2.12.7.22 DTC P0131 P0132 P0133 P0134..............2-670
2.12.7.23 DTC P0135.................................................2-677
2.12.7.24 DTC P0137 P0138 P0140..........................2-680
2.12.7.25 DTC P0141.................................................2-686
2.12.7.26 DTC P0171 P0172 P1167 P1171 P2187 P2188.
2-689
2.12.7.27 DTC P0222 P0223.....................................2-692
2.12.7.28 DTC P0230.................................................2-694
2.12.7.29 DTC P0261 P0262.....................................2-695
2.12.7.30 DTC P0264 P0265.....................................2-700
2.12.7.31 DTC P0267 P0268.....................................2-704
2.12.7.32 DTC P0270 P0271.....................................2-709
2.12.7.33 DTC P0300.................................................2-713
2.12.7.34 DTC P0324 P0325.....................................2-721
2.12.7.35 DTC P0335 P0336.....................................2-726
2.12.7.36 DTC P0340 P0341.....................................2-731
2.12.7.37 DTC P0351 P0352.....................................2-737
2.12.7.38 DTC P0420.................................................2-738
2.12.7.39 DTC P0458 P0459.....................................2-742
2.12.7.40 DTC P0480 P0481.....................................2-746
2.12.7.41 DTC P0502.................................................2-746
2.12.7.42 DTC P0506 P0507.....................................2-750
2.12.7.43 DTC P0562 P0563.....................................2-753
2.12.7.44 DTC P0571.................................................2-758
2.12.7.45 DTC P0601 P0602 P0604 P0606 P060A P1516
P2101.........................................................................2-760
2.12.7.46 DTC P0641 P0651.....................................2-761
2.12.7.47 DTC P0646 P0647.....................................2-763
2.12.7.48 DTC P0650.................................................2-764
2.12.7.49 DTC P0685.................................................2-766
2.12.7.50 DTC P2104 P2105 P2106 P2110..............2-771
2.12.7.51 DTC P2119.................................................2-773
2.12.7.52 DTC P2122 P2123.....................................2-776
2.12.7.53 DTC P2127 P2128.....................................2-780
2.12.7.54 DTC P2135.................................................2-784
2.12.7.55 DTC P2138.................................................2-786
2.12.7.56 DTC P2610.................................................2-788
2.12.7.57 DTC P0633 U0167 U0426.........................2-788
2.12.7.58 Crankshaft Rotation Normal, But The Engine Can
Not Start.....................................................................2-790
2.12.7.59  Electronic  Throttle  Body  (ETC)  Adaptive  Learn
Program......................................................................2-794

2.12.8 Removal and Installation....................2-795

2.12.8.1 Acceleration Pedal Replacement.................2-795

2.13 Fuel System JL4G15-D.............2-797

2.13.1 4G15-D Fuel System Overview.......................2-797

2.13.1 Diagnostic Information and Procedures. . .2-
798

2.13.1.1 Fuel Pump Inoperative.................................2-798
2.13.1.2 All Fuel Injectors Inoperative........................2-803

2.13.2 Removal and Installation....................2-807

2.13.2.1 Fuel Injector Replacement...........................2-807

2.14 Auxiliary Emission Control JL4G15-D
2-811

2.14.1  4G15-D  auxiliary  emission  control  devices,  an
overview.....................................................................2-811

2.14.1 Component Locator............................2-812

2.14.1.1 Component Locator......................................2-812

2.14.2 Diagnostic Information and Procedures. . .2-
813

2.14.2.1 Canister Solenoid Valve Inoperative............2-813

2.15 Engine Anti-theft System JL4G15-D. .
2-817

2.15.1 4G15-D Engine Anti-theft System Overview.........2-
817

2.15.1 Diagnostic Information and Procedures. . .2-
818

2.15.1.1 Engine Anti-theft System Warning Lamp Flashing,
The Vehicle Can Not Be Started................................2-818

2.16 Engine Mechanical Systems JL4G15-
D........................................................2-823

2.16.1 4G15-D Engine Mechanical System Overview.....2-
823

2.16.1 Specifications.....................................2-824

2.16.1.1 Fastener Tightening Specifications..............2-824
2.16.1.2 Mechanical System Specifications...............2-826
2.16.1.3  Intake  and  Exhaust  Valves  Lifter  Specifications
Table..........................................................................2-828
2.16.1.4 Intake and Exhaust Valves Lifter Selection Table.
2-830

2.16.2 System Working Principle...................2-832

2.16.2.1 System Working Principle............................2-832

2.16.3 Removal and Installation....................2-833

2.16.3.1 

4G15-D 

Mechanical 

Parts 

Disassemble

Instructions.................................................................2-833
2.16.3.2 Electronic Throttle Body Replacement.........2-833

Engine

Table of Contents

2-7

2.17 Exhaust System JL4G15-D.......2-835

2.17.1 4G15-D Engine Exhaust System Overview.....2-835

2.17.1 Specifications.....................................2-836

2.17.1.1 Fastener Tightening Specifications..............2-836

2.18 Engine Cooling System JL4G15-D. 2-
837

2.18.1 4G15-D Engine Cooling System Overview.....2-837

2.18.1 Specifications.....................................2-838

2.18.1.1 Cooling System Specifications.....................2-838

2.18.2 Schematic...........................................2-839

2.18.2.1 Schematic.....................................................2-839

2.18.3 Diagnostic Information and Procedures. . .2-
840

2.18.3.1 Cooling Fan Circuit Diagnosis......................2-840
2.18.3.2 High Speed Cooling Fan Inoperative...........2-841
2.18.3.3 Low Speed Cooling Fan Inoperative............2-844
2.18.3.4 Cooling Fan Always Runs At Low-Speed.....2-848
2.18.3.5 Cooling Fan Always Runs At High Speed..........2-
850

2.19 Lubrication System JL4G15-D........2-
854

2.19.1 4G15-D Engine Lubrication System Overview......2-
854

2.19.1 Specifications.....................................2-855

2.19.1.1 Oil Pump Specifications...............................2-855

2.20 Ignition System JL4G15-D........2-856

2.20.1 4G15-D Engine Ignition System Overview......2-856

2.20.1 Specifications.....................................2-857

2.20.1.1 Ignition System Specification.......................2-857

2.20.2 Component Locator............................2-858

2.20.2.1 Component Locator......................................2-858

2.20.3 Schematic...........................................2-859

2.20.3.1 Schematic.....................................................2-859

2.20.4 Diagnostic Information and Procedures. . .2-
861

2.20.4.1 Spark Plug No Arcing...................................2-861

2.20.5 Removal and Installation....................2-864

2.20.5.1 Camshaft Position Sensor Replacement......2-864
2.20.5.2 Ignition Coil Replacement............................2-866
2.20.5.3 High-voltage Damping Line Replacement..........2-
868

2.21 Starting / Charging System JL4G15-D
..........................................................2-871

2.21.1  4G15-D  Engine  Starting  /  Charging  System
Overview....................................................................2-871

2.21.1 Specifications.....................................2-872

2.21.1.1 Starter Motor Specifications.........................2-872
2.21.1.2 Generator Specifications..............................2-872

2-8

Table of Contents

Engine

2.1 Warnings and Notices

2.1.1 Warnings and Notices

Battery Disconnect Warning

Warning!

Warning:  Unless  directed  otherwise,  the  ignition  and
start switch must be in the OFF or LOCK position, and
all  electrical  loads  must  be  OFF  before  servicing  any
electrical  component.  Disconnect  the  negative  battery
cable  to  prevent  an  electrical  spark  should  a  tool  or
equipment  come  in  contact  with  an  exposed  electrical
terminal. Failure to follow these precautions may result
in  personal  injury  and/or  damage  to  the  vehicle  or  its
components.

Exhaust Service Warning

Warning!

Warning: In order to avoid being burned, do not service
the exhaust system while it is still hot. Service the system
when it is cool.

Fuel and Evaporative Emission Pipe Warning

Warning!

Warning: In order to reduce the risk of fire and personal
injury observe the following items:

–

Replace all fuel pipes that are nicked, scratched or
damaged during installation, do not attempt to repair
the sections of the fuel pipes

–

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

–

Always  cover  vapor  pipes  with  a  wet  towel  before
using  a  torch  near  them.  Also,  never  expose  the
vehicle  to  temperatures  higher  than  115°C  (239°F)
for more than one hour, or higher than 90°C (194°F)
for any extended period.

–

Apply a few drops of clean engine oil to the male pipe
ends  before  connecting  fuel  pipe  fittings.  This  will
ensure proper reconnection and prevent a possible
fuel  leak.  (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!

Warning: Wrap a shop towel around the fuel pressure
connection in order to reduce the risk 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 an approved container when the connection
of the fuel pressure gage is complete.

Fuel Pipe Fitting Warning

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  risk  of  fire  and  personal
injury. This will ensure proper reconnection and prevent
a possible fuel leak. During normal operation, the O-rings
located  in  the  female  connector  will  swell  and  may
prevent proper reconnection if not lubricated.

Fuel Storage Warning

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.

Fuel  vapors  in  Evaporative  Emission  Components
Warning

Warning!

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

Gasoline/Gasoline vapors Warning

Warning!

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 nearby.

Engine

Warnings and Notices

2-9

Lower O-Ring Removal Warning

Warning!

Warning:  Verify  that  the  lower  (small)  O-ring  of  each
injector does not remain in the lower manifold in order to
reduce the risk of fire and personal injury. If the O-ring is
not removed with the injector, the replacement injector
with  new  O-rings  will  not  seat  properly  in  the  injector
socket. Unreasonable seating could cause a fuel leak.
When  replacing  the  injector,  replace  the  lower  O-ring
together.

Radiator Cap Removal Warning

Warning!

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

Cooling System Service Warning

Warning!

Warning: If pressure cap is removed while the engine is
still hot and under pressure during service, the cooling
coolant will boil immediately and spray into the operators
body, causing serious burns.

Relieving Fuel Pressure Warning

Warning!

Warning: Remove the fuel tank cap and relieve the fuel
system  pressure  before  servicing  the  fuel  system  in
order  to  reduce  the  risk  of  personal  injury.  After  you
relieve the fuel system pressure, a small amount of fuel
may be released 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!

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

2-10

Warnings and Notices

Engine