2.2.7.43 DTC P0562 P0563 .................................... 281 

2.2.7.44 DTC P0571 ............................................... 287 

2.2.7.45 DTC P0601 P0602 P1516 P2101 .............. 289 

2.2.7.46 DTC P0641 P0651 .................................... 291 

2.2.7.47 DTC P0646, P0647 ................................... 294 

2.2.8 Removal and installation ............................... 329 

2.2.8.1 Replacement of Engine Control Module   .. 329 

2.2.8.2 Engine coolant temperature sensor ............. 330 

2.2.8.3 Replacement of Intake Pressure Temperature 
Sensor ..................................................................... 331 

2.2.8.4 Replacement of Electronic Acceleration Pedal 
Assembly ................................................................ 332 

2.3 Fuel System. ..................................................... 337 

2.3.1 Specifications ................................................. 337 

2.3.1.1 Fastener Specifications ............................... 337 

2.3.2 Description and Operation   ........................... 338 

2.3.3 System operating principle. ........................... 340 

2.3.4 Component position   ..................................... 341 

2.3.5 Disassemble drawings ................................... 345 

2.3.6 Electrical schematic diagram ......................... 346 

2.3.7 Diagnostic Procedures and Description ......... 347 

2.3.8 Removal and installation ............................... 349 

2.4 Auxiliary Emission Control Device .................. 361 

2.4.1 Specifications ................................................. 361 

2.4.2 Description and Operation ............................. 362 

2.4.3 System operating principle ............................ 364 

2.4.4 Component position ....................................... 365 

2.4.5 Electrical schematic diagram ......................... 367 

2.4.6 Diagnostic message and steps   ...................... 368 

2.4.6 Removal and installation ............................... 373 

2.5 Engine Anti-theft System   ............................... 377 

2.5.1 Specifications ................................................. 377 

2.5.2 Description and Operation ............................. 377 

2.5.3 System operating principle. ........................... 379 

2.5.4 Component position   ..................................... 380 

2.5.5 Disassemble drawings. .................................. 381 

2.5.6 Electrical schematic diagram ......................... 382 

2.5.7 diagnostic message and steps ......................... 383 

2.5.8 Removal and installation. ............................. .410 

 

 

2.6 Mechanical system (4G20/4G24) ..................... 413 

2.6.1 Specifications ..............................................   413 

2.6.2 Description and operation ............................. 422 

2.6.3 System operating principle ............................ 423 

2.6.4 Component position ...................................... 426 

2.6.5 Part disassembly drawing .............................. 427 

2.6.6 Electrical schematic diagram ......................... 431 

2.6.7 Diagnostic information and procedures ......... 432 

2.6.8 Removal and installation ............................... 446 

2.6.9 Special Tools and Equipment ........................ 511 

2.7 Exhaust System ................................................ 514 

2.7.1 Specifications   .............................................. 514 

2.8 Cooling system ................................................. 534 

2.8.1 Specifications ................................................ 534 

2 . 9 Lubrication system (4G20/4G24) ................... 588 

2.9.1 Specifications ................................................ 588 

2.10 Ignition System ............................................. .607 

2.10.1 Specifications   ............................................ 607 

2.11 Start Charging System .................................... 624 

2.11.1 Specifications .............................................. 624 

2.11.2 Description and operation ........................... 626 

2.11.3 System operating principle .......................... 628 

2.11.4 Part position figure ...................................... 630 

2.11.5 Diagnostic information and procedures ....... 632 

2.11.6 Removal and installation ............................. 639 

2.12 control system (4G18 with Delphi systems)... 645 

2.12.1 Specifications   ............................................ 645 

2.12.2 Description and Operation ........................... 650 

2.12.3 System operating principle .......................... 654 

2.12.4 Component Location ................................... 664 

2.12.5 Disassemble drawings ................................. 666 

2.12.6 Electrical schematic diagram ....................... 667 

2.2.7 Diagnostic information and procedures ......... 674 

2.12.8 Removal and installation   ........................... 918 

2.13 Mechanical system(4G18) .............................. 927 

2.13.1 Specifications .............................................. 927 

2.13.2 Description and Operation ........................... 936 

2.13.3 System Operating Principle ......................... 937 

2.13.4 Component position ..................................... 940 

2.13.5 Part disassembly drawing ............................ 941 

2.13.6 Electrical schematic diagram ....................... 946 

2.13.7 Diagnostic Information and Procedures ...... 947 

2.13.7.1 Diagnosis Descriptions ............................. 947 

2.13.7.2 Visual Inspection ...................................... 947 

2.13.8 Removal andinstallation. ............................. 966 

2.13.9 Special Tools and Equipment .................... 1058 

2.13.9.1 Special Tools List ................................... 1058 

2.14 Lubrication system (4G18) ........................... 1061 

2.14.1 Specifications ............................................. 1061 

2.14.1.1 Fastener Tightening Specification   ........ 1061 

2.14.2 Description and Operation ......................... 1062 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.14.2.1 Operated and description. ...................... .1062 

2.14.3 System operating principle ........................ 1063 

2.14.3.1 Lubrication Schematic ............................ 1063 

2.14.4 Component position   ................................ 1064 

2.14.4.1 Component position ............................... 1064 

2.14.5 Disassemble drawings ............................... 1065 

2.14.5.1 Disassembly diagram   ........................... 1065 

2.14.6 Electrical schematic diagram ..................... 1066 

2.14 .6.1 Electrical Schematic Diagram ............... 1066 

2.14.7 Diagnostic message and steps   ................. 1067 

2.14.7.1 Diagnosis descriptions ............................ 1067 

2.14.7.2 Visual inspection .................................... 1067 

2.14.8 Removal and installation ........................... 1072 

2.14.8.1 Replacement of Oil Pump ...................... 1072 

2.1 Warnings and notices 

2.1.1 Warning and precaution 

Warning on Battery Disconnection 

Warning: Unless directed otherwise in the operating procedures, the ignition key must be at the 
OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical 
component. Disconnect the negative battery cable if a tool or any equipment easily comes in 
contact within exposed electrical terminal. Failure to follow these precautions may result in 
personal injury and/or damage to the vehicle or its components. 

Warning for air exhaust system maintenance   

Warning: When air exhaust system is too hot, please do not repaired air exhaust system to avoid 
scald Please repair it after air exhaust system cooled 

Warning for fuel and evaporation air exhaust pipe 

Warning: reduce fire and personal injury, please you are comply with ways as follow: 

z  Replace all fuel pipes that are nicked, scratched or damaged during installation, do not 

attempt to repair the fuel pipes. 

z  Do not hammer directly on the clips of fuel harness body when installing new fuel pipes. 

z  Always cover fuel vapor pipes with a wet towel before using a torch near them. Also, never 

expose the vehicle to temperature higher than 115℃ (239℉) for more than one hour, or 
higher than 90℃ (194℉) for any extended period. 

z  Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel 

pipe fittings, which will ensure proper reconnection and prevent a possible fuel leakage. 
(During normal operation, the O-rings located in the female connector will swell and may 
prevent proper reconnection if not lubricated.)   

Fuel Gage Leak Warning 

Warning: Wrap a shop towel around the fuel pressure connection in order to reduce the risks of 
fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection 
of the fuel pressure gage. Place the towel in a proper container when the connection of the fuel 
pressure gage is complete. 

Fuel Pipe Fitting Warning 

Warning: Always apply a few drops of clean engine oil to the male pipe ends before connecting 
the fuel pipe fittings in order to reduce the risks of fire and personal injury. This will ensure proper 
reconnection and prevent a possible fuel leakage. During normal operation, the O-rings located in 
the female connector will swell and may prevent proper reconnection if not lubricated. 

Warning on Installing Stop Bracket of Fuel Distributing Pipe 

Warning: The stop bracket of fuel distributing pipe must be installed on the engine assembly.  
When vehicle’s frontal collision happens, stop bracket can be considered as a guard board of fuel 
distributing pipe.  If stop bracket of fuel distributing pipe is not installed, fuel injection may 
cause fire and result in personal burn when vehicle’s frontal collision happens. 

Fuel Storage Warning 

Warning: Do not drain the fuel into an open container. Never store the fuel in an open container 
due to the possibility of a fire or an explosion. 

Warning on Fuel Vapors in Evaporative Emission Components 

Warning: Do not breathe the air through the EVAP tubes or hoses. The fuel vapors inside the 
EVAP components may cause personal injury. 

Gasoline/Gasoline Vapors Warning 

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Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition 
source is present. Never drain or store gasoline or diesel fuel in an open container, due to the 
possibility of fire or explosion. Have a dry chemical fire extinguisher prepared nearby. 

Warning on Lower O-ring Removal of Fuel Injector 

Warning: Verify that the lower (small) O-ring of each injector does not remain in the lower 
manifold in order to reduce the risks of fire and personal injury. If the O-ring is not dismantled 
with the injector, the replaced injector with new O-rings will not be seated properly in the injector 
socket. Improper seating could cause fuel leakage. When reassembling the injector, replace the 
lower O-ring together. 

Warning relating to the disassemble of radiator cap 

Warning: To avoid being burned, do not remove the radiator cap while the engine is still hot. The 
cooling system will release scalding fluid and steam under high pressure if radiator cap is removed 
while the engine and radiator are still hot. 

Warning on Cooling System Maintenance 

If pressure cap is removed while the engine is still hot and under pressure during maintenance, the 
engine coolant will boil immediately and spray into the operator's body, causing serious burns. 

Releasing Fuel Pressure Warning 

Warning: Remove the fuel tank cap and release the fuel system pressure before servicing the fuel 
system in order to reduce the risk of personal injury. After you release the fuel system pressure, a 
small amount of fuel may release when servicing the fuel circuit, the fuel injection pump, or the 
connections. In order to reduce the risk of personal injury, cover the fuel system components with 
a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in 
an approved container when the disconnection is complete. 

Road Test Warning 

Warning: Take a road test under safe conditions while obeying all traffic laws. Do not attempt any 
operation that could jeopardize vehicle control. Failure to obey these precautions will lead to 
serious personal injury and vehicle damage. 

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