check engine light ISUZU KB P190 2007 Workshop Manual PDF

6E–94 ENGINE DRIVEABILITY AND EMISSIONS
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and
steady for about five seconds with the ignition “ON” and
the engine stopped. Ignition feed voltage is supplied to
the check engine lamp bulb through the meter fuse.
The Engine Control Module (ECM) turns the check
engine lamp “ON” by grounding the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the
following items:
• Inspect the ECM harness and connections for improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection,
and damaged harness.
• If the engine runs OK, check for a faulty light bulb, an open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
• If the engine cranks but will not run, check for an open ECM ignition or battery feed, or a poor ECM to
engine ground.
No Check Engine Lamp (MIL)
Step Action Value(s) Yes No
1 Check the “Meter” fuse (15A). If the fuse is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 2

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ENGINE DRIVEABILITY AND EMISSIONS 6E–109
• The fuel injector(s).
4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using a
Tech 2 Scan Tool.
Following are applicable to the vehicle with
closed Loop System:
If an extremely lean condition occurs, the oxygen
sensor(s) will stop toggling. The oxygen sensor
output voltage(s) will drop below 500 mV. Also, the
fuel injector pulse width will increase.
Important: Make sure the fuel system is not
operating in the “Fuel Cut-Off Mode.”
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly
as the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF.
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
• Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service .
• Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and
personal injury that may result from fuel
spraying on the engine, verify that the fuel rail is
positioned over the fuel injector ports and verify
that the fuel injector retaining clips are intact.
• Pressurize the fuel system by connecting a 20 amp fused jumper between B+ and the fuel
pump relay connector.
• Visually and physically inspect the fuel injector nozzles for leaks.
17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may
cause a 45 to set. Driveability conditions associated with rich conditions can include hard starting
(followed by black smoke) and a strong sulfur smell
in the exhaust.
20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a 44 to
set. Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.
22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure.
Command the fuel pump ON with the scan tool. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
psi) may damage the fuel pressure regulator. Caution: To reduce the risk of fire and personal
injury:
• It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
• A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Located on the intake manifold which is at the top right part of the engine.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Pressure Gauge Installation
1. Remove the fuel pressure fitting cap.
2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located on the upper right side of the
engine.
3. Reinstall the fuel pump relay.

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ENGINE DRIVEABILITY AND EMISSIONS 6E–203
2 1. Connect the Tech 2. 2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0: Diagnostic Trouble Code”.
Is the DTC P0562 stored as “Present Failure”? — Go to Step 3Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”. 2. Select “Clear DTC Information” with the Tech2 andclear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed This Ignition” in “F2: DTC Information”.
Was the DTC P0562 stored in this ignition cycle? — Go to Step 4Refer to
Diagnostic Aids and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”. 2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14.5V Go to Step 6Go to Step 5
5 Using the DVM and check the battery voltage at the battery terminal.
Does the tester indicate enough battery voltage?
10 - 14.5V Go to Step 6Check the
charging
system, charge or replace the battery
6 Check for poor/faulty connection at the ECM connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
— Verify repair Go to Step 7
7 Check for poor/faulty connection of the ECM ground at the inlet manifold. If a poor/faulty connection is
found, repair as necessary.
Was the problem found?
— Verify repair Go to Step 8
8 Is the ECM programmed with the latest software release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 9
9 Replace the ECM. Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
Step
Action Value(s) Yes No
16
2
17
12
C-56(J2)
E-60(J1)
E-72

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ENGINE DRIVEABILITY AND EMISSIONS 6E–205
2 1. Connect the Tech 2. 2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0: Diagnostic Trouble Code”.
Is the DTC P0563 stored as “Present Failure”? — Go to Step 3Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”. 2. Select “Clear DTC Information” with the Tech2 andclear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed This Ignition” in “F2: DTC Information”.
Was the DTC P0563 stored in this ignition cycle? — Go to Step 4Refer to
Diagnostic Aids and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”. 2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the headlights, etc..
Does the Tech 2 indicate correct ignition voltage? Less than 16V Go to Step 5Check the
charging
system and Go to Step 5
5 Is the battery jamp start cable incorrectly connecting? —Ve r if y
procedure Go to Step 6
6 Is the ECM programmed with the latest software release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 7
7 Replace the ECM. Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
Step
Action Value(s) Yes No

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ENGINE DRIVEABILITY AND EMISSIONS 6E–217
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM SYSTEM RESET
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The engine control module (ECM) monitors unexpected
ECM reset. This will not turn on MIL light on, only
records code DTC P1625.
Diagnostic Aids
Check for the follwing conditions:
• P1625 alone stored does not need diagnosis. Clear DTC code.
NOTE: DTC P1625 is a DTC to record a ECM reset
history. If DTC P1625 is not reset and no engine
abnormality occurs after learing the DTC, no farther
diagnostic procedures are required.
Diagnostic Trouble Code (DTC) P1625 ECM System Reset
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P1625 B ECM System Reset ECM reset has occurred other than “On”. Engine control disabled.
StepAction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” performed?
—Go to Step 2Go to
On Board
Diagnostic
(OBD) System Check
2 1. Connect the Tech 2. 2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0: Diagnostic Trouble Code”.
Is the DTC P1625 stored as “Present Failure”? — Go to Step 3Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”. 2. Select “Clear DTC Information” with the Tech2 andclear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed This Ignition” in “F2: DTC Information”.
Was the DTC P1625 stored in this ignition cycle? — Go to Step 4Refer to
Diagnostic Aids and Go to Step
4
4 Is the Immobilizer function programmed in the ECM? — Verify repair Go to Step 5
5 Is the ECM programmed with the latest software release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Replace the ECM. Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —

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6E–232 ENGINE DRIVEABILITY AND EMISSIONS
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the “On-Board
Diagnostic (OBD) System Check” and verify all of the
following items:
• The engine control module (ECM) and malfunction indicator lamp (MIL = Check Engine Lamp) are
operating correctly.
• There are no Diagnostic Trouble Code(s) stored.
• Tech 2 data is within normal operating range. Refer to Typical Scan Data Values.
• Verify the customer complaint and locate the correct symptom in the table of contents. Perform the
procedure included in the symptom chart.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time. This check should include the following items:
• ECM grounds for cleanliness, tightness and proper location.
• Vacuum hoses for splits, kinks, and proper connection, shown on the “Emission Control System
Schematics”. Check thoroughly for any type of leak or
restriction.
• Air intake ducts for collapsed or damaged areas.
• Air leaks at throttle body mounting area, manifold absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
• Ignition wires for cracking, harness, and carbon tracking.
• Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn
on the malfunction indicator lamp (MIL) or store a
Diagnostic Trouble Code. Do NOT use the Diagnostic
Trouble Code (DTC) charts for intermittent problems.
The fault must be present to locate the problem.
Most intermittent problems are cased by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions.
• Poor mating of the connector halves or a terminal not fully seated in the connector (backed out).
• Improperly formed or damaged terminal.
• All connector terminals in the problem circuit should be carefully checked for proper contact tension.
• Poor terminal-to-wire connection. This requires removing the terminal form the connector body to
check.
• Ignition coils shorted to ground and arcing at ignition wires or plugs. • MIL (Check Engine Lamp) wire to ECM shorted to
ground.
• Poor ECM grounds. Refer to the ECM wiring diagrams.
Road test the vehicle with a Digital Multimeter
connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Using Tech 2 to help detect intermittent conditions. The
Tech 2 has several features that can be used to located
an intermittent condition.
An intermittent MIL (Check Engine Lamp) with no stored
Diagnostic Trouble Code may be caused by the
following:
• Ignition coil shorted to ground and arcing at ignition wires or plugs.
• MIL (Check Engine Lamp) wire to ECM short to ground.
• Poor ECM grounds. Refer to the ECM wiring diagrams.
Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
to the ignition control module for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
If problem has not been found, refer to ECM connector
symptom tables.
• Check the “Broadcast Code” of the ECM, and compare it with the latest Isuzu service bulletins and/
or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECM’s reprogrammable
memory has been released.
To check the “Broadcast Code”, connect the Tech 2,
then look for “ID info.” then select “Broadcast Code”.
This should display a 4 character code, such as “XBYA”
(example only).
This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
If the “Broadcast Code” is not the most current
available, it is advisable to reprogram the ECM’s
EEPROM memory, which may either help identify a
hard-to find problem or may fix the problem.
The Service Programming System (SPS) will not allow
incorrect software programming or incorrect calibration
changes.

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6E–234 ENGINE DRIVEABILITY AND EMISSIONS
12 Visually/physically inspect the secondary ignitionwires. Check for the following conditions:
• Verify that all ignition wire resistance are less than the specified value.
• Verify that ignition wires are correctly routed to eliminate cross-fitting.
• Verify that ignition wires are not arcing to ground. Spraying the secondary ignition wires with a light
mist of water may help locate an intermittent
problem.
Was a problem found? #1 cyl. 4.4k
Ω
#2 cyl. 3.6k Ω
#3 cyl. 3.1k Ω
#4 cyl. 2.8k ΩVerify repair Go to Step 13
13 1. Disconnect the spark plug high tension cable from No.1 spark plug.
2. Install a spark tester at the end of the disconnected ignition coil.
3. Clip the spark tester to a good ground.
4. Observe the spark tester while the engine is cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same
as “No Spark”.) — Go to Step 21Go to Step 14
14 1. Disconnect the ignition coil harness connector. 2. Check for an open or short circuit between theignition coil and the ECM.
Was a problem found? — Verify repair Go to Step 15
15 1. Ignition “On”. 2. Using a Digital Voltmeter (DVM) check the ignitionwire coil at the ignition coil harness connector.
Was the voltage equal to the specified value? Battery
voltage Go to Step 16Verify repair
16 1. Ignition “Off”. 2. With DVM, check for an open in the ground wire atthe ignition coil harness connector.
Was the ground wire OK? — Go to Step 17Verify repair
17 Replace the ignition coil, verify the repair. Attempt to start the engine.
Is there still a problem? — Go to Step 18Verify repair
18 Use an ohmmeter to check the ignition coil primary winding resistance.
Was the primary winding resistance approximately
equal to the specified value? 0.8-18kΩGo to Step 19 Go to Step 20
19 Use an ohmmeter to check the ignition coil secondary winding resistance.
Was the primary winding resistance hear around the
to the specified value? 2.5kΩ Go to Step 21 Go to Step 20
20 Replace the ignition coil. — Verify repair —
21 1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
excessive fouling? —Correct the
fouling
condition Go to Step 22
Step
Action Value(s) Yes No

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ENGINE DRIVEABILITY AND EMISSIONS 6E–237
7 1. Using a Tech 2, display the engine coolanttemperature and note the value.
2. Check the resistance of the engine coolant temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?
—Go to Step 8Replace the
ECT sensor. Verify repair
8 1. Using a Tech 2, display the MAP sensor value in comparison with atmosphere temperature.
2. Check for a faulty, plugged, or incorrectly installed MAP sensor.
Was the problem found? — Verify repair Go to Step 9
9 Visually/physically inspect all spark plug high-tension cables. Check for the following conditions:
• Verify that the resistance of all spark plug high- tension cables are less than the specified value.
• Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting.
• Verify that the all spark plug high-tension cables are not arcing to ground.
Spraying the spark plug high-tension cables with a
light mist of water may help locate an intermittent
problem.
Was a problem found? #1 cyl. 4.4k
Ω
#2 cyl. 3.6k Ω
#3 cyl. 3.1k Ω
#4 cyl. 2.8k ΩVerify repair Go to Step 10
10 Check for proper ignition voltage output with a spark tester.
Was the problem found? — Verify repair Go to Step 11
11 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs.
Was a problem found? — Verify repair Go to Step 12
12 Check for a loose ignition control module ground. Was a problem found? — Verify repair Go to Step 13
13 1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specifiedresistance.
Did the coil require replacement? 2.5kΩ Verify repair Go to Step 14
Step
Action Value(s) Yes No
Temperature (°C) Resistance (Ω) (Approximately)
-20 26740
0 9120
20 3500
40 1464
60 664
80 333
100 175
120 102

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ENGINE DRIVEABILITY AND EMISSIONS 6E–243
9 Check the fuel pressure. Refer to 6E-108 page“Fuel
System Diagnosis
”.
Was a problem found? — Verify repair Go to Step 10
10 Monitor “ B1S1 (Bank 1 Sensor 1) Status ” on the Tech
2.
Is the “ B1S1 (Bank 1 Sensor 1) Status ” in the rich
condition? — Verify repair Go to Step 11
11 Check items that can cause the engine to run rich. Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found? — Verify repair Go to Step 12
12 Check items that can cause the engine to run lean. Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found? — Verify repair Go to Step 13
13 Check for proper ignition voltage output with the spark tester.
Was a problem found? — Verify repair Go to Step 14
14 Check for a loose ignition control module ground. Was a problem found? — Verify repair Go to Step 15
15 Visually/physically inspect all spark plug high-tension cables. Check for the following conditions:
• Verify that the resistance of all spark plug high- tension cables are less than the specified value.
• Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting.
• Verify that the all spark plug high-tension cables are not arcing to ground.
Spraying the spark plug high-tension cables with a
light mist of water may help locate an intermittent
problem.
Was a problem found? #1 cyl. 4.4k
Ω
#2 cyl. 3.6k Ω
#3 cyl. 3.1k Ω
#4 cyl. 2.8k ΩVerify repair Go to Step 16
16 1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specifiedresistance.
Did the coil require replacement? 2.5kΩ Verify repair Go to Step 17
17 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs.
Was a problem found? — Verify repair Go to Step 18
18 1. Check the injector connectors. 2. If any of the connectors are connected at animproper cylinder, connect as necessary.
Was a problem found? — Verify repair Go to Step 19
19 Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams.
Was a problem found? — Verify repair Go to Step 20
20 Visually/physically check the vacuum hose for splits, kinks and proper connections and routing.
Was a problem found? — Verify repair Go to Step 21
Step
Action Value(s) Yes No

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6E–246 ENGINE DRIVEABILITY AND EMISSIONS
10 Monitor “B1S1 (Bank 1 Sensor 1) Status ” on the Tech
2.
Is the “ B1S1 (Bank 1 Sensor 1) Status ” in the rich
condition? — Go to Step 11Go to Step 12
11 Check items that can cause the engine to run rich. Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found? — Verify repair Go to Step 12
12 Check items that can cause the engine to run lean. Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found? — Verify repair Go to Step 13
13 Check for proper ignition voltage output with the spark tester.
Was a problem found? — Verify repair Go to Step 14
14 Check for a loose ignition control module ground. Was a problem found? — Verify repair Go to Step 15
15 Visually/physically inspect all spark plug high-tension cables. Check for the following conditions:
• Verify that the resistance of all spark plug high- tension cables are less than the specified value.
• Verify that the all spark plug high-tension cables are correctly fitted to eliminate cross-fitting.
• Verify that the all spark plug high-tension cables are not arcing to ground.
Spraying the spark plug high-tension cables with a
light mist of water may help locate an intermittent
problem.
Was a problem found? #1 cyl. 4.4k
Ω
#2 cyl. 3.6k Ω
#3 cyl. 3.1k Ω
#4 cyl. 2.8k ΩVerify repair Go to Step 16
16 1. Check the ignition coil secondary resistance. 2. Replace the coil if it is greater than the specifiedresistance.
Did the coil require replacement? 2.5kΩ Verify repair Go to Step 17
17 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs.
Was a problem found? — Verify repair Go to Step 18
18 Check the ECM grounds to verify that they are clean and tight. Refer to the ECM wiring diagrams.
Was a problem found? — Verify repair Go to Step 19
19 Visually/physically check the vacuum hose for splits, kinks and proper connections and routing.
Was a problem found? — Verify repair Go to Step 20
Step
Action Value(s) Yes No

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