WORKSHOP MANUAL F&G-SERIES ENGINE EMISSION 6SD1-TC (COMMON RAIL) SECTION 6E iSU2U 1suzu rdNOTICE Betoro using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you caretully read and thoroughly understand the information contained in Section 0A under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL", {All material contained in this Manual is besed on the latest product information available at the timo of publication. All rights are reserved to make changes at any time without prior notice. Applicable Model : FVR, FVD, GVR, GVD, FVM, FVL, FVZ, FVY ‘This Manual is applicable to 2003 year model and later vehicles.Contents Chapter 1 Overview of IE system [Overview and specifications of IE system... 1-2 Overview of IE system. sevens Specifications of IE system . ld Electronically controlled fuel injection system (ommon-rail type). - cere LB GS (Variable Geometry Turbo System) | 3 (Output of ide position signal to brake intensive control unit. 7 Ourpurof engine rotations to tachometer. 1-7 Speed Limiter (SLD) .......+ 18 External view of en lg Engine contol unit inpuvourput ist... 1-10 2. TE system schematic connection diagram .. 1-12 3. Control wnit’sesoriswitch installing positon. 1-14 4, Functions of inputioatput and vehicle behavior ‘upon failure influence) E19 S. Others... sees seve EAL Object and procedure for aceclerterlearaing lcarning of accelerator pedal idling position and full-thrortle position) 1-21 Qadjusiment data... ee. eee eee P22 Chapter 2 Failure Diagnosis 1.Self-diagnosis of IE system... “Metod of choeking the di ‘by SERVICE ENGINE SOON lamp... . 2-2 Erasing the diagnostic trouble code by memory clear switch (connector) 123 Tech 2 Operation manual... 26 2. Vehicle diagnostic procedure 216 3. Diagnostic trouble codes list. 219 Chapter 3 Functional diagnosis Checking of SERVICE ENGINE SOON lamp ighting circuit system (SERVICE ENGINE ‘SOON lamp docs not turn ON). BD (Checking the SERVICE ENGINE SOON lamp ‘lashing control system (SERVICE ENGINE, SOON lamp does not flashing) . 239 (Checking the Tech I ce TS Checking the engine starting system 37 Checking the power supply cirevit........3-20 (Cheeking the fuel system eee. cece eee 324 Checking the intake system 3.26 (Checking the staring system... 00.22, 3-28 ‘Checking the exhaust system 332 Checking the parking switeh ......2.....3-36 Idling speed cannot be adjusted 2341 ling speed cannot be decreased 3.43 Chapter 4 Checking procedure for each diagnostic trouble code 1 CMP sensor system trouble 43 13 CKP sensor system trouble... b8 2 Atmospheric temperatize sensor system twoubie 413 39 Waceremperature scasor system woul. 4-19 © Accelerator sensor sytem touble «4-25 23 Vehicle speed sensor system trouble... . 4-31 5 Boos: sensor system trouble 4.38 9 CPU monitoring IC trouble. we Gad 3 A/D conversion error/charger sirouittrovble sees 6 £9 High boost trouble... . . a FAB £2 Low boos trouble 456 Di Atmospheric presse sesor trouble «460 U3 Fuel pressure sensor output fixed ..... 4-62 4S Common sail pressure rouble, «1.1467 Common rl presstre trouble (pump excessive pressare feed)... 4.74 Injector power system trouble (Common 1 “Injector 1, 3, 5 Systems"). ..... 4-81 159 Injector power system trouble (Common 2 injector 2,46 Systoms"). 21s. -86 Sl Fuel temperate sensor trouble |... 491 214 PCVI system short cireuit (battery and power supply ciel E18 PCV2 system short circuit batery and 495 power supply circuit) trouble... -.4.99 Supply pump no presture feed ar mein pend. 103 527 Pump no pressure feed (Fel outfhoW) svc eeseeeeveeses 4108 BH Accelerator switch of rouble... 4-113 id Accelerator switch on trouble... 4-118 Fic pressure sonsor Buble... 4-128 EEE PCV system haces, shor (GND circuit) trouble me 4128 PCV2 system hamess, short (GND circuit) trouble . see 18S ZI No.! eylinder No. injector drive syscm wouble sede No.2 eylinder No injector dive system iroube aor No3 cylinder No3 injector dive SYStem HOU evo eceseseves ee A150Contents 0.4 cylinder No.6 injstor drive system trouble. ass 25 No.5 cylinder No.? injector drive system trouble oe 160 B37 Nos oplinder No.t injector drive system trouble 4-168 55) Magnetic valve "AP dive system trouble 4168 13 Magnetic valve "3" drive system trouble . corres 13 Magnetic valve "C* drive system MOUbIC a 24182 {08 Main relay system io ar) Starter switch trouble. 2196 AS Pai-sfe (Mametc vave eu) relay "A" system rouble 4.199 PCY relay system trouble 14-208 18 BOL data eror... 4-208 53 Excessive high revolution enor... 4-210 Chapter 8, Checking Mothod for Symptom Engine stall. . 52 Engine hunting, rough idle... 55 Lack output power of engine, insufficieat blow up, pulsating combustion 58 White smoke (lange)... ses. S12 Black smoke (large) 55 Chapter 6 Wiring check 1. Preface 62 Wentfication of wites 6.2.2... .2 se 62 Wiring specifications 62 Fuse . : 63 Relay. ....-.- ro 63, Handling of connectors and hamess.. 6-4 2. Vehicle wiring harness 610 3. Wiring check... - ell Engine control unit power source, GND cireuit. cell NE, G and fuel pressure sensor cireuit. |. 6-12 ‘Boos, all speod accelerator sensor eieuit.. 6-13 Accelerator sensor and accelerator switch circuit old ‘Water temperature, fuel temperature and atmospheric temperature sensor circuit. 6-15 PCY (pump coatrol valve), PCV relay circuit... 616 Injector (TWV) circuit... 2... ..2..1617 Magnetic valve, magnetic valve fail safe relay circuit... Vehicle speod sensor eet Starting cizeuit (key switch, slow blow fuse and fuse circuit) os 619 = 6-20 ‘Moter eireuit (SERVICE ENGINE SOON lamp, tachometer output) Self-diagnosis circuit (diagnosis switch, ‘memory clear switeh and Tech IL connector circtit) "Neutral circuit (Except automatic transmission vehicles) Clutch switch circuit Brake switeh circuit Reverse circuit . Idling control switeh and idling control selector switch eirenit Exlaaust brake cizuit . 621 62 623 2624 625 626 627 6-28 Chapter 7 How to use IE System Inspection Tools 1. Tech IL, Tech I. Chapter 8 Others Inspection item chart for IE system condition . Abbreviation list Programming / upload / download fuel delivery rate data... 2... 72 72 82 83 85How to read this Manual ‘This IE System Troubleshooting Mannal describes the inspection procedure for the IE System (an electronically controlled fuel injection system (common-rail)) ‘This maaual will help you in correct and speedy service operation for the TE System, Chapter 1 Overview of IE system ‘© Specifications of IE system ‘© Control mechanism of TE system ‘© Inpatioutput of IE system ‘+ Sensor & actuator insalling postion of each engine Chapter 2 Failure diagnosis ‘© View of diagnostic trouble codes ‘* TE lamp does not light ON, or the diagnosis monitor displays no data, ‘© Contents of diagnostic trouble codes Chapter 3 Functional diagnosis ‘* Checking method for proper operation of IE System or its funetions Chapter 4 Checking procedure for each diagnostic trouble code ‘© Checking method when a diagnostic trouble is displayed Chapter 5 Checking method for symptom (when no trouble code lights ON) '* When no diagnostic trouble cod is displayed, how to know the position to be checked based on the failure condition Chapter 6 Wiring check ‘+ Wiring connection condition ‘+ Connector inspection method ‘© Wire arrangement Chapter 7 How to use IE system inspection tools ‘¢ How to use the wiring harness for checking the witing hamess checker, Teel Il, and voltage Chapter 8 Others ‘© Check sheet of IE system and simplified troubleshootingChapter 1 Overview of IE systemChapter 1 Overview of IE system 1. Overview and specifications of IE system Overview of IE system ‘The LE system is un clectronie control system which controls the engine combustion condition optimally according to tae traveling requirements ofthe vehicle. ‘The IE system comprises the following components: 1. Electronically controlled fue! injection system (eommon-rail type) 2. VGS turbo control 3. Idle coal ‘Tae IE system Ins other functions as follows in addition to the engine control function, ‘A, Engine speed output to tachometer B. Self-diagnosis function Specifications of IE system List of IE system specications st Engine model | Oust SES vg riasls 228) |€ ets) (2 Bs) lz 2] [8 kW iPS} * faa] _68D7-TC _|aoeKw za0PS}| _O | 0] 0 (O- Standard equipmentOverview and specifications of IE system Electronically controlled fuel injection system (common-rail type) ‘Tho engine control unit (ECU) acquires information (signals fom many sensors) such as eagine speed, vine load and others. Based on such information, BCU sends electric signals to the supply pump, injector, to control the fuel injection rate und injection timing properly For each cylinder.» © Injection rate controt ‘The two-way valve (TWV) inthe injector is controlled based on the signals mainly fom the engine speed and accelerator opening to control the fuel injection rate properly. © Injection pressure control By controlling the fuel pressure in the common-rail, the injection pressure is controlled. Proper pressure in the common-rail is calculated based on the engine specd, fuel injection rate, and other conditions. By fing the supply pump (PCV: Pump Coattol Valve), fuel ina proper quantity is discharged and fed 10 the common-rail under controlled pressure © Injection timing control ‘Tho injoction timing control substitutes for the timer, Proper fuel injection timing is ealeulated based oa the engine speed and fuel injection rate 1o control the TW (two-way valve) inthe injector © Injection rate control In order to improve the combustion in the cylinder, a sipall quantity of fuel i injected (pilot injection) first and ignited, and then the second injection (main injection) follows. The injection timing and the injection quantity are controlled by controlling the TWY (ts0-way valve) in the injector, ‘System schematic diagram 13Overview and specifications of IE system ‘System control schematic diagram i i | i i i | i i i | | i i | L 14 Engine canal unit (£CU) ‘002! eencor input —a CHP engine speea) uUPeyindor écinion) 9 Fuel proseure sansot ‘Gam pensation [Bate hue inaction ra Pov opening|cocing ‘scsion Injotor (TW) pow supply ume, timing decision Fuel pressure sensor Vabice ‘luton switeh signal ste. Gonmonal ‘ normally high prezsure) ume STS] rast tac S oosisrator sencoringut ‘or soitehinpat ASR demand signal (uol cu gna) sensor input ww (hee Way valve) JNOverview and specifications of IE system IE VGS (Variable Geometry Turbo System) Air eylindor stroke distance (No. of stops of magnctio valve) is obtained from the engine speod, which is ‘compensated according to information from various inputs to obtain the final stroke distance (No. of stages ‘of magnetic valve) for the air eylindst. The VGS magnetic valve is operated by thc number of steps decided and the air cylinder is moved under air ‘pressnse to contol the nozzle vane angle in the turbine housing. soestes, Engine sposd— pte Input tom ‘wien of. ‘Magnes vave cv erst Engine contol unit 15Overview and specifications of IE system © Idling control switch The iding speed can be adjusted by operating the idling contol switch. The upper limit of speed varies depencing onthe engine model, vehicle specifications an engine warming vp contion. uP 4 While the UP side of the switch is pushed, the engine speed ———————— _inereases and te iting spood is incresed necondingy. DOWN While the DOWN side ofthe switch is pushod, te engine speed decreases andthe idling speed can be deceased, only dow tthe lower limit 16Overview and specifications of IE system Output of idle position signal to brake intensive control ‘Tho engine eontral unit issues the “accelerator pedal stepping condition (stepped not stepped)” to the brake integrated control unit as idle position signal output. The brake intensive control unit operates or releases the exhaust brake according to the “accelerator pedal stepping condition" sent from the engine control unit and the operating condition of the exhaust brake I clutch pedal, ete. which is directly detected POWER SUPPLYIKEY ON) Exh Brake SW. -G—{_ engine control Unit mv Output of engine rotations to tachometer ‘The engine control unit sends the “engine speed pulse (4 pulses per spoed of engine)" 1 the tachometer and the tachometer onrpet. ‘The tachometer indicates the engine speed. according to the "engine speed pulse” sent from the engine control unit NE sensor sti | orem SET | eco Geonser saan 17Overview and specifications of IE system Speed Limiter (SLD) ‘The speed limiter (SLD) is control ia the ECM which limits vehicle specd not to exceed a setting value. ‘Tae limit of vehicle speed is performed by fuel rate control in the ECM. Fuel rate is controlled based on ‘chicks specd signal and engine specd signal. Vehicle speed signal is inputted tothe spoed meter control unit (VSS control uni), The VSS contro] unit tectifies vehicle speed signal according to vehicles and oxtputs the signal to ECM and mete. Engine spced is compured by the ECM based on the crank position (CKP) sensor. 18 Meier Giher civ <——_ com be] ves ow Fu Injection Contra! lcrank Position (CkPy| f pySensor wr Vehicle SpeedSensor (ss)Overview and specifications of IE system External view of engine control unit sSpecccoocoow wWovoscoEEonM g@eeeseseasan Note: Operate the control unit suited to the vehicle according to the "Commment" and “Applicable engine identication name" described on the label Ifa control unit not fitted for the vehicle is use, fallure may result 19ications of IE system Engine control unit inputfoutput list 110 cnet < Uae Cnt a ph titOverview and specifications of IE systemChapter 1 Overview of IE system (varview and specifistons of IE system 2. IE system schematic connection diagram 5 | StooChapter 1 Overview of IE system 3. Control unit/sensor/switch installing position 114Control unit/sensor/swite! FUSEBOX ——_—RELAYEOX EXHAUST BRAKE SWITCH * IOLEUP SWITCH “IDLE DOWN GvnTeH ACCELERATOR SENSOR + ACCELERATOR SWITCH Diagnectie Swit (White) Memory Clear Switch (Bice) * Date Link Connector [Neticls eavippee with no mult warning] seviceControl unit/sensor/switch installing position 1-16Control unit/sensor/switch installing position Cab rear member Legend Ouv co) @uve) @MV(A)Control unit/sensor/switch installing position Engine (6801-70) od oa snet \ LY e ee ge LS SP o a vom) Le PES = A, | L1/| sage pom Sa ance Mt nperaure censor - “\ \ Ie 2 at“ ae 1-18Chapter 1 Overview of IE system 4. Functions of input/output and vehicle behavior upon failure (influence) reson ieee oe a oa lest tf iteteeniasiid, §— saint ug iam Te | dail eur erence i co 77 Sara cee : [SP I vas sr [onc tunoae tthe a i = ae Lae | * Check by SERVICE ENGINE SOON lamp ‘© Chock by Tech Il (with the Tech II connected) ‘= Check by diagnosis monitor (with the diagnosis monitor connected) } | a ° sea | Tater | fee | came | trator ene e ™ Tater | Tiler | Stet | came | tater mene e jon ° set [ee [set [oe [amare [oe [on ° Sot | ter | set | ate, [Semvasvamises |e [ae [ene © Set | see | set | bey [srmieyaein=| 0 | os [nw . smal | Seth | Sat | esa. | srmsitayvamisem | @ | as Jew ° Sel | ser | set | be, [Smieeamism | 0 | a [ae ° set | Sot | et | comtany_| Srv | 276 [rw ° a ° set | tet by [Suet att, [peas Moet | tr | Stet | cate = 2 2.20Diagnostic trouble codes list fa trance |Get | ee cone, | mhntnteng tn a permease Beer | aepenmsene ees Eagar esntnneta Sn Hote iepnarmcennnnee | tn tr man a lnc] SO Leo veces Sener) Jen Zager (RPM | Taine tits [enna betaine = oo Se Eanes [andre [I TANCae |e ee 7 ee Lc a Ye eV renr roars ae aioe ee oe = eaate oh RRS aa mrataene a eo aa PaO = fone SSE [ae eee! @ fanaa (EERE |e 221Diagnostic trouble codes list tx | ter | ee Seeseegmeetes st e ‘cant at sat oun anda & « ° set] ee | ae aatcinmior | @ | #2 ° eer | aie net * ° vor [ver | se | oe, [Beer eh © Saet_[ Ber colt, [anartat ” f ee ee ° set | Set | ez | atm, [peeemmsuse | @ | a EC] TA | at feowmnwere fe [ee ° a ° Se |e | ee [ome me [eae * vont [ter [sem [amt [amnesia [oe [ae ° See [er Ba a rere e ser [ees [ast [cr pnw [| ° Se [Se [ee [ete [amen es ° cot | Gam | ot | eatin is ° 2.22Chapter 3 Functional diagnosis Preface For the purpose of keeping engine operation normal or to restore the engine operation to normal condition, functional diagnosis is made. If some engine control functions are not properiy working, the engine control unit diagnoses erroneously o7 some error showing 10 diagnostic trouble code occurs so that dingnosis cannot be made correctly. Follow ihe inspection procedure described on the following pages for diagnosis (check or repeir) of functions. (Checking of SERVICE ENGINE SOON lamp lighting circuit system (SERVICE ENGINE SOON lamp dos not turn ON) ‘Checking the SERVICE ENGINE SOON lamp flashing coatrol system (SERVICE ENGINE SOON lap das ot aig (Checking the Tech It 0 Checking te engine stating system... 2... Checking the power supply circuit ‘Checking the foe! system a 3 Checking the intake system. : Checking the staring system CCheeking the exhaust system Checking the parking switeh Tdling speed cannot he adjusted ling speed cannot be deercasedChapter 3 Functional diagnosis Checking of SERVICE ENGINE SOON lamp lighting circuit system (SERVICE ENGINE SOON lamp does not turn ON) ll SERVICE ENGINE SOON lamp circuit ENGINE CONTROL UNIT CONNECTO! OU HARNESS INSTRUMENT {LOWER} INSTRUMENT (UPPER) HARNESS HANES D Ey ono S39 cAseOND a2Checking of service engine soon lamp lighting circuit system nd OU SERVICE ENGINE SOON lamp does not turn ON) Engine control unit power source, GND circuit ENGINE CONTROL UNIT CONNECTOR EGU HAFNESS SDE. Le FET DIAG CONNECTOR TONTOONNECTOR INSTRUMENT (LOWER) HARNESS 33Checking of service engine soon lamp lighting circuit system (SERVICE ENGINE SOON lamp does nof turn ON) Connection of meter connector SERVICE ENGINE SOON Lame CONNECTOR © CONNECTORD (CONNECTOR E ‘CAUTION Euse box USE FUBE W/TH THE SPECIFED CAPACITY Jeo nts TS] rel Elmo ee [imc ay I gl ts Blaecowmny lee eton [| [GB lsu re (se |esreraa || Es el [ee fe ee at Bae [Ble m (S| B[unsew [Blemenom [S| eI Kein fs \eiwone [Blows [ane na ISB ree wrccmreard © | ae ome [Siero [Blewwruarven [| [B]ocorwecn [| eke be aChecking of service engine soon lamp lighting circuit system nd OU SERVICE ENGINE SOON lamp dovs not turn ON) Circuit description Power to opecate the meter (SERVICE ENGINE SOON lamp) is supplied through the fuse. Lighting up and going out of the lamp are controlled with the engine contro] unit. (The engine contol unit is Tocated in the cireuit between the power source and GND (ground) circuit to gperate the lamp control ‘switeh in the control unit and light up or extinguish the lamp.) Possible causes Faulty power supply circuit (starter switch circuit, ct.) Faulty main unit (indicator, communication circuit) SERVICE ENGINE SOON lamp (bulb) burnt out Faulty meter main assembly (including circuits) Disconnected wire of meter power source cireuit Discoanected wire of lamp driving cireuit Faulty engiae control unit Faulty engine control unit power circuit (key ON) Faulty engine control unit power source circuit (main relay eieuit) Faulty engine control unit GND eizeuit 35Checking of service engine soon lamp lighting circuit system GBERUICE ENGINE SOON any Goss hotturn BN? Troubleshooting (Checking steps and corrective actions) Perform the checking and corrective actions following the steps shown below. Siena] ‘Ghacking and Carredtive Actions Result YES [NO 1 | Check the fises Fuses are nanmal | Step3 | Step? (Check ithe fuse far meter power anu dhe fases for Engine Control Unit (No. 17 forkey ON signal and No. 45 for main relzy power) are normal | Replace the ses, and check ifthe SERVICE ENGINE SOON amp] Lamp ON (operated) |) Step? Step ums on (operated) when the starter switch is turned on again. | Check the voltage is applied to fses for need ECU. Batty voliage | Step 4 | Giecin| 1 Remove the fases No.L1, 17, and 45. te 2, Torn tho starter switch o. power 3, Measure the voltage at each fise siounting place. source Is the voltage normal valin teat [1 Disconnect the harness from the Engine Control Ua Tarp ON (operated) | Step? | Step 2.Ground (GND) the connector (No. 105 pin) ofthe Engine Control Unit. 3.Turm the starter switch on S| Check the connector and harness of the miler eireul Wo faultistound | Stsp7 | Steps 1. Disconnect the harness from he meter, 2, Disconnect the harness from the Engine Control Unit 3, Check the eonncetors for corrsion, looscncss, opening, or iting conditions of pins, 4. Rofering tothe circuit diagrams, check the following circuits Between power source and meter 1) Fuse No.17 to instrument (upper) harness eenncetor 2) Motoew instrument (ower) hers connoctor ‘Betwoon Engine Control Unit end meter 1) Engine Contro! Unit to instrument (lower harness eonncetor 2)ECU hamess connector to instrument (upper) hamest| 3) Meter to instrument (lower) harmess connector Are the harnesses and connectors normal? 36Checking of service engine soon lat 9 OU SERVICE ENGINE SOON t lighting circuit system amp does not turn ON) ‘Checking and Corrective Actions Result YES NO Repair Tauly pats (coanectors and hamesses) in the meter zou, | After repai, check if the lamps other than SERVICE ENGINE /SCON lamp tum on (operate) when the starter switch is tuned on again ‘Lamp ON (operated) Siep 1 Step 7 [Check ths METER lamp bal is the bull broken? Bulb i nomad Supe Spe Replace the METER lamp bulb After repair, cheok if the SERVICE ENGINE SOON Trp turns on] (operates) when the starter site is turned on again, Did the meter (Lamp) operate’) Tamp ON (operated) Sep sepa [Check the power source forthe Eagine Control Uni 1. Diseuomect the harness from the Engine Control Unit, 2, Turn the starter switch on. 3, Measure the voltage at the connector of Engine Control Unit (80.13 and 23 pins), Is the voltage normal value? Battery voltae Slept Sept Reni the hamess between fs No.1 and Engine Control Unit [After repair, check if the Tamps ether than SERVICE ENGINE| ]SOON tamp tur on (operate) when the starter switch is tumed on] again Lamp ON (operated) Step 17 Step 11 7 [Check the wiain relay cireuie (hamesses and connestor) and the| relays, 1. Disconnoet the harness from the Engine Contra Unit, 2, Remove the main relay. 3. Check the connectors for corrosion, looseness, opening, ot fitting conditions of pins. 4. Referiag tothe circuit diagrams, check the following circuits ‘Fngine Control Unit to instrusent (lower) harness connector FECT hamest comncetor to main relay Fuse Nod§ to main relay Fuso No.4S fo frame (FI) hamess connoetor Instrument (lowe) hamess connector to ground paint 5, Cheek the relay for fmetion. Are the hamesses, connectors, and relays normal No fas found Step 3 Step 12 a7Checking of s (SERVICI ENGINE SOON lamp does not IN) ce engine soon lamp lighting crcult system t turn (Checking and Corrective Actions: Result YES |_NO 12 [Repair faulty harness, connector, or relay inthe main relay circuit [After repair, chock if the lamps other than SERVICE ENGINE SOON lamp turn om (operate) when the starter switch is turned ca agin TLaaip ON (oparaied) ‘Step 17 | Sep 13 3B [Chook the GND for Engine Control Unit L. Diseonneet the harness from the Engine Control Uait, 2. Check the connoeters for corrosion, looseness, opening, of fing conditions of pins. 3. Referring to the citeuit disgrams, chock the folowing circuits: ‘Engine Contol Unit to instrument (lower) hamess counector [BCU hamess comuector to frame (F#) hamess connector + Instrument (lower) harness connector to ground point Aso the harnesses and connectors uot? No foul is Found ‘Sep 15 | Step 4 rr "Ropar Faulty harnesses and connectors in ts grond clcuit for ths ‘Engine Contol Unit. [After repeir, chock if the lamps other than SERVICE ENGINE SOON lamp tur on (operate) when the starter switch is turned on again, Lamp ON (operated) Sep 17 | Step 15 Replave the meter anerbly, [After repair, check if the lamps other than SERVICE ENGINE| SOON lamp turn on (operate) when the starter switch is turned on again amp ON (operated) Step 17 | Step 16 16 Replace the Engine Control Unit After the Engine Control Unit was replaced, perform the accelerator learning, Did corrective actions complete? ‘Seep 17 7 Restore the vehicle, and perform the repair check. Cheak | 38Checking the SERVICE ENGINE SOON lamp flashing control system (SERVICE ENGINE SOON lamp does not flashing) lH SERVICE ENGINE SOON lamp circuit ENGINE GONTAOL UNIT GONNEGTOR: fo ruse2 nsTRUWENT (LOWER) INSTRUMENT (UPPER) HARNESS HARNESS 5 DAG SWITCH cca Lies ca ona ‘aa cl | Yeaunect33 Lo arseano [MEMORY LEAR GWiTEN | 39Checking the SERVICE ENGINE SOON lamp flashing control system (SERVICE ENGINE SOON lamp does not flashing) Connection of meter connector SERVICE ENGINE SOON Lame CONNECTOR © CONNECTORD (CONNECTOR E ‘CAUTION Euse box USE FUBE W/TH THE SPECIFED CAPACITY Jeo nts TS] rel Elmo Ez plead ay I gl ts Blaecowmny lee eton [| [GB lsu re (se |esreraa || Es el [ee fe ee at Bae [Ble m (S| B[unsew [Blemenom [S| eI Kein fs \eiwone [Blows [ane na ISB ree wrccmreard © | ae ome [Siero [Blewwruarven [| [B]ocorwecn [| eke be a 340Checking the SERVICE ENGINE SOON lamp flashing control eystom (SERVICE ENGINE SOON lamp does not flashing) Circuit description Power 10 operate the meter (SERVICE ENGINE SOON lamp) is supplicd through the fuse No.11 Lighting up and going out of the lamp lashing are controlled with the engine contral unit, (The engine ‘control unit is locatsd inthe circuit between the power souree and (GND), to operate the lamp control switch jn the engine control unit and lighting up or extinguish the lamp flashing.) Possible causes Faulty meter main assembly (including cireuits) Shorted lamp driving circuit, Faulty diagnostic switch circuit Faulty engiae contol unit |B Troubleshooting (Checking steps and corrective actions) Perform the checising and corrective actions following the steps shown below. sions ‘Checking and Corrective Actons Recut Yes | NO 1 | Check the diagnostic switch (connector) eieuit. No faultis found | Step3 | Step? 1. Disconnect the harness from the Engine Couttal Unit 2. Check the connectors for corrosion, looseness, opening, ot iting conditions of pias. 3. Refering tothe circuit diagrams, check the following ercuits Between Engine Control Unit and diagnostic switch (connector) 1) Engine Control Unit to instrument (lower) harness connector 2) BCU hamess connector to diagnostic switch (connector) ‘Between diagnostic switch (connector) and ground (GND) 1) Diagnostic switch (connector) to frame (F#) harness eonnoctr| 2} Instrument (lower) harness connector and ground (GND) Are the harnesses and connectors normal? 2 [Repair fully hamesses and conncetors ia the Gaguowic switch] flashing (operat) | Sep® | Sep (connector circuit, attChecking the SERVICE ENGINE SOON lamp flashing control system (SERVICI ENGINE SOON lamp does not flashing) ‘Checking and Corrective Actions Rest Yes ‘Check the connector snd haness ofthe meter cient 1. Disconnect the barness ftom the meter 2, Disconnect the harness from the Engine Control Unit 3, Cheek the eonncetors for corrosion, looseness, opening, or fitting concitions of pins 4, Refering tothe circuit diagrams, check the following circuits Engine Control Unit to instrument lower) aess connector ECU hamess connector to instrument (upper) harness connector Meter to instrument (lower) hamess comeetor Are the harnesses and connectors normal? TNo fas found Step & Step Repair faulty parts (connectors and hamesses) inthe meter rca ‘asking (operated) Sepe Seps [Replace the mister assembly, and connect al harnesses Tor the Fagine Control Unit, ee ‘Sarier swiich ON: Lamp ON ‘Starter switch OFF: Lamp OFF ‘Sup Bene ATTSe vopair, chook Whe Tampe thor Than’ SERVICE: ENGINE ‘SOON lamp Mashing (operate) whon tho starter switch is tured on] again Tasking (oporaiod) Tepe SapT Replace the Bagine Control Unit “After the Engine Control Unitis replaced, perform the seesterator Teaming, Did corrective action complete? sepe estore the vehicle, and perform the repair heck Check 342Checking the Tech Il I Self-diagnosis circuit (Engine control unit) |HeINE CONTROL UNIT CONNECTOR [ETAR] 343hocking the Tech Il atd Circuit description ‘There are Two Tech Il communication circuits provided; one in the signal communication cireuit from the engine control unit tothe Tec IT and other in the signal received cireit from the Tech I to the engine control unit, ‘The signal from the transmission side is used for the "monitor" mode to read the self-diagnosis codes or engine data with the Tech I ‘The signal from the reception sie is used for the "communication mad” to erase the self-diagnosis codes, cte., or for the "inspeetion mode" to cheek the accelerator learning or switches. Possible causes Faulty cizouit from the engine contvel unit connector to Tech IL councetor (disconnected wire, shoxtcireuit, cic.) Eaulty engine control unit Eaulty Tech LI connector power soureeChecking the Tech It Troubleshooting (Checking steps and corrective actions) Perform the checising and corrective actions following the steps shown below. Sens] ‘Checking and Correctve Actons Reso (Check the fise Is the power fuse for Tech I normal? Fise is normal Seep} | Step? Replace the fuse, and turn the starter switch ow epain to check the| Tech for function, Dax the Tech I aperate? Tamp ON [aperated) Siep 15 | Step 3 [Check the Tech TT power supply. [Check ifthe voltage is applied tothe Tech I when the tater swith is turned on. Is the voltage applied? Battery voltage Sep7 | Steps [Check ithe voltage is applied to the fuse when the starter switch is turned on. Is the voltage applied? Batiery voltage SepT | Sapo Repair the power supply circuit forthe Tech TE After repair, check the Tech TT operation when che starter switch is cured on again Does the Tech M operate? Tech l opertee Bepls | Sepe 3 Repair or replace the power supply eeu (See Section 6, Wiring chock "powce supply circuit") Affe ropair, check the Tech IT operation when the starter switch is turned on again Does the Tech I operate? "Tech I operates Siep 15 | Siop 7 (Check the Tech I connector Cea 1. Diseouneet the harness from the Engine Coutrol Unit. 2, Check the comectors for corrosion, looseness, opening, ¢ Siting conditions of pins. 5. Referring tothe circuit diagrams, check the following citevits Between Engine Contol Unit and Tech Il connector 1) Engine Conteol Unit instrument (laser) hamcss connector 2)ECU hamess connector to Tech Il connector Are the hamesses and connectors normal? No faults Found Siep 1S | Siep ® [Repair Taully harnesses and eomnectars the Teoh M1 connector ict After repair, check the Tech IL operation when the starter switch is turned on again, Does the Tech Il operate? Tech operates Sep lS] Sep [Cheek the fise @A) inside the Teoh I Is te fuse (2A) normal? No faults Found Siep 1S | Sep 10 [Replace the fase (ZA) inside the Tech I After repair, check the Tech IL operation when the starter switch is turned on nit ows the Tech M1 operate? Tech aperater Sep ls | Sep 345