check oil OPEL FRONTERA 1998 Workshop Manual

6E–5 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Conditions for Clearing the MIL/DTC 6E–159. . . . .
Diagnostic Aids 6E–159. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1562
(Flash DTC 35) System Voltage Too Low
at Cranking 6E–160. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–160. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–160. . . . . . .
Conditions for Clearing the MIL/DTC 6E–160. . . . .
Diagnostic Aids 6E–160. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1587
(Flash DTC 25) Brake SW Malfunction 6E–161. . . .
Circuit Description 6E–161. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–161. . . . . . .
Conditions for Clearing the MIL/DTC 6E–161. . . . .
Diagnostic Aids 6E–161. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1588
(Flash DTC 25) Brake SW Malfunction 6E–163. . . .
Circuit Description 6E–163. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–163. . . . . . .
Conditions for Clearing the MIL/DTC 6E–163. . . . .
Diagnostic Aids 6E–163. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0601
(Flash DTC 55) ECM Checksum Error 6E–165. . . . .
Action Taken When the DTC Sets 6E–165. . . . . . .
Conditions for Clearing the MIL/DTC 6E–165. . . . .
Diagnostic Aids 6E–165. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0650
(Flash DTC 77) Check Engine Lam Circuit
Open/Short 6E–166. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–166. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–166. . . . . . .
Conditions for Clearing the MIL/DTC 6E–166. . . . .
Diagnostic Aids 6E–166. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0654
(Flash DTC 27) Tachometer Circuit
Open/Short 6E–168. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–168. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–168. . . . . . .
Conditions for Clearing the MIL/DTC 6E–168. . . . .
Diagnostic Aids 6E–168. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1655
(Flash DTC 17) Thermo Relay Circuit
Open/Short 6E–170. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–170. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–170. . . . . . .
Conditions for Clearing the MIL/DTC 6E–170. . . . .
Diagnostic Aids 6E–170. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1657
(Flash DTC 76) ECM Main Relay Circuit
Open/Short 6E–172. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–172. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–172. . . . . . .
Conditions for Clearing the MIL/DTC 6E–172. . . . .
Diagnostic Aids 6E–172. . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code (DTC) P1589
(Flash DTC 47) Transmission SW Circuit
Open/Short 6E–174. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–174. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–174. . . . . . .
Conditions for Clearing the MIL/DTC 6E–174. . . . .
Diagnostic Aids 6E–174. . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 6E–176. . . . . . . . . . . . . . . . . . . . .
Default Matrix Table 6E–199. . . . . . . . . . . . . . . . . . . . .
On–Vehicle Service Camshaft Position
(CMP) Sensor 6E–201. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–201. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–201. . . . . . . . . . . . . . . . . .
Installation Procedure 6E–201. . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–202. . . . . . . . .
Removal Procedure 6E–202. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–202. . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–203.
Removal Procedure 6E–203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–203. . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E–203. . . . . . .
Removal Procedure 6E–203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–204. . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–204.
Removal Procedure 6E–204. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–205. . . . . . . . . . . . . . . . . .
Oil Temperature (OT) Sensor 6E–205. . . . . . . . . . . . .
Removal Procedure 6E–205. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–206. . . . . . . . . . . . . . . . . .
Malfunction Indicator Lamp (MIL) 6E–206. . . . . . . . . .
Removal and Installation Procedure 6E–206. . . . . .
Engine Control Module (ECM) 6E–206. . . . . . . . . . . .
Service Precaution 6E–206. . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge (ESD) Damage 6E–206. . .
Removal Procedure 6E–207. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–208. . . . . . . . . . . . . . . . . .
EEPROM 6E–208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E–208. . . . . . . . . . . . . . . . . . . .
Functional Check 6E–208. . . . . . . . . . . . . . . . . . . . . .
Intake Throttle Position (ITP) Sensor 6E–208. . . . . . .
Removal Procedure 6E–208. . . . . . . . . . . . . . . . . . . .
Function Check 6E–209. . . . . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–209. . . . . . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E–210. . . . . . . . . . . . .
Removal Procedure 6E–210. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–210. . . . . . . . . . . . . . . . . .
Installation Procedure 6E–210. . . . . . . . . . . . . . . . . .
Air Cleaner/Air Filter 6E–211. . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–211. . . . . . . . . . . . . . . . . .
Accel Position (AP) Sensor 6E–211. . . . . . . . . . . . . . .
Removal Procedure 6E–211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–212. . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement 6E–212. . . . . . . . . . .

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case

6E–25 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
General Service Information
Serviceability Issues
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Accordingly, if commercially sold sensor
or switch is installed, it makes a wrong diagnosis and turn
on the MIL (“Check Engine” lamp).
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the MIL (“Check
Engine” lamp).
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the MIL
(“Check Engine” lamp) to turn on if the vehicle is not
maintained properly. Restricted oil filters, fuel filters, and
crankcase deposits due to lack of oil changes or improper
oil viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle
fault”, but with the sensitivity of OBD diagnostics, vehicle
maintenance schedules must be more closely followed.
Related System Faults
Many of the OBD system diagnostics will not run if the
ECM detects a fault on a related system or component.
Visual/Physical Engine Compartment
Inspection
Perform a careful visual and physical engine
compartment inspection when performing any diagnostic
procedure or diagnosing the cause of an emission test
failure. This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual/physical inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Serial Data Communications
Class II Serial Data Communications
This vehicle utilizes the “Class II” communication system.
Each bit of information can have one of two lengths: longor short. This allows vehicle wiring to be reduced by
transmitting and receiving multiple signals over a single
wire. The messages carried on Class II data streams are
also prioritized. If two messages attempt to establish
communications on the data line at the same time, only
the message with higher priority will continue. The device
with the lower priority message must wait.
On this vehicle the Tech 2 displays the actual values for
vehicle parameters. It will not be necessary to perform
any conversions from coded values to actual values.
On-Board Diagnostic (OBD)
On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is
a pass or fail reported to the diagnostic executive. When
a diagnostic test reports a pass result, the diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The diagnostic test has passed during the current
ignition cycle.
The fault identified by the diagnostic test is not
currently active.
When a diagnostic test reports a fail result, the diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The fault identified by the diagnostic test is currently
active.
The fault has been active during this ignition cycle.
The operating conditions at the time of the failure.
Comprehensive Component Monitor
Diagnostic Operation
Comprehensive component monitoring diagnostics are
required to operate engine properly.
Input Components:
Input components are monitored for circuit continuity and
out-of-range values. This includes rationality checking.
Rationality checking refers to indicating a fault when the
signal from a sensor does not seem reasonable. Accel
Position (AP) sensor that indicates high throttle position
at low engine loads or MAP voltage. Input components
may include, but are not limited to the following sensors:
Intake Air Temperature (IAT) Sensor
Crankshaft Position (CKP) Sensor
Intake throttle Position (ITP) Sensor
Engine Coolant Temperature (ECT) Sensor
Camshaft Position (CMP) Sensor
Manifold absolute Pressure (MAP) Sensor
Accel Position Sensor
Fuel Temp Sensor
Rail Pressure Sensor
Oil Temp Sensor
EGR Pressure Sensor
Vehicle Speed Sensor

6E–26
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Output Components:
Output components are diagnosed for proper response to
control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are not
limited to, the following circuit:
EGR VSV
EGR EVRV
Electronic Transmission controls
Injector
Intake throttle
Glow plug
MIL control
Refer to ECM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors a
vehicle system or component. Conversely, an active test,
actually takes some sort of action when performing
diagnostic functions, often in response to a failed passive
test.
Intrusive Diagnostic Tests
This is any on-board test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
reach a minimum of 70
C (160F) and rise at least 22C
(40
F) over the course of a trip.
Freeze Frame
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle
information at the moment an emissions-related fault is
stored in memory and when the MIL is commanded on.
These data can help to identify the cause of a fault. Refer
to
Storing And Erasing Freeze Fame Data for more
detailed information.
Failure Records
Failure Records data is an enhancement of the OBD
Freeze Frame feature. Failure Records store the same
vehicle information as does Freeze Frame, but it will store
that information for any fault which is stored in on-board
memory, while Freeze Frame stores information only for
emission-related faults that command the MIL on.
Common OBD Terms
Diagnostic
When used as a noun, the word diagnostic refers to any
on-board test run by the vehicle’s Diagnostic
Management System. A diagnostic is simply a test run on
a system or component to determine if the system or
component is operating according to specification. There
are many diagnostics, shown in the following list:
EGR
engine speed
vehicle speed
ECT
MAP
VSV
IAT
ITP
AP
FT (Fuel Temp)
RP (Rail Pressure)
OT (Oil Temp)
EGR EVRV
Idle SW
Brake SW
The Diagnostic Executive
The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
Commanding the MIL (“Check Engine” lamp) on and
off
DTC logging and clearing
Freeze Frame data for the first emission related DTC
recorded
Current status information on each diagnostic
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process
of logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the
time of assembly and that there are not multiple faults
present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by
the diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction
is a system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (“Check Engine” lamp) is
illuminated.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with “Check Engine”
lamp.
Basically, the MIL is turned on when the ECM detects a
DTC that will impact the vehicle emissions.
When the MIL remains “ON” while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.
DTC Types
Characteristic of Code

6E–35 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Guid to the System
Fuel Injection system is an HEUI (Hydraulically
Actuated, Electronically Controlled, Unit, Injector)
type. In this type of injector system, the oil
pressurized by means of High Pressure Oil Pump
(16) is fed through Rail Pressure Control Valve (10)
and Oil Rail (7) to Injector (29) from which fuel is
injected under this oil pressure.
For diagnosis, therefore, the Rail Pressure as well as
the Electric Circuit must be inspected.
On-Board Diagnostic (OBD) System Check
A Group
060RW135

6E–39 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Control Module ECM
Diagnosis
To read and clear diagnostic trouble codes, use a Tech 2.
IMPORTANT:Use of a Tech 2 is recommended to clear
diagnostic trouble codes from the ECM memory.
Diagnostic trouble codes can also be cleared by turning
the ignition “OFF” and disconnecting the battery power
from the ECM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the ECM will cause
all diagnostic information in the ECM memory to be
cleared. Therefore, all the diagnostic tests will have to be
re-run.
Since the ECM can have a failure which may affect only
one circuit, following the diagnostic procedures in this
section will determine which circuit has a problem and
where it is.
If a diagnostic chart indicates that the ECM connections
or the ECM is the cause of a problem, and the ECM is
replaced, but this does not correct the problem, one of the
following may be the reason:
There is a problem with the ECM terminal
connections. The terminals may have to be removed
from the connector in order to check them properly.
The problem is intermittent. This means that the
problem is not present at the time the system is being
checked. In this case, refer to the
Symptoms portion
of the manual and make a careful physical inspection
of all components and wiring associated with the
affected system.
There is a shorted solenoid, relay coil, or harness.
Solenoids and relays are turned “ON” and “OFF” by
the ECM using internal electronic switches called
drivers. A shorted solenoid, relay coil, or harness will
not damage the ECM but will cause the solenoid or
relay to be inoperative.
Multiple ECM Information Sensor
DTCS Set
Circuit Description
The Engine Control Module ECM monitors various
sensors to determine the engine operating conditions.
The ECM controls fuel delivery, spark advance,
transmission operation, and emission control device
operation based on the sensor inputs.
The ECM provides a sensor ground to all of the sensors.
The ECM applies 5 volts through a pull-up resistor, and
determines the status of the following sensors by
monitoring the voltage present between the 5-volt supply
and the resistor:
The fuel temperature (FT) sensor
The engine coolant temperature (ECT) sensor
The Intake air temperature (IAT) sensor
The ECM provides the following sensors with a 5-volt
reference and a sensor ground signal:
The Intake throttle position sensor
The manifold absolute pressure sensor
The rail pressure sensor
The accelerator position sensor
The oil temperature sensor
The camshaft position sensor
The crankshaft position sensor
The EGR pressure sensor
The ECM monitors the signals from these sensors in
order to determine their operating status.
Diagnostic Aids
IMPORTANT:Be sure to inspect ECM and engine
grounds for being secure and clean.
A short to voltage in one of the sensor input circuits may
cause one or more of the following DTCs to be set:
P0337
P0342
P1193
P1404
P1405
P1488
IMPORTANT:If a sensor input circuit has been shorted
to voltage, ensure that the sensor is not damaged. A
damaged sensor will continue to indicate a high or low
voltage after the affected circuit has been repaired. If the
sensor has been damaged, replace it.
An open in the sensor ground circuit between the ECM
and the splice will cause one or more of the following
DTCs to be set:
P0337
P0342
P0117
A short to ground in the 5-volt reference A or B circuit will
cause one or more of the following DTCs to be set:
P0112
P0117
P0182
P0197
An open in the 5-volt reference circuit A, between the
ECM and the splice will cause one or more of the following
DTCs to be set:
P0107
P0405
P1194
P0122
An open in the 5-volt reference circuit B, between the
ECM and the splice will cause one or more of the following
DTCs to be set:
P1485
Check for the following conditions:
Poor connection at ECM. Inspect the harness
connectors for backed-out terminals, improper
mating, broken locks, improperly formed or damage
terminals, and a poor terminal-to-wire connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness is not damaged, observe an
affected sensor’s displayed value on the Tech 2 with
the ignition “ON” and the engine “OFF” while you
move the connectors and the wiring harnesses
related to the following sensors:
ECT Sensor

6E–40
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
MAP Sensor
CMP Sensor
CKP Sensor
EGR Pressure Sensor
EGR VSV
RPCV
IAT Sensor
Intake Throttle Motor
Fuel Temperature Sensor
Oil Temperature Sensor
Rail Pressure Sensor
Multiple ECM Information Sensor DTCs Set
StepActionVa l u e ( s )Ye sNo
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Turn the ignition “OFF,” disconnect the ECM.
2. Turn the ignition “ON,” check the 5 volt reference D
circuit for the following conditions:
D poor connection at the ECM.
An open between the ECM connector and the
splice.
D short to ground.
D short to voltage.
Is there an open or short?
—Go to Step 3Go to Step 4
3Repair the open or short.
Is the action complete?
—Verify repair—
4Check the sensor ground circuit for the following
conditions:
A poor connection at the ECM or the affected
sensors.
An open between the ECM connector and the
affected sensors.
Is there an open or a poor connection?
—Go to Step 5Go to Step 6
5Repair the open or the poor connection.
Is the action complete?
—Verify repairGo to Step 6
6Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—
Go to OBD
System
Check
—

6E–49 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
Circuit Description
In this type of injector system, the Engine Control Module
(ECM) triggers the correct driver inside the injector, which
then triggers the correct injector based on the 57X signal
received from the crankshaft position sensor (CKP).
During crank, the ECM monitors the CKP 57X signal. The
CKP signal is used to determine which cylinder will fire
first. After the CKP 57X signal has been processed by the
ECM, it will command all four injectors to allow a priming
shot of fuel for all the cylinders. After the priming, the
injectors are left “OFF” during the next four 57X reference
pulses from the CKP. This allows each cylinder a chance
to use the fuel from the priming shot. During this waiting
period, a camshaft position (CMP) signal pulse will have
been received by the ECM. The CMP signal allows the
ECM to operate the injectors sequentially based on
camshaft position. If the camshaft position signal is not
present at start-up, the ECM will begin sequential fuel
delivery with a 1-in-4 chance that fuel delivery is correct.
The engine will run without a CMP signal, but will set a
DTC code.
Diagnostic Aids
An intermittent problem may be caused by a poor
connection, rubbed-through wire insulation or a wirebroken inside the insulation. Check for the following
items:
Poor connection or damaged harness – Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wore connection, and
damaged harness.
Faulty engine coolant temperature sensor – Using a
Tech 2, compare engine coolant temperature with
manifold air temperature on a completely cool engine.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
4. An obvious cause of low fuel pressure would be an
empty fuel tank.
5. The engine will easily start and run if a few injectors
are disabled. It is not necessary to test all injectors
at this time since this step is only a test to verify that
all of the injectors have not been disabled by fuel
contamination.
8.If there is an open or shorted driver circuit, DTCs
0201-0204 should be set.
Engine Cranks But Will Not Run
StepActionVa l u e ( s )Ye sNo
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
2Check the 15 A injector fuse, the 15 A engine device
fuse, and the 15A ECM fuse.
Was a fuse blown?
—Go to Step 3Go to Step 4
3Check for a short to ground and replace the fuse.
Is the action complete?
—Verify repair—
4Is fuel tank empty?
—
Fill the fuel
tank
Go to Step 5
5Is the right fuel using?
—Go to Step 6
Replace the
fuel
6Is the right engine oil using?
—Go to Step 7
Replace the
engine oil
7Using the Tech–2.
Is DTC P0192 or P0193 set? (Check rail pressure
system)
—
Go to DTC
P0192 or
DTC P0193
Go to Step 8
8Using the Tech–2.
Is DTC P0201 – P0204 set? (Check inject circuit fault)
—
Go to DTC
P0201 –
P0204
Go to Step 9
9Using the Tech–2.
Is DTC P1657 set? (Check ECM Main relay)
—
Go to DTC
P1657
Go to Step 10

6E–53 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
System Check
StepActionVa l u e ( s )Ye sNo
1Move the valve up and down to check the slide
resistance.
Is the slide resistance large?
—Go to Step 8Go to Step 2
21. Set the transmission at “Park” or “Neutral”.
2. Put the engine in warming-up operation by idling.
(The engine temperature should be 80
C or more)
3. Disconnect the vacuum hose from the EGR valve.
4. Apply a vacuum of 250 mmHg to the EGR valve by
the vacuum pump (mighty pack).
Does the vibration due to engine operation become
larger?
—Go to Step 3Go to Step 9
31. Check if there is not any damage on the vacuum
hose from the vacuum pump to the EGR valve.
2. Install the vacuum pump (mighty pack) to the EGR
valve.
Does the vacuum became 250 mmHg or more at that
time?
250 mmHg or
more
Go to Step 4Go to Step 8
4Install the EGR valve and the vacuum hose formally
and increase the engine revolution speed to 3000 rpm.
Can both EGR valve 1 and EGR valve 2 be opened and
closed?
—
The system is
normal
Go to Step 5
5Measure the resistance of the VSV: EGR coil.
Is the resistance value in the range of 30
to 50 ?30 50 Go to Step 6Go to Step 10
6Measure the resistance of the EVRV: EGR coil.
Is the resistance value in the range of 10
to 13 ?10 13 Go to Step 7Go to Step 11
7Was the harness open or poor connection?—Go to Step 12Go to Step 13
8Replace the EGR valve ASM.
Is the action complete?
—Verify repair—
9Clean or replace the EGR valve ASM.
Is the action complete?
—Verify repair—
10Replace the EGR VSV.
Is the action complete?
—Verify repair—
11Replace the EGR EVSV.
Is the action complete?
—Verify repair—
12Repair the harness.
Is the action complete?
—Verify repair—
13Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repair—

6E–82
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0192 (Flash DTC 63)
Rail Pressure Sensor Low Voltage
060RW135
Circuit Description
The rail pressure (RP) sensor responds to changes in oil
manifold pressure.
The ECM monitors the RP signals for voltages outside the
normal range of the RP sensor. If the ECM detects a RP
signal voltage that is excessively low, DTC P0192 will be
set.
Action Taken When the DTC Sets
The ECM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
Conditions for Clearing the MIL/DTC
DTC P0192 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the ECM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
RP display on the Tech 2 while moving connectors and
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault.
If DTC P0192 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.
If it is determined that the DTC occurs intermittently,
performing the DTC P0192 Diagnostic Chart may isolate
the cause of the fault.