Intake Air Distribution and Filtering - Throt
tle Body Elbow4.0L NA V8 -
AJ27/3.2L NA V8 - AJ26
Re
moval and Installation
Remov
al
S
pecial Tool(s)
Re
lease tool - quick fit
310-044 (JD 182)
R
elease tool 5 /16 - quick fit
310-054 (JD 203)
1. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT
THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND
UNDERSTOOD.
Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. D
epressurize fuel sy
stem; refer to 19.50.02
3. Remove air cleaner cover / intake assembly; refer to 19.10.30.
4. Remove throttle body; refer to 19.70.04.
5. R
elease intake elbow from right-hand support bracket.
Re
lease brake servo vacuum pi
pe and disconnect pipe.
1. Disconnect vacuum pipe.
2. Remove bolt.
6. Release intake elbow from le ft-hand support bracket.
1. Disconnect vacuum pipe.
2. Disconnect engine breather T-piece.
3. Remove bolt.
4. Loosen, but do not remove two bolts.
The ru nning loss
system has the following features :
a
normall
y open pressure control valve is fi
tted at the lefthand side of the tank.
two charcoal
canisters are connected in series to reduce th
e concentration of fuel in vapour vented to atmosphere.
a t
ank pressure sensor and canister close
valve are fitted to allow the on-board di agnostic facility to test for leaks in
the fuel and evaporative system.
The pressure control valve allows continuo us venting of vapour to the charcoal canisters during normal running but prevents
fuel entering the vent line duri ng refueling. Fuel vapour from the tank passes through the valve to the lefthand canister and
a third pipe connects the valve to the fill er neck. When refueling, the difference in pressure betw een the tank interior and
the open filler neck causes the valve to cl ose, shutting off the vapour vent line. Wh en the fuel cap is replaced, the pressures
are equalised and the pressure control valve opens the vent line to the canisters.
The canister close valve is a solenoid operated device controlled by the ECM. The valve is normally open and is closed only
during the leak test sequence.
The fuel pressure sensor is fitted to th e evaporative loss flange and provides a volt age to the ECM which is proportional to
Ite
m
Par
t
Number
De
scr
iption
1—Vapour outl
et rol
lover valve
2—Evaporative flan
ge assembly
3—Tank vapour outlet pipe
4—Breather pipe
5—Pressure control
valve
6—Vapour pipe to canister
7—Charcoal cani
sters
8—Cani
st
er close valve
9—Vent pi
pe ai
r filter
10—Canister purge ou
tlet pipe
11—Vapour pipe conn
ecting canisters
12—EVAP canister purge v
a
lve
13—Vacuu
m
control signal from induction elbow
14—EVAP pu
rge valve outlet to induction elbow
Running Loss Sys
tem
The system has the
following features :
o
n
-board refueling vapour recovery (ORVR) to reduce the fu
el vapour vented directly to atmosphere from the filler
nozzle when refueling.
two ch arcoal
canisters are connected in series to reduce th
e concentration of fuel in vapour vented to atmosphere.
a t
ank pressure sensor and canister close
valve are fitted to allow the on-board di agnostic facility to test for leaks in
the fuel and evaporative system.
The canister close valve is a solenoid operated device controlled by the ECM. The valve is normally open and is closed only
during the leak test sequence.
The fuel pressure sensor is fitted to th e evaporative loss flange and provides a volt age to the ECM which is proportional to
tank vapour pressure.
Op era
tion of ORVR System
The ORVR system enabl
e
s fuel vapour generated during re-fueling to be collected by
the charcoal canisters. During normal
running of the vehicle, the vapour is collected and purged in the same way as for non-ORVR systems.
Ite
m
Par
t
Number
De
scr
iption
1—Grade vent
valve outl
et
2—Vapour outl
et from fil
l level vent valve (FLVV)
3—F
L
VV pressure relief valve outlet pipe
4—N
a
rrow diameter fuel filler tube
5—Charcoal can
i
sters
6—Cani
st
er close valve
7—Vent pi
pe ai
r filter
8—Vapour pipe
conn
ecting canisters
9—Canister purge ou
tlet pipe
10—EVAP canister purge v a
lve (engine bay)
11—Vacuu
m
control signal from induction elbow
12—EVAP pu
rge valve outlet to induction elbow
Running Loss with On-board R
efuelin
g Vapour Recovery (ORVR) System
Exhaus
t leak
Low e
xhaust temperature
Cat
alyst monitor sensor failure
P0151Le
ft-hand H02S sense circuit low
voltage
H02
S disconnected
H0
2S to ECM wiring open circuit
H0
2S short circuit to ground
H0
2S failure
F
or left-hand HO2S circuit tests, GO
to Pinpoint Test H.
.
P0152Le
ft-hand H02S sense circuit high
voltage
H02
S sensing circuit short circuit to
high voltage
H0
2S ground braided shield open
circuit
H0
2S failure
F
or left-hand HO2S circuit tests,GO to
Pinpoint Test H.
.
P0153Le
ft-hand H02S sense circuit slow
response
Engine
misfire
H02
S disconnected
H0
2S mechanical damage
H0
2S to ECM wiring intermittent
open circuit
H02
S sensing circuit short circuit to
high voltage
H0
2S short circuit to ground
H0
2S ground braided shield open
circuit
H0
2S heater circuit fault
Exhaus
t leak
Low e
xhaust temperature
Injector fl
ow partially blocked
Catal
yst efficiency decrease
H0
2S failure
Chec
k for 'engine misfire detected'
DTCs. For HO2S circ uit tests, GO to
Pinpoint Test H.
. Check for exhaust
leak
s,
REFER to Section 309
-00
Exhaust
Sy
stem
.
Chec
k injectors,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
P0155Left-hand H02S heater
circuit
malfunction
H02
S disconnected
H0
2S heater power supply open
circuit
H0
2S heater to ECM wiring short
circuit or open circuit
H0
2S heater failure
F
or left-hand HO2S heater circuit
tests,GO to Pinpoint Test I.
.
P0157Le
ft-hand catalyst monitor sensor
sense circuit low voltage
Catal
yst monitor sensor
disconnected
Catal
yst monitor sensor to ECM
wiring open circuit
Catal
yst monitor sensor short
circuit to ground
Cat
alyst monitor sensor failure
F
or left-hand catalyst monitor sensor
circuit tests,GO to Pinpoint Test J.
.
P0158Le
ft-hand catalyst monitor sensor
sense circuit high voltage
Catal
yst monitor sensor sensing
circuit short circuit to high voltage
Catalyst
monitor sensor ground
braided shield open circuit
Cat
alyst monitor sensor failure
F
or left-hand catalyst monitor sensor
circuit tests,GO to Pinpoint Test J.
.
P0160Le
ft-hand catalyst monitor sensor
sense circuit no activity
Catal
yst monitor sensor
disconnected
Catal
yst monitor sensor
mechanical damage
Catal
yst monitor sensor to ECM
wiring open circuit
Catal
yst monitor sensor sensing
circuit short circuit to high voltage
Catal
yst monitor sensor short
circuit to ground
Catalyst
monitor sensor ground
braided shield open circuit
Exhaus
t leak
Low e
xhaust temperature
Cat
alyst monitor sensor failure
F
or left-hand catalyst monitor sensor
circuit tests,GO to Pinpoint Test J.
.
Check f
or exhaust leaks,
REFER to Section 309
-00
Exhaust
Sy
stem
.
P0171Right
-hand cylinders combustion
too lean
Air
intake leak between MAF senso
r and th
rottle
F
uel filter system blockage
F
uel injector blockage
F
uel pressure regulator failure (low
fuel pressure)
Low f
uel pump output
Check ai
r intake system for leaks,
REFER to Section 303
-1
2 Intake Air
Distribu
tion and Filtering
.
Check the fuel fi
lter,
REFER to Section 310
-01
Fuel Tank
and Lines.
Chec
k the fuel injectors and fuel
H02S harness wiri
ng fault
E
x
haust leak (before catalyst)
ECM receivi
n
g incorrect signal from
one or more of the following
sensors - ECT, MAF, IAT, TP
pr essure regulator,
REF
ER to Section 303
-04
Fu
el
Charging and Con
t
rols
.
Chec k the
fuel pressure. Check the
exhaust system for leaks,
REFER to Section 309
-00 Ex
haust
Sy
ste
m
.
R e
fer to pinpoint tests for sensors
listed.
P0172Right -
hand cylinders combustion
too rich
Engine m
isfire
Bl
ocked air
filter
F
u
el system return blockage
Leak
i
ng fuel injector(s)
F
u
el pressure regulator failure
(high fuel pressure)
ECM receivi n
g incorrect signal from
one or more of the following
sensors - ECT, MAF, IAT, TP
Chec k for 'en
gine misfire detected'
DTCs. Check the air filter element,
REFER to Section 303
-1 2
Intake Air
Distribu
tion and Filterin
g
.
Chec k the
fuel lines,
REFER to Section 310
-01 Fu
el Tank
and Lines.
Chec k the
fuel injectors and fuel
pressure regulator,
REFER to Section 303
-04 Fu
el
Charging and Con
t
rols
.
R e
fer to pinpoint tests for sensors
listed.
P0174L e
ft-hand cylinders combustion
too lean
Air in
take leak between MAF senso
r and th
ro
ttle
F
u
el filter system blockage
F
u
el injector blockage
F
u
el pressure regulator failure (low
fuel pressure)
Low fu
el pump output
H0
2S harness wiri
ng fault
E
x
haust leak (before catalyst)
ECM receivi
n
g incorrect signal from
one or more of the following
sensors - ECT, MAF, IAT, TP
Check the ai r intak
e system for leaks,
REFER to Section 303
-1 2
Intake Air
Distribu
tion and Filterin
g
.
Check the fuel fi lter,
REF
ER to Section 310
-01
Fu
el Tank
and Lines.
Chec k the
fuel injectors and fuel
pressure regulator,
REFER to Section 303
-04 Fu
el
Charging and Con
t
rols
.
Chec k the
fuel pressure. For HO2S
circuit tests,GO to Pinpoint Test H.
,
a n
dGO to Pinpoint Test
I.
. Check
the
exhaust system for leaks,
REFER to Section 309
-00 Ex
haust
Sy
ste
m
.
R e
fer to pinpoint tests for sensors
listed.
P0175L e
ft-hand cylinders combustion
too rich
Engine m
isfire
Bl
ocked air
filter
F
u
el system return blockage
Leak
i
ng fuel injector(s)
F
u
el pressure regulator failure
(high fuel pressure)
ECM receivi n
g incorrect signal from
one or more of the following
sensors - ECT, MAF, IAT, TP
Chec k for 'en
gine misfire detected'
DTCs. Check air filter element,
REFER to Section 303
-1 2
Intake Air
Distribu
tion and Filterin
g
.
Chec k the
fuel lines,
REFER to Section 310
-01 Fu
el Tank
and Lines.
Chec k the
fuel injectors and fuel
pressure regulator,
REFER to Section 303
-04 Fu
el
Charging and Cont
rols
.
Re
fer to pinpoint tests for sensors
listed.
P0201 Fu
el injector circuit malfunction,
cyl 1
Injector discon n
ected
Inject
or wir
ing open or short circuit
Injector fail
ure
F
o
r fuel injector
circuit tests,
REFER to Section 303
-04 Fu
el
Charging and Con
t
rols
. P0202F
u
el injector circuit malfunction,
cyl 3
P0203F u
el injector circuit malfunction,
cyl 5
P0204F u
el injector circuit malfunction,
cyl 7
P0205F u
el injector circuit malfunction,
cyl 2
P0206F u
el injector circuit malfunction,
cyl 4
P0207F u
el injector circuit malfunction,
cyl 6
P0208F u
el injector circuit malfunction,
leak
/blockage
EVAP valve failure
P0444Evaporati
ve emissions system
(EVAP) valve circuit open circuit
EVAP t
o ECM drive circuit open
circuit or high resistance
EVAP failu
re
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0445Evaporati
ve emissions system
(EVAP) valve circuit short circuit
E
VAP to ECM drive circuit short
circuit to ground
EVAP failu
re
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0447Cani
ster close valve (CCV) circuit
open circuit
CCV to ECM
drive circuit open
circuit, high resi stance or short
circuit to ground
EVAP failu
re
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0448Cani
ster close valve (CCV) circuit
short circuit
CCV to
ECM drive circuit short
circuit to high voltage
CCV failure
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0452F
uel tank pressure (FTP) sensor
circuit low voltage
FTP
sensor disconnected
FTP
sensor to ECM sense circuit
open circuit or short circuit to
ground
FTP sen
sor to ECM power supply
circuit open circuit or short circuit
to ground
F
TP sensor failure
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0453F
uel tank pressure (FTP) sensor
circuit high voltage
FTP
sensor to ECM signal ground
circuit open circuit
F
TP sensor to ECM wiring (supply,
sense, signal, ground) short circuit
to each other
FTP
sensor to ECM sense circuit
short circuit to high voltage
F
TP sensor failure
F
or evaporative emissions pinpoint
tests,
REFER to Section 303
-1
3 Evaporative
Emiss
ions
.
P0460Fue
l level sense signal
performance
Fue
l level sensor
to instrument
cluster circuits in termittent short or
open circuit
F
uel level sensor failure
Instrument cluster
faul
t (incorrect
fuel level data)
F
or fuel level sensor
circuit tests,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
P0506Idl
e rpm lower than expected
Ai
r intake blockage
Acce
ssory drive overload
(defective/siezed component)
Thr
ottle valve stuck closed
Throttl
e assembly failure
Chec
k the air intake system.
REFER to Section 303
-1
2 Intake Air
Distribu
tion and Filtering
.
Check t
he accessory drive
components,
REFER to Section 303
-0
5 Accessory
Dr
ive
.
F
or throttle body information,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
P0507Idle rpm
higher than expected
Inta
ke air leak between MAF
sensor and throttle
Inta
ke air leak between throttle
and engine
Engine
breather leak
Cruis
e (speed) control vacuum
failure
Thr
ottle valve stuck open
Throttl
e assembly failure
Chec
k the air intake system.
REFER to Section 303
-1
2 Intake Air
Distribu
tion and Filtering
.
Chec
k the engine breather system,
REFER to Section 303
-08
Engine
Emissi
on Control
.
F
or cruise (speed) control information,
REFER to Section 310
-03
Speed
Control.
F
or throttle body information,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
P0560Vehicle voltage
malfunction
ECM battery
power supply open
circuit, high resistance
F
or ECM power supply circuit tests,
GO to Pinpoint Test AD.
.
P0566Cruise (speed) contr
ol
CANCEL
switch ON fault
Cru
ise (speed) control switches
internal steering wheel short circuit
to ground
For cru
ise (speed) control circuit tests,
REFER to Section 310
-03
Speed
op
en circuit
ECM ground circuit faul
t (relay coil
drive)
P1235Vacuu m
switching valve (VSV) 1
circuit range/ performance
(mechanical guard position)
Vac u
um leak/blockage between the
throttle elbow and the throttle
vacuum actuator
Vacuu m
actuator failure
Mechanica
l
guard actuator
seized/spring broken
Carr y out mechanical checks
for
vacuum leak/blockag e, failed vacuum
actuator, and broken /siezed actuator
spring.
P1236Vacuu m
switching valve (VSV) 1
(vacuum) circuit failure
VSV 1 disconne cted
VSV 1 to ECM drive circu
i
t high
resistance, open circuit or short
circuit
VSV 1 powe r supply open
circuit
VSV 1 failu
r
e
For VSV tests,
REF
ER to Section 310
-03
Sp
eed
Control.
P1237Vacuu
m
switching valve (VSV) 2
(atmosphere) circuit failure
VSV 2 disconne cted
VSV 2 to ECM drive circu
i
t high
resistance, open circuit or short
circuit
VSV 2 power supply open
circuit
VSV 2 failu
r
e
For VSV tests,
REF
ER to Section 310
-03
Sp
eed
Control.
P1238Vacuu
m
switching valve (VSV) 3
(release) circuit failure
VSV 3 disconne cted
VSV 3 to ECM drive circu
i
t high
resistance, open circuit or short
circuit
VSV 3 powe r supply open
circuit
VSV 3 failu
r
e
For VSV tests,
REF
ER to Section 310
-03
Sp
eed
Control.
P1240Sensor r
e
fere
nce voltage
malfunction (throttle sensors, fuel
tank pressure se nsor) (ECM pins
EM10-21; EM11-8)
ECM t o
sensors reference voltage
short circuit to ground, short circuit
to high voltage, op en circuit, high
resistance
TP sensor , pedal position and
mechan
ical guard sensor(s), fuel
tank pressure sens or failure(s)
Fo
r sensor reference voltage circuit
tests,GO to Pinpoint Test V.
.
P1241Sensor re
ferenc
e voltage low
(throttle sensors, fuel tank
pressure sensor) (ECM pins EM10-
21; EM11-8)
ECM t o
sensors reference voltage
short circuit to ground
TP sensor , APP
and mechanical
guard sensor(s), fuel tank pressure
sensor failure(s)
F o
r sensor reference voltage circuit
tests,GO to Pinpoint Test V.
.
P1242Sensor re
ferenc
e voltage high
(throttle sensors, fuel tank
pressure sensor) (ECM pins EM10-
21; EM11-8)
ECM t o
sensors reference voltage
circuit open circuit, high resistance,
short circuit to high voltage
TP sensor , APP
and mechanical
guard sensor(s), fuel tank pressure
sensor failure(s)
F o
r sensor reference voltage circuit
tests,GO to Pinpoint Test V.
.
P1243Sensor re
ference ground
malfunction (throttle sensors, fuel
tank pressure sensor, ECT sensor,
IAT sensor, IAT sensor 2) (ECM
pins EM10-20; EM11-12)
ECM t o
sensors reference ground
circuit open circuit, high resistance
Throttle sensors, fuel
tank pressure
sensor, ECT sensor, IAT sensor,
IAT sensor 2 failures
F o
r sensor reference ground circuit
tests,GO to Pinpoint Test W.
.
P1245Engine crank signal low voltage Starter relay coi
l to ECM/BPM
circuit open circuit
For en gin
e crank circuit tests,GO to
Pinpoint Test X.
.
P1246Engine crank signal high voltage Starter relay coi
l to ECM/BPM
circuit short circuit to B+ voltage
B P
M failure
For en
gin
e crank circuit tests,GO to
Pinpoint Test X.
.
P1250Engine load
malfunction
Air in
take leak
Engine breath
er leak
TP sens
or circuit fault (DTC P0121)
Throttle
valve spring failure
Check air i
ntake system for leaks,
REFER to Section 303
-12
Intake Air
Distribution and Filterin
g
.
Check engi
ne breather system for
leaks,
REFER to Section 303
-08 En
gine
Emissi
on Control.
Se e
pinpoint test for P0121. For
throttle body information,
REFER to Section 303
-04 Fu
el
Charging and Con
t
rols
.
P1251Thr
o
ttle position malfunction
(engine off)
TP sensor to ECM wiri
ng open
circuit or high resistance
F o
r TP sensor circ
uit tests,GO to
Pinpoint Test D.
, andGO to Pinpoint
Pinpoint Tests
f
ailure
P1611Thr
ottle angle malfunction
TP sensor
circuit fault (refer to
P0121)
APP sensor circuit faul
t (refer to
P0121)
Throttl
e assembly failure
ECM failu
re
Se
e pinpoint tests for components
listed. For throttle body information,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
Contact deal
er technical support for
advice on possible ECM failure.
P1612Throttl
e offset malfunction
TP sensor
circuit fault (refer to
P0121)
APP sensor circuit faul
t (refer to
P0121)
Throttl
e assembly failure
ECM failu
re
Se
e pinpoint tests for components
listed. For throttle body information,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
Contact deal
er technical support for
advice on possible ECM failure.
P1637CAN AB
S/TCCM token missing
CAN
open circuit fault - ABS/TCCM
to ECM
CAN s
hort circuit fault
ABS/TCCM failu
re
ECM failu
re
F
or network circuit tests,
REFER to Section 418
-00
Module
Comm
unications Network
.
P1638CAN INST token missingCAN
open circuit fault - INST to
ECM
CAN s
hort circuit fault
INST
failure
ECM failu
re
F
or network circuit tests,
REFER to Section 418
-00
Module
Comm
unications Network
.
P1642CAN c
ircuit malfunction
CAN s
hort circuit fault
Control modul
e failure - check for
additional logged DTCs to locate
control module source
F
or network circuit tests,
REFER to Section 418
-00
Module
Comm
unications Network
.
P1643CAN TC
M token missing
CAN
open circuit fault - TCM to
ECM
CAN s
hort circuit fault
TCM failure
ECM failu
re
F
or network circuit tests,
REFER to Section 418
-00
Module
Comm
unications Network
.
P1646F
uel pump 2 relay malfunction.
NOTE: This DTC applies only to
the S/C fuel pump 2
F
uel pump 2 relay failure
F
uel pump 2 relay to ECM circuit
fault
F
uel pump 2 relay coil power
supply open circuit
ECM ground circuit faul
t (relay coil
drive)
F
or fuel pump 2 relay circuit tests,
REFER to Section 303
-04
Fuel
Charging and Con
trols
.
P
INPOINT TEST A : DTC P0101, P0102, P0103; MASS AIR FLOW (MAF) SENSOR
RANGE/PERFORMANCE, HIGH/LOW VOLTAGE
•
NOTE: Before commencing this
test, check the air filter for blockage, the engine air inta ke and breather systems for
leaks, and the TPS for additional DTCs.
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
A1: CHECK
THE MAF SENSOR SENS
E CIRCUIT FOR HIGH RESISTANCE
Di
sconnect the battery negative terminal.
1
D
isconnect the ECM electrical connector, EM12.
2
Di
sconnect the MAF sensor electrical connector, PI35.
3
Meas
ure the resistance between EM12, pin 13 (GY) and PI35, pin 02 (GY).
4
Is th
e resistance greater than 5 ohms?
Yes REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
DTC. TEST the system for normal operation.
No GO to A2
.
A2: CHECK
THE MAF SENSOR SENSE CI
RCUIT FOR SHORT TO HIGH VOLTAGE
R
econnect the battery negative terminal.
1
Turn the ignition swi
tch to the ON
position.
2
M
easure the voltage between the MAF sensor electrical connector, PI35, pin 02 (GY) and GROUND.
3
Is th
e voltage greater than 3 volts?