Group 13

13-1
GROUP 13
FUEL
CONTENTS
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
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FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B
13A-1
GROUP 13A
DIESEL FUEL
CONTENTS
GENERAL INFORMATION . . . . . . . . 13A-6 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-68

CODE NO. P0103 AIR FLOW SENSOR CIRCUIT
SERVICE SPECIFICATIONS. . . . . . . 13A-10 HIGH INPUT . . . . . . . . . . . . . . . . . . . . . . . . 13A-75
CODE NO. P0106 MANIFOLD ABSOLUTE
PRESSURE SENSOR RANGE/PERFORMANCE
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SEALANTS OR ADHESIVES . . . . . . 13A-10
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-78
CODE NO. P0107 MANIFOLD ABSOLUTE
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13A-11 PRESSURE SENSOR CIRCUIT LOW INPUT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-83
TROUBLESHOOTING . . . . . . . . . . . . 13A-12 CODE NO. P0108 MANIFOLD ABSOLUTE
DIAGNOSIS TROUBLESHOOTING FLOW 13A-12 PRESSURE SENSOR CIRCUIT HIGH INPUT
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-91
DIAGNOSIS CODE CHART . . . . . . . . . . . . 13A-21 CODE NO. P0112 EGR GAS TEMPERATURE
SENSOR CIRCUIT LOW INPUT <Euro5> . 13A-94
DIAGNOSIS CODE PROCEDURES . . . . . 13A-26
CODE NO. P0112 INTAKE AIR TEMPERATURE
CODE NO. P0003 SUCTION CONTROL VALVE
SENSOR NO.1 CIRCUIT LOW INPUT <Except Euro5>
OPEN <Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-99
CODE NO. P0004 SUCTION CONTROL VALVE CODE NO. P0113 EGR GAS TEMPERATURE
BATTRY SHORT <Euro5> . . . . . . . . . . . . . 13A-29 SENSOR CIRCUIT HIGH INPUT <Euro5> . 13A-104
CODE NO. P0016 CRANKSHAFT/CAMSHAFT CODE NO. P0113 INTAKE AIR TEMPERATURE
POSITION SENSOR PHASE PROBLEM . . 13A-32 SENSOR NO.1 CIRCUIT HIGH INPUT <Except
CODE NO. P0047 VARIABLE GEOMETRY Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-109
SOLENOID VALVE LOW <Euro5> . . . . . . . 13A-34
CODE NO. P0117 ENGINE COOLANT
CODE NO. P0048 VARIABLE GEOMETRY TEMPERATURE SENSOR CIRCUIT LOW INPUT
SOLENOID VALVE HIGH <Euro5> . . . . . . 13A-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-113
CODE NO. P0072 NO.1 INTAKE AIR TEMPERATURE CODE NO. P0118 ENGINE COOLANT
SENSOR CIRCUIT LOW INPUT <Euro5> . 13A-43 TEMPERATURE SENSOR CIRCUIT HIGH INPUT
CODE NO. P0072 INTAKE AIR TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-119
SENSOR NO.2 CIRCUIT LOW INPUT <Except Euro5> CODE NO. P0122 THROTTLE POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-48 CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-124
CODE NO. P0073 NO.1 INTAKE AIR TEMPERATURE CODE NO. P0123 THROTTLE POSITION SENSOR
SENSOR CIRCUIT HIGH INPUT <Euro5>. 13A-53 CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-131
CODE NO. P0073 INTAKE AIR TEMPERATURE CODE NO. P0182 FUEL TEMPERATURE SENSOR
SENSOR NO.2 CIRCUIT HIGH INPUT <Except CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-134
Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-57 CODE NO. P0183 FUEL TEMPERATURE SENSOR
CODE NO. P0088 COMMON RAIL HIGH PRESSURE CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-139
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-60 CODE NO. P0191 RAIL PRESSURE SENSOR
CODE NO. P0089 SUCTION CONTROL VALVE RANGE/PERFORMANCE PROBLEM . . . . 13A-143
STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-63 CODE NO. P0192 RAIL PRESSURE SENSOR
CODE NO. P0093 FUEL LEAK PROBLEM 13A-64 CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-147
CODE NO. P0102 AIR FLOW SENSOR CIRCUIT LOW CODE NO. P0193 RAIL PRESSURE SENSOR
13A-2
CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-155 TEMPERATURE SENSOR CIRCUIT LOW INPUT

CODE NO. P0201 NO.1 INJECTOR CIRCUIT <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-231
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-158 CODE NO. P0428 NO. 2 EXHAUST GAS
CODE NO. P0202 NO.2 INJECTOR CIRCUIT TEMPERATURE SENSOR CIRCUIT HIGH INPUT
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-161 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-234
CODE NO. P0202 NO.2 INJECTOR CIRCUIT CODE NO. P0489 EGR VALVE POSITION SENSOR
MALFUNCTION <Except Euro5> . . . . . . . . 13A-164 CIRCUIT LOW INPUT <Euro5> . . . . . . . . . 13A-240
CODE NO. P0203 NO.3 INJECTOR CIRCUIT CODE NO. P0490 EGR VALVE POSITION SENSOR
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-167 CIRCUIT HIGH INPUT <Euro5> . . . . . . . . . 13A-248
CODE NO. P0203 NO.3 INJECTOR CIRCUIT CODE NO. P0502 VEHICLE SPEED SENSOR LOW
MALFUNCTION <Except Euro5> . . . . . . . . 13A-170 INPUT <2WD-M/T and 4WD vehicles> . . . . 13A-251
CODE NO. P0204 NO.4 INJECTOR CIRCUIT CODE NO. P0513 IMMOBILIZER MALFUNCTION
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-254
CODE NO. P0204 NO.4 INJECTOR CIRCUIT CODE NO. P0515 BATTERY TEMPERATURE
MALFUNCTION <Except Euro5> . . . . . . . . 13A-176 SENSOR SYSTEM <Euro5> . . . . . . . . . . . . 13A-255
CODE NO. P0219 ENGINE OVERSPEED CODE NO. P0545 NO. 1 EXHAUST GAS
CONDITION . . . . . . . . . . . . . . . . . . . . . . . . 13A-178 TEMPERATURE SENSOR CIRCUIT LOW INPUT
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<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-260
CODE NO. P0234 TURBOCHARGER OVERBOOST
CONDITION <Except Euro5> . . . . . . . . . . . 13A-179 CODE NO. P0546 NO. 1 EXHAUST GAS
TEMPERATURE SENSOR CIRCUIT HIGH INPUT
CODE NO. P0299 TURBOCHARGER UNDER BOOST
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-263
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-180
CODE NO. P0551 POWER STEERING FLUID
CODE NO. P0301 NO. 1 CYLINDER INJECTOR
PRESSURE SWITCH SYSTEM . . . . . . . . . 13A-268
MALFUNCTION (NO INJECTION) . . . . . . . 13A-180
CODE NO. P0603 EEP ROM MALFUNCTION <Except
Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-270
CODE NO. P0604 RANDOM ACCESS MEMORY
(RAM) MALFUNCTION . . . . . . . . . . . . . . . . 13A-271
CODE NO. P0605 READ ONLY MEMORY (FLASH
ROM) MALFUNCTION . . . . . . . . . . . . . . . . 13A-271
CODE NO. P0606 ENGINE-ECU (MAIN CPU)
CODE NO. P0335 CRANK ANGLE SENSOR SYSTEM
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . 13A-272
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-184
CODE NO. P0607 ENGINE-ECU (SUB CPU)
CODE NO. P0336 CRANK ANGLE SENSOR RANGE/
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . 13A-272
PERFORMANCE PROBLEM . . . . . . . . . . . 13A-190
CODE NO. P0620 ALTERNATOR CONTROL
CODE NO. P0340 CAMSHAFT POSITION SENSOR
CIRCUIT <Euro5> . . . . . . . . . . . . . . . . . . . . 13A-273
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-192
CODE NO. P0341 CAMSHAFT POSITION SENSOR
OPEN <Except Euro5> . . . . . . . . . . . . . . . . 13A-276
RANGE/PERFORMANCE PROBLEM . . . . 13A-198
CODE NO. P0381 GLOW PLUG OPEN/SHORT
BATTERY SHORT <Except Euro5> . . . . . . 13A-279
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-200
CODE NO. P062F EEPROM MALFUNCTION <Euro5>
CODE NO. P0401 EGR FLOW INSUFFICIENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-282
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-204
CODE NO. P0630 CHASSIS NUMBER NOT
CODE NO. P0402 EGR FLOW EXCESSIVE <Euro5>
PROGRAMMED . . . . . . . . . . . . . . . . . . . . . 13A-282
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-209
CODE NO. P0638 THROTTLE VALVE CONTROL
CODE NO. P0403 EGR VALVE DC MOTOR
SERVO STUCK . . . . . . . . . . . . . . . . . . . . . . 13A-284
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-215
CODE NO. P0642 ANALOG SENSOR REFERENCE
CODE NO. P0405 EGR VALVE POSITION SENSOR
VOLTAGE NO.1 TOO LOW . . . . . . . . . . . . 13A-286
CIRCUIT LOW INPUT <Except Euro5> . . . 13A-219
CODE NO. P0406 EGR VALVE POSITION SENSOR
VOLTAGE NO.1 TOO HIGH . . . . . . . . . . . . 13A-287
CIRCUIT HIGH INPUT <Except Euro5> . . . 13A-227
CODE NO. P064C GLOW CONTROL UNIT
CODE NO. P0420 CATALYST MALFUNCTION
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-229
CODE NO. P0427 NO. 2 EXHAUST GAS
VOLTAGE NO.2 TOO LOW . . . . . . . . . . . . 13A-290
13A-3
CODE NO. P0653 ANALOG SENSOR REFERENCE SENSOR (MAIN) CIRCUIT HIGH INPUT . . 13A-341
VOLTAGE NO.2 TOO HIGH . . . . . . . . . . . . 13A-291 CODE NO. P2124 ACCELERATOR PEDAL POSITION
CODE NO. P0683 GLOW CONTROL UNIT SENSOR (MAIN) CIRCUIT HIGH INPUT
COMMUNICATION ABNORMALITY <Euro5> INTERMITTENT . . . . . . . . . . . . . . . . . . . . . 13A-345
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-292 CODE NO. P2127 ACCELERATOR PEDAL POSITION
CODE NO. P1203 CAPACITOR INSUFFICIENT SENSOR (SUB) CIRCUIT LOW INPUT . . . 13A-349
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2128 ACCELERATOR PEDAL POSITION
CODE NO. P1204 CAPACITOR EXCESSIVE SENSOR (SUB) CIRCUIT HIGH INPUT . . . 13A-357
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2138 ACCELERATOR PEDAL POSITION
CODE NO. P1272 PRESSURE LIMITER SENSOR (MAIN AND SUB) RANGE/PERFORMANCE
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-297 PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-360
CODE NO. P1273 SUPPLY PUMP INSUFFICIENT CODE NO. P2146 INJECTOR COMMON 1
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-300 (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
CODE NO. P1274 SUPPLY PUMP PROTECTION <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-368
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-301 CODE NO. P2146 INJECTOR COMMON 1
CODE NO. P1275 SUPPLY PUMP EXCHANGE (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-302 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-371
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CODE NO. P1276 FUEL FILTER EXCHANGE CODE NO. P2147 INJECTOR COMMON 1
<Vehicles with fuel filter pressure switch> . 13A-304 (CYLINDER NO. 1 AND NO. 4) CIRCUIT EARTH
SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-374
CODE NO. P1277 FUEL FILTER FREEZE <Vehicles
with fuel filter pressure switch> . . . . . . . . . . 13A-307 CODE NO. P2147 INJECTOR COMMON CIRCUIT
GND SHORT <Except Euro5> . . . . . . . . . . 13A-378
CODE NO. P1298 VARIABLE GEOMETRY
TURBOCHARGER CONTROL SYSTEM CODE NO. P2148 INJECTOR COMMON 1
MALFUNCTION (HIGH PRESSURE) <Euro5> (CYLINDER NO. 1 AND NO. 4) CIRCUIT BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-383
CODE NO. P1299 VARIABLE GEOMETRY CODE NO. P2148 INJECTOR COMMON CIRCUIT
TURBOCHARGER CONTROL SYSTEM BATTERY SHORT <Except Euro5> . . . . . . 13A-387
MALFUNCTION (LOW PRESSURE) <Euro5> CODE NO. P2149 INJECTOR COMMON 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1427 NO. 3 EXHAUST GAS <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-392
TEMPERATURE SENSOR CIRCUIT LOW INPUT CODE NO. P2149 INJECTOR COMMON 2
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-310 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1428 NO. 3 EXHAUST GAS <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-396
TEMPERATURE SENSOR CIRCUIT HIGH INPUT CODE NO. P2150 INJECTOR COMMON 2(CYLINDER
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-313 NO. 2 AND NO. 3) CIRCUIT EARTH SHORT <Euro5>
CODE NO. P1497 DPF SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-399
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-319 CODE NO. P2151 INJECTOR COMMON 2(CYLINDER
CODE NO. P1498 EXCESSIVE PM ACCUMULATED NO. 2 AND NO. 3) CIRCUIT BATTERY SHORT
IN DPF <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-320 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-403
CODE NO. P1499 ABNORMALLY HIGH DPF CODE NO. P2228 BAROMETRIC PRESSURE
TEMPERATURE <Euro5> . . . . . . . . . . . . . 13A-320 SENSOR CIRCUIT LOW INPUT . . . . . . . . . 13A-406
CODE NO. P1608 BATTERY CURRENT SENSOR CODE NO. P2229 BAROMETRIC PRESSURE
SYSTEM <Euro5>. . . . . . . . . . . . . . . . . . . . 13A-322 SENSOR CIRCUIT HIGH INPUT . . . . . . . . 13A-407
CODE NO. P1625 INJECTION QUANTITY CODE NO. P2413 EGR SYSTEM PERFORMANCE
COMPENSATION VALUE ERROR . . . . . . 13A-327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-408
CODE NO. P1626 INJECTION QUANTITY CODE NO. P2454 EXHAUST DIFFERENTIAL
COMPENSATION VALUE ERROR NOT CODING PRESSURE SENSOR CIRCUIT LOW INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-411
CODE NO. P2118 THROTTLE VALVE CONTROL DC CODE NO. P2455 EXHAUST DIFFERENTIAL
MOTOR CURRENT MALFUNCTION . . . . . 13A-329 PRESSURE SENSOR CIRCUIT HIGH INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-417
CODE NO. P2122 ACCELERATOR PEDAL POSITION
SENSOR (MAIN) CIRCUIT LOW INPUT . . 13A-333 CODE NO. P252F ENGINE OIL LEVEL
CODE NO. P2123 ACCELERATOR PEDAL POSITION
13A-4
CODE NO. U1073 BUS OFF . . . . . . . . . . . 13A-420 4LLC SWITCH SYSTEM <M/T-High power engine
CODE NO. U1101 A/T-ECU TIME-OUT <A/T> vehicle> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-505
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-421 CONDENSER FAN RELAY SYSTEM <Vehicles with A/
CODE NO. U1102 ASTC-ECU TIME-OUT <Except C condenser fan> . . . . . . . . . . . . . . . . . . . . 13A-507
vehicles for Morocco> . . . . . . . . . . . . . . . . . 13A-422 A/C SWITCH SYSTEM . . . . . . . . . . . . . . . . 13A-509
CODE NO. U1109 ETACS TIME-OUT . . . . 13A-424 A/C COMPRESSOR RELAY SYSTEM . . . . 13A-512
CODE NO. U1110 A/C-ECU TIME-OUT <Euro5> POWER STEERING FLUID PRESSURE SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-425 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-514
CODE NO. U1117 ETACS-ECU (IMMOBILIZER-ECU) GLOW SYSTEM <Except Euro5> . . . . . . . . 13A-520
TIME-OUT. . . . . . . . . . . . . . . . . . . . . . . . . . 13A-427 PTC HEATER RELAY SYSTEM . . . . . . . . . 13A-525
CODE NO. U1190 THE NETWORK SYSTEM BLOWER SWITCH SYSTEM <Euro5> . . . . 13A-528
DIAGNOSIS CODE OUTPUT PERMITTED SIGNAL
REAR WINDOW DEFOGGER SYSTEM <Euro5>
CANNOT BE RECEIVED . . . . . . . . . . . . . . 13A-428
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-533
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13A-429
DPF LAMP SYSTEM <Euro5> . . . . . . . . . . 13A-537
CHECK CHART CLASSIFIED BY PROBLEM
DATA LIST REFERENCE TABLE . . . . . . . . 13A-542
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-432
ACTUATOR TEST REFERENCE TABLE . . 13A-574
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-433
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CHECK AT THE ENGINE-ECU TERMINALS
COMMUNICATION WITH ENGINE-ECU IS NOT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-576
POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . 13A-433
INSPECTION PROCEDURE USING AN
THE ENGINE WARNING LAMP DOES NOT
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-586
ILLUMINATE RIGHT AFTER THE IGNITION SWITCH
IS TURNED TO THE "ON" POSITION . . . . 13A-438
THE ENGINE WARNING LAMP REMAINS ON-VEHICLE SERVICE . . . . . . . . . . . 13A-589
ILLUMINATING AND NEVER GOES OUT OR IS EVACUATION OF WATER FROM FUEL FILTER
BLINKING . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
STARTING IMPOSSIBLE (NO INITIAL FUEL LINE AIR-BLEEDING . . . . . . . . . . . . 13A-589
COMBUSTION) <M/T> . . . . . . . . . . . . . . . . 13A-445 FUEL FILTER CARTRIDGE REPLACEMENT
STARTING IMPOSSIBLE (NO INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
COMBUSTION) <A/T> . . . . . . . . . . . . . . . . 13A-453 FUEL LINE LEAK CHECK. . . . . . . . . . . . . . 13A-590
STARTING IMPOSSIBLE (STARTER OPERATIVE COMPONENT LOCATION . . . . . . . . . . . . . 13A-591
BUT NO INITIAL COMBUSTION). . . . . . . . 13A-462 ENGINE CONTROL RELAY CONTINUITY CHECK
IMPROPER STARTING (LONG TIME TO START) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-464 ENGINE COOLANT TEMPERATURE SENSOR
IMPROPER IDLING . . . . . . . . . . . . . . . . . . 13A-466 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
THE ENGINE STALLS WHEN DECELERATING INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-595
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-468
INTAKE AIR TEMPERATURE SENSOR NO.1 CHECK
POOR ACCELERATION. . . . . . . . . . . . . . . 13A-471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-595
A LARGE AMOUNT OF FUEL CONSUMPTION INTAKE AIR TEMPERATURE SENSOR NO.2 CHECK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-473 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-595
KNOCKING, ABNORMAL NOISE. . . . . . . . 13A-475 SUCTION CONTROL VALVE CHECK . . . . 13A-596
WHITE SMOKE. . . . . . . . . . . . . . . . . . . . . . 13A-477 FUEL TEMPERATURE SENSOR CHECK . 13A-596
BLACK SMOKE . . . . . . . . . . . . . . . . . . . . . 13A-479 COMMON RAIL CHECK . . . . . . . . . . . . . . . 13A-596
BATTERY RUNDOWN <Euro5>. . . . . . . . . 13A-481 THROTTLE VALVE CONTROL SERVO CHECK
BATTERY RUNDOWN <Except Euro5>. . . 13A-486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-596
OVERHEATING . . . . . . . . . . . . . . . . . . . . . 13A-487
ENGINE-ECU POWER SUPPLY SYSTEM 13A-488 FUEL INJECTOR . . . . . . . . . . . . . . . . 13A-598
ENGINE-ECU BATTERY BACK-UP SYSTEM FUEL INJECTOR REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-598
1ST AND 2ND RAIL SWITCH SYSTEM <M/T>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-497 COMMON RAIL AND SUPPLY PUMP13A-604
BACK-UP LAMP SWITCH SYSTEM <M/T> 13A-501 COMMON RAIL AND SUPPLY PUMP REMOVAL AND
13A-5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-604 CAMSHAFT POSITION SENSOR . . . 13A-613

CAMSHAFT POSITION SENSOR REMOVAL AND
SUCTION CONTROL VALVE . . . . . . 13A-610 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 13A-613
SUCTION CONTROL VALVE REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-610 CRANK ANGLE SENSOR . . . . . . . . . 13A-613
CRANK ANGLE SENSOR REMOVAL AND
THROTTLE BODY ASSEMBLY . . . . 13A-612 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 13A-613
THROTTLE BODY ASSEMBLY REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-612 ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13A-614
ENGINE-ECU REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-614
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13A-6 DIESEL FUEL
GENERAL INFORMATION
GENERAL INFORMATION
M1133000101089
The common rail fuel injection system consists of ECU. The engine-ECU carries out activities such as
sensors which detect the condition of the diesel fuel injection control and idle speed control. In addi-
engine, an engine electronic control unit (engine- tion, the engine-ECU is equipped with several self-
ECU) which controls the system based on signals diagnosis functions which make troubleshooting eas-
from these sensors, and actuators which operate ier in the event that a problem develops.
according to control commands from the engine-
FUEL INJECTION CONTROL
The injector drive time, the injection timing and the
fuel pressure are controlled so that the appropriate
quantities of fuel are supplied to the engine in
response to engine conditions which can change fre-
quently. A single injector is mounted at each cylinder.
The supply pump increases the fuel pressure to the
pressure which is required for high-pressure injec-
tion, and then send the fuel each injector.
IDLE SPEED CONTROL
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The idle speed is kept at the optimum speed by con- The engine-ECU drives the fuel injector to keep the
trolling the fuel injection quantity in accordance with engine running at the pre-set idle target speed in
changes in idling conditions and engine load during accordance with the engine coolant temperature and
idling. A/C and other electrical load.
SELF-DIAGNOSIS FUNCTION
• When an abnormality is detected in any of the • The RAM data relating to the sensors and actua-
sensors or actuators, the engine warning lamp tors which is stored in the engine-ECU can be
illuminates to warn the driver. read using the M.U.T.-III. In addition, the actuator
• When an abnormality is detected in any of the can be force-driven under certain conditions.
sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is
output.
OTHER CONTROL FUNCTIONS

1. Power Supply Control Controls the condenser fan motor relay based on the
When the ignition switch ON signal is input by the A/C switch, A/C load signal, engine coolant tem-
ignition switch, the engine-ECU turns ON the perature and vehicle speed input signals.
power transistor for controlling the engine control 6. PTC Heater Relay Control <Vehicle with PTC
relay. As a result, current flows through the coil in heater>
the engine control relay, causing the relay switch The PTC heater is turned ON is accordance with the
to turn ON and supply power to the sensors and A/C operation at the engine cold state.
actuators. 7. DPF System Control <Euro5>
2. Glow Control [Refer to GROUP 17 − Emission Control − Diesel
Refer to GROUP 16 Particulate Filter (DPF) System <Euro5> − Gen-
(Refer to , GROUP 16 − Glow System). eral Information (DPF system) ].
3. EGR Control 8. Variable Geometry Turbocharger Control
Refer to GROUP 17 <Euro5>
[Refer to , GROUP 17 − Engine And Emission Con- Performing the duty control over the variable geome-
trol − Exhaust Gas Recirculation (EGR) System]. try control solenoid valve, the engine-ECU opens
4. A/C Relay Control and closes the nozzle vane located in the turbo-
Turns the compressor clutch of the A/C ON and OFF. charger assembly. This allows the boost pressure
5. Condenser Fan Motor Relay Control to be obtained in accordance with the engine
operation.
9. Alternator Output Current Control <Euro5>
DIESEL FUEL
GENERAL INFORMATION
13A-7
Prevents the alternator output current from increas-
ing suddenly and the idle speed from varying
such as when the headlamp is turned on.
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13A-8 DIESEL FUEL
GENERAL INFORMATION
FUEL INJECTION SYSTEM DIAGRAM

<Euro5>
1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
2 Crank angle sensor position sensor ECU valve A/C relay
3 Camshaft position (main) Barometric 2 Throttle valve
pressure Condenser fan relay
sensor Accelerator pedal control servo
sensor (DC motor) Glow control unit
4 Engine coolant position sensor
(sub) 3 Injector PTC heater relay
temperature sensor <Vehicles with
5 Rail pressure sensor Power steering 4 EGR valve PTC heater>
fluid pressure (DC motor)
6 Intake air temperature switch Glow indicator lamp
sensor No. 1 5 Variable geometry
Vehicle speed sensor control solenoid Engine warning lamp
7 EGR gas temperature valve
sensor Power supply Tachometer
8 Manifold absolute Ignition switch-IG Alternator G terminal
pressure sensor Ignition switch-ST CAN communication
9 Fuel temperature (output signal)
A/C switch
sensor
10 Throttle position A/C load signal
sensor Back-up lamp
11 EGR valve switch <M/T>
position sensor 1st and 2nd rail switch
12 No. 1 exhaust gas <M/T>
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temperature sensor 4LLC switch <M/T>
13 No. 2 exhaust gas PTC heater control
temperature sensor signal <Vehicles
(catalyst temperature) with PTC heater>
14 No. 3 exhaust gas Battery current sensor
temperature sensor Battery temperature
(DPF temperature) sensor
15 Exhaust differential Glow diagnosis signal 10 Throttle position sensor
pressure sensor
CAN communication 2 Throttle valve control servo (DC motor)
(input signal)
8 Manifold absolute pressure sensor
11 EGR valve position sensor
1 Air flow sensor 4 EGR valve (DC motor)
Air 6 Intake air temperature
sensor No. 1
7 EGR gas temperature
sensor
5 Rail pressure sensor

To brake system
To fuel tank
5 Variable geometry 3 Camshaft
control solenoid valve position Supply
sensor pump
3 Injector
Variable geometry
actuator 9 Fuel
temperature
sensor
4 Engine coolant
temperature sensor 1 Suction control
valve
Catalytic 2 Crank angle sensor
converter
12
No. 1 exhaust
gas temperature Catalytic From fuel
sensor DPF
converter 15 Exhaust differential pressure sensor Fuel filter tank
13
No. 2 exhaust gas 14 No. 3 exhaust gas temperature sensor
temperature sensor (catalyst temperature) (DPF temperature) AKB00240 AB
DIESEL FUEL
GENERAL INFORMATION
13A-9
<Except Euro5>
1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
position sensor ECU valve
2 Crank angle sensor (main) A/C relay
3 Camshaft position Barometric 2 Throttle valve Glow plug relay
Accelerator pedal pressure control servo
sensor position sensor PTC heater relay
sensor (DC motor)
4 Engine coolant (sub) <Vehicles with PTC
temperature sensor Power steering fluid 3 Injector heater>
5 Rail pressure sensor pressure switch 4 EGR valve Glow indicator lamp
6 Intake air temperature Vehicle speed (DC motor) Engine warning lamp
sensor No. 1 sensor Tachometer
7 Intake air temperature Power supply CAN communication
sensor No. 2 Ignition switch-IG (output signal)
8 Manifold absolute Ignition switch-ST
pressure sensor A/C switch
9 Fuel temperature A/C load signal
sensor Back-up switch
10 Throttle postion <M/T>
sensor 1st and 2nd rail
11 EGR valve position switch <M/T>
sensor PTC heater control
12 Fuel filter pressure signal <Vehicles
switch with PTC heater>
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<Vehicles for Russia CAN
and Morocco> communication
(input signal)
7 Intake air temperature sensor No. 2

10 Throttle position sensor
2 Throttle valve control servo (DC motor)
11 EGR valve position sensor
1 Air flow sensor 4 EGR valve (DC motor)
6 Intake air temperature
Air sensor No. 1
8 Manifold absolute
pressure sensor
5 Rail pressure sensor

To brake system
To fuel tank
3 Camshaft
position
sensor Supply
pump
Turbocharger 3 Injector
9 Fuel
temperature
4 Engine coolant sensor
temperature sensor 1 Suction control
2 Crank angle sensor valve
Catalytic
Waste gate converter
actuator
12 Fuel filter pressure switch From fuel
<Vehicles for Russia and Morocco> Fuel filter tank
AKB00239AB
13A-10 DIESEL FUEL
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1133000300488
Items Specifications
Engine coolant temperature Engine coolant temperature at − 14 − 17
sensor resistance kΩ 20°C
Engine coolant temperature at 5.1 − 6.5
0°C
20°C
40°C
60°C
80°C
Intake air temperature sensor Intake air temperature at −20°C 13 − 17
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No.1 resistance kΩ Intake air temperature at 0°C 5.4 − 6.6
Intake air temperature at 20°C 2.3 − 3.0
Intake air temperature sensor Intake air temperature at −20°C 13 − 18
No.2 resistance kΩ <Except Intake air temperature at 0°C 5.1 − 6.9
Euro5>
Injector coil resistance Ω (at 20°C) Approximately 0.45
Suction control valve resistance Ω (at 20°C) Approximately 2.1
Fuel temperature resistance kΩ (at 20°C) 2.0 − 3.0
Throttle valve control servo resistance (at 20°C) Ω 0.3 − 100
SEALANTS
M1133000500385
Item Specified sealant

Engine coolant temperature sensor threaded portion 3M Nut Locking Part No. 4171 or equivalent
Semi-circular packing Three bond 1212D, Three bond 1217G (Mitsubishi
Cylinder head Part No. 1000A923) or equivalent
DIESEL FUEL
SPECIAL TOOLS
13A-11
SPECIAL TOOLS
M1133000600746
Tool Number Name Use

MB991955 M.U.T.-III sub assembly CAUTION
a a: MB991824 a: Vehicle communication For vehicles with CAN
b: MB991827 interface (V.C.I.) communication, use M.U.T.-III
c: MB991910 b: M.U.T.-III USB cable main harness A to send
d: MB991911 c: M.U.T.-III main harness simulated vehicle speed. If
MB991824 e: MB991825 A (Vehicles with CAN you connect M.U.T.-III main
b f: MB991826 communication system) harness B instead, the CAN
d: M.U.T.-III main harness communication does not
B (Vehicles without CAN function correctly.
communication system) • Reading diagnosis code
MB991827 e: M.U.T.-III adapter • Diesel system inspection
harness • Measurement of fuel
c
f: M.U.T.-III trigger harness pressure
• Fuel line leak check
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MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MB991658 Test harness • Measurement of voltage

during troubleshooting
• Inspection using an
oscilloscope
MB991658
MB991709 Test harness • Measurement of voltage

during Troubleshooting
• Inspection using an
oscilloscope
13A-12 DIESEL FUEL
TROUBLESHOOTING

MB992188 Fuel injection pipe wrench Removal and installation of fuel
injection pipe
MB992042 Engine coolant Removal and installation of the

temperature sensor wrench engine coolant temperature
sensor
MB992042
MB990784 Ornament remover Carbon deposit cleaning
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MB990784
MB991614 Angle gauge Installation of injector holder bolt
MB991614
MB992048 Sprocket holder Injection pump sprocket bolt

removal and installation
B992048
MB992098 Injection pump sprocket Injection pump sprocket removal

puller
B992098
MB992099 Crank pulley puller
B992099
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1133003700430
Refer to , GROUP 00 − How to Use Troubleshooting/ shooting.
Inspection Service Points − Contents of Trouble-
DIESEL FUEL
TROUBLESHOOTING
13A-13
WARNING DIAGNOSIS FUNCTION
M1133003800954
A high-tension voltage is flowing between
the engine-ECU and the injectors while the ENGINE WARNING LAMP (CHECK
engine is running. Handle them carefully to ENGINE LAMP)
avoid receiving electric shocks from the volt-
age.
CAUTION
After replacing the engine-ECU, register the Engine warning lamp
injector identification code and learn fuel injec-
20engine lamp)
(Check
tion. (Refer to GROUP 00 − Precautions Before

Service − What The Common Rail Engine Learns
)
CAUTION
AK500611 AB
After replacing the injector, register the injector
identification code and learn fuel injection. (Refer When the abnormal condition occurs with respect to
to GROUP 00 − Precautions Before Service − the items of electronically controlled fuel injection
What The Common Rail Engine Learns ). system shown in the table, the engine warning lamp
is illuminated. When the lamp remains illuminated
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CAUTION
after the engine start, or when the lamp is illuminated
After replacing the supply pump, learn the supply
while the engine is running, check the diagnosis
pump. (Refer to GROUP 00 − Precautions Before
code output. There are two methods for checking the
Service − What The Common Rail Engine Learns
indicator lamp burn out: When the ignition switch is in
).
ON position, the indicator lamp is illuminated, and
CAUTION then extinguished few seconds later. When the igni-
The vehicle equipped with the DPF shall initialize tion switch is in ON position and the engine starts,
the learning value after the following parts are the indicator lamp is extinguished.
replaced (Refer to GROUP 00 − Precautions
Before Service − Initialization Procedure for
Learning Value in Diesel Particulate Filter (DPF)
System <Euro5> ).
• DPF
• Exhaust differential pressure sensor
• Catalytic converter
• Engine oil
ENGINE WARNING LAMP INSPECTION ITEMS

CAUTION
The engine warning lamp continuously illuminates when the engine-ECU malfunctions.
Code No. Diagnosis item

− Engine-ECU
P0003* Suction control valve open <Euro5>
P0004* Suction control valve battery short <Euro5>
P0016* Crank angle sensor/camshaft position sensor phase problem
P0047* Variable geometry control solenoid valve circuit low input <Euro5>
P0048* Variable geometry control solenoid valve circuit high input <Euro5>
P0072 Intake air temperature sensor No.1 circuit low input <Euro5>
P0072 Intake air temperature sensor No. 2 circuit low input <Except Euro5>
P0073 Intake air temperature sensor No.1 circuit high input <Euro5>
13A-14 DIESEL FUEL
TROUBLESHOOTING

P0073 Intake air temperature sensor No. 2 circuit high input <Except Euro5>
P0088* Common rail pressure malfunction
P0089* Suction control valve stuck
P0093* Fuel leak problem
P0102 Air flow sensor circuit low input
P0103 Air flow sensor circuit high input
P0106* Manifold absolute pressure sensor range/performance problem
P0107* Manifold absolute pressure sensor circuit low input
P0108* Manifold absolute pressure sensor circuit high input
P0112 EGR gas temperature sensor circuit low input <Euro5>
P0112 Intake air temperature sensor No. 1 circuit low input <Except Euro5>
P0113 EGR gas temperature sensor circuit high input <Euro5>
P0113 Intake air temperature sensor No. 1 circuit high input <Except Euro5>
P0117 Engine coolant temperature sensor circuit low input
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P0118 Engine coolant temperature sensor circuit high input
P0122 Throttle position sensor circuit low input
P0123 Throttle position sensor circuit high input
P0182 Fuel temperature sensor circuit low input
P0183 Fuel temperature sensor circuit high input
P0191* Rail pressure sensor range/performance problem
P0192* Rail pressure sensor low input
P0193* Rail pressure sensor high input
P0201* No. 1 Injector circuit malfunction
P0234* Turbocharger overboost condition <Except Euro5>
P0299* Turbocharger under boost condition
P0301* No. 1 cylinder injector malfunction (No injection)
P0335* Crank angle sensor system
P0336* Crank angle sensor range/performance problem
P0340* Camshaft position sensor system
P0341* Camshaft position sensor range/performance problem
P0381 Glow plug open/short malfunction <Euro5>
P0401 EGR flow insufficient <Euro5>
P0403 EGR valve (DC motor) malfunction
P0405 EGR valve position sensor circuit low input <Except Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-15
P0406 EGR valve position sensor circuit high input <Except Euro5>
P0420* Catalyst malfunction <Euro5>
P0427* No. 2 exhaust gas temperature sensor (catalyst temperature) circuit low input <Euro5>
P0428* No. 2 exhaust gas temperature sensor (catalyst temperature) circuit high input <Euro5>
P0489 EGR valve position sensor circuit low input <Euro5>
P0490 EGR valve position sensor circuit high input <Euro5>
P0502 Vehicle speed sensor low input
P0513* Immobilizer malfunction
P0545* No. 1 exhaust gas temperature sensor circuit low input <Euro5>
P0546* No. 1 exhaust gas temperature sensor circuit high input <Euro5>
P0551 Power steering fluid pressure switch system
P0603 EEPROM malfunction <Except Euro5>
P0604 Random access memory (RAM) malfunction
P0605* Read only memory (FLASH ROM) malfunction
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P0606* Engine-ECU (main CPU) malfunction
P0607* Engine-ECU (sub CPU) malfunction
P0628* Suction control valve open <Except Euro5>
P0629* Suction control valve battery short <Except Euro5>
P062F EEPROM malfunction <Euro5>
P0630* Chassis number not programmed
P0638 Throttle valve control servo stuck
P0642* Analog sensor reference voltage No. 1 too low
P0643* Analog sensor reference voltage No. 1 too high
P064C Glow control unit malfunction <Euro5>
P0652* Analog sensor reference voltage No. 2 too low
P0653* Analog sensor reference voltage No. 2 too high
P0683 Glow control unit communication abnormality <Euro5>
P1203* Capacitor insufficient charging
P1204* Capacitor excessive charging
P1272 Pressure limiter malfunction
P1273* Supply pump insufficient flow
P1274* Supply pump protection
P1275* Supply pump exchange
P1276 Fuel filter exchange <Except Euro5>
P1298* Variable geometry turbocharger control system malfunction (high pressure)
<Euro5>
P1299* Variable geometry turbocharger control system malfunction (low pressure)
<Euro5>
P1427* No. 3 exhaust gas temperature sensor (DPF temperature) circuit low input <Euro5>
P1428* No. 3 exhaust gas temperature sensor (DPF temperature) circuit high input <Euro5>
P1497* DPF system malfunction <Euro5>
13A-16 DIESEL FUEL
TROUBLESHOOTING

P1498* Excessive PM accumulated in DPF <Euro5>
P1499* Abnormally high DPF temperature <Euro5>
P1608* Battery current sensor system <Euro5>
P1625* Injection quantity compensation valve error
P1626* Injection quantity compensation valve not coding
P2118 Throttle valve control (DC motor) current malfunction
P2122* Accelerator pedal position sensor (main) circuit low input
P2123* Accelerator pedal position sensor (main) circuit high input
P2127* Accelerator pedal position sensor (sub) circuit low input
P2128* Accelerator pedal position sensor (sub) circuit high input
P2138* Accelerator pedal position sensor (main and sub) range/performance problem
P2146* Injector common 1 (cylinder No. 1 and No. 4) circuit open
P2147* Injector common circuit earth short
P2148* Injector common circuit battery short
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P2149* Injector common 2 (cylinder No. 2 and No. 3) circuit open
P2150* Injector common 2 circuit earth short <Euro5>
P2151* Injector common 2 circuit battery short <Euro5>
P2228 Barometric pressure sensor circuit low input
P2229 Barometric pressure sensor circuit high input
P2413 EGR system performance
P2454* Exhaust differential pressure sensor circuit low input <Euro5>
P2455* Exhaust differential pressure sensor circuit high input <Euro5>
NOTE: .
• After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected. However, for items marked with a "*" in the diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
• When the fuel runs out, the engine warning lamp would illuminate possibly. Supplying the fuel turns off the
engine warning lamp, but the diagnosis code No. P1272 and P1273 are stored.
METHOD OF READING AND ERASING 2. After repairing, re-check using the M.U.T.-III and
DIAGNOSIS CODES check that the abnormal input and output have
Refer to , GROUP 00 − How to Use Troubleshooting/ returned to normal as a result of the repairs.
Inspection Service Points − How to Cope with Inter- 3. Erase the diagnosis code memory.
mittent Malfunctions. 4. Remove the M.U.T.-III, and then start the engine
again and carry out a road test to confirm that the
INSPECTION USING M.U.T.-III DATA LIST problem has disappeared.
AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
DIESEL FUEL
TROUBLESHOOTING
13A-17
PROVISIONAL DIAGNOSIS CODE CON- 2. Turn the ignition switch to the "ON" position.
FIRMED 3. Select "MPI/GDI/DIESEL" from System select
If detecting the malfunction during the first drive Screen of the M.U.T.-III.
cycle, the engine-ECU temporarily stores the diagno- 4. Select "Special Function" from MPI/GDI/DIESEL
sis code as the provisional diagnosis code. If detect- Screen.
ing the same malfunction during the next drive cycle, 5. Select "Provisional DTCs" from Special Function
the engine-ECU determines that the malfunction Screen.
exists. The engine-ECU outputs the diagnosis code.
On the M.U.T.-III it is possible to display the stored FREEZE FRAME DATA
provisional diagnosis code which the engine-ECU When the engine-ECU detects a malfunction and
had detected during the first drive cycle. This makes stores a diagnosis code, it also stores a current sta-
it possible to confirm in one drive cycle whether the tus of the engine. This function is called "Freeze
malfunction could happen again after the repair. frame data". By analyzing this "Freeze frame" data
CONFIRMATION METHOD with the M.U.T.-III, an effective troubleshooting can
1. After the ignition switch is in "LOCK" (OFF) be performed.
position, connect the M.U.T.-III to the diagnosis The display items of freeze frame data are shown
connector. below.
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DISPLAY ITEM LIST
Item No. Data Unit
2 Ignition cycle −
4 Accumulated minute*1 min
500*2 Air flow sensor g/s
501*2 Throttle position sensor (main) %
507*2 Target exhaust gas recirculation valve %
508*2 Barometric pressure sensor kPa
509*2 Relative throttle position sensor %
511*2 Accelerator pedal position sensor (main) %
512*2 Accelerator pedal position sensor (sub) %
516*2 Engine coolant temperature sensor °C

525*2 Manifold absolute pressure sensor kPa
526*2 Crank angle sensor r/min
527*2 Vehicle speed km/h
529*2 Intake air temperature sensor °C

530*2 Time since engine running*3 sec
537*2 Power supply voltage V
541*2 Throttle valve control servo %
560*2 Rail pressure sensor kPa
573*2 Exhaust gas recirculation error %

NOTE: *1: Accumulated time of current malfunction from time point when malfunction is detected.
NOTE: *2: The items of Freeze Frame Data can be seen by selecting "Freeze Frame Data (OBD)" on "Self-
diagnosis" screen of M.U.T.-III. When system malfunctions are detected, the first detected malfunction data
only is stored.
13A-18 DIESEL FUEL
TROUBLESHOOTING
NOTE: *3: Time between engine start and malfunction detection.
FAIL-SAFE FUNCTION REFERENCE TABLE

When the diagnostic function detects a sensor or actuator fault or an abnormality in the control condition, the
vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction

Accelerator pedal position • The accelerator pedal opening is controlled as 0%.
sensor • Idle rotations are 1,300 r/min (both main and sub are faulty or have a
characteristic error).
Accelerator pedal position The amount of depression of the accelerator pedal is detected with using the
sensor (main) accelerator pedal position sensor (sub) signal, which is calculated by taking
half of the normal value.
Accelerator pedal position The amount of depression of the accelerator pedal is detected with using the
sensor (sub) accelerator pedal position sensor (main) signal, which is calculated by taking
half of the normal value.
Throttle position sensor Power to the throttle valve control servo is interrupted.
Crank angle sensor The engine is stopped (fuel injection and pump pressure feed are stopped).
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Camshaft position sensor • Rail pressure is controlled in the range from 50 to 100 MPa.
• Fuel injection is restricted (output restriction).
• The open angle of the accelerator pedal is controlled.
• The engine is stopped when a characteristic error of the crank angle
sensor occurs (fuel injection and pump pressure feed are stopped).
Engine coolant temperature • Engine coolant temperature is controlled as 80 °C (−25 °C at startup).
sensor • EGR control is stopped (fully closed).
Rail pressure sensor • Rail pressure is controlled in the range from 50 to 100 MPa.
• The throttle valve is shut (opening fixed)
• EGR control is stopped (fully closed).
Fuel temperature sensor Fuel temperature is controlled as 45 °C (−25 °C at startup).
Air flow sensor • EGR control is stopped (fully closed).
• Control is performed using the previous value.
Manifold absolute pressure • Manifold absolute pressure is controlled as 100 kPa.
sensor • EGR control is stopped (fully closed).
Barometric pressure sensor • Barometric pressure is controlled as 100 kPa.
Intake air temperature • Intake air temperature is controlled as 50 °C.
sensor No. 1 • EGR control is stopped (fully closed).
Intake air temperature • Intake air temperature is controlled as 50 °C.
sensor No. 2 <Except • EGR control is stopped (fully closed).
Euro5>
EGR valve position sensor EGR control is stopped (fully closed).
No. 1 exhaust gas • The throttle valve is shut (fully closed).
temperature sensor <Euro5> • Exhaust gas recirculation control is stopped (fully closed).
• DPF regeneration prohibited
temperature sensor (catalyst • Exhaust gas recirculation control is stopped (fully closed).
temperature) <Euro5> • DPF regeneration prohibited
DIESEL FUEL
TROUBLESHOOTING
13A-19
temperature sensor (DPF • Exhaust gas recirculation control is stopped (fully closed).
temperature) <Euro5> • DPF regeneration prohibited
Exhaust differential pressure • The throttle valve is shut (fully closed).
sensor <Euro5> • Exhaust gas recirculation control is stopped (fully closed).
• DPF regeneration prohibited
Injector EGR control is stopped (fully closed).
Suction control valve • Rail pressure is controlled in the range from 50 to 100 MPa.
EGR valve (DC motor) EGR control is stopped (fully closed).
Throttle valve control servo Power to the throttle valve control servo is interrupted.
Rail pressure too high • The throttle valve is shut (opening fixed)
• The engine is stopped (fuel injection and pump pressure feed are
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stopped).
Fuel leak The engine is stopped (fuel injection and pump pressure feed are stopped).
Engine overrun • The throttle valve is shut (opening fixed)
• The engine is stopped (fuel injection and pump pressure feed are
stopped).
Boost pressure too high • Fuel injection is restricted (output restriction).
Engine-ECU (RAM error) The engine is stopped (fuel injection and pump pressure feed are stopped).
Engine-ECU (sensor power • The accelerator pedal opening is controlled as 0%.
error) • Idle rotations are 1,300 r/min.
Engine-ECU (flash ROM • Rail pressure is controlled in the range from 50 to 100 MPa.
error, CPU error) • Fuel injection is restricted (output restriction).
Engine-ECU (insufficient • Rail pressure is controlled in the range from 50 to 100 MPa.
charging of capacitor for • Fuel injection is restricted (output restriction).
injector) • The open angle of the accelerator pedal is controlled.
Engine-ECU (excessive The engine is stopped. (The fuel injection and pump delivery pressure are
charging of capacitor for stopped).
injector)
Injector drive circuit error The engine is stopped. (The fuel injection and pump delivery pressure are
stopped).
Pressure limiter open valve • Rail pressure is controlled in the range from 50 to 100 MPa.
error • Fuel injection is restricted (output restriction).
13A-20 DIESEL FUEL
TROUBLESHOOTING

Supply pump error • Rail pressure is controlled in the range from 50 to 60 MPa
• A/C is cut <Except the driving condition that the fuel pressure exceeds the
seizure resistance>
• The throttle valve is shut (fully closed) <Except the driving condition that
the fuel pressure exceeds the seizure resistance>
• Exhaust gas recirculation control is stopped (fully closed).
• When the burn-in limit is exceeded, the engine is stopped gradually
Injector correction data • Rail pressure is controlled in the range from 50 to 100 MPa.
(Error data, unwritten) • Fuel injection is restricted (output restriction).
Variable geometry control • Rail pressure is controlled in the range from 50 to 100 MPa. <Except
solenoid valve error <Euro5> when the malfunction of battery short circuit exists>
• Fuel injection is restricted (output restriction). <Except when the
malfunction of battery short circuit exists>
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• The open angle of the accelerator pedal is controlled. <Except when the
malfunction of battery short circuit exists>
• The throttle valve is shut (fully closed).
Catalytic converter <Euro5> • The throttle valve is shut (fully closed).
• DPF regeneration prohibited.
DPF <Euro5> • The throttle valve is shut (fully closed).
• DPF regeneration prohibited.
INSPECTION CHART FOR DIAGNOSIS

CODES
M1133004000962
Diagnosis Diagnosis item Reference page

code No.
P0003 Suction control valve open <Euro5> P.13A-26
P0004 Suction control valve battery short <Euro5> P.13A-29
P0016 Crank angle sensor/camshaft position sensor phase problem P.13A-32
P0047 Variable geometry control solenoid valve circuit low input <Euro5> P.13A-48
P0048 Variable geometry control solenoid valve circuit high input <Euro5> P.13A-57
P0072 Intake air temperature sensor No. 1 circuit low input <Euro5> P.13A-43
P0072 Intake air temperature sensor No. 2 circuit low input <Except Euro5> P.13A-48
P0073 Intake air temperature sensor No. 1 circuit high input <Euro5> P.13A-53
P0073 Intake air temperature sensor No. 2 circuit high input <Except Euro5> P.13A-57
P0088 Common rail high pressure malfunction P.13A-60
P0089 Suction control valve stuck P.13A-63
DIESEL FUEL
TROUBLESHOOTING
13A-21
code No.
P0093 Fuel leak problem P.13A-64
P0102 Air flow sensor circuit low input P.13A-68
P0103 Air flow sensor circuit high input P.13A-75
P0106 Manifold absolute pressure sensor range/performance problem P.13A-78
P0107 Manifold absolute pressure sensor circuit low input P.13A-83
P0108 Manifold absolute pressure sensor circuit high input P.13A-91
P0112 EGR gas temperature sensor circuit low input <Euro5> P.13A-94
P0112 Intake air temperature sensor No. 1 circuit low input <Except Euro5> P.13A-99
P0113 EGR gas temperature sensor circuit high input <Euro5> P.13A-104
P0113 Intake air temperature sensor No. 1 circuit high input <Except Euro5> P.13A-109
P0117 Engine coolant temperature sensor circuit low input P.13A-113
P0118 Engine coolant temperature sensor circuit high input P.13A-119
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P0122 Throttle position sensor circuit low input P.13A-124
P0123 Throttle position sensor circuit high input P.13A-131
P0182 Fuel temperature sensor circuit low input P.13A-134
P0183 Fuel temperature sensor circuit high input P.13A-139
P0191 Rail pressure sensor range/performance problem P.13A-143
P0192 Rail pressure sensor circuit low input P.13A-147
P0193 Rail pressure sensor circuit high input P.13A-155
P0201 No. 1 injector circuit malfunction P.13A-158
P0202 No. 2 injector circuit malfunction <Euro5> P.13A-161
P0202 No. 2 injector circuit malfunction <Except Euro5> P.13A-164
P0219 Engine overspeed condition P.13A-178
P0234 Turbocharger overboost condition <Except Euro5> P.13A-179
P0299 Turbocharger under boost condition P.13A-180
P0301 No. 1 Cylinder injector malfunction (No injection) P.13A-180
P0335 Crank angle sensor system P.13A-184
P0336 Crank angle sensor range/performance problem P.13A-190
P0340 Camshaft position sensor system P.13A-192
13A-22 DIESEL FUEL
TROUBLESHOOTING

code No.
P0341 Camshaft position sensor range/performance problem P.13A-198
P0381 Glow plug open/short malfunction <Euro5> P.13A-200
P0401 EGR flow insufficient <Euro5> P.13A-204
P0402 EGR flow excessive <Euro5> P.13A-209
P0403 EGR valve (DC motor) malfunction P.13A-215
P0405 EGR valve position sensor circuit low input <Except Euro5> P.13A-219
P0406 EGR valve position sensor circuit high input <Except Euro5> P.13A-227
P0420 Catalyst malfunction <Euro5> P.13A-229
P0427 No. 2 exhaust gas temperature sensor (catalyst temperature) circuit P.13A-231
low input <Euro5>
P0428 No. 2 exhaust gas temperature sensor (catalyst temperature) circuit P.13A-234
high input <Euro5>
P0489 EGR valve position sensor circuit low input <Euro5> P.13A-240
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P0490 EGR valve position sensor circuit high input <Euro5> P.13A-248
P0502 Vehicle speed sensor low input <2WD-M/T and 4WD vehicles> P.13A-251
P0513 Immobilizer malfunction P.13A-254
P0515 Battery temperature sensor system <Euro5> P.13A-255
P0545 No. 1 exhaust gas temperature sensor circuit low input <Euro5> P.13A-260
P0546 No. 1 exhaust gas temperature sensor circuit high input <Euro5> P.13A-263
P0551 Power steering fluid pressure switch system P.13A-268
P0603 EEPROM malfunction <Except Euro5> P.13A-270
P0604 Random access memory (RAM) malfunction P.13A-271
P0605 Read only memory (FLASH ROM) malfunction P.13A-271
P0606 Engine-ECU (main CPU) malfunction P.13A-272
P0607 Engine-ECU (sub CPU) malfunction P.13A-272
P0620 Alternator control circuit <Euro5> P.13A-273
P0628 Suction control valve open <Except Euro5> P.13A-276
P0629 Suction control valve battery short <Except Euro5> P.13A-279
P062F EEPROM malfunction <Euro5> P.13A-282
P0630 Chassis number not programmed P.13A-282
P0638 Throttle valve control servo stuck P.13A-284
P0642 Analog sensor reference voltage No. 1 too low P.13A-286
P0643 Analog sensor reference voltage No. 1 too high P.13A-287
P064C Glow control unit malfunction <Euro5> P.13A-288
P0652 Analog sensor reference voltage No. 2 too low P.13A-290
P0653 Analog sensor reference voltage No. 2 too high P.13A-291
P0683 Glow control unit communication abnormality <Euro5> P.13A-292
DIESEL FUEL
TROUBLESHOOTING
13A-23
code No.
P1203 Capacitor insufficient charging P.13A-296
P1204 Capacitor excessive charging P.13A-296
P1272 Pressure limiter malfunction P.13A-297
P1273 Supply pump insufficient flow P.13A-300
P1274 Supply pump protection P.13A-301
P1275 Supply pump exchange P.13A-302
P1276 Fuel filter exchange <Vehicles with fuel filter pressure switch> P.13A-304
P1277 Fuel filter freeze <Vehicles with fuel filter pressure switch> P.13A-307
P1298 Variable geometry turbocharger control system malfunction (high P.13A-327
pressure) <Euro5>
P1299 Variable geometry turbocharger control system malfunction (low P.13A-328
pressure) <Euro5>
P1427 No. 3 exhaust gas temperature sensor (DPF temperature) circuit low P.13A-310
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input <Euro5>
P1428 No. 3 exhaust gas temperature sensor (DPF temperature) circuit P.13A-313
high input <Euro5>
P1497 DPF system malfunction <Euro5> P.13A-319
P1498 Excessive PM accumulated in DPF <Euro5> P.13A-320
P1499 Abnormally high DPF temperature <Euro5> P.13A-320
P1608 Battery current sensor system <Euro5> P.13A-322
P1625 Injection quantity compensation value error P.13A-327
P1626 Injection quantity compensation value not coding P.13A-328
P2118 Throttle valve control (DC motor) current malfunction P.13A-329
P2122 Accelerator pedal position sensor (main) circuit low input P.13A-333
P2123 Accelerator pedal position sensor (main) circuit high input P.13A-341
P2124 Accelerator pedal position sensor (main) circuit high input intermittent P.13A-345
P2127 Accelerator pedal position sensor (sub) circuit low input P.13A-349
P2128 Accelerator pedal position sensor (sub) circuit high input P.13A-357
P2138 Accelerator pedal position sensor (main and sub) range/performance P.13A-360
problem
P2146 Injector common 1 (cylinder No. 1 and No. 4) circuit open <Euro5> P.13A-368
P2146 Injector common 1 (cylinder No. 1 and No. 4) circuit open <Except P.13A-371
Euro5>
P2147 Injector common 1 (cylinder No. 1 and No. 4) circuit earth short P.13A-374
<Euro5>
P2147 Injector common circuit earth short <Except Euro5> P.13A-378
P2148 Injector common 1 (cylinder No. 1 and No. 4) circuit battery short P.13A-383
<Euro5>
P2148 Injector common circuit battery short <Except Euro5> P.13A-387
13A-24 DIESEL FUEL
TROUBLESHOOTING

code No.
P2149 Injector common 2 (cylinder No. 2 and No. 3) circuit open <Euro5> P.13A-392
P2149 Injector common 2 (cylinder No. 2 and No. 3) circuit open <Except P.13A-396
Euro5>
P2150 Injector common 2 circuit earth short <Euro5> P.13A-399
P2151 Injector common 2 circuit battery short <Euro5> P.13A-403
P2228 Barometric pressure sensor circuit low input P.13A-406
P2229 Barometric pressure sensor circuit high input P.13A-407
P2413 EGR system performance P.13A-408
P2454 Exhaust differential pressure sensor circuit low input <Euro5> P.13A-411
P2455 Exhaust differential pressure sensor circuit high input <Euro5> P.13A-417
P252F Engine oil level malfunction <Euro5> P.13A-419
U1073 Bus off P.13A-420
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U1101* A/T-ECU time-out <A/T> P.13A-421
U1102* ASTC-ECU time-out <Except vehicles for Morocco> P.13A-422
U1109* ETACS-ECU time-out P.13A-424
U1110* A/C-ECU time-out <Euro5> P.13A-425
U1117* ETACS-ECU (Immobilizer- ECU) time-out P.13A-427
U1190 The network system diagnosis code output permitted signal can not P.13A-428
be received
NOTE: *:When the diagnosis codes relating to the CAN communication error are output, make sure of the
vehicle equipment. When the vehicle is not equipped with the system the engine-ECU communicates to, the
diagnosis code is always output. This is not abnormal.
DIESEL FUEL
TROUBLESHOOTING
13A-25
DIAGNOSIS CODE PROCEDURES
Code No. P0003: Suction Control Valve Open <Euro5>
Suction Control Valve Circuit
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
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SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKA00106 AB
OPERATION • 2 seconds later after the ignition switch has been

• The voltage is applied from the engine-ECU (ter- in "ON" position or the engine has started up.
minal No. 131) to the suction control valve (termi- • The supply pump and injector are being normally
nal No. 1) via the power transistor in the engine- controlled.
ECU. • The fuel injection rate is 4 mm3/st or more.
• The voltage is earthed to the engine-ECU (termi-
nal No. 146) from the suction control valve (termi- Judgment Criterion
nal No. 2). • When the driving duty ratio of the suction control
valve is higher than the specified value, the driv-
FUNCTION ing current is lower than the specified value.
• The engine-ECU performs duty control over the
suction control valve. PROBABLE CAUSES
• The engine-ECU checks whether the amount of • Failed suction control valve
current for driving duty is adequate. • Open/short circuit or harness damage in suction
control valve circuit or loose connector contact
TROUBLE JUDGMENT • Failed engine-ECU
Check Conditions
• Battery positive voltage is 8 − 16 V
13A-26 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Connector check: C-103 engine-ECU

connector
STEP 1. Connector check: A-47 suction control Connector: C-103
valve connector <L.H. drive vehicles>
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
<R.H. drive vehicles>
AK503644 AB
Q: Is the check result normal?

YES : Go to Step 2 .
NO : Repair or replace the connector.
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C-103 (B)
STEP 2. Check suction control valve itself.
• Check suction control valve itself (Refer to P.13A- 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
596). 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
Q: Is the check result normal? 158 157156 155 154 153 152 151 150 149 148 147 146
YES : Go to Step 3 . Harness side connector AKA00090 AB

NO : Replace the suction control valve.
DIESEL FUEL
TROUBLESHOOTING
13A-27
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
• Check power supply line for open/short circuit Connector: C-103
and damage. <L.H. drive vehicles>
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B) <R.H. drive vehicles>
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C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 Harness side connector AKA00090 AB
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB

Connector: A-47
2 1
Connector: A-47 Harness side
2 1 connector
Harness side A-47 (GR)
connector
A-47 (GR)
AK503644 AB
• Check earthing line for open/short circuit and

AK503644 AB
damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
STEP 6. M.U.T.-III diagnosis code

• Reconfirmation of diagnosis code.
Q: Is the diagnosis code set?
13A-28 DIESEL FUEL
TROUBLESHOOTING
YES : Replace the engine-ECU. When the engine-

ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
Forcible DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
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Code No. P0004: Suction Control Valve Battery Short <Euro5>
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION ECU.
• The voltage is applied from the engine-ECU (ter- • The voltage is earthed to the engine-ECU (termi-
minal No. 131) to the suction control valve (terminal No. 146) from the suction control valve (termi-
nal No. 1) via the power transistor in the engine- nal No. 2).
DIESEL FUEL
TROUBLESHOOTING
13A-29
FUNCTION YES : Go to Step 2.
• The engine-ECU performs duty control over the NO : Repair or replace the connector.
suction control valve.
• The engine-ECU checks whether the amount of STEP 2. Check suction control valve itself.
current for driving duty is adequate. • Check suction control valve itself (Refer to P.13A-
596).
TROUBLE JUDGMENT
Check Conditions YES : Go to Step 3.
• Battery positive voltage is 8 − 16 V NO : Replace the suction control valve.
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up
• The supply pump and injector are being normally STEP 3. Connector check: C-103 engine-ECU
controlled. connector
• The fuel injection rate is 4 mm3/st or more. Connector: C-103
Judgment Criterion
• When the driving duty ratio of the suction control
valve is lower than the specified value, the driving
current is higher than the specified value.
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PROBABLE CAUSES
• Failed suction control valve C-103 (B)
• Short circuit in suction control valve circuit or
loose connector contact <R.H. drive vehicles>
• Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-47 suction control

valve connector C-103 (B)
Connector: A-47
2 1 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
Harness side 143 142 141 140 139138 137 136 135 134 133 132 131
connector 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-47 (GR) Harness side connector AKA00090 AB

YES : Go to Step 4.
AK503644 AB

13A-30 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
C-103 (B) C-103 (B)
<R.H. drive vehicles> <R.H. drive vehicles>
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C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB Harness side connector AKA00090 AB
Connector: A-47 Connector: A-47

2 1 2 1
Harness side Harness side

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.
YES : Go to Step 5. YES : Go to Step 6.
STEP 6. M.U.T.-III diagnosis code.

DIESEL FUEL
TROUBLESHOOTING
13A-31
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Code No. P0016: Crank Angle Sensor/Camshaft Position Sensor Phase Problem
OPERATION PROBABLE CAUSES

• Refer to Code No. P0335: Crank Angle Sensor • Failed crank angle sensor
System P.13A-184 • Failed camshaft position sensor
• Refer to Code No. P0340: Camshaft Position • Failed timing chain
Sensor System P.13A-192 • Failed engine-ECU
FUNCTION DIAGNOSTIC PROCEDURE

• The engine-ECU monitors the signals input from
the crank angle sensor and camshaft position
sensor. STEP 1. M.U.T.-III diagnosis code.
• The engine-ECU compares these input pulse sig- Q: Is any other diagnosis code than P0016 output?
nals to check the position relations for validity. YES : Inspection chart for diagnosis codes (Refer
to P.13A-21).
TROUBLE JUDGMENT NO : Go to Step 2 .
Check Conditions
• Battery positive voltage is 8 − 16 V STEP 2. Check the timing chain.
• One of the following two is true. • See the timing marks to check for skipped gear
1. 2 seconds have passed after the ignition teeth.
switch is turned on, the crank angle sensor
and camshaft position sensor output signals
are normal, and the engine rotation speed is
NO : Repair.
1,200 r/min or lower.
2. Cranking is in progress, the engine rotation
speed is 350 r/min or faster, and the engine STEP 3. Check crankshaft sensing vane.
coolant temperature is −30°C or higher. Q: Is the check result normal?
Judgment Criterion
NO : Replace the crankshaft sprocket.
• The phase shift angle between the crank and
camshaft position sensor signals exceeds its
threshold value. STEP 4. Check camshaft sensing vane.
YES : Go to Step 5 . NO : Replace the camshaft.
13A-32 DIESEL FUEL
TROUBLESHOOTING

• After clearing the diagnosis code through M.U.T.-
III, start the engine and confirm whether the diag-
nosis code is output.
Q: Is the diagnosis code set? register the injector identification code and
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
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DIESEL FUEL
TROUBLESHOOTING
13A-33
Code No. P0047: Variable Geometry Control Solenoid Valve Circuit Low Input <Euro5>
Variable geometry control solenoid valve circuit
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
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A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00128 AD
• The engine-ECU (terminal No. 17) makes the

OPERATION power transistor in the unit be in "ON" position,
• Power is supplied to the variable geometry con- and that makes currents go on the variable
trol solenoid valve (terminal No. 2) from the geometry control solenoid valve (terminal No. 1).
engine control relay (terminal No. 3).
13A-34 DIESEL FUEL
TROUBLESHOOTING
FUNCTION YES : Go to Step 3 .

• The variable geometry control solenoid valve NO : Repair or replace the connector.
controls the vacuum pressure introduced into the
variable geometry actuator, using the signal from STEP 3. Perform resistance measurement at A-56
the engine-ECU. This allows the boost pressure variable geometry control solenoid valve
to be adequate for the driving conditions. connector.
TROUBLE JUDGMENT Connector: A-56
Check Conditions A-56 (BR)

• Battery positive voltage is 8 − 16 V.
• 2 seconds later after the engine has started up.
Judgment Criterion
• Variable geometry control solenoid valve output
voltage is 0.4 V or less (driving current is abnor- 2 1
mally low). Harness side
connector AK900982AC
PROBABLE CAUSES
• Disconnect connector, and measure at solenoid
• Failed variable geometry control solenoid valve
valve side.
• Open/short circuit or harness damage in variable
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• Resistance between terminal No. 1 and No. 2.
geometry control solenoid valve circuit or loose
connector contact OK: 10 − 14 Ω (at 20°C)
• Failed engine-ECU Q: Is the check result normal?
DIAGNOSIS PROCEDURE NO : Replace the variable geometry control
solenoid valve.
STEP 1. M.U.T.-III actuator test
• Item 36: Variable geometry control solenoid valve STEP 4. Perform voltage measurement at A-56
OK: The variable geometry actuator is oper- variable geometry control solenoid valve
ated connector.
Connector: A-56
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/ A-56 (BR)
NO : Go to Step 2 .
2 1
STEP 2. Connector check: A-56 variable
Harness side
geometry control solenoid valve connector connector AK900982AC
Connector: A-56
• Disconnect connector, and measure at harness
side.
A-56 (BR)
• Ignition switch: ON
• Voltage between terminal No. 2 and earth.
OK: System voltage
2 1 YES : Go to Step 6 .
Harness side NO : Go to Step 5 .

DIESEL FUEL
TROUBLESHOOTING
13A-35
STEP 5. Connector check: A-20X engine control STEP 6. Perform voltage measurement at C-105
relay connector engine-ECU connector.
Connector: A-20X Connector: C-105
A-20X
2 1
3
4 C-105 (B)
Relay box's side
connector AK501321 AC
Connector: A-56
A-56 (BR)
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C-105 (B)
2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Harness side
connector AK900982AC 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal? Harness side connector AKA00089 AB

YES : Check and repair harness between A-56
(terminal No. 2) variable geometry control • Disconnect connector, and measure at harness
solenoid valve connector and A-20X side.
(terminal No. 3) engine control relay • Ignition switch: ON
connector. • Voltage between terminal No. 17 and earth.
• Check power supply line open/short OK: System voltage
circuit
NO : Go to Step 7 .
13A-36 DIESEL FUEL
TROUBLESHOOTING

STEP 7. Connector check: C-105 engine-ECU
(terminal No. 1) variable geometry control
connector
solenoid valve connector and C-105
Connector: C-105 (terminal No. 17) engine-ECU connector.
• Check output line for open/short
circuit.

connector
C-105 (B)
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-56
C-105 (B)
A-56 (BR)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

2 1
Harness side Q: Is the check result normal?
connector AK900982AC YES : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-37
STEP 9. Check harness between A-56 (terminal
NO : Repair the damaged harness wire.
No. 1) variable geometry control solenoid valve
connector and C-105 (terminal No. 17) engine-
ECU connector. STEP 10. Check harness between A-56 (terminal
Connector: A-56
connector and A20X (terminal No. 3) engine
A-56 (BR)
control relay connector.
Connector: A-56
A-56 (BR)
2 1
Harness side
2 1
Connector: C-105
<L.H. drive vehicles> Harness side
cardiagn.com
Connector: A-20X
A-20X
C-105 (B)
2 1
3
<R.H. drive vehicles> 4
Relay box's side
• Check power supply line for damage.

C-105 (B) NO : Repair the damaged harness wire.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
STEP 11. M.U.T.-III actuator test
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 • Item 36: Variable geometry control solenoid valve
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
OK: The variable geometry actuator is oper-
Harness side connector AKA00089 AB ated
• Check output line for damage. Q: Is the check result normal?
13A-38 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the engine-ECU. When the engine-
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-39
Code No. P0048: Variable Geometry Control Solenoid Valve Circuit High Input <Euro5>
Variable geometry control solenoid valve circuit
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
cardiagn.com
A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00128 AD
• The engine-ECU (terminal No. 17) makes the

OPERATION power transistor in the unit be in "ON" position,
• Power is supplied to the variable geometry con- and that makes currents go on the variable
trol solenoid valve (terminal No. 2) from the geometry control solenoid valve (terminal No. 1).
engine control relay (terminal No. 3).
13A-40 DIESEL FUEL
TROUBLESHOOTING
FUNCTION DIAGNOSIS PROCEDURE

• The variable geometry control solenoid valve
controls the vacuum pressure introduced into the
variable geometry actuator, using the signal from STEP 1. Connector check: A-56 variable
the engine-ECU. This allows the boost pressure geometry control solenoid valve connector, C-
to be adequate for the driving conditions. 105 engine-ECU connector
Connector: A-56
TROUBLE JUDGMENT
Check Conditions A-56 (BR)
• 2 seconds later after the engine has started up.
Judgment Criterion
• Variable geometry control solenoid valve output 2 1
voltage is 4.5 V or more (driving current is abnor-
Harness side
mally high). connector AK900982AC
PROBABLE CAUSES Connector: C-105

• Short circuit in variable geometry control solenoid <L.H. drive vehicles>
valve circuit or loose connector contact
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Are the check results normal?

DIESEL FUEL
TROUBLESHOOTING
13A-41
ECU connector. STEP 3. M.U.T.-III diagnosis code
Connector: A-56
Q: Is diagnosis code set?
A-56 (BR) YES : Replace the engine-ECU. When the engine-
2 1 register the injector identification code and
Harness side
connector AK900982AC Precautions Before Service − What The
Connector: C-105 registering the injector identification code,
cardiagn.com
C-105 (B) Inspection Service Points − How to Cope
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit.

13A-42 DIESEL FUEL
TROUBLESHOOTING
Code No. P0072: Intake Air Temperature Sensor No. 1 Circuit Low Input <Euro5>
Intake Air Temperature Sensor No. 1 Circuit
A-135 Intake air temperature

sensor No. 1 (integrated in
1 2 3 4 5 air flow sensor)
1 2
B-L Y-L
cardiagn.com
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
AKA00356 AB
OPERATION TROUBLE JUDGMENT

• A power voltage of 5 V is applied to the intake air
Check Conditions
temperature sensor No. 1 output terminal (termi-
nal No. 2) from the engine-ECU (terminal No. 62).
• The power voltage is earthed to the engine-ECU
in "ON" position or the engine has started up.
(terminal No. 86) from the intake air temperature
sensor No. 1 (terminal No. 1). Judgment Criterion
• The intake air temperature sensor No. 1 output
FUNCTION voltage is 0.09 V or less for 0.5 second.
• The intake air temperature sensor No. 1 converts
the intake air temperature into a voltage and PROBABLE CAUSES
inputs the voltage signal to the engine-ECU. • Failed intake air temperature sensor No. 1
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in intake air tem-
rects the fuel injection amount, etc. perature sensor No.1 circuit or loose connector
• The intake air temperature sensor No. 1 is a kind contact
of resistor, which has characteristics to reduce its • Failed engine-ECU
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.
DIESEL FUEL
TROUBLESHOOTING
13A-43
DIAGNOSIS PROCEDURE STEP 4. Perform Voltage measurement at A-135
air flow sensor connector.
STEP 1. M.U.T.-III data list Connector: A-135
• Item 43: Intake air temperature sensor No. 1
OK: At ambient temperature (atmospheric
temperature) or equivalent.
with Intermittent Malfunctions ). Harness side A-135 (B)
connector AKA00399AB
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-135 air flow sensor
connector
Connector: A-135
OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .

connector
Harness side A-135 (B) Connector: C-105
connector AKA00399AB <L.H. drive vehicles>

STEP 3. Check intake air temperature sensor No.

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself
(Refer to P.13A-595). <R.H. drive vehicles>
NO : Replace the air flow sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-44 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
cardiagn.com
C-105 (B) Diesel Particulate Filter (DPF) System −
STEP 8. Perform resistance measurement at A-
135 air flow sensor connector.
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side A-135 (B)

Harness side connector AKA00089 AB connector AKA00399AB
• Check output line for short circuit. • Disconnect connector, and measure at harness
Q: Is the check result normal? side.
YES : Go to Step 7 . • Resistance between terminal No. 1 and earth.
NO : Repair the damaged harness wire. OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-45
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-135 (terminal
connector No. 1) air flow sensor connector and C-105
Connector: C-105
(terminal No. 86) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line for damage.
Connector: A-135
C-105 (B)

Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-46 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> Connector: A-135
C-105 (B)

<R.H. drive vehicles> connector AKA00399AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for damage.

DIESEL FUEL
TROUBLESHOOTING
13A-47
Code No. P0072: Intake Air Temperature Sensor No. 2 Circuit Low Input <Except Euro5>
A-136
(MU802409)
Intake air temperature
sensor No. 2
1 2
2 1
B-P L-R
cardiagn.com
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00091 AB

Check Conditions
sensor (terminal No. 2). Judgment Criterion
FUNCTION voltage is 0.05 V or less (the intake air tempera-
• The intake air temperature sensor No. 2 converts ture is above 150°C or equivalent) for 0.5 second.
the intake air temperature into a voltage and
inputs the voltage signal to the engine-ECU. PROBABLE CAUSES
• In response to the signal, the engine-ECU cor- • Failed intake air temperature sensor No. 2
rects the fuel injection amount, etc. • Short circuit or harness damage in intake air tem-
• The intake air temperature sensor No. 2 is a kind perature sensor No. 2 circuit or loose connector
of resistor, which has characteristics to reduce its contact
resistance as the intake air temperature rises. • Failed engine-ECU
the fuel temperature, and becomes lower as the
intake air temperature rises.
13A-48 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4. Perform voltage measurement at A-136

intake air temperature sensor No. 2 connector.
temperature) or equivalent. A-136 (B)

2 1
with Intermittent Malfunctions ). Harness side
connector
NO : Go to Step 2 . AK501317 AB

side.
STEP 2. Connector check: A-136 intake air
temperature sensor No. 2 connector
Connector: A-136
OK: 4.5 − 4.9 V
cardiagn.com
A-136 (B) YES : Go to Step 8 .
NO : Go to Step 5 .

2 1 connector
Harness side Connector: C-105
connector AK501317 AB <L.H. drive vehicles>


C-105 (B)
2 itself.
NO : Replace the intake air temperature sensor
No. 2.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-49
No. 1) intake air temperature sensor No. 2 • Item 8: Intake air temperature sensor No. 2
connector and C-105 (terminal No. 38) engine- OK: At ambient temperature (atmospheric
ECU connector. temperature) or equivalent.
Connector: A-136 Q: Is the check result normal?
A-136 (B) Inspection Service Points − How to Cope
2 1 (Refer to GROUP 00 − Precautions Before
Harness side Service − How to Perform Chassis Number
connector AK501317 AB Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> learn fuel injection (Refer to GROUP 00 −
Common Rail Engine Learns ).
cardiagn.com
136 intake air temperature sensor No. 2
C-105 (B) connector.
Connector: A-136
A-136 (B)
2 1
C-105 (B) Harness side
connector AK501317 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 2 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB OK: Continuity (2 Ω or less)

• Check output line for short circuit. Q: Is the check result normal?
NO : Go to Step 9 .
13A-50 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) intake air temperature sensor No. 2
Connector: C-105
<L.H. drive vehicles> ECU connector.
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check earthing line for damage.

DIESEL FUEL
TROUBLESHOOTING
13A-51
Connector: C-105
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-52 DIESEL FUEL
TROUBLESHOOTING
Code No. P0073: Intake Air Temperature Sensor No. 1 Circuit High Input <Euro5>

1 2
B-L Y-L
cardiagn.com
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
temperature sensor No.1 output terminal (termi-
nal No. 2) of air flow sensor connector from the
engine-ECU (terminal No. 62).
(terminal No. 86) from the intake air temperature Judgment Criterion
sensor No. 1 (terminal No. 1). • The intake air temperature sensor No. 1 output
voltage is 4.87 V or more for 0.5 second.
FUNCTION
• The intake air temperature sensor No. 1 converts PROBABLE CAUSES
the intake air temperature into a voltage and • Failed intake air temperature sensor No. 1
inputs the voltage signal to the engine-ECU. • Open circuit or harness damage in intake air tem-
• In response to the signal, the engine-ECU cor- perature sensor No. 1 circuit or loose connector
rects the fuel injection amount, etc. contact
• The intake air temperature sensor No. 1 is a kind • Failed engine-ECU
of resistor, which has characteristics to reduce its
DIESEL FUEL
TROUBLESHOOTING
13A-53
air flow sensor No. 1 connector.
• Refer to Data List Reference Table P.13A-542.
a. Item 43: Intake air temperature sensor No. 1
Harness side
Inspection Service Points − How to Cope connector
A-135 (B)
AKA00399AB
NO : Go to Step 2 . • Disconnect connector, and measure at harness
side.
connector
OK: 4.5 − 4.9 V
Connector: A-135
cardiagn.com
NO : Go to Step 5 .

connector
Connector: C-105
Harness side A-135 (B) <L.H. drive vehicles>

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
(Refer to P.13A-595).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-54 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
cardiagn.com
C-105 (B) Diesel Particulate Filter (DPF) System −
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Harness side connector AKA00089 AB connector AKA00399AB
• Check output line for open circuit. • Disconnect connector, and measure at harness
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-55
Connector: C-105
<L.H. drive vehicles> • Check earthing line open circuit and damage.
Connector: A-135
C-105 (B)

Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-56 DIESEL FUEL
TROUBLESHOOTING
Code No. P0073: Intake Air Temperature Sensor No. 2 Circuit High Input <Except Euro5>
A-136
(MU802409)
sensor No. 2
1 2
2 1
B-P L-R
cardiagn.com
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00091 AB

Check Conditions
FUNCTION voltage is 4.9 V or more (the intake air tempera-
• The intake air temperature sensor No. 2 converts ture is below −40°C or equivalent) for 0.5 second.
the intake air temperature into a voltage and
inputs the voltage signal to the engine-ECU. PROBABLE CAUSES
• In response to the signal, the engine-ECU cor- • Failed intake air temperature sensor No. 2
rects the fuel injection amount, etc. • Open circuit in intake air temperature sensor No.
• The intake air temperature sensor No. 2 is a kind 2 circuit or loose connector contact
the fuel temperature, and becomes lower as the
intake air temperature rises.
DIESEL FUEL
TROUBLESHOOTING
13A-57
intake air temperature sensor No. 2 connector.
temperature) or equivalent. A-136 (B)

2 1
connector

side.
STEP 2. Connector check: A-136 intake air
temperature sensor No. 2 connector
Connector: A-136
OK: 4.5 − 4.9 V
cardiagn.com
A-136 (B) YES : Go to Step 8 .
NO : Go to Step 5 .

2 1 connector


C-105 (B)
2 itself.
NO : Replace the intake air temperature sensor
No. 2.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-58 DIESEL FUEL
TROUBLESHOOTING
No. 1) intake air temperature sensor No. 2 • Item 8: Intake air temperature sensor No. 2
connector and C-105 (terminal No. 38) engine- OK: At ambient temperature (atmospheric
ECU connector. temperature) or equivalent.
2 1 (Refer to GROUP 00 − Precautions Before
Connector: C-105
cardiagn.com
136 intake air temperature sensor No. 2
C-105 (B) connector.
Connector: A-136
A-136 (B)
2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for open circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-59
Connector: C-105
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check earthing line for open circuit.

Code No. P0088: Common Rail High Pressure Malfunction
OPERATION • Sensor signals are input from the rail pressure

• 5 V power is supplied from the engine-ECU (ter- sensor (terminal No. 2) to the engine-ECU (termi-
minal No. 70) to the rail pressure sensor (terminal nal No. 64).
No. 1).
• The rail pressure sensor (terminal No. 3) is FUNCTION
earthed to the engine-ECU (terminal No. 88). • The engine-ECU monitors the signals input from
the rail pressure sensor.
13A-60 DIESEL FUEL
TROUBLESHOOTING
• Based on The input signals, the engine-ECU STEP 3. Connector check: C-105 engine-ECU
checks whether the fuel pressure in the common connector and A-47 suction control valve
rail exceeds the maximum withstand pressure of connector.
the system.
Connector: C-105
TROUBLE JUDGMENT <L.H. drive vehicles>
Check Conditions
• Rail pressure sensor is normal
Judgment Criterion
• The rail pressure exceeds the threshold value of C-105 (B)
an abnormal high pressure for 3 seconds (contin-
uous or accumulated).
PROBABLE CAUSES
• Failed suction control valve
• Failed rail pressure sensor
cardiagn.com
DIAGNOSIS PROCEDURE
C-105 (B)
STEP 1. M.U.T.-III diagnosis code 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Q: Is any other diagnosis code than P0088 output? 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

YES : Inspection chart for diagnosis codes (Refer 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
to P.13A-21). Harness side connector AKA00089 AB

NO : Go to Step 2 .
Connector: A-47
STEP 2. Check suction control valve itself 2 1
• Check suction control valve itself (Refer to P.13A- Harness side
596). connector
Q: Is the check result normal? A-47 (GR)

NO : Replace the suction control valve. After
replacing the suction control valve, learn the
supply pump (Refer to GROUP 00 − AK503644 AB
Common Rail Engine Learns ). Q: Are the check results normal?
DIESEL FUEL
TROUBLESHOOTING
13A-61
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
13A-62 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Perform output wave pattern STEP 7. Replace the common rail assembly and
measurement at A-47 suction control valve fuel injection tubes.
(Using an oscilloscope). • After replacing the common rail assembly and
fuel injection tubes, re-check the trouble symp-
Connector: A-47
2 1
toms
Harness side
Q: Does trouble symptom persist?
connector YES : Replace the engine-ECU. When the engine-
A-47 (GR) (Refer to GROUP 00 − Precautions Before
AK503644 AB learn fuel injection (Refer to GROUP 00 −
• Engine: Idling Precautions Before Service − What The
• Connect the oscilloscope special patterns pickup Common Rail Engine Learns ). After
to engine-ECU terminal No. 146 and earth. registering the injector identification code,
OK: The waveform should show a pattern out the forcible DPF regeneration. (Refer to
similar to the illustration of inspection proce- GROUP 17 − Emission Control − Diesel
cardiagn.com
dure using an oscilloscope (Refer to P.13A- Particulate Filter (DPF) System − Forcible
586). DPF Regeneration ).
Q: Is the check result normal? NO : The check is end.
supply pump (Refer to GROUP 00 −
Code No. P0089: Suction Control Valve Stuck
OPERATION • 2 seconds later after the ignition switch has been

• Battery power is supplied from the engine-ECU in "ON" position or the engine has started up
(terminal No. 131) to the suction control valve
Judgment Criterion
(terminal No. 1).
• The actual rail pressure remains higher than the
• The engine-ECU (terminal No. 146) turns on the
objective rail pressure by 10 MPa or more for a
power transistor to flow current to the suction
certain interval.
control valve (terminal No. 2).
PROBABLE CAUSES
FUNCTION
the rail pressure sensor.
• The engine-ECU monitors the difference between
DIAGNOSIS PROCEDURE
the target fuel pressure and actual fuel pressure
to check whether the suction control valve is
open or fixed. STEP 1. M.U.T.-III actuator test.
• Refer to Actuator Test Table P.13A-574.
TROUBLE JUDGMENT a. Item 19: Suction control valve
Check Conditions Q: Is the check result normal?
• Battery positive voltage is 8 − 16 V YES : Go to Step 2 .
NO : Go to Step 4 .
DIESEL FUEL
TROUBLESHOOTING
13A-63
STEP 2. Make a check on the following items. STEP 4. Replace the suction control valve.
• Check for foreign matters (water, kerosene, etc.) • After the suction control valve, learn the supply
in fuel and replace if necessary. pump. (Refer to GROUP 00 − Precautions Before
• Check fuel filter itself. Service − What The Common Rail Engine Learns
).
YES : Go to Step 3 . • After learning the supply pump assembly, re-
NO : Make a repair or replacement for items check the trouble symptoms
whose checking results are abnormal. Q: Does trouble symptom persist?
STEP 3. M.U.T.-III diagnosis code. ECU is replaced, write the chassis number
• Reconfirmation of diagnosis code (Refer to GROUP 00 − Precautions Before
Q: Is the diagnosis code set? Writing ). After replacing the engine-ECU,
YES : Replace the engine-ECU. When the engine- register the injector identification code and
ECU is replaced, write the chassis number learn fuel injection (Refer to GROUP 00 −
(Refer to GROUP 00 − Precautions Before Precautions Before Service − What The
Service − How to Perform Chassis Number Common Rail Engine Learns ). After
Writing ). After replacing the engine-ECU, registering the injector identification code,
cardiagn.com
learn fuel injection (Refer to GROUP 00 − out the forcible DPF regeneration. (Refer to
Precautions Before Service − What The GROUP 17 − Emission Control − Diesel
Common Rail Engine Learns ). After Particulate Filter (DPF) System − Forcible
registering the injector identification code, DPF Regeneration ).
the vehicle equipped with the DPF carries NO : The check is end.
DPF Regeneration ).
Code No. P0093: Fuel Leak Problem

• Refer to Code No. P0192: Rail Pressure Sensor
Check Conditions
Circuit Low Input P.13A-147.
FUNCTION • 2 seconds later after the ignition switch has been
• The engine-ECU monitors the signals input from in "ON" position or the engine has started up
the rail pressure sensor. • The engine speed is 600 r/min or more
• The engine-ECU controls the suction control • Rail pressure sensor is normal
valve so that necessary fuel pressure can be Judgment Criterion
obtained before fuel injection. • The fuel discharge rate of the supply pump con-
• The engine-ECU compares the fuel pressure tinues to exceed its threshold value against the
immediately before fuel injection and the fuel fuel injection rate.
pressure after injection to check whether. The
pressure drop greatly exceeds the expected PROBABLE CAUSES
range determined based on fuel consumption. • Fuel leakage or fuel line blocked
The engine-ECU detects fuel leaks in this way. • Failed injector
13A-64 DIESEL FUEL
TROUBLESHOOTING
• Failed rail pressure sensor. STEP 4. Connector check: A-44 rail pressure
• Harness damage in rail pressure sensor circuit or sensor connector and C-105 engine-ECU
loose connector contact. connector.
Connector: A-44
DIAGNOSTIC PROCEDURE

Q: Is any other diagnosis code than P0093 set?
YES : Inspection chart for diagnosis codes (Refer
to P.13A-21). 3 2 1
NO : Go to Step 2 . A-44 (B)
Harness side
STEP 2. Detection of fuel line leakage Connector: C-105

• Check whether fuel is leaking from a high-pres- <L.H. drive vehicles>
sure fuel line.
cardiagn.com
NO : Replace the parts of an abnormal location.
C-105 (B)
STEP 3. Release the air from the fuel line.
• After releasing the air from the fuel line, continue
idle operation for about five minutes and recheck <R.H. drive vehicles>
for trouble symptoms.
Q: Does the trouble symptom persist?
NO : The check is end.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-65
STEP 5. Check harness between A-44 (terminal STEP 6. Check harness between A-44 (terminal
No. 1) rail pressure sensor connector and C-105 No. 2) rail pressure sensor connector and C-105
(terminal No. 70) engine-ECU connector. (terminal No. 64) engine-ECU connector.
3 2 1 3 2 1
A-44 (B) A-44 (B)
connector AK501327 AB connector AK501327 AB

cardiagn.com
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-131, and repair if necessary. connector A-131, and repair if necessary.
• Check power supply line for damage. • Check output line for damage.
13A-66 DIESEL FUEL
TROUBLESHOOTING
No. 3) rail pressure sensor connector and C-105
STEP 8. Detection of fuel leakage from injector
Connector: A-44
body
• Remove the injector. Check whether there is the
evidence of the fuel leakage from the injector
body.
3 2 1 NO : Replace the abnormal injector. After
A-44 (B) replacing the injector, register the injector
Harness side
connector AK501327 AB identification code and learn fuel injection.
Connector: C-105 Service − What The Common Rail Engine
Learns ).
STEP 9. Replace the common rail assembly and
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fuel injection tubes.
• After replacing the common rail assembly and
C-105 (B)
toms.
<R.H. drive vehicles> YES : Replace the engine-ECU. When the engine-
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 registering the injector identification code,
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB GROUP 17 − Emission Control − Diesel
NOTE: Before checking harness, check intermediate DPF Regeneration ).
connector A-131, and repair if necessary. NO : The check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-67
Code No. P0102: Air flow Sensor Circuit Low Input
Air Flow Sensor Circuit
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
cardiagn.com
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00355 AB
OPERATION • The air flow sensor (terminal No. 3) outputs a

• Power is supplied by the engine control relay (ter- sensor signal, which is input into the engine-ECU
minal No. 3) to the air flow sensor (terminal No. (terminal No. 140).
5), and the air flow sensor (terminal No. 4) is
earthed through the engine-ECU (terminal No.
155).
13A-68 DIESEL FUEL
TROUBLESHOOTING
FUNCTION STEP 3. Perform voltage measurement at A-135

• The air flow sensor outputs pulse signal that var- air flow sensor connector.
ies in accordance with the intake air volume.
• In response to the signal, the engine-ECU con- Connector: A-135
trols EGR control, etc.
TROUBLE JUDGMENT
Check Conditions
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 0.50 V or
less.
side.
PROBABLE CAUSES • Ignition switch: ON
• Failed air flow sensor • Voltage between terminal No. 5 and earth.
• Open/short circuit or harness damage in air flow OK: System voltage
sensor circuit or loose connector contact
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• Failed engine-ECU YES : Go to Step 5 .
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 4. Connector check: A-20X engine control
STEP 1. M.U.T.-III data list relay connector
Connector: A-20X
a. Item 114: Air flow sensor
Q: Is the check result normal? A-20X
Inspection Service Points − How to Cope 2 1
with Intermittent Malfunctions ). 3
NO : Go to Step 2 . 4
Relay box's side
connector
STEP 2. Connector check: A-135 air flow sensor AK501321 AC
connector Connector: A-135

Connector: A-135

DIESEL FUEL
TROUBLESHOOTING
13A-69
YES : Check and repair harness between A-20X
(terminal No. 3) engine control relay
connector
connector and A-135 (terminal No. 5) air
flow sensor connector. Connector: C-103
• Check power supply for open/short <L.H. drive vehicles>
circuit.

C-103 (B)
Connector: A-135
cardiagn.com
Harness side A-135 (B) C-103 (B)
• Disconnect connector, and measure at harness 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
side. 117 116
• Resistance between terminal No. 4 and earth. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
OK: Continuity (2 Ω or less) Harness side connector AKA00090 AB

YES : Go to Step 9 . Q: Is the check result normal?
NO : Go to Step 6 . YES : Go to Step 7 .
13A-70 DIESEL FUEL
TROUBLESHOOTING
No. 4) air flow sensor connector and C-103 Connector: A-135
Connector: A-135


connector AKA00399AB Connector: C-103
Connector: C-103
cardiagn.com
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-71
YES : Intermittent malfunction (Refer to GROUP YES : Go to Step 12 .
00 − How to Use Troubleshooting/ NO : Go to Step 10 .
with Intermittent Malfunctions ). STEP 10. Connector check: C-103 engine-ECU
connector
(Refer to GROUP 00 − Precautions Before Connector: C-103
registering the injector identification code, C-103 (B)
out the forcible DPF regeneration. (Refer to <R.H. drive vehicles>
DPF Regeneration ).
cardiagn.com
STEP 9. Perform voltage measurement at A-135
C-103 (B)
Connector: A-135
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Harness side
connector
A-135 (B) NO : Repair or replace the connector.
AKA00399AB

side.
OK: 4.9 − 5.1 V
13A-72 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Check harness between A-135 (terminal STEP 12. Perform voltage measurement at C-103
No. 3) air flow sensor connector and C-103 engine-ECU connector.
(terminal No. 140) engine-ECU connector. Connector: C-103
Connector: A-135 <L.H. drive vehicles>
C-103 (B)
Harness side A-135 (B) <R.H. drive vehicles>

Connector: C-103
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Harness side A-135 (B)
Harness side connector AKA00090 AB • Measure engine-ECU terminal voltage.
• Check output line for short circuit. • Disconnect A-135 air flow sensor connector.
YES : Replace the air flow sensor. • Voltage between terminal No. 140 and earth.
NO : Repair the damaged harness wire. OK: 4.9 − 5.1 V
NO : Go to Step 13 .
DIESEL FUEL
TROUBLESHOOTING
13A-73
(terminal No. 3) air-flow sensor connector
connector
and C-103 (terminal No. 140) engine-ECU
Connector: C-103 connector.
<L.H. drive vehicles> • Check output line for open circuit.

connector
Connector: C-103
C-103 (B)
C-103 (B)
cardiagn.com
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: A-135
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Harness side YES : Go to Step 8 .
A-135 (B)
connector AKA00399AB NO : Repair or replace the connector.

13A-74 DIESEL FUEL
TROUBLESHOOTING
Code No. P0103: Air Flow Sensor Circuit High Input
Air Flow Sensor Circuit
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
cardiagn.com
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00355 AB
OPERATION • The air flow sensor (terminal No. 3) outputs a

• Power is supplied by the engine control relay (ter- sensor signal, which is input into the engine-ECU
minal No. 3) to the air flow sensor (terminal No. (terminal No. 140).
5), and the air flow sensor (terminal No. 4) is
earthed through the engine-ECU (terminal No.
155).
DIESEL FUEL
TROUBLESHOOTING
13A-75
FUNCTION STEP 3. Perform resistance measurement at A-
• The air flow sensor outputs pulse signal that var- 135 air flow sensor connector.
ies in accordance with the intake air volume.
• In response to the signal, the engine-ECU con- Connector: A-135
trols EGR control, etc.
TROUBLE JUDGMENT
Check Conditions
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 4.72 V or
more.
side.
PROBABLE CAUSES • Resistance between terminal No. 4 and earth.
• Failed air flow sensor OK: Continuity (2 Ω or less)
• Open circuit in air flow sensor circuit or loose Q: Is the check result normal?
connector contact
cardiagn.com
• Failed engine-ECU NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
connector
STEP 1. M.U.T.-III data list Connector: C-103
• Refer to Data List Reference Table P.13A-542. <L.H. drive vehicles>
with Intermittent Malfunctions ). C-103 (B)
NO : Go to Step 2 .
connector
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
connector AKA00399AB Harness side connector AKA00090 AB

NO : Repair or replace the connector. NO : Repair or replace the connector.
13A-76 DIESEL FUEL
TROUBLESHOOTING
No. 4) air flow sensor connector and C-103
STEP 6. M.U.T.-III data list
Connector: A-135
Harness side NO : Replace the engine-ECU. When the engine-
A-135 (B)
connector AKA00399AB ECU is replaced, write the chassis number
Connector: C-103 Service − How to Perform Chassis Number
cardiagn.com
C-103 (B) the vehicle equipped with the DPF carries
<R.H. drive vehicles> GROUP 17 − Emission Control − Diesel
DPF Regeneration ).

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 YES : Intermittent malfunction (Refer to GROUP
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Inspection Service Points − How to Cope
Harness side connector AKA00090 AB NO : Replace the air flow sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-77
Code No. P0106: Manifold Absolute Pressure Sensor Range/Performance Problem
Manifold Absolute Pressure Sensor Circuit
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
cardiagn.com
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

R: Red P: Pink V:Violet PU: Purple SI:Silver
AKA00093 AB
OPERATION • The following 3 conditions are formed:

• A power voltage of 5 V is applied to the manifold 1. The engine cooling water temperature is from
absolute pressure sensor power terminal (termi- −5 to 80 °C.
nal No. 1) from the engine-ECU (terminal No. 72) 2. The air intake temperature is from −5 to 80
and earthed to the engine-ECU (terminal No. 31)
°C.
from the manifold absolute pressure sensor (ter-
3. The atmospheric pressure is from 76 to 120
minal No. 3).
kPa.
• The sensor signal is inputted to the engine-ECU
(terminal No. 37) from the manifold absolute Judgment Criterion
pressure sensor output terminal (terminal No. 2). • When an idle state and an engine rotation speed
of 2,000 r/min continue for three seconds, mani-
FUNCTION fold absolute pressures are read and the differ-
• The manifold absolute pressure sensor converts ence between them goes under 800 Pa for 1
the manifold absolute pressure into a voltage sig- second.
nal and inputs the signal to the engine-ECU.
• In response to the signal, the engine-ECU cor- PROBABLE CAUSES
rects the fuel injection amount, etc. • Failed manifold absolute pressure sensor
• Manifold absolute pressure sensor circuit har-
TROUBLE JUDGMENT ness damage or loose connector contact.
Check Conditions • EGR cooler clogged.
• Battery positive voltage is 8 − 16 V • EGR pipe (A, B) clogged.
• 2 seconds later after the ignition switch has been • Failed engine-ECU
13A-78 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE YES : Go to Step 5.

NO : Go to Step 4.

• Refer to Data List Reference Table P.13A-542. STEP 4. Connector check: C-105 engine-ECU
connector
a. Item 6: Manifold absolute pressure sensor
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 10.
NO : Go to Step 2.
STEP 2. Connector check: A-105 manifold

absolute pressure sensor connector
Connector: A-105 C-105 (B)
3 2 1
Harness side
A-105 (L) connector <R.H. drive vehicles>
cardiagn.com
AK900797 AB C-105 (B)
Q: Is the check result normal? 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

YES : Go to Step 3. 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
NO : Repair or replace the connector. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector

STEP 3. Perform voltage measurement at A-105 AKA00089 AB
manifold absolute pressure sensor connector.

Connector: A-105
Connector: A-105 3 2 1
3 2 1 Harness side
Harness side A-105 (L) connector
A-105 (L) connector
AK900797 AB
AK900797 AB
• Use special tool test harness (MB991709) to con- YES : Check and repair harness between A-105
nect connector, and measure at pick-up harness. (terminal No. 1) manifold absolute pressure
• Ignition switch: ON sensor connector and C-105 (terminal No.
• Voltage between terminal No. 1 and earth. 72) engine-ECU connector.
OK: 4.9 − 5.1 V • Check power supply line for damage.
Q: Is the check result normal? NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-79
STEP 5. Perform voltage measurement at A-105 STEP 6. Connector check: C-105 engine-ECU
manifold absolute pressure sensor connector. connector
Connector: A-105 Connector: C-105
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
• Use special tool harness (MB991709) to connect
connector, and measure at pick-up harness.
OK: 0.5 V or less
cardiagn.com
Q: Is the check result normal? C-105 (B)
YES : Go to Step 7.
NO : Go to Step 6. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB

(terminal No. 3) manifold absolute pressure
sensor connector and C-105 (terminal No.
31) engine-ECU connector.
13A-80 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Perform voltage measurement at A-105 STEP 8. Perform voltage measurement at C-105
manifold absolute pressure sensor connector. engine-ECU connector.
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
OK: The voltage should be 0.7 − 1.2 V. When
the accelerator pedal is quickly depressed
cardiagn.com
from the idling state, the voltage temporarily C-105 (B)
rises.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
NO : Replace the manifold absolute pressure

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
sensor. Harness side connector AKA00089 AB
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
• Measure engine-ECU terminal voltage.

OK: The voltage should be 0.7 − 1.2 V. When
the accelerator pedal is quickly depressed
from the idling state, the voltage temporarily
rises.
YES : Go to Step 9.
NO : Check and repair harness between A-105
DIESEL FUEL
TROUBLESHOOTING
13A-81
NO : Replace the EGR cooler.
connector
Connector: C-105
<L.H. drive vehicles> STEP 11. Check on clogged EGR pipe (A, B).
• Check whether the EGR pipe (A, B) is being
clogged or not.
NO : Replace the EGR pipe (A, B).
C-105 (B)
cardiagn.com
C-105 (B) NO : Replace the engine-ECU. When the engine-
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 (Refer to GROUP 00 − Precautions Before
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 Writing ). After replacing the engine-ECU,
Q: Is the check result normal? Precautions Before Service − What The
YES : Go to Step 10. Common Rail Engine Learns ). After
NO : Repair or replace the connector. registering the injector identification code,
STEP 10. Check on clogged EGR cooler. out the forcible DPF regeneration. (Refer to
NOTE: When checking the clogged EGR cooler,
make a visual check or use an air blower.
DPF Regeneration ).
• Check whether the EGR cooler is being clogged
or not.
13A-82 DIESEL FUEL
TROUBLESHOOTING
Code No. P0107: Manifold Absolute Pressure Sensor Circuit Low Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
cardiagn.com
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00093 AB
OPERATION Judgment Criterion

• A power voltage of 5 V is applied to the manifold • The manifold absolute pressure sensor output
absolute pressure sensor power terminal (termi- voltage should is lower than 0.28 V for 0.5 sec-
nal No. 1) from the engine-ECU (terminal No. 72) onds.
and earthed to the engine-ECU (terminal No. 31)
from the manifold absolute pressure sensor (ter- PROBABLE CAUSES
minal No. 3). • Failed manifold absolute pressure sensor
• The sensor signal is inputted to the engine-ECU • Open/short or harness damage circuit in manifold
(terminal No. 37) from the manifold absolute absolute pressure sensor circuit or loose connec-
pressure sensor output terminal (terminal No. 2). tor contact
FUNCTION
• The manifold absolute pressure sensor converts DIAGNOSIS PROCEDURE
the manifold absolute pressure into a voltage sig-
• In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc.
TROUBLE JUDGMENT Q: Is the check result normal?
Check Conditions YES : Intermittent malfunction (Refer to GROUP
• Battery positive voltage is 8 − 16 V 00 − How to Use Troubleshooting/
• 2 seconds later after the ignition switch has been Inspection Service Points − How to Cope
in "ON" position or the engine has started up with Intermittent Malfunctions ).
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-83
NO : Go to Step 4 .
Connector: A-105
3 2 1 STEP 4. Perform voltage measurement at C-105
Harness side engine-ECU connector.
A-105 (L) connector
Connector: C-105
AK900797 AB
C-105 (B)
NO : Repair or replace the connector. <R.H. drive vehicles>
cardiagn.com
Connector: A-105
3 2 1
Harness side C-105 (B)
A-105 (L) connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK900797 AB • Measure engine-ECU terminal voltage.

• Use special tool test harness (MB991709) to con- • Voltage between terminal No. 72 and earth.
nect connector, and measure at pick-up harness.
• Ignition switch: ON OK: 4.9 − 5.1 V
• Voltage between terminal No. 1 and earth. Q: Is the check result normal?
OK: 4.9 − 5.1 V YES : Go to Step 8 .
NO : Go to Step 5 .
13A-84 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) manifold absolute pressure sensor
Connector: C-105
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check power supply line for short circuit.


DIESEL FUEL
TROUBLESHOOTING
13A-85
connector
with Intermittent Malfunctions ). Connector: A-105
3 2 1
Harness side
ECU is replaced, write the chassis number A-105 (L) connector
Common Rail Engine Learns ). After AK900797 AB

Connector: C-105
the vehicle equipped with the DPF carries <L.H. drive vehicles>
DPF Regeneration ).
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check power supply line for open
circuit and damage.
13A-86 DIESEL FUEL
TROUBLESHOOTING
105 manifold absolute pressure sensor
connector.
Connector: A-105
3 2 1 No. 3) manifold absolute pressure sensor
Harness side connector and C-105 (terminal No. 31) engine-
A-105 (L) connector ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB

side.
AK900797 AB
OK: Continuity (2 Ω or less)
Connector: C-105
cardiagn.com

connector
Connector: C-105 C-105 (B)
C-105 (B)
<R.H. drive vehicles> C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B) • Check earthing line for damage.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 YES : Go to Step 7 .
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-87
Connector: A-105
3 2 1 STEP 14. Check harness between A-105 (terminal
Harness side No. 2) manifold absolute pressure sensor
A-105 (L) connector connector and C-105 (terminal No. 37) engine-
ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
• Use special tool test harness (MB991709) to con-

AK900797 AB
OK: 0.7 − 1.2 V
Connector: C-105
cardiagn.com

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B) • Check output line for short circuit.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 YES : Replace the manifold absolute pressure
sensor.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 NO : Repair the damaged harness wire.

13A-88 DIESEL FUEL
TROUBLESHOOTING
STEP 15. Perform voltage measurement at C-105 STEP 16. Connector check: C-105 engine-ECU
engine-ECU connector. connector
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Connector: A-105
• Ignition switch: ON 3 2 1
• Voltage between terminal No. 37 and earth. Harness side
A-105 (L) connector
OK: 0.7 − 1.2 V
AK900797 AB

YES : Check and repair check harness between
A-105 (terminal No. 2) manifold absolute
pressure sensor connector and C-105
• Check output line for open circuit and
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-89
connector
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-90 DIESEL FUEL
TROUBLESHOOTING
Code No. P0108: Manifold Absolute Pressure Sensor Circuit High Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
cardiagn.com
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00093 AB

• A power voltage of 5 V is applied to the manifold • The manifold absolute pressure sensor output
absolute pressure sensor power terminal (termi- voltage should exceed 4.72 V for 0.5 seconds.
nal No. 1) from the engine-ECU (terminal No. 72)
and earthed to the engine-ECU (terminal No. 31) PROBABLE CAUSES
from the manifold absolute pressure sensor (ter- • Failed manifold absolute pressure sensor
minal No. 3). • Open circuit in manifold absolute pressure sensor
• The sensor signal is inputted to the engine-ECU circuit or loose connector contact
(terminal No. 37) from the manifold absolute • Failed engine-ECU
pressure sensor output terminal (terminal No. 2).
DIAGNOSIS PROCEDURE
FUNCTION
• The manifold absolute pressure sensor converts
the manifold absolute pressure into a voltage sig-
• In response to the signal, the engine-ECU cor- a. Item 6: Manifold absolute pressure sensor
rects the fuel injection amount, etc. Q: Is the check result normal?
TROUBLE JUDGMENT 00 − How to Use Troubleshooting/
Check Conditions Inspection Service Points − How to Cope
• Battery positive voltage is 8 − 16 V with Intermittent Malfunctions ).
• 2 seconds later after the ignition switch has been NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-91
NO : Go to Step 4 .
Connector: A-105
3 2 1 STEP 4. Connector check: C-105 engine-ECU
A-105 (L) connector
Connector: C-105
AK900797 AB
C-105 (B)
cardiagn.com
105 manifold absolute pressure sensor
connector.
Connector: A-105
3 2 1 C-105 (B)
Harness side
A-105 (L) connector 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AK900797 AB YES : Go to Step 5 .
• Disconnect connector, and measure at harness NO : Repair or replace the connector.
side.
13A-92 DIESEL FUEL
TROUBLESHOOTING
No. 3) manifold absolute pressure sensor
ECU connector. STEP 6. M.U.T.-III data list
Connector: A-105
3 2 1 a. Item 6: Manifold absolute pressure sensor
A-105 (L) connector
AK900797 AB (Refer to GROUP 00 − Precautions Before
Connector: C-105 Writing ). After replacing the engine-ECU,
cardiagn.com
C-105 (B) out the forcible DPF regeneration. (Refer to
DPF Regeneration ).

C-105 (B) Q: Is the check result normal?
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Replace the manifold absolute pressure
Harness side connector AKA00089 AB sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-93
Code No. P0112: EGR Gas Temperature Sensor Circuit Low Input <Euro5>
EGR Gas Temperature Sensor Circuit
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
cardiagn.com
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00262 AB

• A power voltage of 5 V is applied to the EGR gas
Check Conditions
temperature sensor output terminal (terminal No.
2) from the engine-ECU (terminal No. 36).
(terminal No. 30) from the EGR gas temperature
• The EGR gas temperature sensor output voltage
FUNCTION is 0.11 V or less (the EGR gas temperature is
• The EGR gas temperature sensor converts the above 500°C or equivalent).
EGR gas temperature into a voltage and inputs
the voltage signal to the engine-ECU. PROBABLE CAUSES
• The EGR gas temperature sensor is a kind of • Failed EGR gas temperature sensor
resistor, which has characteristics to reduce its • Short circuit or harness damage in EGR gas tem-
resistance as the EGR gas temperature rises. perature sensor circuit or loose connector contact
Therefore, the sensor output voltage varies with • Failed engine-ECU
the EGR gas temperature, and becomes lower as
the EGR gas temperature rises.
13A-94 DIESEL FUEL
TROUBLESHOOTING

EGR gas temperature sensor connector.
• Refer to Data List Reference Table P.13A-542
A-157 (B)
a. Item 8: EGR gas temperature sensor
with Intermittent Malfunctions ). 2 1
NO : Go to Step 2 . Harness side
connector AKB00263 AB
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .
2 1 STEP 5. Connector check: C-105 engine-ECU

Connector: C-105
STEP 3. Check EGR gas temperature sensor

itself.
• Check EGR gas temperature sensor itself (Refer C-105 (B)
to GROUP 17 − Emission Control − Exhaust Gas
Recirculation (EGR) System − EGR Gas Temper- <R.H. drive vehicles>
ature Sensor Check ).
NO : Replace the EGR gas temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-95
No. 2) EGR gas temperature sensor connector • Refer to Data List Reference Table P.13A-542
and C-105 (terminal No. 36) engine-ECU a. Item 8: EGR gas temperature sensor
connector.
Connector: A-157 YES : Intermittent malfunction (Refer to GROUP
A-157 (B)
2 1 Service − How to Perform Chassis Number
Harness side Writing ). After replacing the engine-ECU,
connector AKB00263 AB register the injector identification code and
Connector: C-105
cardiagn.com
C-105 (B)

<R.H. drive vehicles> 157 EGR gas temperature sensor connector.
Connector: A-157
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector • Disconnect connector, and measure at harness

AKA00089 AB
side.
• Check output line for short circuit. • Resistance between terminal No. 1 and earth.
Q: Is the check result normal? OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
13A-96 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) EGR gas temperature sensor connector
Connector: C-105
<L.H. drive vehicles> connector.
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-97
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-98 DIESEL FUEL
TROUBLESHOOTING
Code No. P0112: Intake Air Temperature Sensor No. 1 Circuit Low Input <Except Euro5>

1 2
B-L Y-L
cardiagn.com
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
FUNCTION voltage is 0.09 V or less for 0.5 second.
• The intake air temperature sensor No. 1 converts
the intake air temperature into a voltage and PROBABLE CAUSES
inputs the voltage signal to the engine-ECU. • Failed intake air temperature sensor No. 1
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in intake air tem-
rects the fuel injection amount, etc. perature sensor No.1 circuit or loose connector
• The intake air temperature sensor No. 1 is a kind contact
DIESEL FUEL
TROUBLESHOOTING
13A-99
DIAGNOSIS PROCEDURE STEP 4. Perform Voltage measurement at A-135
with Intermittent Malfunctions ). Harness side A-135 (B)
NO : Go to Step 2 .
side.
connector
Connector: A-135
OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .

connector
Harness side A-135 (B) Connector: C-105
connector AKA00399AB <L.H. drive vehicles>


C-105 (B)
1 itself.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-100 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
cardiagn.com
C-105 (B) 135 air flow sensor connector.
Connector: A-135
C-105 (B) Harness side A-135 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for short circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-101
Connector: C-105
Connector: A-135
C-105 (B)

Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-102 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
C-105 (B)

<R.H. drive vehicles> connector AKA00399AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-103
Code No. P0113: EGR Gas Temperature Sensor Circuit High Input <Euro5>
EGR Gas Temperature Sensor Circuit
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
cardiagn.com
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00262 AB

• A power voltage of 5 V is applied to the EGR gas
Check Conditions
temperature sensor output terminal (terminal No.
2) from the engine-ECU (terminal No. 36).
(terminal No. 30) from the EGR gas temperature
• The EGR gas temperature sensor output voltage
FUNCTION is 4.96 V or more (the EGR gas temperature is
• The EGR gas temperature sensor converts the below −50°C or equivalent).
EGR gas temperature into a voltage and inputs
the voltage signal to the engine-ECU. PROBABLE CAUSES
• The EGR gas temperature sensor is a kind of • Failed EGR gas temperature sensor
resistor, which has characteristics to reduce its • Open circuit in EGR gas temperature sensor cir-
resistance as the EGR gas temperature rises. cuit or loose connector contact
Therefore, the sensor output voltage varies with • Failed engine-ECU
the EGR gas temperature, and becomes lower as
the EGR gas temperature rises.
13A-104 DIESEL FUEL
TROUBLESHOOTING

EGR gas temperature sensor connector.
A-157 (B)
a. Item 8: EGR gas temperature sensor
with Intermittent Malfunctions ). 2 1
NO : Go to Step 2 . Harness side
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .
2 1 STEP 5. Connector check: C-105 engine-ECU

Connector: C-105
STEP 3. Check EGR gas temperature sensor

itself.
• Check EGR gas temperature sensor itself (Refer C-105 (B)
to GROUP 17 − Emission Control − Exhaust Gas
Recirculation (EGR) System − EGR Gas Temper- <R.H. drive vehicles>
ature Sensor Check ).
NO : Replace the EGR gas temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-105
No. 2) EGR gas temperature sensor connector • Refer to Data List Reference Table P.13A-542
and C-105 (terminal No. 36) engine-ECU a. Item 8: EGR gas temperature sensor
connector.
A-157 (B)
Connector: C-105
cardiagn.com
C-105 (B)

<R.H. drive vehicles> 157 EGR gas temperature sensor connector.
Connector: A-157
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector • Disconnect connector, and measure at harness

AKA00089 AB
side.
• Check output line for open circuit. • Resistance between terminal No. 1 and earth.
NO : Go to Step 9 .
13A-106 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-107
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-108 DIESEL FUEL
TROUBLESHOOTING
Code No. P0113: Intake Air Temperature Sensor No. 1 Circuit High Input <Except Euro5>

1 2
B-L Y-L
cardiagn.com
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
temperature sensor No.1 output terminal (termi-
nal No. 2) of air flow sensor connector from the
(terminal No. 86) from the intake air temperature Judgment Criterion
sensor No. 1 (terminal No. 1). • The intake air temperature sensor No. 1 output
FUNCTION
• The intake air temperature sensor No. 1 converts PROBABLE CAUSES
the intake air temperature into a voltage and • Failed intake air temperature sensor No. 1
inputs the voltage signal to the engine-ECU. • Open circuit or harness damage in intake air tem-
• In response to the signal, the engine-ECU cor- perature sensor No. 1 circuit or loose connector
rects the fuel injection amount, etc. contact
• The intake air temperature sensor No. 1 is a kind • Failed engine-ECU
of resistor, which has characteristics to reduce its
DIESEL FUEL
TROUBLESHOOTING
13A-109
air flow sensor No. 1 connector.
a. Item 43: Intake air temperature sensor No. 1
Harness side
Inspection Service Points − How to Cope connector
A-135 (B)
AKA00399AB
NO : Go to Step 2 . • Disconnect connector, and measure at harness
side.
connector
OK: 4.5 − 4.9 V
Connector: A-135
cardiagn.com
NO : Go to Step 5 .

connector
Connector: C-105
Harness side A-135 (B) <L.H. drive vehicles>

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-110 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
cardiagn.com
C-105 (B) 135 air flow sensor connector.
Connector: A-135
C-105 (B) Harness side A-135 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for open circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-111
Connector: C-105
<L.H. drive vehicles> • Check earthing line open circuit and damage.
Connector: A-135
C-105 (B)

Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-112 DIESEL FUEL
TROUBLESHOOTING
Code No. P0117: Engine Coolant Temperature Sensor Circuit Low Input
Engine Coolant Temperature Sensor Circuit
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
cardiagn.com
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00095 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
63). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 87) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The engine coolant temperature sensor converts
the engine coolant temperature into a voltage sig-
nal, and inputs the voltage to the engine-ECU.
• In response to the signal, the engine-ECU con-
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. • The engine coolant temperature sensor output
voltage is 0.15 V or less for 0.5 second.
PROBABLE CAUSES
• Failed engine coolant temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-113
• Short circuit or harness damage in engine cool- STEP 3. Perform resistance measurement at A-
ant temperature sensor circuit or loose connector 107 engine coolant temperature sensor
contact connector.
Connector: A-107
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III data list A-107 (B)

• Item 7: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature 2 1
(atmospheric temperature) or equivalent. Harness side
Engine hot state: At 80 − 120°C connector AK501323 AB
Q: Is the check result normal? • Disconnect connector, and measure at sensor

YES : Intermittent malfunction (Refer to GROUP side.
00 − How to Use Troubleshooting/ • Resistance between terminal No. 1 and No. 2.
Inspection Service Points − How to Cope OK:
with Intermittent Malfunctions ). Engine coolant temperature at −20°C: 14 − 17
cardiagn.com
NO : Go to Step 2 . kΩ
Engine coolant temperature at 0°C: 5.1 − 6.5
STEP 2. Connector check: A-107 engine coolant kΩ
temperature sensor connector Engine coolant temperature at 20°C: 2.1 − 2.7
kΩ
Connector: A-107
kΩ
Engine coolant temperature at 60°C: 0.48 −
0.68 kΩ
A-107 (B)
0.36 kΩ
2 1 Q: Is the check result normal?
Harness side
connector AK501323 AB NO : Replace the engine coolant temperature
sensor.
STEP 4. Perform voltage measurement at A-107 • Voltage between terminal No. 1 and earth.
engine coolant temperature sensor connector. OK: 4.5 − 4.9 V
NO : Go to Step 5 .
A-107 (B)
2 1
Harness side

side.
13A-114 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) engine coolant temperature sensor
ECU connector.
Connector: C-105
A-107 (B)
C-105 (B)
2 1
Harness side
<R.H. drive vehicles> connector AK501323 AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120 °C
DIESEL FUEL
TROUBLESHOOTING
13A-115
connector
DPF Regeneration ).
cardiagn.com
107 engine coolant temperature sensor
connector. C-105 (B)
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-107 (B) Harness side connector AKA00089 AB

2 1
Harness side

side.
13A-116 DIESEL FUEL
TROUBLESHOOTING
No. 2) engine coolant temperature sensor
ECU connector. STEP 11. Connector check: C-105 engine-ECU
connector
Connector: A-107
Connector: C-105
A-107 (B)
2 1
Connector: C-105 <R.H. drive vehicles>

cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-117
ECU connector.
Connector: A-107
A-107 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-118 DIESEL FUEL
TROUBLESHOOTING
Code No. P0118: Engine Coolant Temperature Sensor Circuit High Input
Engine Coolant Temperature Sensor Circuit
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
cardiagn.com
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00095 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
63). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 87) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The engine coolant temperature sensor converts
the engine coolant temperature into a voltage sig-
nal, and inputs the voltage to the engine-ECU.
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. • The engine coolant temperature sensor output
PROBABLE CAUSES
• Failed engine coolant temperature sensor
• Open circuit in engine coolant temperature sensor circuit or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-119
• Failed engine-ECU STEP 3. Perform resistance measurement at A-
DIAGNOSIS PROCEDURE connector.
Connector: A-107
OK:
Engine cold state: At ambient temperature A-107 (B)
Engine hot state: At 80 − 120°C
Q: Is the check result normal? 2 1
YES : Intermittent malfunction (Refer to GROUP Harness side
connector
00 − How to Use Troubleshooting/ AK501323 AB
Inspection Service Points − How to Cope • Disconnect connector, and measure at sensor
with Intermittent Malfunctions ). side.
NO : Go to Step 2 . • Resistance between terminal No. 1 and No. 2.
OK:
STEP 2. Connector check: A-107 engine coolant Engine coolant temperature at −20°C: 14 − 17
cardiagn.com
temperature sensor connector kΩ
Connector: A-107
kΩ
kΩ
A-107 (B)
kΩ
0.68 kΩ
2 1
Harness side 0.36 kΩ
Q: Is the check result normal? YES : Go to Step 4 .
YES : Go to Step 3 . NO : Replace the engine coolant temperature
NO : Repair or replace the connector. sensor.

engine coolant temperature sensor connector. NO : Go to Step 5 .
Connector: A-107
A-107 (B)
2 1
Harness side

side.
OK: 4.5 − 4.9 V
13A-120 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) engine coolant temperature sensor
ECU connector.
Connector: C-105
A-107 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open circuit.


OK:
Engine cold state: At ambient temperature
Engine hot state: At 80 − 120 °C
DIESEL FUEL
TROUBLESHOOTING
13A-121
connector
DPF Regeneration ).
cardiagn.com
connector. C-105 (B)
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-107 (B) Harness side connector AKA00089 AB

2 1
Harness side

side.
13A-122 DIESEL FUEL
TROUBLESHOOTING
ECU connector.
Connector: A-107
A-107 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-123
Code No. P0122: Throttle Position Sensor Circuit Low Input
Throttle Position Sensor Circuit
A-132
(MU805200) Hall IC
Electronic-controlled
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
cardiagn.com
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
13A-124 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 3. Perform voltage measurement at A-132

• The throttle position sensor output voltage is 0.15 electronic-controlled throttle valve connector.
V or less for 0.5 second.
Connector: A-132
PROBABLE CAUSES
• Failed throttle position sensor
• Open/short circuit or harness damage in throttle
position sensor circuit or loose connector contact
A-132 (B)
DIAGNOSIS PROCEDURE 6 5 4 3 2 1
Harness side
• Refer to Data List Reference Table P.13A-542. • Disconnect connector, and measure at harness
a. Item 45: Throttle position sensor side.
Q: Is the check result normal? • Voltage between terminal No. 2 and earth.
00 − How to Use Troubleshooting/ OK: 4.9 − 5.1 V
cardiagn.com
Inspection Service Points − How to Cope Q: Is the check result normal?
with Intermittent Malfunctions ). YES : Go to Step 7 .
NO : Go to Step 2 . NO : Go to Step 4 .
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-125
No. 2) electronic-controlled throttle valve • Refer to Data List Reference Table P.13A-542.
connector and C-105 (terminal No. 93) engine- a. Item 45: Throttle position sensor
ECU connector.
A-132 (B)
6 5 4 3 2 1 Service − How to Perform Chassis Number
connector AK604705 AB register the injector identification code and
Connector: C-105
cardiagn.com
C-105 (B) DPF Regeneration ).
<R.H. drive vehicles> STEP 7. Perform resistance measurement at A-

132 electronic-controlled throttle valve
connector.
Connector: A-132
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-132 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 6 5 4 3 2 1
Harness side
Harness side connector AKA00089 AB connector AK604705 AB
• Check power supply line for open/short circuit. • Disconnect connector, and measure at harness
NO : Go to Step 8 .
13A-126 DIESEL FUEL
TROUBLESHOOTING
connector No. 4) electronic-controlled throttle valve
Connector: C-105
Connector: A-132
C-105 (B)
A-132 (B)
<R.H. drive vehicles> 6 5 4 3 2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-127
connector
Connector: C-105
<L.H. drive vehicles> STEP 12. Connector check: C-105 engine-ECU
connector
Connector: C-105
C-105 (B)

C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

electronic-controlled throttle valve connector.
Connector: A-132
A-132 (B)
6 5 4 3 2 1
Harness side

OK: 3.7 V or higher.
13A-128 DIESEL FUEL
TROUBLESHOOTING
No. 1) electronic-controlled throttle valve No. 2) electronic-controlled throttle valve
connector and C-105 (terminal No. 40) engine- connector and C-105 (terminal No. 93) engine-
ECU connector. ECU connector.
A-132 (B) A-132 (B)

6 5 4 3 2 1 6 5 4 3 2 1

cardiagn.com
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit. • Check power supply line for damage.
YES : Go to Step 14 . YES : Replace the electronic-controlled throttle
NO : Repair the damaged harness wire. valve.
DIESEL FUEL
TROUBLESHOOTING
13A-129
No. 1) electronic-controlled throttle valve
ECU connector.
Connector: A-132
A-132 (B)
6 5 4 3 2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open circuit and damage.

13A-130 DIESEL FUEL
TROUBLESHOOTING
Code No. P0123: Throttle Position Sensor Circuit High Input
Throttle Position Sensor Circuit
A-132
(MU805200) Hall IC
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
cardiagn.com
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
DIESEL FUEL
TROUBLESHOOTING
13A-131
Judgment Criterion STEP 3. Perform resistance measurement at A-
• The throttle position sensor output voltage is 4.85 132 electronic-controlled throttle valve
V or more for 0.5 second. connector.
PROBABLE CAUSES Connector: A-132
• Failed throttle position sensor
• Open circuit or harness damage in throttle posi-
tion sensor circuit or loose connector contact
DIAGNOSIS PROCEDURE A-132 (B)

6 5 4 3 2 1
STEP 1. M.U.T.-III data list Harness side
a. Item 45: Throttle position sensor • Disconnect connector, and measure at harness
side.
Q: Is the check result normal? • Resistance between terminal No. 4 and earth.
00 − How to Use Troubleshooting/ OK: Continuity (2 Ω or less)
cardiagn.com
Inspection Service Points − How to Cope Q: Is the check result normal?
with Intermittent Malfunctions ). YES : Go to Step 7 .
NO : Go to Step 2 . NO : Go to Step 4 .
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-132 DIESEL FUEL
TROUBLESHOOTING
No. 4) electronic-controlled throttle valve • Refer to Data List Reference Table P.13A-542.
connector and C-105 (terminal No. 34) engine- a. Item 45: Throttle position sensor
ECU connector.
A-132 (B)
6 5 4 3 2 1 Service − How to Perform Chassis Number
connector AK604705 AB register the injector identification code and
Connector: C-105
cardiagn.com
C-105 (B) DPF Regeneration ).
<R.H. drive vehicles> STEP 7. Replace the electronic-controlled

throttle valve assembly
• After replacing the electronic-controlled throttle
valve assembly, re-check the trouble symptoms.
YES : Check end.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB learn fuel injection (Refer to GROUP 00 −
• Check earthing line for open circuit and damage. Precautions Before Service − What The
Q: Is the check result normal? registering the injector identification code,
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-133
Code No. P0182: Fuel Temperature Sensor Circuit Low input
Fuel Temperature Sensor Circuit
A-46
(MU802406)
Fuel temperature sensor
1 2
2 1
BR Y-B
cardiagn.com
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00097AB

• A power voltage of 5 V is applied to the fuel tem-
Check Conditions
perature sensor output terminal (terminal No. 1)
from the engine-ECU (terminal No. 55).
(terminal No. 79) from the fuel temperature sen-
sor (terminal No. 2). Judgment Criterion
• The fuel temperature sensor output voltage is
FUNCTION 0.10 V or less for 0.5 second.
• The fuel temperature sensor converts the fuel
temperature into a voltage and inputs the voltage PROBABLE CAUSES
signal to the engine-ECU. • Failed fuel temperature sensor
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in fuel tempera-
rects the fuel injection amount, etc. ture sensor circuit or loose connector contact
• The fuel temperature sensor is a kind of resistor, • Failed engine-ECU
which has characteristics to reduce its resistance
as the fuel temperature rises. Therefore, the sen-
sor output voltage varies with the fuel tempera-
ture, and becomes lower as the fuel temperature
rises.
13A-134 DIESEL FUEL
TROUBLESHOOTING

fuel temperature sensor connector.
• Item 21: Fuel temperature sensor
OK: At ambient temperature (fuel tempera-
ture) or equivalent.
YES : Intermittent malfunction (Refer to GROUP A-46 (B)
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-46 fuel temperature
sensor connector
Connector: A-46
OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .
A-46 (B)
2 1 connector

STEP 3. Check fuel temperature sensor itself.

C-105 (B)
• Check fuel temperature sensor itself (Refer to
P.13A-596).
NO : Replace the fuel temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-135
No. 1) fuel temperature sensor connector and C- • Item 21: Fuel temperature sensor
105 (terminal No. 55) engine-ECU connector. OK: At ambient temperature (fuel tempera-
Connector: A-46 ture) or equivalent.
A-46 (B)
2 1 ECU is replaced, write the chassis number
Harness side (Refer to GROUP 00 − Precautions Before
connector AK501326 AB Service − How to Perform Chassis Number
Connector: C-105
cardiagn.com
C-105 (B) GROUP 17 − Emission Control − Diesel
<R.H. drive vehicles> DPF Regeneration ).
STEP 8. Perform resistance measurement at A-46

Connector: A-46
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side
• Check output line for short circuit. connector AK501326 AB
Q: Is the check result normal? • Disconnect connector, and measure at harness

YES : Go to Step 7 . side.
NO : Repair the damaged harness wire. • Resistance between terminal No. 2 and earth.
NO : Go to Step 9 .
13A-136 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) fuel temperature sensor connector and C-
Connector: C-105
105 (terminal No. 79) engine-ECU connector.
Connector: A-46
C-105 (B)
A-46 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-137
Connector: C-105
Connector: A-46
A-46 (B)
C-105 (B)
2 1
<R.H. drive vehicles> Harness side

Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-138 DIESEL FUEL
TROUBLESHOOTING
Code No. P0183: Fuel Temperature Sensor Circuit High Input
Fuel Temperature Sensor Circuit
A-46
(MU802406)
1 2
2 1
BR Y-B
cardiagn.com
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00097AB

• A power voltage of 5 V is applied to the fuel tem-
Check Conditions
perature sensor output terminal (terminal No. 1)
of the air flow sensor connector from the engine-
ECU (terminal No. 55).
(terminal No. 79) from the fuel temperature sen- Judgment Criterion
sor (terminal No. 2). • The fuel temperature sensor output voltage is
4.95 V or more for 0.5 second.
FUNCTION
• The fuel temperature sensor converts the intake PROBABLE CAUSES
air temperature into a voltage and inputs the volt- • Failed fuel temperature sensor
age signal to the engine-ECU. • Open circuit or harness damage in fuel tempera-
• In response to the signal, the engine-ECU cor- ture sensor circuit or loose connector contact
rects the fuel injection amount, etc. • Failed engine-ECU
• The fuel temperature sensor is a kind of resistor,
which has characteristics to reduce its resistance
as the intake air temperature rises. Therefore, the
sensor output voltage varies with the fuel temper-
ature, and becomes lower as the fuel tempera-
ture rises.
DIESEL FUEL
TROUBLESHOOTING
13A-139
• Item 21: Fuel temperature sensor
OK: At ambient temperature (fuel tempera-
ture) or equivalent.
YES : Intermittent malfunction (Refer to GROUP A-46 (B)
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-46 fuel temperature
sensor connector
Connector: A-46
OK: 4.5 − 4.9 V
cardiagn.com
NO : Go to Step 5 .
A-46 (B)
2 1 connector

STEP 3. Check fuel temperature sensor itself.

C-105 (B)
• Check fuel temperature sensor itself (Refer to
P.13A-596).
NO : Replace the fuel temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-140 DIESEL FUEL
TROUBLESHOOTING
No. 1) fuel temperature sensor connector and C- • Item 21: Fuel temperature sensor
105 (terminal No. 55) engine-ECU connector. OK: At ambient temperature (fuel tempera-
Connector: A-46 ture) or equivalent.
A-46 (B)
Harness side (Refer to GROUP 00 − Precautions Before
connector AK501326 AB Service − How to Perform Chassis Number
Connector: C-105
cardiagn.com

Connector: A-46
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side
• Check output line for open circuit. connector AK501326 AB

NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-141
Connector: C-105
<L.H. drive vehicles> • Check earthing line for open circuit and damage.
Connector: A-46
C-105 (B)
A-46 (B)
2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-142 DIESEL FUEL
TROUBLESHOOTING
Code No. P0191: Rail Pressure Sensor Range/Performance Problem
Rail Pressure Sensor Circuit
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
cardiagn.com
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

R: Red P: Pink V:Violet PU: Purple SI: Silver
AKA00196 AD

• 5 V power is supplied from the engine-ECU (ter- • A difference between the objective and actual rail
minal No. 70) to the rail pressure sensor (terminal pressures exceeds 15 MPa for 0.5 second, and
No. 1). the rail pressure sensor has an output voltage
• The rail pressure sensor (terminal No. 3) is variation of 0.01 V or less.
earthed to the engine-ECU (terminal No. 88).
• Sensor signals are input from the rail pressure PROBABLE CAUSES
sensor (terminal No. 2) to the engine-ECU (termi- • Failed rail pressure sensor
nal No. 64). • Failed suction control valve
• Fuel line blocked
FUNCTION • Failed engine-ECU
the rail pressure sensor. DIAGNOSIS PROCEDURE
• Based on these signals, the engine-ECU checks
the rail pressure sensor for errors.
TROUBLE JUDGMENT • Check suction control valve itself (Refer to P.13A-
596).
Check Condition
• Engine is running. Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-143
NO : Replace the suction control valve. After NO : Repair or replace the connector.
supply pump (Refer to GROUP 00 − STEP 4. Check harness between A-44 (terminal
Precautions Before Service − What The No. 3) rail pressure sensor connector and C-105
Common Rail Engine Learns ). (terminal No. 88) engine-ECU connector.
Connector: A-44
STEP 2. Connector check: A-44 rail pressure
sensor connector.
Connector: A-44
3 2 1
A-44 (B)
Harness side
3 2 1
A-44 (B) Connector: C-105
Harness side <L.H. drive vehicles>
cardiagn.com

YES : Go to Step 3.
STEP 3. Connector check: C-105 engine-ECU C-105 (B)

connector
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate

connector A-131, and repair if necessary.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 5.
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-144 DIESEL FUEL
TROUBLESHOOTING
No. 1) rail pressure sensor connector and C-105 No. 2) rail pressure sensor connector and C-105
3 2 1 3 2 1
A-44 (B) A-44 (B)

cardiagn.com
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-145
rail pressure sensor connector.
Connector: A-44 Service − How to Perform Chassis Number
3 2 1 the vehicle equipped with the DPF carries
A-44 (B)
Harness side out the forcible DPF regeneration. (Refer to
connector AK501327 AB GROUP 17 − Emission Control − Diesel
• Use special tool test harness (MB991658) to con- Particulate Filter (DPF) System − Forcible
nect connector, and measure at pick-up harness. DPF Regeneration ).
• Engine: Idling (after warning up) NO : Replace the common rail assembly and fuel
• Voltage between terminal No. 2 and earth. injection tubes.
OK: 1.15 − 1.75 V
cardiagn.com
13A-146 DIESEL FUEL
TROUBLESHOOTING
Code No. P0192: Rail Pressure Sensor Circuit Low Input
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
cardiagn.com
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00196 AD

• A power voltage of 5 V is applied to the rail pres-
Check Conditions
sure sensor power terminal (terminal No. 1) from
the engine-ECU (terminal No. 70) and earthed to
the engine-ECU (terminal No. 88) from the rail
pressure sensor (terminal No. 3).
• The sensor signal is inputted to the engine-ECU Judgment Criterion
(terminal No. 64) from the rail pressure sensor • The rail pressure sensor output voltage is 0.70 V
output terminal (terminal No. 2). or less for 0.5 second.
FUNCTION PROBABLE CAUSES

• The rail pressure sensor converts the rail pres- • Failed rail pressure sensor
sure into a voltage signal and inputs the signal to • Open/short circuit or harness damage in rail pres-
the engine-ECU. sure sensor circuit or loose connector contact
• In response to the signal, the engine-ECU cor- • Failed engine-ECU
rects the fuel injection quantity.
DIESEL FUEL
TROUBLESHOOTING
13A-147
DIAGNOSIS PROCEDURE YES : Go to Step 9 .
NO : Go to Step 4 .

• Refer to Data List Reference Table P.13A-542. STEP 4. Perform voltage measurement at C-105
engine-ECU connector.
a. Item 63: Rail pressure sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
sensor connector
Connector: A-44
cardiagn.com
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
rail pressure sensor connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
3 2 1
A-44 (B)
Harness side

OK: 4.9 − 5.1 V
13A-148 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) rail pressure sensor connector and C-105
Connector: C-105
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-149
connector
with Intermittent Malfunctions ). Connector: C-105
learn fuel injection (Refer to GROUP 00 − C-105 (B)
DPF Regeneration ).
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
3 2 1
A-44 (B)
Harness side

YES : Check intermediate connector A-131, and
repair if necessary. If intermediate
connector is normal, check and repair
harness between A-44 (terminal No. 1) rail
circuit and damage.
13A-150 DIESEL FUEL
TROUBLESHOOTING
Connector: A-44
Connector: C-105
3 2 1
A-44 (B)
Harness side

C-105 (B)
side.
OK: Continuity (2 Ω or less) <R.H. drive vehicles>
cardiagn.com

connector C-105 (B)
Connector: C-105
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
<L.H. drive vehicles> 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side
C-105 (B) NOTE: Before checking harness, check intermediate

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 Q: Is the check result normal?
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Repair the damaged harness wire.

DIESEL FUEL
TROUBLESHOOTING
13A-151
Connector: A-44
Connector: C-105
3 2 1
A-44 (B)
Harness side

C-105 (B)
• Engine: Idle (after warning up)
• Voltage between terminal No. 2 and earth. <R.H. drive vehicles>
OK: 1.15 − 1.75 V
cardiagn.com
STEP 13. Connector check: C-105 engine-ECU C-105 (B)

connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: C-105 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side

C-105 (B) connector A-131, and repair if necessary.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
YES : Replace the common rail assembly.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-152 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Connector: A-44
• Engine: Idle (after warning up)
OK: 1.15 − 1.75 V
3 2 1
A-44 (B)
Harness side

connector is normal, check and repair check
harness between A-44 (terminal No. 2) rail
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-153
connector
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-154 DIESEL FUEL
TROUBLESHOOTING
Code No. P0193: Rail Pressure Sensor Circuit High Input
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
cardiagn.com
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00196 AD

• A power voltage of 5 V is applied to the rail pres-
Check Conditions
sure sensor power terminal (terminal No. 1) from
the engine-ECU (terminal No. 70) and earthed to
the engine-ECU (terminal No. 88) from the rail
pressure sensor (terminal No. 3).
(terminal No. 64) from the rail pressure sensor • The rail pressure sensor output voltage is 4.85 V
output terminal (terminal No. 2). or more for 0.5 second.

• The rail pressure sensor converts the rail pres- • Failed rail pressure sensor
sure into a voltage signal and inputs the signal to • Open circuit in rail pressure sensor circuit or
the engine-ECU. loose connector contact
• In response to the signal, the engine-ECU cor- • Failed engine-ECU
rects the fuel injection quantity.
DIESEL FUEL
TROUBLESHOOTING
13A-155
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
sensor connector
Connector: A-44
cardiagn.com
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Perform resistance measurement at A-44 NO : Repair or replace the connector.
Connector: A-44
3 2 1
A-44 (B)
Harness side

side.
13A-156 DIESEL FUEL
TROUBLESHOOTING
Connector: A-44
3 2 1 with Intermittent Malfunctions ).
Harness side
A-44 (B) NO : Replace the engine-ECU. When the engine-
connector AK501327 AB ECU is replaced, write the chassis number
cardiagn.com
C-105 (B) the vehicle equipped with the DPF carries
DPF Regeneration ).

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 YES : Intermittent malfunction (Refer to GROUP
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Replace the common rail assembly.
DIESEL FUEL
TROUBLESHOOTING
13A-157
Code No. P0201: No. 1 Injector Circuit Malfunction
No. 1 Injector Circuit
A-42
No. 1
1 2 injector G
cardiagn.com
Y
1 2
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AJ
OPERATION • Battery positive voltage is 8 V or more.

• Driving power is supplied from the engine-ECU • Except during the engine cranking period
(terminal No. 1) to the No. 1 injector (terminal No. • When an engine-ECU internal capacitor is
2). allowed to be charged
• The engine-ECU (terminal No. 2) turn on the
Judgment Criterion
power transistor to flow current to the No. 1 injec-
• When the peak current of the No. 1 injector circuit
tor (terminal No. 1).
is not detected, the circuit is judged to be open.
FUNCTION
PROBABLE CAUSES
• The engine-ECU monitors peak current during
• Failed No. 1 injector
injector drive control to detect disconnection in
• Open/short circuit or harness damage in No. 1
the injector No. 1 circuit.
injector circuit or loose connector contact
Check Conditions
• Ignition switch is in ON position
13A-158 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Check harness between No. 1 injector

CAUTION connector and engine-ECU connector.
A high-tension voltage is flowing between the Connector: A-42
engine-ECU and the injectors while the engine is
running. Handle them carefully to avoid receiving
electric shocks from the voltage.
A-42 (GR)
STEP 1. Connector check: A-42 No. 1 injector

connector
1 2
Connector: A-42
Harness side
connector AKA00186 AB
Connector: C-105
A-42 (GR) <L.H. drive vehicles>
1 2
cardiagn.com
Harness side
C-105 (B)
STEP 2. Check No. 1 injector itself.

• Check No. 1 injector itself (Refer to P.13A-595).
NO : Replace the No. 1 injector. After replacing C-105 (B)
the Injector, register the injector
identification code and learn fuel injection 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Service − What The Common Rail Engine 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).
Check harness between A-42 (terminal No. 1) No. 1

injector connector and C-105 (terminal No. 2)
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-159
STEP 4. Check harness between A-42 (terminal STEP 5. Connector check: C-105 engine-ECU
No. 2) No. 1 injector connector and C-105 connector
A-42 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B) STEP 6. M.U.T.-III diagnosis code

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 Q: Is the diagnosis code set?
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check power supply line for open/short circuit Writing ). After replacing the engine-ECU,
and damage. register the injector identification code and
Q: Is the check result normal? learn fuel injection (Refer to GROUP 00 −
YES : Go to Step 5 . Precautions Before Service − What The
NO : Repair or replace the connector. Common Rail Engine Learns ). After
DPF Regeneration ).
13A-160 DIESEL FUEL
TROUBLESHOOTING
Code No. P0202: No. 2 Injector Circuit Malfunction <Euro5>
A-41
No. 2
1 2 injector R-L
cardiagn.com
P-B
73 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AN

(terminal No. 73) to the No. 2 injector (terminal • When an engine-ECU internal capacitor is
No. 2). allowed to be charged
Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-161
A-41 (GR)
connector
1 2
Connector: A-41
Harness side
Connector: C-105
A-41 (GR)
1 2
cardiagn.com
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-162 DIESEL FUEL
TROUBLESHOOTING
A-41 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-163
Code No. P0202: No. 2 Injector Circuit Malfunction <Except Euro5>
A-41
No. 2
1 2 injector R-L
cardiagn.com
W-L
25 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AK

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-164 DIESEL FUEL
TROUBLESHOOTING

A-41 (GR)
connector
1 2
Connector: A-41
Harness side
Connector: C-105
A-41 (GR)
1 2
cardiagn.com
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-165
A-41 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Repair or replace the connector. Common Rail Engine Learns ).
13A-166 DIESEL FUEL
TROUBLESHOOTING
A-130
No. 3
1 2 injector L-O
cardiagn.com
W-L
49 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AP

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-167
STEP 1. Connector check: A-130 No. 3 injector A-130 (GR)

connector
1 2
Connector: A-130
Harness side
Connector: C-105
A-130 (GR)
1 2
cardiagn.com
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-168 DIESEL FUEL
TROUBLESHOOTING
A-130 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-169
A-130
No. 3
1 2 injector L-O
cardiagn.com
W-L
25 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AL

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-170 DIESEL FUEL
TROUBLESHOOTING

STEP 1. Connector check: A-130 No. 3 injector A-130 (GR)

connector
1 2
Connector: A-130
Harness side
Connector: C-105
A-130 (GR)
1 2
cardiagn.com
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-171
A-130 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
13A-172 DIESEL FUEL
TROUBLESHOOTING
A-129
No. 4
1 2 injector Y-G
cardiagn.com
R-Y
25 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AO

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-173
A-129 (GR)
connector
1 2
Connector: A-129
Harness side
Connector: C-105
1 2
cardiagn.com
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-174 DIESEL FUEL
TROUBLESHOOTING
A-129 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-175
A-129
No. 4
1 2 injector Y-G
cardiagn.com
Y
1 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AM

(terminal No. 1) to the No. 4 injector (terminal No. • When an engine-ECU internal capacitor is
2). allowed to be charged
Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-176 DIESEL FUEL
TROUBLESHOOTING

A-129 (GR)
connector
1 2
Connector: A-129
Harness side
Connector: C-105
1 2
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Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-177
A-129 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0219: Engine Overspeed Condition
OPERATION
• Refer to Code No. P0335: Crank Angle Sensor
System P.13A-184.
13A-178 DIESEL FUEL
TROUBLESHOOTING
FUNCTION YES : Inspection chart for diagnosis codes (Refer

• The engine-ECU monitors the engine speeds to P.13A-21).
based on the signals from the crank angle sen- NO : Replace the engine-ECU. When the engine-
sor. ECU is replaced, write the chassis number
• The engine-ECU checks whether the engine (Refer to GROUP 00 − Precautions Before
speeds are too high. Service − How to Perform Chassis Number
TROUBLE JUDGMENT register the injector identification code and
Check Condition learn fuel injection (Refer to GROUP 00 −
• Ignition switch is in ON position Precautions Before Service − What The
Judgment Criterion registering the injector identification code,
• Engine speed is 5,500 r/min or more the vehicle equipped with the DPF carries
PROBABLE CAUSE
DPF Regeneration ).
DIAGNOSIS PROCEDURE
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Q: Is any other diagnosis code than P0219 output?
Code No. P0234: Turbocharger Overboost Condition <Except Euro5>
FUNCTION NO : Replace the waste gate actuator.
• The engine-ECU checks whether the boost pres-
sure is not higher than the specified value. STEP 2. M.U.T.-III diagnosis code
TROUBLE JUDGMENT
Check Condition YES : Replace the engine-ECU. When the engine-
• Engine is running ECU is replaced, write the chassis number
Judgement Criterion (Refer to GROUP 00 − Precautions Before
• The boost pressure exceeds the abnormality Service − How to Perform Chassis Number
determination value for 3 seconds. Writing ). After replacing the engine-ECU,
PROBABLE CAUSES learn fuel injection (Refer to GROUP 00 −
• Failed the waste gate actuator Precautions Before Service − What The
• Failed the engine-ECU Common Rail Engine Learns ). After
DIAGNOSIS carry out the forcible DPF regeneration.
STEP 1. Check waste gate actuator itself. Forcible DPF Regeneration ).
• Check waste gate actuator itself (Refer to NO : Intermittent malfunction (Refer to GROUP
GROUP 15 − On-vehicle Service − Waste Gate 00 − How to Use Troubleshooting/
Actuator Check ). Inspection Service Points − How to Cope
Q: Is the check result normal? with Intermittent Malfunctions ).
DIESEL FUEL
TROUBLESHOOTING
13A-179
Code No. P0299: Turbocharger Under Boost Condition

• The engine-ECU checks whether the boost pres- NO : Repair.
sure is not lower than the specified value.
STEP 3. Check turbocharger supercharging
TROUBLE JUDGMENT
pressure..
Check Condition • Check turbocharger supercharging pressure
• Engine is running (Refer to GROUP 15 − On-vehicle − Turbo-
Judgment Criterion charger Supercharging Pressure Check ).
• The opening degree of accelerator pedal is 23% Q: Is the check result normal?
for 3 seconds and the boost pressure is not lower YES : Go to Step 4 .
than the specified value. NO : Repair.
PROBABLE CAUSES
• Intercooler air hose disconnected or damaged
• Vacuum hose of manifold absolute pressure sen-
sor disconnected or damaged Q: Is the check result normal?
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• Failed manifold absolute pressure sensor YES : Replace the engine-ECU. When the engine-
• Failed engine-ECU ECU is replaced, write the chassis number
DIAGNOSIS Service − How to Perform Chassis Number
STEP 1. Check on intercooler air hose. learn fuel injection (Refer to GROUP 00 −
• Check whether the intercooler air hose is discon- Precautions Before Service − What The
nected or damaged. Common Rail Engine Learns ). After
YES : Go to Step 2 . the vehicle equipped with the DPF carries
NO : Repair. out the forcible DPF regeneration. (Refer to
STEP 2. Check on vacuum hose of manifold DPF Regeneration ).
absolute pressure sensor. NO : Intermittent malfunction (Refer to GROUP
• Check whether the vacuum hose of manifold 00 − How to Use Troubleshooting/
absolute pressure sensor is disconnected or Inspection Service Points − How to Cope
damaged. with Intermittent Malfunctions ).
Code No. P0301: No. 1 Cylinder Injector Malfunction (No Injection)
FUNCTION • Crank angle sensor is normal.

• The Engine-ECU, by monitoring the variation in
Judgment Criterion
the engine revolution, detects the non-fuel injec-
• The variation in the engine revolution is more
tion state.
than the specified value.
TROUBLE JUDGMENT
PROBABLE CAUSES
Check Conditions • Failed No. 1 injector
• During the normal engine operation • No. 1 fuel injection pipe clogged
• Engine coolant temperature is 80°C or higher. • Failed Engine-ECU
13A-180 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE YES : Clean or replace the No. 1 fuel injection

pipe.
CAUTION NO : Replace the No.1 injector. After replacing
A high-tension voltage is flowing between the the injector, register the injector
engine-ECU and the injectors while the engine is identification code and learn fuel injection
running. Handle them carefully to avoid receiving (Refer to GROUP 00 − Precautions Before
electric shocks from the voltage. Service − What The Common Rail Engine
Learns ). Then go to Step 3 .
• After erasing the diagnosis code through M.U.T.- STEP 3. M.U.T.-III diagnosis code
III, operate the engine in the warm-up state and • After erasing the diagnosis code through M.U.T.-
confirm and confirm whether the diagnosis code III, operate the engine in the warm-up state and
is output confirm and confirm whether the diagnosis code
Q: Is the diagnosis code set? is output.
00 − How to Use Troubleshooting/ ECU is replaced, write the chassis number
Inspection Service Points − How to Cope (Refer to GROUP 00 − Precautions Before
with Intermittent Malfunctions ). Service − How to Perform Chassis Number
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STEP 2. Check for No.1 fuel injection pipe register the injector identification code and
clogged learn fuel injection (Refer to GROUP 00 −
• Remove the No.1 fuel injection pipe. Precautions Before Service − What The
• Check whether No.1 fuel injection pipe is clogged Common Rail Engine Learns ). After
or not. registering the injector identification code,
Q: Is it clogged?
DPF Regeneration ).
FUNCTION • No. 2 fuel injection pipe clogged

• The Engine-ECU, by monitoring the variation in • Failed Engine-ECU
tion state. DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT CAUTION
A high-tension voltage is flowing between the
Check Conditions engine-ECU and the injectors while the engine is
• During the normal engine operation running. Handle them carefully to avoid receiving
• Engine coolant temperature is 80°C or higher. electric shocks from the voltage.
• Crank angle sensor is normal.
Judgment Criterion STEP 1. M.U.T.-III diagnosis code
• The variation in the engine revolution is more • After erasing the diagnosis code through M.U.T.-
than the specified value. III, operate the engine in the warm-up state and
confirm and confirm whether the diagnosis code
PROBABLE CAUSES is output
DIESEL FUEL
TROUBLESHOOTING
13A-181
• After erasing the diagnosis code through M.U.T.-
III, operate the engine in the warm-up state and
is output.
STEP 2. Check for No. 2 fuel injection pipe
clogged
• Remove the No. 2 fuel injection pipe.
• Check whether No. 2 fuel injection pipe is
clogged or not.
Q: Is it clogged? register the injector identification code and
YES : Clean or replace the No. 2 fuel injection learn fuel injection (Refer to GROUP 00 −
pipe. Precautions Before Service − What The
NO : Replace the No. 2 injector. After replacing Common Rail Engine Learns ). After
the injector, register the injector registering the injector identification code,
identification code and learn fuel injection the vehicle equipped with the DPF carries
(Refer to GROUP 00 − Precautions Before out the forcible DPF regeneration. (Refer to
Service − What The Common Rail Engine GROUP 17 − Emission Control − Diesel
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Learns ). Then go to Step 3 . Particulate Filter (DPF) System − Forcible
DPF Regeneration ).

• The Engine-ECU, by monitoring the variation in
CAUTION
A high-tension voltage is flowing between the
tion state.
TROUBLE JUDGMENT running. Handle them carefully to avoid receiving
Check Conditions
• During the normal engine operation
• Engine coolant temperature is 80°C or higher. STEP 1. M.U.T.-III diagnosis code
• Crank angle sensor is normal. • After erasing the diagnosis code through M.U.T.-
Judgment Criterion confirm and confirm whether the diagnosis code
• The variation in the engine revolution is more is output
than the specified value.
PROBABLE CAUSES YES : Go to Step 2 .
• Failed No. 3 injector NO : Intermittent malfunction (Refer to GROUP
• No. 3 fuel injection pipe clogged 00 − How to Use Troubleshooting/
• Failed Engine-ECU Inspection Service Points − How to Cope
STEP 2. Check for No. 3 fuel injection pipe

clogged
• Remove the No. 3 fuel injection pipe.
• Check whether No. 3 fuel injection pipe is
clogged or not.
Q: Is it clogged?
13A-182 DIESEL FUEL
TROUBLESHOOTING
YES : Clean or replace the No. 3 fuel injection YES : Replace the engine-ECU. When the engine-
pipe. ECU is replaced, write the chassis number
NO : Replace the No. 3 injector. After replacing (Refer to GROUP 00 − Precautions Before
the injector, register the injector Service − How to Perform Chassis Number
identification code and learn fuel injection. Writing ). After replacing the engine-ECU,
(Refer to GROUP 00 − Precautions Before register the injector identification code and
Service − What The Common Rail Engine learn fuel injection (Refer to GROUP 00 −
Learns ). Then go to Step 3 . Precautions Before Service − What The
STEP 3. M.U.T.-III diagnosis code registering the injector identification code,
• After erasing the diagnosis code through M.U.T.- the vehicle equipped with the DPF carries
III, operate the engine in the warm-up state and out the forcible DPF regeneration. (Refer to
confirm and confirm whether the diagnosis code GROUP 17 − Emission Control − Diesel
is output. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
Q: Is the diagnosis code set? NO : The check is end.
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• The Engine-ECU, by monitoring the variation in NO : Intermittent malfunction (Refer to GROUP
the engine revolution, detects the non-fuel injec- 00 − How to Use Troubleshooting/
tion state. Inspection Service Points − How to Cope
TROUBLE JUDGMENT
Check Conditions STEP 2. Check for No.4 fuel injection pipe
• During the normal engine operation clogged
• Engine coolant temperature is 80°C or higher. • Remove the No. 4 fuel injection pipe.
• Crank angle sensor is normal. • Check whether No.4 fuel injection pipe is clogged
Judgment Criterion or not.
• The variation in the engine revolution is more Q: Is it clogged?
than the specified value. YES : Clean or replace the No. 4 fuel injection
pipe.
PROBABLE CAUSES NO : Replace the No. 4 injector. After replacing
• Failed No. 4 injector the injector, register the injector
• No. 4 fuel injection pipe clogged identification code and learn fuel injection
• Failed Engine-ECU (Refer to GROUP 00 − Precautions Before
Service − What The Common Rail Engine
DIAGNOSIS PROCEDURE Learns ). Then go to Step 3 .
CAUTION
A high-tension voltage is flowing between the STEP 3. M.U.T.-III diagnosis code
engine-ECU and the injectors while the engine is • After erasing the diagnosis code through M.U.T.-
running. Handle them carefully to avoid receiving III, operate the engine in the warm-up state and
electric shocks from the voltage. confirm and confirm whether the diagnosis code
is output.
STEP 1. M.U.T.-III diagnosis code Q: Is the diagnosis code set?
is output
DIESEL FUEL
TROUBLESHOOTING
13A-183
DPF Regeneration ).
Code No. P0335: Crank Angle Sensor System
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Crank Angle Sensor Circuit
A-07
MU802337
Crank
angle
sensor
1 2 3
3 2 1
R G-R B-W
3 2 1
A-133
P G-R B-Y
C-105 68 67 91
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
Wire colour code

AKA00100 AB
13A-184 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 2. Connector check: A-07 crank angle

• A power voltage of 5 V is applied to the crank sensor connector
angle sensor power terminal (terminal No. 3)
from the engine-ECU (terminal No. 68) and Connector: A-07
earthed to engine-ECU (terminal No. 91) from the
crank angle sensor (terminal No. 1).
(terminal No. 67) from the crank angle sensor
A-07 (B)
output terminal (terminal No. 2).
FUNCTION 3 2 1
• The crank angle sensor detects the crank angle Harness side
(position) and inputs a pulse signal to the engine- connector AK501329 AB
ECU.
• In response to the signal, the engine ECU detects Q: Is the check result normal?
the engine speed, controls the fuel injection tim- YES : Go to Step 3 .
ing and fuel injection quantity, etc. NO : Repair or replace the connector.
TROUBLE JUDGMENT STEP 3. Perform voltage measurement at A-07
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Check Condition crank angle sensor connector.
• Battery positive voltage is 6 − 16 V. Connector: A-07
Judgment Criterion
• The number of output pulses from the crank
angle sensor per engine rotation is one or less.
A-07 (B)
PROBABLE CAUSES
• Failed crank angle sensor
• Open/short circuit in crank angle sensor circuit or 3 2 1
loose connector contact Harness side
• Failed engine-ECU connector AK501329 AB

DIAGNOSIS PROCEDURE nect connector, and measure at pick-up harness.
STEP 1. M.U.T.-III data list • Voltage between terminal No. 2 and earth.
• Refer to Data List Reference Table OK: 4.9 − 5.1 V
a. Item 2: Engine revolution Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP NO : Go to Step 4 .
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-185
C-105 (B) C-105 (B)
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C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-07 (B) A-07 (B)
3 2 1 3 2 1
• Measure engine-ECU terminal voltage. Q: Is the check result normal?

• Disconnect A-07 crank angle sensor connector. YES : Check intermediate connector A-133, and
• Ignition switch: ON repair if necessary. If intermediate
• Voltage between terminal No. 67 and earth. connector is normal, check and repair
OK: 4.9 − 5.1 V harness between A-07 (terminal No. 2)
Q: Is the check result normal? crank angle sensor connector and C-105
YES : Go to Step 5 . (terminal No. 67) engine-ECU connector.
NO : Go to Step 6 . • Check output line for open circuit and
damage.
13A-186 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) crank angle sensor connector and C-105
Connector: C-105
Connector: A-07
A-07 (B)
C-105 (B)
3 2 1
Harness side
Connector: C-105
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


• Refer to Data List Reference Table
a. Item 2: Engine revolution
DIESEL FUEL
TROUBLESHOOTING
13A-187
connector
DPF Regeneration ).
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C-105 (B)
crank angle sensor connector. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connector: A-07 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-07
A-07 (B)
3 2 1
• Use special tool test harness (MB991709) to con- 3 2 1

Harness side
• Ignition switch: ON connector AK501329 AB
OK: 4.9 − 5.1 V Q: Is the check result normal?
harness between A-07 (terminal No. 3)
crank angle sensor connector and C-105
• Check power supply line for open/
short circuit and damage.
13A-188 DIESEL FUEL
TROUBLESHOOTING
07 crank angle sensor connector.
Connector: A-07
No. 1) crank angle sensor connector and C-105
Connector: A-07
A-07 (B)
3 2 1

3 2 1
side.
• Resistance between terminal No. 1 and earth. Harness side
Connector: C-105
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connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
• Check earthing line for open circuit and damage.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-189
STEP 14. Perform output wave pattern
measurement at A-07 crank angle sensor (Using
an oscilloscope).
STEP 15. Check the crankshaft sensing blade.
Connector: A-07
NO : Replace the crankshaft sensing blade
A-07 (B)
STEP 16. M.U.T-III data list
• Refer to Data List Reference Table
3 2 1
a. Item 2: Engine revolution
Harness side
connector AK501329 AB Q: Is the check result normal?
• Use special tool test harness (MB991709) to con- 00 − How to Use Troubleshooting/
nect connector, and measure at pick-up harness. Inspection Service Points − How to Cope
• Engine: Idling with Intermittent Malfunctions ).
• Transmission: Neutral <M/T> or P range <A/T> NO : Replace the crank angle sensor
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OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to P.13A-586), its maximum value
should be 4.8 V or more, and its minimum
valve should be 0.6 V or less with no noise in
waveform.
Code No. P0336: Crank Angle Sensor Range/Performance Problem

• Refer to Code No. P0335: Crank Angle Sensor • Failed crank angle sensor
System P.13A-184. • Open/short circuit in crank angle sensor circuit or
loose connector contact
• The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the engine- DIAGNOSIS PROCEDURE
ECU.
• In response to the signal, the engine-ECU
detects the engine speed, controls the fuel injec- STEP 1. Installation check of crank angle sensor
tion timing and fuel injection quantity, etc • Check whether the crank angle sensor is cor-
rectly installed.
TROUBLE JUDGMENT
Check Conditions YES : Go to Step 2 .
• Battery positive voltage is 6 − 16 V. NO : Repair or replace the crank angle sensor.
• Engine speed is 350 r/min or more
Judgment Criterion STEP 2. M.U.T.-III diagnosis code
• The number of pulses from the crank shaft posi- • Reconfirmation of diagnosis code.
tion sensor per engine rotation is abnormal. Q: Is the diagnosis code set?
13A-190 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
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DIESEL FUEL
TROUBLESHOOTING
13A-191
Code No. P0340: Camshaft Position Sensor System
Camshaft Position Sensor Circuit
A-43
MU802337 Camshaft
position
sensor
1 2 3
3 2 1
R-B L-Y B-W
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1 2 3
A-131
R-B L-Y B-W
C-105 69 66 90
1 2 3 4 5 6 7 8 9 10 10 11
111213141516171819
12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
Wire colour code

AKA00197AB

• A power voltage of 5 V is applied to the camshaft
Check Condition
position sensor power terminal (terminal No. 3)
from the engine-ECU (terminal No. 69) and
earthed to engine-ECU (terminal No. 90) from the Judgment Criterion
camshaft position sensor (terminal No. 1). • The number of output pulses from the camshaft
• The sensor signal is inputted to the engine-ECU position sensor per engine rotation is one or less.
(terminal No. 66) from the camshaft position sen-
sor output terminal (terminal No. 2). PROBABLE CAUSES
• Failed camshaft position sensor
FUNCTION • Open/short circuit or harness damage in cam-
• The camshaft position sensor detects the top shaft position sensor circuit or loose connector
dead center on the compression stroke of the No. contact
1 cylinder and inputs a pulse signal to the engine- • Failed engine-ECU
ECU.
13A-192 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at C-105

STEP 1. Connector check: A-43 camshaft Connector: C-105
position sensor connector <L.H. drive vehicles>
Connector: A-43
C-105 (B)
A-43 (B)
3 2 1
Harness side

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C-105 (B)
camshaft position sensor connector. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connector: A-43 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-43
A-43 (B)
3 2 1
Harness side
• Use special tool harness (MB991709) to connect A-43 (B)

3 2 1
• Ignition switch: ON Harness side
connector
• Voltage between terminal No. 2 and earth. AK501330 AB
OK: 4.9 − 5.1 V • Measure engine-ECU terminal voltage.

• Disconnect A-43 camshaft position sensor con-
Q: Is the check result normal? nector.
NO : Go to Step 3 .
OK: 4.9 − 5.1 V
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-193
connector
Connector: C-105 harness between A-43 (terminal No. 2)
camshaft sensor connector and C-105
damage.
C-105 (B)
connector
<R.H. drive vehicles> Connector: C-105
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C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-43
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-43 (B) 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side Harness side connector AKA00089 AB

13A-194 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between A-43 (terminal STEP 7. M.U.T.-III diagnosis code
No. 2) camshaft position sensor connector and • Reconfirmation of diagnosis code.
C-105 (terminal No. 66) engine-ECU connector. Q: Is the diagnosis code set?
Connector: A-43 YES : Replace the engine-ECU. When the engine-
A-43 (B)
3 2 1 Precautions Before Service − What The
Harness side Common Rail Engine Learns ). After
connector AK501330 AB registering the injector identification code,
Connector: C-105 out the forcible DPF regeneration. (Refer to
DPF Regeneration ).
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C-105 (B) with Intermittent Malfunctions ).
<R.H. drive vehicles> STEP 8. Perform voltage measurement at A-43

camshaft position sensor connector.
Connector: A-43
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-43 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side
NOTE: Before checking harness, check intermediate connector, and measure at pick-up harness.
connector A-131, and repair if necessary. • Ignition switch: ON
• Check output line for short circuit. • Voltage between terminal No. 3 and earth.
Q: Is the check result normal? OK: 4.9 − 5.1 V
NO : Repair the damaged harness wire. YES : Go to Step 11 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-195
connector No. 3) camshaft position sensor connector and
Connector: C-105
C-105 (terminal No. 69) engine-ECU connector.
C-105 (B) A-43 (B)

3 2 1
Harness side
Connector: C-105
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check power supply line for short circuit and
damage.
13A-196 DIESEL FUEL
TROUBLESHOOTING
43 camshaft position sensor connector.
Connector: A-43
No. 1) camshaft position sensor connector and
Connector: A-43
A-43 (B)
3 2 1
Harness side
• Disconnect connector, and measure at harness A-43 (B)

3 2 1
side.
• Resistance between terminal No. 1 and earth. Harness side
Connector: C-105
cardiagn.com

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-197
NO : Replace the camshaft position sensor.
measurement at A-43 camshaft position sensor
(Using an oscilloscope).
Connector: A-43
A-43 (B)
3 2 1
Harness side

• Engine: Idling
• Transmission: Neutral <M/T> or P range <A/T>
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OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to P.13A-586), its maximum value
should be 4.8 V or more, and its minimum
valve should be 0.6 V or less with no noise in
waveform.
Code No. P0341: Camshaft Position Sensor Range/Performance Problem

• Refer to Code No. P0340: Camshaft Position • Failed camshaft position sensor
Sensor System P.13A-192. • Open/short circuit in camshaft position sensor cir-
cuit or loose connector contact
• The camshaft position sensor detects the top
dead center on the compression stroke of the No. DIAGNOSIS PROCEDURE
1 cylinder and inputs a pulse signal to the engine-
ECU.
STEP 1. Installation check of camshaft position
TROUBLE JUDGMENT sensor
• Check whether the camshaft position sensor is
Check Conditions
correctly installed.
• Engine speed is 350 r/min or more. Q: Is the check result normal?
Judgment Criterion NO : Repair or replace the camshaft position
• The number of output pulses from the camshaft sensor.
position sensor every two engine rotations (from
when one excessive tooth is detected to when
another is detected) is not five. STEP 2. M.U.T.-III diagnosis code
13A-198 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-199
Code No. P0381: Glow Plug Open/Short Malfunction <Euro5>
Glow System Circuit
Fusible link 23 Fusible link 24
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
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1 2
3 OFF Engine control relay
4 ON
2 3
A-151
To engine-ECU
R
6 10 Glow control unit
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
Glow plug Glow plug Glow plug Glow plug
C-103
Wire colour code

AKB00259 AB
13A-200 DIESEL FUEL
TROUBLESHOOTING
OPERATION DIAGNOSTIC PROCEDURE

• The electrical current source is supplied from the
engine control relay (terminal No.3) to the glow
control unit (terminal No.6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No.7) to the unit connector
body earth. Connector: A-151
• The request signal of operating the glow plug is
input into the glow control unit (terminal No. 1)
from the engine-ECU (terminal No.120).
• The voltage for the glow plug is applied from the
battery to the glow control unit (terminal No.10).
• The voltage is applied from the glow control unit 4 3 2 1
8 7 6 5
(terminal No.1, 2, 3 and 4) to each glow plug. 11 10 9 A-151 (B)
• The diagnosis signal is output from the glow con- Harness side
trol unit (terminal No.9) to the engine-ECU (termi- connector AKB00264 AB
nal No.126).
• The voltage applied to the glow control unit (ter- NO : Repair or replace the connector.
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minal No.10) from the battery is applied to each
glow plug in the duty ratio according to the signal
STEP 2. Connector check: A-153 No. 1 glow plug
from the engine ECU.
connector, A-154 No. 2 glow plug connector, A-
TROUBLE JUDGMENT 155 No. 3 glow plug connector and A-156 No. 4
glow plug connector.
Check Conditions
• While the engine is running Connectors: A-153, A-154, A-155 and A-156
• The electrical continuity duty to the glow plug is
17 − 83 %.
Judgment Criterion A-156 (B)
• The information that the glow is abnormal is A-155 (B)
received from the glow control unit.
A-154 (B)
PROBABLE CAUSES 1
A-153 (B)
• Failed glow plug Harness side
• Failed glow control unit
• Open/short circuit or harness damage in glow Q: Is the check result normal?
plug circuit or loose connector contact. YES : Go to Step 3 .
• Failed engine-ECU NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-201
No.1) glow control unit connector and A-153 No. 2) glow control unit connector and A-154
(terminal No.1) No.1 glow plug connector. (terminal No. 1) No.2 glow plug connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
connector AKB00264 AB connector AKB00264 AB
cardiagn.com
A-154 (B)
1 1
Harness side A-153 (B) Harness side
age. age.
13A-202 DIESEL FUEL
TROUBLESHOOTING
No. 3) glow control unit connector and A-155 No. 4) glow control unit connector and A-156
(terminal No. 1) No.3 glow plug connector. (terminal No. 1) No.4 glow plug connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
A-156 (B)
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A-155 (B)
1 1
age. age.
STEP 7. Replace the glow control unit.

• After replacing the glow control unit, reconfirm
whether the diagnosis code is set.
NO : Check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-203
Code No. P0401: EGR Flow Insufficient <Euro5>
OPERATION STEP 2. Connector check: A-45 EGR valve

• Refer to Code No. P0102: Air Flow Sensor Circuit assembly connector
Low Input P.13A-68.
• Refer to Code No. P0403: EGR Valve (DC Motor) Connector: A-45
Malfunction P.13A-215.
• Refer to Code No. P0489: EGR Valve Position
Sensor Circuit Low Input <Euro5> P.13A-240. A-45 (GR)
FUNCTION
• The engine-ECU monitors the EGR flow rate. 3 2 1
6 5 4
TROUBLE JUDGMENT
Harness side
Check Conditions connector AK501331 AB
• Engine is running.
• Normal running (vehicle speed: 65 − 75 km/h,
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transmission: 5th <M/T>, D range <A/T>).
• The intake air temperature is from 20 to 40 °C.
STEP 3. Connector check: C-103 and C-105
Judgment Criterion engine-ECU connectors
• The EGR flow rate is larger than target EGR flow
rate by the rate that is more than the specified Connectors: C-103, C-105
value.
PROBABLE CAUSES
• Failed EGR passage (leakage and clogged EGR
passage)
• Harness damage in EGR valve circuit or loose
connector contact C-103 (B) C-105 (B)
• Failed EGR valve operation
• Harness damage in air flow sensor circuit or
• Failed air flow sensor (abnormal output charac-
teristics)
C-103 (B) C-105 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Q: Is the diagnosis code P0403 or P2413 set? 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
YES : Inspection chart for diagnosis codes (Refer 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
to P.13A-21).
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Go to Step 2 . C-105 Harness side connector
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 Harness side connector

AKB00270 AB

YES : Go to Step 4 . NO : Repair or replace the connector.
13A-204 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve assembly connector.
C-103 (B) C-103 (B)
cardiagn.com
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
• Check output line for damage. • Check output line for damage.
STEP 6. Check harness between C-105 (terminal

No. 81) engine-ECU connector and A-45 (terminal
No. 2) EGR valve assembly connector.
DIESEL FUEL
TROUBLESHOOTING
13A-205
Connector: C-105 STEP 7. Check harness between C-105 (terminal
<L.H. drive vehicles> No. 71) engine-ECU connector and A-45 (terminal
Connector: C-105
C-105 (B)

C-105 (B)
C-105 (B)
cardiagn.com
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-45 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) Connector: A-45
3 2 1
A-45 (GR)
6 5 4
Harness side
3 2 1
• Check earthing line for damage. 6 5 4
Q: Is the check result normal? Harness side
connector
YES : Go to Step 7 . AK501331 AB
NO : Repair the damaged harness wire. • Check power supply line for damage.
13A-206 DIESEL FUEL
TROUBLESHOOTING
STEP 9. Check EGR valve itself.
Connector: C-105
<L.H. drive vehicles> • Check EGR valve itself [Refer to GROUP 17 −
Emission Control − Exhaust Gas Recirculation
(EGR) System − EGR Valve (DC motor) Check ].
NO : Replace the EGR valve assembly.
C-105 (B)
STEP 10. Check EGR passage for deposits.
• Check the EGR valve, the EGR pipe and the
inside of the EGR cooler for deposits. (Refer to
GROUP 17 − Emission Control − EGR Valve And
EGR Cooler − Removal And Installation ).
cardiagn.com
NO : Cleaning or replace the EGR valve, EGR
C-105 (B) pipe and EGR cooler.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-135
Connector: A-45
A-45 (GR)

3 2 1 connector AKA00399AB
6 5 4
• Check output line for damage. NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-207
No. 4) air flow sensor connector and C-103 No. 3) air flow sensor connector and C-103
Harness side A-135 (B) Harness side A-135 (B)

connector AKA00399AB connector AKA00399AB

cardiagn.com
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check earthing line for damage. • Check output line for damage.
STEP 14. Replace the air flow sensor.

• After replacing the air flow sensor, re-check the
trouble symptoms.
13A-208 DIESEL FUEL
TROUBLESHOOTING

cardiagn.com
Code No. P0402: EGR Flow Excessive <Euro5>
OPERATION • Failed air flow sensor (abnormal output charac-

• Refer to Code No. P0102: Air Flow Sensor Circuit teristics)
Low Input P.13A-68. • Failed engine-ECU
• Refer to Code No. P0403: EGR Valve (DC Motor)
Malfunction P.13A-215. DIAGNOSTIC PROCEDURE
• Refer to Code No. P0489: EGR Valve Position
Sensor Circuit Low Input <Euro5> P.13A-240.
FUNCTION Q: Is the diagnosis code P0403 or P2413 set?
• The engine-ECU monitors the EGR flow rate. YES : Inspection chart for diagnosis codes (Refer
to P.13A-21).
TROUBLE JUDGMENT NO : Go to Step 2 .
Check Conditions
• Engine is running STEP 2. Connector check: A-45 EGR valve
• Battery positive voltage is 8 − 16 V. assembly connector
• Vehicle is stopped (transmission: Neutral <M/T>,
Connector: A-45
P range <A/T>)
Judgment Criterion
• The EGR flow rate is smaller than target EGR
A-45 (GR)
flow rate by the rate that is more than the speci-
fied value.
3 2 1
PROBABLE CAUSES
6 5 4
• Failed EGR passage (air suction)
• Harness damage in EGR valve circuit or loose Harness side
connector contact
• Failed EGR valve operation Q: Is the check result normal?
• Harness damage in air flow sensor circuit or YES : Go to Step 3 .
loose connector contact NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-209
STEP 3. Connector check: C-103 and C-105 STEP 4. Check harness between C-103 (terminal
engine-ECU connectors No. 115) engine-ECU connector and A-45
Connectors: C-103, C-105
(terminal No. 6) EGR valve assembly connector.
<L.H. drive vehicles> Connector: C-103
C-103 (B) C-105 (B)

C-103 (B)
cardiagn.com
C-103 (B) C-105 (B)
C-103 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 Connector: A-45

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

AKB00270 AB
A-45 (GR)
3 2 1
6 5 4
Harness side

13A-210 DIESEL FUEL
TROUBLESHOOTING
No. 130) engine-ECU connector and A-45 No. 81) engine-ECU connector and A-45 (terminal
(terminal No. 4) EGR valve assembly connector. No. 2) EGR valve assembly connector.
C-103 (B) C-105 (B)
cardiagn.com
C-103 (B) C-105 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
• Check output line for damage. • Check earthing line for damage.
DIESEL FUEL
TROUBLESHOOTING
13A-211
No. 71) engine-ECU connector and A-45 (terminal No. 57) engine-ECU connector and A-45 (terminal
No. 3) EGR valve assembly connector. No. 1) EGR valve assembly connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
STEP 9. Check EGR valve itself.

• Check EGR valve itself [Refer to GROUP 17 −
Emission Control − Exhaust Gas Recirculation
(EGR) System − EGR Valve (DC motor) Check ].
13A-212 DIESEL FUEL
TROUBLESHOOTING
STEP 10. Check EGR passage for air suction. STEP 12. Check harness between A-135 (terminal
• Check the EGR valve, the EGR pipe and the No. 4) air flow sensor connector and C-103
EGR cooler for the air suction. (terminal No. 155) engine-ECU connector.
Q: Is the check result normal? Connector: A-135
NO : Cleaning or replace the EGR valve, EGR
pipe and EGR cooler.

connector
Connector: A-135
Connector: C-103
cardiagn.com
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-213
No. 3) air flow sensor connector and C-103
STEP 14. Replace the air flow sensor.
Connector: A-135
• After replacing the air flow sensor, re-check the
trouble symptoms.
Harness side
A-135 (B)
connector AKA00399AB ECU is replaced, write the chassis number
<L.H. drive vehicles> Writing ). After replacing the engine-ECU,
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C-103 (B) carry out the forcible DPF regeneration.
<R.H. drive vehicles> Diesel Particulate Filter (DPF) System −
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-214 DIESEL FUEL
TROUBLESHOOTING
Code No. P0403: EGR Valve (DC Motor) Malfunction
EGR Valve (DC motor) Circuit
A-45
(MU802056)
M
EGR valve assembly
1 2 3
4 5 6
6 4
V Y-B
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C-103 115 130
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00102 AB

• The electric current from the engine-ECU (termi-
Check Condition
nal No. 130 and No. 115) to the EGR valve (DC
• Ignition switch is in "ON" position
motor) (terminal No. 4 and No. 6).
Judgment Criterion
FUNCTION • An overcurrent cut-off signal from the EGR valve
• The engine-ECU performs duty control over the drive control integrated circuit (IC) is detected for
EGR valve (DC motor). 0.5 second.
• The engine-ECU performs feedback control over
the EGR valve based on the signals from the PROBABLE CAUSES
EGR position sensor. • Failed EGR valve
• Open/short circuit or harness damage in EGR
DIESEL FUEL
TROUBLESHOOTING
13A-215
connector
STEP 1. Connector check: A-45 EGR valve Connector: C-103
assembly connector <L.H. drive vehicles>
Connector: A-45
A-45 (GR)
C-103 (B)
3 2 1
6 5 4 <R.H. drive vehicles>
Harness side

cardiagn.com
C-103 (B)
STEP 2. Check EGR valve itself
• Check EGR valve itself [Refer to GROUP 17 − 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Exhaust Gas Recirculation (EGR) System − EGR 117 116
valve (DC motor) check ]. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

NO : Replace the EGR valve assembly. Q: Is the check result normal?
13A-216 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
C-103 (B) C-103 (B)
cardiagn.com
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
age. age.

DIESEL FUEL
TROUBLESHOOTING
13A-217
DPF Regeneration ).
cardiagn.com
13A-218 DIESEL FUEL
TROUBLESHOOTING
Code No. P0405: EGR Valve Position Sensor Circuit Low Input <Except Euro5>
EGR valve Position Sensor Circuit
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
cardiagn.com
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

• A power voltage of 5 V is applied to the EGR
Check Conditions
valve assembly power terminal (terminal No. 3)
earthed to the engine-ECU (terminal No. 81) from
the EGR valve assembly (terminal No. 2).
(terminal No. 57) from the EGR valve assembly • The EGR valve position sensor output voltage is
output terminal (terminal No. 1). 0.20 V or less for 0.5 second.

• The EGR valve assembly detects the position of • Failed EGR valve position sensor
the EGR valve and sends the signal to the • Open/short circuit or harness damage in EGR
engine-ECU. valve position sensor circuit or loose connector
• Based on the signal, the engine-ECU performs contact
the feedback control of the EGR valve. • Failed engine-ECU
DIESEL FUEL
TROUBLESHOOTING
13A-219
NO : Go to Step 4 .

a. Item 16: EGR valve position sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
Connector: A-45
cardiagn.com
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
EGR valve assembly connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
OK: 4.9 − 5.1 V
13A-220 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) EGR valve assembly connector and C-105
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-221
YES : Intermittent malfunction (Refer to GROUP YES : Check and repair harness between A-45
00 − How to Use Troubleshooting/ (terminal No. 3) EGR valve assembly
Inspection Service Points − How to Cope connector and C-105 (terminal No. 71)
with Intermittent Malfunctions ). engine-ECU connector.
NO : Replace the engine-ECU. When the engine- • Check power supply line for open
ECU is replaced, write the chassis number circuit and damage.
(Refer to GROUP 00 − Precautions Before NO : Repair or replace the connector.
Writing ). After replacing the engine-ECU, STEP 9. Perform resistance measurement at A-45
register the injector identification code and EGR valve assembly connector.
Precautions Before Service − What The Connector: A-45
STEP 8. Connector check: C-105 engine-ECU A-45 (GR)

connector
Connector: C-105 3 2 1
6 5 4
cardiagn.com
Harness side

side.
C-105 (B) • Resistance between terminal No. 2 and earth.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

13A-222 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-223
EGR valve assembly connector.
Connector: A-45
No. 1) EGR valve assembly connector and C-105
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side

nect connector and measure at pick-up harness. 6 5 4
• Engine: Idling (after warning up) Harness side
connector
AK501331 AB
OK: 2.0 V or higher Connector: C-105

cardiagn.com

connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Replace the EGR valve assembly.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-224 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Measure engine-ECU terminal voltage. Connector: A-45

• Engine: Idling (after warning up)
OK: 2.0 V or higher
A-45 (GR)
NO : Go to Step 16 . 3 2 1
6 5 4
Harness side

(terminal No. 1) EGR valve assembly
connector and C-105 (terminal No. 57)
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-225
connector
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-226 DIESEL FUEL
TROUBLESHOOTING
Code No. P0406: EGR Valve Position Sensor Circuit High Input <Except Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
cardiagn.com
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 4.80 V or more for 0.5 second.

the EGR valve and sends the signal to the • Open circuit in EGR valve position sensor circuit
engine-ECU. or loose connector contact
• Based on the signal, the engine-ECU performs • Failed engine-ECU
the feedback control of the EGR valve.
DIESEL FUEL
TROUBLESHOOTING
13A-227
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
cardiagn.com
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
13A-228 DIESEL FUEL
TROUBLESHOOTING
Connector: A-45
A-45 (GR) Q: Is the check result normal?

3 2 1 Inspection Service Points − How to Cope
cardiagn.com
C-105 (B)
<R.H. drive vehicles> a. Item 16: EGR valve position sensor
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Code No. P0420: Catalyst Malfunction <Euro5>
FUNCTION TROUBLE JUDGMENT

• The engine-ECU injects the fuel with the slower
Check Condition
timing than usual (post injection), so that the oxy-
• On DPF regeneration
gen and HC of exhaust gas burn in the catalyst,
and the exhaust gas temperature raises up to the Judgement Criteria
level which enables the DPF regeneration. • The conditions below continues for 30 seconds.
• The engine-ECU monitors the signals from the • The fuel injection amount exceeds the specified
No. 2 exhaust gas temperature sensor (catalyst value.
temperature) to detect the catalyst inactivation. • The engine speed exceeds the specified value.
DIESEL FUEL
TROUBLESHOOTING
13A-229
• The No. 1 exhaust gas temperature sensor is STEP 2. Forcible DPF regeneration execution
350°C or higher. • Initialise the DPF-related parts, and then delete
• The No. 2 exhaust gas temperature sensor (cata- the diagnosis code (Refer to GROUP 00 − Pre-
lyst temperature) is 450°C or below. cautions before Service − Initialisation Procedure
PROBABLE CAUSES for Learning Value in Diesel Particulate Filter
• Failed No. 1 exhaust gas temperature sensor (DPF) System ).
• Failed No. 2 exhaust gas temperature sensor a. Item 42: DPF system malfunction service
(catalyst temperature) • Carry out the forcible DPF regeneration (Refer to
• Catalytic converter inactive GROUP 17 − Emission Control − Diesel Particu-
late Filter (DPF) System − Forcible DPF Regen-
DIAGNOSIS PROCEDURE eration ).
Q: Is the diagnosis code P0420 or P1497 output?
YES : Replace the catalytic converter. When the
STEP 1. M.U.T.-III data list.
catalytic converter is replaced, initialise the
learning value. (Refer to GROUP 00 −
a. Item 117: No. 1 exhaust gas temperature sen- Precautions before Service − Initialisation
sor Procedure for Learning Value in Diesel
b. Item 118: No. 2 exhaust gas temperature sen- Particulate Filter (DPF) System .) On
sor (catalyst temperature)
cardiagn.com
completion, carry out the forcible DPF
Q: Are the check results normal? regeneration (Refer to GROUP 17 −
YES : Go to Step 2 . Emission Control − Diesel Particulate Filter
NO : Perform the diagnosis code classified check (DPF) System − Forcible DPF Regeneration
procedure for the sensor that has shown an ).
abnormal data value (Refer to Inspection NO : Replace the engine-ECU. When the engine-
Chart for Diagnosis Code P.13A-21). ECU is replaced, write the chassis number
13A-230 DIESEL FUEL
TROUBLESHOOTING
Code No. P0427: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit Low Input
<Euro5>
No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
cardiagn.com
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00271 AB
OPERATION • The No. 2 exhaust gas temperature sensor (cata-

• A power voltage of 5 V is applied to the No. 2 lyst temperature) is a kind of resistor, which has
exhaust gas temperature sensor (catalyst tem- characteristics to reduce its resistance as the cat-
perature) output terminal (terminal No. 1) from alyst temperature rises. Therefore, the sensor
the engine-ECU (terminal No. 59). output voltage varies with the catalyst tempera-
• The power voltage is earthed to the engine-ECU ture, and becomes lower as the catalyst tempera-
(terminal No. 83) from the No. 2 exhaust gas tem- ture rises.
perature sensor (catalyst temperature) (terminal
No. 2). TROUBLE JUDGMENT
Check Conditions
FUNCTION
• The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) converts the catalyst tempera-
ture into a voltage and inputs the voltage signal to
the engine-ECU. Judgment Criterion
• Engine-ECU uses this voltage output for DPF • The No. 2 exhaust gas temperature sensor (cata-
regeneration control. lyst temperature) output voltage is 0.255 V or
less.
DIESEL FUEL
TROUBLESHOOTING
13A-231
PROBABLE CAUSES STEP 3. Check No. 2 exhaust gas temperature
• Failed No. 2 exhaust gas temperature sensor sensor (catalyst temperature) itself.
(catalyst temperature) • Check No. 2 exhaust gas temperature sensor
• Short circuit in No. 2 exhaust gas temperature (catalyst temperature) itself (Refer to GROUP 17
sensor (catalyst temperature) circuit or loose con-
− Emission Control − Diesel Particulate Filter
nector contact
(DPF) System − No. 2 Exhaust Gas Temperature
Sensor (catalyst temperature) Check ).
DIAGNOSTIC PROCEDURE Q: Is the check result normal?
NO : Replace the No. 2 exhaust gas temperature
STEP 1. M.U.T.-III data list sensor (catalyst temperature). After
• Refer to Data List Reference Table P.13A-542. replacing the No. 2 exhaust gas
a. Item 118: No. 2 exhaust gas temperature sensor temperature sensor (catalyst temperature),
(catalyst temperature) carry out the forcible DPF regeneration.
Q: Is the check result normal? (Refer to GROUP 17 − Emission Control −
YES : Intermittent malfunction (Refer to GROUP Diesel Particulate Filter (DPF) System −
00 − How to Use Troubleshooting/ Forcible DPF Regeneration ).
cardiagn.com
NO : Go to Step 2 . connector
Connector: C-105
STEP 2. Connector check: A-159 No. 2 exhaust <L.H. drive vehicles>
gas temperature sensor (catalyst temperature)
connector
Connector: A-159
C-105 (B)
2 1 A-159 (B)
Harness side
connector
C-105 (B)
No. 2 exhaust gas

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
temperature sensor 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
(catalyst temperature)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
YES : Go to Step 3 . NO : Repair or replace the connector.
13A-232 DIESEL FUEL
TROUBLESHOOTING
No. 1) No. 2 exhaust gas temperature sensor
(catalyst temperature) connector and C-105
(terminal No. 59) engine-ECU connector. STEP 6. M.U.T.-III data list
Connector: A-159
a. Item 118: No. 2 exhaust gas temperature sensor
A-159 (B) with Intermittent Malfunctions ).
2 1
Harness side
connector ECU is replaced, write the chassis number
cardiagn.com
No. 2 exhaust gas
temperature sensor
(catalyst temperature) Precautions Before Service − What The
AKB00272 AB (Refer to GROUP 17 − Emission Control −
Connector: C-105 Forcible DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intemediate

DIESEL FUEL
TROUBLESHOOTING
13A-233
Code No. P0428: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit High Input
<Euro5>
No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
cardiagn.com
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00271 AB
OPERATION • The No. 2 exhaust gas temperature sensor (cata-

• A power voltage of 5 V is applied to the No. 2 lyst temperature) is a kind of resistor, which has
exhaust gas temperature sensor (catalyst tem- characteristics to reduce its resistance as the cat-
perature) output terminal (terminal No. 1) from alyst temperature rises. Therefore, the sensor
the engine-ECU (terminal No. 59). output voltage varies with the catalyst tempera-
• The power voltage is earthed to the engine-ECU ture, and becomes lower as the catalyst tempera-
(terminal No. 83) from the No. 2 exhaust gas tem- ture rises.
perature sensor (catalyst temperature) (terminal
No. 2). TROUBLE JUDGMENT
Check Conditions
FUNCTION
• The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) converts the catalyst tempera-
ture into a voltage and inputs the voltage signal to
• Vehicle speed is 20 km/h or higher.
the engine-ECU.
• Engine-ECU uses this voltage for DPF regenera- Judgment Criterion
tion control. • The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) output voltage is 4.95 V or
more.
13A-234 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSES STEP 3. Check No. 2 exhaust gas temperature

• Failed No. 2 exhaust gas temperature sensor sensor (catalyst temperature) itself.
(catalyst temperature) • Check No. 2 exhaust gas temperature sensor
• Open circuit or harness damage in No. 2 exhaust (catalyst temperature) itself (Refer to GROUP 17
− Emission Control − Diesel Particulate Filter
circuit or loose connector contact
(DPF) System − No. 2 Exhaust Gas Temperature
Sensor (catalyst temperature) Check ).
DIAGNOSTIC PROCEDURE Q: Is the check result normal?
STEP 1. M.U.T.-III data list sensor (catalyst temperature). After
• Refer to Data List Reference Table P.13A-542 replacing the No. 2 exhaust gas
a. Item 118: No. 2 exhaust gas temperature sensor temperature sensor (catalyst temperature),
(catalyst temperature) carry out the forcible DPF regeneration.
YES : Intermittent malfunction (Refer to GROUP Diesel Particulate Filter (DPF) System −
00 − How to Use Troubleshooting/ Forcible DPF Regeneration ).
cardiagn.com
with Intermittent Malfunctions ). STEP 4. Perform voltage measurement at A-159
NO : Go to Step 2 . No. 2 exhaust gas temperature sensor (catalyst
temperature) connector.
STEP 2. Connector check: A-159 No. 2 exhaust Connector: A-159
connector
Connector: A-159
2 1 A-159 (B)
Harness side
connector
2 1 A-159 (B)
Harness side
connector
No. 2 exhaust gas

temperature sensor
No. 2 exhaust gas

temperature sensor
AKB00272 AB

side.
AKB00272 AB • Ignition switch: ON
YES : Go to Step 3 . OK: 4.5 − 4.9 V
NO : Repair or replace the connector. Q: Is the check result normal?
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-235
connector. No. 1) No. 2 exhaust gas temperature sensor
Connector: C-105
<L.H. drive vehicles> (terminal No. 59) engine-ECU connector.
Connector: A-159
C-105 (B)
<R.H. drive vehicles> 2 1 A-159 (B)

Harness side
connector
cardiagn.com
No. 2 exhaust gas
C-105 (B) temperature sensor
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-236 DIESEL FUEL
TROUBLESHOOTING
159 No. 2 exhaust gas temperature sensor
(catalyst temperature) connector.
Connector: A-159
Inspection Service Points − How to Cope A-159 (B)
2 1
Harness side
NO : Replace the engine-ECU. When the engine- connector
register the injector identification code and No. 2 exhaust gas
temperature sensor
cardiagn.com
carry out the forcible DPF regeneration. AKB00272 AB
(Refer to GROUP 17 − Emission Control − • Disconnect connector, and measure at harness
Diesel Particulate Filter (DPF) System − side.
Forcible DPF Regeneration ). • Resistance between terminal No. 2 and earth.
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-237
connector No. 2) No. 2 exhaust gas temperature sensor
Connector: C-105
<L.H. drive vehicles> (terminal No. 83) engine-ECU connector.
Connector: A-159
C-105 (B)

Harness side
connector
cardiagn.com
No. 2 exhaust gas
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-238 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Connector check: C-105 engine-ECU (terminal No. 59) engine-ECU connector.
connector.
Connector: A-159
Connector: C-105
2 1 A-159 (B)
C-105 (B)
Harness side
connector
cardiagn.com
No. 2 exhaust gas
temperature sensor
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00272 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-239
Code No. P0489: EGR Valve Position Sensor Circuit Low Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
cardiagn.com
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 0.20 V or less for 0.5 second.

the EGR valve and sends the signal to the • Open/short circuit or harness damage in EGR
engine-ECU. valve position sensor circuit or loose connector
• Based on the signal, the engine-ECU performs contact
the feedback control of the EGR valve. • Failed engine-ECU
13A-240 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .

Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
cardiagn.com
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
EGR valve assembly connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
OK: 4.9 − 5.1 V
DIESEL FUEL
TROUBLESHOOTING
13A-241
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


13A-242 DIESEL FUEL
TROUBLESHOOTING

connector
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

circuit and damage.
DIESEL FUEL
TROUBLESHOOTING
13A-243
Connector: A-45
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side
• Disconnect connector, and measure at harness 3 2 1

side. 6 5 4
• Ignition switch: ON Harness side
connector
AK501331 AB
OK: Continuity (2 Ω or less) Connector: C-105

cardiagn.com

connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-244 DIESEL FUEL
TROUBLESHOOTING
Connector: A-45
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side

nect connector and measure at pick-up harness. 6 5 4
• Engine: Idling (after warning up) Harness side
connector
AK501331 AB
OK: 2.0 V or higher Connector: C-105

cardiagn.com

connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Replace the EGR valve assembly.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-245
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Measure engine-ECU terminal voltage. Connector: A-45

• Engine: Idling (after warning up)
OK: 2.0 V or higher
A-45 (GR)
NO : Go to Step 16 . 3 2 1
6 5 4
Harness side

damage.
13A-246 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-247
Code No. P0490: EGR Valve Position Sensor Circuit High Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
cardiagn.com
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 4.80 V or more for 0.5 second.

the EGR valve and sends the signal to the • Open circuit in EGR valve position sensor circuit
engine-ECU. or loose connector contact
• Based on the signal, the engine-ECU performs • Failed engine-ECU
the feedback control of the EGR valve.
13A-248 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
cardiagn.com
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
DIESEL FUEL
TROUBLESHOOTING
13A-249
Connector: A-45

3 2 1 Inspection Service Points − How to Cope
cardiagn.com
C-105 (B) carry out the forcible DPF regeneration.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 00 − How to Use Troubleshooting/
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-250 DIESEL FUEL
TROUBLESHOOTING
Code No. P0502: Vehicle Speed Sensor Low Input <2WD-M/T and 4WD vehicles>
Vehicle Speed Sensor Circuit
Fusible link 23
W-R
Relay 10
box 20A Engine-ECU
C-103
5V
W-B 103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
A-115
cardiagn.com
3 116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
W-B
W-B
141
W-L
1 4 C-53*¹
A-20X
or
1 2 Engine C-35*²
11
3 control
ON relay W-L
4 OFF
22
2 3
J/C (2)
R C-127
A-28
10 21
W-L
To engine-ECU
R C-30
C-29
2 4
R W-L
1 3
B-01
(MU802723)
Vehicle speed sensor
1 2 3
B
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
AKA00104 AB
DIESEL FUEL
TROUBLESHOOTING
13A-251
OPERATION STEP 2. M.U.T.-III data list
• A power voltage of 5 V is applied to the vehicle • Refer to Data list reference table P.13A-542.
speed sensor (terminal No. 3) from the engine-
a. Item 4: Vehicle speed sensor
FUNCTION YES : Intermittent malfunction (Refer to GROUP
• The vehicle speed sensor converts the vehicle 00 − How to Use Troubleshooting/
speed to the voltage, and then input it into the Inspection Service Points − How to Cope
engine-ECU with Intermittent Malfunctions ).
NO : Go to Step 3 .
TROUBLE JUDGMENT
Check Conditions STEP 3. Connector check: C-103 engine-ECU
• Engine is running connector
• Engine coolant temperature is 80°C or higher
Connector: C-103
• The last fuel injection rate exceeds the specified <L.H. drive vehicles>
value.
• Engine speed is 2,900 r/min or more.
Judgment Criterion
• Vehicle speed is 5 km/h or lower for 2 seconds.
cardiagn.com
PROBABLE CAUSES
• Failed vehicle speed sensor C-103 (B)
• Open/short circuit or harness damage in vehicle
speed sensor circuit or loose connector contact <R.H. drive vehicles>
DIAGNOSIS PROCEDURE
STEP 1. Check the speed meter

C-103 (B)
NO : Check the speed meter (Refer to GROUP 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
54A −Combination Meter − On-vehicle 117 116
Service − Speedometer Check ).

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-252 DIESEL FUEL
TROUBLESHOOTING
No. 114) engine-ECU connector and B-01
(terminal No. 3) Vehicle speed sensor connector.
Connector: C-103
<L.H. drive vehicles> • Reconfirmation of diagnosis code.
C-103 (B)
cardiagn.com
C-103 (B) Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101

117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Connector: B-01
<2WD>
B-01 (B)
<4WD>
B-01 (B)
3 2 1
Harness side

connectors C-30, C-35 <R. H. drive vehicles>, C-53
<L. H. drive vehicles> and C-127, and repair if nec-
essary.
DIESEL FUEL
TROUBLESHOOTING
13A-253
Code No. P0513: Immobilizer Malfunction

• Engine-ECU sends or receives the control sig-
nals to or from ETACS-ECU to certify the ignition
key. STEP 1. M.U.T.-III other system diagnosis code.
• Confirm whether the diagnosis codes are output
NOTE: . from ETACS-ECU.
• If the registered ignition keys are close each
other when starting the engine, radio interfer- Q: Is the diagnosis code output?
ence may cause this code to be displayed. YES : Perform the troubleshooting of immobilizer
• This code may be displayed when registering system (Refer to GROUP 54A − Immobilizer
the key encrypted code. System − Check Chart for Diagnosis Code ).
NO : If diagnosis code P0513 output again after
TROUBLE JUDGMENT the MPI diagnosis code has been erased,
replace the engine-ECU. When the engine-
Check Condition
• Ignition switch is in "ON" position.
Judgment Criterion Service − How to Perform Chassis Number
• The check result of the ETACS-ECU is not suita- Writing ). After replacing the engine-ECU,
cardiagn.com
ble for that of the engine-ECU. register the injector identification code and
PROBABLE CAUSES Precautions Before Service − What The
• Open/short circuit in immobilizer system circuit or Common Rail Engine Learns ). After
loose connector contact registering the injector identification code,
• Failed ETACS-ECU the vehicle equipped with the DPF carries
• Failed engine-ECU out the forcible DPF regeneration. (Refer to
DPF Regeneration ).
13A-254 DIESEL FUEL
TROUBLESHOOTING
Code No. P0515: Battery Temperature Sensor System <Euro5>
Battery Temperature Sensor Circuit
A-152
Battery temperature
1 2 sensor (integrated in
battery current sensor)
3 4
3 2
BR-B GR-L
cardiagn.com
155 39
Engine-ECU
5V
C-103 C-105
103104105106107108109110 111112113 114115 1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24

101 102 118119120121122123124125126127128 129130 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
116 117
131132133134135136137138139140 141142143 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
144 145 146147148149150151152153154155156 157158 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00273AB
OPERATION • The battery temperature sensor is a kind of resis-

• A power voltage of 5 V is applied to the battery tor, which has characteristics to reduce its resist-
temperature sensor output terminal (terminal No. ance as the battery temperature rises. Therefore,
2) from the engine-ECU (terminal No. 39). the sensor output voltage varies with the battery
• The power voltage is earthed to the engine-ECU temperature, and becomes lower as the battery
(terminal No. 155) from the battery temperature temperature rises.
sensor (terminal No. 3).
TROUBLE JUDGMENT
FUNCTION
Check Condition
• The battery temperature sensor converts the bat-
tery temperature into a voltage and inputs the sig-
nal to the engine-ECU.
trols charging and discharging. Judgment Criterion
• The battery temperature sensor output voltage is
more than 4.88 V.
or
DIESEL FUEL
TROUBLESHOOTING
13A-255
• The battery temperature sensor output voltage is STEP 4. Perform voltage measurement at A-152
less than 0.99 V. battery current sensor connector.
PROBABLE CAUSES Connector: A-152
• Failed battery temperature sensor 2 1
4 3
• Open/short circuit or harness damage in battery
temperature sensor circuit or loose connector Harness side
connector
contact
DIAGNOSIS PROCEDURE
A-152 (GR)
AKB00274 AB
• Item No. 402: Battery temperature sensor • Disconnect connector and measure at harness
side.
temperature) of battery temperature sensor,
or equivalent
OK: 4.5 − 4.9 V
cardiagn.com
YES : Intermittent malfunction (Refer to GROUP Q: Is the check result normal?
00 − How to Use Troubleshooting/ YES : Go to Step 8 .
Inspection Service Points − How to Cope NO : Go to Step 5 .
NO : Go to Step 2 . STEP 5. Connector check: C-105 engine-ECU
connector
STEP 2. Connector check: A-152 battery current Connector: C-105
sensor connector <L.H. drive vehicles>
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)

A-152 (GR)
AKB00274 AB

C-105 (B)
STEP 3. Check battery temperature sensor itself.
• Check battery temperature sensor itself (Refer to 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
GROUP 54A − Battery − Inspection − Battery

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Current Sensor Check ). 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Replace the battery current sensor. Q: Is the check result normal?
13A-256 DIESEL FUEL
TROUBLESHOOTING
No. 2) battery current sensor connector and C- • Item No. 402: Battery temperature sensor
105 (terminal No. 39) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-152 temperature) of battery temperature sensor,
2 1 or equivalent
4 3
Harness side YES : Intermittent malfunction (Refer to GROUP
connector
A-152 (GR) ECU is replaced, write the chassis number
AKB00274 AB (Refer to GROUP 00 − Precautions Before
Connector: C-105
<L.H. drive vehicles> Writing ). After replacing the engine-ECU,
cardiagn.com
C-105 (B) (Refer to GROUP 17 − Emission Control −
<R.H. drive vehicles> Forcible DPF Regeneration ).

152 battery current sensor connector.
Connector: A-152
2 1
4 3
C-105 (B)
Harness side
connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB A-152 (GR)

• Check output line for open/short circuit. AKB00274 AB
Q: Is the check result normal? • Disconnect connector and measure at harness

NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-257
connector No. 3) battery current sensor connector and C-
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-258 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)
A-152 (GR)
AKB00274 AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-259
Code No. P0545: No.1 Exhaust Gas Temperature Sensor Circuit Low Input <Euro5>
No. 1 Exhaust Gas Temperature Sensor Circuit
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
cardiagn.com
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00275 AB
OPERATION • The No.1 exhaust gas temperature sensor is a

• A power voltage of 5 V is applied to the No.1 kind of resistor, which has characteristics to
exhaust gas temperature sensor output terminal reduce its resistance as the exhaust gas temper-
(terminal No. 1) from the engine-ECU (terminal ature rises. Therefore, the sensor output voltage
No. 58). varies with the exhaust gas temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the exhaust gas temperature
(terminal No. 82) from the No.1 exhaust gas tem- rises.
perature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The No.1 exhaust gas temperature sensor con-
verts the exhaust gas temperature into a voltage
and inputs the voltage signal to the engine-ECU.
• Engine-ECU uses this voltage output for DPF
regeneration control. Judgment Criterion
• The No.1 exhaust gas temperature sensor output
voltage is 0.255 V or less.
PROBABLE CAUSES
• Failed No.1 exhaust gas temperature sensor
• Short circuit in No.1 exhaust gas temperature sensor circuit or connector damage
13A-260 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the No.1 exhaust gas temperature
DIAGNOSTIC PROCEDURE sensor. After replacing the No.1 exhaust
gas temperature sensor, carry out the
forcible DPF regeneration. (Refer to
STEP 1. M.U.T.-III data list GROUP 17 − Emission Control − Diesel
• Refer to Data List Reference Table P.13A-542. Particulate Filter (DPF) System − Forcible
a. Item 117: No.1 exhaust gas temperature sensor DPF Regeneration ).
YES : Intermittent malfunction (Refer to GROUP STEP 4. Connector check: C-105 engine-ECU
00 − How to Use Troubleshooting/ connector
NO : Go to Step 2 .
STEP 2. Connector check: A-149 No.1 exhaust

gas temperature sensor connector
Connector: A-149
cardiagn.com
C-105 (B)
A-149 (B)
2 1
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Check No.1 exhaust gas temperature
sensor itself. AKA00089 AB
• Check No.1 exhaust gas temperature sensor

itself (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System − No.1
exhaust gas temperature sensor Check ).
DIESEL FUEL
TROUBLESHOOTING
13A-261
Connector: A-149
a. Item 117: No.1 exhaust gas temperature sensor
2 1
Harness side ECU is replaced, write the chassis number
connector AKB00276 AB (Refer to GROUP 00 − Precautions Before
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-262 DIESEL FUEL
TROUBLESHOOTING
Code No. P0546: No. 1 exhaust gas temperature sensor Circuit High Input <Euro5>
No. 1 Exhaust Gas Temperature Sensor Circuit
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
cardiagn.com
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00275 AB
OPERATION • The No. 1 exhaust gas temperature sensor is a

• A power voltage of 5 V is applied to the No. 1 kind of resistor, which has characteristics to
exhaust gas temperature sensor output terminal reduce its resistance as the exhaust gas temper-
(terminal No. 1) from the engine-ECU (terminal ature rises. Therefore, the sensor output voltage
No. 58). varies with the exhaust gas temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the exhaust gas temperature
(terminal No. 82) from the No. 1 exhaust gas tem- rises.
perature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The No. 1 exhaust gas temperature sensor con-
verts the exhaust gas temperature into a voltage
and inputs the voltage signal to the engine-ECU.
• Engine-ECU uses this voltage for DPF regenera-
tion control.
Judgment Criterion
• The No. 1 exhaust gas temperature sensor out-
put voltage is 4.95 V or more.
PROBABLE CAUSES
• Failed No. 1 exhaust gas temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-263
• Open circuit or harness damage in No. 1 exhaust STEP 4. Perform voltage measurement at A-149
gas temperature sensor circuit or loose connector No. 1 exhaust gas temperature sensor connector.
contact
• Failed engine-ECU Connector: A-149

• Refer to Data List Reference Table P.13A-542 A-149 (B)
a. Item 117: No. 1 exhaust gas temperature sensor 2 1
YES : Intermittent malfunction (Refer to GROUP connector AKB00276 AB
00 − How to Use Troubleshooting/ • Disconnect connector, and measure at harness

Inspection Service Points − How to Cope side.
with Intermittent Malfunctions ). • Ignition switch: ON
NO : Go to Step 2 . • Voltage between terminal No. 1 and earth.
OK: 4.5 − 4.9 V
STEP 2. Connector check: A-149 No. 1 exhaust
cardiagn.com
gas temperature sensor connector YES : Go to Step 8 .
Connector: A-149 NO : Go to Step 5 .

connector.
Connector: C-105
A-149 (B)
2 1
Harness side

YES : Go to Step 3 . C-105 (B)

STEP 3. Check No. 1 exhaust gas temperature
sensor itself.
• Check No. 1 exhaust gas temperature sensor
itself (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System − No. 1
exhaust gas temperature sensor Check ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
sensor. After replacing the No. 1 exhaust 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

gas temperature sensor, carry out the 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
forcible DPF regeneration. (Refer to Harness side connector AKA00089 AB

Particulate Filter (DPF) System − Forcible Q: Is the check result normal?
DPF Regeneration ). YES : Go to Step 6 .
13A-264 DIESEL FUEL
TROUBLESHOOTING
No. 1) No. 1 exhaust gas temperature sensor • Refer to Data List Reference Table P.13A-542
connector and C-105 (terminal No. 58) engine- a. Item 117: No. 1 exhaust gas temperature sensor
ECU connector.
A-149 (B) (Refer to GROUP 00 − Precautions Before
Connector: C-105
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C-105 (B)

<R.H. drive vehicles> 149 No. 1 exhaust gas temperature sensor
connector.
Connector: A-149
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-149 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 Harness side
AKA00089 AB
• Check output line for open circuit. side.

Q: Is the check result normal? • Resistance between terminal No. 2 and earth.
YES : Go to Step 7 . OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-265
Connector: C-105
Connector: A-149
C-105 (B)
A-149 (B)
<R.H. drive vehicles> 2 1

Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-266 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-149
C-105 (B)
A-149 (B)
<R.H. drive vehicles> 2 1

Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-267
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
127
B-R
A-115
5
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B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
Wire colour code

AKA00105 AB

• The battery voltage is applied to the power steer-
Check Condition
ing pressure switch (terminal No. 1) from the
• Within 5 seconds after the ignition switch is in the
engine-ECU (terminal No. 127)
"OFF" position.
FUNCTION Judgment Criterion
• It is detected whether a load is applied on the • For 2 seconds, the power steering fluid pressure
power steering fluid pump by steering or not, and switch is in the "ON" position and the engine con-
the signal is inputted to the engine-ECU. When tinuously stops.
the power steering fluid pressure switch "ON" sig-
nal (a large load on the power steering fluid PROBABLE CAUSES
pump) is inputted, the engine-ECU provides the • Failed power steering fluid pressure switch
idle-up control. • Short circuit in power steering fluid pressure
switch circuit or loose connector contact
DIAGNOSIS PROCEDURE
13A-268 DIESEL FUEL
TROUBLESHOOTING
STEP 1. M.U.T.-III data list. STEP 4. Check at A-134 power steering fluid
• Refer to Data List Reference Table P.13A-542. pressure switch connector.
a. Item 75: Power steering fluid pressure switch Connector: A-134
A-134 (B)
NO : Go to Step 2
1
STEP 2. Connector check: A-134 power steering Harness side
pressure switch connector
Connector: A-134
side.
• Voltage between terminal No.1 and earth.
A-134 (B) OK: System voltage
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1 NO : Go to Step 5 .
Harness side
Q: Is the check result normal? connector
YES : Go to Step 3 . Connector: C-103
NO : Repair or replace the connector. <L.H. drive vehicles>
STEP 3. Check power steering pressure switch

itself.
• Disconnect A-134 power steering fluid pressure
switch connector.
• Continuity between terminal No.1 and earth. C-103 (B)
OK: No continuity
YES : Replace the power steering fluid pressure
switch.
NO : Go to Step 4 .
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-269
No. 127) engine-ECU connector and A-134
(terminal No. 1) power steering fluid pressure
switch connector.
Connector: C-103 register the injector identification code and

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a. Item 75: Power steering fluid pressure switch
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Harness side connector AKA00090 AB ECU is replaced, write the chassis number
Connector: A-134 Service − How to Perform Chassis Number
A-134 (B) learn fuel injection (Refer to GROUP 00 −
1 the vehicle equipped with the DPF carries
Harness side out the forcible DPF regeneration. (Refer to
connector AK501383 AB GROUP 17 − Emission Control − Diesel
NOTE: Before checking harness, check intermediate Particulate Filter (DPF) System − Forcible
connectors A-27 and A-115, and repair if necessary. DPF Regeneration ).
Code No. P0603: EEPROM Malfunction <Except Euro5>
TROUBLE JUDGMENT
FUNCTION Check Conditions
• To check whether the information such as the idle • Ignition switch is in ON position
learned value and so on is stored in the memory
of engine-ECU.
13A-270 DIESEL FUEL
TROUBLESHOOTING
Judgement Criterion YES : Replace the engine-ECU. When the engine-

• When the abnormal EEPROM memory data is ECU is replaced, write the chassis number
detected. (Refer to GROUP 00 − Precautions Before
PROBABLE CAUSE Writing ). After replacing the engine-ECU,
• Failed the engine-ECU register the injector identification code and
DIAGNOSIS Precautions Before Service − What The
STEP 1. Reconfirmation of diagnosis codes. 00 − How to Use Troubleshooting/
Q: Is the check result normal? Inspection Service Points − How to Cope
Code No. P0604: Random Access Memory (RAM) Malfunction
FUNCTION YES : Replace the engine-ECU. When the engine-

• The engine-ECU writes information to RAM or ECU is replaced, write the chassis number
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reads information from RAM. (Refer to GROUP 00 − Precautions Before
• The engine-ECU performs an initial check to Service − How to Perform Chassis Number
detect errors in RAM. Writing ). After replacing the engine-ECU,
TROUBLE JUDGMENT learn fuel injection (Refer to GROUP 00 −
Check Condition Precautions Before Service − What The
• Ignition switch is in "ON" position. Common Rail Engine Learns ). After
Judgment Criterion the vehicle equipped with the DPF carries
• A destroyed RAM is detected by engine-ECU ini- out the forcible DPF regeneration. (Refer to
tial check. GROUP 17 − Emission Control − Diesel
PROBABLE CAUSE
DPF Regeneration ).
DIAGNOSIS PROCEDURE Inspection Service Points − How to Cope
III, ignition switch is "ON" position and confirm
whether the diagnosis code is output.
Code No. P0605: Read Only Memory (FLASH ROM) Malfunction

• The engine-ECU reads information from flash
Check Condition
ROM.
• The engine-ECU detects checksum errors.
Judgment Criterion
• In each inspection target area of a flash ROM, a
checksum mismatch is detected three times con-
secutively.
DIESEL FUEL
TROUBLESHOOTING
13A-271
PROBABLE CAUSE YES : Replace the engine-ECU. When the engine-
DIAGNOSIS PROCEDURE Service − How to Perform Chassis Number
STEP 1. M.U.T.-III diagnosis code learn fuel injection (Refer to GROUP 00 −
• After erasing the diagnosis code through M.U.T.- Precautions Before Service − What The
III, ignition switch is "ON" position and confirm Common Rail Engine Learns ). After
whether the diagnosis code is output. registering the injector identification code,
Q: Is the diagnosis code set? the vehicle equipped with the DPF carries
DPF Regeneration ).
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Code No. P0606: Engine-ECU (main CPU) Malfunction

FUNCTION ECU is replaced, write the chassis number
• The engine-ECU check whether the microcom- (Refer to GROUP 00 − Precautions Before
puter, which performs the drive control of the Service − How to Perform Chassis Number
throttle valve, is normal. Writing ). After replacing the engine-ECU,
TROUBLE JUDGMENT learn fuel injection (Refer to GROUP 00 −
Check Condition
Judgment Criterion the vehicle equipped with the DPF carries
• The monitoring microcomputer detects a main out the forcible DPF regeneration. (Refer to
microcomputer error. GROUP 17 − Emission Control − Diesel
PROBABLE CAUSE DPF Regeneration ).
• Failed engine-ECU NO : Intermittent malfunction (Refer to GROUP
DIAGNOSIS Inspection Service Points − How to Cope
Code No. P0607: Engine-ECU (sub CPU) Malfunction
FUNCTION
• The main microcomputer detects errors in the
sub microcomputer used for monitoring.
13A-272 DIESEL FUEL
TROUBLESHOOTING
TROUBLE JUDGMENT YES : Replace the engine-ECU. When the engine-

Check Conditions
• Battery positive voltage is 10 V or more
Judgment Criterion learn fuel injection (Refer to GROUP 00 −
• The main microcomputer detects a main micro- Precautions Before Service − What The
computer error. Common Rail Engine Learns ). After
PROBABLE CAUSE the vehicle equipped with the DPF carries
DIAGNOSIS PROCEDURE Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 1. M.U.T.-III diagnosis code NO : Intermittent malfunction (Refer to GROUP
• After erasing the diagnosis code through M.U.T.- 00 − How to Use Troubleshooting/
III, ignition switch is "ON" position and confirm Inspection Service Points − How to Cope
whether the diagnosis code is output. with Intermittent Malfunctions ).
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Code No. P0620: Alternator Control Circuit <Euro5>
OPERATION or
• When the ignition switch is turned ON, the current • For 30 seconds, the battery backup voltage sub-
should be supplied from the combination meter tracted from the final target generation voltage
(terminal No. 52) to the alternator (terminal No. equals 1.9 V or more.
3). When the engine starts under those condi-
tions, the alternator should generate currents. PROBABLE CAUSES
• The engine-ECU checks the voltage of the bat- • Failed battery
tery backup terminal (terminal No. 103) to moni- • Failed drive belt
tor the electricity generation voltage of the • Loose connector contact
alternator. • Open/short circuit or harness damage in alterna-
tor G-terminal circuit
FUNCTION • Harness damage in battery backup circuit
• The engine-ECU compares the battery voltage • Failed alternator
with the voltage generated from the alternator to • Failed engine-ECU
check whether the electrical generation is normal.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions STEP 1. Checking engine start conditions
• Ignition switch is "ON" position. • Check whether the user uses the booster cable to
• The engine speed is 1 500 r/min or more. start the engine.
• The battery backup voltage is 13.5 V or more.
NOTE: This diagnosis code can be output due to the
• The G-terminal duty ratio is 10.2 % or more and
battery voltage drop.
89.8 % or less.
Q: Have you ever used the booster cable to start the
Judgement Criterion
engine?
• For 30 seconds, the final target generation volt- YES : Delete the diagnosis code and check end.
age subtracted from the battery backup voltage NO : Go to Step 2 .
equals 0.8 V or more.
DIESEL FUEL
TROUBLESHOOTING
13A-273
STEP 2. Battery check STEP 5. Perform voltage measurement at C-103
• Check the battery (Refer to GROUP 54A − Bat- engine-ECU connector.
tery − On-vehicle Service − Battery Test ). Connector: C-103
NO : Replace the battery.
STEP 3. Drive belt tension check

• Drive belt tension check (Refer to GROUP 11A −
On-vehicle Service − Alternator and Power Steer- C-103 (B)
ing Oil Pump Drive Belt Tension Check ).
NO : Replace the drive belt.

connector
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115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
side.
OK: System voltage
NO : Go to Step 6 .
C-103 (B)
STEP 6. Connector check: A-122 alternator
115 114 113 112 111 110 109 108 107 106 105 104 103
connector
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 Connector: A-122

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

NO : Repair or replace the connector. M
4 3 2 1 A-122 (GR)
Harness side

13A-274 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Check harness between C-103 (terminal STEP 8. Check harness between battery and C-
No. 121) engine-ECU connector and A-122 103 (terminal No. 103) engine-ECU connector.
(terminal No. 1) alternator connector. Connector: C-103
Connector: C-103 <L.H. drive vehicles>
C-103 (B)
C-103 (B)
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C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
115 114 113 112 111 110 109 108 107 106 105 104 103 117 116
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
117 116 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-122 connector A-115, and repair if necessary.
M STEP 9. M.U.T.-III diagnosis code

4 3 2 1 A-122 (GR) • Reconfirmation of diagnosis code.
Harness side
connector AKB00292 AB Q: Is diagnosis code set?
NOTE: Before checking harness, check intermediate NO : Intermittent malfunction (Refer to GROUP
connectors A-27 and A-115, and repair if necessary. 00 − How to Use Troubleshooting/
• Check output line for open/short circuit and dam- Inspection Service Points − How to Cope
age. with Intermittent Malfunctions ).
YES : Check the alternator. STEP 10. Replace the drive belt
NO : Repair the damaged harness wire. • After replacing the drive belt, reconfirm whether
the diagnosis code is set.
Q: Is diagnosis code set?
NO : Check end.
DIESEL FUEL
TROUBLESHOOTING
13A-275
STEP 11. Replace the alternator
• After replacing the alternator, reconfirm whether
the diagnosis code is set.
Q: Is diagnosis code set? Writing ). After replacing the engine-ECU,
NO : Check end.
Code No. P0628: Suction Control Valve Open <Except Euro5>
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1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION • The voltage is earthed to the engine-ECU (termi-

• The voltage is applied from the engine-ECU (ter- nal No. 146) from the suction control valve (termi-
minal No. 131) to the suction control valve (terminal No. 2).
nal No. 1) via the power transistor in the engine-
ECU. FUNCTION
• The engine-ECU performs duty control over the
suction control valve.
13A-276 DIESEL FUEL
TROUBLESHOOTING
• The engine-ECU checks whether the amount of YES : Go to Step 2 .

current for driving duty is adequate. NO : Repair or replace the connector.
TROUBLE JUDGMENT
Check Conditions • Check suction control valve itself (Refer to P.13A-
• Battery positive voltage is 8 − 16 V 596).
in "ON" position or the engine has started up. YES : Go to Step 3 .
• The supply pump and injector are being normally NO : Replace the suction control valve.
controlled.
• The fuel injection rate is 4 mm3/st or more.
Judgment Criterion connector
Connector: C-103
valve is higher than the specified value, the driv- <L.H. drive vehicles>
ing current is lower than the specified value.
PROBABLE CAUSES
• Open/short circuit or harness damage in suction
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control valve circuit or loose connector contact
• Failed engine-ECU C-103 (B)
DIAGNOSIS PROCEDURE <R.H. drive vehicles>

valve connector
Connector: A-47
2 1
C-103 (B)
Harness side
connector
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
A-47 (GR)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
AK503644 AB
DIESEL FUEL
TROUBLESHOOTING
13A-277
• Check power supply line for open/short circuit Connector: C-103
and damage. <L.H. drive vehicles>
Connector: C-103
C-103 (B)
cardiagn.com
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Connector: A-47
2 1
Connector: A-47 Harness side
2 1 connector
Harness side A-47 (GR)
connector
A-47 (GR)
AK503644 AB

AK503644 AB
damage.

13A-278 DIESEL FUEL
TROUBLESHOOTING

Code No. P0629: Suction Control Valve Battery Short <Except Euro5>
cardiagn.com
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION FUNCTION
• The voltage is applied from the engine-ECU (ter- • The engine-ECU performs duty control over the
minal No. 131) to the suction control valve (termi- suction control valve.
nal No. 1) via the power transistor in the engine- • The engine-ECU checks whether the amount of
ECU. current for driving duty is adequate.
• The voltage is earthed to the engine-ECU (termi-
nal No. 146) from the suction control valve (termi- TROUBLE JUDGMENT
nal No. 2). Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-279
• 2 seconds later after the ignition switch has been STEP 2. Check suction control valve itself.
in "ON" position or the engine has started up • Check suction control valve itself (Refer to P.13A-
• The supply pump and injector are being normally 596).
controlled.
• The fuel injection rate is 4 mm3/st or more.
YES : Go to Step 3.
Judgment Criterion NO : Replace the suction control valve.
valve is lower than the specified value, the driving STEP 3. Connector check: C-103 engine-ECU
current is higher than the specified value. connector
PROBABLE CAUSES Connector: C-103
• Failed suction control valve <L.H. drive vehicles>
• Short circuit in suction control valve circuit or
DIAGNOSIS PROCEDURE
C-103 (B)
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valve connector <R.H. drive vehicles>
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
AK503644 AB 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Go to Step 2.
YES : Go to Step 4.
13A-280 DIESEL FUEL
TROUBLESHOOTING
C-103 (B) C-103 (B)
cardiagn.com
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-281
Code No. P062F: EEPROM Malfunction <Euro5>
FUNCTION YES : Replace the engine-ECU. When the engine-

• To check whether the information such as the idle ECU is replaced, write the chassis number
cardiagn.com
learned value and so on is stored in the memory (Refer to GROUP 00 − Precautions Before
of engine-ECU. Service − How to Perform Chassis Number
TROUBLE JUDGMENT register the injector identification code and
Check Conditions learn fuel injection (Refer to GROUP 00 −
• Ignition switch is in ON position Precautions Before Service − What The
Judgement Criterion registering the injector identification code,
• When the abnormal EEPROM memory data is carry out the forcible DPF regeneration.
detected. (Refer to GROUP 17 − Emission Control −
PROBABLE CAUSE
• Failed the engine-ECU
DIAGNOSIS Inspection Service Points − How to Cope
STEP 1. Reconfirmation of diagnosis codes.
Code No. P0630: Chassis Number not Programmed
FUNCTION PROBABLE CAUSE

• The chassis number is stored in the engine-ECU • The chassis number is not entered.
by the vehicle manufacturer. • Failed engine-ECU.
TROUBLE JUDGMENT DIAGNOSIS PROCEDURE

Check Condition
• Ignition switch is "ON" position. STEP 1. Check VIN information.
Judgment Criterion • Set M.U.T.-III to the coding mode for chassis
• The entered chassis number data history is not number information.
found. Q: Has VIN (current) been written?
YES : Go to Step 2 . NO : Write VIN. Go to Step 3
13A-282 DIESEL FUEL
TROUBLESHOOTING
STEP 2. M.U.T.-III diagnosis code. STEP 3. M.U.T.-III diagnosis code.

• Reconfirm whether the diagnosis code is output. • Reconfirm whether the diagnosis code is output.
1. Erase the diagnosis codes being output. 1. Erase the diagnosis codes being output.
2. Ignition switch: "LOOK" (OFF) to ON. 2. Ignition switch: "LOOK" (OFF) to ON.
3. Confirm whether the diagnosis code is output. 3. Confirm whether the diagnosis code is output.
Q: Is the diagnosis code output? Q: Is the diagnosis code output?
YES : Replace the engine-ECU. When the engine- YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, Writing ). After replacing the engine-ECU,
register the injector identification code and register the injector identification code and
learn fuel injection (Refer to GROUP 00 − learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Precautions Before Service − What The
Common Rail Engine Learns ). After Common Rail Engine Learns ). After
registering the injector identification code, registering the injector identification code,
the vehicle equipped with the DPF carries the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to out the forcible DPF regeneration. (Refer to
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GROUP 17 − Emission Control − Diesel GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible Particulate Filter (DPF) System − Forcible
DPF Regeneration ). DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP NO : The check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-283
Code No. P0638: Throttle Valve Control Servo Stuck
Throttle valve control servo circuit
A-132
(MU805200)
1 2 3 4 5 6 throttle valve
5 6
G-B G
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C-103 129 114
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00107 AB
OPERATION • 2 seconds later after the ignition switch has

• The electric current from the engine- ECU (termi- been in "ON" position.
nal No. 129 and No. 114) to the throttle valve con- • The engine static state.
trol servo (terminal No. 5 and No. 6) is controlled.
Judgment Criterion
FUNCTION • The difference between the objective and real
• Engine- ECU checks the electronic-controlled openings is 10° or more for 0.5 second.
throttle system for abnormal conditions.
PROBABLE CAUSES
TROUBLE JUDGMENT • Failed throttle valve return spring
• Failed throttle valve operation
Check Conditions • Failed throttle valve control servo
The following conditions are met for 3 seconds. • Throttle valve control servo circuit harness dam-
• Battery positive voltage is 6 − 16 V. age or loose connector contact
13A-284 DIESEL FUEL
TROUBLESHOOTING

connector
STEP 1. Connector check: A-132 electronic- Connector: C-103
controlled throttle valve connector <L.H. drive vehicles>
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side

cardiagn.com
C-103 (B)
STEP 2. Check throttle valve control servo itself.
• Check throttle valve control servo itself (Refer to 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
P.13A-596). 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146

NO : Replace the electronic-controlled throttle
valve. Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-285
STEP 4. Check harness between electronic-
controlled throttle valve connector and engine-
ECU connector.
STEP 5. Replace the electronic-controlled
Connector: A-132
throttle valve assembly.
• After replace the electronic-controlled throttle
valve assembly, re-check the trouble symptoms.
A-132 (B)
6 5 4 3 2 1
Harness side
Connector: C-103 learn fuel injection (Refer to GROUP 00 −
<L.H. drive vehicles> Precautions Before Service − What The
cardiagn.com
C-103 (B) Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
<R.H. drive vehicles> NO : Check end.
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
a. Check harness between A-132 (terminal No.5)

electronic-controlled throttle valve connector and
C-103 (terminal No.129) engine-ECU connector.
b. Check harness between A-132 (terminal No.6)
electronic-controlled throttle valve connector and
C-103 (terminal No.114) engine-ECU connector.
Code No. P0642: Analog Sensor Reference Voltage No. 1 Too Low
FUNCTION • The engine-ECU checks whether the supply volt-

• The engine-ECU applies 5 V to the accelerator age is within the specified range.
pedal position sensor (main).
13A-286 DIESEL FUEL
TROUBLESHOOTING

Check Conditions
• The detected voltage of analog sensor reference Precautions Before Service − What The
voltage No. 1 is 4.86 V or less for 0.5 second. Common Rail Engine Learns ). After
[Power supply for accelerator pedal position sen- registering the injector identification code,
sor (main)] the vehicle equipped with the DPF carries
PROBABLE CAUSE GROUP 17 − Emission Control − Diesel
• Failed engine-ECU Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
DIAGNOSIS PROCEDURE NO : Intermittent malfunction (Refer to GROUP
STEP 1. M.U.T.-III diagnosis code Inspection Service Points − How to Cope
• After erasing the diagnosis code through M.U.T.- with Intermittent Malfunctions ).
cardiagn.com
Code No. P0643: Analog Sensor Reference Voltage No. 1 Too High

• The engine-ECU applies 5 V to the accelerator
pedal position sensor (main).
• The engine-ECU checks whether the supply volt- STEP 1. M.U.T.-III diagnosis code
age is within the specified range. • After erasing the diagnosis code through M.U.T.-
TROUBLE JUDGMENT whether the diagnosis code is output.
Check Conditions Q: Is the diagnosis code set?
• Battery positive voltage is 8 −16 V YES : Replace the engine-ECU. When the engine-
• 2 seconds later after the ignition switch has been ECU is replaced, write the chassis number
in "ON" position or the engine has started up (Refer to GROUP 00 − Precautions Before
Judgment Criterion Writing ). After replacing the engine-ECU,
• The detected voltage of analog sensor reference register the injector identification code and
voltage No. 1 is 5.14 V or more for 0.5 second. learn fuel injection (Refer to GROUP 00 −
[Power supply for accelerator pedal position sen- Precautions Before Service − What The
sor (main)] Common Rail Engine Learns ). After
PROBABLE CAUSE
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-287
Code No. P064C: Glow Control Unit Malfunction <Euro5>
Glow System Circuit
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
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1 2
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
C-103
Wire colour code

AKB00259 AB
13A-288 DIESEL FUEL
TROUBLESHOOTING

engine control relay (terminal No. 3) to the glow
control unit (terminal No. 6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No. 7) to the unit connector
battery to the glow control unit (terminal No.10).
8 7 6 5
trol unit (terminal No. 9) to the engine-ECU (ter- connector AKB00264 AB
minal No.126).
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glow control unit connector.
Check Conditions
• While the engine is running
17 − 83 %.
Judgment Criterion 4 3 2 1
• When a failure of the glow control unit body is 8 7 6 5
11 10 9 A-151 (B)
detected.
Harness side
PROBABLE CAUSES
• Failed glow control unit • Disconnect connector, and measure at harness
• Open/short circuit or harness damage in glow side.
plug power supply circuit or loose connector con- • Voltage between terminal No.10 and earth.
tact. OK: System voltage
(terminal No.10) glow control unit connector
and battery (fusible link 24).
short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-289
No. 10) glow control unit connector and battery
(fusible link 24).
Inspection Service points − How to Cope
Connector: A-151 with intermittent Malfunctions ).
STEP 5. Replace the glow control unit.

• After replacing the glow control unit, reconfirm
whether the diagnosis code is set.
4 3 2 1 Q: Is the diagnosis code set?
8 7 6 5
11 10 9
A-151 (B)
Harness side
connector AKB00264 AB (Refer to GROUP 00 − Precautions Before
• Check power supply line for damage. Writing ). After replacing the engine-ECU,
Q: Is the check result normal? register the injector identification code and
YES : Go to Step 4 . learn fuel injection (Refer to GROUP 00 −
NO : Repair the damaged harness wire. Precautions Before Service − What The
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STEP 4. M.U.T.-III diagnosis code. registering the injector identification code,
• Reconfirmation of diagnosis code. carry out the forcible DPF regeneration.
Q: Is the diagnosis code set? Diesel Particulate Filter (DPF) System −
NO : Check is end.
Code No. P0652: Analog Sensor Reference Voltage No. 2 Too Low
FUNCTION PROBABLE CAUSE

• The engine-ECU applies 5 V to the sensors other • Failed engine-ECU
than the accelerator pedal position sensor (main)
• The engine-ECU checks whether the supply volt- DIAGNOSIS PROCEDURE
age is within the specified range.
TROUBLE JUDGMENT STEP 1. M.U.T.-III diagnosis code

Check Conditions III, ignition switch is "ON" position and confirm
• Battery positive voltage is 8 − 16 V whether the diagnosis code is output.
in "ON" position or the engine has started up Q: Is the diagnosis code set?
Judgment Criterion
• The detected voltage of analog sensor reference
voltage No. 2 is 4.86 V or less for 0.5 second.
[Power supply for other than accelerator pedal
position sensor (main)]
13A-290 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
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Code No. P0653: Analog Sensor Reference Voltage No. 2 Too High

• The engine-ECU applies 5 V to the sensors other
than the accelerator pedal position sensor (main).
• The engine-ECU checks whether the supply volt- STEP 1. M.U.T.-III diagnosis code
age is within the specified range. • After erasing the diagnosis code through M.U.T.-
TROUBLE JUDGMENT whether the diagnosis code is output.
Check Conditions Q: Is the diagnosis code set?
• Battery positive voltage is 8 − 16 V YES : Replace the engine-ECU. When the engine-
• 2 seconds later after the ignition switch has been ECU is replaced, write the chassis number
in "ON" position or the engine has started up (Refer to GROUP 00 − Precautions Before
Judgment Criterion Writing ). After replacing the engine-ECU,
• The detected voltage of analog sensor reference register the injector identification code and
voltage No. 2 is 5.14 V or more for 0.5 second. learn fuel injection (Refer to GROUP 00 −
[Power supply for other than accelerator pedal Precautions Before Service − What The
position sensor (main)] Common Rail Engine Learns ). After
PROBABLE CAUSE
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-291
Code No. P0683: Glow Control Unit Communication Abnormality <Euro5>
Glow System Circuit
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
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1 2
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
C-103
Wire colour code

AKB00259 AB
13A-292 DIESEL FUEL
TROUBLESHOOTING

engine control relay (terminal No. 3) to the glow
control unit (terminal No. 6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No.7) to the unit connector
battery to the glow control unit (terminal No. 10).
8 7 6 5
trol unit (terminal No. 9) to the engine-ECU (ter- connector AKB00264 AB
minal No. 126).
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glow control unit connector.
Check Conditions
• While the engine is running
17 − 83 %.
Judgment Criterion 4 3 2 1
• The diagnosis signal is not received from the 8 7 6 5
11 10 9 A-151 (B)
glow control unit for more than 5 seconds.
Harness side
PROBABLE CAUSES
• Failed glow control unit • Disconnect connector, and measure at harness
• Open/short circuit or harness damage in glow side.
control unit power supply/earth circuit or loose • Ignition switch: ON
connector contact. • Voltage between terminal No. 6 and earth.
• Loose connector contact; open/short circuit or OK: System voltage
harness damage of communication wire between
glow control unit and engine-ECU. Q: Is the check result normal?
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-293
STEP 3. Connector check: A-20X engine control
relay connector
(terminal No.7) glow control unit connector
Connector: A-20X and body earth.
• Check earthing line for open circuit
A-20X and damage.

2 1 No. 1) glow control unit connector and C-103
3
4
Relay box's side Connector: A-151
Connector: A-151
4 3 2 1
8 7 6 5
11 10 9 A-151 (B)
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4 3 2 1
Harness side
8 7 6 5 connector AKB00264 AB
11 10 9 A-151 (B)
connector AKB00264 AB <L.H. drive vehicles>

(terminal No. 6) glow control unit connector
and A-20X (terminal No. 3) engine control
relay connector.
C-103 (B)
short circuit.

151 glow control unit connector.
Connector: A-151
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
4 3 2 1 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
8 7 6 5
11 10 9 A-151 (B) Harness side connector AKA00090 AB
Harness side
• Check signal line for open/short circuit and dam-
age.
side.
• Resistance between terminal No.7 and earth.
13A-294 DIESEL FUEL
TROUBLESHOOTING
No. 9) glow control unit connector and C-103 No. 6) glow control unit connector and A-20X
(terminal No. 126) engine-ECU connector. (terminal No. 3) engine control relay connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
Connector: C-103 Connector: A-20X

A-20X
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2 1
3
C-103 (B) 4
Relay box's side
C-103 (B) STEP 8. M.U.T.-III diagnosis code.

115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 Q: Is the diagnosis code set?
117 116 YES : Go to Step 9 .
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 NO : Intermittent malfunction (Refer to GROUP
Inspection Service points − How to Cope
• Check signal line for open/short circuit and dam- with intermittent Malfunctions ).
age.
Q: Is the check result normal? STEP 9. Replace the glow control unit.
YES : Go to Step 7 . • After replacing the glow control unit, reconfirm
NO : Repair the damaged harness wire. whether the diagnosis code is set.
DIESEL FUEL
TROUBLESHOOTING
13A-295
NO : Check is end.
Code No. P1203: Capacitor Insufficient Charging
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• The engine-ECU monitors the charged state of
the capacitor in the injector drive circuit.
• The engine-ECU checks whether the injector STEP 1. M.U.T.-III diagnosis code
driving voltage is too low due to insufficient • After erasing the diagnosis code through M.U.T.-
charging of the capacitor. III, ignition switch is "ON" position and confirm
TROUBLE JUDGMENT Q: Is the diagnosis code set?
Check Conditions YES : Replace the engine-ECU. When the engine-
• Ignition switch is in "ON" position ECU is replaced, write the chassis number
• Except during the engine cranking period (Refer to GROUP 00 − Precautions Before
• Battery positive voltage is 8 V or more Service − How to Perform Chassis Number
Judgment Criterion register the injector identification code and
• A capacitor in low charge state (40 V or less) is learn fuel injection (Refer to GROUP 00 −
detected in an engine-ECU internal circuit. Precautions Before Service − What The
PROBABLE CAUSE
DPF Regeneration ).
Code No. P1204: Capacitor Excessive Charging
FUNCTION • The engine-ECU checks whether the injector

• The engine-ECU monitors the charged state of driving voltage is too high due to excessive
the capacitor in the injector drive circuit. charging of the capacitor.
13A-296 DIESEL FUEL
TROUBLESHOOTING

Check Conditions
• Except during the engine cranking period
• Battery positive voltage is 8 V or more
• A capacitor in overcharge state (100 V or higher) Precautions Before Service − What The
is detected in an engine-ECU internal circuit. Common Rail Engine Learns ). After
PROBABLE CAUSE the vehicle equipped with the DPF carries
DIAGNOSIS PROCEDURE Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 1. M.U.T.-III diagnosis code NO : Intermittent malfunction (Refer to GROUP
• After erasing the diagnosis code through M.U.T.- 00 − How to Use Troubleshooting/
III, ignition switch is "ON" position and confirm Inspection Service Points − How to Cope
whether the diagnosis code is output. with Intermittent Malfunctions ).
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Code No. P1272: Pressure Limiter Malfunction
TROUBLE JUDGMENT
OPERATION Check Conditions
• Refer to Code No. P0003: Suction Control Valve • Battery positive voltage is 8 − 16 V
Open P.13A-26. <Euro 5> • Engine speed is 600 r/min or more
• Refer to Code No. P0004: Suction Control Valve • 2 seconds later after the ignition switch has been
Battery Short P.13A-29. <Euro 5> in "ON" position or the engine has started up
• Refer to Code No. P0191: Rail Pressure Sensor • Rail pressure is normal
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Judgment Criterion
Circuit Low Input P.13A-147. • After a pressure higher than the pressure of the
• Refer to Code No. P0193: Rail Pressure Sensor pressure limiter opening valve is detected, fuel
Circuit High Input P.13A-155. leakage diagnosis (supply pump discharge rate
• Refer to Code No. P0628: Suction Control Valve excessive) is detected within the predetermined
Open P.13A-276. <Except Euro 5> time.
• Refer to Code No. P0629: Suction Control Valve
PROBABLE CAUSES
Battery Short P.13A-279. <Except Euro 5>
FUNCTION • Failed fuel system
• The engine-ECU controls the fuel discharge rate • Failed common rail assembly
using the suction control valve. • Open/short circuit or harness damage in suction
• The engine-ECU monitors the signals input from control valve circuit or loose connector contact
the rail pressure sensor. • Failed engine-ECU
• The engine-ECU checks whether the pressure
limiter valve is open, based on changes in the DIAGNOSIS PROCEDURE
signals input from the rail pressure sensor (rapid NOTE: This diagnosis code is outputted for an air
drop of pressure after it goes extremely high). penetration in the fuel line of the supply pump due to
lack of fuel. Therefore, bleed air from the fuel line
after the fuel supply, and delete the diagnosis code
through M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-297
STEP 1. M.U.T.-III diagnosis code STEP 5. Connector check: C-103 engine-ECU
Q: Is any other diagnosis code than P1272 output?
connector and A-47 suction control valve
YES : Inspection chart for diagnosis codes (Refer connector
to P.13A-21). Connector: C-103
NO : Go to Step 2 . <L.H. drive vehicles>
STEP 2. Check the fuel filter contamination

NO : Replace the fuel filter then replace the
common rail assembly and fuel injection C-103 (B)
tubes.
STEP 3. Release the air from the fuel line.

• After releasing the air from the fuel line, continue
idle operation for about five minutes and recheck
for abnormal symptoms.
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YES : Replace the common rail assembly and C-103 (B)
common tubes.
NO : Go to Step 4 . 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
STEP 4. Check suction control valve itself 158 157156 155 154 153 152 151 150 149 148 147 146
• Check suction control valve itself (Refer to P.13A- Harness side connector AKA00090 AB
596).
Connector: A-47
2 1
NO : Replace the suction control valve. After Harness side
replacing the suction control valve, learn the connector
supply pump (Refer to GROUP 00 − A-47 (GR)
AK503644 AB

13A-298 DIESEL FUEL
TROUBLESHOOTING
C-103 (B) C-103 (B)
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C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
age. age.
DIESEL FUEL
TROUBLESHOOTING
13A-299
NO : Replace the engine-ECU then replace the
measurement at A-47 suction control valve
common rail assembly and fuel injection
(Using an oscilloscope).
tubes. When the engine-ECU is replaced,
Connector: A-47 write the chassis number (Refer to GROUP
2 1 00 − Precautions Before Service − How to
Harness side Perform Chassis Number Writing ). After
connector replacing the engine-ECU, register the
injector identification code and learn fuel
A-47 (GR)
injection (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail
Engine Learns ). After registering the
injector identification code, the vehicle
AK503644 AB equipped with the DPF carries out the
• Engine: Idling forcible DPF regeneration. (Refer to
• Connect the oscilloscope special patterns pickup GROUP 17 − Emission Control − Diesel
to engine-ECU terminal No. 131 and earth. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
OK: The waveform should show a pattern
similar to the illustration of Inspection proce-
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dure using an oscilloscope (Refer to P.13A- STEP 9. Replace the common rail assembly and
586). fuel injection tubes.
common tubes, re-check the trouble symptoms
YES : Replace the suction control valve. After
Code No. P1273: Supply Pump Insufficient Flow
• The engine-ECU monitors changes in the fuel

OPERATION discharge rate at each injection to detect a fault in
• Refer to Code No. P0003: Suction Control Valve one of the two plungers in the supply pump.
Open P.13A-26. <Euro 5>
• Refer to Code No. P0004: Suction Control Valve TROUBLE JUDGMENT
Battery Short P.13A-29. <Euro 5> Check Condition
• Refer to Code No. P0335: Crank Angle Sensor • Vehicle in steady and stable state (the difference
System P.13A-184. from the last data of the objective common rail
• Refer to Code No. P0340: Camshaft Position pressure is less than 3 MPa and that from the last
Sensor System P.13A-192. data of the final fuel injection rate is less than 2
• Refer to Code No. P0628: Suction Control Valve mm3/st.
Open P.13A-276. <Except Euro 5>
• Refer to Code No. P0629: Suction Control Valve Judgment Criterion
Battery Short P.13A-279. <Except Euro 5> • The inter-cylinder difference in pressure feed
exceeds the predetermined value 500 times con-
FUNCTION secutively.
• The engine-ECU controls the fuel discharge rate
using the suction control valve. PROBABLE CAUSES
• Air penetration due to lack of fuel
13A-300 DIESEL FUEL
TROUBLESHOOTING
• Failed supply pump STEP 2. Replace the supply pump assembly.

• Failed engine-ECU • After the supply pump assembly, learn the sup-
ply pump (Refer to GROUP 00 − Precautions
DIAGNOSIS PROCEDURE Before Service − What The Common Rail Engine
NOTE: This diagnosis code is outputted for an air Learns ).
penetration in the fuel line of the supply pump due to • After learning the supply pump assembly, re-
lack of fuel. Therefore, bleed air from the fuel line check the trouble symptoms.
after the fuel supply, and delete the diagnosis code Q: Does trouble symptom persist?
through M.U.T.-III. YES : Replace the engine-ECU. When the engine-
STEP 1. M.U.T.-III diagnosis code (Refer to GROUP 00 − Precautions Before
• With the air released from the fuel line, supply Service − How to Perform Chassis Number
fuel if necessary. Writing ). After replacing the engine-ECU,
• Continue idle operation for about 5 minutes. register the injector identification code and
Q: Is the diagnosis code P1273 outputted again? Precautions Before Service − What The
YES : Go to Step 2 . Common Rail Engine Learns ). After
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DPF Regeneration ).
Code No. P1274: Supply Pump Protection
PROBABLE CAUSES
OPERATION • Failed supply pump
• Refer to Code No. P0191: Rail Pressure Sensor • Failed common rail assembly
Range/Performance Problem P.13A-143. • Failed engine-ECU
Circuit Low Input P.13A-147. DIAGNOSIS PROCEDURE
Circuit High Input P.13A-155.
FUNCTION Q: Is any other diagnosis code than P1274 output?
• The engine-ECU monitors the signals input from YES : Inspection chart for diagnosis codes (Refer
the rail pressure sensor. to P.13A-21).
• Based on these input signals, the engine-ECU NO : Go to Step 2 .
checks whether the fuel pressure in the common
rail is abnormal.
STEP 2. Check suction control valve itself
TROUBLE JUDGMENT • Check suction control valve itself (Refer to P.13A-
596).
Check Conditions
• Engine is running Q: Is the check result normal?
• Rail pressure sensor is normal YES : Go to Step 3 .
Judgment Criterion replacing the supply pump, learn the supply
• For 1 seconds, the rail pressure stays in the criti- pump (Refer to GROUP 00 − Precautions
cal pressure range in which the supply pump is Before Service − What The Common Rail
burned out. Engine Learns ).
DIESEL FUEL
TROUBLESHOOTING
13A-301
STEP 3. Replace the supply pump assembly.
• After the supply pump assembly, learn the sup-
ply pump (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail Engine
Learns ).
• After learning the supply pump assembly, re-
check the trouble symptoms.
Q: Does trouble symptom persist? Common Rail Engine Learns ). After
YES : Go to Step 4 . registering the injector identification code,
NO : The check is end. the vehicle equipped with the DPF carries
STEP 4. Replace the common rail assembly and GROUP 17 − Emission Control − Diesel
fuel injection tubes. Particulate Filter (DPF) System − Forcible
• After replacing the common rail assembly and DPF Regeneration ).
fuel injection tubes, re-check the trouble symp- NO : The check is end.
toms
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Code No. P1275: Supply Pump Exchange
DIAGNOSIS PROCEDURE
OPERATION
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Q: Is any other diagnosis code than P1275 output?
Circuit Low Input P.13A-147. YES : Inspection chart for diagnosis codes (Refer
• Refer to Code No. P0193: Rail Pressure Sensor to P.13A-21).
Circuit High Input P.13A-155. NO : Go to Step 2 .
FUNCTION STEP 2. Check suction control valve itself

• The engine-ECU monitors the signals input from • Check suction control valve itself (Refer to P.13A-
the rail pressure sensor. 596).
• Based on these input signals, the engine-ECU
checks whether the fuel pressure in the common Q: Is the check result normal?
rail is abnormal. YES : Go to Step 3 .
TROUBLE JUDGMENT replacing the suction control valve, learn the
Check Conditions
• Engine is running
• Rail pressure sensor is normal
Judgment Criterion STEP 3. Replace the supply pump.
• The rail pressure continues to exceed the maxi- • After the supply pump assembly, learn the supply
mum operating pressure of the supply pump for pump. (Refer to GROUP 00 − Precautions Before
15 seconds. Service − What The Common Rail Engine Learns
PROBABLE CAUSES ).
• Failed supply pump • After learning the supply pump, re-check the trou-
• Failed rail pressure sensor ble symptoms.
• Failed engine-ECU Q: Does trouble symptom persist?
13A-302 DIESEL FUEL
TROUBLESHOOTING

STEP 4. Replace the common rail assembly and
fuel injection tubes.
toms.
Q: Does trouble symptom persist? learn fuel injection (Refer to GROUP 00 −
DPF Regeneration ).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-303
Code No. P1276: Fuel Filter Exchange <Vehicles with fuel filter pressure switch>
Fuel filter pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
99 100 101
116 117 110 111 Engine-ECU
128 141142143
131132133134135136137138139140 129 130
144 145 146147148149150151152153154155156 157158
110
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1
A-143 Fuel filter

ON pressure switch
1 2 OFF
Wire colour code

R: Red P: Pink V: Violet PU: Purple
AKB00283 AB

• The battery voltage is applied to the fuel filter
Check Condition
pressure switch (terminal No. 1) from the engine-
• During steady driving after engine warm up.
Judgment Criterion
FUNCTION • Determination of clogged fuel filter.
• The engine-ECU detects the clogged fuel filter by
using the fuel filter pressure switch installed on PROBABLE CAUSES
the fuel filter assembly. • Failed fuel filter pressure switch
• Open/short circuit or harness damage in fuel filter
pressure switch circuit or loose connector contact
13A-304 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .
STEP 1. Connector check: A-143 fuel filter

pressure switch connector STEP 4. Connector check: C-103 engine-ECU
connector
Connector: A-143
Connector: C-103
A-143 (B) <L.H. drive vehicles>
2 1

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STEP 2. Check the fuel filter pressure switch
itself.
Check the fuel filter pressure switch itself (Refer to C-103 (B)
GROUP 13B − Fuel Filter − Fuel Filter Inspection ).
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
YES : Replace the fuel filter body. 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

fuel filter pressure switch connector. Q: Is the check result normal?
Connector: A-143 NO : Repair or replace the connector.
A-143 (B)
2 1
Harness side

side.
OK: System voltage
DIESEL FUEL
TROUBLESHOOTING
13A-305
No. 1) fuel filter pressure switch connector and • Refer to Data List Reference Table P.13A-542.
C-103 (terminal No. 110) engine-ECU connector. a. Item 152: Fuel filter pressure switch
A-143 (B)
2 1
connector AK700919AC Writing ). After replacing the engine-ECU,
Connector: C-103
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143 fuel filter pressure switch connector.
C-103 (B) Connector: A-143
A-143 (B)
2 1
Harness side
C-103 (B) connector AK700919AC

115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 side.
117 116 • Resistance between terminal No. 2 and earth.
143 142 141 140 139138 137 136 135 134 133 132 131

158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB Q: Is the check result normal?

• Check output line for open/short circuit. YES : Go to Step 8 .
Q: Is the check result normal? (terminal No. 2) fuel filter pressure switch
YES : Go to Step 6 . connector and body earth.
• Check earthing line for open circuit
and damage.
13A-306 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) fuel filter pressure switch connector and
Connector: C-103
A-143 (B)
C-103 (B) 2 1

Connector: C-103
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Replace the fuel filter.
Code No. P1277: Fuel Filter Freeze <Vehicles with fuel filter pressure switch>

• The engine-ECU estimates that the fuel filter is
Check Conditions
freezing, using the input signal from the each
• During steady driving
sensor.
• Fuel temperature is lower than specified temper-
• When storing this diagnosis code, the engine-
ature
ECU blinks the glow lamp.
• Engine coolant temperature is lower than speci-
fied temperature
DIESEL FUEL
TROUBLESHOOTING
13A-307
Judgment Criteria DIAGNOSIS PROCEDURE
• Determination of clogged fuel filter
• Fuel pressure hunting occurs more than certain
degree, or difference more than certain degree STEP 1. Reconfirmation of M.U.T.-III diagnosis
exists between target fuel pressure and actual code after warming up the engine
fuel pressure Q: Is any other diagnosis code than P1276 output?
YES : Inspection chart for diagnosis code (Refer
PROBABLE CAUSE to ).
• Fuel filter Freezing NO : Check end.
Code No. P1298: Variable Geometry Turbocharger Control System Malfunction (high pressure)
<Euro5>

• The engine-ECU controls the duty ratio of the NO : Repair the variable geometry turbocharger
variable geometry control solenoid valve so that control system.
the actual boost pressure can become the target
boost pressure.
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TROUBLE JUDGMENT
Check Condition nosis code is output.
Judgment Criterion YES : Replace the engine-ECU. When the engine-
• Actual boost pressure is higher than target boost ECU is replaced, write the chassis number
pressure by more than 6.7 kPa (Refer to GROUP 00 − Precautions Before
PROBABLE CAUSES Writing ). After replacing the engine-ECU,
• Failed variable geometry turbocharger control register the injector identification code and
system learn fuel injection (Refer to GROUP 00 −
• Failed engine-ECU Precautions Before Service − What The
DIAGNOSTIC PROCEDURE registering the injector identification code,
STEP 1. Check the turbocharger supercharging (Refer to GROUP 17 − Emission Control −
pressure. Diesel Particulate Filter (DPF) System −
• Check the turbocharger supercharging pressure Forcible DPF Regeneration ).
(refer to GROUP 15 − On-vehicle Service − Tur-
bocharger Supercharging Pressure Check ).
Q: Is the check result normal? with Intermittent Malfunctions ).
Code No. P1299: Variable Geometry Turbocharger Control System Malfunction (low pressure)
<Euro5>

• The engine-ECU controls the duty ratio of the
Check Condition
variable geometry control solenoid valve so that
the actual boost pressure can become the target
boost pressure.
13A-308 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 2. M.U.T.-III diagnosis code.

• Actual boost pressure is lower than target boost • After clearing the diagnosis code through M.U.T.-
pressure by less than 6.7 kPa III, start the engine and confirm whether the diag-
PROBABLE CAUSES nosis code is output.
• Failed variable geometry turbocharger control Q: Is the diagnosis code set?
system YES : Replace the engine-ECU. When the engine-
DIAGNOSTIC PROCEDURE Service − How to Perform Chassis Number
STEP 1. Check the turbocharger supercharging learn fuel injection (Refer to GROUP 00 −
pressure. Precautions Before Service − What The
• Check the turbocharger supercharging pressure Common Rail Engine Learns ). After
(refer to GROUP 15 − On-vehicle Service − Tur- registering the injector identification code,
bocharger Supercharging Pressure Check ). carry out the forcible DPF regeneration.
YES : Go to Step 2 . Diesel Particulate Filter (DPF) System −
NO : Repair the variable geometry turbocharger
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control system. NO : Intermittent malfunction (Refer to GROUP
DIESEL FUEL
TROUBLESHOOTING
13A-309
Code No. P1427: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit Low Input
<Euro5>
No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
cardiagn.com
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00277 AB
OPERATION • The No. 3 exhaust gas temperature sensor (DPF

• A power voltage of 5 V is applied to the No. 3 temperature) is a kind of resistor, which has char-
exhaust gas temperature sensor (DPF tempera- acteristics to reduce its resistance as the DPF
ture) output terminal (terminal No. 2) from the temperature rises. Therefore, the sensor output
engine-ECU (terminal No. 60). voltage varies with the DPF temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the DPF temperature rises.
(terminal No. 84) from the No. 3 exhaust gas tem-
perature sensor (DPF temperature) (terminal No. TROUBLE JUDGMENT
1). Check Conditions
FUNCTION
• The No. 3 exhaust gas temperature sensor (DPF
temperature) converts the DPF temperature into
a voltage and inputs the voltage signal to the Judgment Criterion
engine-ECU. • The No. 3 exhaust gas temperature sensor (DPF
• Engine-ECU uses this voltage output for DPF temperature) output voltage is 0.255 V or less.
regeneration control.
PROBABLE CAUSES
(DPF temperature)
13A-310 DIESEL FUEL
TROUBLESHOOTING
• Short circuit in No. 3 exhaust gas temperature STEP 3. Check No. 3 exhaust gas temperature
sensor (DPF temperature) circuit or connector sensor (DPF temperature) itself.
damage • Check No. 3 exhaust gas temperature sensor
• Failed engine-ECU (DPF temperature) itself (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter (DPF)
DIAGNOSTIC PROCEDURE System − No. 3 exhaust gas temperature sensor
(DPF temperature) Check ).
STEP 1. M.U.T.-III data list Q: Is the check result normal?
• Refer to Data List Reference Table P.13A-542. YES : Go to Step 4 .
a. Item 119: No. 3 exhaust gas temperature sensor NO : Replace the No. 3 exhaust gas temperature
(DPF temperature) sensor (DPF temperature). After replacing
the No. 3 exhaust gas temperature sensor
YES : Intermittent malfunction (Refer to GROUP (DPF temperature), carry out the forcible
00 − How to Use Troubleshooting/ DPF regeneration. (Refer to GROUP 17 −
Inspection Service Points − How to Cope Emission Control − Diesel Particulate Filter
with Intermittent Malfunctions ). (DPF) System − Forcible DPF Regeneration
NO : Go to Step 2 . ).
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STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Connector check: C-105 engine-ECU
gas temperature sensor (DPF temperature) connector
connector Connector: C-105
Connector: A-158
C-105 (B)
2 1 A-158 (B)
Harness side
connector
No. 3 exhaust gas

temperature sensor
(DPF temperature) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
AKB00278 AB 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-311
(DPF temperature) connector and C-105 (terminal
No. 60) engine-ECU connector. STEP 6. M.U.T.-III data list
Connector: A-158
(DPF temperature)
2 1
connector
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No. 3 exhaust gas
temperature sensor Precautions Before Service − What The
(DPF temperature)
AKB00278 AB (Refer to GROUP 17 − Emission Control −
Connector: C-105 Forcible DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-312 DIESEL FUEL
TROUBLESHOOTING
Code No. P1428: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit High Input
<Euro5>
No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
cardiagn.com
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00277 AB
OPERATION • The No. 3 exhaust gas temperature sensor (DPF

• A power voltage of 5 V is applied to the No. 3 temperature) is a kind of resistor, which has char-
exhaust gas temperature sensor (DPF tempera- acteristics to reduce its resistance as the DPF
ture) output terminal (terminal No. 2) from the temperature rises. Therefore, the sensor output
engine-ECU (terminal No. 60). voltage varies with the DPF temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the DPF temperature rises.
(terminal No. 84) from the No. 3 exhaust gas tem-
perature sensor (DPF temperature) (terminal No. TROUBLE JUDGMENT
1). Check Conditions
FUNCTION
temperature) converts the DPF temperature into
a voltage and inputs the voltage signal to the
engine-ECU. Judgment Criterion
• Engine-ECU uses this voltage for DPF regenera- • The No. 3 exhaust gas temperature sensor (DPF
tion control. temperature) output voltage is 4.95 V or more.
PROBABLE CAUSES (DPF temperature)

DIESEL FUEL
TROUBLESHOOTING
13A-313
• Open circuit or harness damage in No. 3 exhaust STEP 3. Check No. 3 exhaust gas temperature
gas temperature sensor (DPF temperature) cir- sensor (DPF temperature) itself.
cuit or loose connector contact • Check No. 3 exhaust gas temperature sensor
• Failed engine-ECU (DPF temperature) itself (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter (DPF)
DIAGNOSTIC PROCEDURE System − No. 3 exhaust gas temperature sensor
(DPF temperature) Check ).
STEP 1. M.U.T.-III data list Q: Is the check result normal?
• Refer to Data List Reference Table P.13A-542 YES : Go to Step 4 .
a. Item 119: No. 3 exhaust gas temperature sensor NO : Replace the No. 3 exhaust gas temperature
(DPF temperature) sensor (DPF temperature). After replacing
the No. 3 exhaust gas temperature sensor
YES : Intermittent malfunction (Refer to GROUP (DPF temperature), carry out the forcible
00 − How to Use Troubleshooting/ DPF regeneration. (Refer to GROUP 17 −
Inspection Service Points − How to Cope Emission Control − Diesel Particulate Filter
with Intermittent Malfunctions ). (DPF) System − Forcible DPF Regeneration
NO : Go to Step 2 . ).
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STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Perform voltage measurement at A-158
gas temperature sensor (DPF temperature) No. 3 exhaust gas temperature sensor (DPF
connector temperature) connector.
A-158 (B) 2 1 A-158 (B)

2 1
connector connector
No. 3 exhaust gas No. 3 exhaust gas

temperature sensor temperature sensor
(DPF temperature) (DPF temperature)
AKB00278 AB AKB00278 AB

OK: 4.5 − 4.9 V
NO : Go to Step 5 .
13A-314 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> No. 60) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
cardiagn.com
No. 3 exhaust gas
(DPF temperature)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-315
158 No. 3 exhaust gas temperature sensor (DPF
temperature) connector.
Connector: A-158
(DPF temperature)
Inspection Service Points − How to Cope A-158 (B)
2 1
NO : Replace the engine-ECU. When the engine- Harness side
connector
register the injector identification code and No. 3 exhaust gas
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temperature sensor
(DPF temperature)
carry out the forcible DPF regeneration. AKB00278 AB
(Refer to GROUP 17 − Emission Control − • Disconnect connector, and measure at harness
Diesel Particulate Filter (DPF) System − side.
Forcible DPF Regeneration ). • Resistance between terminal No. 1 and earth.
NO : Go to Step 9 .
13A-316 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> No. 84) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
cardiagn.com
No. 3 exhaust gas
(DPF temperature)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-317
STEP 11. Connector check: C-105 engine-ECU No. 60) engine-ECU connector.
connector.
Connector: A-158
Connector: C-105
2 1 A-158 (B)
C-105 (B)
Harness side
connector
cardiagn.com
No. 3 exhaust gas
temperature sensor
(DPF temperature)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00278 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Go to Step 7 . NO : Repair the damaged harness wire.
13A-318 DIESEL FUEL
TROUBLESHOOTING
Code No. P1497: DPF System Malfunction <Euro5>
FUNCTION STEP 2. M.U.T.-III data list.

• The engine-ECU monitors the input signals from • Item 208: Short interval DPF regeneration count
sensors to check if the DPF regeneration is exe-
cuted normally. OK: 10 or more
Q: Is the short interval DPF regeneration counting 10
TROUBLE JUDGMENT or more?
Check Condition YES : Go to Step 4 .
• On DPF regeneration NO : Go to Step 3 .
Judgement Criterion
STEP 3. Forcible DPF regeneration execution
• The DPF regeneration status continues for 30
• Initialise the DPF-related parts, and then delete
minutes or more.
the diagnosis code (Refer to GROUP 00 − Pre-
Check Condition cautions before Service − Initialisation Procedure
• Ignition switch is in "ON" position for Learning Value in Diesel Particulate Filter
Judgement Criterion (DPF) System ).
• The regeneration with short interval continues for a. Item 42: DPF system malfunction service
cardiagn.com
specified times. • Carry out the forcible DPF regeneration (Refer to
GROUP 17 − Emission Control − Diesel Particu-
PROBABLE CAUSES late Filter (DPF) System − Forcible DPF Regen-
• Failed No. 2 exhaust gas temperature sensor eration ).
(catalyst temperature) Q: Is the diagnosis code P0420 or P1497 set?
• Failed No. 3 exhaust gas temperature sensor YES : Replace the catalytic converter. When the
(DPF temperature) catalytic converter is replaced, initialise the
• Failed exhaust differential pressure sensor learning value (Refer to GROUP 00 −
• Failed exhaust differential pressure sensor ambi- Precautions before Service − Initialisation
ent air temperature sensor Procedure for Learning Value in Diesel
• Catalytic converter inactive Particulate Filter (DPF) System ). On
• The engine oil-containing ash is loaded to the completion, carry out the forcible DPF
DPF inside. regeneration (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter
DIAGNOSIS PROCEDURE (DPF) System − Forcible DPF Regeneration
).
STEP 1. M.U.T.-III data list. NO : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 118: No. 2 exhaust gas temperature sen- (Refer to GROUP 00 − Precautions Before
sor (catalyst temperature) Service − How to Perform Chassis Number
b. Item 119: No. 3 exhaust gas temperature sen-
sor (DPF temperature)
c. Item 120: Exhaust differential pressure sensor Precautions Before Service − What The
Q: Are the check results normal? Common Rail Engine Learns ). After
YES : Go to Step 2 . registering the injector identification code,
NO : Perform the diagnosis code classified check carry out the forcible DPF regeneration.
procedure for the sensor that has shown an (Refer to GROUP 17 − Emission Control −
abnormal data value (Refer to Inspection Diesel Particulate Filter (DPF) System −
Chart for Diagnosis Code P.13A-21). Forcible DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-319
YES : Proceed to troubleshooting for black smoke
STEP 4. Forcible DPF regeneration execution
(Refer to Inspection Procedure 13 P.13A-
• Initialise the DPF-related parts, and then delete
479).
the diagnosis code (Refer to GROUP 00 − Pre-
NO : Replace the DPF. When the DPF is
cautions before Service − Initialisation Procedure
replaced, initialise the learning value (Refer
for Learning Value in Diesel Particulate Filter
to GROUP 00 − Precautions Before Service
(DPF) System ).
− Initialisation Procedure For Learning
a. Item 42: DPF system malfunction service
Value in Diesel Particulate Filter (DPF)
• Carry out the forcible DPF regeneration 2 times
System ).
(Refer to GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible DPF
Regeneration ).
NOTE: Carry out the DPF regeneration 2 times
because the assumption of the accumulated
amount of the DPF is not stable.
• M.U.T.-III data list
a. Item 156: Soot loading by differential pressure
OK: 3 g/L or less
cardiagn.com
Code No. P1498: Excessive PM Accumulated in DPF <Euro5>
FUNCTION Judgement Criterion

• The engine-ECU monitors the input signals from • Driving distance exceeds the specified value after
sensors to estimate the PM amount loaded to the the last DPF regeneration.
DPF inside.
• If the PM is loaded more than the specified PROBABLE CAUSE
amount, the DPF regeneration is automatically • The PM is abnormally loaded to the DPF inside.
executed under certain conditions in order to
eliminate the PM. DIAGNOSIS PROCEDURE
• If the PM is excessively loaded, the engine-ECU
does not execute the automatic DPF regenera- STEP 1. Forcible DPF regeneration execution
tion. It makes the engine warning lamp illuminate • Carry out the forcible DPF regeneration (Refer to
and the DPF lamp blink. GROUP 17 − Emission Control − Diesel Particu-
late Filter (DPF) System − Forcible DPF Regen-
TROUBLE JUDGMENT
eration ).
Check Condition
Q: Is the diagnosis code output?
to P.13A-21).
NO : Check end.
Code No. P1499: Abnormally high DPF temperature <Euro5>

• The DPF may be have melting damage if the
Check Condition
temperature exceeds the specified value.
• On DPF regeneration
• The engine-ECU monitors the signals from No. 3
exhaust gas temperature sensor (DPF tempera-
ture) to check if the DPF is under the specified
temperature.
13A-320 DIESEL FUEL
TROUBLESHOOTING
Judgement Criterion DIAGNOSIS PROCEDURE

temperature) detects the abnormally high temper-
ature. STEP 1. M.U.T.-III data list.
or • Refer to Data List Reference Table P.13A-542.
• The estimated DPF centre temperature exceeds a. Item 119: No. 3 exhaust gas temperature sen-
the specified value. sor (DPF temperature)
PROBABLE CAUSE YES : Replace the DPF. When the DPF is
• Damage by the DPF with high temperature replaced, initialise the learning value (Refer
to GROUP 00 − Precautions Before Service
− Initialisation Procedure For Learning
Value in Diesel Particulate Filter (DPF)
System ).
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
abnormal data value (Refer to Inspection
Chart for Diagnosis Code P.13A-21).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-321
Code No. P1608: Battery Current Sensor System <Euro5>
Battery Current Sensor Circuit
A-152
Hall IC
1 2 Battery current sensor
3 4
1 4 3
R-B BR-Y BR-B
cardiagn.com
C-103 148 138 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKB00279 AB

• A power voltage of 5 V is supplied to the battery
Check Condition
current sensor (terminal No. 1) from the engine-
ECU (terminal No. 148) and is earthed to the
engine-ECU (terminal No. 155) from the battery Judgment Criterion
current sensor (terminal No. 3). • The battery current sensor output voltage is 0.2 V
• The battery current sensor (terminal No. 4) out- or less.
puts a sensor signal, which is input into the or
engine-ECU (terminal No. 138). • The battery current sensor output voltage is 4.8 V
or more.
FUNCTION
• The battery current sensor detects a battery cur- PROBABLE CAUSES
rent and inputs a signal into the engine-ECU. • Failed battery current sensor
• In response to the signal, the engine-ECU con- • Open/short circuit or harness damage in battery
trols charging and discharging. current sensor circuit or loose connector contact
13A-322 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .
STEP 1. Connector check: A-152 battery current

sensor connector STEP 4. Connector check: C-103 engine-ECU
connector
Connector: A-152
2 1 Connector: C-103
4 3 <L.H. drive vehicles>
Harness side
connector
A-152 (GR) C-103 (B)

AKB00274 AB
cardiagn.com
STEP 2. Check battery current sensor itself.
• Check battery current sensor itself (Refer to
GROUP 54A − Battery − Inspection − Battery C-103 (B)
Current Sensor Check ).
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
YES : Go to Step 3 . 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
NO : Replace the battery current sensor. 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

battery current sensor connector.
Connector: A-152 NO : Repair or replace the connector.
2 1
4 3
Harness side
connector
A-152 (GR)
AKB00274 AB
• Disconnect connector and measure at harness

side.
OK: 4.9 − 5.1 V
DIESEL FUEL
TROUBLESHOOTING
13A-323
STEP 5. Check harness between A-152 (terminal STEP 6. M.U.T.-III diagnosis code
No. 1) battery current sensor connector and C- • Reconfirmation of diagnosis code.
103 (terminal No. 148) engine-ECU connector. Q: Is the diagnosis code set?
Connector: A-152 YES : Replace the engine-ECU. When the engine-
4 3
connector
A-152 (GR) Common Rail Engine Learns ). After
AKB00274 AB registering the injector identification code,
Connector: C-103 (Refer to GROUP 17 − Emission Control −
cardiagn.com
C-103 (B)
<R.H. drive vehicles> 152 battery current sensor connector.
Connector: A-152
2 1
4 3
Harness side
connector
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
A-152 (GR)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00274 AB
158 157156 155 154 153 152 151 150 149 148 147 146
• Disconnect connector and measure at harness

side.
• Check power supply line for open/short circuit. • Resistance between terminal No. 3 and earth.
NO : Repair the damaged harness wire. YES : Go to Step 10 .
NO : Go to Step 8 .
13A-324 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-325
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-326 DIESEL FUEL
TROUBLESHOOTING
No. 4) battery current sensor connector and C-
Connector: A-152
2 1
4 3
Harness side
connector
A-152 (GR)
AKB00274 AB
Connector: C-103
cardiagn.com
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for open/short circuit and dam-

age.
Code No. P1625: Injection Quantity Compensation Value Error
TROUBLE JUDGMENT
FUNCTION Check Condition
• Correction data of the injector built in the engine • Ignition switch is in "ON" position.
is written to the engine-ECU.
• The engine-ECU checks whether the correction Judgment Criterion
data thus written is valid. • An error is detected during three-side majority
decision check or upper/lower limit check of an
injector correction value.
DIESEL FUEL
TROUBLESHOOTING
13A-327
PROBABLE CAUSE STEP 2. Rewrite the injector identification code
• Failed engine-ECU data again.
• Rewrite the injector identification code data
DIAGNOSIS PROCEDURE (Refer to GROUP 00− Precautions Before Serv-
ice − Injector Identification Code Registration
STEP 1. Injector identification code data check Procedure ).
• Check whether injector identification code data is • After rewriting the injector identification code data
correctly written to the engine-ECU in M.U.T.-III. again, recheck for abnormal symptoms.
ECU is replaced, write the chassis number ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, Writing ). After replacing the engine-ECU,
register the injector identification code and register the injector identification code and
learn fuel injection (Refer to GROUP 00 − learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Precautions Before Service − What The
Common Rail Engine Learns ). After Common Rail Engine Learns ). After
cardiagn.com
registering the injector identification code, registering the injector identification code,
the vehicle equipped with the DPF carries the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible Particulate Filter (DPF) System − Forcible
DPF Regeneration ). DPF Regeneration ).
NO : Go to Step 2 .
Code No. P1626: Injection Quantity Compensation Value Not Coding
DIAGNOSIS PROCEDURE
FUNCTION
• The engine-ECU checks whether injector correc-
STEP 1. Write the injector identification code
tion data is written to the engine-ECU.
data.
TROUBLE JUDGMENT • Write the injector identification code data (Refer
to GROUP 00 − Precautions Before Service −
Check Condition Injector Identification Code Registration Proce-
• Ignition switch is in "ON" position. dure ).
Judgment Criterion • After writing the injector identification code data,
• No record of writing injector correction data recheck for abnormal symptoms.
PROBABLE CAUSE
YES : Replace the engine-ECU. When the engine- registering the injector identification code,
ECU is replaced, write the chassis number the vehicle equipped with the DPF carries
(Refer to GROUP 00 − Precautions Before out the forcible DPF regeneration. (Refer to
Service − How to Perform Chassis Number GROUP 17 − Emission Control − Diesel
Writing ). After replacing the engine-ECU, Particulate Filter (DPF) System − Forcible
register the injector identification code and DPF Regeneration ).
learn fuel injection (Refer to GROUP 00 − NO : The check is end.
13A-328 DIESEL FUEL
TROUBLESHOOTING
Code No. P2118: Throttle Valve Control (DC Motor) Current Malfunction
Throttle valve control servo circuit
A-132
(MU805200)
1 2 3 4 5 6 throttle valve
5 6
G-B G
cardiagn.com
C-103 129 114
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00107 AB

• Current supplied from the engine-ECU (terminal
Check Condition
No. 129 and No. 114) to the throttle valve control
servo (terminal No. 5 and No. 6) is adjusted.
Judgment Criterion
FUNCTION • An overcurrent cut-off signal from the throttle
• The throttle valve control servo drive IC in the valve control servo drive integrated circuit (IC) is
engine-ECU monitors current flowing in the throt- repeatedly detected for 0.5 second.
tle control servo and cuts energization if it detects
overcurrent. PROBABLE CAUSES
• Failed throttle control servo
• Short circuit in throttle valve control servo circuit
or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-329
connector.
STEP 1. Connector check: A-132 electronic- Connector: C-103
controlled throttle valve connector. <L.H. drive vehicles>
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side

cardiagn.com
C-103 (B)
STEP 2. Check throttle valve control servo itself
• Check throttle valve control servo itself (Refer to 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
P.13A-596). 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146

NO : Replace the throttle body assembly.
13A-330 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) electronic-controlled throttle (terminal No. 5) electronic-controlled throttle
valve connector. valve connector.
C-103 (B) C-103 (B)
cardiagn.com
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-132 (B) A-132 (B)

6 5 4 3 2 1 6 5 4 3 2 1
• Check output line for short circuit. • Check output line for short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-331
DPF Regeneration ).
cardiagn.com
13A-332 DIESEL FUEL
TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input
Accelerator Pedal Position Sensor (main) Circuit
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
cardiagn.com
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB

• A power voltage of 5 V is applied to the accelera-
Check Conditions
tor pedal position sensor (terminal No. 1) from the
• Accelerator pedal position sensor (sub) is normal
(terminal No. 151) from the accelerator pedal Judgment Criterion
position sensor (terminal No. 2). • Accelerator pedal position sensor (main) output
• The sensor signal is inputted to the engine-ECU voltage is lower than 0.2 V for 0.3 seconds.
(terminal No. 150) from the accelerator pedal
position sensor output terminal (terminal No. 3). PROBABLE CAUSES
• Failed accelerator pedal position sensor
FUNCTION • Open/short circuit or harness damage in acceler-
• The accelerator pedal position sensor (main) out- ator pedal position sensor circuit or loose con-
puts voltage which corresponds to the accelera- nector contact
tor pedal depression. • Failed engine-ECU
• The engine-ECU checks whether the voltage is
within a specified range.
DIESEL FUEL
TROUBLESHOOTING
13A-333

accelerator pedal position sensor connector.
a. Item 9: Accelerator pedal position sensor
(main) Connector: C-115
NO : Go to Step 2 .
STEP 2. Connector check: C-115 accelerator

pedal position sensor connector
Connector: C-115
cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB

<R.H. drive vehicles> side.
OK: 4.9 − 5.1 V
C-115 (B) YES : Go to Step 7 .
NO : Go to Step 4 .
6 5 4 3 2 1

13A-334 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 1) accelerator pedal position sensor
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check power supply line for open/short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-335
NO : Go to Step 8 .
(main) STEP 8. Connector check: C-103 engine-ECU
connector
YES : Intermittent malfunction (Refer to GROUP Connector: C-103
Service − How to Perform Chassis Number C-103 (B)
register the injector identification code and <R.H. drive vehicles>
cardiagn.com
GROUP 17 − Emission Control − Diesel C-103 (B)
DPF Regeneration ). 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
<L.H. drive vehicles> Q: Is the check result normal?
C-115 (B)
C-115 (B)
6 5 4 3 2 1

side.
13A-336 DIESEL FUEL
TROUBLESHOOTING
No. 2) accelerator pedal position sensor
connector
Connector: C-115
C-115 (B)
C-103 (B)
cardiagn.com
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
<L.H. drive vehicles> 158 157156 155 154 153 152 151 150 149 148 147 146

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-337
accelerator pedal position sensor connector. connector
C-115 (B)
C-103 (B)

cardiagn.com
C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Ignition switch: ON AKA00090 AB
OK: 0.7 − 1.3 V YES : Go to Step 13 .
13A-338 DIESEL FUEL
TROUBLESHOOTING
No. 3) accelerator pedal position sensor and C- No. 1) accelerator pedal position sensor
103 (terminal No. 150) engine-ECU connector. connector and C-103 (terminal No. 149) engine-
ECU connector.
Connector: C-115
C-115 (B)
C-115 (B)

cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector 6 5 4 3 2 1
AK700804 AB
Connector: C-103
C-103 (B)
C-103 (B)
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for short circuit. AKA00090 AB

NO : Repair the damaged harness wire. YES : Replace the accelerator pedal position
sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-339
ECU connector.
Connector: C-115
C-115 (B)
cardiagn.com
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-340 DIESEL FUEL
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (main) Circuit High Input
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
cardiagn.com
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB

Check Conditions
• Accelerator pedal position sensor (sub) is normal
• Accelerator pedal position sensor (sub) output
voltage is 0.125 V or higher and 1.4 V or lower.
position sensor (terminal No. 2).
• DTC No. P2124 is memorized.
position sensor output terminal (terminal No. 3). • Accelerator pedal position sensor (main) output
voltage exceeds 4.8 V for 0.25 seconds.
FUNCTION
• The accelerator pedal position sensor (main) out- PROBABLE CAUSES
puts voltage which corresponds to the accelera- • Failed accelerator pedal position sensor
tor pedal depression. • Open circuit in accelerator pedal position sensor
• The engine-ECU checks whether the voltage is circuit or loose connector contact
within a specified range. • Failed engine-ECU
DIESEL FUEL
TROUBLESHOOTING
13A-341

• Refer to Data List Reference Table P.13A-542. STEP 3. Perform resistance measurement at C-
115 accelerator pedal position sensor connector.
NO : Go to Step 2 .

Connector: C-115
cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1

C-115 (B) NO : Go to Step 4 .
6 5 4 3 2 1

13A-342 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-343
STEP 6. M.U.T.-III data list STEP 7. Replace the accelerator pedal position
• Refer to Data List Reference Table P.13A-542. sensor
a. Item 9: Accelerator pedal position sensor • After replacing the accelerator pedal position
(main) sensor, re-check the trouble symptoms.
YES : Intermittent malfunction (Refer to GROUP YES : The check is end.
00 − How to Use Troubleshooting/ NO : Replace the engine-ECU. When the engine-
Inspection Service Points − How to Cope ECU is replaced, write the chassis number
with Intermittent Malfunctions ). (Refer to GROUP 00 − Precautions Before
NO : Replace the engine-ECU. When the engine- Service − How to Perform Chassis Number
ECU is replaced, write the chassis number Writing ). After replacing the engine-ECU,
Service − How to Perform Chassis Number learn fuel injection (Refer to GROUP 00 −
Writing ). After replacing the engine-ECU, Precautions Before Service − What The
register the injector identification code and Common Rail Engine Learns ). After
learn fuel injection (Refer to GROUP 00 − registering the injector identification code,
Precautions Before Service − What The the vehicle equipped with the DPF carries
Common Rail Engine Learns ). After out the forcible DPF regeneration. (Refer to
cardiagn.com
the vehicle equipped with the DPF carries Particulate Filter (DPF) System − Forcible
out the forcible DPF regeneration. (Refer to DPF Regeneration ).
DPF Regeneration ).
13A-344 DIESEL FUEL
TROUBLESHOOTING
Code No. P2124: Accelerator Pedal Position Sensor (Main) Circuit High Input Intermittent
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
cardiagn.com
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB
OPERATION • The engine-ECU checks whether the voltage is

• A power voltage of 5 V is applied to the accelera- within a specified range.
engine-ECU (terminal No. 149). TROUBLE JUDGMENT
• The power voltage is earthed to the engine-ECU Check Conditions
(terminal No. 151) from the accelerator pedal • Ignition switch is in "ON" position
position sensor (terminal No. 2). • Accelerator pedal position sensor (sub) is normal
position sensor output terminal (terminal No. 3). • Accelerator pedal position sensor (main) output
voltage exceeds 4.8 V for 0.05 seconds.
FUNCTION
• The accelerator pedal position sensor (main) out- PROBABLE CAUSES
puts voltage which corresponds to the accelera- • Failed accelerator pedal position sensor
tor pedal depression. • Open circuit in accelerator pedal position sensor
DIESEL FUEL
TROUBLESHOOTING
13A-345

NO : Go to Step 2 .

Connector: C-115
cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1

6 5 4 3 2 1

13A-346 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-347
a. Item 9: Accelerator pedal position sensor • After replacing the accelerator pedal position
(main) sensor, re-check the trouble symptoms.
cardiagn.com
DPF Regeneration ).
13A-348 DIESEL FUEL
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (sub) Circuit Low Input
Accelerator Pedal Position Sensor (sub) Circuit
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
cardiagn.com
Y-R L B-Y
C-103 134 135 136
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00110 AB

Check Conditions
• Accelerator pedal position sensor (main) is nor-
mal
position sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • Accelerator pedal position sensor (sub) output
(terminal No. 135) from the accelerator pedal voltage is lower than 0.125 V for 0.3 seconds.
position sensor output terminal (terminal No. 6).
PROBABLE CAUSES
FUNCTION • Failed accelerator pedal position sensor
• The accelerator pedal position sensor (sub) out- • Open/short circuit or harness damage in acceler-
puts voltage which corresponds to the accelera- ator pedal position sensor circuit or loose con-
tor pedal depression. nector contact
• The engine-ECU checks whether the voltage is • Failed engine-ECU
within a specified range.
DIESEL FUEL
TROUBLESHOOTING
13A-349

(sub) Connector: C-115
NO : Go to Step 2 .

Connector: C-115
cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1

OK: 4.9 − 5.1 V
C-115 (B) YES : Go to Step 7 .
NO : Go to Step 4 .
6 5 4 3 2 1

13A-350 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-351
NO : Go to Step 8 .
(sub) STEP 8. Connector check: C-103 engine-ECU
connector
YES : Intermittent malfunction (Refer to GROUP Connector: C-103
Service − How to Perform Chassis Number C-103 (B)
register the injector identification code and <R.H. drive vehicles>
cardiagn.com
GROUP 17 − Emission Control − Diesel C-103 (B)
DPF Regeneration ). 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

side.
13A-352 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-115
C-115 (B)
C-103 (B)
cardiagn.com
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-353
accelerator pedal position sensor connector. connector
C-115 (B)
C-103 (B)

cardiagn.com
C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Ignition switch: ON AKA00090 AB
OK: 0.2 − 0.8 V YES : Go to Step 13 .
13A-354 DIESEL FUEL
TROUBLESHOOTING
No. 6) accelerator pedal position sensor No. 4) accelerator pedal position sensor
connector and C-103 (terminal No. 135) engine- connector and C-103 (terminal No. 134) engine-
ECU connector. ECU connector.
C-115 (B) C-115 (B)
cardiagn.com
C-115 (B) C-115 (B)
6 5 4 3 2 1 6 5 4 3 2 1
Harness side connector AK700804 AB Harness side connector AK700804 AB

C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for short circuit. • Check power supply line for damage.
YES : Go to Step 14 . YES : Replace the accelerator pedal position
NO : Repair the damaged harness wire. sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-355
ECU connector.
Connector: C-115
C-115 (B)
cardiagn.com
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-356 DIESEL FUEL
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (sub) Circuit High Input
Accelerator Pedal Position Sensor (sub) Circuit
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
cardiagn.com
Y-R L B-Y
C-103 134 135 136
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00110 AB

Check Conditions
• Accelerator pedal position sensor (main) is nor-
position sensor (terminal No. 5).
mal
• Accelerator pedal position sensor (main) output
voltage is 0.2 V or higher and 2.8 V or lower.
position sensor output terminal (terminal No. 6).
Judgment Criterion
FUNCTION • Accelerator pedal position sensor (main) output
• The accelerator pedal position sensor (sub) out- voltage exceeds 2.4 V for 0.3 seconds.
puts voltage which corresponds to the accelera-
tor pedal depression. PROBABLE CAUSES
• The engine-ECU checks whether the voltage is • Failed accelerator pedal position sensor
within a specified range. • Open circuit in accelerator pedal position sensor
DIESEL FUEL
TROUBLESHOOTING
13A-357

(sub) Connector: C-115
NO : Go to Step 2 .

Connector: C-115
cardiagn.com
C-115 (B)
C-115 (B)
6 5 4 3 2 1

6 5 4 3 2 1

13A-358 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-359
a. Item 10: Accelerator pedal position sensor • After replacing the accelerator position sensor,
(sub) re-check the trouble symptoms.
cardiagn.com
DPF Regeneration ).
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem
OPERATION Check Conditions

• Refer to Code No. P2122: Accelerator Pedal • Battery positive voltage is 6 − 16 V
Position Sensor (main) Circuit Low Input P.13A- • 2 seconds later after the ignition switch has been
333. in "ON" position or the engine has started up
• Refer to Code No. P2127: Accelerator Pedal • Engine speed is 600 r/min or more.
Position Sensor (sub) Circuit Low Input P.13A- • Accelerator pedal position sensor (main) output
349. voltage is 0.2 V or higher and 4.8 V or lower.
• Accelerator pedal position sensor (sub) output
FUNCTION voltage is 0.125 V or higher and 2.375 V or lower.
• Engine-ECU checks the accelerator pedal posi-
tion sensor output signal characteristics for Judgment Criterion
abnormal conditions. • When a change in the accelerator pedal position
sensor (sub) output voltage is less than the spec-
TROUBLE JUDGMENT ified value for 0.2 second, the difference between
the opening indicated by the accelerator pedal
Check Condition
position sensor (main) and that by the accelerator
pedal position sensor (sub) is 18 % or more of the
Judgment Criterion specified value.
• When an error is detected on the High side of the
accelerator pedal position (main) for 0.1 second, PROBABLE CAUSES
the accelerator pedal position sensor (sub) is • Failed accelerator pedal position sensor
faulty on the High/Low side. • Accelerator pedal position sensor circuit harness
damage or loose connector contact
13A-360 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Perform resistance measurement at C-

STEP 1. Connector check: C-115 accelerator Connector: C-115
pedal position connector <L.H. drive vehicles>
Connector: C-115
C-115 (B)
C-115 (B)
cardiagn.com
C-115 (B)
C-115 (B) 6 5 4 3 2 1
6 5 4 3 2 1
Harness side connector AK700804 AB side.
YES : Go to Step 2 . OK: Continuity (2 Ω or less)
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-361
YES : Check and repair harness between C-115
(terminal No. 2) accelerator pedal position
connector
Connector: C-103 151) engine-ECU connector.
STEP 4. Perform resistance measurement at C-

Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
Connector: C-115
<L.H. drive vehicles> 6 5 4 3 2 1

side.
C-115 (B) • Resistance between terminal No. 5 and earth.
<R.H. drive vehicles> NO : Go to Step 5 .
C-115 (B)
6 5 4 3 2 1

13A-362 DIESEL FUEL
TROUBLESHOOTING

connector
STEP 6. Perform voltage measurement at C-115

Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
Connector: C-115
<L.H. drive vehicles> 6 5 4 3 2 1

C-115 (B) • Ignition switch: ON
OK: 4.9 − 5.1 V
<R.H. drive vehicles> YES : Go to Step 8 .
NO : Go to Step 7 .
C-115 (B)
6 5 4 3 2 1

DIESEL FUEL
TROUBLESHOOTING
13A-363
connector
<L.H. drive vehicles> • Check power supply line for damage.

C-115 (B) accelerator pedal position sensor connector.
Connector: C-115
C-115 (B)
cardiagn.com
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-115 (B)
6 5 4 3 2 1

C-103 (B) nect connector, and measure at pick-up harness.
<R.H. drive vehicles> • Voltage between terminal No. 4 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 9 .
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-364 DIESEL FUEL
TROUBLESHOOTING

connector
<L.H. drive vehicles> • Check power supply line for damage.

Connector: C-103
C-103 (B)
C-103 (B)
cardiagn.com
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: C-115
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
OK: 0.7 − 1.3 V
C-115 (B)
6 5 4 3 2 1

DIESEL FUEL
TROUBLESHOOTING
13A-365
YES : Replace the accelerator pedal position
sensor.
ECU connector.
Connector: C-115
<L.H. drive vehicles> engine-ECU connector.
Connector: C-103
C-115 (B)
C-103 (B)
cardiagn.com
C-115 (B)
6 5 4 3 2 1
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
Connector: C-103 130 129 128 127 126 125 124 123 122 121120 119 118
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B) OK: 0.2 − 0.8 V
<R.H. drive vehicles> Q: Is the check result normal?

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-366 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Check harness between C-115 (terminal STEP 14. Connector check: C-103 engine-ECU
No. 6) accelerator pedal position sensor connector
connector and C-103 (terminal No. 135) engine- Connector: C-103
ECU connector. <L.H. drive vehicles>
Connector: C-115
C-103 (B)
C-115 (B)
cardiagn.com
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
6 5 4 3 2 1 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103

C-103 (B) Q: Is the diagnosis code set?
<R.H. drive vehicles> ECU is replaced, write the chassis number
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 the vehicle equipped with the DPF carries
117 116 out the forcible DPF regeneration. (Refer to
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector Particulate Filter (DPF) System − Forcible

AKA00090 AB
DPF Regeneration ).
• Check output line for damage. NO : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use Troubleshooting/
YES : Replace the accelerator pedal position Inspection Service Points − How to Cope
sensor. with Intermittent Malfunctions ).
DIESEL FUEL
TROUBLESHOOTING
13A-367
Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Euro5>
OPERATION YES : Go to Step 2 .

• Refer to Code No. P0201: No. 1 Injector Circuit NO : Repair or replace the connector.
Malfunction P.13A-158.
• Refer to Code No. P0204: No. 4 Injector Circuit STEP 2. Check Injector itself
Malfunction P.13A-158. <Euro5> • Check No. 1 injector and No. 4 injector itself
FUNCTION
• The engine-ECU monitors peak current from the Q: Is the check result normal?
No. 1 and No. 4 injector drive circuits. YES : Go to Step 3 .
NO : Replace the injector. After replacing the
TROUBLE JUDGMENT Injector, register the injector identification
Check Conditions code and learn fuel injection (Refer to
• Ignition switch is in "ON" position. GROUP 00 − Precautions Before Service −
• Except during the engine cranking period What The Common Rail Engine Learns ).
• Battery positive voltage is 8 V or more.
Judgment Criterion
cardiagn.com
connector
• When the peak current is not detected in injector
circuits No. 1 and No. 4 Connector: C-105
PROBABLE CAUSES
• Open/short circuit in No. 1 and No. 4 injector cir-
cuit or loose connector contact
DIAGNOSIS PROCEDURE
WARNING
the engine-ECU and the injectors while the
engine is running. Handle them carefully to
age.
C-105 (B)
STEP 1. Connector check: A-42 No. 1 injector 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
connector and A-129 No. 4 injector connector 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connectors: A-42, A-129 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-42 (GR)
A-129 (GR)
1 2
Harness side

13A-368 DIESEL FUEL
TROUBLESHOOTING
No. 1) engine-ECU connector and A-42 (terminal No. 25) engine-ECU connector and A-129
No. 2) No. 1 injector connector. (terminal No. 2) No. 4 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
connector AKA00186 AB connector AKA00189AB
• Check power supply line for open/short circuit. • Check power supply line for open/short circuit.

No. 1) No. 1 injector connector.
DIESEL FUEL
TROUBLESHOOTING
13A-369
Connector: C-105 STEP 7. Check harness between C-105 (terminal
<L.H. drive vehicles> No. 27) engine-ECU connector and A-129
(terminal No. 1) No. 4 injector connector.
Connector: C-105
C-105 (B)

C-105 (B)
C-105 (B)
cardiagn.com
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-42 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) Connector: A-129
1 2
A-129 (GR)
Harness side
• Check earthing line for open/short circuit. 1 2

connector
YES : Go to Step 7 . AKA00189AB
NO : Repair the damaged harness wire. • Check earthing line for open circuit.

13A-370 DIESEL FUEL
TROUBLESHOOTING

cardiagn.com
Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Except Euro5>
OPERATION DIAGNOSIS PROCEDURE

• Driving power is supplied from the engine-ECU
WARNING
(terminal No. 1) to the No. 1 injector terminal (ter-
minal No. 2) and No. 4 injector (terminal No. 2).
FUNCTION engine is running. Handle them carefully to
• The engine-ECU monitors peak current from the avoid receiving electric shocks from the volt-
No. 1 and No. 4 injector drive circuits. age.
TROUBLE JUDGMENT
Check Conditions connector and A-129 No. 4 injector connector
• Except during the engine cranking period Connectors: A-42, A-129
Judgment Criterion A-42 (GR)
circuits No. 1 and No. 4
A-129 (GR)
PROBABLE CAUSES 1 2
Harness side
• Failed No. 4 injector connector AKA00190 AB
• Open/short circuit in No. 1 and No. 4 injector cir-
cuit or loose connector contact Q: Are the check results normal?
STEP 2. Check Injector itself

• Check No. 1 injector and No. 4 injector itself
DIESEL FUEL
TROUBLESHOOTING
13A-371
Injector, register the injector identification
code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service − Connector: C-105
What The Common Rail Engine Learns ).

connector
Connector: C-105
C-105 (B)
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector A-42 (GR)

AKA00089 AB

YES : Go to Step 4 . 1 2
NO : Repair or replace the connector. Harness side

13A-372 DIESEL FUEL
TROUBLESHOOTING
No. 2) No. 4 injector connector. No. 1) No. 1 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
connector AKA00189AB connector AKA00186 AB
• Check power supply line for open/short circuit. • Check earthing line for open/short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-373
Connector: C-105
<L.H. drive vehicles> • After erasing the diagnosis code through M.U.T.-
C-105 (B) (Refer to GROUP 00 − Precautions Before
<R.H. drive vehicles> register the injector identification code and
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2147: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Earth Short <Euro5>
OPERATION FUNCTION
• Refer to Code No. P0201: No. 1 Injector Circuit • The engine-ECU monitors voltage application to
Malfunction P.13A-158. the injector during no injector energization to
• Refer to Code No. P0204: No. 4 Injector Circuit detect errors in the No. 1 and No. 4 injector drive
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Conditions
13A-374 DIESEL FUEL
TROUBLESHOOTING
• Except during the engine cranking period YES : Go to Step 2 .

• Battery positive voltage is 8 V or more. NO : Repair or replace the connector.
• When an engine-ECU internal capacitor is
allowed to be charged STEP 2. Connector check: C-105 engine-ECU
Judgment Criterion connector.
• Short-circuit to the ground is detected in the injec- Connector: C-105
tor drive circuit. <L.H. drive vehicles>
PROBABLE CAUSES
• Short circuit in injector circuit or loose connector
contact
C-105 (B)
DIAGNOSIS PROCEDURE <R.H. drive vehicles>
WARNING
cardiagn.com
age. C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
STEP 1. Connector check: A-42 No. 1 injector 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector and A-129 No. 4 injector connector. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connectors: A-42, A-129

A-129 (GR)
1 2
Harness side

DIESEL FUEL
TROUBLESHOOTING
13A-375
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
• Check earthing line for short circuit. • Check earthing line for short circuit.
13A-376 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
• Check power supply line for short circuit. • Check power supply line for short circuit.

NO : Replace the injector.
DIESEL FUEL
TROUBLESHOOTING
13A-377
nosis code is set.
cardiagn.com
Code No. P2147: Injector Common Circuit Earth Short <Except Euro5>

• The engine-ECU monitors voltage application to
WARNING
the injector during no injector energization to
detect errors in the injector drive circuit.
TROUBLE JUDGMENT engine is running. Handle them carefully to
Check Conditions
• Ignition switch is in "ON" position. age.
• Battery positive voltage is 8 V or more. STEP 1. Connector check: A-41, A-42, A-129 and
• When an engine-ECU internal capacitor is A-130 injector connectors
allowed to be charged
Connectors: A-41, A-42, A-129 and A-130
Judgment Criterion
• Short-circuit to earth is detected in the injector A-42 (GR)
drive circuit. A-41 (GR)
PROBABLE CAUSES A-130 (GR)

• Failed injector A-129 (GR)
• Short circuit in injector circuit or loose connector 1 2
contact Harness side
• Failed engine-ECU connector AKA00192 AB

YES : Go to Step 2.

• Check injector itself (Refer to P.13A-595).
13A-378 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 3.

connector
Connector: C-105
C-105 (B)
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AKA00089 AB

YES : Go to Step 4. 1 2
• Check earthing line for short circuit.

YES : Go to Step 5.
DIESEL FUEL
TROUBLESHOOTING
13A-379
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
13A-380 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
• Check earthing line for short circuit. • Check power supply line for short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-381
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
13A-382 DIESEL FUEL
TROUBLESHOOTING

Connector: C-105
nosis code is set.
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2148: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Battery Short <Euro5>
OPERATION FUNCTION
Malfunction P.13A-158. the injector during no injector energization to
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Condition
DIESEL FUEL
TROUBLESHOOTING
13A-383
Judgment Criterion YES : Go to Step 2 .
• Short-circuit to the battery is detected in the injec- NO : Repair or replace the connector.
tor drive circuit.
PROBABLE CAUSES
connector.
contact Connector: C-105
DIAGNOSIS PROCEDURE
WARNING
C-105 (B)
engine is running. Handle them carefully to <R.H. drive vehicles>
age.
cardiagn.com
connector and A-129 No. 4 injector connector.
Connectors: A-42, A-129 C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-42 (GR)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-129 (GR)
1 2 Q: Is the check result normal?
Harness side YES : Go to Step 3 .
connector AKA00190 AB NO : Repair or replace the connector.

13A-384 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-385
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2

NO : Replace the injector.
13A-386 DIESEL FUEL
TROUBLESHOOTING

nosis code is set.
cardiagn.com
Code No. P2148: Injector Common Circuit Battry Short <Except Euro5>

• The engine-ECU monitors voltage application to
WARNING
detect errors in the injector drive circuit.
TROUBLE JUDGMENT engine is running. Handle them carefully to
Check Condition
• Ignition switch is in "ON" position. age.
Judgment Criterion
• Short-circuit to earth is detected in the injector STEP 1. Connector check: A-41, A-42, A-129 and
drive circuit. A-130 injector connectors
Connectors: A-41, A-42, A-129 and A-130
PROBABLE CAUSES
• Failed injector
A-42 (GR)
A-41 (GR)
contact
• Failed engine-ECU A-130 (GR)
A-129 (GR)
1 2
Harness side

YES : Go to Step 2.

DIESEL FUEL
TROUBLESHOOTING
13A-387
YES : Go to Step 3.

connector
Connector: C-105
C-105 (B)
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AKA00089 AB

YES : Go to Step 4. 1 2

YES : Go to Step 5.
13A-388 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-389
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
13A-390 DIESEL FUEL
TROUBLESHOOTING
No.25) engine-ECU connector and A-41 (terminal No. 25) engine-ECU connector and A-130
No. 2) No. 2 injector connector. (terminal No. 2) No. 3 injector connector
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-391
Connector: C-105
nosis code is set.
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Euro5>

• Refer to Code No. P0202: No. 2 Injector Circuit
Check Conditions
Malfunction P.13A-161. <Euro5>
FUNCTION • When an engine-ECU internal capacitor is
• The engine-ECU monitors peak current from the allowed to be charged
No. 2 and No. 3 injector drive circuits.
13A-392 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 2. Check Injector itself

• When the peak current is not detected in injector • Check No. 2 injector and No. 3 injector itself
circuits No. 2 and No. 3 (Refer to P.13A-595).
PROBABLE CAUSES Q: Is the check result normal?
• Failed No. 2 injector YES : Go to Step 3 .
• Failed No. 3 injector NO : Replace the injector. After replacing the
• Open/short circuit or harness damage in No. 2 Injector, register the injector identification
and No. 3 injector circuit or loose connector con- code and learn fuel injection (Refer to
tact GROUP 00 − Precautions Before Service −
• Failed engine-ECU What The Common Rail Engine Learns ).

WARNING connector
A high-tension voltage is flowing between Connector: C-105
the engine-ECU and the injectors while the <L.H. drive vehicles>
age.
cardiagn.com
C-105 (B)
connector and A-130 No. 3 injector connector
A-41 (GR)
A-130 (GR)
1 2
C-105 (B)
Harness side
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Repair or replace the connector. Harness side connector AKA00089 AB

DIESEL FUEL
TROUBLESHOOTING
13A-393
No. 2) No. 2 injector connector. No. 1) No. 2 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR) A-41 (GR)
1 2 1 2
connector AKA00187AB connector AKA00187AB
• Check power supply line for open circuit and • Check earthing line for open/short circuit and
damage. damage.
13A-394 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 2) No. 3 injector connector. (terminal No. 1) No. 3 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-130 (GR) A-130 (GR)
1 2 1 2
connector AKA00188 AB connector AKA00188 AB
• Check power supply line for open/short circuit • Check earthing line for open/short circuit and
and damage. damage.

DIESEL FUEL
TROUBLESHOOTING
13A-395
cardiagn.com
Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Except Euro5>

Driving power is supplied from the engine-ECU (ter-
WARNING
minal No. 25) to the No. 2 injector (terminal No. 2)
and No. 3 injector (terminal No. 2).
FUNCTION engine is running. Handle them carefully to
• The engine-ECU monitors peak current from the avoid receiving electric shocks from the volt-
No. 2 and No. 3 injector drive circuits. age.
TROUBLE JUDGMENT
Check Conditions connector and A-130 No. 3 injector connector
• Except during the engine cranking period Connectors: A-41, A-130
• When an engine-ECU internal capacitor is
allowed to be charged A-41 (GR)
Judgment Criterion A-130 (GR)

circuits No. 2 and No. 3 1 2
Harness side
PROBABLE CAUSES connector AKA00191 AB
• Failed No. 3 injector Q: Are the check results normal?
• Open/short circuit or harness damage in No. 2 YES : Go to Step 2 .
and No. 3 injector circuit or loose connector con- NO : Repair or replace the connector.
tact
• Failed engine-ECU STEP 2. Check Injector itself
13A-396 DIESEL FUEL
TROUBLESHOOTING

connector
Connector: C-105
C-105 (B)
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-41
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB A-41 (GR)

YES : Go to Step 4 . 1 2
• Check power supply line for open circuit and

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-397
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
• Check earthing line for open/short circuit and • Check power supply line for open/short circuit
damage. and damage.
13A-398 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-130
A-130 (GR)
1 2
Harness side

damage.
Code No. P2150: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Earth Short <Euro5>
OPERATION FUNCTION
Malfunction P.13A-161. <Euro5> the injector during no injector energization to
Malfunction P.13A-167. circuit.
TROUBLE JUDGMENT • Ignition switch is in "ON" position.

Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-399
• When an engine-ECU internal capacitor is YES : Go to Step 2 .
allowed to be charged NO : Repair or replace the connector.
Judgment Criterion
• Short-circuit to the earth is detected in the injector STEP 2. Connector check: C-105 engine-ECU
drive circuit. connector.
Connector: C-105
PROBABLE CAUSES <L.H. drive vehicles>
contact
C-105 (B)
DIAGNOSIS PROCEDURE
WARNING
cardiagn.com
age.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-41 (GR)

1 2
Harness side

13A-400 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-401
No. 2) No. 2 injector connector (terminal No. 2) No. 3 injector connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2

GROUP 00 − Precautions Before Service −
13A-402 DIESEL FUEL
TROUBLESHOOTING

nosis code is set.
cardiagn.com
Code No. P2151: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Battery Short <Euro5>

WARNING
Malfunction P.13A-167. <Euro5> the engine-ECU and the injectors while the
FUNCTION avoid receiving electric shocks from the volt-
• The engine-ECU monitors voltage application to age.
detect errors in the No. 2 and No. 3 injector drive
circuit.
TROUBLE JUDGMENT Connectors: A-41, A-130
Check Condition
A-41 (GR)
Judgment Criterion
• Short-circuit to the battery is detected in the injec- A-130 (GR)
tor drive circuit.
1 2
PROBABLE CAUSES
Harness side
• Short circuit in injector circuit or loose connector connector AKA00191 AB
contact
• Failed No. 2 injector Q: Are the check results normal?
• Failed No. 3 injector YES : Go to Step 2 .
• Failed engine-ECU NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-403
connector. No. 75) engine-ECU connector and A-41 (terminal
Connector: C-105
C-105 (B)
C-105 (B)

cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 3 . Connector: A-41
A-41 (GR)
1 2
Harness side

13A-404 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 1) No. 3 injector connector. No. 2) No. 2 injector connector
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-405
Connector: C-105
<L.H. drive vehicles> • Check No. 2 injector and No. 3 injector itself
C-105 (B) code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service −

nosis code is set.
cardiagn.com
C-105 (B) YES : Replace the engine-ECU. When the engine-
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-130 Precautions Before Service − What The
A-130 (GR) Diesel Particulate Filter (DPF) System −
1 2 NO : Intermittent malfunction (Refer to GROUP
Harness side 00 − How to Use Troubleshooting/
connector AKA00188 AB Inspection Service Points − How to Cope
• Check power supply line for short circuit. with Intermittent Malfunctions ).
Code No. P2228: Barometric Pressure Sensor Circuit Low Input

• The barometric pressure sensor converts the bar-
Check Conditions
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU.
• In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc.
Judgment Criterion
• The barometric pressure sensor output voltage is
1.60 V or less for 0.5 second.
13A-406 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSE YES : Intermittent malfunction (Refer to GROUP

• Failed barometric pressure sensor 00 − How to Use Troubleshooting/
DIAGNOSIS PROCEDURE with Intermittent Malfunctions ).
STEP 1. M.U.T.-III data list (Refer to GROUP 00 − Precautions Before
• Refer to Data List Reference Table P.13A-542. Service − How to Perform Chassis Number
a. Item 5: Barometric pressure sensor Writing ). After replacing the engine-ECU,
Q: Is the check result normal? register the injector identification code and
DPF Regeneration ).
cardiagn.com
Code No. P2229: Barometric Pressure Sensor Circuit High Input

• The barometric pressure sensor converts the bar-
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU. STEP 1. M.U.T.-III data list
• In response to the signal, the engine-ECU cor- • Refer to Data List Reference Table P.13A-542.
rects the fuel injection amount, etc. a. Item 5: Barometric pressure sensor
TROUBLE JUDGMENT YES : Intermittent malfunction (Refer to GROUP
Check Conditions 00 − How to Use Troubleshooting/
• Battery positive voltage is 8 − 16 V Inspection Service Points − How to Cope
• 2 seconds later after the ignition switch has been with Intermittent Malfunctions .)
in "ON" position or the engine has started up NO : Replace the engine-ECU. When the engine-
Judgment Criterion (Refer to GROUP 00 − Precautions Before
• The barometric pressure sensor output voltage is Service − How to Perform Chassis Number
4.80 V or less for 0.5 second. Writing ). After replacing the engine-ECU,
PROBABLE CAUSE
• Failed barometric pressure sensor
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-407
Code No. P2413: EGR System Performance
OPERATION STEP 2. Check EGR valve itself

• System power is supplied from the engine-ECU • Check EGR valve itself [Refer to GROUP 17 −
(terminal No. 115) to the EGR valve (terminal No. Emission Control System − Exhaust Gas Recir-
6). culation (EGR) System − EGR valve check ].
• The engine-ECU (terminal No. 130) turns on the
power transistor to flow current to the EGR valve Q: Is the check result normal?
(terminal No. 4). YES : Go to Step 3 .
FUNCTION
• The engine-ECU performs duty control over the STEP 3. Connector check: C-105 engine-ECU
EGR valve (DC motor). connector
• The engine-ECU performs feedback control over
the EGR valve based on the signals from the Connector: C-105
EGR position sensor.
TROUBLE JUDGMENT
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Check Condition
Judgment Criterion C-105 (B)
• The EGR valve in sticking state (a high duty state
continues for the predetermined time or more) is
repeatedly detected.
PROBABLE CAUSES
• Failed EGR valve
• Open/short circuit or harness damage in EGR
C-105 (B)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
STEP 1. M.U.T.-III diagnosis code 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is any other diagnosis code than P2413 output? Harness side connector AKA00089 AB
YES : Inspection chart for diagnosis codes (Refer
to P.13A-21). Q: Is the check result normal?
NO : Go to Step 2 . YES : Go to Step 4 .
13A-408 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
age. age.

DIESEL FUEL
TROUBLESHOOTING
13A-409
DPF Regeneration ).
cardiagn.com
13A-410 DIESEL FUEL
TROUBLESHOOTING
Code No. P2454: Exhaust Differential Pressure Sensor Circuit Low Input <Euro5>
Exhaust Differential Pressure Sensor Circuit
A-148 Output signal

Exhaust differential
1 2 3 pressure sensor
Earth Power source
2 1 3
cardiagn.com
GR-B P-G B-O
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00280 AB

• A power voltage of 5 V is applied to the exhaust
Check Conditions
differential pressure sensor power terminal (ter-
minal No. 3) from the engine-ECU (terminal No.
94) and earthed to the engine-ECU (terminal No.
80) from exhaust differential pressure sensor (ter-
minal No. 2). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The exhaust differential pressure sensor output
(terminal No. 56) from the exhaust differential voltage is 0.49 V or less.
PROBABLE CAUSES
FUNCTION • Failed exhaust differential pressure sensor
• The exhaust differential pressure sensor outputs • Open/short circuit or harness damage in exhaust
the voltage to the engine-ECU in accordance with differential pressure sensor circuit or loose con-
the difference in the voltage between the DPF nector contact
upstream area and the DPF downstream area. • Failed engine-ECU
• The engine-ECU anticipates the amount of PM
accumulated in the DPF through this output volt-
age.
DIESEL FUEL
TROUBLESHOOTING
13A-411
DIAGNOSTIC PROCEDURE YES : Go to Step 9 .
NO : Go to Step 4 .

a. Item 120: exhaust differential pressure sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
Connector: A-148
cardiagn.com
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AKB00281AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
exhaust differential pressure sensor connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-148 (B)
3 2 1
Harness side

side.
OK: 4.9 − 5.1 V
13A-412 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) exhaust differential pressure sensor
Connector: C-105
Connector: A-148
C-105 (B) A-148 (B)
3 2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-413
connector
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-148
A-148 (B)
3 2 1
Harness side

(terminal No. 3) exhaust differential
circuit.
13A-414 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) exhaust differential pressure sensor
Connector: C-105
Connector: A-148
C-105 (B) A-148 (B)
3 2 1
Harness side
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-415
No. 1) exhaust differential pressure sensor
ECU connector. STEP 12. Replace the exhaust differential
pressure sensor
Connector: A-148
• After replacing the exhaust differential pressure
sensor, carry out the forcible DPF regeneration.
Particulate Filter (DPF) System − Forcible DPF
Regeneration ). After carrying out the forcible
A-148 (B) DPF regeneration, re-check the trouble symp-
toms.
3 2 1
connector AKB00281AB YES : Go to Step 7 .
NO : Check end.
Connector: C-105
cardiagn.com
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open/short circuit and dam-

age.
13A-416 DIESEL FUEL
TROUBLESHOOTING
Code No. P2455: Exhaust Differential Pressure Sensor Circuit High Input <Euro5>
Exhaust Differential Pressure Sensor Circuit
A-148 Output signal

Exhaust differential
1 2 3 pressure sensor
Earth Power source
2 1 3
cardiagn.com
GR-B P-G B-O
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00280 AB
OPERATION • The engine-ECU anticipates the amount of PM

• A power voltage of 5 V is applied to the exhaust accumulated in the DPF through this output volt-
differential pressure sensor power terminal (ter- age.
minal No. 3) from the engine-ECU (terminal No.
94) and earthed to the engine-ECU (terminal No. TROUBLE JUDGMENT
80) from the exhaust differential pressure sensor Check Conditions
(terminal No. 2). • Battery positive voltage is 8 − 16 V
• The sensor signal is inputted to the engine-ECU • 2 seconds later after the ignition switch has been
(terminal No. 56) from the exhaust differential in "ON" position or the engine has started up
Judgment Criterion
FUNCTION • The exhaust differential pressure sensor output
• The exhaust differential pressure sensor outputs voltage is 4.79 V or more.
the voltage to the engine-ECU in accordance with
the difference in the voltage between the DPF PROBABLE CAUSES
upstream area and the DPF down stream area. • Failed exhaust differential pressure sensor
• Open circuit in exhaust differential pressure sen-
sor circuit or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-417
DIAGNOSTIC PROCEDURE YES : Go to Step 7 .
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
Connector: A-148
cardiagn.com
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Perform resistance measurement at A- NO : Repair or replace the connector.
148 exhaust differential pressure sensor
connector.
Connector: A-148
A-148 (B)
3 2 1
Harness side

side.
13A-418 DIESEL FUEL
TROUBLESHOOTING
No. 2) exhaust differential pressure sensor
Connector: A-148
3 2 1 NO : Replace the engine-ECU. When the engine-
connector AKB00281AB (Refer to GROUP 00 − Precautions Before
cardiagn.com
STEP 7. Replace the exhaust differential

pressure sensor
• After replacing the exhaust differential pressure
sensor, Carry out the forcible DPF regeneration.
C-105 (B) Particulate Filter (DPF) System − Forcible DPF
Regeneration ). After carrying out the forcible
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 DPF regeneration, re-check the trouble symp-
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
toms.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB YES : Go to Step 6 .
• Check earthing line for open circuit and damage. NO : Check end.
Code No. P252F: Engine Oil Level Malfunction <Euro5>

• The engine oil level may ascend if the fuel runs
Check Condition
into the engine oil on the DPF regeneration.
• The engine-ECU monitors the engine driving con-
ditions to estimate the ascend of engine oil level. Judgement Criterion
• The estimated increased amount of the engine oil
exceeds the 1,000 cc.
PROBABLE CAUSE • The engine oil is increased.

DIESEL FUEL
TROUBLESHOOTING
13A-419
DIAGNOSIS PROCEDURE YES : Replace the engine-ECU. When the engine-
STEP 1. Replace the engine oil. Service − How to Perform Chassis Number
• Replace the engine oil, When the engine oil is Writing ). After replacing the engine-ECU,
replaced, initialise the learning value (Refer to register the injector identification code and
GROUP 00 − Precautions before Service − Initial- learn fuel injection (Refer to GROUP 00 −
isation Procedure for Learning Value in Diesel Precautions Before Service − What The
Particulate Filter (DPF) System ). After initialising Common Rail Engine Learns ). After
the learning value, reconfirm diagnosis code. registering the injector identification code,
Q: Is the diagnosis code set? carry out the forcible DPF regeneration.
NO : Check end.
Code No. U1073: Bus Off
cardiagn.com
CAUTION STEP 2. M.U.T.-III diagnosis code
If diagnosis code U1073 is output from engine- • Reconfirm whether the diagnosis codes are out-
ECU surely perform CAN busline diagnosis. put from engine-ECU.
CAUTION 1. Erase the diagnosis codes being output.
Replace ECU after certainly confirming that the 2. Ignition switch: "LOCK" (OFF) to ON
communication circuits are normal. 3. Confirm whether the diagnosis codes are output.
TROUBLE JUDGMENT Q: Are the diagnosis codes output?
Check Condition YES : Replace the engine-ECU. When the
• All the time engine-ECU is replaced, write the chassis
number (Refer to GROUP 00 − Precautions
Judgment Criterion Before Service − How to Perform Chassis
• When the buss off error is detected. Number Writing ). After replacing the
COMMENT ON TROUBLE SYMPTOM engine-ECU, register the injector
• The failure is possibly caused by malfunction of identification code and learn fuel injection
the harness and connector in CAN busline or by (Refer to GROUP 00 − Precautions Before
malfunction in engine-ECU. Service − What The Common Rail Engine
Learns ). After registering the injector
PROBABLE CAUSE identification code, the vehicle equipped
• Failed engine-ECU with the DPF carries out the forcible DPF
regeneration. (Refer to GROUP 17 −
DIAGNOSIS PROCEDURE Emission Control − Diesel Particulate Filter
(DPF) System − Forcible DPF Regeneration
STEP 1. M.U.T.-III CAN bus diagnostics ). and then go to Step 3 .
• Using M.U.T.-III, perform CAN busline diagnosis.
Q: Is the check result normal? Inspection Service Points − How to Cope
YES : Go to Step 2 . with Intermittent Malfunctions ).
NO : Correct CAN busline (Refer to GROUP 54C
− Troubleshooting − Can Bus Diagnostics
Table ), and then go to Step 3 .
13A-420 DIESEL FUEL
TROUBLESHOOTING
• Reconfirm whether the diagnosis codes are out-
put from engine-ECU.
1. Erase the diagnosis codes being output.
2. Ignition switch: "LOCK" (OFF) to ON
3. Confirm whether the diagnosis codes are output.
Q: Are the diagnosis codes output?
Code No. U1101: A/T-ECU Time-out <A/T>
CAUTION NOTE: In case of Past trouble, M.U.T.-III CAN bus

If Diagnosis Code U1101 is output from engine- diagnosis cannot detect the failure even if there is
ECU surely perform CAN busline diagnosis. malfunction in CAN bus, so that check CAN
busline in the same way as Intermittent malfunc-
CAUTION tion (Refer to GROUP 00 − How to Use Trouble-
Replace ECU after certainly confirming that the shooting/Inspection Service Points − How to
communication circuits are normal.
cardiagn.com
Cope with Intermittent Malfunctions ). The diag-
NOTE: When the diagnosis codes relating to the nosis codes being output to each ECU with CAN
CAN communication error are output, make sure of communication can narrow down the most sus-
the vehicle equipment. When the vehicle is not pected area (Refer to GROUP 54C − Trouble-
equipped with the system the engine-ECU communi- shooting − Can Bus Diagnostics Table ).
cates to, the diagnosis code is always output. This is
not abnormal. PROBABLE CAUSES
TROUBLE JUDGMENT • Failed of the harness and the connector
• Failed A/T-ECU
Check Conditions • Failed engine-ECU
• The diagnosis code setting enabled signal is
received from ETACS-ECU. DIAGNOSIS PROCEDURE
Judgment Criterion
• The signals cannot be received from A/T-ECU for STEP 1. M.U.T.-III CAN bus diagnosis
0.5 second or more. • Using M.U.T.-III, perform CAN busline diagnosis.
COMMENT ON TROUBLE SYMPTOM Q: Is the check result normal?
Current malfunction
NO : Correct CAN busline (Refer to GROUP 54C
• The failure is possibly caused by malfunction of
− Troubleshooting − CAN Bus Diagnostics
the harness and connector in CAN busline
between engine-ECU and A/T-ECU, by malfunc-
tion in the power supply system of A/T-ECU, in
combination meter itself, in engine-ECU. STEP 2. M.U.T.-III other system diagnosis codes.
Past malfunction
from A/T-ECU.
• Focus on diagnosing malfunction of the harness
and connector in CAN busline between engine- Q: Is the diagnosis code output?
ECU and A/T-ECU as well as malfunction in the YES : Perform the troubleshooting of A/T-ECU
power supply system of A/T-ECU. Refer to past (Refer to GROUP 23A − Check Chart for
trouble (Refer to GROUP 00 − How to Use Trou- Diagnosis Code ).
bleshooting/Inspection Service Points − How to NO : Go to Step 3 .
Treat Past Trouble ) for the diagnosis procedure.
DIESEL FUEL
TROUBLESHOOTING
13A-421
STEP 3. M.U.T.-III other system diagnosis codes.
• Confirm whether Diagnosis Code U1101: A/T-
ECU time out is output from the following ECU
having CAN communication with automatic trans-
mission.
a. ETACS-ECU
Q: Is the diagnosis code output? Precautions Before Service − What The
NO : Go to Step 5 . registering the injector identification code,
STEP 4. Reconfirmation of diagnosis codes out the forcible DPF regeneration. (Refer to
• Reconfirm whether the diagnosis codes are out- GROUP 17 − Emission Control − Diesel
put from engine-ECU Particulate Filter (DPF) System − Forcible
1. Erase the diagnosis codes being output. DPF Regeneration ). and then go to Step 6
.
NO : Intermittent malfunction in CAN busline
3. Confirm whether the diagnosis codes are output. between engine-ECU and A/T-ECU (Refer
Q: Is the diagnosis code output? to GROUP 00 − How to Use
cardiagn.com
YES : After replacing the A/T-ECU, go to Step 6 . Troubleshooting/Inspection Service Points −
NO : Intermittent malfunction in CAN busline How to Cope with Intermittent Malfunctions
between engine-ECU and A/T-ECU (Refer ).
to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points −
STEP 6. Reconfirmation of diagnosis codes
How to Cope with Intermittent Malfunctions
).
put from engine-ECU
STEP 5. Reconfirmation of diagnosis codes 2. Ignition switch: "LOCK" (OFF) to ON
• Reconfirm whether the diagnosis codes are out- 3. Confirm whether the diagnosis codes are output.
put from engine-ECU
1. Erase the diagnosis codes being output. Q: Is the diagnosis code output?
Code No. U1102 ASTC-ECU Time-out <Except vehicles for Morocco>
CAUTION TROUBLE JUDGMENT

If Diagnosis Code U1102 is output from engine- Check Condition
ECU surely perform CAN busline diagnosis. • The diagnosis code setting enabled signal is
CAUTION received from ETACS-ECU.
Replace ECU after certainly confirming that the Judgment Criterion
communication circuits are normal. • The signals cannot be received from ASTC-ECU
NOTE: When the diagnosis codes relating to the for 65 second or more.
CAN communication error are output, make sure of
the vehicle equipment. When the vehicle is not
equipped with the system the engine-ECU communi-
cates to, the diagnosis code is always output. This is
not abnormal.
13A-422 DIESEL FUEL
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM STEP 2. M.U.T.-III other system diagnosis codes

Current malfunction • Confirm whether the diagnosis codes are output
• The failure is possibly caused by malfunction of from ASTC-ECU.
the harness and connector in CAN busline Q: Is the diagnosis code output?
between engine-ECU and ASTC-ECU, by mal- YES : Perform the troubleshooting of anti-skid
function in the power supply system of ASTC- braking system (Refer to GROUP 35B −
ECU, in ASTC-ECU itself, in engine-ECU. Troubleshooting − Check Chart for
Past malfunction Diagnosis Code ).
• Focus on diagnosing malfunction of the harness NO : Go to Step 3 .
and connector in CAN busline between engine-
ECU and ASTC-ECU as well as malfunction in STEP 3. M.U.T.-III diagnosis code
the power supply system of ASTC-ECU (Refer to • Reconfirm whether the diagnosis codes are out-
GROUP 00 − How to Use Troubleshooting/ put from engine-ECU
Inspection Service Points − How to Cope with 1. Erase the diagnosis codes being output.
Intermittent Malfunctions ). 2. Ignition switch: "LOCK" (OFF) to ON
NOTE: In case of Past trouble, M.U.T.-III CAN bus 3. Confirm whether the diagnosis codes are out-
diagnosis cannot detect the failure even if there is put.
malfunction in CAN bus, so that check CAN
cardiagn.com
busline in the same way as Intermittent malfunc- Q: Is the diagnosis code output?
tion (Refer to GROUP 00 − How to Use Trouble- YES : Go to Step 4 .
NO : Intermittent malfunction in CAN busline
shooting/Inspection Service Points − How to
between engine-ECU and ASTC-ECU
Cope with Intermittent Malfunctions ). The diag-
(Refer to GROUP 00 − How to Use
nosis codes being output to each ECU with CAN
communication can narrow down the most sus-
How to Cope with Intermittent Malfunction ).
pected area. (Refer to GROUP 54C − Explana-
tion About The M.U.T.-III Can Bus Diagnostics ).
STEP 4. Replace the ASTC-ECU
PROBABLE CAUSE • After replacing the ASTC-ECU, re-check the
• Failed of the harness and the connector diagnosis code output.
• Failed ASTC-ECU Q: Is the diagnosis code output?
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III CAN bus diagnostics Writing ). After replacing the engine-ECU,
• Using M.U.T.-III, perform CAN busline diagnosis. register the injector identification code and
NO : Correct CAN busline (Refer to GROUP 54C Common Rail Engine Learns ). After
− Diagnosis − Can Bus Diagnostic Chart ), registering the injector identification code,
and then go to Step 4 . the vehicle equipped with the DPF carries
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-423
Code No. U1109: ETACS-ECU Time-out
CAUTION PROBABLE CAUSES

If Diagnosis Code U1109 is output from engine- • Failed of the harness and the connector
ECU surely perform CAN busline diagnosis. • Failed ETACS-ECU
CAUTION
Replace ECU after certainly confirming that the DIAGNOSIS PROCEDURE
NOTE: When the diagnosis codes relating to the
CAN communication error are output, make sure of STEP 1. M.U.T.-III CAN bus diagnosis
the vehicle equipment. When the vehicle is not • Using M.U.T.-III, perform CAN busline diagnosis.
equipped with the system the engine-ECU communi- Q: Is the check result normal?
cates to, the diagnosis code is always output. This is YES : Go to Step 2 .
not abnormal. NO : Correct CAN busline (Refer to GROUP 54C
TROUBLE JUDGMENT − Troubleshooting − CAN Bus Diagnosis
Check Condition
• The diagnosis code setting enabled signal is
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received from ETACS-ECU. STEP 2. M.U.T.-III other system diagnosis codes.
Judgment Criterion
from ETACS-ECU.
• The signals cannot be received from ETACS-
ECU for 0.5 second or more. Q: Is the diagnosis code output?
YES : Perform the troubleshooting of ETACS-ECU
COMMENT ON TROUBLE SYMPTOM (Refer to GROUP 54B − Diagnostic Code
Chart )
Current malfunction
NO : Go to Step 3 . <A/T>
• The failure is possibly caused by malfunction of
NO : Go to Step 5 . <M/T>
the harness and connector in CAN busline
between engine-ECU and ETACS-ECU by mal-
function in the power supply system of ETACS- STEP 3. M.U.T.-III other system diagnosis codes.
ECU, in ETACS-ECU itself, in engine-ECU. • Confirm whether Diagnosis Code U1109:
ETACS-ECU time out is output from the following
Past malfunction ECU having CAN communication with automatic
• Focus on diagnosing malfunction of the harness transmission.
a. A/T-ECU
ECU and ETACS-ECU as well as malfunction in
the power supply system of ETACS-ECU. Refer Q: Is the diagnosis code output?
to past trouble (Refer to GROUP 00 − How to YES : Go to Step 4 .
Use Troubleshooting/Inspection Service Points − NO : Go to Step 5 .
How to Treat Past Trouble ) for the diagnosis pro-
cedure. STEP 4. Reconfirmation of diagnosis codes
NOTE: In case of Past trouble, M.U.T.-III CAN bus • Reconfirm whether the diagnosis codes are out-
diagnosis cannot detect the failure even if there is put from engine-ECU
malfunction in CAN bus, so that check CAN 1. Erase the diagnosis codes being output.
busline in the same way as Intermittent malfunc- 2. Ignition switch: "LOCK" (OFF) to ON
tion (Refer to GROUP 00 − How to Use Trouble- 3. Confirm whether the diagnosis codes are output.
shooting/Inspection Service Points − How to
Cope with Intermittent Malfunctions ). The diag- Q: Is the diagnosis code output?
nosis codes being output to each ECU with CAN
communication can narrow down the most sus-
pected area (Refer to GROUP 54C − Can Bus
Diagnosis Table ).
13A-424 DIESEL FUEL
TROUBLESHOOTING
YES : After replacing the ETACS-ECU, go to Step YES : Replace the engine-ECU. When the engine-
6. ECU is replaced, write the chassis number
NO : Intermittent malfunction in CAN busline (Refer to GROUP 00 − Precautions Before
between engine-ECU and ETACS-ECU Service − How to Perform Chassis Number
(Refer to GROUP 00 − How to Use Writing ). After replacing the engine-ECU,
Troubleshooting/Inspection Service Points − register the injector identification code and
How to Cope with Intermittent Malfunctions learn fuel injection (Refer to GROUP 00 −
). Precautions Before Service − What The
STEP 5. Reconfirmation of diagnosis codes registering the injector identification code,
• Reconfirm whether the diagnosis codes are out- the vehicle equipped with the DPF carries
put from engine-ECU out the forcible DPF regeneration. (Refer to
2. Ignition switch: "LOCK" (OFF) to ON DPF Regeneration ). and then go to Step 6
3. Confirm whether the diagnosis codes are output. .
Q: Is the diagnosis code output? NO : Intermittent malfunction in CAN busline
between engine-ECU and ETACS-ECU
(Refer to GROUP 00 − How to Use
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How to Cope with Intermittent Malfunctions
).

put from engine-ECU
Code No. U1110: A/C-ECU Time-out <Euro5>
CAUTION TROUBLE JUDGMENT

If Diagnosis Code U1110 is output from engine- Check Conditions
ECU surely perform CAN busline diagnosis. • Ignition switch is in "ON" position.
CAUTION Judgment Criterion
Replace ECU after certainly confirming that the • The signals cannot be received from A/C-ECU for
communication circuits are normal. 0.5 second or more.
NOTE: When the diagnosis codes relating to the
CAN communication error are output, make sure of COMMENT ON TROUBLE SYMPTOM
the vehicle equipment. When the vehicle is not Current malfunction
equipped with the system the engine-ECU communi- • The failure is possibly caused by malfunction of
cates to, the diagnosis code is always output. This is the harness and connector in CAN busline
not abnormal. between engine-ECU and A/C-ECU, by malfunc-
tion in the power supply system of A/C-ECU, in A/
C-ECU itself, in engine-ECU.
DIESEL FUEL
TROUBLESHOOTING
13A-425
Past malfunction YES : Go to Step 4 .
• Focus on diagnosing malfunction of the harness NO : Go to Step 5 .
ECU and A/C-ECU as well as malfunction in the STEP 4. Reconfirmation of diagnosis codes
power supply system of A/C-ECU. Refer to past • Reconfirm whether the diagnosis codes are out-
trouble (Refer to GROUP 00 − How to Use Trou- put from engine-ECU
bleshooting/Inspection Service Points − How to 1. Erase the diagnosis codes being output.
Treat Past Trouble ) for the diagnosis procedure.
NOTE: In case of Past trouble, M.U.T.-III CAN bus 3. Confirm whether the diagnosis codes are output.
diagnosis cannot detect the failure even if there is
malfunction in CAN bus, so that check CAN Q: Is the diagnosis code output?
busline in the same way as Intermittent malfunc- YES : After replacing the A/C-ECU, go to Step 6 .
tion (Refer to GROUP 00 − How to Use Trouble- NO : Intermittent malfunction in CAN busline
shooting/Inspection Service Points − How to between engine-ECU and A/C-ECU (Refer
Cope with Intermittent Malfunctions ). The diag- to GROUP 00 − How to Use
nosis codes being output to each ECU with CAN Troubleshooting/Inspection Service Points −
communication can narrow down the most sus- How to Cope with Intermittent Malfunctions
pected area (Refer to GROUP 54C − Trouble- ).
shooting − Can Bus Diagnostics Table ).
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PROBABLE CAUSES • Reconfirm whether the diagnosis codes are out-
• Failed of the harness and the connector put from engine-ECU
• Failed A/C-ECU
DIAGNOSIS PROCEDURE 3. Confirm whether the diagnosis codes are output.
STEP 1. M.U.T.-III CAN bus diagnosis
Q: Is the check result normal? Service − How to Perform Chassis Number
YES : Go to Step 2 . Writing ). After replacing the engine-ECU,
NO : Correct CAN busline (Refer to GROUP 54C register the injector identification code and
− Troubleshooting − CAN Bus Diagnostics learn fuel injection (Refer to GROUP 00 −
Table ), and then go to Step 6 . Precautions Before Service − What The
STEP 2. M.U.T.-III other system diagnosis codes. registering the injector identification code,
• Confirm whether the diagnosis codes are output carry out the forcible DPF regeneration.
from A/C-ECU. (Refer to GROUP 17 − Emission Control −
Q: Is the diagnosis code output? Forcible DPF Regeneration ). and then go
YES : Perform the troubleshooting of A/C-ECU to Step 6 .
(Refer to GROUP 55B − Troubleshooting − NO : Intermittent malfunction in CAN busline
Diagnostics Chart ). between engine-ECU and A/C-ECU (Refer
NO : Go to Step 3 . to GROUP 00 − How to Use
STEP 3. M.U.T.-III other system diagnosis codes. How to Cope with Intermittent Malfunctions
• Confirm whether Diagnosis Code U1110: A/C- ).
ECU time out is output from the following ECU
having CAN communication with automatic trans-
mission.
a. ETACS-ECU
13A-426 DIESEL FUEL
TROUBLESHOOTING
put from engine-ECU
Code No. U1117 ETACS-ECU (Immobilizer-ECU) Time-out
CAUTION CAUTION
If Diagnosis Code U1117 is output from engine-
ECU surely perform CAN busline diagnosis. Acc position
On position
CAUTION
Range
Replace ECU after certainly confirming that the Lock (off) "A"
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position
NOTE: When the diagnosis codes relating to the Start
CAN communication error are output, make sure of position
the vehicle equipment. When the vehicle is not
equipped with the system the engine-ECU communi-
cates to, the diagnosis code is always output. This is AK503593 AB
not abnormal. When the ignition key is maintained within the

TROUBLE JUDGMENT range "A" (i.e., the ignition switch IG2 is in OFF
position but the cranking does not start) for more
Check Condition
than 1 second, engine-ECU stores diagnosis
code U1117 (the past trouble).
Judgment Criterion NOTE: In case of Past trouble, M.U.T.-III CAN bus
• The signal from the ETACS-ECU is not received diagnosis cannot detect the failure even if there is
for 0.5 second or more. malfunction in CAN bus, so that check CAN busline
in the same way as Intermittent malfunction (Refer to
COMMENT ON TROUBLE SYMPTOM
GROUP 00 − How to Use Troubleshooting/Inspec-
Current malfunction tion Service Points − How to Cope with Intermittent
• The failure is possibly caused by malfunction of Malfunctions ). The diagnosis codes being output to
the harness and connector in CAN busline each ECU with CAN communication can narrow
between engine-ECU and ETACS-ECU, by mal- down the most suspected area. (Refer to GROUP
function in the power supply system of ETACS- 54C − Explanation About The M.U.T.-III Can Bus
ECU, in ETACS-ECU itself, in engine-ECU. Diagnostics ).
Past malfunction PROBABLE CAUSE
• Focus on diagnosing malfunction of the harness • Failed of the harness and the connector
and connector in CAN busline between engine- • Failed engine-ECU
ECU and ETACS-ECU as well as malfunction in • Failed ETACS-ECU
the power supply system of ETACS-ECU (Refer
to GROUP 00 − How to Use Troubleshooting/
DIAGNOSIS PROCEDURE
Inspection Service Points − How to Cope with
Intermittent Malfunctions ).
STEP 1. M.U.T.-III CAN bus diagnostics
DIESEL FUEL
TROUBLESHOOTING
13A-427
YES : Go to Step 2 . YES : Replace the engine-ECU. When the engine-
NO : Correct CAN busline (Refer to GROUP 54C ECU is replaced, write the chassis number
− Diagnosis − Can Bus Diagnostic Chart ), (Refer to GROUP 00 − Precautions Before
and then go to Step 3 . Service − How to Perform Chassis Number
STEP 2. M.U.T.-III other system diagnosis codes
from ETACS-ECU.
Q: Is the diagnosis code output? registering the injector identification code,
YES : Perform the troubleshooting of immobilizer the vehicle equipped with the DPF carries
system (Refer to GROUP 54A − Immobilizer out the forcible DPF regeneration. (Refer to
System − Check Chart for Diagnosis Code ). GROUP 17 − Emission Control − Diesel
NO : Go to Step 3 . Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 3. M.U.T.-III diagnosis code NO : Intermittent malfunction in CAN busline
• Reconfirm whether the diagnosis codes are out- between engine-ECU and ETACS-ECU
put from engine-ECU (Refer to GROUP 00 − How to Use
1. Erase the diagnosis codes being output. Troubleshooting/Inspection Service Points −
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How to Cope with Intermittent Malfunction ).
3. Confirm whether the diagnosis codes are out-
put.
Code No.U1190: The Network System Diagnosis Code Output Permitted Signal Can Not Be Received
TROUBLE JUDGMENT DIAGNOSIS PROCEDURE

Check Condition
• Ignition switch is in "ON" position STEP 1. M.U.T.-III CAN bus diagnostics
Judgment Criterion • Using M.U.T.-III perform the CAN buslines diag-
• The diagnosis enable signal from the ETACS- nosis.
ECU about the abnormal CAN is not received at Q: Is the check result normal?
all for 5 seconds or more after the ignition switch YES : Go to Step 2 .
is on. NO : Repair the CAN busline (Refer to GROUP
54C − Troubleshooting Can Bus
COMMENT ON TROUBLE SYMPTOM
Diagnostics Table ), and then go to Step 3 .
• The ETACS-ECU sends the permitted / not per-
mitted signals for detecting the diagnosis code
(U-code) to each ECU connected with the CAN STEP 2. M.U.T.-III diagnosis code.
busline. When the engine-ECU cannot receive • Reconfirm whether the diagnosis codes are out-
the permitted / not permitted signals for detecting put from engine-ECU.
the diagnosis code (U-code) for 5seconds, the 1. Erase the diagnosis codes being output.
diagnosis code No. U1190 is stored. 2. Ignition switch: "LOCK" (OFF) to "ON".
PROBABLE CAUSES
• Failed ETACS-ECU Q: Are the diagnosis codes output?
• Failed CAN bus YES : Replace the ETACS-ECU, and then go to
• Failed engine-ECU Step 3 .
NO : Check end.
13A-428 DIESEL FUEL
TROUBLESHOOTING
NO : Check end.
put from engine-ECU.
2. Ignition switch: "LOCK" (OFF) to "ON".
Q: Are the diagnosis codes output?
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1133004100754
Items Trouble symptom Inspection

procedure
No.
Communication Communication with engine-ECU is not possible 1
with M.U.T.-III
Engine warning The engine warning lamp does not illuminate right after the ignition switch 2
lamp is turned the "ON" position
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The engine warning lamp remains illuminating and never goes out or is 3
blinking
Starting The starter is impossible to operate. 4
Starting impossible The starter is operative and cranks 5
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting improper It is long cranking to start the engine. 6
(Long time to start)
Improper idling The proper idling speed is not satisfied. 7
Engine stalls The engine stalls when The engine stalls at the deceleration. 8
decelerating
Driving Poor acceleration The engine cannot obtain the 9
acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
A large amount of fuel Compared with before, the fuel 10
consumption consumption is dramatically
increased.
Knocking, Knocking Sharp sound like a hammer striking 11
Abnormal noise on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Abnormal noise Abnormal noise during the engine
operation. (It is presumed that this is
caused by malfunction over the wide
range.)
DIESEL FUEL
TROUBLESHOOTING
13A-429
Items Trouble symptom Inspection
procedure
No.
Exhaust gas White smoke Exhaust gases are extraordinarily 12
white.
Black smoke Exhaust gases are extraordinarily 13
black.
Charging Battery rundown The battery is soon rundown or the 14
performance charging ability of battery is small.
Cooling Overheating The temperature of engine cooling 15
performance water is extremely high.
PROBLEM SYMPTOMS TABLE

Inspection Trouble symptom Reference page
procedure
No.
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1 Communication with engine-ECU is not possible P.13A-433
2 The engine warning lamp does not illuminate right after the ignition P.13A-438
switch is turned the "ON" position
3 The engine warning lamp remains illuminating and never goes out or P.13A-441
is blinking
4 The starter is impossible to operate <M/T> P.13A-445
The starter is impossible to operate <A/T> P.13A-453
5 Starting impossible (Starter operative but no initial combustion) P.13A-462
6 Improper starting (Long time to start) P.13A-464
7 Improper idling P.13A-466
8 The engine stalls when decelerating P.13A-468
9 Poor acceleration P.13A-471
10 A large amount of fuel consumption P.13A-473
11 Knocking, Abnormal noise P.13A-475
12 White smoke P.13A-477
13 Black smoke P.13A-479
14 Battery rundown <Euro5> P.13A-481
Battery rundown <Except Euro5> P.13A-486
15 Overheating P.13A-487
16 Engine-ECU power supply system P.13A-488
17 Engine-ECU battery back-up system P.13A-493
18 1st and 2nd rail switch system <M/T> P.13A-497
19 Back-up lamp switch system <M/T> P.13A-501
20 4LLC switch system <M/T-high power engine vehicle> P.13A-505
21 Condenser fan relay system <Vehicles with A/C condenser fan> P.13A-507
22 A/C switch system P.13A-509
13A-430 DIESEL FUEL
TROUBLESHOOTING
Inspection Trouble symptom Reference page

procedure
No.
23 A/C compressor relay system P.13A-512
24 Power steering fluid pressure switch system P.13A-514
25 Glow system <Except Euro5> P.13A-520
26 PTC heater relay system <Vehicles with PTC heater> P.13A-525
27 Blower switch system <Euro5> P.13A-528
28 Rear window defogger system <Euro5> P.13A-533
29 DPF lamp system <Euro5> P.13A-537
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DIESEL FUEL
TROUBLESHOOTING
13A-431
CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS
M1133604700134
Communication with engine-ECU is not possible
The engine warning lamp does not illuminate right after the
goes out or is blinking
The engine warning lamp remains illuminating and never
The starter is impossible to operate
Starting impossible (Starter operative but no initial combustion)
Starting impossible (Long time to start)
Improper idling
The engine stalls when decelerating
Poor acceleration
A large amount of fuel consumption
Knocking, Abnormal noise
White smoke
Black smoke
Battery rundown
Overheating
ignition switch is turned the "ON" position
Trouble symptoms
Probable causes
Diagnosis connector circuit
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Engine warning lamp
Engine warning lamp circuit
Starter motor
Starter motor relay
Starting system related circuit
Battery
Inhibitor switch
Engine control relay
Engine-ECU power supply circuit
Engine-ECU
Glow system
Timing chain torn
Valve clearance
Compression pressure
Common rail assembly
Suction control valve
Supply pump
Supply pump correction learning
Fuel filter clogged
Fuel line leaking or clogged
Mixing of air with fuel
Improper fuel
Engine oil
Air cleaner clogged
Electronic-controlled throttle valve
EGR system
EGR port clogged
Turbocharger
Injector
Injector identification code registration
Small injection quantity learning
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Engine coolant temperature sensor
Manifold absolute pressure sensor
Accelerator pedal position sensor
Throttle position sensor
Fuel pressure sensor
Engine cooling system
Alternator
AK503602
13A-432 DIESEL FUEL
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with Engine-ECU Is Not Possible
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DIESEL FUEL
TROUBLESHOOTING
13A-433
CAN Communication Circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Engine-ECU
116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Fusible link 20
108 109
R B W
9*¹ or 20*¹ or C-213

10*² 21*² 1
J/C (CAN 2) 12
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C-01 J/B
15A
11 22 13
C-208
R B
C-53*¹ or
6 7 C-35*²
R B
W-B
11 22
J/C (CAN 1)
C-119
10 21
R-L B-L
C-22
MU803797 6 14 16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
4 5
Diagnosis connector
B B
NOTE
Wire colour code
AKA00111AB

• The M.U.T.-III receives data from the engine-ECU • Damaged connector (Engine-ECU connector,
via the CAN bus line. diagnosis connector)
13A-434 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open or short circuit in the DIAGNOSIS PROCEDURE

engine-ECU power supply circuit, open circuit
between diagnosis connector and J/B connector,
and open circuit between diagnosis connector STEP 1. Check the V.C.I. indicator lamp
and earth) illuminates.
• Failed CAN bus line <L.H. drive vehicles>
• Failed M.U.T.-III
Diagnosis
connector
MB991910
MB991824
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MB991827
<R.H. drive vehicles> Diagnosis
connector
MB991910
MB991824
MB991827 AK600277 AC
• Connect the M.U.T.-III to the diagnosis connector.

Q: Is the V.C.I. indicator lamp illuminates in a green
colour?
YES : CAN bus diagnosis (Refer to GROUP 54C −
Troubleshooting − Can Bus Diagnosis Table
).
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-435
STEP 2. Connector check: C-22 diagnosis STEP 3. Perform voltage measurement for open
connector circuit at C-22 diagnosis connector.
C-22 (B) C-22 (B)
C-22 (B) C-22 (B)
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1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10111213 141516 9 10111213 141516
Harness side connector Harness side connector

AK700805 AB AK700805 AB

YES : Go to Step 3 . OK: System voltage
NO : Repair or replace. Q: Is the check result normal?
NO : Repair harness between C-22 (terminal No.
16) diagnosis connector and C-208
(terminal No. 13) J/B connector.
13A-436 DIESEL FUEL
TROUBLESHOOTING
YES : Refer to M.U.T.-III User’ s Manual −

STEP 4. Check for open circuit between
Troubleshooting Procedures.
diagnosis connector C-22 and earth.
NO : Repair harness between diagnosis
Connector: C-22 connector and body earth.
C-22 (B)
C-22 (B)
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1 2 3 4 5 6 7 8
9 10111213 141516

AK700805 AB
• Disconnect connector.
• Check open circuit between terminal No. 4 and
earth also between terminal No. 5 and earth.
DIESEL FUEL
TROUBLESHOOTING
13A-437
Inspection Procedure 2: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
Is Turned the "ON" Position
Engine Warning Lamp (check engine lamp) Circuit
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
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6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00284 AB
13A-438 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 3. Connector check: C-105 Engine-ECU

• Engine-ECU turn on engine warning lamp for 5 connector and C-111 combination meter
seconds to check for burnt-out bulb immediately connector.
after ignition switch is turned to ON.
Connector: C-105
• Damaged connector (Engine-ECU connector,
combination meter connector)
• Damaged harness (Open circuit between engine-
ECU and combination meter)
• Failed combination meter
DIAGNOSIS PROCEDURE
STEP 1. Check indicator illumination.

Q: Does an indicator other than the engine warning
lamp illuminate?
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NO : Inspect combination meter and related
C-105 (B)
circuits (Refer to GROUP 54A −
Combination Meter − Check Chart for
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Trouble Symptoms ). 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Inspection chart for diagnosis code (Refer Connector: C-111
to P.13A-21). <L.H. drive vehicles>
NO : Go to Step 3 .
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

NO : Repair or replace.
DIESEL FUEL
TROUBLESHOOTING
13A-439
STEP 4. Perform resistance measurement for • Resistance between C-105 engine-ECU connec-
open circuit at between C-105 engine-ECU tor terminal No. 46 and C-111 combination con-
connector and C-111 combination meter nector terminal No. 63.
connector. OK: Continuity (2 Ω or less)
Connector: C-105 Q: Is the check result normal?
<L.H. drive vehicles> YES : Go to Step 5 .
NO : Check the intermediate connector C-53 <L.
H. drive vehicles>, C-35 <R. H. drive
vehicles>, and repair if necessary. If
intermediate connector is normal, repair the
harness wire.
C-105 (B)
STEP 5. Check the trouble symptoms.
<R.H. drive vehicles> Q: Does trouble symptom persist?
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C-105 (B) learn fuel injection (Refer to GROUP 00 −
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector out the forcible DPF regeneration. (Refer to

AKA00089 AB
Connector: C-111 Particulate Filter (DPF) System − Forcible
<L.H. drive vehicles> DPF Regeneration ).
C-111 00 − How to Use Troubleshooting/
with Intermittent Malfunction ).
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
• Disconnect C-105 engine-ECU connector and C-

111 combination meter connector, and measure
resistance at the wiring harness.
13A-440 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Remains Illuminating and Never Goes Out or Is
Blinking.
Engine Warning Lamp (check engine lamp) Circuit
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
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6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00284 AB
DIESEL FUEL
TROUBLESHOOTING
13A-441
OPERATION STEP 3. Connector check: C-105 engine-ECU
• Engine-ECU has detected failed sensor or failed connector and C-111 combination meter
actuator. Or failure is possibly caused by short connector
circuit or other faults.
Connector: C-105
combination meter connector)
• Damaged harness (Short circuit between engine-
ECU and combination meter)
DIAGNOSIS PROCEDURE
STEP 1. Check the illuminating condition of the

engine warning lamp.
Q: Is the engine warning lamp blinking?
YES : Carry out the small injection quantity
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learning procedure (Refer to GROUP 00 −
C-105 (B)
Precautions Before Service − Small
Injection Quantity Learning Procedure ). 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Go to Step 2 . 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Inspection chart for diagnosis code (Refer Connector: C-111
to P.13A-21). <L.H. drive vehicles>
NO : Go to Step 3 .
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

13A-442 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-111 54A − Combination Meter − Check Chart for
Trouble Symptoms ).
C-111
C-111
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57 56 55 54 53 52 51
64 63 62 61 60 59 58
• Disconnect C-111 combination meter connector
Q: Does the engine warning lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-443
STEP 5. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
STEP 6. Check injector identification code.

• Check injector identification code (Refer to
GROUP 00 − Precautions Before Service − Injec-
tor Identification code Registration Procedure ).
NO : Register the injector ID.
STEP 7. Small injection quantity learning.

• Carry out the small injection quantity learning
procedure (Refer to GROUP 00 − Precautions
Before Service − Small Injection Quantity Learn-
ing Procedure ).
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB Writing ). After replacing the engine-ECU,

Connector: C-111
C-111
DPF Regeneration ).
NO : The procedure is complete.
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

side.
• Disconnect C-111 combination meter connector.
13A-444 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 4: Starting Impossible (No Initial Combustion) <M/T>
Starting Impossible (no initial combustion) <M/T>
Battery Fusible link 3 Ignition switch

C-307
LOCK
ACC
1 2 3
ST
IG1 IG2 4 5 6
R-B
C-207
2
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J/B
7.5A
5
C-211
W
R-B
B-R A-115
11
A-115
10
B-Y
A-16X
4 2
1 2
3 OFF Starter
relay
4 ON
3 1
B
B-L
B-L
6
A-27 A-115
B-W 8
1 1 G-R C-103
OFF 111 103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
A-10 ON A-110
(MU801211) 116 117
1 131132133134135136137138139140 141142143
1 144 145 146147148149150151152153154155156 157158
Engine-ECU
Starter
Wire colour code

AKB00285 AB
DIESEL FUEL
TROUBLESHOOTING
13A-445
COMMENT ON TROUBLE SYMPTOM STEP 3. Connector check: A-16X starter relay
• Failure is possibly caused by failed starter itself connector
or failed related circuit.
Connector: A-16X
PROBABLE CAUSES
• Failed battery
• Failed starter motor
• Failed starter relay
• Open/short circuit in starter associated circuit or
A-16X
loose connector contact 2 1
• Failed engine-ECU 3
4
DIAGNOSIS PROCEDURE Relay box's side connector AK501014 AC

STEP 1. Check battery voltage. YES : Go to Step 4.
• Measure battery voltage at cranking. NO : Repair or replace.
OK: 8 V or higher
Q: Is the check result normal? STEP 4. Check starter relay.
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YES : Go to Step 2. • Check starter relay (Refer to GROUP 16 − Start-
NO : Check battery (Refer to GROUP 54A − ing System − Starter Relay Check )
Battery − On-vehicle Service − Battery Test Q: Is the check result normal?
). YES : Go to Step 5.
NO : Replace the starter relay.
• Item 40: Starter switch STEP 5. Perform voltage measurement at A-16X
OK: starter relay connector.
ON (Ignition switch: ST)
Connector: A-16X
OFF (Ignition switch: ON)
NO : Go to Step 3.
A-16X
2 1
3
4
Relay box's side connector AK501014 AC
• Disconnect connector, and measure at the har-

ness side.
• Ignition switch: ST
OK: System voltage
YES : Go to Step 8.
NO : Go to Step 6.
13A-446 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Connector check: C-307 ignition switch STEP 7. Check ignition switch.
connector
Connector: A-16X
Connector: C-307
A-16X
C-307 2 1
3
4
<R.H. drive vehicles> Connector: C-307

C-307
C-307
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3 2 1 <R.H. drive vehicles>
6 5 4
Harness side connector AKB00286 AB

YES : Go to Step 7. C-307
3 2 1
6 5 4
• Check ignition switch (Refer to GROUP 54A −

Ignition Switch − Inspection ).
YES : Check intermediate connectors A-115, C-
207 and C-211, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between A-16X (terminal
No. 2) starter relay connector and C-307
(terminal No. 5) ignition switch connector.
short circuit.
NO : Replace the ignition switch.
DIESEL FUEL
TROUBLESHOOTING
13A-447
STEP 8. Perform voltage measurement at A-16X STEP 10. Connector check: A-110 starter
starter relay connector. connector
Connector: A-16X Connector: A-110
A-110 (B)
A-16X
2 1
3
4 1
Relay box's side connector Harness side connector AK700920 AB
AK501014 AC
• Disconnect connector, and measure at the har- Q: Is the check result normal?
ness side. YES : Go to Step 11.
• Voltage between terminal No. 4 and earth. NO : Repair or replace.
OK: System voltage
Q: Is the check result normal? STEP 11. Check harness between A-110 (terminal
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YES : Go to Step 9. No. 1) starter connector and A-16X (terminal No.
NO : Check and repair harness between A16X 3) starter relay connector.
(terminal No. 4) starter relay connector and
battery. Connector: A-110
• Check power supply line for open/ A-110 (B)
short circuit.

16X starter relay connector.
Connector: A-16X 1
Connector: A-16X
A-16X
2 1
3
4
Relay box's side connector AK501014 AC A-16X
2 1
• Disconnect connector, and measure at harness 3
side. 4
• Resistance between terminal No. 1 and earth. Relay box's side connector AK501014 AC
OK: Continuity (2Ω or less)
Q: Is the check result normal? connector A-27, and repair if necessary.
YES : Go to Step 10. • Check output line for open/short circuit.
NO : Check and repair harness between A16X
(terminal No. 1) starter relay connector and Q: Is the check result normal?
body earth.
• Check earth line for open circuit and
damage.
13A-448 DIESEL FUEL
TROUBLESHOOTING
STEP 12. Connector check: C-103 engine-ECU STEP 13. Connector check: A-110 starter
connector connector
Connector: C-103 Connector: A-110
A-110 (B)
C-103 (B) 1

cardiagn.com
C-103 (B) starter connector.
Connector: A-110
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
A-110 (B)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-16X
1

A-16X ness side.
2 1 • Ignition switch: ST
3
4
OK: System voltage
Q: Is the check result normal? YES : Go to Step 16.
YES : Check intermediate connector A-115, and NO : Go to Step 15.
harness between C-103 (terminal No. 111)
starter connector and A-16X (terminal No.
3) starter relay connector.
DIESEL FUEL
TROUBLESHOOTING
13A-449
STEP 15. Connector check: A-16X starter relay STEP 16. Connector check: A-10 starter
connector connector
A-10
A-16X
2 1
3
4 1
AK501014 AC

A-110 (B)
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starter connector.
Connector: A-10
1
A-10

1
harness between A-16X (terminal No. 3)
stater relay connector and A-110 (terminal Harness side connector AK700921 AB
No. 1) starter connector. • Disconnect connector, and measure at the har-
• Check output line for open circuit and ness side.
damage. • Voltage between terminal No. 1 and earth.
OK: System voltage
(terminal No. 1) starter connector and
battery.
short circuit.
13A-450 DIESEL FUEL
TROUBLESHOOTING
STEP 18. Connector check: A-16X starter relay STEP 19. Check harness between C-307 (terminal
connector and C-307 Ignition switch connector No. 5) ignition switch connector and A-16X
(terminal No. 2) starter relay connector.
Connector: A-16X
Connector: C-307
A-16X
2 1 C-307
3
4

C-307
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C-307
<R.H. drive vehicles> 3 2 1

6 5 4
Connector: A-16X
C-307
3 2 1 A-16X
2 1
6 5 4 3
4
YES : Go to Step 19. NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-451
STEP 20. Check harness between A-16X
battery
Connector: A-16X
No. 1) starter connector and battery.
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
1
• Check power supply line for damage. Harness side connector AK700920 AB
NO : Repair the damaged harness wire. Q: Is the check result normal?
YES : Replace the starter.
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(terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter relay connector
Connector: A-16X
A-16X
2 1
3
4
Connector: A-110
A-110 (B)
1

13A-452 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 4: Starting Impossible (No Initial Combustion) <A/T>
Starting Impossible (no initial combustion) <A/T>
Battery Fusible link 3 Ignition switch

C-307
LOCK
1 2 3
ST ACC 4 5 6
IG1 IG2
5
R-B
C-207
2
4
J/B
7.5A
C-211
5
R-B
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A-115
11
W R-B
B-10
5
R-B
10 B-14
MU802645
B-R
Inhibitor P 1 2 3 4 5
switch
R 6 7 8 9 10
D N
9
B-Y
B-10
6
B-Y
A-115
10
A-16X B-Y
4 2
1 2
3 OFF Starter
ON
relay
4
3 1
B-L B
B-L
6 A-115
A-27 8
B-W
1 1 G-R C-103
111
103104105106107108109110 111112113 114115
A-110 101 102 118119120121122123124125126127128 129130
ON
A-10 OFF (MU801211) 116 117
1 1 131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Engine-ECU
Starter
Wire colour code
R: Red P: Pink V: Violet PU: Purple AKB00287 AB
DIESEL FUEL
TROUBLESHOOTING
13A-453
COMMENT ON TROUBLE SYMPTOM STEP 4. Check starter relay
• Failure is possibly caused by failed starter itself • Check starter relay (Refer to GROUP 16 − Start-
or failed related circuit. ing System − Starter Relay Check ).
PROBABLE CAUSES Q: Is the check result normal?
• Failed battery YES : Go to Step 5.
• Failed inhibitor switch NO : Replace the starter relay.
• Failed starter motor
• Failed starter relay STEP 5. Perform voltage measurement at A-16X
• Open/short circuit in starter associated circuit or starter relay connector.
• Failed engine-ECU Connector: A-16X
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage.

A-16X
• Measure battery voltage at cranking. 2 1
OK: 8 V or higher 3
4
cardiagn.com
Q: Is the check result normal? Relay box's side connector
YES : Go to Step 2. AK501014 AC
NO : Check battery (Refer to GROUP 54A − • Disconnect connector, and measure at the har-
Battery-On-vehicle Service − Battery Test ). ness side.
• Item 40: Starter switch OK: System voltage
OK: Q: Is the check result normal?
ON (Ignition switch: ST) YES : Go to Step 11.
OFF (Ignition switch: ON) NO : Go to Step 6.

YES : Go to Step 17. STEP 6. Connector check: B-14 inhibitor switch
NO : Go to Step 3. connector
Connector: B-14
5 4 3 2 1
STEP 3. Connector check: A-16X starter relay
10 9 8 7 6
connector
Harness side
Connector: A-16X connector
B-14 (B)
A-16X AK700823AB
2 1
3
4
YES : Go to Step 7.
Relay box's side connector AK501014 AC NO : Repair or replace.

YES : Go to Step 4. STEP 7. Check inhibitor switch
NO : Repair or replace. • Check inhibitor switch (Refer to GROUP 23A −
On-vehicle Service − Inhibitor Switch Continuity
Check ).
YES : Go to Step 8. NO : Replace the inhibitor switch.
13A-454 DIESEL FUEL
TROUBLESHOOTING
STEP 8. Perform voltage measurement at B-14 STEP 9. Connector check: C-307 ignition switch
inhibitor switch connector connector
Connector: B-14 Connector: C-307
5 4 3 2 1 <L.H. drive vehicles>
10 9 8 7 6
Harness side
connector
C-307
B-14 (B)
AK700823AB
Connector: A-16X
C-307
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A-16X
2 1
3
4
Relay box's side connector AK501014 AC 3 2 1
• Disconnect connector, and measure at the har- 6 5 4
ness side. Harness side connector AKB00286 AB
OK: System voltage YES : Go to Step 10.
YES : Check intermediate connectors A-115 and
B-10, and repair if necessary. If starter relay
connector are normal, check and repair
starter relay connector and B-14 (terminal
No. 9) inhibitor switch connector.
short circuit.
NO : Go to Step 9.
DIESEL FUEL
TROUBLESHOOTING
13A-455
STEP 10. Check ignition switch STEP 11. Perform voltage measurement at A-16X
Connector: B-14
starter relay connector.
5 4 3 2 1
Connector: A-16X
10 9 8 7 6
Harness side
connector
A-16X
B-14 (B) 2 1
3
4
AK700823AB
Connector: C-307
<L.H. drive vehicles> • Disconnect connector, and measure at the har-
ness side.
OK: System voltage
C-307
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NO : Check and repair harness between A-16X
battery.
<R.H. drive vehicles> • Check power supply line for open/
short circuit.

16X starter relay connector.
C-307
Connector: A-16X
3 2 1
6 5 4
A-16X
Harness side connector 2 1
AKB00286 AB
3
• Check ignition switch (Refer to GROUP 54A − 4
Ignition switch − Inspection ). Relay box's side connector AK501014 AC

YES : Check intermediate connectors A-115, B- side.
10, C-207 and C-211, and repair if • Resistance between terminal No. 1 and earth.
necessary. If starter relay connectors are
OK: Continuity (2Ω or less)
normal, check and repair harness between
B-14 (terminal No. 10) inhibitor switch Q: Is the check result normal?
connector and C-307 (terminal No. 5) YES : Go to Step 13.
ignition switch connector. NO : Check and repair harness between A-16X
• Check power supply line for open/ (terminal No. 1) starter relay connector and
short circuit. body earth.
NO : Replace the ignition switch. • Check earth line for open circuit and
damage.
13A-456 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Connector check: A-16X starter relay STEP 15. Check harness between A-110 (terminal
connector No. 1) starter connector and A-16X (terminal No.
Connector: A-16X
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
1
YES : Go to Step 14. Connector: A-16X
STEP 14. Connector check: A-110 starter
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connector
A-16X
Connector: A-110 2 1
A-110 (B) 3
4

• Check output line for open/short circuit.
1
AK700920 AB YES : Go to Step 16.
DIESEL FUEL
TROUBLESHOOTING
13A-457
STEP 16. Connector check: C-103 engine-ECU STEP 17. Connector check: A-110 starter
connector. connector
Connector: C-105 Connector: A-110
A-110 (B)
C-105 (B)
1
cardiagn.com
C-105 (B) starter connector.
Connector: A-110
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 A-110 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-16X
1

A-16X ness side.
2 1 • Ignition switch: ST
3
4
OK: System voltage
Q: Is the check result normal? YES : Go to Step 20.
YES : Check intermediate connector A-115, and NO : Go to Step 19.
starter connector and A-16X (terminal No.
13A-458 DIESEL FUEL
TROUBLESHOOTING
STEP 19. Connector check: A-16X starter relay STEP 20. Connector check: A-10 starter
connector connector
A-10
A-16X
2 1
3
4 1
AK501014 AC

A-110 (B)
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starter connector.
Connector: A-10
1
A-10

1
starter relay connector and A-110 (terminal Harness side connector AK700921 AB
No. 1) starter connector. • Disconnect connector, and measure at the har-
• Check output line for open circuit and ness side.
damage. • Voltage between terminal No. 1 and earth.
OK: System voltage
(terminal No. 1) starter connector and
battery.
short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-459
STEP 22. Connector check: B-14 inhibitor switch STEP 23. Check harness between B-14 (terminal
connector and C-307 ignition switch connector No. 10) inhibitor switch connector and C-307
Connector: B-14
(terminal No. 5) ignition switch connector.
5 4 3 2 1 Connector: B-14
10 9 8 7 6 5 4 3 2 1
Harness side 10 9 8 7 6
connector Harness side
connector
B-14 (B)
B-14 (B)
AK700823AB
AK700823AB
Connector: C-307
C-307
cardiagn.com
C-307

C-307
C-307
3 2 1
6 5 4 3 2 1
Harness side connector 6 5 4
AKB00286 AB
YES : Go to Step 23. NOTE: Before checking harness, check starter relay
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
13A-460 DIESEL FUEL
TROUBLESHOOTING
STEP 24. Connector check: A-16X starter relay STEP 26. Check harness between A-16X
connector (terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter connector
Connector: A-16X
Connector: A-16X
A-16X
2 1
A-16X
3 2 1
4 3
Relay box's side connector 4
AK501014 AC
YES : Go to Step 25. Connector: A-110
A-110 (B)
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(terminal No. 2) starter relay connector and B-14
(terminal No. 9) inhibitor switch connector
Connector: A-16X
1
NOTE: Before checking harness, check starter relay

connectors A-27, and repair if necessary.
A-16X
2 1 • Check output line for damage.
3
4
Relay box's side connector AK501014 AC NO : Repair the damaged harness wire.
Connector: B-14
5 4 3 2 1 STEP 27. Check harness between A-10 (terminal
10 9 8 7 6 No. 1) starter connector and battery.
Harness side
connector Connector: A-10
A-10
B-14 (B)
AK700823AB
NOTE: Before checking harness, check starter relay 1

connectors A-115 and B-10, and repair if necessary. Harness side connector
• Check power supply line for damage. AK700921 AB

YES : Go to Step 26. Q: Is the check result normal?
NO : Repair the damaged harness wire. YES : Replace the starter.
DIESEL FUEL
TROUBLESHOOTING
13A-461
Inspection Procedure 5: Starting Impossible (Starter operative but no initial combustion)
PROBABLE CAUSES STEP 4. M.U.T.-III data list.

• Failed battery • Item 40: Starter switch
• Improper fuel used
• Fuel contaminated with foreign matter OK:
• Injector leaking or clogged ON (Ignition switch: ST)
• Failed injector OFF (Ignition switch: ON)
• Fuel injection learning failure Q: Is the check result normal?
• Fuel filter clogged YES : Go to Step 5 .
• Fuel line leaking or clogged NO : Check for starting impossible to operate
• Failed fuel pressure limiter valve (Refer to Inspection Procedure 4 P.13A-445
• Failed rail pressure sensor <M/T> or P.13A-453 <A/T>).
• Failed supply pump (suction control valve)
• Failed glow system STEP 5. Check timing belt for breakage.
• Timing belt broken
• Air cleaner clogged YES : Go to Step 6 .
NO : Replace the timing belt.
• Compression pressure low
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DIAGNOSIS PROCEDURE STEP 6. Confirm the using fuel.
Q: Is the specified fuel being used?
STEP 1. Check battery voltage. YES : Go to Step 7 .
• Measure battery voltage at cranking. NO : Replace fuel.
OK: 8 V or more
STEP 7. Check glow system.
• Check glow system (Refer to Code No. P0381
NO : Check battery (Refer to GROUP 54A − P.13A-200 <Euro5> or Inspection Procedure 25
Battery − On-vehicle Service − Battery test P.13A-520 <Except Euro5>).
). Q: Is the check result normal?
STEP 2. M.U.T.-III diagnosis code. NO : Repair or replace the failed item.

YES : Inspection chart for diagnosis code (Refer STEP 8. Check fuel supply line.
to P.13A-21). • Check for fuel leakage and clogging
NO : Go to Step 3 . • Check fuel filter for clogging
STEP 3. Check injector identification code. YES : Go to Step 9 .
• Check injector identification code (Refer to NO : Repair or replace the failed item.
tor Identification code Registration Procedure ). STEP 9. Priming (air bleeding)
Q: Is the check result normal? • Bleed air
YES : Go to Step 4 . Q: Does trouble symptom persist?
NO : Register the injector ID. YES : Go to Step 10 .
13A-462 DIESEL FUEL
TROUBLESHOOTING
STEP 10. M.U.T.-III actuator test.
NO : Proceed to the diagnostic code procedure
• Refer to Actuator Test Reference Table P.13A-
for the sensor that does not output
574.
waveforms (Refer to Inspection Chart for
a. Item 19: Suction control valve Diagnosis Code P.13A-21).
STEP 15. Check compression pressure.
• Check compression pressure (Refer to GROUP
11A − On-vehicle Service − Compression Pres-
sure Check ).
Common Rail Engine Learns ). Q: Is the check result normal?
NO : Check and repair the engine itself.
STEP 11. Check suction control value itself.
• Check suction control value itself (Refer to
P.13A-596). STEP 16. Check injector itself.
NO : Replace the suction control valve. After YES : Go to Step 17 .
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replacing the suction control valve, learn the NO : Replace the injector at the failed cylinder.
supply pump (Refer to GROUP 00 − After replacing the Injector, register the
Precautions Before Service − What The injector identification code and learn fuel
Common Rail Engine Learns ). injection (Refer to GROUP 00 − Precautions
Engine Learns ).
b. Item 64: Rail pressure target
a. Item 5: Barometric pressure sensor
Q: Are the check results normal? b. Item 7: Engine coolant temperature sensor
c. Item 8: EGR gas temperature sensor
<Euro5>
d. Item 8: Intake air temperature sensor No. 2
STEP 13. Replace the rail pressure sensor. <Except Euro5>
• Replace the common-rail assembly. e. Item 21: Fuel temperature sensor
Q: Does trouble symptom persist? f. Item 43: Intake air temperature sensor No. 1
STEP 14. Check the waveforms of crank angle procedure for the sensor that has shown an
sensor and camshaft position sensor. abnormal data value (Refer to Inspection
• Check the waveforms during cranking. Chart for Diagnosis Code P.13A-21).
Q: Are waveforms being output?
DIESEL FUEL
TROUBLESHOOTING
13A-463
DPF Regeneration ).
cardiagn.com
Inspection Procedure 6: Improper Starting (Long time to start)
PROBABLE CAUSES STEP 2. M.U.T.-III diagnosis code.

• Failed battery
• Improper fuel used Q: Is the diagnosis code set?
• Fuel contaminated with foreign matter YES : Inspection chart for diagnosis code (Refer
• Injector leaking or clogged to P.13A-21).
• Failed injector NO : Go to Step 3 .
• Fuel injection learning failure
• Fuel filter clogged STEP 3. M.U.T.-III data list.
• Fuel line leaking or clogged • Refer to Data List Reference Table (Refer to
• Failed fuel pressure limiter valve P.13A-542).
• Failed rail pressure sensor a. Item 5: Barometric pressure sensor
b. Item 7: Engine coolant temperature sensor
• Failed supply pump correction learning
c. Item 8: EGR gas temperature sensor
• Failed glow system
<Euro5>
• Failed EGR system operation
• Failed engine-ECU d. Item 8: Intake air temperature sensor No. 2
• Compression pressure low <Except Euro5>
e. Item 16: EGR valve position sensor
DIAGNOSIS PROCEDURE f. Item 17: EGR valve target position
g. Item 21: Fuel temperature sensor
h. Item 43: Intake air temperature sensor No. 1
• Measure battery voltage during cranking. Q: Are the check results normal?
OK: 8 V or more YES : Go to Step 4 .
Q: Is the check result normal? procedure for the sensor that has shown an
YES : Go to Step 2 . abnormal data value (Refer to Inspection
NO : Check battery (Refer to GROUP 54A − Chart for Diagnosis Code P.13A-21).
Battery − On-vehicle Service − Battery Test
).
13A-464 DIESEL FUEL
TROUBLESHOOTING
• Check injector identification code (Refer to
tor Identification code Registration Procedure ). STEP 11. M.U.T.-III actuator test.
574.
NO : Register the injector ID. a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. YES : Go to Step 12 .
• Carry out the supply pump correction learning
(Refer to GROUP 00 − Precautions Before Serv- replacing the suction control valve, learn the
ice − Supply Pump Correction Learning ). supply pump (Refer to GROUP 00 −
Q: Does trouble symptom persist? Common Rail Engine Learns ).
STEP 6. Small injection quantity learning.
P.13A-596).
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procedure (Refer to GROUP 00 − Precautions Q: Is the check result normal?
Before Service − Small Injection Quantity Learn- YES : Go to Step 13 .
ing Procedure ). NO : Replace the suction control valve. After
Q: Does trouble symptom persist? supply pump (Refer to GROUP 00 −
STEP 7. Confirm the using fuel.

Q: Is the specified fuel being used? • Refer to Data List Reference Table P.13A-542.
YES : Go to Step 8 . a. Item 63: Rail pressure sensor
NO : Replace fuel. b. Item 64: Rail pressure target
STEP 8. Check glow system. YES : Go to Step 15 .
• Check glow system (Refer to Code No. P0381 NO : Go to Step 14 .
P.13A-200 <Euro5> or Inspection Procedure 25
P.13A-520 <Except Euro5>).
STEP 14. Replace the rail pressure sensor.
Q: Is the check result normal? • Replace the common-rail assembly.
NO : Repair or replace the failed item.
STEP 9. Check fuel supply line.
• Check for fuel leakage and clogging.
STEP 15. Check the waveforms of crank angle
• Check fuel filter for clogging.
sensor and camshaft position sensor.
Q: Is the check result normal? • Check the output waveforms on an oscilloscope
YES : Go to Step 10 . (Refer to P.13A-586).
STEP 10. Priming (air bleeding) NO : Proceed to the inspection procedure by
• Bleed air. diagnosis code for the abnormal waveform
(Refer to Inspection Chart for Diagnosis
Code P.13A-21).
DIESEL FUEL
TROUBLESHOOTING
13A-465
STEP 16. Check compression pressure. STEP 18. Check the trouble symptoms.
• Check compression pressure (Refer to GROUP Q: Does trouble symptom persist?
11A − On-vehicle Service − Compression Pres- YES : Replace the engine-ECU. When the engine-
sure Check ). ECU is replaced, write the chassis number
Q: Is the check result normal? (Refer to GROUP 00 − Precautions Before
YES : Go to Step 17 . Service − How to Perform Chassis Number
NO : Check and repair the engine itself. Writing ). After replacing the engine-ECU,
STEP 17. Check injector itself. learn fuel injection (Refer to GROUP 00 −
• Check injector itself (Refer to P.13A-595). Precautions Before Service − What The
NO : Replace the injector at the failed cylinder. out the forcible DPF regeneration. (Refer to
After replacing the Injector, register the GROUP 17 − Emission Control − Diesel
injector identification code and learn fuel Particulate Filter (DPF) System − Forcible
injection (Refer to GROUP 00 − Precautions DPF Regeneration ).
Before Service − What The Common Rail NO : Intermittent malfunction (Refer to GROUP
Engine Learns ). 00 − How to Use Troubleshooting/
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Inspection Procedure 7: Improper Idling
PROBABLE CAUSES STEP 2. Check injector identification code.

• Improper fuel used • Check injector identification code (Refer to
• Fuel contaminated with foreign matter GROUP 00 − Precautions Before Service − Injec-
• Injector leaking or clogged tor Identification code Registration Procedure ).
• Failed injector
• Fuel injection learning failure Q: Is the check result normal?
• Fuel filter clogged YES : Go to Step 3 .
• Fuel line leaking or clogged NO : Register the injector ID.
• Failed fuel pressure limiter valve
• Failed rail pressure sensor STEP 3. M.U.T.-III data list.
• Failed supply pump (suction control valve) • Refer to Data List Reference Table P.13A-542.
• Failed supply pump correction learning a. Item 16: EGR valve position sensor
• Failed EGR system operation b. Item 17: EGR valve target position
• Failed valve clearance adjustment
• Failed engine-ECU Q: Are the check results normal?
• Compression pressure low YES : Go to Step 4 .
DIAGNOSIS PROCEDURE procedure for the sensor that has shown an
Q: Is the diagnosis code set? STEP 4. Confirm the using fuel.
to P.13A-21).
NO : Go to Step 2 .
NO : Replace fuel.
13A-466 DIESEL FUEL
TROUBLESHOOTING
• Check the output waveforms on an oscilloscope
STEP 6. Priming (air bleeding)
• Bleed air.
NO : Proceed to the inspection procedure by
Q: Does trouble symptom persist? diagnosis code for the abnormal waveform
YES : Go to Step 7 . (Refer to Inspection Chart for Diagnosis
NO : The procedure is complete. Code P.13A-21).
STEP 7. M.U.T.-III actuator test. STEP 12. Check compression pressure.

• Refer to Actuator Test Reference Table P.13A- • Check compression pressure (Refer to GROUP
574. 11A On-vehicle Service − Compression Pressure
a. Item 19: Suction control valve Check ).
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NO : Replace the suction control valve. After NO : Check and repair the engine itself.
STEP 13. Check valve clearance.
• Check valve clearance (Refer to GROUP 11A −
On-vehicle Service − Valve Clearance Check and
Adjustment ).
P.13A-596). NO : Adjust the valve clearance.
YES : Go to Step 9 . STEP 14. M.U.T.-III actuator test.
a. Item 15: Injector No. 1
Precautions Before Service − What The b. Item 16: Injector No. 2
Common Rail Engine Learns ). c. Item 17: Injector No. 3
d. Item 18: Injector No. 4
STEP 9. M.U.T.-III data list. Q: Are the check results normal?
NO : Replace the injector at the failed cylinder.
After replacing the Injector, register the
Q: Are the check results normal? injection (Refer to GROUP 00 − Precautions
YES : Go to Step 11 . Before Service − What The Common Rail
NO : Go to Step 10 . Engine Learns ).
STEP 10. Replace the rail pressure sensor. STEP 15. Check injector itself.
• Replace the common-rail assembly. • Check injector itself (Refer to P.13A-595).
Q: Does trouble symptom persist? Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-467
NO : Replace the injector at the failed cylinder. NO : Perform the diagnosis code classified check
After replacing the Injector, register the procedure for the sensor that has shown an
injector identification code and learn fuel abnormal data value (Refer to Inspection
injection (Refer to GROUP 00 − Precautions Chart for Diagnosis Code P.13A-21).
Engine Learns ). STEP 17. Check the trouble symptoms.
STEP 16. M.U.T.-III data list. YES : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 5: Barometric pressure sensor (Refer to GROUP 00 − Precautions Before
b. Item 6: Manifold absolute pressure sensor Service − How to Perform Chassis Number
c. Item 7: Engine coolant temperature sensor Writing ). After replacing the engine-ECU,
d. Item 8: EGR gas temperature sensor register the injector identification code and
<Euro5> learn fuel injection (Refer to GROUP 00 −
e. Item 8: Intake air temperature sensor No. 2 Precautions Before Service − What The
<Except Euro5> Common Rail Engine Learns ). After
f. Item 9: Accelerator pedal position sensor registering the injector identification code,
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g. Item 21: Fuel temperature sensor
h. Item 43: Intake air temperature sensor No. 1
i. Item 45: Throttle position sensor Particulate Filter (DPF) System − Forcible
Q: Are the check results normal? DPF Regeneration ).
Inspection Procedure 8: The Engine Stalls When Decelerating
PROBABLE CAUSES DIAGNOSIS PROCEDURE

• Fuel contaminated with foreign matter
• Injector leaking or clogged STEP 1. M.U.T.-III diagnosis code.
• Failed injector Q: Is the diagnosis code set?
• Fuel injection learning failure YES : Inspection chart for diagnosis code (Refer
• Fuel filter clogged to P.13A-21).
• Fuel line leaking or clogged NO : Go to Step 2 .
• Failed fuel pressure limiter valve
• Failed rail pressure sensor STEP 2. Check idling condition.
• Failed supply pump correction learning Q: Is the idling condition normal?
• Failed EGR system operation YES : Go to Step 3 .
NO : Proceed to troubleshooting for improper
• Failed engine-ECU idling (Refer to Inspection Procedure 7
• Compression pressure low P.13A-466).
• Air cleaner clogged
13A-468 DIESEL FUEL
TROUBLESHOOTING
STEP 3. M.U.T.-III data list. STEP 6. Small injection quantity learning.

• Refer to Data List Reference Table P.13A-542. • Carry out the small injection quantity learning
a. Item 5: Barometric pressure sensor procedure (Refer to GROUP 00 − Precautions
b. Item 6: Manifold absolute pressure sensor Before Service − Small Injection Quantity Learn-
c. Item 7: Engine coolant temperature sensor ing Procedure ).
d. Item 8: EGR gas temperature sensor Q: Does trouble symptom persist?
<Euro5> YES : Go to Step 7 .
e. Item 8: Intake air temperature sensor No. 2 NO : The procedure is complete.
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check air cleaner.
(main)
g. Item 10: Accelerator pedal position sensor YES : Go to Step 8 .
(sub) NO : Replace air cleaner.
h. Item 13: Accelerator pedal position sensor
(main) learned closed position
i. Item 16: EGR valve position sensor
j. Item 17: EGR valve target position Q: Is the specified fuel being used?
k. Item 21: Fuel temperature sensor
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NO : Replace fuel.
l. Item 43: Intake air temperature sensor No. 1
m. Item 45: Throttle position sensor
n. Item 46: Throttle position sensor learned
closed position
Chart for Diagnosis Code P.13A-21). STEP 10. Priming (air bleeding)
• Bleed air.
STEP 4. Check injector identification code. Q: Does trouble symptom persist?
• Check injector identification code (Refer to YES : Go to Step 11 .
GROUP 00 − Precautions Before Service − Injec- NO : The procedure is complete.
Q: Is the check result normal? STEP 11. M.U.T.-III actuator test.
YES : Go to Step 5 . • Refer to Actuator Test Reference Table P.13A-
NO : Register the injector ID. 574.
a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. Q: Is the check result normal?
• Carry out the supply pump correction learning YES : Go to Step 12 .
(Refer to GROUP 00 − Precautions Before Serv- NO : Replace the suction control valve. After
ice − Supply Pump Correction Learning ). replacing the suction control valve, learn the

P.13A-596).
DIESEL FUEL
TROUBLESHOOTING
13A-469
574.
Precautions Before Service − What The a. Item 15: Injector No. 1
Common Rail Engine Learns ). b. Item 16: Injector No. 2
c. Item 17: Injector No. 3
d. Item 18: Injector No. 4
• Refer to Data List Reference Table P.13A-542. Q: Are the check results normal?
a. Item 63: Rail pressure sensor YES : Go to Step 19 .
Q: Are the check results normal? injector identification code and learn fuel
YES : Go to Step 15 . injection (Refer to GROUP 00 − Precautions
NO : Go to Step 14 . Before Service − What The Common Rail
Engine Learns ).
• Replace the common-rail assembly. STEP 19. Check injector itself.
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STEP 15. Check the waveforms of crank angle After replacing the Injector, register the
sensor and camshaft position sensor. injector identification code and learn fuel
• Check the output waveforms on an oscilloscope injection (Refer to GROUP 00 − Precautions
(Refer to P.13A-586). Before Service − What The Common Rail
Engine Learns ).
NO : Proceed to the inspection procedure by STEP 20. Check the trouble symptoms.
diagnosis code for the abnormal waveform
(Refer to Inspection Chart for Diagnosis YES : Replace the engine-ECU. When the engine-
Code P.13A-21). ECU is replaced, write the chassis number
STEP 16. Check compression pressure. Service − How to Perform Chassis Number
• Check compression pressure (Refer to GROUP Writing ). After replacing the engine-ECU,
11A − On-vehicle Service − Compression Pres- register the injector identification code and
sure Check ). learn fuel injection (Refer to GROUP 00 −
NO : Check and repair the engine itself. registering the injector identification code,
STEP 17. Check valve clearance. GROUP 17 − Emission Control − Diesel
• Check valve clearance (Refer to GROUP 11A − Particulate Filter (DPF) System − Forcible
On-vehicle Service − Valve Clearance Check and DPF Regeneration ).
Adjustment ). NO : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use Troubleshooting/
YES : Go to Step 18 . Inspection Service Points − How to Cope
NO : Adjust the valve clearance. with Intermittent Malfunction ).
13A-470 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 9: Poor Acceleration
PROBABLE CAUSES STEP 4. M.U.T.-III data list.

• Failed boost pressure control system • Refer to Data List Reference Table P.13A-542.
• Failed turbocharger
a. Item 5: Barometric pressure sensor
• Fuel contaminated with foreign matter b. Item 6: Manifold absolute pressure sensor
• Injector leaking or clogged c. Item 7: Engine coolant temperature sensor
• Failed injector d. Item 8: EGR gas temperature sensor
• Fuel injection learning failure <Euro5>
• Fuel filter clogged e. Item 8: Intake air temperature sensor No. 2
• Fuel line leaking or clogged <Except Euro5>
• Failed fuel pressure limiter valve f. Item 9: Accelerator pedal position sensor
• Failed rail pressure sensor (main)
• Failed supply pump (suction control valve) g. Item 10: Accelerator pedal position sensor
• Failed supply pump correction learning (sub)
• Failed EGR system operation h. Item 13: Accelerator pedal position sensor
• Failed valve clearance adjustment (main) learned closed position
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j. Item 17: EGR valve target position
• Air cleaner clogged
DIAGNOSIS PROCEDURE l. Item 43: Intake air temperature sensor No. 1
closed position
to P.13A-21). NO : Perform the diagnosis code classified check
NO : Go to Step 2 .
STEP 2. Check idling condition. Chart for Diagnosis Code P.13A-21).
YES : Go to Step 3 . STEP 5. Supply pump correction learning.
NO : Proceed to troubleshooting for improper • Carry out the supply pump correction learning
idling (Refer to Inspection Procedure 7 (Refer to GROUP 00 − Precautions Before Serv-
P.13A-466). ice − Supply Pump Correction Learning ).
STEP 3. Check injector identification code. YES : Go to Step 6 .
• Check injector identification code (Refer to NO : The procedure is complete.
tor Identification code Registration Procedure ). STEP 6. Small injection quantity learning.
Q: Is the check result normal? • Carry out the small injection quantity learning
YES : Go to Step 4 . procedure (Refer to GROUP 00 − Precautions
NO : Register the injector ID. Before Service − Small Injection Quantity Learn-
ing Procedure ).

STEP 7. Check air cleaner.
DIESEL FUEL
TROUBLESHOOTING
13A-471
NO : Replace air cleaner. NO : Replace the suction control valve. After
STEP 8. Confirm the using fuel. supply pump (Refer to GROUP 00 −
Q: Is the specified fuel being used? Common Rail Engine Learns ).
NO : Replace fuel.
STEP 9. Checking the turbocharging pressure. a. Item 63: Rail pressure sensor
• Check the turbocharging pressure (Refer to
GROUP 15 − On-vehicle Service − Turbocharger
Supercharging Pressure Check ). Q: Are the check results normal?
• Replace the common-rail assembly.
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• Check fuel filter for clogging. YES : Go to Step 20 .
NO : Repair or replace the failed item. STEP 16. Check the waveforms of crank angle
• Bleed air.
NO : Proceed to the inspection procedure by
(Refer to Inspection Chart for Diagnosis
STEP 12. M.U.T.-III actuator test. Code P.13A-21).
574.
a. Item 19: Suction control valve • Refer to Actuator Test Reference Table P.13A-
Q: Is the check result normal? 574.
YES : Go to Step 13 . a. Item 15: Injector No. 1
NO : Replace the suction control valve. After b. Item 16: Injector No. 2
c. Item 17: Injector No. 3
Precautions Before Service − What The d. Item 18: Injector No. 4
Common Rail Engine Learns ). Q: Are the check results normal?
P.13A-596). injection (Refer to GROUP 00 − Precautions
Q: Is the check result normal? Before Service − What The Common Rail
Engine Learns ).
13A-472 DIESEL FUEL
TROUBLESHOOTING
STEP 18. Check compression pressure. STEP 20. Check the trouble symptoms.
• Check compression pressure (Refer to GROUP Q: Does trouble symptom persist?
11A − On-vehicle Service − Compression Pres- YES : Replace the engine-ECU. When the engine-
sure Check ). ECU is replaced, write the chassis number
NO : Check and repair the engine itself. Writing ). After replacing the engine-ECU,
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Inspection Procedure 10: A Large Amount of Fuel Consumption

• Injector leaking
• Failed injector STEP 1. M.U.T.-III diagnosis code.
• Fuel injection learning failure Q: Is the diagnosis code set?
• Fuel filter clogged YES : Inspection chart for diagnosis code (Refer
• Failed rail pressure sensor to P.13A-21).
• Failed supply pump (suction control valve) NO : Go to Step 2 .
• Failed EGR system operation STEP 2. Check whether other trouble symptoms
• Failed turbocharger are occurring.
• Failed thermostat
• Failed engine-ECU Q: Are other trouble symptoms occurring?
• Compression pressure low YES : Inspection Chart for Trouble Symptoms
• Air cleaner clogged (Refer to P.13A-429).
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-473
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check turbocharger itself.
(main)
(sub) NO : Replace the turbocharger.
STEP 8. Check the cooling system.
i. Item 16: EGR valve position sensor • Check how the engine coolant level rises.
j. Item 17: EGR valve target position
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l. Item 43: Intake air temperature sensor No. 1 NO : Check the cooling system.
closed position
• Bleed air.
Chart for Diagnosis Code P.13A-21). STEP 10. M.U.T.-III actuator test.
574.
• Check injector identification code (Refer to a. Item 19: Suction control valve
GROUP 00 − Precautions Before Service − Injec- Q: Is the check result normal?
tor Identification code Registration Procedure ). YES : Go to Step 11 .
STEP 5. Supply pump correction learning.
• Carry out the supply pump correction learning
(Refer to GROUP 00 − Precautions Before Serv- STEP 11. Check suction control valve itself.
ice − Supply Pump Correction Learning ). • Check suction control value itself (Refer to
P.13A-596).
NO : The procedure is complete. YES : Go to Step 12 .
13A-474 DIESEL FUEL
TROUBLESHOOTING
a. Item 63: Rail pressure sensor injector identification code and learn fuel
b. Item 64: Rail pressure target injection (Refer to GROUP 00 − Precautions
Q: Are the check results normal? Before Service − What The Common Rail
YES : Go to Step 14 . Engine Learns ).
STEP 13. Replace the rail pressure sensor. Q: Does trouble symptom persist?
• Replace the common-rail assembly. YES : Replace the engine-ECU. When the engine-
Q: Does trouble symptom persist? ECU is replaced, write the chassis number
YES : Go to Step 16 . (Refer to GROUP 00 − Precautions Before
NO : The procedure is complete. Service − How to Perform Chassis Number
STEP 14. Check compression pressure. register the injector identification code and
• Check compression pressure (Refer to GROUP learn fuel injection (Refer to GROUP 00 −
11A − On-vehicle Service − Compression Pres- Precautions Before Service − What The
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sure Check ).
Q: Is the check result normal? the vehicle equipped with the DPF carries
YES : Go to Step 15 . out the forcible DPF regeneration. (Refer to
NO : Check and repair the engine itself. GROUP 17 − Emission Control − Diesel
STEP 15. Check injector itself. DPF Regeneration ).
• Check injector itself (Refer to P.13A-595). NO : Intermittent malfunction (Refer to GROUP
Inspection Procedure 11: Knocking, Abnormal Noise

• Failed injector
• Fuel injection learning failure STEP 1. M.U.T.-III diagnosis code.
• Failed fuel pressure limiter valve Q: Is the diagnosis code set?
• Failed supply pump (suction control valve) YES : Inspection chart for diagnosis code (Refer
• Failed supply pump correction learning to P.13A-21).
• Failed EGR system operation NO : Go to Step 2 .
• Compression pressure low STEP 2. Check idling condition.
idling. (Refer to Inspection Procedure 7
P.13A-466).
DIESEL FUEL
TROUBLESHOOTING
13A-475
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Priming (air bleeding)
(main) • Bleed air.
g. Item 10: Accelerator pedal position sensor Q: Does trouble symptom persist?
(sub) YES : Go to Step 8 .
h. Item 13: Accelerator pedal position sensor NO : The procedure is complete.
i. Item 16: EGR valve position sensor STEP 8. Check the waveforms of crank angle
j. Item 17: EGR valve target position sensor and camshaft position sensor.
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l. Item 43: Intake air temperature sensor No. 1 (Refer to P.13A-586).
m. Item 45: Throttle position sensor Q: Is the check result normal?
n. Item 46: Throttle position sensor learned YES : Go to Step 9 .
closed position NO : Proceed to the inspection procedure by
Q: Are the check results normal? diagnosis code for the abnormal waveform
YES : Go to Step 4 . (Refer to Inspection Chart for Diagnosis
NO : Perform the diagnosis code classified check Code P.13A-21).
abnormal data value (Refer to Inspection STEP 9. M.U.T.-III actuator test.
Chart for Diagnosis Code P.13A-21). • Refer to Actuator Test Reference Table P.13A-
574.
STEP 4. Check injector identification code. a. Item 15: Injector No. 1
• Check injector identification code (Refer to b. Item 16: Injector No. 2
GROUP 00 − Precautions Before Service − Injec- c. Item 17: Injector No. 3
tor Identification code Registration Procedure ). d. Item 18: Injector No. 4
Q: Is the check result normal? Q: Are the check results normal?
NO : Register the injector ID. NO : Replace the injector at the failed cylinder.
STEP 5. Supply pump correction learning. injector identification code and learn fuel
• Carry out the supply pump correction learning injection (Refer to GROUP 00 − Precautions
(Refer to GROUP 00 − Precautions Before Serv- Before Service − What The Common Rail
ice − Supply Pump Correction Learning ). Engine Learns ).
YES : Go to Step 6 . STEP 10. Check compression pressure.
NO : The procedure is complete. • Check compression pressure (Refer to GROUP
sure Check ).
NO : Check and repair the engine itself.
13A-476 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Check valve clearance. STEP 13. Check the trouble symptoms.
• Check valve clearance (Refer to GROUP 11A − Q: Does trouble symptom persist?
On-vehicle Service − Valve Clearance Check and YES : Replace the engine-ECU. When the engine-
Adjustment ). ECU is replaced, write the chassis number
NO : Adjust the valve clearance. Writing ). After replacing the engine-ECU,
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Inspection Procedure 12: White Smoke

• Injector leaking or clogged
• Failed injector STEP 1. M.U.T.-III diagnosis code.
• Fuel injection learning failure Q: Is the diagnosis code set?
• Fuel filter clogged YES : Inspection chart for diagnosis code (Refer
• Fuel line leaking or clogged to P.13A-21).
• Failed fuel pressure limiter valve NO : Go to Step 2 .
• Failed rail pressure sensor
• Failed supply pump (suction control valve) STEP 2. Check idling condition.
• Failed EGR system operation Q: Is the check result normal?
• Air cleaner clogged idling (Refer to Inspection Procedure 7
P.13A-466).
DIESEL FUEL
TROUBLESHOOTING
13A-477
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check air cleaner.
(main)
(sub) NO : Replace air cleaner.
j. Item 17: EGR valve target position Q: Is the specified fuel being used?
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NO : Replace fuel.
l. Item 43: Intake air temperature sensor No. 1
closed position
Chart for Diagnosis Code P.13A-21). STEP 10. Priming (air bleeding)
• Bleed air.
STEP 4. Check injector identification code. Q: Does trouble symptom persist?
• Check injector identification code (Refer to YES : Go to Step 11 .
GROUP 00 − Precautions Before Service − Injec- NO : The procedure is complete.
Q: Is the check result normal? STEP 11. M.U.T.-III actuator test.
YES : Go to Step 5 . • Refer to Actuator Test Reference Table P.13A-
NO : Register the injector ID. 574.
a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. Q: Is the check result normal?
• Carry out the supply pump correction learning YES : Go to Step 12 .
(Refer to GROUP 00 − Precautions Before Serv- NO : Replace the suction control valve. After
ice − Supply Pump Correction Learning ). replacing the suction control valve, learn the

P.13A-596).
13A-478 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the suction control valve. After NO : Check and repair the engine itself.
supply pump (Refer to GROUP 00 − STEP 17. Check injector itself.
Precautions Before Service − What The • Check injector itself (Refer to P.13A-595).
STEP 13. M.U.T.-III data list. NO : Replace the injector at the failed cylinder.
• Refer to Data List Reference Table P.13A-542. After replacing the Injector, register the
a. Item 63: Rail pressure sensor injector identification code and learn fuel
b. Item 64: Rail pressure target injection (Refer to GROUP 00 − Precautions
Q: Are the check results normal? Before Service − What The Common Rail
YES : Go to Step 15 . Engine Learns ).
STEP 14. Replace the rail pressure sensor. Q: Does trouble symptom persist?
• Replace the common-rail assembly. YES : Replace the engine-ECU. When the engine-
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YES : Go to Step 18 . (Refer to GROUP 00 − Precautions Before
NO : The procedure is complete. Service − How to Perform Chassis Number
STEP 15. Check the waveforms of crank angle learn fuel injection (Refer to GROUP 00 −
sensor and camshaft position sensor. Precautions Before Service − What The
• Check the output waveforms on an oscilloscope Common Rail Engine Learns ). After
(Refer to P.13A-586). registering the injector identification code,
Q: Is the check result normal? the vehicle equipped with the DPF carries
YES : Go to Step 16 . out the forcible DPF regeneration. (Refer to
NO : Proceed to the inspection procedure by GROUP 17 − Emission Control − Diesel
diagnosis code for the abnormal waveform Particulate Filter (DPF) System − Forcible
(Refer to Inspection Chart for Diagnosis DPF Regeneration ).
Code P.13A-21). NO : Intermittent malfunction (Refer to GROUP
STEP 16. Check compression pressure. Inspection Service Points − How to Cope
• Check compression pressure (Refer to GROUP with Intermittent Malfunction ).
sure Check ).
Inspection Procedure 13: Black Smoke
PROBABLE CAUSES • Failed supply pump correction learning

• Improper fuel used • Failed EGR system operation
• Injector leaking or clogged • Failed glow system
• Failed injector • Failed engine-ECU
• Fuel injection learning failure • Compression pressure low
• Failed fuel pressure limiter valve • Failed turbocharger
• Failed rail pressure sensor • Improper engine oil volume or viscosity
DIESEL FUEL
TROUBLESHOOTING
13A-479

STEP 5. Supply pump correction learning.
Q: Is the diagnosis code set? • Carry out the supply pump correction learning
YES : Inspection chart for diagnosis code (Refer (Refer to GROUP 00 − Precautions Before Serv-
to P.13A-21). ice − Supply Pump Correction Learning ).
NO : Go to Step 2 .
STEP 2. Check idling condition. NO : The procedure is complete.
YES : Go to Step 3 . STEP 6. Small injection quantity learning.
idling (Refer to Inspection Procedure 7 procedure (Refer to GROUP 00 − Precautions
P.13A-466). Before Service − Small Injection Quantity Learn-
ing Procedure ).
STEP 3. M.U.T.-III data list. Q: Does trouble symptom persist?
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a. Item 5: Barometric pressure sensor NO : The procedure is complete.
b. Item 6: Manifold absolute pressure sensor
c. Item 7: Engine coolant temperature sensor STEP 7. Confirm the using fuel.
d. Item 8: EGR gas temperature sensor
<Euro5>
e. Item 8: Intake air temperature sensor No. 2 NO : Replace fuel.
<Except Euro5>
f. Item 9: Accelerator pedal position sensor
STEP 8. Check engine oil.
(main)
g. Item 10: Accelerator pedal position sensor Q: Are the oil volume and viscosity normal?
(sub) YES : Go to Step 9 .
h. Item 13: Accelerator pedal position sensor NO : Replenish or change engine oil.
i. Item 16: EGR valve position sensor STEP 9. Check glow system.
j. Item 17: EGR valve target position • Check glow system (Refer to Code No. P0381
k. Item 21: Fuel temperature sensor P.13A-200 <Euro5> or Inspection Procedure 25
l. Item 43: Intake air temperature sensor No. 1 P.13A-520 <Except Euro5>).
m. Item 45: Throttle position sensor Q: Is the check result normal?
n. Item 46: Throttle position sensor learned YES : Go to Step 10 .
closed position NO : Repair or replace the failed item.

YES : Go to Step 4 . STEP 10. Check turbocharger itself.
procedure for the sensor that has shown an YES : Go to Step 11 .
abnormal data value (Refer to Inspection NO : Repair the turbocharger.

STEP 4. Check injector identification code. sensor and camshaft position sensor.
• Check injector identification code (Refer to • Check the output waveforms on an oscilloscope
GROUP 00 − Precautions Before Service − Injec- (Refer to P.13A-586).
13A-480 DIESEL FUEL
TROUBLESHOOTING

NO : Proceed to the inspection procedure by NO : The procedure is complete.
(Refer to Inspection Chart for Diagnosis STEP 16. Check compression pressure.
Code P.13A-21). • Check compression pressure (Refer to GROUP
STEP 12. M.U.T.-III actuator test. sure Check ).
• Refer to Actuator Test Reference Table P.13A- Q: Is the check result normal?
574. YES : Go to Step 17 .
a. Item 19: Suction control valve NO : Check and repair the engine itself.
YES : Go to Step 13 . STEP 17. Check injector itself.
NO : Replace the suction control valve. After • Check injector itself (Refer to P.13A-595).
supply pump (Refer to GROUP 00 − Q: Is the check result normal?
Precautions Before Service − What The YES : Go to Step 18 .
cardiagn.com
STEP 13. Check suction control valve itself. injection (Refer to GROUP 00 − Precautions
• Check suction control value itself (Refer to Before Service − What The Common Rail
P.13A-596). Engine Learns ).
YES : Go to Step 14 . STEP 18. Check the trouble symptoms.
STEP 14. M.U.T.-III data list. register the injector identification code and
• Refer to Data List Reference Table P.13A-542. learn fuel injection (Refer to GROUP 00 −
a. Item 63: Rail pressure sensor Precautions Before Service − What The
b. Item 64: Rail pressure target Common Rail Engine Learns ). After
STEP 15. Replace the rail pressure sensor. DPF Regeneration ).
• Replace the common-rail assembly. NO : Intermittent malfunction (Refer to GROUP
Q: Does trouble symptom persist? 00 − How to Use Troubleshooting/
Inspection Procedure 14: Battery rundown <Euro5>
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSES

• Failure is possibly caused by failed alternator, • Failed battery
failed generation control circuit or other faults. • Open/short circuit or harness damage in alterna-
tor L terminal circuit
• Short circuit in alternator G terminal
DIESEL FUEL
TROUBLESHOOTING
13A-481
• Failed alternator STEP 4. Perform voltage measurement at A-122
• Failed engine-ECU alternator connector.
DIAGNOSIS PROCEDURE Connector: A-122
STEP 1. Check battery.

• Check battery (Refer to GROUP 54A − Battery −
On-vehicle Service − Battery Test ).
Q: Is the check result normal? M
YES : Go to Step 2 . 4 3 2 1 A-122 (GR)
NO : Replace the battery. Harness side
STEP 2. M.U.T.-III diagnosis code. • Disconnect connector, and measure at harness

side.
to P.13A-21).
NO : Go to Step 3 . OK: System voltage
cardiagn.com
STEP 3. Connector check: A-122 alternator YES : Go to Step 7 .
connector NO : Go to Step 5 .
Connector: A-122
STEP 5. Connector check: C-111 combination
meter connector
Connector: C-111
C-111
M
4 3 2 1 A-122 (GR)
Harness side

C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

13A-482 DIESEL FUEL
TROUBLESHOOTING
YES : Check the combination meter (Refer to

GROUP 54A − Combination Meter −
No. 3) alternator connector and C-111 (terminal
Trouble Symptom Chart ).
No. 52) combination meter connector.
Connector: A-122

connector
Connector: C-103
M
4 3 2 1 A-122 (GR)
Harness side
Connector: C-111
<L.H. drive vehicles> C-103 (B)
C-111 <R.H. drive vehicles>
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
C-111 158 157156 155 154 153 152 151 150 149 148 147 146

57 56 55 54 53 52 51
64 63 62 61 60 59 58

connectors A-27, C-14 <R.H. drive vehicles> and C-
54 <L.H. drive vehicles>, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-483
STEP 8. Perform voltage measurement at C-103 STEP 9. Check harness between C-103 (terminal
engine-ECU connector. No. 121) engine-ECU connector and A-122
Connector: C-103
(terminal No. 1) alternator connector.
C-103 (B)
C-103 (B)
cardiagn.com
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Disconnect connector, and measure at harness AKA00090 AB
side. Connector: A-122

OK: System voltage
NO : Go to Step 9 . M
4 3 2 1 A-122 (GR)
Harness side

connectors A-27 and A-115, and repair if necessary.
13A-484 DIESEL FUEL
TROUBLESHOOTING
STEP 10. Connector check: C-111 combination STEP 11. Check harness between A-122 (terminal
meter connector No. 3) alternator connector and C-111 (terminal
Connector: C-111 No. 52) combination meter connector.
Connector: A-122
C-111
M
4 3 2 1 A-122 (GR)
Harness side
<R.H. drive vehicles> connector AKB00292 AB
Connector: C-111
C-111
C-111
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57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB <R.H. drive vehicles>

NO : Repair or replace the connector. C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

connectors A-27, C-14 <R.H. drive vehicles> and C-
54 <L.H. drive vehicles>, and repair if necessary.
YES : Check the alternator.
DIESEL FUEL
TROUBLESHOOTING
13A-485
Connector: C-103 with Intermittent Malfunctions ).
<L.H. drive vehicles> NO : Replace the engine-ECU. When the engine-
<R.H. drive vehicles> Common Rail Engine Learns ). After
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Engine: Idling after warm-up
• Transmission: Neutral <M/T> or P range <A/T>
OK: The voltage increases when the head-
lamp switch and the rear window defogger
switch are turned ON from OFF.
Inspection Procedure 14: Battery Rundown <Except Euro5>

• Failed battery
• Failed alternator
• Damaged harness (Circuit related to charging STEP 1. Check battery.
system has an open circuit or is earthed) • Check battery (Refer to GROUP 54A − Battery −
• Damaged connector (Circuit related to charging On-vehicle Service − Battery Test ).
system) Q: Is the check result normal?
YES : Check charging system (Refer to GROUP
16 − Charging System − On-vehicle Service
− Output Current Test ).
NO : Replace the battery.
13A-486 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 15: Overheating

• Failed cooling fan system
• Insufficient or deteriorated engine coolant
• Failed thermostat STEP 1. Check cooling system.
• Failed water pump • Check cooling fan system (Refer to GROUP 55A
• Failed radiator core − Troubleshooting − Symptom Procedures
<manual A/C>, Refer to GROUP 55B − Trouble-
shooting − Symptom Procedures <automatic A/
C>).
YES : Check cooling system.
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-487
Inspection Procedure 16: Engine-ECU Power Supply System
Power Supply and Ignition Switch-IG Circuit
Fusible link 23
W-R
Ignition switch
C-307
LOCK
10 R
Relay
20A box ST ACC 1 2 3
IG1 IG2 4 5 6
W-B 2
A-115 L-B
3 C-207
4
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9
J/B
W-B W-B 7.5A
4 1
A-20X 14
C-208
1 2 Engine
OFF control W
3 relay C-53*¹
ON
4 or
C-35*²
3 2 8
R
Y-G B-W
R R C-103
101 102 118 104 C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Power
source 116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
C-103 116 117 145 Engine-ECU
B B B
NOTE
Wire colour code
R: Red P: Pink V: Violet PU: Purple SI:Silver
AKB00288 AB
OPERATION sensor and actuator.

• When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the engine PROBABLE CAUSES
control relay in the ON position. Accordingly, the • Failed battery
battery voltage is supplied to the engine-ECU, • Failed ignition switch
13A-488 DIESEL FUEL
TROUBLESHOOTING
• Failed engine control relay STEP 4. Perform voltage measurement at A-20X

• Damaged harness (Open circuit between engine- engine control relay connector.
ECU and engine control relay, engine control
relay and relay box, engine-ECU and earth, and Connector: A-20X
open circuit between engine-ECU and J/B)
• Damaged connector (Engine-ECU connector, A-20X
diagnosis connector)
2 1
DIAGNOSIS PROCEDURE 3
4
Relay box's side
STEP 1. Check battery voltage. connector AK501321 AC
• Measure battery voltage during cranking.
• Remove relay, and measure at harness side.
OK: 8 V or more • Voltage between terminal No. 1 and earth, also
Q: Is the check result normal? between terminal No. 4 and earth.
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery test Q: Is the check result normal?
cardiagn.com
). YES : Go to Step 5 .
NO : Check intermediate connector A-115, and
STEP 2. Check engine control relay itself. connector is normal, check and repair
• Check engine control relay itself (Refer to P.13A- harness between A-20X (terminal No. 1 and
594). terminal No. 4) engine control relay
Q: Is the check result normal? connector and battery.
NO : Replace the engine control relay. STEP 5. Connector check: C-103 engine-ECU
connector.
STEP 3. Connector check: A-20X engine control Connector: C-103
relay connector <L.H. drive vehicles>
Connector: A-20X
A-20X
2 1 C-103 (B)
3
4 <R.H. drive vehicles>
Relay box's side

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-489
Connector: C-103
STEP 6. Perform voltage measurement at C-103 <L.H. drive vehicles>
engine-ECU connector
Connector: C-103
C-103 (B)

C-103 (B)
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 • Disconnect connector, and measure at harness
side.
• Short-circuit terminal No. 118 to earth.
• Disconnect connector, and measure at harness • Voltage between terminal No. 101 and earth also
side. between terminal No. 102 and earth.
• Voltage between terminal No. 118 and earth. OK: System voltage
OK: System voltage
YES : Go to Step 7 . NO : Repair the harness wire.
NO : Repair the harness wire.
13A-490 DIESEL FUEL
TROUBLESHOOTING
STEP 8. Check for open circuit between engine-
ECU connector C-103 and earth.
Connector: C-103
<L.H. drive vehicles> STEP 9. Connector check: C-103 engine-ECU
connector.
Connector: C-103
C-103 (B)

C-103 (B)
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Harness side connector AKA00090 AB 117 116
• Disconnect connector, and measure at harness 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
side.
• Check open circuit between terminal No. 145 and AKA00090 AB
earth. Q: Is the check result normal?

DIESEL FUEL
TROUBLESHOOTING
13A-491
STEP 10. Check for open circuit between engine- STEP 11. Perform voltage measurement at C-103
ECU connector C-103 and earth. engine-ECU connector.
C-103 (B) C-103 (B)
cardiagn.com
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Disconnect connector. • Disconnect connector, and measure at harness

• Check open circuit between terminal No. 116 and side.
earth also between terminal No. 117 and earth. • Ignition switch: ON
NO : Repair the harness wire. Q: Is the check result normal?
NO : Check intermediate connector C-53 <L. H.
drive vehicles> or C-35 <R. H. drive
intermediate connector is normal, check and
repair harness between C-103 (terminal No.
104) engine-ECU connector and C-208 J/B
connector.

13A-492 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
cardiagn.com
Inspection Procedure 17: Engine-ECU Battery Back-up System
Battery back-up circuit
Fusible link 23
W-R
10 Relay
20A box
W-B
A-115
3
W-B
C-103 103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Battery
116 117 backup Engine-ECU
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00116 AB
OPERATION engine-ECU from a battery.

• Backup power source is directly supplied to an
DIESEL FUEL
TROUBLESHOOTING
13A-493
PROBABLE CAUSES STEP 3. Connector check: C-103 engine-ECU
• Damaged harness (Open circuit between engine- connector and A-115 intermediate connector.
ECU and relay box)
• Damaged connector (Engine-ECU connector) Connector: C-103
DIAGNOSIS PROCEDURE

• Measure battery voltage during cranking.
C-103 (B)
OK: 8 V or more
Q: Is the check result normal? <R.H. drive vehicles>
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery test
).
cardiagn.com
C-103 (B)
Connector: C-103 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-115
C-103 (B)
A-115

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB A-115

side.
OK: System voltage
1 2 3 4
Q: Is the check result normal? 5 6 7 8 9 10
YES : Go to Step 5 . Harness side connector

YES : Go to Step 4 . NO : Repair or replace.
13A-494 DIESEL FUEL
TROUBLESHOOTING

STEP 4. Check for open circuit between C-103
(terminal No. 103) engine-ECU connector and A- NO : Repair the harness wire.
115 (terminal No. 3) intermediate connector.
Connector: C-103
C-103 (B)
cardiagn.com
C-103 (B)
DPF Regeneration ).
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Connector: A-115
A-115
A-115
1 2 3 4
5 6 7 8 9 10
AK700922 AB
• Disconnect connector.
DIESEL FUEL
TROUBLESHOOTING
13A-495
Inspection Procedure 18: 1st and 2nd Rail Switch System <M/T>
1st and 2nd Rail Switch Circuit
Ignition switch (IG1)
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
cardiagn.com
10
L-Y
1
B-06
MU802662
ON 1st and 2nd rail switch
1 2 OFF
G-Y
C-29
4
G-Y
A-115
6
G-Y
C-105 11
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00289 AC
OPERATION • An engine-ECU controls an engine speed to be 3,

• The 1st and 2nd rail switches detect that a trans- 000 r/min or less so that an excessive load can-
mission is shifted into the 1st speed gear posi- not be applied to a drive train system due to a
tion. sudden start in the first gear position.
PROBABLE CAUSES • Failed 1st and 2nd rail switch

13A-496 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open circuit between 1st and YES : Go to Step 4 .

2nd rail switch and engine-ECU, and open circuit NO : Repair or replace.
between 1st and 2nd rail switch and J/B)
• Damaged connector (Engine-ECU connector, 1st STEP 4. Perform voltage measurement at B-06
and 2nd rail switch connector) 1st and 2nd rail switch connector.
Connector: B-06
DIAGNOSIS PROCEDURE

a. Item 72: 1st and 2nd rail switch B-06 (GR)
1 2
YES : Go to Step 7 . Harness side
NO : Go to Step 2 . connector AK503584AB

STEP 2. Check 1st and 2nd rail switch itself side.
• Check 1st and 2nd rail switch itself (Refer to • Ignition switch: ON
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GROUP 22B − Transmission − Transmission • Voltage between terminal No. 1 and earth.
Inspection <2WD>, GROUP 22C − Transmission OK: System voltage
− Transmission Inspection <4WD>). Q: Is the check result normal?
YES : Go to Step 3 . NO : Check intermediate connector C-30, and
NO : Replace the 1st and 2nd rail switch. repair if necessary. If intermediate
harness between B-06 (terminal No. 1) 1st
STEP 3. Connector check: B-06 1st and 2nd rail and 2nd rail switch connector and C-208
switch connector (terminal No. 2) J/B connector.
Connector: B-06
B-06 (GR)
1 2
Harness side
connector AK503584AB

DIESEL FUEL
TROUBLESHOOTING
13A-497
STEP 5. Connector check: C-105 engine-ECU STEP 6. Perform voltage measurement at C-105
connector engine-ECU connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Repair or replace. • Ignition switch: ON
OK:
System voltage (Shift lever position: 1st)
0 V (Shift lever position: Neutral)
NO : Check intermediate connectors A-115 and
C-29, and repair if necessary. If intermediate
connectors are normal, check and repair
engine-ECU connector and B-06 (terminal
No. 2) 1st and 2nd rail switch connector.

13A-498 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-499
Inspection Procedure 19: Back-up Lamp Switch System <M/T>
Back-up Lamp Switch Circuit
Ignition switch (IG1)
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
cardiagn.com
10
L-Y
2
B-02
MU802601
ON Back-up lamp switch
1 2 OFF
R-G
C-29
13
R-G
A-28
9
R-G
C-105 9
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00290AB
OPERATION • An engine-ECU controls an engine speed to be 3,

• A backup lamp switch detects that a transmission 000 r/min or less so that an excessive load can-
is shifted into a reverse gear position. not be applied to a drive train system due to a
sudden start in a reverse gear position.
PROBABLE CAUSES • Failed back-up lamp switch

13A-500 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open circuit between back- YES : Go to Step 4 .

up lamp switch and engine-ECU, and open circuit NO : Repair or replace.
between back-up lamp switch and J/B)
• Damaged connector (Engine-ECU connector, STEP 4. Perform voltage measurement at B-02
back-up lamp switch connector) back-up lamp switch connector.
Connector: B-02
DIAGNOSIS PROCEDURE

a. Item 73: Reverse shift switch
B-02 (B)
YES : Go to Step 7 . Harness side
NO : Go to Step 2 . connector AK501385AB

STEP 2. Check back-up lamp switch itself side.
• Check back-up lamp switch itself (Refer to • Ignition switch: ON
cardiagn.com
GROUP 22B − Transmission − Transmission • Voltage between terminal No. 2 and earth.
Inspection <2WD>, GROUP 22C − Transmission OK: System voltage
− Transmission Inspection <4WD>). Q: Is the check result normal?
YES : Go to Step 3 . NO : Check intermediate connector C-30, and
NO : Replace the back-up lamp switch. repair if necessary. If intermediate
harness between B-02 (terminal No. 2)
STEP 3. Connector check: B-02 back-up lamp back-up lamp switch connector and C-208
switch connector (terminal No. 2) connector.
Connector: B-02
B-02 (B)
2 1
Harness side
connector AK501385AB

DIESEL FUEL
TROUBLESHOOTING
13A-501
STEP 5. Connector check: C-105 engine-ECU STEP 6. Perform voltage measurement at C-105
connector engine-ECU connector.
C-105 (B) C-105 (B)
cardiagn.com
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Repair or replace. • Ignition switch: ON
OK:
System voltage (Shift lever position: Reverse)
0 V (Shift lever position: Neutral)
NO : Check intermediate connectors A-28 and C-
29, and repair if necessary. If intermediate
connectors are normal, check and repair
engine-ECU connector and B-02 (terminal
No. 1) back-up lamp switch connector.

13A-502 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-503
Inspection Procedure 20: 4LLC Switch System <M/T-High power engine vehicle>
4LLC Switch Circuit
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
13
L-B
A-115
7
cardiagn.com
L-R
C-29
5
L-R
B-05
MU802653 4LLC switch
OFF ON
1
Wire colour code

AKB00291 AB
OPERATION • Damaged connector (Engine-ECU connector,

• A 4LLC switch detects that a transmission is 4LLC switch connector)
shifted into a 4LLC position. • Failed engine-ECU
• An engine-ECU controls an engine speed to be 3,
000 r/min or less so that an excessive load can- DIAGNOSIS PROCEDURE
not be applied to a drive train system due to a
sudden start in a reverse gear position.
STEP 1. Check 4LLC switch itself
PROBABLE CAUSES • Check 4LLC switch itself (Refer to GROUP 22A −
• Failed 4LLC switch On-vehicle service − 4LLC detection switch conti-
• Damaged harness (Open circuit between 4LLC nuity check ).
switch and engine-ECU, and open circuit Q: Is the check result normal?
between 4LLC switch and J/B) YES : Go to Step 2 .
NO : Replace the 4LLC switch.
13A-504 DIESEL FUEL
TROUBLESHOOTING
STEP 2. Connectors check: B-05 4LLC switch STEP 3. check harness between C-105 (terminal
connector and C-105 engine-ECU connector No. 13) engine-ECU connector and B-05 (terminal
Connector: B-05
No. 1) 4LLC switch connector.
Connector: B-05
B-05
B-05
1
Harness side 1
connector
AK801710AB
AK801710AB
Connector: C-105
cardiagn.com
C-105 (B)
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 3 . NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors C-29 and A-115, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-505
DPF Regeneration ).
cardiagn.com
13A-506 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 21: Condenser Fan Relay System <Vehicles with A/C condenser fan>
Condenser Fan Relay Circuit
Ignition switch
C-307
R LOCK
1 2 3 ST ACC
IG1 IG2
4 5 6
L-R
Fusible link 20
C-207
6
W
16 J/B
7.5A
cardiagn.com
5 Relay
20A box 9
C-210
L-R
4
1
A-14X
1 2
OFF Condenser fan relay
3
ON
4
2
3
L-B LG-R
A-115
A-120 2 1
MU802601
A/C condenser
1 2 M fan motor LG-R
21 C-105
1
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
B 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Engine-ECU
Wire colour code

AKB00293 AB

• The A/C condenser fan relay is controlled by turn- • Failed condenser fan relay
ing on and off the power transistor in the engine- • Failed condenser fan motor
ECU. • Damaged harness (Open or short circuit between
• In response to the A/C switch signal, A/C load engine-ECU and condenser fan relay, Open cir-
signal, vehicle speed and engine coolant temper- cuit between condenser fan motor and earth,
ature, the engine-ECU controls the condenser condenser fan relay and J/B, condenser fan relay
fan relay. and relay box, and open circuit between con-
denser fan relay and condenser fan motor)
DIESEL FUEL
TROUBLESHOOTING
13A-507
• Damaged connector (condenser fan relay con- YES : Go to Step 3 .
nector, condenser fan motor connector, Engine- NO : Check condenser fan system (Refer to
ECU connector) GROUP 55A − Troubleshooting − Trouble
• Failed engine-ECU Symptom Chart <Manual A/C>, GROUP
55B − Troubleshooting − Trouble Symptom
DIAGNOSIS PROCEDURE Chart <Automatic A/C>).
STEP 1. M.U.T.-III data list STEP 3. Connector check: C-105 engine-ECU

• Refer to Data List Reference Table P.13A-542. connector.
a. Item 26: A/C load signal Connector: C-105
NO : Check A/C system (Refer to GROUP 55A −
Troubleshooting − Check Chart for Trouble
Symptoms <Manual A/C>, GROUP 55B −
Troubleshooting − Trouble Symptom Chart
<Automatic A/C>). C-105 (B)
cardiagn.com
STEP 2. Check at C-105 engine-ECU connector. <R.H. drive vehicles>
Connector: C-105
C-105 (B)
C-105 (B) 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
<R.H. drive vehicles> 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B) Service − How to Perform Chassis Number
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 register the injector identification code and
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector Common Rail Engine Learns ). After

AKA00089 AB
• Disconnect connector, and measure at harness the vehicle equipped with the DPF carries
side. out the forcible DPF regeneration. (Refer to
• Ignition switch: ON GROUP 17 − Emission Control − Diesel
• Short-circuit terminal No. 21 to earth. Particulate Filter (DPF) System − Forcible
OK: Condenser fan motor rotates DPF Regeneration ).
13A-508 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 22: A/C Switch System
A/C Switch circuit

A/C evaporator air outlet thermistor <Manual A/C> or
A/C-ECU <Automatic A/C>
BR-W
C-105
8
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
cardiagn.com
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00119 AF
OPERATION • Failed A/C system

• The battery voltage is applied to the engine-ECU • Open/short circuit in A/C circuit or loose connec-
(terminal No. 8) from the A/C switch module. tor contact
PROBABLE CAUSES
• Failed A/C
DIESEL FUEL
TROUBLESHOOTING
13A-509
connector
STEP 1. Perform voltage measurement at C-105 Connector: C-105
engine-ECU connector. <L.H. drive vehicles>
Connector: C-105
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector Q: Is the check result normal?

AKA00089 AB
• Measure engine-ECU terminal voltage. NO : Repair or replace.
• Engine: Idling
• A/C set temperature:
Maximum Cool when temperature in cabin is
• Item 25: A/C switch
25°C or more
a. Engine: Idling
Maximum Hot when temperature in cabin is 25°C
or less b. A/C set temperature:
• Voltage between terminal No. 8 and earth. Maximum Cool when temperature in cabin is
25°C or more
OK:
Maximum Hot when temperature in cabin is
System voltage (when A/C is ON)
25°C or less
0.5 V or less (when A/C is OFF)
OK:
Q: Is the check result normal? ON (when A/C is ON)
YES : Go to Step 2 . OFF (when A/C is OFF)
Troubleshooting − Check Chart for Trouble Q: Is the check result normal?
Symptoms <Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>).
13A-510 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
cardiagn.com
DIESEL FUEL
TROUBLESHOOTING
13A-511
Inspection Procedure 23: A/C Compressor Relay System
A/C Compressor Relay Circuit
Ignition switch
C-307
LOCK
R
1 2 3 ST ACC
IG1 IG2
4 5 6
4
Fusible link 20
L-R
C-207
W 6
16 J/B
4 Relay
box 7.5A
10A
9
cardiagn.com
C-210
B-O L-R
A-115 A-28
4 7
B-O L-R
4 1
A-21X
1 2 OFF A/C compressor relay

3 ON
4
3 2
L-W
A-28
4
L-W O
A-27
5
L-W
C-105
1 19
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
A-33
MU802655
A/C 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
compressor 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
1 clutch assembly
Engine-ECU
A/C compressor and clutch assembly
Wire colour code

AKB00294 AB
13A-512 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 2. Connector check: C-105 engine-ECU

• When the A/C switch "ON" signal is input to the connector
engine-ECU, the engine-ECU places the A/C
compressor relay in the "ON" position. Accord- Connector: C-105
ingly, the battery voltage supplied to the A/C com-
pressor operates the magnet clutch.
PROBABLE CAUSES
• Failed A/C compressor relay
• Failed A/C compressor assembly
• Damaged harness (Open circuit between A/C C-105 (B)
compressor relay and condenser fan relay, A/C
compressor relay and engine-ECU, A/C com-
pressor relay and A/C compressor, and open cir-
cuit between A/C compressor relay and relay
box)
• Damaged connector (A/C compressor relay con-
nector, A/C compressor connector, Engine-ECU
connector)
cardiagn.com
C-105 (B)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
STEP 1. M.U.T.-III data list 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Refer to Data List Reference Table P.13A-542. Harness side connector AKA00089 AB
a. Item 25: A/C switch
b. Item 26: A/C load signal Q: Is the check result normal?
c. Item 27: A/C relay YES : Go to Step 3.
YES : Go to Step 2.
NO : Check A/C system (Refer to GROUP 55A − STEP 3. Check the trouble symptoms.
Troubleshooting − Trouble Symptom Chart Q: Does trouble symptom persist?
<Manual A/C>, GROUP 55B − YES : Replace the engine-ECU. When the engine-
Troubleshooting − Trouble Symptom Chart ECU is replaced, write the chassis number
<Automatic A/C>). (Refer to GROUP 00 − Precautions Before
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-513
Inspection Procedure 24: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
127
B-R
A-115
5
cardiagn.com
B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
Wire colour code

AKA00105 AB

• It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When STEP 1. Connector check: A-134 power steering
the power steering fluid pressure switch "ON" sig- fluid pressure switch connector
nal (a large load on the power steering fluid Connector: A-134
pump) is inputted, the engine-ECU provides the
idle-up control.
PROBABLE CAUSES A-134 (B)

• Failed power steering fluid pressure switch
• Damaged harness (Open or short circuit between
power steering fluid pressure switch and engine- 1
ECU)
Harness side
• Damaged connector (Engine-ECU connector, connector AK501383 AB
power steering fluid pressure switch connector)
13A-514 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
STEP 2. Perform voltage measurement at A-134 <L.H. drive vehicles>
power steering fluid pressure switch connector.
Connector: A-134
A-134 (B)
C-103 (B)

1
Harness side

side.
cardiagn.com
• Voltage between terminal No. 1 and earth. C-103 (B)
OK: System voltage
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
117 116
YES : Go to Step 8 . 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146

OK: System voltage
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-515
YES : Check intermediate connectors A-27 and A-
115, and repair if necessary. If intermediate
connector
connector are normal, check and repair
Connector: C-103 harness between A-134 (terminal No. 1)
<L.H. drive vehicles> power steering fluid pressure switch
C-103 (B) STEP 5. Connector check: C-103 engine-ECU

connector
Connector: C-103
cardiagn.com
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 <R.H. drive vehicles>

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-134
C-103 (B)
A-134 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
1
Harness side Harness side connector AKA00090 AB
13A-516 DIESEL FUEL
TROUBLESHOOTING

No. 1) power steering fluid pressure switch
ECU connector.
Connector: A-134 ECU is replaced, write the chassis number
A-134 (B)
1 Common Rail Engine Learns ). After
Harness side registering the injector identification code,
connector AK501383 AB the vehicle equipped with the DPF carries
Connector: C-103
DPF Regeneration ).
cardiagn.com
C-103 (B) Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
NOTE: Before checking harness, check intermediate C-103 (B)

• Check output line for short circuit. 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101

143 142 141 140 139138 137 136 135 134 133 132 131
YES : Go to Step 7 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
NO : Repair the harness wire. Harness side connector AKA00090 AB

STEP 7. M.U.T.-III data list • Engine: Idling
• Refer to Data List Reference Table P.13A-542. • Voltage between terminal No. 127 and earth.
a. Item 75: Power steering fluid pressure switch OK:
Q: Is the check result normal? System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
DIESEL FUEL
TROUBLESHOOTING
13A-517
NO : Go to Step 9 .
No. 1) power steering fluid pressure switch
STEP 9. Connector check: C-103 engine-ECU ECU connector.
connector
Connector: A-134
Connector: C-103
A-134 (B)
1

Connector: C-103
cardiagn.com
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 <R.H. drive vehicles>

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Replace the power steering fluid pressure
switch.
13A-518 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-103
C-103 (B)
cardiagn.com
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-519
Inspection Procedure 25: Glow System <Except Euro5>
Glow System Circuit
Fusible link 24 Engine control relay Ignition switch (IG1)
L-B
C-207
4
15
J/B 7.5A
6
W R C-209
B-W
12
J/C (5)
C-132
15
cardiagn.com
A-11 A-11 B-W
1 1 C-112
1 A-112 36
MU802601 C-112
Glow
plug 31 32 33 34 35 36
OFF 1 2
relay ON
37 38 39 40 41 42
A-111 C-111
1 Combination Glow MU801586
1 A-111 2 meter
51 52 53 54 55 56 57
51 58 59 60 61 62 63 64
L C-111
W-R B-R
C-53*¹ or
24 C-35*²
L
1 20 22
A-06
1 Glow
plugs Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles C-105
Wire colour code
AKA00122 AB

• The engine-ECU controls the glow plug relay and • Failed glow control relay
glow indicator lamp based on the signal of the • Failed glow plug
engine coolant temperature sensor in order to
easily start the engine at the cool condition.
13A-520 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open or short circuit between STEP 2. Connector check: C-105 engine-ECU
engine-ECU and glow plug relay, and open or connector and C-111 combination meter
short circuit between glow plug relay and glow connector.
plug, Open circuit between engine control relay
and glow plug relay, engine control relay and fusi- Connector: C-105
ble link, and open circuit between engine-ECU
and combination meter)
glow plug relay connector, combination meter
connector)
C-105 (B)
DIAGNOSIS PROCEDURE
STEP 1. Check the glow indicator lamp
illuminates.
• Engine coolant temperature: 40°C or lower
cardiagn.com
Q: Is the glow indicator lamp illuminates?
YES : Go to Step 4 . C-105 (B)
NO : Go to Step 2 .
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-111
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

DIESEL FUEL
TROUBLESHOOTING
13A-521
STEP 3. Perform voltage measurement at C-105 STEP 4. Connector checks: A-11, A-111 and A-
engine-ECU connector. 112 glow plug relay connectors.
Connector: C-105 Connector: A-11, A-111 and A-112
AC501628
A-111 (GR)
A-11
C-105 (B) A-112 (B)

Fuel filter
1
A-11, A-111
<R.H. drive vehicles> Harness side connector
2 1
A-112 Harness side connector AK501004 AB

cardiagn.com
C-105 (B) NO : Repair or replace.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 STEP 5. Check the glow plug relay itself.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
• Check the glow plug relay itself (Refer to GROUP
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
16 − Glow System − On-vehicle Service − Glow
Harness side connector AKA00089 AB Plug Relay Check ).
• Disconnect connector, and measurement at har- Q: Is the check result normal?
ness side. YES : Go to Step 6 .
• Ignition switch: ON NO : Replace the glow plug relay.
OK: System voltage STEP 6. Perform voltage measurement at A-11
glow plug relay connector.
YES : Replace the engine-ECU. When the engine- Connector: A-11 AC501628
Writing ). After replacing the engine-ECU, A-11
Precautions Before Service − What The Fuel filter
Common Rail Engine Learns ). 1
NO : Check intermediate connector C-53 <L. H. Harness side connector AK501005 AB
drive vehicles> or C-35 <R. H. drive • Disconnect connector, and measurement at har-
vehicles>, and repair if necessary. If ness side.
intermediate connector is normal, check and • Voltage between terminal No. 1 and earth.
repair harness between C-111 (terminal No.
51) combination meter connector and C-105 OK: System voltage
(terminal No. 28) engine-ECU connector. Q: Is the check result normal?
NO : Check harness between fusible link No. 24
and A-11 (terminal No. 1) glow plug relay
connector.
13A-522 DIESEL FUEL
TROUBLESHOOTING
NO : Replace the glow plug.
glow plug relay connector.
Connector: A-112 AC501628
No. 1) glow plug relay connector and A-06
(terminal No. 1) glow plug connector.
Connector: A-111 AC501628
A-111 (GR)
A-112 (B)
Fuel filter
2 1
• Disconnect connector, and measurement at har-

ness side. Fuel filter
• Voltage between terminal No. 1 and earth. 1
OK: System voltage
Q: Is the check result normal? Connector: A-06
cardiagn.com
NO : Check harness between A-112 (terminal No.
1) glow plug relay connector and A-20X
(terminal No. 3) engine control relay A-06
connector.
STEP 8. Check glow plug itself. 1

• Check glow plug itself (Refer to GROUP 16 − Harness side connector AK700923 AB
Glow System − On-vehicle Service − Glow Plug
Check ). Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-523
connector No. 2) glow plug relay connector and C-105
Connector: C-105
<L.H. drive vehicles> Connector: A-112 AC501628
C-105 (B) A-112 (B)

Fuel filter
2 1
<R.H. drive vehicles> Harness side connector AK501006 AB
Connector: C-105
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-524 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 26: PTC Heater Relay System <Vehicle with PTC Heater>
PTC Heater Circuit
Fusible link 25 Ignition switch (IG2)
L-R C-207
6
16
J/B
7.5A
9
C-210
L-R
R R A-28
7
L-R
C-148
L-R 4
cardiagn.com
L-R
PTC heater 2 3 2 3 PTC heater
relay 1 relay 2
A-140X A-141X
ON ON
2 OFF OFF 2
1 3 1 3
4 4
4 1 4 1
B-L B-Y
2 2 A/C switch module <Manual A/C>
Y-G or A/C-ECU <Automatic A/C>
Y-L
C-149 C-150
PTC C-148 PTC C-148
Heater 1 2 Heater 2 1
1 2 1 2 L-W
1 1 C-52
3
B Y-GR B G-O
L-W
43 44 6
Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
C-105
Wire colour code
AKB00307 AB
DIESEL FUEL
TROUBLESHOOTING
13A-525
OPERATION YES : Go to Step 2 .
• When the PTC heater operation request signal NO : Check PTC heater system (Refer to
(battery voltage) is input into the engine-ECU GROUP 55A − Troubleshooting − Trouble
(terminal No. 6) from the A/C switch module Symptom Chart <manual A/C>, GROUP
<manual A/C> or A/C-ECU <automatic A/C>, the 55B − Troubleshooting − Trouble Symptom
engine-ECU turns ON the PTC heater relay 1 and Chart <automatic A/C>).
2 after satisfying all the operation conditions.
Operation conditions of PTC heater relay 1 STEP 2. PTC heater 1 operation check
a. Engine coolant temperature is under 80°C Connector: C-105
b. 2 seconds later after the engine has start up. <L.H. drive vehicles>
c. The PTC heater request signal has been input
continuously 2 seconds or more
d. The battery voltage continues to be 12.3 V or
more for 12 seconds or more.
Operation conditions of PTC heater relay 2
a. Engine coolant temperature is under 75°C. C-105 (B)
b. The PTC heater 1 has been ON continuously
45 seconds or more. <R.H. drive vehicles>
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c. Heater switch (warm up switch) is ON or vehi-
cle speed is 20km/h or more.
d. The battery voltage continues to be 12.9 V or
more for 12 seconds or more.
PROBABLE CAUSES
• Failed PTC heater relay C-105 (B)
• Failed PTC heater
• Damaged harness (Open circuit between PTC 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
heater relay and engine-ECU, PTC heater relay

and J/B, PTC heater relay and PTC heater, PTC
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
heater and body earth, and open circuit between Harness side connector AKA00089 AB
PTC heater relay and fusible link 25.
• Damaged connector (PTC heater relay connec- • Disconnect the C-105 connector.
tor, PTC heater connector, engine-ECU connec- • Using the jumper wire, connect terminal No. 43 to
tor). earth.
• Failed engine-ECU OK: The PTC heater 1 operates.
NO : Check PTC heater system (Refer to
STEP 1. M.U.T.-III data list GROUP 55A − Troubleshooting − Trouble
• Refer to Data List Reference Table P.13A-542. Symptom Chart <manual A/C>, GROUP
a. Item 76: PTC heater relay 1 55B − Troubleshooting − Trouble Symptom
Chart <automatic A/C>).
b. Item 77: PTC heater relay 2
13A-526 DIESEL FUEL
TROUBLESHOOTING
STEP 3. PTC heater 2 operation check. STEP 4. Connector check: C-105 engine-ECU
Connector: C-105
connector.
C-105 (B)
C-105 (B)

C-105 (B)
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Disconnect the C-105 connector. AKA00089 AB
• Using the jumper wire, connect terminal No. 44 to Q: Is the check result normal?
earth. YES : Go to Step 5 .
OK: The PTC heater 2 operates. NO : Repair or replace.
YES : Go to Step 4 . STEP 5. Check the trouble symptoms.
NO : Check PTC heater system (Refer to
GROUP 55A − Troubleshooting − Trouble
Symptom Chart <manual A/C>, GROUP
55B − Troubleshooting − Trouble Symptom
Chart <automatic A/C>).
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-527
Inspection Procedure 27: Blower Switch System <Euro5>
Blower Switch Circuit
Blower switch
L-B
10
J/C (9)
C-10
3
L-B
C-52*¹ or
C-34*²
1*¹ or
4*²
G-Y
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C-103 125
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
NOTE
Wire colour code
AKB00331 AB

• The battery voltage is applied to the engine-ECU • Failed A/C system
(terminal No. 125) from the blower switch. • Open/short circuit or harness damage in blower
switch circuit or loose connector contact
• When the blower fan is turned ON and the battery
voltage is applied to the engine-ECU, the engine-
ECU increases the idle speed.
13A-528 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Perform voltage measurement at C-10

joint connector.
STEP 1. Connector check: C-10 joint connector. Connector: C-10
Connector: C-10 <L. H. drive vehicles>
<L. H. drive vehicles>
C-10 (GR)
C-10 (GR)
5 4 3 2 1
5 4 3 2 1 12 11 10 9 8 7 6 AB
12 11 10 9 8 7 6 AB Harness side connector

<R. H. drive vehicles>
C-10 (GR)
C-10 (GR)
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AKB00330 AB
AKB00330 AB • Disconnect connector, and measure at the har-

ness side.
Q: Is the check result normal? • Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-529
connector. No. 3) joint connector and C-103 (terminal No.
Connector: C-103
<L. H. drive vehicles>
C-10 (GR)
C-103 (B)
5 4 3 2 1
12 11 10 9 8 7 6 AB
C-10 (GR)
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C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00330 AB
158 157156 155 154 153 152 151 150 149 148 147 146
Harness side connector Connector: C-103

AKA00090 AB
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

connector C-52 <L. H. drive vehicles>, C-34 <R. H.
drive vehicles>, and repair if necessary.
13A-530 DIESEL FUEL
TROUBLESHOOTING
YES : Replace the engine-ECU.

No. 3) joint connector and C-103 (terminal No.
Connector: C-10
connector. <L. H. drive vehicles>
Connector: C-103
C-10 (GR)
5 4 3 2 1
C-103 (B) 12 11 10 9 8 7 6 AB

C-10 (GR)
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C-103 (B)
AKB00330 AB
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 Connector: C-103
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Go to Step 6.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

drive vehicles>, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-531
YES : Go to Step 7. YES : Intermittent malfunction (Refer to GROUP
NO : Repair the damaged harness wire. 00 − How to Use Troubleshooting/
STEP 7. Perform voltage measurement at C-103 with Intermittent Malfunctions ).
Connector: C-103 Symptoms <Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>).
C-103 (B)
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C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Engine: Idling
OK:
System voltage (when A/C is ON)
1 V or less (when A/C is OFF)
13A-532 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 28: Rear Window Defogger System <Euro5>
Rear Window Defogger Circuit
Rear window
defogger relay
J/B
19
7.5A
10
C-208
*1 *2
L-O
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10
L-O J/C (8)

C-08
11
L-O
C-53*¹ or
C-35*²
19
B-G
C-105 10
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00332 AB

• The battery voltage is applied to the engine-ECU • Failed rear window defogger system
(terminal No. 10) from the rear window defogger • Open/short circuit or harness damage in rear win-
relay. dow defogger relay circuit or loose connector
contact
• When the rear window defogger is turned ON and
the battery voltage is applied to the engine-ECU,
the engine-ECU increases the idle speed.
DIESEL FUEL
TROUBLESHOOTING
13A-533
STEP 1. Check the rear window defogger.

The rear defogger system should work normally STEP 3. Perform voltage measurement at C-105
(Refer to GROUP 54A, Printed Heater Lines Check ). engine-ECU connector.
Connector: C-105
NO : Check rear window defogger relay system
(Refer to GROUP 55A − Troubleshooting −
Check Chart for Trouble Symptoms
<Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>). C-105 (B)
STEP 2. Connector check: C-105 engine-ECU <R.H. drive vehicles>

connector.
Connector: C-105
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
<R.H. drive vehicles> Harness side connector AKA00089 AB

• Engine: Idling
OK:
System voltage (when rear window defogger
C-105 (B) is ON)
1 V or less (when rear window defogger is
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
OFF)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Go to Step 4 .

13A-534 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Connector check: C-208 junction block STEP 5. Check harness between C-208 (terminal
connector. No. 10) junction block connector and C-105
Connector: C-208
<L. H. drive vehicles> Connector: C-208
Junction block (Front view) <L. H. drive vehicles>
C-208 Junction block (Front view)
C-208

Junction block <R. H. drive vehicles>
(Front view) Junction block
(Front view)
Harness side
connector
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C-208
C-208
AKB00333 AB
AKB00333 AB
YES : Go to Step 5. Connector: C-105
NO : Repair or replace the connector. <L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

drive vehicles> and C-35 <R. H. drive vehicles>, and
repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-535
YES : Replace the engine-ECU.
No. 10) junction block connector and C-105
STEP 6. Connector check: C-208 junction block
Connector: C-208
connector. <L. H. drive vehicles>
Junction block (Front view)
Connector: C-208
<L. H. drive vehicles> C-208
Junction block (Front view)
C-208

Junction block
<R. H. drive vehicles> (Front view)
Junction block
(Front view) Harness side
connector
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Harness side
connector
C-208
C-208
AKB00333 AB
AKB00333 AB Connector: C-105

YES : Go to Step 7.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

drive vehicles> and C-35 <R. H. drive vehicles>, and
repair if necessary.
13A-536 DIESEL FUEL
TROUBLESHOOTING

Inspection Procedure 29: DPF Lamp System <Euro5>
DPF Lamp Circuit
C-113
Combination meter
1 2 3 4 5 6 7 8 9 10 11 12
DPF
13 14 15 16 17 18 19 20 21 22 23 24
lamp
1
C-113
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G-R
C-53*¹ or
C-35*²
17
V-W
C-105 47
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00340 AB

• Engine-ECU turn on DPF lamp for 5 seconds to
check for burnt-out bulb immediately after ignition
switch is turned to ON. STEP 1. M.U.T.-III actuator test.
• Engine-ECU has detected failed DPF system. Or • Refer to Actuator Test Table P.13A-574.
failure is possibly caused by open or short circuit a. Item 44: DPF lamp
or other faults. Q: Is the check result normal?
PROBABLE CAUSES 00 − How to Use Troubleshooting/
• Damaged connector (Engine-ECU connector, Inspection Service Points − How to Cope
combination meter connector) with Intermittent Malfunction ).
• Damaged harness (Open or short circuit between NO : Go to Step 2 .
engine-ECU and combination meter)
• Failed engine-ECU STEP 2. Check indicator illumination.
Q: Does an indicator other than the DPF lamp
illuminate?
DIESEL FUEL
TROUBLESHOOTING
13A-537
STEP 4. Connector check: C-105 Engine-ECU
NO : Inspect combination meter and related
connector and C-113 combination meter
circuits (Refer to GROUP 54A −
connector.
Combination Meter − Check Chart for
Trouble Symptoms ). Connector: C-105

to P.13A-21).
NO : Go to Step 4 . C-105 (B)
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C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
Harness side connector AKB00260AB

13A-538 DIESEL FUEL
TROUBLESHOOTING
STEP 5. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-113 54A − Combination Meter − Check Chart for
Trouble Symptoms ).
C-113
C-113
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12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
• Disconnect C-113 combination meter connector
Q: Does the DPF lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-539
STEP 6. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
C-105 (B)
cardiagn.com
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13

side.
• Disconnect C-113 combination meter connector.
13A-540 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Perform resistance measurement for • Resistance between C-105 engine-ECU connec-
open circuit at between C-105 engine-ECU tor terminal No. 47 and C-113 combination con-
connector and C-113 combination meter nector terminal No. 1.
connector. OK: Continuity (2 Ω or less)
Connector: C-105 Q: Is the check result normal?
<L.H. drive vehicles> YES : Go to Step 8 .
NO : Check the intermediate connector C-53 <L.
H. drive vehicles>, C-35 <R. H. drive
intermediate connector is normal, repair the
harness wire.
C-105 (B)
<R.H. drive vehicles> Q: Does trouble symptom persist?
cardiagn.com
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector out the forcible DPF regeneration. (Refer to

AKA00089 AB
Connector: C-113 Particulate Filter (DPF) System − Forcible
<L.H. drive vehicles> DPF Regeneration ).
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
• Disconnect C-105 engine-ECU connector and C-

113 combination meter connector, and measure
resistance at the wiring harness.
DIESEL FUEL
TROUBLESHOOTING
13A-541
Data List Reference Table
M1133004201011
Item Check item Inspection conditions Value to be Code No. Reference

No. determined or page
as normal inspection
procedure
No.
1 Battery Ignition switch: ON System Procedure P.13A-488
voltage voltage No. 16
2 Engine • Engine: Cranking Compare engine Matched Code No. P.13A-184
revolution • Tachometer: speed on tachometer P0335
Connected with the value
displayed on M.U.T.-
III
• Engine: Idle When the engine 1,100 r/min
operation coolant temperature: <Euro5>
• Transmission: −20 °C 900 r/min
Neutral <M/T> or <Except
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P range <A/T> Euro5>
• A/C switch: OFF
When the engine 1,100 r/min
coolant temperature: <Euro5>
0 °C
900 r/min *1
650 r/min
<Vehicles for
Morocco>
When the engine 700 r/min *2
coolant temperature:
25 °C 850 r/min *1
When the engine 600 r/min
coolant temperature: <Euro5-M/T>
40 °C
650 r/min *3
800 r/min *1
80 °C
650 r/min *4
700 r/min *5
13A-542 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
3 Target Idle • Engine: Idle When the engine 1,100 r/min Code No. P.13A-184
speed operation coolant temperature: <Euro5> P0335
• Transmission: −20 °C 900 r/min
• A/C switch: OFF
0 °C
900 r/min *1
650 r/min
<Vehicles for
Morocco>
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25 °C 850 r/min *1
40 °C
650 r/min *3
800 r/min *1
80 °C
650 r/min *4
700 r/min *5
4 Vehicle Drive 40 km/h Approximatel Code No. P.13A-251
speed y 40 km/h P0502
sensor
5 Barometric Ignition switch: ON Altitude 0 m 101 kPa Code No. P.13A-406,
pressure Altitude 600 m 95 kPa P2228, P.13A-407
sensor P2229
Altitude 1,200 m 88 kPa
Altitude 1,800 m 81 kPa
6 Manifold Ignition switch: ON Altitude: 0 m 101 kPa Code No. P.13A-78,
absolute or Idle operation Altitude: 600 m 95 kPa P0106, P.13A-83,
pressure P0107, P.13A-91
sensor Altitude: 1,200 m 88 kPa P0108
Altitude: 1,800 m 81 kPa
• Engine coolant When engine is The voltage in
temperature: 85 − suddenly raced. accordance
95°C with the boost
• Lights and all pressure in
accessories: OFF the inlet
• Transmission: manifold
Neutral <M/T> or
P range <A/T>
DIESEL FUEL
TROUBLESHOOTING
13A-543
procedure
No.
7 Engine Ignition switch: ON When the engine −20°C Code No. P.13A-113,
coolant or the engine coolant temperature P0117, P.13A-119
temperature running is −20°C P0118
sensor When the engine 0°C
coolant temperature
is 0°C
When the engine 20°C
coolant temperature
is 20°C
coolant temperature
is 40°C
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coolant temperature
is 80°C
8 EGR gas Ignition switch: ON When the intake air −20°C Code No. P.13A-94,
temperature or the engine temperature is − P0112, P.13A-104
sensor running 20°C P0113
<Euro5> When the intake air 0°C
temperature is 0°C
When the intake air 20°C
temperature is 20°C
When the EGR is Varies
introduced depending on
the
temperature
in the inlet
manifold
8 Intake air Ignition switch: ON When the intake air −20°C Code No. P.13A-48,
sensor No. 2 running 20°C P0073
<Except When the intake air 0°C
Euro5> temperature is 0°C
13A-544 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
9 Accelerator Ignition switch: ON Release the 700 − 1,300 Code No. P.13A-333,
pedal accelerator pedal mV P2122, P.13A-341,
position Depress the Increases in P2123, P.13A-345
sensor accelerator pedal response to P2124
(main) gradually the pedal
depression
stroke
Depress the 4,000 mV or
accelerator pedal more
fully
10 Accelerator Ignition switch: ON Release the 200 − 800 mV Code No. P.13A-349,
pedal accelerator pedal P2127, P.13A-357
position Increases in P2128
cardiagn.com
Depress the
sensor (sub) accelerator pedal response to
gradually the pedal
depression
stroke
Depress the 2,000 mV or
accelerator pedal more
fully
11 Accelerator Ignition switch: ON Release the 0% Code No. P.13A-333,
pedal accelerator pedal P2122, P.13A-341,
(main) gradually the pedal
depression
stroke
Depress the 98 % or more
accelerator pedal
fully
12 Accelerator Ignition switch: ON Release the 20 % or Code No. P.13A-349,
pedal accelerator pedal below P2127, P.13A-357
position Depress the Increases in P2128
sensor (sub) accelerator pedal response to
gradually the pedal
depression
stroke
accelerator pedal
fully
15 Vehicle Drive 40 km/h Approximatel − −
speed y 40 km/h
sensor
DIESEL FUEL
TROUBLESHOOTING
13A-545
procedure
No.
16 EGR valve • Engine: After Idling 50 % or Code No. P.13A-240,
position warming up the more*6 P0489, P.13A-248
sensor engine P0490, <Euro5>
3,500 r/min or more 10 % or
• Transmission: <Euro5> P.13A-219,
below
Neutral <M/T> or P0405,
P.13A-227
P range <A/T> P0406
<Except
<Except
Euro5>
Euro5>
17 EGR valve • Engine: After Idling 50 % or more Code No. P.13A-240,
target warming up the 3,500 r/min or more 10 % or P0489, P.13A-248
position engine below P0490, <Euro5>
• Transmission: <Euro5> P.13A-219,
Neutral <M/T> or P0405,
P.13A-227
cardiagn.com
P range <A/T> P0406
<Except
<Except
Euro5>
Euro5>
21 Fuel Ignition switch: ON When the fuel −20°C Code No. P.13A-134,
sensor running 20°C P0183
When the fuel 0°C
temperature is 0°C
When the fuel 20°C
When the fuel 40°C
When the fuel 80°C
25 A/C switch Engine: Idling after A/C switch: OFF OFF Procedure P.13A-512
warming up the A/C switch: ON ON No. 22
engine (The A/C
compressor in
operation)
26 A/C load • Engine: Idling A/C compressor ON Procedure P.13A-507
signal after warming up clutch not in No. 23
<Vehicles the engine operation
with • A/C switch: ON When the A/C OFF
automatic A/ compressor clutch is
C> under high load
27 A/C relay Engine: Idling after A/C switch: OFF OFF Procedure P.13A-512
warming up the A/C switch: ON ON (A/C No. 23
engine compressor
clutch in
operation)
13A-546 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
28 AT/MT Ignition switch: ON Vehicles with M/T M/T − −
switch Vehicles with A/T A/T
29 Condenser Ignition switch: ON A/C switch: OFF OFF Procedure P.13A-507
fan relay (engine coolant No. 21
<Vehicles temperature at 97°C
with A/C or lower)
condenser A/C switch: ON and ON
fan> vehicle speed is
lower than 50 km/h
30 Control relay Ignition switch: ON ON − −
33 Engine Ignition switch: "OFF" → "ON" "ON" → Procedure P.13A-438
check lamp "OFF" (after 5 No. 2
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seconds have
elapsed)
35 Glow lamp • Ignition switch: "OFF" → "ON" "ON" → − −
• Engine coolant temperature: lower than "OFF" (After
60 °C several
seconds have
elapsed)
36 Glow plug Ignition switch: Engine coolant ON − −
relay "OFF" → "ON" temperature: lower
than 60 °C
Engine coolant OFF
temperature: higher
than 60 °C
38 Ignition Ignition switch: ON ON − −
switch
40 Starter Ignition switch: ON Engine: Except OFF − −
switch cranking
Engine: Cranking ON
42 Neutral Ignition switch: ON Selector lever: N or N or P − −
switch <A/ P range
T> Selector lever: D or R
Except N or P range
DIESEL FUEL
TROUBLESHOOTING
13A-547
procedure
No.
43 Intake air Ignition switch: ON Intake air −20°C Code No. P.13A-43,
temperature temperature: −20°C P0072, P.13A-53
sensor No. 1 Intake air 0°C P0073, <Euro5>
temperature: 0°C <Euro5> P.13A-99,
P0112,
Intake air 20°C P.13A-57
P0113
temperature: 20°C <Except
<Except
Euro5>
Intake air 40°C Euro5>
temperature: 40°C
Intake air 80°C
temperature: 80°C
45 Throttle • Remove the Fully close the 300 − 700 mV Code No. P.13A-124,
position intake air hose at throttle valve with P0122, P.13A-131
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sensor the throttle body your finger P0123
• Disconnect the Fully open the 4,000 mV or
connector of the throttle valve with higher
electronic- your finger
controlled throttle
valve
• With the special
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
and No. 4 of the
disconnected
connectors
• Ignition switch:
ON (engine
stopped)
13A-548 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
47 Throttle • Remove the Fully close the 0 − 5 deg Code No. P.13A-124,
position intake air hose at throttle valve with P0122, P.13A-131
sensor the throttle body your finger P0123
• Disconnect the Fully open the 73 deg or
connector of the throttle valve with higher
electronic- your finger
controlled throttle
valve
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
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and No. 4 of the
disconnected
connectors
ON (engine
stopped)
DIESEL FUEL
TROUBLESHOOTING
13A-549
procedure
No.
56 Engine • Engine: Cranking Compare engine Matched − −
revolution • Tachometer: speed on tachometer
Connected with the value
displayed on M.U.T.-
III
• Engine: Idle When the engine 1,100 r/min
operation coolant temperature: <Euro5>
• Transmission: −20°C 900 r/min
• A/C switch: OFF
0°C
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900 r/min *1
650 r/min
<Vehicles for
Morocco>
25°C 850 r/min *1
40°C
650 r/min *3
800 r/min *1
80°C
650 r/min *4
700 r/min *5
63 Rail • Engine coolant Idling Rail pressure Code No. P.13A-143,
pressure temperature: 85 − target ± 10 P0191, P.13A-147,
sensor 95°C MPa P0192, P.13A-155
• Lights and all Depress the Rail pressure P0193
accessories: OFF accelerator pedal target ± 15
• Transmission: gradually MPa
Neutral <M/T> or
P range <A/T>
64 Rail • Engine coolant Idling 20 − 35 MPa Code No. P.13A-143,
pressure temperature: 85 − Depress the Increases in P0191, P.13A-147,
target 95°C accelerator pedal response to P0192, P.13A-155
• Lights and all gradually the pedal P0193
accessories: OFF depression
• Transmission: stroke
Neutral <M/T> or
P range <A/T>
13A-550 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
66 Supply Ignition switch: ON −300 to 300 − −
pump mA
learned
value
67 Supply • Engine coolant Idling 1,700 − 1,900 − −
pump target temperature: 85 − mA
value 95°C Depress the Decreases in
• Lamps and all accelerator pedal response to
accessories: OFF gradually the pedal
• Transmission: depression
Neutral <M/T>, P stroke
range <A/T>
72 1st and 2nd Ignition switch: ON Shift position: 1st or ON Procedure P.13A-497
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rail switch 2nd No. 18
<M/T> Shift position: except OFF
1st or 2nd
73 Reverse Ignition switch: ON Shift position: ON Procedure P.13A-501
shift switch reverse No. 19
<M/T> Shift position: except OFF
reverse
75 Power Engine: Idle Steering wheel OFF Procedure P.13A-514
steering fluid operation stationary No. 24
pressure Steering wheel ON
switch turning
76 PTC heater • Engine coolant temperature: lower than ON Procedure P.13A-525
relay 1 75°C No. 26
<Vehicles • Heater temperature setting: Maximum
with PTC • Blower fan: ON
heater> • 2 seconds later after the engine has
start up
Other than the above OFF
77 PTC heater • Engine coolant temperature: lower than ON
relay 2 75°C
<Vehicles • Heater switch (warm up switch) is ON or
with PTC vehicle speed is 20 km/h or more
heater> • Heater temperature setting: Maximum
• Blower fan: ON
• 2 seconds later after the engine has
start up
• The PTC heater 1 has been ON
Other than the above OFF
DIESEL FUEL
TROUBLESHOOTING
13A-551
procedure
No.
114 Air flow • Engine coolant Idle operation 725 − 935 Code No. P.13A-68,
sensor temperature: 85 − mg/cyl P0102, P.13A-75,
95°C P0103
• Lights and all
accessories: OFF
• Transmission:
Neutral <M/T> or
P range <A/T>
117 No. 1 Engine: Idling after When the exhaust 150°C Code No. P.13A-260,
exhaust gas warming up the gas temperature is P0545, P.13A-263
temperature engine 150°C P0546
sensor When the exhaust 300°C
<Euro5> gas temperature is
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300°C
When the exhaust 450°C
gas temperature is
450°C
gas temperature is
600°C
gas temperature is
750°C
118 No. 2 Engine: Idling after When the catalyst 150°C Code No. P.13A-231,
exhaust gas warming up the temperature is P0427, P.13A-234
sensor When the catalyst 300°C
(catalyst temperature is
temperature 300°C
) <Euro5>
When the catalyst 450°C
temperature is
450°C
temperature is
600°C
temperature is
750°C
13A-552 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
119 No. 3 Engine: Idling after When the DPF 150°C Code No. P.13A-310,
exhaust gas warming up the temperature is P1427, P.13A-313
sensor (DPF When the DPF 300°C
temperature temperature is
) <Euro5> 300°C
When the DPF 450°C
temperature is
450°C
When the DPF 600°C
temperature is
600°C
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When the DPF 750°C
temperature is
750°C
120 Exhaust • Remove the Release the both −2.5 to 2.5 Code No. P.13A-411,
differential pressure hoses, nipples to the open kPa P2454, P.13A-417
pressure which are air. P2455
sensor connected to the Connect the manual Changes
<Euro5> both nipple of the pump (pressure- depending on
exhaust application type) to the pressure.
differential the one of the
pressure sensor. nipples, and
• Ignition switch: pressurise it.
ON
• Exhaust
differential
pressure sensor
ambient air
temperature: 0 −
85°C
131 Clutch Ignition switch: ON Depress the clutch OFF − −
switch <M/ pedal
T> Release the clutch ON
pedal
135 Brake lamp Ignition switch: ON Release the brale OFF − −
switch pedal
Deplesse the brale ON
pedal
DIESEL FUEL
TROUBLESHOOTING
13A-553
procedure
No.
142 Variable • Engine coolant Idling 45 − 55 % − −
geometry temperature: 85 − When engine is Increases
control 95°C suddenly raced
solenoid • Lamps and all
valve duty accessories: OFF
before • Transmission:
compensati Neutral <M/T>, P
on <Euro5> range <A/T>
143 Variable • Engine coolant Idling Variable − −
geometry temperature: 85 − geometry
control 95°C control
solenoid • Lamps and all solenoid
valve duty accessories: OFF valve duty
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after • Transmission: before
compensati Neutral <M/T>, P compensation
on <Euro5> range <A/T> ±10 %
When engine is Variable
suddenly raced geometry
control
solenoid
valve duty
before
compensation
±10 %
152 Fuel filter Ignition switch: ON OFF Code No. P.13A-304
pressure • Engine: Idling ON P1276
switch • Squeeze the fuel hose with one's fingers
<Vehicles at the inlet side of the fuel filter
for Russia
and
Morocco>
214 DPF lamp Ignition switch: ON When DPF lamp is OFF − −
<Euro5> not illuminated
When DPF lamp is ON
illuminated
320 Accelerator Ignition switch: ON Release the 0% Code No. P.13A-333,
pedal accelerator pedal P2122, P.13A-341,
(main) (After gradually the pedal
compensati depression
on) stroke
accelerator pedal
fully
13A-554 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
326 4L mode • Ignition switch: Transfer position: OFF − −
<M/T-high ON except 4LLc
power • Transmission: Transfer position: ON
engine Neutral 4LLc
vehicle>
401 Alternator G • Engine: Idling after warming up the Increased − −
duty engine
<Euro5> • Head lamp switch: OFF → ON
402 Battery Ignition switch: ON When the battery −20°C Code No. P.13A-255
temperature or engine running temperature sensor P0515
sensor ambient air
<Euro5> temperature is −
20°C
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When the battery 0°C
temperature sensor
ambient air
temperature is 0°C
temperature sensor
ambient air
temperature sensor
ambient air
temperature sensor
ambient air
NOTE: *1: Except Euro5 and vehicles for Morocco
NOTE: *2: Euro5, vehicles for Morocco
NOTE: *3: Euro5-A/T, vehicles for Morocco
NOTE: *4: Euro5-A/T, Except Euro5-2WD-Except high rider
NOTE: *5: Except Euro5-high rider and 4WD
NOTE: *6: At an outside temperature of approximately 20°C. When the EGR valve position sensor is checked
at the outside temperature of 20°C or more, the value would be possibly below the opening degree (normal
value). Also, the value would be possibly below the opening degree (normal value) under the following condi-
tions:
• When the volumetric efficiency of the intake air is reduced due to the higher intake air temperature
Engine-ECU Monitor Item
• Items useful for grasping the engine control condition by the engine-ECU are provided in this monitor item
section.
DIESEL FUEL
TROUBLESHOOTING
13A-555
• Values of these monitor items vary greatly depending on marginal difference of measurement conditions,
difference of the environment, aged deterioration of vehicles and so on, and it is difficult to show the pre-
cise specification values. Therefore, check conditions, display range and movement of values are
described.
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
13 Accelerato Learning value of not depressed Ignition switch: ON 700 − 1,300mV
r pedal accelerator pedal state is shown
position
sensor
(main)
learned
closed
position
46 Throttle Learning value of fully closed Ignition switch: ON 9 deg or less
position throttle valve state is shown
sensor
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learned
closed
position
57 Fuel Indicates the final injection • Engine: After warm-up, idle 3 − 10 mm3/st
quantity quantity operation
final • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
58 Fuel Indicates the pre injection quantity • Engine: After warm-up, idle 0.5 − 3 mm3/st
quantity operation
pre • Lights and all accessories:
OFF
or P range <A/T>
59 Fuel Indicates the limit of injection Engine: After warm-up, 2,000r/ 35 mm3/st or
quantity quantity determined by the min more
smoke charging pressure
limit
60 Fuel Indicates the pilot injection Ignition switch: When engine 40 − 50 mm3/st
quantity quantity determined by water ON coolant
start temperature temperature
is 0°C
When engine 30 − 40 mm3/st
coolant
temperature
is 70°C
61 Fuel Interval between end of pilot Engine: After warm-up 200 − 2,000 us
injection injection and start of main injection
interval
pilot
13A-556 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
62 Fuel Main injection timing Engine: After warm-up, idle −3 to 4°CA
injection operation
timing
main
65 Supply Although the fuel discharge Ignition switch: ON 2*
pump quantity is decided depending on
learned the drive current of the suction
status control valve of the supply pump,
learning is executed in idle state
because there is a machine
difference. The learned status is
indicated.
78 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 1 cylinder at 25 MPa
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pressure 1
− No. 1
cylinder
pressure 1
− No. 2
cylinder
pressure 1
− No. 3
cylinder
pressure 1
− No. 4
cylinder
pressure 2
− No. 1
cylinder
pressure 2
− No. 2
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-557
m n item numerical
No. value
pressure 2
− No. 3
cylinder
pressure 2
− No. 4
cylinder
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pressure 3
− No. 1
cylinder
pressure 3
− No. 2
cylinder
pressure 3
− No. 3
cylinder
pressure 3
− No. 4
cylinder
pressure 4
− No. 1
cylinder
13A-558 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
pressure 4
− No. 2
cylinder
pressure 4
− No. 3
cylinder
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pressure 4
− No. 4
cylinder
pressure 5
− No. 1
cylinder
pressure 5
− No. 2
cylinder
pressure 5
− No. 3
cylinder
pressure 5
− No. 4
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-559
m n item numerical
No. value
106 Idle speed Target torque for idle speed control • Engine: After warm-up, idle 50 − 120 Nm
control (ISC) operation
torque • Lights and all accessories:
OFF
or P range <A/T>
116 Request • Indicates the DPF regeneration Ignition switch: ON Changes
of mode request mode. depending on
DPF Not request: Not reached to the the vehicle
regenerati load amount which requires the status.
on regeneration
<Euro5> Distance1: State in which the
regeneration is required by the
actual driving distance
Distance2: State in which the
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distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
126 No. 2 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.2 exhaust gas temperature
re sensor sensor (catalyst temperature).
(catalyst
temperatu
re) max
value
<Euro5>
13A-560 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
127 No. 3 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.3 exhaust gas temperature
re sensor sensor (DPF temperature).
(DPF
temperatu
re) max
value
<Euro5>
128 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at No. 3 the time of the highest km
exhaust temperature of the temperatures,
gas saved in the engine-ECU, that are
temperatu detected by the No.3 exhaust gas
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re sensor temperature sensor (DPF
(DPF temperature).
temperatu
re) max
value
<Euro5>
145 Odometer Indicates the total driving distance Ignition switch: ON 0 − 1,999,999
calculated saved to the odometer. km
by engine-
ECU
148 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
DPF times saved to the engine-ECU.
regenerati
on
<Euro5>
151 Status of Indicates the calibrated value to Ignition switch: ON 0−3
soot load calculate the soot load amount by
by the difference pressure.
differential
pressure
<Euro5>
153 Soot Indicates the driving distance after Ignition switch: ON 0 − 2,550 km
loading by the last DPF regeneration.
distance 1
<Euro5>
154 Soot Indicates the driving distance Ignition switch: ON 0 − 2,550 km
loading by calculated by subtracting the
distance 2 driving distance on natural
<Euro5> regeneration from the distance
after the last DPF regeneration.
DIESEL FUEL
TROUBLESHOOTING
13A-561
m n item numerical
No. value
155 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the quantity survey.
accumulat
ion
<Euro5>
156 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the difference
differential pressure.
pressure
<Euro5>
160 Last DPF • Last DPF regeneration request Ignition switch: ON Displays the
regenerati mode last DPF
on mode Not request: Not reached to the regeneration
<Euro5> load amount which requires the request mode.
regeneration
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quantity survey
difference pressure
by the M.U.T.-III.
190 Odometer Indicates the driving distance for Ignition switch: ON 0 − 1,999,999
for DPF by the mounted DPF. km
engine-
ECU
<Euro5>
191 Nonunifor Indicates the non-uniform soot Ignition switch: ON 0 − 100 g
m soot load amount.
accumulat
ion
<Euro5>
13A-562 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
192 Max value Indicates the maximum Ignition switch: ON or DPF −400 to 2,150
of DPF temperature of last DPF regeneration °C
temperatu regeneration saved to the engine
re (last ECU.
DPF
regenerati
on)
<Euro5>
193 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance1" launches.
distance 1
<Euro5>
194 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
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on start request mode of "Summ"
accumulat launches.
ion
<Euro5>
195 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
on start request mode of "Pressure
differential difference" launches.
pressure
<Euro5>
196 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance2" launches.
distance 2
<Euro5>
197 DPF Indicates the present estimated Ignition switch: ON or DPF −400 to 2,150
temperatu DPF centre temperature. regeneration °C
re
<Euro5>
198 Engine oil Indicates the estimated engine oil Engine: Idle operation −1,000 to 1,500
level level difference. cc
calculated
<Euro5>
199 Engine oil Indicates the estimated descend Engine: Idle operation −1,000 to 1,500
consumpti of the engine oil level. cc
on
calculate
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-563
m n item numerical
No. value
200 Fuel Indicates the estimated ascend of Engine: Idle operation −1,000 to 1,500
dilution engine oil level. cc
calculated
by engine-
ECU
<Euro5>
201 Pre- Indicates the target amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on remain regeneration step 1.
soot value
<Euro5>
202 Pre- Indicates the current amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on soot regeneration step 1.
value
cardiagn.com
<Euro5>
204 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 2 times before DPF
on mode 2 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 2 times
<Euro5> Distance1: State in which the before
quantity survey
difference pressure
by the M.U.T.-III.
13A-564 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
<Euro5> Distance1: State in which the before.
cardiagn.com
quantity survey
difference pressure
by the M.U.T.-III.
quantity survey
difference pressure
by the M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-565
m n item numerical
No. value
cardiagn.com
quantity survey
Pressure diff.: State in which the
difference pressure
by the M.U.T.-III.
208 Short Indicates the times of DPF Ignition switch: ON Displays the
interval regeneration performed under the regeneration
DPF distance of 10 km or less after the times.
regenerati last DPF regeneration.
on count
<Euro5>
217 Variable Indicates the target boost Engine: Excessive acceleration 0 − 340 kPa
geometry pressure. after warm-up
turbochar
ger
feedback
target
boost
pressure
<Euro5>
219 Fuel Indicates the main injection Engine: Idle operation 0 − 90 mm3/st
injection quantity of the injector.
quantity
main
220 Fuel Indicates the after injection Engine: Idle operation or DPF 0 − 25.5 mm3/
injection quantity. regeneration st
quantity
after
13A-566 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
221 Fuel Indicates the 1st post injection On DPF regeneration 0 − 25.5 mm3/
injection quantity on the DPF regeneration. st
quantity
post 1
222 Fuel Indicates the 2nd post injection On DPF regeneration 0 − 25.5 mm3/
quantity
post 2
223 Fuel Indicates the 3rd post injection On DPF regeneration 0 − 25.5 mm3/
quantity
post 3
224 Differentia Indicates the temperature when Ignition switch: ON −35 to −26°C
l pressure the compensation amount (M0) of
learning exhaust differential pressure
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temperatu sensor was saved.
re (M0)
<Euro5>
225 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M0) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M0) differential pressure sensor
<Euro5> ambient air temperature is
between −35 and −26°C.
226 Differentia Indicates the temperature when Ignition switch: ON −25 to −16 °C
re (M1)
<Euro5>
229 Differentia Indicates the temperature when Ignition switch: ON −15 to −6°C
re (M2)
<Euro5>
learning pressure sensor when exhaust
DIESEL FUEL
TROUBLESHOOTING
13A-567
m n item numerical
No. value
231 Differentia Indicates the temperature when Ignition switch: ON −5 to 4 °C
re (M3)
<Euro5>
between −5 and 4°C.
234 Differentia Indicates the temperature when Ignition switch: ON 5 to 14°C
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re (M4)
<Euro5>
between 5 and 14°C.
re (M5)
<Euro5>
re (M6)
<Euro5>
between 25 to 34°C.
13A-568 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
241 Differentia Indicates the temperature when Ignition switch: ON 35 to 44 °C
re (M7)
<Euro5>
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re (M8)
<Euro5>
re (M9)
<Euro5>
l pressure the compensation amount (M10)
learning of exhaust differential pressure
re (M10)
<Euro5>
l pressure amount (M10) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M10) sensor ambient air temperature is
<Euro5> between 65 to 74°C.
DIESEL FUEL
TROUBLESHOOTING
13A-569
m n item numerical
No. value
251 Differentia Indicates the temperature when Ignition switch: ON 75 to 84 °C
re (M11)
<Euro5>
zero (M11) the exhaust differential pressure
<Euro5> sensor ambient air temperature is
between 75 to 84°C.
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re (M12)
<Euro5>
<Euro5> between 85 and 94°C.
re (M13)
<Euro5>
re (M14)
<Euro5>
13A-570 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
re (M15)
<Euro5>
318 DPF Indicating DPF regeneration On DPF regeneration Indicating DPF
regenerati remaining time. If DPF regeneration
on temperature is low, numerical remaining time
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remaining value is not reduced.
time
<Euro5>
321 DPF Showing whether DPF Ignition switch: ON ON (during
regenerati regeneration is being performed or DPF
on not. regeneration),
<Euro5> OFF (during
not DPF
regeneration)
328 DPF Showing whether engine-ECU Ignition switch: ON ON (during
regenerati requires DPF regeneration or not. DPF
on request regeneration
<Euro5> request), OFF
(during not
DPF
regeneration
request)
377 Max value Indicating maximum temperature Ignition switch: ON −400 to 2,150
of DPF of DPF regeneration stored in °C
temperatu engine-ECU
re
<Euro5>
384 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at DPF the maximum DPF temperature km
temperatu saved to the engine-ECU.
re max
value
<Euro5>
391 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
Regenerat request times saved to the engine-
ion ECU.
Request
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-571
m n item numerical
No. value
404 Battery Indicates the learning value of Ignition switch: ON −6 to 6 A
current battery current sensor calibration.
sensor
(learning
value)
<Euro5>
435 Last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery is judged to be low at
deteriorat the last time.
ed
odometer
<Euro5>
436 2nd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat two times before.
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ed
odometer
<Euro5>
437 3rd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat three times before.
ed
odometer
<Euro5>
452 Battery • Indicates learning conditions of Ignition switch: ON Varies
current battery current sensor depending on
sensor calibration. the learning
(learning • Message "Completed" means conditions
value of learning has been completed.
neutral Message "Not completed"
point) means learning has been not
<Euro5> completed.
454 Battery Indicates the battery deterioration. Ignition switch: ON ON
degrade (deteriorated)*2
judgement , OFF (not
flag deteriorated)
<Euro5>
455 Battery Indicates the battery full charge Ignition switch: ON ON (the battery
full-charge control is being taken. full charge
mode flag control is being
<Euro5> taken.),
OFF (the
battery full
charge control
is not taken.)
13A-572 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
488 Brake Shows the driving distance when Ignition switch: ON 0 − 1,999,999
override the engine-ECU activates the km
operated previous brake override control.
odometer
<Euro5>
489 Fuel Indicates the final target torque • Engine: After warm-up, idle 0 − 60 Nm
torque operation
target • Lights and all accessories:
OFF
or P range <A/T>
490 Fuel Indicates the pilot injection • Engine: After warm-up, idle 0 − 3 mm3/st
injection quantity operation
quantity • Lights and all accessories:
pilot 1 OFF
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or P range <A/T>
pilot 2 OFF
or P range <A/T>
pilot 3 OFF
or P range <A/T>
NOTE: *1: This item is indicated as follows. FF: Initial condition, 0: Non-learning state, 1: Temporary learning
completed status, 2: Learning completed status, 3: Non-learning state.
NOTE: *2: The deterioration level does not request that the battery must be replaced soon.
DIESEL FUEL
TROUBLESHOOTING
13A-573
Actuator Test Reference Table
M1133004400711
Item Check item Drive Inspection Value to be determined Code No. or Reference
No. contents conditions as normal inspection page
procedure
No.
1 Engine Turn the Ignition switch: The warning lamp turns Procedure P.13A-
check lamp warning ON on. No. 2, 3 438,
lamp on or P.13A-441
off
2 Glow lamp Turn the Ignition switch: The glow lamp turns on. − −
glow lamp ON
on or off
3 Glow plug Turning the Ignition switch: Battery charge is − −
relay relay from ON energized to the glow plug
OFF to ON when the glow plug relay
is ON.
4 A/C relay Turning the Ignition switch: The A/C compressor Procedure P.13A-512
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relay from ON clutch makes an audible No. 23
OFF to ON sound.
5 Condenser Turning the Ignition switch: The condenser fan rotates Procedure P.13A-507
fan relay relay from ON No. 21
<Vehicles OFF to ON
with A/C
condenser
fan>
15 Injector No. 1 Cut off No. 1 • Ignition ON → Engine is Code No. P.13A-158
injector switch: ON OFF changed P0201
• Engine: Idling (becomes
• Vehicle unstable)
speed: 0 km/
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
injector switch: ON OFF changed P0202 <Euro5>,
• Engine: Idling (becomes P.13A-164
• Vehicle unstable) <Except
speed: 0 km/ Euro5>
h
running
13A-574 DIESEL FUEL
TROUBLESHOOTING
procedure
No.
speed: 0 km/ Euro5>
h
running
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speed: 0 km/ Euro5>
h
running
19 Suction Turn the • Ignition The suction control valve Code No. P.13A-26,
control valve suction switch: ON of supply pump is driven. P0003, P.13A-29,
control valve • Engine: not P0004, P.13A-63
from OFF to running P0089 <Euro5>
ON <Euro5>
P.13A-63,
P0089,
P.13A-
P0628,
276,
P0629
<Except P.13A-279
Euro5> <Except
Euro5>
25 EGR valve 0 Lift position • Ignition EGR valve lift driven into − −
% reaches 0 % switch: ON 0% position
• Engine: Idling
• Vehicle
speed: 0 km/
h
26 EGR valve Lift position • Ignition EGR valve lift driven into − −
50 % reaches 50 switch: ON 50% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
DIESEL FUEL
TROUBLESHOOTING
13A-575
procedure
No.
27 EGR valve Lift position • Ignition EGR valve lift driven into − −
100 % reaches 100 switch: ON 100% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
28 Throttle Throttle • Ignition Throttle valve is driven − −
valve 0 deg valve is 0 switch: ON into 0 deg position
deg open • Engine: not
running
running
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running
36 Variable Turn the Engine: Idling Variable geometry Code No. P.13A-34,
geometry variable actuator is operated. P0047, P.13A-40
control geometry P0048
solenoid control
valve solenoid
<Euro5> valve from
OFF to ON
44 DPF lamp Turn the Ignition switch: Turn the DPF lamp on. Procedure P.13A-537
<Euro5> DPF lamp ON No. 29
on
CHECK AT THE ECU TERMINALS NOTE: .

M1133004500901 1. Make the voltage measurement with the
TERMINAL VOLTAGE CHECK CHART engine-ECU connector connected.
WARNING 2. You may find it convenient to pull out the
A high-tension voltage is flowing between engine-ECU to make it easier to reach the
the engine-ECU and the injectors while the connector terminals.
engine is running. Handle them carefully to 3. The chart procedures do not have the particu-
avoid receiving electric shocks from the volt- lar order.
age. CAUTION
1. Connect a needle-nosed wire probe to a voltmeter Short-circuiting the positive (+) probe between a
probe. connector terminal and earth could damage the
2. Insert the needle-nosed wire probe into each of vehicle wiring, the sensor, engine-ECU or all of
the engine-ECU connector terminals from the wire them. Be careful to prevent this!
side, and measure the voltage while referring to 3. If voltmeter shows any division from standard
the check chart. value, check the corresponding sensor, actuator
and related electrical wiring, then repair or
replace.
13A-576 DIESEL FUEL
TROUBLESHOOTING
4. After repair or replacement, recheck with the

voltmeter to confirm that the repair has corrected
the problem.
Engine-ECU Connector Terminal Arrangement

Engine-ECU connector
D-213 D-215
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24 92103104105106107108109110
93 94 95 96 97 98111112113100 114115
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
10191
102 99 129130101
118119120121122123124125126127128
102 103 104 105 106 107 108 109
116 117 110 111
112 113 114 115 116 117 118 119
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 131132133134135136137138139140 141142143
128 129 130
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 144120
145121146147148149150151152153154155156
122 123 124 125 126 127 157158
AK800887AB
Terminal Check item Inspection condition (engine status) Normal condition:

No.
6 PTC heater control • Heater temperature setting: Maximum System voltage
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signal <Vehicles • Blower fan: ON
with PTC heater> Other than the above 1 V or less
8 A/C switch Engine: Idle speed A/C switch: OFF 1 V or less
(after warning up) A/C switch: ON (A/C System voltage
compressor in
operation)
9 Back-up lamp shift Ignition switch: ON Shift position: Reverse System voltage
switch Shift position: Except 1 V or less
<M/T> reverse
10 Rear window Engine: Idling after Rear window defogger: 1 V or less
defogger relay warning up the OFF
<Euro5> engine Rear window defogger: System voltage
ON
11 1st and 2nd shift Ignition switch: ON Shift position: 1st System voltage
switch Shift position: Except 1 V or less
<M/T> 1st
12 A/C load signal • Engine: Idling A/C compressor clutch 1 V or less
<Vehicles with after warning up not in operation
automatic A/C> the engine A/C compressor clutch 1 V or less ⇔ System
• A/C switch: ON in operation voltage (Changes
repeatedly)
13 4LLC switch <M/T- Ignition switch: ON Shift position: Except 1 V or lower
high power engine 4LLC
vehicle> Shift position: 4LLC System voltage
17 Variable geometry Ignition switch: ON System voltage
solenoid control Engine: Acceleration Changed in accordance
valve <Euro5> with amount of depression
of accelerator pedal
DIESEL FUEL
TROUBLESHOOTING
13A-577
No.
19 A/C compressor Engine: Idle speed A/C switch: OFF System voltage
relay (after warning up) A/C switch: ON (A/C 1 V or less
compressor in
operation)
20 Glow plug relay Ignition switch: OFF Engine coolant 1 V or less → System
<Except Euro5> → ON temperature: lower than voltage (after several
60 °C seconds have elapsed)
Engine coolant System voltage
temperature: higher
than 60 °C
21 Condenser fan relay Engine: Idling after A/C switch: OFF System voltage
<Vehicles with A/C warming up the A/C switch: ON 1 V or less ⇔ System
condenser fan> engine voltage (Changes
repeatedly)
22 Glow lamp • Ignition switch: OFF → ON 1 V or lower → System
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• Engine coolant temperature: lower than voltage (after several
60°C seconds have elapsed)
36 EGR gas Engine: Idling after Intake air temperature: 4.2 − 4.6 V
temperature sensor warming up the 20 °C
<Euro5> engine Intake air temperature: 3.7 − 4.1 V
50 °C
Intake air temperature: 2.7 − 3.1 V
100 °C
200 °C
400 °C
37 Manifold absolute Ignition switch: ON 0.7 − 1.2 V
pressure sensor Engine: Acceleration Increases
38 No. 2 intake air Ignition switch: ON Intake air temperature: 4.0 − 4.6 V
temperature sensor −20 °C
<Except Euro5> Intake air temperature: 3.1 − 3.7 V
0 °C
20 °C
40 °C
60 °C
80 °C
13A-578 DIESEL FUEL
TROUBLESHOOTING

No.
39 Battery temperature Ignition switch: ON Battery temperature 3.9 − 4.5 V
sensor <Euro5> ambient air
temperature: −20 °C
Battery temperature 3.2 − 3.8 V
ambient air
temperature: 0 °C
ambient air
temperature: 20 °C
ambient air
temperature: 40 °C
ambient air
temperature: 60 °C
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ambient air
temperature: 80 °C
40 Throttle position • Remove the Fully close the throttle 0.3 − 0.7 V
sensor intake air hose at valve with your finger
the throttle body Fully open the throttle 4.0 V or more
• Disconnect the valve with your finger
connector of the
electronic-
controlled throttle
valve
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
and No. 4 of the
disconnected
connectors
ON (engine
stopped)
43 PTC heater relay 1 • Engine coolant temperature: lower than 1 V or less
<Vehicles with PTC 75°C
heater> • Heater temperature setting: Maximum
• Blower fan: ON
• 2 seconds later after the engine has start
up
Other than the above System voltage
DIESEL FUEL
TROUBLESHOOTING
13A-579
No.
44 PTC heater relay 2 • Engine coolant temperature: lower than 1 V or lower
<Vehicles with PTC 75°C
heater> • Heater switch (warm up switch) is ON or
vehicle speed is 20 km/h or more
• Blower fan: ON
• Heater temperature setting: Maximum
• 2 seconds later after the engine has start
up
• The PTC heater 1 has been ON
Other than the above System voltage
46 Engine check lamp Ignition switch: LOCK (OFF) → ON 1 V or lower → System
voltage (after 5 seconds
have elapsed)
47 DPF lamp Ignition switch: LOCK (OFF) → ON 1 V or lower → System
voltage (after 5 seconds
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have elapsed)
55 Fuel temperature Ignition switch: ON Fuel temperature: −20 3.9 − 4.5 V
sensor °C
Fuel temperature: 0 °C 3.1 − 3.7 V
56 Exhaust differential • Remove the Leave each end open. 0.5 − 1.5 V
pressure sensor pressure hoses, Connect a manual Changes depending on
<Euro5> which are pump (pressure- the pressure
connected to application type) to the
each end of the nipple on one side, and
exhaust apply pressure.
differential
pressure sensor.
ON
57 Exhaust gas Engine: Idling (after warning up) 2.0 V or more
recirculation Engine: 3,500 r/min (after warning up) 1.5 V or less
position sensor
58 No. 1 exhaust gas Engine: Idling after Exhaust gas 4.0 − 4.6 V
temperature sensor warming up the temperature: 200 °C
<Euro5> engine Exhaust gas 2.4 − 3.0 V
temperature: 400 °C
Exhaust gas 1.2 − 1.8 V
Exhaust gas 0.5 − 1.1 V
13A-580 DIESEL FUEL
TROUBLESHOOTING

No.
59 No. 2 exhaust gas Engine: Idling after Catalyst temperature: 4.0 − 4.6 V
temperature sensor warming up the 200 °C
(catalyst engine Catalyst temperature: 2.4 − 3.0 V
temperature) 400 °C
<Euro5>
Catalyst temperature: 1.2 − 1.8 V
600 °C
Catalyst temperature: 0.5 − 1.1 V
800 °C
60 No. 3 exhaust gas Engine: Idling after DPF temperature: 200 4.0 − 4.6 V
temperature sensor warming up the °C
(DPF temperature) engine DPF temperature: 400 2.4 − 3.0 V
<Euro5>
°C
DPF temperature: 600 1.2 − 1.8 V
°C
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DPF temperature: 800 0.5 − 1.1 V
°C
62 No. 1 intake air Ignition switch: ON Intake air temperature: 4.0 − 4.6 V
temperature sensor −20 °C
0 °C
20 °C
40 °C
60 °C
80 °C
63 Engine coolant Ignition switch: ON Engine coolant 4.4 − 4.9 V
temperature sensor temperature: −20 °C
Engine coolant 4.4 − 4.6 V
temperature: 0 °C
temperature: 20 °C
temperature: 40 °C
temperature: 60 °C
temperature: 80 °C
64 Rail pressure Engine: Idling (after warning up) 1.15 − 1.75 V
sensor
66 Camshaft position Engine: Cranking 0.1 − 3.0 V*
sensor Engine: Idling 0.5 − 1.5 V*
DIESEL FUEL
TROUBLESHOOTING
13A-581
No.
67 Crank angle sensor Engine: Cranking 1.5 − 4.5 V*
Engine: Idling 2.5 − 3.5 V*
68 Crank angle sensor Ignition switch: ON 4.9 − 5.1 V
power supply
69 Camshaft position Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
70 Rail pressure Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
71 Exhaust gas Ignition switch: ON 4.9 − 5.1 V
recirculation
position sensor
power supply
72 Manifold absolute Ignition switch: ON 4.9 − 5.1 V
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pressure sensor
power supply
93 Throttle position Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
94 Exhaust differential Ignition switch: ON 4.9 − 5.1 V
pressure sensor
power supply
<Euro5>
101 Battery Ignition switch: ON System voltage
102
103 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
104 Ignition switch-IG Ignition switch: ON System voltage
110 Fuel filter pressure Engine: Idling (after warning up) System voltage
switch <Vehicles for • Engine: Acceleration 1 V or less
Russia and • Squeeze the fuel hose with one's fingers at
Morocco> the inlet side of the fuel filter.
111 Ignition switch-ST Engine: Cranking System voltage
114 Throttle valve Engine: Stopped from idling speed Voltage changed for few
control servo seconds
(positive)
115 Exhaust gas Engine: Idling (after warning up) 1 − 3 V*
recirculation motor Engine: 3,500 r/min (after warning up) 1.0 V or less
(positive)
118 Engine control relay Ignition switch: "LOCK" (OFF) System voltage
Ignition switch: ON 1 V or less
13A-582 DIESEL FUEL
TROUBLESHOOTING

No.
120 Glow control unit Engine: Idling Engine coolant System voltage
<Euro5> temperature: lower than
40°C
Engine coolant 1 V or less
temperature: lower than
80°C
121 Alternator G • Engine: Idle operation after warm-up Voltage increase
terminal <Euro5> • Head lamp switch: OFF → ON
• Rear window defogger switch: OFF → ON
125 Blower switch Engine Idle speed Blower fan: OFF 1 V or less
<Euro5> (after warning up) Blower fan: ON System voltage
126 Glow diagnostic Engine: Idling Engine coolant System voltage
signal <Euro5> temperature: lower than
40°C
Engine coolant 1 V or less
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temperature: lower than
80°C
127 Power steering fluid Engine: Idling When steering wheel is System voltage
pressure switch stationary
When steering wheel is 1.0 V or less
turned
129 Throttle valve Engine: Stopped from idling speed Voltage changed for few
control servo seconds
(negative)
131 Suction control Engine: Idling 5 − 6 V*
valve (positive) Engine: Acceleration Decreases
134 Accelerator pedal Ignition switch: ON 4.9 − 5.1 V
position sensor
(sub) power supply
135 Accelerator pedal Ignition switch: ON Release the accelerator 0.2 − 0.8 V
position sensor pedal
(sub) Depress the accelerator 2.0 V or more
pedal fully
138 Battery current The battery is being discharged. The value changes by the
sensor <Euro5> • Engine: Cranking value less than 3.5 V.
The battery is being charged. The value changes by the
• Leave the ignition switch being in the ON value more than 3.5 V*2
position for several minutes, and then after
the engine start.
140 Air flow sensor Engine: Gradually increase the speed Voltage increase
141 Vehicle speed • Ignition switch: ON 0 ⇔ 5 V (Changes
sensor • Move the vehicle forward slowly repeatedly)
148 Battery current Ignition switch: ON 4.9 − 5.1 V
sensor power
supply <Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-583
No.
149 Accelerator pedal Ignition switch: ON 4.9 − 5.1 V
position sensor
(main) power supply
150 Accelerator pedal Ignition switch: ON Release the accelerator 0.7 − 1.3 V
position sensor pedal
(main) Depress the accelerator 4.0 V or more
pedal fully
NOTE: *:The average voltage is shown when an NOTE: .
analog voltmeter is used (because the average volt- 1. When measuring resistance and checking
age might not be shown stably when digital voltmeter continuity, a harness for checking contact pin
is used). pressure should be used instead of inserting a
test probe.
CHECK CHART FOR RESISTANCE AND 2. The chart procedures do not have the particu-
CONTINUITY BETWEEN TERMINALS lar order.
1. Turn the ignition switch to "LOCK" (OFF) position. CAUTION
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2. Disconnect the engine-ECU connector. If the terminals that should be checked are mis-
3. Measure the resistance and check for continuity taken, or if connector terminals are not correctly
between the terminals of the engine-ECU shorted to earth, damage may be caused to the
harness-side connector while referring to the vehicle wiring, sensors, engine-ECU and/or ohm-
check chart. meter. Be careful to prevent this!
4. If the ohmmeter shows any deviation from the
standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
repair or replace.
5. After repair or replacement, recheck with the
ohmmeter to confirm that the repair or
replacement has corrected the problem.
13A-584 DIESEL FUEL
TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU harness side connector
D-215 D-213
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK800888 AB
Terminal No. Inspection item Normal condition (Check condition)

1−2 No. 1 injector Approximately 0.45 Ω (at 20°C)
73 − 75 No. 2 injector
<Euro5>
25 − 75 <Except
Euro5>
49 − 50
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No. 3 injector
<Euro5>
25 − 50 <Except
Euro5>
25 − 27 No. 4 injector
<Euro5>
1 − 27 <Except
Euro5>
17 − 101 Variable geometry control solenoid 10 − 14 Ω (at 20°C)
valve <Euro5>
30 − 36 EGR gas temperature sensor 55 − 78 kΩ (at −20°C)
<Euro5> 29 − 41 kΩ (at 0°C)
17 − 23 kΩ (at 20°C)
10 − 14 kΩ (at 40°C)
7.1 − 8.8 kΩ (at 60°C)
4.8 − 5.9 kΩ (at 80°C)
32 − 38 No. 2 intake air temperature sensor 13 − 18 kΩ (at −20°C)
<Except Euro5> 5.1 − 6.9 kΩ (at 0°C)
2.0 − 3.0 kΩ (at 20°C)
0.9 − 1.5 kΩ (at 40°C)
0.40 − 0.78 kΩ (at 60°C)
0.23 − 0.42 kΩ (at 80°C)
39 − 155 Battery temperature sensor <Euro5> 4.9 − 5.3 kΩ (at 0°C)
2.2 − 2.6 kΩ (at 20°C)
1.0 − 1.4 kΩ (at 40°C)
55 − 79 Fuel temperature sensor 2.0 − 3.0 kΩ (at 20 °C)
58 − 82 No. 1 exhaust gas temperature 120 − 560 kΩ (at 20°C)
sensor
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-585
Terminal No. Inspection item Normal condition (Check condition)
sensor (catalyst temperature)
<Euro5>
sensor (DPF temperature)
<Euro5>
62 − 86 No. 1 intake air temperature sensor 13 − 18 kΩ (at −20°C)
4.8 − 7.0 kΩ (at 0°C)
2.1 − 2.8 kΩ (at 20°C)
0.9 − 1.5 kΩ (at 40°C)
0.47 − 0.69 kΩ (at 60°C)
0.27 − 0.39 kΩ (at 80°C)
63 − 87 Engine coolant temperature sensor 14 − 17 kΩ (at −20°C)
5.1 − 6.5 kΩ (at 0°C)
2.1 − 2.7 kΩ (at 20°C)
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0.9 − 1.3 kΩ (at 40°C)
0.48 − 0.68 kΩ (at 60°C)
0.26 − 0.36 kΩ (at 80°C)
116 − Body Engine-ECU earth Continuity (2 Ω or less)
earth
117 − Body
earth
145 − Body
earth
114 − 129 Throttle valve control servo 0.3 − 100 Ω (at 20 °C)
131 − 146 Suction control valve Approximately 2.1 Ω (at 20°C)
INSPECTION PROCEDURE USING CAMSHAFT POSITION SENSOR AND

OSCILLOSCOPE CRANK ANGLE SENSOR
M1133004600588
The output signals of the sensors and the conditions Measurement Method
of the actuation signals of the actuators can be Crank angle sensor
inspected visually by observing the waveforms on connector
the oscilloscope. Special patterns
1 2 3 pick-up Oscilloscope
1 2 3
Camshaft position
sensor connector
AK501436 AB
1. Disconnect the camshaft position sensor harness (MB991709) in between (All terminals
connector and connect the special tool test should be connected).
13A-586 DIESEL FUEL
TROUBLESHOOTING
2. Connect the oscilloscope special pattern pickup to 2. Connect the oscilloscope special pattern pickup to
camshaft position sensor terminal No. 2. engine-ECU terminal No. 67 (When checking the
3. Disconnect the crank angle sensor intermediate crank angle sensor signal wave pattern.)
connector and connect the special tool test
harness (MB991709) in between. Standard Wave Pattern
4. Connect the oscilloscope special pattern pickup to Observation conditions
crank angle sensor terminal No. 2. Function Special patterns
Alternate Method (Test harness not available) Pattern height Low
1. Connect the oscilloscope special pattern pickup to Pattern selector Display
engine-ECU terminal No. 66 (When checking the Engine speed Idle
camshaft position sensor signal wave pattern.)
Standard Wave Pattern
(V) 2 engine revolutions
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(1 camshaft revolution)
Crank angle
sensor output
wave pattern 5
Camshaft
position 5
sensor output
wave pattern
0
Time
AK501437AB
Wave Pattern Observation Points Wave pattern characteristics

• Check that cycle time T becomes shorter when Rectangular wave pattern is output even when
the engine speed increases. the engine is not started.
•
Examples of Abnormal Wave Patterns

•
AK501439
AK501438
Example 2
Cause of problem
Example 1
Loose timing belt
Cause of problem Abnormality in sensor disk
Sensor interface malfunction
Wave pattern characteristics
DIESEL FUEL
TROUBLESHOOTING
13A-587
Wave pattern is displaced to the left or right. 1. Disconnect the suction control valve connector,
and then connect the special tool test harness
SUCTION CONTROL VALVE (MB991658) in between (All terminals should be
Measurement Method connected).
2. Connect the oscilloscope special pattern pickup to
Oscilloscope terminal No. 1, of the suction control valve
connector.
Alternate Method (Test harness not available)

1 2
1. Connect the oscilloscope special pattern pickup to
Special engine-ECU terminal No. 131.
patterns
pickup
AK900016 AB

(V)
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5
Time
0
AK501441 AB
Observation conditions
Function Special patterns
Pattern height Variable
Variable knob Adjust while viewing
the wave pattern
Pattern selector Display
Engine Idle
Engine load is high
AK501442 AB
Wave Pattern Observation Points

When fuel pressure rises while the engine load is
high, the driving time of the suction control valve
becomes short.
13A-588 DIESEL FUEL
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
EVACUATION OF WATER FROM FUEL
Hand pump
FILTER
M1133001200406
Air plug
<Vehicles with steel fuel filter case>
Water is in the fuel filter when fuel filter indicator
lamp illuminates. Evacuate water by the following
procedures.
Hand pump AC503662AB
1. Remove the fuel filter air plug and O-ring

<Vehicles with air plug>.
2. Cover the circumference of the air plug hole with
cloth and use a hand pump repeatedly until no
bubbles come out of the air plug hole <Vehicles
Drain plug with air plug>.
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AC506328AB
3. Replace the air plug and O-ring with a new one.
1. Loosen the drain plug. Tighten the air plug to the specified torque
2. After water is evacuated by using an hand pump, <Vehicles with air plug>.
tighten the drain plug. Tightening torque: 5.0 ± 1.0 N⋅m
4. Repeat until the hand pump operation becomes
<Vehicles with plastic fuel filter case> stiff.
Water is in the fuel filter when fuel filter indicator
lamp illuminates. Evacuate water by the following <Vehicles with plastic fuel filter case>
procedures.
When the following service work(s) is done, refill the
fuel tank and then evacuate air from the fuel line.
• Fuel hose or pipe is removed
Hand pump • Fuel filter is replaced
• Fuel injector is removed
• If necessary for access, fuel is drained from the
fuel tank.
Drain plug
Hand pump
ACB01923AB
1. Loosen the drain plug.

2. After water is evacuated by using an hand pump,
tighten the drain plug.
EVACUATION OF AIR FROM FUEL LINE

M1133001300362 ACB01924AB

1. Repeat until the hand pump operation becomes
When the following service work(s) is done, refill the stiff.
fuel tank and then evacuate air from the fuel line.
• Fuel hose or pipe is removed FUEL FILTER REPLACEMENT
• Fuel filter is replaced M1133010800387
• Fuel injector is removed <Vehicles with steel fuel filter case>
• If necessary for access, fuel is drained from the Refer to GROUP 13B − Fuel Filter .
fuel tank.
DIESEL FUEL
ON-VEHICLE SERVICE
13A-589
<Vehicles with plastic fuel filter case> CAUTION
Refer to GROUP 13B − Fuel Filter . Before connecting or disconnecting the M.U.T.-
III, turn the ignition switch to the "LOCK" (OFF)
FUEL LINE LEAK CHECK position.
M1133011700189
NOTE: Since the fuel injection pipe connection on <LH drive vehicles>
the fuel injector assembly side is located inside the
engine (rocker cover), visual check for fuel leak can-
not be performed. Due to this, use the oil leak detec-
tion agent to check for fuel leak. As for other fuel
injection pipe and the fuel supply pump pipe connec-
Diagnosis
tion, visually check for fuel leak. connector
NOTE: The oil leak detection agent detects oil leak
by colour change when it is applied to the area to be MB991910
checked. For details on how to use the product, refer
to the instruction manual.
MB991824
1. Remove the engine cover assembly upper (Refer
to GROUP 11A − Engine Assembly ).
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CAUTION
Degrease the area between the flare nut and the
pipe of the fuel injection pipe by fully spraying
the parts cleaner.
Rocker cover
MB991827 AC509179AB
Fuel <RH drive vehicles>

injection Diagnosis
pipe connector
Flare nut ACA00283 AC

MB991910
2. Carefully degrease the flare nut at the fuel injector
assembly side of the fuel injection pipe with parts
cleaner (MZ100387) or equivalent. MB991824
3. If the parts cleaner remains in the area between
the flare nut for connection and the fuel injection
pipe, the oil leak detection agent detects that
there is a fuel leak. Therefore, use an air gun to
blow off the remaining parts cleaner and fully dry
the degreased area.
4. Apply the oil leak detection agent to the flare nut
and the pipe of the fuel injection pipe. MB991827 AC501413AC
NOTE: It is easy to detect the oil leak when the oil
leak detection agent is dry enough because the 5. Ensure that the ignition switch is at the "LOCK"
colour changes clearly. Use a dryer to dry the oil (OFF) position.
leak detection agent when it is hard to dry. 6. Start up the personal computer.
7. Connect special tool M.U.T.-III USB cable
(MB991827) to V.C.I. (MB991824) and the
personal computer.
8. Connect special tool M.U.T.-III main harness A
(MB991910) to the V.C.I.
13A-590 DIESEL FUEL
ON-VEHICLE SERVICE
9. Connect the M.U.T.-III main harness A to the 16.Turn the ignition switch to the "LOCK" (OFF)
diagnosis connector of the vehicle. position, and stop the engine.
10.Turn the V.C.I. power switch to the "ON" position. 17.Disconnecting the M.U.T.-III is the reverse of the
NOTE: When the V.C.I. is energized, the V.C.I. connecting sequence.
indicator lamp will be illuminated in a green col- 18.Check the colour change of the oil leak detection
our. agent at the flare nut and pipe of the fuel injection
11.Start the M.U.T.-III system on the personal pipe to check if the fuel is leaking from the fuel
computer and turn the ignition switch to the "ON" injection pipe connection at the fuel injector
position. assembly side.
12.Start the engine, and let it run at idle. 19.Visually check other fuel line connections for fuel
13.Select "MPI/GDI/DIESEL" from System select leak.
Screen of the M.U.T.-III. 20.If the fuel is leaking, replace the fuel injection pipe
and the fuel supply pump pipe. (Refer to P.13A-
14.Select "SPECIAL FUNCTION" from MPI/GDI/
DIESEL Screen. 604.)
15.Select "FUEL LEAKAGE CHECK" from Test 21.If the fuel is not leaking, wipe off the oil leak
Screen. Carry out the fuel leakage check (during detection agent using parts cleaner (MZ100387)
the test, the engine speed and the fuel pressure is or equivalent completely.
2,000 r/min and 180 MPa for 20 seconds 22.Install the engine cover assembly upper (Refer to
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respectively) five times in a row (20 seconds × 5 GROUP 11A − Engine Assembly ).
times = 100 seconds).
COMPONENT LOCATION
M1133004700660
Name Symbol Name Symbol

Accelerator pedal position sensor V 1st and 2nd rail switch <M/T> R
A/C compressor relay Q Fuel filter pressure switch <Vehicle for I
Russia and Morocco>
A/C switch Y Fuel temperature sensor N
Air flow sensor (incorporating intake air J Glow control unit <Euro5> I
temperature sensor No. 1)
Back-up lamp switch <M/T> S Glow plug relay <Except Euro5> I
Battery current sensor (incorporating P Injector C
battery temperature sensor) <Euro5>
Camshaft position sensor E Intake air temperature sensor No. 2 G
<Except Euro5>
Crank angle sensor M Manifold absolute pressure sensor G
Diagnosis connector X No. 1 exhaust gas temperature sensor B
<Euro5>
DPF lamp <Euro5> W No. 2 exhaust gas temperature sensor a
(catalyst temperature) <Euro5>
EGR gas temperature sensor <Euro5> D No. 3 exhaust gas temperature sensor b
(DPF temperature) <Euro5>
EGR valve (DC motor) (incorporating F Power steering fluid pressure switch K
EGR valve position sensor)
Electronic-controlled throttle valve G PTC heater relay 1,2 <Vehicles with PTC H
(incorporating throttle position sensor) heater>
Engine-ECU Z Rail pressure sensor E
Engine control relay Q Starter relay Q
DIESEL FUEL
ON-VEHICLE SERVICE
13A-591
Name Symbol Name Symbol
Engine coolant temperature sensor O Suction control valve L
Engine warning lamp (check engine U Variable geometry control solenoid valve L
lamp) <Euro5>
Exhaust differential pressure sensor A Vehicle speed sensor <2WD-M/T, 4WD> T
<Euro5>
A B C D E F G H I
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J K L M N O P Q
AKB00282AB
13A-592 DIESEL FUEL
ON-VEHICLE SERVICE
<2WD-M/T> <4WD-M/T> <4WD-A/T>
R S T R S T T
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<L. H. drive vehicles> <R. H. drive vehicles>
U V W X Y Z Z Y X U W V
a b
AKB00329 AB
DIESEL FUEL
ON-VEHICLE SERVICE
13A-593
ENGINE CONTROL RELAY CONTINUITY 1. Remove the engine coolant temperature sensor
CHECK using the special tool engine coolant temperature
M1133008300459 sensor wrench (MB992042).
Engine control
relay
1 2
3
4
Equipment side
connector AK501444 AB AKX01622
Tester Battery Voltage Normal State 2. With temperature sensing portion of engine
Connection coolant temperature sensor immersed in hot
Terminal water, check resistance.
1−2 No voltage Continuity Standard value:
3−4 No voltage No continuity 14 − 17 kΩ (at −20°C)
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5.1 − 6.5 kΩ (at 0°C)
Voltage (Connect Continuity (2 Ω
2.1 − 2.7 kΩ (at 20°C)
positive (+) terminal of or less)
0.9 − 1.3 kΩ (at 40°C)
battery to terminal No.
0.48 − 0.68 kΩ (at 60°C)
1 and negative (−)
0.26 − 0.36 kΩ (at 80°C)
terminal of battery to
terminal No. 2.) 3. If the resistance deviates from the standard value
greatly, replace the sensor.
ENGINE COOLANT TEMPERATURE
SENSOR CHECK
M1133005000404
Engine coolant
temperature sensor
AKX01623AD
1 2
4. Apply sealant to threaded portion.
Equipment side
connector AK501445AB Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Tighten the engine coolant temperature sensor to
MB992042 the specified torque, using engine coolant
temperature sensor wrench, special tool
(MB992042).
Tightening torque: 29 ± 10 N⋅m
AK503116 AC
13A-594 DIESEL FUEL
ON-VEHICLE SERVICE
INJECTOR CHECK
M1133008100314
Injector
No. 1 intake
1 2 air temperature
sensor AK603026AB
Equipment side
connector AKA00359AB 4. Measure resistance while heating the sensor
using a hair drier.
1. Disconnect the injector connector.
Normal condition:
2. Measure the resistance between terminals No. 1
and No. 2. Temperature (°C) Resistance (kΩ)
Standard value: Approximately 0.45 Ω (at Higher Smaller
20°C)
5. If the value deviates from the standard value or
3. If not within the standard value, replace the
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the resistance remains unchanged, replace the air
injector. After replacing the injector, register the flow sensor assembly.
injector identification code and learn fuel injection.
6. Install the air flow sensor and tighten it to the
specified torque.
Service − What The common Rail Engine Learns
). Tightening torque: 0.7 ± 0.1 N⋅m
INTAKE AIR TEMPERATURE SENSOR No. INTAKE AIR TEMPERATURE SENSOR No.
1 CHECK 2 CHECK <Except Euro5>
M1133010400301
M1133010300296
1 2 3 4 5 sensor No.2
Equipment side
connector
Air flow sensor

(incorporating intake
air temperature sensor
No.1)
1 2
Equipment side
AKA00360 AB
1. Disconnect the air flow sensor connector. 1. Disconnect the intake air temperature sensor No.
2 connector.
2. Measure resistance between terminals No. 1 and
No. 2. 2. Measure resistance between terminals No. 1 and
No. 2.
Standard value:
13 − 17 kΩ (at −20°C) Standard value:
5.4 − 6.6 kΩ (at 0°C) 13 − 18 kΩ (at −20°C)
2.3 − 3.0 kΩ (at 20°C) 5.1 − 6.9 kΩ (at 0°C)
1.0 − 1.5 kΩ (at 40°C) 2.0 − 3.0 kΩ (at 20°C)
0.56 − 0.76 kΩ (at 60°C) 0.9 − 1.5 kΩ (at 40°C)
0.31 − 0.43 kΩ (at 80°C) 0.40 − 0.78 kΩ (at 60°C)
0.23 − 0.42 kΩ (at 80°C)
3. Remove the air flow sensor
3. Remove the intake air temperature sensor No. 2
DIESEL FUEL
ON-VEHICLE SERVICE
13A-595
FUEL TEMPERATURE SENSOR CHECK
Intake air temperature M1133006800317
sensor No.2
1 2
Equipment side
connector
AK501451AB
4. Measure resistance while heating the sensor AK501453 AB

using a hair drier.
1. Disconnect the fuel temperature sensor
Normal condition:
connector.
Temperature (°C) Resistance (kΩ) 2. Measure resistance between terminal No. 1 and
Higher Smaller No. 2
Standard value: Approximately 2.0 − 3.0 kΩ
5. If the value deviates from the standard value or
(at 20 °C)
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the resistance remains unchanged, replace the
intake air temperature sensor No. 2 sensor 3. If not within the standard value, replace the supply
assembly. pump assembly. After replacing the supply pump,
6. Install the air flow sensor and tighten it to the learn the supply pump. (Refer to GROUP 00 −
specified torque. Precautions Before Service − What The common
Rail Engine Learns ).
Tightening torque: 13.5 ± 1.5 N⋅m
COMMON RAIL CHECK
SUCTION CONTROL VALVE CHECK M1133010600253
M1133010500290
CAUTION
High pressure fuel is supplied to the common
1 2 rail. It is dangerous to remove the rail pressure
Equipment side sensor and rail pressure limiter from the com-
connector mon rail because it may cause fuel leaks. Do not
Suction control
valve remove the rail pressure sensor and rail pressure
limiter from the common rail.
AK501452 AB
1. Disconnect the suction control valve connector.

2. Measure resistance between terminal No. 1 and Common rail
No. 2
Standard value: Approximately 2.1 Ω (at 20
°C)
AK501454AB
3. If not within the standard value, replace the
suction control valve. After replacing the suction 1. Visually check the common rail for cracks,
control valve, learn the supply pump. (Refer to damage, and corrosion.
GROUP 00 − Precautions Before Service − What 2. If an abnormality is found, replace the common
The common Rail Engine Learns ). rail.
13A-596 DIESEL FUEL
ON-VEHICLE SERVICE
THROTTLE VALVE CONTROL SERVO CHECK THE COIL RESISTANCE

CHECK
M1133010700283 1 2 3 4 5 6
OPERATION CHECK Equipment side
1. Remove the air intake hose from the throttle body. connector
2. Turn the ignition switch to "ON" position.

3. Make sure that the throttle valve is open.
4. Turn the ignition switch to "OFF" position. Electronic-controlled
throttle valve
(incorporating throttle
position sensor) AK501458 AB
1. Disconnect the electronic - controlled throttle

valve connector.
2. Measure resistance between terminal No. 5 and
No. 6 at the throttle valve control servo connector.
Standard value: 0.3 − 100 Ω (at 20 °C)
3. If resistance is outside the standard value, replace
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the throttle body assembly.
DIESEL FUEL
FUEL INJECTOR
13A-597
FUEL INJECTOR
REMOVAL AND INSTALLATION
M1133009400299
Pre-removal Operation Post-installation Operation

• Inlet Manifold Removal (Refer to GROUP 15 − Inlet Mani- • Fuel Injection Pipe Installation (Refer to P.13A-604).
fold ). • Inlet Manifold Installation (Refer to GROUP 15 − Inlet
• Fuel Injection Pipe Removal (Refer to P.13A-604). Manifold ).
<Except Euro5>
N 4 3.0 ± 1.0 N·m to 10 ± 2 N·m

1
5N
10
6
7N
10 9N
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8N
15 ± 2 N·m 11 14
15 ± 2 N·m 10 ± 1 N·m to +120˚ – +125˚
N 13
(Engine oil)
15
11 16
12
17
N 13
18 N
10 ± 2 N·m
10 ± 2 N·m
2 AC502869AE
13A-598 DIESEL FUEL
FUEL INJECTOR
Removal steps Removal steps (Continued)

• When the fuel injector is replaced, 8. Rocker cover gasket B
register the injector identification 9. Rocker cover gasket C
code and perform the fuel injection >>B<< 10. Semi-circular packing
learning (Refer to GROUP 00 − >>A<< 11. Eye bolt
Precautions before Service, What >>A<< 12. Fuel leakage pipe
the Common Rail Engine Learns ) >>A<< 13. Fuel leak-off gasket
<Installation only>. >>A<< 14. Injector holder bolt
1. Breather hose connection >>A<< 15. Injector supporter
2. Harness bracket >>A<< 16. Pivot boss
3. Timing belt front upper cover >>A<< 17. Fuel injector
>>D<< 4. Oil seal >>A<< 18. Nozzle gasket
>>D<< 5. Oil seal
<<A>> >>C<< 6. Rocker cover assembly
7. Rocker cover gasket A
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DIESEL FUEL
FUEL INJECTOR
13A-599
<Euro5>
N 5 3.0 ± 1.0 N·m to 10 ± 2 N·m
8
1
6N
23 ± 6 N·m 12
12
9N
11 N
7 10 N
13 16
15 ± 2 N·m
15 ± 2 N·m 10 ± 1 N·m to +120˚ – +125˚
N 15
(Engine oil)
17
13 18
14
19
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N 15
20 N
10 ± 2 N·m
10 ± 2 N·m
3 AC805674 AD

• When the fuel injector is replaced, >>D<< 6. Oil seal
register the injector identification 7. Vacuum pipe and hose assembly
code and perform the fuel injection connection
learning (Refer to GROUP 00 − <<A>> >>C<< 8. Rocker cover assembly
Precautions before Service, What 9. Rocker cover gasket A
the Common Rail Engine Learns ) 10. Rocker cover gasket B
<Installation only>. 11. Rocker cover gasket C
1. Breather hose connection >>B<< 12. Semi-circular packing
2. Harness bracket >>A<< 13. Eye bolt
3. Solenoid valve and harness >>A<< 14. Fuel leakage pipe
bracket assembly >>A<< 15. Fuel leak-off gasket
4. Timing belt front upper cover >>A<< 16. Injector holder bolt
>>D<< 5. Oil seal >>A<< 17. Injector supporter
13A-600 DIESEL FUEL
FUEL INJECTOR
Removal steps (Continued) CAUTION

>>A<< 18. Pivot boss Do not clean the injection part of the nozzle with
>>A<< 19. Fuel injector
a resin spatula.
>>A<< 20. Nozzle gasket
REMOVAL SERVICE POINT

<<A>> ROCKER COVER ASSEMBLY REMOVAL Fuel injector
Timing belt rear cover

Camshaft sprocket mounting bolt
A: Nozzle side face
Injection part of the nozzle AC900270 AB
(1) Using a resin spatula, scrape off the carbon

deposit on the fuel injector nozzle side face
AC502870AB ("A" shown in the figure).
1. Turn the crankshaft clockwise, and remove the
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Fuel injector
timing belt rear cover mounting bolts shown in the
figure from the gap of the camshaft sprocket.
9
5 2 8
4
3 AC900203 AB
(2) Spray the carburetor cleaner (MZ100139) or

equivalent to the nozzle side face ("A" shown
7 1 10 6 in the figure).
AC502871AB
CAUTION
2. In the order shown in the figure, loosen the rocker Do not touch the injection part of the nozzle with
cover assembly mounting bolts, and then remove hand or wipe it with a rag.
the rocker cover assembly. (3) Leave the injection part for a while until the
carbon deposit melts down, and then blow air
INSTALLATION SERVICE POINTS to the injection part.
>>A<< NOZZLE GASKET/FUEL INJECTOR/PIVOT
BOSS/INJECTOR SUPPORTER/INJECTOR
HOLDER BOLT/FUEL LEAK-OFF GASKET/FUEL
Cylinder head
LEAKAGE PIPE/EYE BOLT INSTALLATION
1. Clean the fuel injector assembly (nozzle) and the
cylinder head (fuel injector insertion hole) by
following the procedure below.
MB990784
AC900204AB
(4) Insert special tool ornament remover

(MB990784) to the cylinder head (fuel injector
insertion hole) with turning the special tool as
shown, and scrape off the carbon deposit.
DIESEL FUEL
FUEL INJECTOR
13A-601
CAUTION Tightening torque: 10 ± 1 N⋅m
In order to prevent carbon from adhering to the CAUTION
inner surface of the cylinder, blow air with the • If the bolt is tightened less than the specified
piston in the TDC position. lower limit of 120°, the bolt may become
(5) Remove the special tool, and blow off the loose. Be sure to tighten correctly.
carbon deposit on the cylinder head (fuel • If the bolt is tightened in excess of the speci-
injector insertion hole) by air. fied upper limit of 125°, loosen the nut com-
(6) Check that there is no carbon deposit pletely and repeat the entire procedures.
remaining on the contact surface of the fuel
injector nozzle gasket.
NOTE: Repeat step 4 to step 6 several times
until the carbon deposit is completely removed.
MB991614
Injector holder bolt
Fuel injector
Injector supporter
AC502873AB
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Pivot boss
8. Using special tool angle gauge (MB991614),
Nozzle tighten the injector holder bolt in the illustrated
gasket sequence by a further 120° to 125°.
AC502872 AB
2. Install the nozzle gasket, fuel injector, pivot boss, >>B<< SEMI-CIRCULAR PACKING
and injector supporter to the cylinder head as INSTALLATION
shown in the figure.
3. Apply a small amount of engine oil to the seat
surface and thread of injector holder bolt, and Semi-circular packing
then temporarily tighten the bolt to the cylinder
head.
4. Set the fuel leak-off gasket to the fuel leakage
pipe, and temporarily tighten to the fuel injector
and to the cylinder head using the eye bolt.
5. Tighten the eye bolt of the fuel injector side to the
specified torque. AC502874AB
Tightening torque: 15 ± 2 N⋅m Apply specified sealant to portions indicated in illus-

tration.
6. Tighten the eye bolt of the cylinder head side to
the specified torque. Specified sealant: Three bond 1217G or
equivalent
NOTE: Install the semi-circular packing immediately
7. Tighten the injector holder bolt to the specified after applying sealant.
torque.
13A-602 DIESEL FUEL
FUEL INJECTOR
>>C<< ROCKER COVER ASSEMBLY CAUTION

INSTALLATION After the installation, until a sufficient period of
time (one hour or more) elapses, do not apply the
10mm oil or water to the sealant application area or
start the engine.
4. Tighten the rocker cover assembly mounting bolts
to the specified torque in the order shown in the
Semi-
circular
figure again.
10mm
packing Tightening torque: 10 ± 2 N⋅m
Cylinder head
AC502875AB >>D<< OIL SEAL INSTALLATION
1. Apply specified sealant to portions indicated in Socket wrench

illustration. Rocker cover
Specified sealant: Three bond 1217G or

equivalent
NOTE: Install the rocker cover assembly immedi-
ately after applying sealant.
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2. Install the rocker cover assembly to the cylinder Oil seal
head. (Engine oil)
AC502876AB
2
6 9 3
Socket wrench
7
8
Oil seal Rocker cover
4 10 1 5
AC502871AC
(Engine oil)
3. Tighten the rocker cover assembly mounting bolts AC502877AB
to the specified torque in the order shown in the Apply engine oil to the oil seal outer surface and
figure. drive in with a socket wrench.
DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
13A-603
M1133009600389
CAUTION
• The reinstallation histories of the removed fuel injection pipe and fuel supply pump pipe are up to
five times. To count how many times the fuel injection pipe and fuel supply pump pipe are rein-
stalled, record the number of the reinstallation histories on the service booklet by adding this lat-
est number of the histories, which is usually "1", to the previous one. Use a new fuel injection pipe
or fuel supply pump pipe when the total reinstallation history numbers reach five times, or when
the fuel injector assembly, common rail assembly or supply pump assembly is replaced. In this
case, record " a new fuel injection pipe or fuel supply pump pipe, the number of the reinstallation
histories is zero" on the service booklet.
• If a fuel leak is present in the fuel injection pipe and fuel supply pump pipe once, do not reuse it
and replace with a new one.
• If the fuel injector assembly, common rail assembly or supply pump assembly is replaced, the
contact surface (seal surface) between the fuel injection pipe and fuel supply pump pipe, and the
other side component is changed, do not reuse the fuel injection pipe and fuel supply pump pipe
and replace with a new one.
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• When the injection pipe is reinstalled, confirm there is no foreign material on the seal surface or in
the pipe and then install it not to deviate from the axis, fitting the seal surface.
Pre-removal Operation Post-installation Operation
• Inlet Manifold Removal (Refer to GROUP 15 − Inlet Mani- • Inlet Manifold Installation (Refer to GROUP 15 − Inlet
fold ). Manifold ).
• Fuel Line Leak Check (Refer to P.13A-590).
<Except Euro5>
20 ± 2 N·m
11 N
17 ± 2 N·m 6
35 ± 5 N·m
8 N
12 10
10 ± 2 N·m 35 ± 5 10 ± 2 N·m
N·m
10 ± 2 N·m
7 35 ± 5 N·m
2 6 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
9
64 ± 5 N·m
24 ± 4 N·m
24 ± 4 N·m
5
AC502865 AG
13A-604 DIESEL FUEL
Supply pump assembly removal Fuel injection pipe removal

steps steps (Continued)
• When the supply pump assembly <> >>B<< 4. Fuel supply pump pipe
is replaced, perform the supply <<C>> >>B<< 6. Fuel injection pipe
pump learning.(Refer to GROUP Common rail assembly removal
00 − Precautions before Service, steps
What the Common Rail Engine 2. Fuel return hose
Learns ) <Installation only>. 3. Fuel inline hose
• Timing belt (Refer to GROUP 11A <> >>C<< 4. Fuel supply pump pipe
− Timing belt ). <<C>> >>A<< 6. Fuel injection pipe
<<A>> >>D<< 1. Injection pump sprocket >>A<< 7. Eye bolt
2. Fuel return hose >>A<< 8. Fuel return gasket
3. Fuel inline hose >>A<< 9. Common rail assembly
<> >>C<< 4. Fuel supply pump pipe >>A<< 10. Eye bolt
>>C<< 5. Supply pump assembly >>A<< 11. Fuel return gasket
Fuel injection pipe removal >>A<< 12. Fuel return pipe
steps
2. Fuel return hose <Euro5>
3. Fuel inline hose
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20 ± 2 N·m
12 N
20 ± 2 N·m 6
35 ± 5 N·m
9N
13 11
35 ± 5
10 ± 2 N·m N·m 10 ± 2 N·m
10 ± 2 N·m
35 ± 5
8 N·m 6 35 ± 5 N·m
10 ± 2 N·m
2 7 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
10
64 ± 5 N·m 24 ± 4 N·m
24 ± 4 N·m
5
AC805678 AB
DIESEL FUEL
13A-605
Supply pump assembly removal 1. Using special tool sprocket holder (MB992048),
steps lock the injection pump sprocket, and then loosen
• When the supply pump assembly the injection pump sprocket mounting nut.
is replaced, perform the supply
pump learning.(Refer to GROUP Injection pump
00 − Precautions before Service, sprocket MB992098
What the Common Rail Engine
Learns ) <Installation only>.
• Timing belt (Refer to GROUP 11A
− Timing belt ).
<<A>> >>D<< 1. Injection pump sprocket
MB992099
2. Fuel return hose
3. Fuel inline hose
<> >>C<< 4. Fuel supply pump pipe AC502178 AB
>>C<< 5. Supply pump assembly
Fuel injection pipe removal 2. Using the special tools below, remove the
steps injection pump sprocket.
2. Fuel return hose • Injection pump sprocket puller (MB992098)
3. Fuel inline hose • Crank pulley puller (MB992099)
<> >>B<< 4. Fuel supply pump pipe
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<<C>> >>B<< 6. Fuel injection pipe
Common rail assembly removal <> FUEL SUPPLY PUMP PIPE REMOVAL
steps CAUTION
2. Fuel return hose When removing the fuel supply pump pipe, the
3. Fuel inline hose fuel pressure in the fuel line is high. Thus, wait
<> >>C<< 4. Fuel supply pump pipe for 3 minutes or longer after the engine stops,
<<C>> >>A<< 6. Fuel injection pipe
and cover the fuel supply pump pipe with a rag or
7. Fuel injection pipe bracket
>>A<<
similar materials to prevent the fuel splash, and
8. Eye bolt
>>A<< 9. Fuel return gasket then disconnect the fuel supply pump pipe.
>>A<< 10. Common rail assembly
>>A<<
<<C>> FUEL INJECTION PIPE REMOVAL
11. Eye bolt
>>A<< 12. Fuel return gasket
>>A<< 13. Fuel return pipe
REMOVAL SERVICE POINTS

<<A>> INJECTION PUMP SPROCKET REMOVAL
Injection pump
MB992048 sprocket MB992188
AC901507AB
Using special tool fuel injection pipe wrench

(MB992188), remove the fuel injection pipe assem-
bly No.1 to No.4.
AC503013 AB
13A-606 DIESEL FUEL
INSTALLATION SERVICE POINTS

>>A<< FUEL RETURN PIPE/FUEL RETURN GAS-
KET/EYE BOLT/COMMON RAIL ASSEMBLY/FUEL
INJECTION PIPE INSTALLATION
MB992188
AK600656 AB
Common rail
Fuel return pipe assembly
AC502866AB
1. Temporarily tighten the fuel return pipe with bolts.

2. Tighten the eye bolt and the fuel return gasket
located at the cylinder head side to the specified
cardiagn.com
torque.
MB992188
Tightening torque:
AK600668 AB
17 ± 2 N⋅m <Except Euro5>
20 ± 2 N⋅m <Euro5> 5. Using special tool fuel injection pipe wrench
CAUTION (MB992188), start tightening the fuel injector
• When operating, do not support the common assembly side flare nut in the fuel injection pipe,
rail assembly by holding the rail pressure lim- and then tighten the fuel injector assembly side
iter and the pressure sensor at both ends. flare nut and common rail assembly side flare nut
alternately in several steps to the specified torque.
• Before the installation, make sure that there is
no foreign object or rust to the thread and to Tightening torque: 35 ± 5 N⋅m
the high-pressure pipe sheet surface. 6. Tighten the common rail assembly to the specified
torque.
Pressure Tightening torque: 24 ± 4 N⋅m
sensor
Pressure limiter 7. Tighten the eye bolt and the fuel return gasket
located at the common rail assembly side to the
specified torque.
Common rail
8. Tighten the fuel return pipe to the specified
torque.
AC502867AB Tightening torque: 10 ± 2 N⋅m
9. Tighten the bolts of the fuel injection pipe to the
3. Temporarily tighten the common rail assembly
specified torque.
with bolts, holding the common rail assembly.
4. Align the fuel injection pipe centre axis with the
other side components (fuel injector assembly 10.Tighten the common rail assembly side flare nut
and common rail assembly) centre axis to install in the fuel supply pump pipe and the supply pump
the fuel injection pipe. Then, tighten the flare nut assembly side flare nut alternately in several
temporarily until the tip of pipe (seal surface) steps to the specified torque.
contacts with the other side components. Tightening torque: 35 ± 5 N⋅m
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.
DIESEL FUEL
13A-607
>>B<< FUEL INJECTION PIPE/FUEL SUPPLY
PUMP PIPE INSTALLATION
CAUTION
MB992188
Pressure
sensor
Pressure limiter
AK600656 AB
Common rail
AC502867AB
• When operating, do not support the common

rail assembly by holding the rail pressure lim-
iter and the pressure sensor at both ends.
• Before the installation, make sure that there is
no foreign object or rust to the thread and to
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the high-pressure pipe sheet surface. MB992188
1. Loosen the common rail assembly mounting bolts AK600668 AB
so that the common rail assembly will be in the

3. Using special tool fuel injection pipe wrench
temporarily installed state.
(MB992188), start tightening the fuel injector
2. Align the fuel injection pipe centre axis with the assembly side flare nut in the fuel injection pipe,
other side components (fuel injector assembly and then tighten the fuel injector assembly side
and common rail assembly) centre axis to install flare nut and common rail assembly side flare nut
the fuel injection pipe. Then, tighten the flare nut alternately in several steps to the specified torque.
temporarily until the tip of pipe (seal surface)
contacts with the other side components.
NOTE: When the fuel injection pipe is installed, 4. Tighten the common rail assembly to the specified
tighten the flare nut while shaking the pipe lightly torque.
to align the centre axis of both components. Tightening torque: 24 ± 4 N⋅m
5. Tighten the common rail assembly side flare nut in
the fuel supply pump pipe and the supply pump
assembly side flare nut alternately in several
steps to the specified torque.
>>C<< SUPPLY PUMP ASSEMBLY/FUEL SUPPLY

PUMP PIPE INSTALLATION
1. Temporarily tighten the supply pump assembly
with bolts.
2. Align the fuel supply pump pipe centre axis with
the other side components (common rail
assembly and supply pump assembly) centre axis
to install the fuel supply pump pipe. Then, tighten
the flare nut temporarily until the tip of pipe (seal
surface) contacts with the other side components.
NOTE: When the fuel supply pump pipe is
installed, tighten the flare nut while shaking the
pipe lightly to align the centre axis of both compo-
nents.
13A-608 DIESEL FUEL
3. Tighten the common rail assembly side flare nut in >>D<< INJECTION PUMP SPROCKET
the fuel supply pump pipe and the supply pump INSTALLATION
assembly side flare nut alternately in several
Injection pump
steps to the specified torque. MB992048 sprocket
4. Tighten the supply pump assembly bolts to the
specified torque.
5. Tighten the fuel supply pump pipe bolt.
AC503013 AB
In the same manner as for removal, using special

tool sprocket holder (MB992048), lock the injection
pump sprocket, and then tighten the injection pump
sprocket mounting nut to the specified torque.
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DIESEL FUEL
SUCTION CONTROL VALVE
13A-609
M1133011900213
Pre-removal and Post-installation Operation

• Battery and Battery Tray Stay Removal and Installation
(Refer to GROUP 54A − Battery ).
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48 ± 6 N·m
(Engine oil)
N7
2 N 6
5
1
8.9 ± 1.9 N·m
4
N3
(Engine oil)
AC704545 AC
Removal steps REMOVAL SERVICE POINT

• Supply pump assembly correction <<A>> SUCTION CONTROL VALVE/GASKET/O-
learning (Refer to GROUP 00 − RING REMOVAL.
Precautions Refer Service, Supply
Pump Correction Learning 1. Clean the area around the suction control valve
procedure ) <only at installation>. with a cleaner, etc.
1. Battery wiring cable connection CAUTION
2. Engine oil level gauge and guide Pay attention not to let foreign materials get into
assembly the supply pump assembly during and after the
3. O-ring
suction control valve removal.
4. Suction control valve connector
connection 2. Loosen the suction control valve mounting bolts,
<<A>> >>A<< 5. Suction control valve and remove the suction control valve from the
<<A>> >>A<< 6. Gasket supply pump assembly.
<<A>> >>A<< 7. O-ring 3. Remove the gasket
4. Remove the o-ring from the supply pump
assembly.
13A-610 DIESEL FUEL
INSTALLATION SERVICE POINT

>>A<< O-RING/GASKET/SUCTION CONTROL
VALVE INSTALLATION Suction control
CAUTION valve connector
• Pay attention not to let the suction control
valve be contaminated with foreign material
when installing it.
• Pay attention not to let foreign materials get
into the supply pump assembly during the Supply pump AC704546AB
suction control valve installation.
1. Fit the O-ring to the O-ring groove on the supply 3. Apply a drop of new engine oil to the O-ring in the
pump assembly. supply pump assembly groove, and insert the
2. Install the gasket to the suction control valve. suction control valve by hands until it contacts
with the supply pump assembly. When inserting
the suction control valve, make sure that the
suction control valve connector is in the direction
shown in the figure.
CAUTION
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Tighten the two suction control valve mounting
bolts evenly.
4. Tighten the suction control valve mounting bolts to
the specified torque.
DIESEL FUEL
THROTTLE BODY ASSEMBLY
13A-611
THROTTLE BODY ASSEMBLY
M1133007600435
3.0 ± 0.5 N·m
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13 ± 2 N·m
5N
3
6.0 ± 1.0 N·m
AC502843AD
Removal steps INSTALLATION SERVICE POINT

1. Engine cover >>A<< THROTTLE BODY GASKET INSTALLA-
2. Inter cooler outlet air hose TION
connection
3. Throttle body connector
4. Throttle body
>>A<< 5. Throttle body gasket Projection
Throttle body
gasket
Throttle body AC502844AB
Install the throttle body gasket as shown in the illus-

tration.
13A-612 DIESEL FUEL
CAMSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR

M1133010000091
(Engine oil)
3N
2
11 ± 1 N·m
AC502938 AC
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1. Camshaft position sensor 2. Camshaft position sensor
connector 3. O-ring
CRANK ANGLE SENSOR

M1133010200147

• A/C Compressor Drive Belt Removal and Installation
(Refer to GROUP 11A − Crankshaft Pulley ).
44 ± 8 N·m
N 5
(Engine oil)
4
11 ± 1 N·m
3 2
1
22 ± 4 N·m AC805916 AC
DIESEL FUEL
ENGINE-ECU
13A-613
<<A>> 1. A/C compressor assembly <<A>> A/C COMPRESSOR ASSEMBLY
2. A/C compressor bracket assembly REMOVAL
3. Crankshaft position sensor
connector 1. With the hose installed, remove the A/C
4. Crankshaft position sensor compressor assembly from the bracket.
5. O-ring 2. After removing the A/C compressor assembly,
secure it with a cord in the location where the
removal and installation of the crankshaft position
sensor cannot be hindered.
ENGINE-ECU
M1133009200767
CAUTION
• After having replaced the engine-ECU, use the M.U.T.-III to register the chassis number. [Refer to
GROUP 00 − Precautions before Service, How to perform chassis number (Chassis No.) writing ].
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• When the engine-ECU is replaced, register the injector identification code and perform the small
injection quantity learning. (Refer to GROUP 00 − Precautions before Service, What the Common
Rail Engine Learns ).
• When the engine-ECU is replaced, make the battery current sensor learn the neutral point by
using M.U.T.-III (Refer to GROUP 00 − Precautions before Service, Battery Current Sensor Calibra-
tion ) <Euro5>.
<LH drive vehicles>
5.0 ± 2.0 N·m

5.0 ± 2.0 N·m
6
4 5
5.0 ± 2.0 N·m

3
2
AC508203 AD

1. Scuff plate 4. Engine-ECU
2. Cowl side trim 5. ECU lower bracket
3. Engine-ECU connectors 6. ECU upper bracket
13A-614 DIESEL FUEL
ENGINE-ECU
<RH drive vehicles>
8
5.0 ± 2.0 N·m
6 5.0 ± 2.0 N·m

7
5 3
5.0 ± 2.0 N·m
7.5 ± 1.5 N·m
2
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AC805918 AB
Removal steps 1. Drill in the break off bolt a hole deep enough for
1. Scuff plate the tap to stand.
2. Cowl side trim 2. Use the recommended tool screw extractor set
<<A>> >>A<< 3. Brake off bolt (MB992678) or equivalent to remove the break off
4. ECU cover
bolt.
5. Engine-ECU connectors
6. Engine-ECU
7. ECU lower bracket INSTALLATION SERVICE POINT
8. ECU upper bracket >>A<< BREAK OFF BOLT INSTALLATION <RH
DRIVE VEHICLES>
REMOVAL SERVICE POINT Tighten the break off bolt until its head is broken off.
<<A>> BREAK OFF BOLT REMOVAL <RH DRIVE
VEHICLES>
Break off bolt

ECU bracket
MB992678 or equivalent AC609908AG

13B-1
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-2 FUEL GAUGE UNIT DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13B-5
SPECIAL TOOL(S) . . . . . . . . . . . . . . 13B-2 FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13B-5
FUEL FILTER . . . . . . . . . . . . . . . . . . . 13B-6
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ON-VEHICLE SERVICE. . . . . . . . . . . 13B-2
FUEL LEAK CHECK OF FUEL TANK . . . . 13B-2 FUEL FILTER REMOVAL AND INSTALLATION
<Vehicles with steel fuel filter case> . . . . . . 13B-6
FUEL DRAINING . . . . . . . . . . . . . . . . . . . . 13B-3
FUEL FILTER REMOVAL AND INSTALLATION
<Vehicles with plastic fuel filter case> . . . . . 13B-8
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-4
FUEL FILTER INSPECTION . . . . . . . . . . . . 13B-9
FUEL TANK REMOVAL AND INSTALLATION
...................................... 13B-4
13B-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100725
Fuel tank is mounted on the front of the rear axle to
reduce the shock at impact. A fuel cut valve, which
prevents fuel leakage when the vehicle banks or rolls
over, has been located inside the fuel tank for fewer
openings and hose bonding points on the fuel tank
top surface.
SPECIAL TOOLS
M1135000601143

MB992145 Fuel leak check cap Fuel leak check
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B992145
MB992264 Fuel hand pump Fuel draining
B992264
MB992265 Fuel hose adaptor A
B992265
MB992266 Fuel hose adaptor B
B992266
ON-VEHICLE SERVICE
FUEL LEAK CHECK OF FUEL TANK
M1135005900566 MB992145
CAUTION
Always check the fuel leak of fuel tank with the
vehicle loaded. If it is checked with the fuel tank
removed, the fuel tank may be damaged.
AC600149 AC
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-3
1. Remove the fuel tank cap, install special tool fuel 5. Leave it for approximately 3 minutes and check
leak check cap (MB992145). that the pressure is not weakened.
6. If the pressure is weakened, apply soapy water to
each part with pressurized state and check the
leak while confirming if air bubbles are seen.
MB992145 Pressure
gauge
FUEL DRAINING
M1135006900321
CAUTION
• Working area should be airy and kept from
flame.
• Prepare a fire extinguisher before working.
• Install the earth lines to the vehicle and fuel
Trigonal joint tank to prevent static electricity, and water the
work place to keep the footing from slipping.
• Touch the vehicle with hands to release the
Air gun charged static.
• Keep the drained fuel in the safety place.
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Hose blocking plier
Fuel hose
AC600150AB
2. Install the hose and pressure gauge to the special

tool (MB992145) as shown.
Fuel tank hose

Fuel pipe AC711661 AB
Fuel filler
neck 1. Disconnect the fuel pipe on the side of fuel tank
from the fuel hose on the front side of fuel tank.
Hose
blocking
plier MB992265
Rear tire (LH) MB992264
AC711418 AC
Fuel hose
3. Remove the splash shield rear (LH) (Refer to
GROUP 42 − Splash Shield ), and block the fuel
tank hose. Fuel hose
(bore: 7.6 mm)
CAUTION AC711667AB
• Do not pressurize suddenly.
• Do not pressurize 11.76 kPa or more to pre- 2. Connect the special tools fuel hand pump
vent the damage of components. (MB992264), fuel hose adaptor A (MB992265)
4. Pressurize while checking the pressure gauge and two fuel hoses (Inner diameter 7.6 ± 0.4 mm)
and hold if it reaches from 9.80 to 11.76 kPa. to the disconnected fuel hose.
3. Operate the special tool (MB992264) to drain fuel
from the fuel tank.
13B-4 FUEL SUPPLY
FUEL TANK
FUEL TANK
M1135001902913

• Rear Splash Shield (LH) Removal and Installation (Refer
to GROUP 42 − Splash Shield ).
18
2.5 ± 0.4 N·m

7
20
17
11
9
12 N 19
4 16
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3
2 15
10
5
14
1
13
6N
55 ± 3 N·m
N 6
55 ± 3 N·m
AC805923 AB
Fuel tank removal steps Fuel tank removal steps

1. Fuel filler hose connection 11. Fuel gauge unit
2. Vapour hose connection 12. Packing
3. Levelling hose connection 13. Front lower protector
4. Fuel return pipe connection 14. Fuel tank
5. Fuel main pipe connection Fuel filler neck removal steps
<<A>> >>A<< 6. Self-locking nut 15. Fuel filler hose
<<A>> 7. Fuel gauge unit connector and 16. Vapour hose
harness clamp 17. Levelling hose
<<A>> 8. Fuel tank assembly 18. Fuel filler cap
9. Fuel return hose 19. Fuel filler neck
10. Fuel main hose 20. Packing
FUEL SUPPLY
FUEL TANK
13B-5
REMOVAL SERVICE POINT 3. Disconnect fuel gauge unit connector, and
<<A>> SELF-LOCKING NUT/FUEL GAUGE UNIT harness clamp. Then, remove the fuel tank
CONNECTOR AND HARNESS CLAMP/FUEL assembly.
TANK ASSEMBLY REMOVAL
INSTALLATION SERVICE POINT
CAUTION
Be careful not to open circuit in the harness >>A<< SELF-LOCKING NUT INSTALLATION
when removing the fuel tank assembly. CAUTION
Front lower protector Fuel tank

Fuel tank assembly
or reinforcement part
Self-locking nut
Transmission jack
AC504246AB AC505408 AC
When tightening the self-locking nut, be careful
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1. Support the fuel tank assembly using the
transmission jack, and remove self-locking nuts. not to let the nut touch the bent part of the rein-
forcement of the fuel lower protector and the fuel
2. Using the transmission jack while taking care of
tank.
the fuel harness, lower the fuel tank assembly
until the fuel harness installation position over the DISASSEMBLY AND REASSEMBLY
fuel tank assembly can be checked. M1135051100251
FUEL GAUGE UNIT
AC611598AB
Disassembly steps FUEL GAUGE UNIT CHECK

1. Fuel in-tank filter M1135003100586
2. Fuel tank gauge Refer to GROUP 54A − On-vehicle Service, Fuel

Gauge Unit Check .
13B-6 FUEL SUPPLY
FUEL FILTER
FUEL FILTER
REMOVAL AND INSTALLATION <Vehicles with steel fuel filter case>
M1135002800559
Post-installation Operation
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
1 1
7N
5.0 ± 1.0 N·m
6
N5
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12 ± 2 N·m
2
4
6.0 ± 1.0 N·m
N 3 0.6 ± 0.2 N·m
AC807196 AB

>>B<< 1. Fuel line hose connection <<A>> FUEL FILTER REMOVAL
2. Fuel filter assembly
3. Fuel line plug (drain plug)
4. Water level switch
<<A>> >>A<< 5. Fuel filter
6. Fuel filter pump
7. Fuel line plug (air plug) and O-
ring
AC502833AB
Fix the fuel filter body to a vice, and then remove the
fuel filter using an oil filter wrench.
INSTALLATION SERVICE POINTS

>>A<< FUEL FILTER INSTALLATION
1. Clean the mounting surface on the fuel filter body
side.
FUEL SUPPLY
FUEL FILTER
13B-7
2. Tighten the fuel filter to the specified torque from >>B<< FUEL LINE HOSE INSTALLATION
the point where the gasket contacts the mounting
surface.
Tightening torque: Approximately 3/4 − 1
turn (12 ± 2 N⋅m)
20 – 25 mm
AC503372AB
If the pipe has a stepped part, connect securely up to

the stepped part. If the pipe has no stepped part,
insert so that the inserted portion 20 − 25 mm long.
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13B-8 FUEL SUPPLY
FUEL FILTER
REMOVAL AND INSTALLATION <Vehicles with plastic fuel filter case>

M1135002800560
Post-installation Operation
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
2 11 ± 2 N·m
N 6
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1
N 7
11 ± 2 N·m
N 4
8 11 ± 2 N·m
ACB01919AB
Fuel filter removal steps Removal steps (Continued)

1. Fuel filter protector B 7. O-ring
<<A>> >>A<< 5. Fuel filter cap 8. Fuel filter case
6. Fuel filter and O-ring • Glow plug control relay and
7. O-ring bracket (Refer to GROUP 16 −
Removal steps Glow System, Glow Plug Relay )
1. Fuel filter protector B 9. Fuel filter protector A
>>B<< 2. Fuel line hose C connection
>>B<< 3. Fuel line hose B connection REMOVAL SERVICE POINTS
4. Fuel line plug (drain plug) and O- <<A>> FUEL FILTER CAP REMOVAL
ring
1. Loosen the drain plug to drain the fuel. Then,
<> >>A<< 5. Fuel filter cap
6. Fuel filter and O-ring tighten the drain plug.
FUEL SUPPLY
FUEL FILTER
13B-9
Mark
OP E N
Fastener
nut
ACB01912 AB ACB01914AB
2. Insert a flat-tipped screwdriver into the groove of 2. Securely tighten the fastener nut until the mark is
the fastener nut. in the position shown in the figure (until it clicks in
3. Loosen the fastener nut using the flat-tipped place).
screwdriver until it can be loosened by hand.
>>B<< FUEL LINE HOSE CONNECTION
<> FUEL FILTER CAP REMOVAL
cardiagn.com
Under 2 mm
Fastener
nut ACB02187AB
ACB01912 AB Securely insert the fuel line hose to the fuel filter and
install the hose clip in the position shown in the fig-
1. Insert a flat-tipped screwdriver into the groove of ure.
the fastener nut.
2. Loosen the fastener nut using the flat-tipped INSPECTION
screwdriver until it can be loosened by hand. M1135002900233

INSTALLATION SERVICE POINTS WATER LEVEL SWITCH CHECK
>>A<< FUEL FILTER CAP INSTALLATION 1. Connect the circuit tester to the water level switch.
1 2
Float
ACB01913 AC502835 AC
1. Install the fuel filter cap by aligning the marks on 2. There should be continuity when the float is
the fuel filter cap and the fuel filter case. raised, while there is no continuity when it is
lowered.
3. Replace the fuel filter assembly if it is faulty.
13B-10 FUEL SUPPLY
FUEL FILTER
<Vehicles with plastic fuel filter case> 3. Replace the fuel filter assembly if it is faulty.
WATER LEVEL SWITCH CHECK
1. Connect the circuit tester to the water level switch. FUEL FILTER VACUUM SWITCH CHECK
Float
ACB01916AB
ACB01915AB
1. Connect the circuit tester to the fuel filter vacuum

2. There should be continuity when the float is
switch and check to see that there is continuity
raised, while there is no continuity when it is
between the terminals.
lowered.
2. Replace the fuel filter assembly if it is faulty.
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13-1

DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A

GENERAL INFORMATION . . . . . . . . 13A-6 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-68

CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-155 TEMPERATURE SENSOR CIRCUIT LOW INPUT

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-604 CAMSHAFT POSITION SENSOR . . . 13A-613

IDLE SPEED CONTROL

OTHER CONTROL FUNCTIONS

FUEL INJECTION SYSTEM DIAGRAM

5 Rail pressure sensor

7 Intake air temperature sensor No. 2

5 Rail pressure sensor

Item Specified sealant

Tool Number Name Use

MB991658 Test harness • Measurement of voltage

MB991709 Test harness • Measurement of voltage

Tool Number Name Use

MB992042 Engine coolant Removal and installation of the

MB990784 Ornament remover Carbon deposit cleaning

MB991614 Angle gauge Installation of injector holder bolt

MB992048 Sprocket holder Injection pump sprocket bolt

MB992098 Injection pump sprocket Injection pump sprocket removal

MB992099 Crank pulley puller

tion. (Refer to GROUP 00 − Precautions Before

ENGINE WARNING LAMP INSPECTION ITEMS

Code No. Diagnosis item

Code No. Diagnosis item

Code No. Diagnosis item

500*2 Air flow sensor g/s

501*2 Throttle position sensor (main) %

507*2 Target exhaust gas recirculation valve %

508*2 Barometric pressure sensor kPa

509*2 Relative throttle position sensor %

511*2 Accelerator pedal position sensor (main) %

512*2 Accelerator pedal position sensor (sub) %

516*2 Engine coolant temperature sensor °C

526*2 Crank angle sensor r/min

527*2 Vehicle speed km/h

529*2 Intake air temperature sensor °C

537*2 Power supply voltage V

541*2 Throttle valve control servo %

560*2 Rail pressure sensor kPa

573*2 Exhaust gas recirculation error %

NOTE: *3: Time between engine start and malfunction detection.

FAIL-SAFE FUNCTION REFERENCE TABLE

Malfunctioning item Control contents during malfunction

Malfunctioning item Control contents during malfunction

INSPECTION CHART FOR DIAGNOSIS

Diagnosis Diagnosis item Reference page

Diagnosis Diagnosis item Reference page

Diagnosis Diagnosis item Reference page

Code No. P0003: Suction Control Valve Open <Euro5>

Suction Control Valve Circuit

116 117 Engine-ECU

Wire colour code

OPERATION • 2 seconds later after the ignition switch has been

DIAGNOSIS PROCEDURE STEP 3. Connector check: C-103 engine-ECU

<R.H. drive vehicles>

Q: Is the check result normal?

YES : Go to Step 3 . Harness side connector AKA00090 AB

C-103 (B) <R.H. drive vehicles>

<R.H. drive vehicles>

Harness side connector AKA00090 AB