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ENGINE ELECTRICAL 6D – 1
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
General Description . . . . . . . . . . . . . . . . 6D–1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–3
Main Data and Specification . . . . . . . . . . 6D–4
Starting System . . . . . . . . . . . . . . . . . . . . . 6D–5
General Description . . . . . . . . . . . . . . . . 6D–5
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–7
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–8Charging System . . . . . . . . . . . . . . . . . . . . 6D–15
General Description . . . . . . . . . . . . . . . . 6D–15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–16
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–17
Main Data and Specification . . . . . . . . . . 6D–22
QOS4 Preheating System . . . . . . . . . . . . . . 6D–23
General Description . . . . . . . . . . . . . . . . 6D–23
System Diagram . . . . . . . . . . . . . . . . . . . 6D–23
Inspection of QOS4 System Operation . . 6D–24
BATTERY
GENERAL DESCRIPTION
DIAGNOSIS
There are six battery fluid caps at the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes permit
the escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self-
discharge than a conventional type battery.
1. VISUAL INSPECTION (Step 1)
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK (Step 2)
There is a built-in hydrometer (Charge test indicator) at
the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE – Go to
Step 3.3. FLUID LEVEL CHECK (Step 3)
The fluid level should be between the upper level line
and lower level line on side of the battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.
4. VOLTAGE CHECK (Step 4)
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure
(2) below.
(2) Determine fast charge amperage from
specification. (See Main Data and Specifications in
this section.)
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.

ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.

6E±1 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
4JX1±TC 3.0L ENGINE
DRIVEABILITY AND EMISSIONS
CONTENTS
Specification 6E±7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Specifications 6E±7. . . . . . . . . . . . . . .
Diagrams and Schematics 6E±8. . . . . . . . . . . . . . . .
ECM Wiring Diagram (1 of 6) 6E±8. . . . . . . . . . . .
ECM Wiring Diagram (2 of 6) 6E±9. . . . . . . . . . . .
ECM Wiring Diagram (3 of 6) 6E±10. . . . . . . . . . . .
ECM Wiring Diagram (4 of 6) 6E±11. . . . . . . . . . . .
ECM Wiring Diagram (5 of 6) 6E±12. . . . . . . . . . . .
ECM Wiring Diagram (6 of 6) 6E±13. . . . . . . . . . . .
ECM Pinouts 6E±14. . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32-Way Connector ± J1
RED ± Upper 6E±14. . . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32-Way Connector ± J1
RED ± Lower 6E±15. . . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32-Way Connector ± J2
BLUE ± Upper 6E±16. . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 32-Way Connector ± J2
BLUE ± Lower 6E±17. . . . . . . . . . . . . . . . . . . . . . . .
ECM Pinout Table, 5-Way Connector ± J3 6E±18
Component Locator 6E±19. . . . . . . . . . . . . . . . . . . . .
Sensors and Miscellaneous Component
Locators 6E±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations Charts 6E±23. . . . . . . . . . . . . . . . . . . .
Diagnosis 6E±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strategy-Based Diagnostics 6E±24. . . . . . . . . . . . .
Strategy-Based Diagnostics 6E±24. . . . . . . . . . . . .
DTC Stored 6E±24. . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC 6E±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Matching Symptom 6E±24. . . . . . . . . . . . . . . . .
Intermittents 6E±24. . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found 6E±24. . . . . . . . . . . . . . . . . . . . .
Verifying Vehicle Repair 6E±24. . . . . . . . . . . . . . . .
General Service Information 6E±25. . . . . . . . . . . . . .
Serviceability Issues 6E±25. . . . . . . . . . . . . . . . . . .
Visual/Physical Engine Compartment
Inspection 6E±25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge of Tools Required 6E±25. . . . . .
Serial Data Communications 6E±25. . . . . . . . . . . . . .
Class II Serial Data Communications 6E±25. . . . .
On-Board Diagnostic (OBD) 6E±25. . . . . . . . . . . . . .
On-Board Diagnostic Tests 6E±25. . . . . . . . . . . . .
Comprehensive Component Monitor
Diagnostic Operation 6E±25. . . . . . . . . . . . . . . . . .
Common OBD Terms 6E±26. . . . . . . . . . . . . . . . . .
The Diagnostic Executive 6E±26. . . . . . . . . . . . . . .
DTC Types 6E±26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying Vehicle Repair 6E±27. . . . . . . . . . . . . . . . Reading Flash Diagnostic Trouble Codes 6E±27.
Reading Diagnostic Trouble Codes Using
a TECH 2 6E±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tech 2 Scan Tool 6E±29. . . . . . . . . . . . . . . . . . . . . .
Getting Started 6E±30. . . . . . . . . . . . . . . . . . . . . . . .
DTC Modes 6E±32. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Information Mode 6E±32. . . . . . . . . . . . . . . . .
Injector Test 6E±32. . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Valve Test 6E±32. . . . . . . . . . . . . . . . . . . . . . .
Rail Pressure Control Valve Test 6E±32. . . . . . . . .
Injector Balance Test 6E±32. . . . . . . . . . . . . . . . . . .
Data Programming in Case of ECM Change 6E±32
Rail Pressure Sensor Programming 6E±33. . . . . .
Injector Group Sign Programming
(Injector Change) 6E±33. . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic (OBD) System Check 6E±35.
Circuit Description 6E±37. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E±37. . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module ECM Diagnosis 6E±39. . . .
Multiple ECM Information Sensor DTCS Set 6E±39
Circuit Description 6E±39. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E±39. . . . . . . . . . . . . . . . . . . . . . . .
EGR (Exhaust Gas Recirculation) Diagnosis 6E±41
Tech 2 Data Definitions and Ranges 6E±41. . . . . . .
Typical Scan Data Values 6E±41. . . . . . . . . . . . . . . .
Test Conditions 6E±41. . . . . . . . . . . . . . . . . . . . . . . .
4JX1-TC Engine (Automatic and Manual
Transmission) 6E±42. . . . . . . . . . . . . . . . . . . . . . . .
No Malfunction Indicator Lamp (MIL) 6E±44. . . . . . .
Circuit Description 6E±44. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E±44. . . . . . . . . . . . . . . . . . . . . . . .
Malfunction Indicator Lamp (MIL) ªONº
Steady 6E±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit description 6E±47. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E±47. . . . . . . . . . . . . . . . . . . . . . . .
Engine Cranks But Will Not Run 6E±49. . . . . . . . . . .
Circuit Description 6E±49. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E±49. . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation (EGR) System
Check 6E±52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E±52. . . . . . . . . . . . . . . . . . . . .
ECM Diagnostic Trouble Codes 6E±54. . . . . . . . . . .
ECM Diagnostic Trouble Codes 6E±54. . . . . . . . .
Diagnostic Trouble Code (DTC) P0107
(Flash DTC 34)
MAP Sensor Circuit Low Voltage 6E±56. . . . . . . . . .

6E±16
4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
ECM Pinout Table, 32-Way Connector ± J2 BLUE ± Upper
060RW138
J2 ± BLUE
PINSIGNAL
1INJECTOR A RTN
2INJECTOR B RTN
3INJECTOR C RTN
4INJECTOR D RTN
5CLASS 2
6SDATA
7RAIL OIL PRESSURE
8IDLE SW
9IGN SW
10BATTERY
11QUICK WARM REQ. SW
12PARTIAL IDLE SW
13CERAMIC HTR REQUEST SW
14INTAKE SW S2B
15INTAKE SW S1T
16INTAKE SW S1B

6E±17 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
ECM Pinout Table, 32-Way Connector ± J2 BLUE ± Lower
060RW137
J2 ± BLUE
PINSIGNAL
17COOLANT TEMP OUT
18OIL TEMPERATURE
19TDC/CAM
20SPARE ANALOG 2
21INTAKE AIR TEMPERATURE
22+5VRTN2
23BOOST/INLET PRESSURE
24+5VRTN3
25ACCELERATOR POSITION
26+5VRTN1
27EGR VACUUM PRESSURE
28INTAKE SM S2T
29DIAGNOSTIC REQUEST SW
30COOLANT TEMPERATURE
31A/T PARK SW
32CRANKSHAFT

6E±23 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
Abbreviations Charts
List of abbreviations which may be used in this section.
Abbreviations
TermAbbreviationsTerm
A/CAir ConditionerBLKBlack
A/TAutomatic TransmissionBLUBlue
ACCAccessoryBRNBrown
APAccel PositionGRNGreen
ASMAssemblyGRYGray
CKPCrank PositionLT BLULight Blue
CMPCam PositionLT GRNLight Green
DLCData Link ConnectorORNOrange
DTCDiagnosis Trouble CodePNKPink
DVMDigital Volt MeterREDRed
ECMEngine Control ModuleVIOViolet
ECTEngine Coolant TemperatureWHTWhite
EGRExhaust Gas RecircurationYELYellow
EVRVElectric Vacuum Regulating Valve
EXHExhaust
FTFuel Temperature
IATIntake Air Temperature
IGIgnition
ITPIntake Throttle Position
M/TManual Transmission
MAPManifold Absolute Pressure
MILMulfunction Indicator Lamp
OBDOn-Board Diagnostic
OTOil Temperature
QOSQuick on Start System
QWSQuick Warming-Up System
RPRail Pressure
RPCVRail Pressure Control Valve
SRSSupplemental Restraint System
STStart
SWSwitch
TEMPTemperature
TODTorque on Demand
VSSVehicle Speed Sensor
VSVVacuum Switching Valve
HEUIHydraulically Actuated Electronically Controlled Unit
InjectorInjector

6E±57 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
DTC P0107 ± MAP Sensor Circuit Low Voltage

StepActionValue(s)Ye sNo
1Was the ªOn-Board Diagnostic (OBD) System Checkº
performed?
ÐGo to Step 2
Go to OBD
System
Check
2Put the engine into an idling status.
Is the MAP voltage value displayed on the Tech 2 below
the specified value?
0.25 VGo to Step 3
Refer to
Diagnostic
Aids
and
Symptom
Diagnosis
31. Turn off the ignition switch.
2. Remove the sensor connector connection.
3. Jumper between harness pins ªredº and ªblueº
wires.
4. Turn on the ignition switch ªONº.
Is the MAP voltage reading above the specified value?
4 VGo to Step 5Go to Step 4
41. Turn off the ignition switch.
2. Remove the jumper wire.
3. Connect the relay & solenoid checker
(5-8840-0386-0) to the battery voltage, then check
the MAP signal circuit (blue wire).
4. Turn on the ignition switch.
Is the value displayed on the Tech 2 above the specified
value?
4 VGo to Step 6Go to Step 7
5Check the terminal connection at the MAP sensor and
repair or replace terminal if necessary.
Is the action complete?
ÐVerify repairÐ
6Repair the 5V power circuit (red) harness or Replace
the ECM (Refer to the Data Programming in Case of
ECM change).
Is the action complete?
ÐVerify repairÐ
7Repair the signal circuit (blue) harness or Replace the
ECM (Refer to the Data Programming in Case of ECM
change).
Is the action complete?
ÐVerify repairÐ

6E±135 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
DTC P0405 ± EGR Pressure Sensor Low Voltage

 
StepNo Ye s Value(s) Action
31. Turn off the ignition switch.
2. Remove the sensor connector connection.
3. Jumper between harness pins ªredº and ªblueº
wires.
4. Turn on the ignition switch ªONº.
Is the EGR pressure sensor voltage reading above the
specified value?
4 VGo to Step 5Go to Step 4
41. Turn off the ignition switch.
2. Remove the jumper wire.
3. Connect the relay & solenoid checker
(5-8840-0386-0) to the battery voltage, then check
the EGR pressure sensor signal circuit (blue wire).
4. Turn on the ignition switch.
Is the value displayed on the Tech 2 above the specified
value?
4 VGo to Step 6Go to Step 7
5Check the terminal connection at the EGR pressure
sensor and repair or replace terminal if necessary.
Is the action complete?
ÐVerify repairÐ
6Repair the 5V power circuit (red) harness or Replace
the ECM (Refer to the Data Programming in Case of
ECM change).
Is the action complete?
ÐVerify repairÐ
7Repair the signal circuit (blue) harness or Replace the
ECM (Refer to the Data Programming in Case of ECM
change).
Is the action complete?
ÐVerify repairÐ