STRUCTURE AND OPERATION 3. Electronic Control Unit Connection Diagram _ STARTER Sm | sranren snot ais fecriieinenty ECU main power relay yoo ie } (memory clear : OPEN) © eatery | | T 2 tf 7) Torque cit switch pcp | VY ‘Models with toraue cut function> ! Diagnosis switch | ——20-ve— Iector ee rake ‘etter = E fete tee Engine weed vener I at bs Crlnder recognition sensor [|= Ra Accelerator pedal position sensor Acre puso 98 i ae eee ee ee ea ie s8.oM Water temperature sensor as Fuel temperature sensor (outlet) fy — ‘sa le31 ee Intake ar temperature sonsor YE Electronic control unit {| —— SG SPEED OUTS aig “Models with auto shifter> |__| mm TI, Tachometer (jt ne 136-18 Engine electronic control unit 691 186-113E Engine electronic control unit Glow drive relay or 1 | 1 Ba == : shuter nay manetic vive Models with aux bra | on Sn ramets eae Mod 1 Engine warning lamp (red) ott Saas 4 Engine waring amo (oranas) on ent, —— Exhaust shutter indeatr lamp Modes with aur brake? oy Pihaust anaes wih eae bre? Glow ndstr amp ] Vehicle speed sensor PTO switch Model wth power take-of> ao - Ar conditioner switch at a ing earl eth Mode with ats’ t ‘Transmission neutral switch “Models with manual gear shifter> os oe : t : brake sth Model with ir bra Auxiliary brake cut switch ol start wth Select switch Models wth ato ahiter> =|) muti-Use Tester connector fi CAN communication Machinery side | electronic control unit EGR: Exhaust gas recirculation } Boost pressure sensor PTO: Power take-off CAN: Controller area network + ling speed adjustment potentiometer xs 80 if Fuel injection rate adustment resistor aig 0 PTO adjustment resistor TF Models with power take-off im $F on tenpratire sensor oe) a +] $80 uction contro wave) Supply pum A:GFO4A B:GFa5A c:0F82a Test Pty| pave star) |apesyarse cerenmnond feocoonsamsool | |roroeATcOo ia | [ete | | pa z fsb jf (| ia | [ot 7s 691 186-2 136-19TROUBLESHOOTING 1. Diagnosis Procedure + The system can be efficiently inspected for faults using a Multi-Use Tester-IIL ‘System inspection can be accomplished basically in two ways according to trouble symptom and diagnosis code as shown below. + Check against each diagnosis code stored in memory by the electronic control unit + Response to transient fault Warning famp it ee Vehicle in serice shop) (ead gna cote. See 6} Fault code output Normal code output Normal code output ater cleared etek oars soo caro] _ [Reape overt ee GOO) se Clear stored diagnosis code. (See Gr00,) ‘Start the engine. ‘Aer starting the engine, check for diagnosis cade and warning lamp lighting, diagnosis code is ssued and ‘warning lamp is it, check fait again. Crear stored diagnosis code. (See GOO} 136-2013E 2. Diagnostic Precautions Before measuring voltage, check the battery for charged condition and specific gravity If system inspection is per- formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. To avoid having electrical parts damaged, set the starter switch to LOCK or OFF before disconnecting and recon- necting battery cables. Before disconnecting connectors, set the starter switch to LOCK or OFF, then allow at least 20 seconds. Voltage may remain in electric parts or connected circuit. ‘When performing measurement with the tester, handle the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in connector or between connector and car body. Resistance is affected by temperature. Determine the necessity of resistance measurement following given tem perature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition 136-21TROUBLESHOOTING 3. Inspections Based on Diagnosis Codes 3.1 Diagnosis code list * Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. + The Multi-Use Tester is capable of showing more detailed diagnosis codes. Code Message Cate ies Code Message eae in P0107 [Atmospheric Pressure Sensor 18 0380 | Relay for Glow Relay 26 P0108 | Atmospheric Pressure Sensor 19 P0500 | Vehicle Speed Sensor 25 O12 [INT Air Temp. SNSR (Low) 4 0506 [idle Volume 3t POTTS [INT Air Temp. SNSR (High) 4 0507 [idle Volume 31 POTI7_| Water Temp SNSR (Low) 2 PO510 [Accel SW 65 P0118 | Water Temp SNSR (High) 2 P0600 [CAN Communication 7 P0121 | Accel Pedal Check (Plausi 58 P0605 [ECU Hardware (ROM) 33 P0122 | Accel Pedal Sensor 1 24 P0616 | Starter Safety Relay (Low) 48 P0123 | Accel Pedal Sensor 1 24 0617 | Starter Safety Relay (High) 8 0182 [Fuel Temp. Sensor inlet}Low | 41 Pit71 [@ Adjustment Resistor (Low) 34 P0183 [Fuel Temp. Sensor (inlet) High | 41 P i172 [@ Adjustment Resistor (High) 34 0187 | Fuel Temp. Sensor (outlet) 56 P1176 [PTO Adjustment Resistor @ P0188 | Fuel Temp. Sensor (outlet) 56 Pit77_| PTO Adjustment Resistor 2 P0191 [CRS Pressure SNSR (Plausi 1 P1200 | Injector Gircut 2 e P0192 [ORS Pressure SNSR (Low) i P1210 | Injector Gircut 3 a 0193 [CRS Pressure SNSR (High) 1 P1240 | Flow Limiter -Cylindert 7 0200 | Injector Circuit 1 @ P1241 | Flow Limiter-Cylinder2 72 0201 Injector MIV-Gylindert (Load) 37 P1242 | Flow Limiter-Cylinder3 73 0202 Injector MIV-Cylinder2 (Load) 38 P1243 | Flow Limiter-Cylindera 74 0203 | Injector MIV-Cylinder3 (Load) 38 P1244 | Flow Limiter -CylinderS 75 0204 | Injector MIV-Cylinder4 (Load) 08 P1245 | Flow Limiter -Cylinder6 76 P0205 | Injector MV-GyiinderS (Load) 6 P1255 |CRS Press MV 1 (Low) 6 P0206 | Injector MAV-Gylinder6 (Load) a7 P1256 |CRS Press MIV 1 (High) 3 P0218 | Engine Overrunning o7 P1257 [Common Rail Pressure MIV 1 3 ai} P0222 [Accel Pedal Sensor 2 16 Pi267 [EGR 1 or P0223 | Accel Pedal Sensor 2 16 P1268 |EGR 1 7 0237 | Boost Press SNSR (Low) 32 P1272 |EGR2 68 P0238 | Boost Press SNSR (High) 32 P1273 |EGR2 68 P0251 | Common Rail Pressure Defect 36 [P1277 |EGR3 69 P0262 [Common Rail Pressure Defect | 36 P1276 |EGRS 68 P0263 [Common Rail Pressure Defect _| _22 1462 | Exhaust Brake MV 1 aati aaa P0254 | Common Rail Pressure Defect 23 P1463 | Exhaust Brake MV 1 93 P0255 | Common Rail Pressure MIV 1 23 P1605 [ECU System (EEPROM) 33 P0256 | Common Rail Pressure MIV 1 23 0257 [Common Rail Pressure MIV 1 23 P0335 | Engine Revolution SNSR 15 P0340 [Camshaft Position SNSR 12 136-22[43E] 3.2. Diagnosis code generation conditions and inspection items P0107: Atmospheric Pressure Sensor (warning lamp flashes: 19) ‘Atmospheric pressure sensor (incorporated into engine electronic control unit) voltage is below standard value (1.9 V) Generation condition Recoverabiity ‘System recovers if signal becomes normal with starter switch in ON position + Control is effected with atmospheric pressure assumed as constant 101 KPa Control effected by electronic control unit {1,03 kgfiom’}. (Exhaust emissions worsen.) + Exhaust gas recirculation control is stopped, ‘Service data '38: Atmospheric Pressure Inspection Electrical equipment [Engine electronic control unit P0108: Atmospheric Pressure Sensor (warning lamp flashes: 19) ‘Atmospheric pressure sensor (incorporated into engine electronic control unit) voltage is above standard value (4.7 V) Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, ‘Generation condition + Control i effected with atmospheric pressure assumed as constant 101 kPa ‘Control effected by electronic control unit. {1.03 kafiem?). (Exhaust emissions worsen.) + Exhaust gas recirculation control is stopped. ‘Service data ‘38: Almospheric Pressure Inspection Electrical equipment Engine electronic control unit P0112: INT Air Temp. SNSR (Low) (warning lamp flashes: 44) ‘Generation condition Intake air temperature sensor voltage is below standard value (0.1 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position. ‘Boost air temperature is assumed as constant -20°C during engine startup and Control effected by electronic control unit | a¢ constant 25°C while vehicle is being driven. Service data 27: Intake Air Temperature Inspection | Electronic control unit connector Intake air temperature sensor Electrical equipment #305: Intake air temperature sensor P0113: INT Air Temp. SNSR (High) (warning lamp flashes: 44) Generation condition| Intake air temperature sensor voltage is above standard value (48 V). Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, ‘Boost air temperature is assumed as constant ~20°C during engine startup and Control effected by electronic control unit | a5'constant 25°C while vehicle is being driven. Service data 27: Intake Air Temperature Inspection [Electronic control unit connector | GIB: Intake air temperature sensor Electrical equipment #305: Intake air temperature sensor P0117: Water Temp SNSR (Low) (warning lamp flashes: 21) ‘Generation condition Water temperature sensor voltage is below standard value (0.1 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, + Water temperature is assumed as constant -20°C during engine startup and Control effected by electronic control unit, as constant 80°C while vehicle is being driven. (Exhaust emissions worsen.) + Exhaust gas recirculation control is stopped, Service data 35: Water Temperature Inspection | Electronic control unit connector | GBD: Water temperature sensor Electrical equipment #262: Water temperature sensor 136-23TROUBLESHOOTING P0118: Water Temp SNSR (High) (warning lamp flashes: 21) (Generation condition Water temperature sensor voltage is above standard value (4.8 V) Recoverability ‘System recovers i signal becomes normal with starter switch in ON position. Control effected by electronic control unit + Water temperature is assumed as constant ~20°C during engine startup and as constant 80°C while vehicle is being driven. (Exhaust emissions worsen.) + Exhaust gas recirculation control is stopped. Inspection Service data 36: Water Temperature Electronic control unit connector (G@_ Water temperature sensor Electrical equipment #262: Water temperature sensor P0121: Ac :cel Pedal Check (Plausibility) (warning lamp flashes: 58) Generation condition ‘Output voltage difference of accelerator pedal position sensors 1 and 2 is out- side standard range. Recoverability ‘System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Controt is effected using value of 30% with accelerator pedal depressed and us- Ing value of 0% with accelerator pedal not depressed. (Output is reduced.) Inspection ‘Service data 22: Accel Pedal Position (unfitered), 23: Accel Pedal Position tered), 24: Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2 Electronic control unit connector @. Accelerator pedal position sensor [Electrical equipment #324: Accelerator pedal position sensor P0122: Accel Pedal Sensor 1 (warning I: lamp flashes: 24) (Generation condition [Accelerator pedal position sensor 1 voltage is below standard value Recoverabil ity ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit, + Controls effected using accelerator pedal position sensor 2. + Ifboth sensors 1 and 2 are faulty, contol is effected on assumption that acce!- trator pedal is depressed 30% when accelerator switch is on and the pedal is not depressed when the switch is off Inspection Service data 22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (fitered), 24: Accel Pedal Sensor Voltage 1 Electronic control unit connector GB: Accelerator pedal position sensor Electrical equipment #324: Accelerator pedal position sensor P0123: Accel Pedal Sensor 1 (warning lamp flashes: 24) [Generation condition [Accelerator pedal position sensor 1 voltage is above standard value. Recoverabi ity ‘System recovers if signal becomes normal with starter s (ON position Control effected by electronic control unit + Control is effected using accelerator pedal position sensor 2 + If both sensors 1 and 2 are faulty, control is effected on assumption that accel- erator pedal is depressed 30% when accelerator switch is on and the pedal is ‘not depressed when the switch is off. Inspection Service data '22: Accel Pedal Position (unfitered), 23: Accel Pedal Position (fitered), 24: Accel Pedal Sensor Voltage 1 Electronic control unit connector '@): Accelerator pedal position sensor Electrical equipment #324; Accelerator pedal position sensor 136-24P0182: Fuel Temp. Sensor (inlet) Low (warning lamp flashes: 41) 13E ‘Generation condition Fuel temperature sensor (inlet) voltage is below standard value (0.1 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, ‘Control effected by electronic contral unit __| Fuel temperature is assumed to be constant 40°C. ‘Service data 36: Fuel Temperature (inlet) Inspection | Electronic control unit connector QB: Fuel temperature sensor (inlet) Electrical equipment #823: Fuel temperature sensor (inlet) P0183: Fuel Temp. Sensor (inlet) High (warning lamp flashes: 41) ‘Generation condition Fuel temperature sensor voltage is above standard value (4.8 V). Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, | Control effected by electronic control unit Fuel temperature is assumed to be constant 40°C. ‘Service data 36: Fuel Temperature (inlet) Inspection | Electronic control unit connector (GB: Fuel temperature sensor (inlet) Electrical equipment #323: Fuel temperature sensor (inlet) P0187: Fuel Temp. Sensor (outlet) (wart ning lamp flashes: 56) Generation condition Fuel temperature sensor (outlet) voltage is below standard value (0.1 V). Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit Fuel temperature is assumed as constant 40°C during engine startup and as constant 80°C while vehicle is being driven Service data 37: Fuel Temperature Inspection [Electronic control unit connector Fuel temperature sensor (outlet) Electrical equipment #323: Fuel temperature sensor (outlet) P0188: Fuel Temp. Sensor (outlet) (war ning lamp flashes: 56) Generation condition Fuel temperature sensor (outlet) voltage is above standard value (4.8 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit Fuel temperature is assumed as constant 40°C during engine startup and as, constant 80°C while vehicle is being driven. Service data 37; Fuel Temperature Inspection [Electronic control unit connector (G Fue temperature sensor (outlet) Electrical equipment #323: Fuel temperature sensor (outlet) P0191: CRS Pressure SNSR (Plausi ) (warning lamp flashes: 11) Generation condition All three conditions listed below are satisfied simultaneously while engine is be- ing cranked or while vehicle is being driven, + “Engine speed ijecton amount, commen rll pressure and ful type are with in specification + Difference between actual common rail pressure and target common rail pressure is greater than standard value. + Extent of changes in actual common rai pressure is smaller han standard value, Recoverabilty ‘System recovers (power is re-supplied to electronic control unit) if signal be- comes normal when starter switch is turned OFF ~» ON. Controt effected by electronic control unit ‘Common rail pressure open loop control is effected, + Exhaust gas recirculation control is stopped. Service data Inspection 07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, 0B: Difference Common Rail Pressure, OC: Difference Common Rail Pressure Electrical equipment #319: Common rail pressure sensor 136-25TROUBLESHOOTING P0192: CRS Pressure SNSR (Low) (warning lamp flashes 1) Generation condition ‘Common rail pressure sensor voltage is below standard value (0:7 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit + Common rail pressure open loop control is effected. ‘+ Exhaust gas recirculation control is stopped. Inspection Service data (07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, (0B: Difference Common Rail Pressure, OC: Difference Common Rail Pressure Electrical equipment #319: Common rail pressure sensor P0193: CRS Pressure SNSR (High) (warning lamp flashes: 11) (Generation condition [Common rail pressure sensor voltage is above standard value (4.95 V). Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit + Common rail pressure open loop control is effected, + Exhaust gas recirculation control is stopped. Inspection Service data 07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, 0B: Difference Common Rail Pressure, OC: Difference Common Rail Pressure Electrical equipment #319: Common rail pressure sensor P0200: Injector Circuit 1 (wart flashes: 82) Either one of injector magnetic valves (No. 1, 2 or 3 cylinder) is short-circuited, or Generation condition Sper creuted ‘+ When short-circuited: System recovers (power is re-supplied to electronic, control unit) if signal becomes normal when starter switch is tuned OFF —> Recoverabilty ON. ‘+ When open-circuited: System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit ~ + Main injections only enabled *+ Common rail pressure upper limit provided. + Injection rate limited to predetermined value. + Exhaust gas recirculation control stopped. ‘+ Inter-cylinder injection amount correction valve (FCCB) learning disabled + Exhaust gas recirculation control stopped. ‘+ Inter-cylinder injection amount correction valve (FCCB) learning disabled. Inspection ‘Actuator test BBB: Injector Test 1, BD: Injector Test 3, BF: Injector Test 5 Electronic control unit connector GB: Injector magnetic valve Electrical equipment #582: Injector magnetic valve P0201: Injector MIV - Cylinder (Load) ( (warning lamp flashes: 37) Generation ‘condition Injector magnetic vaive (No. 1 cylinder) is short-circuited or open-circulted. Recoverabil ity ‘System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit + Fuel injection stopped for faulty cylinder + Exhaust gas recirculation control stopped. + Inter-cylinder injection amount correction valve (FCCB) leaming disabled. Inspection ‘Actuator test BB: Injector Test 1 Electronic control unit connector QB: Injector magnetic valve Electrical equipment #582: Injector magnetic valve 136-2613E P0202: Injector M/V - Cylinder2 (Load) (warning lamp flashes: 38) Generation condition Injector magnetic valve (No. 2 cylinder) is short-circuited or open-circuited Recoverabilty ‘System recovers if signal becomes normal with siarter switch in ON position Control effected by electronic control unit + Fuel injection stopped for faulty cylinder + Exhaust gas recirculation control stopped. + Inter-cylinder injection amount correction valve (FCB) learning disabled ‘Actuator test BF: Injector Test 5 Inspection Electronic control unit connector GB Injector magnetic valve Electrical equipment #582: Injector magnetic valve P0203: Injector M/V - Cylinder3 (Load) (warning lamp flashes: 39) Generation condition Injector magnetic valve (No. 3 cylinder) is short-circuited or open-circulted| Recoverability ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit * Fuel injection stopped for faulty cylinder + Exhaust gas recitculation control stopped. + Inter-cylinder injection amount correction valve (FCCB) learning disabled. ‘Actuator test BD: Injector Test 3 Inspection [Electronic control unit connector [@- Injector magnetic valve Electrical equipment #562: Injector magnetic valve P0204: Injector M/V - Cylinder (Load) (warning lamp flashes: 08) Generation condition Injector magnetic valve (No. 4 cylinder) is shor-crcuited or open-circuited Recoverabilty System recovers if signal becomes normal with starter switch in ON position, ‘Control effected by electronic control unit, ‘+ Fuel injection stopped for faulty cylinder + Exhaust gas recirculation control stopped. + Inter-oylinder injection amount correction valve (FCCB) learning disabled ‘Actuator test (CO: Injector Test 6 Inspection | Electronic control unit connector (G_ injector magnetic vaive Electrical equipment #582; Injector magnetic valve P0205: Injector MIV - Cylinders (Load) (warning lamp flashes: 46) Generation condition Injector magnetic valve (No. 5 cylinder) is shori-ciroulted or open-circuited. Recoverability ‘System recovers if signal becomes normal with starter switch in ON postion, Controt effected by electronic control unit + Fuel injection stopped for faulty cylinder + Exhaust gas recirculation control stopped. + _Inter-cyiinder injection amount correction valve (FCCB) learning disabled, ‘Actuator test BC: Injector Test 2 Inspection | Electronic control unit connector |G: injector magnetic valve Electrical equipment #582: Injector magnetic valve P0206: Injector M/V - Cylinders (Load) (warning lamp flashes: 47) Generation condition Injector magnetic valve (No. 6 cylinder) is short-circuited or open-circuited, Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Contro! effected by electronic control unit ‘+ Fuel injection stopped for faulty cylinder + Exhaust gas recirculation control stopped + Inter-cylinder injection amount correction valve (FCCB) learning disabled, [Actuator test BE: Injector Test 4 Inspection [Electronic control unit connector | @D: injector magnetic valve Electrical equipment #582; Injector magnetic valve ®p 136-27TROUBLESHOOTING P0219: Engine Overrunning (warning lamp flashes: 07) Generation condition Engine speed is higher than specified level. Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Inspection | Electrical equipment Control effected by electronic control unit | Common rail system is deactivated (engine stopped immediately). Engine electronic control unit 0222: Accel Pedal Sensor 2 (warning lamp flashes: 16) Generation condition ‘Accelerator pedal position sensor 2 voltage is below standard value, Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit, + Control's effected using accelerator pedal position sensor 1 + Ifboth sensors 1 and 2 are faulty, controls effected on assumption that accel- ‘erator pedal is depressed 30% when accelerator switch is on and the pedal is not depressed when the switch is of Service data 22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (fitered), 25: Accel Pedal Sensor Voltage 2 'nspection | Electronic control unit conne ctor | GB: Accelerator pedal position sensor Electrical equipment #324: Accelerator pedal position sensor P0223: Accel Pedal Sensor 2 (warning lamp flashes: 6) Generation condition [Accelerator pedal position sensor 2 voltage is above standard value Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, Controt effected by electronic control unit + Controls effected using accelerator pedal position sensor 1 ‘+ Ifboth sensors 1 and 2 are faulty, contro is effected on assumption that accel erator pedal is depressed 30% when accelerator switch is on and the pedal is not depressed when the switch is off Service data 22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (fitered), 25: Accel Pedal Sensor Voltage 2 Inspection | Eiectronic control unit canner ctor | GED: Accelerator pedal position sensor Electrical equipment #324: Accelerator pedal position sensor P0237: Boost Press SNSR (Low) (warning lamp flashes: 32) Generation condition ‘Boost pressure sensor voltage is below standard value (0.3 V). Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Control is effected with boost pressure assumed as constant 101 KPa (1.03 kgf/ om ‘Service data Inspection 26: Boost Pressure Electrical equipment #318: Boost pressure sensor P0238: Boost Press SNSR (High) (warning lamp flashes: 32) ‘Generation condition ity | Recaverabl above standard value (4.7 V) ‘System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Controls effected with boost pressure assumed as constant 107 KPa (1.03 kal omy. Service data 26: Boost Pressure Inspection Electrical equipment #318: Boost pressure sensor 136-2813E P0251: Common Rail Pressure Defect (warning lamp flashes: 36) Generation condition Fuel is leaking from high-pressure part of system (calculated value). Recoverabilly ‘System recovers (power is re-supplied to electronic control unit) if signal be- comes normal when starter switch is tumed OFF ~» ON. Control effected by electronic control unit ‘Actuator test 'B9: Fuel Leak Check ~ Aibleeding of fuel system (See Gr13A) + Inspection of fuel piping (rom supply pump to common ral) (See Gr13A.) Inspection + Fuel iter (See Grt3A) Other + Supply pump (Have work performed by DENSO Service Station ), main body ‘of common rail Pressure limiter (Have work performed by DENSO Service Station.) + Injectors (Have work performed by DENSO Service Station.) P0252: Common Rail Pressure Defect (warning lamp flashes: 36) Generation condition ‘Common rail pressure is 100 high and fuel leakage (calculated value) exceeds standard value Recoverabilty System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit [- ‘Actuator test 'B9: Fuel Leak Check ‘Air bleeding of fuel system (See Gr13A) Inspection of fuel piping (See Gr13A ) Inspection | op Fuel iter (See Gr13A}) ‘Supply pump (Have work performed by DENSO Service Station.) Pressure limiter (Have work performed by DENSO Service Station.) Injectors (Have work performed by DENSO Service Station.) P0253: Common Rail Pressure Defect (warning lamp flashes: 22) Generation condition ‘Common rail pressure is abnormally high (above 245 MPa (higher than operat- ing pressure of pressure imiter)) Recoverabilty ‘System recovers (power is re-supplied to electronic control unit) if signal be- ‘comes normal when starter switch is tured OFF -> ON, [Control effected by electronic control unit, ‘Common rail system is deactivated (engine stopped immediately). Inspection | Other + Inspection of fuel piping (See Gr13A,) * Inspection or replacement of supply pump. (Have work performed by DENSO service Station.) + Pressure limiter (Have work performed by DENSO Service Station), main body of common rail + Injectors (Have work performed by DENSO Service Station.) P0254: Common Rail Pressure Defect (warning lamp flashes: 23) Generation condition ‘Common rail pressure is slightly too high (lower than operating pressure of pres-| sure limiter) Recoverabilty ‘System recovers (power is re-supplied to electronic control unit) if signal be- ‘comes normal when starter switch is turned OFF -> ON. Control effected by electronic control unit, ‘Main injections only enabled + Common rail pressure upper limit provided. + Injection rate limited to predetermined value. + Exhaust gas recirculation control stopped. (Common rail pressure and injection quantity are limited.) [Actuator test 189: Fuel Leak Check * Inspection of fuel piping (See Gr13A.} + Inspection or replacement of supply pump. (Have work performed by DENSO Inepection | nar ‘Service Station.) + Pressure limiter (Have work performed by DENSO Service Station.), main body of common rail + Injectors (Have work performed by DENSO Service Station.) wo 136-29TROUBLESHOOTING P0255: Common Rail Pressure MIV 1 (warning lamp flashes: 23) ‘Common rail pressure exceeds standard value for longer than standard period during low-speed use of supply pump. Generation condition Recoverabilty| System recovers if signal becomes normal with starter switch in ON postion (Control effected by electronic control unit | Normal control [Actuator test 89; Fuel Leak Check * Inspection or replacement of supply pump (Have work performed by DENSO Inspection Service Siation) Other + Pressure limiter (Have work performed by DENSO Service Station.) main body of common rai + Injectors (Have work performed by DENSO Service Station.) P0256: Common Rail Pressure M/V 4 (warning lamp flashes: 23) ‘Common rail pressure exceeds standard value for longer than standard period during mid-range-speed or high-speed use of supply pump. Generation condition Recoverability ‘System recovers if signal becomes normal with starter switch in ON position. + Main injections only enabled. + Common rail pressure upper limit provided. + Injection rate limited to predetermined value. (Common rail pressure and injection quantity are limited.) Control effected by electronic control unit * Inspection of fuel piping (See Gr13A.) + Inspection or replacement of supply pump. (Have work performed by DENSO ‘Service Station.) ‘+ Pressure limiter (Have work performed by DENSO Service Station.), main body of common rail + Injectors (Have work performed by DENSO Service Station.) Inspection | Other P0257: Common Rail Pressure MIV 1 (warning lamp flashes: 23) Pressure-feed malfunction occurs because of faull in supply pump assembly {fault in one cylinder) ; ‘System recovers (power is re-supplied to electronic control unit) i signal be- peceent ‘comes normal when starter switch is turned OFF -» ON. + Main injections only enabled + Common rail pressure upper limit provided, + Injection rate limited to predetermined value. (Common rail pressure and injection quantity are limited.) ‘+ Inspection or replacement of supply pump (Have work performed by DENSO ‘Generation condition Controt effected by electronic control unit Inspection | Other Service Staton.) P0335: Engine Revolution SNSR (warning lamp flashes: 15) Generation condition Engine speed sensor emits no pulses. Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position * Controls effected using cylinder recognition sensor. (If cylinder recognition ene ‘sensor also becomes faulty, engine is stopped.) ‘Service data Of: Engine Revolution Inspection | Electronic control unit connector Engine speed sensor Electrical equipment #263: Engine speed sensor P0340: Camshaft Position SNSR (warning lamp flashes: 12) Generation condition Cylinder recognition sensor emits no pulses. Recoverabilly ‘System recovers if signal becomes normal with starter switch in ON position. + Controls effected using engine speed sensor. if engine speed sensor also Control effected by electronic control unit becomes faully, engine is stopped.) Service data (01: Engine Revolution Inspection | Electronic control unit connector | @B: Cylinder recognition sensor Electrical equipment #820: Cylinder recognition sensor 13E-3013E P0380: Relay for Glow Relay (warning lamp flashes: 26) Generation condition Giow drive relay is shor-crcuted or open crclted or overload. Recoverabiliy System recovers i signal Becomes normal with slarer switch ON postion Control effected by elecronic control unt |» Suspend glow control Service data 80: Glow relay Inspection [Auster test AF: Relay for glow relay Electronic contol unt connector | @ID: Glow dive relay Elecvical equipment #201: Glow drive relay P0500: Vehicle Speed Sensor (warning lamp flashes: 25) Generation condition No vehicle speed sensor signal is received. Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit __|+ Engine speed is limited Inspection [Service data 3C: Vehicle Speed P0506: Idle Volume (warning lamp flashes: 31) Generation condition Idling speed adjustment potentiometer voltage is below standard value. Recoverability System recovers if signal becomes normal with starter ewitch in ON position, Control effected by electronic control unit | Control is effected on assumption that voltage is constantly 0 V. ‘Service data 38: Idle Volume Voltage Inspection | Electronic control unit connector | BD: Iding speed adjustment potentiometer Electrical equipment #157: Idling speed adjustment potentiometer P0507: Idle Volume (warning lamp flashes: 31) Generation condition Idling speed adjustment potentiometer voltage Is above standard value. Recoverabil ity [System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit __| Controls effected on assumption that voltage is constantly 0 V. Service data ‘3B: Idle Volume Voltage Inspection [Electronic control unit connector | GED: Idling speed adjustment potentiometer Electrical equipment #157: Idling speed adjustment potentiometer P0510: Accel SW (warning lamp flashes: 65) ae cel pedal eich sas abpomal won compared wih acaerator Recoverabilty ‘System recovers i signal becomes normal with starter switch in ON positon, [Control effected by electronic contol unit__| Normal controls effected using accelerator pedal position sensor signals Service dala 73: Accel SW Inspection | Electronic control unit connector | €1D: Accelerator pedal switch Electical equipment #029: Accelerator pedal switch P0600: CAN Communication (warning lamp flashes: -) Generation condition Error occurs in CAN communication with machinery side electronic control unit Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit | Engine speed is limited Service data 4A: Speed Limiter Reference Speed Inspection * Combination of engine electronic control unit and machinery side electronic, ‘Other Control unit is confirmed + Vehicle speed sensor error is confirmed. 136-31TROUBLESHOOTING P0605: ECU Hardware (ROM) (warning lamp flashes: 33) Generation condition Main CPU in electronic control unit is abnormal ‘System recovers (power is re-supplied to electronic control unl) i signal be- eee comes normal when starter switch is turned OFF > ON. + Common rail system control is disabled (engine is stopped immediately) if Eells tec ‘mutual diagnoses of main CPU and sub CPU become impossibie Inspection [ Other, Engine electronic control unit P0616: Starter Safety Relay (Low) (warning lamp flashes: 48) Generation condition Safety relay is shorted to power supply circu. Recoverabilty ‘System recovers if signal becomes with starter switch ON position. ‘Control effected by electronic control unit [+ Continuous energization prevention function suspended, ‘Service data 8F: Starter safety relay ‘Actuator test Bt: Slarter safety relay Inspection Electronic control unit connector Safety relay Electrical equipment #201: Safety relay P0617: Starter Safety Relay (High) (warning lamp flashes: 48) Generation condition Safety relay is short-circuited to ground circuit, or open circuited. Recoverability ‘System recovers if signal becomes with starter switch ON position Control effected by electronic control unit __| Continuous energization prevention function suspended. Service data (BF: Starter safety relay ‘Actuator test Bi: Starter safety relay Inspection Electronic control unit connector | @ED: Safety relay Electrical equipment #201: Safety relay P1171: Q Adjustment Resistor (Low) (warning lamp flashes: 34) ‘Generation condition Fuel injection rate adjustment resistor voltage is below standard value (0.6 V). Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control is effected using fuel injection rate adjustment resistor No. 1. (Output is Control effected by electronic contol unit Seto seduced) Service data 3E: Q Adjustment Resistor No. Inspection | Electronic control unit connector | @EB: Fuel injection rate adjustment resistor Electrical equipment #828: Fuel injection rate adjustment resistor P1172: Q Adjustment Resistor (High) (warning lamp flashes: 34) Generation condition Fuel injection rate adjustment resistor voltage is above standard value (4.36 V), Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. preppy Control is effected using fuel injection rate adjustment resistor No. 1. (Output is, Control effected by electronic control unit | ty reduced) Service data 3E: Q Adjustment Resistor No. Inspection | Electronic control unit connector Fuel injection rate adjustment resistor Electrical equipment #828: Fuel injection rate adjustment resistor P1176: PTO Adjustment Resistor (warning lamp flashes: 62) Generation cndtion PTO resistor vtage Is Baow slandard va (06V) Recoversbiy am recovers slgal becomes nomel wi later wih In ON postion conte feed by ecto colt [ODES ed ih PTO eto decd ain ep rv Tapecton [Seve data at: PTO Adjustment easter No | 136-32P1177: PTO Adjustment Resistor (warni 13E jing lamp flashes: 62) Generation condition PTO resistor voltage is below standard value (4.36V) Recoverabilty System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit, ‘Control's effected with PTO resistor deactivated (fluctuation map for driving is used) Inspection [Service data ‘41: PTO Adjustment resistor No. P1200: Injector Circuit 2 (warning lamp flashes: 82) Generation condition Either one injector magnetic valves (No. 4, 5 or 6 cylinder) is short-circuited, or open-circuited. Recoverabilty + When short-circuited: System recovers (power is re-supplied to electronic contro! unit) if signal becomes normal when starter switch is turned OFF —> ON. ‘+ When open-circuited: System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit ‘ + Main injections only enabled. ‘+ Common rail pressure upper limit provided + Injection rate limited to predetermined value. ‘+ Exhaust gas recirculation control stopped. ‘+ FCB learning disabled. ‘+ Auto cruise contro! stopped. ‘+ Exhaust gas recirculation control stopped. ‘+ FCCB learning disabled Actuator tests, BC: Injector Test 2, BE: Injector Test 4, CO: Injector Test 6 Inspection | Electronic control unit connector (G: injector magnetic valve Electrical equipment #582: Injector magnetic valve P1210: Injector Circuit 3 (warning lamp flashes: 82) Generation condition Injector drive circuit voltage in engine electronic control unit is too low or too igh. Recoverability ‘System recovers (power is re-supplied to electronic control unit) If signal be- ‘comes normal when starter switch is tumed OFF -> ON. Controt effected by electronic control unit, ‘ + Common rail pressure lower limit provided. + Idling speed is increased. + FCCB learning disabled *+_Drive with the constant current, ‘ + Common rail system controls disabled (engine is stopped immediately). Actuator tests ‘BB: Injector Test 1, BD: Injector Test 2, BD: Injector Test 3, BE: Injector Test 4, BF: Injector Test 5, CO: Injector Test 6 Inspection | Electronie control unit connector Injector magnetic valve Electrical equipment #582; Injector magnetic valve Other Engine electronic control unit P1240: Flow F - Cylindert (warnin: 1g lamp flashes: 71) Inter-cylinder injection amount correction value (FCCB) is higher than standard Soe vvalue and fluctuation in engine speed is greater than standard value. Recoverability ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit | FCCB learning Is disabl ‘Service data 43: Flow Limiter (#1) Inspection se = ‘Other + Flow damper (Have work performed by DENSO Service Station ) 13E-33TROUBLESHOOTING P1241: Flow Limiter - Cylinder2 (warning lamp flas! 72) ‘Generation condition Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value, Recoverabilty ‘System recovers If signal becomes normal with starter switch in ON position Control effected by electronic control unit | FCB learning is disabled Service data 44: Flow Limiter (#2) Inspection Other + Flow damper (Have work performed by DENSO Service Station.) P1242: Flow Limiter - Cylinder3 (warning lamp flashes: 73) Inter-cylinder injection amount correction value (FCCB) is higher than standard Caan value and fluctuation in engine speed is greater than standard value. Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit | FCCB learning is disabled. ‘Service data 45; Flow Limiter (#3) Inspection Other + Flow damper (Have work performed by DENSO Service Siation) 1243: Flow Limiter - Cylinder4 (warning lamp flashes: 74) Inter-cylinder injection amount correction value (FCCB) is higher than standard ee value and fluctuation in engine speed is greater than standard value. Recoverabiity System recovers if signal becomes normal with starter switch in ON postion (Control effected by electronic control unit | FCOB leaming is disabled Service data 46: Flow Limiter (#4) Inspection Other + Flow damper (Have work performed by DENSO Service Station) P1244: Flow Limiter - CylinderS (warning lamp flashes: 75) Generation condition Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value. Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit FCCB learning is disabled, ‘Service data Inspection 47; Flow Limiter (#6) Other + Flow damper (Have work performed by DENSO Service Station) P1245: Flow Limiter - Cylinders (warning lamp flashes: 76) Generation condition Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value. Recoverability ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit FCOB leaming is disabled. Service data 48; Flow Limiter (#6) Inspection Other + Flow damper (Have work performed by DENSO Service Station.) P1255: CRS Press MIV 4 (Low) (warnin: lamp flashes: 63) Generation condition ‘SCV (suction control valve) is short-circuited to ground, or open circuited, (or coils broken Recoverabilty ‘System recovers (power is re-supplied to electronic control unt) i signal be- comes normal when starter switch is turned OFF -» ON. Control effected by electronic control unit + Main injections only enabled + Common rail pressure upper limit provided. + Injection rate limited to predetermined value. + Exhaust gas recirculation control stopped. ‘Actuator test 189: Fuel Leak Check Inspection | Electronic control unit connector @z SCV (suction control vaive) Electrical equipment #574: SCV (suction control valve) 136-3413E P1256: CRS Press MIV 1 (High) (warning lamp flashes: 63) [Generation condition SCV (suction control valve) is shorted to power supply circuit ‘System recovers (power is re-supplied to electronic control unit) if signal be- ‘comes normal when starter switch is turned OFF — ON, = Main injections only enabled. + Common ral pressure upper limit provided. ‘+ Injection rate limited to predetermined value. + Exhaust gas recirculation control stopped. [Actuator test 'B9: Fuel Leak Check Inspection [Electronic control unit connector | €B: SCV (suction contol vaive) system Electrical equipment #574; SCV (suction contol valve) system Recoverabilty Control effected by electronic control unit P1257: Common Rail Pressure M/V 1 (warning lamp flashes: 63) [Generation condition ‘SCV (suction control valve) binds and fais to operate. ‘System recovers (power is re-supplied to electronic control unit) if signal be- ‘comes normal when starter switch is tumed OFF -» ON, ‘+ Main injections only enabled ‘+ Common rail pressure upper limit provided. + Injection rate limited to predetermined value. + Exhaust gas recirculation control stopped Recoverabilty Control effected by electronic control unit. ‘Actuator test 89; Fuel Leak Check Inspection [Electronic control unit connector | BB: SCV (suction control valve) Electrical equipment 5TH. SCV (suction contro valve) P1267: EGR 1 (warning lamp flashes: 67) Exhaust gas recirculation solenoid valve (M/V-1) is shorted-circulted to ground, Generation condition (or open circuited, Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit | Exhaust gas recirculation control is stopped Service data 1F: EGR Position Inspection [Actuator test A EGR 1 Electrical equipment #590: Exhaust gas recirculation solenoid valve P1268: EGR 4 (warning lamp flashes: 67) Exhaust gas recirculation solenoid valve (M/V-1) is shorted to power supply cir- Generation condition cuit Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, [Control effected by electronic control unit__| Exhaust gas recirculation control is sloped, ‘Service data 1F: EGR Position Inspection [Actuator test AT EGR1 Electrical equipment #530; Exhaust gas recirculation solenoid valve P1272: EGR 2 (warning lamp flashes: 68) ‘Exhaust gas recirculation solenoid valve (M/V-2) is shorted-circuited to ground, open circuited, Generation condition Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position, Control effected by electronic control unit _| Exhaust gas recirculation control is stopped [Service data 1F: EGR Position Inspection [Actuator test AZ: EGR 2 Electrical equipment #530: Exhaust gas recirculation solenoid valve 136-35TROUBLESHOOTING P1273: EGR 2 (warning lamp flashes: 68) Generation condition Exhaust gas recirculation solenoid valve (MIV-2) is shorted to power supply cir- cut Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit___| Exhaust gas recirculation control is stopped. e ‘Service data 1F: EGR Position Inspection | Actuator test Az: EGR2 a a Electrical equipment #530: Exhaust gas recirculation solenoid valve P1277: EGR 3 (warning lamp flashes: 69) Generation condition Exhaust gas recirculation solenoid valve (MIV-3) is shorted-cireuited to ground, (or open circuited, Recoverability ‘System recovers if signal becomes normal with starter switch in ON position. Contral effected by electronic control unit __| Exhaust gas recirculation control is stopped. Service data 1F: EGR Position Inspection | Actuator test a3: EGR 3 Electrical equipment #530: Exhaust gas recirculation solenoid valve P1278: EGR 3 (warning lamp flashes: 69) Generation condition ‘Exhaust gas recirculation solenoid valve (MI/V-3) is shorted to power supply cir- cult Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. ‘Control effected by electronic control unit __| Exhaust gas recirculation control is stopped. ‘Service data 1F: EGR Position Inspection | Actuator test AS: EGR 3 Electrical equipment #530: Exhaust gas recirculation solenoid valve P1462: Exhaust Brake MIV 1 (warning I lamp flashes: 93) Generation condition ‘Short-crcuit or open-circuit occurs in exhaust shutter 3-way magnetic valve grounding circuit, Recoverabiity ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit | Auxiliary brake lamp controls stopped. inspection [SeNe data 87; Exhaust Brake MV 1 ‘Actuator test [AC: Exhaust Brake 1 P1463: Exhaust Brake M/V 1 (warning I lamp flashes: 93) Generation condition Exhaust shutter 3-way magnetic valve (output side) is shorted to power supply circuit Recoverabilty ‘System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit /Auxliary brake control is stopped. Service data 87: Exhaust Brake MV 1 inspection . Actuator test /AG: Exhaust Brake 1 P1605: ECU System (EEPROM) (warning lamp flashes: 33) Generation condition ‘CPU in engine electronic control unit is faulty. Recoverabilty ‘System recovers (power is re-supplied to electronic control unit) if signal be- ‘comes normal when starter switch is turned OFF ~> ON. Control effected by electronic control unit ‘Common rail system control is disabled (engine is stopped immediately) if mutu- al diagnoses of main CPU and sub CPU become impossible. Inspection [Other Engine electronic control unit 13E-364. Multi-Use Tester Service Data * Itis possible to see service data and actuator tests simultaneously. 13E We Tem Baia inspeaion conlion Requirement aaa ae Value covesponds to tachometer 01 [Engine Reveuton WEEE om [Racing engine unning) ‘| YaUE Cor 02 [Reference nection Quantiy [ummm % __|Starterawich ON O% or [Reterence Common Rail Tum % | sarter switch ON 2010 20% op [Aguel Common RaiPes ummm % | siarterswitch ON o% op |Diterence Commer al Taggers [enone tng Oa erower Diference Common Ra GE presane BEE % [Engine idling 0% or lower iding Oe ne pee: TActuator test) Peace GEBBSTEP JA EGR 1, A2: EGR 2, pa EGR 2 Aeselerator pedal nt depressed [D% Accelerator pedal gradual de- Accel Pedal Poston (une Value gral inreases. 2 eet {al Position (unf anne % pressed lue gradually increases. Feclon pa S| Reset pedal nl depressed [ Accelerator peda redualy de- 28 | Accel Pedal Postion (teres) | mmmm % [presses Value gradual increases Rec FORTIN STs a ecelraor peda gradual de- 24 [Accel Peal SensorVotage t|mmmm v | scleaor Pedal taduay 3 9 a5 04 15 a ovelerator pedal gradual de- 25 |AcelPesal Sensor Votage2|mmmm v | scliaos pedal tadualy 3 oa 4 15 | awn Equal to atmospheric pressure fae bee tmet Mum intlg) [Press the accelerator pedal . down after starting the engine peels. a Vale coresponde cambio. a perature, gee Value comeaponds to ambient Tan aa perature, 25. | Water Tomperatre LUE C |Eiin rca warming up| vate roa neues Ergne epped ae WaT | aye gradual decreases aca Value corresponds to ambient Tem erature 36 | Fuel Temr eee ‘ ve Temperaure ny NRSC, | igen oes orig Ve oa TOTO | I Engine stopped ater warming Taye gradualy decreases, 1 leas Vale corresponds to anbent Te | oo perature | a7 |ruet temperature RELIC | ngno poss oWarnig i vous ea Haare Engine stopped afer WSS Vas gracualy cecreases, | Altitude: Om : 1 KPa (29.8 in.Hg) 38 | Atmospheric Pressure Gane kPa fmm inticy [Attuce: 600 m 85 KPa (28.4 no) | 2 Idle Volume Votage anny [SOWioFAst 2610 12V | ea 13E-37TROUBLESHOOTING No. item Data inspection condition Requirement cv Value corresponds to speedometer ac | Vehicle Speed Vehicle in motion uel ingication Number matches number marked {/ersta51607181 3€ Ja Adjustment Resistor No, | 2/04/8167 . on el mjecton ate aston TATASTETTOT ‘Number matches number marked 41 [PTO Adjustment resistor |312/3415/671 7 Number 42. |Power Supply Voltage nny _|Starer switch ON Value matches battery voltage 43. [Flow Limiter (1) Starter switch ON 0 44 [Flow Limiter (#2) ‘Starter switch ON 0 45. | Flow Limiter (3) ‘Starter switch ON 0 46. | Flow Liiter (#4) Starter switch ON 0 47_ | Fiow Limiter #5) ‘Starter switch ON ° | 48 | Fiow Limiter (#6) ‘Starter switch ON 0 ‘an. |$Peed Limiter Reference Vehicle speed limited Value is same as vehicie speed Speed dhring vehicle spend resticvon Tis adjusting or Temporary end or 40 [Pump Adjustment Site Enghe ing tis ads or Temporary ee Engine ting =100 0 100 mA ee Engine wing 1001 + 100 ma soars [ON 7 2 | ete een Starter switch in position except | opp START i ‘Starter Switch in ON position ON 72 | starter SW (M) ONOFF | Siar switch in psion except Sa OFF a Accelerator pedal not depressed | ON ool cee ‘Accelerator pedal depressed ‘OFF = ‘Auxiliary brake switch ON ‘ON 76. | Ausiiary Brake Sw 1 oworr [uate este san oy [ot ‘Transmission: Neutral ON Ce eae ONIOFF ‘Transmission: Other than neutral | OFF os AV applied (On Automatic tranemasion vehicles, shiver | ON ‘7B | \dle Up Cancel SW ON/OFF inl cr Epeetion) 724V not applied (On Automatic | OFF (On MT vehicles, no connec- transmission vehicles, shift lever | tion is made to idle up cancel termi- iN position) ral) ‘Air conditioner compressor run- | Gy ing 7C | Air Conditioner SW 1 ON/OFF ‘ir conditioner compressornot | orp running [Actuator test] BG: Arr Conditioner SW 1 ‘Warm-up switch ON ‘ON eee ooo Warm-up switch OFF OFF ion: Tst and Reverse |ON 7F | Torque Cut Sw J ON/OFF Transmision: Ofherthan anges | er ‘Switch ON ON a2 |PTOSW | ONOFF Sutch OFF OFF 136-3813E Wo. Tem Data inspection condition Requirement Diagnosis switch OFF (use [oy ted) 83 | Diagnosis sw ONIOFF cea Diagnosis switch ON (use re | opp moved) ‘Memory clear switch OFF (use oy fitted) VOFF fai | erence piace! Memory clear switch ON (fuse | ope removed) 86 | Auniary Brake Cul SW | ON/OFF ‘Anytime ON ‘Auxiliary brake operating ON 87 | Exhaust Brake MV 1 oNIoFF ‘Auxiliary brake not operating [OFF [Actuator test) AC: Exhaust Brake 1 ‘unilary Brake Indicator ‘asia brake operating ON 8c ONIOFF Lamp ‘Auxiliary brake not operating OFF ‘Actuaior testis performed | ON 20 | Glow relay ONloFF ‘Actuator tests nt performed [OFF Actuator test] AF: Relay for glow relay ‘Actuator testis performed [ON 8 | Glow relay indicatoriamp | ON/OFF [Actuator tests nt performed [OFF [ctuator test] B0: Glow indicator lamp ‘Actuator testis performed [ON 8F Starter safety celay ONDOFF [Actuator tests nat performed [OFF (Actuator test] BT: Starter safely relay 1 Starter switch ON (engine not 91 MIL Lar INIOFF emis . amp ee No error after engine startup [OFF {Actualor test] B3: MIL Lamp Starter swiich ON (engine not started) bid 92. Diagnosis Lamp ONIOFF No error after engine startup | OFF [Actuator test] 64; Diagnosis Lamp 136-39TROUBLESHOOTING 5. Actuator Tests Performed Using Multi-Use Tester + Itis possible to see service data and actuator tests simultaneously. ‘No. a Item Explanation Confirmation method at [EGR Switch ONOFF exhaust gas recreulaton Solero | oc e-aing sound o exhaust gos Valve (automatic reset ater sx seconds) Operating aa [EGR? {Gan be executed under the folowing conations_|T@feulaton solenad valve whan * Vehicle: stopped (vehicle speed 0 km/h) [Service data] A3 |EGR3 + Starter switch: ON 1F: EGR Position + Engine: Stopped AG | Exhaust Brake 1 ‘Switch ON/OFF exhaust shutter 3-way magnetic valve (automatic reset after six seconds) [Can be executed under the following conditions] + Vehicle: stopped (vehicle speed 0 km/h) + Starter switch: ON + Engine: Stopped Operating sound of exhaust shut- ter 3-way magnetic valve when /tured ONIOFF [Service data] 87: Exhaust Brake MV 1 Auxiliary Brake Indicator Lamp ‘Switch ON/OFF auxiliary brake indicator lamp (automatic reset after six seconds) [Can be executed under the following conditions] + Vehicle: stopped (vehicle speed 0 kmvh) [+ Starter switch: ON + Engine: Stopped ONIOFF condition of indicator lamp [Service data] 8C: Aunilary Brake Indicator Lamp AF | Relay for glow relay ‘Switch ON/OFF grow drive relay (automatic reset after six seconds) [Can be executed under the following conditions] ‘+ Vehicle: stopped (vehicle speed 0 krn/h) + Starter switch: ON + Engine: Stopped Operating sound of glow drive re- lay when turned ON/OFF [Service data] 8D: Glow Ralay ‘Switch ON/OFF glow indicator lamp (automatic reset after six seconds) ONIOFF condition of indicator + Starter switch: ON + Engine: Stopped one (eae cited ener he Cloning condos eee Seda 20 |cowindeatriame |e ee coat ny) (ere deta « Scr teak" oe }* Engine: Stopped = Swich ONOFF story utc Sloat) Opeaing sound tele ly cere tad ues te lowing contins). | when thal ONGFE 1 | Starter safety relay * Vehicle: stopped (vehicle speed 0 km/h) [Service data] BF: Starter Safety Relay 83 [MIL Lamp ‘Switch ON/OFF engine warning lamp (orange) (automatic reset after six seconds) [Can be executed under the following conditions] + Vehicle: stopped (vehicle speed 0 km/h) + Starter switch: ON + Engine: Stopped CONIOFF condition of warning lamp (orange) [Service data] St: MIL Lamp 84 | Diagnosis Lamp Switch ON/OFF engine warning lamp (ed) (automatic reset atter six seconds) [Can be executed under the following conditions] + Vehicle: stopped (vehicle speed 0 kr) + Starter swith: ON + Engine: stopped ONIOFF condition of warning lamp (red) [Service data] 92: Diagnosis Lamp 86 | Air Conditioner SW1 ‘Switch to air conditioner operation condition (dling Up contro) (automatic reset aftr six seconds) [Can be executed under the following conditions] +” Vehicle: stopped (vehicle speed 0 kmh) + Transmission: neutral + Engine: ating Increaseldecrease of engine revo- lution [Service data} 7C: Air Conditioner SW1 88 | Idle Up Cancel Sw ‘Switch to idle up cancel condition (automatic reset after six seconds) [Can be executed under the following conditions] + Vehicle: stopped (vehicle speed 0 km) + Transmission: neutral Idling speed tow idle [Service data] 7B: Idle Up Cancel SW 13€-4013E No Tem Explanation Confirmation method Increase rl pressure fora specified six seconds [Can be executed under the following conditions) B9 | Fuel Leak Check + Vehicle: stopped (vehicle speed 0 km/h) Peterhead settled 2 Transmission neutral ‘system (pipe, hose) 5 Diagnosis switch: OFF (cemoval of use) | Force the seleced injector magnetic valve tobe [injector magnetic valve (No? BB | Injector Tet 1 |seactvated cyinder) should stop. {Can be executed under the following conditions) 2¢ injector Test 2 Vehicle stopped (vehicle speed Okmmh) | Hjetor magnetic valve (No.5 Transmission neutral cinder) should stop. {No present dagnosis codes generated Injecior magnetic valve (No. BD | injector Tests cjnder) should stop. Injector magnetic valve (No.6 Be | Meet leet cylinder) should stop. Injector magnetic valve (No? ea] inbecion Testo ‘cylinder) should stop. ae Injector magnetic valve (No.4 CO | tnjoctor Test 6 cylinder) should stop. The sence data: Pump Ad- mp Adjustment Value Clea |D2!t# the compensation information (pump lean- per Ba C2 | Pump Adjustment Value Clear ng condton) in engine electronic contol unit |fstent Sat” csplays “Ur- 136-41TROUBLESHOOTING 6. I ization of Supply Pump Unit Difference Learning Value in Engine Electron- ic Control Unit + Following replacement of the supply pump, this item is used to erase the adjustment value (learning value) in the ‘engine electronic control unit and program the current supply pump data into the engine electronic control unit. ‘Aiso following replacement of the engine electronic control unit with a new one, itis necessary to program in the current supply pump data. 6.1 After replacement of supply pump or replacement (re-use) of engine electronic control unit Replacement of supply pump or replacement (re-use) of engine electronic control unit Erase the compensation information (pump learning condition) in the electronic control unit. Perform actuator test C2: Pump Adjustment Value Clear ’ Start engine. Allow it to warm up fully then run at low idle speed for 30 seconds. v Check service data 4D: Pump Adjustment State. Learning, Temporal leaning completed or Learning completed will be shown. Y End of programming 6.2 After replacement of engine electronic unit with new one Replacement of engine electronic control unit with new one v ‘Start engine. Allow it to warm up fully then run at low idle y Check service data 4D: Pump Adjustment State. Leaming, Temporal leaning completed or Learning completed will be shown. End of programming 6.3 Check after engine electronic control unit programming If the measurement values (which show the learning values) shown by service data 52: Pump Adjustment Value (Last Time) and 53: Pump Adjustment Value (This Time) are out of specification, a defect in the supply pump or in the engine electronic control unit is conceivable so you must replace the supply pump or engine electronic control unit. (Initialize the engine electronic control unit again after replacing the supply pump or engine electronic control unit.) 136-4213E 7. Inspections Performed at Electronic Control Unit Connectors ‘+ These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being correctly transmitted via the vehicle hamess and connectors. The white-on-black numbers (GB , @B , and so on) correspond to the similarly printed reference numbers in sec- tion °3. Inspections based on diagnosis codes’. 7.4 Electronic control unit connector terminal layout A:GFI4A, 8:GF35A C:GF32A 0-GF35B E:GFaIA Tels aa [z]0 = 57691 7.2 Inspection instructions + Some inspections are performed with the connectors removed. Others are performed with the connectors fitted. Observe the following caution: CAUTION A + Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause short circuits between terminals using the tester probes. + When the supply pump has been replaced, perform the “Initialization of supply pump u difference learning value” using the MUT and erase the compensation information (pump learning con the Ecu. Check item Measurement method {Conditions} + Starter switch OFF o + Disconnect connector. Perform inspection on vehicle-side connector. tance of intake air temperature sen- | Reduirements} Resistance of intake ar temperature sen- Torin £28626 + O°C: 5.88 + 0.588 KO + 20°C: 2.45 £0.245 ka + 80°C: 0.322 + 0.0483 ka [Conditions] + Starter switch OFF + Disconnect connector. Perform inspection on vehicle-side connector. (Requirements) Resistance of water temperature sensor _ | Terminals: £24-B26 + 20°C: 2.45 £0.14 ka + 80°C: 0.32 k0 (reference value) + 110°C: 147.1 +20 (reference value) 13E-43TROUBLESHOOTING (Check item ‘Measurement method @ ‘Output voltage of accelerator pedal posi tion sensor (Conditions) + Starter switch ON + Vehicie-side harness connected (Perform inspection on back of connector) {Requirements} Terminals (+}-(-) A24-D30 (accelerator pedal position sensor 1) {823-028 (accelerator pedal positon sensor 2) + With accelerator pedal not depressed: 0.85 + 0.1 V + With accelerator pedal depressed: 4.15 + 0.1 V Resistance of fuel temperature sensor (in- let) [Conditions] + Starter switch OFF |= Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] “Terminals: €30-B27 + -20°C: 15.01.54 + 20°C: 2.45 £0.24 KO + 80°C: 0.318 + 0.008 ka ie Resistance of fuel temperature sensor (outlet) {Conditions} + Starter switch OFF Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E31-626 220°C: 2.45°3 8 KO + 80°C: 0.318 0.01 ko + m0°C: 0.1417 £0.01 ka Resistance of injector magnetic valve {Conditions} © Starter switch OFF + Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals 11'0r1D2.08 (injector magnetic valve: No.1 cyinder) 1 oF 02.03 (injector magnetic valve: No. 2 cyinder) 1 oF D2:D4 (injector magnetic valve: No. 3 cyinder) Et oF £2.E5 (injector magnetic valve: No. 4 cylinder) 1 or £2.67 (injector magnetic valve: No. 5 cylinder) 1 or £2.66 (injector magnetic valve: No. 6 cylinder) +045 £0.11 (20°C) @ Resistance of engine speed sensor {Conditions} + Starter switch OFF + Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: 82-81 + 125.8 + 17.0 (20°C) ‘Output of cylinder recognition sensor (Conditions) + Starter switch OFF + Disconnect connector. Perform inspection on vehicle-side connector. [Requirements) ‘Terminals: D31-D33 (+5 V to GND) + 200 to 1800 £2 (Resistance serves as rough indication only. Pulse output moni- tor is needed for confirmation of functionality.) Output voltage of idling speed adjustment potentiometer {Conditions} + Starter switch ON + Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] Terminals (+)-(-): A32-B27 + AUTO position: 4.0 + 0.1. V + SLOW position: 3.0 +0.2V + FAST position: 4.0 #0.1V Push + SLOW position: 4.3 |= FAST position: 3.6V Pull + SLOW position: 3.0V + FAST position: 1.0V 136-4413E (Check item ‘Measurement method Continuity of accelerator pedal switch {Conditions} + Starter switch OFF = Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] + Terminals: 820 and chassis earth ‘+ With accelerator pedal depressed: no continuity is found, ‘+ With accelerator pedal not depressed: continuity is found. Resistance of fuel injection rate adjustment resistor [Conditions] Starter switch OFF ‘+ Disconnect connector. Perform inspection on vehicle-side connector. (Requirements) Terminals: 835-827 + No, 1 resistor: 270 + 135.0 No. 2 resistor: 510 + 25.5 0 No. 3 resistor: 820 + 41 92 No. 4 resistor: 1300 + 65.0 No. 5 resistor: 2000 # 100.0 No. 6 resistor: 3300 + 165.0 No. 7 resistor: 5600 # 280.0 No. 8 resistor: 15000 + 750 0. No. 9 resistor: 390 + 19.5 0 No. 10 resistor: 4300 + 215 No. 11 resistor: 9100 + 455.0 Qe Resistance of SCV (suction control valve) {Conditions} Starter switch OFF Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: £14-£16, E14-€17, £15-€16, £15-£17 + 792020 @ Glow drive relay voltage [Conditions] + Keep the vehicle hamesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) + Carry out the actuator test “AF-Relay for Glow Relay” using Mult-Use Tester. {Normal status} Terminals (+)(-): C7 and body earth + Battery voltage Safety relay voltage [Conditions] + Keep the vehicle hamesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) [Normal status) Terminals (+)(-): B18 and body earth + Relay ON: 24V + Relay OFF: 0V 136-45INSPECTION OF ELECTRICAL EQUIPMENT OFF=-7—> ON +P e-3 + 05mm q [boca @ 58338 Knob | #029 Inspection of accelerator pedal switch ‘Switch position [Terminals with continuity OFF = ‘ON 1-2 + Ifthere is any abnormality, replace the switch, #187 Inspection of idling speed adjustment potentiom + Apply 5 V DC to terminals 1 and 2 of the idling speed adjustment potentiometer. + Turn the knob fully counterclockwise. Then, measure the output voltage across terminals 2 and 3 (see the diagrams on the left) while slowly turning the knob clockwise. a ‘Knob position ‘Output voltage AUTO (07) 40201V ‘Standard value SLOW (30°) 30#02V FAST (300°) 10201V / oh (GND sic Output voltage @ aw L 9 sa $ sor01 3 43338! Eroso1 3 nao Fier (on Ge ao) oh tin a bs + IFany measurement is out of specification, replace the idling speed adjustment potentiometer. + Apply 5V DC to terminals 1 and 2 of the idling speed adjustment potentiometer. ‘+ Measure the output voltage across terminals 2 and 3 with the knob in the positions show below. Knob position ‘Output voliage SLOW 30V PULL Standard value FAST 10V SLOW 43V PUSH FAST 36V SLOW 1001056 136-46 + if any measurement is out of specification, replace the idling speed adjustment potentiometer.af OSA, ra s24 ow 54064 57212) 13E #201 Inspection of relay (normally open type with 5 pins) ‘+ Test for continuity and proper operation. If there is any abnor- mality, replace the relay. #262 Inspection of water temperature sensor + Place the water temperature sensor in a container filled with en- gine oil + Heat the oil to each of the specified temperatures. Stir the oil well while doing so. ‘+ Measure the resistance between terminals 1 and 2. ae 2.45 £014 KO : 032k Standard value aorc (reference value) 0" warden 20583 psas24 + Ifeither measurement is out of specification, replace the sensor. #263 Inspection of engine speed sensor + Measure the resistance between terminals 1 and 2. Standard value (at 20°C) 12552178 + Ifthe measurement is out of specification, replace the sensor. #305 Inspection of intake air temperature sensor * Clean the sensor as dirty sensor terminals may provide false output signals. (See Gri5.) + Place the boost air temperature sensor in a container filled with engine oil + Heat the oil to each of the specified temperatures. Stir the oil well while doing so + Measure the resistance between terminals 1 and 2. orc 5.88 + 0.588 KO. Standard value 20°C 248 £0,245 KO 80°C (0.322 © 0.0483 ka + Ifeither measurement is out of specification, replace the sensor. 136-47INSPECTION OF ELECTRICAL EQUIPMENT sia Svcs. 1) GND Air pressure 678436, #318 Inspection of boost pressure sensor + Apply 5 V DC to terminals 3 and 1 * Apply air pressure. Gradually increase it and, while doing so, measure the output voltage occurring at terminals 2 and 1 (see the diagram on the left) Air pressure (Gauge pressure) 101.67 KPa {1.0 kgtlem?) eres, |_ Powe av + any measurement is out of specification, replace the sensor. Voltage Standard value Approx. 3.2V #319 Inspection of common rail pressure sensor + The sensor cannot easily be inspected in isolation, so you must evaluate it indirectly by inspection of system harnesses and re- lated parts + Ifthere is no abnormality in any related part but the system is ab- normal, replace the common rail pressure sensor. #320 Inspection of cylinder recognition sensor + Measure the resistance between terminals 1 and 2. (The resis tance serves as a rough indication only. A pulse output monitor is needed for confirmation of functionality.) 58928) 58312 ‘Standard value 200 to 1800 0 + Ifthe measurement is out of specification, replace the sensor. #323. Inspection of fuel temperature sensor + Measure the resistance between terminals 1 and 2. 57215) 136-48 20°C 15.041.5k0 Standard value 20°C 2.45 £0.24 KO 80°C (0.318 £ 0.008 ka + If any measurement is out of specification, replace the supply pump. + Measure the resistance between terminals 1 and 2. 20°C 245K ‘Standard value are 0318 0.01 KR To" 01417 2001 ka + Ifany measurement is out of specification, replace the sensor.‘Accelerator pedal position sensor connector Accelerator pedal 2 | Position sensor Accelerator pedal “T] switen ‘Accelerator pedal switch connector Accelerator pedal Accelerator Switch connector pedal switch Stopper bolt ‘Accelerator pedal position sen Lever poston © 583106: ‘Stopper bolt 34802] [13E] #324 Inspection of accelerator pedal position sensor Inspection} + Apply 5 V DC to terminals 4 and 6 and terminals 1 and 3 of the accelerator pedal position sensor connector. + Measure the output voltage at terminals 5 and 6 (sensor 1) and the output voltage at terminals 2 and 3 (sensor 2) with the lever in each specified position Lever position Output voltage Taling position A 08s 20.1V Standard value |Aecelerator pedal switch operating position B eae Ful load position © 416201 A Position in which accelerator pedal switch is fully pushed in by lever B: Position at which continuity between terminals 1 and 2 of ac- celerator pedal switch connector disappears as accelerator pedal is pushed downward C: Position in which lever is touching stopper bolt + if any output voltage is out of specification, make an adjustment. + If any output voltage is still out of specification when you have made an adjustment, replace the sensor. [Adjustment] * To adjust the output voltage for the accelerator pedal switch op- erating position A. use nut D. + To adjust the output voltage for the full load position C, loosen nut E and make the adjustment using the stopper bolt. + After making the adjustment, lock the stopper bolt in position with the nut. 136-49INSPECTION OF ELECTRICAL EQUIPMENT wv-sexy WP wt #530 Inspection of exhaust gas recirculation solenoid valve + Perform the following checks. If there is any abnormality, replace OO: Preumatic continu ity 583336, 58305) 136-50 ae exn,—(EXH) the exhaust gas recirculation solenoid valve, ae aes eae (1) Check of operation * Gradually increase from zero the voltage applied to terminals 1 el 5 and 4 (M/V-1), 2 and 5 (M/V-2), or 3 and 6 (M/V-3). ota + Observe the voltage when the exhaust gas recirculation sole- wer [wate Mee noid valve operates. (Determine the solenoid valve's OFF-ON a (un ive MAC ‘operation from the operating sound.) ‘oun [our [ext Standard value y- [ON] O--O (min. operating voltage) deere wy [RT OFO | (rin. operating voltage) IN_[OUT] ExH (2) Check of cor wa [ONT O-FO are 2 waver [ON ots Air pressure applied during check: 930 kPa {9.5 kgficm?} iN [our [ex myv-a [ON] O-F-O jorFl | O-FO #574 Inspection of SCV (suction control valve) + Measure the resistance between terminals 1 and 2. ‘Standard value 7.92029 + Ifthe measurement is out of specification, replace the supply pump, #582 Inspection of injector ‘+ Measure the resistance between terminals 1 and 2. ‘Standard value (at 20°C) 0.452010 + Ifthe measurement is out of specification, replace the injector.eaas| #828 Inspection of fuel injection rate adjustment resistor ‘+ Measure the resistance of the resistor number marked on the fuel injection rate adjustment resistor. 13E Standard value (at 20°C) Resistor No. 1 27021350 51042550 6202410 1300 + 65.0 2000 + 100 33002 165.9 5600 = 260 82 15000 750.0 3002 1950 10 43002 215.0 t 9100 = 4550 + Ifthe measurement is out of specification, replace the fuel injec- tion rate adjustment resistor with one that has the same resistor number and same specified resistance. CAUTION A, ‘+ The fuel injection rate adjustment resistor is matched to the engine. If you replace it, be sure to replace it with one that has the same resistor number. 136-51