engine ISUZU KB P190 2007 Workshop Repair Manual

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-347
Repair Instructions
Engine Control Module (ECM)
Replacement
Description
The following A - G steps provide an overview
procedure to replace and reprogram an ECM. Each A -
G steps is explained further in this section.
A. Recoding Fuel Injector ID Code
Each fuel injector is designated with 24 hexadecimal
characters (0 - 9 or A - F) that MUST be programmed
into the ECM for correct engine fueling for each specific
cylinder. These characters can be retrieved in one of
following places:
Retrieving the Fuel Injector ID Code Data from the
ECM
The current fuel injector ID code data can be retrieved
with a scan tool. If the old ECM cannot be
communicated with a scan tool, go to the next
procedure.
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Injector ID Code.
4. Record 24 digits of each fuel injector ID code.
5. After complete the recording, turn OFF the scan tool.
6. Turn OFF the ignition.
Retrieving the Fuel Injector ID Code Data with a
Non-communicating ECM
If a scan tool does not communicate, the fuel injector ID
codes must be recorded from the factory affixed label
on the cylinder head cover or each fuel injector harness
connector housing. Recording from the label on cylinder head cover
Notice: Only perform this procedure if the fuel injectors
are not being replaced in the past.
1. Record all numbers of each cylinder on the label.
Legend 1. Cylinder #1 fuel injector ID code
2. Cylinder #2 fuel injector ID code
3. Cylinder #3 fuel injector ID code
4. Cylinder #4 fuel injector ID code
5. Injector ID code label

Recording from each fuel injector
1. Disconnect each fuel injector harness connector.
A. Record the fuel injector ID codes manually from the old ECM.
B. Reset the immobilizer security information in the old ECM. (If so equipped)
C. Replace the old ECM with the new ECM.
D. Program the immoblizer security information into the new ECM. (If so equipped)
E. Program the latest software and calibrations into the new ECM using the Service Programming System
(SPS).
F. Program the recorded fuel injector ID codes and the vehicle identification number (VIN) into the ECM using
a scan tool programming function.
G. Perform the fuel supply pump relearn procedure by allowing the engine to idle in Park or Neutral until
normal operating temperature is achieved.
RTW76ESH002501
1
2
3
4
5
4JJ1
5F
5F
5F
5F 05
F8
DE
DE 00
00
E6 F5 FB
F8
D2
DB 00
00
DC ED F7
E7
DE E8 08
02
00
02 F5
FC F4
F4 19
EC
CB
DE FF
ED
CA D1 04
EE E3
EA 49
B9
A1
B9
SAMPLE

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ISUZU KB P190 2007

6E-348 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
2. Record all numbers of each cylinder on theharness connector housing. The correct order for
the fuel injector ID codes of the following
illustration is as follows:
5F 05 00 FB 00 F7 08 F5 19 FF 04 49
Legend
1. Fuel injector ID code
2. Fuel injector

B. Resetting Immobilizer Security Information (If so
equipped)
Reset immobilizer security information in the old ECM.
Refer to Resetting and Programming Guidelines in
immobilizer section. If the old ECM cannot be
communicated with a scan tool, go to the next produce.
C. Removal and Installation
Removal Procedure 1. Disconnect the negative battery cable.
2. Loosen bolts (7) and remove the ECM cover (6). (If so equipped)
3. Disconnect the ECM harness connectors.
4. Loosen nuts (1) and remove the ECM with bracket (2) from the base bracket (3).
5. Loosen bolts (4) and remove the ECM (5). Installation Procedure
1. Install the ECM (5) to the bracket (2) and tighten bolts (4).
2. Install the ECM with bracket (2) to the base bracket (3) and tighten nuts (1).
3. Connect the ECM harness connectors.
4. Install the ECM cover (6) and tighten bolts (7).
5. Connect the negative battery cable.
D. Programming Immobilizer Security Information
(If so equipped)
Programming immobilizer security information into the
ECM. Refer to Resetting and Programming Guidelines
in immobilizer section.
E. Programming Software and Calibrations
Program latest software/ calibrations if released. Refer
to Service Programming System (SPS) Description and
SPS (Remote Procedure) or SPS (Pass-Thru
Procedure) in this section.
F. Programming Fuel Injector ID Codes and VIN 1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Program ECU.
RTW76ESH002601
5F 05 00
FB 00 F7
SAMPLE
08 F5 19
FF 0 4 49
2
1
RTW76EMH000301
5
1
2
3
4
6
7

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-349
4. In order to get programming approval, the on-screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the “Tech 2” on the Diagnostic Tool Selection screen and click “Next”.
f. Click “Close” on the Security Access Enabled screen.
g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Install a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Program ECU.
8. Verify the VIN on the screen if programmed at previously described SPS. If not programmed or
incorrect VIN, input correct VIN.
9. Input 24 digits of each fuel injector ID code.
10. After complete the programming, turn OFF the ignition for 30 seconds.
11. Start the engine and let idle.
12. Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.
G. Supply Pump Relearn 1. Install a scan tool.
2. Start the engine and let idle until engine coolant temperature reads 65 °C (149 °F) or higher while
observing the Supply Pump Status parameter with
a scan tool. The scan tool parameter changes
status Not Learn > Learning > Learned.
3. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.Service Programming System (SPS)
Description
The service programming system (SPS) allows a
technician to program a control module through the
data link connector (DLC). The information transfer
circuit that is used at the DLC is the same serial data
circuit used by the scan tool for retrieving DTCs,
displaying data, clearing DTCs etc. This procedure
offers the ability to install software/ calibrations
matched to a particular vehicle.
Most control modules have two types of memory. The
software/ calibrations reside in the flash memory. The
two types of memory are listed below:
• Electrically Erasable Programmable Read Only Memory (EEPROM)
This type of memory allows selected portions of
memory to be programmed while other portions
remain unchanged.
Certain learned values reside in the EEPROM,
such as:
- The vehicle identification number (VIN)
- The software/ calibrations identification numbers
- The control module security information
• Flash Read Only Memory-Flash Memory Flash memory has increased memory storage
capacity. During programming, all information
within this type of memory is erased, and then
replaced with entirely new information.
Service Programming Methods
The two methods of programming an ECM are listed
below:
• Remote Programming
• Pass Thru Programming
For information on programming an ECM using one of
the methods listed above, refer to Service
Programming System (SPS) (Remote Procedure) or
Service Programming System (SPS) (Pass-Thru
Procedure).
Before Programming a Control Module
Important: DO NOT program an existing ECM with the
identical software/ calibration package. This procedure is not
a short cut to correct the driveability condition. This is an
ineffective repair. An ECM should only be programmed when
the following occurs:
• When a service procedure instructs you to replace the ECM.
• An updated software/ calibrations is released.
Ensure that the following conditions are met before
programming an ECM:
• The scan tool PCMCIA card is programmed with the latest software.
• The TIS 2000 is installed with the latest software.

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6E-350 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
• The hardware key is plugged into the computerport.
• Vehicle system voltage: - There are no charging system concerns. Allcharging system concerns must be repaired
before programming the ECM.
- The battery voltage is greater than 12 volts but less than 16 volts. The battery must be fully
charged before programming the ECM.
- A battery charger is NOT connected to the vehicles battery. Incorrect system voltage or
voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
- Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF or
disable systems such as:
◊ Heating, ventilation, and air conditioning
(HVAC) systems
◊ Headlights
◊ Room lights
◊ Accessory equipment
• The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of
the ignition switch during the programming
procedure unless instructed to do so.
• All tool connections are secure: - The RS-232 cable
- The connection at the DLC
- The voltage supply circuits
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or
ECM damage may occur.
• If you are performing the Pass-Thru programming procedure using a notebook computer without the
power cord, ensure that the internal battery is fully
charged.
Service Programming System (SPS)
(Remote Procedure)
Notice: Some module will not accept SPS remote
procedure using 10MB PCMCIA card. In such case,
use 32MB PCMCIA card or SPS pass-thru procedure.
The Remote SPS method is a three-step process that
involves the following procedures:
1. Connecting the scan tool to the vehicle and obtaining the information from the ECM.
2. Connecting the scan tool to the terminal and downloading a new calibration file from the
terminal into the scan tool memory.
3. Reconnecting the scan tool to the vehicle and uploading the new calibration file into the ECM. Performing the Remote Procedure
1. Connect a scan tool to the vehicle and obtain the ECM information using the following procedure:
Notice: Ensure the ECM is installed in the vehicle and
the battery is fully charged before programming.
a. Install a scan tool.
b. Turn ON the ignition, with the engine OFF.
c. Select Service Programming System (SPS) > Request Info.
d. If there is already stored in the scan tool, the existing data is displayed on the screen. The
scan tool asks user to keep existing data "Keep
Data" or "Continue" to request new vehicle
information from the ECM. If there is no data in
the scan tool, it will immediately start vehicle
identification.
e. Select the vehicle description by following the on-screen instructions based on stamped VIN
or affixed VIN plate on the vehicle.
f. During obtaining information, the scan tool is receiving information from all modules at the
same time. But only ECM information is
displayed on the screen.
g. Turn OFF all accessories and press "Okay".
h. Verify that the correct VIN is displayed on the scan tool. If the VIN is incorrect or no VIN,
record the correct VIN.
2. Turn OFF the ignition.
3. Turn OFF the scan tool and disconnect from the vehicle.
4. Transfer the data from the terminal to the scan tool using the following procedure:
Notice: The TIS supports service programming with
the Tech 2 scan tool only.
a. Connect the scan tool to the terminal.
b. Launch the TIS application.
c. Select the Service Programming System at the main screen.
d. Highlight the following information on the Select Diagnostic Tool and Programming Process
screen, then click "Next".
• Select Diagnostic Tool - Tech 2
• Select Programming Process - Identify whether an existing ECM is being
reprogrammed or an ECM is being replaced
with a new one
• Select ECU Location - Vehicle
e. Verify the connections on the Preparing for Communication screen, then click "Next".
f. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen, then click
"Next".

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-351
Notice:If the ECM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the ECM from
another vehicle is installed, input correct VIN by same
way.
g. Highlight Engine on the Select System Typescreen, then click "Next", if on-screen
instruction displayed.
h. Complete the following information based on the service ID plate on the Validate Vehicle
Data screen until "Next" is highlighted, then
click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
i. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the ECM and reprogramming with the
same download is not allowed.
j. Click "Reprog".
k. The Transfer Data screen will appear until the progress bar reaches 100%.
5. Close the application and return to the TIS application selection screen after the download is
completed.
6. Turn OFF the scan tool and disconnect from the terminal.
7. Transfer the data from the scan tool to the ECM using the following procedure:
a. Install a scan tool.
b. Turn ON the ignition, with the engine OFF.
c. Select Service Programming System (SPS) > Program ECU.
d. Turn OFF all accessories and press "Continue".
e. Programming in Process will appear until the progress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the ECM since communication between
the ECM and other modules are interrupted. Clear DTC
in any module after programming.
f. Press "Continue" and exit the program after thescan tool displays "Programming Was
Successful".
8. Turn OFF the ignition.
9. Turn OFF the scan tool and disconnect from the vehicle.Service Programming System (SPS) (Pass-
Thru Procedure)
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughout
the programming process. The vehicle must be in close
proximity to the terminal while using Pass-Thru.
1. Launch the TIS application.
2. Select the Service Programming System at the main screen.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process screen,
then click "Next":
• Select Diagnostic Tool-Select Pass - Thru
• Select Programming Process - Identify whether as existing ECM is being reprogrammed or an
ECM is being replaced with a new one.
• Select ECU Location - Vehicle
4. Complete all vehicle data on the Preparing for Communication/ Determine Vehicle screen until
"Next" is highlighted, then click "Next".
5. Follow the instruction on the Preparing for Communication screen, then click "Next".
Notice: In order to reduce the potential for signal loss,
the RS-232 cable should not be more than 25 feet long.
6. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen, then click "Next".
Notice: If the ECM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the ECM from
another vehicle is installed, input correct VIN by same
way.
7. Highlight Engine on the Select System Type screen, then click "Next", if on-screen instruction
displayed.
8. Complete the following information based on the service ID plate on the Validate Vehicle Data
screen until "Next" is highlighted, then click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
9. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the ECM and reprogramming with the
same download is not allowed.
10. Click "Reprog".

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6E-352 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
11. The Transfer Data screen will appear until theprogress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the ECM since communication between
the ECM and other modules are interrupted. Clear DTC
in any module after programming.
12. Close the application and return to the TIS application selection screen after the download is
completed.
13. Turn OFF the ignition.
14. Turn OFF the scan tool and disconnect from the vehicle.

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-353
Description and Operation
Engine Control Module (ECM) Description
Engine Control Module (ECM) Service Precautions
Important:The symbol ! warns you of an electric shock
hazard. To avoid shock and possible serious injury, DO NOT
touch the terminals. When disconnecting the harness
connectors, always turn OFF the ignition switch or disconnect
the battery cable.
The engine control module (ECM) is designed to
withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. When testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a DMM. The ECM should remain connected to the
ECM harness.
The ECM is located inside of engine compartment via
mounting bracket and is behind air cleaner case. The
ECM mainly controls the following. • The fuel system control
• The exhaust gas recirculation (EGR) system control
• The preheating (glow) system control
• The A/C compressor control
• The immobilizer control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
diagnostic function of the system. The ECM can
recognize operational problems, alert the driver
through the malfunction indicator lamp (MIL), and store
diagnostic trouble codes (DTCs). DTCs identify the
system faults to aid the technician in making repairs.
RTW56ESH000201
RTW56ESH004401

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6E-354 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
ECM Input & Output
ECM Voltage Description
The ECM supplies a buffered voltage to various
switches and sensors. The ECM can do this because
resistance in the ECM is so high in value that a test
lamp may not illuminate when connected to the circuit.
An ordinary shop voltmeter may not give an accurate
reading because the voltmeter input impedance is too
low. Use a 10-megaohm input impedance DMM, to
ensure accurate voltage readings. The input and/ or
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special
drivers. The ECM controls most components with
electronic switches which complete a ground circuit
when turned ON. Aftermarket Electrical and Vacuum Equipment
Aftermarket or add-on electrical and vacuum
equipment is defined as any equipment which connects
to the vehicle's electrical or vacuum systems that is
installed on a vehicle after the vehicle leaves the
factory. No allowances have been made in the vehicle
design for this type of equipment. No add-on vacuum
equipment should be added to this vehicle. Add-on
electrical equipment must only be connected to the
vehicle's electrical system at the battery power and
ground. Add-on electrical equipment, even when
installed to these guidelines, may still cause the
powertrain system to malfunction. This may also
include equipment not connected to the vehicle
electrical system such as portable telephones and
audios. Therefore, the first step in diagnosing any
powertrain fault is to eliminate all aftermarket electrical
equipment from the vehicle. After this is done, if the
fault still exists, the fault may be diagnosed in the
normal manner.
RTW76EMF000501
Sensor inputs
· Intake air temperature (IAT) sensor
· Mass air flow (MAF) sensor
· Engine coolant temperature (ECT) sensor
· Fuel temperature (FT) sensor
· Barometric pressure (BARO) sensor
· Boost pressure sensor (High output engine)
· Accelerator pedal position (APP) sensor
· EGR position sensor
· Intake throttle position sensor
· Crankshaft position (CKP) sensor
· Camshaft position (CMP) sensor
· Fuel rail pressure (FRP) sensor
· Vehicle speed sensor (VSS)
Switch input
· Ignition switch (ON/start position)
· Clutch switch (M/T)
· Brake switch
· Neutral switch
· Cruise main switch
· Cruise cancel switch
· Cruise resume/ accel. switch
· Cruise set/ cast switch
· Fuel filter switch
· A/C switch
· Diagnostic request switch
Fuel injection control
· Fuel rail pressure (FRP) regulator
· Fuel injector #1
· Fuel injector #2
· Fuel injector #3
· Fuel injector #4
Relay control outputs
· Glow relay
· Fuel pump relay
· Starter cut relay
· A/C compressor relay
Lamp control
· Malfunction indicator lamp (MIL)
· Service vehicle soon (SVS) lamp
· Glow indicator lamp
· Fuel filter lamp
Communication
· Controller area network (CAN)
Actuator control
· Intake throttle solenoid
· EGR solenoid
· Swirl control solenoid
· Turbocharger nozzle control solenoid
(High output engine)ECM

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-355
Electrostatic Discharge Damage
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. By comparison, as much as
4,000 volts may be needed for a person to feel even
the zap of a static discharge. There are several ways
for a person to become statically charged. The most
common methods of charging are by friction and
induction.
• An example of charging by friction is a person sliding across a vehicle seat.
Important: To prevent possible electrostatic discharge
damage, follow these guidelines:
• Do not touch the ECM connector pins or soldered components on the ECM circuit board.
• Do not open the replacement part package until the part is ready to be installed.
• Before removing the part from the package, ground the package to a known good ground on
the vehicle.
• If the part has been handled while sliding across the seat, while sitting down from a standing
position, or while walking a distance, touch a
known good ground before installing the part.
• Charge by induction occurs when a person with well insulated shoes stands near a highly charged
object and momentarily touches ground. Charges
of the same polarity are drained off leaving the
person highly charged with opposite polarity.
Malfunction Indicator Lamp (MIL) Operation
The MIL is located in the instrument panel cluster. The
MIL will display the following symbols when
commanded ON: The MIL indicates that an emission related fault (Type
A or B) has occurred (Euro 4 specification) or engine
performance related fault has occurred (except Euro 4
specification) and vehicle service is required. The
following is a list of the modes of operation for the MIL:
• The MIL illuminates when the ignition switch is turned ON, with the engine OFF. This is a bulb test
to ensure the MIL is able to illuminate.
• The MIL turns OFF after the engine is started if a diagnostic fault is not present.
• The MIL remains illuminated after the engine is started if the ECM detects a fault. A DTC is stored
any time the ECM illuminates the MIL due to an
emission related fault (Euro 4 specification), and
engine performance related fault has occurred
(except Euro 4 specification).
Service Vehicle Soon (SVS) Lamp Operation (Euro
4 Specification)
The service vehicle soon (SVS) lamp is located in the
instrument panel cluster. The SVS lamp will display the
following symbol when commanded ON:
The SVS lamp indicates that a non-emission related
fault (Type C) has occurred and vehicle service
required. The following is a list of the modes of
operation for the SVS lamp:
• The SVS lamp illuminates when the ignition switch is turned ON, with the engine OFF. This is a bulb
test to ensure the SVS lamp is able to illuminate.
• The SVS lamp turns OFF after the engine is started if a diagnostic fault is not present.
• The SVS lamp remains illuminated after the engine is started if the ECM detects a fault. A DTC is
stored any time the ECM illuminates the SVS lamp
due to a non-emission related fault.
RTW76ESH001901
RTW76ESH002901

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6E-356 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Engine Control Component Description
Accelerator Pedal Position (APP) Sensor
Legend1. Accelerator pedal position (APP) sensor
2. Accelerator pedal bracket
3. Nut

The APP sensor is mounted on the accelerator pedal
control assembly. The sensor is made up of three
individual sensors within one housing. The ECM uses
the APP sensors to determine the amount of
acceleration or deceleration that is desired. The APP
sensors are potentiometer type sensors. Each APP
sensor provides a different signal to the ECM on the
each signal circuit, which relative to the position
changes of the accelerator pedal angle. The APP
sensor 1 signal voltage is low at rest and increases as
the pedal is depressed. The APP sensor 2 and APP
sensor 3 signal voltage is high at rest and decreases as
the pedal is depressed. Barometric Pressure (BARO) Sensor
The BARO sensor is located on the intake manifold.
The BARO sensor is a transducer that varies voltage
according to changes the barometric pressure. The
BARO sensor provides a signal to the ECM on the
signal circuit, which is relative to the pressure changes
of the barometric pressure. The ECM should detect a
low signal voltage at a low barometric pressure, such
as high altitude place. The ECM should detect high
signal voltage at a high barometric pressure. The ECM
uses this voltage signal to calibrate the fuel injection
quantity and injection timing for altitude compensation.
Boost Pressure Sensor
Legend 1. Boost pressure sensor

RTW56ESH000301
1
2
3
RTW76ESH002401
RTW76ESH003801
1

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