6wg1 Emissions & Diagnostics

WORKSHOP MANUAL
C&E-SERIES
ENGINE EMISSION & DIAGNOSTICS

6WG1-TCC & TCS (COMMON RAIL)
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
“GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS
MANUAL”.
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
Applicable Model : C & E-Series
This Manual is applicable to 2003 year model and later vehicles.

Contents
Chapter 1 Overview of IE system Checking the power take off (PTO) . . . . . . . 3-41
1. Overview and specifications of IE system. . . . . 1-2 Checking the power take off (PTO) switch . 3-44
Overview of IE system . . . . . . . . . . . . . . . . 1-2 Checking the parking switch . . . . . . . . . . . . 3-49
Specifications of IE system . . . . . . . . . . . . 1-2 Idling speed cannot be adjusted . . . . . . . . . . 3-54
Electronically controlled fuel injection system Idling speed cannot be decreased . . . . . . . . . 3-57
(common-rail type) . . . . . . . . . . . . . . . . . 1-3
EGR (Exhaust Gas Recircuration) . . . . . . . 1-5 Chapter 4 Checking procedure for each
Idling control switch . . . . . . . . . . . . . . . . . . . 1-6 diagnostic trouble code
Output of idle position signal to brake intensive Diagnostic trouble codes list . . . . . . . . . . . . . 4-4
control unit. . . . . . . . . . . . . . . . . . . . . . . . 1-7 14 CMP sensor system trouble. . . . . . . . . . . . 4-8
Output of engine rotations to tachometer . . 1-7 15 CKP sensor system trouble . . . . . . . . . . . 4-13
Speed Limiter (SLD) . . . . . . . . . . . . . . . . . 1-8 22 Atmospheric temperature sensor system
Auto cruise control . . . . . . . . . . . . . . . . . . . 1-9 trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
External view of engine control unit . . . . 1-11 23 Water temperature sensor system trouble. . 4-24
Engine control unit input/output list. . . . . 1-12 24 Accelerator sensor system trouble . . . . . 4-30
2. IE system schematic connection diagram . . 1-14 25 Vehicle speed sensor system trouble . . . . 4-36
3. Control unit/sensor/switch installing position. 1-16 28 All speed accelerator sensor error/
4. Functions of input/output and vehicle behavior No operate PTO. . . . . . . . . . . . . . . . . . . . 4-43
upon failure (influence) . . . . . . . . . . . . . . 1-21 32 Boost sensor system trouble . . . . . . . . . . 4-46
5. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 33 CPU monitoring IC trouble. . . . . . . . . . . 4-52
Object and procedure for accelerator learning 35 A/D conversion error/charger
(learning of accelerator pedal idling position circuit trouble . . . . . . . . . . . . . . . . . . . . . 4-54
and full-throttle position) . . . . . . . . . . . 1-23 42 High boost trouble. . . . . . . . . . . . . . . . . . 4-56
Q adjustment data. . . . . . . . . . . . . . . . . . . 1-24 65 Low boost trouble . . . . . . . . . . . . . . . . . . 4-62
71 Atmospheric pressure sensor trouble . . . 4-68
Chapter 2 Failure Diagnosis 115 Fuel pressure sensor output fixed . . . . . 4-70
1. Self-diagnosis of IE system . . . . . . . . . . . . 2-2 118 Common-rail pressure trouble. . . . . . . . 4-75
Method of checking the diagnostic trouble code 151 Common rail pressure trouble
by SERVICE ENGINE SOON lamp . . . . . 2-2 (pump excessive pressure feed) . . . . . . . 4-82
Erasing the diagnostic trouble code by memory 158 Injector power system trouble (Common 1
clear switch (connector) . . . . . . . . . . . . . 2-3 "Injector 1, 3, 5 Systems") . . . . . . . . . . . 4-89
Tech 2 Operation manual . . . . . . . . . . . . . . 2-6 159 Injector power system trouble (Common 2
2. Vehicle diagnostic procedure . . . . . . . . . . 2-16 "Injector 2, 4, 6 Systems") . . . . . . . . . . . 4-94
217 PCV1 system short circuit (battery and
Chapter 3 Functional diagnosis power supply circuit) trouble. . . . . . . . . 4-99
Checking of SERVICE ENGINE SOON lamp 218 PCV2 system short circuit (battery and
lighting circuit system (SERVICE ENGINE power supply circuit) trouble. . . . . . . . 4-103
SOON lamp does not turn ON). . . . . . . . . . 3-2 226 Supply pump no pressure feed or
Checking the SERVICE ENGINE SOON lamp pressure limiter operated . . . . . . . . . . . 4-107
flashing control system (SERVICE ENGINE 227 Pump no pressure feed
SOON lamp does not flashing) . . . . . . . . . . . 3-9 (Fuel outflow) . . . . . . . . . . . . . . . . . . . 4-112
Checking the Tech II . . . . . . . . . . . . . . . . . . 3-13 241 Accelerator switch off trouble . . . . . . . 4-117
Checking the engine starting system . . . . . . 3-17 242 Accelerator switch on trouble . . . . . . . 4-122
Checking the power supply circuit . . . . . . . . 3-20 245 Fuel pressure sensor Trouble. . . . . . . . 4-127
Checking the fuel system . . . . . . . . . . . . . . . 3-26 247 PCV1 system harness, short
Checking the intake system . . . . . . . . . . . . . 3-28 (GND circuit) trouble . . . . . . . . . . . . . 4-132
Checking the starting system . . . . . . . . . . . . 3-29 248 PCV2 system harness, short
Checking the exhaust system . . . . . . . . . . . . 3-33 (GND circuit) trouble . . . . . . . . . . . . . 4-137
Checking the EGR . . . . . . . . . . . . . . . . . . . . 3-38
Contents
271 No.1 cylinder No.1 injector drive

system trouble . . . . . . . . . . . . . . . . . . . 4-142
system trouble . . . . . . . . . . . . . . . . . . . 4-146
system trouble . . . . . . . . . . . . . . . . . . . 4-150
system trouble. . . . . . . . . . . . . . . . . . . 4-154
system trouble . . . . . . . . . . . . . . . . . . . 4-158
system trouble . . . . . . . . . . . . . . . . . . . 4-162
413 Magnetic valve "E" drive
system trouble . . . . . . . . . . . . . . . . . . . 4-166
443 Magnetic valve "D" drive
system trouble . . . . . . . . . . . . . . . . . . . 4-173
416 Main relay system trouble . . . . . . . . . . 4-180
417 Starter switch trouble. . . . . . . . . . . . . . 4-185
424 Fail-safe (Magnetic valve cut)
relay "B" system trouble . . . . . . . . . . . 4-189
421 PCV relay system trouble . . . . . . . . . . 4-193
518 EOL data error. . . . . . . . . . . . . . . . . . . 4-196
543 Excessive high revolution error. . . . . . 4-198
Chapter 5 Checking Method for Symptom

Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Engine hunting, rough idle . . . . . . . . . . . . . . . 5-5
Lack output power of engine, insufficient
blow up, pulsating combustion . . . . . . . . . . 5-8
White smoke (large) . . . . . . . . . . . . . . . . . . . 5-12
Black smoke (large) . . . . . . . . . . . . . . . . . . . 5-14
Chapter 6 How to use IE System Inspection

Tools
1. Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chapter 7 Others
Inspection item chart for IE system
condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Abbreviation list . . . . . . . . . . . . . . . . . . . . . . . 7-3
Programming / upload / download fuel
delivery rate data . . . . . . . . . . . . . . . . . . . . 7-5
How to read this Manual
This IE System Troubleshooting Manual describes the inspection procedure for the IE System (an electronically
controlled fuel injection system (common-rail)).
This manual will help you in correct and speedy service operation for the IE System.
Chapter 1 Overview of IE system

• Specifications of IE system
• Control mechanism of IE system
• Input/output of IE system
• Sensor & actuator installing position of each engine
Chapter 2 Failure diagnosis

• View of diagnostic trouble codes
• IE lamp does not light ON, or the diagnosis monitor displays no data
• Contents of diagnostic trouble codes
Chapter 3 Functional diagnosis

• Checking method for proper operation of IE System or its functions
Chapter 4 Checking procedure for each diagnostic trouble code

• Checking method when a diagnostic trouble is displayed
Chapter 5 Checking method for symptom (when no trouble code lights ON)
• When no diagnostic trouble code is displayed, how to know the position to be checked based on
the failure condition
Chapter 6 How to use IE system inspection tools

• How to use the wiring harness for checking the wiring harness checker, Tech II, and voltage
Chapter 7 Others
• Check sheet of IE system and simplified troubleshooting
Chapter 1
Overview of IE system
1. Overview and specifications of IE system
■ Overview of IE system
The IE system is an electronic control system which controls the engine combustion condition optimally
according to the traveling requirements of the vehicle. The IE system comprises the following components:
1. Electronically controlled fuel injection system (common-rail type)
2. EGR control
3. Idle control
The IE system has other functions as follows in addition to the engine control function.
A. Engine speed output to tachometer
B. Self-diagnosis function
■ Specifications of IE system
List of IE system specifications
(common-rail type)
Electronically controlled fuel

injection system
Self-diagnosis function
Engine model Output E

G
R
kW {PS}
6WG1-TC 316 kW {430 PS} O O O
O - Standard equipment
1-2
Overview and specifications of IE system
■ Electronically controlled fuel injection system (common-rail type)

The engine control unit (ECU) acquires information (signals from many sensors) such as engine speed,
engine load and others. Based on such information, ECU sends electric signals to the supply pump, injector,
etc. to control the fuel injection rate and injection timing properly for each cylinder.。
Injection rate control
The two-way valve (TWV) in the injector is controlled based on the signals mainly from the engine speed
and accelerator opening to control the fuel injection rate properly.
Injection pressure control
By controlling the fuel pressure in the common-rail, the injection pressure is controlled. Proper pressure
in the common-rail is calculated based on the engine speed, fuel injection rate, and other conditions. By
controlling the supply pump (PCV: Pump Control Valve), fuel in a proper quantity is discharged and fed
to the common-rail under controlled pressure
Injection timing control
The injection timing control substitutes for the timer. Proper fuel injection timing is calculated based on
the engine speed and fuel injection rate to control the TWV (two-way valve) in the injector.
Injection rate control
In order to improve the combustion in the cylinder, a small quantity of fuel is injected (pilot injection) first
and ignited, and then the second injection (main injection) follows. The injection timing and the injection
quantity are controlled by controlling the TWV (two-way valve) in the injector.
System schematic diagram
Atmospheric temperature sensor
Sensor signals Engine control unit
from switches, etc. (ECU)
Atmospheric pressure sensor

Voltage (built in ECU)
load
circuit
⋅ Accelerator sensor
⋅ Accelerator switch
⋅ All speed
Accelerator sensor
Injector
Pressure limiter
Fuel leak pipe
Starter motor Common-rail fuel

pressure sensor
Flow damper
Supply pump
Air
cleaner
Water temperature
sensor Fuel filter
Fuel tank
CMP sensor
CKP sensor
Flywheel Feed pump Pre-fuel filter
1-3
System control schematic diagram
Engine control unit (ECU)
Accelerator sensor input

Boost sensor input
Basic fuel injection rate
CKP (engine speed)
sensor
CMP (cylinder distinction)
sensor
Compensation Water temperature sensor input,

accelerator sensor input,
start switch input
Fuel pressure sensor
ASR demand signal (fuel cut signal)
Vehicle speed sensor input,
clutch switch signal, etc.
Compensation
PCV
opening/closing Injector (TWV) power supply time,
timing decision timing decision
Fuel pressure sensor

Common-rail
(normally high pressure)
TWV
(Two Way Valve)
PCV
Supply
Injector
pump
Fuel tank
1-4
■ EGR (Exhaust Gas Recirculation)

The EGR system returns a portion of the exhaust gas to the intake manifold. The exhaust gas circulates in the
intake manifold where it mixes with the fresh air entering the engine. The burned exhaust gases reduce the
combustion temperature. When combustion temperature is reduced, fewer nitrogen oxides (NOx) are
produced.
The EGR valve is between the intake manifold and the exhaust manifold. The valve opens and closes to
control the volume of exhaust gas being returned to the intake manifold.
A cooler installed to the EGR passage cools the EGR gases. The cooled gases mixing with the fresh air
entering the engine further lower the combustion temperature. This system (called a cooled EGR) provides
significantly greater NOx reduction than an uncooled EGR system.
A check valve prevents EGR gas backflow. Because the EGR gas is allowed to flow in only one direction,
the volume of the gas delivered to the intake manifold is increased.
• 6W engine EGR control: EGR valve operation (One-way, cooled EGR)
1-5
■ Idling control switch

The idling speed can be adjusted by operating the idling control switch. The upper limit of speed varies
depending on the engine model, vehicle specifications and engine warming up condition.
UP
While the UP side of the switch is pushed, the engine speed
increases and the idling speed is increased accordingly.
UP
DOWN
While the DOWN side of the switch is pushed, the engine speed
DOWN
decreases and the idling speed can be decreased, only down to the
lower limit.
High Low
UP UP
DOWN DOWN
1-6
■ Output of idle position signal to brake intensive control unit

The engine control unit issues the "accelerator pedal stepping condition (stepped/not stepped)" to the brake
integrated control unit as idle position signal output.
The brake intensive control unit operates or releases the exhaust brake and retarder according to the
"accelerator pedal stepping condition" sent from the engine control unit and the operating condition of the
exhaust brake lever, retarder lever, clutch pedal, etc. which is directly detected.
Accelerator
Accelerator opening
Engine control unit
sensor
Idle position
signal output
Exhaust brake switch Exhaust brake
magnetic valve
Brake intensive
control unit
Clutch switch
■ Output of engine rotations to tachometer

The engine control unit sends the "engine speed pulse (4 pulses per speed of engine)" to the tachometer and
the tachometer output.
The tachometer indicates the engine speed. according to the "engine speed pulse" sent from the engine
control unit.
CKP sensor Tachometer

Engine speed Engine control unit output
CMP sensor Tachometer
1-7
■ Speed Limiter (SLD)

The speed limiter (SLD) is control in the ECM which limits vehicle speed not to exceed a setting value.
The limit of vehicle speed is performed by fuel rate control in the ECM. Fuel rate is controlled based on
vehicle speed signal and engine speed signal.
Vehicle speed signal is inputted to the speed meter control unit (Pulse Maching Device). The Pulse Maching
Device rectifies vehicle speed signal according to vehicles and outputs the signal to ECM and meter.
Engine speed is computed by the ECM based on the crank position (CKP) sensor.
Meter
Other C/U
Pulse
Engine ECM Maching
Device
Fuel Injection Control
C r a n k Po s i t i o n ( C K P ) Ve h i c l e S p e e d S e n s o r
Sensor (VSS)
1-8
■ Auto cruise control

Even if it does not operate an accelerator, it is the function which can maintain and run setting speed (within
the limits of 40 - 80 km/h).
If a cruise set switch is operated when a cruise main switch is turned “ON” (a CRUISE MAIN lamp lights
up) and the speed of choice is reached, it will be in an autocruise state and a CRUISE SET lamp will light
up.
Momentary acceleration function

During an autocruise run, if an accelerator is operated, accelerating temporarily will come out.
It returns to the autocruise state if operation of an accelerator is stopped, even if vehicles speed will slow
down.
Set coast function (Autocruise setting speed is lowered)

During an autocruise run, if a cruise set switch is pushed, while pushing,
it slows down. If a cruise set switch is detached when it slows down to the speed of choice,
setting speed will be updated at the vehicles speed at that time.
Set accelerator function (Autocruise setting speed is gathered)

During an autocruise run, if a cruise resume switch is operated, while operating it,
vehicles speed rises. If a cruise resume switch is detached
when vehicles speed rises to the speed of choice, setting speed will be updated
at the vehicles speed at that time.
Release of Autocruise
An autocruise function is canceled on condition that following either.
1. The cruise main switch was set to “OFF” (cruise main switch : OFF).
2. Vehicles speed became below 30 km/h.
3. Vehicles speed fell more than 40 km/h from cruise setting speed.
4. The cruise set switch and the cruise resume switch were operated simultaneously.
(Cruise set switch : ON and a cruise resume switch : ON)
5. Abnormalities occurred in the engine control system.
6. Engine stop
7. The clutch pedal was stepped on (clutch switch : OFF).
8. The foot brake was stepped on (brake switch-1:ON or brake switch-2:ON).
9. The exhaust brake lever was operated (exhaust brake switch : ON).
10. The Retaeder lever was operated (Retaeder switch : ON)
11. The cruise cancellation switch was operated (cruise cancellation switch : OFF).
12. The gearshift was made neutral (neutral switch : ON).
Resume function (return in the autocruise state)

When an autocruise function is canceled, returning to the auto-cruise state before release
by operating a cruise resume switch comes out. A CRUISE SET lamp lights up at this time.
However, when it cancels on condition that the “1 ~ 6” clause of “release of autocruise”,
it cannot return to the auto-cruise state before release.
1-9
Auxiliary brake linkage autocruise control

It is the function to suppress a vehicles speed rise on a loose downward slope by interlocking an auxiliary
brake (an exhaust brake and Retardar) automatically during an autocruise run.
It aims at the operation reductions of incidence (brake operation by vehicles speed rise etc.) of a driver.
When it puts to a downward slope during an autocruise run and vehicles speed exceeds cruise setting
speed, an exhaust brake is operated first and the rise of vehicles speed is suppressed. When vehicles speed
rises during an exhaust brake operation, in addition to an exhaust brake, Retardar is also operated, and the
rise of vehicles speed is suppressed. When vehicles speed slows down to cruise setting speed, the operation
of an auxiliary brake is canceled. (It cancels by Retardar first and, next, cancels in order of an exhaust
brake.)
Downward slope Downward slope Flat way

Exhaust brake and retader Exhaust brake operates.
operates.
Downward slope
If it exceeds cruise setting speed, an exhaust brake will operate and a speed rise will be suppressed.
When vehicles speed rises further, in addition to an exhaust brake, Retardar operates, and the rise of
vehicles speed is suppressed.
Autocruise exhaust
brake operate signal
Engine control Brake intensive

unit Autocruise retarder control unit
operate signal
Vehicle speed signal (25pulse)

Retader Exhaust
Pulse matching device
M/V brake M/V
Vehicle speed sensor
Flat way
The auxiliary brake (exhaust brake and Retardar) operation under autocruise run is performed through a
brake intensive control unit. An engine control unit sends an operation signal to a brake intensive control
unit. A brake intensive control unit performs an operation and release of an auxiliary brake (an exhaust
brake and Retardar) according to this operation signal.
1-10
■ External view of engine control unit
Label
1 10 41 50 81 90
11 20 51 60 91 100
21 30 61 70 101 110
31 40 71 80 111 120
Note: Operate the control unit suited to the vehicle according to the "Comment" and "Applicable engine
identification name" described on the label.
If a control unit not fitted for the vehicle is used, failure may result.
1-11
■ Engine control unit input/output list

O: Circuit used -: Unused circuit : Circuit used properly depending on vehicles
Pin Pin
Name of signal Name of signal
No. No.
1 - - 41 Accelerator sensor 1 signal (SIG) O
2 Brake intensive control unit (Exh. B) 42 - -
3 - - 43 - -
4 - - 44 Accelerator sensor 1 power source VCC 1 O
5 - - 45 Accelerator sensor 1 GND O
6 Memory clear switch signal (SIG ) O 46 - -
7 Clutch switch signal (SIG ) O 47 - -
8 Brake intensive control unit (Exhaust) O 48 CKP sensor (+) signal (SIG) O
9 - - 49 CMP sensor (+) signal (SIG) O
10 Idling control UP switch signal (SIG ) O 50 - -
11 Cruise cancel switch 51 - -
12 Brake intensive control unit 52 - -
13 Key switch (ON) signal (SIG ) O 53 Atmosphere temperature sensor signal (SIG) O
14 Cruise main relay 54 - -
15 Air low pressure switch signal (SIG ) O 55 Fuel pressure sensor GND O
16 PTO signal 56 Boost, all speed accelerator sensor O
17 Stop lamp switch signal (SIG ) 57 CKP sensor (-) signal (SIG) O
18 Cruise set switch 58 CMP sensor (-) signal (SIG) O
19 Parking switch signal (SIG ) O 59 CaseGND O
20 Accelerator switch signal (SIG ) O 60 - -
21 Pump control valve (PCV )1 O 61 Boost sensor signal (SIG) O
22 Pump control valve (PCV )1 O 62 Fuel pressure sensor signal (SIG) O
23 Key switch (ON) signal (SIG ) O 63 All speed accelerator sensor signal (SIG)
24 Starter switch signal (SIG ) O 64 - -
25 Diagnosis switch O 65 - -
26 SW: Stop lamp O 66 AIR, WATER temperature sensor common GND O
27 Idling control change-over switch signal (SIG ) O 67 - -
28 Cruise resume switch 68 - -
29 Idling control DOWN switch signal (SIG ) O 69 - -
30 Water temperature sensor signal (SIG ) O 70 - -
31 Pump control valve (PCV )2 O 71 Fuel pressure sensor signal (SIG) O
32 Pump control valve (PCV )2 O 72 Boost, all speed accelerator sensor Power source O
33 Neutral signal (SIG ) O 73 Fuel pressure sensor Power source O
34 - - 74 - -
35 - - 75 Vehicle speed sensor signal (SIG) O
36 SW: Back lamp O 76 CKP sensor shield O
37 SW: Retarder 77 CMP sensor shield O
38 - - 78 - -
39 - - 79 - -
40 - - 80 Brake intensive control unit -
1-12
Pin
Name of signal
No.
81 Power source GND O
82 Power source GND O
83 - -
84 - -
85 Injector 6 (4th cylinder） O
86 Injector 5 (2nd cylinder) O
87 Injector 4 (6th cylinder) O
88 Injector 3 (3rd cylinder) O
89 Injector 2 (5th cylinder) O
90 Injector 1 (1st cylinder) O
91 Main relay O
92 EGR magnetic valve fly-back O
93 EGR magnetic valve fly-back O
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 Injector power source common 1 O
101 Main relay O
102 ECU GND O
103 - -
104 - -
105 Service engine soon lamp O
106 EGR magnetic valve O
107 Cruise set lamp
108 Brake intensive control unit
109 Main relay O
111 ECU GND O
112 Output signal to tachometer (SIG) O
113 Tech-II RXD O
114 Tech-II TXD O
115 - -
116 EGR magnetic valve O
117 EGR fail safe relay O
118 Main relay O
1-13
2. IE system schematic connection diagram
Battery Relay
Main Relay +BP PCV1

91
101 22
MAIN R/L 21
109
OFF 118 PCV2
ACC KEY 13 31
ON 23 32
Starter START 24
Switch START (+)
41 48
(-) CKP Sensor
44 57
45 77
Accel Sensor
42 (+)
49
54 (-) CMP Sensor
58
46
77
Accel switch 62 SIG
20
M/V; M/V; 71 SIG Fuel Pressure
8
Retader Exhaust 73 5V Sensor
Brake 2 GND
control 55
unit 108
Service Engine Lamp 61 SIG
105 5V
72 Boost Sensor
Reterder Switch GND
37 56
Brake Control Unit Parking Switch
19 SIG
Air Pressure Switch 63
5V All Speed
15 Accel Sensor
GND
Idole manual Switch
27
Idole Control Switch UP
10 GND
DOWN 66
29 SIG Water Temp Sensor
Brake Control Unit 30
Clutch Switch
7
Diag Switch
25
GND
Memory Clear Switch Atomospheric
6 53 SIG
Temp Sensor
Backup Lamp Switch
36 Idole Possition Out Brake Control
P.T.O Switch 80
Intensive Unit
16
Sub Stater Neutral Relay

Switch Stater
Relay
Neutral Switch
33
in
114
Tech 2 out
113
Tacho out
Meter 112
Atmospheric
Vehicle Pressure
Speed Sensor
Pulse Signal
Vehicle Speed Matching 75
Sensor Device
B A
1-14
B A
Fly Back
93 100
110
R/L:EGR Fail Safe 119

120
90 Injector 1
Cylinder
117 99 #1
M/V D :EGR1 89 Injector 2

Cylinder
116 98 #5
M/V E :EGR2 Injector 3
88
106 Cylinder
97 #3
Fly Back
92
87 Injector 4
Cylinder
96 #6
86 Injector 5
Cylinder
95 #2
85 Injector 6
Cylinder
94 #4
Stop Lamp Relay
Brake Sig 2
17
26
Brake Sig 2
Stop Lamp
Switch
Cruise Main Switch

14
Cruise Set Lamp

107
Cruise resume Switch
28
Cruise set Switch
18
Cruise Cansel Switch 1
11
Cruise Cansel Switch 2
12
(Exhaust Brake
Brake Intensive Control Unit Switch SIG)
With Auto Cruise
81 82 102111 59
GND
1-15
3. Control unit/sensor/switch installing position
Right below the steering wheel

Pulse matching Device
Brake Intensive Control Unit
Engine Control Unit
1-16
Control unit/sensor/switch installing position
PTO Switch
Relay Box
• Exhaust Brake Switch • Cruise Resume Switch
Fuse Box
• Reterder Switch • Cruise Cancel Switch
H 5 10
10
15
20
40
60 80
100
Cruise Set Switch
C 15
25 20 120
5
H
30
0 140
E
• Accelerator Sensor
• Accelerator Switch
Clutch Switch Idle Control Switch
• Data Link Connector

Cruise Main Switch • Diag Switch
• Memory Clear Switch
Service Engine Soon Lamp
Cruise Main Lamp
CRUISE
MAIN
Cruise Set Lamp
CRUISE
SET
1-17
Atmosphere
Temperature
Sensor
Transmission
• Vehicle Speed Sensor
• Neutral Switch
• Back up Lamp Switch
Brake Valve
• Brake Switch 1 Cab rear member
• Brake Switch 2 • Magnetic Valve
Battery
Air tank
⋅ Air low pressure switch
1-18
Cab rear member
1 2
1 EGR Magnetic Valve "D"

2 EGR Magnetic Valve "E"
1-19
Engine
Fuel Pressure Sensor
Water Temperature Sensor CMP Sensor
EGR Valve
Boost Sensor
EGR Valve
CKP Sensor
PCV
1-20
4. Functions of input/output and vehicle behavior upon failure (influence)
Diagnostic trouble
Input/output name Pin No. Function Vehicle behavior upon failure
code (engine)
Control unit power source Engine stall, improper starting, SERVICE ENGINE SOON lamp
91, 101 Power supply to engine control unit -
(battery) light up
Main relay 109, 118 Power supply relay to engine control unit driven Engine stall, improper starting 416
<Self-diagnosis taking place>

Deteriorated exhaust gas, large exhaust brake operating sound,
Magnetic valve, D, E 106, 116 EGR SERVICE ENGINE SOON lamp ON when idling continues. 413, 443
< Self-diagnosis not taking place>
Black smoke, output shortage, deteriorated exhaust braking force
Magnet valve Upon the magnetic valve system failure
Power supply to the magnetic valve cannot be cut off when the
Fail safe relay 117 (413, 443), 424
magnetic valve fails.
(power cut relay) power supply to the magnetic valve is cut off.
Magnetic valve 92, 93 Reduction of magnetic valve electrical noise Vehicle trouble cannot be felt. 413, 443
Fly-back
Detection of accelerator pedal opening (traveling accelerator) Output shortage, improper engine power up (slow reaction to
Accelerator sensor 41, 44, 45, 24
* Mutual diagnosis with "accelerator switch ON" accelerator pedal), SERVICE ENGINE SOON lamp light up
Detection of accelerator pedal stepping condition Output shortage, improper engine power up, (slow reaction to
Accelerator switch 20 241,242
* Mutual diagnosis with "accelerator sensor input" accelerator pedal, SERVICE ENGINE SOON lamp light up
Detection of external accelerator opening (working PTO cannot be controlled (accelerator cannot be changed over).
All speed accelerator sensor 56, 63, 72 -
accelerator) External accelerator does not work.
Output shortage, improper engine power up, idling condition
Boost sensor 56, 61, 72 Detection of boost pressure 32,42
continued, SERVICE ENGINE SOON lamp light up
Detection of water temperature (engine cooling water White smoke generated and unsmooth starting when extremely
Water temperature sensor 30, 66 23
temperature) cold, idling continued, SERVICE ENGINE SOON lamp light up
White smoke generated when extremely cold,
Atmospheric temperature sensor 53, 66 Detection of open air temperature 22
SERVICE ENGINE SOON lamp light up
Atmospheric pressure sensor In ECU Detection of atmospheric pressure Deterioration of exhaust gas 71
Idling continued and SERVICE ENGINE SOON lamp light up
Detection of engine speed, injection cylinder, injection * Engine speed can be detected with the CMP sensor but vehicle
CKP sensor 48, 57, 76 15
timing trouble cannot be felt.
Idling continued and SERVICE ENGINE SOON lamp light up
* Engine speed can be detected with the CKP sensor but vehicle
CMP sensor 49, 58, 77 Detection of injection cylinder, backup of CKP sensor 14
trouble cannot be felt.
Output shortage 245,115,151,
Fuel pressure sensor 55, 62, 71, 73 Detection of fuel pressure in common-rail
SERVICE ENGINE SOON lamp light up 118
Power supply to injector (TWV)
100, 110,
Injector (TWV) power source For common 1, injector 1,3 5 Engine stop 158,159
119, 120
For common 2, injector 2,4,6
Engine control unit controls the injector (TWV) based on
Output shortage, improper engine power up, deteriorated exhaust 271,272,273,
Injector (TWV) 85 - 90 the power supply time/timing, hereby controlling the fuel
gas, SERVICE ENGINE SOON lamp light up 274,275,276
injector volume and injection timing.
22, 21, Fuel pressure in the common-rail is controlled by Output shortage, improper engine power up, deteriorated exhaust 217,218,
PCV(Pump control valve)
31, 32 opening/closing timing of PCV. gas, SERVICE ENGINE SOON light up 247,248
22, 21, Engine stop.
PCV (Power supply) Detection of drive power supply to PCV 421
31, 32 SERVICE ENGINE SOON lamp light up.
Auto cruise does not work, speed limiter does not work, SERVICE
Vehicle speed sensor 75 Detection of vehicle speed 25
ENGINE SOON lamp light up only for vehicles equipped with NR.
Transmission of "idle position" to brake integrated control Exhaust brake does not work, exhaust brake not released with the
Accelerator opening (idle output) 80 -
unit accelerator pedal
Transmission of "engine speed" to tachometer and tacho Tachometer does not work, engine speed not recorded on the tacho
Tachometer output 112 -
graph graph
Detection of exhaust brake (magnetic valve) operating
Exhaust brake operation input 8 Black smoke generated -
condition
Start switch Black smoke generated, hunting, unsmooth starting when extremely
24 Detection of engine start condition 417
(start switch at "S" position) cold, SERVICE ENGINE SOON lamp light up
Start switch Engine stop,
13, 23 Detection of start switch condition 416
(start switch at "ON" position) SERVICE ENGINE SOON lamp light up
Auto cruise does not work.
Accelerator opening does not return to 0% with the foot brake
Brake switch 2 26 Detection of foot brake stepping condition operation upon the failure of the accelerator sensor. -
* Cannot be felt when the accelerator sensor is normal and the auto
cruise is not used.
<Manual transmission vehicle>
Detection of clutch pedal stepping condition
Clutch switch 7 <Semi-auto clutch vehicle, ECOGIT, MIX vehicle> Auto cruise does not work. -
Detection of clutch connecting condition
(disconnected/connected)
Detection of idle control selector switch operating condition
AUTO mode and MANUAL mode of the idle control cannot be
Idle control selector switch 27 (changing over between AUTO mode and MANUAL −
changed .
mode)
Idle control UP switch 10 Idle control switch UP side operating condition Idling speed cannot be adjusted (increased). -
1-21
Functions of input/output and vehicle behavior upon failure (influence)
Diagnostic trouble
Input/output name Pin No. Function Vehicle behavior upon failure
code (engine)
Idle control DOWN switch 29 Idle control switch "DOWN" operating condition Idling speed cannot be adjusted (decreased). -
PTO control (accelerator change-over or governor property change-
Parking brake switch 19 Detection of parking brake operating condition -
over) is impossible.
Low air pressure switch 15 Detection of air pressure condition Deteriorated exhaust gas -
Back lamp switch 36 Detection of shift lever operating condition (reverse position) Slightly too high vehicle reverse speed -
Neutral switch 33 Detection of shift lever operating condition (neutral position) Auto cruise does not work. -
Detection of diagnosis switch (20-pin connector (black)) Self-diagnosis code cannot be recognized with the SERVICE -
Diagnosis switch 25
operating condition ENGINE SOON lamp.
Detection of memory clear switch (2-pin connector (white)) Diagnostic trouble code cannot be erased.
Memory clear switch 6 -
operating condition * Can be erased with Tech II.
Diagnostic trouble system trouble cannot be recognized. Diagnostic
Engine control system trouble indicated by the lamp light up.
Service engine soon lamp 105 trouble code cannot be recognized. -
Self-diagnosis code indicated by the lamp blinking.
* Can be recognized with Tech II.
Engine control condition cannot be recognized. Diagnostic trouble
Diagnosis related Engine control condition and self-diagnosis data 518
code cannot be recognized.
⋅ Diagnosis signal (transmission) 113, 114 transmitted to Tech II (Accelerator
* Can be recognized with SERVICE ENGINE SOON lamp.
⋅ Diagnosis signal (reception) "Accelerator learning" data from Tech II recognized learning only)
"Accelerator learning" impossible.
59, 81, 82, GND for the control unit, magnetic valve drive power,
GND (earth) Vehicle trouble cannot be felt. -
102, 111 injector power, case and others
1-22
5. Others
■ Object and procedure for accelerator learning (learning of accelerator pedal idling
position and full-throttle position)
Accelerator learning (learning of idling position and full-throttle position) process has been adopted from
’00 model in order to control the inconstant fuel injection rate according to the accelerator pedal operating
distance, for the purpose of improving the fuel cost performance.
By learning the "idling position" and "full-throttle position" for each vehicle, excess play of the accelerator
pedal can be reduced and the effective stroke distance to the pedal opening (actual accelerator opening) can
be increased. As a result, wasteful fuel consumption when the vehicle is traveling at a constant speed can be
reduced.
Accelerator learning procedure

Tech II is used for the accelerator learning. The "idling position" and "full-throttle position" of the vehicle
are read into Tech II once and then written (recorded) into the control unit.
Follow the instructions displayed on the screen of Tech II. (Refer to Item 2, "Learning of Accelerator",
Chapter 6,"How to use the IE System Inspection Tools" for details.)
Carry out the accelerator learning process:
• after replacing the engine control unit,
• after replacing the accelerator sensor or bracket assembly, and
• after adjusting the floor bolt.
Be sure to perform the accelerator learning process while
the floor bolt is properly adjusted, If not, output shortage
or other trouble may be caused. (Refer to the description
of the accelerator link mechanism below.)
Accelerator link mechanism

The accelerator link (ENG CONT BRKT) is provided with a
stopper used to control (assure) the operating angle of the
accelerator sensor lever for the accelerator link itself. As a
result, the operating angle of the accelerator pedal is controlled
with the accelerator link. Therefore, the floor bolt does not
function as a stopper; it is set up as a pedal protection function. Stopper
mechanism
Adjust the floor bolt as illustrated below.
When the accelerator

pedal is fully
stepped on
1.0 - 2.0mm (gap)
Stopper bolt
Lock nut
1-23
Others
■ Q adjustment data
A sticker is attached to the vehicle body to indicate the Q adjusting data at the time of the shipment of the
vehicle. It is used to compare the description with that of the Tech II.
Sticker position
Q adjustment data No. Timing compensation

(Q1, Q2, Q3 from the left) resistance value (unused)
Q adjustment value T compe.
Control No. in plant

(varying depending on vehicle)
-
Vehicle model
Sticker
1-24
Chapter 2
Failure diagnosis
1. Self-diagnosis of IE system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Method of checking the diagnostic trouble code by SERVICE ENGINE SOON lamp . . . . . . . . . 2-2
Erasing the diagnostic trouble code by memory clear switch (connector) . . . . . . . . . . . . . . . 2-3
Tech 2 Operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2. Vehicle diagnostic procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
1. Self-diagnosis of IE system
Diagnostic trouble codes can be checked or erased in the following procedure.

<Check of diagnostic trouble code>
• Check by SERVICE ENGINE SOON lamp
• Check by Tech II (with the Tech II connected)
• Check by diagnosis monitor (with the diagnosis monitor connected)
<Erasure of diagnostic trouble code>
• Erasure by memory clear switch (with the connector connected)
• Erasure by Tech II (using the communication mode)
• Erasure by diagnosis monitor
■ Method of checking the diagnostic trouble code by SERVICE ENGINE SOON lamp
As shown in the figure below, the indication method is different between vehicles with multi-warning system
and those without multi-warning system.
Diagnostic trouble codes can be checked by the service engine soon lamp blinking as before. In this case,
the indication should be changed over by operating the multi-warning switch. Immediately after the
indication is changed over, the self-diagnose code is kept indicated and so the indication at that moment is
not correct.
SERVICE ENGINE SOON lamp

[Vehicle equipped with no multi warning]
– + 15
10 20
5 25
H
0 X100 r/min 30
TRIP A
ODO B
L
2-2
Self-diagnosis of IE system
● Diagnostic trouble code blinking pattern

Service engine soon lamp (in case of code "23")
t4 t3 t2 t3 t2 t1 t2 t1 t2 t1 t4 t1 = About 0.3 sec.

t2 = About 0.6 sec.
ON
t3 = About 1.2 sec.
t4 = About 2.4 sec.
OFF
Tens digit Units digit
Service engine soon lamp (in case of code "413")
t4 t1 t2 t1 t2 t1 t2 t1 t2 t3 t2 t1 t2 t1 t2 t1 t4
ON
OFF
Hundreds digit Tens digit Units digit
● Contents of diagnostic trouble codes

• Engine stop ➡ Both the diagnostic trouble code for the current condition and past one in the
memory are indicated at the same time.
• Engine running ➡ Only the current diagnostic trouble code is indicated.
■ Erasing the diagnostic trouble code by memory clear switch (connector)

The diagnostic trouble codes can be erased by operating the memory clear switch connector installed in the
inspection cover on the vehicle.
2-3
● Connector installing position
● Diagnositic trouble code indication procedure

The three-digit self-diagnosis code flashes starting from hundred’s figure, while the two-digit self-
diagnosis code flashes starting from ten’s figure to indicate the self-diagnosis code.
Please read the self-diagnosis code from the flashing.
If the plural self-diagnosis codes are indicated, the same self-diagnosis code is flashed repeatedly in
steps of three times.
Please read it correctly.
• DTC outputting is done in decreasingly order of DTC number.

• Indication is changed over on completion of output DTC indication.
• DTC indicator is stopped with diagnostic switch being off.
• When there no DTC output, "1" is outputted in normal DTC code.
• After indicating 3 times pear 1 DTC, shift is conducted to the next DTC. (After making a round, the
indications are repeated again.)
• If only 1 code is present, that code will be flashed coutinuously.
Example Diagnosis Trouble Code Output
2-4
● Self-diagnosis code erasing procedure

Under the following condition, the diagnosis code memorized in EEPROM is cleared.
Condition 1
Condition 2
Condition 1:
Check the memory clear switch “OFF”.
Key switch "ON" continues 1 sec. or more.
Memory clear switch "ON" continues 1 sec. or more.
Memory clear switch "OFF" continues 0.5 sec. or more.
Memory clear switch
2-5
Tech II Operation manual
● Diagnosis Strategy-Based Diagnostics

Strategy-Based Diagnostics
The strategy-based diagnostic is uniform approach to repair all Electrical/Electronic (E/E) systems. The
diagnostic flow can always be used to resolve an E/E system problem and is a starting point when
repairs are necessary. The following steps will instruct the technician how to proceed with a diagnosis:
1. Verify the customer complaint.
To verify the customer complaint, the technician should know the normal operation of the system. =
not present (History)
2. Perform preliminary checks.

• Conduct a thorough visual inspection.
• Review the service history.
• Detect unusual sounds or odors.
• Gather diagnostic trouble code information to achieve an effective repair. = Intermittent
3. Check bulletins and other service information. System checks contain information on a system that may
not be supported by one or more DTCs. System checks verify proper operation of the system. This will
lead the technician in an organized approach to diagnostics. = Present
● Reading Diagnostic Trouble Codes Using the Tech II Scan Tool

The procedure for reading diagnostic trouble code (s) is to use a diagnostic Scan Tool. When reading
DTC (s), follow instructions supplied by the tool manufacturer.
Clearing Diagnostic Trouble Codes.

IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each
diagnostic procedure. When DTC (s) is cleared, the Failure Record data that may help diagnose and
intermittent fault will also be erased from the memory.
To clear Diagnostic Trouble Codes (DTCs), use the diagnostic Scan Tool "clear information" or
"Programming" function. When the DTC (s) is cleared the following instructions are supplied by the tool
manufacturer.
Tech II Features
NOTE1: Install the Tech II Adapter and supply voltage is 12 volts for Tech II.
NOTE2: The DLC cable is only to be used for diagnosis of Tech II
Refer to users guide of the Tech II.
To prevent system damage, the ignition key must be "OFF" when disconnecting or reconnecting
battery power.
1. Tech II is a 12 volts system. Do not apply 24 volts.

2. After connecting and/or installing the Vehicle Communication Interface (VCI) module, PCMCIA card
and DLC connector to the Tech II, connect the tool to the vehicle DLC.
3. Make sure the Tech II is powered OFF when removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes.
5. The Tech II has two snapshots.
2-6
6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the
handling of the card.
7. The Tech II can plot a graph when replaying snapshot.
8. Always return to the Main Menu by pressing the EXIT key several times before shutting down.
9. To clear Diagnostic Trouble codes (DTCs), open Application Menu and press "F1: Clear DTC info".
2-7
● Tech II Overview
Tech II is useful for engine diagnoses and system checks. Although trouble diagnosis can be performed
without Tech II, using Tech II will increase efficiency.
Tech II is portable, compact and light tester. Connected with the self-test connector of the vehicle, TechII
performs various diagnoses and tests by communicating with ECM.
Tech II Scan Tool

From 98 MY, Isuzu is recommended to use Tech 2. Refer to Tech 2 scan tool user guide.
1
9
TE
CH
2
AD
AP
TE
R
8
2
6
1
7
PS
8
W
1
Legend (5) Signal selective Switch

(1) PCMCIA Card (6) Adapter Cable
(2) Tech2 (7) Connector for DLC
(3) DLC Cable (8) Adapter DLC Cable
(4) Tech2 Adapter (9) Selective Switch
2-8
Tech 2 Features
1. Tech 2 is a 12 volt system. Do not apply 24 volt.
2. After connecting and/or installing, the Vehicle Communications Interface (VCI) module, PCMCIA card
and DLC connector to the Tech 2, connect the tool to the vehicle DLC.
3. Make sure the Tech 2 is powered OFF when removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes which is 10 times greater than the memory of the
Tech 1 Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the
handling of the card.
7. The Tech 2 can plot a graph when replaying a snapshot.
8. Always return to the Main Menu by pressing the EXIT key several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open Application Menu and press “F1: Clear DTC Info”.
Getting Started
Before operating the Isuzu PCMCIA card with the Tech 2, the
following steps must be performed:
1. The Isuzu PCMCIA card (1) inserts into the Tech 2 (2).
2. Connect the adapter cable (6) to the DLC cable (3) and the
Tech 2 adapter (4).
3. Connect the DLC cable (3) to the Tech 2 (2).
4. Make sure the vehicle starter key is off.
5. Connect the adapter DLC cable (8) to the vehicle DLC.
6. Select “3” position of the selective switch (9).
7. Switch the signal selective switch (5).
1 side : Use when taking in data from ECM to Tech 2.
ex) Programming (Upload Fuel Rate Data), Data
Display, Read DTC
TE
CH
2
AD
AP
2 side : Use when commanding from Tech 2 to ECM.

TE
R
2
6
1
ex) Programming (Download Fuel Rate Data),

PS
8
W
1
Special Functions, Clear DTC

8. The vehicle starter switch turns on.
9. Verify the Tech 2 power up display.
1
Press (ENTER) To Continue
2-9
20 Pins Connector Pin assignment
Pin No. 3 = Power supply

Pin No. 4 = TechⅡ signal (TXD)
Pin No. 12 = TechⅡ signal (RXD)
Pin No. 13 = Ground earth
Operation of Tech II
1. Check the initial display appears.
Main Menu 2. Press [ENTER].

The Main menu appears.
F0: Diagnostics
F1: Service Programming System (SPS)
F2: View Capture Data
F3: Tool Options
F4: Download / Upload Help
3. Select [F0] and press [ENTER].

Vehicle Identification
Select one of following The Vehicle Identification display to select Model
Model Year(s)
appears.
(3) 2003
(2) 2002
(1) 2001
(Y) 2000
(X) 1999
(W ) 1998
1/3
(3) 2003
2-10
4. Select Applicable Model Year.
Select one of following For instance "2003" and press [ENTER].
Vehicle Type(s)
(UB) Trooper, Bighorn
(UE) Rodeo / Amigo, Wizerd/MU
(UG) V-Cross
(UC) Frontier, LAO-Rodeo
(TF) LUV (C＊, E＊, L＊, F＊)
(TB) Panther
(N*) ELF, NPR, NQR
(C＊, E＊, L＊, F＊) Heavy, Medium Duty
8/8
(C*, E*, L*, F*) Heavy, Medium Duty
5. Select [Heavy, Medium Duty] and press [ENTER].

System Selection Menu
(3) 2003 (C＊, E＊, L＊, F＊) Heavy, Medium Duty
The System Selection Menu appears.
F0: Engine
F1: Transmission
F2: Chassis
F3: Body

Select one of following
The Vehicle Identification display to select engine
Engine appears.
(IE) 6SD1-TC (Common Rail)
(IE) 6HK1-TC (Common Rail)
(IE) 6WG1-TC (Common Rail)
6HK1 (LG4)
2/9
(IE) 6WG1-TC (Common Rail)
7. Select engine model 6SDI-TC (Common Rail) and

System Identification
(C＊, E＊, L＊, F＊) Heavy, Medium Duty press [ENTER].
Engine/ (IE) 6WG1-TC (Common Rail) The System Identification display to turn on ignition
appears.
If the engine identification is "OK", set the Ignition key
Turn On Ignition! from "OK" to "Start" and press the soft key "Confirm"
according to the instruction on the screen. If the
operation is incorrect, press the [EXIT] key and you
Confirm
will be back to the main menu. Then restart selection.
System Identification
8. Turn on the ignition and press [Confirm]. The
(C＊, E＊, L＊, F＊) Heavy, Medium Duty System identification display to enter ROM ID.
Engine/ (IE) 6WG1-TC (Common Rail)
number appears.
ROM Identification 3E080 210
Enter the ROM Identification number then confirm it.
Confirm
2-11
Engine
9. After engine display appears, select [F0] and press
[ENTER].
F0: Diagnostics Trouble Codes
F1: Data Display
F2:Snapshot
F3:Programming
F4:Special Functions

Diagnostic Trouble Codes
The Diagnostic Trouble Codes display appears.
F0: Road DTC info Ordered By Priority
F1: Clear DTC Information

Clear DTC Information
The Clear DTC Information display appears.
Engine: (IE) 6WG1-TC (Common Rail) Press [Yes] and the DTC number is cleared.
Do you want to clear DTCs? (Yes / No)
NO YES
12. The Clear DTC Information display appears.

Press [Continue] and then return to the Diagnostic
Trouble Codes display.
Clear DTC Information Successful
Continue
13. After the DTC number is cleared, check and

confirm the DTC number.
Engine: (IE) 6WG1-TC (Common Rail)
Please Check DTCs.
Confirm
2-12
14. Select the Snapshot Options display.

Snapshot Options
Trigger Type : Manual Trigger

F0: Manual Trigger
F1: Any Code
F2: Single Code
Trigger Point : Center
F4: Beginning
F5: Center
F6: End
Record Review
Snapshot Data
2-13
Flow Chart for Snapshot relay (Plotting Graph)
Press the enter-key in the initial display.
Select "VIEW CAPTURE DATA"
If snapshot options are displayed, decide a

trigger type, and select "REVIEW DATA".
When the data triggered by vehicle is

displayed, select the data.
(Plural display of data depending on the
number of times of triggering.)
Data is displayed on the screen.

To see the graph, select "PLOT" in the
lower part of the monitor screen.
Changed to the item selection screen,

push the enter key up to three times.
And select "ACCEPT" under screen.
The graph is displayed on the screen.
2-14
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle informaion)
Procedure Base on Data Display Procedure Base on Trigger Type Decision

After confirming FLOW "MAIN MENU After confirming FLOW "MAIN MENU
DIAGNOSIS" -ID, select "DATA DISPLAY" DIAGNOSIS" -ID, select "SNAP SHOT"
from APPLICATION MENU. from APPLICATION MENU.
After the display of vehicle data, select

"QUICK SNAPSHOT" in the lower part Select when the items have been displayed.
of the monitor screen
After the display of snapshot option,

decide a trigger type, and select "RECORD
SNAPSHOT".
After the lapse of some time, push "EXIT" If (STANDBY) blinks, and the upper right
button of the screen, select "TRIGGER".
Confirm the trigger type.
If "CONTINUE" is displayed in the lower part

of the monitor screen after the screen is
changed, select the data.
If "PLOT" is displayed in the lower part of the

monitor screen, select "PLOT".
When changed to the item selecting screen,

push the enter key in accordance with the
items up to three items and select "ACCEPT"
in the lower part of the monitor screen.
The graph is displayed on the screen.
2-15
2. Vehicle diagnostic procedure
■ Troubleshooting (Checking steps and corrective actions)

Perform the checking and corrective actions following the steps shown below.
Steps Checking and Corrective Actions Result YES NO
1 Confirm the user information (checking the vehicle condition) - Step 2 Confirm the
using the check sheet (Section 8). user
Did you check the vehicle condition? information
2 Check the SERVICE ENGINE SOON lamp for lighting. Lamp Step 3 Chapter 3
1. Turn the starter switch on. turns on Check the
(At this time, do not start the engine.) SERVICE
Does the SERVICE ENGINE SOON lamp turn on? ENGINE
SOON lamp
lighting circuit
(SERVICE
ENGINE SOON
lamp does not
turn on)
3 Check the SERVICE ENGINE SOON lamp for flashing. Lamp Step 4 Chapter 3
1. Turn the starter switch on. flashing Check the
2. Connect the diagnostic switch (connector). ENGINE
Does the SERVICE ENGINE SOON lamp flashing? SOON lamp
flashing
control system
(SERVICE
ENGINE
SOON lamp
does not
flashing)
4 Connect the Tech II. Tech II Step 5 Chapter 3
1. Turn the starter switch off. turns on, Check the
2. Connect the Tech II to the connector. and the Tech II
3. Turn the starter switch on. Engine
4. Turn the Tech II on. Control Unit
5. Using the Tech II, communicate with the Engine Control is
Unit. recognized
Does the Tech II turn on, and is the Engine Control Unit
recognized?
5 Using the Tech II, read and record diagnostic trouble codes. - Step 6 -
1. Recording current and past codes: Memo 1
2. Read diagnostic trouble codes with the engine in stop status
Did the corrective actions complete?
2-16
Vehicle diagnostic procedure

6 Confirm the diagnostic trouble codes in Memo 1 to check if - Checking by Step 7
diagnostic trouble codes 33 and 35 are detected or not. diagnostic
Are the diagnostic trouble codes 33 and 35 detected? trouble code
list
7 Check if the engine starts. - Step 8 Chapter 3
Does the engine start? Checking the
engine starting
system
(3-24)
8 Using the Tech II read and record diagnostic trouble code. - Step 9 Step 6
(Recording current code: Memo 2)
(Read the diagnostic trouble code with the engine running)
Did corrective actions complete?
9 Compare the Memo 1 with Memo 2 to check the diagnostic trouble - Chapter 4 Step 10
codes. Checking by
Current code . . .? diagnostic
Past code . . . . . .? trouble code
*If normal, the diagnostic trouble code "1" is displayed.
Is current code displayed?
10 Is past code of diagnostic trouble codes displayed in step 9? - - Step 11
11 Check the common rail system. - - Chapter 4

Check to the items for diagnostic trouble codes "14 and 15" Checking
(checking engine timing sensors), "271-276" (checking injector procedure for
related), and "115, 118, 151, 245, 226, 227" (checking common rail each diagnostic
fuel pressure related, and supply pump). trouble code
2-17
Vehicle diagnostic procedure

12 Check the Engine Control Unit (engine control condition). Using - Step 4 Step 13
the Tech II, perform various tests to check if the tests terminated
successfully or the test results are normal.
(Conduct various tests by referring to Section 6 Tech II)
• Fuel Pressure Control
Changing the fuel pressure in common rail, check if actual
pressure follows the set pressure, or the fuel leaks from the fuel
piping when the pressure is raised.
• Injection Timing
Changing the fuel injection timing, check if the injection timing
control operates according to the variations of engine speeds or
exhaust gas conditions. (White smoke in case of negative
advance)
• RPM Control
Changing the set idling speeds, check if actual idling speed
follows the set speed and the idling control operates normally.
• Pilot Injector Stop
Stop the pilot injector, and check from the change in engine
sound at idling if the pilot injection control operates normally.
• Injection Stop
Stop the injection, and check if the engine stops.
• Exhaust Brake Control
With the engine in stop status, check the exhaust brake and
retarder for function.
• Magnetic (Solenoid) Valve
Check the magnetic valves for function.
Note that the quantity and applications of magnetic valves are
different depending on the engine.
Did the tests terminate successfully, or are the test results normal?
13 Repair or replace the parts judged faulty in step 12. - Check the -
Did corrective actions complete? repair
2-18
Chapter 3
Functional diagnosis
Preface
For the purpose of keeping engine operation normal or to restore the engine operation to normal condition,
functional diagnosis is made. If some engine control functions are not properly working, the engine control unit
diagnoses erroneously or some error showing no diagnostic trouble code occurs so that diagnosis cannot be made
correctly.
Follow the inspection procedure described on the following pages for diagnosis (check or repair) of functions.
Checking of SERVICE ENGINE SOON lamp

lighting circuit system (SERVICE ENGINE SOON lamp does not turn ON) . . . . . . . . . . . . 3-2
Checking the SERVICE ENGINE SOON lamp flashing control system
(SERVICE ENGINE SOON lamp does not flashing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Checking the Tech II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Checking the engine starting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Checking the power supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Checking the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Checking the intake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Checking the starting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Checking the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Checking the EGR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Checking the power take off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Checking the power take off (PTO) switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Checking the parking switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Idling speed cannot be adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Idling speed cannot be decreased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Chapter 3 Functional diagnosis
Checking of SERVICE ENGINE SOON lamp lighting circuit
system (SERVICE ENGINE SOON lamp does not turn ON)
■ SERVICE ENGINE SOON lamp circuit
Battery Relay
SBF 3 SBF 5 Fuse 50
SBF 1
Starter Switch Fuse 22

"ON"
Fuse 11 Fuse 5
Battery
Meter
3 19
DLC
Service 4 12 13
CPU
Engine
Soon
Lamp
TXD RXD
Tacho
out
105 112 114 113
Engine Control Unit
25 6
Memory
Diag
Clear
Switch
Switch
3-2
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
■ Engine control unit power source, GND circuit
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
3-3
■ Connection of meter connector
CAUTION
USE FUSE WITH THE SPECIFIED CAPACITY.
Fuse box FUSE CAPACITIES OTHER THAN SPECIFIED MAY CAUSE
BREAKEDOWN OF THE SYSTEM.
1 Headlight(Upper)/ 11 Meter 21 Air dryer 26 Tail light illumination 36 46
Cornering light Blower motor Engine ECU
7.5A Left 7.5A Speed sensor 7.5A 15A 15A 15A
2 Headlight(Upper)/ 12 Back up light 22 27 37 Condenser fan motor 47
Checker Stop light ABS
7.5A Right 7.5A Sub starter 7.5A 15A 15A Compressor 15A
3 Headlight(Lower)/ 13 Power take off 23 ZF transmission 28 38 48
Starter Switch Wiper ABS
7.5A Left 7.5A Retarder Exhaust brake 7.5A 15A 15A 15A
4 Headlight(Lower)/ 14 24 29 Receptacle 39 Retractable 49 (Power Outlet)
Air Suspension Air Suspension
7.5A Right 7.5A 7.5A 15A Cigarette lighter 15A mirror 15A Receptacle, 12V
5 Click Dome light 15 25 Pretensioner Seat 30 40 (Power outlet) 50 Cab Air Sus
Engine ECU Turn signal
7.5A Cornering Light Power tilt lock 7.5A 10A Belt SRS 15A 15A Receptacle, 12V 15A (Actuator)
6 16 31 Spare (IGN) 41
Engine Stop Engine ECU Fog light
7.5A 7.5A 15A (Batt.) 15A
7 17 32 Power window 42 Spare IGN.
Door lock Engine ECU
7.5A 7.5A 15A (Assistant side) 15A (Key on)
8 Radio 18 33 Power window 43 Anti Jack Brake lock
ABS
7.5A Cassete stereo 7.5A 15A (Driver side) 15A Diff Lock Spot light
9 Engine ECU 19 34 Engine ECU 44
Cab Air Sus Window Washer
7.5A 7.5A 15A 15A
10 Engine ECU 20 35 45 Engine ECU
7.5A 15A
3-4
■ Circuit description
Power to operate the meter (SERVICE ENGINE SOON lamp) is supplied through the fuse.
Lighting up and going out of the lamp are controlled with the engine control unit. (The engine control unit
is located in the circuit between the power source and GND (ground) circuit to operate the lamp control
switch in the control unit and light up or extinguish the lamp.)
■ Possible causes
⋅ Faulty power supply circuit (starter switch circuit, etc.)
⋅ Faulty main unit (indicator, communication circuit)
⋅ SERVICE ENGINE SOON lamp (bulb) burnt out
⋅ Faulty meter main assembly (including circuits)
⋅ Disconnected wire of meter power source circuit
⋅ Disconnected wire of lamp driving circuit
⋅ Faulty engine control unit
⋅ Faulty engine control unit power circuit (key ON)
⋅ Faulty engine control unit power source circuit (main relay circuit)
⋅ Faulty engine control unit GND circuit
3-5

1 Check the fuses. Fuses are normal Step 3 Step 2
Check if the fuse for meter power and the fuses for Engine Control
Unit (No. 17 for key ON signal and No. 34 for main relay power) are
normal.
2 Replace the fuses, and check if the SERVICE ENGINE SOON lamp Lamp ON (operated) Step 17 Step 3
turns on (operated) when the starter switch is turned on again.
3 Check if the voltage is applied to fuses for need ECU. Battery voltage Step 4 Checking
1. Remove the fuses No.11, 17, and 34. the
2. Turn the starter switch on. power
3. Measure the voltage at each fuse mounting place. source
Is the voltage normal value? circuit
4 1. Disconnect the harness from the Engine Control Unit. Lamp ON (operated) Step 9 Step 5
2.Ground (GND) the connector (No.105 pin) of the Engine Control
Unit.
3.Turn the starter switch on.
5 Check the connector and harness of the meter circuit. No fault is found Step 7 Step 6
1. Disconnect the harness from the meter.
2. Disconnect the harness from the Engine Control Unit.
3. Check the connectors for corrosion, looseness, opening, or fitting
conditions of pins.
4. Referring to the circuit diagrams, check the following circuits:
⋅ Between power source and meter
1) Fuse No.17 to instrument (upper) harness connector
2) Meter to instrument (lower) harness connector
⋅ Between Engine Control Unit and meter
1) Engine Control Unit to instrument (lower) harness connector
2) ECU harness connector to instrument (upper) harness
connector
3) Meter to instrument (lower) harness connector
Are the harnesses and connectors normal?
3-6

6 Repair faulty parts (connectors and harnesses) in the meter circuit. Lamp ON (operated) Step 18 Step 7
After repair, check if the lamps other than SERVICE ENGINE
SOON lamp turn on (operate) when the starter switch is turned on
again.
7 Check the METER lamp bulb. Bulb is normal Step 9 Step 8
Is the bulb broken?
8 Replace the METER lamp bulb. Lamp ON (operated) Step 17 Step 9
After repair, check if the SERVICE ENGINE SOON lamp turns on
(operates) when the starter switch is turned on again.
Did the meter (lamp) operate?
9 Check the power source for the Engine Control Unit. Battery voltage Step 11 Step 10
2. Turn the starter switch on.
3. Measure the voltage at the connector of Engine Control Unit
(No.13 and 23 pins).
Is the voltage normal value?
10 Repair the harness between fuse No.17 and Engine Control Unit. Lamp ON (operated) Step 17 Step 11
again.
11 Check the main relay circuit (harnesses and connectors) and the No fault is found Step 13 Step 12
relays.
2. Remove the main relay.
conditions of pins.
⋅ Engine Control Unit to instrument (lower) harness connector
⋅ ECU harness connector to main relay
⋅ Fuse No.34 to main relay
⋅ Fuse No.34 to frame (Ft) harness connector
⋅ Instrument (lower) harness connector to ground point
5. Check the relays for function.
Are the harnesses, connectors, and relays normal?
3-7

12 Repair faulty harness, connector, or relay in the main relay circuit. Lamp ON (operated) Step 17 Step 13
again.
13 Check the GND for Engine Control Unit. No fault is found Step 15 Step 14
conditions of pins.
⋅ ECU harness connector to frame (Ft) harness connector
⋅ Instrument (lower) harness connector to ground point
14 Repair faulty harnesses and connectors in the ground circuit for the Lamp ON (operated) Step 17 Step 15
Engine Control Unit.
again.
15 Replace the meter assembly. Lamp ON (operated) Step 17 Step 16
again.
16 Replace the Engine Control Unit. - Step 17 -
*After the Engine Control Unit was replaced, perform the
accelerator learning.
17 Restore the vehicle, and perform the repair check. - Check -
end
3-8
(SERVICE ENGINE SOON lamp does not flashing)
■ SERVICE ENGINE SOON lamp circuit
Battery Relay
SBF 3 SBF 5 Fuse 50
SBF 1

"ON"
Fuse 11 Fuse 5
Battery
Meter
3 19
DLC
Service 4 12 13
CPU
Engine
Soon
Lamp
TXD RXD
Tacho
out
105 112 114 113
Engine Control Unit
25 6
Memory
Diag
Clear
Switch
Switch
3-9
■ Connection of meter connector
CAUTION
3 Headlight(Lower)/ 13 Power take off 23 ZF transmission 28 38 48
Starter Switch Wiper ABS
5 Click Dome light 15 25 Pretensioner Seat 30 40 (Power outlet) 50 Cab Air Sus
Engine ECU Turn signal
6 16 31 Spare (IGN) 41
Engine Stop Engine ECU Fog light
7.5A 7.5A 15A (Batt.) 15A
7 17 32 Power window 42 Spare IGN.
Door lock Engine ECU
8 Radio 18 33 Power window 43 Anti Jack Brake lock
ABS
7.5A 7.5A 15A 15A
7.5A 15A
3-10
Power to operate the meter (SERVICE ENGINE SOON lamp) is supplied through the fuse No.11.
Lighting up and going out of the lamp flashing are controlled with the engine control unit. (The engine
control unit is located in the circuit between the power source and (GND), to operate the lamp control switch
in the engine control unit and lighting up or extinguish the lamp flashing.)
■ Possible causes
⋅ Faulty meter main assembly (including circuits)
⋅ Shorted lamp driving circuit
⋅ Faulty diagnostic switch circuit

1 Check the diagnostic switch (connector) circuit. No fault is found Step 3 Step 2
conditions of pins.
⋅ Between Engine Control Unit and diagnostic switch (connector)
2) ECU harness connector to diagnostic switch (connector)
⋅ Between diagnostic switch (connector) and ground (GND)
1) Diagnostic switch (connector) to frame (Ft) harness connector
2) Instrument (lower) harness connector and ground (GND)
2 Repair faulty harnesses and connectors in the diagnostic switch flashing (operate) Step 8 Step 3
(connector) circuit.
3-11

3 Check the connector and harness of the meter circuit. No fault is found Step 8 Step 4
1. Disconnect the harness from the meter.
conditions of pins.
⋅ ECU harness connector to instrument (upper) harness connector
⋅ Meter to instrument (lower) harness connector
4 Repair faulty parts (connectors and harnesses) in the meter circuit. flashing (operated) Step 8 Step5
5 Replace the meter assembly, and connect all harnesses for the Engine Starter switch ON: Step 8 Step 6
Control Unit, etc. Lamp ON
Starter switch OFF:
Lamp OFF
6 After repair, check if the lamps other than SERVICE ENGINE flashing (operated) Step 8 Step 7
SOON lamp flashing (operate) when the starter switch is turned on
again.
*After the Engine Control Unit is replaced, perform the accelerator
learning.
Did corrective action complete?
end
3-12
Checking the Tech II
■ Self-diagnosis circuit (Engine control unit)
Battery Relay
SBF 3 SBF 5 Fuse 50
SBF 1

"ON"
Fuse 11 Fuse 5
Battery
Meter
3 19
DLC
Service 4 12 13
CPU
Engine
Soon
Lamp
TXD RXD
Tacho
out
105 112 114 113
Engine Control Unit
25 6
Memory
Diag
Clear
Switch
Switch
3-13
There are Two Tech II communication circuits provided; one in the signal communication circuit from the
engine control unit to the Tech II and other in the signal received circuit from the Tech II to the engine control
unit.
The signal from the transmission side is used for the "monitor" mode to read the self-diagnosis codes or
engine data with the Tech II.
The signal from the reception side is used for the "communication mode" to erase the self-diagnosis codes,
etc., or for the "inspection mode" to check the accelerator learning or switches.
■ Possible causes
⋅ Faulty circuit from the engine control unit connector to Tech II connector (disconnected wire, short circuit,
etc.)
⋅ Faulty Tech II connector power source
3-14

1 Check the fuse. Fuse is normal Step 3 Step 2
Is the power fuse for Tech II normal?
2 Replace the fuse, and turn the starter switch on again to check the Lamp ON (operated) Step 15 Step 3
Tech II for function.
Does the Tech II operate?
3 Check the Tech II power supply. Battery voltage Step 7 Step 4
Check if the voltage is applied to the Tech II when the starter switch
is turned on.
Is the voltage applied?
4 Check if the voltage is applied to the fuse when the starter switch is Battery voltage Step 7 Step 6
turned on.
5 Repair the power supply circuit for the Tech II. Tech II operates Step 15 Step 6
After repair, check the Tech II operation when the starter switch is
turned on again.
6 Repair or replace the power supply circuit. Tech II operates Step 15 Step 7
(See Section 6, Wiring check "power supply circuit")
turned on again.
7 Check the Tech II connector circuit. No fault is found Step 15 Step 8
conditions of pins.
⋅ Between Engine Control Unit and Tech II connector
2) ECU harness connector to Tech II connector
8 Repair faulty harnesses and connectors in the Tech II connector Tech II operates Step 15 Step 9
circuit.
turned on again.
9 Check the fuse (2A) inside the Tech II. No fault is found. Step 15 Step 10
Is the fuse (2A) normal?
10 Replace the fuse (2A) inside the Tech II. Tech II operates Step 15 Step 11
turned on again.
3-15

11 Check the diagnosis harness. No fault is found. Step 15 Step 12
Is the diagnosis harness normal?
12 Repair or replace the diagnosis harness. Tech II operates Step 15 Step 13
After repair or replacement, check again the Tech II operation.
13 Check the Tech II. Tech II turns on (starts) Step 15 Step 14
1. Remove the Tech II from the vehicle.
2. Install the 100V power adapter to the Tech II.
3. Turn the Tech II on.
Does the Tech II turn on (start)?
14 Replace the Tech II. - Step 15 -
15 Check the communicating condition between Engine Control Unit Communication enabled Step 19 Step 16
and Tech II.
1. Install the Tech II on the vehicle.
2. Communicate with the Engine Control Unit (IE system). (Two
kinds of program cards are provided, each for power train and for
chassis. For the IE system, use the card for power train.)
Is the communication with Engine Control Unit enabled?
16 Check the Tech II (program card). Communication enabled Step 17 Step 14
1. Install the Tech II on the vehicle.
2. Communicate with the systems (Air suspension etc.) except the
engine. (Two kinds of program cards are provided, each for power
train and for chassis.)
Is the communication with the systems except engine enabled?
17 Replace the Tech II (program card for power train), and Communication enabled Step 19 Step 18
communicate with the Engine Control Unit (IE system).
Is the communication with Engine Control Unit enabled?
learning.
end
3-16
Checking the engine starting system
■ Possible causes
⋅ Faulty starting system (starter, starter relay, starter circuit, battery, etc.)
⋅ Engine control system down (faulty Engine Control Unit, power source, GND, etc.)
⋅ Faulty supply pump (main body, PCV, feed pump)
⋅ Faulty injectors
⋅ Faulty common rail
⋅ Faulty fuel system (empty fuel, faulty piping, filter, air mixing, frozen fuel, etc.)
⋅ Faulty intake system (filter, etc.)
⋅ Faulty exhaust system (exhaust brake, etc.)
⋅ Engine trouble

1 Check the battery voltage, and if faulty, recharge or replace the - Step 2 -
battery.
Did the corrective action complete?
2 Check the starter operation. Starter operates Step 3 Checking
Does the starter operate? the starter
circuit
After
repair and
check,
step 3
3 Check the starter for function. - Step 4 Referring
1. Turn the starter switch off. to the
2. Remove the starter. engine
3. Check the starter, and repair or replace, if faulty. repair
Did corrective actions complete? manual,
check the
starter,
then after
repair or
replacement,
step 4
4 With the starter removed, check the flywheel (ring gear) and starter - Step 5 -
pinion, and repair or replace if faulty.
5 After repair, start the engine again. Engine starts Step 18 Step 6
Does the engine start?
3-17

6 Check the fuel system. (Go to "Checking the fuel system") - Step 7 Check
Did corrective action complete? the fuel
system,
and
after
repair
and
check,
step 7
7 After repair or replacement, start the engine again. Engine starts Step 18 Step 8
8 Check the intake system. (Go to "Checking the intake system") - Step 9 Check
Did corrective action complete? the
intake
system,
and
after
repair
and
check,
step 9
9 Check the exhaust system. (Go to "Checking the exhaust system") - Step 10 Check
Did corrective action complete? the
exhaust
system,
and
after
repair
and
check,
step 10
11 Check the fuel injection timing. At flywheel: BTDC 0° Step 13 Step 12
Check the mechanical timing at two places of supply pump and At supply pump
flywheel. (coupling): Scribed line
Is the mechanical timing normal? coincides with pointer
12 Adjust the engine mechanical timing. Engine starts Step 18 Step 13
After adjustment, start the engine again.
3-18

13 Check if the diagnostic trouble codes have been detected. The specified diagnostic Step 14 Checking
(Diagnostic trouble codes that stop the engine by the backup control) trouble codes are not by
1. Connect the Tech II. detected diagnosti
2. Check if the following diagnostic trouble codes are detected. c trouble
Diagnostic trouble codes: 14, 15, 227, 118, 158, 159 code.
Are diagnostic trouble codes detected? After
repair
and
check,
step 14
learning.
16 After repair, start the engine again. Engine starts Step 18 Step 17
17 Check mechanical parts of the engine, and repair if faulty. - Step 18 -
⋅ Valves
⋅ Compressive pressure
⋅ Timing gear
⋅ Piston and crank related parts
end
3-19
Checking the power supply circuit
■ Power Supply Circuit (including starter switch signal circuit)
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
3-20
■ Arrangement of fuses
CAUTION
3 Headlight(Lower)/ 13 Power take off 23 ZF transmission 28 38 Wiper 48
Starter Switch ABS
5 Click Dome light 15 Engine ECU 25 Pretensioner Seat 30 Turn signal 40 (Power outlet) 50 Cab Air Sus
6 16 31 Spare (IGN) 41 Fog light
Engine Stop Engine ECU
7.5A 7.5A 15A (Batt.) 15A
7 Door lock 17 Engine ECU 32 Power window 42 Spare IGN.
8 Radio 18 ABS 33 Power window 43 Anti Jack Brake lock
7.5A 7.5A 15A 15A
7.5A 15A
3-21
The power is supplied to respective units through two systems; the one is battery direct power supplied via
the Slow Blow Fuse (SBF) No.1, and the other is the power supplied to the SBF via the battery relay that
operates when the starter switch is in ON position and then the power is supplied from the SBF to each unit.
The Engine Control Unit and meter are driven by the power supplied via the battery relay.
The starter switch and power tilt circuit are driven by the battery direct power.
■ Possible causes
⋅ Faulty battery (liquid quantity, specific gravity, etc.)
⋅ Blown slow blow fuse (SBF)
⋅ Blown fuses
⋅ Faulty battery relay (internal disconnection, sticking, etc.)
⋅ Faulty starter switch
⋅ Faulty harnesses (disconnection, shortcircuit, etc.)
1) SBF (SBF box harness) - Frame (Ft) harness - Starter switch/fuse box "instrument (lower) harness"
2) Battery relay (SBF box harness) - Ground point "frame (Ft) harness"
3) Faulty battery cables (loose connection, etc.)

1 Check the Slow Blow Fuses (SBF No.1 - 7). SBF's are normal Step 3 Step 2
1. Turn the starter switch off. (not blown)
Remove the SBF box cover, and check SBF's.
2 Replace the SBF's. - Step 3 -
3 Check if the voltage is applied to the Slow Blow Fuse (SBF) No.1. Battery voltage Step 5 Step 4
Is the voltage applied to the SBF No.1?
4 Check the battery for voltage, cable condition or disconnection, and - Step 5 -
repair or replace if faulty.
5 Check if the voltage is applied to the fuse (No.28). Battery voltage Step 7 Step 6
(Power is supplied to the left terminal of the fuse)
Is the voltage applied to the fuse (No.28)?
3-22

6 Check the fuse power supply circuit for disconnection, and repair or - Step 7 -
replace faulty part.
1. Disconnect negative terminal of the battery.
2. Check the following circuit for continuity:
⋅ Power supply terminal of fuse No.28 to frame (Ft) harness
connector
⋅ Instrument (lower) harness connector to Slow Blow Fuse box
harness connector
⋅ Slow Blow Fuse No.1 to frame (Ft) harness connector
7 Check if the voltage is applied to the frame (Ft) harness connector, Starter switch OFF: 0V Step 8 Step 13
pin 1 "instrument (slow) harness" when the starter switch is turned Starter switch ON:
ON (OFF/0V to ON/battery voltage). (Battery relay power supply Battery voltage
circuit)
Is the battery voltage applied to the frame (Ft) harness connector?
8 Check if the voltage is applied to the battery relay connector "frame Starter switch OFF: 0V Step 9 Step 16
(Ft) harness" when the starter switch is turned ON (OFF/0V to Starter switch ON:
ON/battery voltage). Battery voltage
Is the battery voltage applied to the battery relay connector?
9 Check if the voltage is applied to the Slow Blow Fuses (SBF) No.2 - Starter switch OFF: 0V Step 10 Step 18
6 when the starter switch is turned ON (OFF/0V to ON/battery Starter switch ON:
voltage). Battery voltage
Is the battery voltage applied to the SBF No.2 - 6?
10 Check if the voltage is applied to the frame (Ft) harness connector Starter switch OFF: 0V Step 11 Step 19
(slow blow fuse box harness) when the starter switch is turned ON Starter switch ON:
(OFF/0V to ON/battery voltage). Battery voltage
11 Check if the voltage is applied to the instrument (lower) harness Starter switch OFF: 0V Step 12 Step 21
connector, pin 1 "frame (Ft) harness" when the starter switch is Starter switch ON:
turned ON (OFF/0V to ON/battery voltage). Battery voltage
12 Check if the voltage is applied to the fuses shown in the circuit Starter switch OFF: 0V Step 13 Step 23
diagram when the starter switch is turned ON (OFF/0V to Starter switch ON:
ON/battery voltage). Battery voltage
Is the battery voltage applied to each fuse?
3-23

13 Check the starter switch circuit for continuity. 0.5Ω or less Step 15 Step 14
⋅ Starter switch connector to frame (Ft) harness connector
⋅ Starter switch connector to fuse No.28
Is the circuit normal?
14 Repair or replace the starter switch circuit "instrument (lower) - Step 8 -
harness".
15 Replace the starter switch. - Step 8 -
Did the corrective action complete?
16 Check the battery relay circuit "frame (Ft) harness". 0.5Ω or less Step 9 Step 17
⋅ Confirm the continuity between instrument (lower) harness
connector and battery relay connector "frame (Ft) harness" to
check for disconnection in the circuit.
⋅ Check the circuit between battery relay connector and ground
point "frame (Ft) harness" for disconnection.
17 Repair or replace faulty circuit "frame (Ft) harness". - Step 9 -
18 Replace the battery relay. - Step 10 -
19 Check the Slow Blow Fuse (SBF) circuit (slow blow fuse box 0.5Ω or less Step 11 Step 20
harness).
⋅ Confirm the continuity between SBF 2-6 and frame (Ft) harness
connector (slow blow fuse box harness) to check for
disconnection in the circuit.
20 Repair or replace faulty circuit (slow blow fuse box harness). - Step 11 -
21 Check the frame (Ft) harness. 0.5Ω or less Step 12 Step 22
⋅ Confirm the continuity between instrument (lower) harness
connector and slow blow fuse box harness connector to check
for disconnection in the circuit. (SBF No.2 - 6 circuit)
3-24

22 Repair or replace the frame (Ft) harness in the circuit between - Step 12 -
instrument (lower) harness connector and slow blow fuse box
harness connector.
23 Check the power supply circuit for each fuse, and repair or replace if - Step 24 -
faulty.
⋅ Power supply terminal of each fuse to frame harness connector
(Power is supplied to the left terminal of the fuse)
24 Check for the continuity in the Engine Control Unit power circuit, - Step 26 Step 25
and repair or replace if disconnected.
⋅ Fuse No.45 - Main relay - Engine Control Unit
⋅ Fuse No.17 - Engine Control Unit
25 Repair or replace the Engine Control Unit power circuit "instrument - Step 26 -
(lower) harness".
end
3-25
Checking the fuel system
■ Possible causes
⋅ Empty fuel tank, or frozen fuel
⋅ Air mixing in fuel piping
⋅ Clogged fuel filters (main, pre, gauze filters)
⋅ Fuel quality
⋅ Clogged supply pump gauze filter, faulty feed pump
⋅ Faulty fuel piping (squeezed, bent, clogged, disconnected)
⋅ Faulty fuel tank (mixing of foreign materials, bent/cracked piping in tank)


1 Check the fuel quantity. - Step 2 Refill,
Is the fuel quantity enough? and go
to step 2
2 Check the fuel quality. Engine starts Step 8 Step 3
1. Drain the fuel from the fuel tank.
2. Refill the specified fuel.
3. Bleed the air from the fuel piping.
4. Start the engine.
3 Bleed the air from the fuel piping (perform with the priming pump - Step 8 Bleed
only). (The air bleeding by a dry-shot operation of the injector is the air,
executed in step 4.) and go
(Air bleeding section: Fuel tank - Feed pump - Fuel filter - Supply to step 4
pump)
At this time, if no fuel comes to the fuel filter, check the overflow
valve on the supply pump and replace it if faulty. If the overflow
valve is normal, connect the fuel hose at the top of fuel tank reversely
(reversed IN and OUT) to bleed the air, and when the fuel comes,
check the fuel tank by referring to step 7.
4 Bleed the air from the fuel piping. (Bleed the air by a dry-shot - Step 8 Bleed
operation of the injector.) the air,
(Air bleeding section: Supply pump - Common rail - Injector) By this and go
operation, bleed the air from the piping. If the air bleeding failed, the to step 5
engine control may be faulty. Thus, check the diagnostic trouble
codes.
3-26
Checking the fuel system

5 Check if the fuel filters are normal. - Step 8 Step 6
(Fuel filter and pre-fuel filter)
Clean or replace, if the filters are blocked with dust or clogged.
6 Check the fuel piping for abnormality and fuel leakage. - Step 8 Step 7
Check if the pipes are squeezed, bent, cracked, or loose, or if dust is
present in the injector or pump filters. Repair or replace, if faulty.
7 Check the fuel tank. - Step 8 -
Check if:
⋅ Foreign materials mix in
(Foreign materials block the fuel suction port)
⋅ Fuel suction pipe is bent
⋅ Fuel suction pipe is cracked
⋅ Fuel tank is deformed
⋅ Fuel tank is installed properly
⋅ Air breather in the fuel tank cap is clogged
⋅ Water mixes in the fuel tank
Repair or replace the fuel tank, if faulty.
8 Restore the vehicle, and bleed the air again from the fuel piping and - Check -
perform the repair check. end
3-27
Checking the intake system
■ Possible causes
⋅ Blocked air cleaner
⋅ Faulty intake piping (squeezed or damaged intake duct, piping, intercooler, etc.)

1 Check the air cleaner warning lamp condition in the meter. Lamp OFF Step 9 Step 2
Is the air cleaner warning lamp OFF?
2 Clean or replace the air cleaner - Step 9 Step 3
3 Check if the water or dust exists in the air cleaner case. No water or dust exists Step 9 Step 4
Is the inside of case normal?
4 Clean the inside of air cleaner case. Check the water drain valve, and - Step 9 Step 5
if faulty, repair or replace.
5 Check if the intake piping is squeezed or damaged. No water or dust exists Step 9 Step 6
Is the intake piping normal?
6 Repair or replace the intake piping, if it is squeezed or damaged. - Step 9 Step 7
7 Check if the intercooler piping is squeezed, damaged, or installed - Step 9 Step 8
improperly.
Is the intercooler piping normal?
8 Repair or replace the intercooler piping, if squeezed or damaged. - Step 9 -
9 Restore the vehicle, and perform the repair check - Check -
end
3-28
Checking the starting system
■ Starting circuit (including neutral signal circuit)
SBF 1
Fuse 28
Starter SW
Battery Relay
ON Start
Starter Relay Fuse 9

Battery
SBF 4
Starter:C
24
Engine Control Unit
33
Sub starter
SBF 3 No 12 SW Neutral Relay
Neutral
SW
3-29
The power is supplied to the starter to start the engine when the starter relay in the starter circuit operates.
For manual transmission vehicles, the starter relay operates when the starter switch is turned to the "S"
position.
For automatic transmission vehicles, the starter relay operates when the starter switch is turned to the "S"
position and the neutral relay operates.
In the sub starter circuit, the starter relay operates when the starter switch is turned to the "ON" position and
the neutral relay operates.
■ Possible causes
⋅ Faulty starter circuit (starter, starter relay, starter circuit, battery, etc.)
⋅ Faulty starter switch
⋅ Faulty neutral relay
⋅ Faulty control unit
⋅ Faulty neutral switch

1 Check the starter circuit and Slow Blow Fuse (SBF). 0.5Ω or less Step 3 Step 2
Confirm the continuity in the following circuits harness and
connector to check for disconnection:
⋅ Starter relay to Slow Blow Fuse (SBF) No. 3
⋅ Starter relay to starter (C Pin)
⋅ Starter relay to frame ground
⋅ Starter to frame (starter ground)
⋅ Slow Blow Fuse (SBF) No. 3
2 Repair or replace the starter circuit. Starter starts Step 15 Step 3
After repair or replacement, check again if the starter starts.
Does the starter operate?
3 Check the starter relay circuit. Starter switch Step 15 Step 4
1. Turn the starter switch off. OFF: 0V
2. Disconnect the harness (relay coil side: 2-pin connector) from the Starter switch
starter relay. S: Battery voltage
Check if the voltage is applied to the starter relay connector (harness
side) when the starter switch is turned to the "S" position (OFF/0V to
S/battery voltage). (Starter relay power supply circuit)
Is the battery voltage applied to the starter relay connector?
3-30

4 Check the circuit between starter switch and starter. Starter switch Step 15 Step 6
1.Disconnect the instrument (lower) harness and the frame (Ft) OFF: 0V
harness. Starter switch
2.Check if the voltage is applied to the frame (Ft) harness connector S: Battery voltage
"instrument (lower) harness" when the starter switch is turned to
the "S" position (OFF/0V to S/battery voltage). (Starter relay
power supply circuit)
5 Repair or replace the circuit between instrument (lower) harness Starter operates Step 15 Step 6
connector and starter relay "frame (Ft) harness".
After repair or replacement, check again if the starter operates.
6 Check the continuity in the circuit between starter switch and frame 0.5Ω or less Step 15 Step 7
(Ft) harness connector "instrument (lower) harness" to check for
disconnection.
Manual vehicles:
⋅ Starter switch to frame (Ft) harness connector
Automatic vehicles:
⋅ Starter switch to neutral relay
⋅ Neutral relay to frame (Ft) harness connector
⋅ Neutral relay circuit (coil-side circuit)
7 Repair or replace the circuit between starter switch and frame (Ft) Starter operates Step 15 Step 8
harness connector "instrument (lower) harness"
8 Check the relays (neutral relay, etc.), and replace if faulty. Starter operates Step 15 Step 9
9 Check the starter switch. 0.5Ω or less Step 15 Step 10
Check if the connector pins No.2 and 3 on the starter switch side are
continuous when the starter switch is turned to the "S" position.
Are the pins continuous?
10 Replace the starter switch. Starter operates Step 15 Step 11
11 Check the type of transmission. - Step 15 Step 12
Is the transmission type, automatic
3-31

12 Check the automatic system and neutral circuit, and repair or replace Starter operates Step 5 Step 13
if faulty.
13 Check the starter relays, and replace if faulty. Starter operates Step 15 Step 14
14 Replace the main starter. - Step 15 -
15 Restore the vehicle, and perform the repair check. Check
end
3-32
Checking the exhaust system
■ Exhaust brake circuit
Battery Relay
SBF 3
SBF 1 Fuse 13
Starter Switch
"ON"
VSS Control Unit Check

Exhaust Retardar
Connector
Brake Switch
Battery 2 Switch
A3 A18 A12 B4
Brake Intensive Control Unit
A9 B6 A20 A1 A11 A5 A17

GND
APP Clutch Retardar Exhaust

SW SIG Request Brake
SIG SIG Request
Retardar Exhaust SIG
Magnetic Brake
Valve Magnetic
Valve 8 80 7 108 2 37 12
Engine Control Unit
3-33
In the exhaust brake circuit, the power is supplied from the fuse No.13, and when the exhaust brake switch
(combination switch) is turned on, the signals are sent to thebrake intgrated control unit. At the same time,
the signals (exhaust brake switch signals) are also sent to the Engine Control Unit. Upon signal reception, the
brake intensive control unit operates the exhaust brake magnetic valve, and this operating signal is also sent
to the Engine Control Unit.
■ Possible causes
⋅ Faulty exhaust brake (exhaust brake is kept closed, air cylinder does not return, etc.)
⋅ Faulty exhaust brake magnetic valve
⋅ Faulty brake integrated control unit
⋅ Faulty exhaust brake switch system

1 Check the exhaust brake operation. Engine starts, and exhaust Step 10 Step 2
1. Turn the starter switch on. brake operates (OK) (NG)
2. Start the engine and idle it.
3. Disconnect the connector (PA1 pin, green) inside the inspection
cover.
4. Turn on the exhaust brake switch lever.
Does the engine start? Does the exhaust brake operate?
2 Check the exhaust brake switch. ON ↔ OFF indication on Step 4 Step 3
1. Connect the Tech II. the screen is changed (OK) (NG)
2. Shift the gear to the neutral position. over by switch operation
4. Check the switch inputs with the Tech II.
5. Operate the exhaust brake switch.
6. Check if the ON/OFF indication on the Tech II screen is changed
over by the switch operation.
Is the ON/OFF indication changed by switch operation?
3-34

3 Check the exhaust brake switch circuit for the continuity, and repair Exhaust brake operates Step 10 Step 4
or replace faulty parts. (OK) (NG)
⋅ Combination switch itself
⋅ Fuse No.13 to combination switch
⋅ Combination switch to base harness connector
⋅ Base harness connector to Engine Control Unit
⋅ Combination switch to floor (left) harness connector
⋅ Instrument (lower) harness connector to sheet harness
connector
⋅ Floor (left) harness connector to brake integrated control unit
connector (A)
After repair or replacement, check again the exhaust brake operation
using the connector (PA1 pin, green) inside the inspection cover.
Does the exhaust brake operate?
4 Using the circuit tester, measure the resistance of exhaust brake Magnetic valve, Step 6 Step 5
magnetic valve. Pin to pin: 34 - 40 Ω (OK) (NG)
Is the resistance value normal? Pin to body: ∞Ω
5 Replace the exhaust brake magnetic valve. Exhaust brake operates Step 10 Step 6
After repair or replacement, check again the exhaust brake operation (OK) (NG)
6 Check the exhaust brake magnetic valve circuit for the continuity, Exhaust brake operates Step 10 Step 7
and repair or replace faulty parts. (OK) (NG)
⋅ Brake integrated control unit connector (A) to floor (left)
harness connector
⋅ Sheet harness connector to instrument (lower) harness
connector
⋅ Floor (left) harness connector to frame (Ft) harness connector
⋅ Floor (left) harness connector to engine control unit
⋅ Instrument (lower) harness connector to member harness
connector
⋅ Frame (Ft) harness connector to exhaust brake magnetic valve
⋅ Member harness connector to earth point
After repair or replacement, check again the exhaust brake operation
3-35

7 Check the operation of exhaust brake magnetic valve. ON ↔ OFF indication on Step 8 Step 9
1. Connect the Tech II. the screen is changed (OK) (NG)
2. Shift the gear in the neutral position. over by switch operation
4. Check the switch inputs with the Tech II.
over by disconnecting/connecting the connector (PA1 pin, green)
inside the inspection cover.
Is the ON/OFF indication changed by disconnecting/connecting the
connector (PA1 pin, green)?
8 Replace the exhaust brake valve - Step 10 -
9 Replace the brake intensive control unit, and check the power supply - Step 10 -
and GND circuit of the brake integrated control unit, and repair or
replace if faulty.
end
3-36
■ External view, Pin assignment and resistance value of magnetic valve

<External view of magnetic valve> <Pin assignment of magnetic valve>
Pin No. Signal name
1 Magnetic valve (coil)
2 1 2 Magnetic valve (coil)
Z type
connector (gray),
2 pins
<Magnetic valve resistance value>

Pants checked Resistance value Remarks
1 ⇔ 2 34 - 40∞Ω Between magnetic valve coils
Z type connector
1 ⇔ body ∞ Between magnetic valve coil and body
(gray) 2 poles
2 ⇔ body ∞ Between magnetic valve coil and body
Note: The resistance value varies depending on the temperature of the magnetic valve main unit.
3-37
Checking the EGR
■ EGR circuit
Battery Relay
SBF 3
SBF 1 Fuse 16
Starter Switch
"ON"
Battery
Fly Back
EGR 1 EGR 2
Magnetic Magnetic
Valve "D" Valve "E"
Fail Safe Relay "B"
(Normal close)
117 116 105 92 93
Engine Control Unit
81 82 102 111 59
3-38
Checking the EGR
■ Possible causes
⋅ EGR valve malfunction
⋅ Air pipe malfunction (Crushed areas, breakage, looseness, gas leakage, etc.)
⋅ Magnetic valve malfunction
⋅ Engine Control Unit malfunction

1 Check the engine coolant level and replenish if required. - Go to -
Is the action complete? Step 2
2 Check the installation of the air pipes (leading to the magnetic valve, - Go to -
EGR) and the harnesses. Reinstall the parts if there is a problem. Step 3
Is the action complete?
3 Displayed Go to Go to
Chapter 3 Step 4
Check for DTC 413, 443 and 424. (DTC's) for
separate
inspection
procedure
4 1. Starter switch ON (do not start the engine). Magnetic valve operation Go to Go to
2. Remove the air pipes from the EGR valve air cylinder. Step 6 Step 5
5 Repair or replace the magnetic valve. - Go to -
6 Check the air cylinder operation. Normal Go to Go to
Step 8 Step 7
7 Repair or replace the magnetic valve. - Go to -
8 Check EGR valve operation. EGR operates Verify Go to
1. Disconnect the EGR valve from the engine. repair Step 9
2. Connect the air pipes to the EGR.
Does the EGR operates?
9 Repair or replace the EGR valve. - Verify -
Is the action complete? repair
3-39
Checking the EGR
■ Magnetic Valve Arrangement

Cab rear member
1 2

3-40
Checking the Power Take Off (PTO)
■ PTO circuit
Battery Relay
SBF 3
SBF 1 Fuse 11 Fuse 13
Starter Switch
"ON"
Battery
PTO PTO
Lamp Switch
16
Engine Control Unit
73 63 56
Vcc SIG GND
5V
PTO
Magnetic
Valve
Boost Sensor
All Speed Accele Sensor
3-41
■ Possible causes
⋅ Failure to follow PTO operation procedure
⋅ All-speed accelerator sensor malfunction (Device, bad installation, poor adjustment, etc.
⋅ Parking switch malfunction
⋅ PTO switch malfunction
⋅ Sensor and/or switch circuit malfunction (Open or short circuit)
⋅ PTO magnetic valve malfunction
⋅ ECU malfunction
⋅ PTO relay malfunction
⋅ PTO idle switch malfunction (Optional auxiliary equipment circuits for concrete pumper)
■ Pre-Inspection checks
⋅ Connector installation (Looseness and damage)
⋅ Harness condition (Fraying, twisting, breakage, etc.)
⋅ Battery voltage (At least 24 volts)

1 The PTO will not operate unless the following conditions are met. Correct Go to Go to
⋅ Parking brake on (Lever pulled up) procedure/ Step 2 Step 3
⋅ Gearshift lever in neutral position conditions met
⋅ Engine at idle
⋅ Clutch pedal depressed (Manual transmission only)
To turn the PTO off –
1. Run the engine at idle.
2. Gearshift lever NEUTRAL.
3. PTO switch OFF.
4. Release the parking brake.
2 Follow the correct operating procedure. PTO operation Go to Go to
Step 3 Step 1
3 Check the accelerator pedal and external accelerator lever positions Pedal and lever at Go to Go to
when the PTO is not in use. original positions – Step 5 Step 4
Engine at idle
4 Return the accelerator pedal and external accelerator lever to their - Go to Go to
original positions. Step 5 Step 3
Was a problem found?
3-42

5 Confirm that the PTO operation is correct and that the governor ⋅ PTO operation – Idle Go to Go to
characteristics change when the vehicle is switched from on-road speed does not change Step 7 Step 6
operation to PTO operation. ⋅ On-road operation –
Refer to Chapter 1 (Engine control system overview – PTO control) Idle speed changes
for governor characteristics during on-road and PTO operation.
⋅ Idle speed does not change during PTO operation even when the
idle control switch is moved.
⋅ Idle speed changes during on-road operation when the idle
control switch is moved. If it does not change refer to ‘Idle speed
cannot be adjusted’ (inspection and repair are required).
6 Check the PTO switch circuit. Display shows ON when Go to Go to PTO
1. Gearshift lever NEUTRAL. the switch is on and OFF Step 7 switch
2. Starter switch ON. when the switch is off. maintenance
3. PTO idle switch ON and OFF. procedure
7 Check the external accelerator (all-speed accelerator sensor) ⋅ 0.3~0.5 volts Go to Go to
adjustment. (Accelerator at idle Step 8 DTC28
1. Remove the harness from the ECU. position) procedure
2. Measure the all-speed sensor output voltage. ⋅ 4.2~4.5 volts
(Accelerator at full-
open position)
8 Check the parking switch. Display shows ON when Go to Go to
1. Gearshift lever NEUTRAL. the switch is on and OFF Step 9 Parking
2. Starter switch ON. when the switch is off. switch
3. Parking switch OFF. procedure
9 Check the PTO operation (correct change between on-road Done (Engine speed Verify Go to
accelerator and external accelerator). changes with the repair Step 10
accelerator being used)
10 Replace the ECU. - Verify -
3-43
Checking the Power Take Off (PTO) Switch
■ PTO switch circuit
Battery Relay
SBF 3
Starter Switch
"ON"
Battery
PTO PTO
Lamp Switch
16
Engine Control Unit
73 63 56
Vcc SIG GND
5V
PTO
Magnetic
Valve
Boost Sensor
3-44
The PTO switch turns the magnetic valve on and off.
The ECU senses PTO magnetic valve power to control PTO operation.
PTO on and off operation (switching) depends on PTO switch position, sensor data (all-speed accelerator
sensor and others), and the parking brake operation signal.
■ Possible problems
⋅ PTO switch malfunction
⋅ PTO magnetic valve malfunction
⋅ Engine Control Unit malfunction
⋅ PTO relay malfunction
⋅ Switching circuit malfunction (Open or shorted)
⋅ PTO idle switch malfunction

1 Measure the voltage at the No. 13 fuse (PTO magnetic valve power ⋅ Starter switch Go to Go to
supply). OFF = 0 volts Step 3 Step 2
1. Starter switch OFF. ⋅ Starter switch
2. Measure the voltage at the No. 13 fuse. ON = battery voltage
(at least 24 volts)
2 3. Repair or replace the No. 13 fuse circuit (refer to the schematic in ⋅ Starter switch - -
Chapter 5. OFF = 0 volts
4. Measure the voltage at the No. 13 fuse (refer to Step 1). ⋅ Starter switch
ON = battery voltage
(at least 24 volts)
3 Measure the resistance (continuity) of the closed (on) PTO switch. Less than 0.5 W Go to Go to
Was a problem found? Step 5 Step 4
4 Replace the PTO switch. - Go to -
5 Measure the resistance (continuity) of the PTO switch circuits at the Less than 1 Ω Go to Go to
points specified below. Step 7 Step 6
Dump lever PTO switch
⋅ No. 13 fuse ↔ right-side floor harness connector
⋅ Instrument lower harness connector ↔ PTO switch
⋅ Right-side floor harness connector ↔ ECU
Instrument panel PTO switch
⋅ No. 13 fuse ↔ Instrument upper harness connector
⋅ Instrument lower harness connector ↔ PTO switch
⋅ Instrument upper harness connector ↔ ECU
6 Repair or replace the PTO switch circuit. - Go to -
3-45

7 Measure the resistance (continuity) of the PTO magnetic valve Less than 1 Ω Go to Go to
circuits at the points specified below. Step 9 Step 8
Dump lever PTO switch
⋅ Right-side floor harness connector ↔ frame harness connector
⋅ Instrument lower harness connector ↔ PTO magnetic valve
⋅ PTO magnetic valve ↔ frame (ground)
Instrument panel PTO switch
⋅ Instrument upper harness connector ↔ front frame harness
connector
⋅ Instrument lower harness connector ↔ PTO magnetic valve
⋅ PTO magnetic valve ↔ frame (ground)
8 Repair or replace the PTO magnetic valve. - Go to -
9 Measure the resistance between the PTO magnetic valve terminals. 27~33 Ω Go to Go to
Step 18 Step 10
10 Replace the PTO magnetic valve. - Go to Go to
Is the action complete? Step 18 Step 11
11 Repair or replace the PTO switch. - Go to -
12 Measure the resistance (continuity) of the PTO magnetic circuit at Less than 1 Ω Go to Go to
the points specified below. Step 14 Step 13
⋅ PTO relay ´ front frame harness connector
⋅ Instrument lower harness connector ´ PTO magnetic valve
⋅ PTO magnetic valve ´ frame (ground)
13 Repair or replace the PTO switch. - Go to -
14 Measure the resistance between the PTO magnetic valve terminals. 27~33 W Go to Go to
Step 16 Step 15
15 Replace the PTO magnetic valve. - Go to -
16 Check the control unit. Battery voltage Go to Go to
1. Disconnect all harnesses. (At least 24 volts) Step 18 Step 17
2. Gearshift lever NEUTRAL.
3. Remove the PTO relay.
4. Starter switch ON.
5. Turn the PTO ON.
6. Measure the voltage at terminal 3 of the PTO relay.
7. Repeat Steps 5 and 6 for the PTO instrument panel switch and the
PTO dump lever switch.
17 Replace the control unit. - Go to -
3-46

18 Check the ECU (PTO switch circuit). Display shows ON when Verify Go to
1. Gearshift lever NEUTRAL. the switch is on and OFF repair Step 19
2. Starter switch ON. when the switch is off.
3. Operate the PTO switch.
Was a problem found?
19 Replace the ECU. - Verify -
Instrument Panel PTO Switch General Appearance and Circuit Resistances
3-47
■ Instrument Panel PTO Switch General Appearance and Circuit Resistances
Measuring point Ω)
Resistance (Ω
Terminal 1 ↔ Terminal 2 Less than 0.5
■ Dump Lever PTO Switch
Measuring point Ω)
Resistance (Ω Switch position
Less than 0.5 ON
Terminal 1 ↔ Terminal 2
∞ OFF
3-48
Checking the parking switch
■ Parking switch circuit (including low air pressure switch circuit)
Battery Relay
SBF 3
SBF 1 Fuse 11
Starter Switch
"ON"
Parking Air Low Brake

Lamp Pressure Warning
Lamp Lamp
Battery
Wheel Park
Air Warning Relay
Buzzer
Air Low Pressure
Switch
Parking SIG. Air

Low
Pressure
Parking SIG.
(Wheel Park)
Switch
19 15
Engine
Control Unit
3-49
The parking switch is installed in the vicinity of wheel park (frame harness). The parking switch turns on
when the parking lever is pulled (when the air in the wheel park chamber is bled).
The wheel park switch circuit is supplied with the power from the parking lamp in the meter, and connected
to the frame ground via the switch.
■ Possible causes
⋅ Faulty parking switch itself
⋅ Faulty parking switch circuit
⋅ Faulty meter itself
⋅ Faulty meter circuit
⋅ Faulty Engine Control Unit

1 Check if the voltage is applied to the parking switch. Lamp ON Step 15 Step 2
1. Disconnect the harness from the parking switch.
3. Ground the parking switch connector (pins on power supply side).
Does the parking lamp in the meter turn on?
2 Check the parking lamp in the meter for broken bulb. - Step 15 Step 3
Is the lamp normal?
3 Replace the parking lamp in the meter. Lamp ON Step 15 Step 4
After repair or replacement, check if the lamp turns on.
Does the lamp turn on?
4 Check the meter (lamp) power. Battery voltage Step 15 Check
1. Turn the starter switch on. the
2. Check if the voltage is applied to the meter connector. power
Is the voltage applied? supply
circuit
3-50

5 Check for continuity of the following circuits between meter 0.5Ω or less Step 15 Step 6
(parking lamp) and parking switch.
⋅ Meter to instrument (lower) harness connector
⋅ Instrument (upper) harness connector to frame (Ft) harness
connector
⋅ Instrument (upper) harness connector to Engine Control Unit
connector
⋅ Instrument (lower) harness connector to wheel park switch
⋅ Instrument (lower) harness connector to frame (Rr) harness
connector
⋅ Frame (Ft) harness connector to wheel park switch
Are the circuits normal?
6 Repair or replace faulty meter (parking lamp) circuit. Lamp ON Step 15 Step 7
After repair or replacement, check if the lamp turns on when the
wheel park is operated.
7 Check the parking switch ground circuit. - Step 15 Step 8
8 Repair or replace the parking switch ground circuit. Lamp ON Step 15 Step 9
9 Check again if the voltage is applied to the parking switch. Lamp ON Step 15 Step 10
1. Disconnect the harness from the parking switch.
3. Ground the parking switch connector (pins on power supply side).
Does the parking lamp in the meter turn on?
10 Replace the meter. - Step 15 Step 11
3-51

11 Check the parking switch operation. Lamp ON (when the Step 15 Step 12
1. Check that the air pressure is normal. parking lever is pulled)
2. Check if the parking lamp turns on when the parking lever is
pulled.
3. Check if the parking lamp turns off when the parking lever is
released.
Does the parking lamp operate (on/off) normally?
12 Check the parking switch. Lamp ON Step 15 Step 13
13 Check the Parking Switch ON ↔ OFF indication on Step 15 Step 14
1. Connect the Tech II. the screen is changed
2. Shift the gear to the neutral position. over by switch operation
4. Using the Tech II, check the inputs of each switch.
5. Operate the parking switch.
14 Replace the engine control unit. - Step 15 -
end
3-52
■ External view and operation of parking switch
Air pressure in wheel park 1 2 Switch

About 460kPa (4.7 kg/cm ) or less
2
O O ON
About 460kPa (4.7 kg/cm ) or more
2
OFF
3-53
Idling speed cannot be adjusted
■ Idle speed control circuit
Battery Relay
SBF 3
SBF 1 Fuse 17
Starter Switch
"ON"
Idle
Battery Accele Manual Clutch
Switch Switch Switch
Starter Open:Auto (N.C)
Switch Close:Manual Idle
"ON" Control
Switch
SIG Down Up
13 23 20 27 29 10 7
Engine Control Unit
44 41 45
Vcc SIG GND
5V
Accele Sensor
3-54
■ Possible causes
⋅ Improper Idle control switch position
⋅ Faulty idle control switch (up/down)
⋅ Faulty idle control selector switch
⋅ Faulty switch input circuit (idle control switch, idle control selector switch, etc.)
⋅ Faulty sensor system (accelerator sensor, all speed accelerator sensor, etc.)
⋅ Faulty PTO
⋅ Engine Control Unit

1 Check the idle control selector switch for position. - Step 3 Step 2
Is the switch in "AUTO" position?
2 Set the idle control selector switch in "MANU" position, and adjust Adjustable Step 7 Step 3
the idling speed by using the idle control switch (press up or down
side).
Is the idling speed adjustable?
3 Check the Engine Control Unit (each switch input circuit). “MANUAL (Open)” Step 5 Step 4
1. Connect the Tech II. indication on the screen is
2. Shift the gear to the neutral position. changed over by switch
3. Turn the starter switch on. operation
5. Disconnect idle control switch.
Is the display of the screen of Tech II change?
4 Repair or replace the circuits by referring to each switch circuit After Adjustable Step 7 Step 5
repair or replacement, adjust again the idling speed.
5 Check the PTO. - Step 6 Check
Perform the "PTO check", and repair or replace if faulty. PTO
6 Check the Engine Control Unit. - Step 7 -
1. Turn the starter switch off.
2. Replace the Engine Control Unit.
3. Start the engine and check for operation.
7 Restore the vehicle and perform the repair check. - Check -
end
3-55
■ External view and operation of idling control switch
<External view of idling control switch>
Idling control switch
UP
2 1
3
Connector
DOWN
060HY00486
<Operation of idling control switch>
When With UP With DOWN

released side pressed side pressed
UP UP UP
DOWN DOWN DOWN
3 3 3
2 2 2
1 1 1
Measuring point Switch operating condition Resistance value Remarks

3⇔1 Released ∞
UP pressed 0.5Ω or less
2⇔3 UP circuit
Idling control switch Released ∞
DOWN pressed 0.5Ω or less
2⇔1 DOWN circuit
Released ∞
3-56
Idling speed cannot be decreased
■ Idle speed control circuit
Battery Relay
SBF 3
SBF 1 Fuse 17
Starter Switch
"ON"
Idle
"ON" Control
Switch
SIG Down Up
13 23 20 27 29 10 7
Engine Control Unit
44 41 45
Vcc SIG GND
5V
Accele Sensor
3-57
■ Possible causes
⋅ Improper Idle control switch position
⋅ Faulty idle control switch (up/down)
⋅ Faulty idle control selector switch
⋅ Faulty switch input circuit (idle control switch, idle control selector switch, etc.)
⋅ Faulty sensor system (accelerator sensor, all speed accelerator sensor, etc.)
⋅ Faulty PTO
⋅ Engine Control Unit
⋅ Faulty injection (nozzle)

1 Check the idle control selector switch for position. - Step 3 Step 2
Is the switch in "AUTO" position?
2 Set the idle control selector switch in "MANU" position, and adjust Adjustable Step 8 Step 3
the idling speed by using the idle control switch (press up or down
side).
3 Check the Engine Control Unit (each switch input circuit). “MANUAL (Open)” Step 5 Step 4
1. Connect the Tech II. indication on the screen is
2. Shift the gear to the neutral position. changed over by switch
3. Turn the starter switch on. operation
5. Disconnect idle control switch.
Is the display of the screen of Tech II change?
4 Repair or replace the circuits by referring to each switch circuit After Adjustable Step 5 -
repair or replacement, adjust again the idling speed.
Check the PTO.
5 Perform the "PTO check", and repair or replace if faulty. - Step 6 Check
Did corrective actions complete? PTO
6 Check the water temperature sensor. - Step 7 Chapter
Referring to the diagnostic trouble code "23", check the sensor, and 4
repair or replace if faulty. diagnostic
Did corrective actions complete? trouble
code
''23''
3-58

7 Check the injection operation. Injector is normal Step 9 Step 8
1. Connect the Tech II. (Engine sound changes)
3. Using the Tech II, conduct the injector test.
(In the "Injection Power Balance" test, stop the injector every
cylinder, and the injector is normal if the engine sound changes
when the injection is stopped.)
Does the engine sound change?
8 Replace the injector of the cylinder where the engine sound does not - Step 9 -
change.
10 Restore the vehicle and perform the repair check. - Check -
end
3-59
■ External view and operation of idling control switch
<External view of idling control switch>
Idling control switch
UP
2 1
3
Connector
DOWN
060HY00486
<Operation of idling control switch>
When With UP With DOWN

released side pressed side pressed
UP UP UP
DOWN DOWN DOWN
3 3 3
2 2 2
1 1 1
Measuring point Switch operating condition Resistance value Remarks

3⇔1 Released ∞
UP pressed 0.5Ω or less
2⇔3 UP circuit
Idling control switch Released ∞
DOWN pressed 0.5Ω or less
2⇔1 DOWN circuit
Released ∞
3-60
Chapter 4
Checking procedure for each
diagnostic trouble code
Preface
When any diagnostic trouble code is displayed, check and repair according to the flow chart on the following
pages.
Caution: Try to take notes of check results. To record information on customers, make use of the "IE
Check Sheet".
When no diagnostic trouble code is displayed, check and repair referring to Chapter 5, Checking Method for
Symptom.
Diagnostic troble Codes list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

14 CMP sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
15 CKP sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
22 Atmospheric temperature sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
23 Water temperature sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
24 Accelerator sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
25 Vehicle speed sensor system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
28 All speed accelerator sensor error/ No operate PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
32 Boost sensor system trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
33 CPU monitoring IC trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
35 A/D conversion error/charger circuit trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
42 High boost trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
65 Low boost trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
71 Atmospheric pressure sensor trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
115 Fuel pressure sensor output fixed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
118 Common-rail pressure trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
151 Common rail pressure trouble(pump excessive pressure feed) . . . . . . . . . . . . . . . . . . . . . . 4-82
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 Systems") . . . . . . . . . . . . . . . 4-89
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 Systems") . . . . . . . . . . . . . . . 4-94
217 PCV1 system short circuit (battery and power supply circuit) trouble . . . . . . . . . . . . . . . . 4-99
218 PCV2 system short circuit (battery and power supply circuit) trouble . . . . . . . . . . . . . . . 4-103
226 Supply pump no pressure feed or pressure limiter operated . . . . . . . . . . . . . . . . . . . . . . . 4-107
227 Pump no pressure feed (Fuel outflow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
241 Accelerator switch off trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
242 Accelerator switch on trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
245 Fuel pressure sensor Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
247 PCV1 system harness, short (GND circuit) trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
248 PCV2 system harness, short (GND circuit) trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
271 No.1 cylinder No.1 injector drive system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
413 Magnetic valve "E" drive system trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-166
443 Magnetic valve "D" drive system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-173
416 Main relay system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180
417 Starter switch trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185
424 Fail-safe (Magnetic valve cut) relay "B" system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . 4-189
421 PCV power supply system trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-193
518 EOL data error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-196
543 Excessive high revolution error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-198
Diagnostic trouble codes list
Backup control
diagnostic Judge
Item Failure Contents Time
trouble code DATA Control
15 CKP sensor trouble CKP pulse not input while CMP pulse is - - Control with CMP sensor only
(Memorized) input at the engine speed more than 40rpm
14 CMP sensor trouble CKP pulse not input while CMP pulse is - - Control with CKP sensor only
(Memorized) input at the engine speed more than 450rpm
15&14 CKP & CMP both sensor error No pulse input between CKP & CMP with 2.5 sec. - Stop of power supply to TWV and PCV
(Not Memorized) the starter SW ON. continued
245 Fuel pressure sensor system PC sensor output value larger than 4.7V or 0.1 sec. Common-rail pressure regulation (max. 60MPa)
(Memorized) trouble smaller than 0.7V continued Fuel injection rate Prospective control
(max. 120 mm3/st)
115 Fuel pressure sensor output When the common rail pressure is larger Approx. Common-rail pressure regulation (max. 60MPa)
(Memorized) fixed than 10 MPa, PC sensor output value does 9sec. Fuel injection rate Prospective control
not change. continued (max. 120 mm3/st)
151 Common-rail pressure Trouble PCV closing timing is after 217.5°CR or Approx. Common-rail pressure regulation (max. 60MPa)
(Memorized) (pump excessive pressure feed) the difference between the target common- 9 sec. Fuel injection rate Prospective control
rail pressure and actual common rail continued (max. 120 mm3/st)
pressure is larger than 10MPa.
226 Supply pump no pressure feed PCV closing timing is below PCV closing Common-rail pressure regulation (max. 25MPa) -
(Memorized) or pressure limiter operated timing control value + 1°CA or the 1 sec. Fuel injection rate
common-rail pressure F/B control value is continued (max. 120 mm3/st)
below -60°CA.
227 Pump no pressure feed When the actual common-rail pressure is Approx. Common-rail pressure regulation (max. 25MPa) When the time elapsed exceeded the value
(Memorized) (fuel out flow) below the target common-rail pressure 9 sec. Fuel injection rate obtained from the difference between the
+5MPa, the PCV closing timing is below continued (max. 120 mm3/st) target common-rail pressure and actual
the PCV closing timing limit value +1°CA common-rail pressure, the control stops
or common-rain pressure F/B control value (power supply to TWV and PCV is stopped).
is below 50°CA
118 Common-rail pressure trouble Actual common-rail pressure exceeded 0.2 sec. Common-rail pressure regulation (max. 60MPa) When the actual common-rail pressure
(Memorized) about 125MPa. continued Fuel injection rate exceeded about 130MPa for about 0.2 seconds,
(max. 120 mm3/st) the control stops (power supply to TWC and
PCV stops).
23 Water temperature sensor Water temperature sensor output value is 1 sec. Controlled water temperature at start Control based on the backup value.
(Memorized) system trouble over 4.8V or below 0.1V. continued = -20°C
Other controlled water temperature
= 55°C
24 Accelerator sensor system Accelerator sensor output value is over 1 sec. Held until ECU is turned OFF. When trouble 2 or 4 is judged, accelerator opening is controlled (fixed to
(Memorized) trouble 4.8V or below 0.1V. continued 0%).
When the accelerator SW is turned OFF, the accelerator is opened to 10% in 1.5 seconds and then
increased to 46% in 1.5 seconds (up to 46% at the maximum). When the accelerator switch is turned
ON, the accelerator opening is reduced to 10% in 1 second. After that, the accelerator opening is
controlled from 10% to 46% (1.5 sec.) and then 46% to 10% ( 1 sec.) with the accelerator switch.
241 Accelerator SW OFF trouble Accelerator switch was turned OFF when 1 sec. Controlled accelerator opening (max. 80% ) -
(Memorized) the accelerator sensor output value is continued
below 0.65V.
242 Accelerator SW ON trouble Accelerator switch was turned ON when 0.5 sec. Controlled accelerator opening (max. 25% ) Control based on the accelerator backup map
(Memorized) the accelerator sensor output value continued (work map)
exceeded 3.06V.
271 1st cylinder injector drive Disconnection of injector1 coil or harness - Fuel injection rate (max. 180 mm3/st) -
(Memorized) system trouble (disconnected
wire on the TWV side)
272 2nd cylinder injector drive Disconnection of injector2 coil or harness - Fuel injection rate (max. 180 mm3/st) -
273 3rd cylinder injector drive Disconnection of injector3 coil or harness - Fuel injection rate (max. 180 mm3/st) -
274 4th cylinder injector drive Disconnection of injector4 coil or harness - Fuel injection rate (max. 180 mm3/st) -
275 5th cylinder injector drive Disconnection of injector5 coil or harness Fuel injection rate (max. 180 mm3/st) -
276 6th cylinder injector drive Disconnection of injector6 coil or harness - Fuel injection rate (max. 180 mm3/st) -
158 TWV power source system TWV1, 3, 5 harness power source short - - Power supply to TWV and PCV is stopped.
(Memorized) trouble (Common 1 "injector 1, circuit or common 1 harness power source
3, 5 system) short circuit
159 TWV power source system TWV2, 4, 6, harness power source short - - Power supply to TWV and PCV is stopped.
(Memorized) trouble (Common 2 "injector 2, circuit or common 1 harness power source
4, 6 system) short circuit
217 PCV 1 system short circuit When the PCV1 is turned ON, Key SW= Common-rail pressure regulation (max. 60MPa) PCV1 is turned OFF.
(Memorized) (battery, power source system trouble PCV1 drive voltage ON
circuit)
218 PCV 2 system short circuit When the PCV2 is turned ON, Key SW= Common-rail pressure regulation (max. 60MPa) PCV1 is turned OFF.
(Memorized) (battery, power source system trouble PCV2 drive voltage ON
circuit)
247 Disconnection or short circuit of When the PCV1 is turned OFF, Key SW= Common-rail pressure regulation (max. 60MPa) -
(Memorized) PCV1 system (GND circuit) trouble PCV1 drive voltage ON
4-4
Note: Failure indication symbols of the service engine soon lamp (in user mode) are listed in the table below.
O: Conditional lighting up (going out at a speed more than 650rpm and lighting up again when the engine speed below 650rpm continued for 20 seconds) ◎ : Lights up continuously. -: Does not light up.

failure indication
EGR PTO Auto cruise Control recovery conditions Remarks
DIAG SW DIAG SW
open (user) short circuit (dealer)
Regular Regular Reset CKP pulse was input. O 1.5
control control completely.
Regular Regular Reset CMP pulse was input. O 1.4

Regular Regular Reset CKP pulse or CMP pulse was input. ◎ 1.4
control control completely. 1.5
Control Control Reset Fuel pressure sensor output value is below ◎ 2.4.5
stopped. stopped. completely. 4.7V and above 0.7V.
Control Control Reset Fuel pressure sensor output value was ◎ 1.1.5
stopped. stopped. completely. changed.
Control 1.5.1
stopped. Control Reset Engine stalls and actual common-rail ◎
stopped. completely. pressure is below 10MPa.
Control 2.2.6
stopped. Regular Reset Once the engine stalls, the engine does ◎
control completely. not stop.
Control Regular Once the engine stalls, the engine does ◎ 2.2.7
stopped. control Reset not stop.
completely.
Control Control Reset When the actual common-rail pressure is ◎ 1.1.8

stopped. stopped. completely. below 110MPa and control stops, the
engine stalls and actual common-rail
pressure is below 10MPa.
Regular Regular Regular Water temperature sensor output is over O 2.3

control control control 0.1V and below 4.8V.
Control Control Reset Held until ECM power source is turned ◎ 2.4
stopped. stopped completely. OFF.
Regular Regular Reset Held until ECM power source is turned ◎ 2.4.1
control control completely. OFF.
Control Control Reset Held until ECM power source is turned ◎ 2.4.2
stopped. stopped. completely. OFF.
Control Control Reset Current side is normal or engine does not ◎ 2.7.1 Injector
stopped. stopped. completely. stall once it stalled.
Control Control Reset Engine does not stall once it stalled. ◎ 1.5.8
stopped. stopped. completely. (COM1 system)
Control Control Reset Engine does not stall once it stalled. ◎ 1.5.9
stopped. stopped. completely. (COM2 system)
Control Control Reset Normal PCV1 drive voltage ◎ 2.1.7

stopped. stopped. completely. (PCV1)
Control Control Reset Normal PCV2 drive voltage ◎ 2.1.8 When the trouble has been memorized as a
stopped. stopped. completely. (PCV2) past failure, the SERVICE ENGINE SOON
lamp lights up.
Control Control Reset Held until ECM power source is turned ◎ 2.4.7 When the trouble has been memorized as a
stopped. stopped. completely. OFF. (PCV1) past failure, the SERVICE ENGINE SOON
lamp lights up.
4-5
Backup control
diagnostic Judge
Item Failure Contents Time
trouble code DATA Control
248 Disconnection or short circuit of When the PCV2 is turned OFF, Key SW= Common-rail pressure regulation (max. 60MPa) -
(Memorized) PCV2 system (GND circuit) trouble PCV2 drive voltage ON
421 PCV power source trouble When the PCV is turned OFF, After the key Main relay is turned OFF 5 seconds after the -
(Memorized) trouble PCV drive voltage SW = OFF key SW=OFF
22 Atmospheric temperature sensor Fuel temperature sensor output value is 1 sec. Controlled atmospheric temperature at start Control based on the backup value.
(Memorized) trouble over 4.8V or below 0.1V. continued = -25°C
Other controlled water temperature
= 25°C
32 Boost sensor system Trouble At the time of engine stall, boost relative 1 sec. Control boost relative pressure Control based on the backup value.
(Memorized) pressure is over 20kPa or below 32 kPa. continued = 0kPa
42 High boost trouble High boost pressure was detected. 0.5 sec. - -
(Memorized) continued
65 Low boost trouble Low boost pressure was detected. 25 sec. - -

543 Excessive high engine speed Engine speed is more than specified. - - Power supply to TWV and PCV is stopped.
(Memorized) 2950rpm
71 Atmospheric pressure sensor Atmospheric temperature sensor output 1 sec. Controlled atmospheric temperature = 100kPa Control based on the backup value.
(Memorized) trouble value is over 4.7V or below 1.9V. continued
25 Vehicle speed sensor trouble Vehicle speed sensor output value is below 1 sec. Service engine soon lamp lights ON on -
(Memorized) 0.5V continued vehicles equipped with NR control.
416 Main relay trouble Main relay = OFF output (when key 5 sec. - -
(Not SW=OFF, power supply to ECU is not cut continued
Memorized) off)
443 M/V:D drive system trouble Drive voltage trouble when M/V D=ON 1.2 sec. - -
413 M/V:E drive system trouble Drive voltage trouble when M/V E=ON 1.2 sec. - -
424 Fail safe relay [B] system Improper relay drive voltage when F/S 1 sec. - M/V D, and E control is stopped
(Memorized) trouble REL B=ON. continued
EGR M/V relay error
518 EOL data error Learned accelerator voltage value data is - - Control based on the backup value.
(Not Memorized) not input.
28 All speed accelerator sensor When PTO/SW=ON, the all speed 1 sec. When an error occurrence is judged, all speed accelerator opening is controlled (fixed to 0%).
error/No operate PTO accelerator sensor output value is over continued After that, when the accelerator pedal opening decreases below 5%, control is made as the all
4.8V or below 0.1V. speed accelerator opening = accelerator pedal opening.
417 Starter switch trouble When the engine speed exceeded 1.6 sec. - -
(Memorized) 1000rpm, starter SW S signal was detected continued
continuously.
33 IC for CPU monitor trouble Trouble of IC for CPU monitor was - Control of fuel injection rate (60 mm3/st max.) Control based on the backup value.
(Memorized) detected trouble.
35 A/D conversion error Trouble of A/D conversion was detected. - - All analog input system is controlled by
(Memorized) backup value.
35 Charge circuit trouble Incorrect charge voltage was detected. - - Power supply to TWV and PCV is stopped.
(Memorized)
- CPU trouble CPU trouble - - Power supply to TWV and PCV is stopped.
42.32 High boost trouble Diagnostic trouble 42 displayed after 0.5S, 0.5 sec. - -
continued 10 S and then 32 displayed. 10 sec.
continued
65 Low boost trouble Low boost range is judged to be 2 sec. - -

insufficient at ACC: more than 50% and continued
continued for 25 sec.
4-6
Note: Failure indication symbols of the service engine soon lamp (in user mode) are listed in the table below.
O: Conditional lighting up (going out at a speed more than 650rpm and lighting up again when the engine speed below 650rpm continued for 20 seconds) ◎ : Lights up continuously. -: Does not light up.

failure indication
EGR PTO Auto cruise Control recovery conditions Remarks
DIAG SW DIAG SW
open (user) short circuit (dealer)
Control Control Reset Held until ECM power source is turned ◎ 2.4.8
stopped. stopped. completely. OFF. (PCV2)
Regular Regular Reset - ◎ 4.2.1

Regular Regular Regular Atmospheric temperature sensor output is O 2.2

control control control over 0.1V and below 4.8V
Control Regular Reset When the engine installs, boost relative O 3.2
stopped. control completely. pressure is below 20kPa or over 16kPa.
Control Regular Reset Held until ECM is turned OFF. ◎ 4.2

stopped. control completely.
Regular Regular Regular Held until ECM is turned OFF. - 6.5

control control control
Regular Regular Reset When the engine speed decreases below -

control control completely. specified value, 5.4.3
2750rpm
Control - Reset Atmosphere sensor output is over 1.9V - 7.1

stopped. completely. and below 4.7V.
Regular Regular Reset Vehicle speed sensor voltage is over 0.5V - 2.5
control control completely. and vehicle speed pulse is input.
Regular Regular Reset Held until ECM is turned OFF. O 4.1.6

Control Control Reset Held until ECM is turned OFF. O 4.4.3

stopped. stopped. completely.
Control Control Reset Held until ECM is turned OFF. O 4.1.3

Control Control Reset When F/S REL B=ON, relay drive O 4.2.4
stopped. stopped. completely. voltage is normal.
Regular Regular Reset Leaned value data of accelerator voltage ◎ 5.1.8

control control completely. was input to ECM.
Control Regular Reset Held until ECM is turned OFF. - 2.8

Regular Regular Reset Starter SW=OFF - 4.1.7

Regular Regular Reset Held until ECM is turned OFF. ◎ 3.3

Control Regular Reset Normal A/D conversion ◎ 3.5

Control Control Reset Once the engine installs, it does not install ◎ 3.5
stopped. stopped. completely. anymore.
Control Control Reset - ◎ -

- - - - ◎ (A) 4.2
(B) 3.2
- - - - - 6.5
4-7
14 CMP sensor system trouble (1/5)
■ CMP sensor circuit (including CKP sensor and fuel pressure sensor circuit)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
Vcc SIG GND (+) (-) (+) (-) SIG SIG Vcc GND
5V 5V
All Speed
Accele Sensor
Boost CKP CMP Fuel Pressure

Sensor Sensor Sensor Sensor
4-8
The CMP sensor detects the camshaft revolutions in the supply pump to judge the cylinders. The voltage is
generated to output the pulse signals, when the pulsar provided on the camshaft crosses the CMP sensor
leading end. The Engine Control Unit reads this pulse signals, and based on this signals, it judges the
cylinders. In case of CMP sensor trouble, the CKP sensor installed on the flywheel judges the cylinders. Also,
the sensor circuit is shielded to prevent electrical noise invasion.
■ Vehicle behaviors in case of a trouble

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idles continuously for 20 seconds)
• Instantaneous revolution drop (0 rpm during diagnosis until switching to CKP sensor)
• Low starting performance
• Varying revolutions (hunting)
• Rough idling
• When both CKP sensor and CMP sensor failed, the SERVICE ENGINE SOON lamp turns on (continuous
ON)and the engine stops
■ Diagnostic conditions
At the engine revolutions over 400 rpm (idling), the pulses from the CKP sensor are entered (at 450-time
input), but no pulses are entered from the CMP sensor. Under this condition, the control unit judges as "CMP
sensor system trouble" and displays "diagnostic trouble code: 14".
The judgment time varies depending on the number of engine revolutions. The judgment time becomes
longer when the engine revolutions are low, and it becomes shorter as the engine revolutions increase.
■ Warning during diagnosis (SERVICE ENGINE SOON lamp ON)

In the event of CMP sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on when the engine revolutions below 650 rpm continue for 20 seconds. The
lamp turns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in CMP sensor (+) circuit
• Disconnection in CMP sensor (-) circuit
• Faulty sensor (faulty sensor inside or sensing block)
• Faulty cam shaft internal supply pump
• Internal trouble of Engine Control Unit
■ Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses
for abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair
if faulty.
4-9

1 Check the detected diagnostic trouble code. - Step 2 Refer to
1.Start the engine and idle it. diagnostic
2. Using the Tech II, check the detected diagnostic trouble code. help, and
Is the detected diagnostic trouble code current trouble? go to
step 4
past
trouble
2 Measure resistance value of the CMP sensor circuit. Between pins 49 and 58: Step 6 Step 3
1. Turn the starter switch off. 1850 - 2450Ω
2. Disconnect the harness from the Engine Control Unit. (at about 20°C)
3. Using a tester, measure resistance value of the sensor. Between pins 49-77 and
Is the resistance value normal? GND: ∞Ω
Between pins 58-77 and
GND: ∞Ω
3 Using a circuit tester, measure resistance value of the "CMP sensor". Between sensor pins: Step 5 Step 4
1. Turn the starter switch off. #1 and #2 1850 - 2450Ω
2. Disconnect the harness from the sensor. (at about 20°C)
3. Using a tester, measure resistance value of the sensor. Between sensor body and
Is the resistance value normal? each pin: ∞Ω
4 Replace the CMP sensor - Step 6 -
5 Repair or replace the harnes of CMP sensor circuit. Also, check the - Step 6 -
connectors for connection.
⋅ Engine Control Unit to engine harness connector (ECU harness,
CMP sensor circuit)
⋅ ECU harness connector to CMP sensor connector
⋅ Engine harness to CMP sensor connector
6 Check the harnesses for shortcircuit. - Step 7 Step 8
2. Install the circuit tester between sensor each pin and GND
(frame or engine body).
Note: If the harness is disconnected from the CMP sensor,
diagnostic trouble code "14" may be detected, and therefore
clear the diagnostic trouble code after the check finished.
4. Check if the voltage is applied to the harnesses.
Is the voltage applied to each pin?
4-10

7 Repair or replace the CMP sensor circuit connector. - Step 8 -
⋅ Engine Control Unit to engine harness connector (ECU harness,
CMP sensor circuit)
⋅ ECU harness connector to CMP sensor connector
⋅ Engine harness connector to CMP sensor connector
8 Check the Engine Control Unit. - Step 10 Step 9
2. Confirm that the harness is connected to the Engine Control
Unit.
3. Connect the Tech II and clear the diagnostic trouble codes.
Note: Be sure clear the diagnostic trouble codes, as the engine
stops if the codes 14 and 15 are detected simultaneously.
4. Disconnect the harness from the CKP sensor.
Note: The diagnostic trouble code 15 is detected if the harness is
disconnected from the CKP sensor, and thus clear the code
after the check finished.
5. Start the engine, and check the engine condition.
10 With the CKP sensor removed, check if the idling is stable. - Step 14 Step 11
Using the Tech II, check with the "Engine Speed" of engine data that
the engine speed is stable, free from variations or hesitation.
Is the idling stable?
11 Check the CMP sensor installation. - Step 13 Step 12
1. Check the CMP sensor for evidence of play or floating.
Is the sensor installed correctly?
12 Install the CMP sensor correctly. - Step 10 -
13 Replace the supply pump. - Step 10 -
4-11

14 Restore the vehicle. - Step 15 -
1. Stop the engine.
2. Connect the harnesses to the sensors.
4. Connect the Tech II, and clear the diagnostic trouble codes.
15 Confirm that the diagnostic trouble codes have been cleared, and - Repair After
conduct the test run again to check that no diagnostic trouble code is end referring
detected. to
Is diagnostic trouble code detected? diagnostic
help,
step 1
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
■ External view, pin assignment, and resistance value of CMP sensor

<External view of CMP sensor> <Pin assignment of CMP sensor>
Pin No. Signal name Wire color/diameter

1 (-) L/0.5
2 (+) P/0.5
- Shield Shield
(-) (+)
1 2
<Resistance value of CMP sensor>

Parts checked Resistance value Remarks
2-pin 1 ⇔ 2 1850 - 2450Ω Between (-) and (+) at about 20°C
connector 1 ⇔ Body ∞Ω Between (-) and shield
(white) 2 ⇔ Body ∞Ω Between (-) and shield
Note: The resistance value varies depending on the temperature (engine warming condition).
4-12
15 CKP sensor system trouble (1/5)
■ CKP sensor circuit (including CMP sensor and fuel pressure sensor circuit)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-13
The CKP sensor detects the number of engine revolutions. The voltage is generated to output the pulse
signals, when the sensing hole provided in the flywheel crosses the CKP sensor leading end. The Engine
Control Unit reads this pulse signals, and based on this signals, it recognizes the engine revolutions, injection
timing, and injection cylinders. In case of CKP sensor trouble, the CMP sensor installed on the supply pump
detects the number of engine revolutions. Also, the sensor circuit is shielded to prevent electrical noise
invasion.

• Instantaneous revolution drop (0 rpm during diagnosis until switching to CMP sensor)
• Low starting performance
• Rough idling
• When both CKP sensor and CMP sensor failed, the SERVICE ENGINE SOON lamp turns on (continuous
ON)and the engine stops
At the engine revolutions over 400 rpm, the pulses from the CMP sensor are entered (at 40-time input), but
no pulses are entered from the CKP sensor. Under this condition, the control unit judges as "CKP sensor
system trouble" and displays "diagnostic trouble code: 15". The judgment time varies depending on the
number of engine revolutions. The judgment time becomes longer when the engine revolutions are low, and
it becomes shorter as the engine revolutions increase.

In the event of CKP sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on when the engine revolutions (idling) below 650 rpm continue for 20 seconds.
The lamp turns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Disconnection or shortcircuit in CKP sensor (+) circuit
• Disconnection in CKP sensor (-) circuit
• Faulty sensor installation (gap, play)
• Faulty flywheel sensing hole (clogging, soil, scratch)
■ Diagnostic help
if faulty.
4-14

1. Start the engine and idle it. diagnostic
2. Using the Tech II, check the detected diagnostic trouble help, and
code. go to
Is the detected diagnostic trouble code current trouble? step 4
past
trouble
2 Using a circuit tester, measure resistance value of the "CKP Between sensor pins: Step 4 Step 3
sensor". 109 - 143Ω
1. Turn the starter switch off. (at about 20°C)
2. Disconnect the harness from the sensor. Between sensor body and
3. Using a tester, measure resistance value of the sensor. each pin: ∞Ω
Is the resistance value normal?
3 Replace the CKP sensor - Step 4 -
4 Check the harnesses for shortcircuit. - Step 5 Step 6
2. Install the circuit tester between sensor each pin and GND
Note: If the harness is disconnected from the CKP sensor,
diagnostic trouble code "15" may be detected, and
therefore clear the diagnostic trouble code after the
check finished.
4. Check if the voltage is applied to the harnesses.
5 Repair or replace the harnesses of CKP sensor circuit. - Step 6 -
⋅ Engine Control Unit to engine harness connector (ECU
harness, CKP sensor circuit)
⋅ ECU harness connector to CKP sensor connector (engine
6 Check the harness for disconnection or shortcircuit. Between 48 and 57 pins: Step 8 Step 7
1. Turn the starter switch off. 109 - 143Ω
2. Confirm that the harness is connected to the CKP sensor. (at about 20°C)
3. Disconnect the harness from the Engine Control Unit. Between 48 and 76 pins/GND
4. Using a tester, measure resistance value of the connector ∞Ω
for the Engine Control Unit. Between 57 and 76 pins/GND
Is the resistance value normal? ∞Ω
4-15

7 Repair or replace the harnesses of CKP sensor circuit. Also, - Step 8 -
check the connectors for connection.
⋅ Engine Control Unit to engine harness connector (ECU
⋅ ECU harness connector to CKP sensor connector (engine
2. Confirm that the harness is connected to the Engine
Control Unit.
3. Connect the Tech II and clear the diagnostic trouble
codes.
Note: Be sure clear the diagnostic trouble codes, as the
engine stops if the codes 14 and 15 are detected
simultaneously.
4. Disconnect the harness from the CMP sensor.
Note: The diagnostic trouble code 14 is detected if the
harness is disconnected from the CMP sensor, and
thus clear the code after the check finished.
5. Start the engine, and check the engine condition.
10 With the CMP sensor removed, check if the idling is stable. - Step 14 Step 11
Using the Tech II, check with the "Engine Speed" of engine
data that the engine speed is stable, free from variations or
hesitation.
Is the idling stable?
11 Check the CKP sensor installation. - Step 13 Step 12
1. Check the CKP sensor for evidence of play or floating.
Is the sensor installed correctly?
12 Install the CKP sensor correctly. - Step 10 -
13 Check the flywheel, and clean, repair, or replace if faulty. - Step 10 -
⋅ Check from sensor installation hole
OK -> Check by referring to diagnostic help
NG -> Flywheel
⋅ Faulty CKP sensor (soil, scratch)
⋅ Faulty flywheel sensing hole (clogging, soil, scratch)
4-16

1. Stop the engine.
2. Connect the harnesses to the sensors.
4. Connect the Tech II, and clear the diagnostic trouble
codes.
15 Confirm that the diagnostic trouble codes have been cleared, - Repair After
and conduct the test run again to check that no diagnostic end referring
trouble code is detected. to
help,
step 1
■ External view, pin assignment, and resistance value of CKP sensor

<External view of CKP sensor> <Pin assignment of CMP sensor>
1 2 Pin No. Signal name Wire color/diameter

(-) (+)
1 (-) L/0.5
2 (+) P/0.5
- Shield Shield
<Resistance value of CKP sensor>

2-pin 1 ⇔ 2 1850 - 2450Ω Between (-) and (+) at about 20°C
connector 1 ⇔ Body ∞Ω Between (-) and shield
(white) 2 ⇔ Body ∞Ω Between (-) and shield
Note: The resistance value varies depending on the temperature (engine warming condition).
4-17
22 Atmospheric temperature sensor system trouble (1/6)
■ Atmospheric temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit)
SBF 3
Fuse 11
Engine Control Unit
75 30 66 53
SIG SIG GND SIG
Pulse
Matching 2
1
Device
4
3 10 12
IGN SIG GND
Meter
Water Atmospheric
Temperature Temperature
Sensor Sensor
Vehicle
Speed
Sensor
(VSS)
4-18
The atmospheric temperature sensor detects the temperature (atmospheric temperature) outside the vehicles.
The voltage is applied to the atmospheric temperature sensor provided in the front lid, and that voltage value
is used as a signal. The Engine Control Unit reads variations in the applied voltage, and based on this signal,
it optimizes the fuel injection control. In the event of atmospheric temperature sensor trouble, the Engine
Control Unit performs the control with the backup values. Also, the sensor circuit GND is used in common
to respective temperature sensors.

• Trouble at cold engine
White smoke
The control unit judges as "atmospheric temperature sensor system trouble" and displays "diagnostic trouble
code: 22" when the voltage applied to the atmospheric temperature sensor exceeds 4.8V, or the voltage below
0.1V continues fore more than one second.

In the event of atmospheric temperature sensor system trouble, the SERVICE ENGINE SOON lamp for the
vehicles without the multi-warning display turns on when the engine revolutions (idling) below 650 rpm
continue for 20 seconds. The lamp turns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Disconnection or shortcircuit in atmospheric temperature sensor (SIG) circuit
• Disconnection in atmospheric temperature sensor (GND) circuit
■ Diagnostic help
if faulty.
4-19

step 2
past
trouble
2 Check if diagnostic trouble codes "23" are detected simultaneously. - Step 3 Step 7
Are diagnostic trouble codes "22" and "23" detected simultaneously?
3 Check the harness (GND) for disconnection or shortcircuit. Between pin 66 and Step 5 Step 4
1. Turn the starter switch off. GND:∞Ω
2. Disconnect the harness from the Engine Control Unit. (without jumpr)
3. Disconnect the harness from the atmospheric temperature Between pins 53 and 66:
sensor. (Jumper: 2 - 1)
4. Using a jumper wire between connector pins on atmospheric 0.5Ω or less
temperature sensor side, measure resistance value of connector
on the Engine Control Unit side.
4 Repair or replace the harness of atmospheric temperature sensor - Step 5 -
circuit. Also, check the connectors for connection.
5 Check the atmospheric temperature sensor circuit (GND) for - Step 6 Step 7
shortcircuit.
2. Disconnect the harness from the sensor.
4. Install the circuit tester between connector pin on sensor side
and GND (frame or engine body).
6. Measure voltage in the atmospheric temperature sensor circuit.
4-20

7 Check the harness (SIG) for disconnection or shortcircuit. Between pin 53 and Step 9 Step 8
1. Turn the starter switch off. GND:
2. Disconnect the harness from the Engine Control Unit. ∞Ω
3. Disconnect the harness from the atmospheric temperature sensor. (without jumper)
4. Using a jumper wire between connector pins on atmospheric Between pins 53 and 66:
temperature sensor side, measure resistance value of connector (Jumper: 2 - 1)
on the Engine Control Unit side. 0.5Ω or less
9 Check the atmospheric temperature sensor circuit (SIG) for shortcircuit. - Step 10 Step 11
10 Repair or replace the atmospheric temperature sensor circuit. Also, - Step 11 -
11 Check the atmospheric temperature sensor. - Step 13 Step 12
Giving temperature changes to the atmospheric temperature sensor,
measure the sensor internal resistance. (At cold engine, compare
water temperature with atmospheric temperature using the Tech II.
Also, measure resistance by referring to the chart on the next page.)
Does the resistance value change according to the temperature, and
is the resistance value normal?
Replace the atmospheric temperature sensor.
12 Did corrective actions complete? - Step 13 -
Check the voltage applied to the atmospheric temperature sensor, "power".
13 1. Turn the starter switch off. Between sensor pin 1 and Step 15 Step 14
2. Install the harness to the engine control unit. GND:
3. Install the circuit tester between connector pins and GND 5V (4.75 - 5.25V)
(frame and engine body etc.) on the sensor side.
Note: If the harness is disconnected from the atmospheric
temperature sensor, diagnostic trouble code "22" may be
detected, and therefore clear the diagnostic trouble code after
the check finished.
5. Measure the voltage in the atmospheric temperature sensor
"power" circuit.
4-21

14 Is the applied voltage normal? - Step 15 -
Replace the Engine Control Unit.
15 Did corrective actions complete? Between sensor pin 2-1 Step 17 Step 16
Using the circuit tester, check the atmospheric temperature sensor and GND:
"GND" for continuity. 5V
1. Turn the starter switch off. (4.75 - 5.25V)
2. Confirm that the harness is connected to the engine control unit.
3. Install the circuit tester between connector pins on the sensor side.
Note: If the harness is disconnected from the atmospheric
temperature sensor, diagnostic trouble code "22" may be
detected, and therefore clear the diagnostic trouble code
after the check finished.
5. Measure the voltage in the atmospheric temperature sensor
"GND" circuit.
Is the applied voltage normal?
1. Stop the engine.
2. Connect the harnesses.
18 Did corrective actions complete? - Repair After
Confirm that the diagnostic trouble codes have been cleared, and end referring
conduct the test run again to check that no diagnostic trouble code is to
detected. diagnostic
Is diagnostic trouble code detected? help,
step 1
4-22
■ Appearance, pin assignment and resistance value of atmospheric temperature sensor

<Pin assignment of atmospheric temperature sensor> <Name of terminals of atmospheric sensor>
Pin No. Signal name Wire color / wire dia.
1 SIG VR/0.5
2 GND YR/0.5
2
1 <Resistance characteristic of atmospheric temperature sensor>
100
<Installation position of atmospheric temperature sensor>
Resistance value（kΩ）
10
1
0.1
-40 -30 -20 -10 0 10 20 30 40

Temperature（°C）
Washer Tank Connector Box
<Resistance value of atmospheric temperature sensor>

Temperature of temperature-
Parts checked Resistance value sensitive portion Remarks
1 ⇔ 2 3.74kΩ 20°C Between thermistors for IE
EJ mark II
9.77kΩ 0°C
connector
1 ⇔ Body ∞ - Between thermistor for IE and body
(black), 2 pins
2 ⇔ Body ∞ - Between thermistor for IE and body
Note: Resistance value varies depending on the temperature of the temperature-sensitive portion.
4-23
23 Water temperature sensor system trouble (1/6)
■ Water temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit).
SBF 3
Fuse 11
Engine Control Unit
75 30 66 53
SIG SIG GND SIG
Pulse
Matching 2
1
Device
4
3 10 12
IGN SIG GND
Meter
Water Atmospheric
Sensor Sensor
Vehicle
Speed
Sensor
(VSS)
4-24
The water temperature sensor detects the engine cooling water temperature. The voltage is applied to the
water temperature sensor provided on the cylinder body or housing, and that voltage value is used as a signal.
The Engine Control Unit reads variations in the applied voltage, and based on this signal, it optimizes the fuel
injection control. In the event of water temperature sensor trouble, the Engine Control Unit performs the
control with the backup values. Also, the sensor circuit GND is used in common to respective temperature
sensors.

• Trouble at cold engine
Low starting performance
White smoke
Rough idling
The control unit judges as "water temperature sensor system trouble" and displays "diagnostic trouble code:
23" when the voltage applied to the atmospheric temperature sensor exceeds 4.8V, or the voltage below 0.1V
continues fore more than one second.

In the event of water temperature sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles
without the multi-warning display turns on when the engine revolutions (idling) below 650 rpm continue for
20 seconds. The lamp turns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Disconnection or shortcircuit in water temperature sensor (SIG) circuit
• Disconnection in water temperature sensor (GND) circuit
■ Diagnostic help
if faulty.
4-25

step 2
past
trouble
2 Check if diagnostic trouble codes "22" are detected simultaneously. - Step 3 Step 7
Are diagnostic trouble codes "23" and "22" detected simultaneously?
3 Check the harness (GND) for disconnection or shortcircuit. Between pin 66 and Step 5 Step 4
1. Turn the starter switch off. GND:∞Ω
2. Disconnect the harness from the Engine Control Unit. (without jumper)
3. Disconnect the harness from the water temperature sensor. Between pins 30 and 66:
4. Using a jumper wire between connector pins on water (Jumper: 3 - 1)
temperature sensor side, measure resistance value of connector 0.5Ω or less
4 Repair or replace the harness of water temperature sensor circuit. - Step 5 -
Also, check the connectors for connection.
5 Check the water temperature sensor circuit (GND) for shortcircuit. Voltage is applied Step 6 Step 7
6. Measure voltage in the water temperature sensor circuit.
7 Check the harness (SIG) for disconnection or shortcircuit. Between pin 30 and Step 9 Step 8
2. Disconnect the harness from the Engine Control Unit. ∞Ω (without jumper)
3. Disconnect the harness from the water temperature sensor. Between pins 30 and 66:
4. Using a jumper wire between connector pins on water (Jumper: 3 - 1)
temperature sensor side, measure resistance value of connector 0.5Ω or less
4-26

9 Check the water temperature sensor circuit (SIG) for shortcircuit. - Step 10 Step 11
11 Check the water temperature sensor. About 40°C: 1.25kW Step 13 Step 12
Giving temperature changes to the water temperature sensor, About 80°C: 350W
measure the sensor internal resistance. (Put the sensor in the beaker (See chart)
and heat it to measure resistance. Or, with all harnesses connected,
start the engine and check the water temperature with the Tech II.
When the temperature reached the specified value, stop the engine,
disconnect the harness from the Engine Control Unit, and measure
the resistance at the connector.)
Does the resistance value change according to the temperature, and
is the resistance value normal?
12 Replace the water temperature sensor. - Step 13 -
13 Check the voltage applied to the water temperature sensor, "power" Between sensor pin 1 and Step 15 Step 14
pin. GND:
1. Turn the starter switch off. 5V (4.75 - 5.25V)
2. Install the harness on the engine control unit.
3. Install the circuit tester between connector pins and GND
(frame and engine body etc.) on the sensor side.
Note: If the harness is disconnected from the water temperature
sensor, diagnostic trouble code "23" may be detected, and
therefore clear the diagnostic trouble code after the check
finished.
5. Measure the voltage in the water temperature sensor "power"
circuit.
4-27

15 Using the circuit tester, check the water temperature sensor "GND" Between sensor pin 3-1 Step 17 Step 16
for continuity. and GND:
1. Turn the starter switch off. 5V (4.75 - 5.25V)
3. Install the circuit tester between connector pins on the sensor
side.
Note: If the harness is disconnected from the water temperature
sensor, diagnostic trouble code "23" may be detected, and
therefore clear the diagnostic trouble code after the check
finished.
5. Measure the voltage in the water temperature sensor "GND"
circuit.
Is the voltage normal?
1. Stop the engine.
detected. to
help,
step 1
4-28
■ Appearance, pin assignment and resistance value of water temperature sensor

< Appearance of water temperature sensor> < pin assignment of water temperature sensor>
Temperature-sensitive Pin No. Signal name Wire color / wire dia.
portion for meter
1 SIG (For engine) Y/0.5
2 SIG (For meter) YG/0.5
Temperature-sensitive
portion for IE 3 GND (For engine) YR/0.5
<Resistance characteristic of water temperature sensor>

3 2
100
1
RV connector (blue),
3 pins
Resistance value（kΩ）
10
1
0.1
3 2 1 -50 0 50 100
Temperature（°C）
<Resistance value of water temperature sensor>

Temperature of temperature-
Parts checked Resistance value sensitive portion Remarks
RV connector 1 ⇔ 2 ∞ - Between thermistor for IE and thermistor
(blue), 3 pins 1 ⇔ 3 350Ω 80°C Between thermistors for IE
1.25kΩ 40°C
1 ⇔ body ∞ - Between thermistor for IE and body
2 ⇔ 3 ∞ - Between thermistor for IE and thermistor
2 ⇔ body 52Ω 80°C Between thermistorfor IE and body
3 ⇔ body ∞ - Between meter for IE and body
Note: Resistance value varies depending on the temperature of the temperature-sensitive portion.
4-29
24 Accelerator sensor system trouble (1/6)
■ Accelerator sensor circuit (including accelerator switch circuit)
Battery Relay
SBF 3
SBF 1 Fuse 17
Starter Switch
"ON"
Idle
"ON" Control
Switch
SIG Down Up
13 23 20 27 29 10 7
Engine Control Unit
44 41 45
Vcc SIG GND
5V
Accele Sensor
4-30
The accelerator sensor detects the throttle opening. The voltage is applied to the accelerator sensor provided
on the accelerator pedal link, and the voltage value returned to the Engine Control Unit is used as a signal.
The Engine Control Unit reads the voltage changes from the accelerator sensor, and based on this signals, it
optimizes the throttle opening and fuel injection control. In the event of accelerator sensor trouble, the Engine
Control Unit makes control using the accelerator switch signal and backup value.
Also, the accelerator learning must be executed when the accelerator was repaired or replaced.

• SERVICE ENGINE SOON lamp turns on (continuous ON)
• Lack of output power
• Faulty accelerator pedal reaction (responsibility)
The control unit judges as "accelerator temperature sensor system trouble" and displays "diagnostic trouble
code: 24" when the output voltage applied to the accelerator temperature sensor exceeds 4.8V, or the voltage
below 0.1V continues fore more than one second.

In the event of accelerator sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles
without the multi-warning display turns on, regardless of engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in accelerator sensor (power) circuit
• Disconnection or shortcircuit in accelerator sensor (SIG) circuit
• Disconnection or shortcircuit in accelerator sensor (GND) circuit
• Faulty accelerator installation (disordered, loose)
• Faulty accelerator pedal (disordered, loose, faulty link, faulty spring)
■ Diagnostic help
if faulty.
4-31

1. Start the engine and idle it. Current diagnostic
2. Using the Tech II, check the detected diagnostic trouble code. trouble: help, and
Is the detected diagnostic trouble code current trouble? 24 go to
step 4
past
trouble
2 Check the harness for disconnection or shortcircuit. Pins 41 - 44: 0.5Ω or less Step 4 Step 3
1. Turn the starter switch off. (Jumper: 4 - 1)
2. Disconnect the harness from the Engine Control Unit. Pins 41 - 45: 0.5Ω or less
3. Disconnect the harness from the accelerator sensor. (Jumper: 4 - 2)
4. Using a jumper wire between connector pins on accelerator Pins 44 - 45: 0.5Ω or less
sensor side, measure resistance value of connector on the (Jumper: 2 - 1)
Engine Control Unit side. Each pin - body (GND):
Is the resistance value normal? ∞Ω (Without jumpr)
3 Repair or replace the accelerator sensor circuit. Also, check the - Step 4 -
4 Check the accelerator sensor circuit for shortcircuit. - Step 5 Step 6
4. Install the circuit tester between connector each pin on sensor
side and GND (frame or engine body).
6. Measure the voltage in the accelerator sensor circuit.
5 Repair or replace the accelerator sensor circuit. Also, check the - Step 6 -
6 Check the voltage applied to the accelerator sensor, "power" pin. Between sensor pin Step 8 Step 7
1. Turn the starter switch off. 1and GND:
2. Install the harness on the engine control unit. 5V(4.75 - 5.25V)
3. Install the circuit tester between connector pins on the sensor Between sensor pin
side and GND (frame and engine body etc.). 3and GND:
4. Turn the starter switch on. 5V (4.75 - 5.25V)
Note: If the harness is disconnected from the accelerator sensor,
5. Measure the voltage in the accelerator sensor "power" circuit.
4-32

8 Using the circuit tester, check the accelerator sensor "GND" for Between sensor pin Step 10 Step 9
continuity. 1 - 2 and GND:
1. Turn the starter switch off. Idle 0.3 - 0.6V
2. Confirm that the harness is connected to the engine control unit. Full 3.5 - 4.8V
3. Install the circuit tester between connector pins on the sensor Between sensor pin
side. 1 - 3 and GND:
4. Turn the starter switch on. 5.07 - 5.17V
Note: If the harness is disconnected from the accelerator sensor,
5. Measure the voltage in the accelerator sensor circuit.
Is the voltage normal?
10 Check the accelerator pedal link, bracket, and spring for installation - Step 11 -
or trouble, and repair or replace if faulty.
11 Using the Tech II, check the accelerator sensor. - Step 13 Step 12
2. Connect the Tech II.
4. Connect the Tech II, and perform "Accelerator sensor, SW
check" in "Inspection" menu to check if the sensor is normal.
Is the accelerator sensor normal?
12 Replace the accelerator sensor. - Step 13 -
13 Confirm that the diagnostic trouble codes are cleared, and conduct - Step 15 Step 14
the test run again to check that no diagnostic trouble code is detected.
Is diagnostic trouble code detected?
1. Stop the engine.
4-33

detected. to
help,
step 1
Note:Be sure to execute the accelerator learning after the Engine Control Unit or accelerator sensor was
repaired or replaced.
4-34
■ External view, pin assignment and resistance value of accelerator sensor

< External view of accelerator sensor > < Pin assignment of accelerator sensor >
1 GND G/0.5
2 SIG Y/0.5
3 5V L/0.5
POWER GND
3 2 1
SIG
MFW36ESH000101
< External view of bracket assembly >
<Accelerator sensor output voltage>

Output voltage in the table below is that when the sensor is connected to the engine control unit.
Accelerator
Parts checked Output voltage Remarks
pedal position
Accelerator 1⇔3 - 5.07 - 5.17V
sensor connector 1⇔2 Idling position 0.35 - 0.65V New sensor
0.31 - 0.69V Used sensor
Full-throttle (Idling voltage Permissible if the full
position + 3.5V - 4.80V) voltage is below 4.8V and
the difference between the
full voltage and idling
voltage is "more than 3.5V".
4-35
25 Vehicle speed sensor system trouble (1/7)
■ Vehicle speed sensor circuit (including pulse matching device circuit)
SBF 3
Fuse 11
Engine Control Unit
75 30 66 53
SIG SIG GND SIG
Pulse
Matching 2
1
Device
4
3 10 12
IGN SIG GND
Meter
Water Atmospheric
Sensor Sensor
Vehicle
Speed
Sensor
(VSS)
4-36
The vehicle speed sensor detects the vehicle speed. The vehicle speed sensor is installed on the transmission
or transfer output. The vehicle speed sensor is driven via the drive gears and the sensor shaft rotates. When
the shaft rotates, the voltage is generated by the magnet (magnetic force) attached to the sensor, and the pulse
signals are outputted. For the sensor output signals, the time (frequency) between pulse signals changes
according to the vehicle speeds (sensor shaft revolutions). (Low frequency pulses are outputted when the
sensor shaft revolutions are low, or high frequency pulses if high. The Engine Control Unit converts the
vehicle speed sensor signals into the vehicle speeds, which are used for the auto cruise or NR control. As the
pulse signals (frequencies) from the vehicle speed sensor vary depending on the type of vehicles because of
different transmissions, differential gear ratios, or tire radii, the pulse matching device is installed to correct
the pulse signals so that the vehicle speed information can be used exactly for meters and various controls.
(It corrects the vehicle speed sensor shaft revolutions to 637 rpm when the vehicle speed is 60 km/h.) For the
pulse signals, the voltage changes between high level (about 14V) and low level (about 2V).
he control unit judges as "vehicle speed sensor trouble" and displays "diagnostic trouble code: 25", when the
vehicle speed pulse signal voltage level is high and the state below 0.5V continues for more than one second,
or when no vehicle speed pulse signals are entered during auto cruise operation.

In the event of vehicle speed sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles
without the multi-warning display turns on, regardless of engine running condition if NR is attached to the
vehicles. (Continuous ON)
For the vehicles without NR, the SERVICE ENGINE SOON lamp does not turn on, but the trouble is
indicated with the diagnostic trouble code only.
■ Possible causes
• Faulty vehicle speed sensor circuit (power supply, SIG, GND, pulse matching device)
• Faulty sensor installation condition (loose, faulty shaft)
• Faulty drive gear for vehicle speed sensor shaft rotation (transmission, etc.)
• Faulty internal circuit of pulse matching device
■ Diagnostic help
if faulty.
4-37

step 2
past
trouble
2 Check the speedometer operation. - Step 3 Step 9
Does the meter operate normally during the vehicle running?
3 Check the harnesses for disconnection or shortcircuit. Pulse matching device: Step 5 Step 4
1. Turn the starter switch off. 12-pin connector
2. Disconnect the harness from the Engine Control Unit. (Bt. pulse matching
3. Disconnect the harness from the pulse matching device. device pin 2 and Engine
4. Using a jumper wire, connect between connector pin on the Control Unit - pin 75)
pulse matching device side and GND (frame or body). Jumper: 0.5Ω or less
5. Install the circuit tester between connector pin on the Engine Without jumper: ∞Ω
Control Unit side and GND (frame or body), and measure
resistance.
4 Repair or replace the vehicle speed sensor circuit. Also, check the - Step 5 -
5 Check the pulse matching device power circuit for disconnection. Pulse matching device: Step 7 Step 6
1. Turn the starter switch off. 12-pin connector,
2. Install the circuit tester between connector pin on sensor side Between. pin 4 and GND:
and GND (frame or engine body). Battery voltage
4. Measure voltage in the pulse matching device power circuit.
Is the voltage applied normal?
6 Repair or replace the pulse matching device power circuit. Also, - Step 7 -
4-38

7 Check the harness for disconnection or shortcircuit. Pulse matching device: Step 9 Step 8
1. Turn the starter switch off. 12-pin connector,
2. Disconnect the harness from the vehicle speed sensor. Bt. pins 3 and 10
3. Disconnect the harness from the pulse matching device device. (Jumper bt. vehicle speed
4. Using a jumper wire between connector pins on vehicle speed sensor⋅POW and SIG):
sensor side, measure resistance value of connector on the pulse 0.5Ω or less
matching device side. (Without jumper): ∞Ω
Is the resistance value normal? Between pins 3 and 12
(Jumper bt. vehicle speed
sensor POW and GND):
0.5Ω or less
(Without jumper): ∞Ω
Between pins 10 and 12
(Jumper bt. vehicle speed
sensor SIG and GND):
0.5Ω or less
(Without jumper): ∞Ω
8 Repair or replace the vehicle speed sensor circuit. Also, check the - Step 9 -
9 Check the vehicle speed sensor condition. - Step 11 Step 10
2. Remove the vehicle sensor.
3. Check the shaft for wear, damage, or disengagement.
Is the vehicle sensor shaft normal?
10 Replace the vehicle speed sensor shaft. - Step 19 -
11 Check again the diagnostic trouble code. - Step 19 Step 12
1. Connect the Tech II, and clear the diagnostic trouble code.
2. Start the engine and conduct the test.
3. Connect the Tech II, and check the diagnostic trouble code.
Is the diagnostic trouble code detected?
12 Replace the vehicle speed sensor, and check again if the diagnostic - Step 19 Step 13
trouble code is detected.
1. Replace the vehicle speed sensor.
13 Check if the diagnostic trouble code is detected in other systems Diagnostic trouble code is Step 14 Step 18
besides IE system. detected in other systems
Is the diagnostic trouble code "25" detected in the Air suspention besides IE system
system?
4-39

14 Check the vehicle speed sensor drive gears. - Step 16 Step 15
Are the drive gears normal?
15 Repair or replace the vehicle speed sensor drive gears. - Step 17 -
16 Replace the pulse matching device. - Step 17 -
1. Stop the engine.
2. Connect the harnesses on the boost sensor.
detected. to
help,
step 1
4-40
■ External view, pin assignment and output voltage of vehicle speed sensor
< External view of vehicle speed sensor > < Pin assignment of accelerator sensor >
1 power source Y/0.5

2 GND B/0.5
3 SIG W/0.5
3 2 1
<Output voltage of vehicle speed sensor>

Output voltage in the table below is obtained when the vehicle speed sensor is connected to the vehicle.
Parts checked Shaft condition Output voltage Remarks
090II 1 ⇔ 2 - battery voltage (28V)
water-proof 3 ⇔ 2 Not rotating 1.0 - 3.0V Vehicle stop
connector, 3 pins or
Sensor side: 12.0 - 15.0V
(Black) Not rotating Pulse signal that the voltage Vehicle
Harness side: changes between 1.0 - 3.0V and traveling
(gray) 12.0 - 15.0V
<Checking the output voltage of vehicle sensor>
The vehicle sensor is designed so that the output voltage is changed according to the shaft rotating angle. The
output voltage during the "Vehicle traveling" in the above table can be checked by turning the shaft by hand.
(The output voltage changes between 1.0-3.0V and 12.0-15.0V by turning the shaft by 7.2°.)
* The pulse matching device converts the input signal before outputting it. Therefore, it cannot be checked
in the same manner as the vehicle speed sensor. (The output voltage of the pulse matching device cannot
be checked with a circuit tester. Oscilloscope or other similar measuring instrument which can check
waveform is required.)
1 Remove the vehicle speed sensor.

2 Connect the vehicle sensor connector.
3 Turn the starter switch off.
4 Turn the vehicle sensor shaft slowly using a circuit tester and
measure the output voltage.
■ Vehicle speed sensor tightening torque Shaft

Tighten the vehicle speed sensor with the specified tightening torque as shown below.
* If the tightening torque more than specified is applied, the sensor may be damaged or fail.
Specified tightening torque: 24.52 - 34.32 N-m (2.5 - 3.5 kgf⋅m)

4-41
■ External view, pin assignment and output voltage of pulse matching device
<External view of pulse matching device> <Pin assignment of pulse matching device>
Pin No. Pin No. Signal name
(12 pins) (8 pins)
1 1 8-pulse signal output (SIG)
2 4 25-pulse signal output (SIG)
3 7 Power supplied to vehicle speed sensor
4 8 Pulse matching device power source
10 2 Pulse signal input
12 5 GND
1 2 3 4
1 2 3 4 5 6 7 8
5 6 7 8 9 10 1112
<Pulse matching device output voltage>

Output voltage in the table below is obtained when the pulse matching device is connected to the vehicle.
Parts checked Vehicle sensor Output voltage Remarks

shaft condition
Pulse matching 12 pins 4⇔B - Battery voltage (28V)
device connector 8 pins 5⇔8
12 pins 3⇔B - Battery voltage (28V)
(12 pins
8 pins 5⇔7
or 8 pins)
12 pins 0⇔B Not rotating 1.0 - 3.0V or 10PIN:
8 pins 2⇔5 (vehicle stop) 12.0 - 15.0V Measurement of 25-
Rotating Pulse signal which changes between pulse input signal
(vehicle traveling) 1.0 - 3.0V and 12.0 - 15.0V from vehicle speed
sensor
12 pins 2 ⇔ B Not rotating 1.0 - 3.0V 2PIN:
8 pins 4 ⇔ 5 (vehicle stop) Measurement of
Rotating Pulse signal which changes between 25-pulse output
(vehicle traveling) 1.0 - 3.0V and 12.0 - 15.0V signal
12 pins 1 ⇔ B Not rotating 0 - 1.5V Measurement of

8 pins 1 ⇔ 5 (vehicle stop) 8-pulse output
Rotating Pulse signal which changes between signal
(vehicle traveling) 0 - 1.5V and meter power source
(8.0V) - 0.5V
4-42
28 All Speed Accelerator Sensor Error / No operate PTO (1/3)
■ PTO circuit
Battery Relay
SBF 3
Starter Switch
"ON"
Battery
PTO PTO
Lamp Switch
16
Engine Control Unit
73 63 56
Vcc SIG GND
5V
PTO
Magnetic
Valve
Boost Sensor
4-43
The external accelerator and all-speed accelerator sensor control engine speed during PTO operation. The
external accelerator performs the same function as the accelerator pedal inside the vehicle.
The all-speed accelerator sensor receives power from the ECU. When the PTO lever is operated, the output
voltage changes. This results in a data signal being returned to the ECU. Based on this data, the ECU
calculates the all-speed accelerator opening angle to control the accelerator.
Whenever the all-speed sensor is repaired or replaced, adjustment is required.
■ Possible problems
• Incorrect PTO operating sequence
• All-speed accelerator sensor wrongly installed or poorly adjusted
• Engine Control Unit malfunction
• Sensor circuit malfunction (Open or shorted)
Note: DTC 28 is displayed when the PTO switch or all speed acclerator sensor is not installed to vehicle.

1 Measure the resistance (conductivity) between the ECU and the all- Less than 1 Ω Go to Go to
speed accelerator sensor at the measuring points specified below. Step 3 Step 2
• ECU ↔ member harness connector
• Member harness connector ↔ all-speed accelerator sensor
2 Repair or replace the circuitry between the ECU and the all-speed - Go to -
accelerator sensor. Step 3
Is the action complete?
3 Measure the all-speed accelerator sensor output voltage. • Idle = Verify Go to
1. Remove the harness from the ECU. 0.3~0.5volts repair Step 4
2. Starter switch ON. • Full-open =
3. Measure the output voltage at the idle position and the full-open 4.2~4.5volts
position.
4 Check the ECU. 5 volts Go to Go to
1. Remove all harnesses except the all-speed accelerator sensor Step 6 Step 5
harness.
2. Starter switch ON.
3. Measure the power supply voltage at the all-speed accelerator
sensor connector.
5 Replace the ECU. - Go to -
6 Replace the all-speed accelerator sensor. - Go to -
7 Adjust the external accelerator (all-speed accelerator sensor). - Verify -
4-44
■ All-Speed Accelerator Sensor Connector (External View)

<External view of pulse matching device> <Pin assignment of pulse matching device>
1 2 3
All-speed accelerator sensor harness voltages and wire color
Terminal Voltage Wire color

1 5 Black
2 SIG Green
3 GND Red
All-speed accelerator sensor harness voltages (Between terminals)

Measuring point (Voltage check connector) Accelerator pedal position Output (V)
A—C No depression 4.6~4.9
Idle 0.3~0.5
B—C
Full 4.2~4.5
4-45
32 Boost sensor system trouble (1/6)
■ Boost sensor circuit
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-46
The boost sensor is detects the intake manifold inside pressure. The boost sensor is installed on the intake
manifold. The boost sensor output voltage changes (the output voltage is low when the intake manifold inside
pressure is low, and it becomes high as the pressure rises) if the intake manifold inside pressure changes
according to the engine (turbocharger) condition.
The Engine Control Unit reads this output voltage change and converts it into the boost pressure for control.
The boost sensor power supply (5V) and GND circuit is common to the all speed accelerator sensor, and it is
connected to the Engine Control Unit. The sensor circuit is shielded to protect from electrical noise.

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idling continues for 20 seconds)
• Black smoke
The control unit judges as "boost sensor trouble" and displays "diagnostic trouble code: 32", if the relative
boost pressure exceeds 20kPa or if the state below -32kPa continues for one second, when the engine stalls.
If the "high boost trouble (diagnostic trouble code: 42)" is also displayed, the boost pressure is faulty, and
accordingly check and repair by referring to "high boost trouble (diagnostic trouble code: 42)".

In the event of boost sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
■ Possible causes
• Disconnection or shortcircuit in boost sensor (5V, SIG, GND) circuit
• Faulty sensor installation condition (loose)
• Faulty intake system (intercooler, intake pipe, air cleaner, etc.)
■ Diagnostic help
Check the intake system including air cleaner for clogging, the connectors for loose connection, the harnesses
for abrasion or folding, the wires inside harnesses for abrasion or shortcircuit. Also, perform functional
diagnosis to check the operation and control, and repair if faulty.
4-47

step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. Between pins 61 and 72: Step 4 Step 3
2. Disconnect the harness from the Engine Control Unit. 0.5Ω or less
3. Disconnect the harness from the boostr sensor. (Without jumper) ∞Ω
4. Using a jumper wire between connector pins on boost sensor Between pins 61 and 56:
side, measure resistance value of connector on the Engine (Jumper: 1 - 2)
Control Unit side. 0.5Ω or less
Is the resistance value normal? (Without jumper) ∞Ω
Between pins 72 and 56:
(Jumper: 3 - 2)
0.5Ω or less
(Without jumper) ∞Ω
3 Repair or replace the harness of boost sensor circuit. Also, check the - Step 4 -
4 Check the boost sensor circuit for shortcircuit. - Step 5 Step 6
6. Measure voltage in the boost sensor circuit.
5 Repair or replace the harness of boost sensor circuit. - Step 6 -
4-48

6 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin 3 and Step 8 Step 7
1. Turn the starter switch off. GND: 5V
2. Install the harness on the engine control unit. (4.75 - 5.25V)
side. and GND (frame and engine body etc.)
Note: If the harness is disconnected from the boost sensor,
5. Measure the voltage in the boost sensor "power" circuit.
7 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin 2 and Step 9 Step 8
1. Turn the starter switch off. GND: 0.5Ω or less
side.
5. Measure the resistance value in the boost sensor circuit.
9 Check the boost sensor. - Step 10 Step 11
2. Remove the boost sensor.
3. Check the boost sensor for clogging or presence of foreign
materials.
Are foreign materials present on the boost sensor?
10 Clean the boost sensor and install it again. - Step 12 -
4-49

11 Replace the boost sensor. - Step 12 -
13 Check the intake system. - Step 14 See
Did corrective actions complete? functional
diag:
Intake
system
to check,
then step
14
1. Stop the engine.
detected. to
help,
step 1
4-50
■ External view, pin assignment and output voltage of boost sensor

<External view of boost sensor> <Pin assignment of boost sensor>
1 SIG R/0.5
2 GND B/0.5
3 5V W/0.5
3 1 2
POWER SIG GND
<Boost sensor output characteristic diagram>

Connector
4.5
Output voltage
2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg)

Air intake port
Boost pressure
(absolute voltage)
<Boost sensor output voltage>
The output voltage shown in the table below are obtained when the boost sensor is connected with the engine
control unit. Refer to the "Boost sensor output characteristic diagram" for the relation between the voltage
and output voltage.
Parts checked Boost pressure Output voltage Remarks
EJ mark II connector 3 ⇔2 - 5.07 - 5.17V
(black), 3 pins 1 ⇔2 101.3kPa {760mmHg} 0.8 - 1.2V Equivalent to
atmospheric pressure
4-51
33 CPU monitoring IC trouble (1/2)
■ Description of diagnostic trouble code

The central processing unit (CPU), memory (RAM), and CPU monitoring IC are built in the Engine Control
Unit.
If this diagnostic trouble code occurred, whether the CPU in the Engine Control Unit operates normally
(including calculation and various controls) is not sure, and thus this diagnostic trouble code "CPU
monitoring IC trouble" is displayed.
■ Vehicle behaviors in the event of this diagnostic trouble code

In the event of CPU monitoring IC trouble, the Engine Control Unit judges as "CPU monitoring IC trouble"
and displays "diagnostic trouble code: 33".

In the event of CPU monitoring IC trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning display
turns on, regardless of the engine running condition. (Continuous ON)
■ Possible cause
• Internal trouble of EngineControl Unit

1 Check the detected diagnostic trouble code. - Step 2 Step 6
1. Using the Tech II, check the detected diagnostic trouble code.
Is the detected diagnostic trouble code current trouble?
2 Check the diagnostic trouble code. - Step 6 Step 3
2. Turn the starter switch off once.
4. Connect the Tech II and check the diagnostic trouble code.
3 Check the battery voltage and Engine Control Unit connector for - Step 5 Step 4
abnormality.
Is any abnormality found?
4 Repair faulty parts found in step 3. - Step 6 -
5 Replace Engine Control Unit. - Step 6 -
4-52
33 CPU monitoring IC trouble (2/2)

1. Stop the engine.
7 Confirm that the diagnostic trouble codes have been cleared, and - Repair Step 2
conduct the test run again to check that no diagnostic trouble code is end
detected.
4-53
35 A/D conversion error/charger circuit trouble (1/2)

The engine control unit converts signals from switches and sensors (analog signal) to digital signals to be
used for various calculation and control. When this conversion (A/D conversion) is not successful, a
diagnostic trouble code "A/D conversion error" is indicated.
A power source pressure-up circuit for the injector is provided in the engine control unit. If a trouble is
detected in this circuit, the diagnostic trouble code, "charge circuit trouble" is indicated.
■ Vehicle behavior in case of a trouble

• A/D conversion error
Service engine soon lamp lights up (continuous ON).
Lack of output power
Rough idling
• Charging circuit trouble
Service engine soon lamp lights up (continuous ON).
Engine stops.
When a trouble of IC for monitoring CPU in the engine control unit is detected, it is diagnosed as "A/D
conversion error/charge circuit trouble" and "diagnostic trouble code: 35" is indicated.
■ Warning during diagnosis (SERVICE ENGINE SOON lamp light ON)

In the event of failure in the engine control unit, "Service engine soon lamp" lights up. (continuous ON)
■ Possible causes
• Internal trouble of engine control unit
• Faulty injector system circuit
4-54
35 A/D conversion error/charger circuit trouble (2/2)

1 Check the detected diagnostic trouble code. - Step 2 Step 8
1. Using the Tech II, check the detected diagnostic trouble code.
Is the detected diagnostic trouble code current trouble?
2 Check the diagnostic trouble code. - Step 6 Step 3
2. Turn the starter switch off once.
4. Connect the Tech II and check the diagnostic trouble code.
3 Check the battery voltage and Engine Control Unit connector for - Step 5 Step 4
abnormality.
Is any abnormality found?
4 Repair faulty parts found in step 3. - Step 2 -
5 Referring to diagnostic trouble codes "158, 159", check the injector Step 7 Step 6
system circuit.
Is the injector system circuit normal?
6 Repair the injector system circuit. - Step 8 -
1. Stop the engine.
9 Confirm that the diagnostic trouble codes have been cleared, and - Repair Step 2
conduct the test run again to check that no diagnostic trouble code is end
detected.
4-55
42 High boost trouble (1/6)
■ Boost sensor circuit (including all speed accelerator sensor circuit)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-56

• SERVICE ENGINE SOON lamp turns on (Continuous ON)
• Black smoke
The control unit judges as "high boost trouble" and displays "diagnostic trouble code: 42", if the state where
actual boost pressure is higher than reference boost pressure continues for more than 0.5 second though the
boost pressure always changes during the engine running.
Further, if an abnormal state continues for more than 10 seconds, "diagnostic trouble code: 42" is also
displayed.

In the event of boost pressure trouble, the SERVICE ENGINE SOON lamp for the vehicles without the multi-
warning display turns on, regardless of the engine running conditions. (Continuous ON)
■ Possible causes
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty sensor installation (loose)
• Faulty turbocharger (main body, VGS (air cylinder, magnetic valve, air piping, shaft, etc.))
• Faulty exhaust brake (main body, control air cylinder, etc.)
■ Diagnostic help
4-57

step 2
past
trouble
diag:
Intake
system
to check,
then
step 3
3 Check the exhaust system. - Step 4 See
diag:
Intake
system
to check,
then
step 4
(Jumper: 3 - 2)
0.5Ω or less
4-58

6 Check the boost sensor circuit for shortcircuit. - Step 8 Step 7
6. Measure voltage in the boosCMP sensor circuit.
8 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin Step 9 Step 9
1. Turn the starter switch off. 3 and GND:
2. Install the harness on the engine control unit. 5V (4.75 - 5.25V)
3. Install the circuit tester between connector each pins on the
sensor side and GND (frame and engine body etc.).
9 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin Step 11 Step 10
2. Confirm that the harness is connected to the engine control unit. 0.5W or less
side.
11 Check the boost condition. -4 to 4kPa Step 15 Step 12
2. Connect the harness to the boost sensor.
4. Connect the Tech II, and check the "relative boost" of the
engine data.
5. Start the engine and idle it.
Is the data normal?
4-59

materials.
1. Stop the engine.
2 Turn the starter switch on.
detected. to
help,
step 1
4-60

1 SIG W/0.5
2 GND B/0.5
3 +5V R/0.5

3 1 2
POWER SIG GND 4.5
Output voltage
2.5
Connector
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg)

Boost pressure
(absolute voltage)
Air intake port
LFW36ESH001201
and output voltage.

EJ mark II connector 3 ⇔ 2 - 5.07 - 5.17V
(black), 3 pins 1 ⇔ 2 101.3kPa {760mmHg} 0.8 - 1.2V Equivalent to
4-61
65 Low boost trouble (1/6)
■ Boost sensor circuit
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-62

• Black smoke
The control unit judges as "low boost trouble" and displays "diagnostic trouble code: 65", if the state where
actual boost pressure is lower than reference boost pressure continues fore more than about 25 seconds,
though the boost pressure always changes during the engine running when the throttle opening is over 80%.

In the event of boost pressure trouble, the SERVICE ENGINE SOON lamp for the vehicles without the multi-
warning display does not turn on, but the trouble is indicated with the diagnostic trouble code only.
■ Possible causes
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty turbocharger (main body, etc.)
• Faulty exhaust brake (main body, control air cylinder, etc.)
■ Diagnostic help
4-63

step 2
past
trouble
diag:
Intake
system
to check,
then
step 3
diag:
Intake
system
to check,
then
step 4
(Jumper: 3 - 2)
0.5Ω or less
4-64

6 Check the boost sensor circuit for shortcircuit. Voltage is applied Step 8 Step 7
6. Measure voltage in the boosCMP sensor circuit.
8 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin Step 9 Step 9
2. Install the harness on the engine control unit. 5V (4.75 - 5.25V)
3. Install the circuit tester between connector each pins on the
sensor side and GND (frame and engine body etc.).
9 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin Step 11 Step 10
2. Confirm that the harness is connected to the engine control unit. 0.5Ω or less
side.
11 Check the boost condition. -4 to 4kPa Step 15 Step 12
2. Connect the harness to the boost sensor.
4. Connect the Tech II, and check the "relative boost" of the
engine data.
5. Start the engine and change the engine speed from idling to high
speed range. Also, conduct the test run and check numeric value.
Is the data normal?
4-65

materials.
1. Stop the engine.
2 Turn the starter switch on.
detected. to
diagnostic
help,
step 1
4-66

1 SIG W/0.5
2 GND B/0.5
3 +5V R/0.5

3 1 2
POWER SIG GND
4.5
Output voltage
Connector 2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg)

Boost pressure
(absolute voltage)
Air intake port
LFW36ESH001201
and output voltage.
EJ mark II connector 3 ⇔ 2 - 5.07 - 5.17V
(black), 3 pins 1 ⇔ 2 101.3kPa {760mmHg} 0.8 - 1.2V Equivalent to
4-67
71 Atmospheric pressure sensor trouble (1/2)
■ Atmospheric pressure sensor circuit (built in Engine Control Unit)
060MX113
The atmospheric pressure sensor detects the atmospheric pressure. The atmospheric pressure sensor is
installed in the Engine Control Unit.
Upon change of atmospheric pressure due to the altitude or weather conditions, the output voltage of the
atmospheric pressure sensor changes (the output voltage is low when atmospheric pressure is low, and it
becomes high as the atmospheric pressure rises). The Engine Control Unit reads this change in output voltage
and converts it into the atmospheric pressure, and based on this signal, it optimizes the fuel injection control
and calculates relative pressure of the boost pressure.
In the event of atmospheric pressure sensor trouble, the Engine Control Unit makes control with the backup
value.
Note: The Engine Control Unit cannot be disassembled. Replace the Engine Control Unit if the atmospheric
pressure sensor is faulty.

• During the running at a highland
White smoke
The control unit judges as "atmospheric pressure sensor trouble" and displays "diagnostic trouble code: 71",
when the voltage applied to the atmospheric pressure sensor exceeds 4.7V or when the state below 1.9V
continues for more than one second.

In the event of atmospheric pressure sensor system trouble, the SERVICE ENGINE SOON lamp for the
vehicles without the multi-warning display does not turn on, but the trouble is indicated with the diagnostic
trouble code only.
4-68
71 Atmospheric pressure sensor trouble (2/2)
■ Possible causes
• Faulty sensor (faulty sensor internal circuit, detector, or installation)
• Internal trouble of Engine Control Circuit
■ Diagnostic help
Clear the diagnostic trouble code and conduct the test run, and if the diagnostic trouble code is again
displayed, replace the Engine Control Unit, as the atmospheric pressure sensor is built in the Engine Control
Unit. Also, in the test run, run the vehicle from a lowland up to a highland to check if a trouble is detected.

step 2
past
trouble
2. Start the engine and conduct the test run. (Run vehicle at a
highland, if possible)
3 3. Connect the Tech II, and check the diagnostic trouble code. - Step 4 -
4 Replace the Engine Control Unit. - Repair After
Did corrective actions complete? end referring
Confirm that the diagnostic trouble codes have been cleared, and to
conduct the test run again to check that no diagnostic trouble code is diagnostic
detected. help,
Is not diagnostic trouble code detected? step 1
4-69
115 Fuel pressure sensor output fixed (1/5)
■ Fuel pressure sensor circuit (including CKP sensor and CMP sensor circuit)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-70
The fuel pressure sensor detects the common rail inside pressure. The fuel pressure sensor is installed on the
common rail.
The fuel pressure sensor output voltage changes (the output voltage is low when the fuel pressure inside
common rail is low, and it becomes high as the pressure rises) if the fuel pressure inside common rail changes
according to the engine condition. The Engine Control Unit reads this output voltage change and converts it
into the fuel pressure inside common rail for control.
The fuel pressure sensor power supply (5V), SIG, and GND circuit is independent, and it is connected to the
The sensor circuit is shielded to protect from electrical noise.

• White smoke/black smoke
• Rough idling
• Poor starting performance
If the state where the common rail fuel pressure (over 10MPa) continues for more than about 9 seconds when
the diagnostic trouble code "245" is not detected and the supply pump is normal (not fail-safe mode), the
Engine Control Unit judges as "fuel pressure sensor output fixed" and displays "diagnostic trouble code:
115".

In the event of fuel pressure trouble, the SERVICE ENGINE SOON lamp for the vehicles without the multi-
warning display turns on, regardless of the engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector)
■ Diagnostic help
if faulty.
4-71

step 2
past
trouble
2 Check the harness for disconnection or GND for shortcircuit. Between pins 62 and 71: Step 4 Step 3
1. Turn the starter switch off. 0.5Ω or less
2. Disconnect the harness from the Engine Control Unit. (Without jumper)
3. Disconnect the harness from the fuel pressure sensor. Between pins 73 and 55:
. Using a jumper wire between connector pins on fuel pressure (Jumper: 3 - 1)
sensor side, measure resistance value of connector on the 0.5Ω or less
Engine Control Unit side. (Without jumper) ∞Ω
Is the resistance value normal? Between pins 62 and 55:
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
3 Repair or replace the fuel pressure sensor circuit. Also, check the - Step 4 -
4 Check the fuel pressure sensor circuit for shortcircuit. - Step 6 Step 5
4. Install the circuit tester between connector each pin on sensor
side and GND (frame or engine body).
6. Measure voltage in the fuel pressure sensor circuit.
4-72

5 Repair or replace the harness of fuel pressure sensor circuit. - Step 6 -
6 Check the fuel pressure inside common rail. - Step 10 Step 7
2. Using the Tech II, conduct the "Fuel Pressure Control" test to
check if actual pressure follows the specified pressure.
Did actual pressure follow the specified pressure?
7 Check the fuel pressure sensor. - Step 8 Step 9
2. Remove the fuel pressure sensor from the common rail.
3. Check the fuel pressure sensor for presence of foreign
materials.
Are foreign materials present on the fuel pressure sensor?
8 Clean the fuel pressure sensor and install it on the common rail. - Step 10 -
9 Replace the fuel pressure sensor. - Step 10 -
2. Bleed the air mixing in the fuel.
3. Start the engine and conduct the test run.
1. Stop the engine.
detected. to
help,
step 1
4-73
■ External view, pin assignment, and output voltage of fuel pressure sensor
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
<Output characteristic chart of fuel pressure sensor>

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
At Vc=5V, actual reading ON 4.2V(160MPa)
OFF 1.0V( 0MPa)
4-74
118 Common-rail pressure trouble (1/7)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-75
common rail.

• Rough idling
• Engine stops
The Engine Control Unit judges as "common rail pressure trouble" and displays "diagnostic trouble code:
118" when diagnostic trouble code "245" is not detected and the state where actual common rail pressure
exceeds about 125MPa continues for more than 0.2 second.
(The Engine Control Unit stops the engine when actual common rail pressure exceeds about 130MPa.)

■ Possible causes
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND)
• Injector internal trouble
• Supply pump internal trouble
• Flow damper operated
• Pressure limiter not operated yet
• Faulty piping (clogging, squeezed) in fuel system (on leak side)
4-76
■ Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses for
abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair if
faulty.
The fuel pressure rises over the specified value, if the pressure limiter does not operate. Replace the pressure
limiter, when the diagnosis could not find out a faulty part but the diagnostic trouble code is detected frequently.

step 2
past
trouble
4. Connect the Tech II, and check the diagnostic trouble code. -
3 Check the supply pump for mounting condition. Step 5 Step 4
2. Run the engine to position the No.1 cylinder in the top dead center.
3. Check the mating mark on the supply pump. -
Is the alignment mark on the supply pump in correct position?
4 Adjust the supply pump mounting condition. - Step 5 -
5 Check the injectors for fuel injecting operation. Step 9 Step 6
Note: At this time, if the injector related trouble code has been
detected, check and repair the injector related parts before
this checking.
2. Using the Tech II, conduct the "Cylinder Power Balance" test
and stop each cylinder injector to check if fuel is injected
normally.
The engine speed and sound will vary if the injector is stopped
when the injector injects fuel normally.
The engine speed and sound will not vary if the injector is
stopped when the injector is faulty and does not inject fuel.
Does the injector inject fuel normally?
4-77

6 Check the fuel piping system. - Step 9 Step 7
1. Stop the engine.
2. Check the fuel piping of the cylinder where the engine speed
and sound did not vary in step 5. (Clogged or squeezed high
pressure piping, leak side piping)
Is the fuel piping system normal?
7 Check the fuel piping system, and repair or replace. - Step 9 Step 8
(Repair or replace the fuel piping of the cylinder where the engine
speed and sound did not vary in step 5.)
8 Replace the injector. - Step 9 -
(Replace the injector of the cylinder where the engine speed and
sound did not vary in step 5.)
9 Check again the fuel system including piping and filters, and repair - Step 10 -
or replace if faulty.
4. Using a jumper wire between connector pins on fuel pressure (Jumper: 3 - 1)
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
4-78

11 Repair or replace the harness of fuel pressure sensor circuit. Also, - Step 12 -
4. Install the circuit tester between each pin on the sensor
connector and GND (frame or engine body).
14 Check the fuel pressure inside common rail. Followed Step 18 Step 15
3. Check the fuel pressure sensor for presence of foreign materials.
18 Check again the fuel pressure. - Step 21 Step 19
1. Perform again the steps 14 to 16.
2. Check the fuel pressure.
Are data normal, and also does actual pressure follow the specified
value?
4-79

19 Check the supply pump. - Step 21 Step 20
1. Stop the engine.
2. Disconnect the fuel high pressure piping between supply pump
and common rail.
Note: As the fuel flows out, prevent the fuel from running out and
wipe the fuel that flowed out with waste cloth.
3. Disconnect the harnesses from PCV1 and PCV2.
Note: If the harnesses are disconnected from the PCV, the
diagnostic trouble codes "247, 248" will be detected, and thus
clear the trouble codes after the check finished.
4. Start the starter.
Note: As the fuel may flow out suddenly, prevent the fuel from
running out and wipe the fuel that flowed out with waste cloth.
5. Check if the fuel is discharged from the supply pump (delivery
valve).
Is the fuel discharged from the supply pump (delivery valve)?
Did correction actions complete?
21 Check the flow damper operation. - Step 25 Step 22
2. Start the engine and change the engine speed.
3. Using the Tech II, check how many times the flow damper
operates.
Does the number of flow damper operating times increase during
engine running?
22 Check the fuel piping where the number of flow damper operating - Step 23 Step 24
times increases (between common rail and injector) for leakage.
Does the fuel leak?
23 Repair or replace the fuel piping (between common rail and injector). - Step 24 -
24 Bleed the air mixing in the fuel. - Step 25 -
25 Replace the flow damper. - Step 26 -
4-80

2. Restore the vehicle.
detected. to
help,
step 1
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-81
151 Common rail pressure trouble (pump excessive pressure feed) (1/7)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-82
common rail.

• Rough idling
The Engine Control Unit judges as "common rail pressure trouble (pump excessive pressure feed)" and
displays "diagnostic trouble code: 151" if the difference between actual common rail fuel pressure and target
common rail fuel pressure is over 10MPa (PC differential pressure) and this state continues for more than
about 9 seconds during the engine running or if the PCV close timing is 217.5°CA and this state continues
for more than about 9 seconds at the water temperature over 60°C when the diagnostic trouble codes "245,
115" are not detected and the supply pump and CKP sensor are operating normally (not fail-safe mode).

■ Possible causes
• Injector internal trouble
• Supply pump internal trouble
• Flow damper operated
• Pressure limiter not operated yet
• Faulty piping (clogging, squeezed) in fuel system (on leak side)
4-83
■ Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses for
abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair if faulty.
The fuel pressure rises over the specified value, if the pressure limiter does not operate. Replace the pressure
limiter, when the diagnosis could not find out a faulty part but the diagnostic trouble code is detected frequently.


step 2
past
trouble
3 Check the supply pump for mounting condition. - Step 5 Step 4
2. Run the engine to position the No.1 cylinder in the top dead center.
3. Check the mating mark on the supply pump.
Is the mating mark on the supply pump in correct position?
4 Adjust the supply pump mounting condition. - Step 5 -
5 Check the fuel piping system. - Step 7 Step 6
1. Stop the engine.
2. Check the fuel piping of the cylinder where the engine speed
and sound did not vary in step 5. (Clogged or squeezed high
pressure piping, leak side piping)
Is the fuel piping system normal?
6 Repair or replace the fuel piping (between common rail and injector). Step 23 -
7 Check the fuel piping system, and repair or replace. - Step 9 Step 8
(Repair or replace the fuel piping of the cylinder where the engine
speed and sound did not vary in step 5.)
8 Bleed the air mixing in the fuel. - Step 24 -
4-84
151 Common rail pressure trouble (pump excessive pressure feed) (4//7)

9 Check the injectors for fuel injecting operation. - Step 9 Step 6
Note:At this time, if the injector related trouble code has been
detected, check and repair the injector related parts before
this checking.
2. Using the Tech II, conduct the "Injection Power Balance" test
and stop each cylinder injector to check if fuel is injected
normally.
The engine speed and sound will vary if the injector is stopped
when the injector injects fuel normally.
The engine speed and sound will not vary if the injector is
stopped when the injector is faulty and does not inject fuel.
Does the injector inject fuel normally?
10 Check again the fuel system including piping and filters, and repair - Step 11 -
or replace if faulty.
11 Check the injector. - Step 12 -
(Replace the injector of the cylinder where the engine speed and
sound did not vary in step 5.)
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
4-85

14 Check the fuel pressure sensor circuit for shortcircuit. Voltage is applied Step 16 Step 15
4. Install the circuit tester between each pin on the sensor
connector side and GND (frame or engine body).
3. Check the fuel pressure sensor for presence of foreign
materials.
18 Check the fuel pressure inside common rail. Followed Step 20 Step 19
20 Check again the fuel pressure. - Step 21 Step 19
1. Perform again the steps 14 to 16.
2. Check the fuel pressure.
Are data normal, and also does actual pressure follow the specified
value?
4-86

21 Check the supply pump. - Step 23 Step 22
1. Stop the engine.
2. Disconnect the fuel high pressure piping between supply pump
and common rail.
Note: As the fuel flows out, prevent the fuel from running out and
wipe the fuel that flowed out with waste cloth.
3. Disconnect the harnesses from PCV1 and PCV2.
Note: If the harnesses are disconnected from the PCV, the
diagnostic trouble codes "247, 248" will be detected, and
thus clear the trouble codes after the check finished.
4. Start the starter.
Note: As the fuel may flow out suddenly, prevent the fuel from
running out and wipe the fuel that flowed out with waste cloth.
5. Check if the fuel is discharged from the supply pump (delivery
valve).
Is the fuel discharged from the supply pump (delivery valve)?
22 Replace the flow damper. - Step 23 -
2. Restore the vehicle.
conduct the test run again to check that no diagnostic trouble code is end referrin
detected. g to
Is diagnostic trouble code detected? possible
causes,
step 1
4-87
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-88
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (1/5)
■ Injector circuit
Engine Control Unit
90 110 89 88 59 87 86 85 120
Injector Injector Injector Injector Injector Injector
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
(Cylinder#1) (Cylinder#5) (Cylinder#3) (Cylinder#6) (Cylinder#2) (Cylinder#4)
4-89
The fuel injection quantity and injection timing of the injectors are controlled by the energizing time. The
voltage (over 100V) raised in the Engine Control Unit is applied to the TWV (Two Way Valve) in the
injectors provided on the engine block or head, and the signals are returned to the Engine Control Unit via
the injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:
The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF to prevent an
electric shock during the checking and repair.

• Engine stops
The control unit judges as "TWV Power System Trouble (Common 1 "Injector 1, 3, 5 Systems")" and
displays "diagnostic trouble code: 158" when battery voltage is shortcircuited to the TWV (Two Way Valve)
drive circuit in the injector.

In the event of injector power system trouble, the SERVICE ENGINE SOON lamp for the vehicles without
the multi-warning display turns on, regardless of the engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in injector (power side) circuit
• Disconnection or shortcircuit in injector (driving side) circuit
• Faulty TWV (faulty shortcircuit of internal coil)
■ Diagnostic help
if faulty.
■ Injector (TWV) numbers and cylinder numbers

Common1 Injector 1 (No.1 cylinder)
Injector 3 (No.3 cylinder)
4-90

1 Check the diagnostic trouble code. - Step 2 If
1. Try to start the engine (perform cranking). started,
<Engine cannot start, if current code 158 has been detected> refer to
2. Using the Tech II, check the diagnostic trouble code. diagnostic
Is the detected diagnostic trouble code current trouble? help,
then
step 2
2 Check the harness for disconnection or shortcircuit. Between pin 110 and Step 4 Step 3
1. Turn the starter switch off. each pin: ∞Ω
2. Disconnect the harness from the Engine Control Unit. Between pin 110 and
3. Disconnect the harness from the Injector 1, 3, 5. body (GND): ∞Ω
4. Measure resistance value of connector on the Engine Control Between pin 90 and each
Unit side. pin: ∞Ω
Is the resistance value normal? Between pin 90 and body
(GND): ∞Ω
Between pin 88 and each
pin: ∞Ω
Between pin 88 and body
(GND): ∞Ω
pin: ∞Ω
(GND): ∞Ω
3 Repair or replace the harness of TWV circuit. Also, check the - Step 4 -
4 Check the harness in power supply system and TWV system for Between pin 110 and Step 6 Step 5
shortcircuit. GND: 0V
1. Turn the starter switch off. Between pin 90 and
2. Disconnect the harness from the Engine Control Unit. GND: 0V
3. Disconnect the harness from the Injector 1, 3, 5. Between pin 88 and
4. Turn the starter switch on. GND: 0V
5. Measure potential difference of the connector on the Engine Between pin 86 and
Control Unit. GND: 0V
6 Using a circuit tester, measure the resistance of TWV. Between TWV pins: 0.3 - Step 8 Step 7
1. Turn the starter switch off. 1.3Ω (at about 20°C)
2. Using a circuit tester, measure internal resistance of TWV. Between TWV body and
7 Replace the TWV. - Step 8 -
4-91

1. Stop the engine.
detected. to
help,
step 1
4-92
■ External view, pin assignment and resistance value of injector
<External view of injector>
6WG1
<Resistance value of injector>
Resistance value between pins 0.3 - 1.3Ω
4-93
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-94
injectors provided on the engine block or head, and the signals are returned to the Engine Control Unit via
the injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:
The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF to prevent an
electric shock during the checking and repair.

• Engine stops
The control unit judges as "TWV Power System Trouble (Common 2 "Injector 2, 4, 6 Systems")" and
displays "diagnostic trouble code: 159" when battery voltage is shortcircuited to the TWV (Two Way Valve)
drive circuit in the injector.
In the event of injector system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on, regardless of the engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in injector (power side) circuit
• Disconnection or shortcircuit in injector (driving side) circuit
• Faulty TWV (faulty shortcircuit of internal coil)
■ Diagnostic help
if faulty.

4-95

1 Check the diagnostic trouble code. - Step 2 If
1. Try to start the engine (perform cranking). started,
<Engine cannot start, if current code 159 has been detected> refer to
2. Using the Tech II, check the diagnostic trouble code. diagnostic
Is the detected diagnostic trouble code current trouble? help,
then
step 2
1. Turn the starter switch off. each pin: ∞Ω
4. Measure resistance value of connector on the Engine Control body (GND): ∞Ω
Unit side. Between pin 89 and each
Is the resistance value normal? pin: ∞Ω
(GND): ∞Ω
pin: ∞Ω
(GND): ∞Ω
pin: ∞Ω
(GND): ∞Ω
4 Check the harness in power supply system and TWV system for Between pin 120 and Step 6 Step 5
shortcircuit. GND: 0V
1. Turn the starter switch off. Between pin 89 and
2. Disconnect the harness from the Engine Control Unit. GND: 0V
3. Disconnect the harness from the Injector 2, 4, 6. Between pin 87 and
4. Turn the starter switch on. GND: 0V
5. Measure potential difference of the connector on the Engine Between pin 85 and
Control Unit. GND: 0V
6 sing a circuit tester, measure the resistance of TWV. Between TWV pins: 0.3 - Step 8 Step 7
2. Using a circuit tester, measure internal resistance of TWV. Between TWV body and
7 Replace the TWV. - Step 8 -
4-96

1. Stop the engine.
detected. to
help,
step 1
4-97
6WG1
4-98
217 PCV1 system short circuit (battery and power supply circuit) trouble (1/4)
■ PCV circuit (including the PCV relay circuit)
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-99
The Pump Control Valve (PCV) controls the fuel feedrate to the common rail. Upon signal (voltage)
transmission to the PCV provided on the supply pump, the PCV valve closes and the fuel is compressively
fed from the supply pump to the common rail.
The Engine Control Unit operates the PCV, using the switch function. The longer PCV operation time causes
more fuel to be fed to the common rail, and the common rail internal pressure to be increased.
Two PCV's are installed on the supply pump, and if either PCV failed, another PCV operates the engine to
prevent engine stop.
CAUTION:
If the harnesses for PCV1 and PCV2 are connected reversely, the diagnostic trouble code is not detected but
the engine stops.

• SERIVCE ENGINE SOON lamp turns on (continuous ON)
• Rough idling
The control unit judges as "PCV1 system short (battery, power supply system circuit) trouble" and displays
"diagnostic trouble code: 217" if the signal voltage from the PCV1 is high when the starter switch is turned
on and the supply pump is normal.

In the event of PCV system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the multi-
■ Possible causes
• Shortcircuit in PCV circuit
• Faulty PCV (faulty internal shortcircuit)
■ Diagnostic help
if faulty.
4-100

step 2
past
trouble
2 Check the harness for shortcircuit or disconnection. Between pins 21 and 22: Step 4 Step 3
2. Disconnect the harness from the Engine Control Unit. Between pin 21 and each
3. Disconnect the harness from the PCV1. pin: ∞Ω
4. Measure resistance value of the connector on the Engine Between pin 22 and each
Control Unit side. pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
3 Repair or replace the harness of PCV circuit. Also, check the - Step 4 -
⋅ Engine Control Unit to PCV connector
(Faulty vehicle harness of ECU harness or engine harness)
4 Using a circuit tester, measure the resistance of PCV1. Between PCV pins: 2.6 - Step 6 Step 5
2. Using a circuit tester, measure internal resistance of PCV1. Between PCV body and
5 Replace the PCV1 (supply pump). - Step 7 -
1. Stop the engine.
detected. to
help,
step 1
4-101
■ External view, pin assignment and resistance value of PCV
<External view of PCV> Because the PCV, pins are not identified.
<Resistance value of PCV>
<Arrangement of PCV>
EGR Valve
Boost Sensor
EGR Valve
CKP Sensor
PCV
4-102
■ PCV circuit (including the PCV relay circuit)
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-103
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV2 system short (battery, power supply system circuit) trouble" and displays
"diagnostic trouble code: 218" if the signal voltage from the PCV2 is high when the starter switch is turned
on and the supply pump is normal.

■ Possible causes
■ Diagnostic help
if faulty.
4-104

step 2
past
trouble
(GND): ∞Ω
(GND): ∞Ω
3 Repair or replace the harness of PCV circuit. Also, check the - Step 4 -
1. Stop the engine.
detected. to
help,
step 1
4-105
<Arrangement of PCV>
EGR Valve
Boost Sensor
EGR Valve
CKP Sensor
PCV
4-106
226 Supply pump no pressure feed or pressure limiter operated (1/5)
■ Fuel system diagram
Fuel filter
Common rail Injector
Flow
Fuel pressure sensor damper
Overflow valve
PCV
Pressure limiter
Feed pump
Supply pump Fuel tank
Pre-filter
4-107
The Engine Control Unit supervises the common rail internal pressure based on the fuel pressure sensor
signals, and if the pressure is low, it controls the Pump Control Valve (PCV) on the supply pump to raise the
common rail internal pressure. The common rail internal pressure cannot be raised if the fuel feed to the
supply pump failed or the supply pump troubled.
In the event that the common rail internal pressure rises over the specified value, the pressure limiter installed
on the common rail operates to reduce the fuel pressure so as to prevent the engine mechanical troubles.

• Lack of output power ( after the failure diagnostic, fuel injection is limited )
The control unit judges as "common rail pressure trouble (pump no pressure feed)" and displays "diagnostic
trouble code: 226", if the state where the PCV close timing to the PCV close timing limit is below +1°CA or
common rail internal fuel pressure F/B control amount is below -60°CA continues for more than one second,
when diagnostic trouble codes 245, 217, 218, 247, and 248 are not detected.
(If actual fuel pressure is lower than the target common rail internal fuel pressure of Engine Control Unit)

In the event of diagnostic trouble code "226" detection, the SERVICE ENGINE SOON lamp for the vehicles
■ Possible causes
• Air mixing in high pressure fuel piping
• Pressure limiter operated (operated at the pressure below specified value, deteriorated internal sealing)
• Internal trouble of injector
• Internal trouble of supply pump, faulty installation
• Faulty piping of fuel system (fuel leakage, clogging, squeezed, etc.)
• Faulty fuel filters (main, pre goes) (clogging overflow valve trouble, etc.)
• Faulty fuel tank (clogging, low fuel level, extended tank, etc.)
• Engine Control Unit trouble
■ Diagnostic help
Check the fuel feed piping to the supply pump for abnormality, the fuel fed from the supply pump for leakage,
the supply pump for abnormally, and the Engine Control Unit for abnormality in this order.
4-108

step 2
past
trouble
2 Check the fuel quantity, and refill if less. - Step 3 -
1. Stop the engine.
2. Check the fuel quantity.
3 Clear the diagnostic trouble code, and again conduct the test run to - Step 26 Step 4
confirm that the diagnostic trouble code is not detected.
4 Exchange the IN and OUT of fuel hose on the fuel tank (reverse connection). - Step 5 -
5 Clear the diagnostic trouble code, and again conduct the test run to - Step 6 Return
confirm that the diagnostic trouble code is not detected. the fuel
Is the diagnostic trouble code detected? hose to
origin,
and go to
Step 7
6 Restore the fuel hose as original, and check and clean the fuel tank. - Step 26 Step 7
Clear the diagnostic trouble code, and again conduct the test run to
7 Check the fuel piping for leakage or squeezing. - Step 8 Step 10
Check the pre-filter, fuel filter, gauze filter (inlet of supply pump) for
clogging.
Is fuel leakage from piping or filter clogging detected?
8 Repair or replace the fuel piping. - Step 9 -
Clean the pre-filter and gauze filter, and replace the fuel filter.
Perform the air bleeding (air bleeding including dry-shot of injectors).
10 Check the overflow valve for the fuel filter. - Step 11 -
11 Confirm that the diagnostic trouble codes have been cleared, and conduct - Step 26 Step 12
the test run again to check that no diagnostic trouble code is detected.
4-109

12 Check for fuel leakage from the fuel high pressure piping and - Step 13 Step 26
common rail.
raise the specified pressure.
3. Stop the engine, and check the fuel high pressure piping and
common rail for fuel leakage.
Is fuel leakage detected?
13 Repair or replace the parts where the fuel leaks. - Step 14 -
14 Check with the oil level gauge if the oil level rises and you smell light oil. - Step 15 Step 26
Was abnormality detected?
15 Fuel leaks from some injectors. Check the pipe joints, and replace - Step 16 -
faulty injectors.
16 Perform the air bleeding (air bleeding including dry-shot of - Step 17 -
injectors). (Between supply pump, common rail, and injectors)
17 Confirm that the diagnostic trouble code has been cleared, then conduct - Step 26 Step 18
again the test run to check that no diagnostic trouble code is detected.
18 Check the injectors for fuel injecting operation. - Step 19 See diag.
Note: At this time, if the injector related trouble code has been codes
detected, check and repair the injector related parts before this "271 -
checking. 276" and
1. Start the engine. Sec. 3
2. Using the Tech II, conduct the "Injection Power Balance" test "Checking
and stop each cylinder injector to check if fuel is injected Fuel
normally. System"
The engine speed and sound will vary if the injector is stopped when to check
the injector injects fuel normally. and
Does the injector inject injecting operation fuel normally? replace
injector
and fuel
piping,
then
step 16
19 Check the pressure limiter. - Step 20 -
Perform the air bleeding (air bleeding including dry-shot of
4-110

20 Confirm that the diagnostic trouble code has been cleared, then - Step 26 Step 21
conduct again the test run to check that no diagnostic trouble code is
detected.
21 Check the supply pump (PCV). - Step 22 Step 23
2. Disconnect the harness from PCV1.
Note: If the harness is disconnected from PCV1, the diagnostic
trouble code "247" is detected, and thus clear the diagnostic
trouble code after the check finished.
Does the engine run?
1. Stop the engine.
2. Connect the harness to the PCV1.
injectors).
detected.
1. Stop the engine.
4. Connect the Tech II to clear the diagnostic trouble codes.
27 Confirm that the diagnostic trouble code has been cleared, then - Repair -
conduct again the test run to check that no diagnostic trouble code is end
detected.
4-111
227 Pump no pressure feed (Fuel outflow) (1/5)
■ Fuel system diagram
Fuel filter
Common rail Injector
Flow
Fuel pressure sensor damper
Overflow valve
PCV
Pressure limiter
Feed pump
Supply pump Fuel tank
Pre-filter
4-112
The Engine Control Unit supervises the common rail internal pressure based on the fuel pressure sensor
signals, and if the pressure is low, it controls the Pump Control Valve (PCV) on the supply pump to raise the
common rail internal pressure. The common rail internal pressure cannot be raised if the fuel feed to the
supply pump failed or the supply pump troubled.
In the event that the common rail internal pressure rises over the specified value, the pressure limiter installed
on the common rail operates to reduce the fuel pressure so as to prevent the engine mechanical troubles.

• Engine stops
• Lack of output power ( after the failure diagnostic, fuel injection is limited)
The control unit judges as "pump no pressure feed (fuel outflow)" and displays "diagnostic trouble code:
227", if the state where actual common rail pressure is below the target common rail pressure +5MPa and the
PCV close timing is below the PCV close timing limit +1°CA or common rail pressure F/B control amount
is below -50°CA continues for more than 8.4 seconds, when diagnostic trouble code "226" is detected and
also the codes 245, 217, 218, 247, and 248 are not detected.
(If actual fuel pressure is lower than the target common rail internal fuel pressure of Engine Control Unit)

In the event of diagnostic trouble code "227" detection, the ENGINE CONTROL lamp for the SERVICE
ENGINE SOON lamp for the vehicles without the multi-warning display turns on, regardless of engine
running condition. (Continuous ON)
■ Possible causes
• Air mixing in high pressure fuel piping
• Pressure limiter operated (operated at the pressure below specified value, deteriorated internal sealing)
• Internal trouble of injector
• Internal trouble of supply pump, faulty installation
• Faulty piping of fuel system (fuel leakage, clogging, squeezed, etc.)
• Faulty fuel filters (main, pre gauze) (clogging overflow valve trouble, etc.)
• Faulty fuel tank (clogging, low fuel level, extended tank, etc.)
• Engine Control Unit trouble
■ Diagnostic help
Check the fuel feed piping to the supply pump for abnormality, the fuel fed from the supply pump for leakage,
the supply pump for abnormally, and the Engine Control Unit for abnormality in this order. The content of
checking is same as diagnostic trouble code "226".
4-113

step 2
past
trouble
2 Check the fuel quantity, and refill if less. - Step 3 -
1. Stop the engine.
2. Check the fuel quantity.
4 Exchange the IN and OUT of fuel hose on the fuel tank (reverse connection). - Step 5 -
5 Clear the diagnostic trouble code, and again conduct the test run to - Step 6 Return
confirm that the diagnostic trouble code is not detected. the hose
Is the diagnostic trouble code detected? to origin,
and go to
Step 7
6 Restore the fuel hose as original, and check and clean the fuel tank. - Step 26 Step 7
Clear the diagnostic trouble code, and again conduct the test run to
7 Check the fuel piping for leakage or squeezing. - Step 8 Step 10
Check the pre-filter, fuel filter, gauze filter (inlet of supply pump) for
clogging.
Is fuel leakage from piping or filter clogging detected?
8 Repair or replace the fuel piping. - Step 9 -
Clean the pre-filter and gauze filter, and replace the fuel filter.
injectors).
10 Check the overflow valve for the fuel filter. - Step 11 -
11 Confirm that the diagnostic trouble codes have been cleared, and Step 26 Step 12
conduct the test run again to check that no diagnostic trouble code is -
detected.
4-114

12 Check for fuel leakage from the fuel high pressure piping and - Step 13 Step 14
common rail.
raise the specified pressure.
3. Stop the engine, and check the fuel high pressure piping and
common rail for fuel leakage.
Is fuel leakage detected?
13 Repair or replace the parts where the fuel leaks. - Step 14 -
14 Check with the oil level gauge if the oil level rises and you smell light - Step 15 Step 16
oil.
Was abnormality detected?
15 Fuel leaks from some injectors. Check the pipe joints, and replace - Step 16 -
faulty injectors.
16 Perform the air bleeding (air bleeding including dry-shot of - Step 17 -
17 Confirm that the diagnostic trouble code has been cleared, then conduct - Step 26 Step 18
again the test run to check that no diagnostic trouble code is detected.
18 Check the injectors for fuel injecting operation. - Step 19 See diag.
Note: At this time, if the injector related trouble code has been codes
detected, check and repair the injector related parts before "271 -
this checking. 276" and
1. Start the engine. Sec. 3
2. Using the Tech II, conduct the "Injection Power Balance" test "Checkin
and stop each cylinder injector to check if fuel is injected g Fuel
normally. System"
The engine speed and sound will vary if the injector is stopped to check
when the injector injects fuel normally. and
The engine speed and sound will not vary if the injector is replace
stopped when the injector is faulty and does not inject fuel. injector
Does the injector inject fuel normally? and fuel
piping,
then
step 16
19 Check the pressure limiter. - Step 20 -
injectors).
(Between supply pump, common rail, and injectors)
4-115

detected.
22 Check the supply pump (PCV). - Step 25 -
1. Stop the engine.
2. Connect the harness to the PCV1.
injectors).
detected.
1. Stop the engine.
4. Connect the Tech II to clear the diagnostic trouble codes. -
27 Confirm that the diagnostic trouble code has been cleared, then - Repair -
conduct again the test run to check that no diagnostic trouble code is end
detected.
4-116
241 Accelerator switch off trouble (1/5)
■ Accelerator circuit (including accelerator sensor circuit)
Battery Relay
SBF 3
SBF 1 Fuse 17
Starter Switch
"ON"
Idle
"ON" Control
Switch
SIG Down Up
13 23 20 27 29 10 7
Engine Control Unit
44 41 45
Vcc SIG GND
5V
Accele Sensor
4-117
The accelerator switch detects the accelerator pedal stroke. When the voltage is applied to the accelerator
switch provided on the accelerator link and the switch turns on (the accelerator pedal in idle position), the
voltage is applied to the Engine Control Unit as a signal.
The Engine Control Unit reads the change in voltage from the accelerator switch, and based on this signal, it
judges the accelerator pedal position. (When the switch turns off, the control unit judges the accelerator pedal
is in other than idle position.)
In the event of accelerator switch trouble, the Engine Control Unit makes control with the accelerator sensor
signals and backup values. Also, the accelerator learning must be executed after the accelerator switch was

The control unit judges as "accelerator switch OFF trouble" and displays "diagnostic trouble code: 241" if
the state where no voltage is applied from the accelerator switch continues for more than one second when
the accelerator sensor is normal and the accelerator sensor signal voltage is below 0.65V.

In the event of accelerator switch trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on, regardless of engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in accelerator switch (power) circuit
• Disconnection or shortcircuit in accelerator switch (SIG) circuit
• Faulty switch (faulty switch inside or rod)
• Faulty accelerator switch installation (disordered, loose)
• Faulty accelerator sensor
■ Diagnostic help
if faulty.
4-118

1 Check the detected diagnostic trouble code. - Step 2 See
1. Start the engine and run it in the idling state. diagnostic
2. Using the Tech II, check the diagnostic trouble code detected. help,
Is the detected diagnostic trouble code a current code? then step
2 Past
code
2 Check the harness for disconnection or GND short. ⋅ With starter SW OFF, Step 8 Step 3
1. Turn the starter switch off. and pedal in idle position,
3. Install the circuit tester between connector pin and GND (frame GND: 0V
or engine body). ⋅ With starter SW ON,
4. Measure voltage of the accelerator switch circuit. and pedal in idle position,
Is the applied voltage normal? Between pin 20 and
GND: Battery voltage
⋅ With starter SW OFF,
and pedal in other than
idle position,
Between pin 20 and
GND: 0V
⋅ With starter SW ON,
idle position,
Between pin 20 and
GND: 0V
Between pin 2 and GND:
Battery voltage
0V
3 Check the accelerator switch circuit (power). - Step 5 Step 4
3. Disconnect the harness from the accelerator switch.
4. Install the circuit tester between switch connector pin and GND
5. Measure voltage of the accelerator switch circuit.
4-119

4 Repair or replace the harness of accelerator switch circuit (power). - Step 5 -
5 Check the accelerator switch. - Step 7 Step 6
3. Install the circuit tester between the switch connector pins.
4. Check if the switch functions (continuous) when the accelerator
switch is operated.
Is the switch function normal?
6 Replace the accelerator switch. - Step 8 -
7 Repair or replace the harness of the accelerator switch circuit - Step 8 -
(between switch and Engine Control Unit). Also, check the
connector for connection.
8 Check the accelerator pedal link, bracket, spring, accelerator sensor, - Step 9 -
etc. for installation or any trouble, and repair or replace if faulty.
9 Adjust the accelerator switch. - Step 10 -
1. Stop the engine.
12 Confirm that the diagnostic trouble code has been cleared, then - Repair See
conduct again the test run to check that no diagnostic trouble code is end diagnostic
detected. help,
Is the diagnostic trouble code detected? then
step 1
Note: The accelerator learning must be executed after the Engine Control Unit or accelerator switch was
4-120
■ External view, pin assignment and resistance value of accelerator switch
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
<External view of bracket assembly> <Accelerator switch resistance value>
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
Idling condition Accelerator is pressed on
101HY00002
<Accelerator switch resistance value>

Accelerator pedal condition
Parts checked Remarks
(accelerator switch rod condition)
S type 1 ⇔ 2 Idling position 0.5Ω or less
connector (with rod pressed on)
(white), 2 pins
Full-throttle position ∞
(rod not pressed on)
1 ⇔ Body - ∞
2 ⇔ Body - ∞
4-121
242 Accelerator switch on trouble (1/5)
■ Accelerator switch circuit(including accelerator sensor circuit)
Battery Relay
SBF 3
SBF 1 Fuse 17
Starter Switch
"ON"
Idle
"ON" Control
Switch
SIG Down Up
13 23 20 27 29 10 7
Engine Control Unit
44 41 45
Vcc SIG GND
5V
Accele Sensor
4-122
The accelerator switch detects the accelerator pedal stroke. When the voltage is applied to the accelerator
switch provided on the accelerator link and the switch turns on (the accelerator pedal in idle position), the
voltage is applied to the Engine Control Unit as a signal.
The Engine Control Unit reads the change in voltage from the accelerator switch, and based on this signal, it
judges the accelerator pedal position. (When the switch turns off, the control unit judges the accelerator pedal
is in other than idle position.)
In the event of accelerator switch trouble, the Engine Control Unit makes control with the accelerator sensor
signals and backup values. Also, the accelerator learning must be executed after the accelerator switch was

• Faulty accelerator pedal reaction (responsibility)
The control unit judges as "accelerator switch ON trouble" and displays "diagnostic trouble code: 242" if the
state where no voltage is applied from the accelerator switch continues for more than 0.5 second when the
accelerator sensor is normal and the accelerator sensor signal voltage is below 3.06V.

In the event of accelerator switch trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on, regardless of engine running condition. (Continuous ON)
■ Possible causes
• Disconnection or shortcircuit in accelerator switch (power) circuit
• Disconnection or shortcircuit in accelerator switch (SIG) circuit
• Faulty switch (faulty switch inside or rod)
• Faulty accelerator switch installation (disordered, loose)
• Faulty accelerator sensor
■ Diagnostic help
if faulty.
4-123

1 Check the detected diagnostic trouble code. - Step 2 See
2. Using the Tech II, check the diagnostic trouble code detected. help,
Is the detected diagnostic trouble code a current code? then step
2 Past
code
2 Check the harness for disconnection or short. ⋅ With starter SW OFF, Step 8 Step 3
1. Turn the starter switch off. and pedal in idle position,
3. Install the circuit tester between connector pin and GND (frame GND: 0V
or engine body). ⋅ With starter SW ON,
4. Measure voltage of the accelerator switch circuit. and pedal in idle position,
Is the applied voltage normal? Between pin 20 and
GND: Battery voltage
idle position,
Between pin 20 and
GND: 0V
idle position,
Between pin 20 and
GND: 0V
Battery voltage
0V
3 Check the accelerator switch circuit (power). - Step 5 Step 4
4. Install the circuit tester between switch connector pin and GND
5. Measure voltage of the accelerator switch circuit.
4-124

4 Repair or replace the harness of accelerator switch circuit (power). - Step 5 -
5 Check the accelerator switch. - Step 7 Step 6
3. Install the circuit tester between the switch connector pins.
4. Check if the switch functions (continuous) when the accelerator
switch is operated.
Is the switch function normal?
6 Replace the accelerator switch. - Step 8 -
7 Repair or replace the harness of the accelerator switch circuit - Step 8 -
(between switch and Engine Control Unit). Also, check the
connector for connection.
8 Check the accelerator pedal link, bracket, spring, accelerator sensor, - Step 9 -
etc. for installation or any trouble, and repair or replace if faulty.
9 Adjust the accelerator switch. - Step 10 -
1. Stop the engine.
12 Confirm that the diagnostic trouble code has been cleared, then - Repair See
conduct again the test run to check that no diagnostic trouble code is end diagnostic
detected. help,
Is the diagnostic trouble code detected? then
step 1
4-125
■ External view, pin assignment and resistance value of accelerator switch
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
<External view of bracket assembly> <Accelerator switch resistance value>
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
Idling condition Accelerator is pressed on
101HY00002
<Accelerator switch resistance value>
Accelerator pedal condition

Parts checked Remarks
(accelerator switch rod condition)
S type 1 ⇔ 2 Idling position 0.5Ω or less
connector (with rod pressed on)
(white), 2 pins
Full-throttle position ∞
(rod not pressed on)
1 ⇔ Body - ∞
2 ⇔ Body - ∞
4-126
245 Fuel pressure sensor trouble (1/5)
■ Fuel pressure sensor (including CKP sensor and CMP sensor circuit)
Engine Control Unit
63 72 61 56 48 57 76 49 58 77 62 71 73 55
5V 5V
All Speed
Accele Sensor

4-127
common rail.
■ Vehicle behaviors
• Rough idling
The Engine Control Unit judges as "fuel pressure sensor trouble" and displays "diagnostic trouble code: 245",
if the state where the voltage detected by the Engine Control Unit is over 4.7V (VB/5V SIG shortcircuit) or
below 0.7V (disconnected) or GND shortcircuit continues for 0.1 second.

In the event of fuel pressure sensor system trouble, the SERVICE ENGINE SOON lamp for the vehicles
■ Possible causes
■ Diagnostic help
if faulty.
4-128

step 2
past
trouble
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
6. Measure voltage in the pressure sensor circuit.
4-129

6 Check for the voltage applied to the fuel pressure sensor "power". Between sensor pin 3 and Step 8 Step 7
1. Turn the starter switch off. GND: 5V (4.75 - 5.25V)
2. Connect the harness to the Engine Control Unit.
3. Install the circuit tester between sensor connector pin and GND
Note: If the harness is disconnected from the fuel pressure sensor,
the diagnostic trouble code "245" is detected, and thus clear the
diagnostic trouble code after the check finished.
5. Measure the voltage of the fuel pressure sensor "power" circuit.
7 With the circuit tester, check for continuity of fuel pressure sensor "GND". Between sensor pin 1 and Step 9 Step 8
2. Confirm that the harness has been connected to the Engine
Control Unit.
3. Install the circuit tester between sensor connector pins.
Note: If the harness is disconnected from the fuel pressure sensor,
the diagnostic trouble code "245" is detected, and thus
5. Measure the resistance of the fuel pressure sensor circuit.
1.Turn the starter switch off.
2.Remove the fuel pressure sensor from the common rail.
3.Check the fuel pressure sensor for presence of forreign matelils.
1. Stop the engine.
2. Connect the harnesses to the fuel pressure sensor.
4-130

14 Confirm that the diagnostic trouble code has been cleared, then Repair See
conduct again the test run to check that no diagnostic trouble code is - end diagnostic
detected. help,
Is the diagnostic trouble code detected? then step
1
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-131
247 PCV1 system harness, short (GND circuit) trouble (1/5)
■ PCV circuit
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-132
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV1 system short (GND circuit) trouble" and displays "diagnostic trouble code:
247" if the signal voltage from the PCV1 is low when the starter switch is turned on and the supply pump,
CKP sensor is normal.

■ Possible causes
■ Diagnostic help
if faulty.
4-133

step 2
past
trouble
(GND): ∞Ω
(GND): ∞Ω
3 Check the harness for disconnection or shortcircuit. Between pins 1 and 2: 0V Step 5 Step 4
1. Turn the starter switch off. Between pin 1 and body
2. Disconnect the harness from the Engine Control Unit. (GND): battery voltage
3. Disconnect the harness from the PCV1. Between pin 2 and body
4. Measure voltage value of the connector on the PCV1 side. (GND): 0V
Is the voltage value normal?
4 Repair or replace the harness of PCV power supply circuit. Also, - Step 6 -
5 Repair or replace the harness of Engine Control Unit to PCV1. Also, - Step 6 -
4-134

1. Stop the engine.
detected. to
help,
step 1
4-135
<Arrangement of PCV >
EGR Valve
Boost Sensor
EGR Valve
CKP Sensor
PCV
4-136
■ PCV circuit (including PCV relay circuit)
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-137
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV2 system short (GND circuit) trouble" and displays "diagnostic trouble code:
248" if the signal voltage from the PCV2 is low when the starter switch is turned on and the supply pump,
CKP sensor is normal.

■ Possible causes
■ Diagnostic help
if faulty.
4-138

step 2
past
trouble
(GND): ∞Ω
(GND): ∞Ω
3 Check the harness for disconnection or shortcircuit. Between pins 1 and 2: 0V Step 5 Step 4
1. Turn the starter switch off. Between pin 1 and body
2. Disconnect the harness from the Engine Control Unit. (GND): battery voltage
3. Disconnect the harness from the PCV2. Between pin 2 and body
4. Measure voltage value of the connector on the PCV2 side. (GND): 0V
4 Repair or replace the harness of PCV power supply circuit. Also, - Step 6 -
5 Repair or replace the harness of Engine Control Unit to PCV2. Also, - Step 6 -
4-139

1. Stop the engine.
detected. to
help,
step 1
4-140
<Arrangement of PCV >
EGR Valve
Boost Sensor
EGR Valve
CKP Sensor
PCV
4-141
271 No.1 cylinder No.1 injector drive system trouble (1/4)
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-142
injectors provided on the cylinder head, and the signals are returned to the Engine Control Unit via the
injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF
to prevent an electric shock during the checking and repair.

• Rough idling
The control unit judges as "No.1 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 271" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.

■ Possible causes
• Disconnection or GND shortcircuit in injector (power side) circuit
• Disconnection or GND shortcircuit in injector (driving side) circuit
• Faulty TWV (faulty disconnection of internal coil)
■ Diagnostic help
if faulty.

4-143

2. Using the Tech II, check the diagnostic trouble code. help, and
step 2
past
trouble
1. Turn the starter switch off. 0.3 - 1.3Ω
2. Disconnect the harness from the Engine Control Unit. Between each pin and
3. Install the circuit tester between connector pins. GND: ∞Ω
4. Measure resistance of the No.1 cylinder No.1 injector (TWV) Between each pin and
circuit. injector body: ∞Ω
Is the resistance value normal? Between TWV pins: 0.3 -
1.3Ω (at about 20°C)
3 Using the circuit tester, measure the resistance of the No.1 cylinder Between TWV body and Step 5 Step 4
No.1 injector (TWV) circuit. each pin: ∞Ω
2. Disconnect the harness from the injector (TWV).
3. Using a circuit tester, measure internal resistance of TWV.
4 Replace the No.1 injector. - Step 5 -
1. Turn the starter switch off. 0.5Ω or less (with jumper)
3. Disconnect the harness from the TWV. GND: ∞Ω
4. Using a jumper wire between TWV connector pins, measure Between each pin and
resistance of the connector on the Engine Control Unit. injector body: ∞Ω
6 Repair or replace the harness of injector (TWV) circuit. Also, check - Step 7 -
the connectors for connection.
4-144

1. Stop the engine.
detected. to
help,
step 1
6WG1
4-145
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-146

• Rough idling

■ Possible causes
• Disconnection or GND shortcircuit in injector (driving side) circuit)
■ Diagnostic help
if faulty.

4-147

step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. ⋅ Between pins 86 and Step 5 Step 3
1. Turn the starter switch off. 110: 0.3 - 1.3Ω
2. Disconnect the harness from the Engine Control Unit. ⋅ Between each pin and
4. Measure resistance of the No.2 cylinder No.5 injector (TWV) ⋅ Between each pin and
3 Using the circuit tester, measure the resistance of the No.2 cylinder Between TWV pins: 0.3 - Step 5 Step 4
injector (TWV) circuit. 1.3Ω (at about 20°C)
1. Turn the starter switch off. Between TWV body
2. Disconnect the harness from the No.5 injector (TWV). and each pin: ∞Ω
3. Using a circuit tester, measure internal resistance of No.5
injector.
1. Turn the starter switch off. 0.5Ω or less (jumper)
3. Disconnect the harness from the No.5 injector. GND: ∞W
4. Using a jumper wire between No.5 injector connector pins, Between each pin and
measure resistance of the connector on the Engine Control Unit. injector body: ∞Ω
6 replace the harness of injector (TWV) circuit. Also, check the - Step 7 -
1. Stop the engine.
4-148

detected. to
help,
step 1
6WG1
4-149
■ Injection circuit
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-150

• Rough idling

■ Possible causes
■ Diagnostic help
if faulty.

4-151

step 2
past
trouble
1. Turn the starter switch off. 03 - 1.3Ω
injector (TWV) circuit. 1.3W (at about 20°C)
1. Turn the starter switch off. Between TWV body and
2. Disconnect the harness from the No.3 injector (TWV). each pin: ∞Ω
3. Using a circuit tester, measure internal resistance of No.3
injector.
1. Turn the starter switch off. 0.5Ω or less (jumper)
3. Disconnect the harness from the No.3 injector. GND: ∞Ω
4.Using a jumper wire between No.3 injector connector pins, Between each pin and
measure resistance of the connector on the Engine Control injector body: ∞Ω
Unit.
6 Repair or replace the harness of injector (TWV) circuit. Also, check - Step 7 -
1. Stop the engine.
4-152

detected. to
help,
step 1
6WG1
4-153
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-154

• Rough idling

■ Possible causes
■ Diagnostic help
if faulty.

4-155

step 2
past
trouble
1. Turn the starter switch off. 0.3 -1.3Ω
No.6 injector (TWV) circuit. 1.3W (at about 20°C)
1. Turn the starter switch off. Between TWV body and
3. Disconnect the harness from the No.6 injector. Between each pin and
4. Using a jumper wire between No.6 injector connector pins, GND: ∞Ω
measure resistance of the connector on the Engine Control Between each pin and
Unit. injector body: ∞Ω
6 Repair or replace the harness of No.6 injector (TWV) circuit. Also, - Step 7 -
1. Stop the engine.
4-156

detected. to
help,
step 1
6WG1

4-157
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-158

• Rough idling

■ Possible causes
■ Diagnostic help
if faulty.

4-159

step 2
past
trouble
1. Turn the starter switch off. 0.3 - 1.3Ω
No.2 injector (TWV) circuit. 1.3Ω (at about 20°C)
1.Turn the starter switch off. Between TWV body and
3. Disconnect the harness from the No.2 injector. Between each pin and
4. Using a jumper wire between TWV connector pins, measure GND: ∞Ω
resistance of the connector on the Engine Control Unit. Between each pin and
Is the resistance value normal? injector body: ∞Ω
1. Stop the engine.
detected. to
help,
step 1
4-160

6WG1
4-161
Engine Control Unit
90 110 89 88 59 87 86 85 120
1 2 3 4 5 6
Common2
Common1

#1 #2 #3 #4 #5 #6
4-162

• Rough idling

■ Possible causes
■ Diagnostic help
if faulty.

4-163

step 2
past
trouble
No.4 injector (TWV) circuit. 1.3Ω (at about 20° C)
1.Turn the starter switch off. Between TWV body and
3. Disconnect the harness from the No.4 TWV. Between each pin and
4. Using a jumper wire between No.4 TWV connector pins, GND: ∞Ω
measure resistance of the connector on the Engine Control Between each pin and
Unit. injector body: ∞Ω
1. Stop the engine.
detected. to
help,
step 1
4-164

6WG1

4-165
413 Magnetic valve "E" drive system trouble (1/7)
■ EGR magnetic valve circuit
Battery Relay
SBF 3
SBF 1 Fuse 16
Starter Switch
"ON"
Battery
Fly Back
EGR 1 EGR 2
Magnetic Magnetic
Valve "D" Valve "E"
Fail Safe Relay "B"
(Normal close)
117 116 105 92 93
Engine Control Unit
81 82 102 111 59
4-166
The magnetic valve "E" is used to supply air to the EGR valve.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays EGR, M/V relays and further
it is connected to the Engine Control Unit via magnetic valves.
The Engine Control Unit controls each magnetic valve, and in the event of a trouble detection, it control the
magnetic valve fail-safe relays to stop the power supply to the magnetic valves and thus to stop each control.

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idles continuously for 20
seconds)
Lack of output power/slow response
• When magnetic valve "E" is not driven
The control unit judges as "magnetic valve "E" drive system trouble" and displays "diagnostic trouble
code: 413" when the state where the operating voltage from magnetic valve "E" is faulty (no power
supply or low potential) continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "E" is driven
The control unit judges as "magnetic valve "E" drive system trouble" and displays "diagnostic trouble
code: 413" when the state where the operating voltage from magnetic valve "E" is faulty (high potential)
continues for 1.2 seconds. (Power supply short, engine control unit GND disconnection, etc.)

In the event of water temperature sensor system trouble , the SERVICE ENGINE SOON lamp for the
vehicles without the multi-warning display turns on when the engine revolutions (idling) below 650rpm
continue for 20 seconds. The lamp truns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Disconnection or shortcircuit in magnetic valve (power side) circuit
• Disconnection or GND shortcircuit in magnetic valve (driving side) circuit
• Faulty magnetic valve (faulty disconnection of internal coil)
• Faulty magnetic valve fail safe relay (EGR, M/V relay)
■ Diagnostic help
if faulty.
■ Magnetic valve numbers and cylinder numbers

• Magnetic valve (D) EGR1
• Magnetic valve (E) EGR2
4-167

step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. Between pins 105 and Step 6 Step 3
1. Turn the starter switch off. 92/93: 34 - 40Ω
3. Install the circuit tester between connector pins.
4. Measure resistance of the magnetic valve (E) circuit.
3 Measure the resistance of the magnetic valve (E). Between pins: 34 - 40Ω Step 5 Step 4
1.Turn the starter switch off. Between each pin and
2. Disconnect the harness from the magnetic valve (E). body (GND): ∞Ω
3. Using a circuit tester, measure internal resistance of magnetic
valve (E).
4 Replace the magnetic valve (E). - Step 6 -
5 Repair or replace the magnetic valve (E). Also, check the connectors - Step 6 -
for connection.
1. Turn the starter switch off. GND: Starter switch
2. Disconnect the harness from Engine Control Unit. OFF: 0V
3. Install the circuit tester between Engine Control Unit pin and ON: Battery voltage
GND (frame or body).
4. Measure voltage value in the fail safe relay circuit.
7 Check the harness for disconnection or shortcircuit. ⋅ ISO relay Step 9 Step 8
1. Turn the starter switch off. Between pin relay 2 and
2. Disconnect the fail safe relay. GND:
3. Install the circuit tester between fail safe relay pin and GND Between pin relay 5 and
(frame or body). GND:
4. Measure voltage value in the fail safe relay circuit. Starter switch OFF: 0V
Is the voltage value normal? ON: Battery voltage
8 Repair or replace the fail safe relay circuit (power side). Also, check - Step 10 -
⋅ Fail safe relay to fuse, power circuit.
9 Replace the fail safe relay. - Step 10 -
4-168

10 Check the harness for disconnection or shortcircuit. Jumper position Step 12 Step 11
1. Turn the starter switch off. (Engine Control Unit)
2. Connect the fail safe relay. pin 117
3. Disconnect the harness from magnetic valve (E). Between M/V pin 2 and
4. Disconnect the harness from Engine Control Unit. GND: Starter switch
5. Using a jumper wire, connect the circuit tester between Engine OFF: 0V
Control Unit pin and GND (frame or body). ON: Battery voltage
6. Install the circuit tester between magnetic valve (E) pin and
7. Measure voltage value in the magnetic valve (E) circuit.
11 Repair or replace the fail safe relay or the magnetic valve (E) power - Step 12 -
side circuit.
2. Disconnect the harness from Engine Control Unit. Between pin 82 and
3. Install the circuit tester between Engine Control Unit pin and GND: 0.5Ω or less
GND (frame or body). Between pin 102 and
4. Measure resistance value in the Engine Control Unit (GND) GND: 0.5Ω or less
circuit. Between pin 111 and
Is the resistance value normal? GND: 0.Ω or less
Between pin 59 and
GND: 0.5Ω or less
Between pin 59 and other
pin (power/SIG): ∞Ω
13 Repair or replace the Engine Control Unit (GND) circuit. - Step 14 -
1. Stop the engine.
4-169

detected. to
help,
step 1
4-170
■ External view, pin assignment and resistance value of magnetic valve
<External view of magnetic valve >
2 1
Z type connector
(gray) 2 pins
060HY00469
<Installation of magnetic valve >
1 2

Resistance value of magnetic valve >
Resistance value between pins 34 - 40Ω
4-171
■ External view, pin assignment and resistance value of fail safe relay
<External view of fail safe relay > <Circuit of fail safe relay >
⋅ ISO relay ⋅ ISO relay
1
3
5 1
4 2
4
3
2
5
<Installation position of fail safe relay >

⋅ ISO relay
Pin No.
ISO Signal name
1
relay
2 3 4
1 Relay contact point (normal open): secondary side
5 Relay coil: secondary side
2
3 Relay contact point (normal close) : secondary side
4 Relay coil: primary side
5 Relay contact point: primary side
<Circuit of fail safe relay >
Relay Box (C) D

Fail Safe Relay : No. 14 C
B
Main Relay : No. 13 A
1 4 7 10 13
2 5 8 11 14
3 6 9 12
4-172
443 Magnetic valve "D" drive system trouble (1/7)
■ EGR magnetic valve circuit
Battery Relay
SBF 3
SBF 1 Fuse 16
Starter Switch
"ON"
Battery
Fly Back
EGR 1 EGR 2
Magnetic Magnetic
Valve "D" Valve "E"
Fail Safe Relay "B"
(Normal close)
117 116 105 92 93
Engine Control Unit
81 82 102 111 59
4-173
The magnetic valve "D" is used to supply air to the EGR valve.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (EGR, M/V relays), and
further it is connected to the Engine Control Unit via magnetic valves.

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idles continuously for 20
seconds)
Lack of output power/slow response
• When magnetic valve "D" is not driven
The control unit judges as "magnetic valve "D" drive system trouble" and displays "diagnostic trouble
code: 443" when the state where the operating voltage from magnetic valve "D" is faulty (low potential)
continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "D" is driven
The control unit judges as "magnetic valve "D" drive system trouble" and displays "diagnostic trouble
code: 443" when the state where the operating voltage from magnetic valve "D" is faulty (no power
supply or high potential) continues for 1.2 seconds. (Power supply short, engine control unit GND
disconnection, etc.)

In the event of water temperature sensor system trouble , the SERVICE ENGINE SOON lamp for the
vehicles without the multi-warning display turns on when the engine revolutions (idling) below 650rpm
continue for 20 seconds. The lamp truns off when the engine revolutions exceed 650 rpm.
■ Possible causes
• Disconnection or shortcircuit in magnetic valve (power side) circuit
• Disconnection or GND shortcircuit in magnetic valve (driving side) circuit
• Faulty magnetic valve (faulty disconnection of internal coil)
• Faulty magnetic valve fail safe relay (EGR, M/V relay)
■ Diagnostic help
if faulty.
■ Injector magnetic valve numbers and cylinder numbers

• Magnetic valve (D) EGR1
• Magnetic valve (E) EGR2
4-174


step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. Between pins 116 and Step 6 Step 3
1. Turn the starter switch off. 92/93: 34 - 40Ω
3. Install the circuit tester between connector pins. body (GND):∞Ω
4. Measure resistance of the magnetic valve (D) circuit.
3 Measure the resistance of the magnetic valve (D). Between pins: 34 - 40Ω Step 5 Step 4
1.Turn the starter switch off. Between each pin and
2. Disconnect the harness from the magnetic valve (D). body (GND): ∞Ω
3. Using a circuit tester, measure internal resistance of magnetic
valve (D).
4 Replace the magnetic valve (D). - Step 6 -
5 Repair or replace the magnetic valve (D). Also, check the connectors - Step 6 -
for connection.
1. Turn the starter switch off. GND: Starter switch
2. Disconnect the harness from Engine Control Unit. OFF: 0V
3. Install the circuit tester between Engine Control Unit pin and ON: Battery voltage
4. Measure voltage value in the fail safe relay circuit.
7 Check the harness for disconnection or shortcircuit. Between pin relay 5 and Step 9 Step 8
2. Disconnect the fail safe relay. Between pin relay 1 and
3. Install the circuit tester between fail safe relay pin and GND GND:
(frame or body). Starter switch OFF: 0V
4. Measure voltage value in the fail safe relay circuit. ON: Battery voltage
8 Repair or replace the fail safe relay circuit (power side). Also, check - Step 10 -
⋅ Fail safe relay to fuse, power circuit.
4-175

9 Replace the fail safe relay. - Step 10 -
10 Check the harness for disconnection or shortcircuit. Jumper position Step 12 Step 11
1. Turn the starter switch off. (Engine Control Unit)
2. Connect the fail safe relay. pin 117
3. Disconnect the harness from magnetic valve (D). Between M/V pin 2 and
4. Disconnect the harness from Engine Control Unit. GND: Starter switch
5. Using a jumper wire, connect the circuit tester between Engine OFF: 0V
Control Unit pin and GND (frame or body). ON: Battery voltage
6. Install the circuit tester between magnetic valve (D) pin and
7. Measure voltage value in the magnetic valve (D) circuit.
11 Repair or replace the fail safe relay or the magnetic valve (D) power - Step 12 -
side circuit.
2. Disconnect the harness from Engine Control Unit. Between pin 82 and
3. Install the circuit tester between Engine Control Unit pin and GND: 0.5Ω or less
GND (frame or body). Between pin 102 and
4. Measure resistance value in the Engine Control Unit (GND) GND: 0.5Ω or less
circuit. Between pin 111 and
Is the resistance value normal? GND: 0.5Ω or less
Between pin 59 and
GND: 0.5Ω or less
Between pin 59 and other
pin (power/SIG): ∞Ω
13 Repair or replace the Engine Control Unit (GND) circuit. - Step 14 -
1. Stop the engine.
4-176

detected. to
help,
step 1
4-177
■ External view, pin assignment and resistance value of magnetic valve
<External view of magnetic valve >
2 1
Z type connector
(gray) 2 pins
060HY00469
<Installation position of magnetic valve >
1 2

<Resistance value of magnetic valve >

Resistance value between pins 34 - 40Ω
4-178
■ External view, pin assignment and resistance value of fail safe relay
<External view of fail safe relay > <Circuit of fail safe relay >
⋅ ISO relay ⋅ ISO relay
1
3
5 1
4 2
4
3
2
5
<Installation position of fail safe relay >

⋅ ISO relay
Pin No.
ISO Signal name
1
relay
2 3 4
5
3 Relay contact point (normal close) : secondary side
5 Relay contact point: primary side
<Circuit of fail safe relay >
Relay Box (C) D

B
1 4 7 10 13
2 5 8 11 14
3 6 9 12
4-179
416 Main relay system trouble (1/5)
■ Main relay circuit (including engine control unit GND circuit)
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-180
The main relay supplies the power to the Engine Control Unit. When the starter switch is in "ON" or "S"
position, the Engine Control Unit turns on the main relay to supply the main power to the Engine Control
Unit.

• SERVICE ENGINE SOON lamp turns on (ON condition: when the engine idling lasts for 20 seconds)
• Large battery consumption in the event of relay trouble
The control unit judges as "main relay system trouble" and displays "diagnostic trouble code: 416" when the
voltage is applied from the main relay after the starter switch turned off.

In the event of main relay system trouble, the SERVICE ENGINE SOON lamp for the vehicles without the
■ Possible causes
• Disconnection or shortcircuit in main relay circuit
• Faulty main relay
■ Diagnostic help
if faulty.
4-181

step 2
past
trouble
2 Check the main relay circuit (coil side) for shortcircuit. Between pin 109 and Step 4 Step 3
1. Turn the starter switch off. body (GND): 0V
2. Disconnect the main relay. Between pin 118 and
3. Disconnect the harness from Engine Control unit. body (GND): 0V
5. Measure voltage value of the connector pins on the Engine
Control Unit.
3 Repair or replace the harness between main relay (coil side) and - Step 4 -
Engine Control Unit. Also, check the connectors for connection.
4 Check the main relay. Starter switch OFF: 0V Step 6 Step 5
1. Connect the main relay. ON: Battery voltage
2. Measure voltage on the Engine Control Unit connector when (Pin 91 to GND/pin 111
starter switch operates. or 101 to GND)
5 Is the voltage value normal? - Step 7 -
Repair or replace the main relay or main relay power side circuit.
7 Restore the vehicle. - Step 8
1. Stop the engine.
detected. to
help,
step 1
4-182
■ External view, pin assignment and resistance value of main relay
<External view of main relay > <Circuit of main relay >
1
3
5 1
4 2
4
3 Pin No. Signal name
2
5
* ISO relay
3 Relay contact point (normal close): secondary side
<Pin assignment of main relay > 5 Relay contact point: primary side
2 3 4
<Installation position of main relay >
Relay Box (C) D

B
1 4 7 10 13
2 5 8 11 14
3 6 9 12
4-183
< Resistance value of main relay >

Single unit 2⇔
⇔4 240 - 290Ω
of relay 1⇔
⇔5 ∞ No power supplied to relay coil
0.5Ω or less Power supplied to relay coil
3⇔
⇔5 0.5Ω or less No power supplied to relay coil
∞ Power supplied to relay coil
4-184
417 Starter switch trouble (1/4)
■ Starter switch circuit
SBF 1
Fuse 28
Starter SW
Battery Relay
ON Start
Starter Relay Fuse 9

Battery
SBF 4
Starter:C
24
Engine Control Unit
33
Sub starter
SBF 3 No 12 SW Neutral Relay
Neutral
SW
4-185
here are two kinds of starter switch signals, key positions "ON" and "S", and each key position is detected.
According to the key position, the voltage is applied to the Engine Control Unit as a signal.
With the starter switch in "ON" position, the battery relay operates to supply the power, and the Engine
Control Unit reads the voltage of the supplied power via fuses, and with this voltage it drives various sensors,
relays, injectors and magnetic valves.
With the starter switch in "S" position, the Engine Control Unit uses this signal for fuel injection control at
the start of the engine.

• Starter malfunction
• Starter switch misoperation
The control unit judges as "starter switch trouble" and displays "diagnostic trouble code: 417" if state where
the voltage of starter switch (key position "S") signal is applied is detected continuously when the engine
speed exceeds 1000 rpm.

The SERVICE ENGINE SOON lamp does not turn on even if the starter switch system failed, but the trouble
is indicated with the diagnostic trouble code only.
■ Possible causes
• Shortcircuit in starter switch circuit
• Faulty switch
• Faulty internalswitch
■ Diagnostic help
if faulty.
4-186

1 Check if diagnostic trouble code other than "417" is detected. - Step 2 See
Is diagnostic trouble code other than "417" detected? check
steps by
diag.
trouble
code,
and after
check,
step 2
2 Check the starter operation. - Step 3 Step 5
Does the starter operate when the starter switch is in "ON" position?
3 Check the harness for GND short. ⋅ Starter SW other than Step 9 Step 4
1. Turn the starter switch off. "S" position, Between pin
2. Disconnect the harness from the Engine Control Unit. 24 and GND: 0V
3. Install the circuit tester between connector pin and GND (frame ⋅ Starter SW "S" position,
or engine body). Between pin 24 and
4. Measure voltage of the starter switch circuit. GND: Battery voltage
4 Check the harness for shortcircuit. Between pins 24 and 13: Step 5 Step 6
1. Turn the starter switch off. ∞Ω
2. Disconnect the harness from the starter switch. Between pins 24 and 23:
3. Measure resistance of the connector on Engine Control Unit ∞Ω
side. Between pin 24 and other
Is the resistance value normal? pins: ∞Ω
0.5Ω or less
5 Check the starter switch. - Step 7 Step 3
6 Repair or replace the harnesses of starter switch circuit. Also, check - Step 7 -
4-187

7 Check the starter for abnormality. - Step 8 See engine
1. Turn the starter switch off. repair
2. Remove the starter. manual to
3. Check the starter, and repair or replace if faulty. check the
Did corrective actions complete? starter, and
after repair
or
replacement,
step 8
8 With the starter removed, check the flywheel (ring gear) and starter - Step 9 -
pinion, and repair or replace if faulty.
1. Stop the engine.
2. Connect the harnesses to boost sensor
conduct the test run again to check that no diagnostic trouble code is end referring to
detected. diagnostic
Is diagnostic trouble code detected? help, step 1
4-188
424 Fail-safe (Magnetic valve cut) relay "B" system trouble (1/4)
■ Magnetic valve circuit
Battery Relay
SBF 3
SBF 1 Fuse 16
Starter Switch
"ON"
Battery
Fly Back
EGR 1 EGR 2
Magnetic Magnetic
Valve "D" Valve "E"
Fail Safe Relay "B"
(Normal close)
117 116 105 92 93
Engine Control Unit
81 82 102 111 59
4-189
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (EGR, M/V relays), and
further it is connected to the Engine Control Unit via magnetic valves.

• SERVICE ENGINE SOON lamp turns on (ON condition: when the engine idling lasts for 20 seconds)
• Fail-safe relay "B" (Disconnection, GND short) (when the relay does not operate)
The control unit judges as "fail-safe relay "B" system trouble" and displays "diagnostic trouble code:
418" when the state where the operating voltage from fail-safe relay "B" is faulty (no power supply or
low potential) continues for one second.
• Fail-safe relay "B" (Power supply short) (when the relay operates)
The control unit judges as "fail-safe relay "B" system trouble" and displays " diagfrom fail-safe relay
"B" is faulty (high potential) continues for one second.

In the event of fail-safe relay system trouble, the SERVICE ENGINE SOON lamp for the vehicles without
the multi-warning display turns on when the engine revolutions (idling) below 650 rpm continue for 20
seconds. The lamp turns off when the engine revolutions exceed 650 rpm. (Conditional ON)
■ Possible causes
• Fail-safe relay circuit
• Faulty fail-safe relay itself (disconnection of internal coil, etc.)
• Internal trouble of engine control unit
■ Diagnostic help
if faulty.
4-190
■ Fail-safe relay "B" and applications

For VGS magnetic valve cut
step 2
past
trouble
2 Check the fail safe relay circuit (coil side) for shortcircuit. Between pin 117 and Step 4 Step 3
1. Turn the starter switch off. body (GND): 0V
2. Disconnect the fail safe relay.
3. Disconnect the harness from Engine Control unit.
5. Measure voltage value of the connector pins on the Engine
Control Unit.
3 Repair or replace the harness between fail safe relay (coil side) and - Step 4
4 Check the fail safe relay. Starter switch OFF: 0V Step 6 Step 5
1. Connect the fail safe relay. ON: Battery voltage
2. Measure voltage on the Engine Control Unit connector when (Pin 115 to GND)
starter switch operates.
5 Repair or replace the fail safe relay or fail safe relay power side - Step 7
circuit.
6 Check the Engine Control Unit. - Step 7
1. Stop the engine.
8 Confirm that the diagnostic trouble codes have been cleared, and - Repair No:
conduct the test run again to check that no diagnostic trouble code is end After
detected. referring
Is diagnostic trouble code detected? to
diagnostic
help,
step 1
4-191
<Installation position of main relay >
Relay Box (C) D

B
1 4 7 10 13
2 5 8 11 14
3 6 9 12
4-192
421 PCV power supply system trouble (1/3)
■ PCV circuit
Battery Relay
SBF 3
Fuse 17 Fuse 45
SBF 1
Starter Switch
"ON"
Accel SW
Fuse 34 Clutch SW
Idle UP/DOWN SW
Idle Manu SW
Main Relay
Battery
PCV 1 PCV 2
Starter
Switch
"ON"
SIG
109 118 91 109 13 23 21 22 31 32
Engine Control Unit
81 82 102 111 59
4-193

• Large battery consumption when the relay troubled
The control unit judges as "PCV power supply system trouble" and displays "diagnostic trouble code: 421"
when the voltage is applied from the PCV1 or PCV2 after the starter switch turned off.

■ Possible causes
• Disconnection and shortcircuit in PCV circuit
• Faulty PCV power supply
• Faulty PCV (faulty internal circuit)
■ Diagnostic help
if faulty.
4-194

step 2
past
trouble
2 Check the PCV power supply circuit for shortcircuit. Between PCV harness Step 4 Step 3
1. Turn the starter switch off. connector and body
2. Disconnect the fuse No.16. (GND): 0V
3. Disconnect the harness from Engine Control unit. Between ECU harness
4. Disconnect the harness from PCV1 or PCV2. connector and body
5. Measure voltage value of the connector pins on the PCV. (GND): 0V
3 Repair or replace the harness between fuse and PCV or PCV and - Step 4 -
4 Check the PCV power supply sircuit. Starter switch OFF: 0V Step 6 Step 5
1. Connect the PCV fuse. ON: Battery voltage
2. Measure voltage on the PCV connector when starter switch
operates.
5 Repair or replace the PCV power supply circuit. - Step 6 -
1. Stop the engine.
detected. to
help,
step 1
4-195
518 EOL data error (1/2)

This "diagnostic trouble code: 518 (EOL data error)" does not indicate the detection of IE system trouble.
It has been set to ensure the accelerator learning situation.
If this diagnostic trouble code occurred, execute the "accelerator learning" using the Tech II.
For the "accelerator learning", see Chapter 1 IE System General Description and Chapter 7 How to Use IE
System Inspection Tools.

• Poor accelerator feeling
(The fuel injection amount varies with the accelerator pedal operation.)
The Engine Control Unit immediately judges as "EOL data error" and displays "diagnostic trouble code: 518"
if it recognized that the accelerator learning has not been executed.

If the accelerator learning has not been executed, the SERVICE ENGINE SOON lamp for the vehicles
without the multi-warning display turns on, regardless of engine running condition. (Conditional ON)
■ Possible causes
• Accelerator learning has not been executed
• Engine Control Unit internal trouble
• Tech II related troubles (harness, Tech II itself, program card)
■ Diagnostic help
If the accelerator learning failed or other troubles occur, check diagnostic trouble codes, or the connectors for
loose connection, the harnesses for abrasion or folding, the wires inside harnesses for abrasion or short with
other circuits. Also, perform functional diagnosis to check the operation and control, and repair if faulty.
4-196
518 EOL data error (2/2)

1 Check if diagnostic trouble code other than "518" is detected. - Step 2 See the
Is diagnostic trouble code other than "518" detected? check
steps by
diag.
trouble
code, and
after
check,
step 2
2 Execute the accelerator learning. - Step 5 Step 3
Did the accelerator learning complete normally?
3 Execute the accelerator learning using other vehicle. - Step 5 step 4
Did the accelerator learning complete normally?
4 Adjust, repair, or replace the parts judged as faulty during the - Step 5 -
accelerator learning.
1. Stop the engine.
detected. to
help,
step 1
4-197
543 Excessive high revolution error (1/2)

This "diagnostic trouble code: 543 (excessive high revolution error)" does not indicate the detection of IE
system trouble.
It has been set to confirm whether faulty engine running state (overrun) occurred in the past, and it helps you
find out causes when the engine troubled (seizure, damage, etc.).
The Engine Control Unit judges as "excessive high revolution error" and displays "diagnostic trouble code:
543" if the number of engine revolutions recognized by the Engine Control Unit exceeds the specified value.
⋅ Specified revolutions All engines: 2950 rpm

If the even of excessive high revolution detection, the SERVICE ENGINE SOON lamp for the vehicles
without the multi-warning display does not turn on, but the trouble is indicated with the diagnostic trouble
code only.
■ Possible causes
• Transmission shifting failure by driver
• Misoperation at downhill
■ Diagnostic help
if faulty.
4-198
543 Excessive high revolution error (2/2)

1 Check the operating conditions (for miss operation that caused - Step 2 -
engine overrun). (Ask the driver about past operating conditions)
Was there misoperation?
2 Tell the driver that there was engine overrun due to miss operation, - Step 4 Step 3
and instruct proper operation.
3 Check if there is any influence of engine overrun (faulty engine - Step 4
itself), and repair or replace faulty parts.
1. Stop the engine.
detected. to
help,
step 1
4-199
Chapter 5
Checking method for symptom
Preface
Method for symptom and repair according to the flow chart as shown on the following pages. At this time, give
consideration to the presumed factors and refer to the description of functional checks and checking methods for
each diagnostic trouble code.
Caution: Try to take notes of check results. Make use of the "IE Check Sheet" when recording
information on customers.
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Engine hunting, rough idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lack output power of engine, insufficient blow up, pulsating combustion . . . . . . . . . . . . . . . . . 5-8
White smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Black smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Chapter 5 Checking method for symptom
Engine stall (1/3)
■ Possible causes
• Faulty fuel system (empty tank, frozen fuel, air mixing in fuel piping, faulty filters (clogged, main, pre, gauze
filters), faulty piping, fuel quality, fuel tank (dust, faulty duel suction port, etc.))
• Faulty intake system (clogged filters, faulty intake piping, etc.)
• Faulty supply pump (including feed pump) (fuel no pressure feed)
• Faulty common rail (flow damper, pressure limiter operated/deteriorated internal sealing)
• Faulty injectors (no fuel injection)
• System backup due to trouble (fail-safe), system down
• Faulty engine (seizure, low compression pressure, other mechanical troubles)
• ACG trouble
• Chassis related troubles (clutch, transmission, brake, etc.)
• Influence of retrofit electrical parts (radio equipment, lamps, etc.)
• Engine Control Unit troubles (main body, power supply, GND, etc.)
■ Diagnostic help
if faulty.


1 Check if the SERVICE ENGINE SOON lamp turns on. Lamp ON Step 2 See
1. Turn the starter switch on. "Check
Does the SERVICE ENGINE SOON lamp turn on? ENGINE
SOON
lamp
lighting
circuit
system",
and after
repair and
check,
step 2
2 Check if the SERVICE ENGINE SOON lamp flashing Flashing Step 3 See
1. Turn the starter switch on. "Sec.3
(At this time, do not start the engine.) Check
2. Connect the diagnostic switch (connector). SERVICE
Does the SERVICE ENGINE SOON lamp flashing? ENGINE
SOON
lamp
flashing
circuit
system",
and after
repair and
check,
step 3
5-2
Engine stall (2/3)

3 Check the diagnostic trouble code. - See Step 4
1. Connect the Tech II. "Chapter
2. Turn the starter switch on. 4 Check
3. Check the diagnostic trouble code. by
Is the diagnostic trouble code detected? trouble
code"
and after
repair
and
check,
step 4
4 Start the engine. Engine starts Step 5 step 5
5 Check the fuel line system. - Step 16 See
1. Perform "check fuel line system", and repair or replace if faulty. "Sec.3
2. Start the engine, and run the vehicle to check for trouble. Check
Has the engine trouble been fixed? fuel
system"
and after
repair
and
check,
step 6
6 Check the supply pump (feed pump). - Step 9 step 7
1. Operate the priming pump through the air bleeding procedure,
and check if the fuel is forcibly fed to the fuel filter.
Is the fuel fed forcibly to the fuel filter?
7 Replace the supply pump (feed pump). - Step 10 Step 8
Did corrective actions complete and engine trouble been fixed?
8 Check the engine mechanical parts, and repair if faulty. - Step 16 Step 9
Valve system
Injection nozzles
Compression pressure
Timing gears
Pistons and crank related parts
9 Check the intake system. - Step 16 Step 10
1. Perform "check intake system", and repair or replace if faulty.
2. Start the engine, and run the vehicle to check for trouble.
Has the engine trouble been fixed?
10 Check retrofit electrical parts such as radio equipment and line-stop - Step 11 Step 16
alarm lamp display for condition.
Does the engine stall when retrofit electrical parts turn off?
11 Reinstall electrical parts, or remove them. - Step 16 Step 12
12 Check the ACG. - Step 16 Step 13
Check if the charge warning lamp in the meter lights up during the
engine running.
Is the charge warning lamp OFF and engine trouble been fixed?
5-3
Engine stall (3/3)

13 Replace the ACG. Also, check the charge warning lamp system, and - Step 16 Step 14
repair or replace if faulty.
Does the engine stall?
15 Check the chassis related parts (clutch, transmission, etc.) and repair - Step 16 -
if faulty.
16 Restore the vehicle, and perform repair check. - Check -
end
5-4
Engine hunting, rough idle (1/3)
■ Possible causes
• Faulty switch (reverse, neutral) input circuit system (switches, harnesses, etc.)
• Faulty sensor (CKP, CMP, fuel pressure) input circuit system (sensors, harnesses, etc.)
• Faulty accelerator sensor, all speed accelerator sensor system (sensors, harnesses, etc.)
• Faulty engine (mechanical troubles of supply pump, flywheel, injectors, common rail, etc.)
• System backup due to troubles (fail-safe)
■ Diagnostic help
if faulty.

1 Check the fuel. - Step 23 Step 2
1. Replace fuel in the fuel tank and piping.
Has the engine hunting trouble been fixed?
2 Check the fuel system. - Step 23 See
1. Perform "check fuel system", and repair or replace if faulty. "Sec.3
Has the engine hunting trouble been fixed? fuel
system"
and after
repair
and
check,
step 3
3 Bleed the air from the fuel, and check again if the trouble recurs. - Step 23 Step 4
4 Check the intake system. - Step 23 No: See
1. Perform "check intake system", and repair or replace if faulty. "Sec.3
Has the engine hunting trouble been fixed? intake
system"
and after
repair
and
check,
step 5
5-5

Does the engine hunting when retrofit electrical parts turn off?
6 Reinstall electrical parts, or remove them. - Step 23 Step 7
7 Check retrofit electrical parts such as additional lamps (triple tail - Step 23 Step 8
lamps) for condition.
Is harness normal (no shortcircuit), or is the ground wire connected
to the frame properly?
8 Reinstall retrofit electrical parts such as additional lamps (triple tail - Step 23 Step 9
lamps) for condition.
9 Check the reverse switch input circuit. ON ↔ OFF indication on Step 11 Step 10
1. Connect the Tech II. the screen is changed over
2. Shift the gear to the neutral position. by switch operation
4. Using the Tech II, check the switch inputs.
5. Shift the gear to the reverse position.
6.Check if the ON/OFF indication on the Tech II screen is changed
10 Referring to the reverse switch circuit (Chapter 6 Wiring check - Step 11 -
"reverse circuit"), repair or replace the circuit.
11 Check the neutral switch input circuit. ON ↔ OFF indication on Step 13 Step 12
5. Shift the gear to without neutral position.
6. Check if the ON/OFF indication on the Tech II screen is
changed over by the switch operation.
12 Referring to the neutral switch circuit (Section 6 Wiring check - Step 13 -
"neutral circuit"), repair or replace the circuit.
13 Check the CKP sensor and CMP sensor. - Step 15 Step 14
Check the CKP sensor and CMP sensor for play or loose connection.
Are sensors installed normally?
14 Reinstall the CKP sensor and CMP sensor. - Step 15 -
15 Check the CKP sensor for signal detection. - Step 23 Step 16
2. Disconnect the harness from the CKP sensor.
(For this work, the diagnostic trouble code is detected, and thus be
sure to clear the trouble code after restoring the vehicle.)
5-6

16 Check the flywheel and CKP sensor, and repair or replace if they are - Step 17 -
damaged, rust, or dirty.
17 Check the accelerator sensor for signal detection. - Step 18 Sec.4
Referring to the diagnostic trouble code "24", check the accelerator "Check
sensor. by
Did corrective actions complete? diagnostic
trouble
code",
and after
repair
and
check,
step 18
18 Check the external accelerator (all speed accelerator sensor) for - Step 19 -
signal detection.
Referring to the "external accelerator check", check the accelerator
sensor.
19 Check the common rail system. - Step 23 Step 20
1. Referring to the diagnostic trouble codes "14, 15" (checking
engine timing sensors), "271 - 276" (checking injector related
parts), and "115, 118, 151, 245, 226, 227" (checking common
rail fuel pressure related parts and supply pump), perform
checking, and repair or replace if faulty.
2. Start the engine, and check for trouble.
3. Start the engine and check for trouble.
21 Return the Engine Control Unit to the home position. - Step 22 -
22 Check the engine mechanical parts, and repair if faulty. - Step 23 -
⋅ Valve system (valve clearance, etc.)
⋅ Compression pressure
⋅ Mechanical timing
end
5-7
Lack output power of engine, insufficient blow up,
pulsating combustion (1/4)
■ Possible causes
• Faulty exhaust system (exhaust brake, faulty exhaust piping, etc.)
• Faulty. EGR
• Faulty PTO
• Faulty engine (mechanical troubles of compress pressure, valve clearance, turbo charger , EGR, supply
pump, injectors, common rail, etc.)
• Switch (exhaust brake) faulty input circuit system (switch, harness)
■ Diagnostic help
if faulty.

1 Check the fuel. - Step 24 Step 2
1. Replace fuel in the fuel tank and piping.
2 Check the supply pump (feed pump). - Step 24 Step 3
1. Operate the priming pump through the air bleeding procedure,
and check if the fuel is forcibly fed to the fuel filter.
Is the fuel fed forcibly to the fuel filter and engine trouble been fixed?
3 Replace the supply pump (feed pump). - Step 24 Step 4
4 Check the fuel system. - Step 24 See
Has the engine hunting trouble been fixed? fuel
system"
and after
repair
and
check,
step 5
⋅ Valve system (valve clearance. etc,)
⋅ Turbo charger -
Has the engine trouble been fixed?
5-8
Lack output power of engine, insufficient blow up, pulsating combustion (2/4)

1. Perform "check intake system", and repair or replace if faulty. "Sec.3
Has the engine hunting trouble been fixed? intake
system"
and after
repair
and
check,
step 7
1. Perform "check exhaust system", and repair or replace if faulty. "Sec.3
Has the engine hunting trouble been fixed? exhaust
system"
and after
repair
and
check,
step 8
8 Check the exhaust pipe for clogging or squeezing. - Step 10 Step 9
Is the exhaust pipe normal?
9 Repair or replace the exhaust pipe. - Step 10 -
10 Check the boost sensor. - Step 11 Sec.4
Referring to the diagnostic trouble code "32", perform checking, and "Check
repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 11
11 Check if there are squeezed portions or holes in the intercooler - Step 13 Step 12
(visual check).
Is the intercooler normal?
12 Repair or replace the intercooler. - Step 13 -
13 Check the accelerator pedal for full stroke position. Clearance: 1 - 2 mm Step 15 Step 14
With the starter switch in OFF position, check if the clearance to the
floor stopper bolt is proper when the accelerator pedal is depressed
fully.
Is the clearance to the floor stopper bolt proper?
14 Adjust the floor stopper bolt. - Step 15 -
5-9

15 Execute the accelerator learning. - Step 16 -
16 Check the single parts performance of accelerator sensor. - Step 17 Sec.4
Referring to the diagnostic trouble code "24", perform the checking "Check
accelerator, and repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 17
Does the engine hunting trouble been fixed when retrofit electrical
parts turn off?
18 Reinstall electrical parts, or remove them. - Step 19 -
19 Check the vehicle speed sensor system of vehicle speed sensor and - Step 20 Sec.4
pulse matching device, etc. "Check
Referring to the diagnostic trouble code "25", perform the checking by
vehicle speed sensor, and repair or replace if faulty. diagnostic
Did corrective actions complete? trouble
code",
and after
repair
and
check,
step 20
20 Check the PTO. - Step 24 See
1. Perform "check PTO", and repair or replace if faulty. "Sec.3
Has the engine hunting trouble been fixed? PTO"
and after
repair
and
check,
step 21
5-10

Has the white smoke (large) trouble been fixed?
23 Check the chassis related parts and repair if faulty. - Step 24 -
⋅ Clutch
⋅ Transmission
⋅ Brake related. etc,
end
5-11
White smoke (1/3)
■ Possible causes
• Fuel quality (use of other than standard product)
• Air mixing in fuel system
• Faulty water temperature sensor, atmospheric temperature sensor, or boost sensor
• Faulty air breather pipe (clogging)
• Engine troubles (low compression pressure, pistons, turbocharger, oil coming up or down, etc.)
■ Diagnostic help
if faulty.


1 Check the fuel. - Step 9 See
Has the white smoke trouble been fixed? fuel
system"
and after
repair
and
check,
step 2
⋅ Piston system (ring abrasion)
⋅ Faulty air breather pipe (clogging)
⋅ Turbo charger
⋅ Oil coming up or down, etc.
3 Check the water temperature sensor. - Step 4 Sec.4
Referring to the diagnostic trouble code "23", perform the checking, "Check
and repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 4
5-12
White smoke (2/3)

4 Check the atmospheric temperature sensor. - Step 5 Sec.4
trouble
code",
and after
repair
and
check,
step 5
5 Check the boost sensor. - Step 6 Sec.4
trouble
code",
and after
repair
and
check,
step 6
6 Check the atmospheric pressure sensor. - Step 7 Sec.4
trouble
code",
and after
repair
and
check,
step 7
Has the white smoke trouble been fixed?
end
5-13
Black smoke (1/2)
■ Possible causes
• Fuel quality (use of other than standard product)
• Faulty exhaust system (exhaust brake, faulty exhaust piping, etc.)
• Faulty. EGR
• Engine troubles (valve clearance, turbocharger, oil coming up, etc.)
• Faulty boost sensor, neutral switch input circuit system (sensors, switches, harnesses, etc.)
• Engine oil deterioration
■ Diagnostic help
if faulty.

1 Check the intake system. - Step 11 -
1. Perform "check intake system", and repair or replace if faulty.
Has the black smoke trouble been fixed?
Valve system (valve clearance. etc,)
Compression pressure
Turbo charger
Referring to the diagnostic trouble code "32", perform the checking,
and repair or replace if faulty.
5 Check the engine oil. - Step 11 Step 6
1. Replace the engine oil and oil filter.
6 Check the fuel system. - Step 11 Step 7
1. Perform "check fuel system", and repair or replace if faulty.
5-14
Black smoke (2/2)

8 Check the neutral switch input circuit. ON ↔ OFF indication on Step 10 Step 9
5. Shift the gear to without neutral position.
6. Check if the ON/OFF indication on the Tech II screen is
changed over by the switch operation.
9 Ckeck the neutral switch circuit repair or replace the circuit. - Step 10 -
10 Check the Engine Control unit. - Step 11 -
end
5-15
Chapter 6
How to use IE system
inspection tools
Chapter 6 How to use IE system inspection tools
1. Tech II
■ Tech II
Tech II is used to check the control unit for each signal reading condition and self-diagnosis condition.
As shown in the figure below, connect the Tech II to the diagnostic connector.
6-2
Tech II
● Special functions
The magnetic valve operating condition and the injection system are inspected by sending the magnetic valve
operating signal from the Tech II to the control unit and operating the control unit forcedly.
(The special functions are inspected by stopping or starting the engine.)
Menu F3: Actuator of the menu and press the ENTER key.
F0: Diagnostic Trouble Codes
F1: Data Display
F2: Snap Shot
F3: Actuator Test
F4: Programming
Items of the Special Functions are displayed.

F0: Relays
F0: Exh. Brake

Note: After selecting the items, refer to each menu.
F1: Solenoid Valve
F1: Magnetic Valves
F0: M/V EGR
F2: Engine Controls
F0: Rail Pressure Control
F1: Injection Timing
F2: RPM Control
F3: Injection Balancing
F4: Pilot Injection stop
F5: Injection Stop
• Fuel pressure control

Fuel Pressure Control
Change the fuel pressure in the common rail and check if
System Voltage V
Vehicle Speed km/h the actual pressure follows the set pressure and check for
Desired Idle Speed RPM leak from the fuel piping when the pressure is increased.
Engine Speed RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum V
Final Accelerator Opening %
Quit Decrease Increase
LFW36ESH001101
• Injection timing
Injection Timing
Change the fuel injection timing and check the exhaust
System Voltage V
Vehicle Speed km/h gas condition or engine condition.
Desired Idle Speed RPM
Engine Speed RPM

6-3
LFW36ESH001401
Tech II
RPM Control
• RPM control
Change the idling speed and check if the actual speed
System Voltage V
Vehicle Speed km/h follows up the set values.
Engine Speed RPM
• Cylinder power balance

Cylinder Power Balance
Inspect the fuel injection condition from the injector by
System Voltage V
Vehicle Speed km/h stopping the injectors in succession for each cylinder.
Desired Idle Speed RPM For normal injectors, the engine sound is changed when
Engine Speed RPM
the fuel injection is stopped. Select the injectors with
APP (Accelerator Pedal Position) Angle % the software key, "Next".
Quit Off Next
• Pilot injection stop

Pilot Injector Stop
Inspect the fuel injection control (pilot injection) at the
System Voltage V
Vehicle Speed km/h
idling speed by stopping the pilot injection.
Engine Speed RPM
Quit Off
LFW36ESH001001
6-4
Tech II
• Injection stop
Injector Stop
Inspect the engine stop control. When the test is carried
System Voltage V
Vehicle Speed km/h out at the start of the engine, the engine stops.
Engine Speed RPM
Quit Off
LFW36ESH001301
• Exhaust brake control

Exhaust Brake Relay
Inspect the exhaust brake operating condition while the
Exhaust Brake OFF
engine stops. At this time, the EXH. lamp (on the
installation panel) lights up.
Quit Active
Solenoid Valve
• Solenoid valve
Inspect the operation of the magnetic valves A, B and C
M/V D (EGR) Inactive
M/V E (EGR) Inactive
while the engine stops.
Select the M/V with the software key, "Next".
D: EGR E: EGR
Quit On Next
6-5
Tech II
■ Programming
Set up the accelerator learning. Communicate with Tech II and control unit and write the set values into the
control unit.
Menu F4: Programming on the menu and press the ENTER
F0: Diagnostic Trouble Codes
F1: Data Display
key.
F2: Snap Shot
F3: Actuator Test
F4: Programming
Programming items are displayed.

Programming
Note) After electing the following items, refer to each
F0: Upload Fuel Delivery Rate Data menu.
F1: Download Fuel Delivery Rate Data
F2: Accelerator Learning Data • Upload Fuel Delivery Rate Data
• Download Fuel Delivery Rate Data
• Acceleraror learning Data
6-6
Tech II
● Accelerator learning
Have the control unit memorize the idling position and full-throttle position of the accelerator pedal.
This accelerator learning should be carried out always after:
o replacing the control unit
o replacing the accelerator sensor
o Replacing the accelerator bracket assembly.
(Set the starter switch to "ON" and stop the engine during the accelerator learning.)
Programming
A. Menu F2: Accelerator learning Data on the menu and
press the ENTER key.
F0: Upload Fuel Delivery Rate Data
F2: Accelerator Learning Data
B. Enter the current date and press the software key,

Accelerator Learning Data
"Program".
Engine: (IE) 6WG1 (Common Rail)
Use up/down arrow keys to change value.

Use left/right arrow keys to select field.
Date Setting
01-01-2003
Program Abort
C. Set up the Full-stroke position for the accelerator pedal

Stepping the accelerator pedal all the way through the
Engine: (IE) 6WG1 (Common Rail) stroke and press the software key "Program".
Current Accel Learn Voltage (Full)
Note) Check that there is a gap of 1 - 2mm between the
Current Accel Learn Voltage (Idle) pedal and floor stopper bolt when the pedal is
Press [Program] to Store Voltage (Full) fully stepped on.
Shaded values indicates learning values before

Program Abort
changing. (Full/Idle)
These values can be checked on the data display.
6-7
Tech II

D. Set the idle position of the accelerator pedal.
(C ＊, E＊, L＊, F＊) Heavy, Medium Duty Leave the foot from the accelerator pedal and press the
software key, "Program".
Current Accel Learn Voltage (Full)
Shaded values indicates accelerator learning values to
Current Accel Learn Voltage (Idle)
be set up
Press [Program] to Store Voltage (Full)
Press [Program] to Store Voltage (Idle)
Program Abort
E. When the "Programming Completed" is indicated, the

(C ＊, E＊, L＊, F＊) Heavy, Medium Duty

accelerator learning has completed.
Engine: (IE) 6WG1 (Common Rail) Check that the learning values set up as described above
are the same as the accelerator position learning value
Programming Completed!
(Full/Idle) in the data display.
Confirm
6-8
Chapter 7
Others
O
ECM power source system (including fuse and relay) (416, 421) O
O O
Starter switch
Control system (including wiring harness)
O O
Battery, starter related
Use this chart when repairing damages. (Refer to "Troubleshooting Manual , for details.)
Control unit 33, 35

Vehicle speed sensor 25
O O
O O
CMP sensor 14
CKP sensor 15
O O
Atmospheric temperature sensor 22
Inspection item chart for IE system condition
Water temperature sensor 23
O O O O
O
Boost sensor 32
O
Fuel pressure sensor 245, 115
O
Accelerator sensor switch 24, 241, 242
O
O
M/V: D, E 413, 443, 424
O O
O
Short circuit of injector (+B⋅GND) 158, 159
Note: Self-diagnosis codes in ( ) indicate that they may be caused in that item.
O
O
Disconnected wire of injector 271 - 276
Disconnected wire or short circuit of PCV 217, 218,
O
(contents of pump) 247, 248
O O O
O O O O O O O O
O
Supply pump excessive pressure feed 151, 118
Supply pump no pressure feed pressure limiter operated 226, 227
O
Abnormal turbo (including excessively high boost) (42)
Disconnected, leaking or clogged boost sensor hose
Engine mechanical
O O
Clogged or leaking inter cooler
Defective EGR
O
O
O
O O
Defective injector (including flow damper operation)
O
Clogged air cleaner
Chapter 7 Others
Clogged fuel clogged fuel hose (226, 227)

( )
O
O
O
O
O
system foreign substance in the fuel tank
fuel filter, (226, 227)
( )
O
O
O
O
O
Clogged filter
pre-filter, etc.
O
O
O
Air mixed (improper air vent, fuel shortage) (226, 227)
DTC
Inspection
item
White smoke large
Pulsating combustion
Black smoke large
Engine hunting
Failure condition
Defective start
Engine stall
7-2
Abbreviation list
Abbreviation
ABDC After Bottom Dead Center GSU Gear Shift Unit
ABS Antilock Brake System GVW, (GVM) Gross Vehicle Weight, (Mass)
AC Alternating Current HC Hydrocarbon
ACC Accessory HID High Intensity Discharge
ACG Alternating Current Generator H-Gear Hypoid Gear
AOH Brake Air Over Hydraulic Brake HSA Hill Start Aide
ACT Air Control Transmission / Actuator HT Hypoid Tandem
API American Petrol Institute HUD Head Up Display
ASM (Assy) Assembly IC Integrated Circuit
ASR Anti Slip Regulator ID Plate Identification Plate
ASSIT Assistant IE System ISUZU Economy System
ATDC After Top Dead Center IGN Ignition
ATF Automatic Transmission Fluid IN Intake, Inlet
A/C Air Conditioner INT/S Intake Shutter
A/T, AT Automatic Transmission / Air Tank ISC Idle Speed Control
A/F Air Fuel Ratio ISO International Standardization Organization
BAT, BATT Battery I/PUMP Injection Pump
BBDC Before Bottom Dead Center JIS Japanese Industrial Standard
BRG, Brg Bearing J/C Joint Connector
BKT, BRKT Bracket K/D Kick Drive
BTDC Before Top Dead Center LCD Liquid Crystal Display
CAN Control Area Network LED Light Emitting Diode
CAS Cab Air Suspension LIM Linesman
CCS Combined Charging System LSD Limited Slip Differential
CLU Change Lever Unit LSPV Load Sensing Proportioning Valve
CNG Compression Natural Gas LT Leading & Trailing
CO Carbon Oxide LTD Limited
CONN Connector L/H, LH Left Hand
CPU Central Processing Unit MPV Multi Protection Valve
C/U Control Unit M/T, MT Manual Transmission
DC Direct Current M/V Magnetic Valve
DD Direct Drive NC Normal Close
DI Direct Injection NE Number of Engine
DLC Data Link Connector NR Noise Reducer
DTC Diagnostic Trouble Code NO Normal Open
D2L Dual Two Leading NOx Nitrogen Oxide
EBS Electronic Brake System N-TDC Number - Top Dead Center
ECU Engine Control Unit / Electronic Control Unit OD Over Drive
ECM Engine Control Module OPT Option
ECS Electronic Control Suspension P Pole(S)
EGR Exhaust Gas Recirculation PCV Pump Control Valve/Positive Crankcase Ventilation
EHT Electrical & Hydraulic Timer PM Particulate Matter
EMI Electro Magnetic Interference POS Position
EVT Electronic Variable Timer PS Pre-Stroke
Exh, EXH Exhaust PTO Power Take Off
Ft, FRT Front PWM Pulse Width Modulation
FWD Forward PWR Power Source
F⋅Ft-Axle Forward･Front - Axle P/L Pilot Lamp
F⋅Rr-Axle Forward･Rear - Axle P/S Power Steering
F/B Feedback QOS Quick On System
F/C Fuel Cut Rr, RR Rear
F/L, FL Fusible Link R⋅Ft-Axle Rearward･Front - Axle
GND Ground R⋅Rr-Axle Rearward･Rear - Axle
7-3
Abbreviation list
Abbreviation
REF Reference
RET Retarder
RP Rail Pressure
RWD Rearward
R/H, RH Right Hand
R/L Relay
SAE Society of Automotive Engineers
SBF Slow Blow Fuse
S-Gear Spiral Gear
SIG Signal
SLD Shield
SRS Supplemental Restraint System
SSPS Speed Sensing Power Steering
ST Starter / Start
STD Standard
STRG Steering
SW Switch
TCM Transmission Control Module
TICS Timing & Injection rate Control System
TWV Two Way Valve
VGS Turbo Variable Geometry turbocharger System
WOT Wide Open Throttle
W/B, WB Wheel Base
W/L Warning Lamp
2L 2 (Two) Leading
7-4
■ Programming / Upload / Download Fuel Delivery Rate Data
Upload the Q data (1-3) stored in the ECM to Tech II and download that data from Tech II to ECM.
This process is required in the following cases.
⋅ After replacing the ECM, store the Q data which has been in the former ECM to new ECM.
Programming
⋅ Select "Upload Fuel Delivery Rate Data" in the
menu and press the ENTER key.
F2: Accelerator Leaning Date
Upload Fuel Delivery Rate Data

⋅ Press the software key, Yes .
*1
Do you want Upload data?
No Yes
⋅ Press the software key, Confirm .

Now the uploading has been completed.
*1
Upload Successful
Confirm
⋅ By pressing the EXIT key, the menu is displayed

again
*1
Cycle Ignition, Then Press Exit
7-5
● Programming
Programming ⋅ Select "Download Fuel Delivery Rate Data" in the

menu and press the ENTER key.
F2: Accelerator Leaning Data
Download Fuel Delivery Rate Data

⋅ Press the software key, Yes .
*1
Do you want Download data?
No Yes
⋅ Now downloading has been completed.

By pressing the software key, Confirm , the menu
*1
is displayed again.
Check that the Q data in the former ECM and that
Programming Completed: in the new ECM are the same with the Fuel Rate
Data of the Data Display.
Confirm
Caution: Programming is possible only when the following conditions are met:
⋅ No DTC is displayed.
⋅ Engine is stop.
⋅ SW21 of Tech II Adapter is on the reception (RXD) side.
(Set the SW21 to the reception side when clearing DTC also.)
7-6
6WGEED-WE-0335AR
You are requested to order this manual using the

manual number that is shown above.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Jan., 2003

No.6WGEED-WE-0335AR

6wg1 Emissions &amp; Diagnostics

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6wg1 Emissions &amp; Diagnostics

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WORKSHOP MANUAL

ENGINE EMISSION & DIAGNOSTICS

International Service & Parts

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on the latest

Applicable Model : C & E-Series

This Manual is applicable to 2003 year model and later vehicles.

271 No.1 cylinder No.1 injector drive

Chapter 5 Checking Method for Symptom

Chapter 6 How to use IE System Inspection

Chapter 1 Overview of IE system

Chapter 2 Failure diagnosis

Chapter 3 Functional diagnosis

Chapter 4 Checking procedure for each diagnostic trouble code

Chapter 6 How to use IE system inspection tools

1. Overview and specifications of IE system

Electronically controlled fuel

Engine model Output E

■ Electronically controlled fuel injection system (common-rail type)

System schematic diagram

Atmospheric temperature sensor

Sensor signals Engine control unit

from switches, etc. (ECU)

Atmospheric pressure sensor

Starter motor Common-rail fuel

Flywheel Feed pump Pre-fuel filter

System control schematic diagram

Engine control unit (ECU)

Accelerator sensor input

Compensation Water temperature sensor input,

Fuel pressure sensor

■ EGR (Exhaust Gas Recirculation)

■ Idling control switch

■ Output of idle position signal to brake intensive control unit

■ Output of engine rotations to tachometer

CKP sensor Tachometer

■ Speed Limiter (SLD)

■ Auto cruise control

Momentary acceleration function

Set coast function (Autocruise setting speed is lowered)

Set accelerator function (Autocruise setting speed is gathered)

Resume function (return in the autocruise state)

Auxiliary brake linkage autocruise control

Downward slope Downward slope Flat way

Engine control Brake intensive

Vehicle speed signal (25pulse)

Vehicle speed sensor

■ External view of engine control unit

■ Engine control unit input/output list

2. IE system schematic connection diagram

Main Relay +BP PCV1

Sub Stater Neutral Relay

R/L:EGR Fail Safe 119

M/V D :EGR1 89 Injector 2

Stop Lamp Relay

Cruise Main Switch

Cruise Set Lamp

3. Control unit/sensor/switch installing position

Right below the steering wheel

Brake Intensive Control Unit

Engine Control Unit

Clutch Switch Idle Control Switch

• Data Link Connector

Service Engine Soon Lamp

6wg1 Emissions & Diagnostics

6wg1 Emissions & Diagnostics