WORKSHOP MANUAL F<-SERIES EMISSION AND ELECTRICAL DIAGNOSIS 6SDI-TC/6HEI-TCN/6HEI-TCC/6HEI-TSS SECTION 6E ISU2UNOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section OA under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL". All material contained in this Manual is based on latest product information available at the time of publication. All rights are reserved to make changes at any time without Prior notice, Applicable Model : F <-SERIES ‘SDI-TC/GHEI-TCN/GHEL-TCC/6HEL-TCS ‘This manual is applicable to 1997 year model and later vehicles.THIS MANUAL INCLUDES THE FOLLOWING SECTIONS: SECTION NO. CONTENTS: 6 EMISSION AND ELECTRICAL DIAGNOSISEMISSION AND ELECTRICAL DIAGNOSIS 6E-1 SECTION 6E EMISSION AND ELECTRICAL DIAGNOSIS YV CAUTION: ‘When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. Ifthe correct part number fastener is not available, a fastener of equal size and strength for (stronger) ‘may be used. Fasteners that are not reused, and those requiring thread locking compound, will be celled out. The correct torque values must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. CONTENTS PAGE General Description .. 6E-3 Abbreviations and Symbols. 6E-3 Introduction to Isuzu Electrical Control Engine System ... 6E5 Engine ECU Wiring Diagram 6E-6 ‘System Component Location .. 6E7 Engine ECU Terminal Assignment . 6E-9 Diagnostic Procedure... 6E-10 How to read DTC.. 6E-13 Non DTC Failure Procedure / Cancellation DTC 6E-13 DTC Code List 6E-14 DTC 33. Memory (RAM) error... 6E-16 DTC 543 Excessive high revolution error. 6E-17 DTC 10 Rack senso 6E-18 DTC 15 Ne Sensor Error . GE-25 DTC 29 Pre-Stroke Servo System Error 6HEI-TCN/C/S. 6E-30 DTC 29 Pre-Stroke Servo System Error 6SDI-TC . 6E-37 DTC 291 Pre-Stroke Sensor Error 6HEI-TCN/C/S. 65-44 DTC 291 Pre-Stroke Sensor Error 6SDI-TC... vo GE-50 DTC 292 Pre-Stroke Learning program Error 6HEI-TCN/C/S... . 6E-56 DTC 292 Pre-Stroke Learning program Error 6SDI-TC 6E-62 DTC 23 Coolant Temperature Sensor Error 6HEI-TCN/C/S.. 6E-68 6E-75 DTC 23 Coolant Temperature Sensor Error 6SDI-TC ..6E-2 EMISSION AND ELECTRICAL DIAGNOSIS DTC 71 Atmosphere Pressure Sensor Error 6GHEI-TCN/C/S. DTC 413 Magnetic Valve Failure for IVES. DTC 423 Pre-Stroke Power Source Fuse Off 6E-81 6E-82 6E-87EMISSION AND ELECTRICAL DIAGNOSIS 6E-3 ABBREVIATIONS ‘The following abbreviations may appear in this manual. ABBREVIATION MEANING ABBREVIATION | MEANING AIC ‘AIR CONDITIONER: N NEUTRAL (TRANSMISSION ACC ACCESSORY GEAR) ACT ACTUATOR Ne ENGINE REVOLUTION AssiT ASSISTANT OFF ‘TURN OFF (SWITCH/LAMP) BATT BATTERY ON. TURN ON (SWITCH/LAMP) orT OPTION cas CAB AIR SUSPENSION osc STANDARD WAVE FORM. cas CU | CAB AIR SUSPENSION CONTROL| VOLTAGE UNIT CONN CONNECTOR PIBRAKE PARKING BRAKE cu CONTROL UNIT PGND | POWER GROUND (TO BooY | EARTH) pc DIRECT CURRENT PIN PIN or TERMINAL DICONN DIAGNOSIS CONNECTOR PAL PILOT (WARNING) LAMP. DIAG DIAGNOSIS PRESS PRESSURE omv DIGITAL MULT! VOLTMETER PS PRE-STROKE pte DIAGNOSTIC TROUBLE CODE | P/T POWER TRAIN PWR POWER SOURCE ecu ELECTRICAL CONTROL UNIT | EMI ELECTRIC MAGNETIC FIELD RH RIGHT HAND (SIDE) INTERFERENT RHD RIGHT HAND DRIVE EXH EXHAUST Ri RELAY RR REAR FRT FRONT S/ASB SHOCK ABSORBER GND GROUND (BODY EARTH) sic | SIGNAL SiD SHIELD IN INLET, INTAKE, ss SPEED SENSOR PUMP INJECTION PUMP. ss cjU SPEED SENSOR CONTROL UNIT IVES ISUZU VARIABLE ELECTRICAL | STD STANDARD AND ECONOMY SWIRL SYSTEM | SUSP SUSPENSION sw SWITCH tH LEFT HAND (SIDE) LHD LEFT HAND DRIVE Tics TIMING AND INJECTION RATE CONTROL SYSTEM MAG MAGNETIC Tov TRAILER COCK VALVE mo. PRE-STROKE LEVER DRIVE. | MEM, -CLR MEMORY CLEAR wit WARNING LAMP ME/CONN: MEMORY ERASER CONNECTOR MN MAGNETIC VALVE6-4 EMISSION AND ELECTRICAL DIAGNOSIS PARTS FOR ELECTRICAL CIRCUIT Wiring Wire Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single colar. Wires belonging to a system's sub circuits will have a colored stripe. Striped wires use the following code to show wire size and colors, Example: 08 GB Singlo color Colored stripe — Red (Stripe color) —— Green (Base color) \_ wire size (0.5 mm) Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table. Wire Color Coding Color-coding Meaning |___ Color-coding Meaning _ 8 “Black Br | Brown w White lg Light green [oR | Red - Gr __ Gray | _ Groen Pink __Y : Yellow Sb Sky blue ol Blue v | Violet o Orange ‘Dutside diameter Wire size Tho size of wire, used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The following wire size and load capacity, shown below, are specified by JIS (Japanese Industrial Standard) (Nominal size means approximate cross sectional areal Cross sectional area ‘Outside diameter | Allowable current (A) (mm) (mm) - Z os om 18 3 oes oes 22 % 125 a8? Fa n 3 bet 28 | is 3 53 3 as 3 S207 te % 3 $382 os @ ’ 1338 7 % 20 20.61 82 7EMISSION AND ELECTRICAL DIAGNOSIS 6E-5 Introduction to Isuzu Electrical controlled engine system TICS (Timing and Injection rate Control System) TICS system indicates target pre-stroke position by engine load condition, which is measured by rack position, and engine revolution with adjustment based on all sensor signals. The system detects actual pre- stroke position, then feedback pre-stroke actuator to meet target pre-strake position, Engine revaiution —Lo | Determine pre Torgetpre-stroke position siroke postion = [+f Adjustment j Actual pre-stroke Steet oo (Comparnon HOR "Boost pressure Comparison = Wter tmp + Switch contion signal te 1 ‘Actuator driver Engine loas —f->| Control unit Prosstoke actuator — Pre-stroke sensor IVES (Isuzu Variable Electrical and Economy Swirl system) Based on engine load condition, which is measured by rack position, and engine revolution, current swirl condition (magnetic valve position) is calculated. Appropriate swirl condition is adjusted by all sensor signals. ‘Swirl condition is controlled by IVES magnetic valve activation, which operates valve in Inlet manifold controlled by high pressure air. Bararmine Engine revolution | , omens paraten | —ef Aasment | — Engine load —}e| operation 1 Signatinpt = —| _ - b + Boost prossure _ — Water temp | + Swath coneltion i signals et seanpon “Actuator driver Control unit loet valve Ale cytindar6E-6 EMISSION AND ELECTRICAL DIAGNOSIS. Engine ECU Wiring Diagram ccuwn [5 NeSeNsoR tse uy: Ps tan cur 3 sw staat rs =| ean sivsainceness | i_@- 38) | aHELTeS ONLY 3 le) 3 | RACK SENSOR pi @G uy | a ) | _swo 5 | 8 >—wly 3 omens y coolarenr (4) sensor | _ ay wha 39 Armoaphere ae 95 Swinias ___fp9) || ae T J) por aamorto | ; a evens [= ee ? (PASO OUT ts Taco METER ECU-GNO2 = &] >: 48) { ——— ne =) f Lo EMI-GND- Ga) a ~ CASE EARTHEMISSION AND ELECTRICAL DIAGNOSIS _6E-7 Component location (GHEI-TCN/C/S, 6SDI-TC) Engine ECU Compresed air low pressure eniten (only SHELTCS) Wes ‘magnetic valve (GHELTCS only) Engine (6HEI-TCN/C/S) Coolant temperature sensor (dull Pro-stroke sensor Pro-stroke actuator ack sensor Engine revolution sanaor6E-8 EMISSION AND ELECTRICAL DIAGNOSIS Engine (6SDI-TC)EMISSION AND ELECTRICAL DIAGNOSIS 6E-9 Engine ECU Terminal Assignment en ae . i Vn SS tony *” BEEEEEEEE bE be BEEEEEEEC EEE pba: CCEEEE EE 14 = pa 48 26pin connector 28 38 22pIn connector ~ ~ HEN] ORE! eso] 7 |SHEI) GHET [6SDI [hej tome no none __ [ta] tel heart LES Se 5 ib 3 a = {ake our £ 75 [ PS SENSOR ( = = Stra Senson wa ee vice FT eaeucenees vies [35 frevepspmmcur——|-S-—¢ ia = "5 : [PS SENSOR (GND) Bre sensor sto a 3 a is ace — OE =6E-10 EMISSION AND ELECTRICAL DIAGNOSIS DIAGNOSTIC PROCEDURE Diagnostic procedure Note Take notes of present Diagnostic trouble code (OTC) during diagnosis, especially multiple DTC present. Even though DTC can be cleared, diagnose related area in the system. Because DTC means there is or was some failure, the failure may happen later. (CSanrswon_] | +) Wil malfunction + Electieal source! ‘ground openishout + Control unit malfunction “Wiel malfunction + Diagnostic SW circuit malfunction “ECU electrical source circuit malfunction SECU self matfunction Ee] jentined area J} —— ‘What is DTC OV or not? °F History ode or Tatars What is OTC Currently faire Dt or not? y presents, Not ‘Some failure mode ean not be duplicated if engine failure ‘enot warmed up or fload of engine s not applied. ‘System does nat have on ‘Saree SW OFF 5 Fifer to the DTC ist Sianer SW OFF Peter Tantirm cleared OTC code.EMISSION AND ELECTRICAL DIAGNOSIS GE-11 Self diagnosis function 1 2. DTC is recorded in ECU EEPROM, and it can be cleared by starter switch ‘OFF* or by removing ECU off the vehicle. Clear DTC In order to clear DTC stored in ECU EEPROM, operate memory clear switch. DTC clear procedure 1 Check if the memory connector is off. Tum starter switch off, and turn starter switch on. Leave starter key on for 1 sec Disconnect memory connector after step 3, memory is cleared for 0.5 sec after disconnected. ‘Tum starter off, and on. Check DTC cleared. H DTC still exist, repeat step 1 though step 4. ‘Tum starter switch off and finish this process, Memory clear switch position Confirm DTC code for dealer mode Diagnosis code is detected by flashing W/L.6E-12 EMISSION AND ELECTRICAL DIAGNOSIS Detect DTC by Warning Lamp (W/L) Operation Connect Diagnosis connector, then W/L starts to flash. Flashing signal give DTC code, refer to ‘the how to read DTC" Display Engine revolution=0-sdisplay present code and history code Engine revolution¢0—sdisplay present code only Note: if no failure occurs ar no history code is stored, flash ‘001" code.EMISSION AND ELECTRICAL DIAGNOSIS 6E-13 How to read DTC Three different flashing digits indicate number is started from three-digits number, two different flashing, digits indicate number is started from two-digit number in order. Identify DTC from flashing number. When multiple DTC present, same DTC repeats three times and then turn to next DTC. [Example] Case of OTC 42, Unit see Sipe Be Light eon se eg Ta aoa, on i OFF Twodigit lexample} Case of aigits OTE 242 Unit see oy Mo igi aa | pe 12 pe 02 gene on ore wd Jt Tmee-disit Twodigt __Onedig _‘Three digit The check procedure of non DTC failure (user mode) When diagnosis sw is OFF, W/L on indicates the system failure. ‘There are three different ways of WIL indication, 1.0 warning light (WIL) ON sun. '—" refer to DTC list, DTC is recorded, but no WiL on. 2. conditionally WiL on... * refer to DTC list Addition to DTC triggers, condition lasts more than 20 sec at less than 600 PRM (Nel engine revolution, then W/L light ON. 3. always W/L on "refer to DTC list When DTC triggers, W/L always light on. Note: W/L indicates the following in case of no failure N light on Neeo light off Cancellation of DTC When DTC is triggered, perform back-up mode, One type of DTCs are canceled even though during back-up mode, if itis detected failure is no more. The other type of DTCs are not canceled until ECU is reset, First type of DTC means ne damage to engine even for driving, second DTC means engine damage may occur by driving.6E-14 EMISSION AND ELECTRICAL DIAGNOSIS. Diagnosis Trouble Code (DTC) list Euroll 6SD1-TC/6HE1-TCN/6HE1-TCC/GHE1-TCS Pa oe ee sca fee a ESTERS oe ed ane $e oe fare ae ae ene | tin | —abarravie fein avon epee 7 ns menace meres ba [tere a7 acres —— aaa ap oer a | -aodey © ie \ | fo - Se aes ofcereca ieee Spas sarin ago es. 4 ee ae pe ace ee t ee Note ‘user mode display is as follows; © :4ess than 600 rpm and last more than for 20 sec © :lighton continuously © no ight on 2 rack sensor ouput (igh sie) dlagnoss volage are diferent among engines; GHEL-TCSICIN es01TC 8.rack sensor output lw side) cngnosis vollage are: SHELTCSICIN ——— 02V es0/TC 4. Prestroke angle (uritdeg) equivalent to 28 doy CA are ciferent OHELTCS SSD/-TCCN @s01TC 5. if ¢3.deg CA diference between target and actual angle, turn on always. it-3 deg CA ciference between target and actual angle, does tur on. 6. the following condition is not detected 2st 7. DTCé other than code 33 not detected at less than 18 volsEMISSION AND ELECTRICAL DIAGNOSIS 6E-15 ae pissy parca SS a : aie | RE 1 — o ie — Te esta Te 4 ae 2 hs ene lp 9 lp fateeheeesercins |B [is more (8 8 8 i ~ eae co aE oO neo vtage comes |) pote nen igo on lo Ob 7 nen) Fa hee — SIS ge nies on 4 E lo 3 é| a6E-16 EMISSION AND ELECTRICAL DIAGNOSIS DTC 33 Memory (RAM) Error ‘STEP ACTION Yes NO Replace ECU SolvedEMISSION AND ELECTRICAL DIAGNOSIS 6E-17 DTC 543 Excessive high engine revolution error ‘STEP ACTION YES NO. 1 | 1 Stoner SWON GotoDTC 1 | Goto Step? 2. Connect diagnosis connector, read WIL flashing, 3, DTC code 15 is displayed? 2 This failure is caused by engine over runt Solved Inspect by the following step. Inspect engine it self Inspect memory clear connecter off | 3. Starter switch ON - Connect memory connecter for more than Isec, then | disconnect it. 5. Connect diagnosis connecter, then read flashing of, wit. 6. Confirm if DTC is cleared.6E-18 EMISSION AND ELECTRICAL DIAGNOSIS DTC 10 Rack sensor Engine ECL Connector 25pin sic. 307 L213J viniy @ 2s! sos | | | Lewy 0 ‘SIG Rack — | ERAT | Sor Engine ECU Harnese Injection Pump Rack Sensor Connector 'SWP 3pin whiteEMISSION AND ELECTRICAL DIAGNOSIS 6E-19 Engine ECU Connector (Gray! 26pin connector Engine ECU6E-20 EMISSION AND ELECTRICAL DIAGNOSIS Voltage check extension harness (service special tool) Voltage check extension hamess is available as special tool to determine rack sensor failure or not. Connect the extension harness between rack sensor and vehicle harness, then measure tester out put voltage. SS a eel feck senor = Connect to vehicle hares PartNo Connect to rack sensor SWP 3pin connget to rack sensor SWP 3pin No conriection Connector fortester Part No, 182625-8300 ‘in connector for voltage measurement.EMISSION AND ELECTRICAL DIAGNOSIS 6E-21 <6HEI-TCN/C/S> _= TICS connector ‘grav 6pin © Rack sensor (oehite) spin Governor <6SDI-TC> Tics connector soovton es Rack sensor 2D eho in Rack sendor Governer (unite 3pint Injoetion pump sido connector {Located in connostor box) Terminal ] Color af Tam | sional name | Coen [sie ‘@NDSE-22 EMISSION AND ELECTRICAL DIAGNOSIS Output voltage check by the extension harness ne min pump herness (ook senso Vehicle Ciruit ester (OM) Aacksonsor — Connaetor box Voltage chock ‘Connector for voltage 1. Connect voltage check extension harness to vehicle harness and I/pump harness (rack sensor). 2. Turn on Ignition key on, and measure output voltage. Use DMV (Digital Multi Volt meter) Output voltage rere Traine condition] Outoutvotage]| Remark Connector [= terminal «> eterninal | 45-5801 | for vohage | (+6V) (GND) — - | measure: 5 erin « terminal ile postion] ie postion” | 187810) SSOUTC Iwhite Spin) | (SIG) (GND) SHELTON. | _ [enevres — Wie postion | Novum Check by t than 1.01}. |changod value l {ul posiEMISSION AND ELECTRICAL DIAGNOSIS 6E-23 DTC 10 Rack sensor error 2. Disconnect the extension harness, then connect rack sensor connector. 3. Connect ECU 26pin connector 4 Starter sw on. 5. Run engine 6. Connect diagnosis connector. then read Wil flashing, 7. Was DTC 10 displayed? STEP ACTION YES NO 7 Starter aw off Goto Step Goto Step2 2, Disconnect rack sensor connector inside of connector | box, insert the extension harness between rack sensor | and engine ECU harness 3. Starter sw on. 4 Measure output voltage at b terminal and e terminal by the extension harness 6. Operate Ifpump levor from idling to full position at no | | engine run. | 6. Did output vottage change more than 1.0V? 2 1. Starter sw OFF Goto Step3 | Ropairor 2. Disconnect engine ECU 26pin connector Replace engine 3. Disconnect rack sensor connector | ECU harness 4. Check continuity of rack sensor «5V at No.8 and No.4 | of engine ECU connector? ______5.Was resistance value less than 1 ohm? _ - . 3 1. Inspect if rack sensor circuit (+5V) has short circu Goto Step4 | Repair or Measure at ECU connector No.8 and body ground. Replace engine 2. Was resistance infinity.? _ ECU harness _| 4/1. Inspect if rack sensor circuit (SIG) has continuity. Goto StepS | Repair or ‘Measure at ECU connector No. terminal and rack Roplace engine sensor connector No.2. ECU harness 2. Was resistance less than 1 ohm? - _ S| 1. Inspect if rack sensor circuit (SIG) has shor eiroul Repair 07 Measure at ECU connector No. terminal and body Replace engine ground. | ECU harness | 2. Was resistance infinity? _____| Goto Step 66. - & 1. Inspect if rack sensor circuit (GND) has continuity. | Repair or Measure at ECU connector No.21 terminal and rack Replace engine sensor connector No.1 ECU harness 2. Was resistance less than 1 ohm? a 7 | 1. Inspect if rack sensor circuit (GND) has short circuit. | GotoStep8 | Repair or Measure at ECU connector No.21 terminal and body | | Ropiace engine ground | ECU harness 2. Was resistance infinity? | - B _t-Inspectif rack sensor circuit {each terminal has short | Goto Step 11 | Repair or circuit? measure among ECU connector No.8, 9,21. | | Replace engine 2.Was resistance infinity? | _ ECU 9 1.Stan sw off Goto Step 10 2. Disconnect ECU 26 pin connector | Replace engine 3. Disconnect rack sensor connector ECU harness 4. Inspoot if rack sensor circuit (SIG) has continuity? Measure at ECU connector No.9 terminal and rack sensor connector No.2. ___8. Was resistance less than 1. ohm? ~_ 10 1. Start sw off Goto Step 11 | Goto Step 126E-24 EMISSION AND ELECTRICAL DIAGNOSIS DTC 10 Rack sensor error 3. Starter sw ON 4, Connect memory clear connector for more than 1 sec, then disconnect. 5, Connect diagnosis connector, then read WiL flashing. 6. Was DTC cleared? STEP. ACTION Yes. NO. 1 1. Start sw off TPump replace | Goto Step 12 2. Replace ECU 3, Starter sw on 4, Run Engine 5. Connect diagnosis connector, then read WiL flashing ______| 6. Was DTC 10 displayed? _ 12 | 1. Stop engine Solved Go back to 2. Confirm memory clear connector off Step 1wos EMISSION AND ELECTRICAL DIAGNOSIS GE-25 DTC 15 Ne sensor error Engine ECU Connecter (26pin) rae Engine ECU Harness Ne Sensor Connector 'SWP Spin white fa Ne Sensor Ne Sensor6E-26 EMISSION AND ELECTRICAL DIAGNOSIS Engine ECU Connector (Gray) 26pin connector Diagnosis connector Memory clear connectorEMISSION AND ELECTRICAL DIAGNOSIS 6E-27 Ne sensor appearance, terminal assignment Ne sensor appearance {Gr20n 3oin) Ne sensor side connector Located in connector box) Tanna we WO" | Saal name | SE ote Measure Ne-sensor resistance Circuit tester OMY) ar Connect box ‘Moaaure resistance berwoen these fac (gr0n 3pin) ‘Ne sensor side connector {Located in connector box! WDC remove ot venice naess CG + — nie sensor SS) Tone sansor Resistance ——irapestion are esis [Remark Tonk B= 251K) = GRO Groom ap) ws Shield 8|8 8/8 Shield <- Bod)6E-28 EMISSION AND ELECTRICAL DIAGNOSIS Inspect gap of Ne-sensor Ly / . Ht dy (4 8 £ capEMISSION AND ELECTRICAL DIAGNOSIS 6E-29 DTC 15 Ne-sensor error a 5. Was DTC 15 displayed? - 2. Inspect Ne-sensor gap. | 3. Was gap value less than the following? 6HEI-TCNIC/S less than 1 mm. | 6SDI-TC _lessthantmm | STEP ACTION [ves NO 1 | 1 Starter SW OFF Goto Step? | Goto Stops 2. Disconnect ECU 26pin connector 3. Measure resistance of Ne-sensor circuit at ECU 26pin connector, No.10 and 23 terminal | _ | 4. Was resistance between 2.1 - 2.5 chm? _ 2 | 1. Inspect if Ne-sonsor circuit has short circuit. Measure | GotoStep6 | Goto Step5 at ECU connector terminal No.10, 23 and body ground 2. Was resistance infinity? _ _ _ 3 1. Disconnect Ne-sensor connector 3pin in the connector | Go to Step 4 Replace Ne box. sensor 2, Measure resistance Ne-sensor circuit between SIG terminal (no.1 terminal) and GND (No.2 terminal at Ne-sensor side connector i 3. Was resistance between 2.1 -2.5 ohm? { 411. Inspect if Ne-sensor circuit has short circuit between [Repair or replace’ Replace Ne each terminal and SLD. Probe between No.1 terminal | engine ECU sensor and No.3, and between No.2 terminal and 3 of Ne- hamess sensor side connector. | 2. Was resistance infinity? ee _ | | 1. Disconnect Ne-sensor 3pin connector inside connector ‘Repair or replace) box engineECU | Replace Ne- 2. Inspect if No-sensor circuit has short circuit between hamess sensor each terminal and body ground. Probe between each No.1 terminal, No.2, No.3, and body ground. © 1. Connect ECU 26pin connector Goto Step7 2. Starter SW on. 3. Start engine Goto Stop 9 4. Connect diagnosis connector, then read WiL flashing S.Was OTC 15 displayed? . _ 7/1. Starter switch OFF Got Steps Adjust gap value| 1, Replace Ne-sensor "Replace ECU 2. Starter SW on 3. Run engine 4. Connect diagnosis connector, then read WIL flashing Go to Stop 9 1: Stop engine run Saved 2.contirm I memory clet connector of, should be off 3. Storer SW on | 4. Connect memory lear connector for more then 1 2ee, | then disconnect it, | 5. Connect diagnosis connector, then read Wl flashing | 8. Was OTC cloared? | Go back to step 1}E-30 EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) DTC 29 Pre-stroke servo system error Engine Harness for ECU Connector (25pin) ACT) == ACT | ACT (a -GyOS Shield | i Pre-stroke || [eves No — 3 Acwator fl : 805 | swe fz i} way “ES | S 6 at ose, co 2 Sv05| ow ear Ty 60. ow - E| oe : 6 MOL ~ wos 3 ono] Engine ECL Harness Side Injection Pump Side B12 Engine ECU Harness Side Instrument Harnese Side Frame Harness SideEMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-31 Engine ECU Connector Engino ECU harness (Gray) 22pin connector — Grey) 26pin connector Diagnosis connector TE ‘Memory clear connector6E-32 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) TICS Connector ‘SWP 6pin Gray Engine ECU Haness - Inst Harness Connector ‘SDL 20pin Black jason Inst Harness ~ Frame Harness Connector SDL 22pin BlackEMISSION AND ELECTRICAL DIAGNOSIS (6HEL-TCN/C/S) 6E-33 (TES cenpecr aE) ~ evi nn es ug) ab6 — || 5600 ~ ack sensor (ohiteh 3910 Governar Pre-stroke sensor, pre-stroke actuator terminal assignment + To Injection pump (aray 6pint Injection pump side connector {Located in eonnactor box) Temninal | signai name Wire re-stroke actuator) |W [ Pre stroke actuntor() «| Pre-stroke sensor (Osci | 86E-34 EMISSION AND ELECTRICAL DIAGNOSIS (6HEL-TCN/C/S! Measure resistance at injection pump side Grout tomer OMY mmo Leave vehicle harness off proana, Injection = aime J sume | + To injection pump so {gray 6pin) Injection pump side connector ‘Located n connector box) Resistance values inspection area Tenneson | i torminel «> wrminal| 68 ~ 6. lal (aray 6pin} [ Tid 12210) "erminal oo ‘eninal_+ 55-6410 [terminal «+ aiterminat| ee Body = aaa, Body [ee Tieminal| 28> 25600) + i ‘Tterminal_e+ Bod Resistance values are various depend on temperature especially engine warm-up condition.EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-35 DTC 29 Pre-stroke servo system error STEP ‘ACTION YES NO 1 | 1. napeet injection nozzle hole plug or not Repair or replace) Go to Stop2 2.Was injection nozzle hole plugged? WNozzle Z| 1 Startar sw off Goto Step3 | Goto Step 11 2, Disconnect ECU 26pin connector 3. Measure pre-stroke circuit resistance between OSC and GND at ECU connecter. Probe No.6 and No.19 terminal of 26pin connector Was resistance within 11.0 and 12.2 ohm? | Measure pre-stroke sensor circult resistance between | GotoStep4 | Goto Step 12 OSC and MDL at ECU connector. Probe No.6 and | No.7 terminal of 26pin connector. 2. Was resistance within §.5-6.1 ohm? ___| | 1: Measure pre-stroke sensor circuit resistance between GotoStep5 | Goto Step 13 MDL and GND at ECU connector. Probe No.6 andj No.19 terminal of 26pin connector 2. Was resistance within 5.5-6.1 ohm? _ 5 1. Inspect if pra-stroke sensor circuit has short circuit Goto Stop6 | Goto Stop 14 between each terminal and SLD? Probe No.6, 7, 19 and 20 terminal. 2, Was resistance infinity? _ 6 1. Measure resistance of pre-stroke actuator circuit Goto? Goto Step 15 between + and - at ECU connecter. Probe at No.1 terminal and No.14 2, Was resistance 2.45-2.95 ohm? 1 T | 1. Inspect short circuit of pre-stroke sensor and actuator | GotoStep8 | Goto Step 16 | circuit between each torminal and body ground at | ECU connector. Probe No.1, 14, 6, 7, 19 terminal and body ground. Was resistance infinity? - _ Inspect open circuit of pre-stroke GND circuit at ECU | Goto Step 17 | Goto Step® connector check continuity between 47 and 38 terminal of 22pin terminal 2. Was resistance less than 2 ohm? 3 1. Inspect open circuit of pre-stroke GND circuit at ECU | Repair or replace! Goto Step 10 | connector instrument harness side. Check continuity engine ECU between No.14 and 18 terminal at ECU harness harness instrument harness side 22pin connector. 2. Was resistance less than 2 ohm? 70] 1-Inspect open circuit of pre-stroke GND circut at ECU Repair or replace! Repair and connector frame harness side, Check continuity Instrument | replace frame between No.16 and 15 terminal at ECU harness frame harness harness harness side 22pin connector. 2.Was resistance less than 2 ohm? 17 77 Remove TICS 6pin connector in connector box Repair or replace) Replace Vpump: 2. Measure pre-stroke sensor circuit resistance between ECU harness OSC and No.16 and GND at TICS connector Pump, side. Probe at No.4 terminal and No.6 of 6pin connector. 3. Was resistance 11.0-12.2 ohm?6E-36 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) DTC 29 Pre-stroke servo system error ‘STEP ACTION. YES. NO. |, Remove TICS 6pin connector in connector box 2. Measure pre-stroke sensor circuit resistance between OSC and MLD at TICS connector /Pump side. Probe at No. terminal and No.6 of 6pin connector. . Was resistance §.5-6.1 ohm? Remove TICS 6pin connector in connector box . Measure pre-stroke sensor circuit resistance between MLD and GND at TICS connector VPump side. Probe at No.4 terminal and No.6 of 6pin connector. Was resistance 5.5-6.1 ohm? Repair or raplace| ECU harness Repair or repiace| ECU harness Replace iPump Ropiace (Pump 14 |. Remove TICS 6pin connector in connector box Inspect short circuit in pre-stroke sensor circuit between each terminal and SLD at TICS connector Pump side. Probe at No.4, 5, 6 terminal and No.3 of, 6pin connector. ‘Was resistance infinity? Repair or replace] ECU harness Replace iPump 18 |. Remove TICS 6pin connector in connector box. | Measure pre-stroke sensor circuit resistance between | +and ~at TICS connector /Pump side. Probe at No.1 | terminal and No.2 of 6pin connector. Was resistance 2.45-2.95 ohm? Repair or replace| ECU harness Replace (Pump 16 7 roe Remove TICS 6pin connector in connector box Inspect short circuit in pre-stroke sensor circuit and actuator circuit between each terminal and body ground at TICS connector Pump side. Probe at No.1, 2, 4,5, 6 terminal and body ground of 6pin connector. Was resistance infinity? . Connector ECU 22pin connector and 26pin connector Starter sw on Start engine Connect diagnosis connector and read WIL flashing Was DTC 29 displayed? Repair or replace) ECU harness Goto Step 18 Replace Pump Go to Step 19 8 Replace ECU Starter sw on Run engine Connect diagnosis connector and read WiL flashing Replace WPurnp Go to Step 19 19 Was DTC 29 displayed! — + ‘Stop engine run Check memory clear connector off | Starter sw on | |. Connect memory clear connector for more than 1 sec disconnect. Connect diagnosis connector and read Wil flashing Was DTC cleared? Go back to steptEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-37 DTC 29 Pre-stroke servo system error Engine Harness for ECU Connector (26pin) wos ose [ress M01 it = cre | [__ acter v ACT) -svas shits | a fs rrearate [vos GNo 8 A) actuator 03) Pat {GTTa, swe ape of} oon svos| | ty] +Bos P|.) Pre-suoke | uP | Sensor wos} Ll Shied bi) Leno, Engine ECU Harness Side Injection Pump Side Engine Harness for ECU Connector (2pin} Ground Bias Engine ECU Harness Side Ingteument Harness Side Frama Harness Side6E-38 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) Engine ECU Connector (Gray) 26pin connector Engine ECU Diagnosis connector =] ac Memory clear connectorEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-39 TICS Connector ‘SWP 6pin Gray Engine ECU Haness ~ Inst Harness Connector SDL 200i Beck foes Inst Harness ~ Frame Harness Connector SDL 22pin Black8E-40 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) “TCS connector to 800 mes. Rack sensor ~ CA (ohne 3pin Governor Pre-stroke sensor, pre-stroke actuator terminal assignment + To injection pump (ray 6pind Injection pump site connector {Cocated in connector box! Tenia ‘Slgnal Name ee 1__| Prosstroke actuator =) [|G 2 | Preatroke actuator w _|_¥ 1 [sri aoc aw ro-aroxo soneor (GND | -atroke sensor (MDLI -stroke sensor OSC} |EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-41 Measure resistance at injection pump side Creuttewer OMITTED )+— Leave vehicle harness ot Resistance values DP) anne, Er Ses Measure resistance between these =» Toinjeetion pump loray Brin) Injoction pump side connector ——esetion area Hesistence [Remark Connector | terminal «+ terminal) 55~ 6110) [OSC <> MOL (gray Spin! |e terminal <> 4°terminal |11.0- 12.21@1] OSC GND terminal i] eo | OSC Shield terminal < |S teeminal <> terminal < = Shiet terminal = Body al o> terminal Shiel [a termina «Body Resistance values are various depend temperature especially engine warm-up condition.EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) DTC 29 Pre-stroke servo system error STEP ACTION, ves | NO 1 7. Inspect injection nozzle hole plug or not Repair or replace Goto Step2 Was injection nozzle hole plugged? |. Starter sw off 2, Disconnect ECU 26pin connector 3, Measure pre-stroke circuit resistance between OSC and GND at ECU connecter. Probe No.6 and No.19 | ‘terminal of 26pin connector | 4.Was resistance within 11,0 and 12.2ohm?__ - 3 | 1. Measure pre-stroke sensor circuit resistance between | GotoStep4 | Goto Step 12 OSC and MDL at ECU connector. Probe No.6 and No.7 terminal of 26pin connector. 2. Was resistance within 5.56.1 ohm? ao + 1. Measure pre-stroke sensor circuit resistance between | Goto StepS | Goto Step 13 MDL and GND at ECU connector. Probe No.6 and No.19 terminal of 26pin connector .2 within §.6-6.1 ohm? oe _ 5 1. Inspect if pre-stroke sensor circuit has short circuit GotoStep6 | Goto Step 14 between each terminal and SLD Probe No.6, 7, 19 and | 20 terminal 2. Was resistance infinity? 11. Measure resistance of pre-stroke actuator circuit between + and ~ at ECU connecter. Probe at No.1 terminal and No.14 | 2. Was resistance 2.45-2.95 ohm? 7 ‘Inspect short circuit of pre-stroke sensor and actuator | GotoStep& | Goto Step 16 circuit between each terminal and body ground at | ECU connector. Probe No.1, 14, 6, 7, 19 terminal and body ground. __2. Was resistance infinity? Goto Step 11 “Goto Step 15 | 8 1. Inspect open circuit of pre-stroke GND circuit at ECU | GotoStep17 Goto Step® connector check continuity between 47 and 38 | _ terminal of 22pin terminal | 2. Was resistance less than 2 ohm? L a 1. Inspect open circuit of pre-stroke GND circuit at ECU Repair or replace| Go to Step 10 connector instrument harness side, Check continuity engine ECU between No.14 and 18 terminal at ECU harness. harness instrument harness side 20pin connector. 2. Was resistance less than 2 ohm? 70 | 1. Inspect open circuit of pre-stroke GND circuit at ECU [Repair or replace! Repair and connector frame hamess side. Check continuity instrument | replace frame between No.16 and 15 terminal at ECU harness frame harness harness hamess side 22pin connector __2. Was resistance less than 2 ohm? T7741 Remove TICS 6pin connector in connector Box. Repair or replace) Replace Upump 2, Measure pre-stoke seneor circuit resistance between | ECU harness OSC and GND at TICS connector VPump side. Probe at Ne terminal and No.6 of Bpin connector | 3. Was resistance 11.0-122 ohm?EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-43 DTC 29 Pre-stroke servo system error ‘STEP ACTION YES NO. 12 3. Was resistance §.5-6.1 ohm? Remove TICS 6pin connector in connector box Measure pre-stroke sensor circuit resistance between | ECU harness OSC and MOL at TICS connector YPump side. Probe at No.5 terminal and No. of 6pin connector. Repair or replace, Replace VPump 3 3. Was resistance 5.5-6.1 Remove TICS 6pin connector in connector box Repair or replacel Measure pre-stroke sensor circuit resistance between | ECU harness MDL and GND at TICS connector Pump side. Probe at No terminal and No.5 of Spin connector. hm? Replace VPump 18 3. Was resi Remove TICS 6pin connector in connector box Repair or replace| . Inspect short circuit in pre-stroke sensor circuit ECU harness between each terminal and SLO at TICS connector Pump side. Probe at No.4, 5, 6 terminal and No.3 of Gpin connector. tance infinity? Replace VPump 5 3. Was resistance 2.45-2.95 ohm? Remove TICS 6pin connector in connector Box Repair or replace Measure pre-stroke sensor circuit resistance between | ECU harness + and - at TICS connector /Pump side. Probe at No.1 terminal and No.2 of 6pin connector. Replace (Pump 16 Remove TICS 6pin connector in connector Box Repair or replace) 2. Inspect short circuit in pre-stroke sensor circuit and, ECU harness actuator circuit between each terminal and body ground at TICS connector /Pump side. Probe at No.1, 2, 4, 5, 6 terminal and body ground of 6pin connector. Was resistance infinity? Replace /Pump 7 |. Connect diagnosis connector and read Wil flashing Was DIC 29 displayed? Connector ECU 22pin connector and 26pin connector Go to Step 18 Starter sw on Start engine Goto Step 19 8 Replace ECU Replace IPump. Starter sw on i Run engine Connect diagnosis connector and read W/L flashing Was DTC 29 displayed? Go to Step 19 19 ‘Stop engine run Solved Check memory clear connector off Starter sw on Connect memory clear connector for more than 1 sec disconnect Connect diagnosis connector and read WIL flashing Was DTC cleared? Go back to step?6E-44 EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) DTC 291 Pre-stroke sensor error Engine Harness for ECU Connector (26pin) wos ox | oes tee Act seg fa swe dP th van Ite ate] ‘way “[Us] 3/9} | snigaiose, eno» see Bos S05 | | wos | wos Engine ECU Harness Side Injection Pump Side TICS Connector ‘SWP 6pin GrayEMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-45 Engine ECU Connector Engine ECU harnese (Gray) 26pin connostor Diagnosis connector6E-46 EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) _- TES connector (graviepin (weitel Spin Governor Pre-stroke sensor, pre-stroke actuator terminal as: Se To injection pump (oray 6pind Injection purnp side e |oeated in connector bom Terminal re-eroke 2] Shield (MDL Pi © | Pre-stroke sonsar (GND) Pre-stroke sensor (MOL) Pre-stroke sensor (080)EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-47 Measure resistance at injection pump side Sheu teteroMy) ETT + \ Measure resistance ‘between these Leave vehicle harness off 5) > Toinjection pump (gray 6pin) Injection pump side connector ocated in connector bom Resistance values Tnepontion area Resinance [Romar Connecor [terminal ev Wteuninal) 65 ~a in] | O86 ++ MOL ‘gray 6pin} Te terminal — 4 terminal |11.0~ 122 [ai] OSC.» GND [eterminal = terminal) 0 | OSC Shi ‘terminal + — Body co SC Boy terminal <> Towrminal]| 68 ~ 670 MoUs GND Sotwinal <> c-terminal| eo | MOL +> Shield “terminal «7 Body ML “terminal terminal 285 101 2 terminal ‘co ‘toreninal Body a Resistance values are various depend on temperature especially engine warm-up condition.6E-48 EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) DTC 291 Pre-stroke sensor error MDL and GND at ECU connector. Probe No.7 and | No.19 terminal of 26pin connector. | 2, Was resistance within §.5-6.1 ohm? 4 1. Inspect if pre-stroke sensor circuit has sh between each terminal and SLD. Probe No.6, 7, 19 and 20 terminal. 2.Was resistance infinity? 5 1. Measure shout circuit of pre-stroke sensor circuit Goto lt between each terminals and body ground at ECU connecter. Probe at No.6, 7, 20 terminal and body ground. 2. Was resistance oo? STEP ACTION. ves NO. 1 T. Starter sw off Goto Step2 Goto Steps 2. Disconnect ECU 26pin connector 3, Measure pre-stroke circuit resistance between OSC. and GND at ECU connecter. Probe No.6 and No.19 terminal of 26pin connecter. ____| 4. Was resistance within 11.0 and 12.2 ohm? | 2 1. Measure pre-stroke sensor circuit resistance between | Goto Step3 | Goto Step7 OSC and MDL at ECU connector. Probe No.6and No.7 terminal of 26pin connector. ____| 2: Was resistance within 5.5-6.1 ohm? _ _ 3 1. Measure pre-stroke sensor circuit resistance between | Goto Step4 | Goto Step9 Gi Go to Step 10 2, Measure pre-stroke sensor circuit resistance between ECU ‘OSC and GND at TICS connector VPump side. Prove at | No.4 and No.6 terminal. | 1. Romove TICS 6pin connector in connector box Repair or replace Replace Vpump (OSC and MDL at TICS connector /Pump side. probe at No.5 terminal and No.6 of 6pin connector. 3. Was resistance 11,0-12.2 ohm? 7 1, Remove TICS pin connector in connector box Repair or replace) Replace pump 2. Measure pre-stroke sensor circuit resistance between ECU MDL and GND at TICS connector Pump side. Probe at No. torminal and No.5 of 6pin connector. | . Inspect short circuit in pre-stroke sensor circuit ECU between each terminal and SLD at TICS connector Pump side. Probe at No.4, 5, 6 terminal and No.3 of Gpin connector. 3. Was resistance infinity? Repair or replace _3. Was resistance 5.5-6.1 ohm? 4} @ | 1. Remove TICS 6pin connector in connector. Repair or replace) Replace \ipump 2. Measure pre-stroke sensor circuit resistance betwoen ECU Replace lipump 0 Inspect short circuit of pre-stroke sensor circuit ECU between each terminal and pump body ground. Probe at No.4, 5, 6 and body ground of 6pin connector. 3. Was resistance infinity? Disconnect TICS 6pin connector in connector box Repair or replace’ Replace lipumpEMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) 6E-49 DTC 291 Pre-stroke sensor error ‘STEP ACTION YES NO 1 2 Connect ECU 26pin connector Goto Step 12 | Goto Step 13 . Starter SW on. Starter SW on Run engine | Connector diagnosis connector, read WIL flashing displayed? _ a ECU Replace Pump | Goto Step 13 | Run engine Connect diagnosis connector, read W/L flashing Was 291 displayed? _ 3 ‘Stop engine run Solved "Go back to Step Check sw on Starter sw on Connect memory clear connector for more than 1 sec and disconnect Connect diagnosis connector and read P/L flushing Was DTC cleared?6E-50 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) DTC 291 Pre-stroke sensor error Engine Harness for ECU Connector (25pin) _Wos osc__ | i’ | ACT) ACT Gy05_ Shield Pro-stroke 8. _ ‘acre Actuator 3] rewrote 4 Sensor Shisid (MOL) GND! Injection Pump Sie TICS Connector SWP 6pin GrayEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-51 Engine EGU Connector IGray) 260in connector Diagnosis connectorGE-52_ EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) TICS connector ioe ay Rac sensor connector (woh Spin Governor Pre-stroke sensor, pre-stroke actuator terminal assignment <= To injection pump 2 {ray Bin) Injection pump aide connector (Ueested In connecter box) Terminal NO. © _[Pre-stroke sensor (O50) ] —LEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-53 Measure resistance at injection pump side + Toinjection puma ‘gray 6pin) Injection purnp side connector (Cocated in connector box) Resistance values Tnspeation area Resistance Connector | «terminal «+ Drerminal] 6.5 ~ 6.10) (aray 65in) [5 terminal «+e terminal [11.0~ 122 19) terminal cs Eterminel | oo terminal o> Body = minal | 88-6 110) = sterminal shied] > Body Body 4 > erminal| oo Shield ‘terminal «) Body a Body ‘terminal «> “terminal 248 = 2.96101 = terminal «> Body ee Body ‘iteminal =» Body | ce Body Resistance values are various depend on temperature especially engine warm-up condition,6E-54 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) DTC 291 Pre-stroke sensor error STEP. ACTION. YES NO. 1 T Starter sw off Goto Step2 | Goto Steps 2. Disconnect ECU 26pin connector 3, Measure pre-stroke circuit resistance betwoen OSC. and GND at ECU connecter. Probe No.6 and No.18 terminal of 26pin connecter. 4. Was resistance within 11.0 and 12.2 ohm? | 2 1. Measure pro-stroke sensor circuit resistance between | Goto Step3 | Goto Step? OSC and MDL at ECU connector, Probe No.6 and No.7 terminal of 26pin connector. 2. Was resistance within 5. nee 3 7. Measure pre-stroke sensor circuit resistance between | Goto Step 4 | Goto Step 9 MDL and GND at ECU connector. Probe No.7 and No.19 terminal of 26pin connector. 2, Was resistance within 5.5-6.1 ohm?_ _ a 1. Inspect if pre-stroke sensor circuit has short circuit Go to Step between each terminal and SLO. Probe No.6, 7, 19 and 20 terminal, 2. Was resistance infinity? _ _ | 5 1. Inspect if short circuit of pro-stroke sensor circuit Goto Goto Step 10 between each terminals and body ground at ECU connecter. Probe at No.6, 7, 20 terminal and body ground. 2. Was resistance infinity ohm? 6 1. Remove TICS pin connector in connector box Repair or replace) Replace Ipump 2. Measure pre-stroke sensor circuit resistance between ECU OSC and GND at TICS connector Pump side. 3. Was resistance 11.0-12.2 ohm? 7 1. Remove TICS 6pin connector in connector box | Repair or replace| Replace pump 2, Measure pre-stroke sensor circuit resistance between ECU OSC and MDL at TICS connector /Pump side. Probe ‘at No.5 terminal and No.6 of 6pin connector. L 3. Was resistance 6.5-6.1 ohm? _. 8 1. Remove TICS 6pin connector in connector Repair or replace Replace Vpump 2, Measure pre-stroke sensor circuit resistance between ECU MDL and GND at TICS connector \/Pump side, Probe at No.4 terminal and No.5 of 6pin connector. . | 3. Was resistance 5.5-6.1 oh | 9 1, Remove TICS 6pin connector in connector box Repair or replace Replace l/pump. 2. Inspect short circuit in pre-stroke sensor circuit ECU between each terminal and SLD at TICS connector liPump side. Probe at No.4, §, 6 terminal and No.3 of, | 6pin connector. _3.Was resistance infinity? a = 70 1. Disconnect TICS Bpin connector in connector box | Repair or replace| Replace pump 2. Inspect short circuit of pre-stroke sensor circuit ECU between each terminal and pump body ground. Probe at No.4, 5, 6 and body ground of Bpin connector. 3. Was resistance infinity?EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-55 DTC 291 Pre-stroke sensor error ‘STEP ACTION YES NO. 11 Connect ECU 28pin connector Starter SW on . Run engine Connector diagnosis connector, read WL flashing Was 291 displayed? Goto Step 12 Goto Step 13 2 Replace ECU . Starter SW on. Run engine Connect diagnosis connector, read Wil flashing Was 281 displayed? _ “Replace /Pump: Go to Step 13 3 ‘Stop engine run Check sw on Starter sw on Connect memory clear connector for more than 1 sec and disconnect Connect diagnosis connector and read P/L flushing Was DTC cleared? sowed —] Go back to Step)GE-56 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) DTC 292 Pre-stroke learning program error Engine Harness for ECU Connector (26pin} wos ose Acris a L acre) 9 Sy0s shies | 4 13) Pro-sroke 3 w act) | Actuator ——— sos |* am ff S108, = B05 wos Engine ECU Harness Sie Injection Pump SideEMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-57 Engine ECU Connector Gray) 26pin connector — 69 s&—6E-58 EMISSION AND ELECTRICAL DIAGNOSIS (6HEL-TCN/C/S) pee 9OG00 ies Rack sensor (white) Spin / Governor Pre-stroke sensor, pre-stroke actuator terminal assignment + To injection pump ‘ray pint Injgction pump side connector (Cocated tm connector Box) Terminal | Wire | Ka Signal Name a ~| Preatroke Ww t_ 2 [ Pre-stroke sensor |OSCiEMISSION AND ELECTRICAL DIAGNOSIS (SHEI-TCN/C/S) 6E-59 Measure resistance at injection pump side Creu restor DMV) FJ ~ Leave vehiete harness off at or enna __.| pump onneet box Injection pump side connector (Located in connector box) Resistance values — inspection area Fesitancs Remark Connector | = terminal © Sterminal| 68-6110) | OSC MDL (aray 601) FS terminal c+ teeminal 17.0722 (2 [terminal cy terminal oo inal «+ Body oo OSC Baty Swrminal o aiteminall 65— 6410) [MDL GND terminal «> aterminat| co | MDL +> Shin S terminal <> co | MOL ‘terminal « Resistance values are various depend on temperature especially engine warm-up condition.EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) DTC 292 Pre-stroke learning program error STEP ACTION YES NO. 1 | 1. Starter sw off Goto Step2 | Goto Step? 2. Disconnect ECU 26pin connector 3. Measure pre-stroke circuit resistance between OSC and GND at ECU connecter. Probe No.6 and No.19 terminal of 26pin connecter. 4, Was resistance within 11.0 and 12.2 ohm? 2 7. Measure pro-stroke sensor circuit resistance botwoen | GotoStep3 | Goto Steps OSC and MDL at ECU connector. Probe No.6 and No.7 terminal of 26pin connector. 2. resistance within 5.5-6.1 ohm? 3 1. Measure pre-stroke sensor circuit resistance between | GotoStep4 | Goto Step$ MDL and GND at ECU connector. Probe No.7 and No.19 terminal of 26pin connector. 2. in §.5-6.1 ohm? 1. Inspect if pre-stroke sensor circuit has short circuit Goto Step5 | Goto Step 10 between each terminal and SLD. Probe No.6, 7, 19 and 20 terminal, 2. Was resistance infinity? | 71. Measure resistance of pre:stroke actuator circuit Goto7 Goto Step 171 between + and - at ECU connecter. Probe at No.1 terminal and No.14 2. Was resistance 2.45-2.95 ohm? __ 6 1. Inspect short circuit of pre-stroke sensor and actuator | GotoStep13 | Goto Step 12 circuit between each terminal and body ground at ECU connector. Probe No.1, 14,6, 7, 19 terminal and | body ground. 2. Was resistance infinity? 7 1. Remove TICS 6pin connector in conneator box Repair or replace) Replace Vpump 2. Measure pre-stroke sensor circuit resistance between | ECU harness | OSC and GND at TICS connector /Pump side. | 3. Was resistance 11.0-12.2 ohm? _ e T. Ramove TICS 6pin connector in connector Box Repair or replace) Replace Upump 2, Measure pre-stroke sensor circuit resistance between | ECU harness OSC and MDL at TICS connector /Pump side. Probe at No.5 terminal and No.6 of 6pin connector. 3. Was resistance 5.5-6.1 ohm? _ _ 1, Remove TICS 6pin connector in connector. Repair or replace Replace pump 2. Measure pre-stroke sensor circuit resistance between ECU harness MDL and GND at TICS connector Pump side. Probe at No.4 terminal and No.5 of 6pin connector 3, Was resistance 5.5:6.1 ohm? _ 70 | 1. Remove TICS 6pin connector in connector box Repair of replace) Replace Vpump | 2. Inspect short circuit in pre-stroke sensor circuit ECU harness between each terminal and SLD at TICS connector | Pump side. Probe at No.4, 5, 6 terminal and No.3 of, 1 6pin connector. 3. Was resistance infinity? IEMISSION AND ELECTRICAL DIAGNOSIS (HEI-TCN/C/S) 6E-61 DTC 292 Pre-stroke learning program error STEP ‘ACTION YES. NO 11 | 7: Ramave TICS Gpin connector in connector Box pair or replace, Replace Upurnp 2, Measure pre-stroke sensor circuit resistance between | ECU harness + and at TICS connector iPumnp side. Probe at No.1 | | terminal and No.2 of 6pin connector. 3. Was resistance 2.45-2.95 ohm? : _ : TZ] 1 Remove TICS 6pin connector in connector box Repair or replace] Replace Vipump | 2! inspect short circuit in pre-stroke sensorcireuit and | ECU harass actuator circut between each terminal and body | {round st TICS connector Pump side, Prove at No.1 | 2:4, 5, 6 terminal and body ground of 6pin connector | 3. Was resistance infinity? “| 7 13 | 1. Connect ECU 26pin connector Goto Step 14 | Go to Step 1! 2 Starter SW on 3. Run engine 4 Connector diagnosis connector, read WIL flashing 5, Was DIC 292 displayed? a 14 1. Replace ECU Replace Pump — Go to Step 15 2 Starter SW on +3. Run engine | | 4. Connect diagnosis connector, read W/L flashing. | | 5: Was 292 displayed? ___| 15/1. Stop engine run Solved [Go backto Stent 2. Cheok memory clear connector off 3. Starter sw on 4. Connect memory clear connector for more than 1 sec and disconnect, 5. Connect diagnosis connector and read WiL flashing | 6. Was DTC cleared?6E-62_ EMISSION AND ELECTRICAL DIAGNOSIS (6SDL-TC) DTC 292 Pre-stroke learning program error Engine Harness for ECU Connector (26pin) wos osc _[-pos EOL petit | eS Acie cyos shi ~} Presote a GND . acres [5] atnior > rq Te eL 2]4]4) F swe elle) Shigld (OSC, GND} | =H ose L. eee | wou Siti [wo Engine ECU Hovness Side Injection Pump Sido TICS Connector SWP 6pin GrayEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-63 Engine ECU Connector iS (Gray) 22pin connector (Gray) 26pin connector Engine ECU Diagnosis connector SE] a= Memory clear connector oO6E-64 EMISSION AND ELECTRICAL DIAGNOSIS (GSDI-TC) TICS connector (gray) 6pm Rack sensor -— GOA ‘oeite) Spin Governor Pre-stroke sensor, pre-stroke actuator terminal assignment —- Toinieotion pump “PL To injection pune age tells) {gray Bin) Injection pump side connector {ocated in connector box) Inspection a ak “Connector | « terminal «+ ite MDL (ray 6050) [5 Terminal «> terminal 11,0~ 122 [al GNo ‘terminal <> terminal oe = Shield ‘terminal os Bady Body > terminal Resistance values are various depend on temperature especially engine warm-up condition.6E-66 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) DTC 292 Pre-stroke learning program error step | ‘ACTION YES NO 1 | 1. Starter aw off Goto Step? 1 Goto Step7 | 2. Disconnect ECU 26pin connector | 3. Measure pro-stroke circuit resistance between OSC |“ and GND at ECU connecter. Probe No.6 and No.19 | | termina of 26pin connecter. | | 4, Was resistance within 11.0 and 12.2 ohm? 7. Measure pre-stroke sensor circuit resistance between | GotoStep3 | Goto Step® OSC and MDL at ECU connector. Probe No.6 and No.7 terminal of 26pin connector. 2. Was resistance within 5,5-6.1 ohm? 3 | 1. Measure pre-stroke sensor circuit resistance between | GotoStep4 | GotoStep§ | “MDL and GND at ECU connector. Probe No.7 and | | __No.19 terminal of 26pin connector. 2, Was resistance within 5.5-6.1¢hm? @ | 1. Inspect if pre-stroke sensor circuit has short circuit between each terminal and SLD? Probe No.6, 7, 19 and 20 terminal of 26pin connector 2. Was resistance infinity? 3) 1. Measure resistance of pre-stroke actuator circuit Goto7 Got Step 11 between + and~ at ECU connecter. Probe at No.1 terminal and No.14 | 2. Was resistance 2.45-2,95 ohm? é 1. inspect short circuit of pre-stroke sensor and actuator | Goto Step 13 | Goto Step 12 circuit between each terminal and body ground at ECU connector. Probe No.1, 14, 6, 7, 19 terminal and body ground 2. Was resistance infinity? | - 7 1. Remove TICS 6pin connector in connector box Repair or replace| Replace pump 2, Measure pre-stroke sensor circuit resistance between ECU harness OSC and GND at TICS connector VPump side | 3.Was resistance 11.0-12.2 ohm? | 3 T. Remove TICS 6pin connector in connector Box Repair or replace! Replace Vbump 2. Measure pre-stroke sensor circuit resistance between ECU harness OSC and MDL at TICS connector Pump side. Probe at No.5 terminal and No.6 of 6pin connector. 3. Was resistance 5.5-6.1 ohm? 3 7. Remove TICS 6pin connector in connector. Repair or replace) Replace Upump 2, Measure pre-stroke sensor circuit resistance between | ECU harness MDL and GND at TICS connector Pump side. Probe at No.4 terminal and No.5 of 6pin connector. | 3. Was resistance 5.5-6.1 ohm? Remove TICS 6pin connector in connector Box Repair or replace| Replace vpump 2. inspect short circuit in pre-stroke sensor circuit ECU harness | between each terminal and SLD at TICS connector Pump side. Probe at No.4, 5, 6 terminal and No.3 of 6pin connector. 3. Was resistance infinity? I 2 to Step 5 10EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-67 DTC 292 Pre-stroke learning program error STEP ACTION YES NO. " 1. Remove TICS 6pin connector in connector box Repair or replace] Replace pump 2. Measure pre-stroke sensor circuit resistance between | ECU harness + and ~ at TICS connector Pump side. Probe at No.1 | terminal and No.2 of 6pin connecter. | 3. Was resistance 2.48-2.95 ohm? _ Z| 1. Remove TICS 6pin connector in connactor box | Repair or replace) Replace Upump 2 Inspect short circuit in pre-stroke sensor circuit and ECU harness | ~ actuator circuit between each terminal and body ‘ground at TICS connector |/Pump side. Prove at No.1, 2, 4,8, 6 terminal and body ground of 6pin connector ___|s. finity? | _ 13 1, Connect ECU 26pin connector Goto Step 14 | Goto Step 15 2: Starter SW on 3. Run engine 4. Connector diagnosis connector, read W/L flashing 5. Was DTC 292 displayed? _ _ 14 1. Replace ECU Replace Pump | Go to Step 15 2. Starcer SW on. 3. Run engine 4, Connect diagnosis connector, read WIL flashing 5.Was 282 displayed? et _ 15 | 1. Stop engine run Solved Go back to Step 2. Check memory clear connector off 3. Starter sw on 4. Connact memory clear connector for more than 1 see and disconnect Connect diagnosis connector and read WiL flashing Was DTC cleared?6E-68 EMISSION AND ELECTRICAL DIAGNOSIS (6HELTCN/C/S) DTC 23 Coolant temperature fuse sensor error mJ Coolant | ‘Tomporsture \ : eas resistance Connector Engine ECU Connector t260in) r — tae ‘(Coolant if Temperature z Senger (Dua (s 2 5 sor fl Sileshy 1B) adendod [abgocto | sit me 3 | Engine ECU Harness i 8) eos any 3) rhein 3 | epesian( ined smu Instrument Harness (Upper)EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) 6E-69 Engine ECU Connector (Gray) 26pin connector Engine ECU Diagnosis connector Memory clear connector Oo aGE-70 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) Engine ECU Haness ~ Inst Harness Connector SDL 20pin Black Instrument Harness ~ Frame Harness Connector ‘SDL 22pin Black th Daca Us SHawoww, Instrument Harness ~ Instrument Harness [Upper] Connector SMJ 84pin GrayEMISSION AND ELECTRICAL DIAGNOSIS (BHEI-TCN/C/S) 6E-71 Coolant Temporature Sensor Connector EJ Mark tlt 3pin Black eS Frame Harness - Engine Harness Connector SWP 6pin Gray at ap tals)6E-72 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCN/C/S) Coolant temperature sensor, terminal assignment Appearance of Dual Coolent Temperature Sensor Sensing part for engine Sensing part for meter To coolant tempereture sensor Terminal = a Signal Name 1 Thenmistarforangine | 6 (Bleck 3pin) | Thermisterformeter | ¥ a [thermisterforengine 8 Coolant temperature sensor (dual side connector Measurement of resistance of coolant ‘Measurement resistance at coolant temperature sensor. ‘ireut tester (DMV) | Leave vehicle hamess off y ns ieee = . —— Messure resistance sensor (ath etween both ands Measurement point -> To coolant tomp sensor te {Stock pint Coolant temperature sensor tl side connector Resistance value table-1 Trepeaton terminal esistaran | Meosuredvmaaroure omar hemisorfor engine «> Therm for meter (Black 3pim) | terminal «+» terminal Themister for engine | Connector ‘terminal <> 7 terminal Cteeminal = “—"Themisterfor engine <> Theemister for meter ‘eiminot 27 Body “hers for meter [[Serminal Body This for meter 2 Bly GN Note: Resistance value is various depend on sensing part temperature,EMISSION AND ELECTRICAL DIAGNOSIS (GHEI-TCN/C/S) 6E-73 DTC 23 Coolant temperature sensor error STEP ACTION. YES NO. 1 7. Starter SW off 2. Disconnect ECU 26 pin connector 3. Measure resistance of coolant temperature sensor circuit at ECU connector. Probe at No.5 and No.18 terminals of 26 pin connector 4. Was resistance less than 1 ohm or infinity? Refer to Table-1 Goto Step3 | Goto Step2 2 1 Inspect short circuit of coolant temperature sensor circuit between each terminals and body ground. Probe at No.5 and No.18 terminals of 26 pin connector 2. Was resistance infinity? Goto Step 11 | Goto Step 4 ¥ 1. Measure resistance of coolant temperature sensor circuit at instrument hamess side of connector between ECU harness and instrument harness. Probe at No.3 and 12 terminal of ECU connector 20 pin by instrument harness. 2. Was resistance less than 1 ohm or infinity? 3. Regarding sensor characteristic, refer to Table-1 Goto step5 | Repair or replace) engine ECU harness 4 1. Inspect short circuit of coolant temperature sensor circuit between each terminals and body ground at instrument harness side of connector between ECU harness and instrument harness. Probe at No.3, 12 terminal and Body GND of ECU connector __|_ 2. Was resistance infinity? 5 1. Measure resistance of coolant temperature sensor circuit at frame harness side of connector. Probe at No.4 and 14 terminal of connector for instrument 2. Was resistance less than 1 ohm or infinity? 3, Regarding sensor characteristic, refer to Table-1 Repair or replace) Goto step 6 engine ECU harness Go te Siap7 [Repair or replacd instrument harness 6 1. Inspect short circuit of coolant temperature sensor cireuit at frame harness side of connector between each terminals and body ground. Probe at No.4, No.14 and body ground of 22 pin connector to instrument harness at frame harness side. 2. Was resistance infinity? Repair or replace’ Goto Step8 frame harness, 7 7. Measure resistance of coolant temperature sensor cireuit at connector of engine harness to frame harness at engine harness side of connector. Probe at No.4 and § terminal of engine harness connector (6pin} to frame. 2. Was resistance less than 1 ohm or infinity? 3. Regarding sensor characteristic, refer to Table-1 Goto Step Repair or replace) frame harness 8 1. Inspect short circuit of coolant temperature sensor circuit at engine harness side of connector to frame harness between each terminals and body ground, Probe at No.4, § terminal and body ground of engine harness connector to frame harness. 2. Was resistance infinity? Repair coolant Goto Stop 10 temperature sensor6E-74 EMISSION AND ELECTRICAL DIAGNOSIS (GHEL-TCN/C/S) DTC 23 Coolant temperature sensor error STEP AGTION YES NO 9] 1 Disconnect coolant temperature sensor, which 1s Repair or replace| Repair or roplacs| connect (Spin to engine harness frame harness | engine harness 2. Measure rosistance of coolant temperature sensor circuit at coolant temperature sensor side connector. Probo No.1 and No.3 pin connector 3.Was resistance less than 1 ohm or infinity? 4.Regarding sensor characteristic, refer to Table-1 0. Disconnect coolant temperature sensor, which is ‘apair oF replace) Replace coolant connect to engine harness | coolant temperature 2.Inspect short circuit of coolant temperature sensor —_|—_temperature sensor circuit between each terminals and body ground. sensor Probe at No.1, 3 terminals of 3 pin connector and | body ground 3. Was resistance infinity? TT} 1 Connect 26 pin ECU connector Goto Stop 12 | Goto Stop 13 2 Starter SW on 3. Run engine 4 Connect diagnosis connector, and read WiL flashing i 5. Was DTC 23 displayed? _ __| 7211. Replace coofant temperature sensor Roplace ECU | Goto Step 13 2. Starter on 3. Run engine 4. Connact diagnosis connector, and read Wil flashing 5. Was DTC 23 displayed? WF TStopenginerun alved back io Step] 2. Confirm memory clear connector off | 3. Starter SW on | 4. Connect diagnosis connector, and read Wit flashing | 5.Was DTC cleared?EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-75 DTC 23 Coolant temperature sensor error Fosistance fo Meter to =f —-&_-fcootant Ea. Ante for Engine = aah sou @ Engine ECU Harness Frame Harnoae Laos Instrument Haeness (Upper)6E-76 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) Engine ECU Connector (Gray! 26pin connector Diagnosis connector =z] GE Memory clear connectorEMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-77 Engine ECU Haness ~ Inst Harness Connector SDL 20pin Black fescebaia Instrument Harness ~ Frame Harness Connector SDL 22pin Black Com SMV 56pin White —s aos Sao Instrument Harness ~ Instrument Harness (Upperl Connector SMJ 84pin Gray =. Connector to Meter Coolant Temporature Sensor Connector =) EJ Mark tlt 3pin Black FRI G6E-78 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) Coolant temperature sensor, terminal assignment Appearance of Dual Coolant Temperature Sensor Sensing port for engine [Black 3pin? Sensing part for meter ——t Tecoolant tempercture sensor Coolant temperature sensor (dual) side connector ret a Measurement of resistance of coolant Circuit ester (OMVI VED <— Leave vehicle narness off y = ooo i £ A '®: ) | \ Measure resistance ‘sensor (dualh Measurement point eine Resistance value table-2 (Black 3601 [terminal <= termine! | 260 | Themister for engine Terminal «+ Body oo ‘Thomister for engine «> Thermister for meter Themisterfor engine «> Thormister for meter terminal <5 terminal [Ce terminal => Body. Thermister for meter ~ [terminal Body “Thermister for meter “7 Body GND. Note: Resistance value is various depend on sensing part temperature.EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) 6E-79 DTC 23 Coolant temperature sensor error ACTION YES NO. 7. Starter SW off Goto Step 3 | Goto Step2 2, Disconnect ECU 26 pin connector 3, Measure resistance of coolant temperature sensor circuit at ECU connector. Probe at No.5 and No.18 terminals of 26 pin connector 4. Was resistance less than 7 ohm or infinity? Regarding sensor characteristic, refer to Table-2 inspect short circuit of coolant temperature sensor Goto SiepS | Goto Sept circuit betweon ach terminals and body ground. Probe at No.8 and No.18 terminals of 26 pin connector 2, Was resistance or infinity? Measure resistance of coolant temperature sensor Gato steps [Repair or repioc circuit at instrument harness side of connector engine harness between ECU harness and instrument harness. Probe at No.3 and 12 terminal of ECU connector 20 pin by insteument harness. | 2. Was resistance less than 1 ohm of infinity? | 3. Regarding sensor characteristic, refer to Table-2 7. Inspect short circuit of coolant temperature sensor Repair or raplace’ Go to step 6 circuit between each terminals and body ground at _—_—_engine harness instrument harness side of connector between ECU harness and instrument harness. Probe at No.3, 12 terminal and Body GND of ECU connector 2. Was resistance infinity? 7. Measure resistance of coolant temperature sensor Goto Step7 | Repair or replace circuit at frame harness side of connector. Probe at instrument No.4 and 14 terminal of connector for instrument harness 2. Was resistance less than 1 ohm or infinity? 1. Inspect short circuit of coolant temperature sensor [Repair or replace! Goto Step 8 circuit at frame harness side of connector between instrument, | each terminals and body ground. Probe at No.4, harness No.14 and body ground of 22 pin cannector to | instrument harness at frame harness side. | Was resistance infinity? Disconnect coolant temperature sensor pin to frame Replace coolant Repair or replace| harness temperature frame harness . Measure resistance of coolant temperature sensor sensor circuit at coolant tomperature sensor side. Probe at No.1 and 3 terminal of 3 pin connector. Was resistance less than 1 ohm or infinity? garding sensor characterist bo-2 Disconnect coolant temperature sensor 3 pin to frame Repair or replace Go to Step 10 harness frame harness 2, Measure short circuit of coolant temperature sensor circuit at coolant temperature sensor side between zach terminal and body ground. Probe at No.1, No terminals of 3 pin connector and body ground. Was resistance infinity? Connect 26 pin ECU connactor Goto Step 10” Goto Step 77 Starter SW on Aun engine Connect diagnosis connector, and read W/L flashing Was DTC 23 displayed?E-80 EMISSION AND ELECTRICAL DIAGNOSIS (6SDI-TC) DTC 23 Coolant temperature sensor error step] ACTION YES NO. 10 | 1. Replace coolant temperature sensor Replace ECU | Goto Stepit | 2. starter on 3. Run engine 4. Connect diagnosis connector, and read Wil flashing 5. Was DTC 23 displayed? Wi Stop engine run Solved | Go back to stept i [2 corer eso acer oamreesr on | | & Starter sw on | 1 Conmct gnosis conrad read Washing | 5 WooorC closes?EMISSION AND ELECTRICAL DIAGNOSIS (GHEL-TCN/C/S) 6E-81 71 Atmosphere pressure sensor error ACTION [ves NO [Replace ECU Solved6E-82 EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCS) DTC 413 Magnetic valve error for IVES Connector to ECU (269in) Engine Harness Frame Harness Engine ECU Haness ~ Inst Harness Connector SDL 20pin Black Dpbiiaiberstd Instrument Harness ~ Frame Harness Connector SDL 22pin Black Magnetic Valve Connector for IVES M Type 2pin GrayEMISSION AND ELECTRICAL DIAGNOSIS (6HELTCS) 6E-83, Engine EGU Connector (Gray) 26pin connector Memory clear connector —8 A—6E-84 EMISSION AND ELECTRICAL DIAGNOSIS (GHEL-TCS) Magnetic valve error for IVES Magnetic valve appearence Connecter Magnetic Valve Side Connector Term Ne. Fesitance « Esch terminal vo body grund) 62EMISSION AND ELECTRICAL DIAGNOSIS (6HEI-TCS) 6E-85 DTC 413 Magnetic valve error for IVES ‘STEP ACTION YES NO + | 1 Starer Swett Goto Step? | Goto Steps 2-Disconnest ECU 26 pin connector 3. Measure magnetic valve circuit resistance at ECU connector. Probe at No.12 and No.25 terminal of 26 pin connector | 4. Was resistance within 45 and 49 ohm? 2 | 1-Inspect short circuit of the magnetic valve circuit Goto Step | Goto Stop! between each terminals and body ground. Probe No.12, 25 terminal of 26 pin connector and body ground. 2. Was resistance infinity? i 377 Measure resistance of the magnate valve oveult at | Ropair or replace) Go to Steps instrument harness side of connector between ECU | ECU harness harness and instrument harness. Probe No.1 and No.10 terminal of 20 pin connector _2, Was resistance within 45:49 ohm? a 1. Inspect if magnetic vaive circuit has short circuit Repair or replace Goto Siepé Detween each terminals and body ground at ECU harness instrument harness side of connector botwaen ECU and instrument harness. Probe No.1, 10 2pin : connector) and body ground i 2.Was resistance infinity? 37. Measure resistance of magnetic valve circuit at Wame | Repalr or replace) Goto Step harness side of connector between instrument instrument harness and frame hamess. Probe at No. terminal harness and No.6 of 22pin connector. 2. Was resistance 45-49 ohm? & iv inspect if short circuit of the magnetic vaive veut Repair or replace’ Go to Stop8 between each torminals and body ground at frame instrument harness side of connector between instrument harness | harness and frame harness. Probe at No.5, 8 of 22pin | connector and body ground. | 2, Was resistance infinity? : i 7 T4-Disconnect the magnetic vaive from frame harness | Repair or replace! Replace 2: Measure the magnetic valve resistance. Probe at No.1 instrument magnetic IVES terminal and No.2 of 2 pin connector. | harness 3. Was resistance 45-43 ohm? | @ 74. Disconnect the magnetic valve from frame harness | Repair or replace) Replace 2. inspect if short circuit of the magnetic valve circuit | frame harness magnetic IVES batween the valve itself and body ground. Probe at No.1, 2 terminal of 2 pin connectors and body ground. 3. Was resistance infinity? s 377. Connect ECU 26 pin connector Goto Step 10 Cote Steptt 2. Starter SW on 3. Run engine 4, Depress accele pedal for more than 1 sec. 5. Connect diagnosis connector, read Wil flashing 6. Was DTC 413 displayed?6E-86 EMISSION AND ELECTRICAL DIAGNOSIS (6HELTCS) DTC 413 Magnetic valve error for IVES ACTION YES NO. Starter SW off Replace IVES magnetic valve Starter SW on Run engine Depress accele pedal for more than 1 sec. Connect diagnosis connector and read W/L flashing Was DTC 413 displayed? Replace ECU Goto step 17 7 | Stop engine run Check memory clear connector off . Starter SW on Connect memory clear connector for more than 1 sec. and disconnect Connect diagnosis connector and read W/L flashing Was DTC cleared? Daived | Go back to step |EMISSION AND ELECTRICAL DIAGNOSIS 6E-87 DTC 423 Pre-stroke power source fuse off Pre-stroke power cu A125 vos Engine Harness, Instcument Harness Engine ECU Haness ~ Inst Harness Connector [Pre-stroke Cut relay Connector e6E-88 EMISSION AND ELECTRICAL DIAGNOSIS Engine ECU Connector (Gray) 26pin connector Engine ECU Diagnosis connectorEMISSION AND ELECTRICAL DIAGNOSIS 6E-89 Relay and fuse location6-90 EMISSION AND ELECTRICAL DIAGNOSIS Inspection of pre-stroke power cut relay Relay Relay circuit Relay terminal assignment c 2 $20 wa aesye 180 relay Resistance values 7 nepection area | Resistance value] Remark Measure | 20) relay alt (terminal No power on: Power on coil ‘No power on co Power onEMISSION AND ELECTRICAL DIAGNOSIS 6E-91 DTC 423 Pre-stroke power source fuse off STEP ACTION YES NO 1 7. Starter SW off Replace fuse | Goto Steps 2isfuse 45 off? _ —__ 2 1. Is pro-stroke power cut relay available? Goto Step3 | install rola 3 1. Remove pre-stroke cut relay Goto Step 4 | Replace relay 2. Measure pre-stroke cut relay contact resistance. Probe No.3 and No.5 terminal of pre-stroke power cut relay 3. Was resistance less than 1 ohm? 7 7. Starter SW off Goto StepS | Repair or replace| 2. Inspect continuity of pre-stroke circuit. Probe fuse 45 | instrument ‘and pre-stroke power cut relay terminal No.5 at harness between) instrument harness i fuse and relay 3. Was resistance less than 1 ohm? | 5} Remove fuse 45 pre-stroke cut relay Goto Step 6 | Ropar or replace) 2. Inspect if short citcuit exist in pre-stroke power circuit. instrument Probe at the cut rolay No.5 terminal and body ground harness between| 3. Was resistance infinity? - fuse and relay _ © | 1. Remove ECU 22 pin connector | GotoStep7 | Goto Stops | 2. inspect continuity of pre-stroke circuit. Probe the cut relay No.3 terminal and ECU connector No.27. 3. Was resistance less than 1 ohm? 7 T-Inspect f short circuit exist in pre-stroke power circuit, | Goto Step8 Goto StepTo Probe the cut relay No.3 terminal and body ground. | 2. Was resistance infinity? F __| 1 Inspect if short circuit exist in the cut relay. Probe at | Goto Step 72 Goto Stepit the cut relay No.4 terminal and body ground 2. Was resistance infinity? J 71. Disconnect connector betwesn ECU harness and Ropair or replace’ Repair oF replace) | instrument harness 20 pin. instrument | ECU harness 2, Inspect continuity of pre-stroke power supply circuit. harness between | Probe instrument harness 20 pin connector No.7 and ECU harness ECU connector No.27 at ECU harness side. connector and 3. Was resistance less than 1 ohm? relay | 70 | 1. Disconnect C20 pin connector between ECU harness Repair or replace| Repair ar replace | and instrument harness instrument | ECU harness | 2. Inspect if short circuit exist in pre-stroke power supply harness between: circuit. Probe ECU connector No.27 and body ground | ECU harness 8. Was resistance infinity? connector and relay rT 1 Disconnect 20 pin connector between ECU harness Repair or replace) Repair or replace) and instrument harness instrument ECU harness 2. Inspect if short circuit exist in pre-stroke power cut _harness between) relay supply circuit. Probe ECU connector No.36 and ECU harness body ground connector and 3, Was resistance infinity? relay TZ Install fuse 45 Goto step 13 Goto Stept4 | 2. Connect 22 pin ECU connector | 3. Starter SW on | 4. Run engine 6. Connect diagnostic connector, read Wit flashing 6. Was DTC 423 displayed?6E-92 EMISSION AND ELECTRICAL DIAGNOSIS DTC 423 Pre-stroke power source fuse off Check memory clear connector off Starter sw on Connect memory clear connector for more than 1sec. and disconnect. Connect diagnostic connector and read Wit flashing. Was DTC cleared? ‘STEP ‘ACTION YES NO 13__| 1 Sterer SWoff Replace ECU | Goto Stepi4 2, Replace pre-stroke cut off relay 3. Starter SW on 4. Run engine 5. Connect diagnostic connector, read W/L flashing 6. Was DTC 423 displayed __ | 14 | 1.Stop engine run Solved | Go back to step 2. 3. 46HSEED-WE-775HK You are requested to order this manual using the manual number that is shown above. This manual is applicable for vehicles in all countries except the USA and Canada. All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by ISUZU MOTORS LIMITED INTERNATIONAL SERVICE DEPARTMENT Tokyo, Japan First edition June., 1997 7706-01K-0.1GHSEED-WE-775HK PRINTED IN JAPAN,