Professional Documents
Culture Documents
F&G-SERIES
ENGINE EMISSION
6SD1-TC (COMMON RAIL)
SECTION 6E
Applicable Model : FVR, FVD, GVR, GVD, FVM, FVL, FVZ, FVY
274 No.4 cylinder No.6 injector drive Magnetic valve, magnetic valve fail safe
system trouble. . . . . . . . . . . . . . . . . . . 4-155 relay circuit . . . . . . . . . . . . . . . . . . . . . . 6-18
275 No.5 cylinder No.2 injector drive Vehicle speed sensor circuit . . . . . . . . . . . 6-19
system trouble . . . . . . . . . . . . . . . . . . . 4-160 Starting circuit (key switch,
276 No.6 cylinder No.4 injector drive slow blow fuse and fuse circuit) . . . . . . 6-20
system trouble . . . . . . . . . . . . . . . . . . . 4-164 Meter circuit (SERVICE ENGINE SOON
411 Magnetic valve "A" drive lamp, tachometer output) . . . . . . . . . . . 6-21
system trouble . . . . . . . . . . . . . . . . . . . 4-168 Self-diagnosis circuit (diagnosis switch,
412 Magnetic valve "B" drive memory clear switch and Tech II
system trouble . . . . . . . . . . . . . . . . . . . 4-175 connector circuit) . . . . . . . . . . . . . . . . . 6-22
415 Magnetic valve "C" drive Neutral circuit (Except automatic
system trouble . . . . . . . . . . . . . . . . . . . 4-182 transmission vehicles). . . . . . . . . . . . . . 6-23
416 Main relay system trouble . . . . . . . . . . 4-189 Clutch switch circuit. . . . . . . . . . . . . . . . . 6-24
417 Starter switch trouble. . . . . . . . . . . . . . 4-194 Brake switch circuit . . . . . . . . . . . . . . . . . 6-25
418 Fail-safe (Magnetic valve cut) Reverse circuit . . . . . . . . . . . . . . . . . . . . . 6-26
relay "A" system trouble . . . . . . . . . . . 4-199 Idling control switch and idling control
421 PCV relay system trouble . . . . . . . . . . 4-203 selector switch circuit . . . . . . . . . . . . . . 6-27
518 EOL data error. . . . . . . . . . . . . . . . . . . 4-208 Exhaust brake circuit . . . . . . . . . . . . . . . . 6-28
543 Excessive high revolution error. . . . . . 4-210
Chapter 7 How to use IE System Inspection
Chapter 5 Checking Method for Symptom Tools
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 1. Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Engine hunting, rough idle . . . . . . . . . . . . . . . 5-5 Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lack output power of engine, insufficient
blow up, pulsating combustion . . . . . . . . . . 5-8 Chapter 8 Others
White smoke (large) . . . . . . . . . . . . . . . . . . . 5-12 Inspection item chart for IE system
Black smoke (large) . . . . . . . . . . . . . . . . . . . 5-15 condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Abbreviation list . . . . . . . . . . . . . . . . . . . . . . . 8-3
Chapter 6 Wiring check Programming / upload / download fuel
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 delivery rate data . . . . . . . . . . . . . . . . . . . . 8-5
Identification of wires . . . . . . . . . . . . . . . . 6-2
Wiring specifications . . . . . . . . . . . . . . . . . 6-2
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Handling of connectors and harness. . . . . . 6-4
2. Vehicle wiring harness . . . . . . . . . . . . . . . 6-10
3. Wiring check. . . . . . . . . . . . . . . . . . . . . . . 6-11
Engine control unit power source,
GND circuit. . . . . . . . . . . . . . . . . . . . . . 6-11
NE, G and fuel pressure sensor circuit . . . 6-12
Boost, all speed accelerator sensor circuit. . 6-13
Accelerator sensor and accelerator
switch circuit. . . . . . . . . . . . . . . . . . . . . 6-14
Water temperature, fuel temperature and
atmospheric temperature sensor circuit . . 6-15
PCV (pump control valve),
PCV relay circuit . . . . . . . . . . . . . . . . . 6-16
Injector (TWV) circuit . . . . . . . . . . . . . . . 6-17
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 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 8 Others
• Check sheet of IE system and simplified troubleshooting
Chapter 1
Overview of IE system
Chapter 1 Overview 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. VGS turbo 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)
Self-diagnosis function
kW {PS}
349 6SD1-TC 206 kW {280 PS} O O O
O - Standard equipment
1-2
Overview and specifications of IE system
⋅ Accelerator sensor
⋅ Accelerator switch Fuel
⋅ All speed temperature
Accelerator sensor control
Injector
Pressure limiter
Fuel leak pipe
Flow damper
Supply pump
Air
cleaner
Water temperature
sensor Fuel filter
Fuel tank
CMP sensor
CKP sensor
1-3
Overview and specifications of IE system
PCV
opening/closing Injector (TWV) power supply time,
timing decision timing decision
TWV
(Two Way Valve)
PCV
Supply
Injector
pump
Fuel tank
1-4
Overview and specifications of IE system
Air tank
No. of
change-over
Decision of steps of VGS C
Engine speed No. of change-over Compensation
steps of VGS
B
Inputs
⋅ Input from A
switches, etc.
Nozzle vane
1-5
Overview and specifications of IE system
UP UP
DOWN DOWN
1-6
Overview and specifications of IE system
Exh.Brake SW.
NE sensor Tachometer
Engine speed output
Engine control unit
G sensor Tachometer
1-7
Overview and specifications of IE system
Meter
Other C/U
1-8
Overview and specifications of IE system
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.
1-9
Overview and specifications of IE system
1-10
Overview and specifications of IE system
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 - -
93 VGS magnetic valve feed-back O
94 Injector 6 (4th cylinder) O
95 Injector 5 (2nd cylinder) O
96 Injector 4 (6th cylinder) O
97 Injector 3 (3rd cylinder) O
98 Injector 2 (5th cylinder) O
99 Injector 1 (1st cylinder) O
100 Injector power source common 1 O
101 Main relay O
102 ECU GND O
103 - -
104 - -
105 Service engine soon lamp O
106 - -
107 - -
108 R/L; Retarder -
109 Main relay O
110 Injector power source common 1 O
111 ECU GND O
112 Output signal to tachometer (SIG) O
113 Tech-II RXD O
114 Tech-II TXD O
115 VGS fail sale relay (FS REL A) O
116 - -
117 - -
118 Main relay O
119 Injector power source common 2 O
120 Injector power source common 2 O
1-11
1-12
R/L ; P.C.V
1.25 1.25
Wire diameter
1.25 Use wire of φ1.25 for the pims 21, 22, 31, 32, 81, 82, 91, 100,
101, 102, 110, 111, 119, and 120.
R/L ; MAIN 1.25 +BP 91 PUMP CONTROL VALVE (PCV)1 Wire of φ0.85 is permissible for the pims 85-90 and 94-99 for
1.25 1.25 which the shielded wire is used.
101 22
MAIN R/L 21
109
Plating of pin
OFF 118 PUMP CONTROL VALVE (PCV)2
All of the ECU pins should be gold-plated.
ACC KEY 13 31
ON 32
23
KEY SW START 24 100
START 41 SIG 110
CASE GND
44 VCC
119
ACCEL 45 GND
120
SENSOR 42 SIG
54 VCC 90 TWV1
46 GND 99 1ST CYLINDER
SW ; ACCEL(N.C.)
20 86 TWV5
SW ; EXB. BRAKE 95 2ND CYLINDER
8
SIG 62
SIG 71 FUEL PRESSURE
VCC 73 SENSOR
GND 55
SW ; RETARDER
37
SIG 61
M/V ; RETARDER VCC 72 BOOST SENSOR
GND 56
SW ; NEUTRAL
33
R/L ; VGS FAIL SAFE (N.C.)
STOP LAMP
RELAY
115
M/V ; A(VGS1)
1
26
BRAKE SIG.2 M/V ; B(VGS2)
SW ; STOP LAMP 3
M/V ; C(VGS3)
39
FLY BAG
93
TRANSMITTED
114
TECH II RECEIVED
113
TACHOMETER OUTPUT
METER 112
ATMOSPHERIC
PRESSURE
SENSOR
VEHICLE PULSE COMPRESSOR R/L
VEHICLE SPEED SIG
SPEED MATCHING 75
SENSOR DEVICE 4
81 82 102 101 59 *Pin (4) is used when the engine idling speed is
increased for the air conditioning system.
CASE GND
THERMO SW AIR CONDITION MODE SW
1-13
Overview and specifications of IE system
Chapter 1 Overview of IE system
1-14
Control unit/sensor/switch installing position
・ACCELERATOR SENSOR
・Diagnostic Switch (White)
・ACCELERATOR SWITCH
・Memory Clear Switch (Blue)
・Date Link Connector
SERVICE
ENGINE
SOON
1-15
Control unit/sensor/switch installing position
Atmosphere
temperature sensor
(in open slit)
Battery
Air tank
⋅ Air low pressure switch
1-16
Control unit/sensor/switch installing position
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
1-17
Control unit/sensor/switch installing position
Engine (6SD1-TC)
CKP sensor
Supply pump
× PCV
× CMP sensor
1-18
Chapter 1 Overview of IE system
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
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
Output shortage when hot,
Fuel temperature resister 52, 66 Detection of fuel temperature 211
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.
SERVICE ENGINE SOON lamp light up
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.
SERVICE ENGINE SOON lamp light up
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
85 - 90, Output shortage, improper engine power up, deteriorated exhaust 271,272,273,
Injector (TWV) the power supply time/timing, hereby controlling the fuel
94 - 99 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
PCV (pump control valve) relay 22, 21, Engine stop.
Detection of drive power supply to PCV relay 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)
1-19
Functions of input/output and vehicle behavior upon failure (influence)
1-20
Chapter 1 Overview of IE system
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.
Stopper bolt
Lock nut
1-21
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
1-22
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
3. Diagnostic trouble codes list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Chapter 2 Failure diagnosis
1. Self-diagnosis of IE system
■ 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
2-2
Self-diagnosis of IE system
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
2-3
Self-diagnosis of IE system
3 1
2-4
Self-diagnosis of IE system
Condition 2
3 1 Condition 1:
Check the memory clear switch (Blue) ÒOFFÓ.
2
2-5
Self-diagnosis of IE system
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
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.
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
Self-diagnosis of IE system
● 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.
9
TE
CH
2
AD
AP
TE
R
8
2
6
1
7
PS
8
W
1
2-8
Self-diagnosis of IE system
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 ÒF1: Clear DTC InfoÓ.
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).
3 1
4. Make sure the vehicle starter key is off.
2 5. Connect the adapter DLC cable (8) to the vehicle DLC.
6. Select Ò3Ó position of the selective switch (9).
Legend 7. Switch the signal selective switch (5).
(1) Dianostic Switch (White) 1 side : Use when taking in data from ECM to Tech 2.
(2) Memory Clear Switch (Blue) ex) Programming (Upload Fuel Rate Data), Data
(3) Data Link Connector (DLC) Display, Read DTC
2 side : Use when commanding from Tech 2 to ECM.
ex) Programming (Download Fuel Rate Data),
TE
6
1
7
PS
2-9
Self-diagnosis of IE system
Operation of Tech II
1/3
(3) 2003
2-10
Self-diagnosis of IE system
Vehicle Identification
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
(3) (C*, E*, L*, F*) Heavy, Medium Duty
F0: Engine
F1: Transmission
F2: Chassis
F3: Body
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) 6SD1-TC (Common Rail)
number appears.
ROM Identification 6SD1: 22116040
Enter the ROM Identification number then confirm it.
6SD1-TC (Common rail)
Confirm
2-11
Self-diagnosis of IE system
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
NO YES
Continue
Confirm
2-12
Self-diagnosis of IE system
2-13
Self-diagnosis of IE system
2-14
Self-diagnosis of IE system
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle informaion)
After the display of vehicle data, select Select when the items have been displayed.
"QUICK SNAPSHOT" in the lower part
of the monitor screen
After the lapse of some time, push "EXIT" If (STANDBY) blinks, and the upper right
button of the screen, select "TRIGGER".
2-15
Chapter 2 Failure diagnosis
2-16
Vehicle diagnostic procedure
2-17
Vehicle diagnostic procedure
2-18
Chapter 2 Failure diagnosis
Backup control
diagnostic Judge
trouble Item Failure Contents Time
code DATA Control
15 CKP pulse not input while CMP pulse is - - Control with CMP sensor only
(Memorized) CKP sensor trouble input at the engine speed more than 40rpm
14 CKP pulse not input while CMP pulse is - - Control with CKP sensor only
(Memorized) CMP sensor trouble input at the engine speed more than 450rpm
When the common rail pressure is larger Approx. Common-rail pressure regulation (max. 60MPa)
115 Fuel pressure sensor output than 10 MPa, PC sensor output value does 9sec. Fuel injection rate Prospective control
(Memorized) fixed not change. continued (max. 50 mm3/st)
PCV closing timing is after 217.5°CR or Approx. Common-rail pressure regulation (max. 60MPa)
151 Common-rail pressure Trouble the difference between the target 9 sec.
common-rail pressure and actual common Fuel injection rate Prospective control
(Memorized) (pump excessive pressure feed) continued (max. 50 mm3/st)
rail pressure is larger than 10MPa.
242 Accelerator switch was turned ON when the 0.5 sec. Control based on the accelerator backup map
Controlled accelerator opening (max. 25% )
(Memorized) Accelerator SW ON trouble accelerator sensor output value exceeded 3.06V. continued (work map)
159 TWV power source system trouble TWV2, 4, 6, harness power source short circuit - -
(Memorized) (Common 2 "injector 2, 4, 6 system) or common 1 harness power source short circuit Power supply to TWV and PCV is stopped.
217 PCV 1 system short circuit (battery, When the PCV1 is turned ON, Key SW= PCV1 is turned OFF.
(Memorized) power source system circuit) trouble PCV1 drive voltage ON Common-rail pressure regulation (max. 60MPa)
218 PCV 2 system short circuit (battery, When the PCV2 is turned ON, Key SW=
(Memorized) power source system circuit) Common-rail pressure regulation (max. 60MPa) PCV1 is turned OFF.
trouble PCV2 drive voltage ON
247 Disconnection or short circuit of When the PCV1 is turned OFF, Key SW= -
(Memorized) PCV1 system (GND circuit) Common-rail pressure regulation (max. 60MPa)
trouble PCV1 drive voltage ON
248 Disconnection or short circuit of When the PCV2 is turned OFF, Key SW= -
(Memorized) PCV2 system (GND circuit) Common-rail pressure regulation (max. 60MPa)
trouble PCV2 drive voltage ON
421 When the PCV is turned OFF, After the key Main relay is turned OFF 5 seconds after the -
(Memorized) PCV power source trouble trouble PCV drive voltage SW = OFF key SW=OFF
2-19
Diagnostic trouble codes list
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.
Regular Regular Regular Reset CKP pulse or CMP pulse was input. 1á4
control control control completely. ◎ 1á5 O
Control Regular Control Reset Fuel pressure sensor output value was ◎
changed. 1á1á5 O
stopped. control stopped. completely.
Control Regular Regular Reset Once the engine stalls, the engine ◎
does not stop. 2á2á6 O
stopped. control control completely.
Control Regular Regular Reset Once the engine stalls, the engine ◎
does not stop. 2á2á7
stopped. control control completely. O
Control Regular Control Reset Engine does not stall once it stalled. 1á5á8
stopped. control stopped. completely. ◎ (COM1 system) O
Control Regular Control Reset Engine does not stall once it stalled. 1á5á9
stopped. control stopped. completely. ◎ (COM2 system)
O
2-20
Diagnostic trouble codes list
Backup control
diagnostic Judge
trouble Item Failure Contents Time DATA Control
code
65 25 sec.
(Memorized) Low boost trouble Low boost pressure was detected. continued - -
When PTO/SW=ON, the all speed When an error occurrence is judged, all speed accelerator opening is controlled (fixed to 0%).
All speed accelerator sensor 1 sec.
- accelerator sensor output value is over After that, when the accelerator pedal opening decreases below 5%, control is made as the all
error continued
4.8V or below 0.1V. speed accelerator opening = accelerator pedal opening.
When the engine speed exceeded
417 1.6 sec.
(Memorized) Starter switch trouble 1000rpm, starter SW S signal was - -
continued
detected continuously.
- CPU trouble CPU trouble - - Power supply to TWV and PCV is stopped.
2-21
Diagnostic trouble codes list
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.
Regular Regular Regular Regular Fuel temperature sensor output is over - 2á1á1 O
control control control control 0.1V or below 4.8V
Control Regular Regular Reset When the engine installs, boost relative
O 3á2 O
stopped. control control completely. pressure is below 20kPa or over 16kPa.
Regular Regular Regular Regular Held until ECU is turned OFF. - 6á5 O
control control control control
Regular Regular Regular Reset Vehicle speed sensor voltage is over - 2á5
control control control completely. 0.5V and vehicle speed pulse is input. O
Regular Regular Regular Reset Held until ECU is turned OFF. O 4á1á6 O
control control control completely.
Control Regular Regular Reset Held until ECU is turned OFF. O 4á4á3 O
stopped. control control completely.
Control Regular Regular Reset Held until ECU is turned OFF. O 4á1á3 O
stopped. control control completely.
Control Control Control Reset When F/S REL A=ON, relay drive O 4á1á8 O
stopped. stopped. stopped. completely. voltage is normal.
Control Regular Control Reset When F/S REL B=ON, relay drive O 4á2á4 O
stopped. control stopped. completely. voltage is normal.
Control Control Control Reset Once the engine installs, it does not ◎ 3á5 O
stopped. stopped stopped. completely. install anymore.
Control ◎ (A) 42
- - - - O
stopped (B) 32
- - - - - - 6á5 O
2-22
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.
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
BrW 0.5
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
ECU HARNESS
BrW 0.5
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
FUSE 2 37 38 39 40 40 39 38 37
41 42 43 44
SMJ 44 43 42 41 1 2 3 4 5 6 7
(WHITE) 8 9 10 11 12 13 14 15
48 47 46 45
45 46 47 48
42 49 50 51 52 53 54 55 56 57 58 59 60
60 59 58 57 56 55 54 53 52 51 50 49
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
LgB 0.5
1 1
DIAG. SWITCH
B 0.5 B 1.25
B 1.25
RL 0.5
ECU GND
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
CASE GND
1 1
B 0.5
3-2
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
VW 1.25
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
2 4
B2
3
Y 0.5
FUSE 45
VG 2
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
25 26 27 28 DIAG. CONNECTOR
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
3-3
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
CONNECTOR A CONNECTOR B
CAUTION
USE FUSE WITH THE SPECIFIED CAPACITY.
Fuse box FUSE CAPACITIES OTHER THAN SPECIFIED MAY CAUSE
BREAKEDOWN OF THE SYSTEM.
1 Headlight(Upper)/ 11 21 26 Tail light Fog light 36 46
Meter Blower motor
7.5A Left 7.5A 15A illumination 15A
2 Headlight(Upper)/ 12 Back up light 22 27 37 Condenser fan motor 47
Stop light
7.5A Right 7.5A Sub starter Horn 15A 15A Compressor
3 Headlight(Lower)/ 13 Power take off 23 28 38 Wiper 48
Starter(relay)
7.5A Left 7.5A Exhaust brake 15A 15A Window washer
4 Headlight(Lower)/ 14 24 29 (Power outlet) 39 49
7.5A Right 15A Receptacle
5 Click Dome light 15 25 30 40 Cigarette lighter 50
Transfer low Turn signal
7.5A Back up 7.5A 15A 15A
6 16 4WD 31 41 12V Consent
7.5A 15A
7 Door lock 17 Transfer high 32 Power window(Right) 42
7.5A 7.5A 15A
8 Radio 18 33 Power window(Left) 43
Auto T/M ECU
7.5A Cassete stereo 7.5A 15A
9 Glow plug(Relay) 19 34 Auto T/M ECU 44
7.5A 15A
10 20 Engine ECU 35 45 Engine ECU
7.5A 15A
3-4
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
■ 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
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
3-6
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
3-7
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
3-8
Checking the SERVICE ENGINE SOON lamp flashing control system
(SERVICE ENGINE SOON lamp does not flashing)
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
BrW 0.5
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
ECU HARNESS
BrW 0.5
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
FUSE 2 37 38 39 40 40 39 38 37
41 42 43 44
SMJ 44 43 42 41 1 2 3 4 5 6 7
(WHITE) 8 9 10 11 12 13 14 15
48 47 46 45
45 46 47 48
42 49 50 51 52 53 54 55 56 57 58 59 60
60 59 58 57 56 55 54 53 52 51 50 49
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
LgB 0.5
1 1
DIAG. SWITCH
B 0.5 B 1.25
B 1.25
RL 0.5
ECU GND
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
CASE GND
1 1
B 0.5
3-9
Checking the SERVICE ENGINE SOON lamp flashing control system
(SERVICE ENGINE SOON lamp does not flashing)
CONNECTOR A CONNECTOR B
CAUTION
USE FUSE WITH THE SPECIFIED CAPACITY.
Fuse box FUSE CAPACITIES OTHER THAN SPECIFIED MAY CAUSE
BREAKEDOWN OF THE SYSTEM.
1 Headlight(Upper)/ 11 21 26 Tail light Fog light 36 46
Meter Blower motor
7.5A Left 7.5A 15A illumination 15A
2 Headlight(Upper)/ 12 Back up light 22 27 37 Condenser fan motor 47
Stop light
7.5A Right 7.5A Sub starter Horn 15A 15A Compressor
3 Headlight(Lower)/ 13 Power take off 23 28 38 Wiper 48
Starter(relay)
7.5A Left 7.5A Exhaust brake 15A 15A Window washer
4 Headlight(Lower)/ 14 24 29 (Power outlet) 39 49
7.5A Right 15A Receptacle
5 Click Dome light 15 25 30 40 Cigarette lighter 50
Transfer low Turn signal
7.5A Back up 7.5A 15A 15A
6 16 4WD 31 41 12V Consent
7.5A 15A
7 Door lock 17 Transfer high 32 Power window(Right) 42
7.5A 7.5A 15A
8 Radio 18 33 Power window(Left) 43
Auto T/M ECU
7.5A Cassete stereo 7.5A 15A
9 Glow plug(Relay) 19 34 Auto T/M ECU 44
7.5A 15A
10 20 Engine ECU 35 45 Engine ECU
7.5A 15A
3-10
Checking the SERVICE ENGINE SOON lamp flashing control system
(SERVICE ENGINE SOON lamp does not flashing)
■ Circuit description
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
⋅ Faulty engine control unit
3-11
Checking the SERVICE ENGINE SOON lamp flashing control system
(SERVICE ENGINE SOON lamp does not flashing)
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.
7 Replace the Engine Control Unit. - Step 8 -
*After the Engine Control Unit is replaced, perform the accelerator
learning.
Did corrective action complete?
8 Restore the vehicle, and perform the repair check. - Check -
end
3-12
Checking the Tech II
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
DIAG. SW. 26 25 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
101 102 103 104 105 106 107 108 109 110
111 112 113 114 115 116 117 118 119 120
RL 0.5
1 LgB 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
G 0.5 (BLACK)
1 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
WR 0.5 WR 0.5
LR 0.5 LR 0.5
25
JOINT CONNECTOR(2)
13
26
4
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 1.25
B 1.25
13
ECU HARNESS
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
LR 0.5 (MT)
WR 0.5 (AT)
TECH II CONNECTOR
3-13
Checking the Tech II
■ Circuit description
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 engine control unit
⋅ Faulty Tech II connector power source
3-14
Checking the Tech II
3-15
Checking the Tech II
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
3-17
Checking the engine starting system
3-18
Checking the engine starting system
3-19
Checking the power supply circuit
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
2 4
B 0.5
3
BW 0.5
5
CONTROL UNIT POWER SUPPLY RW 1.25
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
VG 2 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL2
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
B2
R/L; STARTER
1 2
3-20
Checking the power supply circuit
■ Arrangement of fuses
CAUTION
USE FUSE WITH THE SPECIFIED CAPACITY.
Fuse box FUSE CAPACITIES OTHER THAN SPECIFIED MAY CAUSE
BREAKEDOWN OF THE SYSTEM.
1 Headlight(Upper)/ 11 21 26 Tail light Fog light 36 46
Meter Blower motor
7.5A Left 7.5A 15A illumination 15A
2 Headlight(Upper)/ 12 Back up light 22 27 37 Condenser fan motor 47
Stop light
7.5A Right 7.5A Sub starter Horn 15A 15A Compressor
3 Headlight(Lower)/ 13 Power take off 23 28 38 Wiper 48
Starter(relay)
7.5A Left 7.5A Exhaust brake 15A 15A Window washer
4 Headlight(Lower)/ 14 24 29 (Power outlet) 39 49
7.5A Right 15A Receptacle
5 Click Dome light 15 25 30 40 Cigarette lighter 50
Transfer low Turn signal
7.5A Back up 7.5A 15A 15A
6 16 4WD 31 41 12V Consent
7.5A 15A
7 Door lock 17 Transfer high 32 Power window(Right) 42
7.5A 7.5A 15A
8 Radio 18 33 Power window(Left) 43
Auto T/M ECU
7.5A Cassete stereo 7.5A 15A
9 Glow plug(Relay) 19 34 Auto T/M ECU 44
7.5A 15A
10 20 Engine ECU 35 45 Engine ECU
7.5A 15A
3-21
Checking the power supply circuit
■ Circuit description
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 starter switch
⋅ Faulty harnesses (disconnection, shortcircuit, etc.)
3-22
Checking the power supply circuit
3-23
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)
3-24 3-24
Checking the fuel system
3-25
Checking the intake system
■ Possible causes
⋅ Blocked air cleaner
⋅ Faulty intake piping (squeezed or damaged intake duct, piping, intercooler, etc.)
⋅ Faulty VGS turbo (operation failure, air cylinder does not return, etc.)
3-26
Checking the intake system
8-step type
3–0.2
6–0.2
9–0.4
Port 3 Port 2 Port 1 12–0.2
15–0.4
18–0.4
21–0.6 (Full stroke)
Port 1 X O X O X O X O
Port 2 X X O O X X O O
Port 3 X X X X O O O O
3-27
Checking the staring system
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
11 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BG 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 NEUTRAL SIGNAL
11 ECU HARNESS
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
BG 0.5
NEUTRAL SWITCH
SWP
1 2
(GRAY)
BG 0.5
STARTER HARNESS
3-28
Checking the staring system
■ Circuit description
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 (regardless of the type of transmission).
■ Possible causes
⋅ Faulty starter circuit (starter, starter relay, starter circuit, battery, etc.)
⋅ Faulty starter switch
⋅ Faulty neutral relay
⋅ Faulty control unit (automatic transmission vehicles)
⋅ Faulty neutral switch
3-29
Checking the staring system
3-30
Checking the staring system
3-31
Checking the exhaust system
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
18 18
CRUISE EXHAUST DRIVE OUTPUT SIGNAL
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LY 0.5
1 2 3 4
1
8
2
9
3
10
4
11
5
12 13 14
6 7 7 6
14 13 12
5 4
11
3
10
2
9
1
8 30
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
(WHITE)
FUSE 13 1
LY 0.5
29 30
33 34
31 32
35 36
32 31
36 35
30 29
34 33
2 3 4 37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
5 50 51 52 53 54 55 56 56 55 54 53 52 51 50
30 46
EXHAUST BRAKE RELAY
46
3
5 1
GND EXHAUST BRAKE
4 2
MAGNETIC VALVE
1 2
LY 0.5 BL 0.5
3-32
Checking the exhaust system
■ Circuit description
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 the brake integrated 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 integrated 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
3-33
Checking the exhaust system
3-34
Checking the exhaust system
Z type
connector (gray),
2 pins
Note: The resistance value varies depending on the temperature of the magnetic valve main unit.
3-35
Checking the parking switch
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YG 0.5
AIR LOW
PRESSURE SW
BUZZER:AIR (SIG)
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21 PARKING SW (SIG)
1 2 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LB 0.5 LB 0.5
FUSE 11
ECU HARNESS
1 2 3 4 5 6
18
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25 4 3 2 1
FUSE 12
37 38 39 40 40 39 38 37 9 8 7 6 5
41 42 43 44 SMJ 44 43 42 41
45 46 47 48
(WHITE) 48 47 46 45
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
6 5 4 3 2 1
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 12 13 14 14 13 12 11 10 9 8
11
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
TO CONNECT
2 1 (WHITE) 32 31 30 29
4 3 29 30 31 32
SW: 33 34 35 36 36 35 34 33
42 41 40 39 38 37
PARKING 37
43
38
44
39
45 46
40
47
41
48
42
49 49 48 47 46 45 44 43
50 51 52 54 55 56 56 55 54 53 52 51 50
53
YG 0.5
GND
BL 0.5
1 2
SWP 3 4
(GRAY)
1 2
BL 0.5
SWP
(GRAY)
1 2
BL 0.5
SWP
(GRAY)
1 2
FVM/Z BL 0.5
3-36
Checking the parking switch
■ Circuit description
The parking switch is installed in the vicinity of wheel park (frame (Ft) 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 (Ft) ground via the switch.
■ Possible causes
⋅ Faulty parking switch itself
⋅ Faulty parking switch circuit
⋅ Faulty meter itself
⋅ Faulty meter circuit
⋅ Faulty Engine Control Unit
3-37
Checking the parking switch
3-38
Checking the parking switch
3-39
Checking the parking switch
3-40
Idling speed cannot be adjusted
■ 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
3-41
Idling speed cannot be adjusted
UP
2 1
3
Connector
DOWN
060HY00486
3 3 3
2 2 2
1 1 1
3-42
Idling speed cannot be decreased
■ 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)
3-43
Idling speed cannot be decreased
3-44
Idling speed cannot be decreased
UP
2 1
3
Connector
DOWN
060HY00486
3 3 3
2 2 2
1 1 1
3-45
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.
After completion of inspections and repair, be sure to clear the memory in the DMU (data memory unit) and engine
control unit.
■ CMP sensor circuit (including CKP sensor and fuel pressure sensor circuit)
ENGINE CONTROL UNIT CONNECTOR 120 PIN
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-3
14 CMP sensor system trouble (2/5)
■ Circuit description
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.
■ 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.
■ 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.
4-4
14 CMP sensor system trouble (3/5)
4-5
14 CMP sensor system trouble (4/5)
4-6
14 CMP sensor system trouble (5/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
(-) (+)
1 2
Note: The resistance value varies depending on the temperature (engine warming condition).
4-7
15 CKP sensor system trouble (1/5)
■ CKP sensor circuit (including CMP sensor and fuel pressure sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-8
15 CKP sensor system trouble (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in CKP sensor (+) circuit
• Disconnection in CKP sensor (-) circuit
• Faulty sensor (faulty sensor inside or sensing block)
• Faulty sensor installation (gap, play)
• Faulty flywheel sensing hole (clogging, soil, scratch)
• 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
15 CKP sensor system trouble (3/5)
4-10
15 CKP sensor system trouble (4/5)
4-11
15 CKP sensor system trouble (5/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-12
22 Atmospheric temperature sensor system trouble (1/6)
■ Atmospheric temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit)
FUEL TEMP. RESISTER FUEL TEMP. RESISTER (SIG)
LB 0.5
1
LR 0.5
2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
WATER TEMP. SENSOR (SIG)
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 ATMOSPHERIC TEMP. SENSOR (SIG)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40 40 39 38 37
1
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
YV 0.5 WATER TEMP. (MAIN)
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
8 9 10 11 12 13 14
14 13 12 11 10 9 8
15 16 17 18 19 20
20 19 18 17 16 15 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
42
36 35 34 33 METER CONNECTOR
42 41 40 39 38 37
43 44 45 46 47 48 49
49 48 47 46 45 44 43
50 51 52 53 54 55 56
56 55 54 53 52 51 50
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5
4-13
22 Atmospheric temperature sensor system trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in atmospheric temperature sensor (SIG) circuit
• Disconnection in atmospheric temperature sensor (GND) circuit
• Faulty sensor (faulty sensor inside or sensing block)
• 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.
4-14
22 Atmospheric temperature sensor system trouble (3/6)
4-15
22 Atmospheric temperature sensor system trouble (4/6)
4-16
22 Atmospheric temperature sensor system trouble (5/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-17
22 Atmospheric temperature sensor system trouble (6/6)
1 SIG VR/0.5
2 GND YR/0.5
1 2
100
MFW31ASH002501
Resistance value(kΩ)
Temperature(°C)
Legend 1
1 Atmospheric temperature sensor
4-18
23 Water temperature sensor system trouble (1/6)
■ Water temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit).
FUEL TEMP. RESISTER FUEL TEMP. RESISTER (SIG)
LB 0.5
1
LR 0.5
2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
WATER TEMP. SENSOR (SIG)
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 ATMOSPHERIC TEMP. SENSOR (SIG)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40 40 39 38 37
1
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
YV 0.5 WATER TEMP. (MAIN)
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
8 9 10 11 12 13 14
14 13 12 11 10 9 8
15 16 17 18 19 20
20 19 18 17 16 15 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
42
36 35 34 33 METER CONNECTOR
42 41 40 39 38 37
43 44 45 46 47 48 49
49 48 47 46 45 44 43
50 51 52 53 54 55 56
56 55 54 53 52 51 50
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5
4-19
23 Water temperature sensor system trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in water temperature sensor (SIG) circuit
• Disconnection in water temperature sensor (GND) circuit
• Faulty sensor (faulty sensor inside or sensing block)
• 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.
4-20
23 Water temperature sensor system trouble (3/6)
4-21
23 Water temperature sensor system trouble (4/6)
4-22
23 Water temperature sensor system trouble (5/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-23
23 Water temperature sensor system trouble (6/6)
100
1
RV connector (blue),
3 pins
Resistance value(kΩ)
10
1
0.1
3 2 1 -50 0 50 100
060HY00017
Temperature(°C)
060MX157
1.25kΩ 40°C
1 ⇔ body ∞ - Between thermistor for IE and body
Note: Resistance value varies depending on the temperature of the temperature-sensitive portion.
4-24
24 Accelerator sensor system trouble (1/6)
GyG 0.5
40 PIN 80 PIN
L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 1.25 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
LO 0.5
Y 0.5
ECU HARNESS
1
8 7 6 5 4 3 2 1
2
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
ACCELERATOR SENSOR
4-25
24 Accelerator sensor system trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• 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 sensor (faulty sensor inside or sensing block)
• Faulty accelerator installation (disordered, loose)
• Faulty accelerator pedal (disordered, loose, faulty link, faulty spring)
• 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.
4-26
24 Accelerator sensor system trouble (3/6)
4-27
24 Accelerator sensor system trouble (4/6)
4-28
24 Accelerator sensor system trouble (5/6)
Note:Be sure to execute the accelerator learning after the Engine Control Unit or accelerator sensor was
repaired or replaced.
4-29
24 Accelerator sensor system trouble (6/6)
1 GND G/0.5
2 SIG Y/0.5
3 5V L/0.5
POWER GND
3 2 1
SIG
MFW36ESH000101
4-30
25 Vehicle speed sensor system trouble (1/7)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
31 32 33 34 35 36 37 38 39 40
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(FROM PULSE MATCHING DEVICE)
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
PL 0.5
ECU HARNESS
PL 0.5
Y 0.5
4 3 2 1
12 PIN
12 1110 9 8 7 6 5
W 0.5
B 0.5
1 2 3 4 5 6 7 7 6 5 4 3 2 1
21 22 23 24 24 23 22 21
43 44 45 46 47 48 49 46
49 48 47 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
4-31
25 Vehicle speed sensor system trouble (2/7)
■ Circuit description
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).
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Faulty vehicle speed sensor circuit (power supply, SIG, GND, pulse matching device)
• Faulty sensor (faulty sensor inside or sensing block)
• 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
• 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.
4-32
25 Vehicle speed sensor system trouble (3/7)
4-33
25 Vehicle speed sensor system trouble (4/7)
4-34
25 Vehicle speed sensor system trouble (5/7)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-35
25 Vehicle speed sensor system trouble (6/7)
■ External view, pin assignment and output voltage of vehicle speed sensor
< External view of vehicle speed sensor > < Pin assignment of accelerator sensor >
Pin No. Signal name Wire color / wire dia.
3 2 1
060HY00276
■ 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
060H1000120
4-37
32 Boost sensor system trouble (1/6)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
W 0.5
B 0.5
R 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK
ECU HARNESS
1 2 3
(BLACK)
W 0.5
B 0.5
R 0.5
ENGINE HARNESS
4-38
32 Boost sensor system trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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)".
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in boost sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor inside or sensing block)
• Faulty sensor installation condition (loose)
• Faulty intake system (intercooler, intake pipe, air cleaner, etc.)
• Internal trouble of Engine Control Unit
■ 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.
4-39
32 Boost sensor system trouble (3/6)
4-40
32 Boost sensor system trouble (4/6)
4-41
32 Boost sensor system trouble (5/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-42
32 Boost sensor system trouble (6/6)
1 SIG R/0.5
2 GND B/0.5
3 5V W/0.5
3 1 2
POWER SIG GND
2.5
0.5
66.7 200 333.3(kPa)
LFW36ESH001201
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
4-43
33 CPU monitoring IC trouble (1/2)
■ Diagnostic conditions
In the event of CPU monitoring IC trouble, the Engine Control Unit judges as "CPU monitoring IC trouble"
and displays "diagnostic trouble code: 33".
■ Possible cause
• Internal trouble of EngineControl Unit
4-44
32 CPU monitoring IC trouble (2/2)
4-45
35 A/D conversion error/charger circuit trouble (1/2)
■ Diagnostic conditions
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.
■ Possible causes
• Internal trouble of engine control unit
• Faulty injector system circuit
4-46
35 A/D conversion error/charger circuit trouble (2/2)
4-47
42 High boost trouble (1/6)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
W 0.5
B 0.5
R 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK
ECU HARNESS
1 2 3
(BLACK)
W 0.5
B 0.5
R 0.5
ENGINE HARNESS
4-48
42 High boost trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in boost sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty sensor installation (loose)
• Faulty intake system (intercooler, intake pipe, air cleaner, etc.)
• Faulty turbocharger (main body, VGS (air cylinder, magnetic valve, air piping, shaft, etc.))
• Faulty exhaust brake (main body, control air cylinder, etc.)
• Internal trouble of Engine Control Unit
■ 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.
4-49
42 High boost trouble (3/6)
4-50
42 High boost trouble (4/6)
4-51
42 High boost trouble (5/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-52
42 High boost trouble (6/6)
1 SIG W/0.5
2 GND B/0.5
3 +5V R/0.5
2.5
Connector
0.5
66.7 200 333.3(kPa)
LFW36ESH001201
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.
4-53
65 Low boost trouble (1/6)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
W 0.5
B 0.5
R 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK
ECU HARNESS
1 2 3
(BLACK)
W 0.5
B 0.5
R 0.5
ENGINE HARNESS
4-54
65 Low boost trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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%.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in boost sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty sensor installation (loose)
• Faulty intake system (intercooler, intake pipe, air cleaner, etc.)
• Faulty turbocharger (main body, VGS (air cylinder, magnetic valve, air piping, shaft, etc.))
• Faulty exhaust brake (main body, control air cylinder, etc.)
• Internal trouble of Engine Control Unit
■ 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.
4-55
65 Low boost trouble (3/6)
4-56
65 Low boost trouble (4/6)
4-57
65 Low boost trouble (5/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-58
65 Low boost trouble (6/6)
1 SIG W/0.5
2 GND B/0.5
3 +5V R/0.5
Connector 2.5
0.5
66.7 200 333.3(kPa)
LFW36ESH001201
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
4-59
71 Atmospheric pressure sensor trouble (1/2)
060MX113
■ Circuit description
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.
■ Diagnostic conditions
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.
4-60
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.
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-61
115 Fuel pressure sensor output fixed (1/5)
■ Fuel pressure sensor circuit (including CKP sensor and CMP sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-62
115 Fuel pressure sensor output fixed (2/5)
■ Circuit description
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
Engine Control Unit.
The sensor circuit is shielded to protect from electrical noise.
■ Diagnostic conditions
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".
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector)
• 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.
4-63
115 Fuel pressure sensor output fixed (3/5)
4-64
115 Fuel pressure sensor output fixed (4/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-65
115 Fuel pressure sensor output fixed (5/5)
■ External view, pin assignment, and output voltage of fuel pressure sensor
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
Pin No. Signal name Wire color / wire dia.
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
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)
4-66
118 Common-rail pressure trouble (1/7)
■ Fuel pressure sensor circuit (including CKP sensor and CMP sensor circuit)
ENGINE CONTROL UNIT CONNECTOR 120 PIN
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-67
118 Common-rail pressure trouble (2/7)
■ Circuit description
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
Engine Control Unit.
The sensor circuit is shielded to protect from electrical noise.
■ Diagnostic conditions
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
• Loose connection of connectors
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND)
• Faulty sensor (faulty sensor internal circuit, detector)
• Faulty sensor installation (loose)
• 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)
• Internal trouble of Engine Control Unit
4-68
118 Common-rail pressure trouble (3/7)
■ 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.
4-69
118 Common-rail pressure trouble (4/7)
4-70
118 Common-rail pressure trouble (5/7)
4-71
118 Common-rail pressure trouble (6/7)
4-72
118 Common-rail pressure trouble (7/7)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
■ External view, pin assignment, and output voltage of fuel pressure sensor
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
Pin No. Signal name Wire color / wire dia.
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
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)
4-73
151 Common rail pressure trouble (pump excessive pressure feed) (1/7)
■ Fuel pressure sensor circuit (including CKP sensor and CMP sensor circuit)
ENGINE CONTROL UNIT CONNECTOR 120 PIN
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-74
151 Common rail pressure trouble (pump excessive pressure feed) (2/7)
■ Circuit description
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
Engine Control Unit.
The sensor circuit is shielded to protect from electrical noise.
■ Diagnostic conditions
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
• Loose connection of connectors
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector)
• Faulty sensor installation (loose)
• 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)
• Internal trouble of Engine Control Unit
4-75
151 Common rail pressure trouble (pump excessive pressure feed) (3/7)
■ 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.
4-76
151 Common rail pressure trouble (pump excessive pressure feed) (4//7)
4-77
151 Common rail pressure trouble (pump excessive pressure feed) (5/7)
4-78
151 Common rail pressure trouble (pump excessive pressure feed) (6/7)
4-79
151 Common rail pressure trouble (pump excessive pressure feed) (7/7)
■ External view, pin assignment, and output voltage of fuel pressure sensor
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
Pin No. Signal name Wire color / wire dia.
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
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)
4-80
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (1/5)
■ Injector circuit
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-81
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in injector (power side) circuit
• Disconnection or shortcircuit in injector (driving side) circuit
• Faulty TWV (faulty shortcircuit of internal coil)
• 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.
4-82
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (3/5)
4-83
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (4/5)
4-84
158 Injector power system trouble (Common 1 "Injector 1, 3, 5 systems") (5/5)
6SD1-TC
6SD1
4-85
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 systems") (1/5)
■ Injector circuit
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-86
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 systems") (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Warning during diagnosis (SERVICE ENGINE SOON lamp ON)
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
• Loose connection of connectors
• Disconnection or shortcircuit in injector (power side) circuit
• Disconnection or shortcircuit in injector (driving side) circuit
• Faulty TWV (faulty shortcircuit of internal coil)
• 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.
4-87
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 systems") (3/5)
4-88
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 systems") (4/5)
4-89
159 Injector power system trouble (Common 2 "Injector 2, 4, 6 systems") (5/5)
6SD1
6SD1-TC
4-90
211 Fuel temperature sensor trouble (1/4)
■ Fuel temperature sensor circuit (including water temperature sensor and atmospheric
temperature sensor circuits)
FUEL TEMP. RESISTER FUEL TEMP. RESISTER (SIG)
LB 0.5
1
LR 0.5
2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
WATER TEMP. SENSOR (SIG)
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 ATMOSPHERIC TEMP. SENSOR (SIG)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40 40 39 38 37
1
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
YV 0.5 WATER TEMP. (MAIN)
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
8 9 10 11 12 13 14
14 13 12 11 10 9 8
15 16 17 18 19 20
20 19 18 17 16 15 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
42
36 35 34 33 METER CONNECTOR
42 41 40 39 38 37
43 44 45 46 47 48 49
49 48 47 46 45 44 43
50 51 52 53 54 55 56
56 55 54 53 52 51 50
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5
■ Circuit description
The fuel temperature resister detects the fuel temperature. The voltage is applied to the fuel temperature
resister provided on the fuel leak pipe, 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 fuel temperature resister trouble, the Engine Control Unit performs the control with the backup
values. Also, the resister circuit GND is used in common to respective temperature resister.
■ Diagnostic conditions
The control unit judges as "fuel temperature resister system trouble" and displays "diagnostic trouble code:
211", when the voltage applied to the fuel temperature resister exceeds 4.8V or when the state below 0.1V
continues for more than one second.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in fuel temperature resister circuit
• Disconnection in fuel temperature resister circuit
• Faulty sensor (faulty sensor internal circuit, detector)
• 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.
4-92
211 Fuel temperature sensor trouble (3/4)
4-93
211 Fuel temperature sensor trouble (4/4)
■ External view, pin assignment and resistance value of fuel pressure sensor
< External view of fuel temperature sensor > <Name of terminals of fuel temperature sensor >
Pin No. Signal name Wire color / wire dia.
1 GND LB/0.5
1
2 SIG LR/0.5
4-94
217 PCV1 system short circuit (battery and power supply circuit) trouble (1/4)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
KEY SW [ON] SIG
Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
SWP
12 11 10 9 9 10 11 12
PCV2 (SIG)
1 2 1 2
16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12
(GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 2 G 1.25 G 1.25
1 2 3 4
FUSE 20
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
VW 0.5
FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B 8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
ACG E TERMINAL
BL
4-95
217 PCV1 system short circuit (battery and power supply circuit) trouble (2/4)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Shortcircuit in PCV circuit
• Faulty PCV (faulty internal shortcircuit)
• 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.
4-96
217 PCV1 system short circuit (battery and power supply circuit) trouble (3/4)
4-97
217 PCV1 system short circuit (battery and power supply circuit) trouble (4/4)
<External view of PCV> Because the PCV, pins are not identified.
<Arrangement of PCV>
PCV1
PCV2
4-98
218 PCV2 system short circuit (battery and power supply circuit) trouble (1/4)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
KEY SW [ON] SIG
Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
SWP
12 11 10 9 9 10 11 12
PCV2 (SIG)
1 2 1 2
16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12
(GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 2 G 1.25 G 1.25
1 2 3 4
FUSE 20
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
VW 0.5
FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B 8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
ACG E TERMINAL
BL
4-99
218 PCV2 system short circuit (battery and power supply circuit) trouble (2/4)
■ Circuit description
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.
■ Diagnostic conditions
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
• Loose connection of connectors
• Shortcircuit in PCV circuit
• Faulty PCV (faulty internal shortcircuit)
• 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.
4-100
218 PCV2 system short circuit (battery and power supply circuit) trouble (3/4)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-101
218 PCV2 system short circuit (battery and power supply circuit) trouble (4/4)
<External view of PCV> Because the PCV, pins are not identified.
<Arrangement of PCV>
PCV1
PCV2
4-102
226 Supply pump no pressure feed or pressure limiter operated (1/5)
Fuel filter
Flow
Fuel pressure sensor damper
Feed pump
Pre-filter
4-103
226 Supply pump no pressure feed or pressure limiter operated (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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)
■ 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.
4-104
226 Supply pump no pressure feed or pressure limiter operated (3/5)
4-105
226 Supply pump no pressure feed or pressure limiter operated (4/5)
4-106
226 Supply pump no pressure feed or pressure limiter operated (5/5)
4-107
227 Pump no pressure feed (Fuel outflow) (1/5)
Fuel filter
Flow
Fuel pressure sensor damper
Feed pump
Pre-filter
4-108
227 Pump no pressure feed (Fuel outflow) (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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)
■ 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".
4-109
227 Pump no pressure feed (Fuel outflow) (3/5)
4-110
227 Pump no pressure feed (Fuel outflow) (4/5)
4-111
227 Pump no pressure feed (Fuel outflow) (5/5)
4-112
241 Accelerator switch off trouble (1/5)
GyG 0.5
40 PIN 80 PIN
L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 1.25 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
LO 0.5
Y 0.5
ECU HARNESS
1
8 7 6 5 4 3 2 1
2
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
ACCELERATOR SENSOR
4-113
241 Accelerator switch off trouble (2/5)
■ Circuit description
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
repaired or replaced.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• 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 pedal (disordered, loose, faulty link, faulty spring)
• Faulty accelerator sensor
• 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.
4-114
241 Accelerator switch off trouble (3/5)
4-115
241 Accelerator switch off trouble (4/5)
Note: The accelerator learning must be executed after the Engine Control Unit or accelerator switch was
repaired or replaced.
4-116
241 Accelerator switch off trouble (5/5)
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
101HY00002
4-117
242 Accelerator switch on trouble (1/5)
GyG 0.5
40 PIN 80 PIN
L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 1.25 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
LO 0.5
Y 0.5
ECU HARNESS
1
8 7 6 5 4 3 2 1
2
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
ACCELERATOR SENSOR
4-118
242 Accelerator switch on trouble (2/5)
■ Circuit description
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
repaired or replaced.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• 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 pedal (disordered, loose, faulty link, faulty spring)
• Faulty accelerator sensor
• 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.
4-119
242 Accelerator switch on trouble (3/5)
4-120
242 Accelerator switch on trouble (4/5)
4-121
242 Accelerator switch on trouble (5/5)
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
101HY00002
4-122
245 Fuel pressure sensor trouble (1/5)
■ Fuel pressure sensor (including CKP sensor and CMP sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3
FUEL PRESSURE SENSOR (GND)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 5
6 7 8 SWP 8 7 6
9 10 11 12 12 11 10 9 B 0.5
(GRAY)
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
6 5 7 8
8 7 SWP 5 6
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
CMP SENSOR
R 0.5
1 2
P 0.5
CMP SENSOR (Ð)
L 0.5
ECU HARNESS
4-123
245 Fuel pressure sensor trouble (2/5)
■ Circuit description
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
Engine Control Unit.
The sensor circuit is shielded to protect from electrical noise.
■ Vehicle behaviors
• SERVICE ENGINE SOON lamp turns on (continuous ON)
• White smoke/black smoke
• Rough idling
• Poor starting performance
• Varying revolutions (hunting)
• Lack of output power
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND) circuit
• Faulty sensor (faulty sensor internal circuit, detector)
• 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.
4-124
245 Fuel pressure sensor trouble (3/5)
4-125
245 Fuel pressure sensor trouble (4/5)
4-126
245 Fuel pressure sensor trouble (5/5)
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
Pin No. Signal name Wire color / wire dia.
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
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)
4-127
247 PCV1 system harness, short (GND circuit) trouble (1/6)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
KEY SW [ON] SIG
Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
SWP
12 11 10 9 9 10 11 12
PCV2 (SIG)
1 2 1 2
16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12
(GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 2 G 1.25 G 1.25
1 2 3 4
FUSE 20
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
VW 0.5
FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B 8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
ACG E TERMINAL
BL
4-128
247 PCV1 system harness, short (GND circuit) trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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
• Loose connection of connectors
• Shortcircuit in PCV circuit
• Faulty PCV (faulty internal shortcircuit)
• Faulty PCV relay
• 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.
4-129
247 PCV1 system harness, short (GND circuit) trouble (3/6)
4-130
247 PCV1 system harness, short (GND circuit) trouble (4/6)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
<External view of PCV> Because the PCV, pins are not identified.
4-131
247 PCV1 system harness, short (GND circuit) trouble (5/6)
PCV1
PCV2
4-132
247 PCV1 system harness, short (GND circuit) trouble (6/6)
5 1
4 2
4
3
2
5
* ISO relay 060HY00472
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
KEY SW [ON] SIG
Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
SWP
12 11 10 9 9 10 11 12
PCV2 (SIG)
1 2 1 2
16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12
(GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 2 G 1.25 G 1.25
1 2 3 4
FUSE 20
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
VW 0.5
FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B 8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
ACG E TERMINAL
BL
4-134
248 PCV2 system harness, short (GND circuit) trouble (2/6)
■ Circuit description
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.
■ Diagnostic conditions
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
• Loose connection of connectors
• Shortcircuit in PCV circuit
• Faulty PCV (faulty internal shortcircuit)
• Faulty PCV relay
• 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.
4-135
248 PCV2 system harness, short (GND circuit) trouble (3/6)
4-136
248 PCV2 system harness, short (GND circuit) trouble (4/6)
<External view of PCV> Because the PCV, pins are not identified.
4-137
248 PCV2 system harness, short (GND circuit) trouble (5/6)
PCV1
PCV2
4-138
248 PCV2 system harness, short (GND circuit) trouble (6/6)
5 1
4 2
4
3
2
5
* ISO relay 060HY00472
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-140
271 No.1 cylinder No.1 injector drive system trouble (2/5)
■ Circuit description
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 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.
■ Diagnostic conditions
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
• Loose connection of connectors
• 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)
• 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.
4-141
271 No.1 cylinder No.1 injector drive system trouble (3/5)
4-142
271 No.1 cylinder No.1 injector drive system trouble (4/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-143
271 No.1 cylinder No.1 injector drive system trouble (5/5)
6SD1-TC
6SD1
4-144
272 No.2 cylinder No.5 injector drive system trouble (1/5)
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-145
272 No.2 cylinder No.5 injector drive system trouble (2/5)
■ Circuit description
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 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.
■ Diagnostic conditions
The control unit judges as "No.2 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 272" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.
■ Possible causes
• Loose connection of connectors
• 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)
• 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.
4-146
272 No.2 cylinder No.5 injector drive system trouble (3/5)
4-147
272 No.2 cylinder No.5 injector drive system trouble (4/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-148
272 No.2 cylinder No.5 injector drive system trouble (5/5)
6SD1-TC
6SD1
4-149
273 No.3 cylinder No.3 injector drive system trouble (1/5)
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-150
273 No.3 cylinder No.3 injector drive system trouble (2/5)
■ Circuit description
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 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.
■ Diagnostic conditions
The control unit judges as "No.3 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 273" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.
■ Possible causes
• Loose connection of connectors
• 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)
• 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.
4-151
273 No.3 cylinder No.3 injector drive system trouble (3/5)
4-152
273 No.3 cylinder No.3 injector drive system trouble (4/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-153
273 No.3 cylinder No.3 injector drive system trouble (5/5)
6SD1-TC
6SD1
4-154
274 No.4 cylinder No.6 injector drive system trouble (1/5)
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-155
274 No.4 cylinder No.6 injector drive system trouble (2/5)
■ Circuit description
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 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.
■ Diagnostic conditions
The control unit judges as "No.4 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 274" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.
■ Possible causes
• Loose connection of connectors
• 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)
• 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.
4-156
274 No.4 cylinder No.6 injector drive system trouble (3/5)
4-157
274 No.4 cylinder No.6 injector drive system trouble (4/5)
4-158
274 No.4 cylinder No.6 injector drive system trouble (5/5)
6SD1-TC
6SD1
4-159
275 No.5 cylinder No.2 injector drive system trouble (1/4)
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-160
275 No.5 cylinder No.2 injector drive system trouble (2/4)
■ Circuit description
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 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.
■ Diagnostic conditions
The control unit judges as "No.5 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 275" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.
■ Possible causes
• Loose connection of connectors
• 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)
• 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.
4-161
275 No.5 cylinder No.2 injector drive system trouble (3/4)
4-162
275 No.5 cylinder No.2 injector drive system trouble (4/4)
4-163
276 No.6 cylinder No.4 injector drive system trouble (1/4)
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7
12 11 10 9
6 5
SWP 5 6 7
9 10 11 12
8 B 0.5
16 15 14 13 (GRAY) 13 14 15 16
B 0.5 B 0.5
G 0.85
B 0.5
R 0.85
INJECTOR NO. 5 W 0.85
1 2 B 0.85
(CYLINDER #2) L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-164
276 No.6 cylinder No.4 injector drive system trouble (2/4)
■ Circuit description
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 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.
■ Diagnostic conditions
The control unit judges as "No.6 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 276" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.
■ Possible causes
• Loose connection of connectors
• 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)
• 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.
4-165
276 No.6 cylinder No.4 injector drive system trouble (3/4)
4-166
276 No.6 cylinder No.4 injector drive system trouble (4/4)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-167
411 Magnetic valve "A" drive system trouble (1/7)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Sb 0.5
PL 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
4-168
411 Magnetic valve "A" drive system trouble (2/7)
■ Circuit description
The magnetic valve "A" is used to supply air to the air cylinder for VGS. By controlling the air supply to the
air cylinder, the air cylinder for VGS is controlled properly.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays VGS, 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.
■ Diagnostic conditions
• When magnetic valve "A" is not driven
The control unit judges as "magnetic valve "A" drive system trouble" and displays "diagnostic trouble
code: 411" when the state where the operating voltage from magnetic valve "A" is faulty (no power
supply or low potential) continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "A" is driven
The control unit judges as "magnetic valve "A" drive system trouble" and displays "diagnostic trouble
code: 411" when the state where the operating voltage from magnetic valve "A" is faulty (high potential)
continues for 1.2 seconds. (Power supply short, engine control unit GND disconnection, etc.)
■ Possible causes
• Loose connection of connectors
• 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 (VSG, M/V relay)
• 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.
4-169
411 Magnetic valve "A" drive system trouble (3/7)
4-170
411 Magnetic valve "A" drive system trouble (4/7)
4-171
411 Magnetic valve "A" drive system trouble (5/7)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-172
411 Magnetic valve "A" drive system trouble (6/7)
2 1
Z type connector
(gray) 2 pins
060HY00469
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
4-173
411 Magnetic valve "A" drive system trouble (7/7)
■ 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
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-174
412 Magnetic valve "B" drive system trouble (1/7)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Sb 0.5
PL 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
4-175
412 Magnetic valve "B" drive system trouble (2/7)
■ Circuit description
The magnetic valve "B" is used to supply air to the air cylinder for VGS. By controlling the air supply to the
air cylinder, the air cylinder for VGS is controlled properly.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (VGS, 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.
■ Diagnostic conditions
• When magnetic valve "B" is not driven
The control unit judges as "magnetic valve "B" drive system trouble" and displays "diagnostic trouble
code: 412" when the state where the operating voltage from magnetic valve "B" is faulty (low potential)
continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "B" is driven
The control unit judges as "magnetic valve "B" drive system trouble" and displays "diagnostic trouble
code: 412" when the state where the operating voltage from magnetic valve "B" is faulty (no power
supply or high potential) continues for 1.2 seconds. (Power supply short, engine control unit GND
disconnection, etc.)
■ Possible causes
• Loose connection of connectors
• 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 (VGS, M/V relay)
• 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.
4-176
412 Magnetic valve "B" drive system trouble (3/7)
4-177
412 Magnetic valve "B" drive system trouble (4/7)
4-178
412 Magnetic valve "B" drive system trouble (5/7)
4-179
412 Magnetic valve "B" drive system trouble (6/7)
2 1
Z type connector
(gray) 2 pins
060HY00469
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
4-180
412 Magnetic valve "B" drive system trouble (7/7)
■ 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
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-181
415 Magnetic valve "C" drive system trouble (1/7)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Sb 0.5
PL 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
4-182
415 Magnetic valve "C" drive system trouble (2/7)
■ Circuit description
The magnetic valve "C" is used to supply air to the air cylinder for VGS. By controlling the air supply to the
air cylinder, the air cylinder for VGS is controlled properly.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (VGS, 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.
■ Diagnostic conditions
• When magnetic valve "C" is not driven
The control unit judges as "magnetic valve "C" drive system trouble" and displays "diagnostic trouble
code: 415" when the state where the operating voltage from magnetic valve "C" is faulty (no power
supply or low potential) continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "C" is driven
The control unit judges as "magnetic valve "C" drive system trouble" and displays "diagnostic trouble
code: 415" when the state where the operating voltage from magnetic valve "C" is faulty (high
potential)continues for 1.2 seconds. (Power supply short, engine control unit GND disconnection, etc.)
■ Possible causes
• Loose connection of connectors
• 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 (VGS, M/V relay)
• 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.
4-183
415 Magnetic valve "C" drive system trouble (3/7)
4-184
415 Magnetic valve "C" drive system trouble (4/7)
4-185
415 Magnetic valve "C" drive system trouble (5/7)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-186
415 Magnetic valve "C" drive system trouble (6/7)
2 1
Z type connector
(gray) 2 pins
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
4-187
415 Magnetic valve "C" drive system trouble (7/7)
■ 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
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-188
416 Main relay system trouble (1/5)
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
VW 1.25
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
2 4
B2
3
Y 0.5
FUSE 45
VG 2
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
25 26 27 28 DIAG. CONNECTOR
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
4-189
416 Main relay system trouble (2/5)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Disconnection or shortcircuit in main relay circuit
• Faulty main relay
• 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.
4-190
416 Main relay system trouble (3/5)
4-191
416 Main relay system trouble (4/5)
1
3
5 1
4 2
4
3 Pin No. Signal name
2
1 Relay contact point (normal open): secondary side
5
2 Relay coil: secondary side
* ISO relay
3 Relay contact point (normal close): secondary side
4 Relay coil: primary side
<Pin assignment of main relay > 5 Relay contact point: primary side
2 3 4
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-192
416 Main relay system trouble (5/5)
4-193
417 Starter switch trouble (1/5)
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
2 4
B 0.5
3
BW 0.5
5
CONTROL UNIT POWER SUPPLY RW 1.25
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
VG 2 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL2
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
B2
R/L; STARTER
1 2
4-194
417 Starter switch trouble (2/5)
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
VW 1.25
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
2 4
B2
3
Y 0.5
FUSE 45
VG 2
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
25 26 27 28 DIAG. CONNECTOR
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
4-195
417 Starter switch trouble (3/5)
■ Circuit description
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.
■ Diagnostic conditions
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.
■ Possible causes
• Loose connection of connectors
• Shortcircuit in starter switch circuit
• Faulty switch
• Faulty internalswitch
• 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.
4-196
417 Starter switch trouble (4/5)
4-197
417 Starter switch trouble (5/5)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-198
418 Fail-safe (Magnetic valve cut) relay "A" system trouble (1/4)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Sb 0.5
PL 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
4-199
418 Fail-safe (Magnetic valve cut) relay "A" system trouble (2/4)
■ Circuit description
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (VGS, 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.
■ Diagnostic conditions
• Fail-safe relay "A" (Disconnection, GND short) (when the relay does not operate)
The control unit judges as "fail-safe relay "A" system trouble" and displays "diagnostic trouble code:
418" when the state where the operating voltage from fail-safe relay "A" is faulty (no power supply or
low potential) continues for one second.
• Fail-safe relay "A" (Power supply short) (when the relay operates)
The control unit judges as "fail-safe relay "A" system trouble" and displays " diagfrom fail-safe relay
"A" is faulty (high potential) continues for one second.
■ Possible causes
• Loose connection of connectors
• Fail-safe relay circuit
• Faulty fail-safe relay itself (disconnection of internal coil, etc.)
• 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.
4-200
418 Fail-safe (Magnetic valve cut) relay "A" system trouble (3/4)
4-201
418 Fail-safe (Magnetic valve cut) relay "A" system trouble (4/4)
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-202
421 PCV relay system trouble (1/5)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
1
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
19 20
FUSE 45 20
18 17 16 15 14 13 12 11 10 9
19
(WHITE) 9 10 11 12 13 14 15 16 17 18
B2 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
BL
ACG E TERMINAL
4-203
421 PCV relay system trouble (2/5)
■ Circuit description
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.
■ Diagnostic conditions
The control unit judges as "PCV relay 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
• Loose connection of connectors
• Disconnection and shortcircuit in PCV circuit
• Faulty PCV relay
• Faulty PCV (faulty internal circuit)
• 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.
4-204
421 PCV relay system trouble (3/5)
4-205
421 PCV relay system trouble (4/5)
<External view of PCV relay > <Circuit of fail PCV relay >
1
3
5 1
4 2
4
3 Pin No. Signal name
2
5 1 Relay contact point (normal open): secondary side
* Micro ISO relay 2 Relay coil: primary side
3 Relay contact point (normal close) : secondary side
4 Relay coil: secondary side
<Pin assignment of PCV relay > 5 Relay contact point: primary side
2 3 4
R/L R/L
A B
HEAD (LOW) STOP LAMP
R/L
R/L R/L
P/L
FAN WASHER
CHECK
4-206
421 PCV relay system trouble (5/5)
4-207
518 EOL data error (1/2)
■ Diagnostic conditions
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.
■ 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.
4-208
518 EOL data error (2/2)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
4-209
543 Excessive high revolution error (1/2)
■ Diagnostic conditions
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
■ Possible causes
• Transmission shifting failure by driver
• Misoperation at downhill
• 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.
4-210
543 Excessive high revolution error (2/2)
4-211
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.
After completion of check and repair, be sure to clear the memory in the DMU (data memory unit) and engine
control unit.
■ 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 shutter, 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
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.
5-2
Engine stall (2/3)
5-3
Engine stall (3/3)
5-4
Engine hunting, rough idle (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 switch (reverse, neutral) input circuit system (switches, harnesses, etc.)
• Faulty sensor (NE, G, 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.)
• Chassis related troubles (clutch, transmission, brake, etc.)
• Influence of retrofit electrical parts (radio equipment, lamps, etc.)
• System backup due to troubles (fail-safe)
• Engine Control Unit troubles (main body, power supply, GND, etc.)
■ 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.
5-5
Engine hunting, rough idle (2/3)
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.
Did corrective actions complete?
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
3. Turn the starter switch on.
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
over by the switch operation.
Is the ON/OFF indication changed by switch operation?
10 Referring to the reverse switch circuit (Chapter 6 Wiring check - Step 11 -
"reverse circuit"), repair or replace the circuit.
Did corrective actions complete?
11 Check the neutral switch input circuit. ON ↔ OFF indication on Step 13 Step 12
1. Connect the Tech II. the screen is changed over
2. Shift the gear to the neutral position. by switch operation
3. Turn the starter switch on.
4. Using the Tech II, check the switch inputs.
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.
Is the ON/OFF indication changed by switch operation?
12 Referring to the neutral switch circuit (Section 6 Wiring check - Step 13 -
"neutral circuit"), repair or replace the circuit.
Did corrective actions complete?
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 -
Did corrective actions complete?
15 Check the CKP sensor for signal detection. - Step 23 Step 16
1. Start the engine.
2. Disconnect the harness from the CKP sensor.
Has the engine hunting trouble been fixed?
(For this work, the diagnostic trouble code is detected, and thus be
sure to clear the trouble code after restoring the vehicle.)
5-6
Engine hunting, rough idle (3/3)
5-7
Lack output power of engine, insufficient blow up,
pulsating combustion (1/4)
■ 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 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.)
• System backup due to troubles (fail-safe)
• Chassis related troubles (clutch, transmission, brake, etc.)
• Influence of retrofit electrical parts (radio equipment, lamps, etc.)
• System backup due to troubles (fail-safe)
• Switch (exhaust brake) faulty input circuit system (switch, harness)
■ 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.
5-8
Lack output power of engine, insufficient blow up, pulsating combustion (2/4)
5-9
Lack output power of engine, insufficient blow up, pulsating combustion (3/4)
5-10
Lack output power of engine, insufficient blow up, pulsating combustion (4/4)
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, fuel temperature resister, atmospheric temperature sensor, or boost sensor
• Faulty air breather pipe (clogging)
• Engine troubles (low compression pressure, pistons, turbocharger, oil coming up or down, etc.)
• Engine Control Unit troubles (main body, power supply, GND, etc.)
■ 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.
5-12
White smoke (2/3)
5-13
White smoke (3/3)
5-14
Black smoke (1/2)
■ Possible causes
• Fuel quality (use of other than standard product)
• Faulty intake system (clogged filters, faulty intake piping, etc.)
• 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
• Engine Control Unit troubles (main body, power supply, GND, etc.)
■ 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.
5-15
Black smoke (2/2)
5-16
Chapter 6
Wiring check
Chapter 6 Wiring check
1. Preface
■ Identification of wires
Since wires of a large number of circuits are bound in a wiring harness, circuits are identified by colors and
patterns of the wires to facilitate correct wiring. The alphabet in the table below indicates abbreviations of
the identification and used also in the wiring diagram.
Refer to the table below for the abbreviations indicating wire colors.
Symbol B W R G Lg Y L O Br Sb P V Gy
Color of Black White Red green Light Yellow Blue Orange Brown Light Pink Violet Gray
wire green blue
Black, the base cover, is used for the earth circuit. e.g.: 3BW
B base color
W trace color
3 sizes
■ Wiring specifications
Wiring size is respectively determined according to the load to be applied to it. Size and allowable load
stipulated by the JIS standard are shown in the table below. When installing optional parts or units, select
wiring size based on the load. Never connect a power source or GND of different units to the IE system or
other electric systems.
6-2
Preface
■ Fuse
A fuse is usually installed in series to the automobile circuit to be protected.
It is designed so that, if over-current flows to the circuit due to short-circuit or some other reason, the fuse
melts to shut off the current in the circuit and protect the units in the circuit. Before replacing the fuse, be
sure to find out the cause of the fuse blown out and use a fuse of the same amperage as the former one.
If a fuse of different amperage is used, fire or other significant troubles may result.
15 15
Capacity (A) Color of housing
7.5 Transparent brown
10 Transparent red
15 Transparent blue
20 Transparent yellow
■ Relay
Battery, electrical parts and their control switches are usually forced to be positioned separately at a certain
distance. For this reason, long wires are required and voltage drop takes place (example 1 in the figure
below). Using a relay between the battery and electric load, the voltage drop can be avoided (example 2 in
the figure below). The switch controls the relay only so that the current through the switch can be reduced
and the switch can be more compact.
Load Load
Relay
1
2
6-3
Preface
NG
6-4
Preface
Lead rod
Lead rod
Lead rod
6-5
Preface
Terminal
Connector housing Harness
opening
Pin
Connector housing
opening
Pin
6-6
Preface
OK
When checking the continuity using a circuit tester, be sure
to apply the lead rod of the circuit tester from the harness
side (in case of a female pin only).
15
D08HW074
D08RV704
6-7
; ;
Preface
NG
OK
6-8
Preface
NG
OK
6-9
2. Vehicle wiring harness
● Vehicle equipped
Instrument (upper)
harness
Instrument(lower)
harness Member
harness
To engine
Frame harness
Connector box
ECU harness
Engine control unit
Note: Wires are connected with the sensors, switches or control units through multiple harnesses. Refer
to "Collection of GIGA wiring diagrams" for details.
6-10
3. Wiring check
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
VW 1.25
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
2 4
B2
3
Y 0.5
FUSE 45
VG 2
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
25 26 27 28 DIAG. CONNECTOR
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
6-11
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
Y 0.5 W 0.5
Br 0.5 B 0.5
(WHITE) B 0.5 Gy 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
1 2
ECU HARNESS
6-12
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
W 0.5
B 0.5
R 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
BOOST SENSOR
EJ MARK ECU HARNESS
123
(BLACK)
W 0.5
B 0.5
R 0.5
ENGINE HARNESS
6-13
Wiring check
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
Y 0.5
LO 0.5
ECU HARNESS
1
2 8 7 6 5 4 3 2 1
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
ACCELERATOR SENSOR
6-14
Wiring check
LB 0.5
1
LR 0.5
2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 YB 0.5 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
LW 0.5
LB 0.5
WATER TEMP. SENSOR (SIG)
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 ATMOSPHERIC TEMP. SENSOR (SIG)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40 40 39 38 37
1
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
YV 0.5 WATER TEMP. (MAIN)
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
8 9 10 11 12 13 14
14 13 12 11 10 9 8
15 16 17 18 19 20
20 19 18 17 16 15 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
42
36 35 34 33 METER CONNECTOR
42 41 40 39 38 37
43 44 45 46 47 48 49
49 48 47 46 45 44 43
50 51 52 53 54 55 56
56 55 54 53 52 51 50
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5
6-15
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 1.25
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
1
RB 0.5 2 3 4 B 0.5
5
VG 2
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
19 20
FUSE 45 20
18 17 16 15 14 13 12 11 10 9
19
(WHITE) 9 10 11 12 13 14 15 16 17 18
B2 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
FRAME GND
BL
ACG E TERMINAL
6-16
Wiring check
INJECTOR 6 INJECTOR 1
INJECTOR 5 INJECTOR 2
INJECTOR 4 INJECTOR 3
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5
SWP 5 6 7 8 B 0.5
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 0.5
R 0.85
B 0.5
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
6-17
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
6-18
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 VEHICLE SPEED SENSOR (SIG)
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21 (FROM PULSE MATCHING DEVICE)
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
PL 0.5
ECU HARNESS
Y 0.5 PL 0.5
4 3 2 1 12 PIN
12 1110 9 8 7 6 5
W 0.5
B 0.5
6-19
Wiring check
■ Starting circuit (key switch, slow blow fuse and fuse circuit)
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.3 2 4
B 0.3
3
BW 0.5
5
CONTROL UMT POWER SUPPLY RW 1.25
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
RW 1.25 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
SWP
2 1
(BLACK) 1 2
6-20
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
12
RB 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1 SDL
TACHOMETER(SIG)OUTPUT
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
27
RB 0.5
BrW 0.5
6 ECU HARNESS
6
16
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
16 25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40
40 39 38 37
41 42 43 44
SMJ
44 43 42 41
(WHITE)
48 47 46 45
45 46 47 48
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
RB 0.5
84 83 82 81 80 79 78 77 76 75 74 73
73 74 75 76 77 78 79 80 81 82 83 84
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
BrW 0.5
6-21
Wiring check
■ Self-diagnosis circuit (diagnosis switch, memory clear switch and Tech II connector circuit)
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
DIAG. SW. 26 25 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
101 102 103 104 105 106 107 108 109 110
111 112 113 114 115 116 117 118 119 120
RL 0.5
1 LgB 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
G 0.5 (BLACK)
1 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
WR 0.5 WR 0.5
LR 0.5 LR 0.5
25
JOINT CONNECTOR(2)
13
26
4
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 1.25
B 1.25
13
ECU HARNESS
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
LR 0.5 (MT)
WR 0.5 (AT)
TECH II CONNECTOR
6-22
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
11 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BG 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22
NEUTRAL SIGNAL
22 23 24 25 26 27 28 29 30 31 32
11 ECU HARNESS
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
BG 0.5
NEUTRAL SWITCH
SWP
1 2
(GRAY)
BG 0.5
STARTER HARNESS
6-23
Wiring check
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
10 10
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
RG 0.5
FUSE 11
1 2
3 4 5
CLUTCH SWITCH
6-24
Wiring check
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10
41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
19
G 0.5
19
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BRAKE SWITCH 2
SWP
2 1
(GRAY)
GW 0.5
FUSE 27
DIODE
1 2
3 1
5 1
SB 0.85 2 3 4 GY 0.3 GW 0.5
1 2
4 2
5
R 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
29 30 31 32 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
G 0.85 48
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
G 0.85
G 0.85
3 2 1 3 2 1
6 5 4 6 5 4
9 8 7 9 8 7
6-25
Wiring check
■ Reverse circuit
ENGINE CONTROL UNIT CONNECTOR 120 PIN
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10
41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.5
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
22 22
ECU HARESS
FUSE 12
Br 0.85
8 9 10 11 12 13 14 14 13 12 11 10 9 8 29
15 16 17 18 19 20 20 19 18 17 16 15
10 9 8 7 6 5 4 3 2 1
SDL 1 2 3 4 5 6 7 8 9 10 21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
11 1213 141516 17 1819 202122
2221201918 17 16 1514131211
(WHITE) SMJ
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
RL 0.5
37 38 39 40 41 42 42 41 40 39 38 37
46 46
17
43 44 45 47 48 49 49 48 47 45 44 43
17 50 51 52 53 54 55 56 56 55 54 53 52 51 50
RL 0.85
29
RL 0.85
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
RL 0.85
SWP
1 2
(GRAY) RL 0.85
1 2 3 1 2 3
4 5 6 4 5 6
7 8 9 7 8 9
6-26
Wiring check
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PB 0.5
P 0.5
PB 0.5
PB 0.5
P 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
PB 0.5
FUSE 11
1 2 3 S TYPE
4 5 6
(WHITE)
P 0.5
IDLE CONTROL SW
6-27
Wiring check
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
18 18
CRUISE EXHAUST DRIVE OUTPUT SIGNAL
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LY 0.5
1 2 3 4
1
8
2
9
3
10
4
11
5
12 13 14
6 7 7 6
14 13 12
5 4
11
3
10
2
9
1
8 30
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
(WHITE)
FUSE 13 1
LY 0.5
29 30
33 34
31 32
35 36
32 31
36 35
30 29
34 33
2 3 4 37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
5 50 51 52 53 54 55 56 56 55 54 53 52 51 50
30 46
EXH. BRAKE RELAY
46
3
5 1
GND EXHAUST BRAKE
4 2
MAGNETIC VALVE
1 2
LY 0.5 BL 0.5
6-28
Chapter 7
How to use IE system
inspection tools
Chapter 7 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.
3 1
2
LFW36ESH000301
7-2
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 F4: Special function of the menu and press the
F0: Diagnostic Trouble Codes
F1: Data Display ENTER key.
F2: Snap Shot
F3: Programming
F4: Special Functions
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
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum V
Final Accelerator Opening %
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.
Desired Idle Speed RPM
Engine Speed RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum V
Final Accelerator Opening %
Quit Off
LFW36ESH001001
7-4
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.
Desired Idle Speed RPM
Engine Speed RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum V
Final Accelerator Opening %
Quit Off
LFW36ESH001301
Quit Active
LFW36ESH000901
Solenoid Valve
• Solenoid valve
Inspect the operation of the magnetic valves A, B and C
M/V A (VGS) Inactive
while the engine stops.
Select the M/V with the software key, "Next".
A: VGS B: VGS C: VGS
Quit On Next
7-5
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 F3: Programming on the menu and press the ENTER
F0: Diagnostic Trouble Codes
F1: Data Display
key.
F2: Snap Shot
F3: Programming
F4: Special Functions
7-6
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
F1: Download Fuel Delivery Rate Data
F2: Accelerator Learning Data
Date Setting
01-01-2001
Program Abort
7-7
Tech II
Program Abort
Confirm
7-8
Chapter 8
Others
O
ECU 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.)
O O
G sensor 14
NE (engine rotation) sensor 15
O O
Atmospheric temperature sensor 22
Inspection item chart for IE system condition
O O O O
O
Boost sensor 32
O
Fuel pressure sensor 245, 115
O
Accelerator sensor switch 24, 241, 242
M/V :A - C 411, 412, 415
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/intake valve
O
O
O
O O
Defective injector (including flow damper operation)
O
Clogged air cleaner
Chapter 8 Others
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
Pulsating combustion
Lack of output power
Black smoke large
Engine hunting
Failure condition
Defective start
Engine stall
8-2
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
8-3
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
8-4
■ 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.
F0: Upload Fuel Delivery Rate Data
F1: Download Fuel Delivery Rate Data
F2: Accelerator Leaning Date
*1
(C*, E*, L*, F*) Heavy, Medium Duty
Engine: (IE) 6SD1 (Common Rail)
No Yes
Upload Successful
Confirm
8-5
● Programming
*1
(C*, E*, L*, F*) Heavy, Medium Duty
Engine: (IE) 6SD1 (Common Rail)
No Yes
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.)
8-6
6SDEED-WE-0325AR
Issued by
Tokyo, Japan