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1A-240 Engine Control System

Diagnostic Aids

Poor connection or damaged harness may cause
intermittents. Check for the following conditions and, if
the fault is detected, repair or replace the faulty portion.

• Poor connection at ECM: Inspect harness

connectors for backed-out pins, improper mating,
broken locks, improperly formed or damaged pins,
and poor pin-to-wire connection.

• Damaged harness: Inspect the wiring harness for

rubbed-through wire insulation or wire broken
inside the insulator. If the harness appears to be
OK, observe the display on Tech 2 while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate the
location of the fault.

Step

Action

Value(s)

Yes

No

1

Perform the "On-Board Diagnostic (OBD)
System Check".

Was the OBD System Check performed?

—

Go to Step 2

Refer to OBD

System Check

and go to Step 2

2

Check the injector connector for installation
and, if mounted improperly, connect it
certainly.

Is the action complete?

—

Go to Step 3

—

3

Review the DTC.

1.

Using Tech 2, check and store the DTC.

2.

Clear the DTC.

3.

Perform test run and review the DTC.

Is DTC278 detected?

—

Go to Step 4

Refer to

Diagnostic Aids

4

Check the common 2 injector drive circuit
(ECM to intermediate connector) for open
wiring.

1.

Disconnect the ECM.

2.

Disconnect the injector connector.

3.

Jumper the injector connector and
measure the resistance at the ECM
connector.

Was the resistance within range?

Pins 4-
ground

(jumpered:

2/3-ground):

0

Ω

(not jumpered):

∞

Ω

Pins 5-
ground

(jumpered:

2/3-ground):

0

Ω

(not jumpered):

∞

Ω

Pins 4-5

(not jumpered):

0

Ω

Go to Step 5

Go to Step 8

5

Check the intermediate connector for fault.

1.

Disconnect ECM side and injector side
connectors from the intermediate
connector.

2.

Remove the intermediate connector from
the engine block.

3.

Jumper the intermediate connector that
was connected to the injectors and
measure the resistance at the
intermediate connector that was
connected to the ECM pins.

Was the resistance within range?

Pins 1-2/3/4

(jumpered:

1-2/3/4): 0

Ω

(not jumpered):

∞

Ω

Pins 2-3/4

(jumpered:
2-3/4): 0

Ω

(not jumpered):

∞

Ω

Pins 3-4

(jumpered:

3-4): 0

Ω

(not jumpered):

∞

Ω

Go to Step 7

Go to Step 6

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Summary of Contents for 4HL1

Page 1: ...WORKSHOP MANUAL 727 N SERIES ENGINE CONTROL SYSTEM 4HL1 ENGINE SECTION 1A International Service Parts Tokyo Japan...

Page 2: ...arefully 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 based...

Page 3: ...Switch System Fault 1A 159 DTC82 Neutral Switch System Fault 1A 163 DTC84 CAN Communication Fault CAN Bus Error 1A 166 DTC86 CAN Communication Fault CAN Timeout Error 1A 169 DTC115 Common Rail Pressu...

Page 4: ...ome types of electronic components may be damaged even by the static electricity of less than 100 V that is usually not sensed by persons Persons sensitivity level is 4 000 V Persons are electrostatic...

Page 5: ...Voltages from ECM The ECM supplies reference voltages to various switches and sensors Resistances of the ECM are very high and this allows the ECM to supply voltages to these devices and voltages act...

Page 6: ...Starter cut relay Glow relay Check engine lamp Tachometer TCM ABS ASR ECU ISS ECU Vehicle functions Atomospheric pressure sensor VIM Vehicle Interface Module ECM Engine Control Module Relay ECO Relay...

Page 7: ...er at low engine speeds and temperatures fixed injection mode where only main injection is made at very low engine speeds during startup and normal injection mode where the fuel injection is made with...

Page 8: ...intake throttle valve When the valve opening gets smaller the drive voltage is increased the output voltage of the ITP sensor becomes lower The valve position is normally calculated using engine cool...

Page 9: ...ensor becomes higher The EGR control is initiated when parameters such as engine speed engine coolant temperature accelerator position atmospheric pressure and system voltage meet the required conditi...

Page 10: ...not detected on the vehicle speed sensor The exhaust brake switch is turned on The engine is running at or above 500 rpm for at least 1 second The idle position switch is turned on and the gear is eng...

Page 11: ...le Side Legend 1 Engine 2 Neutral switch 3 ECM engine control module 4 VIM vehicle interface module 5 Clutch pedal 6 Accelerator pedal 7 DLC data link connector 8 CHECK ENGINE lamp MIL 9 Exhaust brake...

Page 12: ...the thermistor in the sensor alters the resistance in response to the temperature change The resistance is decreased when the coolant temperature is high while increased when the temperature is low Th...

Page 13: ...voltage The valve is closed when the drive voltage is increased while opened when the voltage is decreased The ECM calculates the intake throttle valve opening based on the vehicle running condition...

Page 14: ...ature is high while increased when the resistance is large the temperature is low SCV The SCV suction control valve is installed to the supply pump and controls the suction fuel quantity The SCV is fu...

Page 15: ...stalled to the top of the accelerator pedal and supplies the voltage signal that will change in response to accelerator pedal angle to the ECM The ECM calculates the accelerator pedal position from th...

Page 16: ...utral or parking position Exhaust Brake Solenoid Valve The exhaust brake solenoid valve is installed to the rear of the right front wheel frame some vehicle types have different positions and opens an...

Page 17: ...link connector is installed to the dash side pane of the driver s seat and acts as a communication interface between external diagnostic tool and on board controllers The DLC can also function as a di...

Page 18: ...F000401 X 27 28 No Indication on label Capacity Devices connected 1 CONTROLLER 10A Control unit 2 HAZARD HORN 12V 15A Hazard warning flashing lamp horn HAZARD HORN 24V 10A 3 10A 4 AIR CON 12V 10A Air...

Page 19: ...side mirror ENG CONT 24V 15A ECM 17 MIRROR 10A Electrically operated mirror 18 CIGAR AUDIO 10A Cigarette lighter audio 19 METER 12V 10A Meter METER 24V 15A 20 ENGINE STOP 12V 10A Engine stop HSA 24V...

Page 20: ...per Spare Power Circuit Cooler Relay Bracket 1 19 20 2 3 4 17 5 6 7 8 9 10 11 12 13 14 15 16 18 No Legend 1 12 V On relay 24 V Charge relay 2 Horn relay 3 12 V ABS VSV FICD EXH brake valve 12 V 24 V H...

Page 21: ...ectric PTO AT 12 V OD off relay AT 24 V Idle keep relay for fire engine AT 24 V Idle stop radio relay with CFS 15 24 V PTO main relay for electric PTO MT 24 V Garbage relay for garbage collector AT 24...

Page 22: ...SBF 50A SBF 60A M M M 0 75W B 0 75L Y 0 5Y 0 5W 0 5G 0 5G 0 5R 59 58 68 63 67 66 64 M M M DLC 0 5B 0 5B 0 85B 1 25B 1 25B 1 25B SCV 0 5R B 0 5G W 0 5R G 0 85L B 0 85O 49 46 48 91 83 25 0 5W R 6 8 27...

Page 23: ...71 30 14 49 50 12 44 47 7 17 15 19 57 54 27 26 48 24 73 60 39 52 66 9 0 5L R 0 3LG B 0 3B G 0 5B R 0 85B O 0 3BR W 0 5LG B 0 5B W 1 25W R 1 25W R 1 25W R 0 3O L 0 5G Y 0 5W L 0 5LG R 0 5BR R 0 5B G 0...

Page 24: ...P 3 P 4 4 B 67 SBF 2 50A KEY F 16 15A ENG CONT SBF 5 ECM SBF 3 60A 50A GLOW SBF 1 80A 100A MAIN H 7 3 X 18 117 J 191 118 J 191 5 X 18 2 X 18 9 H 4 0 5 B O 0 5 G O 0 5 B O 0 5 B 0 5 B 0 5 GR W 0 5 LB 0...

Page 25: ...B 0 5 Y BR 0 5 Y 0 5 R B 0 5 Y BR 0 5 B 0 85 B 0 85 B 0 85 B 0 85 B 0 5 Y 0 5 R B 0 5 Y BR 0 5 Y G 0 5 R B H 4 H 8 47 B 352 H 8 H 8 J 7 60 B 350 73 B 349 52 B 351 66 B 349 39 B 352 6 2 B 319 B 319 3 B...

Page 26: ...LG 0 5 G 0 5 G Y 0 3 LG 0 5 LG 0 5B W 0 5 LG 0 5 B W 0 5 B W 0 5 L R 0 5 Y G 0 3 BR W 0 3 O L 0 5 W O 0 5 G W 0 5 V W VIM B 259 6 CFS C U B 229 5 AISIN TCM B 47 20 JATCO TCM B 229 23 AISIN TCM B 47 1...

Page 27: ...0 5 W R 0 5 R 0 5 G Y 0 5 W 0 75 W B 0 75 W G 0 75 L Y 0 75 L 0 75 R 0 75 L 0 75 W R 0 75 W R 0 75 W R 2 E 115 3 E 115 8 E 115 5 E 115 1 E 115 4 E 115 0 75 W R 1 25 L W 1 25 W 0 75 G W 0 75 B 1 25 L R...

Page 28: ...0 J 191 119 J 191 3 B 280 2 B 280 1 B 280 2 J 190 1 J 190 10 H 4 30 H 5 1 H 4 3 H 4 2 H 4 4 H 8 87 J 191 0 5 B 1 25 B 1 25 B 1 25 B 0 5 L R 0 5 L W 0 5 L 0 5 B W 0 5 L R 0 85 O 0 5 L B 0 5 Y B 0 5 Y B...

Page 29: ...elerator sensor 101 867 8 P 5 Frame ground 9 P 1 P 2 Battery 10 P 3 P 4 Battery 24 V 11 E 3 Glow plug 011 010 12 E 115 Injector 040 031 13 E 113 Common rail pressure sensor 040 211 14 E 94 EGR vacuum...

Page 30: ...r connector 33 SBF 1 Main slow blow fuse 810 174 34 SBF 2 Key switch slow blow fuse 810 174 35 SBF 3 Glow slow blow fuse 810 174 36 SBF 5 ECM slow blow fuse 810 174 37 X 18 Main relay 828 531 38 X 22...

Page 31: ...0 024 1 2 3 4 5 005 025 2 4 1 3 004 035 1 2 3 4 004 015 1 5 2 3 6 7 4 8 008 028 1 5 2 6 3 7 4 8 008 021 1 2 002 022 B 79 B 89 B 172 B 274 B 280 B 281 B 282 B 325 No Connector face 8 7 6 5 4 3 2 1 16 1...

Page 32: ...48 47 46 45 44 43 42 13 12 3 51 50 41 2 40 1 39 026 013 1 001 003 1 001 034 1 001 029 E 90 E 93 E 94 E 98 E 111 E 112 E 113 E 114 No Connector face 1 2 3 003 095 002 208 1 2 005 034 1 4 2 3 5 1 2 002...

Page 33: ...14 15 16 17 18 19 20 21 22 022 012 1 3 4 5 6 2 006 005 000 012 J 31 J 50 J 177 J 177 J 191 P 1 24V P 2 24V P 3 24V No Connector face 1 2 002 008 1 2 002 210 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1...

Page 34: ...1 2 3 5 4 005 013 LNW21ASH010801 1 2 3 7 8 9 13 14 15 19 20 21 25 26 27 31 32 33 34 35 36 37 4 5 6 10 11 12 16 17 18 22 23 24 28 29 30 38 39 40 6 5 4 12 11 10 18 17 16 24 23 22 30 29 28 40 39 38 3 2 1...

Page 35: ...2 1 2 1 4 3 2 1 8 7 6 5 13 1211 10 9 18 1716 15 14 H 6 H 7 H 8 LNW21ASH010801 1 2 3 7 8 9 13 14 15 19 20 21 25 26 27 31 32 33 34 35 36 37 4 5 6 10 11 12 16 17 18 22 23 24 28 29 30 38 39 40 6 5 4 12 11...

Page 36: ...93 94 95 96 97 82 83 84 85 86 87 88 89 Pin No Connected to Pin No Connected to 1 Injectors 1 and 3 42 Injector 3 cylinder 4 2 Injectors 1 and 3 43 Injector 1 cylinder 1 3 44 4 Injectors 2 and 4 45 5...

Page 37: ...1 SCV HI 41 Pin No Connected to Pin No Connected to Pin No Connected to Pin No Connected to 82 102 Starter cut relay 83 5 V sensor power 2 IAT 103 84 AP sensor signal 104 85 105 86 106 87 Casing groun...

Page 38: ...1A 36 Engine Control System VIM Pinouts 99 CHECK ENGINE lamp 119 ECM power ground 100 120 ECM power ground 101 121 ECM power ground Pin No Connected to Pin No Connected to LNW21AMF005101...

Page 39: ...rm up QWS switch 50 Exhaust brake switch 13 51 Pin No Connected to Pin No Connected to 14 VS sensor signal 52 VIM power ground 15 ABS ASR controller 53 AT controller 16 AT controller 54 Voice alarm un...

Page 40: ...can reproduce the fault However there may exist two or more causes Current fault The diagnostic flow can always be used to resolve an E E system problem and is a starting point when repairs are necess...

Page 41: ...d be intermittent as defined in Intermittents or could be normal 2 Repair and verify After isolating the cause the repairs should be made Validate for proper operation and verify that the symptom has...

Page 42: ...lassified as non vehicle fault but with the sensitivity of OBD diagnostics vehicle maintenance schedules must be more closely followed Related system faults Many of OBD system diagnostics will not run...

Page 43: ...r component is operating according to specification There are many diagnostics shown in the following list EGR exhaust gas recirculation Engine speed Vehicle speed ECT engine coolant temperature IAT i...

Page 44: ...it and enables backup control according to the DTC set When a fault occurs that will affect the running the ECM turns on the CHECK ENGINE lamp MIL in the meter panel or blinks the exhaust indicator l...

Page 45: ...lerator pedal 3 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 4 Turn on the idle position switch for not less than 1 second but n...

Page 46: ...6 103 120 A B C V Hearing The objective is to comprehend the symptom completely based on the customer complaint and provide accurate diagnostic On Board Diagnostic System Check The objective is to ide...

Page 47: ...tom 2 Failure generation frequency and conditions The reason why this sheet is needed is as follows 1 The symptom may not be reproduced in the service factory 2 The customer complaint is always not re...

Page 48: ...tions Check Engine lamp Fault history DTC Past Present ON Date year month day Date year month day Occasionally ON OFF No cranking No initial combustion Incomplete initial combustion Long cranking 6 se...

Page 49: ...ubbed through wire insulation or wire broken inside the insulator Test Description Number s below refer to the step number s on the Diagnostic Chart 3 The CHECK ENGINE lamp MIL should be ON steady wit...

Page 50: ...to Step 4 4 Check the data communications are normally established 1 Starter switch OFF 2 Install Tech 2 3 Starter switch ON 4 Using Tech 2 display engine data Does Tech 2 display engine data Go to S...

Page 51: ...CHECK ENGINE lamp Does the CHECK ENGINE lamp blink Go to Step 11 Refer to Unblinking CHECK ENGINE Lamp Check and go to Step 11 11 Using Tech 2 check DTC Is DTC detected Go to the appropriate DTC Char...

Page 52: ...nspect harness connectors for backed out pins improper mating broken locks improperly formed or damaged pins and poor pin to wire connection Damaged harness Inspect the wiring harness for rubbed throu...

Page 53: ...h 50 A 1 Remove the SBF 2 Starter switch ON 3 Measure the voltage at the SBF connector Was the voltage within range 16 32V Go to Step 10 Go to Step 6 6 Check the battery voltage for correctness Is the...

Page 54: ...pins Is the starter switch in normal condition Pins 2 3 Continued Go to Step 18 Go to Step 17 17 Replace the starter switch Is the action complete Verify repair and go to Step 23 18 Repair or replace...

Page 55: ...ups to replacing the ECM Is the action complete Verify repair and go to Step 2 23 Re observe the CHECK ENGINE lamp for operation 1 Certainly install necessary components such as connectors fuses and r...

Page 56: ...Inspect harness connectors for backed out pins improper mating broken locks improperly formed or damaged pins and poor pin to wire connection Damaged harness Inspect the wiring harness for rubbed thro...

Page 57: ...cuit in normal condition ECM pin 112 ground Continued Go to Step 8 Go to Step 5 5 Check the DLC ground circuit for open wiring 1 Check the continuity between DLC pin and ground e g frame or body Is th...

Page 58: ...lamp for operation 1 Certainly connect connectors 2 Short DLC pins 4 and 6 3 Starter switch ON and observe the CHECK ENGINE lamp Does the CHECK ENGINE lamp blink The repair is complete Go to Step 1 St...

Page 59: ...e Is the action complete Verify repair and go to Step 4 4 Check the ON signal is input to the ECM from the starter switch 1 Disconnect the ECM 2 Starter switch ON 3 Measure the voltage between ECM con...

Page 60: ...on complete Verify repair and go to Step 12 12 Check the circuit between main relay and ECM for open wiring 1 Remove the main relay 2 Disconnect the ECM 3 Check the continuity between main relay and E...

Page 61: ...2 3 DLC cable 4 SAE 16 19 pin adapter Features of Tech 2 Tech 2 2 is operated at 12 V Therefore 24 V power supply must not be used for this tool If the vehicle electrical system rating is 24 V the ad...

Page 62: ...the SAE 16 19 pin adapter to the DLC cable 3 Connect the DLC cable to Tech 2 4 Check the starter switch is turned off 5 Connect the Tech 2 SAE 16 19 pin adapter to the DLC data link connector black o...

Page 63: ...002 F0 Diagnostic Trouble Codes F0 Read DTC Info As Stored By ECU F1 Clear DTC Information F1 Data Display F0 Data Display F1 Snapshot F2 Programming F0 Write Starting Counter F1 Write Starting Replac...

Page 64: ...cannot select this data display menu A fault presents on the cable between ECM and DLC When an unusual value appears fixedly Example If the engine coolant temperature displayed is fixed to 40 C or 140...

Page 65: ...em 3 After the snapshot option screen appears determine the trigger type and select Record Snapshot at the bottom 4 When Standby blinks at the upper right of the screen select Trigger at the bottom 5...

Page 66: ...ase SCV Current mA Decrease Increase Difference Between Desired And Actual Values MPa within 1 When a fault is found in F0 Common rail Pressure Control Test When a fault is found in this test identify...

Page 67: ...d ITP intake throttle position sensor Test procedure 1 Select Intake Throttle Test from Actuator Test 2 Press Decrease or Increase soft key to check the data list 3 When the data list changes as shown...

Page 68: ...the ECM is faulty 2 The EGR Current valve position does not follow the EGR Target Lift valve position Following under regular error The problem lies in accuracy of EGR valve position sensor Following...

Page 69: ...3 2 5 The value will change depending on temperatures around the engine Coolant Temperature C Normal running phase 55 Startup phase 20 DTC23 is detected 80 DTC84 is detected 20 23 The value will chan...

Page 70: ...0 Desired Injection Quantity mm3 st 50 or less DTC115 DTC118 DTC227 DTC245 or DTC247 is detected Desired Fuel Injection Timing CA 0 Cylinder 1 Compensation mm3 st 0 DTC158 or DTC271 is detected 0 Cyli...

Page 71: ...C84 is detected OFF Exhaust Brake ASR Cutoff Switch ON OFF OFF DTC84 is detected OFF Glow Time Relay ON OFF OFF DTC84 is detected OFF Starter Relay ON OFF OFF DTC84 is detected OFF Glow Time Lamp ON O...

Page 72: ...ed 50 53 The value will change depending on temperatures around the engine Barometric Pressure Sensor V Approx 3 6 The value will change depending on the barometric pressure Barometric Pressure kPa 10...

Page 73: ...tor Sensor V 0 DTC84 is detected 0 3 0 6 PTO Accelerator Opening 0 DTC28 or DTC84 is detected 0 ASR Accelerator Opening 100 DTC84 is detected 100 Starter Switch ON OFF ON DTC84 is detected OFF Ignitio...

Page 74: ...19 21 ECT Sensor Engine Coolant Temperature V Approx 0 6 The value will change depending on temperatures around the engine Coolant Temperature C Normal running phase 55 Startup phase 20 DTC23 is dete...

Page 75: ...ox 1 8 Actual Intake Throttle position CA Approx 30 2 Desired Intake Air Throttle Position CA Approx 30 Intake Throttle Duty Ratio Approx 9 10 Desired Injection Quantity mm3 st 50 or less DTC115 DTC11...

Page 76: ...OFF DTC84 is detected OFF Exhaust Brake AT Cutoff Switch ON OFF OFF DTC84 is detected OFF Exhaust Brake ASR Cutoff Switch ON OFF OFF DTC84 is detected OFF Glow Time Relay ON OFF OFF DTC84 is detected...

Page 77: ...OFF OFF DTC84 is detected OFF PTO Idle Position Switch ON OFF OFF DTC84 is detected OFF QWS Switch ON OFF OFF DTC84 is detected OFF Glow Time Lamp ON OFF OFF DTC84 is detected OFF ECO Relay ON OFF OFF...

Page 78: ...unstable after vibrations are applied to the wiring harness the cause may be faulty harness or imperfect connection of ground circuit 4 63 Engine Speed RPM This parameter refers to the value calculat...

Page 79: ...ltage input to the ECM from the FT fuel temperature sensor Higher fuel temperature provides lower voltage The fuel temperature is a proper criterion for various control configurations e g startup cold...

Page 80: ...e sensor circuit or ECM may be faulty 19 63 SCV Current mA This parameter refers to the value calculated by the ECM based on the pump discharge determined from engine speed common rail pressure Larger...

Page 81: ...When the display deviates from the specified level the intake throttle valve sensors circuit or ECM may be faulty 28 63 Desired Injection Quantity mm3 st This parameter refers to the value calculated...

Page 82: ...ameter refers to the value calculated by the ECM using intake air temperature engine coolant temperature engine speed and desired fuel injection quantity When the display deviates from the specified l...

Page 83: ...ter the key switch is moved to the position ON or ST When the display is fixed the switch circuit or ECM may be faulty 46 63 Clutch Switch ON OFF This parameter refers to the status of the signals inp...

Page 84: ...ed the PTO switch circuit VIM or ECM may be faulty 54 63 A C Switch Air Conditioning ON OFF This parameter refers to the status of the signals input from the A C switch to the VIM It appears on the di...

Page 85: ...appears on the display after the QWS switch in the cab is pressed When the display is fixed the QWS switch circuit VIM or ECM may be faulty 61 63 ECO Relay ON OFF This parameter refers to the status o...

Page 86: ...re kPa This parameter refers to the value calculated by the VIM using the signals from the barometric pressure sensor When the display deviates from the specified level the sensor circuit or ECM may b...

Page 87: ...the signals input from the exhaust brake switch to the VIM It appears on the display after the exhaust brake switch in the cab is pressed When the display is fixed the exhaust brake switch circuit VI...

Page 88: ...switch are met When the display is fixed the relay circuit VIM or ECM may be faulty 22 31 Engine Stop Switch ON OFF This parameter refers to the status of the signals input from the engine stop switc...

Page 89: ...rator position is limited the position is normally reduced from 100 This parameter refers to the percentage calculated by the VIM using the signals input from the AT controller When the display is fix...

Page 90: ...off and the vehicle speed is 0 km h lasts 5 seconds 28 VIM PTO Accelerator Sensor System Fault The PTO accelerator sensor output signal exceeds 4 9 V for 1 second The ECM controls the powertrain usin...

Page 91: ...Pressure Sensor Fixed Output Fault ON The state where the common rail pressure sensor is in normal condition there is no change in common rail pressure sensor output voltage the difference between des...

Page 92: ...ment is disabled on pump overpressure and short pump pressure events 1 to 4 271 Cylinder 1 Injector Drive System Fault ON The battery voltage is at least 16 V the starter switch is turned on and the p...

Page 93: ...ower Poor driveability Wire harnesses and connectors EGR valve and EGR DC motor system EGR valve main relay EGR DC motor ECM EGR Valve Position Sensor EGR Duty Cycle 46 VIM Exhaust Brake System Fault...

Page 94: ...bility Generation of white black smoke Short power Poor driveability Wire harnesses and connectors SCV drive system SCV ECM SCV Duty Ratio SCV Current 271 Cylinder 1 Injector Drive System Fault Short...

Page 95: ...tem fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for...

Page 96: ...cause is open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check perf...

Page 97: ...resistance within range Reference Pins 1 2 Pins 2 3 Approx 120 130 Pins 1 3 Pin 1 2 3 sensor body Go to Step 11 Go to Step 10 10 Replace the CMP sensor Is the action complete Verify repair and go to...

Page 98: ...1A 96 Engine Control System Sensor Description Legend 1 CMP sensor 2 Shield ground 3 Sensor ground 4 Sensor signal LNW21ASF003301 1 2 3 4...

Page 99: ...system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch...

Page 100: ...open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go t...

Page 101: ...e resistance within range Reference Approx 20 250 Pin 1 2 sensor body Go to Step 11 Go to Step 10 10 Replace the CKP sensor Is the action complete Verify repair and go to Step 13 11 Review the DTC 1 C...

Page 102: ...1A 100 Engine Control System Sensor Description Legend 1 CKP sensor 2 Projections on flywheel 3 Sensor signal 4 Sensor signal LNW21ASF003201 3 4 1 2...

Page 103: ...elerator pedal 4 Turn on the idle position switch for not less than 1 second but not more than 3 seconds Release the accelerator pedal 5 Turn off the idle position switch for not less than 1 second bu...

Page 104: ...erform test run and review the DTC Is DTC18 detected Go to Step 6 Refer to Diagnostic Aids 6 1 Replace the VIM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number...

Page 105: ...et intake air temperature 10 C Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear...

Page 106: ...he output voltage is fixed to 0 V the possible cause is short in the circuit Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step...

Page 107: ...M connector measure the resistance Was the resistance within range Pins 91 83 Pins 91 83 ground Go to Step 11 Go to Step 10 10 Repair or replace the faulty harness Is the action complete Verify repair...

Page 108: ...or signal 15 Check DTC22 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and review the DTC Is DTC22 detected Refer to Diagnostic Aids and go to Step 2 Repair is complete Step Ac...

Page 109: ...M will illuminate the CHECK ENGINE lamp MIL The ECM controls the powertrain using the set engine coolant temperature normal running phase 110 C startup phase 20 C EGR and warm up systems are disabled...

Page 110: ...nt intermittent fault 4 If DTC211 is also set the possible cause is the ground circuit common to ECT and FT sensors 10 If the output voltage is fixed to 5 V the possible cause is open wiring in the ci...

Page 111: ...gine data 2 Starter switch ON engine OFF 3 Observe the ECT Sensor display for output voltage Was the voltage within range Approx 0 6 V ECT 80 C Go to Step 18 Go to Step 11 11 Check the ECT sensor outp...

Page 112: ...nnect the ECT sensor and ECM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC Is DTC23 detected Go to Step 19 Refer to Diagnostic Aids 19 1 Replace the ECM IMPORTANT If ne...

Page 113: ...ne Control System 1A 111 Sensor Description Legend 1 ECT sensor 2 Thermistor for ECM 3 Thermistor for meter 4 Sensor ground 5 Sensor signal on ECM 6 Sensor signal on meter LNW21ASF003101 2 3 1 4 6 5 4...

Page 114: ...switch Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the foll...

Page 115: ...to 5 V the possible cause is short in the circuit 8 If pins are jumpered and the resistance reads the cause is open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step...

Page 116: ...90 jumpered pins 1 3 0 not jumpered Pins 94 84 90 108 not jumpered Pins 94 84 90 108 ground not jumpered Go to Step 10 Go to Step 9 9 Repair or replace the faulty harness Is the action complete Verif...

Page 117: ...sor 3 Sensor ground 4 Sensor signal 5 Sensor power 14 Check DTC24 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and review the DTC Is DTC24 detected Refer to Diagnostic Aids an...

Page 118: ...Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn of...

Page 119: ...Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the VS sensor connector for installation and if mounted improperly insta...

Page 120: ...2 Connect the VS sensor connector 3 Starter switch ON 4 While turning the VS sensor shaft slowly measure the voltage between connector pins 2 and 3 Did the voltage change within range 1 0 3 0 V 12 0 1...

Page 121: ...Engine Control System 1A 119 Sensor Description Legend 1 VS sensor 2 Sensor signal 3 Sensor ground 4 Sensor power LNW21ASF002801 2 1 3 4...

Page 122: ...ill not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator peda...

Page 123: ...D System Check and go to Step 2 2 Check the PTO accelerator sensor system for mechanical fault 1 Check the PTO accelerator sensor connector for installation and if mounted improperly install the devic...

Page 124: ...Step 11 Go to Step 10 10 Replace the PTO control lever PTO accelerator sensor Is the action complete Verify repair and go to Step 13 11 Review the DTC 1 Certainly connect the PTO accelerator sensor a...

Page 125: ...repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seco...

Page 126: ...ort Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the idle up volume...

Page 127: ...ontinuity between idle up volume switch connector pins Was the resistance within range Pins 1 2 Discontinued Pins 2 3 Discontinued Pins 1 3 Continued Go to Step 12 Go to Step 11 11 Replace the idle up...

Page 128: ...1A 126 Engine Control System Idle Up Volume Switch Description Legend 1 Power supply 2 Ground 3 Signal 1 2 3 Circuit Diagram 3 2 1 300 0 LNW21ASF000701 X...

Page 129: ...not more than 3 seconds Release the accelerator pedal 5 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 6 After the above operatio...

Page 130: ...ir or replace the faulty harness Is the action complete Verify repair and go to Step 6 6 1 Replace the VIM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of s...

Page 131: ...following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle position switch for not less than 1 second bu...

Page 132: ...Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the ECM connector for installation and if mounted improperly connect it certainly Is the action complete Go to Step 3 3...

Page 133: ...em 1A 131 8 Check DTC34 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and review the DTC Is DTC34 detected Refer to Diagnostic Aids and go to Step 1 Repair is complete Step Act...

Page 134: ...s than 1 second but not more than 3 seconds Release the accelerator pedal 5 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 6 After...

Page 135: ...ir or replace the faulty harness Is the action complete Verify repair and go to Step 6 6 1 Replace the VIM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of s...

Page 136: ...ear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn o...

Page 137: ...ring in the circuit If the output voltage is fixed to 5 V the possible cause is short in the circuit 14 If pins are jumpered and the resistance reads the cause is open wiring If pins are not jumpered...

Page 138: ...nnect the ITP sensor and ECM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC Is DTC43 detected Go to Step 10 Refer to Diagnostic Aids 10 Check the ITP sensor output volta...

Page 139: ...nector pins Does the ITP sensor meet the requirements Pins 1 2 Pins 2 4 Pins 1 2 4 3 5 Discontinued Pins 1 4 Continued Go to Step 18 Go to Step 15 17 Replace the Intake trottle ITP sensor Is the actio...

Page 140: ...e Control System Intake Throttle Valve Description Legend 1 Throttle valve 2 ITP sensor 3 Reduction gears 4 DC motor 5 Sensor ground 6 Sensor signal 7 Motor 8 Sensor power 9 Motor LNW21ASF002101 9 8 7...

Page 141: ...om the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle pos...

Page 142: ...iring If pins are not jumpered and the resistance reads 0 the cause is short 10 If the output voltage is fixed to 5 V the possible cause is open wiring in the circuit If the output voltage is fixed to...

Page 143: ...aulty harness Is the action complete Verify repair and go to Step 9 9 Review the DTC 1 Certainly connect the EGR position sensor and ECM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and...

Page 144: ...Step 19 15 Check the EGR valve position sensor 1 At the EGR valve connector pins measure the resistance Was the resistance within range Reference Pins 1 2 Approx 1 4 2 k Pins 2 3 Approx 6 8 Pins 1 3 A...

Page 145: ...signal 5 Sensor ground 6 Sensor power 7 Motor 8 DC motor 19 Check DTC44 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and review the DTC Is DTC44 detected Refer to Diagnostic A...

Page 146: ...d the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less th...

Page 147: ...se is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the EGR val...

Page 148: ...clear the DTC 3 Perform test run and review the DTC Is DTC45 detected Go to Step 9 Refer to Diagnostic Aids 9 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped with idle stop function...

Page 149: ...ABS ASR Conditions for Setting the DTC With the battery voltage at 20 V or more the engine speed at 500 rpm or more and the exhaust brake turned on the solenoid valve is turned off or exhaust brake t...

Page 150: ...operly formed or damaged pins and poor pin to wire connection Damaged harness Inspect the wiring harness for rubbed through wire insulation or wire broken inside the insulator If the harness appears t...

Page 151: ...ge Pins 75 ground jumpered pins 1 ground 0 not jumpered Go to Step 9 Go to Step 8 8 Repair or replace the faulty harness Is the action complete Verify repair and go to Step 11 9 Review the DTC 1 Using...

Page 152: ...on switch for not less than 1 second but not more than 3 seconds Release the accelerator pedal 5 5 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the ac...

Page 153: ...air or replace the faulty harness Is the action complete Verify repair and go to Step 6 6 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of...

Page 154: ...not more than 3 seconds Release the accelerator pedal 5 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 6 After the above operation...

Page 155: ...air or replace the faulty harness Is the action complete Verify repair and go to Step 6 6 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of...

Page 156: ...Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn of...

Page 157: ...Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the intake throttle connect...

Page 158: ...nectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC Is DTC61 detected Go to Step 9 Refer to Diagnostic Aids 9 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped w...

Page 159: ...lerator pedal 5 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 6 After the above operations are properly completed the CHECK ENGIN...

Page 160: ...nostic Aids 4 1 Replace the VIM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of startups to the replacing VIM Is the action complete Verify repair and go to...

Page 161: ...the CHECK ENGINE lamp MIL The exhaust brake is disabled Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC...

Page 162: ...related to the sensor A change in the display will indicate the location of the fault Test Description Number s below refer to the step number s on the Diagnostic Chart 3 If the DTC is not detected t...

Page 163: ...arter switch OFF 2 Jumper the starter switch connector and measure the resistance at the VIM connector Was the resistance within range Pins 49 ground jumpered pins 2 ground 0 Go to Step 4 Go to Step 1...

Page 164: ...stic Aids 14 1 Replace the VIM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of startups to the replacing VIM Is the action complete Verify repair and go to...

Page 165: ...e is running for at least 180 seconds and the neutral switch is changed from on to off Action Taken When the DTC Sets After the DTC is set the ECM will illuminate the CHECK ENGINE lamp MIL The exhaust...

Page 166: ...formed or damaged pins and poor pin to wire connection Damaged harness Inspect the wiring harness for rubbed through wire insulation or wire broken inside the insulator If the harness appears to be O...

Page 167: ...s the action complete Verify repair and go to Step 10 8 Review the DTC 1 Certainly connect the neutral P N switch and VIM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC...

Page 168: ...DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle position switch for not less...

Page 169: ...stance reads the cause is open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD S...

Page 170: ...ion input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 7 7 Check DTC84 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and revi...

Page 171: ...he DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle position switch for not les...

Page 172: ...stance reads the cause is open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD S...

Page 173: ...ion input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 7 7 Check DTC86 will not be set again 1 Using Tech 2 clear the DTC 2 Perform test run and revi...

Page 174: ...ssure Sensor Fixed Output Fault Legend 1 Fuel tank 2 Fuel filter 3 Supply pump 4 SCV suction control valve 5 FT fuel temperature sensor 6 Common rail 7 Common rail pressure sensor 8 Injector 9 ECM eng...

Page 175: ...aken When the DTC Sets After the DTC is set the ECM will illuminate the CHECK ENGINE lamp MIL The common rail pressure and fuel injection quantity are limited Conditions for Clearing MIL DTC When the...

Page 176: ...3 Bleed the air from the fuel system 4 Perform test run and review the DTC Is DTC115 detected Go to Step 3 Refer to Diagnostic Aids 3 Check the common rail pressure 1 Install Tech 2 2 Starter switch...

Page 177: ...ce the common rail common rail pressure sensor Is the action complete Verify repair and go to Step 9 9 Review the DTC 1 Restore the vehicle 2 Bleed the air from the fuel system 3 Using Tech 2 clear th...

Page 178: ...on complete Go to Step 15 15 Check DTC115 will not be set again 1 Restore the vehicle 2 Bleed the air from the fuel system 3 Using Tech 2 clear the DTC 4 Perform test run and review the DTC Is DTC115...

Page 179: ...ressure Fault Control System Legend 1 Fuel tank 2 Fuel filter 3 Supply pump 4 SCV suction control valve 5 FT fuel temperature sensor 6 Common rail 7 Common rail pressure sensor 8 Injector 9 ECM engine...

Page 180: ...To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle position switch f...

Page 181: ...agnostic Aids 3 1 The flow damper may have been working Leave the vehicle inactive overnight 2 Perform test run and review the DTC Is DTC118 detected Go to Step 4 Refer to Test Description 4 Inspect t...

Page 182: ...CAUTION After the common rail pressure sensor is disconnected DTC245 is set Be sure to clear this DTC245 upon completion of this Step 9 Was the voltage within range Approx 5 V Go to Step 13 Go to Ste...

Page 183: ...5 Repair is complete 15 Inspect the common rail 1 Check the pressure limiter for fuel leak Is the common rail sound Go to Step 17 Go to Step 16 16 Replace the common rail Is the action complete Go to...

Page 184: ...the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not mo...

Page 185: ...on Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the injector connector for insta...

Page 186: ...ect harnesses from injectors for cylinders 1 and 4 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance within range Cylinder 1 pin...

Page 187: ...uipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC158 will not be set again 1 Using Tech 2 clear the D...

Page 188: ...the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not mo...

Page 189: ...e s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the injector connector for installation...

Page 190: ...ect harnesses from injectors for cylinders 2 and 3 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance within range Cylinder 2 pin...

Page 191: ...uipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC159 will not be set again 1 Using Tech 2 clear the D...

Page 192: ...ase 70 C startup phase 20 C Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the...

Page 193: ...t voltage is fixed to 0 V the possible cause is short in the circuit Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer...

Page 194: ...Step 14 12 Check the FT sensor circuit for B short 1 Starter switch OFF 2 Disconnect the ECM 3 At the ECM connector pins measure the resistance Was the resistance within range Pins 48 46 109 114 115...

Page 195: ...test run and review the DTC Is DTC211 detected Refer to Diagnostic Aids and go to Step 2 Repair is complete 19 Review the DTC 1 Certainly connect the FT sensor and ECM connectors 2 Using Tech 2 clear...

Page 196: ...e Sensor Description Legend 1 FT sensor signal 2 FT sensor ground 3 FT sensor 4 Camshaft 5 SCV 6 SCV HI 7 SCV LO 0 1 0 3 0 2 0 5 0 4 0 6 0 8 1 2 3 4 5 6 8 10 20 30 0 20 20 40 60 80 100120 LNW21ASH0104...

Page 197: ...t is at least 1500 mA B short is detected on the circuit between SCV and ECM Action Taken When the DTC Sets After the DTC is set the ECM will illuminate the CHECK ENGINE lamp MIL The common rail press...

Page 198: ...play will indicate the location of the fault Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and...

Page 199: ...cted Go to Step 10 Refer to Diagnostic Aids 10 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of startups to the replacing ECM Is the action...

Page 200: ...Pressure Feed Fuel Leak Legend 1 Fuel tank 2 Fuel filter 3 Supply pump 4 SCV suction control valve 5 FT fuel temperature sensor 6 Common rail 7 Common rail pressure sensor 8 Injector 9 ECM engine cont...

Page 201: ...off the idle position switch for not less than 1 second but not more than 3 seconds Press the accelerator pedal 2 Turn on the idle position switch for not less than 1 second but not more than 3 secon...

Page 202: ...nd review the DTC Is DTC227 detected Go to Step 4 Refer to Test Description 4 Inspect the fuel system according to the following procedures 1 Check the fuel filter for excessive contamination and chok...

Page 203: ...CAUTION After the common rail pressure sensor is disconnected DTC245 is set Be sure to clear this DTC245 upon completion of this Step 9 Was the voltage within range Approx 0 V Go to Step 13 Go to Ste...

Page 204: ...r is complete 15 Inspect the common rail 1 Check the pressure limiter for fuel leak Is the common rail normal in condition Go to Step 17 Go to Step 16 16 Replace the common rail Is the action complete...

Page 205: ...s the powertrain using the set accelerator position 20 Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC f...

Page 206: ...System Check and go to Step 2 2 Check the idle position switch for mechanical fault 1 Check the idle position switch connector for installation and if mounted improperly install the device certainly...

Page 207: ...r for open wiring 1 Disconnect the ECM 2 Jumper the idle position switch connector pin and measure the resistance at the ECM connector Was the resistance within range Pins 110 87 0 Go to Step 11 Go to...

Page 208: ...ols the powertrain using the set accelerator position 20 Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC...

Page 209: ...System Check and go to Step 2 2 Check the idle position switch for mechanical fault 1 Check the idle position switch connector for installation and if mounted improperly install the device certainly...

Page 210: ...M connector Was the resistance within range Pins 110 87 jumpered 0 not jumpered Go to Step 10 Go to Step 9 9 Repair or replace the faulty harness Is the action complete Go to Step 12 10 Review the DTC...

Page 211: ...common rail pressure and fuel injection quantity are limited The ECM declares the common rail pressure sensor fault and stops the related control tasks and fault judgment Conditions for Clearing MIL D...

Page 212: ...e is ground circuit common to ITP sensor and EGR position sensor or common rail pressure sensor 7 If pins are jumpered and the resistance reads the cause is open wiring If pins are not jumpered and th...

Page 213: ...nd ECM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC Is DTC245 detected Go to Step 10 Refer to Diagnostic Aids 10 Check the common rail pressure sensor output voltage 1...

Page 214: ...o to Step 20 15 Check the common rail pressure 1 Install Tech 2 2 Starter switch ON 3 Observe Desired Rail Pressure and Actual Rail Pressure displays 4 Start the engine Run the engine at idle for warm...

Page 215: ...ECM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 20 20 Check DTC245 wi...

Page 216: ...1A 214 Engine Control System Sensor Description Legend 1 Pressure limiter 2 Common rail pressure sensor 3 Sensor ground 4 Sensor signal 5 Sensor power LNW21ASF002901 1 2 5 4 3...

Page 217: ...y Conditions for Setting the DTC The SCV drive current is 1100 mA or less Short to ground between SCV and ECM B short between SCV and ECM short to ground between SCV and ECM or open wiring between SCV...

Page 218: ...ault Test Description Number s below refer to the step number s on the Diagnostic Chart 3 If the DTC is not detected the possible cause is intermittent intermittent fault 5 If pins are jumpered and th...

Page 219: ...Aids and go to Step 2 Repair is complete 10 Review the DTC 1 Certainly connect the SCV and ECM connectors 2 Using Tech 2 clear the DTC 3 Perform test run and review the DTC Is DTC247 detected Go to S...

Page 220: ...1A 218 Engine Control System SCV Description Legend 1 FT sensor signal 2 FT sensor ground 3 FT sensor 4 Camshaft 5 SCV 6 SCV HI 7 SCV LO LNW21ASF002601 5 4 3 1 2 7 6...

Page 221: ...inder 1 injector 1 is terminated Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clea...

Page 222: ...s open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go...

Page 223: ...intermediate connector 2 Disconnect harnesses from the cylinder 1 injector 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance wit...

Page 224: ...uipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC271 will not be set again 1 Using Tech 2 clear the D...

Page 225: ...inder 2 injector 4 is terminated Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clea...

Page 226: ...s open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go...

Page 227: ...intermediate connector 2 Disconnect harnesses from the cylinder 2 injector 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance wit...

Page 228: ...uipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC272 will not be set again 1 Using Tech 2 clear the D...

Page 229: ...inder 3 injector 2 is terminated Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clea...

Page 230: ...s open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go...

Page 231: ...intermediate connector 2 Disconnect harnesses from the cylinder 3 injector 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance wit...

Page 232: ...uipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC273 will not be set again 1 Using Tech 2 clear the D...

Page 233: ...inder 4 injector 3 is terminated Conditions for Clearing MIL DTC When the system fails and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clea...

Page 234: ...s open wiring If pins are not jumpered and the resistance reads 0 the cause is short Step Action Value s Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go...

Page 235: ...intermediate connector 2 Disconnect harnesses from the cylinder 4 injector 3 Measure the resistance between injector terminal and connector pin as well as between connector pins Was the resistance wit...

Page 236: ...quipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 16 16 Check DTC274 will not be set again 1 Using Tech 2 clear the...

Page 237: ...DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 s...

Page 238: ...Is the action complete Go to Step 3 3 Review the DTC 1 Using Tech 2 check and store the DTC 2 Clear the DTC 3 Perform test run and review the DTC Is DTC277 detected Go to Step 4 Refer to Diagnostic Ai...

Page 239: ...within range 0 4 Go to Step 12 Go to Step 10 10 Repair or replace the faulty injector s Is the action complete Go to Step 11 11 Check DTC277 will not be set again 1 Restore the vehicle 2 Using Tech 2...

Page 240: ...1A 238 Engine Control System Injector Description Legend 1 Injector 2 Power supply harness 3 Drive harness LNW21ASH010701 1 2 3...

Page 241: ...DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 s...

Page 242: ...Is the action complete Go to Step 3 3 Review the DTC 1 Using Tech 2 check and store the DTC 2 Clear the DTC 3 Perform test run and review the DTC Is DTC278 detected Go to Step 4 Refer to Diagnostic Ai...

Page 243: ...as the resistance within range 0 4 Go to Step 12 Go to Step 10 10 Replace the faulty injector s Is the action complete Go to Step 11 11 Check DTC278 will not be set again 1 Restore the vehicle 2 Using...

Page 244: ...1A 242 Engine Control System Injector Description Legend 1 Injector 2 Power supply harness 3 Drive harness LNW21ASH010701 1 2 3...

Page 245: ...o the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less than 1 second but not m...

Page 246: ...Yes No 1 Perform the On Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the main relay 1 Remove the main relay 2 At...

Page 247: ...Engine Control System 1A 245 Main Relay Description Legend 1 Contact 1 battery side 2 Contact 2 ECM side 3 Coil 1 battery side 4 Contact 3 5 Coil 2 ECM side LNW21ASF002701 2 3 5 1 4 1 3 5 2 4...

Page 248: ...and the DTC is stored to the ECM even repairing the faulty portion will not clear the DTC from the memory To clear the DTC conduct the following steps 1 Turn off the idle position switch for not less...

Page 249: ...n Board Diagnostic OBD System Check Was the OBD System Check performed Go to Step 2 Refer to OBD System Check and go to Step 2 2 Check the path between starter switch ST and ON circuits for short 1 St...

Page 250: ...ds 9 1 Replace the ECM IMPORTANT If necessary for the vehicle equipped with idle stop function input the number of startups to the replacing ECM Is the action complete Verify repair and go to Step 10...

Page 251: ...minates for 3 seconds to report the memory is cleared 7 Turn off the starter switch Wait for 5 seconds and turn on the starter switch again When Tech 2 has been connected to the vehicle the DTC can be...

Page 252: ...startability at low temperature The engine shows good startability at ordinary temperature but it takes long time to start at low temperature Hunting instable idling The idle speed is instable or vary...

Page 253: ...ure limiter D 14 Injector C 3 Fuel filter pipe tank D 4 Fuel D 12 Valve clearance D 1 Valve timing D 11 Compression D 2 Ring gear D 6 Rotary parts D 10 CKP sensor D 8 CMP sensor D 8 Mechanical timing...

Page 254: ...with the idle stop system turned off Inspect the clutch free system Inspect the system for ASR or AT accelerator cut request Inspect the parking brake or retarder for working Inspect the engine oil fo...

Page 255: ...and Accelerator Pedal Position Sensor displays while operating the accelerator pedal Reference value Idle position 0 approx 0 6 V WOT position 100 approx 4 5 V 4 PTO accelerator sensor 1 Check the ext...

Page 256: ...speed is reduced 3 Injector 1 Perform the injector balance test to check all the injectors are working 2 Observe the Cylinder 1 4 Compensation display for individual cylinders to check all the cylinde...

Page 257: ...cleaner intake pipe Perform the visual check according to the following procedures Check the air cleaner for excessive contamination and choke Check the pipe for damage collapse and poor assembling 6...

Page 258: ...the starter for motor rotation and pinion projection Refer to Starter in Electrical System 14 Common rail flow damper pressure limiter 1 Check the flow damper or pressure limiter is not working 2 Che...

Page 259: ...move the mylar 3 Untwist the conductors 4 Strip the insulator as necessary Installation Procedure 1 Splice the wires using splice clips and rosin core solder 2 Wrap each splice to insulate 3 Wrap the...

Page 260: ...s required Installation Procedure 1 Use splice clips and rosin core solder in order to splice the two wires together 2 Cover the splice with tape in order to insulate it from the other wires 3 Twist t...

Page 261: ...Engine Control System 1A 259 4 Tape the wires with electrical tape Hold in place LNW21ASH005101...

Page 262: ...pins these pins cannot be straightened after they have been improperly bent 3 Cut the wire immediately behind the cable seal Installation Procedure Make certain the connectors are properly seated and...

Page 263: ...System 1A 261 5 Push the pin and the connector to engage the locking tangs 6 Close the secondary locking hinge Special Tools LNW21ASH005401 Illustration Tool No Tool name 5 8840 0388 0 Weather Pack Te...

Page 264: ...II pin looks similar to some Weather Pack pins This pin is not sealed and is used where resistance to the environment is not required Use the standard method when repairing a pin Do not use the Weathe...

Page 265: ...wire and the pin out through the connector IF you reuse the pin reshape the locking tang Installation Procedure Metri Pack pins are also referred to as pull to seat pins 1 In order to install a pin o...

Page 266: ...manual number that is shown above All rights reserved This manual may not be reproduced in whole or in part without the permission in writing of ISUZU MOTORS LIMITED Issued by ISUZU MOTORS LIMITED IN...

Page 267: ...No LG4HL WE 0229DOM...

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