coefficient to correction Open Loop that the ECM has detected internally.
This parameter displays the correction value for the fuel
Clutch Switch
injection amount calculated by the ECM based on input
This parameter displays the input status of the clutch
signals from the engine rpm and basic fuel injection
switch.
amount, etc. (Before starting feedback control)
Memory Clear Switch
Coefficient in which studied mixture ratio is revised
This parameter displays the input status of the memory
This parameter displays the correction coefficient for
clear switch.
the fuel injection amount calculated by the ECM based
on the air-fuel ratio learning control. Diagnostic Switch
This parameter displays the input status of the
Map of Coefficient in which studied mixture ratio is
diagnostic switch.
revised
This parameter displays the correction coefficient map PTO Switch
for the fuel injection amount calculated by the ECM This parameter displays the input status of the PTO
based on the air-fuel ratio learning control. switch.
Coefficient corrected by fuel of different kind Freezer Switch
This parameter displays the correction coefficient for This parameter displays the input status of the
the fuel injection amount calculated by the ECM based refrigerator switch.
on the different fuel control. A/C Switch (Air Conditioning)
Timing to finish jetting This parameter displays the input status of the A/C
This parameter displays the dwell angle (angle after the switch.
top dead center) for finishing fuel injection calculated
Accelerator Pedal Switch
by the ECM.
This parameter displays the status of the accelerator
Throttle Position Sensor Learning Value pedal. Displays "ON" when the ECM detects an
This parameter displays the learning value for the accelerator pedal position of 0%.
intake throttle position sensor.
Neutral Switch
Electronic Control Throttle Default Position This parameter displays the input status of the neutral
This parameter displays the throttle opening angle switch.
when the throttle position is 0% that is set in the ECM in
Starter Switch
advance.
This parameter displays the input status of the ignition
switch "START" signal.

Ignition Switch Status
This parameter displays the input status of the ignition
switch "ON" signal.
Exhaust Brake VSV (Vacuum Switching Valve)
This parameter displays the control status of the
exhaust brake solenoid valve.
O2 Sensor Heater
This parameter displays the control status of the O2
sensor heater.
Warning Lamp
This parameter displays the control status of the MIL.
F/C (Fuel Cut) Solenoid
This parameter displays the control status of the gas
cut valve relay.
F/C 2 (Fuel Cut 2) Solenoid
This parameter displays the control status of the gas
valve relay.
ECM Relay
This parameter displays the control status of the ECM
relay.
Fuel Tank Pressure Sensor
This parameter displays the fuel pressure detected
near the CNG container (CNG cylinder) by the fuel tank
(CNG container) pressure sensor.

Scan Tool Output Controls
Scan Tool Output Controls Descriptions

A/C Relay The purpose of this test is for checking whether the air compressor relay is
operating when commanded ON. Faulty circuit(s) or a faulty air compressor
relay could be considered if not energizing when commanded ON.
F/C (Fuel Cut) Solenoid The purpose of this test is for checking whether the pull-in coil of the
automatic valve is operating when commanded ON. Faulty circuit(s) or a
faulty automatic valve could be considered if not energizing when
commanded ON.
F/C 2 (Fuel Cut 2) Solenoid The purpose of this test is for checking whether the hold-in coil of the
automatic valve is operating when commanded ON. Faulty circuit(s) or a
faulty automatic valve could be considered if not energizing when
commanded ON.
Warning Lamp The purpose of this test is for checking whether the check engine warning
light is operating when commanded ON. Faulty circuit(s) or open bulb could
be considered if not operating when commanded ON.
Injector Operate The purpose of this test is for checking whether the gas injector is operating
when commanded Increase/ Decrease. Faulty gas injector(s) could be
considered if engine does not change speed when commanded Increase/
Decrease.
Electric Control Throttle Operate The purpose of this test is for checking whether the throttle valve is
correctly moved with command. Restricted valve movement by foreign
materials, excessive deposits or a faulty valve could be considered if the
position difference is large.
Ignition Spark Timing Change The purpose of this test is for checking whether the ignition timing is
changing when commanded Increase/ Decrease.
Exhaust Brake Lamp The purpose of this test is for checking whether the exhaust brake indicator
light is operating when commanded ON. Faulty circuit(s) or open bulb could
be considered if not operating when commanded ON.
Exhaust Brake VSV The purpose of this test is for checking whether the exhaust brake solenoid
valve is operating when commanded ON. Faulty circuit(s) or a faulty
solenoid valve could be considered if not energizing when commanded ON.
Desired Idle Speed Change The purpose of this test is for checking whether the idle speed is changing
when commanded Increase/ Decrease.

Scan Tool Does Not Power Up • Scan tool power ground at terminal 4.
Circuit Description • Common signal ground at terminal 5.
The scan tool will power up with the ignition OFF. Some
The data link connector (DLC) is a standardized 16- modules however, will not communicate unless the
cavity connector. Connector design and location is ignition is ON.
dictated by an industry wide standard, and is required
to provide the following: Connector End View Reference: Engine Controls
• Scan tool power battery positive voltage at Connector End Views or ECM Connector End Views
terminal 16.
Circuit/ System Testing Scan Tool Does Not Power Up

Important: Make sure the scan tool and 24 volts
adapter works properly on another vehicle before
using this chart.
1 1. Turn OFF the ignition. —

2. Inspect the Room Lamp, Audio (15A) fuse in
the cabin fuse block.
Is the Room Lamp, Audio (15A) fuse open? Go to Step 2 Go to Step 3

Replace the Room Lamp, Audio (15A) fuse. If the
fuse continues to open, repair the short to ground
on one of the circuits that is fed by the Room Lamp,
2 Audio (15A) fuse or replace the shorted attached —
component.
Did you complete the repair? Go to Step 7 —

1. Check each circuit at the data link connector
(DLC) (B31) for a backed out, spread or
missing terminal.
3 —
2. Repair the terminal as necessary.
Did you find and complete the repair? Go to Step 7 Go to Step 4

Connect a test lamp between the +B circuit (pin 16
4 of B31) at the DLC and a known good ground. —
Does the test lamp illuminate? Go to Step 6 Go to Step 5
Repair the open in the battery voltage circuit to the
5 DLC. —
1. Test each ground circuit at the DLC (pins 4
and 5 of B31) for an open circuit or high
resistance.
6 2. Repair the circuit(s), clean or tighten ground —
as necessary.
Go to Intermittent
Did you find and correct the condition? Go to Step 7 Conditions
1. Connect the scan tool to the DLC.
7 2. Attempt to turn ON the scan tool. —
Does the scan tool ON? System OK Go to Step 1

Scan Tool Does Not Communicate with the Engine Control Module (ECM)
Circuit Description
The ECM communicate with the scan tool over the
Keyword serial data link.
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing Scan Tool Does Not Communicate with the Engine Control Module (ECM)

Did you perform the Diagnostic System Check - Go to Diagnostic
1 Engine Controls? — System Check -
Go to Step 2 Engine Controls
Attempt to establish communication with the ECM.
2 — Go to Intermittent
Does the scan tool communicate with the ECM? Conditions Go to Step 3
1. Inspect the poor connection at the ECM
connector and the in-line connector.
2. Inspect the poor connection at the scan tool
3 connector and the data link connector (DLC). —
3. Repair the connection(s) as necessary.
Did you find and correct the condition? Go to Step 19 Go to Step 4

1. Turn OFF the ignition.
2. Inspect the following slow blow fuses (SBF)
and fuses.
4 • STARTER SW1 (40A) SBF (SBF6) —
• ECU (30A) SBF (SBF1)
• ECM (IG) (10A) fuse (F20)
Is the SBF or fuse open? Go to Step 12 Go to Step 5

2. Replace the ECM main relay with a known
good relay.
5 3. Turn ON the ignition, with the engine OFF. —
4. Attempt to establish communication with the
ECM.
Does the scan tool communicate with the ECM? Go to Step 13 Go to Step 6
2. Disconnect the ECM harness connector.
3. Connect a test lamp to ground and check for
6 voltage at ignition voltage supply circuit at the —
ECM (pin 5 of J95).


2. Remove the ECM main relay.
3. Connect a 3-amp fused jumper wire between
the switch side terminals at the ECM main
relay (pins 1 and 2 of X18) and between the
coil side terminals (pins 3 and 5 of X18)
7 respectively. —
4. Connect a test lamp to ground and the ECM
main relay control circuit and battery voltage
supply circuits (pins 3, 4 and 16 of J95) of the
ECM.

2. Remove the jumper wire.
3. Connect a test lamp to ground and the voltage
8 —
supply circuit at the ECM main relay (pins 1
and 3 of X18).

1. Install the ECM main relay.
2. Connect a test lamp between the ECM main
relay control circuit (pin 16 of J95) and each
9 ECM ground circuit (pins 1, 2, 75, 76, 77 and —
78 of J95) at the ECM.

1. Test the Keyword serial data circuits between
the ECM (pin 24 of J95) and the DLC (pin 7 of
B31) for an open circuit or high resistance.
10 2. Repair the connection(s) or circuit(s) as —
necessary.

2. Inspect for an intermittent, for poor
connections and for corrosion at the harness
11 connector of the ECM (pins 1, 2, 3, 4, 5, 16, —
24, 75, 76, 77 and 78 of J95).

Replace the SBF or fuse. If the SBF or fuse
continues to open, repair the short to ground on
12 one of the circuits that is fed by the SBF or fuse or —
replace the shorted attached component.
Did you complete the replacement? Go to Step 19 —

Replace the ECM main relay.
13 —
Repair the open in the ignition voltage circuit to the
14 ECM. —
Repair the open circuit or high resistance on
15 voltage supply circuit to the ECM main relay . —

Repair the open circuit or high resistance on the
16 circuit between the ECM main relay and the ECM. —
17 ECM ground circuit. —
Important: Replacement ECM must be learned.
Replace the ECM. Refer to ECM Replacement in
18 this section. —

2. Reconnect all previously disconnected fuse,
relay or harness connector(s).
4. Attempt to establish communication with the
ECM.
Does the scan tool communicate with the ECM? System OK Go to Step 3

DTC P0105 (Flash Code 71)
Barometric Pressure Sensor Circuit Error Action Taken When the DTC Sets
• The ECM illuminates MIL when the diagnostic runs
Circuit Description and fails. Refer to DTC Type Definitions for Action
The barometric pressure (BARO) sensor is situated Taken When the DTC Sets - Type A.
inside the engine control module (ECM), and outputs a • Performs control with 100 kPa as the barometric
voltage according to the pressure, and the ECM uses pressure.
the signal to detect the barometric pressure.
The ECM monitors whether the BARO sensor signal Condition for Clearing the DTC
voltage is in a normal range, and sets this DTC when it • Refer to DTC Type Definitions for Condition for
determines that the BARO sensor signal voltage is too Clearing the MIL/ DTC - Type A.
low or high.
Condition for Setting the DTC Connector End Views or ECM Connector End Views
• The ECM detects that the BARO sensor signal
voltage is less than 0.296 volts or more than 4.848
volts for 5 seconds.
Circuit/ System Testing DTC P0105 (Flash Code 71)

1. Clear the DTCs with a scan tool.
2. Turn OFF the ignition for 15 seconds.
4. Monitor the DTC Information with a scan tool.
Did the DTC fail this ignition? Go to Step 3 Go to Step 4

3 this section. —

Observe the DTC Information with a scan tool.
4 —
Are there any DTCs that you have not diagnosed? Go to DTC List System OK

Intake Air Pressure Sensor Circuit Low Condition for Setting the DTC
Voltage • The ECM detects that the MAP sensor signal
voltage is less than 0.1 volts for 3 seconds after
Circuit Description starting the engine.
The manifold absolute pressure (MAP) sensor is
installed on the intake manifold. The MAP sensor Action Taken When the DTC Sets
outputs a voltage according to the pressure inside the • The ECM illuminates MIL when the diagnostic runs
intake manifold, and the engine control module (ECM) and fails. Refer to DTC Type Definitions for Action
uses the signal to detect the manifold absolute Taken When the DTC Sets - Type A.
pressure. The MAP sensor has the following circuits. • After starting the engine
• 5 volts reference circuit Control is performed with the manifold absolute
• Low reference circuit pressure set based on the engine rpm and throttle
valve opening angle.
• MAP sensor signal circuit
The ECM supplies 5 volts to the MAP sensor via the 5 • When the engine is stopped
volts reference circuit, and grounds the sensor to within Control is performed with the barometric pressure
the ECM via the low reference circuit. The MAP sensor value used instead of the manifold absolute
also outputs signal voltage to the ECM via the MAP pressure.
sensor signal circuit. The ECM detects a low manifold
absolute pressure (such as when the engine load is Condition for Clearing the DTC
low) when the signal voltage from the MAP sensor is • Refer to DTC Type Definitions for Condition for
low, and detects a high manifold absolute pressure Clearing the MIL/ DTC - Type A.
(such as when the engine load is high) when the signal
voltage from the MAP sensor is high. Diagnostic Aids
The ECM monitors whether the MAP sensor signal
• If an intermittent condition is suspected, refer to
voltage is in a normal range, and sets this DTC when it
Intermittent Conditions in this section.
determines that the sensor signal voltage is too low.

1. Install a scan tool.
Go to Diagnostic
Does the DTC fail this ignition? Go to Step 3 Aids
2. Disconnect the MAP sensor harness
connector.
3. Connect a DMM between the 5 volts reference
3 circuit (pin 3 of E133) and a known good 4.5 volts
ground.
Is the DMM voltage more than the specified value? Go to Step 7 Go to Step 4

Notice : If the vehivle is for Thailand or Australia,
skip to Step 6.
1. Test the 5 volts reference circuit between the
ECM (pin 110 of E125) and the CNG
pressure/ temperature sensor (pin 3 of E136)
4 for the following conditions: —
• A short to the low reference circuit
• A short to ground
2. Repair the circuit(s) as necessary.

ECM (pin 81 of J95) and the fuel tank (CNG
container) pressure sensor (pin 3 of J200) for
the following conditions:
5 • A short to the low reference circuit —

ECM (pin 111 of E125) and the MAP sensor
(pin 3 of E133) for the following conditions:
• An open circuit
6 —
• High resistance

1. Test the signal circuit between the ECM (pin
94 of E125) and the MAP sensor (pin 2 of
E133) for the following conditions:
7 —

1. Inspect for an intermittent and for poor
connections at the harness connector of the
MAP sensor (pins 2 and 3 of E133).
8 —

9 ECM (pins 94, 110 and 111 of E125 and pin 81 —
of J95).

Replace the MAP sensor. Refer to MAP Sensor in
10 Section 1J Induction (4HV1-CNG). —


1. Reconnect all previously disconnected
harness connector(s).
12 3. Turn OFF the ignition for 15 seconds. —


13 —

Intake Air Pressure Sensor Circuit High Condition for Setting the DTC
Voltage • The ECM detects that the MAP sensor signal
voltage is more than 4.843 volts for 3 seconds after
Circuit Description starting the engine.
The manifold absolute pressure (MAP) sensor is
installed on the intake manifold. The MAP sensor Action Taken When the DTC Sets
outputs a voltage according to the pressure inside the • The ECM illuminates MIL when the diagnostic runs
intake manifold, and the engine control module (ECM) and fails. Refer to DTC Type Definitions for Action
uses the signal to detect the manifold absolute Taken When the DTC Sets - Type A.
pressure. The MAP sensor has the following circuits. • After starting the engine
• 5 volts reference circuit Control is performed with the manifold absolute
• Low reference circuit pressure set based on the engine rpm and throttle
valve opening angle.
• MAP sensor signal circuit
The ECM supplies 5 volts to the MAP sensor via the 5 • When the engine is stopped
volts reference circuit, and grounds the sensor to within Control is performed with the barometric pressure
the ECM via the low reference circuit. The MAP sensor value used instead of the manifold absolute
outputs signal voltage to the ECM via the boost sensor pressure.
signal circuit. The ECM detects a low manifold absolute
pressure (such as when the engine load is low) when Condition for Clearing the DTC
the signal voltage from the MAP sensor is low, and • Refer to DTC Type Definitions for Condition for
detects a high manifold absolute pressure (such as Clearing the MIL/ DTC - Type A.
when the engine load is high) when the signal voltage
from the MAP sensor is high. Diagnostic Aids
The ECM monitors whether the MAP sensor signal
determines that the sensor signal voltage is too high.

Start the engine, and check whether the idling
2 condition is normal. — Go to Applicable
Was the idling condition normal? Go to Step 3 Symptom
Go to Diagnostic
connector.
ground.

1. Connect a DMM between the signal circuit
(pin 2 of E133) and a known good ground.
5 2. Turn ON the ignition, with the engine OFF. 5.5 volts
Is the DMM voltage more than the specified value
6 4.5 volts
at Step 5? Go to Step 7 Go to Step 11
1. Connect a test lamp between the signal circuit
7 2. Connect a DMM between the probe of the test 4.5 volts
lamp and a known good ground.
Connect a DMM between the signal circuit and low
8 reference circuit (pins 1 and 2 of E133). 4.5 volts
Important: The MAP sensor may be damaged if
the sensor 5 volts reference circuit is shorted to a
voltage source.
9 (pin 3 of E133) for the following conditions: —
• A short to battery or ignition voltage
• A short to any 12 volts reference

Important: The MAP sensor may be damaged if
the sensor signal circuit is shorted to a voltage
source.
10 E133) for the following conditions: —

• An open circuit
11 —
• High resistance

E133) for a short to any 5 volts reference
12 circuit. —


1. Test the low reference circuit between the
• An open circuit
13 —
• High resistance

MAP sensor (pins 1 and 2 of E133).
14 —

15 connections at the harness connector of the —
ECM (pins 86 and 94 of E125).




19 —

Intake Air Temperature (IAT) Sensor Circuit Condition for Setting the DTC
Low Voltage • The ECM detects that the IAT sensor signal
voltage is less than 0.1 volts for 5 seconds.
Circuit Description
The intake air temperature (IAT) sensor is installed on Action Taken When the DTC Sets
the intake duct. The IAT sensor is variable resistance, • The ECM illuminates MIL when the diagnostic runs
and measures the temperature of the air entering the and fails. Refer to DTC Type Definitions for Action
engine. The IAT sensor has a signal circuit and low Taken When the DTC Sets - Type A.
reference circuit. The engine control module (ECM) • Performs control with 25°C (77°F) as the intake air
supplies 5 volts to the IAT sensor via the signal circuit, temperature.
and grounds the sensor via the low reference circuit.
When the intake air temperature is low, the resistance Condition for Clearing the DTC
value of the sensor is high, and the higher the intake air
• Refer to DTC Type Definitions for Condition for
temperature, the lower the resistance value of the
Clearing the MIL/ DTC - Type A.
sensor. If the resistance value of the sensor is high, the
ECM detects high voltage in the signal circuit. If the
Diagnostic Aids
resistance value of the sensor is low, it detects low
voltage in the signal circuit. The ECM monitors whether • If an intermittent condition is suspected, refer to
the IAT sensor signal voltage is in a normal range, and Intermittent Conditions in this section.
sets this DTC when it determines that the sensor signal
voltage is too low. Connector End View Reference: Engine Controls

Go to Diagnostic
2. Disconnect the IAT sensor harness connector.
3 (pin 1 of E134) and a known good ground. 4.5 volts
51 of J95) and the IAT sensor (pin 1 of E134)
for the following conditions:
4 —

1. Inspect for an intermittent and for a poor
connection at the harness connector of the
IAT sensor (pin 1 of E134).
5 —


6 connection at the harness connector of the —
ECM (pin 51 of J95).

Replace the IAT sensor. Refer to IAT Sensor in
8 this section. —



10 —

Intake Air Temperature (IAT) Sensor Circuit Condition for Setting the DTC
High Voltage • The ECM detects that the IAT sensor signal
voltage is more than 4.848 volts for 5 seconds.
Circuit Description
The intake air temperature (IAT) sensor is installed on Action Taken When the DTC Sets
the intake duct. The IAT sensor is variable resistance, • The ECM illuminates MIL when the diagnostic runs
and measures the temperature of the air entering the and fails. Refer to DTC Type Definitions for Action
engine. The IAT sensor has a signal circuit and low Taken When the DTC Sets - Type A.
reference circuit. The engine control module (ECM) • Performs control with 25°C (77°F) as the intake air
supplies 5 volts to the IAT sensor via the signal circuit, temperature.
and grounds the sensor via the low reference circuit.
When the intake air temperature is low, the resistance Condition for Clearing the DTC
value of the sensor is high, and the higher the intake air
Diagnostic Aids
resistance value of the sensor is low, it detects low
voltage in the signal circuit. The ECM monitors whether • If an intermittent condition is suspected, refer to
the IAT sensor signal voltage is in a normal range, and Intermittent Conditions in this section.
sets this DTC when it determines that the sensor signal
voltage is too high. Connector End View Reference: Engine Controls

Go to Diagnostic
2. Disconnect the IAT sensor harness connector.
3 (pin 1 of E134) and a known good ground. 5.5 volts
4 4.5 volts
Connect the DMM between the signal circuit and
6 the low reference circuit (pins 1 and 2 of E134). 4.5 volts

Important: The IAT sensor may be damaged if the
sensor signal circuit is shorted to a voltage source.
7 —

• An open circuit
8 —
• High resistance

for a short to any 5 volts reference circuit.
9 —

ECM (pin 70 of J95) and the IAT sensor (pin 2
of E134) for the following conditions:
• An open circuit
10 —
• High resistance

IAT sensor (pins 1 and 2 of E134).
11 —

ECM (pins 51 and 70 of J95).





16 —

Engine Coolant Temperature Circuit Low Input Condition for Setting the DTC
• The ECM detects that the ECT sensor signal
Circuit Description voltage is less than 0.1 volts for 5 seconds.
The engine coolant temperature (ECT) sensor is
installed near the thermostat housing. The ECT sensor Action Taken When the DTC Sets
is variable resistance, and measures the temperature • The ECM illuminates MIL when the diagnostic runs
of the engine coolant. The ECT sensor has a signal and fails. Refer to DTC Type Definitions for Action
circuit and low reference circuit. The engine control Taken When the DTC Sets - Type A.
module (ECM) supplies 5 volts to the ECT sensor via • Performs control with 77°C (171°F) as the engine
the signal circuit, and grounds the sensor to within the coolant temperature.
ECM via the low reference circuit. When the engine
coolant temperature is low, the resistance value of the Condition for Clearing the DTC
sensor is high, and the higher the engine coolant
temperature, the lower the resistance value of the • Refer to DTC Type Definitions for Condition for
sensor. If the resistance value of the sensor is high, the Clearing the MIL/ DTC - Type A.
resistance value of the sensor is low, it detects low Diagnostic Aids
voltage in the signal circuit. • If an intermittent condition is suspected, refer to
The ECM monitors whether the ECT sensor signal Intermittent Conditions in this section.
determines that the sensor signal voltage is too low. Connector End View Reference: Engine Controls

Go to Diagnostic
2. Disconnect the ECT sensor harness
connector.
3 3. Connect a DMM between the signal circuit 4.5 volts
105 of E125) and the ECT sensor (pin 2 of
4 —

ECT sensor (pin 2 of E138).
5 —


ECM (pin 105 of E125).

Replace the ECT sensor. Refer to Engine Coolant
Temperature (ECT) Sensor in Section 1C Engine
7 Cooling (4HV1-CNG). —

8 this section. —


10 —

Engine Coolant Temperature Circuit High Condition for Setting the DTC
Input • The ECM detects that the ECT sensor signal
voltage is more than 4.863 volts for 5 seconds.
Circuit Description
The engine coolant temperature (ECT) sensor is Action Taken When the DTC Sets
installed near the thermostat housing. The ECT sensor • The ECM illuminates MIL when the diagnostic runs
is variable resistance, and measures the temperature and fails. Refer to DTC Type Definitions for Action
of the engine coolant. The ECT sensor has a signal Taken When the DTC Sets - Type A.
circuit and low reference circuit. The engine control • Performs control with 77°C (171°F) as the engine
module (ECM) supplies 5 volts to the ECT sensor via coolant temperature.
the signal circuit, and grounds the sensor to within the
ECM via the low reference circuit. When the engine Condition for Clearing the DTC
coolant temperature is low, the resistance value of the
sensor is high, and the higher the engine coolant
Diagnostic Aids
resistance value of the sensor is low, it detects low • If an intermittent condition is suspected, refer to
voltage in the signal circuit. Intermittent Conditions in this section.
The ECM monitors whether the ECT sensor signal
voltage is in a normal range, and sets this DTC when it Connector End View Reference: Engine Controls
determines that the sensor signal voltage is too high. Connector End Views or ECM Connector End Views

Go to Diagnostic
2. Disconnect the ECT sensor harness
connector.
4 4.5 volts

Important: The ECT sensor may be damaged if
source.
7 E138) for the following conditions: —

• An open circuit
8 —
• High resistance

E138) for a short to any 5 volts reference
9 circuit. —

ECM (pin 85 of E125) and the ECT sensor
• An open circuit
10 —
• High resistance

ECT sensor (pins 1 and 2 of E138).
11 —


Replace the ECT sensor. Refer to Engine Coolant
Temperature (ECT) Sensor in Section 1C Engine
13 Cooling (4HV1-CNG). —





16 —

O2 Sensor 2 Circuit No Activity Detected Action Taken When the DTC Sets
Circuit Description consecutive driving cycle when the diagnostic runs
The O2 sensor is installed between the 3-way catalyst and fails. Refer to DTC Type Definitions for Action
and the silencer, and detects the oxygen density in the Taken When the DTC Sets - Type B.
exhaust gas. The O2 sensor has a signal circuit and • Control is performed by calculating the A/F sensor
low reference circuit. The O2 sensor changes the threshold value, which is based on the engine
electromotive force according to the oxygen density in coolant temperature, basic injection pulse width,
the exhaust gas, and outputs a higher voltage the lower and engine rpm.
the oxygen density is (the more fuel there is).
The ECM monitors the signal voltage of the O2 sensor, Condition for Clearing the DTC
and sets a DTC when the sensor signal voltage does • Refer to DTC Type Definitions for Condition for
not change from a low value. Clearing the MIL/ DTC - Type B.
Condition for Setting the DTC Diagnostic Aids
When all the following conditions are established and • If an intermittent condition is suspected, refer to
continue for 5 minutes: Intermittent Conditions in this section.
• The engine coolant temperature is more than 80°C
(176°F). Connector End View Reference: Engine Controls
• The engine speed is more than 1500 RPM. Connector End Views or ECM Connector End Views
• The O2 sensor signal voltage not active even
once.

2 —
Is DTC P1150, P1151, P1152, P1155, P1156, Go to Applicable

P1157 or P1158 also set? DTC Go to Step 3
1. Start the engine, and depress the accelerator
pedal until the engine speed is higher than
1500 rpm.
2. Observe the O2 Sensor 2 parameter with a
3 scan tool holding the engine speed higher 450 mV
than 1500 rpm for 5 minutes.
Does the scan tool indicate less than the specified Go to Diagnostic
value for 5 minutes? Go to Step 4 Aids
1. Inspect the exhaust pipe for exhaust leakage,
damage, incorrect installation, or corrosion.
4 2. Repair or replace as necessary. —


2. Disconnect the O2 sensor harness connector.
the signal circuit and the low reference circuit
(pins 2 and 3 of J97).
5 4. Turn ON the ignition, with the engine OFF. 50 mV
5. Observe the O2 Sensor 2 parameter with a

scan tool.
Is the O2 Sensor 2 parameter more than the

specified value? Go to Step 9 Go to Step 6
1. Disconnect the jumper wire.
6 (pin 2 of J97) and a known good ground. 50 mV
50 of J95) and the O2 sensor (pin 2 of J97) for
7 —

ECM (pin 69 of J95) and the O2 sensor (pin 3
of J97) for the following conditions:
• An open circuit
8 —
• High resistance

O2 sensor (pins 2 and 3 of J97).
9 —


Replace the O2 sensor. Refer to O2 Sensor in
11 Section 1G Engine Exhaust (4HV1-CNG). —


4. Start the engine, and depress the accelerator
13 pedal until the engine speed is higher than —
1500 rpm.
5. Hold the engine speed higher than 1500 rpm
for 5 minutes.

14 —

O2 Sensor Heater Circuit Open Or Short To • Time elapsed since starting engine is 75
Ground seconds or more.
Circuit Description Condition for Setting the DTC
The O2 sensor incorporates a heater to heat up its When one of the following conditions is established:
internal zirconia element because this element does • A voltage input is not detected from the O2 sensor
not activate (induce an electric potential) unless it has heater when the O2 sensor heater is energized.
reached its minimum active temperature of 300°C • A voltage input was detected from the O2 sensor
(572°F). The engine control module (ECM) turns the heater when the O2 sensor heater was not
heater "ON" when the engine has started and the energized.
conditions for energizing the O2 sensor heater have
been established, and turns the heater "OFF" when the Action Taken When the DTC Sets
engine is stopped. The ECM monitors the operation
status of the O2 sensor heater, and sets a DTC when
consecutive driving cycle when the diagnostic runs
the command it sends to the O2 sensor heater does
and fails. Refer to DTC Type Definitions for Action
not match the operation status of the heater.
Taken When the DTC Sets - Type B.
O2 sensor heater energizing conditions
Condition for Clearing the DTC
When one of the following conditions is satisfied.
1. When all of the following conditions are Clearing the MIL/ DTC - Type B.
established:
• Engine coolant temperature is 70°C (158°F) or Diagnostic Aids
higher when starting.
• Time elapsed since starting engine is 0.5 Intermittent Conditions in this section.
seconds or more.
2. When all of the following conditions are Connector End View Reference: Engine Controls
established: Connector End Views or ECM Connector End Views
• Engine coolant temperature is 50°C (122°F) or
higher when starting.
Circuit/ System Testing DTC P0141 (Flash Code 55) Except Australia

2 3. Start the engine. —
Go to Diagnostic
Monitor the DTC Information with a scan tool.
3 — Go to Applicable
Is DTC P0560 also set? DTC Go to Step 4
3. Connect a DMM between the heater voltage
4 supply circuit (pin 1 of J97) and a known good 12 volts
ground.

Connect a DMM between the heater voltage supply
circuit and the heater control circuit (pins 1 and 4 of
5 J97). 12 volts
Start the engine leaving the DMM connected to the
6 O2 sensor harness connector. 12 volts
Repair the open circuit or short to ground on the
heater voltage supply circuit between the ignition
7 relay (pin 3 of B285) and the O2 sensor (pin 1 of —
J97).

1. Test the heater control circuit between the
of J97) for a short to ground.
8 —

of J97) for an open.
9 —

10 —




4. Start the engine.


15 —
Circuit/ System Testing DTC P0141 (Flash Code 55) for Australia

Go to Diagnostic
3 — Go to Applicable
Is DTC P0560 also set? DTC Go to Step 4
3. Connect a DMM between the heater voltage
4 supply circuit (pin 1 of J97) and a known good 12 volts
ground.
Connect a DMM between the heater voltage supply
circuit and the heater control circuit (pins 1 and 4 of
5 J97). 12 volts
Start the engine leaving the DMM connected to the
6 O2 sensor harness connector. 12 volts
Repair the open circuit or short to ground on the
heater voltage supply circuit between the converter
7 relay (pin 4 of B285) and the O2 sensor (pin 1 of —
J97).

of J97) for a short to ground.
8 —

of J97) for an open.
9 —

10 —






15 —

Exhaust System Parts Lean • The A/F sensor is active.
• The average voltage of the O2 sensor is 0.1 volts
Circuit Description or higher and 0.87 volts or lower.
The air-fuel ratio (A/F) sensor is installed on the • There are 10 or more values of 120 % or more in
exhaust pipe in front of the 3-way catalyst, and detects the air-fuel ratio learning values.
the oxygen density in the exhaust gas. The engine
control module (ECM) calculates the air-fuel ratio using Action Taken When the DTC Sets
the signals from the A/F sensor, compares the value • The ECM illuminates the MIL on the second
with the air-fuel ratio (A/F sensor threshold value) consecutive driving cycle when the diagnostic runs
deemed to be optimal, and adjusts the fuel injection and fails. Refer to DTC Type Definitions for Action
amount accordingly. At this time, the ECM sets an air- Taken When the DTC Sets - Type B.
fuel ratio learning value (correction value). When the
amount of fuel is low and needs to be increased, a Condition for Clearing the DTC
value larger than 100 % is set, and when the amount of
fuel is high and needs to be decreased, a value smaller • Refer to DTC Type Definitions for Condition for
than 100 % is set. Clearing the MIL/ DTC - Type B.
The ECM sets a DTC when the state of the air-fuel ratio
learning value is persistently large. Diagnostic Aids
Condition for Setting the DTC Intermittent Conditions in this section.
When the following conditions are established and
continue for 1 minute: Connector End View Reference: Engine Controls
• When the injection control is under closed-loop
control.

Go to Applicable
Is DTC other than P0171 also set? DTC Go to Step 3
1. Warm up the engine while observing the
Injection Control Phase parameter until it
changes Closed Loop with a scan tool.
2. Observe the Coefficient in which studied
3 mixture ratio is revised parameter with a scan 115 %
tool.
Is the Coefficient in which studied mixture ratio is Go to Diagnostic

revised parameter more than the specified value? Go to Step 4 Aids
1. Inspect the vacuum hose for a disconnection,
cracks or twisting.

1. Inspect the positive crankcase ventilation
(PCV) valve for improper installation.
5 2. Repair as necessary. —


1. Inspect the manifold absolute pressure (MAP)
sensor for the following conditions:
• Improper installation of sensor
6 • Cracks or damage of rubber seal —
2. Repair or replace as necessary.

1. Inspect the intake air temperature (IAT) sensor
for improper installation.

1. Inspect the throttle valve and intake manifold
for intake air leakage.

1. Start the engine and warm up (allow engine
coolant temperature to reach at least 80°C
[176°F]).
9 —
2. Check the idling status. Go to Ignition
System Check and
Was a misfire (unstable idling) detected? Fuel System Check Go to Step 10
1. With the engine warmed up, change the shift
position to neutral, and confirm that the air
conditioning is turned OFF.
10 2. Observe the MAP Sensor (Manifold Absolute 20 - 40 kPa
Pressure) parameter with a scan tool.
Is the MAP Sensor (Manifold Absolute Pressure)

parameter within the specified value? Go to Step 12 Go to Step 11
Observe the IAT Sensor (Intake Air Temperature)
parameter with a scan tool. 0 - 70 °C (32-
12
Is the IAT Sensor (Intake Air Temperature) 158°F)
2. Disconnect the air-fuel ratio (A/F) sensor
harness connector.
14 1.0
4. Observe the Air Fuel Ratio Sensor parameter
with a scan tool.
Is the Air Fuel Ratio Sensor parameter the

becomes Closed Loop with a scan tool.
15 2. Observe the O2 Sensor 2 parameter with a 0.1
scan tool.
Is the O2 Sensor 2 parameter the specified value? Go to Step 18 Go to Step 19


1. Test the AFC circuit between the ECM (pin
118 of E125) and the A/F sensor (pin 3 of
E120) for a short to any voltage circuit.
16 —

1. Test the AFV circuit between the ECM (pin
17 —

Important: The injection learned value, the air fuel
ratio threshold and the fuel compensation rate in
the ECM must be cleared or learned when the A/F
sensor is replaced.
18 Replace the A/F sensor. Refer to Air - fuel ratio (A/ —
F) Sensor in Section 1G Engine Exhaust (4HV1-
CNG).


20 5. Warm up the engine while observing the —
6. Wait for 1 minute in the idling state.

21 —

Exhaust System Parts Rich • The A/F sensor is active.
• The average voltage of the O2 sensor is 0.1 volts
Circuit Description or higher and 0.87 volts or lower.
The air-fuel ratio (A/F) sensor is installed on the • There are 10 or more values of less than 80 % in
exhaust pipe in front of the 3-way catalyst, and detects the air-fuel ratio learning values.
the oxygen density in the exhaust gas. The engine
control module (ECM) calculates the air-fuel ratio using Action Taken When the DTC Sets
the signals from the A/F sensor, compares the value • The ECM illuminates the MIL on the second
with the air-fuel ratio (A/F sensor threshold value) consecutive driving cycle when the diagnostic runs
deemed to be optimal, and adjusts the fuel injection and fails. Refer to DTC Type Definitions for Action
amount accordingly. At this time, the ECM sets an air- Taken When the DTC Sets - Type B.
fuel ratio learning value (correction value). When the
amount of fuel is low and needs to be increased, a Condition for Clearing the DTC
value larger than 100 % is set, and when the amount of
fuel is high and needs to be decreased, a value smaller • Refer to DTC Type Definitions for Condition for
than 100 % is set. Clearing the MIL/ DTC - Type B.
The ECM sets a DTC when the state of the air-fuel ratio
learning value is persistently small. Diagnostic Aids
Condition for Setting the DTC Intermittent Conditions in this section.
When the following conditions are established and
continue for 1 minute. Connector End View Reference: Engine Controls
• When the injection control is under closed-loop
control.

Go to Applicable
Is a DTC other than P0172 also set? DTC Go to Step 3
changes Closed Loop with a scan tool.
2. Observe the Coefficient in which studied
3 mixture ratio is revised parameter with a scan 85 %
tool.
Is the Coefficient in which studied mixture ratio is Go to Diagnostic

revised parameter specified value? Go to Step 4 Aids
1. Inspect the air cleaner element for filth or
damage.

1. Inspect the vacuum hose for clogging.

1. Inspect the positive crankcase ventilation
(PCV) valve for improper installation.

1. Inspect the manifold absolute pressure (MAP)
sensor for the following conditions:
• Improper installation of sensor
7 • Cracks or damage of rubber seal —

1. Inspect the intake air temperature (IAT) sensor
for improper installation.

1. Inspect the throttle valve and intake manifold
• Restricted intake throttle vale by foreign
materials.
9 —
• Excessive deposits at throttle bore.

1. Start the engine and warm up (allow engine
coolant temperature to reach at least 80°C
[176°F]).
10 —
2. Check the idling status. Go to Ignition
System Check and
Was a misfire (unstable idling) detected? Fuel System Check Go to Step 11
1. With the engine warmed up, change the shift
position to neutral, and confirm that the air
conditioning is turned OFF.
11 2. Observe the MAP Sensor (Manifold Absolute 20 - 40 kPa
Pressure) parameter with a scan tool.
Is the MAP Sensor (Manifold Absolute Pressure)

Observe the IAT Sensor (Intake Air Temperature)
parameter with a scan tool. 0 - 70 °C (32 -
13
Is the IAT Sensor (Intake Air Temperature) 158°F)

harness connector.
15 1.0
4. Observe the Air Fuel Ratio Sensor parameter
with a scan tool.
Is the Air Fuel Ratio Sensor parameter the

16 2. Observe the O2 Sensor 2 parameter with a 0.1
scan tool.
Is the O2 Sensor 2 parameter the specified value? Go to Step 19 Go to Step 20

17 —

18 —

sensor is replaced.
CNG).


21 5. Warm up the engine while observing the —
6. Wait for 1 minute in the idling state.

22 —

Fuel Temperature (FT) Sensor Circuit Low Condition for Setting the DTC
Voltage • The ECM detects that the CNG temperature
sensor signal voltage is less than 0.1 volts for 3
Circuit Description seconds.
The CNG pressure/ temperature sensor is installed on
the fuel gallery (Except Australia). The CNG Action Taken When the DTC Sets
temperature sensor is installed on the fuel gallery • The ECM illuminates MIL when the diagnostic runs
(Australia). The CNG temperature sensor is variable and fails. Refer to DTC Type Definitions for Action
resistance, and measures the temperature of the fuel. Taken When the DTC Sets - Type A.
The CNG temperature sensor has a signal circuit and • Performs control with 30°C (86°F) as the fuel
low reference circuit. The engine control module (ECM) temperature.
supplies 5 volts to the CNG temperature sensor via the
signal circuit, and grounds the sensor to within the Condition for Clearing the DTC
ECM via the low reference circuit. When the fuel
temperature is low, the resistance value of the sensor is
high, and the higher the fuel temperature, the lower the
resistance value of the sensor. If the resistance value of
Diagnostic Aids
the sensor is high, the ECM detects high voltage in the
signal circuit. If the resistance value of the sensor is • If an intermittent condition is suspected, refer to
low, it detects low voltage in the signal circuit. Intermittent Conditions in this section.
The ECM monitors whether the CNG temperature
sensor signal voltage is in a normal range, and sets this Connector End View Reference: Engine Controls
DTC when it determines that the sensor signal voltage Connector End Views or ECM Connector End Views
is too low.

Go to Diagnostic
2. Disconnect the CNG pressure/ temperature
sensor harness connector.
102 of E125) and the CNG pressure/
temperature sensor (pin 2 of E136) for the
following conditions:


CNG pressure/ temperature sensor (pin 2 of
5 E136). —


Replace the CNG pressure/ temperature sensor.
Refer to CNG Pressure/ Temperature Sensor in
7 Section 1D Engine Fuel (4HV1-CNG). —

8 this section. —


10 —

Go to Diagnostic
2. Disconnect the CNG temperature sensor
harness connector.

102 of E125) and the CNG temperature
sensor (pin 2 of E127) for the following
conditions:

CNG temperature sensor (pin 2 of E127).
5 —


Replace the CNG temperature sensor. Refer to
CNG Temperature Sensor in Section 1D Engine
7 Fuel (4HV1-CNG). —

8 this section. —



10 —

Fuel Temperature (FT) Sensor Circuit High Condition for Setting the DTC
Voltage • The ECM detects that the CNG temperature
sensor signal voltage is more than 4.848 volts for 3
Circuit Description seconds.
The CNG pressure/ temperature sensor is installed on
the fuel gallery (Except Australia). The CNG Action Taken When the DTC Sets
temperature sensor is installed on the fuel gallery • The ECM illuminates MIL when the diagnostic runs
(Australia). The CNG temperature sensor is variable and fails. Refer to DTC Type Definitions for Action
resistance, and measures the temperature of the fuel. Taken When the DTC Sets - Type A.
The CNG temperature sensor has a signal circuit and • Performs control with 30°C (86°F) as the fuel
low reference circuit. The engine control module (ECM) temperature.
supplies 5 volts to the CNG temperature sensor via the
signal circuit, and grounds the sensor to within the Condition for Clearing the DTC
ECM via the low reference circuit. When the fuel
temperature is low, the resistance value of the sensor is
high, and the higher the fuel temperature, the lower the
resistance value of the sensor. If the resistance value of
Diagnostic Aids
the sensor is high, the ECM detects high voltage in the
signal circuit. If the resistance value of the sensor is • If an intermittent condition is suspected, refer to
low, it detects low voltage in the signal circuit. Intermittent Conditions in this section.
The ECM monitors whether the CNG temperature
sensor signal voltage is in a normal range, and sets this Connector End View Reference: Engine Controls
DTC when it determines that the sensor signal voltage Connector End Views or ECM Connector End Views
is too high.

Go to Diagnostic
4 4.5 volts

Important: The CNG temperature sensor may be
damaged if the sensor signal circuit is shorted to a
voltage source.
7 following conditions: —


8 • An open circuit —
• High resistance

temperature sensor (pin 2 of E136) for a short
9 to any 5 volts reference circuit. —

ECM (pin 84 of E125) and the CNG pressure/
• High resistance

CNG pressure/ temperature sensor (pins 1
11 and 2 of E136). —







16 —

Go to Diagnostic
2. Disconnect the CNG temperature sensor
harness connector.
4 4.5 volts

Important: The CNG temperature sensor may be
voltage source.
7 conditions: —


conditions:
• High resistance

sensor (pin 2 of E127) for a short to any 5
9 volts reference circuit. —

• High resistance

CNG temperature sensor (pins 1 and 2 of
11 E127). —


Replace the CNG temperature sensor. Refer to
CNG Temperature Sensor in Section 1D Engine
13 Fuel (4HV1-CNG). —





16 —

Fuel Pressure Sensor Circuit Low Voltage Condition for Setting the DTC
• The ECM detects that the CNG pressure sensor
Circuit Description signal voltage is less than 0.1 volts for 3 seconds.
The CNG pressure sensor detects the fuel pressure
inside the fuel gallery. The CNG pressure/ temperature Action Taken When the DTC Sets
sensor is installed on the fuel gallery (Except Australia). • The ECM illuminates MIL when the diagnostic runs
The CNG pressure sensor is installed on the fuel and fails. Refer to DTC Type Definitions for Action
gallery (Australia). The CNG pressure sensor converts Taken When the DTC Sets - Type A.
the pressure to a voltage signal and sends that signal • Performs control with 370 kPa as the fuel
to the engine control module (ECM). The CNG pressure.
pressure sensor has the following circuits.
• 5 volts reference circuit Condition for Clearing the DTC
• Low reference circuit • Refer to DTC Type Definitions for Condition for
• CNG pressure sensor signal circuit Clearing the MIL/ DTC - Type A.
The ECM supplies 5 volts to the CNG pressure sensor
via the 5 volts reference circuit, and grounds the sensor Diagnostic Aids
to within the ECM via the low reference circuit. The • If an intermittent condition is suspected, refer to
CNG pressure sensor indicates a high voltage for high Intermittent Conditions in this section.
pressures, and a low voltage for low pressures. The
ECM calculates the fuel pressure from the voltage Connector End View Reference: Engine Controls
signal, and uses it for fuel injection control and other Connector End Views or ECM Connector End Views
control systems.
The ECM monitors whether the CNG pressure sensor
signal voltage is in a normal range, and sets this DTC
when it determines that the sensor signal voltage is too
low.

Go to Diagnostic
3. Connect a DMM between the 5V reference
ground.

Notice : If the vehivle is for Thailand, skip to Step
6.
4 —


• An open circuit
• High resistance


8 and 4 of E136). —

9 ECM (pins 103, 110 and 111 of E125 and pin —
81 of J95).





13 —

Go to Diagnostic
2. Disconnect the CNG pressure sensor harness
connector.
3. Connect a DMM between the 5V reference
ground.
ECM (pin 110 of E125) and the CNG pressure
conditions:
• An open circuit
• High resistance


103 of E125) and the CNG pressure sensor
5 —

CNG pressure sensor (pins 1 and 2 of E136).
6 —


Replace the CNG pressure sensor. Refer to CNG
Pressure Sensor in Section 1D Engine Fuel (4HV1-
8 CNG). —

9 this section. —


11 —

Fuel Pressure Sensor Circuit High Voltage Condition for Setting the DTC
• The ECM detects that the CNG pressure sensor
Circuit Description signal voltage is more than 4.848 volts for 3
The CNG pressure sensor detects the fuel pressure seconds.
inside the fuel gallery. The CNG pressure/ temperature
sensor is installed on the fuel gallery (Except Australia). Action Taken When the DTC Sets
The CNG pressure sensor is installed on the fuel • The ECM illuminates MIL when the diagnostic runs
gallery (Australia). The CNG pressure sensor converts and fails. Refer to DTC Type Definitions for Action
the pressure to a voltage signal and sends that signal Taken When the DTC Sets - Type A.
to the engine control module (ECM). The CNG • Performs control with 370 kPa as the fuel
pressure sensor has the following circuits. pressure.
• 5 volts reference circuit
• Low reference circuit Condition for Clearing the DTC
• CNG pressure sensor signal circuit • Refer to DTC Type Definitions for Condition for
The ECM supplies 5 volts to the CNG pressure sensor Clearing the MIL/ DTC - Type A.
via the 5 volts reference circuit, and grounds the sensor
to within the ECM via the low reference circuit. The Diagnostic Aids
CNG pressure sensor indicates a high voltage for high • If an intermittent condition is suspected, refer to
pressures, and a low voltage for low pressures. The Intermittent Conditions in this section.
ECM calculates the fuel pressure from the voltage
signal, and uses it for fuel injection control and other Connector End View Reference: Engine Controls
control systems. Connector End Views or ECM Connector End Views
The ECM monitors whether the CNG pressure sensor
signal voltage is in a normal range, and sets this DTC
when it determines that the sensor signal voltage is too
high.

Go to Diagnostic
ground.
Connect a DMM between the signal circuit (pin 4 of
4 E136) and a known good ground. 5.5 volts
5 4.5 volts

Important: The CNG pressure sensor may be
damaged if the sensor 5 volts reference circuit is
shorted to a voltage source.
8 for the following conditions: —

voltage source.
9 following conditions: —


• High resistance

temperature sensor (pin 4 of E136) for a short
11 to any 5 volts reference circuit. —

ECM (pin 84 of E125) and the CNG pressure/
• High resistance


13 and 4 of E136). —





18 —

Go to Diagnostic
2. Disconnect the CNG pressure sensor harness
connector.
ground.

5 4.5 volts
8 conditions: —


voltage source.

• An open circuit
10 —
• High resistance

(pin 2 of E136) for a short to any 5 volts
11 reference circuit. —


conditions:
• High resistance

CNG pressure sensor (pins 2 and 3 of E136).
13 —


Replace the CNG pressure sensor. Refer to CNG
Pressure Sensor in Section 1D Engine Fuel (4HV1-
15 CNG). —




18 —

Injector #1 Load Open Circuit or Short Circuit Action Taken When the DTC Sets
to Ground • The ECM illuminates MIL when the diagnostic runs
Circuit Description Taken When the DTC Sets - Type A.
The engine control module (ECM) calculates the • The injection pulse width is shortened (only
optimal fuel injection timing and fuel injection amount controlled by the suction pulse width).
based on the data sent from various sensors. The ECM
supplies power to the gas injector via the engine driver Condition for Clearing the DTC
unit (EDU), and operates (turns "ON") the gas injector • Refer to DTC Type Definitions for Condition for
by grounding the gas injector control circuit according Clearing the MIL/ DTC - Type A.
to the calculated fuel injection timing. It also increases/
decreases the fuel injection amount by changing the Diagnostic Aids
gas injector operation time.
The ECM sets a DTC when an abnormality is detected
in the cylinder #1 gas injector circuit.
Condition for Setting the DTC
• When voltage input has not been detected from
the cylinder #1 gas injector 10 times when the
cylinder #1 gas injector is operated.

Go to Diagnostic
1. Test the cylinder #1 gas injector (High) input
circuit between the ECM (pin 109 of E125)
and the EDU (pin 13 of E126) for the following
conditions:
• An open circuit
• High resistance

1. Test the cylinder #1 gas injector (High) output
circuit between the EDU (pin 27 of E126) and
the gas injector (pin 2 of E139) for the
• An open circuit
• High resistance


1. Test the cylinder #1 gas injector (Low) input
conditions:
• An open circuit
• High resistance

1. Test the cylinder #1 gas injector (Low) output
• An open circuit
• High resistance

Measure the resistance across the cylinder #1 gas
7 injector. 2.0 ohms
Is the resistance less than the specified value? Go to Step 8 Go to Step 12
gas injector (pins 1 and 2 of E139).
8 —

1. Test the monitor circuit of the cylinder #1 gas
injector circuit between the ECM (pin 93 of
E125) and the EDU (pin 17 of E126) for the
• An open circuit
• High resistance

EDU (pins 13, 17, 26, 27 and 35 of E126).
10 —

ECM (pins 93, 101 and 109 of E125).


the ECM must be cleared or learned when the gas
12 injector is replaced. —
Replace the cylinder #1 gas injector. Refer to Gas
Injector in Section 1D Engine Fuel (4HV1-CNG).

Replace the EDU. Refer to Engine Driver Unit
13 (EDU) in this section. —




17 —


Go to Diagnostic
conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance


conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance

8 —

• An open circuit
• High resistance

EDU (pins 14, 18, 28, 29 and 36 of E126).
10 —

ECM (pins 92, 100 and 108 of E125).







17 —


Go to Diagnostic
conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance


circuit between the ECM (pin 99 of E125) and
the EDU (pin 37 of E126) for the following
conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance

8 —

• An open circuit
• High resistance

EDU (pins 15, 30, 31, 37 and 39 of E126).
10 —

ECM (pins 91, 99 and 107 of E125).







17 —


Go to Diagnostic
conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance


circuit between the ECM (pin 98 of E125) and
the EDU (pin 38 of E126) for the following
conditions:
• An open circuit
• High resistance

• An open circuit
• High resistance

8 —

• An open circuit
• High resistance

EDU (pins 16, 32, 33, 38 and 40 of E126).
10 —

ECM (pins 90, 98 and 106 of E125).







17 —

Knock Sensor 1 Circuit Low Input (Bank 1 Or • When the throttle position sensor is in the idle
Single Sensor) position.
• When the neutral switch is "ON".
Circuit Description
Action Taken When the DTC Sets
The knock sensor is installed on the cylinder block to
measure the engine knocking from changes in • The ECM will not illuminate the MIL. Refer to DTC
frequency. The knock sensor has a signal circuit and Type Definitions for Action Taken When the DTC
low reference circuit. The knock sensor consists of a Sets - Type D.
vibrating plate and piezoelectric element, and a voltage • Retards the angle 5° more than that of the normal
is generated when this vibrating plate resonates. ignition timing.
The ECM monitors whether the knock sensor signal
voltage (frequency) is in a normal range, and sets this Condition for Clearing the DTC
DTC when it determines that the sensor signal voltage
is too low.
Clearing the DTC - Type D.
Diagnostic Aids
When all the following conditions are established and
continue for 1 second or more.
• When the knock sensor signal voltage is 0.039
volts or lower. Connector End View Reference: Engine Controls
• When the engine revolution is 1000 rpm or lower. Connector End Views or ECM Connector End Views

Go to Diagnostic
2. Disconnect the knock sensor harness
connector. 532 - 588k
3 3. Measure the resistance across the knock ohms
sensor.
Is the resistance within the specified value? Go to Step 4 Go to Step 9

1. Set the rotary switch on the DMM to mV
range.
4 2. Tap the cylinder block near the knock sensor —
observing the DMM voltage.
Does the DMM voltage change? Go to Step 5 Go to Step 9


48 of J95) and the knock sensor (pin 1 of
• An open circuit
5 —
• High resistance

ECM (pin 67 of J95) and the knock sensor (pin
2 of E145) for the following conditions:
• An open circuit
6 —
• High resistance

knock sensor (pins 1 and 2 of E145).
7 —


Replace the knock sensor. Refer to Knock Sensor
9 in Section 1E Engine Electrical (4HV1-CNG). —


Did the DTC fail this ignition? Go to Step 12 —

12 —

Knock Sensor 1 Circuit High Input (Bank 1 Or • When the throttle position sensor is in the idle
Single Sensor) position.
• When the neutral switch is "ON".
Circuit Description
The knock sensor is installed on the cylinder block to
measure the engine knocking from changes in • The ECM will not illuminate the MIL. Refer to DTC
frequency. The knock sensor has a signal circuit and Type Definitions for Action Taken When the DTC
GND circuit. The knock sensor consists of a vibrating Sets - Type D.
plate and piezoelectric element, and a voltage is • Retards the angle 5° more than that of the normal
generated when this vibrating plate resonates. ignition timing.
The ECM monitors whether the knock sensor signal
voltage (frequency) is in a normal range, and sets this Condition for Clearing the DTC
DTC when it determines that the sensor signal voltage
is too high.
Diagnostic Aids
continue for 1 second or more.
• When the knock sensor signal voltage is 4.829
volts or higher. Connector End View Reference: Engine Controls
• When the engine revolution is 1000 rpm or lower. Connector End Views or ECM Connector End Views

Go to Diagnostic
2. Disconnect the knock sensor harness
connector. 532 - 588k
3 3. Measure the resistance across the knock ohms
sensor.

1. Set the rotary switch on the DMM to mV
range.
4 2. Tap the cylinder block near the knock sensor —
observing the DMM voltage.
Does the DMM voltage change? Go to Step 5 Go to Step 9

48 of J95) and the knock sensor (pin 1 of
5 • A short to any 12 volts or 5 volts —
reference


ECM (pin 67 of J95) and the knock sensor (pin
2 of E145) for the following conditions:
6 • A short to any 12 volts or 5 volts —
reference

knock sensor (pins 1 and 2 of E145).
7 —


Replace the knock sensor. Refer to Knock Sensor
9 in Section 1E Engine Electrical (4HV1-CNG). —

Did the DTC fail this ignition? Go to Step 12 —

12 —

Crankshaft Position Sensor Circuit Condition for Setting the DTC
• When there is no signal input from the crankshaft
Circuit Description position (CKP) sensor for 3 consecutive seconds
The crankshaft position (CKP) sensor is a magnetic coil when cranking.
type sensor and is installed into the flywheel housing.
There are 56 projections on the outer circumference of Action Taken When the DTC Sets
the flywheel (at 6° intervals), and when one of these • The ECM illuminates MIL when the diagnostic runs
projections passes the tip of the CKP sensor, voltage is and fails. Refer to DTC Type Definitions for Action
emitted and becomes a pulse signal. One part of the Taken When the DTC Sets - Type A.
flywheel outer circumference (at 30° intervals) does not
have these projections, and the pulse signal is Condition for Clearing the DTC
interrupted in this area. The engine control module
(ECM) detects the top dead center from the differences
in the input intervals of the pulse signals.
The ECM compares the CKP sensor signal and the
Diagnostic Aids
ignition switch "START" position signal, and sets a DTC
if the CKP sensor signal is not inputted when the • If an intermittent condition is suspected, refer to
ignition switch "START" position signal is being Intermittent Conditions in this section.
inputted.

3. Start the engine (Note a slight start delay may
2 be noticed). —
Go to Diagnostic
Is DTC P0340 also set? Go to Applicable
3 —
DTC Go to Step 4
2. Disconnect the CKP sensor harness
connector.
ground.
6 4.5 volts

Connect a DMM between the 5 volts reference
8 circuit and low reference (pins 2 and 3 of E122). 4.5 volts
ECM (pin 89 of E125) and the CKP sensor
(pin 3 of E122) for an open circuit or high
9 resistance. —

ECM (pin 112 of E125) and the throttle valve
10 resistance. —

11 resistance. —

96 of E125) and the CKP sensor (pin 1 of
• An open circuit
12 —
• High resistance

Important: The CKP sensor may be damaged if
source.
13 96 of E125) and the CKP sensor (pin 1 of —
E122) for a short to battery or ignition voltage.

96 of E125) and the CKP sensor (pin 1 of
E122) for a short to any 5 volts reference.
14 —

CKP sensor (pins 1, 2 and 3 of E122).
15 —


ECM (pins 88, 89, 96 and 112 of E125).

1. Inspect the CKP sensor and sensor rotor for
• Physical damage of sensor
• Loose or improper installation of sensor
• Excessive air gap
• Foreign material passing between sensor
17 and sensor rotor —
• Physical damage of sensor rotor
rotor

Replace the CKP sensor. Refer to Crankshaft
Position (CKP) Sensor in Section 1B Engine
18 Mechanical (4HV1-CNG). —




21 —

Camshaft Position Sensor Circuit Malfunction Condition for Setting the DTC
• When there is no signal input from the camshaft
Circuit Description position (CMP) sensor for 3 consecutive seconds
The camshaft position (CMP) sensor is a hall effect IC when cranking.
sensor and is installed on the rear section of the
cylinder head. The CMP sensor has the following Action Taken When the DTC Sets
circuits. • The ECM illuminates MIL when the diagnostic runs
• 14 volts reference circuit and fails. Refer to DTC Type Definitions for Action
• CMP sensor signal circuit Taken When the DTC Sets - Type A.
• Shield ground circuit
The engine control module (ECM) supplies 14 volts to
the CMP sensor, and the CMP sensor outputs signals • Refer to DTC Type Definitions for Condition for
to the ECM via the CMP sensor signal circuit. The Clearing the MIL/ DTC - Type A.
camshaft gear has sensing holes at 90° intervals, and
when these holes pass the tip of the CMP sensor, this Diagnostic Aids
emits voltage, which becomes a pulse signal. There is • If an intermittent condition is suspected, refer to
also 1 sensing hole for recognizing the cylinder on the Intermittent Conditions in this section.
camshaft gear, and the ECM detects the top dead
center of the cylinder #1 from the differences in input Connector End View Reference: Engine Controls
intervals from this pulse signal. Connector End Views or ECM Connector End Views
The ECM sets this DTC when an signal is not inputted
from the CMP sensor.

2 3. Crank the engine. —
Go to Diagnostic
2. Disconnect the CMP sensor harness
connector.
3. Connect a DMM between the 14V volts
3 reference circuit (pin 3 of E121) and a known 10 volts
good ground.
Connect a DMM between signal circuit (pin 2 of
4 E121) and a known good ground. 10 volts
Connect a test lamp between the signal circuit (pin
5 2 of E121) and battery voltage. —
Connect a test lamp between the shield ground
6 circuit (pin 1 of E121) and battery voltage. —

1. Test the 14V reference circuit between the
ECM (pin 113 of E125) and the CMP sensor
• An open circuit
7 —
• High resistance

97 of E125) and the CMP sensor (pin 2 of
• An open circuit
• High resistance
8 • A short to battery or ignition voltage —
• A short to any 14volts reference

97 of E125) and the CMP sensor (pin 2 of
E121) for a short to ground or short to the low
9 reference. —

Repair the open circuit, high resistance, or short to
voltage on the CMP sensor shield ground circuit
10 between the CMP sensor (pin 1 of E121) and —
chassis ground terminal (J8).

CMP sensor (pins 1, 2 and 3 of E121).
11 —


1. Inspect the CMP sensor for the following
conditions:
• Physical damage of sensor
13 • Foreign material passing between sensor —
and camshaft gear


1. Inspect the camshaft gear for physical
damage.
14 2. Replace as necessary. —

Replace the CMP sensor. Refer to Camshaft
Position (CMP) Sensor in Section 1B Engine
15 Mechanical (4HV1-CNG). —




18 —

Ignition 1 Control Circuit • Accelerator pedal in the idle position.
• DTC P0117, P0118, P0182, and P0183 have not
Circuit Description been detected.
The ignition coil is a device for emitting the high-voltage • Engine coolant temperature 50°C (122°F) or
current required to ignite the spark plug, and higher and lower than 100°C (212°F).
incorporates a power transistor. The power transistor • Fuel temperature 0°C (32°F) or higher and lower
receives an ignition signal from the engine control than 80°C (176°F).
module (ECM), and disconnects the primary current of
the ignition coil. The ECM turns the power transistor Action Taken When the DTC Sets
"ON" according to the ignition timing, establishing a
GND circuit with the primary coil and leading to a
voltage current in the secondary coil, which in turn
Taken When the DTC Sets - Type A.
ignites the spark plug.
The ECM monitors the ignition coil control circuit of
each cylinder, sets a DTC when an abnormality is
detected in the ignition coil control circuit of the cylinder • Refer to DTC Type Definitions for Condition for
#1. Clearing the MIL/ DTC - Type A.

When an ignition signal abnormality is detected 20 • If an intermittent condition is suspected, refer to
times or more in the cylinder #1 with all following Intermittent Conditions in this section.
conditions established.
• Engine speed less than 800 rpm. Connector End View Reference: Engine Controls

Go to Diagnostic
2. Disconnect the ignition coil harness
connectors of the cylinder #1 and cylinder #2.
3. Remove the ignition coils of the cylinder #1
and cylinder #2 , and install the coils by
3 exchanging cylinders to which they were —
installed.
4. Connect the ignition coil harness connectors
of the cylinder #1 and cylinder #2.
Is DTC P0354 set? Go to Step 8 Go to Step 4


2. Disconnect the cylinder #1 ignition coil
harness connector.
3. Connect a DMM between ignition coil control
4 circuit (pin 3 of E130)and a known good 5 volts
ground.
1. Test the ignition coil control circuit between the
ECM (pin 6 of J95) and the cylinder #1 ignition
coil (pin 3 of E130) for the following
conditions:
5 —

conditions:
• An open circuit
• High resistance

ECM (pin 6 of J95).

Replace the ignition coil installed in the cylinder #2 .
Refer to Ignition Coil & Spark Plug in Section 1E
8 Engine Electrical (4HV1-CNG). —

9 this section. —




11 —


times or more in the cylinder #3 with all the following Intermittent Conditions in this section.

Go to Diagnostic
and cylinder #2, and install the coils by
installed.


harness connector.
3. Connect a DMM between the ignition coil
4 control circuit (pin 3 of E128) and a known 5 volts
good ground.
conditions:
5 —

conditions:
• An open circuit
• High resistance

ECM (pin 7 of J95).

Replace the ignition coil installed in the cylinder #4.

9 this section. —




11 —



Go to Diagnostic
installed.


harness connector.
good ground.
conditions:
5 —

conditions:
• An open circuit
• High resistance

ECM (pin 8 of J95).


9 this section. —




11 —



Go to Diagnostic
installed.


harness connector.
good ground.
conditions:
5 —

conditions:
• An open circuit
• High resistance

ECM (pin 9 of J95).


9 this section. —




11 —

Fuel Tank Pressure Sensor Circuit Low Condition for Setting the DTC
Voltage • The ECM detects that the fuel tank (CNG
container) pressure sensor signal voltage is less
Circuit Description than 0.1 volts for 3 seconds.
The fuel tank (CNG container) pressure sensor detects
the fuel pressure near the CNG container (CNG Action Taken When the DTC Sets
cylinder). The fuel tank (CNG container) pressure • The ECM illuminates MIL when the diagnostic runs
sensor is installed on the pressure regulator. The fuel and fails. Refer to DTC Type Definitions for Action
tank (CNG container) pressure sensor converts the Taken When the DTC Sets - Type A.
pressure to a voltage signal and sends that signal to • Performs control with 10 MPa as the fuel pressure.
the engine control module (ECM). The fuel tank (CNG
container) pressure sensor has the following circuits. Condition for Clearing the DTC
• 5 volts reference circuit • Refer to DTC Type Definitions for Condition for
• Low reference circuit Clearing the MIL/ DTC - Type A.
• Fuel tank (CNG container) pressure sensor signal
circuit Diagnostic Aids
The ECM supplies 5 volts to the fuel tank (CNG • If an intermittent condition is suspected, refer to
container) pressure sensor via the 5 volts reference Intermittent Conditions in this section.
circuit, and grounds the sensor to within the ECM via
the low reference circuit. The fuel tank (CNG container) Connector End View Reference: Engine Controls
pressure sensor indicates a high voltage for high Connector End Views or ECM Connector End Views
signal, and uses it for fuel injection control and other
control systems.
The ECM monitors whether the fuel tank (CNG
container) pressure sensor signal voltage is in a normal
range, and sets this DTC when it determines that the
sensor signal voltage is too low.

Go to Diagnostic
2. Disconnect the fuel tank (CNG container)
pressure sensor harness connector.
3 circuit (pin 3 of J200) and a known good 4.5 volts
ground.

Notice : If the vehivle is for Thailand or Australia,
skip to Step 6.
4 —


• An open circuit
• High resistance

55 of J95) and the fuel tank (CNG container)
pressure sensor (pin 2 of J200) for the

fuel tank (CNG container) pressure sensor
8 (pins 2 and 3 of J200). —

9 ECM (pins 110 and 111 of E125 and pins 55 —
and 81 of J95).


Replace the fuel tank (CNG container) pressure
10 sensor. —



13 —

Fuel Tank Pressure Sensor Circuit High Condition for Setting the DTC
Voltage • The ECM detects that the fuel tank (CNG
container) pressure sensor signal voltage is more
Circuit Description than 4.900 volts for 3 seconds.
The fuel tank (CNG container) pressure sensor detects
the fuel pressure near the CNG container (CNG Action Taken When the DTC Sets
cylinder). The fuel tank (CNG container) pressure • The ECM illuminates MIL when the diagnostic runs
sensor is installed on the pressure regulator. The fuel and fails. Refer to DTC Type Definitions for Action
tank (CNG container) pressure sensor converts the Taken When the DTC Sets - Type A.
pressure to a voltage signal and sends that signal to • Performs control with 10 MPa as the fuel pressure.
the engine control module (ECM). The fuel tank (CNG
container) pressure sensor has the following circuits. Condition for Clearing the DTC
• 5 volts reference circuit • Refer to DTC Type Definitions for Condition for
• Low reference circuit Clearing the MIL/ DTC - Type A.
• Fuel tank (CNG container) pressure sensor signal
circuit Diagnostic Aids
The ECM supplies 5 volts to the fuel tank (CNG • If an intermittent condition is suspected, refer to
container) pressure sensor via the 5 volts reference Intermittent Conditions in this section.
circuit, and grounds the sensor to within the ECM via
the low reference circuit. The fuel tank (CNG container) Connector End View Reference: Engine Controls
pressure sensor indicates a high voltage for high Connector End Views or ECM Connector End Views
signal, and uses it for fuel injection control and other
control systems.
The ECM monitors whether the fuel tank (CNG
container) pressure sensor signal voltage is in a normal
range, and sets this DTC when it determines that the
sensor signal voltage is too high.

Go to Diagnostic
Did the DTC fail this ignition? Go to Step 3 Aids
2. Disconnect the fuel tank (CNG container)
pressure sensor harness connector.
ground.
4 J200) and a known good ground. 5.5 volts
5 4.5 volts

(pin 2 of J200) and a known good ground.
7 reference circuit (pins 1 and 2 of J200). 4.5 volts
Important: The fuel tank (CNG container)
pressure sensor may be damaged if the sensor 5
volts reference circuit is shorted to a voltage
source.
ECM (pin 81 of J95) and the MAP sensor (pin
8 3 of J200) for the following conditions: —

Important: The fuel tank (CNG container) pressure
sensor may be damaged if the sensor signal circuit
is shorted to a voltage source.
55 of J95) and the MAP sensor (pin 2 of J200)
9 for a short to any 5 volts reference circuit. —

pressure sensor (pin 2 of J200) for the
• High resistance

pressure sensor (pin 2 of J200) for a short to
11 any 5 volts reference circuit. —

• High resistance


fuel tank (CNG container) pressure sensor
13 (pins 1 and 2 of J200). —


Replace the fuel tank (CNG container) pressure
15 sensor. —



18 —

Exhaust Brake VSV Open Circuit or Short • When voltage input is not detected from the
Circuit exhaust brake solenoid valve when the exhaust
brake solenoid valve is operating.
Circuit Description • When voltage input is detected from the exhaust
brake solenoid valve when the exhaust brake
The exhaust brake solenoid valve is installed in the
solenoid valve is not operating.
right side member section. The exhaust brake solenoid
valve controls the supply of vacuum to the exhaust
brake valve. The exhaust brake solenoid valve is
supplied power voltage via the main relay, and is turned • The ECM illuminates MIL when the diagnostic runs
"ON" by an operation signal from the engine control and fails. Refer to DTC Type Definitions for Action
module (ECM). When the exhaust brake switch is Taken When the DTC Sets - Type A.
turned "ON" and the exhaust brake operating
conditions are established, the ECM turns the exhaust Condition for Clearing the DTC
brake solenoid valve "ON". A monitor circuit is • Refer to DTC Type Definitions for Condition for
incorporated inside the ECM, and this circuit monitors Clearing the MIL/ DTC - Type A.
the operation of the solenoid valve.
The ECM sets a DTC when the exhaust brake solenoid Diagnostic Aids
valve is turned "OFF" even though the ECM is sending
it an operation signal, or when the exhaust brake
solenoid valve is turned "ON" even though the ECM is
not sending it an operation signal.
When one of the following conditions is established and
continue for 2 seconds.

4. Test drive the vehicle, and operate the
2 exhaust brake. —
5. Stop the vehicle, and monitor the DTC

Information with a scan tool.
Go to Diagnostic
2. Disconnect the exhaust brake solenoid valve
harness connector.
3. Connect a test lamp across the exhaust brake
3 solenoid valve harness connector (pins 1 and —
2 of J96).

2. Perform the Exhaust Brake VSV with a scan
4 tool. —
3. Command the solenoid ON.


Connect a test lamp between the ignition voltage
feed circuit (pin 1 of J96) and a known good
5 ground. —

1. Test the control circuit between the ECM (pin
13 of J95) and the exhaust brake solenoid
valve (pin 2 of J96) for a short to ground or
6 short to low reference circuit. —

valve (pin 2 of J96) for the following
conditions:
• High resistance

Repair the open circuit or high resistance in the
exhaust brake solenoid valve ignition voltage circuit
8 between the converter relay (pin 4 of B285) and the —
exhaust brake solenoid valve (pin 1 of J96).

exhaust brake solenoid valve (pins 1 and 2 of
9 J96). —


Replace the exhaust brake solenoid valve. Refer to
Magnetic Valve in Section 1G Engine Exhaust
11 (4HV1-CNG). —



13 4. Test drive the vehicle, and operate the —
exhaust brake.

14 —

4. Test drive the vehicle, and operate the
2 —
exhaust brake.
Go to Diagnostic
2. Disconnect the exhaust brake solenoid valve
harness connector.
3. Connect a test lamp across the exhaust brake
3 solenoid valve harness connector (pins 1 and —
2 of J96).

4 tool. —

feed circuit (pin 1 of J96) and a known good
5 ground. —

valve (pin 2 of J96) for a short to ground or
6 short to low reference circuit. —


valve (pin 2 of J96) for the following
conditions:
• High resistance

exhaust brake solenoid valve ignition voltage circuit
8 between the ignition relay (pin 3 of B285) and the —
exhaust brake solenoid valve (pin 1 of J96).

exhaust brake solenoid valve (pins 1 and 2 of
9 J96). —


11 (4HV1-CNG). —


13 4. Test drive the vehicle, and operate the —
exhaust brake.

14 —

Vehicle Speed Sensor • Gas injector injection control pulse width 10 ms or
higher.
Circuit Description • Engine speed 1500 rpm or higher.
The vehicle speed sensor (VSS) is used by the ECM • No vehicle speed signal input.
and the speedometer to generate a speed signal from
the rotation speed of the transmission output shaft. The Action Taken When the DTC Sets
sensor has following circuits: • The ECM illuminates the MIL on the second
• Ignition voltage feed circuit consecutive driving cycle when the diagnostic runs
• Low reference circuit and fails. Refer to DTC Type Definitions for Action
• VSS signal circuit Taken When the DTC Sets - Type B.
The VSS uses hall elements. They interact with • Performs control with 0 km/h as the vehicle speed.
magnetic fields generated by the rotation of magnets to
output pulse signals. The ECM calculates the vehicle Condition for Clearing the DTC
speed using the VSS. When the ECM detects that a • Refer to DTC Type Definitions for Condition for
VSS signal has not been generated, it detects this Clearing the MIL/ DTC - Type B.
DTC.
Diagnostic Aids
When all the following conditions are established and Intermittent Conditions in this section.
• Neutral switch turned "OFF". Connector End View Reference: Engine Controls

Drive the vehicle while observing the Vehicle
2 Speed parameter with a scan tool. — Go to Diagnostic
Does the scan tool indicate correct vehicle speed? Aids Go to Step 3
2. Disconnect the VSS harness connector.
3 4. Connect a test lamp between the ignition —
voltage feed circuit (pin 1 of J48) and a known
good ground.

Intermittently jump the signal circuit (pin 3 of J48)
with a test lamp that is connected to a known good
ground while observing the Vehicle Speed
4 parameter with a scan tool. —
Does the scan tool indicate any vehicle speed

when the circuit is intermittently pulled to ground? Go to Step 5 Go to Step 8
feed circuit and the low reference circuit (pins 1 and
5 2 of J48). —


low reference circuit between the VSS (pin 2 of
6 J48) and the chassis ground terminal (B52). Clean —
or tighten as necessary.

Repair the open circuit or high resistance between
the ABS (10A) fuse (F7) and the VSS (pin 1 of
7 J48). Check the ABS (10A) fuse first. —

57 of J95) and the VSS (pin 3 of J48) for the
• An open circuit
8 • A short to ground —
• High resistance

VSS (pins 1, 2 and 3 of J48).
9 —


1. Inspect the VSS, driven gear, drive gear or
output shaft for the following conditions:
• Physical damage of sensor, driven gear
or drive gear
• Loose or improper installation of sensor,
11 driven gear or drive gear —
• Transmission output shaft teeth damage
• Excessive transmission output shaft play
Did you find the problems and complete repairs? Go to Step 14 Go to Step 12
Replace the VSS. Refer to Vehicle Speed Sensor in
12 Section 5C Manual Transmission (MYY). —


4. Drive the vehicle while observing the Vehicle
Speed parameter with a scan tool.
Does the scan tool indicate correct vehicle speed? Go to Step 15 Go to Step 3
15 —

Idle Speed Control RPM Too Low Action Taken When the DTC Sets
• The ECM will not illuminate the MIL. Refer to DTC
Circuit Description Type Definitions for Action Taken When the DTC
The engine control module (ECM) adjusts the throttle Sets - Type D.
valve opening angle to control the idling engine speed.
The ECM sets a DTC when the idling speed is lower Condition for Clearing the DTC
than the desired value for a certain amount of time. • Refer to DTC Type Definitions for Condition for
When the following conditions are established and Diagnostic Aids
continue for 30 seconds. • If an intermittent condition is suspected, refer to
• When the throttle valve control is performing idle Intermittent Conditions in this section.
control.
• When the current engine speed is 200 rpm or Connector End View Reference: Engine Controls
lower than the desired engine speed. Connector End Views or ECM Connector End Views

Go to Applicable
Is DTC other than P0506 also set? DTC Go to Step 3
Is an abnormal sound heard from the engine? Go to 4HV1-CNG
Engine in Section
3 — 1B Engine
Mechanical (4HV1-
CNG) Go to Step 4
3. Perform the Desired Idling Speed Change with
a scan tool.
4 4. Command the Desired Idling Speed Increase —
and Decrease while observing the Engine
Speed.
Does the Engine Speed parameter follow within Go to Diagnostic

200 rpm quick enough? Aids Go to Step 5
Observe the Idle Switch parameter with a scan tool.
5 —
Does the scan tool indicate ON? Go to Step 6 Go to Step 8
Observe the Vehicle Speed parameter with a scan
6 tool. —
Does the scan tool indicate 0 km/h? Go to Step 7 Go to Step 9

1. Inspect the fuel system.
• Bending, clogging or defective
connection of the rigid fuel line
• Twisting, bending or defective connection
of the flexible fuel line
• Clogging of the gas filter installed to the
gas injector
7 2. Inspect the air intake system for the following —

conditions:
• Clogging, damage or intake air leakage
in the air cleaner or intake duct
• Intake air leakage in the intake manifold
3. Inspect the exhaust system for clogging.

Refer to DTC P1275 and DTC P1280 to inspect the
accelerator pedal position (APP) sensor circuit, and
8 repair as necessary. —

Refer to DTC P0502 to inspect the vehicle speed
9 sensor circuit, and repair as necessary. —
1. Connect the scan tool.
10 3. Start the engine and let idle for 30 seconds. —

11 —

Idle Speed Control RPM too High Action Taken When the DTC Sets
The engine control module (ECM) adjusts the throttle Sets - Type D.
valve opening angle to control the idling engine speed.
The ECM sets a DTC when the idling speed is higher Condition for Clearing the DTC
than the desired value for a certain amount of time. • Refer to DTC Type Definitions for Condition for
When the following conditions are established and Diagnostic Aids
continue for 30 seconds. • If an intermittent condition is suspected, refer to
• When the throttle valve control is performing idle Intermittent Conditions in this section.
control.
• When the current engine speed is 500 rpm or Connector End View Reference: Engine Controls
higher than the desired engine speed. Connector End Views or ECM Connector End Views

Go to Diagnostic
Is an abnormal sound heard from the engine? Go to 4HV1-CNG
Engine in Section
3 — 1B Engine
Mechanical (4HV1-
CNG) Go to Step 4
3. Perform the Desired Idling Speed Change with
a scan tool.
4 4. Command the Desired Idling Speed Increase —
and Decrease while observing the Engine
Speed.
Does the Engine Speed parameter follow within Go to Diagnostic

200 rpm quick enough? Aids Go to Step 5
Observe the Idle Switch parameter with a scan tool.
5 —
Does the scan tool indicate ON? Go to Step 6 Go to Step 8
Observe the Vehicle Speed parameter with a scan
6 tool. —
Does the scan tool indicate 0 km/h? Go to Step 7 Go to Step 9

1. Inspect the gas injector for damage of tip.
2. Inspect the air intake system for the following
conditions:
• Intake air leakage in the air cleaner or
intake duct
• Intake air leakage in the intake manifold
• Intake air leakage in the positive
crankcase ventilation (PCV) system
3. Inspect the engine control sensors for the
7 following conditions. Refer to Scan Tool Data —
List in this section.
• Compare the Coolant Temperature with
the IAT Sensor (Intake Air Temperature)
and Fuel Temperature Sensor
parameters on a cold engine condition. If
the difference among temperature
reading is more than 5°C (41°F) on a
cold engine, check for high resistance in
each circuit or for a skewed sensor.

Refer to DTC P1275 and DTC P1280 to inspect the
accelerator pedal position (APP) sensor circuit, and
8 repair as necessary. —

Refer to DTC P0502 to inspect the vehicle speed
9 sensor circuit, and repair as necessary. —
1. Connect the scan tool.
10 3. Start the engine and let idle for 30 seconds. —

11 —

Ignition Power Source Error • The ignition switch is ON.
• The starter switch is OFF.
Circuit Description
The vehicle is controlled by a 24 volts power source. Action Taken When the DTC Sets
However, since some of the engine control equipment, • The ECM illuminates MIL when the diagnostic runs
namely the ignition coil, air-fuel ratio (A/F) sensor and fails. Refer to DTC Type Definitions for Action
heater, and O2 sensor heater are rated for 12 volts, Taken When the DTC Sets - Type A.
power is supplied to them after converting the 24 volts
power (from the main power supply circuit) into 12 volts Condition for Clearing the DTC
via the DC-DC converter. The engine control module • Refer to DTC Type Definitions for Condition for
(ECM) monitors the 12 volts power supply voltage via Clearing the MIL/ DTC - Type A.
the 12 volts power supply monitor circuit, and sets DTC
P0560 if the voltage decreases. Diagnostic Aids
Condition for Setting the DTC • If an intermittent condition is suspected, refer to
continue for 3 seconds. Connector End View Reference: Engine Controls
• The ignition power supply voltage is 8.055 volts or Connector End Views or ECM Connector End Views
lower.

2 4. Observe the Ignition Voltage parameter with a 9 volts
scan tool.
Is the Ignition Voltage parameter more than the Go to Diagnostic

specified value ? Aids Go to Step 3
2. Inspect the ECM (IG) (10A) fuse (F20), ECM
3 (15A) fuse (F39), IG COIL (15A) fuse (F40) —
and ECU (30A) slow blow fuse (SBF1).

Replace the fuse or SBF that was open found at
Step 3. If the SBF or fuse continues to open, repair
the short to ground on one of the circuits that is fed
4 by the SBF or fuse or replace the shorted attached —
component.

2. Replace the ignition relay with a known good
relay.
5 9 volts
4. Observe the Ignition Voltage parameter with a
scan tool.
Is the Ignition Voltage parameter more than the

specified value ? Go to Step 23 Go to Step 6

2. Replace the converter relay with a known
good relay.
6 9 volts
scan tool.

3. Connect the DMM between the 12 volts
7 supply monitor circuit (pin 56 of J9) and a 9 volts
known good ground.
2. Remove the converter relay.
3. Connect a test lamp across the converter
8 relay coil side circuits (pins 8 and 10 of B285). —

Probe the ignition voltage feed circuit of the
converter relay coil side (pin 8 of B285) with a test
9 lamp that is connected to a known good ground. —

Connect the DMM between the voltage feed circuit
of the converter relay switch side (pin 2 of B285)
10 and a known good ground. 24 volts
2. Remove the ignition relay.
3. Connect a test lamp across the ignition relay
11 coil side circuits (pins 5 and 7 of B285). —

Probe the ignition voltage feed circuit of the ignition
relay coil side (pin 5 of B285) with a test lamp that
12 is connected to a known good ground. —

of the ignition relay switch side (pin 1 of B285) and
13 a known good ground. 9 volts

1. Test the voltage feed circuit between the
converter relay (pin 4 of B285) and the DC-DC
converter (pin 1 of N18) for the following
conditions:
• An open circuit
• High resistance
2. Repair circuit(s) as necessary.

1. Test the 12 volts supply circuit between the
DC-DC converter (pin 3 of N18) and the
ignition relay (pin 1 of B285) for the following
conditions:
• An open circuit
• High resistance

1. Test the ground circuits between the DC-DC
converter (pins 2 and 4 of N18) and the
chassis ground terminal (J11) for the following
conditions:
• High resistance

Repair the ground circuit between the converter
relay (pin 10 of B285) and the chassis ground
17 terminals (B51 and B60). —

Repair the voltage feed circuit between the ignition
switch (pin 6 of B130) and the converter relay (pin 8
18 of B285). —

Repair the voltage feed circuit between the ECU
(30A) slow blow fuse (SBF1) and the converter
19 relay (pin 2 of B285). —

Repair the ground circuit between the ignition relay
(pin 7 of B285) and the chassis ground terminals
20 (B51 and B60). —

switch (pin 6 of B130) and the ignition relay (pin 5
21 of B285). —


Repair the voltage supply monitor circuit between
the ignition relay (pin 3 of B285) and the ECM (pin
22 56 of J95). —

Replace the ignition relay.
23 —
Replace the converter relay.
24 —
2. Disconnect the DC-DC converter harness
connector.
DC-DC converter (pins 1, 2, 3 and 4 of N18).


Replace the DC-DC converter.
27 —

29 4. Turn ON the ignition, with the engine OFF. 9 volts
scan tool.

30 —


2 4. Observe the Ignition Voltage parameter with a 9 volts
scan tool.
Is the Ignition Voltage parameter more than the Go to Diagnostic

2. Inspect the ECM (IG) (10A) fuse (F20), ECM
3 (15A) fuse (F39), IG COIL (15A) fuse (F40) —
and ECU (30A) slow blow fuse (SBF1).

Replace the fuse or SBF that was open found at
Step 3. If the SBF or fuse continues to open, repair
the short to ground on one of the circuits that is fed
4 by the SBF or fuse or replace the shorted attached —
component.

2. Replace the ignition relay with a known good
relay.
5 9 volts
scan tool.

2. Replace the converter relay with a known
good relay.
6 9 volts
scan tool.

7 supply monitor circuit (pin 56 of J9) and a 9 volts
known good ground.
2. Remove the ignition relay.
3. Connect a test lamp across the ignition relay
8 coil side circuits (pins 5 and 7 of B285). —

Probe the ignition voltage feed circuit of the ignition
relay coil side (pin 7 of B285) with a test lamp that
9 is connected to a known good ground. —


of the ignition relay switch side (pin 1 of B285) and
10 a known good ground. 24 volts
2. Remove the converter relay.
3. Connect a test lamp across the converter
11 relay coil side circuits (pins 8 and 10 of B285). —

Probe the ignition voltage feed circuit of the
converter relay coil side (pin 8 of B285) with a test
12 lamp that is connected to a known good ground. —

of the converter relay switch side (pin 2 of B285)
13 and a known good ground. 9 volts
1. Test the voltage feed circuit between the
ignition relay (pin 3 of B285) and the DC-DC
converter (pin 1 of N18) for the following
conditions:
• An open circuit
• High resistance

1. Test the 12 volts supply circuit between the
DC-DC converter (pin 3 of N18) and the
converter relay (pin 2 of B285) for the
• An open circuit
• High resistance

1. Test the ground circuits between the DC-DC
converter (pins 2 and 4 of N18) and the
chassis ground terminal (J11) for the following
conditions:
• High resistance

Repair the ground circuit between the ignition relay
(pin 5 of B285) and the chassis ground terminal
17 (B53). —


switch (pin 6 of B130) and the ignition relay (pin 7
18 of B285). —

Repair the voltage feed circuit between the ECU
(30A) slow blow fuse (SBF1) and the ignition relay
19 (pin 1 of B285). —

Repair the ground circuit between the converter
relay (pin 10 of B285) and the chassis ground
20 terminal (B53). —

switch (pin 6 of B130) and the converter relay (pin 8
21 of B285). —

Repair the voltage supply monitor circuit between
the converter relay (pin 4 of B285) and the ECM
22 (pin 56 of J95). —

Replace the ignition relay.
23 —
Replace the converter relay.
24 —
2. Disconnect the DC-DC converter harness
connector.
DC-DC converter (pins 1, 2, 3 and 4 of N18).


Replace the DC-DC converter.
27 —


scan tool.

30 —

System Voltage Low Action Taken When the DTC Sets
The engine control module (ECM) monitors whether Sets - Type D.
the power supply voltage on the ECM power supply
circuit is within the normal range. The ECM sets a DTC Condition for Clearing the DTC
when the power supply voltage is too low. The charge • Refer to DTC Type Definitions for Condition for
light inside the IP cluster illuminates when there is an Clearing the DTC - Type D.
abnormality in the charging system.
Diagnostic Aids
When all the following conditions are established and Intermittent Conditions in this section.
• The system voltage is 12 volts or lower. Connector End View Reference: Engine Controls
• The ignition switch is ON. Connector End Views or ECM Connector End Views

4. Load the electrical system by turning ON the
2 16 volts
headlights, A/C, etc. while observing the
System Voltage parameter with a scan tool.
Does the scan tool indicate less than the specified Go to Diagnostic
value? Aids Go to Step 3
Test the charging system. Refer to Charging
System in Section 1E Engine Electrical (4HV1-
3 CNG). —
Did you find a charging system problem? Go to Step 4 Go to Step 5

Repair the charging system. Refer to Charging
4 CNG). —

5 2. Inspect the ECU (30A) slow blow fuse (SBF1). —
Is the SBF open? Go to Step 6 Go to Step 7
Replace the ECU (30A) slow blow fuse (SBF1). If
the SBF continues to open, repair the short to
ground on one of the circuits that is fed by the ECU
6 (30A) slow blow fuse or replace the shorted —
attached component.


2. Replace the ECM main relay with a known
good relay.
7 16 volts
4. Observe the System Voltage parameter with a
scan tool.
Is the System Voltage parameter more than the

3. Connect a test lamp between the ECM main
8 relay control circuit (pin 16 of J95) and a —
known good ground.

the ECM main relay control circuit (pin 16 of
J95) and a known good ground.
9 2. Connect a test lamp between the battery —
voltage feed circuits (pins 3 and 4 of J95) and
a known good ground.

1. Remove the ECM main relay.
2. Connect a test lamp between the voltage
10 supply circuits (pins 1 and 3 of X18) and a —
known good ground.

voltage supply circuit between the ECU (30A) slow
11 blow fuse (SBF1) and the ECM main relay (pins 1 —
and 3 of X18).

ECM main relay control circuit or the battery
12 voltage feed circuit between the ECM main relay —
and the ECM (pins 3, 4 and 16 of J95).

Replace the ECM relay.
13 —
ECM (pins 3, 4 and 16 of J95).
14 —



5. Observe the System Voltage parameter with a
scan tool.
Is the System Voltage parameter more than the

17 —

System Voltage High Action Taken When the DTC Sets
Circuit Description consecutive driving cycle when the diagnostic runs
The engine control module (ECM) monitors whether and fails. Refer to DTC Type Definitions for Action
the power supply voltage on the ECM power supply Taken When the DTC Sets - Type B.
circuit is within the normal range. The ECM sets a DTC
when the power supply voltage is too high. Condition for Clearing the DTC
Condition for Setting the DTC Clearing the MIL/ DTC - Type B.
continue for 5 seconds. Diagnostic Aids
• The system voltage is 30.999 volts or higher. • If an intermittent condition is suspected, refer to
• The ignition switch is ON. Intermittent Conditions in this section.

1. Check whether the battery charger is placed
on the battery.
2 2. If the battery charger is placed, remove it. —
Did you find the and correct the conditions? Go to Step 7 Go to Step 3
3 4. Observe the System Voltage parameter with a 31 volts
scan tool.
Is the System Voltage parameter less than the Go to Diagnostic

Test the charging system. Refer to Charging
4 CNG). —
Did you find a charging system problem? Go to Step 5 Go to Step 6

Repair the charging system. Refer to Charging
5 CNG). —

6 this section. —




8 —

Control Module Internal Performance Action Taken When the DTC Sets
This DTC is applied to the microprocessor (CPU) inside Taken When the DTC Sets - Type A.
the engine control module (ECM).
Condition for Setting the DTC • Refer to DTC Type Definitions for Condition for
• When there is no communication or abnormal Clearing the MIL/ DTC - Type A.
communication with the sub-CPU inside the ECM
continuously for 1 second. Connector End View Reference: Engine Controls

Does the DTC fail this ignition? Go to Step 3 Go to Step 7

1. Test the following ECM ground circuits
between the ECM (pins 1, 2, 75, 76, 77, 78
and 79 of J95) and the chassis ground
3 terminal (J8). —

2. Inspect for an intermittent, for poor tightening
and corrosion at the chassis ground terminal
4 (J8). —
3. Repair the tightening or clean the corrosion as
necessary.

5 ECM (pins 1, 2, 75, 76, 77, 78 and 79 of J95). —

6 this section. —



8 —

Throttle Position Sensor 1 Circuit Condition for Setting the DTC
• When the intake throttle position sensor 1 signal
Circuit Description voltage is 0.1 volts or lower, or 4.863 volts or
The intake throttle position sensor is situated inside the higher for 1.25 consecutive seconds.
throttle valve. The intake throttle position sensor has
two systems, and they each have different Action Taken When the DTC Sets
characteristics. The intake throttle position sensor • The ECM illuminates MIL when the diagnostic runs
outputs a voltage according to the opening angle of the and fails. Refer to DTC Type Definitions for Action
throttle valve, and the engine control module (ECM) Taken When the DTC Sets - Type A.
uses the signal to detect the throttle valve opening • When the intake throttle position sensor 2 is
angle. The intake throttle position sensor has the normal.
following circuits. Performs control using the intake throttle position
• 5 volts reference circuit sensor 2 signal.
• Low reference circuit • When intake throttle position sensor 2 is abnormal.
• Intake throttle position sensor 1 signal circuit Switches each control to the power management
• Intake throttle position sensor 2 signal circuit mode or the forced engine shutdown mode.
The ECM supplies 5 volts to intake throttle position
sensor 1 and 2 via the 5 volts power supply circuit, and Condition for Clearing the DTC
grounds the sensor to within the ECM via the GND • Refer to DTC Type Definitions for Condition for
circuit. The intake throttle position sensor outputs Clearing the MIL/ DTC - Type A.
signal voltage to the ECM via the intake throttle position
sensor signal circuit. The signal voltage of intake Diagnostic Aids
throttle position sensor 1 becomes higher as the • If an intermittent condition is suspected, refer to
throttle valve opens, and the signal voltage of intake Intermittent Conditions in this section.
throttle position sensor 2 becomes higher as the
throttle valve closes. Connector End View Reference: Engine Controls
The ECM monitors whether the intake throttle position Connector End Views or ECM Connector End Views
sensor 1 signal voltage is in a normal range, and sets
this DTC when it determines that the sensor signal
voltage is too high or too low.

Go to Diagnostic
3 Is DTC P1635 also set? — Go to DTC P1635 Go to Step 4
2. Disconnect the throttle valve harness
connector.
ground.
5 5.5 volts

circuit and low reference circuit (pins 1 and 6 of
6 E137). 4.5 volts
Connect a DMM between the position sensor 1
signal circuit (pin 5 of E137) and a known good
7 ground. 4.5 volts
8 5.5 volts
1. Connect a test lamp between the position
sensor 1 signal circuit (pin 5 of E137) and a
known good ground.
• An open circuit
10 —
• High resistance

11 resistance. —

Important: The intake throttle position sensor may
be damaged if the sensor 5 volts reference circuit is

• An open circuit
13 —
• High resistance


1. Test the position sensor 1 signal circuit
between the ECM (pin 104 of E125) and the
throttle valve (pin 5 of E137) for the following
conditions:
• An open circuit
• High resistance

be damaged if the sensor signal circuit is shorted to
a voltage source.
15 conditions: —

throttle valve (pin 5 of E137) for a short to any
16 5 volts reference circuit. —

throttle valve (pins 1, 5 and 6 of E137).
17 —

ECM (pins 87, 89, 104 and 112 of E125).

Important: The throttle idle learned value and the
close throttle learned value in the ECM must be
cleared when the throttle valve is replaced.
19 Replace the throttle valve. Refer to Throttle Valve in —
Section 1J Induction (4HV1-CNG).





22 —

Electronic Throttle Control Limited Condition for Setting the DTC
Performance Mode • When the throttle valve control mode detected the
limited performance mode status.
Circuit Description
The engine control module (ECM) determines the Action Taken When the DTC Sets
throttle valve opening angle according to the state of • The ECM illuminates MIL when the diagnostic runs
the engine. The ECM normally calculates the desired and fails. Refer to DTC Type Definitions for Action
throttle valve opening angle based on the signals from Taken When the DTC Sets - Type A.
the accelerator position (APP) sensor, and the actual • The throttle valve opening angle is limited to
valve opening angle is detected by the intake throttle prevent it from rising above a certain level.
position sensor. When there is a failure in the APP
sensor or intake throttle position sensor, a control mode Condition for Clearing the DTC
is selected for the intake throttle depending on the
failure condition, and the throttle valve is controlled
according to that mode. The limited performance mode
is selected when the throttle valve position sensor is
Diagnostic Aids
normal but a malfunction has been detected in the APP
sensor 1 or 2 (DTC P1271, P1275 or P1280). • If an intermittent condition is suspected, refer to
The ECM sets this DTC when the limited performance Intermittent Conditions in this section.
mode is selected.

Go to Diagnostic
3 Is DTC P1271 also set? — Go to Step 4 Go to Step 5
4 Is DTC P1275 or P1280 also set? — Go to DTC List Go to Step 5
1. Disconnect the accelerator pedal position
(APP) sensor harness connector.
APP sensor (pins 1 to 6 of B5).

ECM (pins 42, 43, 52, 53, 71 and 72 of J95).


7 this section. —



9 —

Air Fuel Ratio Sensor AFC (Base Voltage) Or Action Taken When the DTC Sets
AFV (Supply Voltage) Open • The ECM illuminates MIL when the diagnostic runs
The air-fuel ratio (A/F) sensor is installed on the • Stops energizing the A/F sensor and A/F sensor
exhaust pipe in front of the 3-way catalyst, and detects heater.
the oxygen density in the exhaust gas. The A/F sensor • Switches to injection control when the A/F sensor
has an AFC (High side signal) circuit and AFV (Low has a failure.
side signal) circuit. The engine control module (ECM)
supplies voltage to the A/F sensor via the AFC circuit Condition for Clearing the DTC
and AFV circuit, and receives the changes in voltage
due to the output current in the A/F sensor via the AFC
circuit. The A/F sensor changes the output current
according to the oxygen density in the exhaust gas,
Diagnostic Aids
and outputs a higher current the lower the oxygen
density is (the more fuel there is). • If an intermittent condition is suspected, refer to
The ECM monitors the A/F sensor circuit, and sets a Intermittent Conditions in this section.
DTC when an open circuit is detected in the circuit.
• When during A/F sensor element temperature
feedback (F/B), the desired heater power is 25
watt or higher, and the element resistance value is
250 ohms or higher, for 5 seconds or more.

3. Start the engine and let idle for at least 5
2 minutes. —
Go to Diagnostic
harness connector.
3 3. Connect a DMM between the AFC circuit (pin 1.0 volt
3 of E120) and a known good ground.
Connect the DMM between the AFV circuit (pin 4 of
4 E120) and a known good ground. 1.0 volt
E120) for an open.
5 —


E120) for an open.
6 —

A/F sensor (pins 3 and 4 of E120).
7 —


sensor is replaced.
CNG).


11 —
minutes.

12 —

Air Fuel Ratio Sensor AFV (Supply Voltage) Action Taken When the DTC Sets
Circuit Shorted • The ECM illuminates MIL when the diagnostic runs
Diagnostic Aids
DTC when a short circuit is detected in the AFV circuit.
• When the AFV voltage is 0.3 volts or lower for 3.84
seconds or more.

Go to Diagnostic
harness connector.
3 3. Connect the DMM between the AFV circuit 1.0 volt
• High resistance


A/F sensor (pin 4 of E120).
5 —


sensor is replaced.
CNG).

8 this section. —

9 —
minutes.

10 —

Air Fuel Ratio Sensor AFC (Base Voltage) Action Taken When the DTC Sets
Circuit Shorted • The ECM illuminates MIL when the diagnostic runs
Diagnostic Aids
DTC when a short circuit is detected in the AFC circuit.
• When the AFC voltage is 0.4 volts or lower for 3.84
seconds or more.

Go to Diagnostic
harness connector.
• High resistance


A/F sensor (pin 3 of E120).
5 —


sensor is replaced.
CNG).

8 this section. —

9 —
minutes.

10 —

Air Fuel Ratio Sensor, Release of Heater Action Taken When the DTC Sets
Output • The ECM illuminates MIL when the diagnostic runs
The air-fuel ratio (A/F) sensor incorporates a heater to • Stops energizing the A/F sensor and A/F sensor
heat up its internal zirconia element because this heater.
element does not activate (induce an electric potential) • Switches to injection control when the A/F sensor
unless it has reached its minimum active temperature has a failure.
of 650°C (1202°F). The engine control module (ECM)
turns the A/F sensor heater ON when the engine has Condition for Clearing the DTC
started, and turns the A/F sensor heater OFF when the
engine is stopped. The ECM monitors the A/F sensor
heater circuit, and sets a DTC when an open circuit is
detected in the circuit.
Diagnostic Aids
• When an open circuit is continuously detected in
the A/F sensor heater output circuit for 3.84
seconds.
(Determined by the heater output voltage and
heater output current, for each condition where the
A/F sensor heater is "ON" and "OFF")

Go to Diagnostic
harness connector.
4 3. Connect the DMM between the voltage supply 9 volts
circuit to the sensor heater (pin 2 of E120).
1. Connect the DMM between the voltage supply
circuit to the sensor heater and the sensor
heater control circuit (pins 1 and 2 of E120).
5 9 volts
Repair the open circuit or a short to ground on the
voltage supply circuit to the sensor heater between
6 the ignition relay (pin 3 of B285) and the A/F sensor —
(pin 2 of E120).


ECM (pin 120 of E125) and the A/F sensor
(pin 1 of E120) for an open.
7 —

8 —


sensor is replaced.
CNG).




13 —

Go to Diagnostic

harness connector.
4 3. Connect the DMM between the voltage supply 9 volts
circuit to the sensor heater (pin 2 of E120).
circuit to the sensor heater and the sensor
5 9 volts
Repair the open circuit or a short to ground on the
voltage supply circuit to the sensor heater between
6 the converter relay (pin 4 of B285) and the A/F —
sensor (pin 2 of E120).

ECM (pin 120 of E125) and the A/F sensor
(pin 1 of E120) for an open.
7 —

8 —


sensor is replaced.
CNG).





13 —

Air Fuel Ratio Sensor, Short Circuit of Heater Action Taken When the DTC Sets
Output • The ECM illuminates MIL when the diagnostic runs
The air-fuel ratio (A/F) sensor incorporates a heater to • Stops energizing the A/F sensor and A/F sensor
heat up its internal zirconia element because this heater.
element does not activate (induce an electric potential) • Switches to injection control when the A/F sensor
unless it has reached its minimum active temperature has a failure.
of 650°C (1202°F). The engine control module (ECM)
turns the A/F sensor heater ON when the engine has Condition for Clearing the DTC
started, and turns the A/F sensor heater OFF when the
heater circuit, and sets a DTC when a short circuit is
detected in the circuit.
Diagnostic Aids
• When a short circuit is continuously detected in the
A/F sensor heater output circuit for 3.84 seconds.
(Determined by the heater output voltage and
heater output current, for each condition where the
A/F sensor heater is "ON" and "OFF")

Go to Diagnostic
harness connector.
3 circuit to the sensor heater and the sensor 9 volts
1. Test the sensor heater control circuit between
the ECM (pin 120 of E125) and the A/F sensor
(pin 1 of E120) for a short to ground.
4 —

sensor is replaced.
CNG).


6 this section. —



8 —

Air Fuel Ratio Sensor Heater Error Action Taken When the DTC Sets
The air-fuel ratio (A/F) sensor incorporates a heater to Taken When the DTC Sets - Type A.
heat up its internal zirconia element because this • Stops energizing the A/F sensor and A/F sensor
element does not activate (induce an electric potential) heater.
unless it has reached its minimum active temperature • Switches to injection control when the A/F sensor
of 650°C (1202°F). The engine control module (ECM) has a failure.
turns the A/F sensor heater ON when the engine has
started, and turns the A/F sensor heater OFF when the Condition for Clearing the DTC
heater circuit, and sets a DTC when an activation • Refer to DTC Type Definitions for Condition for
problem is detected with the A/F sensor heater. Clearing the MIL/ DTC - Type A.
• When a malfunction is continuously detected in the • If an intermittent condition is suspected, refer to

A/F sensor heater for 3.84 seconds. Intermittent Conditions in this section.
(Determined by the A/F sensor heater power
accumulation value and sensor resistance value) Connector End View Reference: Engine Controls

2 —
4. After 5 minutes or more have elapsed, monitor
the DTC Information with a scan tool.
Go to Diagnostic
harness connector.
2. Connect the DMM between the AFV circuit
4 (pin 4 of E120) and a known good ground. 1.0 volt
1. Test the sensor AFC circuit between the ECM
(pin 118 of E125) and the A/F sensor (pin 3 of
E120) for an open.
5 —


1. Test the sensor AFV circuit between the ECM
(pin 119 of E125) and the A/F sensor (pin 4 of
E120) for an open.
6 —

7 —


sensor is replaced.
CNG).


11 —
minutes.

12 —

Air Fuel Ratio Sensor Protection Circuit • The heater output current is 25A or higher.
Operation • The AFV voltage is 4.4 volts or higher.
• The AFC voltage is 4.4 volts or higher.
Circuit Description
The air-fuel ratio (A/F) sensor is installed on the Action Taken When the DTC Sets
exhaust pipe in front of the 3-way catalyst, and detects • The ECM illuminates MIL when the diagnostic runs
the oxygen density in the exhaust gas. The A/F sensor and fails. Refer to DTC Type Definitions for Action
has an AFC (High side signal) circuit and AFV (Low Taken When the DTC Sets - Type A.
side signal) circuit. The engine control module (ECM) • Stops energizing the A/F sensor and A/F sensor
supplies voltage to the A/F sensor via the AFC circuit heater.
due to the output current in the A/F sensor via the AFC • Switches to injection control when the A/F sensor
circuit. The A/F sensor changes the output current has a failure.
and outputs a higher current the lower the oxygen Condition for Clearing the DTC
density is (the more fuel there is). • Refer to DTC Type Definitions for Condition for
The ECM monitors the A/F sensor circuit. When an Clearing the MIL/ DTC - Type A.
overcurrent is detected in the heater output current or
when the AFC/AFV circuit shorts with the power supply Diagnostic Aids
circuit, it activates the A/F sensor protection circuit and • If an intermittent condition is suspected, refer to
sets a DTC. Intermittent Conditions in this section.
Condition for Setting the DTC Connector End View Reference: Engine Controls
When one of the following statuses is detected. Connector End Views or ECM Connector End Views

Go to Diagnostic
harness connector.
3 3. Connect the DMM between the AFV circuit 4.5 volts
Connect a DMM between the AFC circuit (pin 3 of

Important: The A/F sensor may be damaged if the
sensor circuit is shorted to a voltage source.

Important: The A/F sensor may be damaged if the
sensor circuit is shorted to a voltage source.

sensor is replaced.
CNG).

8 this section. —

9 —
minutes.

10 —

Throttle Position Sensor 2 Circuit Condition for Setting the DTC
• When the intake throttle position sensor 2 signal
Circuit Description voltage is 0.1 volts or lower, or 4.863 volts or
The intake throttle position sensor is situated inside the higher for 1.25 consecutive seconds.
throttle valve. The intake throttle position sensor has
two systems, and they each have different Action Taken When the DTC Sets
characteristics. The intake throttle position sensor • The ECM illuminates MIL when the diagnostic runs
outputs a voltage according to the opening angle of the and fails. Refer to DTC Type Definitions for Action
throttle valve, and the engine control module (ECM) Taken When the DTC Sets - Type A.
uses the signal to detect the throttle valve opening • When the intake throttle position sensor 1 is
angle. The intake throttle position sensor has the normal.
following circuits. Performs control using the intake throttle position
• 5 volts reference circuit sensor 1 signal.
• Low reference circuit • When intake throttle position sensor 1 is abnormal.
• Intake throttle position sensor 1 signal circuit Switches each control to the power management
• Intake throttle position sensor 2 signal circuit mode or the forced engine shutdown mode.
sensor 1 and 2 via the 5 volts power supply circuit, and Condition for Clearing the DTC
grounds the sensor to within the ECM via the GND • Refer to DTC Type Definitions for Condition for
circuit. The intake throttle position sensor outputs Clearing the MIL/ DTC - Type A.
signal voltage to the ECM via the intake throttle position
sensor signal circuit. The signal voltage of intake Diagnostic Aids
throttle position sensor 1 becomes higher as the • If an intermittent condition is suspected, refer to
throttle valve opens, and the signal voltage of intake Intermittent Conditions in this section.
throttle position sensor 2 becomes higher as the
throttle valve closes. Connector End View Reference: Engine Controls
The ECM monitors whether the intake throttle position Connector End Views or ECM Connector End Views
sensor 2 signal voltage is in a normal range, and sets
this DTC when it determines that the sensor signal

Go to Diagnostic
connector.
ground.
5 5.5 volts

circuit and low reference circuit (pins 1 and 6 of
6 E137). 4.5 volts
Connect a DMM between the position sensor 2
signal circuit (pin 4 of E137) and a known good
7 ground. 4.5 volts
8 5.5 volts
1. Connect a test lamp between the position
sensor 2 signal circuit (pin 4 of E137) and a
known good ground.
• An open circuit
10 —
• High resistance

11 resistance. —

be damaged if the sensor 5 volts reference circuit is

• An open circuit
13 —
• High resistance


conditions:
• An open circuit
• High resistance

be damaged if the sensor signal circuit is shorted to
a voltage source.
15 conditions: —

throttle valve (pin 4 of E137) for a short to any
16 5 volts reference circuit. —

throttle valve (pins 1, 4 and 6 of E137).
17 —

ECM (pins 87, 89, 95 and 112 of E125).






22 —

TPS1 and TPS2 Comparison Error Condition for Setting the DTC
• When intake throttle position sensor 1 and intake
Circuit Description throttle position sensor 2 are operating normally,
The intake throttle position sensor is situated inside the and the difference between the intake throttle
throttle valve. The intake throttle position sensor has position detected by intake throttle position sensor
two systems, and they each have different 1 and the intake throttle position detected by intake
characteristics. The intake throttle position sensor throttle position sensor 2 is 10° or more for 1
outputs a voltage according to the opening angle of the second.
throttle valve, and the engine control module (ECM)
uses the signal to detect the throttle valve opening Action Taken When the DTC Sets
angle. The intake throttle position sensor has the • The ECM will not illuminate the MIL. Refer to DTC
following circuits. Type Definitions for Action Taken When the DTC
• 5 volts reference circuit Sets - Type D.
• Low reference circuit • When DTC P1515, P1516, and P1523 have not
• Intake throttle position sensor 1 signal circuit been detected, or only P1523 has been detected.
Compares the values for intake throttle position
• Intake throttle position sensor 2 signal circuit
sensor 1 and intake throttle position sensor 2, and
the smaller value is used to perform control.
sensor 1 and 2 via the 5 volts reference circuit, and
grounds the sensor to within the ECM via the low • When DTC P1515 and P1516 have been detected.
reference circuit. The intake throttle position sensor Switches each control to the power management
outputs signal voltage to the ECM via the intake throttle mode or the forced engine shutdown mode.
position sensor signal circuit. The signal voltage of
intake throttle position sensor 1 becomes higher as the Condition for Clearing the DTC
throttle valve opens, and the signal voltage of intake • Refer to DTC Type Definitions for Condition for
throttle position sensor 2 becomes higher as the Clearing the DTC - Type D.
throttle valve closes.
The ECM compares the valve opening angle calculated Diagnostic Aids
from the intake throttle position sensor 1 signals and • If an intermittent condition is suspected, refer to
the valve opening angle calculated from the intake Intermittent Conditions in this section.
throttle position sensor 2 signals, and sets a DTC if
they differ greatly. Connector End View Reference: Engine Controls

2 4. Monitor the DTC Information with a scan tool. —
Important: If DTC P1120, P1220 or P1635
also set, diagnose these DTCs first.
Go to Diagnostic
throttle valve (pin 5 of E137) for high
3 resistance. —


throttle valve (pin 4 of E137) for high
4 resistance. —

throttle valve (pins 1, 4, 5 and 6 of E137).
5 —

ECM (pins 87, 95, 104 and 112 of E125).



9 this section. —



11 —

APS1 and APS2 Comparison Error Condition for Setting the DTC
• When the APP sensor 1 and the intake throttle
Circuit Description position sensor 2 are operating normally, and the
The accelerator pedal position (APP) sensor is installed difference between the accelerator opening angle
on the accelerator pedal, and is comprised of two detected by APP sensor 1 and the accelerator
independent sensors that are physically integrated. pedal opening angle detected by APP sensor 2 is
The APP sensor is a potentiometer type sensor, and 10° or more for 1 second.
changes its output voltage according to the accelerator
pedal opening angle. The engine control module (ECM) Action Taken When the DTC Sets
detects the acceleration and deceleration requests of • The ECM illuminates MIL when the diagnostic runs
the driver based on signals from the APP sensor, and and fails. Refer to DTC Type Definitions for Action
controls fuel injection. The APP sensor has the Taken When the DTC Sets - Type A.
following circuits. • When both APP sensor 1 and 2 are normal, or
• APP sensor 1 5 volts reference circuit either APP sensor 1 or APP sensor 2 has a failure.
• APP sensor 1 low reference circuit Switches each control to the limited performance
• APP sensor 1 signal circuit mode.
• APP sensor 2 5 volts reference circuit • When both APP sensor 1 and 2 have a failure.
Performs control using the position of the
• APP sensor 2 low reference circuit
accelerator pedal as the idle position.
• APP sensor 2 signal circuit
The ECM supplies 5 volts to each APP sensor via the 5 Condition for Clearing the DTC
volts reference circuit, and grounds the sensor to within
the ECM via the low reference circuit. The APP sensor
outputs signal voltage to the ECM via each APP sensor
signal circuit. The output voltage of APP sensor 1
Diagnostic Aids
decreases the smaller the accelerator pedal opening
angle, and the output voltage of APP sensor 2 • If an intermittent condition is suspected, refer to
decreases the larger the accelerator pedal opening Intermittent Conditions in this section.
angle.
The ECM compares the accelerator pedal opening Connector End View Reference: Engine Controls
angle calculated from the APP sensor 1 signals and the Connector End Views or ECM Connector End Views
accelerator pedal opening angle calculated from the
APP sensor 2 signals, and sets a DTC if they differ
greatly.

2 4. Monitor the DTC Information with a scan tool. —
Important: If DTC P1275, P1280 or P1639
also set, diagnose these DTCs first.
Go to Diagnostic
1. Test the APP sensor 1 5 volts reference circuit
between the ECM (pin 43 of J95) and the
accelerator position (APP) sensor (pin 4 of B5)
3 for high resistance. —


1. Test the APP sensor 1 low reference circuit
between the ECM (pin 71 of J95) and the APP
sensor (pin 6 of B5) for high resistance.
4 —

1. Test the sensor 1 signal circuit between the
ECM (pin 52 of J95) and the APP sensor (pin
5 of B5) for high resistance.
5 —

6 —

7 —

1. Test the APP sensor 2 signal circuit between
the ECM (pin 53 of J95) and the APP sensor
(pin 2 of B5) for high resistance.
8 —

9 —

ECM (pins 42, 43, 52, 53, 71 and 72 of J95).

Replace the APP sensor. Refer to Accelerator
Pedal Sensor in Section 1I Engine Speed Control
11 System (4HV1-CNG). —







15 —

Accelerator Pedal Position Sensor 1 Circuit Condition for Setting the DTC
• When the APP sensor 1 signal voltage is 0.1 volts
Circuit Description or lower, or 4.848 volts or higher for 1.25
The accelerator pedal position (APP) sensor is installed consecutive seconds.
on the accelerator pedal, and is comprised of two
independent sensors that are physically integrated. Action Taken When the DTC Sets
The APP sensor is a potentiometer type sensor, and • The ECM illuminates MIL when the diagnostic runs
changes its output voltage according to the accelerator and fails. Refer to DTC Type Definitions for Action
pedal opening angle. The engine control module (ECM) Taken When the DTC Sets - Type A.
detects the acceleration and deceleration requests of • When APP sensor 2 is normal.
the driver based on signals from the APP sensor, and Performs limp home mode control.
controls fuel injection. The APP sensor has the
following circuits. • When APP sensor 2 is abnormal.
• APP sensor 1 5 volts reference circuit accelerator pedal as the idle position.
• APP sensor 1 signal circuit Condition for Clearing the DTC
• APP sensor 2 5 volts reference circuit • Refer to DTC Type Definitions for Condition for
• APP sensor 2 low reference circuit Clearing the MIL/ DTC - Type A.
Diagnostic Aids
The ECM supplies 5 volts to each APP sensor via the 5
volts reference circuit, and grounds the sensor to within • If an intermittent condition is suspected, refer to
the ECM via the low reference circuit. The APP sensor Intermittent Conditions in this section.
signal circuit. The output voltage of APP sensor 1 Connector End View Reference: Engine Controls
decreases the smaller the accelerator pedal opening Connector End Views or ECM Connector End Views
angle, and the output voltage of APP sensor 2
decreases the larger the accelerator pedal opening
angle.
The ECM monitors whether the APP sensor 1 signal
determines that the sensor signal voltage is too high or
too low.

Go to Diagnostic
2. Disconnect the accelerator position (APP)
3. Connect the DMM between the APP sensor 1
4 5 volts reference circuit (pin 4 of B5) and a 4.5 volts
known good ground.

5 5.5 volts
Connect the DMM between the sensor 1 5 volts
reference circuit and the APP sensor 1 low
6 reference circuit (pins 4 and 6 of B5). 4.5 volts
Connect the DMM between the APP sensor 1
signal circuit (pin 5 of B5) and a known good
7 ground. 4.5 volts
8 5.5 volts
1. Connect a test lamp between the APP sensor
1 signal circuit (pin 5 of B5) and a known good
ground.
sensor (pin 4 of B5) for the following
conditions:
• An open circuit
• High resistance

Important: The APP sensor may be damaged if
voltage source.
11 conditions: —


conditions:
• High resistance


(pin 5 of B5) for the following conditions:
• An open circuit
13 —
• High resistance

source.
14 (pin 5 of B5) for the following conditions: —

(pin 5 of B5) for a short to any 5 volts

APP sensor (pins 4, 5 and 6 of B5).
16 —







21 —

Accelerator Pedal Position Sensor 2 Circuit Condition for Setting the DTC
• When the APP sensor 2 signal voltage is 0.1 volts
Circuit Description or lower, or 4.848 volts or higher for 1.25
The accelerator pedal position (APP) sensor is installed consecutive seconds.
on the accelerator pedal, and is comprised of two
independent sensors that are physically integrated. Action Taken When the DTC Sets
The APP sensor is a potentiometer type sensor, and • The ECM illuminates MIL when the diagnostic runs
changes its output voltage according to the accelerator and fails. Refer to DTC Type Definitions for Action
pedal opening angle. The engine control module (ECM) Taken When the DTC Sets - Type A.
detects the acceleration and deceleration requests of • When APP sensor 1 is normal.
the driver based on signals from the APP sensor, and Performs limp home mode control.
controls fuel injection. The APP sensor has the
following circuits. • When APP sensor 1 is abnormal.
• APP sensor 1 5 volts reference circuit accelerator pedal as the idle position.
• APP sensor 1 signal circuit Condition for Clearing the DTC
• APP sensor 2 5 volts reference circuit • Refer to DTC Type Definitions for Condition for
• APP sensor 2 low reference circuit Clearing the MIL/ DTC - Type A.
Diagnostic Aids
The ECM supplies 5 volts to each APP sensor via the 5
volts reference circuit, and grounds the sensor to within • If an intermittent condition is suspected, refer to
the ECM via the low reference circuit. The APP sensor Intermittent Conditions in this section.
signal circuit. The output voltage of APP sensor 1 Connector End View Reference: Engine Controls
decreases the smaller the accelerator pedal opening Connector End Views or ECM Connector End Views
angle, and the output voltage of APP sensor 2
decreases the larger the accelerator pedal opening
angle.
The ECM monitors whether the APP sensor 2 signal
determines that the sensor signal voltage is too high or
too low.

Go to Diagnostic
3. Connect the DMM between the APP sensor 2
4 5 volts reference circuit (pin 1 of B5) and a 4.5 volts
known good ground.

5 5.5 volts
Connect the DMM between the sensor 2 5 volts
reference circuit and the APP sensor 1 low
6 reference circuit (pins 1 and 3 of B5). 4.5 volts
Connect the DMM between the APP sensor 2
signal circuit (pin 2 of B5) and a known good
7 ground. 4.5 volts
8 5.5 volts
1. Connect a test lamp between the APP sensor
2 signal circuit (pin 2 of B5) and a known good
ground.
conditions:
• An open circuit
• High resistance

voltage source.
11 conditions: —


conditions:
• High resistance


(pin 2 of B5) for the following conditions:
• An open circuit
13 —
• High resistance

source.
14 (pin 2 of B5) for the following conditions: —

(pin 2 of B5) for a short to any 5 volts

APP sensor (pins 1, 2 and 3 of B5).
16 —







21 —

Electronic Throttle Control Forced Idle Mode Condition for Setting the DTC
• When the throttle valve control mode detected the
Circuit Description forced idling mode status.
The engine control module (ECM) determines the
throttle valve opening angle according to the state of Action Taken When the DTC Sets
the engine. The ECM normally calculates the desired • The ECM illuminates MIL when the diagnostic runs
throttle valve opening angle based on the signals from and fails. Refer to DTC Type Definitions for Action
the accelerator position (APP) sensor, and the actual Taken When the DTC Sets - Type A.
valve opening angle is detected by the intake throttle • Performs control with the forced idling mode with 0
position sensor. When there is a failure in the APP % as the accelerator pedal opening angle.
sensor or intake throttle position sensor, a control mode
is selected for the throttle valve depending on the Condition for Clearing the DTC
failure condition, and the throttle valve is controlled
according to that mode. The forced idling mode is • Refer to DTC Type Definitions for Condition for
selected when the intake throttle position sensor is Clearing the MIL/ DTC - Type A.
normal but a malfunction has been detected in both
APP sensor 1 and 2. Diagnostic Aids
The ECM sets this DTC when the forced idling mode is • If an intermittent condition is suspected, refer to
selected. Intermittent Conditions in this section.


Go to Diagnostic
3 Is DTC P1275 also set? — Go to Step 4 Go to Step 5
Is DTC P1280 also set? Go to Applicable
4 —
DTC Go to Step 5

ECM (pins 42, 43, 52, 53, 71 and 72 of J95).


7 this section. —



9 —

Electronic Throttle Control Power Condition for Setting the DTC
Management Mode • When the throttle valve control mode detected the
power management mode status.
Circuit Description
the accelerator position (APP) sensor, and the actual • Performs control with the power management
valve opening angle is detected by the intake throttle mode.
position sensor. When there is a failure in the APP (Stops energizing the throttle valve (the throttle
sensor or intake throttle position sensor, a control mode valve opening angle being at the default position)
is selected for the throttle valve depending on the and controls the fuel injection cylinders, fuel
failure condition, and the throttle valve is controlled injection amount, and ignition timing based on the
according to that mode. The power management mode accelerator pedal opening angle)
is selected when one of the following conditions is
established, and the engine speed is lower than 3500 Condition for Clearing the DTC
rpm and the manifold absolute pressure is lower than
the expected manifold absolute pressure.
• Both intake throttle position sensor 1 and 2 have a
failure (DTC P1120 and P1220 detected) Diagnostic Aids
• Command - actual TPS comparison error (DTC
P1515 and P1516) detected
The ECM sets this DTC when the power management
mode is selected.

3. Start the engine and depress the accelerator
2 pedal 2 or 3 times. —
Go to Diagnostic
3 Is DTC P1120 or P1220 also set? — Go to Step 4 Go to Step 5
Is DTC P1515 or P1516 also set? Go to Applicable
4 —
DTC Go to Step 5
5 —


ECM (pins 87, 95, 104 and 112 of E125).

7 this section. —


9 —

Electronic Throttle Control Forced Engine Condition for Setting the DTC
Shutdown Mode • When the throttle valve control mode detected the
forced engine shutdown mode status.
Circuit Description
the accelerator position (APP) sensor, and the actual • Performs control with the forced engine shutdown
valve opening angle is detected by the intake throttle mode.
position sensor. When there is a failure in the APP (Stops energizing the throttle valve (the throttle
sensor or intake throttle position sensor, a control mode valve opening angle being at the default position)
is selected for the throttle valve depending on the and stops fuel injection control and ignition control)
failure condition, and the throttle is controlled according
to that mode. The forced engine shutdown mode is Condition for Clearing the DTC
selected when one of the following conditions is
established, and the engine speed is higher than 3500
rpm or the manifold absolute pressure is higher than
the expected manifold absolute pressure.
Diagnostic Aids
• Both intake throttle position sensor 1 and 2 have a
failure (DTC P1120 and P1220 detected) • If an intermittent condition is suspected, refer to
• Command - actual TPS comparison error (DTC
P1515 and P1516) detected
The ECM sets this DTC when the forced engine
shutdown mode is selected.

3. Start the engine and depress the accelerator
2 pedal 2 or 3 times. —
Go to Diagnostic
3 Is DTC P1120 or P1220 also set? — Go to Step 4 Go to Step 5
4 —
DTC Go to Step 5
5 —

ECM (pins 87, 95, 104 and 112 of E125).


7 this section. —



9 —

TPS and MAF Comparison Error • The difference between the manifold absolute
pressure calculated by the ECM (from the engine
Circuit Description rpm and intake throttle position) and the manifold
absolute pressure detected by the MAP sensor is
The engine control module (ECM) normally calculates
80 kPa or more.
the desired throttle valve opening angle based on the
position of the accelerator pedal and the engine rpm, to • The intake throttle position sensor 1 and intake
drive the intake throttle DC motor. The actual valve throttle position sensor 2 are normal.
opening angle is detected by the intake throttle position • The MAP sensor is normal.
sensor, and the ECM calculates the expected manifold • After starting the engine.
absolute pressure based on that value. It also monitors
the operation status of the valve by comparing the Action Taken When the DTC Sets
expected manifold absolute pressure with the manifold
absolute pressure detected by the manifold absolute
pressure (MAP) sensor.
The ECM sets a DTC when there is a large difference
between the calculated expected manifold absolute
pressure and the actual manifold absolute pressure.
Condition for Setting the DTC Clearing the MIL/ DTC - Type A.
Diagnostic Aids


3. Start the engine, slowly depress the
2 accelerator pedal, and then slowly return it to —
its original position.
Go to Diagnostic
3 —
DTC Go to Step 4

2. Inspect the air intake system for the following
conditions:
• Disconnection, cracks or twisting of
vacuum hose
• Improper installation of positive
crankcase ventilation (PCV) valve
• Improper installation of manifold
absolute pressure (MAP) sensor
4 —
• Improper installation of intake air
temperature (IAT) sensor
• Intake air leakage, poor connection of
intake manifold or intake duct.
• Damage of gasket
• Excessive filth of the air cleaner element

2. Observe the MAP Sensor (Manifold Absolute
Pressure) parameter and Barometric Pressure
parameter with a scan tool.
5 ± 5 kPa
Does the scan tool indicate that the difference
between the MAP Sensor (Manifold Absolute
Pressure) and Barometric Pressure is within the
Observe the MAP Sensor (Manifold Absolute
Pressure) parameter while depressing the
accelerator pedal.
6 —
Does the MAP Sensor (Manifold Absolute
Pressure) parameter change according to the
depression amount of the accelerator pedal? Go to Step 14 Go to Step 13
connector.
7 reference circuit (pin 3 of E133) and a known 4.5 volts
good ground.
Connect the DMM between the signal circuit (pin 2
8 of E133) and a known good ground. 4.5 volts
Connect the DMM between the 5 volts reference
circuit and the low reference circuit (pins 1 and 3 of
9 E133). 4.5 volts
(pin 3 of E133) for high resistance.
10 —


E133) for high resistance.
11 —

(pin 1 of E133) for high resistance.
12 —

13 —

2. Perform the Electric Control Throttle Operate
with a scan tool.
14 3. Command the throttle valve Open and Close —
while hearing the engine sound.
Does the engine sound change with each

command? Go to Step 19 Go to Step 18
1. Inspect whether the terminals (pins 1, 2 and 3
of E133) of the MAP sensor harness
connector have a defective connection.
15 —

ECM (pins 86, 94 and 111 of E125).

throttle valve (pins 1 to 6 of E137).
18 —

19 ECM (pins 87, 95, 104, 112, 114, 115, 116 and —
117 of E125).






23 —

Direction Of ECU and TPS Comparison Error • The intake throttle position sensor 1 and intake
1 throttle position sensor 2 are normal.
• DTC P1120, P1220, and P1516 are not currently
Circuit Description detected.
The engine control module (ECM) normally calculates • The throttle valve control status is other than the
the desired throttle valve opening angle based on the desired engine rpm control.
position of the accelerator pedal and the engine rpm, to
drive the intake throttle DC motor. The actual valve Action Taken When the DTC Sets
opening angle is detected by the intake throttle position • The ECM illuminates MIL when the diagnostic runs
sensor, and the ECM monitors the operation status of and fails. Refer to DTC Type Definitions for Action
the valve by comparing the desired valve opening Taken When the DTC Sets - Type A.
angle with the valve opening angle calculated from the • Switches each control to the limited performance
intake throttle position sensor signals. mode.
The ECM sets a DTC when there is a large difference
between the desired valve opening angle and the valve Condition for Clearing the DTC
opening angle calculated from the intake throttle
position sensor signals. • Refer to DTC Type Definitions for Condition for
Diagnostic Aids
continue for 3.5 seconds. • If an intermittent condition is suspected, refer to
• The difference between the desired intake throttle
position and the throttle position detected by the
intake throttle position sensor is 7° or more.

with a scan tool.
3. Command the throttle valve Open and Close
while observing the Desired Throttle Position
2 parameter and TPS Signal (Throttle Position ± 4°
Sensor) parameter.

between the TPS Signal (Throttle Position Sensor)
and Desired Throttle Position is within the specified Go to Diagnostic
Command the throttle valve Open and Close while
hearing the engine sound.
3 —

1. Observe the TPS Signal (Throttle Position
Sensor) parameters with a scan tool.
connector.
5. Observe the Throttle Position Sensor

parameters with a scan tool.
Does the Throttle Position Sensor parameters

change after disconnecting the harness connector? Go to Step 21 Go to Step 17
connector.
3. Connect a test lamp between the motor
5 control (H) circuit (pin 2 of E137) and a known —
good ground.

control (L) circuit and the motor control (H)
circuit (pins 2 and 3 of E137) of the throttle
6 valve harness connector. —
3. Turn ON the ignition, with the engine OFF, and
then turn it OFF again.
Does the test lamp blinking then go out? Go to Step 18 Go to Step 7

control (L) terminal (pin 3 of E137) and a
known good ground.
7 —

2. Disconnect the EDU harness connector.
3. Connect a test lamp between the intake
8 throttle motor (H) input circuits (pins 19 and 20 —
of E126) and a known good ground.

1. Test the intake throttle motor (H) circuit
between the ECM (pins 116 and 117 of E125)
and the EDU (pins 20 and 19 of E126) for the
• An open circuit
• High resistance


between the EDU (pin 25 of E126) and the
conditions:
• An open circuit
• High resistance

3. Connect a test lamp each to the intake throttle
motor (L) input terminal and intake throttle
motor (H) input terminal (pins 19 and 42 and
11 pins 20 and 41 of E126) of the EDU harness —
connector.

1. Test the intake throttle motor control (L) circuit
• An open circuit
• High resistance

conditions:
• An open circuit
• High resistance

3. Connect a test lamp between the motor (L)
14 input circuits (pins 41 and 42 of E126) and a —
known good ground.



1. Test the motor control (L) circuit between the
EDU (pin 24 of E126) and the throttle valve
16 —

1. Test the intake throttle position sensor signal
circuits between the ECM (pins 95 and 104 of
E125) and the throttle valve (pins 4 and 5 of
17 E137) for a short to any voltage circuit. —

throttle valve (pins 2 and 3 of E137).
18 —

EDU (pins 19, 20, 24, 25, 41 and 42 of E126).
19 —

ECM (pins 114, 115, 116 and 117 of E125).






25 —

Direction Of ECU and TPS Comparison Error - The difference between the desired intake
2 throttle position and the intake throttle position
detected by the intake throttle position sensor is
Circuit Description 4° or more.
- The intake throttle position sensor 1 and intake
The engine control module (ECM) normally calculates
throttle position sensor 2 are normal.
the desired throttle valve opening angle based on the
position of the accelerator pedal and the engine rpm, to - The throttle valve control status is other than
drive the intake throttle DC motor. The actual valve the desired engine rpm control.
opening angle is detected by the intake throttle position - The throttle valve control status is other than
sensor, and the ECM monitors the operation status of speed limiter control.
the valve by comparing the desired valve opening
angle with the valve opening angle calculated from the Action Taken When the DTC Sets
intake throttle position sensor signals. • The ECM illuminates MIL when the diagnostic runs
The ECM sets a DTC when there is a large difference and fails. Refer to DTC Type Definitions for Action
between the desired valve opening angle and the valve Taken When the DTC Sets - Type A.
opening angle calculated from the intake throttle
position sensor signals. • Switches each control to the power management
mode or the forced engine shutdown mode.
• When DTC P1120 and P1220 have not been
detected. • Refer to DTC Type Definitions for Condition for
• The throttle valve change amount is less than 0.1°
for a 20 msec interval and continues for 2 seconds Diagnostic Aids
or more.
• The following conditions are established and
continue for 1 second.

with a scan tool.
3. Command the throttle valve Open and Close
while observing the Desired Throttle Position
2 parameter and TPS Signal (Throttle Position ± 4°
Sensor) parameter.

between the TPS Signal (Throttle Position Sensor)
and Desired Throttle Position is within the specified Go to Diagnostic
Command the throttle valve Open and Close while
hearing the engine sound.
3 —

connector.
Does the TPS Signal (Throttle Position Sensor)

parameters change after disconnecting the harness
connector? Go to Step 21 Go to Step 17
connector.
5 control (H) circuit (pin 2 of E137) and a known —
good ground.
Did the test lamp illuminate? Go to Step 6 Go to Step 8

control (L) circuit and the motor control (H)
circuit (pins 2 and 3 of E137) of the throttle
6 valve harness connector. —

control (L) terminal (pin 3 of E137) and a
known good ground.
7 —

3. Connect a test lamp between the intake
8 throttle motor (H) input circuits (pins 19 and 20 —

between the engine control module (ECM)
(pins 116 and 117 of E125) and the EDU (pins
20 and 19 of E126) for the following
conditions:
• An open circuit
9 —
• High resistance


conditions:
• An open circuit
• High resistance

3. Connect a test lamp each to the intake throttle
motor (L) input terminal and intake throttle
motor (H) input terminal (pins 19 and 42 and
11 pins 20 and 41 of E126) of the EDU harness —
connector.

• An open circuit
• High resistance

conditions:
• An open circuit
• High resistance

3. Connect a test lamp between the motor (L)
14 input circuits (pins 41 and 42 of E126) and a —
known good ground.



16 —

1. Test the intake throttle position sensor signal
circuits between the ECM (pins 95 and 104 of
E125) and the throttle valve (pins 4 and 5 of
17 E137) for a short to any voltage circuit. —

18 —

EDU (pins 19, 20, 24, 25, 41 and 42 of E126).
19 —

ECM (pins 114, 115, 116 and 117 of E125).






25 —

Throttle Actuator Control Return Performance Action Taken When the DTC Sets
The engine control module (ECM) leaves the ECM Sets - Type D.
relay turned ON for several seconds after the ignition • When either DTC P1120 and P1220 together, DTC
switch has been turned OFF, and performs learning for P1515, or DTC P1516 is detected.
the throttle valve fully closed position (initial control). Switches each control to the power management
The ECM records the fully closed position based on the mode or the forced engine shutdown mode.
throttle position sensor signal voltage by fully closing • Other than the above.
the throttle valve during initial control. Normal control.
The ECM monitors whether the signal voltage of the
intake throttle position sensor is within the specified Condition for Clearing the DTC
range for both the default position and the fully closed
position, and sets a DTC when the signal voltage is • Refer to DTC Type Definitions for Condition for
outside the specified range. Clearing the DTC - Type D.
When one of the following conditions is established • If an intermittent condition is suspected, refer to
during the throttle valve initial control. Intermittent Conditions in this section.
• When the valve is in the default position. Connector End View Reference: Engine Controls
The intake throttle position sensor signal voltage is Connector End Views or ECM Connector End Views
0.909 volts or lower, or 1.301 volts or higher.
• When the valve is fully closed.
The intake throttle position sensor signal voltage is
0.303 volts or lower, or 0.695 volts or higher.

Go to Applicable
Is DTC P1120, P1220, P1515 or P1516 also set? DTC Go to Step 3
connector.
3 control (L) circuit and the motor control (H) —
circuit (pins 2 and 3 of E137).


3. Connect a test lamp across each throttle
motor (L) input circuit and throttle motor (H)
4 input circuit (pins 41 and 20 and pins 42 and —
19 of E126).

1. Test the throttle motor control (L) circuit
and the EDU (pins 41 and 42 of E126) for a
5 short to ground. —

(pin 3 of E137) for a short to ground.
6 —

1. Test the intake throttle position sensor low
reference circuit between the ECM (pin 87 of
E125) and the throttle valve (pin 6 of E137) for
7 a short to ground. —

EDU (pins 19, 20, 24, 25, 41 and 42 of E126).
8 —

9 —

ECM (pins 114, 115, 116 and 117 of E125).

with a scan tool.
2. Command the throttle valve Open while
observing the Throttle TPS Signal (Throttle
11 Position Sensor) parameter until the throttle —
position reads 84° (fully open).
Does the TPS Signal (Throttle Position Sensor) Go to Diagnostic

parameter change with command? Aids Go to Step 12





16 —

5V Reference #1 Circuit Action Taken When the DTC Sets
The engine control module (ECM) supplies 5 volts to Sets - Type D.
intake throttle position sensor 1 and 2 via the 5 volts
reference #1 circuit. Condition for Clearing the DTC
The ECM monitors whether the 5 volts reference #1 is • Refer to DTC Type Definitions for Condition for
outside the normal range, and sets a DTC when the Clearing the DTC - Type D.
Diagnostic Aids
• When the intake throttle position sensor power Intermittent Conditions in this section.
supply voltage is 3.011 volts or lower, or 7.038
volts or higher for 3 consecutive seconds. Connector End View Reference: Engine Controls

Go to Diagnostic
connector.
3. Connect a DMM between the intake throttle
3 position sensor 5 volts reference circuit (pin 1 4.5 volts
4 5.5 volts
1. Test the intake throttle position sensor 5 volts
E125) and the throttle valve (pin 1 of E137) for
5 a short to ground. —

1. Test the intake throttle position sensor 5 volts
E125 connector) and the throttle valve (pin 1
of E137) for the following conditions:



8 this section. —



10 —

5V Reference #2 Circuit Action Taken When the DTC Sets
The engine control module (ECM) supplies 5 volts to Sets - Type D.
accelerator pedal position (APP) sensor 1 and 2 via the
5 volts reference #2 circuit. The 5 volts reference Condition for Clearing the DTC
circuits are independent for each sensor outside of the • Refer to DTC Type Definitions for Condition for
ECM, but inside the ECM they are put together. Clearing the DTC - Type D.
The ECM monitors whether the 5 volts reference #2 is
outside the normal range, and sets a DTC when the Diagnostic Aids
• When the APP sensor power supply voltage is Connector End View Reference: Engine Controls
3.011 volts or lower, or 7.038 volts or higher for 3 Connector End Views or ECM Connector End Views
consecutive seconds.

Go to Diagnostic
3. Connect a DMM between the APP sensor 1 5
3 volts reference circuit (pin 4 of B5) of the APP 4.5 volts
4 5.5 volts
Connect a DMM between the APP sensor 2 5 volts
reference circuit (pin 1 of B5) and a known good
5 ground. 4.5 volts
6 5.5 volts
sensor (pin 4 of B5) for a short to ground.
7 —


conditions:

9 conditions: —

sensor (pin 1 of B5).
10 —





14 —

PTO Accelerator Sensor Error Condition for Setting the DTC
• When the PTO throttle sensor signal voltage is
Circuit Description 4.829 volts or higher for 3 consecutive seconds.
The PTO throttle sensor is a potentiometer type sensor,
and changes its output voltage according to the PTO Action Taken When the DTC Sets
throttle opening angle. The engine control module • The ECM will not illuminate the MIL. Refer to DTC
(ECM) detects the PTO throttle opening angle based Type Definitions for Action Taken When the DTC
on signals from the PTO throttle sensor, and controls Sets - Type D.
the throttle valve. The PTO throttle sensor has the • Performs control with 0° as the PTO throttle
following circuits. opening angle.
• 5 volts reference circuit • Stops the PTO control of the throttle valve.
• Low reference circuit
• PTO throttle sensor signal circuit Condition for Clearing the DTC
The ECM supplies 5 volts to the PTO throttle sensor via • Refer to DTC Type Definitions for Condition for
the 5 volts reference circuit, and grounds the sensor to Clearing the DTC - Type D.
within the ECM via the low reference circuit. The PTO
throttle sensor also outputs signal voltage to the ECM Diagnostic Aids
via the PTO throttle sensor signal circuit. The larger the
accelerator pedal opening angle, the higher the output • If an intermittent condition is suspected, refer to
voltage of the PTO throttle sensor becomes. Intermittent Conditions in this section.
The ECM monitors whether the PTO throttle sensor
signal voltage is in a normal range, and sets this DTC Connector End View Reference: Engine Controls
when it determines that the sensor signal voltage is too Connector End Views or ECM Connector End Views
high.

Go to Diagnostic
2. Disconnect the PTO throttle sensor harness
connector.
ground.
Connect the DMM between the signal circuit (pin 2
4 of J99) and a known good ground. 5.5 volts
5 4.5 volts

7 the low reference circuit (pins 1and 2 of J99). 4.5 volts
Important: The PTO throttle sensor may be
ECM (pin 62 of J95) and the PTO throttle
sensor (pin 3 of J99) for the following
8 conditions: —

Important: The PTO throttle sensor may be
voltage source.
54 of J95) and the PTO throttle sensor (pin 2
9 of J99) for the following conditions: —

of J99) for the following conditions:
• An open circuit
10 —
• High resistance

of J99) for any 5 volts reference circuit.
11 —

ECM (pin 73 of J95) and the PTO throttle
sensor (pin 1 of J99) for the following
conditions:
• High resistance


PTO throttle sensor (pins 1, 2 and 3 of J99).
13 —


Replace the PTO throttle sensor.
15 —


18 —

Check Engine Warning Light Illumination Circuit System Check
Circuit Description Diagnostic Aids
The check engine warning light has to stay illuminated • If an intermittent condition is suspected, refer to
while the ignition switch is ON, and while the engine is Intermittent Conditions in this section.
stopped. The ignition switch power supply voltage is
applied to the instrument panel (IP) cluster through the
meter fuse. The engine control module (ECM) turns the
check engine warning light "ON" by grounding the
check engine warning light driver circuit.
Circuit/ System Testing Check Engine Warning Light Illumination Circuit System Check

2 3. Perform the Warning Lamp with a scan tool. —
4. Command the check engine warning light ON.
Go to Diagnostic
Does the check engine warning light illuminate? Aids Go to Step 3
3 2. Inspect the Meter (10A) fuse (F21). —
Is the Meter (10A) fuse open? Go to Step 10 Go to Step 4
2. Remove the Meter (10A) fuse (F21).
4. Connect the DMM between the check engine
4 0.5 volts
warning light control terminal (pin 19 of J95)
and a known good ground.
Is the DMM voltage less than the specified value? Go to Step 5 Go to Step 11
2. Install the Meter (10A) fuse (F21).
5 the check engine warning light control circuit —
Does the check engine warning light illuminate? Go to Step 9 Go to Step 6

1. Set the parking brake.
2. Observe the parking brake indicator light in
6 the IP cluster. —
Did the parking brake indicator light illuminate? Go to Step 7 Go to Step 12

2. Disconnect the instrument panel (IP) cluster
harness connector.
3. Test the check engine warning light control
7 circuit between the ECM (pin 19 of J95) and —
the IP cluster (pin 31 of B105) for an open
circuit or high resistance.


IP cluster (pin 31 of B105).
8 —

9 —

Replace the Meter (10A) fuse (F21). If the Meter
(10A) fuse continues to open, repair the short to
ground on one of the circuits that is fed by the
10 Meter (10A) fuse or replace the shorted attached —
component.

Repair the short to any voltage circuit between the
ECM (pin 19 of J95) and the IP cluster (pin 31 of
11 B105). —

Repair the open circuit between the Meter (10A)
12 fuse (F21) and the IP cluster (pin 2 of B105). —
Replace the IP cluster. Refer to Instrument Panel
(IP) Cluster in Section 9E Instrumentation/ Driver
13 Info. —


15 3. Perform the Warning Lamp with a scan tool. —
4. Command the check engine warning light ON.
Does the check engine warning light illuminate? System OK Go to Step 3


Check Engine Warning Light Blinking Circuit System Check
The check engine warning light has to stay illuminated • If an intermittent condition is suspected, refer to
while the ignition switch is ON, and while the engine is Intermittent Conditions in this section.
stopped. The check engine warning light also blinks
when pins 2 and 5 of the PI monitor connector are
short-circuited, and then the diagnostic switch function
is turned ON.
If the check engine warning light does not blink (stays
illuminated) when the diagnostic switch function is
turned "ON", there may be a GND short in the check
engine warning light driver circuit.
Circuit/ System Testing Check Engine Warning Light Blinking Circuit System Check

3. Perform the Warning Lamp with a scan tool.
2 —
4. Command the check engine warning light
OFF.
Does the check engine warning light turn off? Go to Step 5 Go to Step 3
Does the check engine warning light illuminate? Go to Step 4 Go to Step 10

2. Disconnect the IP cluster harness connector.
3. Test the check engine warning light control
circuit between the ECM (pin 19 of J95) and
4 the IP cluster (pin 31 of B105) for a short to —
ground or short to the low reference.

connections at the PI monitor connector (pins
2 and 5 of B283).
5 —

1. Test the diagnostic request switch circuit
between the ECM (pin 30 of J95) and the PI
monitor connector (pin 2 of B283) for an open.
6 —

1. Test the ground circuit between the PI monitor
connector (pin 5 of B283) and the chassis
ground terminals (B51 and B60 [Except
7 Australia], B52 and B53 [for Australia]). —


8 —

Replace the IP cluster. Refer to Instrument Panel
(IP) Cluster in Section 9E Instrumentation/ Driver
9 Info. —


1. Connect all the harnesses.
3. Perform the Warning Lamp with a scan tool.
11 4. Command the check engine warning light ON —
and OFF.
Does the check engine warning light illuminate with

each command? System OK Go to Step 3

Starting System Check
The engine control module (ECM) starts the ignition It is necessary to fully open the valve of the CNG
system based on signals from the crankshaft position container (CNG cylinder) when starting a CNG engine.
(CKP) sensor. When starting the vehicle, the engine will If the valve is not open, the engine will not start
not start if there are no signals from the CKP sensor. because fuel is not supplied.
The engine will also not start if power is not supplied to Explain to the customer that they must confirm that the
the 12 volts power supply circuit, because power valve is open before driving the vehicle.
cannot be supplied to the ignition coil circuit.
Test description
The following number refers to the step number on the
diagnostic chart.
4. Indicates whether fuel is being supplied to inside the
cylinder.
Circuit/ System Testing Starting System Check

Is DTC related to the crankshaft position (CKP)

2 sensor, camshaft position (CMP) sensor, gas —
injector, ignition coil, ignition system power supply, Go to Applicable
or throttle valve set? DTC Go to Step 3
1. Confirm that the amount of fuel is sufficient,
and fill it up if it is not.
2. Confirm that the valve of the CNG container
3 (CNG cylinder) is fully open, and open it if it is —
not.
3. Crank the engine.
Go to Diagnostic
Does the engine start? Aids Go to Step 4
Check whether fuel is reaching the engine.
1. Remove the spark plug of the 1st cylinder.
3. Check whether gas can be smelled near the
4 —
engine head.
4. Perform the same smell check for the other
cylinders.
Go to Fuel System
Did you smell gas? Go to Step 5 Check
Confirm that a good spark is jumping from the
spark plugs of each cylinder.
5 Refer to Ignition Coil and Spark Plug in Section 1E —
Engine Electrical (4HV1-CNG).
Go to Ignition
Did you find any problem? System Check Go to Step 6
1. Inspect the CKP sensor for improper
installation.


1. Inspect the following engine mechanics items.
Refer to 4HV1-CNG Engine in Section 1B
Engine Mechanical (4HV1-CNG).
• Compression pressure
• Valve timing
7 • Starter —
• Battery
• Excess foreign material on oil filter

8 this section. —

Crank the engine.
9 —
Does the engine start? System OK Go to Step 3

Fuel System Check
The fuel system is comprised of the pressure regulator, • If an intermittent condition is suspected, refer to
gas injector, automatic valves, and flexible fuel line and Intermittent Conditions in this section.
rigid fuel line, etc. The engine control module (ECM)
controls the gas injector and the automatic valves. The
automatic valves are situated near the pressure
regulator and the CNG container (CNG cylinder), and
are operated by the ECM via the gas valve relay and
gas cut valve relay. The power supply for the automatic
valves is applied via the ignition relay. In an emergency,
it is possible to force-open the automatic valves by
connecting the terminal of the PI monitor connector.
Circuit/ System Testing Fuel System Check Except Australia

1. Inspect the flexible fuel line and rigid fuel line
for defective connections, cracks or damage.
for fuel leakage.
1 —
Engine Mechanical (4HV1-CNG) and Fuel
System in Section 1D Engine Fuel (4HV1-
CNG).

2. Disconnect the gas injector harness
connectors of all cylinders.
2 1 - 2 ohms
3. Measure the resistance across each gas
injector.

1. Remove the gas injector.
2. Inspect the gas filter fitting or injection hole are
3 of the gas injector for clogged. —
Did you find any problem? Go to Step 22 Go to Step 4

2. Check whether the automatic valves are
4 operating (open). —
Does all the automatic valves operate (open)? Go to Step 23 Go to Step 5

Did none of the automatic valves operate (open) in
5 —
step 4? Go to Step 6 Go to Step 15
Forcibly open the automatic valves.
2. Connect a jumper wire between the terminals
(pins 8 and 7 of B283) of the PI monitor
6 connector. —
connector for 5 seconds, and remove the wire.
Did all the automatic valves operate? Go to Step 17 Go to Step 7


7 2. Inspect the Gas Valve (15A) fuse (F32). —
Is the fuse open? Go to Step 21 Go to Step 8
1. Test the following force valve open circuits for
an open or high resistance.
• Between the Gas Valve (15A) fuse (F32)
and the PI monitor connector (pin 7 of
B283)
• Between the PI monitor connector (pin 6
8 of B283) and the automatic valves (pin 2 —
of J92, J94 and J199)
of B283) and the gas valve relay (pin 4 of
X30)

2. Remove the automatic valve (before
regulator) harness connector.
3. Connect a test lamp between the automatic
valve (before regulator) (pin 2 of J199) and a
known good ground.
9 —
5. Perform the F/C (Fuel Cut) Solenoid with a
scan tool.
6. Command the automatic valve ON.

2. Replace the gas cut valve relay with a known
good relay.
known good ground.
10 —
scan tool.

1. Repair the open circuit or high resistance on
the following circuits.
and the gas cut valve relay (pin 2 of X28)
11 • Between the gas cut valve relay (pin 1 of —
X28) and the automatic valves (pin 2 of
J92, J94 and J199)


known good ground.
12 3. Perform the F/C 2 (Fuel Cut 2) Solenoid with a —
scan tool.

2. Replace the gas valve relay with a known
good relay.
known good ground.
13 —
5. Perform the F/C 2 (Fuel Cut 2) Solenoid with a
scan tool.

and the gas valve relay (pin 2 of X30)
14 • Between the gas valve relay (pin 1 of —
J92 and J94 and pin 3 of J199)

1. Test the valve control circuits between the gas
cut valve relay (pin 1 of X28) and the
automatic valves (pin 2 of J92, J94 and J199)
for an open or high resistance.
15 valve relay (pin 1 of X30) and the automatic —
valves (pin 2 of J92 and J94 and pin 3 of
J199) for an open or high resistance.

1. Test the ground circuit between the automatic
valves (pin 1 of J92, J94 and J199) and the
chassis ground terminal (J9) for an open or
16 high resistance. —

Notice: Disconnect the jumper wire.
1. Test the relay coil of the gas valve relay and
17 the gas cut valve relay for an open. —
2. Replace the relay as necessary.


1. Test the following circuit for an open or high
resistance.
• Between the ECM (pin 14 of J95) and the
gas cut valve relay (pin 3 of X28)
• Between the converter relay (pin 4 of
18 B285) and the gas cut valve relay (pin 5 —
of X28)
• Between the converter relay (pin 4 of
B285) and the gas valve relay (pin 5 of
X30)

automatic valves (pins 1, 2 and 3 of J92, J94
19 and J199). —
2. If a defect is detected, repair as necessary.
Did you find the defect and complete repairs? Go to Step 28 Go to Step 26
3. Inspect whether the terminals (pins 14 and 15
20 of J95) of the ECM harness connector have a —
defective connection.

Replace the Gas Valve (15A) fuse (F32). If the Gas
Valve (15A) fuse continues to open, repair the short
to ground on one of the circuits that is fed by the
21 Gas Valve (15A) fuse or replace the shorted —
attached component.

injector is replaced.
22 Replace the appropriate gas injector that was —
problem found at Step 3. Refer to Gas Injector in
Section 1D Engine Fuel (4HV1-CNG).

Replace the pressure regulator. Refer to Pressure
23 Regulator in Section 1D Engine Fuel (4HV1-CNG). —
Replace the gas cut valve relay.
24 —
Replace the gas valve relay.
25 —

Replace the appropriate automatic valve that did
not operate at Step 4 and Step 6. Refer to
26 Automatic Valve (before Regulator) in Section 1D —
Engine Fuel (4HV1-CNG).


1. Install all previously removed parts and
Reconnect all previously disconnected
2. Remove the spark plug of the cylinder #1.
engine head.
cylinders.
Did you smell gas? System OK Go to Step 1
Circuit/ System Testing Fuel System Check for Australia

for defective connections, cracks or damage.
for fuel leakage.
1 —
Engine Mechanical (4HV1-CNG) and Fuel
System in Section 1D Engine Fuel (4HV1-
CNG).

2. Disconnect the gas injector harness
connectors of all cylinders.
2 1 - 2 ohms
3. Measure the resistance across each gas
injector.

1. Remove the gas injector.
2. Inspect the gas filter fitting or injection hole are
3 of the gas injector for clogged. —

2. Check whether the automatic valves are
4 operating (open). —
Does all the automatic valves operate (open)? Go to Step 23 Go to Step 5

Did none of the automatic valves operate (open) in
5 —
step 4? Go to Step 6 Go to Step 15

Forcibly open the automatic valves.
6 connector. —
connector for 5 seconds, and remove the wire.
Did all the automatic valves operate? Go to Step 17 Go to Step 7

7 2. Inspect the Gas Valve (15A) fuse (F32). —
Is the fuse open? Go to Step 21 Go to Step 8
1. Test the following force valve open circuits for
an open or high resistance.
and the PI monitor connector (pin 7 of
B283)
8 of B283) and the automatic valves (pin 2 —
of J92, J94 and J199)
of B283) and the gas valve relay (pin 4 of
X30)

2. Remove the automatic valve (before
regulator) harness connector.
known good ground.
9 —
scan tool.

2. Replace the gas cut valve relay with a known
good relay.
known good ground.
10 —
scan tool.


11 • Between the gas cut valve relay (pin 1 of —
J92, J94 and J199)

known good ground.
12 3. Perform the F/C 2 (Fuel Cut 2) Solenoid with a —
scan tool.

2. Replace the gas valve relay with a known
good relay.
known good ground.
13 —
5. Perform the F/C 2 (Fuel Cut 2) Solenoid with a
scan tool.

14 • Between the gas valve relay (pin 1 of —
J92 and J94 and pin 3 of J199)

cut valve relay (pin 1 of X28) and the
automatic valves (pin 2 of J92, J94 and J199)
for an open or high resistance.
15 valve relay (pin 1 of X30) and the automatic —
valves (pin 2 of J92 and J94 and pin 3 of
J199) for an open or high resistance.

1. Test the ground circuit between the automatic
valves (pin 1 of J92, J94 and J199) and the
chassis ground terminal (J9) for an open or
16 high resistance. —


Notice: Disconnect the jumper wire.
1. Test the relay coil of the gas valve relay and
17 the gas cut valve relay for an open. —
2. Replace the relay as necessary.

1. Test the following circuit for an open or high
resistance.
18 • Between the ignition relay (pin 3 of B285) —
• Between the ignition relay (pin 3 of B285)

automatic valves (pins 1, 2 and 3 of J92, J94
19 and J199). —
2. If a defect is detected, repair as necessary.
Did you find the defect and complete repairs? Go to Step 28 Go to Step 26
3. Inspect whether the terminals (pins 14 and 15
20 of J95) of the ECM harness connector have a —
defective connection.

Replace the Gas Valve (15A) fuse (F32). If the Gas
Valve (15A) fuse continues to open, repair the short
to ground on one of the circuits that is fed by the
21 Gas Valve (15A) fuse or replace the shorted —
attached component.

injector is replaced.
22 Replace the appropriate gas injector that was —
problem found at Step 3. Refer to Gas Injector in
Section 1D Engine Fuel (4HV1-CNG).

Replace the pressure regulator. Refer to Pressure
23 Regulator in Section 1D Engine Fuel (4HV1-CNG). —
Replace the gas cut valve relay.
24 —
Replace the gas valve relay.
25 —

Replace the appropriate automatic valve that did
not operate at Step 4 and Step 6. Refer to
26 Automatic Valve (before Regulator) in Section 1D —
Engine Fuel (4HV1-CNG).


1. Install all previously removed parts and
Reconnect all previously disconnected
2. Remove the spark plug of the cylinder #1.
engine head.
cylinders.
Did you smell gas? System OK Go to Step 1


Ignition System Check
The ignition system is comprised of the ignition coil and This inspection is important, because the spark plug
spark plug, etc. The ignition coil is a device for emitting affects the overall performance of the engine. When the
a high-voltage current required to ignite the spark plug, spark plug is significantly dirty, the cause of the filth
and has a built-in power transistor. The power must be determined. Possible cause:
transistor receives an ignition signal from the engine • Ignition timing too slow or too fast.
control module (ECM), and disconnects the primary
• Oil in the combustion chamber.
current of the ignition coil. The ignition coil includes a
primary coil and secondary coil. A 12 volts power • Spark plug gap not correct.
voltage is supplied to the primary coil via a DC-DC Etc. Determine the cause, and perform an inspection/
converter, and when the power transistor is turned ON, repair.
a GND circuit is established, and the primary current
flows. The ECM turns the power transistor ON
according to the ignition timing, and immediately turns
it OFF to cause the primary coil to emit self-induced
voltage, and this mutual induction effect causes a high
voltage current to flow in the secondary coil.
Circuit/ System Testing Ignition System Check

harness connector.
3. Remove the ignition coil, and connect the
harness connector.
4. Install the spark plug tester 5-8840-0383-0 to
the ignition coil, and connect the clip of the
1 spark plug tester to a known good ground. 30 kilovolts
5. Check the voltage value with the spark plug
tester while cranking the engine.
6. Perform the above voltage measurement
procedure for the other 3 cylinders.
Is the voltage more than the specified value for all

cylinders? Go to Step 7 Go to Step 2
2. Remove the ignition coil harness connector
that problem found at Step 1.
2 3. Connect a test lamp between the ignition coil —
(pin 3) and a known good ground.
Does the test lamp blink? Go to Step 6 Go to Step 3

ECM and the ignition coil that problem found
at Step 1 for the following conditions:
• An open circuit
• High resistance
3 —
• Short circuit with voltage circuit


1. Test the ground circuit between the ignition
coil (pin 2) and the chassis ground terminal
(E123).
4 2. If an abnormality is detected, repair or replace —
as necessary.

ECM (pins 6, 7, 8 and 9 of J95).

Replace the ignition coil. Refer to Ignition Coil &
Spark Plug in Section 1E Engine Electrical (4HV1-
6 CNG). —

Replace the spark plug. Refer to Ignition Coil &
Spark Plug in Section 1E Engine Electrical (4HV1-
7 CNG). —

8 this section. —

Confirm that a good spark is jumping from the
spark plugs of each cylinder.
9 Refer to Ignition Coil and Spark Plug in Section 1E —
Engine Electrical (4HV1-CNG).
Is a good spark jumping? System OK Go to Step 1


Exhaust System Check
Regarding the exhaust system Exhaust brake operation conditions
The exhaust system is comprised of the exhaust pipe, The solenoid valve is turned ON by the engine control
tail pipe, exhaust brake valve, and vacuum hose, etc. module (ECM) when all of the following conditions are
The exhaust brake valve is opened/closed by turning established.
ON/ OFF the supply of vacuum via a solenoid valve. • When exhaust brake is switched ON.
The exhaust brake valve is normally open, and is
• When the accelerator pedal is in the idle position.
closed using vacuum when a signal from the engine
control module (ECM) is inputted to the solenoid valve, • When there is no abnormality detected in the
turning the solenoid valve ON. When the exhaust brake accelerator pedal position (APP) sensor and
operating conditions are established, the ECM turns exhaust brake solenoid valve, etc.
the exhaust brake solenoid valve ON. • When the clutch pedal is not applied.
• When the vehicle is in gear.
• When cutting fuel for deceleration.
Circuit/ System Testing Exhaust System Check

Inspect the exhaust pipe and tail pipe for
1 collapsing, damage, and exhaust leakage. —
Repair or replace the exhaust pipe or tail pipe.
Refer to Exhaust Pipe in Section 1G Engine
2 Exhaust (4HV1-CNG). —

Inspect the vacuum hose for collapsing, damage or
3 air leakage. —
Repair or replace the vacuum hose. Refer to
4 Vacuum Brake Booster in Section 4B Brake. —
2. Start the engine and perform a test drive to
operate the exhaust brake.
5 —
information with scan tool.
Is DTC P0475 set? Go to DTC P0475 Go to Step 6

tool.
6 3. Command the solenoid ON. —
Could you confirm the sound of the valve hitting the

stopper? System OK Go to Step 7
1. Remove the exhaust brake valve.
2. Install the pressure gauge to the power
chamber.
3. Apply vacuum pressure in the power chamber 53.3 - 93.3 kPa
7 using a vacuum pump until the vacuum (400 -
pressure rise specified value. 700 mmHg)
4. Confirm the movement of the exhaust brake
valve.
Did the exhaust brake valve move smoothly? Go to Step 8 Go to Step 10


1. Apply vacuum pressure in the power chamber
using a vacuum pump until the vacuum
pressure rise specified value.
2. Measure the gap between the valve and body
of the exhaust brake valve. Refer to Exhaust 86.7 - 93.3 kPa
8 Brake in Section 1G Engine Exhaust (4HV1- (650 -
CNG). 700 mmHg)
3. Adjust the gap if the measured value is
outside the specified value.
Did you complete the adjustment? Go to Step 9 —

Inspect the operation of the exhaust brake.
9 tool. —
Could you confirm the sound of the valve hitting the

stopper? Go to Step 12 Go to Step 11
Replace the exhaust brake valve. Refer to Exhaust
10 Brake in Section 1G Engine Exhaust (4HV1-CNG). —
11 (4HV1-CNG). —

Perform a test drive, and check the operation
12 condition of the exhaust brake. —
Did the exhaust brake operate normally? System OK —
Symptoms - Engine Controls

Diagnosis By Symptom Repair or replace the connector terminals of the circuit
with the problem, and make the connection status
Important preliminary inspections before starting
appropriate. Remove the terminals from the connector
Before using the list of symptoms, perform the body and inspect whether the wires of the terminals
Diagnostic System Check - Engine Controls to check have a poor connection.
all of the following. Connect a DMM to the circuit that is suspected of
• The check engine warning light is operating causing the problem, and conduct a road test for the
normally. vehicle. If an abnormal value is displayed when the
• The scan tool data is within the normal range of failure occurs, it can be determined that the circuit that
operation values. Refer to Scan Tool Data List in was being monitored is actually causing the problem.
this section. The scan tool is useful in detecting intermittent states.
The scan tool consists of the following convenient
• Confirm the customer's complaint, and locate the
functions.
appropriate symptom in the table of contents.
Inspect the items presented for this symptom. • The snapshot function records the parameters of
the engine when a failure occurs. It is possible to
Visual inspection and actual inspection review the recorded information and comprehend
the particular operation condition that resulted in
Careful visual inspection and actual inspection are the failure.
required for several symptom procedures. This
procedure is extremely important. By performing visual • By using the plot function of the scan tool, it is
and actual inspections, it is possible to save valuable possible to graph the selected data parameters.
time by fixing problems without performing further This enables for the recorded information to be
inspections. Check the following items. reviewed and for the location of the intermittence
to be confirmed. For details, refer to the user's
• The GND of the ECM is clean, and is fixed manual for the scan tool.
securely in the correct position.
• There is no partitioning or twisting of the vacuum Important: Check for improper installation of optional
hose. It is also appropriately connected. Perform a accessories such as a light or mobile phone if an
thorough inspection to make sure that there are no intermittent fault exists from the beginning and
leaks or clogging. continues to exist.
• The intake air duct is not crushed or damaged. Under the following conditions, DTCs are not recorded,
• The exhaust pipe is not crushed or damaged. and the MIL may illuminate intermittently.
• The wiring and terminals for engine harnesses are • When the GND of the ECM is loose or dirty
appropriately connected, and they are not pinched • When there is an intermittent short circuit to the
or disconnected. GND circuit in the MIL
• When there is an interference in the electric
Intermittent system due to a failure in a relay, a driven solenoid
Important: If an intermittent state exists, inspect in the ECM or a switch. There may be cases where
whether any accessories are improperly installed. the voltage increases sharply due to electric
Inspect whether there are accessories, lights and components. Normally, a problem occurs when a
mobile phones that were additionally installed. Confirm component that is malfunctioning is in operation.
that devices that were additionally installed are not • When the diode has an open circuit
connected to serial data circuits such as of controller
area networks (CAN). Important: In the following list of symptoms, causes for
each symptom are organized. There is no significance
Important: Depending on the problem, the MIL may to the order of this procedure. If the scan tool values do
illuminate and the DTC may be recorded. Intermittent not indicate an abnormality, the next procedure to
faults are often caused by electrical defective perform is for what can be most easily inspected or
connections and defective wiring. Perform a careful what is most likely to be the cause. Refer to Engine
visual inspection, or perform an actual inspection as to Control Module (ECM) in Section 9D Wiring Diagram
whether the following conditions exist for the connector (CNG) to determine the use of a vehicle unique system
that is suspected to be causing the problem. or component.
• Incomplete connection between connectors Use the following diagnosis procedure when
diagnosing symptoms that were claimed.
• Improper seating of terminals
• Intermittent Conditions
• Damage or deformation of terminals
• Abnormal Combustion Noise
• Poor Fuel Economy

• Hard Start
• Rough, Unstable, or Incorrect Idle and Stalling
• High Idle Speed
• Pulsing in Engine Speed
• Surges
• Lack of Power, Sluggishness or Sponginess
• Abnormal Sound/ Abnormal Smell

Intermittent Conditions
Inspection Procedure
Definition:
A problem is not currently occurring, but a past DTC exists. Alternatively, there is a complaint from the customer
not related to the DTC, and that symptom cannot be reproduced.
Preliminary inspection • Before starting the inspection, refer to Important Preliminary
Inspections Before Starting and Visual Inspection and Actual
Inspection.
Harness/connector Intermittent open circuits or short circuits are often caused by the harness/
connector moving due to vibrations, engine torque, and bumps in the
road. Perform the applicable procedure in the following list to test whether
conditions such as those mentioned above exist.
• Move related connectors and wiring while checking the applicable
scan tool data.
• Execute an ON or OFF command to the component using the scan
tool, and move the related connectors and wiring. Check the operation
of the component.
• With the engine operating, move the related connectors and wiring
while checking the operation of the engine.
If harness or connector movement affects the data displayed, component/
system operation, or engine operation, inspect the harness/connector and
repair it as necessary.
Electrical connection of wiring Intermittent faults are often caused by improper terminal connections and
wiring. Perform the following inspections.
• Defective connections between connectors or improper seating to the
connector body of terminals.
• Deformation or damage to terminals. Test the terminals for improper
installation.
• Defective connections between terminals (including pressure bonding
terminals with insulation) and wires. This requires disconnecting of the
terminal from the connector body.
• Corrosion/infiltration of water. Moisture will enter the wiring if the
insulation area is damaged or has holes in it. The conductor inside the
insulation area will corrode, which usually cannot be confirmed
visually. Search for expansion or hardening of wires in circuits that you
suspect.
• Damaged wiring inside the insulation area.
• Wires being pinched, disconnected, or rubbing against other wires.
• Check that the wiring does not come in contact with hot exhaust
system parts.
Power supply and GND of the control Various symptoms can occur due to defective connections with the power
module, and power supply and GND supply or GND.
of the components • Test all control module power supply circuits. In many vehicles, there
are multiple circuits that supply power to the control module. Other
components in the system have separate power supply circuits that
may also need to be tested. Inspect the connections and fuses of the
module/component connectors, as well as intermediate connections
between the power source and the module/components. A test lamp or
a DMM may indicate that voltage is present, but neither tests the ability
of the circuit to carry sufficient current. Check whether the circuit is
carrying the current necessary to operate the component.
• Test all control module GND circuits and system GND circuits. Some
control modules have multiple GND circuits. Other components in the
system have separate GND circuits that may also need to be tested.
Inspect whether the GND is clean, and is properly connected to the
ground connections. Inspect the connections of the components and
the connections of the splice pack (if it is installed). Check whether the
circuit is carrying the current necessary to operate the component.
Temperature sensitivity • Intermittent conditions may occur when the components/connections
reach their operating temperature. Those problems may occur only
when the components/connections are cold, or only when they are hot.
• Failure records or snapshot data can be helpful for this type of
intermittent conditions, where possible.
• If an intermittent fault is related to heat, review the data relating to the
following items.
- High outside air temperature
- Heat emitted under the cab/by the engine
- Heat emitted from the circuits due to defective connections or high
loads
- Load conditions higher than normal, such as when towing
• If an intermittent fault is related to low temperatures, review the data
relating to the following items.
- Low outside air temperature. In extremely low temperatures, ice
may form in a connection or component. Test whether there has
been water infiltration.
- This condition only occurs for a cold start.
- It does not occur after the vehicle has been warmed up.
• Determine if the problem follows a pattern that is temperature related,
using information from the customer.
Electromagnetic interference (EMI) Certain electrical parts/circuits may respond sensitively to the electrical
and electrical noise noise from the EMI, etc. Inspect for the following conditions:
• A harness being too close to high voltage/high current devices such as
the injection part, motor, or generator, due to incorrect wiring. These
components may induce electrical noise on a circuit that could interfere
with normal circuit operation.
• When there is an interference in the electric system due to a failure in
a relay, a driven solenoid in the ECM or a switch. There may be cases
where the voltage increases sharply due to this condition. Normally, a
problem occurs when a component that is malfunctioning is in
operation.
• Improper installation of non-genuine or aftermarket add-on
accessories such as lights, 2-way radios, amplifiers, electric motors,
remote starters, alarm systems, mobile phones, etc. These
accessories may possibly lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test the diode for an open circuit. Certain relays include clamping
diodes.
• Inspect the rectifier bridge of the generator for problems that may
cause AC noise in the electrical system.
Reproducing malfunction conditions • When none of the tests are successful, try reproducing or recording
the failure symptoms.
• An alternative method is to drive the vehicle with the DMM connected
to the circuit you suspect. If an abnormal value is displayed on the
DMM when the problem occurs, this can be helpful in identifying the
defective area.
Scan tool snapshot By connecting the scan tool, you can take a snapshot of the parameters
that can be used via serial data. The snapshot function records the actual
data for a certain period. The recorded data can be played back and
analyzed. The scan tool can also display a single or multiple parameters
as a graph for comparison. The snapshot function can be set to start
manually recording when the symptom occurs, or to start recording when
the DTC is set. Abnormal values in the recorded data may indicate
systems or components that require further inspection. For details, refer to
the user's manual for the scan tool.

Abnormal Combustion Noise
Definition • Check with the customer whether they are using
Fuel inside the intake cover or exhaust system ignites, the specified engine oil and fuel.
causing a large blast sound.
Visual inspection
Preliminary inspection Careful visual inspections are required for several
Before using this section, perform the Diagnostic symptom procedures. This can lead to correcting a
System Check - Engine Controls to check all of the problem without further inspections, and can save
following. valuable time.
The inspection includes the following items:
• Confirm that the engine control module (ECM) and
engine warning light are operating correctly. • Correct connections, tightening and
disconnections of wiring.
• DTC check.
• Whether the power of any commercial accessories
• The scan tool data is within the normal operating
is being taken from the ECM power.
range.
• Whether the ECM ground is clean and securely
• Check the condition of the vehicle, and locate the
installed in the correct location.
Perform the procedure indicated in the diagnostic
steps.
Symptoms Testing Abnormal Combustion Noise

Perform a preliminary/visual inspection. Go to Preliminary
2 — Inspection and
Did you complete the action? Go to Step 3 Visual Inspection
Inspect the intake air system and exhaust system
3 for leakage. —
Did you complete the action? Go to Step 4 —
1. Inspect the related sensors with the following
procedure.
• Inspect the installation condition of the
crankshaft position (CKP) sensor and
4 camshaft position (CMP) sensor for —
abnormal shaking and looseness.
2. Repair as necessary.
Did you find and correct the condition? Check the repair Go to Step 5
1. Inspect the following ignition system items.
• Is there an incorrect installation of the
ignition coil?
• Is there cracking, wear, an inappropriate
5 gap, burn damage, or excessive foreign —
material attached to the spark plug
electrode?

1. Inspect the following fuel system items.
• Has the injector nozzle of the gas injector
become damaged?
6 • Is the gas injector correctly installed, and —
is there fuel leakage?
2. Replace as necessary.
• Has the compression pressure dropped?
• Is the valve clearance appropriate?
• Is the valve stuck or leaking?
• Has the cam of the camshaft become
7 damaged? —
• Is the valve timing appropriate?
• Is there fatigue or damage in the valve
spring?
1. Check all the diagnostic procedures in this
table again.
2. If the problem has still not been resolved after
completing all of the procedures, check the
following items.
8 —
• Scan tool data
• All the wiring in the suspected system
Did you complete the action? Check the repair —


Poor Fuel Economy
Definition • Check the condition of the vehicle, and locate the
The fuel efficiency measured in an actual road test is appropriate symptom in the table of contents.
much lower than expected. Also, the fuel economy is Perform the procedure indicated in the diagnostic
quite lower than was indicated in the previous actual steps.
road test performed for the vehicle. (The odometer • Check with the customer whether they are using
display may be incorrect when the tires in use are the specified engine oil and fuel.
larger than standard tires, which may cause the fuel
economy to seem lower, although it is actually normal.) Visual inspection
Careful visual inspections are required for several
Preliminary inspection symptom procedures. This can lead to correcting a
Before using this section, perform the Diagnostic problem without further inspections, and can save
System Check - Engine Controls to check all of the valuable time.
following. The inspection includes the following items:
• Confirm that the engine control module (ECM) and • Correct connections, tightening and
engine warning light are operating correctly. disconnections of wiring.
• DTC check. • Whether the power of any commercial accessories
• The scan tool data is within the normal operating is being taken from the ECM power.
range. • Whether the ECM ground is clean and securely
Symptoms Testing Poor Fuel Economy

1. Confirm the driving habits of the customer.
• Is the A/C (air conditioning) always ON
(defroster mode ON)?
• Has the tire size been changed?
• Has an excessively heavy load been
transported?
• Has there been too much or too frequent
acceleration?
3 • Is the correct engine oil being used? —
• Has the vehicle been left in gear when
idling (for Smoother vehicles)?
• Is the PTO always turned ON?
2. If any of the above are true, explain to the
customer that the problem is due to their
driving habits.
Were any of the above true? Check the repair Go to Step 4

1. Inspect the following items.
• Is the tire air pressure appropriate?
• Is the clutch slipping?
• Is the brake dragging?
4 • Is the amount of engine oil appropriate? —
• Is the odometer correct?


1. Inspect/repair the related sensors with the
following procedure.
• Use a scan tool to check the Engine
Coolant Temperature, IAT Sensor (Intake
Air Temperature), and Fuel Temperature
Sensor parameters, with the engine cold.
If only one of those values has a
difference of plus or minus 5°C (41°F) or
5 —
more, replace that sensor or circuit.
• Check the air-fuel ratio (A/F) sensor for
excessive foreign material, and remove it
if found.
• Check the O2 sensor for excessive
foreign material, and remove it if found.
• Is the correct fuel being used?
6 • Is there a fuel leakage? —
1. Inspect the following cooling system items.
• Is the amount of engine coolant
appropriate?
• Has the thermostat been left open?
7 • Is the opening temperature of the —
thermostat correct?
• Has the cooling fan been left operating?
1. Inspect the following intake air system items.
• Is there any clogging or air leakage in the
air cleaner or intake duct?
• Is the throttle valve stuck in the closed
position?
8 • Is there intake air leakage in the intake —
manifold?
• Is there a malfunction in the manifold
absolute pressure (MAP) sensor?
1. Inspect the following exhaust system items.
• Is the exhaust brake valve stuck in the
closed position?
9 • Has the catalyst deteriorated? —
• Is there clogging in the exhaust pipes?

• Is the valve gap appropriate?
• Is the valve stuck or leaking?
• Has the cam of the camshaft become
10 damaged? —
• Is there fatigue or damage in the valve
spring?
table again.
following items.
11 —
• Scan tool data


Hard Start
Engine cranks but does not run for long. The engine the specified engine oil and fuel.
ultimately operates, or starts but soon stops.
Visual inspection
• DTC check.
range.
steps.
Symptoms Testing Hard Start

camshaft position (CMP) sensor for
3 abnormal shaking and looseness, and —
install them securely.
• While cranking the engine, use the scan
tool to confirm the Engine Speed
parameter. Inspect the sensor or circuit if
the revolution speed is not displayed.
• While cranking the engine, use the scan
tool to confirm the Fuel Pressure Sensor
the displayed value is outside the range
of 350 to 450 kPa.

ignition coil?
electrode?
• Does the fuel contain moisture?
• Is there excessive fuel leakage?
• Is the gas filter (installed to the gas
injector) clogged?
• Is there an abnormality of the pressure
5 regulator? —
• Is the fuel supply valve of the CNG
container (CNG cylinder) fully open?
• Is the automatic valve open?
• Is there intake air leakage due to
defective packing of the throttle valve?
6 position? —
• Is there intake air leakage in the intake
manifold?
• Is there intake air leakage in the positive
crankcase ventilation (PCV) system?
closed position?
7 • Is there clogging in the exhaust pipes? —
• Has the cranking speed dropped?
8 • Is the valve clearance appropriate? —
• Is there damage or fatigue in the valve
spring?

1. Inspect the following electrical system items.
• Has the battery voltage dropped?
9 2. Charge the battery if a problem is detected. —
table again.
following items.
10 —
• Scan tool data


Rough, Unstable, or Incorrect Idle and Stalling
There is variation in the idling of the engine. Engine the specified engine oil and fuel.
stalling will occur in severe situations.
Visual inspection
• DTC check.
range.
steps.
Symptoms Testing Rough, Unstable, or Incorrect Idle and Stalling

3 abnormal shaking and looseness, and —
install them securely.
• With the vehicle idling, use the scan tool
to confirm the Engine Speed parameter.
Inspect the sensor or circuit if there is
variation in the revolution speed.
to confirm the Fuel Pressure Sensor
of 350 to 450 kPa.

ignition coil?
electrode?
• Is there collapsing or bending in the rigid
fuel line on the fuel supply side?
injector) clogged?
5 • Is there an abnormality of the pressure —
regulator?
• Is the fuel supply valve of the CNG
container (CNG cylinder) fully open?
• Is the automatic valve open?
position?
manifold?
closed position?

8 spring? —
• Is there a problem in the camshaft,

cylinder head, piston, etc?
• Is the output voltage of the generator
correct?
9 • Is there an abnormality of the engine —
mount?
table again.
following items.
10 —
• Scan tool data


High Idle Speed
The idling speed is much higher than the standard the specified engine oil and fuel.
value.
Visual inspection
• DTC check.
range.
steps.
Symptoms Testing High Idle Speed

• Use the scan tool to check the Engine
Speed parameter, and compare the value
with the display on the tachometer.
If the display of the scan tool does not
3 match the display of the tachometer, —
replace the IP cluster circuit or IP cluster.
• Is the amount of engine oil appropriate?

4 the displayed value is outside the range —
of 350 to 450 kPa.
• While checking the APS Signal
(Accelerator Pedal Sensor) parameter
using the scan tool, depress the
accelerator pedal all the way, and check
whether the displayed value changes in
response to the operation of the
accelerator pedal.
If the displayed value does not change,
replace the accelerator pedal position
(APP) sensor.
5 • Has the injector nozzle of the gas injector —
become damaged?
position?
manifold?
• Is there a problem in the manifold

table again.
following items.
7 —
• Scan tool data


Pulsing in Engine Speed
There is a constant pulsation or jerking accompanying the specified engine oil and fuel.
the engine speed. Usually, it becomes particularly
notable as the engine load increases. Visual inspection
steps.
Symptoms Testing Pulsing in Engine Speed

• With the vehicle idling, use a scan tool to
confirm the Fuel Pressure Sensor
of 350 to 450 kPa.
abnormal shaking and looseness, and
3 install them securely. —
accelerator pedal.
(APP) sensor.

ignition coil?
gap, burn damage, or excessive foreign
4 electrode? —
• Inspect whether the voltage output of the
ignition is appropriate using the spark
plug tester 5-8840-0383-0.
injector) clogged?
regulator?
• Is the valve of the CNG container (CNG
cylinder) fully open?
position?
manifold?
closed position?

spring?
8 • Inspect whether the operation of the —
positive crankcase ventilation (PCV)
valve is appropriate.
correct?
9 • Are there any defective connections in —
the related harness connectors?
table again.
following items.
10 —
• Scan tool data


Surges
Definition • Check the condition of the vehicle, and locate the
There is fluctuation in the engine output during stable appropriate symptom in the table of contents.
throttling or cruising. The vehicle speed increases/ Perform the procedure indicated in the diagnostic
decreases even though the accelerator pedal has not steps.
changed. • Check with the customer whether they are using
the specified engine oil and fuel.
Preliminary inspection
Visual inspection
Before using this section, perform the Diagnostic
System Check - Engine Controls to check all of the Careful visual inspections are required for several
following. symptom procedures. This can lead to correcting a
• Confirm that the engine control module (ECM) and problem without further inspections, and can save
engine warning light are operating correctly. valuable time.
• DTC check.
• Correct connections, tightening and
range.
Symptoms Testing Surges

1. Check/inspect the following items, and
perform the solutions.
• Check whether the A/C compressor was
operating when the vehicle speed
fluctuated.
If the A/C compressor was operating,
explain to the customer that the vehicle
behavior is normal.
• Use the scan tool to check the Vehicle
3 Speed parameter, and compare the value —
with the display on the speedometer.
If the display of the scan tool does not
match the display of the tachometer,
replace the IP cluster circuit or IP cluster.
• Check whether the amount of engine oil
is appropriate, and adjust the amount if it
is not.

• With the vehicle idling, use a scan tool to
confirm the Fuel Pressure Sensor
of 350 to 450 kPa.
4 response to the operation of the —
accelerator pedal.
(APP) sensor.
• Use the scan tool to check the Air Fuel
Ratio Sensor and Air Fuel Ratio Sensor
Threshold parameters.
If there is a large difference between the
two values displayed, replace the air-fuel
ratio (A/F) sensor or circuit.
ignition coil?
5 electrode? —
plug tester 5-8840-0383-0.
injector) clogged?
regulator?

position?
manifold?
closed position?
correct?
table again.
following items.
10 —
• Scan tool data


Lack of Power, Sluggishness or Sponginess
The output of the engine is lower than expected, and the specified engine oil and fuel.
the vehicle speed does not or hardly change even
when the accelerator pedal is depressed halfway. Visual inspection
steps.
Symptoms Testing Lack of Power, Sluggishness or Sponginess

1. Confirm the driving habits of the customer.
• Has the tire size been changed?
• Has an excessively heavy load been
transported?
• Has there been too much or too frequent
3 acceleration? —
• Is the correct engine oil being used?
2. If any of the above are true, explain to the
customer that the problem is due to their
driving habits.
Were any of the above true? Check the repair Go to Step 4

• Is the tire air pressure appropriate?
• Is the clutch slipping?
4 • Is the brake dragging? —
• Is the amount of engine oil appropriate?

• Use the scan tool to check the MAP
Sensor (Manifold Absolute Pressure) and
Barometric Pressure parameters with the
engine stopped. If there is a difference of
7.5 kPa or more between the two values,
replace the MAP sensor or circuit.
5 the displayed value is outside the range —
of 350 to 450 kPa.
accelerator pedal.
(APP) sensor.
ignition coil?
6 electrode? —
plug tester 5-8840-0383-0.

position?
manifold?
• Is there a problem in the MAP sensor?
closed position?
10 spring? —
correct?
table again.
following items.
12 —
• Scan tool data


Abnormal Sound/ Abnormal Smell
There is an abnormal sound or smell emitting from the the specified engine oil and fuel.
vehicle.
Visual inspection
• DTC check.
range.
steps.
Symptoms Testing Abnormal Sound/ Abnormal Smell

closed position?
3 • Are the silencer and catalyst damaged? —
• Is there exhaust gas leakage?
• Is there excessive filth on the air cleaner?
• Is the air cleaner or intake duct
4 damaged? —
• Is the intake duct incorrectly installed?
• Check the air-fuel ratio (A/F) sensor for
excessive foreign material, and remove it
5 if found. —
• Check the O2 sensor for excessive
foreign material, and remove it if found.

• Use the scan tool to check the MAP
Sensor (Manifold Absolute Pressure) and
Barometric Pressure parameters with the
engine stopped. If there is a difference of
6 7.5 kPa or more between the two values, —
replace the MAP sensor or circuit.
of 350 to 450 kPa.
ignition coil?
7 electrode? —
plug tester 5-8840-0383-0.
9 spring? —


table again.
following items.
10 —
• Scan tool data

Repair Instructions
Engine Control Module (ECM) Replace-
ment Notice: To prevent damage to the inside of the ECM,
make sure to turn the ignition switch to the "OFF"
Maintenance Precautions position when disconnecting/reconnecting power
Notice: When replacing the ECM, make sure to supply related parts to the ECM (example: battery
disconnect the negative side terminal of the battery cable, ECM connection cord, ECM fuse, jumper cable,
cable before disconnecting the ECM connector. After etc.).
replacing the ECM, make sure to connect the negative
side terminal of the battery cable after connecting the Important: When replacing the ECM, transfer the
ECM connector. serial number of the original ECM to the label of the
new ECM. This enables the ECM parts of the vehicle to
Damage caused by electrostatic discharge be identified for the entire usage period. Do not inscribe
Many of the electrical components used in the control the above information on the metal cover of the ECM.
systems are designed to operate at extremely low
voltages. These components are prone to damage due Important: Make sure to turn the ignition switch to the
to electrostatic discharge, and some may even become "OFF" position when connecting/disconnecting the
damaged by voltages of 100 volts or lower. Compared connectors of the ECM.
with this, the human body requires a voltage of 4000
volts to feel an electrostatic discharge. When performing ECM maintenance, it is usually
There are various ways for a human body to build up necessary to decide whether to replace the ECM.
an electrostatic charge, but the most common are When the result of a trouble diagnosis requires the
friction electricity and electromagnetic induction. An ECM to be replaced, first check whether that part
example of friction electricity occurring is when number is correct. Thereafter, remove the defective
someone slides across the seat of a vehicle. ECM, and install the replacement ECM.
Electrostatic charge by electromagnetic induction
occurs in situations such as when a person wearing Removal
well insulated shoes is standing beside a high 1. Disconnect the negative side terminal of the
electrostatically charge object and is momentarily battery cable.
grounded. At this time, a charge of the same polarity 2. Remove the heater pipe bracket fixing nut, and
flows out, and large charge of the opposing polarity then remove the heater pipe bracket from the ECM
remains with that person. Since electrostatic charges bracket.
can have adverse effects, it is necessary to be cautious
3. Disconnect the harness connectors from the
when performing tests and handling electronic
engine driver unit (EDU).
components.
4. Disconnect the harness connectors from the ECM.
Notice: Follow the policy below to prevent damage due 5. Remove the side cover. (NMR)
to electrostatic discharge. 6. Remove the ECM bracket fixing nuts, and remove
• Do not touch the connection terminal pins of the ECM bracket (with the EDU and ECM) from the
control modules or the soldered parts of circuit stay (NMR) or side cover (NPR).
boards.
• Do not open the packaging of replacement parts
until right before the installation.
• When removing a part from its packaging
container, connect the container to a known good
ground connection of the vehicle.
• When you have slid across a seat to move, sit
down from a standing position, or walked
somewhere while holding a part, ground the part to
a known good ground connection before installing
the part.

7. Remove the ECM fixing bolts, and then remove the 2. Install the ECM bracket (with the EDU and ECM)
ECM from the ECM bracket. to the stay (NMR [Except Australia]/ NLR [for
NMR (Except Australia)/ NLR (for Australia) Australia]) or side cover (NPR), and tighten the
ECM bracket fixing nuts.
2
Tightening torque: 8 N⋅m (0.8 kg⋅m/ 69 lb⋅in)
3. Install the side cover. (NMR [Except Australia]/
NLR [for Australia])
4. Connect the harness connectors to the ECM and
EDU.
1
5. Install the heater pipe bracket to the ECM bracket,
and tighten the heater pipe bracket fixing nut.
4 6. Connect the negative side terminal of the battery
cable.
7. Perform the Fuel Compensation Rate Learn
procedure.
Fuel Compensation Rate Learn

3
LNW71ASH002601
The fuel compensation rate learn procedure is required
when the following service procedures have been
Legend performed:
1. ECM bracket
• Engine control module (ECM) replacement
2. ECM
3. Side cover • Gas injector replacement
4. Stay • Air-fuel ratio (A/F) sensor replacement
NPR
2. Start the engine and let idle until engine coolant
temperature reads 75°C (167°F) or higher while
observing the Engine Coolant Temperature
parameter with a scan tool.
1
3. Clear the learning value of ECM memory.
a. Connect a jumper wire between the terminals
2 (pins 2 and 5 of B283) of the PI monitor
3 connector.
b. Connect a jumper wire between the terminals
connector
c. After 3 seconds have elapsed, the learning
values are returned to their initial values.
d. Disconnect the jumper wire.
4. Holding the engine speed 3000 RPM without load
for 3 minutes while observing the Engine Speed
LNW71ASH002701 parameter with a scan tool.
Legend 5. Observe the Coefficient corrected by fuel of
1. ECM different kind parameter. This parameter should
2. ECM bracket read 99% to 121%.
3. Side cover
Engine Driver Unit (EDU) Replacement
Installation Maintenance Precautions
1. Install the ECM to the ECM bracket, and tighten Notice: When replacing the EDU, make sure to
the ECM fixing bolts. remove the negative side terminal of the battery cable
Tightening torque: 10 N⋅m (1.0 kg⋅m/ 87 lb⋅in) before removing the EDU connector. After replacing the
EDU, make sure to connect the negative side terminal
of the battery cable after connecting the EDU
connector.

Damage caused by electrostatic discharge 3. Remove the EDU fixing nuts, and then remove the
Many of the electrical components used in the control EDU (1) from the engine control module (ECM)
systems are designed to operate at extremely low bracket .
voltages. These components are prone to damage due NMR (Except Australia)/ NLR (for Australia)
to electrostatic discharge, and some may even become
damaged by voltages of 100 volts or lower. Compared
with this, the human body requires a voltage of 4000
1
volts to feel an electrostatic discharge.
There are various ways for a human body to build up
an electrostatic charge, but the most common are
friction electricity and electromagnetic induction. An
example of friction electricity occurring is when
someone slides across the seat of a vehicle.
Electrostatic charge by electromagnetic induction
occurs in situations such as when a person wearing
well insulated shoes is standing beside a high
electrostatically charge object and is momentarily
grounded. At this time, a charge of the same polarity
flows out, and large charge of the opposing polarity
remains with that person. Since electrostatic charges
can have adverse effects, it is necessary to be cautious
when performing tests and handling electronic LNW71ASH002801
components. NPR
Notice: Follow the policy below to prevent damage due

to electrostatic discharge.
• Do not touch the connection terminal pins or the
soldered parts of circuit boards. 1
• Do not open the packaging of replacement parts
until right before the installation.
• When removing a part from its packaging tank,
connect the tank to a known good ground
connection of the vehicle.
• When you have slid across a seat to move, sit
down from a standing position, or walked
somewhere while holding a part, ground the part to
a known good ground connection before installing
the part.
Notice: To prevent damage to the inside of the EDU,

LNW71ASH002901
make sure to turn the ignition switch to the "OFF"
position when disconnecting/reconnecting power
supply related parts to the EDU (example: battery Installation
cable, ECM connection cord, fuse, jumper cable, etc.). 1. Install the EDU (1) to the ECM bracket, and tighten
the EDU fixing nuts.
Important: Make sure to turn the ignition switch to the
Tightening torque: 8 N⋅m (0.8 kg⋅m/ 69 lb⋅in)
"OFF" position when connecting/disconnecting the
connectors of the EDU. 2. Connect the harness connector to the EDU.
3. Connect the negative side terminal of the battery
Removal cable.
1. Disconnect the negative side terminal of the
battery cable.
2. Disconnect the harness connector from the EDU.
Description and Operation

Engine Control Module (ECM) Description Functions of the ECM
Engine control module (ECM) The ECM outputs voltages of 5 volts and 12, 14 volts to
supply power to various sensors and switches.
The engine control module (ECM) is installed inside the
However, since power is supplied via ECM resistance,
engine left side cover, along with the engine driver unit
the resistance value is very high, and the test lamp may
(EDU). The ECM constantly monitors the information
not illuminate even if it is connected to the circuit. In
sent from various sensors, and controls the various
specific cases, since the resistance is too low even
systems of the power train. The ECM performs the
when normal voltmeters are used, it is necessary to
diagnostic functions of the system, detects operational
use a Digital Multimeter with an input impedance of at
problems of the system, warns the driver via the check
least 10 megaohms in order to display correct
engine warning light, and records the DTC (diagnostic
readings. The special tool 5-8840-2691-0 is suitable.
trouble codes). The DTC identifies the area where the
The ECM controls output circuits by controlling the
problem has occurred to assist the repair operation
GND or power supply circuit via a transistor or one of
performed by the technician.
the following 2 devices.
• Output driver module (ODM)
• Quad driver module (QDM)
ECM and components

The ECM is designed to maintain regulation levels of
exhaust gases while obtaining excellent fuel efficiency.
The ECM monitors the various functions of the engine
and the vehicle via the electronic sensors such as the
CKP sensor and vehicle speed sensor.
ECM voltage description

The ECM applies standard voltage to various switches
and sensors. The ECM is able to apply voltage in such
a way because the ECM resistance value is very high,
and the voltage that is actually applied to the circuit is
low. Therefore, the test lamp may not illuminate even if
LNW61ASH001501 it is connected to the circuit. The voltmeter that is
normally used at maintenance factories may not
The engine control system is an electronic control display a correct reading because its input impedance
system for controlling the engine to constantly provide is too low. An accurate voltage reading can be obtained
an optimal combustion state according to the driving by using a Digital Multimeter (for example, 5-8840-
conditions. The major types of control the system 2691-0) with an input impedance of 10 megaohms.
conducts are as follows. Input/output devices for the ECM include an analog-
digital converter, signal buffer, counter, special driver,
• Air-fuel ratio control
etc. The ECM uses electronic switches to control most
• Fuel injection control components, and the GND circuit is closed when a
• Ignition control switch is turned "ON". These switches are arranged in
• Throttle valve control groups of four or seven, with the former being called
The engine control system also has the following "quad driver modules" (QDM), able to control a
system control functions. maximum of four output terminals each, and the latter
• Self-diagnosing function being called "output driver modules" (ODM), able to
individually control a maximum of seven outputs.
• Exhaust brake control However, not all outputs are necessarily used.
• Engine rpm output to tachometer
• CAN communication ECM input/output
Input - parts that the ECM reads signals from
• Engine coolant temperature (ECT) sensor
• Intake air temperature (IAT) sensor
• CNG temperature sensor
• Crankshaft position (CKP) sensor
• Camshaft position (CMP) sensor

• Manifold absolute pressure (MAP) sensor
• CNG pressure sensor
• Throttle position (TP) sensor
• Accelerator pedal position (APP) sensor
• PTO accelerator sensor
• Vehicle speed sensor
• Air-fuel ratio (A/F) sensor
• O2 sensor
• Fuel tank (CNG container) pressure sensor
• Knock sensor
• Ignition switch
• Neutral switch
• Clutch switch
• Parking brake switch
• Diagnostic switch
• Memory clear switch
• Exhaust brake switch
• A/C switch
• Refrigerator switch
• PTO switch
Output - parts the ECM controls
• Ignition coil
• Gas injector
• Throttle valve
• Automatic valve (at tank)
• Automatic valve (before regulator)
• Air-fuel ratio (A/F) sensor heater
• O2 sensor heater
• Exhaust brake solenoid valve
• Starter cut relay
• A/C compressor
• Check engine warning light
• Exhaust brake indicator light

Except Australia
1 2
21
7 6 5
4
20
8
Intake
9
19
10
11
18
17 Exhaust
16
14 12
13
15
LNW91ALF000401
Legend
1. Engine control module (ECM) 12. O2 sensor
2. Accelerator pedal position (APP) sensor 13. Exhaust brake solenoid valve
3. Automatic valve (at tank) (RH) 14. Air-fuel ratio (A/F) sensor
4. CNG container (CNG cylinder) 15. Crankshaft position (CKP) sensor
5. Automatic valve (at tank) (LH) 16. Engine coolant temperature (ECT) sensor
6. Automatic valve (before regulator) 17. Knock sensor
7. Pressure Regulator 18. Manifold absolute pressure (MAP) sensor
8. CNG pressure/ temperature sensor 19. Intake air temperature (IAT) sensor
9. Gas injector 20. Throttle valve
10. Ignition coil 21. Engine driver unit (EDU)
11. Camshaft position (CMP) sensor

For Australia
1 2
21
7 6 5
4
20
9 8
Intake
19 10
11
12
18
Exhaust
17
15 13
14
16
LNW91ALF000701
Legend
1. Engine control module (ECM) 12. Camshaft position (CMP) sensor
2. Accelerator pedal position (APP) sensor 13. O2 sensor
3. Automatic valve (at tank) (RH) 14. Exhaust brake solenoid valve
4. CNG container (CNG cylinder) 15. Air-fuel ratio (A/F) sensor
5. Automatic valve (at tank) (LH) 16. Crankshaft position (CKP) sensor
6. Automatic valve (before regulator) 17. Engine coolant temperature (ECT) sensor
7. Pressure Regulator 18. Manifold absolute pressure (MAP) sensor
8. CNG pressure sensor 19. Intake air temperature (IAT) sensor
9. CNG temperature sensor 20. Throttle valve
10. Gas injector 21. Engine driver unit (EDU)
11. Ignition coil

ECM maintenance precaution Engine Control Component Description
The ECM has been designed to withstand the regular DC-DC converter
current consumption associated with vehicle operation.
The DC-DC converter is a device for converting the
Make sure that the circuit does not overload. When
battery voltage (24 volts) to 12 volts, and is installed
performing tests for an open circuit or short circuit, do
behind the driver seat. Since the air-fuel ratio (A/F)
not ground or apply voltage to the circuit of the ECM,
sensor heater, O2 sensor heater, and ignition coil is
unless otherwise instructed. When performing these
rated for 12 volts, power is supplied to them via the DC-
circuit tests, make sure to use the Digital Multimeter 5-
DC converter.
8840-2691-0.
CAUTION:
Malfunction Indicator Lamp (MIL) Operation A problem will occur in the control systems if you install
The MIL is located in the instrument panel cluster. The commercial electronic equipment using the DC-DC
MIL will display the following symbols when converter as the power supply. If you discover
commanded ON: commercial electronic equipment installed in the
vehicle during a repair, it is necessary to advise the
customer about this.
LNW91ASH002101
• When the ignition switch is turned "ON", the check

MIL illuminates. LNW61ASH000701
• If no trouble is detected, the check MIL turns off 4
seconds after starting the engine. Engine driver unit (EDU)
If any failure is detected, the check MIL remains
illuminated after starting the engine.
ST
ON
Ignition Switch OFF
Start
Engine Start Stop
Continue to ON
Determination (When there is a problem)
ON
Check Engine OFF OFF (When there is no problem)
Warning Light
4 Sec.
LNW71ASH003001
LNW91ASH000801

The engine driver unit (EDU) drives the gas injector The CMP sensor is installed behind the cylinder head,
and throttle motor, and is installed inside the engine left and generates a CMP signal when the sensing wheel
side cover, along with the ECM. Since the gas injector of the camshaft gear passes by it. The ECM
and throttle motor are controlled with electric current, determines the crank angle and cylinder using the CMP
the ECM controls these parts via the EDU. signal and the CKP signal input from the CKP sensor,
and uses them to perform fuel injection control and
Crankshaft position (CKP) sensor calculate the engine rpm.
Engine coolant temperature (ECT) sensor
LNW71ASH003201
The CKP sensor is installed in the flywheel housing, LNW71ASH002101

and generates a CKP signal when the teeth of the
flywheel pass by it. The ECM determines the crank The engine coolant temperature (ECT) sensor is
angle and cylinder using the CKP signal and the CMP installed near the thermostat housing, and the
signal inputted from the CMP sensor, and uses them to thermistor changes the resistance value according to
perform fuel injection control and calculate the engine changes in temperature. The resistance value
rpm. becomes smaller when the engine coolant temperature
is high, and the value becomes larger when the engine
Camshaft position (CMP) sensor coolant temperature is low. The ECM applies 5 volts to
the ECT sensor through the pull-up resistor, and
calculates the engine coolant temperature from
changes in the voltage. This value is used in various
control mechanisms, such as for fuel injection control.
The voltage becomes lower when resistance is small
(temperature is high), and it becomes higher when
resistance is large (temperature is low).
MFW4ADSH001801

Intake air temperature (IAT) sensor The manifold absolute pressure (MAP) sensor is
installed above the intake manifold, and converts the
manifold negative pressure of the intake air systems to
electrical signals. The pressure detection part of the
sensor is comprised of the silicon element in a
diaphragm shape, which emits electricity almost in
proportion to the pressure with a piezoelectric effect
when pressure is applied to both sides of the element.
The ECM calculates the air intake pressure from the
voltage signal sent from the sensor, and uses it to
control the fuel injection, etc.
Air-fuel ratio (A/F) sensor
MFW4ADSH003301
The intake air temperature (IAT) sensor is installed

near the throttle valve, and the thermistor changes the
resistance value according to changes in temperature.
The resistance value becomes smaller when the intake
air temperature is high, and the value becomes larger
when the intake air temperature is low. The engine
control module (ECM) applies 5 volts to the ECT
sensor through the pull-up resistor, and calculates the
engine coolant temperature from changes in the
voltage. This value is used in various control
mechanisms, such as for fuel injection control. The LNW61ASH000901
voltage becomes lower when resistance is small
(temperature is high), and it becomes higher when The air-fuel ratio (A/F) sensor is installed on the
resistance is large (temperature is low). exhaust pipe in front of the 3-way catalyst. Since the A/
F sensor outputs a current value proportional to the air-
Manifold absolute pressure (MAP) sensor fuel ratio to the ECM when it is active, it incorporates a
heater to maintain its active status. The ECM controls
fuel injection so that the air-fuel ratio will be the desired
value, based on the current value from the A/F sensor.
LNW61ASH000801

O2 sensor For Australia
LNW61ASH001101
LNW61ASH001001
The CNG pressure sensor is installed on the fuel

The O2 sensor is installed between the 3-way catalyst
gallery, and detects the fuel pressure inside the fuel
and the silencer. The O2 sensor outputs a voltage
gallery, converts the pressure to a voltage signal, and
signal derived from the oxygen density in the exhaust
sends it to the ECM. The voltage becomes higher when
gas to the ECM when it is active status. The ECM
the pressure is higher, and it becomes lower when the
adjusts the air-fuel ratio control (based on the signal
pressure is lower. The ECM calculates the fuel
from the air-fuel ratio (A/F) sensor in front of the
pressure from the voltage signal sent from the sensor,
catalyst) using the signal from the O2 sensor, to enable
and uses it to control the fuel injection, etc.
more precise air-fuel ratio control. The O2 sensor
incorporates a heater because the element does not
CNG temperature sensor
induce an electric potential unless it has reached its
active temperature. Except Australia
CNG pressure sensor

Except Australia
LNW91ASH000601
LNW91ASH000601

For Australia The knock sensor is installed on the cylinder block to
measure the engine knocking from changes in
frequency. The knock sensor has a signal circuit and
GND circuit. The knock sensor consists of a vibrating
plate and piezoelectric element, and a voltage is
generated when this vibrating plate resonates.
Fuel tank (CNG container) pressure sensor
LNW61ASH001201
The CNG temperature sensor is installed on the fuel

gallery, and the thermistor changes the resistance
value according to changes in temperature. The
resistance value becomes smaller when the fuel
temperature is high, and it becomes larger when the
fuel temperature is low. The ECM applies 5 volts to the
MFW71ASH002401
CNG temperature sensor through the pull-up resistor,
and calculates the fuel temperature from changes in
The fuel tank (CNG container) pressure sensor is
the voltage. This value is used for fuel injection control.
installed near the automatic valve (before regulator)
The voltage becomes lower when resistance is small
manifold, and detects the fuel pressure near the CNG
(temperature is high), and it becomes higher when
container (CNG cylinder), converts the pressure to a
resistance is large (temperature is low).
voltage signal, and sends it to the ECM. The voltage
becomes higher when the pressure is higher, and it
Knock sensor
becomes lower when the pressure is lower. The ECM
Except Australia calculates the fuel pressure from the voltage signal
sent from the sensor, and uses it to control the fuel
injection, etc.
Throttle valve
LNW91ASH000501
LNW61ASH001301

The throttle valve is installed on the intake manifold PTO accelerator sensor
entrance, and adjusts the air intake amount. The
throttle valve is opened/closed by a DC motor. The
ECM controls the motor via the EDU according to the
driving condition of the vehicle. The throttle valve also
has a position sensor, and the ECM recognizes the
opening angle of the valve using signals from the
position sensor. The position sensor contains 2
systems; sensor 1 outputs a higher voltage the larger
the valve opening angle is, and sensor 2 outputs a
higher voltage the smaller the valve opening angle is.
Accelerator pedal position (APP) sensor
MFW31ASH001601
The PTO accelerator sensor is installed outside the cab

as an external accelerator, and supplies a voltage
signal that changes based on the angle of the PTO
accelerator, to the ECM. The ECM calculates the PTO
accelerator angle from the voltage signal, and uses it to
control the throttle valve, etc.
MFW4ADSH003401
The accelerator position (APP) sensor is installed

above the accelerator pedal, and supplies a voltage
signal that changes based on the angle of the
accelerator pedal, to the engine control module (ECM).
The APP sensor contains 2 systems; sensor 1 outputs
a higher voltage the larger the pedal angle is, and
sensor 2 outputs a higher voltage the smaller the pedal
angle is. The ECM calculates the accelerator pedal
position from the voltage signal, and uses it for fuel
injection control and many other controls.

Air/ Fuel Ratio Control System Description
For the 3-way catalytic converter to clean gas under
optimum conditions, the air/ fuel ratios must be
controlled always within a narrow range near
theoretical air/ fuel ratio under any driving conditions.
For this reason, an air-fuel ratio sensor (= Hi-Range
Oxygen Sensor) that detects concentration of oxygen
contained in exhaust gas is installed before the 3-way
catalyst and an O2 sensor is installed after the 3-way
catalyst.
On the basis of the signals from the sensors, the
Engine Control Module (ECM) controls air/ fuel ratios.
The ECM calculates an air/ fuel ratio on the basis of
signals from the air/ fuel ratio sensor and compares the
values with an optimum air/ fuel ratio (Hi-Range
Oxygen sensor threshold value) estimated by the ECM,
and adjusts fuel injection volumes. At this point, the
ECM sets a learned air/ fuel ratio (correction value). If
fuel is too few and must be increased, a value larger
than 100% is specified and if fuel is too much and must
be decreased, a value smaller than 100% is specified.
Under O2 sensor feedback control, on the other hand,
the air/ fuel ratio sensor threshold values are corrected
on the basis of signals from the O2 sensor, allowing
even finer control.
Judgment to be
Electromotive lean Concentration of
Hi-Range Oxygen voltage : Low Fuel Gas oxygen : Low
sensor (Lambda) (Lean signal) Set a higher Increased
learned value High air/fuel ratio
ECM
(F/B control)
Judgment to be
Concentration of rich Electromotive
oxygen : High Fuel Gas voltage : High Hi-Range Oxygen
Decreased Set a lower (Rich signal) sensor (Lambda)
Low air/fuel ratio learned value
LNW91ASF000701

Fuel Injection System Description
The compressed natural gas (CNG) is filled through the
gas filling unit into the CNG container (CNG cylinder)
[high-pressure gas cylinder] up to 20 MPa. The CNG
filled in the tank is led to a pressure-reducing valve
(pressure regulator), through various control valves
and high-pressure pipes. The pressure regulator
reduces a gas pressure from a pressure in the CNG
container (CNG cylinder) (20 MPa) to 0.4 MPa. The
gas under a pressure reduced by the pressure
regulator is led to the fuel gallery, and then injected
through the gas injector into cylinders.
The engine control Module (ECM) decides optimum
fuel injection volumes and fuel injection timing on the
basis of signals from sensors, and controls the gas
injectors.
If fuel supply must be interrupted abruptly upon a
problem such as overrun, the ECM turns on the
Automatic valves provided at CNG container (CNG
cylinder) inlet and pressure regulator to break fuel
supply to the engine.

Except Australia
1
Accelerator pedal position
Engine coolant temperature
Camshaft position
Crankshaft position
Manifold absolute pressure
Intake air temperature
Fuel temperature
Fuel pressure
0.4MPa 20MPa
LNW91ALF000501
Legend
1. Engine control module (ECM) 5. Manual cylinder valve (at tank) with excess flow
2. Pressure Regulator valve (EFV) and automatic valve (at tank)
3. Automatic valve (before regulator) 6. Gas filter
4. CNG container (CNG cylinder) 7. Gas injector

For Australia
1
Accelerator pedal position
Engine coolant temperature
Camshaft position
Crankshaft position
Manifold absolute pressure
Intake air temperature
Fuel temperature
Fuel pressure
0.4MPa 20MPa
LNW91ALF000801
Legend
1. Engine control module (ECM) 4. CNG container (CNG cylinder)
2. Pressure Regulator 5. Automatic valve (at tank)
3. Automatic valve (before regulator) 6. Gas injector

Fuel Injection System Component Descrip-
tion
Gas Injector
The gas injector is controlled by electrical signals from
the ECM via the engine driver unit (EDU). The engine
control module (ECM) determines the fuel injection
timing and fuel injection amount based on the signals
from the crankshaft position (CKP) sensor, camshaft
position (CMP) sensor, accelerator pedal position
(APP) sensor, and engine coolant temperature (ECT)
sensor, etc. The fuel injection amount increases the
longer the gas injector is energized. A gauze filter is
also installed to the gas injector to remove any
impurities that may be mixed in the fuel.
5
Fuel inlet 4
Injection
LNW91AMF000101
Legend
1. Coil 4. Valve seat
2. Plunger 5. Filter
3. Valve 6. Spring
• Operation of the gas injector

When excitation current flows to the gas injector
coil due to electrical signals from the engine
control module (ECM), the plunger is lifted up. This
causes the fuel pressure of 0.4 MPa {4.1kg/cm2}
applied to the fuel gallery to overcome the force of
the spring, which causes the valve to open and
fuel to be injected.

Automatic valve (before regulator), automatic valve
(at tank)
The automatic valves are placed in the high-pressure
circuit to open/close the fuel passage according to
electrical signals from the ECM.
The automatic valve (before regulator) is situated
between the pressure regulator and CNG container
(CNG cylinder), and the automatic valve (at tank) are
situated in the CNG container (CNG cylinder). The
three valves are electromagnetic valves that have the
same structure and function.
The automatic valve operates by suctioning of the
plunger using an exciter coil. This exciter coil has a
strong excitation circuit for suctioning the plunger, and
a slightly weak excitation circuit for retaining the
position of the plunger once it has been suctioned. By
switching between these two excitation circuits, the
automatic valve can have strong and secure suction,
and also reduced energy consumption and
temperature increase when the valve is open (which is
most of the time when the vehicle is running).
Automatic valve (before regulator) Except Australia
1 2
8 7
6
5
9
10
11
Valve Closed Only Pilot Valve Open Valve Open

LNW91AMF000401
Legend
1. Spring 7. Suction
2. Coil 8. Retention
3. Plunger 9. Plunger
4. Body 10. Pilot valve
5. Filter 11. Main valve
6. Ground

Automatic valve (at tank) (RH,LH) [with manual cylinder valve (at tank) and excess flow valve (EFV)] Except
Australia
2 3 4 5 6 7 8
1
9
20 19 18
17 11 10
16
12
15 13
14
LNW91AMF001001
Legend
1. O-ring 11. O-ring
2. Spring 12. Excess flow stop plug
3. Gasket 13. Body
4. Sleeve 14. Pressure relief device (PRD)
5. O-ring 15. Solenoid
6. Gasket 16. Internal excess flow shutter
7. O-ring 17. Spring
8. Pin 18. Compensation ring
9. Handle 19. Nut
10. Shaft 20. Nut

Automatic valve (before regulator), automatic valve (at tank) (RH,LH) for Australia
1 2
8 7
6
5
9
10
11
Valve Closed Only Pilot Valve Open Valve Open

LNW91AMF000401
Legend
1. Spring 7. Suction
2. Coil 8. Retention
3. Plunger 9. Plunger
4. Body 10. Pilot valve
5. Filter 11. Main valve
6. Ground
• Valve closed • Valve open

The plunger is pushed by the spring to shut off the When pressure fills the downstream side with only
pilot valve and main valve. the pilot valve open, and the pressure difference
Also, the gas pressure on the inlet is applied to the with the upstream side becomes approximately 0.4
back of the valve, making it pressed strongly. MPa {4 kg/cm2} or less, the main valve is pulled up
• Only pilot valve open by the plunger and changes to a steady open
The plunger is raised to open the pilot valve. state.
The gas passes around the main valve and flows
downstream from the pilot valve seat. At this time, Notice: Make sure to match the male side of the
the main valve is being pressed by the inlet gas lead wire with the correct color on the vehicle side
pressure, and is therefore not opened with harness. Mis-wiring will cause coil burning and
electromagnetism. The gas that flows out from the malfunctioning.
pilot valve increases the pressure on the
downstream side, and when the pressure
difference with the upstream side becomes small,
the main valve is pulled up with electromagnetism.

Pressure regulator
The pressure regulator is a pressure reducing device to
reduce the pressure of the high-pressure CNG and
supply it to the cylinder as fuel gas.
Engine coolant is also led to and circulated around the
body part of the pressure reducing valve to ensure that
latent heat from the pressure reduction does not hinder
the pressure reducing performance of the valve.
• Structure/operation of the pressure regulator
The pressure regulator is comprised of a two-level
pressure reducing mechanism; primary pressure
reduction and secondary pressure reduction.
When the fuel pressure on the secondary (outlet)
side drops due to fuel consumption, the load on
spring A overcomes the fuel pressure and presses
down valve B to open the fuel passage, causing
the fuel to flow out to the outlet side. When this
causes the fuel pressure on the outlet side to rise
to the specified pressure, that fuel pressure
pushes spring A back, and valve B closes the fuel
passage. Since this causes the fuel pressure in the
fuel passage (primary chamber) to drop, the load
on spring C presses down valve D, fuel flows out
from the fuel inlet side to the primary chamber (fuel
passage), and the fuel pressure in the primary
chamber rises. When this fuel pressure reaches
the specified value, spring C is pushed back, and
valve D is closed. By repeating this process in the
primary pressure reduction mechanism and
secondary pressure reduction mechanism, the
compressed natural gas (CNG) inside the CNG
container (high-pressure gas cylinder) at a
maximum pressure of 20 MPa {203 kg/cm2} is
reduced in pressure to 0.4 MPa {4 kg/cm2}.
• Structure/operation of the relief valve
2 relief valves (1 each on the high-pressure side
and low-pressure side) are attached to the
pressure regulator, to protect the pressure
regulator and subsequent parts. The relief valve on
the high-pressure side (situated in the center of the
passage) protects the secondary pressure
reduction mechanism when any problem occurs in
the primary pressure reduction mechanism. When
the fuel pressure in the passage rises above a
certain level, that fuel pressure pushes up spring
E, which causes valve F to open and release the
excess pressure outside. The relief valve on the
low-pressure side (situated on the fuel outlet side)
protects the pressure regulator and subsequent
parts when any problem occurs in the secondary
pressure reduction mechanism. When the fuel
pressure rises above a certain level, that fuel
pressure pushes up spring G, which causes valve
H to open and release the excess pressure
outside.
18
Section D-D
Section B-B
24
23
25
19
17
7
16
D
A
6
5
4
B
8
3
Section A-A
D
15 A
C
9
10
1
13
14
A
11
12
21
20
Section C-C
22
LNW91AXF000601

Legend
1. Primary side 14. Primary chamber
2. Spring C 15. Passage
3. Secondary side 16. Spring G
4. Adjusting screw 17. Valve H
5. Spring A 18. Fuel outlet
6. Valve B 19. Low-pressure relief valve
7. Engine coolant 20. Spring E
8. Spring E 21. Valve F
9. High-pressure relief valve 22. Passage
10. Valve F 23. Spring G
11. Engine coolant 24. Valve H
12. Fuel inlet 25. Passage
13. Valve D

Ignition System Description
The engine control module (ECM) determines the
ignition timing based on signals from the crankshaft
position (CKP) sensor and camshaft position (CMP)
sensor, and makes adjustments using the engine
coolant temperature and manifold absolute pressure,
based on the state of the engine. The ECM energizes
the ignition coil based on the calculated ignition timing.
Ignition Coil with Built-in Power Switch
DC-DC Power Supply Power Primary Current Ignition

Converter (12V) Switch Coil
Ignition
Signal
Battery Spark
(12V) ECU Plug
Battery Crank Angle CKP

(12V) Revolution Speed Sensor
Battery Voltage Manifold Absolute Pressure MAP

Sensor
Coolant Temperature ECT

Sensor
(Engine)
LNW91AMF000501

Ignition coil
The ignition coil is a device for emitting a high-voltage
current required to ignite the spark plug, and has a
built-in power transistor. The power transistor receives
an ignition signal from the ECM, and disconnects the
primary current of the ignition coil. The ignition coil
includes a primary coil and secondary coil. A 12 volts
power voltage is supplied to the primary coil via a DC-
DC converter, and when the power transistor is turned
"ON", a GND circuit is established, and the primary
current flows. The ECM turns the power transistor "ON"
according to the ignition timing, and immediately turns
it "OFF" to cause the primary coil to emit self-induced
voltage, and this mutual induction effect causes a high
voltage current to flow in the secondary coil.
1 2 3
5
9
11
7
10
8
LNW61AMF001201
Legend
1. Ignition signal 7. Iridium alloy
2. GND 8. Platinum tip
3. Battery (+) 9. Spark plug (type: Denso GX8-1)
4. Boot 10. Plug gap specified value (0.7 to 0.8 mm)
5. Ignition coil 11. Installation threaded portion
6. Spring

Spark plug
When the spark plug is worn or damaged, it may stop
functioning at high engine speeds, even if it works
normally at idling speeds. When there is a problem with
the spark plug, the fuel efficiency, output, vehicle
speed, and startability of the vehicle, etc. decrease,
along with overall engine performance. Make sure to
maintain the spark plug performance by following the
recommendations for periodic inspections and
maintenance. Refer to "Maintenance Notes". When the
spark plug is operating normally, a grayish yellow-
brown powder forms on the insulation of the spark plug.
A small amount of red-brown, yellow, or white powder
may also form on the edge of the insulation around the
central electrode. These are normal by-products of the
combustion of fuel and lubricant containing additives. A
small amount of wear may also appear on the
electrode. When the engine does not run properly it is LNW21ASH002701
said to be "misfiring". This means that the ignition
process is not igniting the air-fuel mixture with the An excessive gap means that the gap between the
appropriate timing. The cause of this problem can be center electrode and the side electrode on the base of
the ignition, CNG system or other factors, but the first the spark plug is too wide, and the spark cannot jump
thing to consider is a problem with the ignition system. consistently. This is caused by inappropriate
The spark voltage may also be reaching the ground adjustment of the gap, or wear to the electrode in the
before it jumps the spark plug gap, causing it to fail usage process. Inspect the size of the gap, and replace
igniting the air-fuel mixture. A misfire may also occur it if it is not within the specified dimensions.
when the tip of the spark plug is overheated, and the If the spark plug gap is too small, the idling state may
air-fuel mixture is ignited before the spark can jump. become unstable.
This condition is called "pre-ignition". When there is excessive wear in the gap, this indicates
The spark plug may also cause misfires due to it being that the engine has been continuously running at high
dirty/damaged, having too wide a gap, and having speeds or with heavy loads, which leads to the spark
cracks or damage in its insulation. When a misfire is plug overheating. Another cause can be the air-fuel
occurring, its cause must be pinpointed and corrected. mixture being too thin.
When the area around the spark plug is damaged by
rust, dry rust attaches itself to the spark plug area of the
combustion chamber. When the engine load is light and
idling has been excessive or has been kept at low
speeds, deposits of foreign material may not burn off
because the temperature of the spark plug does not
increase. This may also occur when the density of the
fuel in the air-fuel mixture is extremely high, or when
the secondary voltage of the ignition system is low.
When the spark plug is damaged by oil, moist oil
attaching itself to the spark plug area of the combustion
chamber can be observed, and the electrode usually
has been slightly worn. This may be caused by the oil
during the break-in of a new engine or of a newly
overhauled engine. The spark plug can be damaged by
foreign material when the red-brown, yellow, or white
powder of the fuel by-products have accumulated a
great amount and misfires are occurring.
LNW21ASH002801
In some cases, these materials may melt and appear
on the insulation material around the center electrode
as a shiny substance. When there is filth/damage only
on one or two cylinders, a suck down of oil from the
valve system clearance or the intake valve seal may be
occurring. In particular, when there is a significant
amount of deposits on the intake valve side of the spark
plug, this can mean that an excessive suck down of oil
is occurring.

If the tightening torque is too low or too high when • Damage due to heat shocks occurs under many
installing the spark plug or the installation of the seat is normal engine operation conditions (high-speed or
performed inappropriately, the spark plug may high-load). Heat shocks cause the temperature at
overheat, and the center electrode may receive the tip of the spark plug to rapidly increase, which
excessive wear. It is necessary to ensure that the plug may crack the insulation material.
and cylinder head seat are joined properly and the heat
conductivity and cooling of the spark plug is being
performed appropriately. If the screw thread of the
spark plug or cylinder head is dirty or damaged, they
may not be attached properly, even when they are
tightened at the appropriate torque. Install the spark
plug properly, and tighten it at the tightening torque
specified in "Specifications/Tightening Torques". If the
tightening torque is too low, the seat may have a poor
connection due to the spark plug being loose. If it is
tightened excessively, the shell of the spark plug will be
stretched, also causing a poor connection with the
seat. In extreme cases, this can also cause damage to
the spark plug.
If there are cracks or damage in the insulation material,
this may cause poor insulation, or heat shocks, etc. to
the insulation material. The upper insulation may
become damaged if it is installed/removed using
LNW21ASH003001
inappropriate tools, if the spark plug is struck from
outside, or if it is dropped onto a hard surface. Cracks Always replace the spark plug if its insulation material
on the upper insulation may not be able to be seen is cracked or damaged.
because it is on the inside of the shell. Also, even if it is
damaged, a problem may not arise until oil or humidity
penetrates into the cracked area.
LNW21ASH002901
Damaged or cracks to the tip of the lower insulation

(around the center electrode) may be caused by heat
shocks (when the operating temperature of the spark
plug suddenly increases).

Throttle Valve Control Description
The throttle valve is opened/closed by a DC motor. The
engine control module (ECM) normally calculates the
desired throttle opening angle based on the angle of
the accelerator pedal and the engine rpm, to drive the
DC motor. The throttle valve performs delicate control,
with various methods set for calculating the desired
throttle opening angle based on the state of the vehicle
when decelerating, when controlling the PTO, and
when the exhaust brake is operating, etc.
Accelerator
Pedal Position
Engine rpm
Vehicle Speed
Engine Coolant
Temperature
Intake Air
Pressure
PTO Accelerator
Sensor Selection of the Determination of
Throttle Motor
Judgement of Desired Intake the Desired Intake
TCM Request
Vehicle Condition Throttle Opening Throttle Opening
Engine rpm
Angle Calculation Angle
Method
PTO Switch
Throttle
Exhaust Brake
Position Sensor
Solenoid Valve
Neutral Switch
Clutch Switch
A/C Relay
Refrigerator
Switch
LNW91AMF000601

Exhaust Brake Control Description Exhaust brake operation conditions
The exhaust brake includes a valve inside the exhaust • When the exhaust brake switch is turned "ON"
pipe, and closing this valve increases resistance in the • When the accelerator pedal is in the idle position
exhaust process, to raise the effect of the engine brake. • When there is no abnormality detected in the
The exhaust brake valve operates with vacuum accelerator position (APP) sensor and exhaust
pressure, and the exhaust brake is controlled by brake solenoid valve, etc.
electrically opening and closing a solenoid valve that
• When the clutch pedal is not applied
controls the supply of vacuum pressure to the exhaust
brake valve. The solenoid valve is turned "ON" by the • When the vehicle is in gear
engine control module (ECM) according to the state of • When cutting fuel for deceleration
the vehicle.
ECM Main Relay
Exhaust Brake Switch
Clutch Switch (M/T)
Exhaust Brake
Accelerator Signal Exhaust Brake
ECM
Opening Angle
Solenoid Valve
Engine rpm
Vehicle Speed
LNW91ASF000901
Special Tools and Equipment

Special Tools and Equipment
Illustration Tool Number/ Description
5-8840-2835-0 (J-35616-
C)
Connector Test Adapter
Kit (With Test Lamp)
5884028350
5-8840-2691-0
Digital Multimeter
5884026910
Tech2 Kit
AAW0Z0SH015701
THA-10
Tech2 DC24 Volt Adapter
2
ADAPTER2
5-8840-0383-0
Spark Plug Tester
MEMO
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LG4HVED-WE-0981_4304110_奥付 2012.8.9 1:20 PM ページ 1
Published: Aug., 2012 All rights reserved.

Fifth Edition
WORKSHOP MANUAL
ENGINE CONTROL SYSTEM
(4HV1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
LG4HVED-WE-0981_4304110_奥付 2012.8.9 1:20 PM ページ 2

No.LG4HVED-WE-0981

LG4HVED WE 0981 - 5th

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Engine Control System (4HV1-CNG) 1A-1

1A-2 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-3

100 212 186 Determine your altitude by contacting a local weather

1A-4 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-5

Action Taken When the DTC Sets - Type B

Conditions for Clearing the MIL/DTC - Type A or

Non-Emissions Related DTCs

Conditions for Clearing the DTC - Type D

1A-6 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-7

1A-8 Engine Control System (4HV1-CNG)

Engine Control Module (ECM)

121 Heater (+)

IP Cluster Data Link Connector

Vehicle Speed Sensor

Engine Control System (4HV1-CNG) 1A-9

Engine Driver Unit (EDU)

Gas Injector #1 (H)

Engine Control Module (ECM)

1A-10 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-11

1A-12 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-13

1A-14 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-15

1A-16 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-17

1A-18 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-19

1A-20 Engine Control System (4HV1-CNG)

Engine Control System (4HV1-CNG) 1A-21

1A-22 Engine Control System (4HV1-CNG)

Connector No. J95 Connector No. J95

Engine Control System (4HV1-CNG) 1A-23

Connector No. E125 Connector No. E125

1A-24 Engine Control System (4HV1-CNG)

Connector color Gray

Air/ Fuel Ratio (A/F) Sensor LNW46ESH003901

Connector No. J92

Automatic Valve (at tank) (LH)

Connector No. E120

Engine Control System (4HV1-CNG) 1A-25

Connector color Black

Automatic Valve (at tank) (RH)

Connector No. J94

1 2 Connector color Black

Automatic Valve (before regulator)

1A-26 Engine Control System (4HV1-CNG)

Connector color Gray

Camshaft Position (CMP) Sensor

Connector No. E136

Engine Control System (4HV1-CNG) 1A-27

CNG Temperature Sensor

Connector No. E122

Engine Coolant Temperature (ECT) Sensor