Sect 1 Troubleshooting 1kd Engine Ce302

1KD_RM.
book 1 ページ２０１３年９月２７日　金曜日　午後１２時４７分
1-1
TROUBLESHOOTING
ECD (ELECTRONIC CONTROL DIESEL)

SYSTEM ........................................................................ 1-2
CAUTIONS ...................................................................... 1-2 0
FUNCTION INSPECTION ............................................... 1-2 1
BASIC INSPECTION....................................................... 1-2
2
PARTS LAYOUT DRAWING ........................................... 1-4
3
DIAGNOSIS CODE LIST................................................. 1-5
LIST OF SYMPTOMS...................................................... 1-7
4
DESCRIPTION OF FUNCTION..................................... 1-10 5
PROCEDURE FOR TROUBLESHOOTING.................. 1-11 6
INSPECTING/DELETING DIAGNOSIS CODE ............. 1-13 7
FREEZE FRAME DATA/DIAGNOSIS
DETAILED INFORMATION ........................................ 1-14
8
INSPECTION OF IRREGULAR PROBLEMS ............... 1-15 9
WORK SUPPORT ......................................................... 1-16 10
CIRCUIT DIAGRAM ...................................................... 1-30 11
ECU TERMINAL LAYOUT ............................................ 1-33
12
ECU DATA MONITOR/ACTIVE TEST........................... 1-39
13
FAIL SAFE LIST............................................................ 1-52
INDIVIDUAL INSPECTION ...................................... 1-293 14
INTAKE AIR FLOW METER S/A INSPECTION ......... 1-294
1KD_RM.book 2 ページ２０１３年９月２７日　金曜日　午後１２時４７分
1-2
1-2
ECD (ELECTRONIC CONTROL DIESEL) SYSTEM

CAUTIONS
1. Precautions for using the 'Engine Diagnostic Program'
WARNING:
• Read the 'Engine Diagnostic Program' instruction manual before using it.
• In operating the machine with the 'Engine Diagnostic Program' connected, be careful of handling so that
the cable of the 'Engine Diagnostic Program' does not hang on the pedal, the shift lever, or the steering
wheel.
• In operating the machine using the tool (such as performing a simulation test), to avoid operations while
controlling the tool, two operators should always work and observe work rules.
FUNCTION INSPECTION
1. Accelerator position sensor (potentiometer) (See the lift truck repair manual for the procedure.)
2. Intake air flow meter
Caution:
• Follow the procedure below to inspect the intake air flow meter S/A.
• With the engine stopped, when a value of [MAF] from [Data monitor] does not meet the standard or when
foreign matter is found in the platinum filament (heater) portion of the intake air flow meter S/A, the meter
should be replaced.
(1) Intake air quantity inspection
SST 09111-36760-71 (09991-70201)
Caution:
• With the engine stopped, keep the machine horizontal and inspect these functions indoors.
• Perform inspection with the intake air flow meter S/A mounted on the intake pipe (with the machine
installed).
• Do not suck air from the exhaust tail pipe in the exhaust duct.
(a) Turn the ignition key switch on and wait for 30 seconds.
(with the engine stopped)
(b) According to the instruction of the 'Engine Diagnostic Program' screen, press [Data monitor] and monitor
[MAF] and read a numerical value.
Reference 1.2 g/sec (0.16 lb/min) or less
(2) Sensor foreign matter adhesion inspection
(a) Visually check the platinum filament (heater) portion in flow paths.
Standard No foreign matter that can be visually checked
Note:
After checking that no foreign matter is found, return the intake air flow meter S/A to the machine.
BASIC INSPECTION
Note:
When the location of a defect cannot be identified even after troubleshooting, it can be pinpointed through
the basic inspection below.
1. Battery inspection (See the machine repair manual for the procedure.)
2. Cranking operation inspection
(1) Inspect if the engine cranks.
Note:
If it does not crank, inspect relevant portions, referring to the LIST OF SYMPTOMS
(See page 1-7 for the procedure.)
1-3
3. Engine start inspection

(1) Inspect if the engine starts.
NOTICE:
• Engine should be cranked by two rotations at minimum when engine starting because ECD system
electrically detects the fuel injected cylinder.
• If it does not start, inspect relevant portions, referring to the LIST OF
SYMPTOMS (See page 1-8 for the procedure.)
4. Air filter inspection (See the machine repair manual for the procedure.)
5. Idle speed inspection
(1) Inspect idling.
Reference: Refer to repair manual of the vehicle (after warm-up, during idling)
6. Fuel pressure inspection
SST: 09240-36770-71
(1) According to the instruction of the screen, press [Data monitor] and monitor [Fuel Press] and measure fuel
pressure.
Reference: 30000 to 50000 kPa (after warm-up, during idling)
7. Fuel property
Inspect if a proper fuel is used as described in the Operator's Manual.
Diesel fuel
For 8FD35U to 8FD80U model
Use only ultra low-sulfur fuel defined by ASTM D0975 No.2-D S15.
Refer to the following table for details.
Detailed Requirement for ASTM D0975 No.2-D S15
Property Unit Value
Distillation Temperature °C 90 % 282 to 338
Kinematic Viscosity mm2/s at 40 °C 1.9 to 4.1
Sulfur ppm (μ g/g) max 15
Cetane index -, min 40
Aromaticity %vol, max 35
Lubricity, HFRR μm, max 520
NOTICE:
• Do not use bio-diesel fuel. Damage to engine will occur.
• In cold weather, use winter diesel fuel to prevent clogging of the fuel filter caused by paraffin precipitation.
In hot weather, do not use winter diesel fuel. Damage to engine will occur.
• Do not use deteriorated fuel which has been stored for a long period of time or impure fuel in which
foreign material, water and etc. is included.
• If fuel is frozen or becomes wax-like substance in winter season, engine may be hard starting, rough idle
after starting or engine rotation is impossible to increase. In that case, fuel for winter use should be used.
Melt the wax generated in the fuel filter by warming.
1-4
PARTS LAYOUT DRAWING
Fuel pressure sensor
Intake air flow meter

Common rail ASSY
Pressure limiter Diesel turbo

pressure sensor
Glow plug ASSY

Injector ASSY
Electric EGR
control valve
Water temperature sensor
Inlet air
temperature sensor
Oil pressure
switch ASSY
Fuel temperature
sensor
Suction control valve ASSY
Crank position
sensor No. 2 Crank position sensor
Turbo charger S/A

1-5
DIAGNOSIS CODE LIST

ECD System
Page for
Diagnosis code Diagnosis item Lamp on Code stored
reference
Turbocharger boost control circuit
P0046   1-54
range / performance
P0047 Turbocharger boost control solenoid circuit low   1-54
P0048 Turbocharger boost control solenoid circuit high   1-54
P007C Charge air cooler temperature sensor circuit low   1-59
P007D Charge air cooler temperature sensor circuit high   1-59
P0087 Fuel rail / system pressure - too low   1-65
P0088 Fuel rail / system pressure - too high   1-72
P0093 Fuel system leak detected - large leak   1-79
P0102 Mass air flow sensor circuit low   1-92
P0103 Mass air flow sensor circuit high   1-92
P0107 Manifold absolute pressure sensor circuit low   1-97
P0108 Manifold absolute pressure sensor circuit high   1-97
P0112 Intake air temperature sensor circuit Low   1-102
P0113 Intake air temperature sensor circuit high   1-102
P0115 Engine coolant temperature sensor circuit   1-108
P0117 Engine coolant temperature sensor circuit low   1-108
P0118 Engine coolant temperature sensor circuit high   1-108
P0180 Fuel temperature sensor "A" circuit   1-113
P0182 Fuel temperature sensor "A" circuit low   1-113
P0183 Fuel temperature sensor "A" circuit high   1-113
P0190 Fuel rail pressure sensor circuit   1-65
P0192 Fuel rail pressure sensor circuit low   1-65
P0193 Fuel rail pressure sensor circuit high   1-65
P0201 Injector circuit / open - (Cylinder 1)   1-118
P0299 Turbocharger underboost   1-131
P0335 Crankshaft position sensor circuit   1-133
P0339 Crankshaft position sensor circuit intermittent ×  1-133
P0340 Camshaft position sensor circuit   1-137
P0405 Exhaust gas recirculation sensor circuit low   1-141
P0406 Exhaust gas recirculation sensor circuit high   1-141
P042E Exhaust gas recirculation control stuck open   1-146
P0489 Exhaust gas recirculation control circuit low   1-151
P0490 Exhaust gas recirculation control circuit high   1-151
P0560 System voltage   1-154
P0606 ECM / PCM processor   1-157
Internal control module monitoring processor
P060A   1-157
performance
Internal control module A/D processing
P060B   1-157
performance
P0617 Starter relay circuit high   1-159
1-6
Page for
Diagnosis code Diagnosis item Lamp on Code stored
reference
P0627 Fuel pump control circuit / open   1-162
P062D Fuel injector driver circuit performance   1-118
P062F Internal control module EEPROM error   1-166
P1229 Fuel pump system   1-169
Motor for turbocharger control circuit
P1251   1-173
(Intermittent)
P2120 Pedal position sensor "D" circuit   1-180
Pedal position sensor "D" circuit
P2121   1-188
range / performance
P2122 Pedal position sensor "D" circuit low   1-180
P2123 Pedal position sensor "D" circuit high   1-180
P2125 Pedal position sensor "E" circuit   1-180
P2127 Pedal position sensor "E" circuit low   1-180
P2128 Pedal position sensor "E" circuit high   1-180
P2138 Pedal position sensor "D" / "E" voltage correlation   1-180
P2226 Barometric pressure circuit   1-191
P2228 Barometric pressure circuit low   1-191
P2229 Barometric pressure circuit high   1-191
Turbocharger boost control position sensor
P2564   1-193
"A" circuit low
Turbocharger boost control position sensor
P2565   1-193
"A" circuit high
U0101 Lost communication with can ×  1-197
1-7
LIST OF SYMPTOMS
ECD System
Page for
Symptom Portion to be inspected
reference
Battery -
Starter 5-2
Does not crank
Starting relay -
Shift lever position -
Fuel filter -
Injector ASSY 1-118
Starter system 1-199
Engine control computer -
Suction control valve ASSY 1-296
Fast idling rough Fuel pressure sensor 1-296
Intake air flow meter 1-294
Fuel property 1-3
Water temperature sensor 1-295
Fuel piping
-
(blocking from the tank to the supply pump)
Troubleshooting of rough idle and large vibration 1-270
Injector ASSY 1-118
Idle speed high
Fuel pressure sensor 1-296
Water temperature sensor 1-295
Accelerator position sensor (potentiometer) -
Injector ASSY 1-118
Electric EGR control valve 1-296
Compression 2-79
Idle speed low Valve clearance 2-78
Fuel piping -
Injector ASSY 1-118
Fuel piping -
Compression 2-79
Valve clearance 2-78
Idle unstable
Fuel property 1-3
Power steering system -
Alternator ASSY (external accessory) 7-4
1-8
Page for
Symptom Portion to be inspected
reference
Injector ASSY 1-118
ECU power supply system 1-290
Compression 2-79
Fuel piping -
Valve clearance 2-78
Hunting Engine control computer -
Fuel property 1-3
Power steering system -
Alternator ASSY (external accessory) 7-4
Injector ASSY 1-118
Fuel filter -
White smoke is discharged Fuel pressure sensor 1-296
Preheating control circuit system 1-206
Fuel property 1-3
Compression 2-79
Turbo charger oil leak and white smoke 1-234
White smoke 1-224
Troubleshooting of black smoke 1-249
Black smoke is discharged
Injector ASSY 1-118
Exhaust system clogging -
Troubleshooting of hard starting and engine stalling 1-212
Preheating control circuit system 1-206
Hard starting, engine stalling Fuel property 1-3
ECU power supply system 1-290
VC power supply system 1-284
Battery -
Lack of power, hesitation, surge Troubleshooting of lack of power, hesitation, and surge (hesi-
1-260
(hesitation) tation)
Rough idling, large vibration
ID code writing abnormality 1-16
Troubleshooting of knocking and abnormal noise 1-277
Knocking, abnormal noise
Turbo charger S/A noise 1-243
1-9
Abnormal engine noise, or noisy engine

Engine status where Example of
Probable cause NOTE:
noise is often heard sound
Put a sound scope on the water pump
body to check.
Water pump bearing • Remove the V-ribbed belt and try to
Rasping sound
defect rotate by hand. If the turning feels
rough or bumpy to the hand, then the
bearing is defective.
Squealing sound Apply engine oil from outside the seal,
During idling
Squeaking Oil seal squeal or spray an anti-squealing agent.
sound • The sound gets smaller or stops.
Inspect the intake manifold and air
cleaner for appropriate installation.
Hissing noise Air suction sound • Try plugging the place where the air
gets in with engine oil, grease or
cloth.
The sound occurs on sudden accelera-
tion from idle.
• Check if the indicator mark of the V-
ribbed belt tensioner ASSY is in the
Squealing sound Belt slipping
range of the standard value.
• Inspect the V-ribbed belt for wear,
cracks and adhered oil.
Piston side knock
Certain engine speed Knocking sound of the
connecting rod bearing
Heard from the lower part of the
Knocking sound Knocking sound of the engine.
crankshaft bearing
Piston pin knocking
sound
Sound volume and pitch are propor-
Whistling sound Turbo charger S/A tional to the turbo charger S/A or
engine speed.
Clicking sound Excess valve clearance Adjust the valve clearance.
Clattering sound or faulty contact (See page 2-77 for the procedure.)
Check by blocking with a wet cloth the
Whole engine speed A "raspberry"
likely location of the leak in the
sound
Exhaust leak exhaust system.
A "put-put"
• The noise becomes louder when the
sound
engine speed is increased.
Note:
It is not abnormal phenomenon engine noise becomes higher when engine revolution is decreased to idle
state after engine revolution increased higher. And this noise tend to become higher at low temperature, but
it is not abnormal phenomenon.
1-10
Excessive engine oil consumption

Cause Inspection or adjustment areas NOTE:
PCV
Leaking to the exterior of the
Engine unit
engine
Turbo charger S/A (See page 1-234 for the procedure)
Cylinder head S/A
Cylinder block S/A
Head gasket
A lot carbon build-up will be visible around
Leaking to the interior of the Oil loss via the piston ring
the top of the piston.
engine
Determined by the condition of the carbon
adhered to the intake valve cap and the top
Oil loss via the valve guide
of the piston, and by the wetness of the
valve cap caused by oil.
Turbo charger S/A (See page 1-234 for the procedure)
DESCRIPTION OF FUNCTION
1. What is the ID code (compensation code)?
Order in which the ID code (1) For the optional injection characteristic of the injector
is read or written ASSY, the engine control computer performs different
ID code injection period compensation for each injector ASSY.
This compensation data is punched as a 30-digit
alphanumeric ID code on the head of the injector ASSY.
The ID code should be written when the injector ASSY or
the engine control computer is replaced.
Caution:
Improper writing of the ID code can cause rough idling or
abnormal noise.
Injector ASSY
No.4 cylinder
No.3 cylinder
No.2 cylinder
No.1 cylinder
1-11
PROCEDURE FOR TROUBLESHOOTING

1 Making diagnosis and checking symptoms (See page 6-12 for the procedure.)
Next
2 Checking diagnosis codes

1. Check diagnosis codes and freeze frame data (See page 1-14
for the procedure.)
2. Delete diagnosis codes and freeze frame data (See page 1-13
for the procedure.)
3. Check diagnosis codes again
Result
Result Go to
A code was output. A
A code was not output. B
B Go to step 4.
3 List of diagnosis codes (main inspection portions) or troubleshooting for each code
1. Check the list of diagnosis codes

Result
Result Go to
A faulty section was identified. A
A faulty section was not identified. B
A Go to step 9.
B Go to step 6.
4 List of symptoms
1. Check the list of symptoms

Result
Result Go to
A Go to step 9.
B
1-12
5 Basic inspection (See page 1-2 for the procedure.)
Result
Result Go to
A Go to step 9.
6 Inspecting with 'Engine Diagnostic Program'
1. Perform [Data monitor] and [Active test]

Result
Result Go to
A Go to step 9.
Inspecting ECU terminal voltage and circuits

7
Next
8 INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)
Next
9 Repairing defective parts
Next
10 Checking diagnosis codes (See page 1-5 for the procedure.)
Next
End
1-13
INSPECTING/DELETING DIAGNOSIS CODE

Note:
• Read the 'Engine Diagnostic Program' instruction manual before using it.
• 'Engine Diagnostic Program' enables you to select not only the normal mode but the check mode. In the
check mode, abnormality detection sensitivity can be improved, compared to the normal mode.
• Perform inspection in the check mode when normal codes are output in the normal mode despite of
possible abnormalities in a signal system of each sensor.
1. Preparation before inspection
(1) Put the shift position to N.
(2) Disable all of outside loads.
2. Inspecting diagnosis codes (reading with 'Engine Diagnostic Program')
(1) To Use check mode, according to the instruction of the 'Engine Diagnostic Program', press [Utility]  select
[Check mode].
(2) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code] and check the
diagnosis code.
3. Deleting diagnosis code memory (using 'Engine Diagnostic Program')
(1) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code]  press
[Clear], to delete the diagnosis code.
SST 09111-36760-71 (09991-70201)
Caution:
• If it cannot be deleted, turn the ignition key switch OFF and then delete it again.
• Do not delete diagnosis codes with 'Engine Diagnostic Program' before making diagnosis and checking
symptoms.
4. Deleting diagnosis codes (by removing fuse)
Engine room relay block (1) Remove the EFI2 fuse (10 A), and in 15 seconds or more
connect the fuse.
Caution:
• Be sure to delete diagnosis code memory after inspecting
and repairing the ECD system. Then, check that normal
codes are output.
• Do not delete diagnosis codes by clearing the battery
(removing the fuse) before making diagnosis and checking
symptoms.
1
EFI2 fuse
2
5. Checking diagnosis results (using 'Engine Diagnostic Program')

SST 09111-36760-71 (09991-70201)
Note:
After repairing the faulty system with the output diagnosis code or when performing a recreation test after
deleting the diagnosis code, check output diagnosis codes.
(1) Use 'Engine Diagnostic Program' to delete the diagnosis code.
(2) Perform a test for checking diagnosis results.
(3) According to the instruction of the 'Engine Diagnostic Program' screen, press [Trouble code].
(4) Check diagnosis code results.
1-14
FREEZE FRAME DATA/DIAGNOSIS DETAILED INFORMATION

1. Checking freeze frame data (reading with 'Engine Diagnostic Program')
With 'Engine Diagnostic Program', according to the instruction of the screen, press [Trouble code].
Indicates existance of freeze frame data with a mark in [FED], press the mark.
SST 09111-36760-71 (09991-70201)
(1) Turn the ignition key switch ON.
(2) Press [Trouble code].
Indicates existance of freeze frame data with a mark in [FED], press the mark.
(3) In the screen displaying the diagnosis code, detected diagnosis codes appear.
(4) Select a diagnosis code for which freeze frame data is checked.
2. Checking chronological freeze frame data
(1) In the screen displaying freeze data, select an item for
which chronological freeze frame data is checked.
DTC detection point
Note:
• Chronological freeze frame data also includes ECU data
recorded at the occurrence of a diagnosis code and around
0.5 sec. 0.5 sec. 0.5 sec.
that point.
• Chronological freeze frame data can be checked when
press a mark in [FED], ' '.
• For chronological freeze frame data, a total number of five
points (including a diagnosis detection point, three points
before detection, one point after detection) can be
displayed.
1 2 3 4
Freeze frame data recording point
3. List of freeze frame data
Item name
Engine Speed Actual VN Position
Calculate Load VN Position Sensor Out
MAF VN Motor Duty
Atmosphere Pressure VN Close Learn Value
MAP VN Close Learn Status
Coolant Temp Initial Engine Coolant Temp
Intake Air Initial Intake Air Temp
Engine Run Time Engine Start Time
Starter Signal Engine Speed (Starter Off)
Injection Volume Starter Count
Pilot 1 Injection Period Electric Duty Feedback Value
Pilot 2 Injection Period Intake Air Temp (Turbo)
Main Injection Period Battery Voltage
After Injection Period Engine Speed of Cyl #1
Pilot 1 Injection Timing Engine Speed of Cyl #2
Pilot 2 Injection Timing Engine Speed of Cyl #3
Main Injection Timing Engine Speed of Cyl #4
After Injection Timing Av Engine Speed of All Cyl
1-15
Item name
Injector Memory Error Time after DTC Cleared
Target Common Rail Pressure Warmup Cycle Cleared DTC
Fuel Press TC and TE1
Fuel Temperature Isochronous Control Target Speed
Target Pump SCV Current Isochronous Control Proportional Term
Pump SCV Learning Value Isochronous Control Integral Term
Accel Position Total Operation Hours
Accel Sens. No.1 Volt % Total Number of Rotations
Accel Sens. No.2 Volt % Total Injection Volume
Target EGR Pos. Pre Glow
Actual EGR Valve Pos. After Glow
EGR Close Lrn. Val. Target Idle Engine Speed
EGR Close Lrn. Status Adjustment Volume Mode Status Value
EGR Operation Prohibit after Confirmation
Target Booster Pressure Fuel Return Temp
VN Turbo Command EGR Motor Duty #1
INSPECTION OF IRREGULAR PROBLEMS

1. Inspecting irregular problems (this can be done only when 'Engine Diagnostic Program' is used)
Note:
Follow the procedure below to change the mode. This allows improvement of disconnection detection
sensitivity and more reliable detection of irregular defects.
(1) Delete diagnosis codes. (See page 1-13 for the procedure and notes.)
(2) Set the check mode. (See page 1-13 for the procedure and notes.)
(3) Perform a simulation (recreation) test. (See page 0-16 for the procedure and notes.)
(4) Visually inspect the connector and each terminal, and inspect the connection condition. (See page 0-11 for
the procedure and notes.)
(5) Inspect the wire harness and connector for excessive force.
(See page 0-13 for the procedure and notes.)
(6) Use a cooling method for inspection. (See page 0-16 for the procedure and notes.)
2. Checking wire harness and connector instantaneous interruption
Note:
If a defective system is found based on an output diagnosis code at the inspection of diagnosis codes
(check mode), its location should be pinpointed in the following way:
(1) After reading the diagnosis code in the check mode, delete diagnosis code memory.
(See page 1-13 for the procedure and notes.)
(2) Select the check mode, and start the engine. (See page 1-13 for the procedure and notes.)
(3) With the engine idling, shake the wire harness and the connector of the defective system where the
diagnosis code was output at the inspection of diagnosis codes (check mode). (See page 0-16 for the
procedure and notes.)
(4) After the wire harness and the connector are shaken, when the engine check indicator turns on, the
connection of them may be poor.
1-16
WORK SUPPORT
1. List of work support steps
When parts requiring initialization and writing have been replaced, initialize and write them by following the steps in
the list below in numerical order.
Work support item
Reading and Saving the Initializing the supply Writing the injector
Replacement
injector compensation code pump ASSY leaned value compensation code
Supply pump ASSY (1)
Engine ASSY (1)
Injector ASSY (1)
Supply pump ASSY +
(1) (2) (3)
engine ECU
Injector ASSY +
(1) (2) (3)
engine ECU
Engine ASSY +
(1) (2) (3)
engine ECU
Engine ECU
(1) (2) (3)
(with old data)
Engine ECU
(1) (2)
(without old data)
Note:
The ID code represents 'Engine Diagnostic Program' saved in the engine control computer (injector
compensation code).
2. Initializing the supply pump ASSY learned value
Caution:
Be sure to perform this precedure (initialization) after replacing the pump ASSY or the engine control
computer.
<Procedure 1/4> Cancel

Select [Supply Pump Initialization]
<Procedure 2/4>
Press [Next] to proceed
<Procedure 3/4>
Check the initial conditions, then press [Next]
Initialization
<Procedure 4/4>
Supply Pump Initialization is complete, press [Exit]
Note:
If an error occurs during the initialization, do it again from <Procedure 1/4>.
1-17

According to the instruction of the 'Engine Diagnostic
Program', press [Utility].
Caution:
Do not start the engine.
(2) <Procedure 1/4>
Select [Supplt Pump Initialization], then press [Select].
(3) <Procedure 2/4>

Press [Next] to proceed.
(4) <Procedure 3/4>

After check the initial conditions, then press [Next].
Caution:
Preform this procedure, the ignition key switch turned on and
the engine stopped.
1-18
(5) <Procedure 4/4>

Supply Pump Initialization is complete, press [Exit].
(6) Start up the engine for warm up.
Caution:
Do not perform racing immediately after the engine is started.
Note:
• If the Engine does not start, do it again <procedure 1/4>.
• The engine warm-up state shall be acondition water temperature is 60 °C (140 °F) or more and fuel
temperature is 20 °C (68 °F) or more.
(a) To check water temperature, in the 'Engine Diagnostic Program' select [Data monitor] and monitor
[Coolant Temp]
Reference 60 °C (140 °F) or more
(b) To check fuel temperature, in the 'Engine Diagnostic Program' Select [Data monitor] and monitor [Fuel
Temperature]
Reference 20 °C (68 °F) or more
• When fuel temperature does not increase due toan environment to be measured, increase engine speed
litlle by little until it reaches NMR (No load Maximum Revolution), make it the steady state, and then
increase the temperature. Do not perform racing rapidly.
(7) Run at idle for one minute or more in the state after engine warm-up.
(8) The initializatin is now completed.
1-19
3. Reading and Saving the injector compensation code

In this procedure, read codes (injector compensation codes) from the engine control computer, and save compensation
codes to the 'Engine Diagnostic Program'.
Cancel
<Procedure 1/6>
Select [Injector compensation]
<Procedure 2/6>
<Procedure 3/6>
Select a function [Read Compensation Code]
<Procedure 4/6>
Select a Cylinder number
Read Compensation Code
In case of reading
<Procedure 5/6> another cylinder compensation code
Appears Cylinder No and Compensation Code Next
Save Replace
(In case of there is no (In case of there is

compensation code) previous compensation code)
<Procedure 6/6>
Press [Replace] or [Save]
Note:
• Due to the defective engine control computer or wire harness, or poor connection of the diagnostic
connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the
diagnostic connector. When they are normal, the engine control computer may be defective.
• For replacement ECU, need to write the compensation codes of each cylinder. Use this saving
compensation codes function to avoid error, writing incorrect compensation code, install another cylinder
No.
• This saving function can save one latest data of each cylinder.
• If using saved data, confirm the saved compensation code and cylinder number, and compensation code
of the top of the injector ASSY are right.
1-20

Caution:
(2) <Procedure 1/6>
Select [Injector Compensation], then press [Select].
(3) <Procedure 2/6>

Press [Next] to proceed, read <NOTICE> message, then press [Next].
(4) <Procedure 3/6>

Select a function [Read Compensation Code], then press
[Next].
1-21
(5) <Procedure 4/6>

Select a Cylinder number from No.1 to 4, then press
[Next].
(6) <Procedure 5/6>
Note:
Appears selected cylinder No. and compensation code.
To save the compensation code, press [Save].
If there is previous saved data, and need to save new compensation data, press [Replace].
If there is no previous saved data, and need to save new

compensation data, press [Save].
Caution:
This saving function can save one latest data of each cylinder.
Confirm the cylinder number, and saved date and time to use
this saved data, in case of writing a compensation code to
replaced engine control computer.
If you need all cylinder compensation codes, repeat this
procedure same times as cilynder numbers.
1-22
(7) <Procedure 6/6>

To read another Cylinder’s injector compensation code, press [Next] and repeat this procedure from
<Procedure 4/6>.
To exit this function, press [Cancel].
1-23
4. Writing the injector compensation code

In this procedure, write codes (injector compensation codes) to the engine control computer.
• Use saved compensation codes in the 'Engine Diagnostic Program'.
• Input manual compensation codes.

Select [Injector compensation]
<Procedure 2/6>
<Procedure 3/6>
Select a function [Set Compensation Code]
<Procedure 4/6>
Select a Cylinder number
Use saved Input manual

compensation codes compensation codes
Replacement Replacement
1)engine control computer 1)engine control computer
2)injector ASSY
3)engine
<Procedure 5-a/6> <Procedure 5-b/6>

Press [Open] Press [Input]
Writing Writing
compensation codes compensation codes
<Procedure 6/6>
Writing is complete
Note:
• Due to the defective engine control computer or wire harness, or poor connection of the diagnostic
connector, a writing abnormally may occur. Inspect and check the connection of the wire harness or the
diagnostic connector. When they are normal, the engine control computer may be defective.
• In case of replacement ECU, need to write the compensation codes of each cylinder. Use saved codes or
input manually.
If using saved data, confirm the saved compensation code and cylinder number, and compensation
code of the top of the injector ASSY are right.
Program can save one latest data of each cylinder.
• In case of replacement ECU, injector ASSY, or engine, need to write the compensation codes of each
cylinder. Input the compensation codes manually.
Confirm the cylinder number and compensation code of the top of the injector ASSY are right.
1-24
Note:
If you use the directly read the compensation code, read the
code (30-digit alphanumerical characters) punched on the
Code head of the injector ASSY.
Injector ASSY

Caution:
(2) Select [Supplt Pump Initialization], then press [Select].
(3) <Procedure 1/6>
Select [Injector Compensation], then press [Select].
(4) <Procedure 2/6>

Press [Next] to proceed, read <NOTICE> message, then press [Next].
\
1-25
(5) <Procedure 3/6>

Select a function [Set Compensation Code], then press
[Next].
(6) <Procedure 4/6>

Select a Cylinder number from No.1 to 4, then press
[Next].
Use a saved compensation code: go to (8)
Input a manual compensation code: go to (9)
(7) <Procedure 5-a/6>

Use a saved compensation code, press [Open]  Confirm [Cylinder Number] and [Saved Date], then press
[Open]  press [Next] to write the saved data.
Caution:
Confirm the saved compensation code, cylinder number, and compensation code of the top of the injector
ASSY are right.
Program can save one latest data of each cylinder.
If the compensation code writing error occurs, write again.
 go to (9)
1-26
(8) <Procedure 5-b/6>

Input a manual compensation code, press [Input]  Using a key to input the code, then press [OK]  press
[Next] to write the data.
Caution:
Confirm the cylinder number, compensation code of the top of the injector ASSY, input compensation code
are right.
If the compensation code writing error occurs, write again.
If the inputted code is incorrect, 'Error Injector Compensation' occurs, input compensation code correctly.
 go to (9)
(9) <Procedure 6/6>

Injector compensation writing is complete.
Press [Next] to continue writing code of the other cylinder,
press [Cancel] to exit this function.
(10) After completing writing, delete the diagnosis code.
1-27
5. Fuel System inspection

Perform this procedure, to air bleeding after fuel system parts replacement, or to check fuel system malfunction.

Select [Fuel System Check]
<Procedure 2/8>
Start the engine
<Procedure 3/8>
Warm up the engine
<Procedure 4/8>
Rise the engine revolution over 1400rpm
Checking the Fuel System
<Procedure 5/8>
Check completed
<Procedure 6/8>
Save data (in case of fuel system malfunction check)
<Procedure 7/8>
Repeat 5 times the procedure
Fuel system parts replacement Fuel system malfunction check
<Procedure 8-a/8> <Procedure 8-b/8>

Keep Idling Data analysis
Note:
• Engine revolution rises, confirm the vehicle not moving.
• Operate acceleration pedal according to the 'Engine Diagnostic Program' screen.
1-28

According to the instruction of 'Engine Diagnostic
(2) <Procedure 1/8>
Select [Fuel System Check], then press [Select]
Until the water temperature becomes 70degC (158degF) or higher, can not proceed.
(3) <Procedure 2/8>

Read the message, and start the engine, keep idling, then
press [Next]
(4) <Procedure 3/8>

Warm up the engine.
The water temperature (engine coolant temperature) is
70 °C (158 °F) or higher, then press [Next].
Note:
Until the water temperature becomes 70 °C (158 °F) or higher,
can not proceed.
1-29
(5) <Procedure 4/8>

Open the acceleration pedal, rise the engine revolution
over 1400rpm, then press [Next].
Fuel system check starts automatically, needs 15sec,
check is completed.
Caution:
Open the acceleration pedal until the check is completed.
Note:
Fuel system check can proceed under the condition that the
engine revolution is over 1400rpm.
If the condition is not satisfied, the check stops.
The engine revolution automatically keep 1400rpm while the
check is proceeding.
The combustion noise becomes louder while the check is
proceeding, this phenomena is not malfunction.
(6) <Procedure 5/8>

Fuel System Check is completed, close the acceleration
pedal, press [Exit].
(7) <Procedure 6/8>

In case of fuel system malfunction check, press [Save].
Input the file name if necessary.
(8) <Procedure 7/8>
Repeat 5 times from <Procedure 1/8>.
Fuel system parts replacement: go to (9)
Fuel system malfunction check: go to (10)
(9) <Procedure 8-a/8>
Keep idling over 3min.
(10) <Procedure 8-b/8>
At <Procedure 1/8> screen, press [Proj info].
Select the saved data in 'Fuel System Check' folder, in
Individual data list window.
Display and confirm the graph from saved data.
1-30
CIRCUIT DIAGRAM
GLOW
IGSW
ECU-IG
GREL
STA
Neutral
GLOW
start relay
ST
T/C shift switch
Ignition Glow plug

switch
Parking brake
switch
AM1
VNM+
VNM-
STA
Turbo
charger
ST
VNVC S/A
VNA
VNE2
Starter
EFI2
BATT
MAIN
EFI
VCPA
VPA
Battery EPA Accelerator
position
VCP2 sensor
+B2
VPA2
EPA2
+B
EDU
MREL
MAIN
A B
1-31
A B
IREL VCS1
PCR1
EDU
E2S1
IJ1+ +B Fuel pressure sensor

Injector ASSY (No.1)
IJ1-
#10 #1 PCV+
IJ2+ PCV-
#20 #2 Suction control
IJ2- valve ASSY
IJ3+ #30 #3 EGM+

IJ3- EGM-
#40 #4
IJ4+
VCEG
INJF INJ1
IJ4-
EGRA
GND
EEGL
Injector driver
Electric EGR
control valve
NE+
VG
NE-
E2G
THA
ETHA Crank position

sensor No.2
G+
G-
P
Crank position sensor
Fuel filter pool switch

1-32
THIA
THF
ETHF ETHI
Inlet air temperature sensor
Fuel temperature sensor
ALT THW
Alternator
ETHW
FPSW W
Fuel filter clogging switch GIND
THWO
W3
Combination meter ASSY

VCPM
PIM
EPIM
Diesel turbo
pressure sensor
TC TC
OBD
CANH
CANL E
CAN+
Diagnostic
CAN- connector
SAS/OPS controller
E1
E01
EC E02
ME01
Atmospheric
pressure sensor
1-33
ECU TERMINAL LAYOUT
A B
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 19 18 17 16 15 14 13 12
46 45 44 43 42 41 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 30 29 28 27 26 25 24 23 22 21 20
86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 41 40 39 38 37 36 35 34 33 32 31
103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 49 48 47 46 45 44 43 42
109 108 107 106 105 104 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 60 59 58 57 56 55 54 53 52 51 50
CAN+
E01 E02 VNM- VNM+ PCV+ CAN- FPSW GREL ALT P INJ1 #1 #2 #3 #4
EGM+ EGM- ME01 PCV- G+ G- VCEG EPIM VCS1 E2S1 PCR1 VG E2G
NE+ NE- VNE2 VNVC VCPM EEGL ETHI ETHF ETHW ETHA
E1 PIM VNA EGRA THIA THF THW THA
W3 CANH CANL BATT +B

W
GIND TC IGSW +B2
THWO EC
MREL IREL STA
EPA2 VCP2 EPA VCPA VPA2 VPA
Reference
Terminal number Input
Measurement condition Reference value
[Terminal symbol] Output
Accelerator fully closed 0.5 to 1.1 V
B53 - B56 [VPA - EPA] Input
Accelerator fully opened 2.6 to 4.5 V
Accelerator fully closed 1.2 to 2.0 V
B54 - B58 [VPA2 - EPA2] Input
Accelerator fully opened 3.4 to 5.0 V
B43 - A109 [STA - E1] Input During cranking 6 V or more
B32 [EC] - Engine ground Ground Always Less than 1 Ω
When the engine check indicator turns
0 to 3 V
on (Ignition key switch ON)
B12 - A109 [W - E1] Output During idling
(When the engine check indicator does 11 to 14 V
not turn on)
1-34

B2 - A109 [BATT - E1] Input Always 11 to 14 V
Engine stop
B1 - A109 [+B - E1] Input 11 to 14 V
Ignition key switch ON
Engine stop
B20 - A109 [+B2 - E1] Input 11 to 14 V
Engine stop
B55 - B56 [VCPA - EPA] Output 4.5 to 5.5 V
Engine stop
B57 - B58 [VCP2 - EPA2] Output 4.5 to 5.5 V
Engine stop
11 to 14 V
B45 - A109 [MREL - E1] Output Engine stop
10 seconds or more elapsed after igni- 0 to 1.5 V
tion key switch turns off
B44 - A109 [IREL - E1] Output During idling 0 to 1.5 V
Pulse generation
B38 - A109 [THWO - E1] Output During idling
(Waveform 1)
Ignition key switch ON, While the glow
0 to 3 V
B30 - A109 [GIND - E1] Output indicator turns on
After warm-up, during idling 11 to 14 V
Ignition key switch ON 11 to 14 V
B26 - A109 [TC - E1] Input Short-circuit between the terminals TC
0 to 1.5 V
and E of the diagnostic connector
Engine stop
B25 - A109 [IGSW - E1] Input 11 to 14 V
Input and Engine stop Pulse generation
B7 - A109 [CANH - E1]
output Ignition key switch ON (Waveform 2)
B6 - A109 [CANL - E1]
Intake temperature 0 to 80 °C
A113 - A90 [THIA - ETHI] Input 0.5 to 3.4 V
(32 to 176 °F) (during warm-up)
Ignition key switch ON (when cool) 0.5 to 3.4 V
A112 - A89 [THF - ETHF] Input
Fuel temperature 20 °C (68 °F) 2.0 to 2.7 V
Cooling water temperature 60 to 120 °C
A111 - A88 [THW - ETHW] Input 0.2 to 1.0 V
A110 - A87 [THA - ETHA] Input 0.5 to 3.4 V
A67 [E2S1] - Engine ground Ground Always Less than 1 Ω
Engine stop
A68 - A67 [VCS1 - E2S1] Output 4.5 to 5.5 V
A66 - A67 [PCR1 - E2S1] Input After warm-up, during idling 1.7 to 2.2 V
A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse generation
A64 [E2G] - Engine ground Ground Always Less than 1 Ω
Pulse generation
A51 - A109 [INJ1 - E1] Input After warm-up, during racing
(Waveform 4)
Pulse generation
A50 - A109 [#1 - E1] Output After warm-up, during idling
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
1-35
Engine stop
B1 - A109 [+B - E1] Input 11 to 14 V
Engine stop
B20 - A109 [+B2 - E1] Input 11 to 14 V
Engine stop
Engine stop
Engine stop
11 to 14 V
10 seconds or more elapsed after 0 to 1.5 V
ignition key switch turns off
Pulse Generation
(Waveform 1)
0 to 3 V
0 to 1.5 V
Engine stop
B7 - A109 [CANH - E1]
B6 - A109 [CANL - E1]
(32 to 176 °F)
Cooling water temperature 60 to 120 °C 0.2 to 1.0 V
A111 - A88 [THW - ETHW] Input
(140 to 248 °F)
Intake temperature 0 to 80 °C 0.5 to 3.4 V
A110 - A87 [THA - ETHA] Input
(32 to 176 °F)
Engine stop
A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse Generation
Pulse Generation
(Waveform 4)
Pulse Generation
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
1-36
1. Oscilloscope waveform
(1) Waveform 1
Item Description
Measurement
THWO - E1
A A terminals
Gauge set 5 V/DIV, 100 ms/DIV
GND Conditions During idling
Note:
Depending on cooling water temperature, A changes.
Water temperature A
30 °C (86 °F) 16 ms
90 °C (194 °F) 278.5 ms
120 °C (248 °F) or
385 ms
more
(2) Waveform 2
Item Description
Measurement CANH - E1
terminals CAN+ - E1
Engine stop
GND Conditions
(3) Waveform 3
Item Description
Measurement CANL - E1
terminals CAN- - E1
Engine stop
Conditions
GND Ignition key switch ON
(4) Waveform 4
Item Description
Measurement
CH1: INJ1 - E1
terminals
Conditions After warm-up, during racing
GND Note:
As the engine speed increases, the waveform cycle gets
shorter.
1-37
(5) Waveform 5
Item Description
CH1 CH1: #1 - E1
GND Measurement CH2: #2 - E1
CH3 terminals CH3: #3 - E1
GND CH4: #4 - E1
CH4
GND
CH2 Conditions After warm-up, during idling
GND
Note:
As the engine speed increases, the waveform cycle gets
shorter.
(6) Waveform 6
Item Description
Measurement
ALT - E1
terminals
Conditions During idling
GND
(7) Waveform 7
Item Description
Measurement CH1: NE+ - NE-
CH1 GND terminals CH2: G+ - G-
Conditions After warm-up, during idling
CH2 GND Note:
• As the engine speed increases, each amplitude becomes
larger.
• As the engine speed increases, the waveform cycle gets
shorter.
(8) Waveform 8
Item Description
Measurement CH1: PCV+ - E1
terminals CH2: PCV- - E1
CH1: 10 V/DIV, 5 ms/DIV
Gauge set
CH1 CH2: 500 mv/DIV, 5 ms/DIV
GND
CH2
GND
1-38
(9) Waveform 9
Item Description
Measurement
VNM+ - E1
terminals
Note:
The waveform depends on operations of the turbo charger S/
A.
(10) Waveform 10
Item Description
Measurement
VNM- - E1
terminals
Note:
The waveform depends on operations of the turbo charger S/
A.
1-39
ECU DATA MONITOR/ACTIVE TEST

1. List of ECU data monitor
(1) With SST, according to the instruction of the screen, display [Data monitor] to inspect computer data.
Note:
• To check the standard, unless otherwise specified, completely warm up the engine, disable all of outside
loads, select the N range, and power off each accessory.
• Results of the inspection in the actual machine are reference values, so actual values may be different
depending on regions or weather.
SST 09111-36760-71(09991-70201)
Description/
Item name Reference Remarks
Display range
• It displays a value output from the crank position
• 50 to 400 r/min:
• Indicates engine sensor No.2.
During cranking
speed. • If the crank position sensor No.2 does not oper-
Engine Speed • 700 to 800 r/min:
• Display range: ate properly, the engine speed becomes about 0
After engine warm-
0 to 6000 r/min r/min or is remarkably different from the actual
up, during idling
engine speed.
13 to 25%: • It displays a value calculated by the engine con-
• Indicates engine
After engine warm-up, trol computer.
Calculate load.
during idling (Disable • Engine load value =
Load • Display range:
all of outside loads, N (Actual fuel injection amount/Maximum fuel injec-
0 to 100%
range) tion amount in the current engine speed) x 100
• It displays a value output from the intake air flow
• 16 to 24 g/sec (2.12
meter S/A.
to 3.17 lb/min):
• Based on intake air quantity, the engine control
After engine warm-
computer controls fuel injection amount, injection
up, during idling
timing, EGR, and others.
• Indicates intake air • 40 to 65 g/sec (5.29
• When intake air quantity is always about 0 g/sec
quantity. to 8.60 lb/min):
(0 lb/min):
MAF • Display range: For engine speed
- The power circuit of the intake air flow meter S/
0 to 655.35 g/sec NMR (No Load Max-
A is disconnected.
(0 to 86.69 lb/min) imum Revolution)
- The VG circuit is disconnected or short-cir-
Note:
cuited.
It changes depend-
- The EVG circuit is disconnected.
ing on the amount of
Symptoms when outside the reference:
EGR.
Rough idling
• With ignition key switch turned on, when a differ-
ence between a value of the atmospheric pres-
sure sensor and that of the intake manifold
pressure sensor is 10 kPa or more, either sensor
has an abnormality.
• With ignition key switch turned on, when atmo-
• Atmospheric pres-
spheric pressure is 0 kPa or 140 kPa, the sensor
Atmosphere sure value. Actual atmospheric
circuit is abnormal.
Pressure • Display range: pressure
• Standard atmospheric pressure: 101 kPa
0 to 250 kPa
• Atmospheric pressure decreases by 1 kPa with
each lifting of 100 m (328 ft). This changes
depending on weather (high or low atmospheric
pressure).
• The atmospheric pressure sensor is contained in
the engine control computer.
1-40
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display [Data monitor] to
inspect computer data.
NOTICE:
• To check the reference, unless otherwise specified, completely warm up the engine, disable all of outside
SST: 09240-36770-71
Description/
Item Name Reference Remarks
Display Range
Engine • Indicates engine speed • 50 to 400 rpm: During • It displays a value output from the
Speed • Display range: cranking crank position sensor No. 2.
0 to 6000 rpm • Refer to repair manual of • If the crank position sensor No. 2 does
the vehicle: After engine not operate properly, the engine
warm-up, during idling speed becomes about 0 rpm or is
remarkably different from the actual
engine speed.
Calculate • Indicates engine load. 10 to 30%: • It displays a value calculated by the
Load • Display range: After engine warm-up, during engine control computer.
0 to 100% idling (disable all of outside • Engine load value =
loads, N range) (Actual fuel injection
amount/Maximum fuel injection
amount in the current engine speed) x
100
MAF • Indicates intake air • 6 to 25 g/sec (0.79 to 3.17 • It displays a value output from the
quantity. lb/min): After engine warm- intake air flow meter S/A.
• Display range: 0 to up, during idling • Based on intake air quantity, the
655.35 g/sec (0 to • 30 to 80 g/sec (3.96 to 10.6 engine control computer controls fuel
86.69 lb/min) lb/min): For engine speed injection amount, injection timing,
NMR EGR, and others.
• When intake air quantity is always
NOTE: about 0 g/sec (0 lb/min):
It changes depending on -The power circuit of the intake air
the amount of EGR. flow meter S/A is disconnected.
-The VG circuit is disconnected or
short-circuited.
-The EVG circuit is disconnected.
-Rough Idling
Atmosphere • Atmospheric pressure Actual atmospheric pressure • With ignition key switch turned on,
Pressure value. when a difference between a value of
• Display range: 0 to 255 the atmospheric pressure sensor and
kPa that of the intake manifold pressure
sensor is 10kPa or more, either
sensor has an abnormality.
• With ignition key switch turned on,
when atmospheric pressure is 0kPa or
140 kPa, the sensor circuit is
abnormal.
• Standard atmospheric pressure: 101
kPa
• Atmospheric pressure decreases by 1
kPa with each lifting of 100 m (328 ft).
This changes depending on weather
(high or low atmospheric pressure).
• The atmospheric pressure sensor is
contained in the engine control
computer.
1-41
Description/
Display range
MAP • Indicates absolute • 90 to 110 kPa • With ignition key switch turned on or during idling,
pressure of the (depending on intake manifold pressure and atmospheric
internal intake atmospheric pressure are almost the same (standard
manifold. pressure): During atmospheric pressure = 101 kPa).
• Display range: idling • With the accelerator fully opened, when intake
0 to 255 kPa • 115 to 160 kPa: For manifold pressure is 20 kPa lower than target
engine speed NMR supercharging pressure for five seconds or more,
you may feel insufficient output.
• It displays a value output from the diesel turbo
pressure sensor.
Insufficient output
Coolant Temp • Indicates engine 70 to 90 °C • When engine cooling water temperature is -40 °C
cooling water tem- (158 to 194 °F): (-40 °F) or 140 °C (284 °F), the sensor circuit is
perature. After engine disconnected or short-circuited.
• Display range: warm-up • After it is left for a long time, engine cooling water
-40 to 140 °C temperature, intake air temperature, and ambient
(-40 to 284 °F) temperature become almost the same.
• It displays a value output from the water temper-
ature sensor.
Symptoms when outside the reference: Difficulty in
starting the engine when cool, rough idling, black
smoke, insufficient output
Intake Air • Indicates intake air A value equal to tem- • After it is left for a long time, engine cooling water
temperature. perature in the posi- temperature, intake air temperature, and ambient
• Display range: tion where the intake temperature become almost the same.
-40 to 140 °C air flow meter S/A is • When intake air temperature is -40 °C
(-40 to 284 °F) mounted (-40 °F) or 140 °C (284 °F), the sensor circuit is
disconnected or short-circuited.
• It displays a value output from the inlet air tem-
perature sensor contained in the intake air flow
meter S/A.
Engine Run • Indicates rotating Rotating time after the • Indicates elapsed time after the engine starts.
Time time after the engine starts
engine starts.
• Display range:
0 to 65535 sec
Starter Signal • Indicates starter ON: During cranking Ignition switch (STA) output:
signals. • ON: Indicates that the engine is cranking.
• Display range: ON/ • OFF: Indicates that the engine is not cranking
OFF Although STA is turned off, the starter continues to
operate.
The STA signal abnormality (P0617) is stored.
Injection • Indicates fuel injec- 5 to 15 mm3/st: • It displays fuel injection amount for each combus-
Volume tion amount. During idling (Disable tion.
• Display range: all of outside loads, N • For the injector ASSY clogging, low fuel quality,
0 to 1279.98 mm 3/ range) fuel filter element clogging, or increased engine
st friction, fuel injection amount will increase.
• For abnormalities such as low intake manifold
pressure or a small quantity of intake air, fuel
injection amount is limited, which causes insuffi-
cient output.
• It displays a value calculated by the engine con-
trol computer.
1-42
Item Name Description/Display Reference Remarks

Range
Pilot 1  Indicates pilot 1 200 to 300 µs: During idling  For symptoms such as knocking, poor
Injection injection period. (water temperature is less drivability, or white smoke, check pilot 1
Period  Display range: 0 than 60 °C (140 °F), disable injection period. (with or without pilot injection)
to 65535 µs all of outside loads, N range)  It displays a value calculated by the engine
control computer
knocking, poor drivability, white smoke
Injection injection period. (complete warm-up, disable drivability, or white smoke, check pilot 2
Period  Display Range: 0 all of outside loads, N range) injection period. (with or without pilot injection)
to 65535 µs  It displays a value calculated by the engine
control computer.
Main  Indicates main 300 to 600 µs: During idling  When fuel pressure becomes 15000 kPa or
Injection injection period. (complete warm-up, disable less, main injection period becomes 0 µs.
Period  Display range: 0 all of outside loads, N range)  For engine hard starting, check main injection
to 65535 µs period. (with or without injection)
 When P0093, P0627 or P062D is output, the
engine stop request is output. In this case,
main injection period becomes 0 µs.
NOTICE:
After the engine check indicator turns on, in
about one minute the engine stops.
Therefore, inspection cannot be performed
with freeze frame data.
 It displays a value calculated by the engine
control computer
After  Indicates after 0 to 400 µs: During idling  For symptoms such as black smoke and poor
Injection injection period. (complete warm-up, disable drivability, check after injection period. (with or
Period  Display range: 0 all of outside loads, N range) without after injection)
control computer.
Pilot 1  Indicates pilot 1 -14 to -5 °CA: Water  It displays a value calculated by the engine
Injection injection timing. temperature is less than 60 °C control computer.
Timing  Display range: -70 (140 °F), during idling, and the
to 20 °CA machine is in the range of
usual atmospheric pressure
Pilot 2  Indicates pilot 2 -10 to -2 °CA: After engine  It displays a value calculated by the engine
Injection injection timing. warm-up, during idling, and control computer.
Timing  Display range: -50 the machine is in the range of
to 20 °CA usual atmospheric pressure.
Main  Indicates main -3 to 1 °CA: After engine  For symptoms such as poor drivability, black
Injection injection timing. warm-up, during idling, and smoke, or white smoke, check main injection
Timing  Display range: -90 the machine is in the range of timing.
to 90 °CA usual atmospheric pressure.  It displays a value calculated by the engine
control computer.
After  Indicates after  It displays a value calculated by the engine
Injection injection timing. control computer.
Timing  Display range: -10
to 50 °CA
1-43
1-44
Item Name Description/ Reference Remarks
Display Range
Fuel Press  Indicates fuel 30000 to 50000kPa:  Fuel pressure means the actual common rail fuel
pressure during idling pressure.
 Display Range: (complete warm-up,  Inspect fuel pressure, comparing to common rail
0 to 655350 kpa disable all of outside target fuel pressure.
loads, N range)  In the stable condition (during idling after warm-
up) fuel pressure is within 5000 kPa of target
value.
 The engine control computer uses fuel pressure
to perform feedback control of common rail target
fuel pressure.
 Fuel injection amount is determined based on
injection timing and fuel pressure. Injection
patterns are also selected based on fuel pressure.
 Starting the engine requires a minimum of 25000
kPa fuel pressure. (note that when fuel pressure
is about to reach its target, a delay is introduced
even in the normal state)
 When fuel pressure is lower than 25000 kPa,
rough idling may occur.
 When fuel pressure decreases from common rail
target fuel pressure by 20000 kPa, output may be
insufficient.
 When the actual fuel pressure is 40000 kPa
higher than common rail target fuel pressure,
P1229 is output.
 When fuel pressure is lower than a target value,
insufficient output will occur without DTC output.
 When fuel pressure is higher than 250000 kPa,
DTC P0088 is output.
 It displays a value output from the fuel pressure
sensor (common rail assy)
Symptoms when outside the reference: Difficulty
starting the engine, poor drivability, insufficient
output, knocking.
Fuel  Indicates fuel Actual fuel temperature  When the engine is completely cooled, fuel
Temperature temperature temperature is equal to ambient temperature.
 Display range: -  It displays a value output from the fuel
40 to 215°C (-40 temperature sensor.
to 419°F)
Target Pump  Indicates a 1600 to 2000 mA:  It displays a calculated value by the engine
SCV Current target value of during idling (complete control computer for target current for driving the
final pump warm-up, disable all suction control valve assy and controls a target
current. outside loads, N range) value of solenoid current.
 Display range: 0  When high fuel pressure is required, a target
to 8192 mA value of solenoid current is higher.
 Typically, a target value of solenoid current is in
the range of 800 to 2500 mA.
 When the target value remains a 3000mA or
more, it indicates that the pump is defective.
(such as a defect due to deposit)
 If it is not in the standard, even when the pump
operates actively, the actual fuel pressure does
not match common rail fuel pressure.
starting the engine, insufficient output, or rough
idling.
1-45
Description/
Display range
• EGR valve fully opened: 100%
• EGR valve fully closed: 0%
• Inspect it comparing to the actual EGR opening
degree #1.
• EGR target opening degree displays a calculated
value by the engine control computer based on
0 to 90%:
sensor output values (such as the intake air flow
Indicates EGR valve After engine warm-up,
meter S/A, inlet air temperature sensor (con-
target opening during idling (com-
Target EGR tained in the intake air flow meter S/A), diesel
degree. plete warm-up, dis-
Pos. turbo pressure sensor).
Display range: able all of outside
0 to 100% loads,
• When EGR target opening degree is not in the
N range)
standard and near 0%, the intake air flow meter
S/A may be abnormal, or an intake or exhaust
system may get clogged.
• When EGR target opening degree is not in the
standard and near 100%, the EGR pipe may get
clogged.
• EGR valve fully opened: 100%
• EGR valve fully closed: 0%
• It is effective to judge if the EGR valve is stuck.
• Inspect it comparing to EGR target opening
degree.
• In the active test, check operations of the EGR
0 to 90%: valve.
• Indicates EGR After engine • When the EGR valve becomes abnormal around
valve actual open- warm-up, during idling a certain temperature, refer to engine cooling
Actual EGR
ing degree. (complete warm-up, water temperature and outside temperature
Valve Pos.
• Display range: disable all of outside which are reference in case of an abnormality.
0 to 100% loads, • The valve position displays a calculated value
N range) output from the EGR valve position sensor.
• EGR valve stuck open: Hard starting (no engine
stalling), black smoke, white smoke, insufficient
output
• EGR valve stuck close: Increase of turbo super-
charging sound
• An EGR fully-closed position learned value is
output voltage from the EGR valve position sen-
sor.
• When the EGR fully-closed position learned
• Indicates an EGR
value becomes the upper or lower limit of the nor-
fully-closed posi-
EGR Close mal range, foreign matter may be involved in the
tion learned value. 0 to 1 V
Lrn. Val. EGR valve.
• Display range:
• The lower limit of the EGR fully-closed position
0 to 5.00 V
learned value is 0 V, and the upper 1 V. When
this value is fixed to either limit, the valve position
sensor may be abnormal, or the valve position
may be misplaced (with foreign matter).
1-46
Description/
Display range
• Completed: It means that fully-closed position
learning is normally completed.
• Not completed: It means that the learned fully-
closed position may not in the correct range.
• Indicates a state of
• When it is not completed, foreign matter may be
EGR fully-closed
involved in the EGR valve.
EGR Close position learning.
Completed Note:
Lrn. Status • Display range:
After the battery cable is disconnected and
Completed/Not
then connected, when the ignition key switch is
completed
never turned off, learning may not be com-
pleted.
Results of inspection in the actual machine:
Ignition key switch ON: Completed
• Indicates that oper- OK:
• OK: In the active test, EGR target opening
EGR ations of EGR are In the active test, EGR
degree bank 1 can be performed.
Operation prohibited. target opening degree
• NG: In the active test, EGR target opening
Prohibit • Display range: OK/ bank 1 can be per-
degree bank 1 cannot be performed.
NG formed.
• Inspect it comparing to intake manifold pressure.
• Indicates target • With the accelerator fully opened, when intake
pressure of super- manifold pressure is 20 kPa lower than target
Target Booster
charging pressure. - supercharging pressure for five seconds or more,
Pressure
• Display range: you may feel insufficient output.
0 to 639.98 kPa • It displays a value calculated by the engine con-
trol computer.
• Indicates super-
Boost charging pressure
It displays a difference between target supercharg-
Pressure deviation. -
ing pressure and intake manifold pressure.
Deviation • Display range:
-320 to 320 kPa
• VN turbo target opening degree is a command of
the engine control computer.
• 0%: The nozzle vane is fully opened.
• Indicates VN turbo
(The actuation rod is contracted)
motor target open-
VN Turbo • 90% or more: The nozzle vane is fully closed(The
ing degree. 0 to 100%
Command actuation rod is extended)
• Display range:
• When VN turbo target opening degree is large,
0 to 100%
the turbo operates effectively.
• The command of the engine control computer
controls nozzle vane opening degree.
• When movement of the nozzle vane becomes
• Indicates actual slow and it is stuck, a difference between this
VNT opening opening degree and VN turbo target opening
Actual VN
degree. 0 to 100% degree is larger, and VN turbo output (duty) also
Position
• Display range: becomes large.
0 to 127.5% • VNT actual opening degree is controlled to suit
VN turbo target opening degree.
• Indicates VNT
opening sensor 1 to 3 V:
VN Position It displays a value output from the nozzle vane
output voltage. After engine
Sensor Out opening degree sensor.
• Display range: warm-up, during idling
0 to 4.99 V
• Indicates the VNT
motor drive duty When movement of the nozzle vane becomes
VN Motor Duty ratio. 2 to 88% slow, output (duty) increases to the direction of
• Display range: 100%.
0 to 127.5%
1-47
Description/
Display range
• Indicates a VNT
fully-closed learn-
VN Close
ing voltage value. 1.0 to 2.0 V -
Learn Value
• Display range:
0 to 4.99 V
• Indicates a VNT
fully-closed posi-
When VN Close Learning is not completed, the
VN Close tion learning his-
ON performance of the machine may decrease. (low
Learn Status tory.
engine output)
• Display range: ON/
OFF
• Indicates that the Allowed:
VN Turbo VN turbo active test VN turbo opening When it is prohibited, the engine control computer
Operation is prohibited. degree can be per- does not allow performing the active test for VN
Prohibit • Display range: formed in the active turbo opening degree.
Allowed/Prohibited test.
cooling water tem- • With freeze frame data, you can determine if an
perature at start- Engine cooling water abnormality occurred at start-up when cool, or
Initial Engine
up. temperature at start- after the engine warm-up.
Coolant Temp
• Display range: up • It displays a value output from the water temper-
-40 to 120 °C ature sensor at engine start-up.
(-40 to 248 °F)
• Indicates initial
intake air tempera-
It displays a value output from the intake air flow
Initial Intake ture. Intake air tempera-
meter S/A (intake temperature sensor) at engine
Air Temp • Display range: ture at engine start-up
start-up.
-40 to 120 °C
(-40 to 248 °F)
Engine Start start time.
- It displays the time required by engine start-up.
Time • Display range:
0 to 267386 ms
speed when the
Engine Speed It displays engine speed immediately after the
starter is turned off. -
(Starter Off) engine starts.
• Display range:
0 to 1593 rpm
• Indicates how
many times the
starter has been It displays how many times the starter has been
Starter Count -
turned on. turned on since ignition key switch was turned on.
• Display range:
0 to 255
• Indicates an electri-
Electric Duty cal load feedback
After electrical load is turned off and then on, ISC
Feedback value. 0 to 5 mm3/st
• Display range: electrical load correction amount increases.
Value
0 to 39.8 mm3/st
1-48
Description/
Display range
• Indicates intake air temperature of the intake
manifold (after the inter cooler ASSY is passed).
• Indicates intake air
• Intake air temperature after turbo charging is set
temperature after
to 170 °C (338 °F) while the fail safe function is
the inter cooler is
Intake Air During idling operating.
passed.
Temp (Turbo) 70 °C (158 °F) or less • When intake air temperature after turbo charging
• Display range:
becomes high, turbo supercharging pressure is
-40 to 190 °C (-40
suppressed, which may cause insufficient output.
to 374 °F)
perature sensor.
• Indicates the check
mode state. Check mode state: Check mode: A particular DTC can be easily
Check Mode
• Display range: Check detected at a high sensitivity.
Check/Normal
When it is 11 V or less, characteristics of electronic
• Indicates battery
parts will be changed.
Battery voltage. 11 to 14 V:
Voltage • Display range: Ignition key switch ON
When it is 5 V or less, it is difficult to start the
0 to 15 V
engine.
• It is used to output alternator power generation
duty and to decide electrical load.
• When injection amount during idling is larger than
normal, it is used to determine if there are electri-
cal load or other causes.
• In the state where Alternate Duty Ratio is not
high (low electrical load), when idling injection
• Indicates the alter-
amount is large, injection amount of the injector
nator power gener-
Alternate Duty ASSY may decrease, or engine friction may be
ation duty ratio. -
Ratio large.
• Display range:
• It is used to judge a power generation request
0 to 100%
state due to an abnormal electrical system.
• Whether or not accessories (such as A/C or the
heater) operate, when Alternate Duty Ratio is
always the maximum value, an abnormality
occurs in the electrical system (such as battery
deterioration).
• It displays a duty value from the ALT terminal.
• It is output only when the engine speed is mea-
sured for each cylinder in the active test.
• Indicates engine speed for each cylinder during
cranking.
Example:
- When compression of the No.1 cylinder is low,
Engine Speed Engine Speed of Cyl #1 is about 300 rpm, Engine
of Cyl #1 Speed of Cyl #2, #3, and #4 is about 200 rpm.
Engine Speed • Indicates cylinder The engine speed of - When compression of the No.2 cylinder is low,
of Cyl #2 engine speed. all cylinders are Engine Speed of Cyl #2 is about 300 rpm, Engine
Engine Speed • Display range: almost the same: Speed of Cyl #1, #3, and #4 is about 200 rpm.
of Cyl #3 0 to 51199 rpm Normal - When compression of the No.3 cylinder is low,
Engine Speed Engine Speed of Cyl #3 is about 300 rpm, Engine
of Cyl #4 Speed of Cyl #1, #2, and #4 is about 200 rpm.
- When compression of the No.4 cylinder is low,
Engine Speed of Cyl #4 is about 300 rpm, Engine
Speed of Cyl #1, #2, and #3 is about 200 rpm.
When the engine speed of all cylinders is not the
same, idling is not stable.
1-49
Description/
Display range
• Indicates the aver-
• It is output only when the engine speed is mea-
Av Engine age engine speed
sured for each cylinder in the active test.
Speed of All of all cylinders. -
• Indicates the average engine speed of all cylin-
Cyl • Display range:
ders during cranking.
0 to 51199 rpm
• Indicates elapsed
time after DTC is
Time after Time after DTC is It displays elapsed time after DTC is deleted (or
deleted.
DTC Cleared deleted shipped from the factory).
• Display range:
0 to 65535 min
• It displays engine warm-up count after DTC is
• Indicates warm-up
deleted.
Warm-up count after DTC is
• (Warm-up Cycle Cleared DTC of data list is
Cycle Cleared deleted. -
deleted) - (Warm-up Cycle Cleared DTC of
DTC • Display range:
freeze frame data is deleted) = Warm-up count
0 to 255
after an abnormality occurs
• Indicates the con-
nection condition
When the TE1/TC terminals are turned on in the
between TC and
active test, the system operates as if the TC termi-
TC and TE1 TE1 in the active -
nal and E terminal of the diagnostic connector are
test.
connected.
OFF
• Indicates the Isoch-
Isochronous ronous Control Tar- 700 to 800 r/min:
It displays a value calculated by the engine control
Control Target get Speed. After engine warm-up,
computer.
Speed • Display range: during idling
0 to 12800 r/min
Isochronous ronous Control
Control Proportional Term. It displays a value calculated by the engine control
-
Proportional • Display range: computer.
Term
-50 to 120 mm3/st
ronous Control
Isochronous Integral Term. It displays a value calculated by the engine control
Control • Display range: -
computer.
Integral Term
-80 to 79.997 mm3/
st
• Indicates the Total
Total Operation Hours.
It displays a value calculated by the engine control
Operation • Display range: -
computer.
Hours 0 to 4500000000
sec
Number of Rota-
Total Number tions. It displays a value calculated by the engine control
-
of Rotations • Display range: computer.
0 to 4290000000
Rotations
Injection Volume.
Total Injection It displays a value calculated by the engine control
• Display range: -
Volume computer.
0 to 33554432 L
(0 to 8864147 gal)
1-50
Description/
Display range
Av Engine • Indicates the aver- - • It is output only when the engine speed is mea-
Speed of All age engine speed sured for each cylinder in the active test.
Cyl of all cylinders. • Indicates the average engine speed of all cylin-
• Display range: ders during cranking.
0 to 51199 rpm
Time after • Indicates elapsed Time after DTC is • It displays elapsed time after DTC is deleted (or
DTC Cleared time after DTC is deleted shipped from the factory).
deleted.
• Display range:
0 to 65535 min
Warm-up • Indicates warm-up - • It displays engine warm-up count after DTC is
Cycle Cleared count after DTC is deleted.
DTC deleted. • (Warm-up Cycle Cleared DTC of data list is
• Display range: deleted) - (Warm-up Cycle Cleared DTC of
0 to 255 freeze frame data is deleted) = Warm-up count
TC and TE1 • Indicates the con- - • When the TE1/TC terminals are turned on in the
nection condition active test, the system operates as if the TC ter-
between TC and minal and E terminal of the diagnostic connector
TE1 in the active are connected.
test.
OFF
Isochronous • Indicates the Isoch- Refer to repair manual
Control Tar- ronous Control Tar- • It displays a target engine speed with the re-
of the vehicle After quest of vehicle is taken.
get Speed get Speed.
engine warm-up,
• Display range:
0 to 12800 r/min during idling
Isochronous • Indicates the Isoch- - • It displays a value calculated by the engine con-
Control ronous Control trol computer.
Proportional Proportional Term.
Term • Display range:
-50 to 120 mm3/st
Integral Term Integral Term.
• Display range:
-80 to 79.997 mm3/
st
Total • Indicates the Total - • It displays a value calculated by the engine con-
Operation Operation Hours. trol computer.
Hours • Display range:
0 to 4500000000
sec
Total Number • Indicates the Total - • It displays a value calculated by the engine con-
of Rotations Number of Rota- trol computer.
tions.
• Display range:
0 to 4290000000
Rotations
Total Injection • Indicates the Total - • It displays a value calculated by the engine con-
Volume Injection Volume. trol computer.
• Display range:
0 to 33554432 L
(0 to 8864147 gal)
1-51
Description/
Display range
Accel Sensor • Indicates the Accel IG-ON: -
Out No.1 Sensor Out No.1 0.75 to 0.95 V
(Accurate) (Accurate). (Accel pedal: Close)
• Display range:
0 to 5.000 V
• Display range:
0 to 5.000 V
Pre Glow • Indicates the Pre - Pre Glow demand: ON
Glow.
• Display range:
ON/OFF
After Glow • Indicates the After - After Glow demand: ON
Glow.
• Display range:
ON/OFF
Target Idle • Indicates the Tar- • It displays a target value of the engine individual
Engine Speed get Idle Engine • Check "Isochronous Control Target Speed" because it
Speed. is not sometimes match with engine speed, while still
• Display range: installed on the vehicle.
0 to 10000 r/min
Fuel Return • Indicates the Fuel - • It displays a value calculated by the engine con-
Temp Return Temp. trol computer.
• Display range:
-40 to 215 °C
(-40 to 419 °F)
EGR Motor • Indicates the EGR 0 to 100% • It displays a value calculated by the engine con-
Duty #1 Motor Duty #1 trol computer.
• Display range:
0 to 127.5 %
2. Active test
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display the [Active test] screen
to perform the active test.
SST: 09240-36770-71
Item name Description Constraint condition

Control the Select Stop fuel injection of each cylinder #1/ With the machine stopped, during engine
Cylinder Fuel Cut #2/#3/#4 (Injection of multiple cylinders rotating
cannot be stopped.)
Check the Cylinder Stop fuel injection of all cylinders. With the machine stopped, when the crank
Compression Measure engine speed during cranking. position sensor and sensor No.2 are in the
normal state
Control the EGR Step Increase or decrease EGR opening With the machine stopped, Ignition key
Position degree. switch ON (Engine stop)
When the test is started, opening
degree shall be 0. It can be increased or
decreased in the range of 0 to 100% by
1%.
Activate the EGR Valve Forced closed of the EGR valve With the machine stopped, during engine
Close rotating after warm-up
1-52
FAIL SAFE LIST

1. Fail safe list
(1) When the codes listed below are recorded in the engine control computer, the machine enters the fail safe
mode.
Diagnosis code Fail safe operation Condition for canceling the fail safe mode
P0046 Limit the engine output. Ignition switch OFF.
Intake temperature (after turbo charging) is fixed
P007C Restore the normal condition.
to 170 °C (338 °F).
Intake temperature (after turbo charging) is fixed
P007D Restore the normal condition.
to 170 °C (338 °F).
P0107 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition.
P0108 Intake manifold pressure is fixed to 101.3 kPa. Restore the normal condition.
P0112 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition.
P0113 Intake temperature is fixed to 60 °C (140 °F). Restore the normal condition.
Temperature is fixed to 119 °C (246 °F) when the
fuel temperature sensor is abnormal.
When fuel temperature is 15 °C (59 °F) or less:
P0115 Restore the normal condition.
Substitute a value of the fuel temperature sensor.
When fuel temperature is 15 °C (59 °F) or more: It
is fixed to 119 °C (246 °F).
When fuel temperature is 15 °C (59 °F) or more: It
is fixed to 119 °C (246 °F).
P0180 Fuel temperature is fixed to 50 °C (122 °F). Restore the normal condition.
Turn the ignition switch OFF and then ON.
P0201 Limit the engine output.
Alternatively, turn STA ON.
1-53
Diagnosis code Fail safe operation Condition for canceling the fail safe mode
P0299 Limit the engine output. Restore the normal condition.
P042E Limit the engine output. Ignition switch OFF.
P060A Limit the engine output. Restore the normal condition.
P060B Limit the engine output. Restore the normal condition.
When only one cylinder is abnormal, engine out-
put is limited.
P062D Ignition switch OFF.
When two or more cylinders are abnormal, the
engine stalls.
P2226 Atmospheric pressure is fixed to 70 kPa. Restore the normal condition.
U0101 Limit the engine output. Restore the normal condition.
1-54
DTC P0046 Turbocharger Boost Control Circuit Range / Performance
DTC P0047 Turbocharger Boost Control Solenoid Circuit Low
DTC P0048 Turbocharger Boost Control Solenoid Circuit High
Circuit description
The VN turbo charger system consists of the VN turbo charger actuator and the engine control computer. The VN
turbo charger has a variable nozzle vane. When the vane is opened and closed, the area of the turbine inlet will be
changed. This allows adjustment of pressure and speed of exhaust gas entering the turbine. When the vane is
closed, supercharging pressure gets higher. When it is opened, supercharging pressure gets lower.
The VN turbo charger actuator consists of the DC motor and the nozzle opening degree sensor. The nozzle opening
degree sensor detects opening degree of the variable nozzle vane. The DC motor controls the variable nozzle vane.
When the engine control computer opens and closes the variable nozzle vane through the DC motor based on the
traveling state, flow speed of exhaust gas is changed, allowing the control of supercharging pressure.
When detecting a disconnection or short-circuit in the DC motor circuit, the engine control computer stores a
diagnosis code and turns on the engine check indicator.
When the variable nozzle vane is stuck close, engine torque when the throttle is opened will be significantly limited.
When the variable nozzle vane is stuck open, a response becomes slow and torque decreases when the throttle is
opened. However, power reduction during high rotation is smaller than that in the stuck close.
P0046
DTC detection conditions
1. Diagnosis conditions
DTC check pattern 2. Abnormal status Inspection position
3. Abnormal period
4. Others
• Disconnection, short-circuit, and
poor connection of the nozzle
opening degree sensor (turbo
1. Ignition key switch ON
In [Active the VN Turbo Open] of the charger S/A).
2. A current of the DC motor is 2.2 A
activsxe test, keep the open (fully • DC motor (Turbo charger S/A)
or more.
opened) and OFF (fully closed) • Wire harness or connector
3. 5 sec. or longer
states for five seconds or more. • Stuck and slow movement of the
4. 1 trip
nozzle vane
(turbo charger S/A)
• Engine control computer
P0047
3. Abnormal period
4. Others
In [Active the VN Turbo Open] of the 2. A duty ratio of the DC motor is
• DC motor (Turbo charger S/A)
active test, keep the open (fully 80% or more, and a current value
• Wire harness or connector
opened) and OFF (fully closed) is 0.5 A or less.
states for five seconds or more. 3. Three seconds or more
4. 1 trip
1-55
P0048
3. Abnormal period
4. Others
In [Active the VN Turbo Open] 2. DC motor overcurrent • DC motor (Turbo charger S/A)
of the active test, keep the open 3. 25 times or more • Wire harness or connector
(fully opened) and OFF (fully closed) (about 0.4 second or more) • Engine control computer
states for five seconds or more. 4. 1 trip
Note:
• The following symptoms may occur when the nozzle vane is stuck close and then DTC P0046, P0047, and
P0048 are stored.
- Hunting where a recovery operation from power reduction is repeated every a few seconds during high-
load traveling.
• The following symptoms may occur when the nozzle vane is stuck open and then DTC P0046, P0047, and
P0048 are stored.
- Insufficient output
- Rising of the engine torque when the accelerator is depressed becomes slow.
Circuit diagram
2 42
VNM+
1 43
VNM-
Shield cable
U A
DC motor (Turbo charger S/A) Engine control
Computer
Inspection procedure
Caution:
When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID code
according to the Operation Support Procedure List. (See page 1-16 for the procedure.)
Note:
Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when
the defect occurred is recorded in the freeze frame data. This information is useful for troubleshooting.
1 Diagnosis code reading
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON. According to the instruction of
the 'Engine Diagnostic Program' screen, read the diagnosis
code. (See page 1-13 for the procedure.)
Result
Result Go to
P0046, P0047, or P0048 is output. A
P0046, P0047, P0048, and other diagnosis codes are output. B
1-56
B Go to the related diagnosis code chart

2 Active test implementation (Test the Turbo Charger Motor)
1. Turn ON the ignition switch.

2. Press [Active test] and select [Test the Turbo Charger Motor]
on the 'Engine Diagnostic Program'.
3. Monitor [VNT Command] and [Actual VN Position] from the
data list items.
4. Implement the active test.
Result
Result Go to
The value of the [Actual VN Position] follows that of the [VNT Command]. A
The value of the [Actual VN Position] does not follow that of the [VNT Command]. B
B Go to step 3.
INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)
3 Turbo charger S/A inspection (individual inspection)
1. Disconnect the DC motor (turbo charger S/A) connector.

2. Measure the resistance between terminals.
Resistance
DC motor (Turbo charger S/A)
Inspection terminal Inspection condition Standard
2 (M+) - 1 (M-) Always 1 to100 Ω

2 1
NG Go to step 6.
M+ M-
OK
Wire harness and connector inspection

4
(DC motor (Turbo charger S/A) - Engine control computer)
1-57
Note:
Engine control computer
Connector on the machine side
See page 0-13 for the inspection procedure and notes of wire
harness and connectors.
A 1. Disconnect the connector A of engine control computer and
the connector U of DC motor (turbo charger S/A).
2. Measure the resistance between terminals using a tester.
(See page 1-33 for the terminal layout.)
Resistance
Inspection
Inspection terminal Standard
condition
42(VNM+) 43(VNM-)
A-42 (VNM+) - U-2 (M-) Always Less than 1 Ω
DC motor (Turbo charger S/A)
Connector on the machine side A-43 (VNM-) - U-1 (M+) Always Less than 1 Ω
U Resistance
Inspection
condition
1 2 A-42 (VNM+) and U-2 (M-) -
Other terminal Always 10 kΩ or more
and body ground
M+ M-
A-43 (VNM-) and U-1 (M+) -
Other terminal Always 10 kΩ or more
and body ground
NG Go to step 6.
OK
5 Turbo charger S/A replacement
1. Replace the turbo charger S/A. (See page 2-19 for the
procedure.)
Next Go to step 7.
6 Wire harness or connector repair or replacement
1. Repair or replace the wire harness or connector.
Next
7 Diagnosis code deletion
SST 09111-36760-71(09991-70201)
2. According to the instruction of the 'Engine Diagnostic Program'
screen, delete the diagnosis code. (See page 1-13 for the
procedure.)
3. After turning OFF the ignition switch, perform the diagnostic
code reading after 30 seconds.
Next
1-58
SST 09111-36760-71(09991-70201)
2. Press [Active test]  select [Activate the VN Turbo Open] on
the 'Engine Diagnostic Program'.
3. Perform the active test and keep the open (fully opened) and
OFF (fully closed) states for 5 seconds or more.
screen, check that no diagnosis code is output. (See page 1-
13 for the procedure.)
Next
End
1-59
DTC P007C Charge Air Cooler Temperature Sensor Circuit Low
DTC P007D Charge Air Cooler Temperature Sensor Circuit High
Circuit description
The inlet air temperature sensor is attached to the intake pipe to measure the intake air temperature. The resistance
value of thermistor included in the inlet air temperature sensor varies with the change in intake air temperature. The
resistance value of thermistor increases as the intake air temperature falls, or decreases as the intake air
temperature rises. The inlet air temperature sensor is connected to the engine control computer, and 5 V power
supply voltage is supplied to the sensor from the THIA terminal of engine control computer via the resistor R. Since
the resistor R and inlet air temperature sensor are connected in series, the resistance value varies with the change in
intake air temperature and also the THIA terminal potential changes. According to this signal, the engine control
computer increases the fuel injection amount or advance the injection timing when the intake air temperature is low
to improve the drivability.
30
20
10
5
3
Resistance
2
[kΩ]
1
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
Temperature [°C]
P007C
3. Abnormal period
4. Others
2. Shorting of inlet air temperature
• Inlet air temperature sensor (for
1 sec. with ignition key switch ON sensor circuit
intake manifold)
3. 0.5 sec. or longer
4. 1 trip
1-60
P007D
3. Abnormal period
4. Others
2. Disconnection of inlet air temper-
• Inlet air temperature sensor (for
1 sec. with ignition key switch ON ature sensor circuit
intake manifold)
4. 1 trip
Related Data List

DTC No. Data list
P007C
Intake air temperature after turbocharging
P007D
Circuit diagram
2 113
THIA
1 90
ETHI
P
Inlet air temperature A
sensor (for intake manifold) Engine control computer
Caution:
according the Operation Support Procedure List.
Note:
1-61
1 'Engine Diagnostic Program' data reading (intake air temperature after turbocharging)
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON and read [Intake Air Temp
(Turbo)] displayed on the 'Engine Diagnostic Program' while
the engine is stopped.
Result
Result Go to
-40 °C (-40 °F) (disconnection) A
190 °C (374 °F) (short circuit) B
*
Same as temperature around intake manifold C
Note:
*: The result is normal at the moment but should be checked
if the defect reappears.
(See page 1-15 for Inspection of irregular problems)
B Go to step 4.
C Go to step 9.
2 'Engine Diagnostic Program' data reading (wire harness disconnection check)

SST(1) 09111-36760-71(09991-70201)
SST(2) 09160-36760-71(09843-18040)
1. Disconnect the connector P of inlet air temperature sensor.
2. Using 'diagnosis check wire No.2', short circuit the terminals
between the terminal 1 and 2 of inlet air temperature sensor
connector of the truck side.
3. Turn the ignition key switch ON.
4. Read [Intake Air Temp (Turbo)] displayed on the 'Engine
Diagnostic Program'.
Standard Display temperature 190 °C (374 °F)
Inlet air Engine
temperature control
Sensor OK Go to step 7.
Computer
Inlet air temperature

sensor (for intake manifold)
1 2
NG
1-62

3
(Engine control computer - Inlet air temperature sensor)
Note:
1. Disconnect the connector A of engine control computer and
Engine control computer the connector P of inlet air temperature sensor.
Connector on the machine side 2. Measure the resistance between terminals using a tester.
A (See page 1-33 for the terminal layout.)
Resistance
Inspection
condition
A-113 (THIA) - P-2 Always Less than 1 Ω
A-90 (ETHI) - P-1 Always Less than 1 Ω
113(THIA) 90(ETHI) Resistance

Inlet air temperature sensor Inspection
(for intake manifold) Inspection terminal Standard
condition
A-113 (THIA) or P-2 -
P Other terminal Always 10 kΩ or more
and body ground
A-90 (ETHI) or P-1 -
1 2 Other terminal Always 10 kΩ or more
and body ground
OK Go to step 6.
NG Go to step 8.
4 'Engine Diagnostic Program' data reading (wire harness short circuit check)
SST 09111-36760-71(09991-70201)
1. Disconnect the inlet air temperature sensor connector.
3. Read [Intake Air Temp (Turbo)] displayed on the 'Engine
Diagnostic Program'
THIA Standard Display temperature -40 °C (-40 °F)
ETHI OK Go to step 7.
Inlet air Engine control
temperature Computer
Sensor
NG

5
(Engine control computer - Inlet air temperature sensor)
Note:
1-63

Engine control computer the connector P of inlet air temperature sensor.
A
Resistance
Inspection
condition
A-113 (THIA) - P-2 Always Less than 1 Ω
A-90 (ETHI) - P-1 Always Less than 1 Ω
90(ETHI) Resistance
113(THIA)
Inlet air temperature sensor Inspection
(for intake manifold) condition
Connector on the machine side A-113 (THIA) or P-2 -
Other terminal and Always 10 kΩ or more
P body ground
A-90 (ETHI) or P-1 -
1 2
body ground
NG Go to step 8.
OK
6 Engine control computer replacement
1. Replace the engine control computer.

Next Go to step 9.
7 Inlet air temperature sensor replacement (for intake manifold)
1. Replace the inlet air temperature sensor.

Next Go to step 9.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
1-64
10 Diagnosis code check
SST 09111-36760-71(09991-70201)
2. Turn ON the ignition switch and wait for 1 second or longer.
screen, check that no diagnosis code is output.
Next
End
1-65
DTC P0087 Fuel Rail / System Pressure - Too Low
DTC P0190 Fuel Rail Pressure Sensor Circuit
DTC P0192 Fuel Rail Pressure Sensor Circuit Low
DTC P0193 Fuel Rail Pressure Sensor Circuit High
Circuit description
The fuel pressure sensor is attached to the common rail ASSY to output the fuel pressure after converting it into an
electric signal to the engine control computer. The engine control computer controls the supply pump ASSY (intake
adjustment valve) according to the signal sent from the fuel pressure sensor to maintain the target fuel pressure in
the common rail ASSY. The fuel pressure sensor uses a semiconductor. Since it changes the internal resistance in
accordance with the fuel pressure, the output voltage becomes proportional to the fuel pressure.
Output voltage characteristic

(with 5 V VC power supply) Fuel pressure sensor internal circuit
VC
4.08
Output voltage
(V) PR
1.00
E2
0 220000
Fuel pressure (kPa)
P0087
3. Abnormal period
4. Others
1. Engine speed 650r/min or more,
8 V or more, injection amount
5mm3/st or more • Wire harness or connector
After running at idle for 60 seconds,
2. Fuel pressure change is smaller • Common rail ASSY
perform racing from idle to NMR for
than threshold (fuel pressure sensor)
30 seconds.
3. Specified frequency • Engine control computer
(Time wise, 0.1 sec. or more)
4. 1 trip
1-66
P0190
3. Abnormal period
4. Others
2. Common rail ASSY (fuel pressure • Wire harness or connector
1 sec. or longer with ignition key sensor) output is 0.55 V or less, • Common rail ASSY
switch ON or 4.9 V or more (fuel pressure sensor)
3. 0.5 sec. or longer • Engine control computer
4. 1 trip
P0192
3. Abnormal period
4. Others
2. Common rail ASSY (pressure
1 sec. or longer with ignition key • Common rail ASSY
sensor) output is 0.55 V or less
switch ON (fuel pressure sensor)
4. 1 trip
P0193
3. Abnormal period
4. Others
2. Common rail ASSY (pressure
1 sec. or longer with ignition key • Common rail ASSY (fuel pressure
sensor) output is 4.9 V or more
switch ON sensor)
4. 1 trip
Related Data List

DTC No. Data list
P0087
P0190 • Common rail target fuel pressure
P0192 • Fuel pressure
P0193
1-67
Note:
• Compare [Fuel Press] with [Target Common Rail Pressure] on the data list. Under stable conditions, the
difference between [Fuel Press] and [Target Common Rail Pressure] is 5000 kPa or less.
• If DTC P0087 is stored, the following symptom may occur.
- Black smoke
- Poor drivability
- Insufficient output due to acceleration limit caused by activated fail-safe function
• If DTC P0190, P0192 or P0193 is stored, the following symptom may occur.
• If DTC P0190, P0192 or P0193 is stored, [Fuel Press] always shows [Target Common Rail Pressure].
• If the truck runs out of fuel, the engine control computer may detect it as a drop in fuel pressure and DTC
P0190 or P0192 may be stored.
• After checking DTC P0087, P0190, P0191, P0192 or P0193 output, read [Fuel Press] from [Data monitor]
using 'Engine Diagnostic Program'.
Engine speed Fuel pressure
At idle Approx. 30000 to 40000 kPa
NMR (no-load) Approx. 95000 to 115000 kPa
Detection overview
• P0087 (constant output from fuel pressure sensor):
- Under normal conditions, the fuel pressure varies by around 1000 to 2000 kPa even in a constant
traveling state. If the fuel pressure does not vary, a diagnosis code is stored. The fuel pressure at idle is
around 30000 to 40000 kPa. The fuel pressure at NMR of engine speed is around 95000 to 115000 kPa.
When a diagnosis code is stored, the engine control computer enters the fail-safe mode and restricts the
engine output. The engine control computer maintains the fail-safe mode until the ignition key switch is
turned OFF.
- The following illustration shows the relation between the engine speed and fuel pressure. When P0087 is
stored, the fuel pressure does not rise with the increase of engine speed.
P0087:
Normal
Abnormality detection
Fuel pressure
Abnormal
Engine speed
Time
• P0190, P0192 or P0193 (fuel pressure sensor circuit disconnected or shorted):

A diagnosis code is stored when the fuel pressure sensor output voltage deviates from the standard
range due to disconnection or shorting of the fuel pressure sensor circuit.
turned OFF.
1-68
NOTICE:
- Black smoke
- Poor drivability
At idle 30000 to 50000 kPa
NMR (no-load) 90000 to 150000 kPa
Detection overview
turned OFF.
- The following illustration shows the relation between the engine speed and fuel pressure. When P0087
is stored, the fuel pressure does not rise with the increase of engine speed.
P0087:
Normal
Fuel pressure
Abnormal
Engine speed
Time

turned OFF.
1-69

2
(Engine control computer - Fuel pressure sensor)

Note:
Connector on the machine side See page 0-13 for the inspection procedure and notes of wire
the connector L of common rail ASSY (fuel pressure sensor).
Resistance
Inspection
66 (PCR1) 67 (E2S1) 68(VCS1)
condition
A-68 (VCS1) - L-1 (VC) Always Less than 1 Ω
Connector on the machine side A-66 (PCR1) - L-2 (PR) Always Less than 1 Ω
L A-67 (E2S1) - L-3 (E2) Always Less than 1 Ω
Resistance
1 2 3 Inspection
condition
A-68 (VCS1) or L-1 (VC) -
VC E2
PR Other terminal and Always 10 kΩ or more
body ground
A-66 (PCR1) or L-2 (PR) -
body ground
A-67 (E2S1) or L-3 (E2) -
body ground
NG Go to step 9.
OK
3 Engine control computer inspection (power supply voltage)

Note:
L 1. Disconnect the connector L of common rail ASSY (fuel
pressure sensor).
2. Measure the voltage between terminals using a tester.
1 2 3 Voltage value
Inspection
VC E2 condition
Ignition key
L-1 (VC) - L-3 (E2) 4.5 to 5.5 V
switch ON
NG Go to step 8.
OK
1-70
4 Common rail ASSY replacement
1. Replace the common rail ASSY.

Next
5 Air bleeding of the fuel system
1. Perform the air bleeding of fuel system.
Next
SST 09111-36760-71(09991-70201)
screen, delete the diagnosis code.
Next
SST 09111-36760-71(09991-70201)
1. Start the engine.
2. After running at idle for 60 seconds, perform racing from idle to
NMR for 30 seconds.
screen, press [Trouble Code]
4. Enter P0087, P0190, P0192 or P0193 on the next screen and
confirm the normal state.
Result
Tester item Result Go to
P0087, P0190, P0192 or P0193
A
is output.
Diagnosis result
Normal B
Abnormal A
Note:
If the diagnosis result check is in process or diagnosis cannot
be made, perform racing again from idle to NMR for 30
seconds.
B End
A
1-71

Next Go to step 10.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
NMR for 30 seconds.
screen, press [Trouble Code].
Note:
seconds.
Next
End
1-72
DTC P0088 Fuel Rail / System Pressure - Too High
Circuit description
The supply pump ASSY is a single type pump having a circuit suitable for suctioning of fuel and force feed processes
that realize a force feed of fuel at high pressure and reduction of drive torque. This circuit controls the suction control
valve ASSY that performs suctioning of fuel by plunger in the suction process.
When this DTC is output, the engine control computer enters the fail-safe mode and restricts the engine output. The
engine control computer maintains the fail-safe mode until the ignition key switch is turned OFF.
P0088
3. Abnormal period
4. Others
• Common rail ASSY (fuel pressure
sensor)
• Suction control valve ASSY
After running at idle for 60 seconds, 2. Rail pressure is 250000 kPa or
• Fuel pressure sensor circuit dis-
perform racing from idle to NMR for more
connection
30 seconds. 3. -
• Disconnection or shorting of suc-
4. 1 trip
tion control valve ASSY circuit
Related Data List

DTC No. Data list
• Fuel pressure
• Target pump current
Note:
• When DTC P0088 is output, check [Fuel Press] in the data list using 'Engine Diagnostic Program'.
Reference value
• Check the freeze frame data of [Fuel Press], [Target Common Rail Pressure] and [Target Pump SCV
Current] using 'Engine Diagnostic Program'.
1-73
Circuit description
P0088
3. Abnormal period
4. Others
After running at idle for 60 seconds, 1.Ignition key switch ON Common rail ASSY (fuel pressure
perform racing from idle to NMR for 2.Rail pressure is 250000 kPa or sensor)
30 seconds. more Suction control valve ASSY
3.- Fuel pressure sensor circuit discon-
4.1 trip nection
Disconnection or shorting of suction
control valve ASSY circuit
Related Data List

DTC No. Data list
• Fuel pressure
NOTICE:
Reference value
1-74
Result
Result Go to
[Fuel press] values of the 3rd and 4th time-series freeze frame data are 250000 kPa or more. B
Other than the above A
Note:
Freeze frame data could be below 250000kPa depend on the
timing to detect the data.
B Go to step 4.
3 Engine control computer inspection (fuel pressure sensor output voltage)
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON .
screen, press [Data monitor] and monitor [Fuel Press].
3. Start up the engine.
4. Excite the wire harness between the sensor and engine
control computer to see if it causes the fuel pressure value to
vary or the engine check indicator to light up.
Excitation method (reference):
Engine wire
Wire to wire Engine control

Computer
Engine wire Fuel pressure sensor

(common rail ASSY)
Note:
Delete a diagnosis code if it has been detected.
Standard Fuel pressure value does not fluctuate due to
excitation and the engine check indicator does
not light.
Result
Result Go to
Fuel pressure value fluctuates due to excitation or the engine check indicator lights up. B
Fuel pressure value does not fluctuate due to excitation and the engine check indicator does not
A
light.
1-75
B Go to step 11.

4
(Suction control valve ASSY - Engine control computer)
Note:
Engine control computer the connector J of suction control valve ASSY.
A (See page 1-33 for the terminal layout.)
Resistance
Inspection
condition
A-41 (PCV+) - J-1 Always Less than 1 Ω
A-81 (PCV-) - J-2 Always Less than 1 Ω
41(PCV+) 81(PCV-)
Resistance
Suction control valve ASSY Inspection

Connector on the machine side condition
J A-41 (PCV+) and J-1 - Other
terminal and Always 10 kΩ or more
body ground
1 2 A-81 (PCV-) and J-2 - Other
body ground
NG Go to step 11.
OK
5 Suction control valve ASSY & Common rail ASSY replacement
1. Replace the suction control valve ASSY and common rail

ASSY.
(See page 3-3 for the procedure.)(See page 3-11 for the
procedure.)
Next
Next
1-76
7 Supply pump learned value initialization
SST 09111-36760-71(09991-70201)
2. press [Trouble Code] on the 'Engine Diagnostic Program' and
delete the detected diagnosis code.
3. Perform "Initializing the supply pump ASSY leaned value".
Note:
• Clear the diagnosis code before performing the learned
value initialization.
• See page 1-16 for the procedure of "Initializing the supply
pump ASSY leaned value".
Next
SST 09111-36760-71(09991-70201)
Next
SST 09111-36760-71(09991-70201)
NMR for 30 seconds.
Result
Tester item Result Go to

P0088 is output. A
Diagnosis result Normal B
Abnormal A
Note:
seconds.
B End

Next Go to step 15.
1-77
Next
SST 09111-36760-71(09991-70201)
control computer to see if it causes the fuel pressure value to
vary or the engine check indicator to light up.
Note:
not light.
Result
Result Go to
Fuel pressure value fluctuates due to excitation or the engine check indicator lights up. A
Fuel pressure value does not fluctuate due to excitation and the engine check indicator does not light. B
B Go to step 15.

Next
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
1-78
SST 09111-36760-71(09991-70201)
NMR for 30 seconds.
Note:
seconds.
Next
End
1-79
DTC P0093 Fuel System Leak Detected - Large Leak
Circuit description
the common rail ASSY.
This diagnosis code indicates a fuel leakage in the high pressure area within the common rail system. After the
engine is started, the engine control computer monitors the fuel pressure within the common rail constantly. The
engine control computer stores this diagnosis code when the fuel pressure drops significantly at fuel injection.
In the common rail system, high pressure fuel is constantly supplied to the supply pump ASSY, common rail ASSY,
injector ASSY and high pressure area within the pipe. The engine control computer adjusts the aperture of the
suction control valve ASSY to maintain the target fuel pressure.
When this diagnosis code is stored, the engine control computer enters the fail-safe mode. In the fail-safe mode, the
engine will be stopped eventually by temporary stop of fuel injection and operation of supply pump ASSY; however,
retreat traveling may be allowed for 1 minute before the engine is stopped. The engine control computer maintains
the fail-safe mode until the ignition key switch is turned OFF.
P0093
3. Abnormal period
4. Others
• Common rail ASSY
(fuel pressure sensor)
• Injector ASSY
Start up and warm up the engine.
• Fuel temperature sensor
Keep the accelerator pedal fully 1. Engine speed 650 r/min or more
• Crank position sensor
open for 5 seconds and then release 2. Fuel pressure drop before/after
• High pressure fuel pipe
the pedal. (*A) fuel injection is larger than thresh-
• Disconnection or shorting of injec-
Make the accelerator pedal fully old
tor driver wiring
open and release the pedal when 3. -
NMR is reached. (*B) 4. 1 trip
tor circuit
Perform above (*A) and (*B) 5 times.
• Fuel filter element ASSY
• Injector driver
Related Data List

DTC No. Data list
• Fuel pressure
P0093
• Common rail target fuel pressure
Note:
When DTC P0093 is output, check [Fuel Press] in the data list using 'Engine Diagnostic Program'.
Reference value
Circuit diagram
See page 1-123 for P0201 circuit diagram.
1-80
Circuit description
This diagnosis code indicates a fuel leakage in the high pressure area within the common rail system. After the engine
is started, the engine control computer monitors the fuel pressure within the common rail constantly. The engine
control computer stores this diagnosis code when the fuel pressure drops significantly at fuel injection.
P0093
3. Abnormal period
4. Others
Start up and warm up the engine. 1. Engine speed 650 r/min or more • Common rail ASSY
Keep the accelerator pedal fully 2. Fuel pressure drop before/after (fuel pressure sensor)
open for 5 seconds and then release fuel injection is larger than thresh- • Injector ASSY
the pedal. (*A) old • Fuel temperature sensor
Make the accelerator pedal fully 3. Specified number of times • Crank position sensor
open and release the pedal when 4. 1 trip • High pressure fuel pipe
NMR is reached. (*B) • Disconnection or shorting of injec-
Perform above (*A) and (*B) 5 times. tor driver wiring
tor circuit
• Injector driver
Related Data List

DTC No. Data list
• Fuel pressure
P0093
NOTICE:
Reference value
Circuit diagram
1-81
4 Refuel
1. Add the fuel.
Next
SST 09111-36760-71(09991-70201)
1. Perform air bleeding of the fuel system using the priming pump
located in the fuel filter cap ASSY. Pump it continuously until
the movement of priming pump knob becomes stiff.
Caution:
• Priming pump operation speed: 2 times/sec. or less
• Operate the priming pump with full stroke.
• The priming pump becomes stiff when the pressure at the
entrance of supply pump ASSY becomes saturated.
• If pumping is stopped during air bleeding, the fuel in the
pipe may return to the tank. Keep pumping until the priming
pump becomes stiff.
• If the priming pump does not become stiff after 200 times or
more of continuous pumping, leakage from the pipe
between the fuel tank and fuel filter or running out of gas
may have occurred.
• If a large amount of air is left in the fuel system, the
common rail fuel pressure cannot be raised to the normal
use level and thus the engine cannot be started.
Caution:
• If a large amount of air is left in the fuel system, it may take
10 seconds or more to start up the engine.
• Do not turn the starter ON continuously for 30 seconds or
more.
• Be careful of running out of battery. (Use a fully charged
battery.)
3. Turn the ignition key switch OFF.
5. Press [Trouble Code] on the 'Engine Diagnostic Program' and
6. Implement the fuel system check (fuel system parts
replacement). (See page 1-16 for the procedure.)
1st time 2nd time 5th time
ON
Fuel system check
OFF
3 min idle
Time
1-82

read the detected diagnosis code.
(1) When no diagnosis code is output, air bleeding is
completed.
(2) Perform the following work if a diagnosis code is output.
9. Press [Trouble Code] and [Clear] on the 'Engine Diagnostic
Program' and delete the detected diagnosis code.
10. Start up and warm up the engine.
11. Keep the accelerator pedal fully open for 5 seconds and then
release the pedal. (*E)
12. Make the accelerator pedal fully open and release the pedal
when NMR is reached. (*F)
13. Perform above (*E) and (*F) 5 times.
MPa
100
Fuel pressure
NMR
Engine speed
Repeat *E and *F 5 times.

Full open
Accelerator pedal
Full open
5 sec. Time
*E *F
Result
Result Go to
Diagnosis code is output. A
Diagnosis code is not output. B
B Diagnosis code is detected due to running out of

fuel, not failure of parts.
A
1-83
6 'Engine Diagnostic Program' data reading (fuel pressure)
SST 09111-36760-71(09991-70201)
4. Check [Fuel Press] value in cranking and idling.
Result
Result Go to
Engine does not start, or engine starts but [Fuel Press] value 2 seconds after switching of starter sig-
B
nal from OFF to ON is less than 20000 kPa.
Other than the above A
B Go to step 12.
7 Fuel filter element ASSY replacement (fuel filter case sub ASSY cleaning)
1. Clean the fuel filter case sub ASSY and replace the fuel filter
element ASSY.
Note:
If fuel filter element ASSY is replaced and installed while
foreign bodies are still left in the fuel filter case sub ASSY, the
injector may not function properly. Therefore, when replacing
the fuel filter element ASSY, make sure to clean inside the fuel
filter case sub ASSY.
Next
SST 09111-36760-71(09991-70201)
1. Perform air bleeding of the fuel system using the priming pump
located in the fuel filter cap ASSY. Pump it continuously until
the movement of priming pump knob becomes stiff.
Caution:
• Priming pump operation speed: 2 times/sec. or less
• Operate the priming pump with full stroke.
• The priming pump becomes stiff when the pressure at the
entrance of supply pump ASSY becomes saturated.
• If pumping is stopped during air bleeding, the fuel in the
pipe may return to the tank. Keep pumping until the priming
pump becomes stiff.
• If the priming pump does not become stiff after 200 times or
more of continuous pumping, leakage from the pipe
between the fuel tank and fuel filter or running out of gas
may have occurred.
• If a large amount of air is left in the fuel system, the
common rail fuel pressure cannot be raised to the normal
use level and thus the engine cannot be started.
1-84

Caution:
• If a large amount of air is left in the fuel system, it may take
10 seconds or more to start up the engine.
• Do not turn the starter ON continuously for 30 seconds or
more.
• Be careful of running out of battery. (Use a fully charged
battery.)
3. Turn the ignition key switch OFF.
6. Start up the engine. (*A)
7. Press [Utillity]  [Fuel System Check] on the 'Engine
Diagnostic Program'. (*B)
1st time 2nd time 5th time
ON
Fuel system check
OFF
10 sec. 3 min idle
Time

(1) When no diagnosis code is output, air bleeding is
completed.
(2) Perform the following work if a diagnosis code is output.
replacement).
Next
9 Work support implementation (Fuel system check / fuel system parts replacement)
1. Implement the fuel system check.

2. Measure the difference between the [Fuel Press] and [Target
Common Rail Pressure] obtained in the fuel system check.
1-85
2800
Engine speed
1400 rpm
Fuel system check

Check start Check stop
ON
OFF
Fuel pressure
under normal
conditions Target fuel pressure
Below
10000 kPa
Fuel pressure
Fuel pressure under abnormal
conditions
Fuel pressure when the pressure limiter is defective
Time
2 sec.
Standard Difference between the target fuel pressure and

the actual fuel pressure two seconds after the
start of fuel system check is less than 10000
kPa.
Note:
• [Target Common Rail Pressure] indicates the target control
fuel pressure of the engine control computer.
• [Fuel Press] indicates the actual fuel pressure in the
common rail.
• When the suction control valve ASSY installed in the supply
pump ASSY is defective, the actual fuel pressure changes
as fuel pressure under the defective conditions in the
illustration.
• Pressure limiter functions to release fuel pressure when the
internal pressure of common rail becomes abnormally high.
Result
Result Go to
Difference between the target fuel pressure and the actual fuel pressure two seconds after the start
A
of active test is less than 10000 kPa
Other than the above B
B Go to step 11.
A
1-86
10 'Engine Diagnostic Program' active test implementation (control the select cylinder fuel cut)
SST 09111-36760-71(09991-70201)
Note:
Conduct the following inspection to identify the defective
cylinder.
2. Press [Active test]  [Control the Select Cylinder Fuel Cut] on
3. Perform control the select cylinder fuel cut active test for each
cylinder to identify the defective cylinder.
Note:
• The defective cylinder produces a small change in idle
speed or idle vibration when a fuel cut is performed during
the engine idling.
• With a normal cylinder, when fuel cut is performed, the
engine falls into rough idle.
Next Go to step 12.
11 Injector ASSY inspection (closing failure inspection)
1. Remove the glow plug ASSY.

2. Visually check if fuel is attached to the glow plug ASSY.
Result
Result Go to
Fuel is attached to the glow plug ASSY. A
Note:
• If fuel is attached to the glow plug ASSY, fuel may be
leaking from the injector ASSY. Replace the injector ASSY.
• After replacing the injector ASSY, check that [Fuel Press]
during cranking is within 5000 kPa of [Target Common Rail
Pressure].
• If fuel is attached to the glow plug ASSY, fuel may be mixed
with engine oil. Check the engine oil level and check if the
engine oil smells like gas oil. When the oil level is above
FULL and the engine oil smells like gas oil, replace the
engine oil.
B Go to step 15.
A
1-87
12 Injector ASSY replacement (defective cylinder)
1. Replace the injector ASSY of defective cylinder.

Note:
• For the cylinder, with which the injector is replaced, make
sure to use a new injection pipe.
• After assembling the injection pipe and leakage pipe
temporarily and positioning the injector according to the
repair manual, tighten the injector to the specified torque.
• If not assembled in the proper order, injector may be
misaligned and become deteriorated, possibly causing a
failure.
• When the injector is deteriorated and causes a failure, this
may result in knocking, rough idling, and other problems.
• Misalignment may degrade the seal-ability between the
injector and injection pipe, possibly resulting in fuel
leakage.
OK
Next
14 Work support implementation (Writing the injector compensation code)
1. Implement the writing the injector compensation code

(Write to the input manual compensation codes.).
Next Go to step 25.
15 'Engine Diagnostic Program' data reading (engine speed)
SST 09111-36760-71(09991-70201)
2. Press [Data monitor] and monitor [Engine Speed]
3. Read the value in cranking and idling after engine warm-up.
Result
Data list item Engine status Reference
Cranking 50 to 400 r/min
Engine Speed
Idling (after warm-up) 720 to 780 r/min
Note:
The value that corresponds to the actual engine speed should
be displayed constantly.
NG Go to step 19.
OK
1-88

NOTICE:
failure.
injector and injection pipe, possibly resulting in fuel leakage.
OK
Next

Next Go to step 25.
SST 09111-36760-71
Result

Engine Speed
Idling (after warm-up) Refer to repair manual of the vehicle
NOTICE:
NG Go to step 19.
OK
1-89
17 Fuel temperature sensor inspection (sensor output)
SST 09111-36760-71(09991-70201)
2. While the engine is stopped, according to the instruction of the
'Engine Diagnostic Program' screen, press [Data monitor] and
read [Fuel Temperature].
Reference [Fuel Temperature] value is roughly the same
as the actual fuel temperature.
Note:
The data monitor [Fuel Temperature] value is roughly the
same as the ambient temperature on the truck that has been
left with the engine stopped overnight.
NG Go to step 24.
OK
18 Inspection of irregular problems
Note:
See page 1-15 for inspection of irregular problems.
Next Go to step 25.
19 Crank position sensor No. 2 replacement
1. Replace the crank position sensor No. 2.

Next Go to step 25.
Wire harness or connector repair/replacement

20
(Engine control computer - Fuel pressure sensor)
Next
SST 09111-36760-71(09991-70201)
control computer to see if it causes the engine check indicator
to light up.
1-90
Excitation method (reference):
Engine wire
Wire to wire Engine control

Computer
Engine wire Fuel pressure sensor

(common rail ASSY)
Note:
not light.
Result
Result Go to
Fuel pressure value fluctuates due to excitation or the engine check indicator lights up. A
Fuel pressure value does not fluctuate due to excitation and the engine check indicator does not
B
light.
B Go to step 25.

Next

Next Go to step 25.
24 Fuel temperature sensor replacement
1. Replace the fuel temperature sensor.

Next
1-91
SST 09111-36760-71(09991-70201)
Next
SST 09111-36760-71(09991-70201)
4. Keep the accelerator pedal fully open for 5 seconds and then
release the pedal. (*A)
5. Make the accelerator pedal fully open and release the pedal
when NMR is reached. (*B)
6. Perform above (*A) and (*B) 5 times.
MPa
100
Fuel pressure
5000 rpm
Engine speed
Repeat *A and *B 5 times.

Full open
Accelerator pedal
Full open
5 sec. Time
*A *B
Standard Diagnosis code is not detected.
Next
End
1-92
DTC P0102 Mass Air Flow Sensor Circuit Low
DTC P0103 Mass Air Flow Sensor Circuit High
Circuit description
The intake air flow meter uses a platinum filament. It has a platinum filament heater, temperature sensor and built-in
control circuit in the housing. When the heater located in a bypass route within the housing is cooled by passing of
intake air, the change in temperature is detected by the temperature sensor. The heater and temperature sensor form
a bridge circuit. The control operation of power transistor to keep the heater at the predetermined temperature is
used as output voltage, and the voltage is output after converting it into frequency by the frequency conversion
circuit. The frequency varies within the range of approx. 250 to 11000 Hz depending on air flow. The engine control
computer calculates the intake air flow based on this frequency value.
The intake air flow meter is not influenced much by the resistance of wire harness and thus the variation in output is
small.
B+
Power transistor
Platinum filament (heater)
Output voltage
Frequency
Temperature conversion circuit
sensor Temperature sensor
Platinum filament
(heater)
Output
frequency
P0102
3. Abnormal period
4. Others
1. Engine speed is below
5000 r/min
3 sec. or longer after engine start • Intake air flow meter
S/A output is 850 Hz or less
3. 3 sec. or longer
4. 1 trip
1-93
P0103
3. Abnormal period
4. Others
1. Engine speed is below
5000 r/min
3 sec. or longer after engine start • Intake air flow meter
S/A output is 9800 Hz or more
3. 3 sec. or longer
4. 1 trip
Related Data List

DTC No. Data list
P0102
Intake air quantity
P0103
Circuit diagram
3 5 65
From MAIN relay +B FG
VG
4 64
E2G
E2G
O
A
Engine control
Computer
Caution:
• When replacing the engine control computer or injector ASSY, initialize and write the corresponding ID
code according to the Operation Support Procedure List. (See page 1-16 for the procedure.)
• Before carrying out the troubleshooting, inspect the fuse of this circuit.
Note:
1-94

1
(intake air flow meter S/A power supply voltage inspection)
Note:
1. Disconnect the connector O of intake air flow meter S/A.
Intake air flow meter 3. Measure the voltage between terminals using a tester.
Voltage value
O
Inspection
condition
1 2 3 4 5 Ignition key
O-3 (+B) - Body ground 11 to 14 V
switch ON
+B
NG Go to step 4.
OK

2
(Engine control computer - Intake air flow meter S/A)
Note:
the connector O of intake air flow meter S/A.
2. Measure the resistance between terminals using a tester. (See
Engine control computer page 1-33 for the terminal layout.)
Resistance
A
Inspection
condition
A-65 (VG) - O-5 (FG) Always Less than 1 Ω
A-64 (E2G) - O-4 (E2G) Always Less than 1 Ω
Resistance
65 (VG) Inspection
64 (E2G) Inspection terminal Standard
condition
Intake air flow meter A-65 (VG) and O-5 (FG) -
Connector on the machine side Other terminal and Always 10 kΩ or more
O body ground
A-64 (E2G) and O-4 (E2G) -
1 2 3 4 5 body ground
OK Go to step 5.
E2G FG
NG
1-95

Next Go to step 9.
4 Inspection and repair of power supply circuit
1. Inspect and repair the power supply circuit.

Next Go to step 9.
5 Intake air flow meter S/A replacement
1. Replace the intake air flow meter S/A.

Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
1. Start up the engine and run at idle for 3 sec. or longer.
screen, read the diagnosis code. (See page 1-13 for the
procedure.)
Result
Result Go to
Either P0102 or P0103 is output. A
B End
Next
1-96
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
2. Perform idling for three sec. or longer
Next
End
1-97
DTC P0107 Manifold Absolute Pressure Sensor Circuit Low
DTC P0108 Manifold Absolute Pressure Sensor Circuit High
Circuit description
The diesel turbo pressure sensor (vacuum sensor) detects the absolute pressure within the intake manifold as a
voltage value by the built-in sensor. The engine control computer determines the basic pilot injection amount and
timing based on this voltage value for turbocharging delays or various elevations.
Voltage (V)
3.586
0.386
kPa
40 320
Intake manifold pressure
P0107
3. Abnormal period
4. Others
1. 2 sec. or longer after engine start
Start up the engine and wait at least 2. Diesel turbo pressure sensor out- • Wire harness and connector
2 seconds and then perform racing put is 0.1 V or less • Diesel turbo pressure sensor
for 1 second or longer. 3. 0.5 sec. or longer • Engine control computer
4. 1 trip
P0108
3. Abnormal period
4. Others
1. 2 sec. or longer after engine start
Start up the engine and wait at least 2. Diesel turbo pressure sensor out- • Wire harness and connector
2 seconds and then perform racing put is 4.8 V or more • Diesel turbo pressure sensor
for 1 second or longer. 3. 0.5 sec. or longer • Engine control computer
4. 1 trip
1-98
Related Data List

DTC No. Data list
P0107
Intake manifold pressure
P0108
Note:
After checking DTC P0107 or P0108 output, read [MAP] on the ECU data monitor screen using 'Engine
Intake manifold absolute pressure Defects
Approx. 15 kPa or less • Shorting with PIM circuit ground system
(113 mmHg) • VC circuit disconnection
• Shorting with PIM circuit of VC circuit
426 kPa or more
• PIM circuit disconnection
(3200 mmHg)
• E2 circuit disconnection
Circuit diagram
3 93
VC VCPM
2 117
PIM PIM
1 72
E EPIM
R A
Diesel turbo pressure sensor Engine control computer
(vacuum sensor)
Caution:
Note:
1-99
1 'Engine Diagnostic Program' data reading (intake manifold pressure)
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON and according to the
instruction of the 'Engine Diagnostic Program' screen, press
[Data monitor] screen while the engine is stopped, and then
read [MAP].
Standard Same as the atmospheric pressure
Result
Result Go to
Abnormal A
*
Normal B
Note:
B Go to step 9.
2 Wire harness and connector inspection

(Engine control computer - Diesel turbo pressure sensor)
Note:
Connector on the machine side the connector R of diesel turbo pressure sensor.
A page 1-33 for the terminal layout.)
Resistance
Inspection
condition
A-93 (VCPM) - R-3 (VC) Always Less than 1 Ω
A-117 (PIM) - R-2 (PIM) Always Less than 1 Ω
72(EPIM) 117(PIM) 93(VCPM) A-72 (EPIM) - R-1 (E) Always Less than 1 Ω
Diesel turbo pressure sensor Resistance
Inspection
R Inspection terminal Standard
condition
A-93 (VCPM) and R-3 (VC) -
1 2 3
body ground
A-117 (PIM) and R-2 (PIM) -
E VC Other terminal and Always 10 kΩ or more
PIM
body ground
A-72 (EPIM) and R-1 (E) -
Always 10 kΩ or more
Other terminal
NG Go to step 8.
OK
1-100
3 Engine control computer inspection (voltage inspection)
Note:
2. Disconnect the connector R of diesel turbo pressure sensor.
Diesel turbo pressure sensor 3. Measure the voltage between terminals using a tester.
Voltage value
R
Inspection
condition
Ignition key
1 2 3 R-3 (VC) - R-1 (E) 4.5 to 5.5 V
switch ON
NG Go to step 7.
E VC
OK
4 Diesel turbo pressure sensor replacement
1. Replace the diesel turbo pressure sensor.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
2. Start up the engine and wait at least 2 seconds and then
perform racing for 1 second or longer.
procedure.)
Result
d
Result Go to
Either P0107 or P0108 is output. A
B End
A
1-101

Next Go to step 9.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
2. Start up the engine and wait at least 2 seconds and then
perform racing for 1 second or longer.
Next
End
1-102
DTC P0112 Intake Air Temperature Sensor Circuit Low
DTC P0113 Intake Air Temperature Sensor Circuit High
Circuit description
The inlet air temperature sensor is installed in the intake air flow meter S/A to measure the intake air temperature.
The resistance value of thermistor included in the inlet air temperature sensor varies with the change in intake air
temperature. The resistance value of thermistor increases as the intake air temperature falls, or decreases as the
intake air temperature rises. The inlet air temperature sensor is connected to the engine control computer, and 5 V
power supply voltage is supplied to the sensor from the THA terminal of engine control computer via the resistor R.
Since the resistor R and inlet air temperature sensor are connected in series, the resistance value varies with the
change in intake air temperature and also the THA terminal potential changes. According to this signal, the engine
control computer increases the fuel injection amount when cool, in order to improve the drivability.
30
20
10
5
3
Resistance
2
[kΩ]
1
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
Temperature [°C]
P-0112
3. Abnormal period
4. Others
2. Shorting of inlet air temperature • Wire harness or connector
0.5 sec. or longer with ignition key
sensor circuit • Intake air flow meter
switch ON
4. 1 trip
1-103
P0113
3. Abnormal period
4. Others
2. Disconnection of inlet air temper- • Wire harness or connector
ature sensor circuit • Intake air flow meter
switch ON
4. 1 trip
Related Data List

DTC No. Data list
P0112
Intake air temperature
P0113
Note:
When P0112 and P0113 are stored, the following symptoms may occur.
- Misfire
- Knocking
- Black smoke
- White smoke
Circuit diagram
1 110
THA
THA
2 87
ETHA
E2
O
Intake air flow meter A
(inlet air temperature sensor) Engine control computer
Caution:
Note:
1-104
1 'Engine Diagnostic Program' data reading (intake air temperature)
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON and read [Intake Air] displayed
on the 'Engine Diagnostic Program' while the engine is
stopped.
Result
Result Go to
*
Same as ambient temperature C
Note:
B Go to step 4.
C Go to step 9.
SST 1 09111-36760-71 (09991-70201)

SST 2 09160-36760-71 (09843-18040)
1. Disconnect the connector O of intake air flow meter S/A.
Intake air flow meter 2. Using "Diagnosis check wire No.2", short circuit the terminals
Connector on the machine side between the terminal O-1 (THA) and O-2 (E2) of the intake air
flow meter S/A connector of the truck side.
O 3. Turn the ignition key switch ON.
4. Read [Intake Air] displayed on the 'Engine Diagnostic Program'.
Standard display temperature 140 °C (284 °F)
1 2 3 4 5 Go to step 7.
OK
THA
E2
NG

(Intake air flow meter S/A - Engine control computer)
Note:
1-105

Engine control computer the connector O of intake air flow meter S/A.
Connector on the machine side 2. Measure the resistance between terminals using a tester. (See
Resistance
Inspection
condition
A-110 (THA) - O-1 (THA) Always Less than 1 Ω
A-87 (ETHA) - O-2 (E2) Always Less than 1 Ω
110 (THA) 87 (ETHA)
OK Go to step 6.
NG Go to step 8.
O
1 2 3 4 5
THA
E2
SST 09111-36760-71(09991-70201)
1. Disconnect the connector of intake air flow meter S/A.
3. Read [Intake Air] displayed on the 'Engine Diagnostic Program'.
Standard display temperature -40 °C (-40 °F)
OK Go to step 7.
NG

(Intake air flow meter S/A - Engine control computer)
Note:
1-106

Engine control computer the connector O of intake air flow meter S/A.
Resistance
Inspection
condition
A-110 (THA) and O-1 (THA) -
Body ground
110 (THA)
NG Go to step 8.
O
1 2 3 4 5
THA
OK

Next Go to step 9.
7 Intake air flow meter S/A replacement

Next Go to step 9.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
1-107
SST 09111-36760-71(09991-70201)
Next
End
1-108
DTC P0115 Engine Coolant Temperature Sensor Circuit
DTC P0117 Engine Coolant Temperature Sensor Circuit Low
DTC P0118 Engine Coolant Temperature Sensor Circuit High
Circuit description
The resistance value of thermistor included in the water temperature sensor varies with the change in water
temperature. The water temperature sensor is connected to the engine control computer in the same manner as the
inlet air temperature sensor. Even if a disconnection or short circuit occurs in the water temperature sensor while the
engine is cool and thus the water and supply pump fuel temperatures are low, the engine can be started or warmed
with the supply pump fuel temperature taken as water temperature.
P0115
3. Abnormal period
4. Others
2. Disconnection or shorting of • Wire harness or connector
water temperature sensor circuit • Water temperature sensor
switch ON
4. 1 trip
P0117
3. Abnormal period
4. Others
2. Shorting of water temperature • Wire harness or connector
sensor circuit • Water temperature sensor
switch ON
4. 1 trip
P0118
3. Abnormal period
4. Others
2. Disconnection of water tempera- • Wire harness or connector
ture sensor circuit • Water temperature sensor
switch ON
4. 1 trip
Related Data List

DTC No. Data list
P0115
P0117 Engine cooling water temperature
P0118
1-109
Note:
When P0115, P0117 and P0118 are stored, the following symptoms may occur.
- Misfire
- Knocking
- Black smoke
- White smoke
Circuit diagram
2 111
THW
1 88
ETHW
Q
Water temperature sensor A
Caution:
Note:
1 'Engine Diagnostic Program' data reading (engine cooling water temperature)
SST 09111-36760-71(09991-70201)
1. Turn the ignition key switch ON and read [Coolant Temp]
displayed on the 'Engine Diagnostic Program' while the engine
is stopped.
Result
Result Go to
*
Same as actual water temperature C
Note:
B Go to step 4.
C Go to step 9.
A
1-110
SST 1 09111-36760-71 (09991-70201)

SST 2 09160-36760-71 (09843-18040)
Åv
1. Disconnect the connector Q of water temperature sensor.

2. Using "Diagnosis check wire No.2", short circuit the terminals
between the terminal Q-2 and Q-1 of diesel engine water
temperature connector.
THW
4. Read [Coolant Temp] displayed on the 'Engine Diagnostic
ETHW Program'.
Water temperature Engine control
Sensor
Reference: display temperature 140 °C (284 °F)
Computer
Result
Result Go to
Connector on the machine side Normal A
Abnormal B
Q
A Go to step 7.
1 2

(Water temperature sensor - Engine control computer)
Note:
Engine control computer the connector Q of water temperature sensor.
Resistance
Inspection
condition
A-111 (THW) - Q-2 Always Less than 1 Ω
A-88 (ETHW) - Q-1 Always Less than 1 Ω
111 (THW) 88 (ETHW) OK Go to step 6.
Water temperature sensor NG Go to step 8.

1 2
1-111
SST 09111-36760-71(09991-70201)
1. Disconnect the connector of water temperature sensor.
3. Read [Coolant Temp] displayed on the 'Engine Diagnostic
Program'.
THW Reference display temperature -40 °C (-40 °F)
Result
ETHW
Water temperature Engine control Result Go to
Sensor Computer
Normal A
Abnormal B
A Go to step 7.

(Water temperature sensor - Engine control computer)
Note:
Engine control computer the connector Q of water temperature sensor.
Resistance
Inspection
condition
A-111 (THW) and Q-2 -
body ground
111 (THW) 88 (ETHW) A-88 (ETHW) and Q-1 -
Water temperature sensor body ground
NG Go to step 8.
Q
1 2
OK

Next Go to step 9.
1-112
7 Water temperature sensor replacement
1. Replace the water temperature sensor.

Next Go to step 9.
Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
Next
End
1-113
DTC P0180 Fuel Temperature Sensor "A" Circuit
DTC P0182 Fuel Temperature Sensor "A" Circuit Low
DTC P0183 Fuel Temperature Sensor "A" Circuit High
Circuit description
The fuel temperature sensor is attached to the supply pump ASSY to detect the fuel temperature. The resistance
value of thermistor included in the fuel temperature sensor varies with the change in fuel temperature. The fuel
temperature sensor is connected to the engine control computer in the same manner as the inlet air temperature
sensor.
P0180
3. Abnormal period
4. Others
1.Ignition key switch ON
2.Disconnection or shorting of fuel • Wire harness or connector
temperature sensor circuit • Fuel temperature sensor
switch ON
3.0.5 sec. or longer • Engine control computer
4.1 trip
P0182
3. Abnormal period
4. Others
2. Shorting of fuel temperature sen- • Wire harness or connector
sor circuit • Fuel temperature sensor
switch ON
4. 1 trip
P0183
3. Abnormal period
4. Others
1.Ignition key switch ON
2.Disconnection of fuel temperature • Wire harness or connector
sensor circuit • Fuel temperature sensor
switch ON
3.0.5 sec. or longer • Engine control computer
4.1 trip
Related Data List

DTC No. Data list
P0180
P0182 Fuel temperature
P0183
1-114
Note:
When P0180, P0182 and P0183 are stored, the following symptoms may occur.
- Misfire
- Knocking
- Black smoke
Circuit diagram
2 112
THF
1 89
ETHF
K
Fuel temperature sensor A
Caution:
according to the Operation Support Procedure List.
Note:
1 'Engine Diagnostic Program' data reading (fuel temperature)
SST 09111-36760-71(09991-70201)
Result
Result Go to
Same as actual fuel temperature* C
Note:
B Go to step 4.
C Go to step 10.
A
1-115
SST 1 09111-36760-71 (09991-70201)

SST 2 09160-36760-71 (09843-18040)
1. Disconnect the connector K of fuel temperature sensor.
2. Using "Diagnosis check wire No.2", short circuit the terminals
Fuel temperature sensor of fuel temperature sensor connector of the truck side.
Connector on the machine side 3. Turn the ignition key switch ON.
K 4. While the engine is stopped, according to the instruction of the
Standard display temperature 140 °C (284 °F) or more
1 2
OK Go to step 5.
NG

(Engine control computer - Fuel temperature sensor)
Note:
harness and connector.
the connector K of fuel temperature sensor.
Resistance
Inspection
condition
A-112 (THF) - K-2 Always Less than 1 Ω
A-89 (ETHF) - K-1 Always Less than 1 Ω
112 (THF) 89 (ETHF)
Fuel temperature sensor OK Go to step 7.
NG Go to step 8.
K
1 2
SST 09111-36760-71(09991-70201)
1. Disconnect the connector of fuel temperature sensor.
Standard display temperature -40 °C (-40 °F)
NG Go to step 6.
OK
1-116
5 Fuel temperature sensor replacement

1. Replace the fuel temperature sensor.
Next Go to step 9.

(Engine control computer - Fuel temperature sensor)
Note:
Engine control computer the connector K of fuel temperature sensor.
Resistance
Inspection
condition
A-112 (THF) and K-2 -
body ground
112 (THF) 89 (ETHF) A-89 (ETHF) and K-1 -
Fuel temperature sensor Other terminal and Always 10 kΩ or more
Connector on the machine side body ground
K NG Go to step 8.
1 2
OK

Next Go to step 10.

Next Go to step 10.
Next
1-117
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
Next
End
1-118
DTC P0201 Injector Circuit / Open - (Cylinder 1)
DTC P062D Fuel Injector Driver Circuit Performance
Circuit description
The injector driver has been adopted to drive the injector at high speed. The injector driver realizes high speed drive
under high fuel pressure conditions by employing the high voltage, fast charging system that uses DC/DC converter.
When the injector driver receives a fuel injection command (IJT) from the engine control computer, it outputs a drive
signal to the fuel injector. When the drive signal is passed to the fuel injector, the injector driver sends an injection
confirmation (IJF) signal of the fuel injector to the engine control computer.
The engine control computer monitors the injector driver constantly, and it causes cylinder cut off or engine stop if an
abnormal state is detected.
1-119
Injector driver circuit diagram:

Injector driver (EDU) *: Fuel injector
T
INJ+3
K
High
INJ+2
From battery A voltage J
generation
INJ+4
circuit I
Command INJ+1
H
signal
IJt1 INJ-1
B L
IJt4 Control INJ-4
Engine C M
control circuit
IJt2 INJ-2
Computer D N
IJt3 INJ-3
E O
R S
IJf
F
Confirmation
signal
P
G
GND
EDU connector
C D E
I O S B CR
G A H D E F
L M N
J K T
P
Be careful of high voltage: H, I, J, K, L, M, N, O, S and T terminals

1-120
P0201
3. Abnormal period
4. Others
1. Battery voltage is 11 V or more
with the engine running except
the case of deceleration fuel cut • Wire harness or connector
2. Disconnection or shorting of • Injector driver
Perform idling for 5 sec. or longer.
injector ASSY (No.1) circuit • Injector ASSY
3. Specified number of times • Engine control computer
(approx. 0.5 sec.)
4. 1 trip
P0202
3. Abnormal period
4. Others
(approx.0.5 sec.)
4. 1 trip
P0203
3. Abnormal period
4. Others
1. Battery voltage is 11 V or more • Wire harness or connector
with the engine running except • Injector driver
the case of deceleration fuel cut
• Injector ASSY
2. Disconnection or shorting of
Perform idling for 5 sec. or longer. • Engine control computer
injector ASSY (No.3) circuit
3. Specified number of times
(approx. 0.5 sec.)
4. 1 trip
1-121
P0204
3. Abnormal period
4. Others
(approx. 0.5 sec.)
4. 1 trip
P062D
3. Abnormal period
4. Others
1. Engine speed 500 r/min or more,
11 V or more
2. Mismatch of drive waveform of • Wire harness or connector
injection between engine control • Injector driver
computer and injector driver • Injector ASSY
(approx. 0.5 sec.)
4. 1 trip
Detection overview
• P0201, P0202, P0203 and P0204:
The engine control computer compares the injection command (IJT) signal and injection confirmation
(IJF) signal for each cylinder. When the engine control computer detects a defect of particular cylinder,
DTC P0201, P0202, P0203 or P0204 is output.
• P062D:
The engine control computer monitors the injection command (IJT) and injection confirmation (IJF)
signals constantly. If the number of IJT signals does not match that of IJF signals, the engine control
computer outputs a diagnosis code.
The injector ASSY is grounded by the field effect transistor (FET) and series resistor, and the resistor
causes voltage drop. The injector driver monitors the voltage drop caused by the resistor and the current
drawn by the injector ASSY. When the injector ASSY current becomes high, the voltage drop caused via
the resistor exceeds the standard level and the IJF signal for the corresponding cylinder is not sent to the
engine control computer.
If an injection confirmation (IJF) signal is not sent from the injector driver to the engine control computer
even though the engine control computer has sent an injection command (IJT) signal to the injector driver
after an engine start, DTC P062D will be output.
When this diagnosis code is output, the engine control computer enters the fail-safe mode, and restricts
the engine output or stops the engine. The fail-safe mode is maintained until the ignition key switch is
turned OFF.
1-122
Abnormality detection:
Injection command signal (IJT)
Injection confirmation signal (IJF)
Engine control computer Injector driver
Injection command
signal
IJT
Abnormal
IJF
Injection confirmation
signal
Normal
1-123
Circuit diagram
5 51
INJF E A INJF
4 50
#10 E A #1
8 49
#20 E A #2
7 48
#30 E A #3
3 47
#40 E A #4
1
IJ1+ C
1 2
F
6
IJ1- D
6
IJ2+ C 1 2
G
4
IJ2- D
5
IJ3+ C
1 2
H
2
IJ3- D
3
IJ4+ D
1 2
I
5
IJ4- D
1-124
2 44
+B C B IREL
EDU
3 20
B +B2
GND C
1
B +B
EDU 45
B MREL
MAIN
EFI
2
B BATT
EFI2
Battery
C D E A B
Injector Engine control
driver (EDU) Computer
Caution:
• Turn the ignition key switch OFF before working for the high voltage circuit.
Note:
1-125
1 Engine start inspection

Result
Result Go to
Engine does not start.*1 A
Engine starts but idles rough.*2 B
Other than the above C
Note:
• *1: P062D is stored.
• *1: If the engine does not start due to a failure of injector
driver after deleting DTC of P062D, P062D will not be stored.
When a failure of injector driver prevents the engine from
starting, [Fuel Press] shows a value higher than [Target
Common Rail Pressure].
• *2: P0201, P0202, P0203 or P0204 is stored.
B Go to step 4.
C Inspection of irregular problems

(See page 1-15 for the procedure)
A
2 Injector driver power supply circuit inspection

Note:
Injector driver harness and connectors.
Connector on the machine side 1. Disconnect the connector C of injector driver.
C
Voltage value
+B GND
1 2 3 Inspection
4 5 6 Inspection terminal Reference
condition
Ignition key
C-2 (+B) - C-3 (GND) 11 to 14 V
switch ON
NG Go to step 15.
OK
3 Wire harness and connector inspection (Engine control computer - Injector driver)
Note:
1-126

Engine control computer the connector E of injector driver.
Resistance
Inspection
condition
A-50 (#1) - E-4 (#10) Always Less than 1 Ω
48 (#3) 50 (#1) A-49 (#2) - E-8 (#20) Always Less than 1 Ω

51 (INJ1)
47 (#4) 49 (#2) A-48 (#3) - E-7 (#30) Always Less than 1 Ω
Injector driver A-47 (#4) - E-3 (#40) Always Less than 1 Ω
A-51 (INJ1) - E-5 (INJF) Always Less than 1 Ω
E
#40 #10 Resistance
Inspection
1 2 3 4 Inspection terminal Standard
5 6 7 8 condition
#20
A-50 (#1) and E-4
INJF (#10) - Other termi-
#30 Always 10 kΩ or more
nal and
body ground
A-49 (#2) and E-8
(#20) - Other termi-
nal and
body ground
A-48 (#3) and E-7
nal and
body ground
A-47 (#4) and E-3
nal and
body ground
A-51 (INJ1) and
E-5 (INJF) - Other
terminal
and body ground
OK Go to step 6.
NG Go to step 15.
SST 09111-36760-71(09991-70201)
procedure.)
Next
1-127
SST 09111-36760-71(09991-70201)
2. Run at idle for 5 sec. or longer.
screen, check the diagnosis code. (See page 1-13 for the
procedure.)
Note:
• When the diagnosis code P0201 is displayed, inspect the
injector ASSY (No.1) circuit.
Next
6 Injector ASSY inspection

1. Disconnect the injector ASSY connector.
Resistance
Inspection
2 1 Inspection terminal Reference
condition
1-2 20 °C (68 °F) 0.85 to 1.05 Ω
NG Go to step 11.
OK
7 Wire harness and connector inspection (Injector driver - Injector ASSY)

Note:
1. Disconnect the connector F, G, H and I of injector ASSY
(No.1), (No.2), (No.3) and (No.4).
2. Disconnect the connector C and D of injector driver.
1-128
SST 09111-36760-71
procedure.)
NOTICE:
Next

2 1 2. Measure the resistance between the terminals using a tester.
Resistance
Inspection Terminal Inspection Reference

Condition
1-2 Always Less than 5Ω
NG Go To Step 11
OK
7 Wire harness and connector inspection (Injector driver – Injector ASSY)

NOTICE:
See page 0-13 for the inspection procedure and notes of wire harness and
connectors.
1. Disconnect the connector F, G, H and I of injector ASSY (No.1), (No. 2), (No. 3) and
(No. 4)
1-129

SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
3. Turning OFF the ignition swich, and after 30 seconds, start the
engine.
NG Go to step 14.
OK
End
11 Injector ASSY replacement (target cylinder)
1. Replace the injector ASSY of the target cylinder indicated by

the individual inspection of injector ASSY or diagnosis code.
Caution:
• For the cylinder, with which the injector ASSY is replaced,
make sure to use a new injection pipe.
• If not assembled in the proper order, injector ASSY may be
failure.
• When the injector ASSY is deteriorated and causes a
failure, this may result in knocking, rough idling, and other
problems.
injector ASSY and injection pipe, possibly resulting in fuel
leak.
Next
Next
1-130

Next Go to step 16.

Next Go to step 16.
15 Wire harness and connector repair or replacement
Next
SST 09111-36760-71(09991-70201)
procedure)
Next
SST 09111-36760-71(09991-70201)
3. Turning OFF the ignition swich, and after 30 seconds, start the
engine.
13 for the procedure)
Next
End
1-131
DTC P0299 Turbocharger Underboost
Circuit description
See page 1-54 for P0046 circuit description.
P0299
3. Abnormal period
4. Others
Turbo charger S/A
Low battery voltage (P0560 detected
simultaneously)
Disconnection of the pipe between
the turbo charger S/A and intake
1. After warm-up, engine speed is
manifold
800 r/min or more
Disconnection of the diesel turbo
2. Supercharging pressure deviation
- pressure sensor hose
is the specified value or more
Diesel turbo pressure sensor
3. 80 sec.
Electric EGR control valve ASSY
4. 1 trip
Modification or clogging of the intake
and exhaust system
Injection system (reduction of fuel
injection amount)
Related Data List

DTC No. Data list
• Target supercharging pressure
P0299
• Intake manifold pressure
Note:
The following symptoms may occur when the variable nozzle is stuck open and DTC P0299 is stored.
• Insufficient output
• Surge or hesitation under light or middle load condition
Circuit diagram
Caution:
Note:
• Use 'Engine Diagnostic Program' to read the freeze frame data. A part of engine operation condition when
• Compare the data lists of [MAP] and [Target Booster Pressure] during acceleration at medium or high
rotation rate to determine the defect condition.
1-132
SST 09111-36760-71(09991-70201)
procedure.)
Result
Result Go to
P0299 is output. A
P0299 and another diagnosis code are output. B

Go to troubleshooting of lack of power, hesitation, and surge (hesitation)

1-133
DTC P0335 Crankshaft Position Sensor Circuit
DTC P0339 Crankshaft Position Sensor Circuit Intermittent
Circuit description
The crank position sensor system consists of the crank angle sensor plate and pickup coil. The crank angle sensor
plate has 34 projections with 2 lost teeth for a top dead center detection, and it is installed to the crankshaft. The
pickup coil outputs a signal 34 times per engine rotation. The engine control computer determines the cylinder and
the phase or angle of camshaft based on G signal, and detects the crankshaft angle and engine speed based on NE
signal.
P0335
3. Abnormal period
4. Others
1. During cranking
2. NE signal is not input
Cranking or engine start
4. 1 trip • Wire harness or connector
• Crank position sensor No. 2
1. After the engine start (600 r/min • Crank angle sensor plate
or more) • Engine control computer
3 sec. or longer after engine start 2. NE signal is not input
3. 3 sec. or longer
4. 1 trip
P0339
3. Abnormal period
4. Others
1. Engine speed 1000 r/min or more
3 seconds after STA ON  OFF
5 sec. or more with a minimum • Crank position sensor No. 2
2. NE signal is not input.
engine speed of 1000 r/min • Crank angle sensor plate
3. 0.05 sec. or more
4. 1 trip
Related Data List

DTC No. Data list
P0335
Engine speed
P0339
Note:
If P0335 and P0339 are stored, the following symptoms may occur.
- Hard starting
- Misfire
- Knocking
- Black smoke
- White smoke
- Engine stalling
1-134
Circuit diagram
1 103
NE+
2 102
NE-
3
Shield cable
M
Crank position sensor No. 2
1 80
G+
2 79
G-
Shield cable
N A
Crank position sensor Engine control
Computer
Caution:
Note:
• Use 'Engine Diagnostic Program' to read the freeze data. A part of engine operation condition when the
defect occurred is recorded in the freeze data. This information is useful for troubleshooting.
• Perform troubleshooting of DTC P0335 and P0339 first. If no defect is found, the mechanical system may
be defective.
1 Crank position sensor No. 2 individual inspection
1. Inspect the crank position sensor No. 2.

NG Go to step 7.
OK
2 Inspection of wire harness and connector

(Engine control computer - Crank position sensor No. 2)
Note:
1-135
1. Disconnect the connector A of the engine control computer

Engine control computer and the connector M of the crank position sensor No. 2.
Resistance
Inspection
condition
A-103 (NE+) - M-1 Always Less than 1 Ω
A-102 (NE-) - M-2 Always Less than 1 Ω
102(NE-) 103(NE+) M-3 - Body ground Always Less than 1 Ω
Crank position sensor No. 2 Resistance
Inspection
M Inspection terminal Standard
condition
A-103 or M-1 -
1 2
body ground
3
A-102 or M-2 -
body ground
NG Go to step 8.
OK
3 Inspection of sensor installation position
1. Inspect the tightening and installation conditions of the crank

position sensor No. 2 bolt.
NG Go to step 9.
OK
4 Crank angle sensor plate individual inspection
1. Inspect the uneven portion and installation condition of the

crankshaft crank angle sensor plate.
NG Go to step 10.
OK
5 Inspection of pump drive shaft pulley

pump drive shaft pulley.
NG Go to step 11.
OK

Next Go to step 12.
1-136
7 Replacement of crank position sensor No. 2
1. Replace the crank position sensor No. 2.

Next Go to step 12.

Next Go to step 12.
9 Repair or replacement of sensor installation position
1. Repair or replace the sensor installation position.

Next Go to step 12.
10 Replacement of crank angle sensor plate No. 1
1. Replace the crank angle sensor plate.

Next Go to step 12.
11 Replacement of pump drive shaft pulley
1. Replace the pump drive shaft pulley.

Next
SST 09111-36760-71(09991-70201)
procedure.)
Next
SST 09111-36760-71(09991-70201)
2. Run the engine at 1000 r/min or more for 5 sec. or longer.
Next
End
1-137
DTC P0340 Camshaft Position Sensor Circuit
Circuit description
A crank position sensor (G signal) consists of a magnet, iron core and pickup coil. The G signal plate has 1 tooth on
its outer circumference and is mounted on the pump drive shaft pulley. When the pump drive shaft pulley rotates, the
protrusion on the G signal plate and the pickup coil air gap change, causing fluctuations in the magnetic field
(magnetic intensity) and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is
mounted on the crank angle sensor plate. The NE signal sensor generates 34 signals at every engine revolution. The
engine control computer detects the standard (reference) crankshaft angle based on G signal, actual crankshaft
angle and engine speed by NE signal.
P0340
3. Abnormal period
4. Others
At STA OFF
1. After the engine start
(650 r/min or more)
2. G signal is not input although NE
signal is input.
Run at idle for 5 sec. or longer. 4. 1 trip
At STA OFF • Wire harness or connector
1. When the engine is running • Crank position sensor
2. NE signal and G signal phases • Pump drive shaft pulley
are not aligned. • Crank position sensor No. 2
4. 1 trip
At STA ON
1. During cranking
(+B voltage 11 V)
Perform cranking for 4 sec. or longer.
2. G signal is not input.
3. 4 sec. or longer
4. 1 trip
Note:
If P0340 is stored, the following symptoms may occur.
- Hard starting
- Misfire
- Knocking
- Black smoke
- White smoke
Circuit diagram
Caution:
1-138
Note:
• Perform troubleshooting of the crank position sensor first. If no defect is found, the crank position sensor
No. 2 may be defective. Perform the following inspections.
- Inspection of crank position sensor No. 2 installation condition
- Inspection of the crank angle sensor plate
- Inspection of crank position sensor No. 2 connector installation condition
- Inspection of the crank position sensor No. 2 circuit
1 Crank position sensor individual inspection
1. Inspect the crank position sensor.

NG Go to step 8.
OK

(Engine control computer - Crank position sensor)
Note:
Engine control computer and the connector N of the crank position sensor.
Resistance
Inspection
condition
A-80 (G+) - N-1 Always Less than 1 Ω
A-79 (G-) - N-2 Always Less than 1 Ω
79 (G-) 80 (G+)
Resistance
Crank position sensor Inspection
condition
N A-80 (G+) or N-1 -
body ground
1 2 A-79 (G-) or N-2 -
body ground
NG Go to step 9.
OK
1-139
3 Inspection of sensor installation position
1. Inspect the tightening and installation conditions of the crank

position sensor bolt.
NG Go to step 10.
OK
4 Pump drive shaft pulley individual inspection

pump drive shaft pulley.
NG Go to step 11.
OK
SST 09111-36760-71 (09991-70201)

procedure.)
Next
6 Inspection of wire harness and connector (Crank position sensor No. 2 circuit)
SST 09111-36760-71 (09991-70201)

3. During idling, check the engine condition when the crankshaft
position sensor No. 2 wire harness is shaken for 5 sec. or
longer.
procedure.)
Result
Result Go to
When the wire harness is shaken, a defect such as rough idle or engine stalling occurs or a diagno-
A
sis code is output.*
Note:
*: A diagnosis code was stored due to the contact resistance
change of the connector. Repair or replace the wire
harness or connector.
A Go to step 12.
B
1-140

Next Go to step 12.
8 Replacement of crank position sensor
1. Replace the crank position sensor.

Next Go to step 12.

Next Go to step 12.
10 Repair or replacement of sensor installation position
1. Repair or replace the sensor installation position.

Next Go to step 12.
11 Replacement of pump drive shaft pulley
1. Replace the pump drive shaft pulley.

Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-141
DTC P0405 Exhaust Gas Recirculation Sensor Circuit Low
DTC P0406 Exhaust Gas Recirculation Sensor Circuit High
Circuit description
The EGR valve position sensor is mounted on the EGR valve to detect EGR valve opening degree. The EGR valve
opening degree detected by the EGR valve position sensor is fed back to the engine control computer to control the
EGR valve opening degree according to engine operation.
P0405
3. Abnormal period
4. Others
2. The output of the EGR valve
5 sec. or longer with ignition key • Electric EGR control valve ASSY
position sensor is 0.2 V or less.
switch ON (EGR valve position sensor)
3. 2 sec. or longer
4. 1 trip
P0406
3. Abnormal period
4. Others
2. The output of the EGR valve
5 sec. or longer with ignition key • Electric EGR control valve ASSY
position sensor is 4.8 V or more.
switch ON (EGR valve position sensor)
3. 2 sec. or longer
4. 1 trip
Detection overview
If the output voltage of the EGR valve position sensor is out of the normal range for 5 sec. or longer, the engine
control computer detects it as abnormality and turns on the engine check indicator.
1-142
Circuit diagram
3 75
VC VCEG
2 115
VTA EGRA
1 92
E2 EEGL
4 86
M+ EGM+
5 85
M- EGM-
Shield cable
S A
Electric EGR Engine control
Control valve ASSY Computer
Caution:
according to the Operation Support Procedure List.
Note:
1-143

(Engine control computer - EGR valve position sensor (Electric EGR control valve))
Note:
Engine control computer and the connector S of the electric EGR control valve ASSY.
Resistance
Inspection
condition
A-75 (VCEG) - S-3 (VC) Always Less than 1 Ω
A-115 (EGRA) - S-2 (VTA) Always Less than 1 Ω
92 (EEGL) 115 (EGRA) 75(VCEG) A-92 (EEGL) - S-1 (E2) Always Less than 1 Ω
Electric EGR
Control valve ASSY Resistance
Inspection
S condition
A-75 (VCEG) and S-3 (VC) -
Other terminal and body Always 10 kΩ or more
1 2 3 4 5 ground
E2
A-115 (EGRA) and S-2 (VTA)
VTA VC - Other terminal and body Always 10 kΩ or more
ground
A-92 (EEGL) and S-1 (E2) -
Other terminal
NG Go to step 7.
OK

(EGR valve position sensor (electric EGR control valve ASSY) power supply voltage
inspection)
Note:
1. Disconnect the connector S of the electric EGR control valve
Electric EGR
Control valve ASSY ASSY.
S
Voltage value
Inspection
Inspection terminal Reference
1 2 3 4 5 condition
Ignition key
S-3 (VC) - S-1 (E2) 4.5 to 5.5 V
switch ON
E2 VC
NG Go to step 6.
OK
1-144
3 Replacement of electric EGR control valve ASSY
1. Replace the electric EGR control valve ASSY.

Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

2. Turn ON the ignition key switch and wait for 5 sec. or longer.
procedure.)
Reference Diagnosis code is not output
NG Go to step 6.
OK
End

Next Go to step 8.

Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
1-145
SST 09111-36760-71 (09991-70201)

Next
End
1-146
DTC P042E Exhaust Gas Recirculation Control Stuck Open
Circuit description
The EGR system recirculates exhaust gas to mix it with intake air so that combustion speed can be delayed. This
keeps combustion temperature low, which is useful for NOX emission reduction.
To control EGR gas amount, the engine control computer controls EGR valve opening degree and throttle valve
opening degree.
P042E
3. Abnormal period
4. Others
1. When the engine is running
2. The EGR valve target opening
degree and actual opening
degree are different to each • Electric EGR control valve ASSY
Warm up the engine and run at idle other. sticking
for 60 sec. Then, run the engine 3. 22 sec. or longer • Non-smooth electric EGR control
maintaining the engine speed at 4. 1 trip valve ASSY operation
NMR for 40 sec. Then, fully close the
1. When the engine is running • Electric EGR control valve ASSY
accelerator with the engine speed at
2. The EGR drive duty exceeds the deposit formation
NMR to decelerate by engine brake.
threshold for 0.5 sec. • Engine control computer
(40 sec. or longer)
4. 1 trip
Related Data List

DTC No. Data list
• Intake air quantity
• EGR fully-closed position learned value
P042E
• EGR fully-closed position learning history
• EGR target opening degree
• EGR actual opening degree #1
Note:
• Actual EGR valve opening rate: Fully closed = 0%, Fully open = 100%
• If DTC P042E is stored, the following symptoms may occur.
Stuck closed abnormality
- Intake air booming noise
- Minor knocking
Stuck open abnormality
- Black smoke
- Vibration at engine stop
- Misfire
- White smoke
- Engine stalling
1-147
Detection overview
If the EGR valve target opening degree and actual opening degree are different to each other, the engine control
computer detects it as EGR valve abnormality and turns on the engine check indicator.
Error detection:
Open
EGR valve target opening degree
Closed
Normal
Open
Abnormal
(movement defect)
EGR valve actual opening degree
Closed
Abnormal (stuck)
Abnormality
judgment value
Abnormality counter
Detection of P042E
Time
Note:
• If there is a large volume of carbon deposits on the electric EGR control valve ASSY, the parts related to
the intake manifold, EGR with cooler pipe S/A and exhaust gas system may also have carbon deposits
inside.
• Carefully check the [Actual EGR Valve Pos.], [Target EGR Pos.] and [MAF] of the freeze frame data.
1-148
Circuit diagram
3 75
VC VCEG
2 115
VTA EGRA
1 92
E2 EEGL
4 86
M+ EGM+
5 85
M- EGM-
Shield cable
S A
Electric EGR Engine control
Control valve ASSY Computer
Caution:
When cleaning the EGR valve, use a cloth moistened with detergent solvent. If these parts are directly
sprayed with or soaked in detergent solvent, they may be damaged.
Note:
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
P042E is output. A
P042E and another diagnosis code are output. B
B To the "DIAGNOSIS CODE LIST"

(See page 1-5 for the procedure).
A
1-149
2 'Engine Diagnostic Program' active test implementation (EGR target opening degree bank 1)
SST 09111-36760-71 (09991-70201)

2. Press [Active test], select [EGR taget opening degree bank1]
3. Select [Target EGR Pos.] and [Actual EGR Valve Pos.] from
the data list item, then press [Start].
Reference The value of [Actual EGR Valve Pos.] must
follow that of [Target EGR Pos.].
NG Go to step 4.
OK
3 'Engine Diagnostic Program' active test implementation (EGR target opening degree bank 1)
SST 09111-36760-71 (09991-70201)

1. Remove the electric EGR control valve ASSY.
2. After removing the electric EGR control valve ASSY, connect
the connector.
4. Press [Active test], select [EGR taget opening degree bank1]
5. When performing the active test, check if the valve of the
electric EGR control valve ASSY opens and closes.
Reference The valve opens and closes.
6. Check that the electric EGR control valve ASSY is fully closed.
Reference The electric EGR control valve ASSY is fully
closed.
Note:
• Hold the electric EGR control valve ASSY against the light
to confirm that the valve completely contacts with the valve
seat.
• If light leaks from the valve, the electric EGR control valve
ASSY is not fully closed.
• If there is a large volume of deposits on the electric EGR
control valve ASSY or intake manifold, remove them.
7. Install the electric EGR control valve ASSY.
OK Go to step 5.
NG

Note:
Before replacing the electric EGR control valve ASSY, inspect
the connecting condition of the wire harness and connector. If
abnormal, replace or repair the wire harness or connector.
Next Go to step 6.
1-150
5 Electric EGR control valve ASSY cleaning
1. Remove the electric EGR control valve ASSY.

2. Visually check the inside of the electric EGR control valve
ASSY and EGR pipe for deposits. If deposits are found, clean
the electric EGR control valve ASSY.
Note:
• If the EGR valve is stuck closed or the EGR with cooler pipe
S/A is clogged, intake air quantity increases, which may
result in engine vibration and larger knocking.
• If the EGR valve is stuck open, the cylinder pressure
increases when the engine is stopped, which may result in
heavier vibration when stopped.
• If the EGR valve does not close properly or is stuck open,
EGR quantity may become excessive and combustion may
become unstable. Or it may result in insufficient output.
3. Install the electric EGR control valve ASSY.
Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 009120-36760-71 (09991-70201)

2. Warm up the engine and run at idle for 60 sec. Then, maintain
the engine speed at NMR for 40 sec. Run the vehicle and fully
close the accelerator with the engine speed at NMR to
decelerate by engine brake.
Next
End
1-151
DTC P0489 Exhaust Gas Recirculation Control Circuit Low
DTC P0490 Exhaust Gas Recirculation Control Circuit High
Circuit description
The electric EGR control valve ASSY opens and closes the EGR valve through the control of the engine control
computer. The EGR position sensor installed on the electric EGR control valve ASSY detects EGR valve opening
degree.
P0489
3. Abnormal period
4. Others
1. When the EGR valve is operating
2. The EGR actuator current is less • Wire harness or connector
Perform idling for 5 sec. or longer. than 0.5 A • Electric EGR control valve ASSY
3. 2 sec. or longer • Engine control computer
4. 1 trip
P0490
3. Abnormal period
4. Others
1. When the EGR valve is operating
2. The EGR actuator current is 8 A
or more or the hall IC tempera-
Perform idling for 5 sec. or longer. • Electric EGR control valve ASSY
ture is 150 °C (302 °F) or more.
3. 2 sec. or longer
4. 1 trip
Related Data List

DTC No. Data list
P0489 • EGR target opening degree
P0490 • EGR actual opening degree #1
Circuit diagram
Caution:
Note:
1-152
1 Inspection of electric EGR control valve ASSY
1. Inspect the electric EGR control valve ASSY.

NG Go to step 4.
OK

(Engine control computer - Electric EGR control valve ASSY)
Note:
Engine control computer and the connector S of the electric EGR control valve.
Resistance
Inspection
condition
S-4 (M+) - A-86 (EGM+) Always Less than 1 Ω
S-5 (M-) - A-85 (EGM-) Always Less than 1 Ω
85 (EGM-) 86 (EGM+)
Resistance
Electric EGR
Control valve ASSY Inspection
S S-4 (M+) or A-86 (EGM+) -
Body ground
S-5 (M-) or A-85 (EGM-) -
1 2 3 4 5 Body ground
NG Go to step 5.
M+ M-
OK

Next Go to step 6.

Next Go to step 6.
Next
1-153
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-154
DTC P0560 System Voltage
Circuit description
Battery power is constantly supplied to the BATT terminal. It is used for diagnosis code storage and freeze frame
data storage, etc. If an error occurs in the BATT terminal system, the engine control computer detects a diagnosis
code.

3. Abnormal period
4. Others
1. Always
2. Disconnection or short circuit of • EFI2 fuse
- the BATT terminal system • Battery
3. 3 sec. or longer • Wire harness or connector
4. 1 trip
Circuit diagram
2
1 2
B BATT
EFI2
MAIN
109
Battery A E1
Caution:
1 'Engine Diagnostic Program' data reading (Accessory battery voltage)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and [Battery Voltage].
Item name Description/Display range Reference
• Indicates battery voltage. 11 to 14 V
Battery Voltage
• Display range: 0 to 65.5 V Ignition key switch ON
1-155
3. Read the [Battery Voltage] displayed on the 'Engine Diagnostic

Program'.
Voltage 11 to 14 V
Result
Result Go to
Abnormal A
Normal B
B Go to step 4.

(Inspection of ECU earth and battery voltage)
Note:
1. Disconnect the connector A and B in the engine control
computer.
2. Measure the voltage between terminals using a tester. (See
page 1-33 for the terminal layout.)
A Resistance
Inspection
condition
A-109 (E1) - Body ground Always Less than 1 Ω
109(E1)
Voltage value
Connector on the machine side Inspection
condition
B
B-2 (BATT) - Body ground Always 11 to 14 V
NG Repair or replacement of wire harness or connec-

tor (Engine control computer - Battery, Body
Earth)
B-2(BATT)
OK
3 Battery individual inspection
1. Fluid level inspection

Reference Fluid level must be in the specified range.
1-156
2. Specific gravity inspection

(1) Inspect the specific gravity of each cell.
Reference 1.25 to 1.29 (fluid temperature 20 °C (68 °F))
Note:
If the measured value does not meet the reference, charge the
battery.
3. Voltage inspection
(1) To eliminate surface charge voltage, stop the engine after
running and turn the ignition key switch ON (within 20
sec.). Then, turn the headlight switch ON.
(2) Turn the ignition key switch OFF and turn the headlight
switch OFF.
(3) Using a tester, measure the battery voltage between the
V terminals.
Voltage 12.5 to 12.9 V (fluid temperature 20 °C (68 °F))
Note:
battery.
(4) Measure the battery voltage during cranking.
Voltage Approx 9.6 V or more
NG Battery replacement
OK
Engine control computer replacement
4 Battery individual inspection
1. Fluid level inspection

Reference Fluid level must be in the specified range.
2. Specific gravity inspection
(1) Inspect the specific gravity of each cell.
Reference 1.25 to 1.29 (fluid temperature 20 °C (68 °F))
Note:
battery.
3. Voltage inspection
(1) To eliminate surface charge voltage, stop the engine after
running and turn the ignition key switch ON (within 20
sec.). Then, turn the headlight switch ON.
(2) Turn the ignition key switch OFF and turn the headlight
switch OFF.
(3) Using a tester, measure the battery voltage between the
V terminals.
Voltage 12.5 to 12.9 V (fluid temperature 20 °C (68 °F))
Note:
battery.
(4) Measure the battery voltage during cranking.
Voltage Approx 9.6 V or more
NG Battery replacement
OK

1-157
DTC P0606 ECM / PCM Processor
DTC P060A Internal Control Module Monitoring Processor Performance
DTC P060B Internal Control Module A/D Processing Performance
Circuit description
P0606, P060A, P060B
3. Abnormal period
4. Others
2. Engine control computer internal
1 sec. or longer with ignition key
abnormality Engine control computer
switch ON
3. -
4. 1 trip
Caution:
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
Diagnosis code is displayed again. A
Diagnosis code is not displayed again. B
B Inspection of irregular problems

A
1-158
Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-159
DTC P0617 Starter Relay Circuit High
Circuit description
While cranking the engine, starter start signal is transferred to the engine control computer STA terminal, too. Starter
start signal is used to increase the fuel injection amount mainly at the engine start time. A diagnosis code is detected
when a starter start signal (STA) is input to the engine control computer after the engine start.
3. Abnormal period
4. Others
(1000 r/min or more) • Wire harness or connector
After the engine start, perform racing
2. STA signal is input. • Engine control computer
for 30 sec.
3. 20 sec. or longer • Ignition (starter) switch ASSY
4. 1 trip
Circuit diagram
2 3
AM1 ST1 ST
Ignition (starter)
switch ASSY T/C shift Neutral start
switch *1 relay *2
AM1 Parking brake

switch *2
STA
43
STA
MAIN 4 1
ST
*1 Shift lever type
3 2 *2 EZ pedal type
B
Engine control
Battery Computer
Starter ASSY
1-160
Caution:
Note:
1 'Engine Diagnostic Program' data reading (Starter signal)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [Starter Signal].
Standard
Ignition switch position Starter signal

ON OFF
START ON
NG Go to step 2.
OK
Inspection of irregular problems (See page 1-15 for the procedure)
2 Ignition (starter) switch ASSY individual inspection
1. Inspect the ignition (starter) switch ASSY.

OK Go to step 4.
NG
3 Replacement of ignition (starter) switch ASSY
1. Replace the ignition (starter) switch ASSY.
Next
4 'Engine Diagnostic Program' data reading (Starter signal)
SST 09111-36760-71 (09991-70201)

Standard
Ignition switch position Starter signal

ON OFF
START ON
OK End
NG
1-161
5 Inspection of wire harness and connector (Engine control computer)
Note:
1. Disconnect the connector B in the engine control computer.
Engine control computer 2. Measure the voltage between terminals using a tester. (See
Connector on the machine side page 1-33 for the procedure.)
B
Voltage value
Inspection terminal Inspection condition Standard

B-43 (STA) - Body Ignition switch
Less than 1 V
ground position ON
B-43 (STA) - Body Ignition switch
6 V or more
43 (STA) ground position START
Note:
Check that the ignition key switch is not at the START position
and the STA terminal is receiving no voltage.
Resistance
Inspection
condition
B-43 (STA) - Other terminal Always 10 kΩ or more
NG Wire harness or connector repair or replacement
OK
SST 09111-36760-71 (09991-70201)

instruction of the 'Engine Diagnostic Program' screen, delete
the diagnosis code. (See page 1-13 for the procedure.)
Next
SST 09111-36760-71 (09991-70201)

1. After the engine start, perform racing for 30 sec.
instruction of the 'Engine Diagnostic Program' screen, delete
the diagnosis code. (See page 1-13 for the procedure.)
Result
Result Go to
P0617 is output. A
B End

1-162
DTC P0627 Fuel Pump Control Circuit / Open
Circuit description
P0627
3. Abnormal period
4. Others
2. Disconnection or short circuit of
Repeat engine stopping operation • Suction control valve ASSY
the suction control valve ASSY
three times after engine starts and • Wire harness or connector
circuit
keep its state for 5 seconds at least. • Engine control computer
3. 0.5 sec.
4. 1 trip
Related Data List

DTC No. Data list
• Fuel pressure
P0627
• Common rail target value
Note:
When DTC P0627 is output, check that the difference between [Fuel Press] and [Target Common Rail
Pressure] in the data list during idling is less than 5000 kPa, using 'Engine Diagnostic Program'.
Circuit diagram
Caution:
• When replacing the supply pump ASSY or suction control valve ASSY, perform the learned value
initialization every time after the replacement. (See page 1-16 for the procedure.)
Note:
1-163
1 Inspection of suction control valve ASSY
1. Inspect the suction control valve ASSY.

NG Go to step 5.
OK

Note:
Engine control computer and the connector J of the suction control valve ASSY.
Resistance
Inspection
condition
41(PCV+) 81(PCV-)
Resistance

Body ground
1 2 A-81 (PCV-) and J-2 - Other
Body ground
NG Go to step 9.
OK
SST 09111-36760-71 (09991-70201)

procedure.)
Next
1-164
SST 09111-36760-71 (09991-70201)

2. Repeat engine stopping operation three times after continuing
idling state for more than 5 seconds.
procedure.)
Result
Result Go to
Diagnosis code is not output. A
P0627 is output or engine start is impossible. B
B Go to step 8.
End
5 Suction control valve ASSY replacement
1. Replace the suction control valve ASSY.

Next
Next
SST 09111-36760-71 (09991-70201)

2. Press [Trouble code] on the 'Engine Diagnostic Program' and
3. Perform the supply pump learned value initialization.
Note:
• See page 1-16 for the procedure of supply pump learned
Next Go to step 10.

Next Go to step 10.
1-165

Next Go to step 10.
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-166
DTC P062F Internal Control Module EEPROM Error
Circuit description
P062F
3. Abnormal period
4. Others
1. -
2. Any of the conditions is met.
- No injector compensation code
1 sec. or longer with ignition key is written. • ID code writing
switch ON - A wrong injector compensation • Engine control computer
code is written.
3. -
4. 1 trip
Note:
When replacing with a new engine control computer, if no injector compensation code is input, DTC P062F is
stored.
4. When replacing with a new engine control computer, input all learned values and codes to the new engine
control computer following the procedure below.
(1) Before replacing the engine control computer, read and save each learned value and code from the original
engine control computer, using 'Engine Diagnostic Program'. (See page 1-16 for the procedure.)
(2) After installing a new engine control computer, input the learned values and codes saved using 'Engine
Diagnostic Program' to the new engine control computer. (See page 1-16 for the procedure.)
(3) Turn the ignition key switch OFF and then 'Engine Diagnostic Program' OFF.
(4) Wait for 30 sec. or longer.
(5) Turn the ignition key switch ON and then 'Engine Diagnostic Program' ON.
(6) Using 'Engine Diagnostic Program', delete DTC P062F stored in the engine control computer. (See page 1-
Note:
• Each injector ASSY has different fuel injection characteristics. To optimize fuel injection, the engine control
computer uses compensation codes to balance the fuel injection which is different among injector ASSY.
• After replacing the engine control computer and 1 or more other parts, DTC P062F is stored when the ignition key
switch is turned ON for the first time. After writing the compensation codes, delete this DTC.
Replacement Work support item
• Reading and Saving the injector compensation code
Engine control computer • Writing the injector compensation code
(Write to the use saved compensation codes)
• Writing the injector compensation code
Injector ASSY (Write to the input manual compensation codes)
1-167
Caution:
• When replacing the fuel injector, write the ID code of a new fuel injector.
• When replacing the engine control computer, save the fuel injector ID codes of all cylinders before the
replacement, and save them to a new engine control computer after the replacement.
• A new injector ASSY has an ID code (30-digit alphanumeric code) on its head. writing of a wrong ID code
causes rough idling and engine vibration, which may shorten engine life.
Note:
• When replacing with new injector ASSY, install the right injector ASSY to the right cylinder because the ID
code is input to the 'Engine Diagnostic Program' for each cylinder once.
• After replacing the engine control computer or fuel injector, DTC P062F is detected when the ignition key
switch is turned ON for the first time.
Caution:
1 Implementation of work support (ID code check)
SST 09111-36760-71 (09991-70201)

Caution:
Do not start up the engine.
screen, press [Utility] and select [Injector Compensation].
Result
Result Go to
No injector compensation code has been input.
The injector compensation code written in the engine control computer is different from that marked A
on the injector ASSY.
B Go to step 3.
2 Implementation of work support (Writing the injector compensation code)
SST 09111-36760-71 (09991-70201)

Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
1-168
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
DTC is not output. A
P062F is output. B
B Go to step 5.
End
Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-169
DTC P1229 Fuel Pump System
Circuit description
This diagnosis code is output when the actual fuel pressure in the common rail is higher than the target although the
engine control computer has output a suction control valve ASSY closing signal. This diagnosis code indicates that
the control valve ASSY may be stuck open or the circuit may be disconnected or short-circuit. When this diagnosis
code is output, the engine control computer enters the fail-safe mode and restricts the engine output. The engine
control computer maintains the fail-safe mode until the ignition key switch is turned OFF.
P1229
3. Abnormal period
4. Others
2. An actual fuel pressure is higher • Suction control valve ASSY
After running at idle for 60 sec., per-
than the target fuel pressure by • Disconnection or short circuit of the
form racing from idle to NMR for 30
40000 kPa or more. suction control valve ASSY circuit
sec.
3. 30 sec. • Engine control computer
4. 1 trip
Related Data List

DTC No. Data list
• Fuel pressure
Note:
• When DTC P1229 is output, check [Fuel Press] and [Target Common Rail Pressure] in the data list using
'Engine Diagnostic Program'. After warm-up, [Fuel Press] is within 4000 kPa of [Target Common Rail
Pressure] during idling under normal conditions.
• If supply pump ASSY operation is defective ([Fuel Press] exceeds [Target Common Rail Pressure]
because the suction control valve ASSY is not easily closed), the value of [Target Pump SCV Current]
uppers.
Circuit diagram
Caution:
Note:
• If this diagnosis code is output, carefully check the [Fuel Press] [Target Common Rail Pressure] and
[Target Pump SCV Current] in the freeze frame data.
1-170
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
Only P1229 is output or P1229 and P0088 are output. A
Besides P1229, P0190, P0191, P0192 or P0193 is output. B
B Inspection of fuel pressure sensor system (DTC

P0190, P0191, P0192 and P0193) (See page 1-65
for the procedure.)
2 'Engine Diagnostic Program' data reading (Fuel pressure and common rail target value)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [Fuel Press] and
[Target Common Rail Pressure].
Standard: After warm-up, [Fuel Press] is within 4000 kPa
of [Target Common Rail Pressure] during
idling.
NG Go to step 3.
OK
INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)
3 Inspection of wire harness and connector (Suction control valve ASSY - Engine control com-
puter) (See page 1-163 for the procedure.)
OK Go to step 6.
NG
Next
1-171
5 Work support implementation (Fuel system check / fuel system malfunction check)
1. Implement the fuel system check. (See page 1-16 for the
procedure.)
2800
Engine speed
1400 rpm
Fuel system check

ON
OFF
Fuel pressure
under normal
Below
10000 kPa
Fuel pressure
conditions
Time
2 sec.
Standard Actual fuel pressure keeps higher than target

fuel pressure, fuel system malfunction occurs.
Note:
common rail.
illustration.
OK Go to step 9.
NG
6 Replacement of suction control valve ASSY

Next
1-172
Next
SST 09111-36760-71 (09991-70201)

2. Press [Trouble code] the 'Engine Diagnostic Program' and
Note:
Next
SST 09111-36760-71 (09991-70201)

procedure.)
Next
SST 09111-36760-71 (09991-70201)

2. After running at idle for 60 sec., perform racing from idle to
NMR for 30 sec.
screen, press [Trouble code]. (See page 1-13 for the
procedure.)
Note:
be made, perform racing again from idle to NMR for 30 sec.
Next
End
1-173
DTC P1251 Motor for Turbocharger Control Circuit (Intermittent)
Circuit description
P1251
3. Abnormal period
4. Others
• Turbo charger S/A
• VN turbo link sticking abnormality
• Low battery voltage (P0560
1. After warm-up, engine speed is
detected simultaneously)
800 r/min or more.
• Inlet air temperature sensor
2. Supercharging pressure is the
During running • Intake air flow meter S/A
specified value * or more
• Electric EGR control valve ASSY
3. 5 sec. or longer
• Modification or clogging of the
4. 1 trip
intake and exhaust system
Note:
*: Specified value varies according to engine speed, atmospheric pressure and engine cooling water
temperature.
Related Data List
DTC No. Data list
• Target supercharging pressure
• Intake air quantity
• EGR target opening degree
P1251
• EGR actual opening degree #1
• VN turbo target opening degree
• VNT actual opening degree
• Atmospheric pressure
Note:
The following symptoms may occur when the VN turbo vane is stuck closed and DTC P1251 is stored.
• Surge during full-load running
• Insufficient output due to output limit
Circuit diagram
Caution:
Note:
1-174
1 Diagnosis code and freeze frame data check
SST 09111-36760-71 (09991-70201)

2. Press [Trouble code] on the 'Engine Diagnostic Program', read
the diagnosis code and record the freeze frame data. (See
page 1-14 for the procedure.)
Result
Result Go to
P1251 is output. A
P1251 and another diagnosis code are output. B
Note:
• DC motor system DTC: P0046, P0047 and P0048
• Nozzle vane position sensor system DTC: P2564 and
P2565(See page 1-193 for the procedure.)
2 Intake system inspection
1. Inspect that there is no leakage or clogging between the air

cleaner case and the turbo charger S/A and between the turbo
charger S/A and the intake manifold.
Result
Result Go to
Leak or clogging A
No leak or clogging B
Note:
• Especially, inspect the hoses and pipes between the air
cleaner and turbo charger S/A.
• Disconnection of the hose or pipe may result in overboost.
Check the hose and pipe between the air cleaner and
compressor for disconnection. Check the high pressure
hose for disconnection due to overboost.
• Check for abnormal disconnection, pipe and hose collapse
and damage inside the intake system.
• Check if the pipes and hoses in the intake system are
connected securely by touching them.
• To check air leak from the intake system, apply soap water
to the intake system and increase engine speed. Check if
bubbles are formed.
• Check the hose between the diesel turbo pressure sensor
and intake manifold for looseness and disconnection.
• Check if the diesel turbo pressure sensor output and wire
harness are normal.
• Check that no alteration is made to the intake system.
B Go to step 4.
A
1-175
3 Repair or replacement of intake system
1. Repair or replace the defective parts of the intake system.
Next
4 Inspection of turbo charger S/A (DC motor behavior)

2. Check the behavior of the DC motor when IG is switched from
ON to OFF.
Standard: When IG is turned OFF, the operation link
should move from A to C as shown in the
illustration and touch the stopper bolt.
The move of the operation link from A to B and
B to C and the move of the motor rod should be
smooth.
A B C
Operation link
Lock nut
Motor rod operation amount

Stopper bolt
(mm (in.))
5 Stopper bolt contact point
0
0 1 1.5 (sec)
Ignition key switch
OFF time
ON
IG switch
OFF
NG Go to step 13.
OK
1-176
5 Implementation of the 'Engine Diagnostic Program' active test (control the EGR step position)
SST 09111-36760-71 (09991-70201)

2. Press [Active test] [Target EGR Position] and [Actual EGR
Valve Pos.] on the 'Engine Diagnostic Program'.
3. Select [Target EGR Position] and [Actual EGR Valve Pos.]
from the data list items.
Result
Result Go to
The value of the [Actual EGR Valve Pos.] does not follow that of the [Target EGR Position]. A
The value of the [Actual EGR Valve Pos.] follows that of the [Target EGR Position]. B
B Go to step 7.
6 Replacement of electric EGR control valve ASSY and cleaning of EGR with cooler pipe S/A
1. Replace the electric EGR control valve ASSY and clean the
EGR with cooler pipe S/A.
(1) Remove the electric EGR control valve ASSY and the
(2) Visually check if there is any deposit in the EGR with
cooler pipe S/A and in the EGR passage. If any deposit is
detected, clean each part.
Caution:
• When cleaning the EGR with cooler pipe S/A, use an air
blow. Pay attention not to push dirt into the pipe.
• Do not wash with water to avoid rust and corrosion.
Note:
S/A is clogged, intake air quantity increases, which may
result in engine vibration and larger knocking.
2. Install a new electric EGR control valve ASSY and EGR with
cooler pipe S/A.
Next Go to step 11.
1-177
7 'Engine Diagnostic Program' data reading (Fuel injection amount)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [Injection Volume].
3. Start up the engine and warm up until engine cooling water
temperature reaches 70 °C (158 °F) or more.
4. After warm-up, check the value of the [Injection Volume] at
NMR.
Note:
Turn OFF the outside load and check when [Coolant Temp] is
70 °C (158 °F) or more.
Result
Result Go to
3/st.
[Injection Volume] is less than 7.0 mm A
B Go to step 11.
8 Replacement of injector ASSY (All cylinders)
1. Replace the injector ASSY. (See page 3-6 for the procedure.)
Caution:
failure.
leakage.
Next
Next
10 Implementation of work support (Writing the injector compensation code)
1. Implement the writing the injector compensation code (Write to

the input manual compensation codes.). (See page 1-16 for
the procedure.)
Next
1-178
SST 09111-36760-71 (09991-70201)

1. Turn ON the ignition key switch.
procedure.)
Next
SST 09111-36760-71 (09991-70201)

2. Check the engine speed from the freeze frame data previously
recorded. Run the vehicle according to the engine speed.
Note:
During running, take snapshots of [MAP] and [Target Boost
Pressure] using 'Engine Diagnostic Program'.
Result
Result Go to
P1251 is not output and the intake manifold pressure exceeds
A
the target supercharging pressure by 20 kPa or less.
Other than the above B*
Note:
*: Go back to the intake system inspection step and inspect
portions not yet inspected.
B Go to step 2.
End
1-179

(Engine control computer - DC motor (Turbo charger S/A))
Note:
Engine control computer and the connector U of the DC motor (turbo charger S/A).
A
Resistance
Inspection
condition
A-42 (VNM+) - U-2 Always Less than 1 Ω
A-43 (VNM-) - U-1 Always Less than 1 Ω
42(VNM+) 43(VNM-)
Resistance
DC motor (Turbo charger S/A) Inspection
Connector on the machine side Inspection terminal Standard
condition
U A-42 (VNM+) and U-2 -
Body ground
1 2 A-43 (VNM-) and U-1 -
Body ground
NG Repair or replacement of wire harness or connec-

tor (DC motor (Turbo charger S/A) - Engine con-
trol computer)
OK
Inspection of turbo charger S/A (DC motor individual inspection)

1-180
DTC P2120 Pedal Position Sensor "D" Circuit
DTC P2122 Pedal Position Sensor "D" Circuit Low
DTC P2123 Pedal Position Sensor "D" Circuit High
DTC P2125 Pedal Position Sensor "E" Circuit
DTC P2127 Pedal Position Sensor "E" Circuit Low
DTC P2128 Pedal Position Sensor "E" Circuit High
DTC P2138 Pedal Position Sensor "D" / "E" Voltage Correlation
Circuit description
The accelerator position sensor is mounted on the accelerator pedal to detect accelerator pedal opening degree.
Because this sensor is electrically controlled by the potentiometer, precise control and reliability can be obtained. The
sensor has 2 types, one for detecting accelerator position and the other one for detecting accelerator position sensor
abnormality. The accelerator position sensor applies voltage that changes from 0 to 5 V to the engine control
computer VPA and VPA2 pedal terminals according to accelerator pedal opening degree. VPA is a signal that
indicates the actual accelerator pedal opening degree used for engine control. VPA2 is a signal that indicates the
information related to the accelerator pedal opening degree that is necessary for abnormality detection. The engine
control computer calculates the current accelerator pedal opening degree according to the input signals from the
VPA and VPA2 terminals. Fuel injection amount is controlled based on accelerator opening degree and engine speed
signals.
*: Accelerator position sensor output voltage (V)
(*) Full open Full open

VCPA
VPA 5
VPA2
EPA 4.7 to 5.0
4.1 to 4.4
VPA
VCP2
VPA2 1.25 to 1.55
EPA2 0.65 to 0.95
Accelerator position Engine control Accelerator opening

Sensor 0 Pedal operation 69 degree
Computer
angle (°)
1-181
P2120
3. Abnormal period
4. Others
• For 3 sec. or longer with ignition
key switch ON and accelerator fully 1. Ignition key switch ON
open 2. VPA voltage is 4.8 V or more, or
• Accelerator position sensor (poten-
• For 3 sec. or longer with ignition VPA voltage is 0.2 V or less and
tiometer)
key switch ON and accelerator VPA2 opening degree is 2.7 ° or
pedal half depressed more (VPA circuit abnormality).
• For 3 sec. or longer with ignition 3. 0.5 sec. or longer
key switch ON and accelerator fully 4. 1 trip
open
P2122
3. Abnormal period
4. Others
key switch ON and accelerator fully
open
2. VPA voltage is 0.2 V or less and • Accelerator position sensor (poten-
VPA2 opening degree is 2.7 ° or tiometer)
key switch ON and accelerator
more (VPA circuit disconnection). • Wire harness or connector
pedal half depressed
4. 1 trip
open
P2123
3. Abnormal period
4. Others
open 1. Ignition key switch ON
• For 3 sec. or longer with ignition 2. VPA voltage is 4.8 V or more
tiometer)
key switch ON and accelerator (VPA short circuit).
pedal half depressed 3. 2 sec. or longer
• For 3 sec. or longer with ignition 4. 1 trip
open
1-182
P2125
3. Abnormal period
4. Others
• For 3 sec. or longer with ignition 1. Ignition key switch ON
key switch ON and accelerator fully 2. VPA2 voltage is 1.2 V or less and
open VPA opening degree is 2.7 ° or
• For 3 sec. or longer with ignition more, or VPA2 voltage is 4.8 V or
tiometer)
key switch ON and accelerator more and VPA voltage is 0.4 V or
pedal half depressed more and 3.45 V or less (VPA2
• For 3 sec. or longer with ignition circuit abnormality).
key switch ON and accelerator fully 3. 0.5 sec. or longer
open 4. 1 trip
P2127
3. Abnormal period
4. Others
key switch ON and accelerator fully 1. Ignition key switch ON
open 2. VPA2 voltage is 1.2 V or less and
• For 3 sec. or longer with ignition VPA opening degree is 0.97° or
tiometer)
key switch ON and accelerator more (VPA2 circuit disconnec-
pedal half depressed tion).
• For 3 sec. or longer with ignition 3. 0.5 sec. or longer
key switch ON and accelerator fully 4. 1 trip
open
P2128

3. Abnormal period
4. Others
open
2. VPA2 voltage is 4.8 V or more • Accelerator position sensor (poten-
and VPA voltage is 0.4 to 3.45 V tiometer)
key switch ON and accelerator
or less (VPA2 short circuit). • Wire harness or connector
pedal half depressed
3. 2 sec. or longer • Engine control computer
4. 1 trip
open
1-183
P2138
3. Abnormal period
4. Others
• For 3 sec. or longer with ignition 1. Ignition key switch ON
key switch ON and accelerator fully 2. The difference between VPA and
open VPA2 voltages is 0.02 V or less,
• For 3 sec. or longer with ignition or VPA voltage is 0.4 V or less
tiometer)
key switch ON and accelerator and VPA2 voltage is 1.2 V or less
pedal half depressed (disconnection or short circuit of
• For 3 sec. or longer with ignition the VPA and VPA2 circuit).
key switch ON and accelerator fully 3. 2 sec. or longer
open 4. 1 trip
Related Data List

DTC No. Data list
P2120
P2122
P2123 • Accelerator pedal opening degree
P2125 • Accelerator No. 1 sensor voltage
P2127 • Accelerator No. 2 sensor voltage
P2128
P2138
Note:
After checking the diagnosis code output, check the accelerator pedal opening degree and accelerator
closing position using SST.
Accelerator pedal Accelerator pedal Accelerator pedal Accelerator pedal
Trouble area
Fully closed (VPA) Fully open (VPA) Fully closed (VPA2) Fully open (VPA2)
System in normal
0.5 to 1.1 V 2.6 to 4.5 V 1.2 to 2.0 V 3.4 to 5.0 V
state
VCPA or VCP2 circuit
0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V
disconnection
EPA or EPA2 circuit
4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V 4.5 to 5.0 V
disconnection
VPA circuit discon-
0 to 0.2 V 0 to 0.2 V 1.2 to 2.0 V 3.4 to 5.0 V nection or short cir-
cuit
VPA2 circuit discon-
0.5 to 1.1 V 2.6 to 4.5 V 0 to 0.2 V 0 to 0.2 V nection or short cir-
cuit
1-184
Circuit diagram
5V
4 55 VCPA
VCPA
6 53 VPA
VPA
5 56 EPA
EPA
5V
1 57 VCP2
VCP2
3 54 VPA2
VPA2
2 58 EPA2
EPA2
T B
Accelerator position sensor Engine control
(potentiometer) Computer
Caution:
Note:
1 'Engine Diagnostic Program' data reading (Accelerator No. 1 sensor voltage/accelerator No. 2
sensor voltage)
SST 09111-36760-71 (09991-70201)

Full open Full close screen, press [Data monitor].
3. Read [Accel Sensor Out No.1] and [Accel Sensor Out No.2] on
Voltage value
Accelerator No. 1 Accelerator No. 2
Pedal status
sensor voltage sensor voltage
Full closed 0.5 to 1.1 V 1.2 to 2.0 V
Full open 2.6 to 4.5 V 3.4 to 5.0 V
Fully closed  Voltage must Voltage must
Fully open  change without change without
Fully closed interruption. interruption.
Result
Result Go to
NG A
OK B
B Go to step 7.
A
1-185
2 Inspection of wire harness and connector (Engine control computer - Accelerator position
sensor (Potentiometer))
Note:
1. Disconnect the connector B of the engine control computer
and the connector T of the accelerator position sensor
(potentiometer).
B page 1-33 for the terminal layout.)
Resistance
Inspection
condition
B-54 (VPA2) - T-3 (VPA2) Always Less than 1 Ω
53 (VPA) B-53 (VPA) - T-6 (VPA) Always Less than 1 Ω
55(VCPA) 57(VCP2)
54 (VPA2) 58 (EPA2) B-58 (EPA2) - T-2 (EPA2) Always Less than 1 Ω
56 (EPA)
B-57 (VCP2) - T-1 (VCP2) Always Less than 1 Ω
B-56 (EPA) - T-5 (EPA) Always Less than 1 Ω
Accelerator position sensor
(potentiometer)
B-55 (VCPA) - T-4 (VCPA) Always Less than 1 Ω
Resistance
T
Inspection
condition
1 2 3 4 5 6 B-54 (VPA2) or
T-3 (VPA2) - Other terminal Always 10 kΩ or more
VCP2 and body ground
VPA2 EPA
EPA2 VCPA VPA B-53 (VPA) or
T-6 (VPA) - Other terminal Always 10 kΩ or more
and body ground
B-58 (EPA2) or
T-2 (EPA2) - Other terminal Always 10 kΩ or more
and body ground
B-57 (VCP2) or
T-1 (VCP2) - Other terminal Always 10 kΩ or more
and body ground
B-56 (EPA) or
T-5 (EPA) - Other terminal Always 10 kΩ or more
and body ground
B-55 (VCPA) or
T-4 (VCPA) - Other terminal Always 10 kΩ or more
and body ground
NG Go to step 6.
OK
1-186
3 Inspection of engine control computer (Voltage inspection)
Note:
1. Install the connector B of the engine control computer.
2. Disconnect the connector T of the accelerator position sensor
Accelerator position sensor (potentiometer).
(potentiometer)
T
Voltage value
Inspection
1 2 3 4 5 6 condition
Ignition key
T-4 (VCPA) - T-5 (EPA) 4.5 to 5.5 V
VCP2 switch ON
EPA
EPA2 VCPA Ignition key
T-1 (VCP2) - T-2 (EPA2) 4.5 to 5.5 V
switch ON
NG Go to step 5.
OK
4 Replacement and adjustment of accelerator position sensor (potentiometer)
1. Replace and adjust the accelerator position sensor

(potentiometer).
Next Go to step 7.

Next Go to step 7.
Next
SST 09111-36760-71 (09991-70201)

Next
1-187
SST 09111-36760-71 (09991-70201)

2. Leave the accelerator pedal fully closed for 3 sec. or longer.
3. Depress the accelerator pedal to the middle for 3 sec. or
longer.
4. Leave the accelerator pedal fully open for 3 sec. or longer.
5. According to the instruction of tne 'Engine Diagnostic Program'
Next
End
1-188
DTC P2121 Pedal Position Sensor "D" Circuit Range / Performance
Circuit description
P2121
3. Abnormal period
4. Others
open 1. Ignition key switch ON
• For 3 sec. or longer with ignition 2. VPA and VPA2 sensor character- • Accelerator position sensor (poten-
key switch ON and accelerator istic abnormality tiometer)
pedal half depressed 3. 2 sec. or longer • Engine control computer
• For 3 sec. or longer with ignition 4.1 trip
open
Circuit diagram
Caution:
Note:
SST 09111-36760-71 (09991-70201)

screen, check the diagnosis code.
Result
Result Go to
P2121 is output. A
Another diagnosis code is output. B

A
1-189
2 'Engine Diagnostic Program' data reading

(Accelerator No. 1 sensor voltage/accelerator No. 2 sensor voltage)
SST 09111-36760-71 (09991-70201)
Full open Full close screen, press [Data monitor].
3. Read [Accel Sensor Out No.1] and [Accel Sensor Out No.2] on
Voltage value
Accelerator No. 1 Accelerator No. 2
Pedal status
sensor voltage sensor voltage
Full close 0.5 to 1.1 V 1.2 to 2.0 V
Full open 2.6 to 4.5 V 3.4 to 5.0 V
Voltage must Voltage must
Fully closed  Fully
change without inter- change without inter-
open  Fully closed
ruption. ruption.
NG Go to step 3.
OK
Inspection of irregular problems (See page 1-15 for the procedure)
3 Replacement and adjustment of accelerator position sensor (potentiometer)
1. Replace and adjust the accelerator position sensor

(potentiometer).
Next
SST 09111-36760-71 (09991-70201)

Next
1-190
SST 09111-36760-71 (09991-70201)

longer.
Result
Result Go to
P2121 is output. A
B End
Next
SST 09111-36760-71 (09991-70201)

Next
SST 09111-36760-71 (09991-70201)

longer.
Next
End
1-191
DTC P2226 Barometric Pressure Circuit
DTC P2228 Barometric Pressure Circuit Low
DTC P2229 Barometric Pressure Circuit High
Circuit description
The atmospheric pressure sensor used for the common rail system is built in the engine control computer. The
engine control computer controls fuel injection amount, fuel injection timing, fuel injection period and common rail
pressure so that they maintain optimal conditions according to atmospheric pressure change.
P2226
3. Abnormal period
4. Others
2. Disconnection or short circuit of
the atmospheric pressure sensor
circuit (engine control computer Engine control computer
switch ON
internal abnormality)
4. 1 trip
P2228
3. Abnormal period
4. Others
2. Short circuit of the atmospheric
pressure sensor circuit (engine
control computer internal abnor- Engine control computer
switch ON
mality)
4. 1 trip
P2229
3. Abnormal period
4. Others
2. Disconnection of the atmo-
spheric pressure sensor circuit
(engine control computer internal Engine control computer
switch ON
abnormality)
4. 1 trip
1-192
Related Data List

DTC No. Data list
P2226
• Atmospheric pressure
P2228
P2229
Note:
• When the ignition ON, [MAP] is almost equivalent to [Atmosphere Pressure].
• Under reference atmospheric pressure, the output of the atmospheric pressure sensor is 101 kPa. For
every 100 m (328 feet) altitude ascending, atmospheric pressure decreases by 1 kPa. This varies
according to weather (high pressure or low pressure).
• If P2226, P2228 and P2229 are stored, the following symptoms may occur.
- Misfire
- Knocking
- Black smoke
- White smoke
Caution:
according to the Operation Support Procedure3 List. (See page 1-16 for the procedure.)
Next
SST 09111-36760-71 (09991-70201)

Next
End
1-193
DTC P2564 Turbocharger Boost Control Position Sensor "A" Circuit Low
DTC P2565 Turbocharger Boost Control Position Sensor "A" Circuit High
Circuit description
The VN turbo charger system mainly consists of a compressor wheel, turbine wheel, nozzle vane, unison ring, DC
motor and nozzle opening degree sensor. The nozzle opening degree sensor consists of a hall element and magnets
connected to the DC motor output shaft. The flux changed by DC motor rotation is converted to electric signal and
sent to the engine control computer.
Through this signal, the engine control computer performs feedback control to adjust the actual nozzle vane position
to the target opening degree.
Magnet
Hall element
VNVC
4.5
Output
voltage
(V)
VNA
0.5
VNE2 Nozzle vane

position
Magnet
Closed Open
Engine control
Nozzle opening degree sensor Computer
(turbo charger S/A)
P2564
3. Abnormal period
4. Others
1. Ignition key switch ON • Wire harness or connector
3 sec. or longer with ignition key 2. VTA1 voltage is 0.1 V or less. • Nozzle opening degree sensor
switch ON 3. 2.1 sec. (turbo charger S/A)
4. 1 trip • Engine control computer
P2565
3. Abnormal period
4. Others
1. Ignition key switch ON • Wire harness or connector
3 sec. or longer with ignition key 2. VTA1 voltage is 4.9 V or more. • Nozzle opening degree sensor
switch ON 3. 2.1 sec. (turbo charger S/A)
4.1 trip • Engine control computer
Note:
The following symptoms may occur when the nozzle vane is stuck open and P2564 and P2565 are stored.
- Surge or hesitation under light or middle load condition
1-194
Circuit diagram
3 94 VNVC
VNVC
1 116 VNA
VTA1
2 95 VNE2
VNE2
V
Nozzle opening degree sensor A
(turbo charger S/A)
Caution:
Note:
SST 09111-36760-71 (09991-70201)

screen, read the diagnosis code.
Result
Result Go to
P2564 or P2565 is output. A
P2564, P2565 and another diagnosis code are output. B

A
1-195
2 Inspection of wire harness and connector (Engine control computer - Nozzle opening degree
sensor (Turbo charger S/A))
Note:
Engine control computer and the connector V of the nozzle opening degree sensor
Connector on the machine side (turbo charger S/A).
A 2. Measure the resistance between terminals using a tester. (See
Resistance
Inspection
condition
V-1 (VTA1) - A-116 (VNA) Always Less than 1 Ω
V-2 (VNE2) - A-95 (VNE2) Always Less than 1 Ω
116 (VNA) 94(VNVC) 95 (VNE2)
Nozzle opening degree sensor V-3 (VNVC) - A-94 (VNVC) Always Less than 1 Ω
(turbo charger S/A)
Connector on the machine side Resistance
V Inspection
condition
V-1 (VTA1) and A-116 (VNA) -
1 2 3 4 5 6
Other terminal and Body Always 10 kΩ or more
ground
VTA1 V-2 (VNE2) and A-95 (VNE2)
VNE2 VNVC
- Other terminal and Body Always 10 kΩ or more
ground
V-3 (VNVC) and A-94 (VNVC)
- Other terminal and Body Always 10 kΩ or more
ground
NG Go to step 6.
OK
3 Inspection of engine control computer

(Nozzle opening degree sensor power supply voltage)
Note:
Nozzle opening degree sensor

1. Disconnect the connector V of the nozzle opening degree
(turbo charger S/A) sensor (turbo charger S/A).
V
Voltage value
Inspection
1 2 3 4 5 6 Inspection terminal Reference
condition
Ignition key
V-3 (VNVC) - V-2 (VNE2) 4.5 to 5.5 V
VNE2 switch ON
VNVC
NG Go to step 5.
OK
1-196
4 Replacement of turbo charger S/A (Nozzle opening degree sensor)
1. Replace the turbo charger S/A.

Next Go to step 7.

Next Go to step 7.
Next
SST 09111-36760-71 (09991-70201)

Next
SST 09111-36760-71 (09991-70201)

Next
End
1-197
DTC U0101 Lost Communication with CAN
Circuit description
SAS/OPS ECU receives the engine speed, accelerator pedal position, accelerator pedal voltage, high water
temperature condition, fuel filter clogging information, fuel filter water clogging information, and abnormal code from
the engine control computer. It sends the engine speed limitation information, torque limitation information, and
engine stop request to the engine control computer.
U0101
3. Abnormal period
4. Other
2. Communication disruption
3 sec. or longer with ignition key between the engine control com-
switch ON puter and machine side controller
• SAS/OPS ECU
4. 1 trip
Circuit diagram
12
40
CANH a CAN+
13
63
CANL a CAN-
1
IG b
2 A
IG2 b Engine control
ECU-IG (SAS-IG)*
Computer
3
E11 b
* Vehicle with option installed
a b
SAS/OPS ECU
Caution:
1-198
SST 09111-36760-71 (09991-70201)

Next
SST 09111-36760-71 (09991-70201)

1. Turn ON the ignition switch
2. Turn on the ignition key switch and wait for 3 sec. or longer.
Result
Result Go to
U0101 is output. A
B Inspection of irregular problems

3 SAS/OPS ECU inspection
Note:
1. Disconnect the connector b of SAS/OPS ECU
SAS/OPS ECU machine side connector
b 3. Measure the voltage between terminals using a tester.
Voltage value
1 2 3 4 5 6 7 Inspection
8 9 10 11 12 13 14 15 16 17 18 19 condition
20 21 22 23 24 25 26 27
Ignition key
28 29 30 31 32 33 34 35 b-1 (IG) - Body ground 11 to14 V
switch ON
IG Ignition key
IG2 E11 b-2 (IG2) - Body ground 11 to 14 V
switch ON
Resistance
Inspection
condition
b-3 (E11) - Body ground Always Less than 1 Ω
OK
1-199
4 Wire harness and connector inspection (Engine control computer - SAS/OPS ECU)
Note:
Engine control computer the connector a of SAS/OPS ECU.
Resistance
Inspection
condition
A-40 (CAN+) - a-12 (CANH) Always Less than 1 Ω
63(CAN-) A-63 (CAN-) - a-13 (CANL) Always Less than 1 Ω

40(CAN+)
SAS/OPS ECU machine side connector NG Wire harness or connector repair or replacement
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CANH CANL
OK
Next
SST 09111-36760-71 (09991-70201)

Next
1-200
SST 09111-36760-71 (09991-70201)

2. Turn on the ignition key switch and wait for 3 sec. or longer.
Result
Result Go to
U0101 is output. A
B End
8 SAS/OPS ECU replacement

1-201
STARTER SYSTEM
Circuit description
While cranking the engine, starter start signal is transferred to the engine control computer STA terminal, too. Starter
start signal is used to increase the fuel injection amount mainly at the engine start up.
Circuit diagram
2 3
AM1 ST1 ST
Ignition (starter)
switch ASSY T/C shift Neutral start
switch *1 relay *2
AM1 Parking brake

switch *2
STA
43
STA
MAIN 4 1
ST
*1 Shift lever type
3 2 *2 EZ pedal type
B
Engine control
Battery Computer
Starter ASSY
Caution:
Before carrying out the troubleshooting, inspect the fuse of this circuit.
Note:
This diagnostic procedure assumes that the engine is in a normal condition and can be crank started by a
starter. If the engine cannot be crank started, perform the inspection of corresponding part according to the
LIST OF SYMPTOMS first (See page 1-7 for the procedure).
1-202
1 'Engine Diagnostic Program' data reading (starter signal)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [Starter Signal]. Read
[Starter Signal] when the starter is started.
Standard
Ignition switch position Inspection condition Starter Signal

ON position OFF
P, N range
STA position ON
NG Go to step 2.
OK
Go to the inspection of related circuit according to the LIST OF SYMPTOMS.
2 Wire harness and connector inspection (Engine control computer - ST relay)
Note:
Engine control computer 2. Remove the ST relay from the LH STEP relay block.
Connector on the machine side 3. Measure the resistance between the machine side connector
B of engine control computer and the ST relay installation relay
block holder terminal with a circuit tester.
Resistance
Inspection
condition
43 (STA) B-43 (STA) -
Always Less than 1 Ω
LH STEP relay block ST relay holder 1 terminal
Resistance
Inspection
condition
B-43 (STA) or ST relay holder
1 terminal - Other terminal Always 10 kΩ or more
1 and body ground
ST 4 3
2
Caution:
When performing measurement by applying a tester stick to a
holder, do not put the tester stick too hard against the holder.
It may damage the holder.
NG Wire harness or connector repair
or replacement
OK

1-203
ENGINE CHECK INDICATOR CIRCUIT
Circuit description
Engine check indicator is used to display the defect of machine, which was detected by the engine control computer.
When the ignition switch is turned on, power is supplied to the engine check indicator circuit. By grounding inside of
the engine control computer, the engine check indicator lights up. Operation of engine check indicator can be visually
checked. When the ignition switch is turned on, the engine check indicator lights up. It turns off after the engine start.
When the engine check indicator remains on or off, troubleshoot as follows.
Circuit diagram
1 16 12
From AM2 relay
GAUGE IG+ EFI W
B
Engine control
Computer
Caution:
1 Engine check indicator lighting inspection
1. Turn the ignition key switch ON. Check that the engine check
indicator lights up. Check that it turns off after the engine start.
Result
Result Go to
With ignition key switch ON, the indicator lights up and it remains on after the engine start.
A
With ignition key switch ON, the indicator lights up. The engine cannot be started.
With ignition key switch ON, the indicator does not light up. The engine can be started. B
With ignition key switch ON, the indicator does not light up. The engine cannot be started. C
With ignition key switch ON, the indicator lights up. It turns off after the engine start. D
B Go to step 5.
C Go to the inspection of VC power supply circuit

D End
A
1-204
SST 09111-36760-71 (09991-70201)

Result
Result Go to
Diagnosis code is output. B
Note:
When a diagnosis code is not output and the engine cannot be
started, it can be some other problem than that with the engine
check indicator circuit.
3 Wire harness and connector inspection (short-circuit inspection)

3. Check that the engine check indicator in the combination
meter ASSY does not light up.
Standard Engine check indicator does not light up
NG Go to step 4.
OK

1-205

(Engine control computer - Combination meter ASSY)
Note:
Engine control computer harness and connectors.
Connector on the machine side 1. Disconnect the connector B of engine control computer and
B the connector of combination meter ASSY.
Resistance
Inspection
condition
12 (W) B-12 (W) and 16 (EFI) -
Combination meter ASSY body ground
or replacement
1 2 3 4 5 6 7 8
9 10 11 1213141516
EFI
OK
Combination meter ASSY repair or replacement
5 Wire harness and connector inspection (Engine control computer - Combination meter ASSY)
Note:
Engine control computer harness and connectors.
1. Disconnect the connector B of engine control computer and
B
the connector of combination meter ASSY.
Resistance
Inspection
condition
12 (W)
B-12 (W) - 16 (EFI) Always Less than 1 Ω
Connector on the machine side NG Wire harness or connector repair
or replacement
1 2 3 4 5 6 7 8
9 10 11 1213141516
EFI
OK
Combination meter ASSY repair or replacement

1-206
PREHEATING CONTROL CIRCUIT SYSTEM
Circuit description
When the ignition switch is turned on, the circuit turns on the glow indicator light according to the coolant
temperature. Glow plug relay turns on and battery voltage is applied to the heating coil of glow plug.
*When atmospheric pressure = 100 kPa
120
12
Indicator
lamp 6 After glow time
lighting time [sec.]
[sec.]
1
1
0
0
-10 0 40 0 10 20 30 40 50
Engine water temperature [°C] Engine water temperature [°C]
*: This may vary slightly depending on the atmospheric pressure.

Circuit diagram
30
1 12
B GIND

GAUGE (Glow indicator lamp)
5 3
AM2
1 2
AM1 ECU-IG
Ignition switch AM2
MAIN
GLOW 2 1
58
4 3
A GREL
Glow plug relay

Glow plug ASSY
Battery
A B
Engine control
Computer
1-207
Caution:
• When replacing the engine control computer, make sure to perform the supply pump ASSY learned value
initialization and injector ID writing. (See page 1-16 for the procedure.)
• When replacing the engine control computer, perform the initialization and writing of ID code.
1 Does the glow indicator lamp light up?
1. Turn the ignition key switch ON and check if the glow indicator
lamp light up.
Result
Result Go to
Glow indicator plug does not light up. A
Glow indicator lamp lights up for 0.5 sec. or longer. B
B Go to step 4.
2 Engine control computer inspection (voltage inspection)
Note:
Engine control computer 2. Turn the ignition key switch ON.
Connector on the machine side 3. Measure the voltage between terminals using a tester. (See
B page 1-33 for the terminal layout.)
Voltage value
Inspection
condition
Ignition key
B-30 (GIND) - Body ground 11 to 14 V
switch ON
30(GIND)
NG Go to step 3.
OK

1-208

(Engine control computer - Combination meter ASSY)
Note:
1. Disconnect the connector B of engine control computer and
the connector of combination meter ASSY.
B
Resistance
Inspection
condition
B-30 (GIND) - 12 (GLW-) Always Less than 1 Ω
Resistance
30(GIND)
Inspection
Combination meter ASSY condition
Connector on the machine side B-30 (GIND) and 12 (GLW-) -
Other terminal and body ground

1 2 3 4 5 6 7 8
9 10 11 1213141516
or replacement
GLW-
OK
Combination meter ASSY replacement
4 Glow indicator lighting time and after glow time inspection
1. Glow indicator lighting time inspection

(1) Turn the ignition key switch ON and measure the lighting
time of glow indicator.
Reference The measured value changes according to the
graph.
2. After glow time inspection
(1) Turn the ignition key switch ON and measure the period
of time the battery voltage flows to the A-58 (GREL)
terminal of engine control computer.
Reference The measured value changes according to the
graph *(when atmospheric pressure is 100
kPa).
1-209
*When atmospheric pressure = 100 kPa
120
12
Indicator
lamp
lighting 6 After glow time
time [sec.]
[sec.]
1
1
0
0
-10 0 40 0 10 20 30 40 50
Engine water temperature [°C] Engine water temperature [°C]
*: This may vary slightly depending on the atmospheric pressure.

NG Engine control computer replacement
OK
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to

6 Glow plug relay ASSY individual inspection
1. Inspect the glow plug relay.

NG Glow plug relay ASSY replacement
OK
1-210

(Engine control computer - Glow plug relay, Glow plug relay - Body ground)
Note:
Engine control computer See page 0-13 for the inspection procedure and notes of wire
A 1. Disconnect the connector A of engine control computer.
2. Remove the glow plug relay.
Resistance
Inspection
condition
58 (GREL)
A-58 (GREL) - Glow plug relay
holder 3 terminal
Glow plug relay holder Resistance
Inspection
1 2 condition
A-58 (GREL) and glow plug
3 4 relay holder 3 terminal - Other Always 10 kΩ or more
terminal and body ground
Caution:
Resistance
Inspection
condition
Glow plug relay holder 4 termi-
nal - Body ground
Caution:
or replacement
OK
1-211
8 Glow plug ASSY inspection (resistance inspection)

Resistance
Inspection
condition
Glow plug ASSY - 20 °C
2.7 to 3.5 Ω
Body ground (68 °F)
NG Glow plug ASSY replacement

OK
9 Glow plug ASSY inspection (installation condition inspection)
1. Check that the glow plug ASSY is installed securely.

NG Install the glow plug ASSY securely.
OK
10 Wire harness and connector inspection (Glow plug relay - Glow plug ASSY)
Glow plug relay holder

1. Remove the glow plug relay from the relay block ASSY.
Resistance
1 2
Inspection
3 4 condition
Glow plug relay
Glow plug wire Holder 2 terminal - Glow Always Less than 1 Ω
plug wire
Caution:
or replacement
OK

1-212
TROUBLESHOOTING OF HARD STARTING AND ENGINE STALLING
Caution:
• Before starting the troubleshooting, check if each ID code (injector compensation code) is normal. (See
• Conduct the air bleeding of fuel line and perform the troubleshooting.
1 Cranking inspection
1. Inspect if the engine cranks.

Result
Result Go to
Engine cranks A
Slow cranking
Note:
B
When the cranking speed is slow and especially when the temperature is low, check if the
grade of engine oil corresponds the recommended grade.
Does not crank C
B Battery inspection
C Go to step 32.
2 Inspection of communication state between 'Engine Diagnostic Program' and engine control
computer.
SST 09111-36760-71 (09991-70201)

2. Check if the normal start up screen is displayed. (Check if the
communication with the engine control computer is possible.)
Note:
Use 'Engine Diagnostic Program', which can communicate
with other vehicle.
Reference communication is possible
(Vehicle can be recognized)
NG Go to the inspection of VC
power source system
OK
SST 09111-36760-71 (09991-70201)

1-213

Result
Result Go to

4 'Engine Diagnostic Program' data reading (saving data at the engine start up and during idling)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [Fuel Press], [Target
Common Rail Pressure], [Engine Speed], [Coolant Temp],
[Injection Volume].
3. Perform ignition key switch ON (5 sec. or longer)  Cranking
 Idling (10 sec. or longer) and save data with the 'Engine
Note:
• Stored data can be used to compare the machine data in
abnormal time and that in normal time. This is helpful in
diagnosis.
• If hard starting occurs when cool, save data when cool and
then warm the engine (Engine coolant temperature is 70 °C
(158 °F) or above and other electric load is off), and save the
idling data after 1 minute for 15 seconds or longer.
Next
5 'Engine Diagnostic Program' data reading (stored data reading)
1. Read the data of [Fuel Press] at the engine start up which was
saved in step 4.
Result
Result Go to
Fuel pressure value is less than 25000 kPa. A
Fuel pressure value exceeds the common rail target fuel pressure value greatly.
B
(Initial ignition does not occur and the engine cannot be started.)
Fuel pressure value exceeds the common rail target fuel pressure value greatly.
C
(Initial ignition occurs or the engine can be started.)
Other than the above D
Note:
• At cranking, when [Coolant Temp] is 0 °C (32 °F) or above,
[Fuel Press] is approx. 30000 to 40000 kPa.
• [Fuel Press] increases drastically during cranking.
1-214
B Go to step 13.
C Go to step 14.
D Go to step 18.
6 Check if the fuel reaches the pump.
1. Remove the inlet hose of supply pump ASSY.

2. Perform priming to check if fuel is there.
Standard Fuel is there
Note:
• If fuel is insufficient, fuel pressure drops.
• Inspect the fuel filter element ASSY for clogging. (Check if
the fuel filter element ASSY is not clogged.)
• At a low temperature, fuel filter element ASSY may become
clogged because fuel turns into wax state.
• If fuel turns into wax state, warm the fuel filter element
ASSY to fuel turns liquid state.
NG Go to step 36.
OK
7 Wire harness or connector inspection

Note:
Connector on the machine side harness and connectors.
the connector J of suction control valve ASSY.
Resistance
Inspection
condition
41(PCV+) 81(PCV-)
Suction control valve ASSY
Connector on the machine side Resistance
J Inspection
condition
A-41 (PCV+) and J-1 - Other
1 2 Always 10 kΩ or more
A-81 (PCV+) and J-2 - Other
NG Go to step 37.
OK
1-215
8 Supply pump ASSY replacement
1. Replace the supply pump ASSY.

Next
Next
SST 09111-36760-71 (09991-70201)

Note:
Next
11 Checking work after defect repair
1. Check if the defect was eliminated.

NG Go to step 12.
OK
End
12 Injector ASSY inspection (closing failure inspection)
1. Remove the glow plug ASSY. (See page 2-10 for the
procedure.)
2. Visually check the glow plug ASSY for fuel spots.
Note:
• If the glow plug ASSY has fuel spots, fuel may be leaking
from the injector ASSY. Replace the injector ASSY.
• After replacing the injector ASSY, check if the [Fuel Press]
during cranking is within 5000 kPa above or below of the
• If the glow plug ASSY has fuel spots, engine oil may be
contaminated with fuel. Check the engine oil level and
check if the engine oil smells like gas oil. When the oil level
is above FULL line and the engine oil smells like gas oil,
change the engine oil.
Next Go to step 28.
1-216
13 Injector driver inspection
1. Even when DTC P062D is not output at hard starting, perform

the diagnosis of DTC P062D (injector driver circuit).
Note:
• When performing the diagnosis of injector driver circuit,
inspect the following points, which may be the cause of
defect.
- Injector driver power supply circuit
- Injector ASSY circuit
- Injector driver
- Engine control computer
• If DTC had been deleted, when the engine does not start
due to the failure of injector driver circuit, DTC P062D
cannot be detected even if the reproduction check shows
the hard starting.
Since DTC P062D cannot be detected at the engine start up,
although the fuel injection signal is output from the engine
control computer, fuel injection is not performed. If you
check the data at the hard starting time using the tool, the
fuel pressure indicates higher value than the common rail
target fuel pressure. This is because an excessive amount
of fuel is supplied to the common rail by the fuel supply
pump.
• If no defect is found by DTC P062D (injector driver circuit)
diagnosis and the fuel pressure at the engine start up is
higher than the common rail target fuel pressure, perform
the following procedure.
NG Go to step 38.
OK
1-217
14 Wire harness or connector inspection

Note:
Engine control computer the connector J of suction control valve ASSY.
Resistance
Inspection
condition
41(PCV+) 81(PCV-)
Resistance

terminal and Body ground
A-81 (PCV-) and J-2 - Other
1 2 terminal and Body ground
NG Go to step 37.
OK

Next
Next
SST 09111-36760-71 (09991-70201)

Note:
Next Go to step 42.
1-218
18 Check of engine coolant temperature at the hard starting
1. Check the condition of engine coolant temperature at the hard

starting.
Result
Result Go to
Engine does not start only when cool. A
Engine does not start both when cool and warm. B
B Go to step 21.
19 'Engine Diagnostic Program' data reading (Engine coolant temperature)
SST 09111-36760-71 (09991-70201)

1. When the engine is warm, leave it for a long time until it is
cooled.
screen, press [Data monitor] and monitor [Coolant Temp].
4. Read the engine coolant temperature displayed on the 'Engine
Reference [Coolant Temp] is same as the ambient
temperature.
Note:
When [Coolant Temp] is low, although the engine is
sufficiently warmed up or when [Coolant Temp] is high,
although when cool, inspect the sensor.
NG Go to step 39.
OK
20 Glow plug ASSY inspection
1. Inspect the glow plug ASSY. (See page 5-16 for the
procedure.)
OK Go to step 41.
NG Go to step 40.
1. Since air may have been introduced to the fuel line because of
fuel shortage, etc., conduct air bleeding of fuel line.
Next
1-219

NG Go to step 23.
OK
End
SST 09111-36760-71 (09991-70201)

1. Read the data of [Injection Volume] during idling after warm
up, which was saved in step 4.
Result
Result Go to
The value of [Injection Volume] exceeds 15 mm3/st. A
B Go to step 25.
24 Injector ASSY replacement
Caution:
repair manual, tighten the injector ASSY to the specified
torque.
failure.
problems.
leak.
Next Go to step 29.
25 'Engine Diagnostic Program' active test implementation (Control the Select Cylinder Fuel Cut)
SST 09111-36760-71 (09991-70201)

2. Press [Active test]  select [Control the Select Cylinder Fuel
Cut] on the 'Engine Diagnostic Program'.
3. Perform the control the select cylinder fuel cut using active test
for each cylinder and check if there is any defect in a specific
cylinder.
1-220
Result
Result Go to
Idle vibration fluctuates differently in a specific cylinder. A
Fluctuates in all cylinders in a similar manner B
Note:
• The defective cylinder, which has less output than other
cylinders, produces a small change in idle speed or idle
vibration when a fuel cut (control the select cylinder fuel
cut) is performed during the engine idling.
• If the idle speed or idle vibration fluctuates largely when
fuel cut (control the select cylinder fuel cut) is performed
during the engine idling, it is a defective cylinder which has
larger output than other cylinders.
• With a normal cylinder, when fuel cut (control the select
cylinder fuel cut) is performed, the engine falls into rough
idle.
B Go to step 41.
26 'Engine Diagnostic Program' active test implementation (Check the Cylinder Copmpression)
SST 09111-36760-71 (09991-70201)

screen, press [Active test]  select [Check the Cylinder
Copmpression] and check the engine rotation.
3. Monitor [Engine Speed of Cyl #1], [Engine Speed of Cyl #2],
[Engine Speed of Cyl #3], [Engine Speed of Cyl #4].
Result
Result Go to
Other than the followings A
The values of [Engine Speed of Cyl #1] - [Engine Speed of Cyl #4] are not different by more than 10
B
rpm from each other.
Note:
When the rotation of one cylinder is higher than that of others
by 100 rpm during cranking, the cylinder may have decrease
in compression.
B Go to step 28.
27 Compression inspection
1. Check the compression of engine.

NG Engine unit inspection, repair
OK
1-221
28 Replacement of injector ASSY of defective cylinder only
1. Replace only the injector ASSY of defective cylinder. (See

Caution:
temporarily and positioning the injector ASSY according to
the repair manual, tighten the injector to the specified
torque.
failure.
problems.
leak.
Next
1. Clean the fuel filter case sub ASSY. When the fuel filter is
noticeably dirty or clogged, replace the fuel filter element
ASSY.
Note:
Next
Next
1. Implement the writing the injector compensation code.

2. Write to the input manual compensation codes.
Next Go to step 42.
1-222
32 Inspection of communication state between 'Engine Diagnostic Program' and engine control
computer.
SST 09111-36760-71 (09991-70201)
2. Check if the normal start up screen is displayed. (Check if the
communication with the engine control computer is possible.)
Note:
Use 'Engine Diagnostic Program', which can communicate
with other vehicle.
Standard Communication is possible (Machine can be
recognized).
NG Go to the inspection of VC power supply system
OK
SST 09111-36760-71 (09991-70201)

screen, read the diagnosis code
Result
Result Go to

34 'Engine Diagnostic Program' data reading (starter signal)
SST 09111-36760-71 (09991-70201)

3. Read the [Starter Signal] displayed on the 'Engine Diagnostic
Program'.
Standard
Item name Conditions Standard

Starter Signal During cranking ON
NG Starter signal inspection

OK
1-223
35 Starter system individual inspection
1. Inspect the starter system.

(1) Inspect the starter relay.
(2) Inspect the starter.
Next Go to step 42.
36 Inspection and repair of the clogging of fuel system (including freezing)
1. Inspect and repair the clogging of fuel system (including

freezing).
Note:
If fuel freezes or turns into wax state, warm the fuel filter
element ASSY to fuel turns liquid state.
Next Go to step 42.

Next Go to step 42.
38 Defective parts repair or replacement
1. Repair or replace the defective parts.

Next Go to step 42.
39 Water temperature sensor replacement

Next Go to step 42.
40 Glow plug ASSY replacement
1. Replace the glow plug ASSY.

Next Go to step 42.
41 Fuel quality inspection
1. Check if gasoline was not filled in for a long time by inquiry.

2. Inspect if fuel, which is obtained from the fuel filter element
ASSY, is not contaminated with water, etc.
Next
Next
End
1-224
WHITE SMOKE
Description of function
1. Defect and symptoms of common rail diesel components
(1) Engine control
Turbo charger S/A system

Turbo charger S/A (Seal ring on the compressor side, seal ring on the turbine side, shaft,
Main defects
oil drain)
White smoke
Symptom
Oil consumption increase
Glow system
Main defects Circuit disconnection and glow plug ASSY defect
Symptom Hard starting, rough idling, knocking, white smoke (when cool)
Data list Check the glow plug indicator lamp.
Diagnosis point Measure the resistance of glow plug ASSY.
Engine
Main defects Decrease in compression
Symptom Rough idling (Insufficient output at all times)
Engine speed by cylinders (#1) to (#4)
• When cranking during the engine speed measurement by cylinders in the active test, if
Data list
there is a cylinder which rotates approximately 100 rpm faster than other cylinders, the
cylinder may have lower compression.
(2) Gas oil injection
Injector ASSY
Main defects Clogging
Symptom Rough idling, insufficient output, black smoke, white smoke, knocking
Data list -
Note:
When the sliding friction of internal parts of injector ASSY (Ex. armature shaft, command piston and plunger)
increases due to the internal dirt, injection amount decreases due to the delay in injector ASSY opening and
insufficient lift amount.
Injector driver
Main defects Defect in circuit: Injector ASSY does not open.
Symptom Hard starting, rough idling, insufficient output, black smoke, white smoke, knocking
Data list -
Diagnosis code When injector driver is defective, DTC may be stored.
Non-standard fuel
Main defects -
Symptom Hard starting, rough idling (especially when cool)
1-225
(3) Diesel EGR
EGR system
• Does not operate smoothly.
Main defects
• Does not open fully.
• Rough idling
• EGR valve stuck closed: Turbo charger S/A sound is loud.
Symptom • EGR valve stuck open: Hard starting (no engine stalling), black smoke, insufficient out-
put (In case of too much EGR amount and heavy load, insufficient output is experi-
enced when the machine starts to move.)
EGR actual opening degree #1 and EGR target opening degree
• Normally, EGR actual opening degree #1 = EGR target opening degree +/-5% (Fully
closed: 0%, Fully open: 100%)
• Using the active test of EGR valve, check if the EGR actual opening degree #1 follows
the EGR target opening degree. (If abnormality occurs, consider the engine coolant
temperature and intake air temperature.)
• When the ignition switch turns on in the engine stop state, EGR valve opens fully.
• When EGR valve does not close, intake air amount decreases when the machine is in
Data list
full-open throttle. Intake manifold pressure decreases compared to the target super-
charging pressure, too, but the difference is not too big.
EGR fully-closed position learned value and EGR fully-closed position learning history
• When the machine is left in idling state, if the EGR fully-closed position learning history
is completed, the normal range of EGR fully-closed position learned value is 0 to 1 V.
• When the EGR fully-closed position learning history is not completed or the EGR fully-
closed position learned value is outside of the normal range (0 to 1 V), EGR valve may
not become fully closed.
Caution:
• When replacing the engine control computer or injector ASSY, initialize and writing the corresponding ID
1. Description of symptom
When engine misfires, fuel which was injected but remained unburned is discharged as
white smoke.
Oil leak inside of the turbo charger S/A
White smoke
In case of oil leak from the seal on the turbine side, a large amount of white smoke is
discharged from the exhaust pipe.
Internal oil leak cannot be seen from outside of the turbo charger S/A.
1 Inquiry (Ask the customer about the condition when white smoke was generated.)
1. Ask the customer about the condition when white smoke was
discharged.
• How was the driving condition when white smoke was
generated?
• Was white smoke discharged continuously or occasionally?
• Was white smoke generated only when cool or both when
cool and warm?
• Was white smoke generated only after the engine start or
also during idling?
2. Examine the defect phenomena and narrow down the possible
causes.
Next
1-226
SST 09111-36760-71 (09991-70201)

screen, read the diagnosis code
Result
Result Go to

3 White smoke inspection (Check when white smoke is discharged)

2. Press the accelerator pedal fully and release it.
3. Check if white smoke is discharged when revving up the
engine.
Caution:
Do not check white smoke indoors.
Note:
• When white smoke is discharged only directly after the
engine start and it disappears later, white smoke does not
come from the turbo charger S/A.
• Whether when cool or warm, when turbo charger S/A is the
cause of abnormality, so much white smoke is generated
that you cannot see beyond several meters.
• With fuel contaminated with oil and with unburnt fuel,
exhaust gas smells differently. When fuel is contaminated
with oil, exhaust gas smells burnt.
• When driving under a close-to-idling condition, unburnt fuel
accumulates in the catalytic converter and generates white
smoke during acceleration.
Result
Result Go to
White smoke is discharged only directly after the engine start. A
White smoke is discharged continuously at all times. B
Oil adhesion in the exhaust pipe, etc. C
B Go to step 23.
C Go to step 24.
A
1-227
4 White smoke inspection (Check the temperature when white smoke is discharged)
1. Check if white smoke is discharged only when the engine

coolant temperature is less than 0 °C (32 °F).
Note:
• When white smoke is generated when the engine coolant
temperature is less than 0 °C (32 °F), the white smoke might
not come from the turbo charger S/A but from unburnt fuel.
• When misfire occurs, unburnt fuel is discharged.
Result
Result Go to
White smoke is discharged when the water temperature is less than 0 °C (32 °F). A
White smoke is discharged independent from the water temperature. B
B Go to step 6.
5 Glow plug ASSY individual inspection
1. Inspect the glow plug ASSY.

NG Glow plug ASSY replacement
OK
6 'Engine Diagnostic Program' data reading (Fuel pressure and target common rail pressure)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [Fuel Press] and
3. Selsect [Start].
Note:
Using 'Engine Diagnostic Program', check the result.
4. Measure the difference between [Target Common Rail
Pressure] and [Fuel Press] during idling after engine warm-up.
Result
Result Go to
[Fuel Press] is within 5000 kPa above or below of the [Target Common Rail Pressure]. A
B Go to step 16.
A
1-228
7 Work support implementation (Injector compensation code check)
SST 09111-36760-71 (09991-70201)

screen, check the injector compensation code (ID code).
Standard The compensation code which is stored in the
engine control computer matches the
compensation code of injector ASSY which is
installed.
NG Work support implementation
(Writing the injector compensation code (select
the input manual compensation codes.).
OK
SST 09111-36760-71 (09991-70201)

cylinder.
Result
Result Go to
Note:
idle.
B Go to step 21.
A
1-229
9 'Engine Diagnostic Program' active test implementation (check the cylinder copmpression)
SST 09111-36760-71 (09991-70201)

Compression] and check the engine rotation.
Result
Result Go to
The values of [Engine Speed of Cyl #1] to [Engine Speed of Cyl #4] are not different by more than 10
B
Note:
in compression.
B Go to step 11.

NG Engine ASSY repair
OK
11 Injector ASSY replacement (Defective cylinder)
Note:
Since compression does not decrease despite of defective
cylinder, this can be judged as defect of injector ASSY.
Caution:
the repair manual, tighten the injector ASSY to the specified
torque.
failure.
problems.
leak.
Next
1-230
Next
SST 09111-36760-71 (09991-70201)

Next
1. Check if white smoke is eliminated.

NG Go to step 15.
OK
End
15 Fuel quality inspection
1. Check if gasoline was not filled in for a long time by inquiry.

2. Inspect if fuel, which is obtained from the fuel filter element
ASSY, is not contaminated with water, etc.
Next
End
16 Check if fuel reaches the pump.

Note:
• When fuel does not flow smoothly because of clogging of
fuel filter element ASSY or when clogging is fixed, fuel
pressure regulation ability deteriorates. (Check if the fuel
filter element ASSY is not clogged.)
clogged because fuel can turn into wax state.
Next
1-231
ASSY.
Note:
injector ASSY may not function properly. Therefore, when
replacing the fuel filter element ASSY, make sure to clean
inside of the fuel filter case sub ASSY.
Next

freezing).
Next
Note:
When fuel filter element S/A or fuel pipe is replaced, bleed air
from the system.
Next
1. Check if white smoke is eliminated.
Next
End
21 'Engine Diagnostic Program' active test implementation (control the EGR step position)

2. Press [Active test] and select [Control the EGR Step Position]
3. Monitor [Target EGR Position] and [Actual EGR Valve Pos.]
Result
Result Go to
The value of the [Actual EGR Valve Pos.] follows that of the [Target EGR Position]. A
The value of the [Actual EGR Valve Pos.] does not follow that of the [Target EGR Position]. B
B Go to step 25.
A
1-232
22 Engine ASSY inspection
1. Inspect the engine and check if white smoke is discharged due

to defect of the engine itself.
(1) Check oil leak into the combustion chamber due to oil
seal defect of valve system.
(2) Check oil leak into the combustion chamber due to nozzle
seat defect of injector ASSY.
(3) Check low compression.
Note:
When detecting an abnormality, repair it, and check that defect
phenomenon does not occur.
Next
End
23 Idling condition inspection

2. Check the condition of idling.
Result
Result Go to
Abnormalities, such as rough idling and engine stall, are observed and white smoke is discharged. A
Engine rotates smoothly when idling but white smoke is discharged. B
A Engine ASSY repair
Inspection of oil leak in turbo charger and white smoke (See page 1-234 for the procedure)
24 Oil leak inspection
1. Remove oil from inside of the front exhaust pipe ASSY.

Note:
Oil adhesion inside of the exhaust pipe generates white
smoke.
2. When oil is leaking, repair the leak.
Next
End
1-233
25 Electric EGR control valve ASSY replacement and EGR with cooler pipe S/A cleaning
Caution:
Note:
S/A is clogged, intake air quantity may increase and result
in larger engine vibration and knocking.
(3) Install a new electric EGR control valve ASSY and EGR
with cooler pipe S/A.
Next
End
1-234
TURBO CHARGER OIL LEAK AND WHITE SMOKE
Overview
Type of oil leak Overview Major defect points
• Oil leak, which flows from the bear-
ing housing, through the sealing of
compressor housing (intake side) • Seal ring on the compressor side
or turbine housing (exhaust side). • Seal ring on the turbine side
• Internal oil leak cannot be seen • Clogging of oil drain
Internal oil leak
from outside of the turbo charger S/ • Damage of shaft
(White smoke)
A. • Burning of shaft and bearing
• In case of oil leak from the seal on • Damage of compressor impeller
the turbine side, a large amount of • Low-quality fuel
white smoke is discharged from the
exhaust pipe.
• Oil leak from inside of turbo
charger S/A to the outside(Ex.
• FIPG seal part
FIPG seal, oil pipe flange or oil pipe
• Oil pipe flange
External oil leak union).
• Oil pipe union
• Including oil leak which can be
• Hose connection of intake pipe
seen from outside of turbo charger
S/A.
1-235
Note:
• Oil leak of turbo charger S/A can be classified into two types. One is internal oil leak and the other is
external oil leak.
• The following illustration shows each part of turbo charger S/A.
• When oil leak and white smoke occur, turbo charger S/A may be replaced by mistake, although it is not the
cause of abnormality.
• When there are traces of oil on the surface of compressor housing or oil spots at the inlet and outlet of
compressor, it may be mistakenly determined that oil leak of turbo charger S/A is the cause of
abnormality.
Oil leak inside of the Bearing housing

compressor housing
Compressor Turbine housing

housing
Oil leak inside of the

Compressor turbine housing
inlet
Seal ring
Turbine wheel
Compressor
impeller
Oil drain
Turbine shaft
FIPG seal part
1-236
Illustration 1
Note:
• This illustration is different from the turbo charger S/A of 1KD engine.
• In case of oil stain as shown in illustration 1, this may be because of oil scattered from the peripheral
components of turbo charger S/A or because of oil leak from the air cleaner hose. Oil stain on the outer
surface of turbo charger S/A is not oil leak from the turbo charger S/A (external oil leak). This is not related
to white smoke, either. To identify the actual oil leak which occurs outside of the turbo charger S/A, check
only the seal part shown in the illustration below.
Illustration 2 Illustration 3
Oil spot at the outlet of
compressor
Oil spot at the inlet of compressor

(Maximum 5 cm2)
Note:
• Since blowby gas, including oil mist, is returned to the intake system by PCV, certain quantity of oil is
introduced into the intake system. Oil level at the compressor inlet (shown in illustration 2) is normal. This
is not oil leak (internal oil leak) from the turbo charger S/A. Oil level at the compressor outlet (shown in
illustration 3) is also normal.
• Surface of compressor impeller may sometimes become black due to blowby gas, but this is not
abnormal.
1-237
Illustration 4
In case of actual oil leak, oil leaks from the seal

part of FIPG.
Note:
• Illustration 4 shows the air leak inspection, performed by putting soapy water at the oil leak position.
Bubbles indicate the leak position.
1. Defects and symptoms of turbo charger S/A parts
Seal Ring on the Compressor Side

Main defects Seal ring damage
• Oil leak into the compressor housing
Symptom
• Oil consumption increase
• In case of compressor seal ring defect, a large amount of oil leak may be found
between compressor outlet and inter cooler and between inter cooler and intake mani-
Remarks fold.
• If there is a large amount of oil leak at the compressor inlet, this is not from the turbo
charger S/A. This may indicate an abnormality of PCV system.
Seal ring on the turbine side

Main defects Seal ring damage
• Oil leak into turbine housing
Symptom • A large amount of white smoke from the exhaust pipe
• Oil consumption increase
• In case of turbine seal ring defect, a large amount of white smoke is discharged contin-
uously.
• When white smoke is discharged only directly after the engine start (and disappears
Remarks later) or only a small amount of white smoke is discharged intermittently, this is not
from the turbo charger S/A. This is due to the defect of some other parts.
• If there is wet oil at the turbine inlet, this is not from the turbo charger S/A. This is due
to the defect of some other parts.
Bearing Housing (Oil Drain Clogging)

Main defects Oil drain clogging due to oil coking
Symptom A large amount of white smoke from the exhaust pipe
Note:
• Oil coking is caused by poor oil management
• When oil drain is clogged because of oil coking, oil cannot be removed smoothly. Oil spills from the
bearing housing to the compressor housing and turbine housing, causing a large amount of smoke
generated from the exhaust pipe.
1-238
Oil drain is clogged due to oil coking
Oil coking
Oil coking
Oil drain
Oil drain
Note:
This illustration is different from the turbo charger S/A of 1KD engine.
Turbine shaft
• Damage
Main defects
• Burning
• Shaft does not rotate.
• Oil leak into the compressor housing
Symptom • A large amount of white smoke from the exhaust pipe
• Sound of turbo charger S/A changes
• In case of turbine shaft defect, insufficient output is experienced due to insufficient
supercharging pressure.
Remarks
• Shaft rotation is felt heavy due to oil viscosity at a low temperature. Do not interpret this
as shaft not rotating smoothly.
Compressor Impeller
Main defects Damage
• Shaft does not rotate.
Symptom • Oil leak into the compressor housing
• In case of compressor impeller defect, a large amount of oil may be found between
compressor outlet and inter cooler and between inter cooler and intake manifold.
Remarks • Due to supercharging pressure, oil may stop at the compressor seal ring part. When
supercharging pressure does not increase due to the damage of compressor impeller,
oil flows out into the compressor housing.
Compressor Housing FIPG Seal Part

Symptom Oil leak from the FIPG seal part
• When oil stain is different from that of FIPG seal part, it can be determined as oil scat-
tered from the peripheral components of turbo charger S/A.
Remarks
• When oil stain reaches the hose connecting part, it can be determined as poor hose
connection.
1-239
Compressor back plate
FIPG seal part
Compressor housing
Oil leak from the FIPG seal part
Note:
Intake Hose
Symptom Oil leak from the hose connecting part between the hose and compressor housing
When there is oil stain at the hose connecting part, it can be determined as poor hose
Remarks
connection.
Compressor outlet
Compressor housing
Oil leak from the hose connecting part
Note:
1-240
1 Oil leak inspection (Oil leak type check)
1. Check if oil leak is internal or external.

Note:
White smoke is not related with external oil leak.
Type of oil leak Overview
Oil leak, which flows from the bearing housing, through the sealing of compressor
housing (intake side) or turbine housing (exhaust side) cannot be seen from out-
Internal oil leak
side of the turbo charger S/A.
(White smoke)
In case of oil leak from the seal on the turbine side, a large amount of white
smoke is discharged from the exhaust pipe.
Oil leak from inside of turbo charger S/A to outside
(Ex. FIPG seal, oil pipe flange, or oil pipe union).
External oil leak
Including oil leak which can be seen from outside
of the turbo charger S/A.
Result
Result Go to
External oil leak A
Internal oil leak B
B Go to step 3.
2 Defective parts replacement (Replacement of parts with oil leak)
1. Replace the parts which have oil leak.
Next
End
3 Defect reproduction test implementation (White smoke)
1. Press the accelerator pedal fully and release it.

2. Check if white smoke is discharged when revving up the
engine.
WARNING:
Result
Result Go to
White smoke is discharged. A
White smoke is not discharged. B
1-241
Caution:
• When white smoke is discharged only for a short time
directly after the engine start, the white smoke does not
come from the turbo charger S/A.
• Whether when cool or warm, when turbo charger S/A is the
cause of abnormality, so much white smoke is generated
that you cannot see beyond several meters.
• With fuel contaminated with oil and with unburnt fuel,
exhaust gas smells different. When fuel is contaminated
with oil, exhaust gas smells burnt.
A Go to the troubleshooting of white smoke
4 Turbo charger S/A individual inspection (Compressor inlet)
1. Remove the air cleaner hose from the compressor inlet.

2. Check if there is an excessive amount of oil or oil deposits at
the compressor impeller.
Note:
• Since a certain amount of oil mist is included in PCV gas
and oil gathers immediately before the compressor inlet,
there may be a certain amount of oil as shown in illustration
2.
• When there is an excessive amount of oil at the compressor
inlet, PCV system may be defective.
3. Install the air cleaner hose.
Next
5 Turbo charger S/A individual inspection (Compressor outlet)
1. Remove the air hose from the compressor outlet.

2. Check if there is an excessive amount of oil or oil deposit at the
compressor outlet.
Note:
Since a certain amount of oil mist is included in PCV gas,
there may be a certain amount of oil as shown in illustration 3.
Result
Result Go to
There is an excessive amount of oil both at the compressor inlet and outlet. A
There is an excessive amount of oil only at the compressor outlet. B
There is not an excessive amount of oil either at the compressor inlet or outlet. C
3. Install the air hose.

A Air induction system (PCV system) inspection
B Go to step 8.
C
1-242
6 Turbine housing individual inspection (turbine inlet)
1. Remove the turbo charger S/A from the engine.

2. Check if there is an excessive amount of wet oil or oil deposit
at the turbine inlet.
Note:
Do not confuse carbon soot with oil.
Next
7 Turbine housing individual inspection (turbine outlet)
1. Check if there is an excessive amount of wet oil or oil deposit

at the turbine outlet.
Note:
• Do not confuse carbon soot with oil.
• When the shaft of turbo charger S/A is tilted, some quantity
of oil flows out of the bearing housing.
• Do not confuse the oil, which flowed out of the bearing
housing when or after removing the turbo charger S/A, with
the oil which had been there before removing the turbo
charger S/A.
• When an excessive amount of oil or oil deposit is found at
the turbine inlet, oil must have come from the exhaust port
of cylinders. This means that more than one cylinders may
be defective.
Result
Result Go to
There is an excessive amount of oil both at the turbine inlet and outlet. A
There is an excessive amount of oil only at the turbine outlet. B
A Engine unit inspection, repair
8 Turbo charger S/A replacement
1. Replace the turbo charger S/A.

Next
Next
End
1-243
TURBO CHARGER S/A NOISE
Note:
Turbo charger S/A noise can be classified into two types. One is whistling noise and the other is chattering
noise. When troubleshooting, determine the type of noise at first.
Overview
Type of noise Description of noise Major defect points
Volume and pitch of whistling noise is in
• Turbo charger S/A (Ex. shaft unstable)
proportion to the speed of turbo charger
• Transmission Gear
Whistling noise S/A or engine speed. When the engine
• Leakage of intake system
speed increases, noise level becomes
• Defect of intake system
clear.
Turbo charger S/A
Note:
Chattering noise has lower pitch than
• Vibration of turbo charger S/A is trans-
whistling noise. This is generated when
mitted to the exhaust pipe and gener-
engine speed is between 1500 to 2500
Chattering noise ates resonance and noise.
rpm. Pitch is relatively stable and is inde-
• Vibration of turbo charger S/A is trans-
pendent from the engine speed and vehi-
mitted to the body (floor) via exhaust
cle speed.
pipe, and vibrates the body, while gen-
erating noise.
1. Defect and symptoms of diesel engine components
Turbo Charger System

Main defects Turbine shaft of turbo charger S/A is unstable.
High-pitched whistling noise
Symptom Note:
Pitch and volume is in proportion to the speed of turbo charger S/A.
Intake system
Main defects Leak
Symptom Noise at the time of intake air leakage
Transmission Gear
Abnormal noise of gear
Symptom Note:
Pitch and volume are in proportion to the speed of transmission gear.
1-244
1 Inquiry (Check the condition of abnormal noise)
1. Ask the customer about the condition when abnormal noise

occurred.
Note:
Following table is helpful to understand the condition when
abnormal noise occurred.
Item Remarks
Engine speed Engine speed range
Accelerator pedal position When accelerating or when decelerating
• Outside temperature
Temperature
• Engine temperature (When cool, warm, etc.)
Road condition Up hill or down hill
• Did the abnormal noise occur suddenly or gradually?
Abnormal noise level
• Did the volume of abnormal noise go up gradually?
• Insufficient power
Other symptoms
• High fuel consumption
What made the customer determine it as abnormal
Abnormal noise recognition
noise?
Next
2 Defect reproduction test implementation
1. Check if abnormal noise explained by the customer can be

heard.
Note:
If abnormal noise is heard, check if it matches the explanation
by the customer.
Result
Result Go to
Abnormal noise, which matches the explanation by the customer, was confirmed. A
Abnormal noise, which matches the explanation by the customer, was not confirmed. B
B Go to step 10.
A
1-245

Result
Result Go to
No leak or clogging detected A
Leak or clogging detected B
Note:
and damage in the intake system.
• To check air leak from the intake system, apply soapy water
to the intake system, increase engine speed and check if
bubbles are formed.
harness are normal.
B Defective parts repair or replacement
A
1-246
4 Defect reproduction test implementation

(Check if the abnormal noise is from the turbo charger S/A.)
SST 09111-36760-71 (09991-70201)
2. Turn on the power of SST.
3. Press [Active test]  select [Activate the VN Turbo Open] on
4. Compare the abnormal noise which is heard under the
condition, which the customer described in the complaints of
abnormal noise* with the abnormal noise, which is heard when
active test is not performed. Check if the abnormal noise
decreases.
Note:
*: Examples are during idling, when racing, and when
driving with throttle fully open.
Result
Result Go to
Abnormal noise decreased (or disappeared). A
Abnormal noise is same as in step 2 (Abnormal noise has not changed). B
Note:
• When [Activate the VN Turbo Open] is performed in the
active test, variable nozzle of turbo charger S/A becomes
fully open regardless of the engine state, and the speed of
turbo charger S/A does not increase.
• When turbo charger S/A is the cause of abnormal noise,
turbo charger speed does not increase when [Activate the
VN Turbo Open] is performed in the active test. Therefore,
abnormal noise decreases.
B Go to step 7.
5 Defect reproduction test implementation (Abnormal noise type check)
1. Check if abnormal noise can be heard when the engine speed

is at NMR and if abnormal noise becomes louder as the engine
speed increases.
Note:
When abnormal noise becomes louder, it is most likely
whistling noise, and when not, it is most likely chattering
noise.
Result
Result Go to
Abnormal noise becomes gradually louder as the engine speed increases.
A
(Abnormal noise is most likely whistling noise.)
Abnormal noise does not become gradually louder as the engine speed increases.
B
(Abnormal noise is most likely chattering noise.)
B Go to step 6.
Turbo charger S/A replacement (See page 2-19 for the procedure)
1-247
6 Exhaust pipe ASSY inspection

(Positioning implementation and abnormal noise check)
1. Disconnect the front exhaust pipe ASSY from the ball joint part
and each exhaust pipe support. Adjust the position of exhaust
pipe and reconnect each exhaust pipe support and ball joint
part.
2. Check if abnormal noise defect is eliminated.
Note:
Positioning of exhaust pipe affects chattering noise.
Result
Result Go to
Abnormal noise is eliminated. A
Abnormal noise is generated as before. B
B Turbo charger S/A replacement

End
7 Defect reproduction test implementation inspection

(Check other source of abnormal noises than turbo charger S/A)
1. Check if there is the source of abnormal sound.

(1) Start up the engine.
(2) Perform racing and check if abnormal noise decreases as
the engine speed decreases.
Note:
• When abnormal noise decreases as the engine speed
decreases, it is gear noise.
• When abnormal noise decreases a while after the engine
speed decreases, it is turbo charger S/A noise.
Next
8 Defective parts replacement
1. Replace the parts, which were identified as the source of

abnormal noise in step 7.
Next
1. Check if abnormal noise is eliminated.
Next
End
1-248
10 Explaining the customer that the sound is normal
1. Explain the customer that the sound which the customer

reported is not abnormal.
Note:
To facilitate the understanding of the customer, it is helpful to
drive another vehicle with the customer.
Next
End
1-249
TROUBLESHOOTING OF BLACK SMOKE
Caution:
Note:
• When knocking also occurs, perform the diagnosis of knocking first.
• The value shown in the flow chart of troubleshooting is just for reference. Depending on the measuring
condition and machine condition, the value of data list may change. Also when the data list value is within
the standard range, there may be a hidden defect factor.
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to

2 Exhaust gas inspection (Black smoke)

2. Perform racing from idle to NMR ten times or more and check
if black smoke is discharged.
Standard Black smoke is discharged less than five times.
Note:
• Even when black smoke is quite thin, as long as it is visible,
it is counted as one time.
• When racing is performed ten times or more and black
smoke is not discharged any more, it is probably because
of soot which accumulated temporarily and it is not a
failure.
NG Go to step 3.
OK
End
1-250

Note:
• Inspect the air cleaner for clogging and the intake and
exhaust system hoses for dislocation.
• Check that inter cooler is not clogged with foreign matters.
• Check that hose or pipe is not disconnected, pinched in, or
leaking.
Standard No air leak or clogging
NG Defective parts repair, replacement
OK
4 Wire harness or connector connecting condition check
1. Check the connecting condition of wire harness and connector,

which are connected to various sensor and actuator, such as
intake air flow meter S/A and diesel turbo pressure sensor.
which are connected to the parts of high fuel system such as
injector and common rail S/A.
Standard Wire harnesses and connectors are securely
connected.
S/A
NG Go to step 33.
OK
SST 09111-36760-71 (09991-70201)

screen, check the injector compensation code (ID code). (See
installed.
NG Go to step 16.
OK
6 'Engine Diagnostic Program' data reading (Saving data of during idling and at NMR)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [MAP], [MAF],
[Atomosphere Pressure] [Engine Speed], [Coolant Temp],
[Intake Air] and [Intake Air temp (Turbo)].
3. Perform the data monitoring to press [Start].
1-251
4. Perform the data storage to press [Stop] and [Save].

Note:
diagnosis.
• Save the data list of during idling after warm up and at NMR.
Next
7 'Engine Diagnostic Program' data reading (manifold air pressure and mass air flow)
SST 09111-36760-71 (09991-70201)

1. Read the data of [MAP] and [MAF] at NMR, which was saved
in step 6.
Result
Result Go to
[MAF] is 40 g/sec. (5.29 lb/min) or more and [MAP] is 105 kPa or more. A
Note:
Data above was measured under the standard atmospheric
pressure. The values may be affected by various factors, such
as altitude and weather.
Standard atmospheric pressure is 101 kPa. For every 100 m
(328 feet) ascending, atmospheric pressure decreases by 1
kPa. Atmospheric pressure changes by weather.
A Go to step 10.
SST 09111-36760-71 (09991-70201)

3. Monitor [Target EGR Position] and [Actual EGR Valve Pos.].
Result
Result Go to
A Go to step 10.
B
1-252
Caution:
Note:
with cooler pipe S/A. (See page 2-12 for the procedure.)
Next Go to step 17.
10 'Engine Diagnostic Program' active test implementation (Control the Select Cylinder Fuel Cut)

cylinder.
Result
Result Go to
Note:
idle.
B Go to step 18.
A
1-253

NOTICE:
diagnosis.
Next
SST 09111-36760-71
in step 6.
Result
Result Go to
NOTICE:
A Go to step 10.
SST 09111-36760-71
Result
Result Go to
A Go to step 10.
B
1-254
ASSY.
Note:
Next
Next

Next

2. Perform racing from idle to NMR ten times and check if black
smoke is discharged.
Note:
Even when black smoke is quite thin, as long as it is visible, it
is counted as one time.
Next
End
SST 09111-36760-71 (09991-70201)

1. Read the data of [Injection Volume] at NMR, which was saved
in step 6.
Result
Result Go to
[Injection Volume] at NMR is less than 7.0 mm3/st. A
B Go to step 20.
A
1-255
19 Injector ASSY replacement (All cylinders)
Caution:
failure.
leakage
.
Next Go to step 14.
20 'Engine Diagnostic Program' data reading (manifold air pressure and atmosphere pressure)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [MAP],
[Atomosphere Pressure].
3. Compare the values of [MAP] and [Atomosphere Pressure] at
engine stop.
Reference Difference between [MAP] and [Atomosphere
Pressure] is less than 8 kPa.
Note:
• When the values of [MAP] and [Atomosphere Pressure] are
same, they are both normal. When the difference is 10 kPa
or more, compare them with the actual atmospheric
pressure. The sensor with the biggest difference is
defective.
• Standard atmospheric pressure is 101 kPa. For every 100 m
Result
Result Go to
The value of [Atomosphere Pressure] and the actual atmospheric pressure are different. A
The value of [MAP] and the actual atmospheric pressure are different. B
The values of [MAP] and [Atomosphere Pressure] are same. C
A Go to step 29.
B Go to step 30.
C
1-256
21 Work support implementation (Fuel system check / fuel system malfunction check)
1. Implement the fuel system check. (See page 1-16 for the
procedure.)
2800
Engine speed
1400 rpm
Fuel system check

ON
OFF
Fuel pressure
under normal
Below
10000 kPa
Fuel pressure
conditions
Time
2 sec.

kPa.
Note:
common rail.
illustration.
NG Go to step 24.
OK
22 'Engine Diagnostic Program' data reading (Engine coolant temperature)
SST 09111-36760-71 (09991-70201)

1. When the engine is warm, leave it for a long time until it is
cooled.
1-257

screen, press [Data monitor] and monitor [Coolant Temp].
4. Read the engine coolant temperature displayed on the 'Engine
Standard [Coolant Temp] is same as the ambient
temperature.
Note:
When [Coolant Temp] is low, although the engine is
sufficiently warm or when [Coolant Temp] is high, although
when cool, inspect the sensor.
NG Go to step 31.
OK
23 'Engine Diagnostic Program' data reading (Intake air temperature and intake air temperature
after turbo)
SST 09111-36760-71 (09991-70201)

1. When the engine is warm,wait until the engine is cooled down.
Note:
When reading data of [Intake Air] and [Intake Air temp (Turbo)]
while the engine is warm, the value may contain error even
under a normal condition. Therefore, read data when the
engine is cool.
screen, press [Data monitor] and monitor[Intake Air] and
[Intake Air temp (Turbo)].
4. Read [Intake Air] and [Intake Air temp (Turbo)] , which are
displayed on the 'Engine Diagnostic Program'.
Standard The values of [Intake Air] and [Intake Air temp
(Turbo)] are same.
NG Go to step 32.
OK
End
24 Wire harness or connector inspection (Suction control valve ASSY - Engine control computer)
NG Go to step 33.
OK

Note:
1-258

• If fuel turns into wax state, warm the fuel filter element
ASSY to fuel turns liquid state.
NG Go to step 34.
OK

Next
Next
SST 09111-36760-71 (09991-70201)

2. Press [Trouble code] and [Clear] on the 'Engine Diagnostic
Note:
Next Go to step 36.

Next Go to step 36.

Next Go to step 36.
31 Water temperature sensor inspection and replacement
1. Inspect the water temperature sensor.

1-259

Note:
Replace it only when the inspection result is NG.
Next Go to step 36.
32 Defective parts inspection and replacement
1. Inspect the intake air flow meter S/A.

2. Inspect the inlet air temperature sensor (for intake manifold).
Note:
4. Replace the inlet air temperature sensor (for intake manifold).
Note:
Next Go to step 36.

Next Go to step 36.

freezing).
Next
Next

2. Perform racing from idle to NMR ten times and check if black
smoke is discharged.
Note:
Even when black smoke is quite thin, as long as it is visible, it
is counted as one time.
Next
End
1-260
TROUBLESHOOTING OF LACK OF POWER, HESITATION, AND SURGE

(HESITATION)
Caution:
Note:
Even when rough idling occurs at the same time, perform the diagnosis of insufficient power first.
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
Diagnosis code is P0299 or not output. A

SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [MAP], [MAF],
[Atomosphere Pressure], [Fuel Press], [Target Common Rail
Pressure], [Engine Speed].
Note:
diagnosis.
Next
1-261
in step 2.
Result
Result Go to
[MAF] is 40 g/sec. (5.29 lb/min) or more and [MAP] is 105 kPa or more.*1 A
[MAP] is less than 90 kPa.*2 B
Other than the above *3 C
Note:
*1: The fuel system may be defective.
*2: The turbo charger S/A system may be defective.
*3: The intake system may be defective or EGR valve may be
defective (valve stuck open or does not close).
B Go to step 11.
C Go to step 24.
1. Read the data of [Fuel Press], [Target Common Rail Pressure]

and [MAP] at NMR, which was saved in step 2.
Result
Result Go to
[MAP] at NMR is less than 160 kPa. A
Difference between [Fuel Press] and [Target Common Rail Pressure] is 20000 kPa or more. B
Note:
• Data above was measured under the standard atmospheric
pressure. The values may be affected by various factors,
such as altitude and weather.
• When the operation of turbo charger S/A is not smooth, the
value of [MAP] saved at an insufficient power time does not
reach the target. When the accelerator pedal is pressed fully
and [Engine Speed] is at NMR, [MAP] is 160 kPa or more.
B Go to step 18.
C Go to step 24.
A
1-262
1. nspect that there is no leakage or clogging between the air

Note:
• Check for abnormal breakage, damage and collapse in the
pipes and hoses of intake system.
bubbles are formed.
NG Go to step 16.
OK
ASSY.
Note:
Next
7 Injector ASSY replacement (All cylinders)
1. Replace the injector ASSY.

Caution:
failure.
leakage.
Next
1-263
in step 2.
Result
Result Go to
NOTICE:
B Go to step 11.
C Go to step 24.

Result
Result Go to
NOTICE:
B Go to step 18.
C Go to step 24.
A
1-264

Result
Result Go to
Note:
• When inspecting the intake system for clogging (due to low
[MAP]), inspect the following items.
- Air cleaner clogging
- Intake hose clogging
Next Go to step 16.
13 Replacement of turbo charger S/A
1. Replace the turbo charger S/A

Next Go to step 17.

Next Go to step 17.

Next Go to step 17.

Next Go to step 17.
Next
End
1-265

Note:
NG Go to step 20.
OK

Next Go to step 21.

freezing).
Next
Next
SST 09111-36760-71 (09991-70201)

Note:
Next
1. Implement the fuel system check (fuel system malfunction

check). (See page 1-16 for the procedure.)
1-266

2800
Engine speed
1400 rpm
Fuel system check

ON
OFF
Fuel pressure
under normal
Below
10000 kPa
Fuel pressure
conditions
Time
2 sec.

kPa.
Note:
common rail.
illustration.
Next
End
1-267

Result
Result Go to
Note:
bubbles are formed.
harness are normal.
B Go to step 27.
SST 09111-36760-71 (09991-70201)

2. Press [Active test] and select [Control The EGR Step Position]
Result
Result Go to
A Go to step 29.
B
1-268
Caution:
Note:
(3) Install the electric EGR control valve ASSY. (See page 2-
Next Go to step 28.
Next
NG Go to step 29.
OK
End
29 Exhaust pipe ASSY FR individual inspection
1. Remove the exhaust pipe ASSY FR.

2. Visually check the internal wall of catalyst upstream exhaust
pipe for carbon deposit build up and catalyst clogging.
Standard Clogged cell is less than 10%.
3. Install the exhaust pipe ASSY FR.
NG Go to step 31.
OK
1-269
30 Replacement of turbo charger S/A
1. Replace the turbo charger S/A

Next Go to step 32.
31 Exhaust pipe ASSY FR replacement
1. Replace the exhaust pipe ASSY FR.

Next Go to step 32.
Next
End
1-270
TROUBLESHOOTING OF ROUGH IDLE AND LARGE VIBRATION
Caution:
Note:
• When knocking and black smoke discharge also occurs, perform the diagnosis of knocking first.
• When insufficient power is experienced at the same time, perform the diagnosis of insufficient power first.
1 Wire harness or connector connecting condition check

which are connected to the parts of high fuel system such as
injector and common rail S/A.
Standard Wire harnesses and connectors are securely
connected.
NG Go to step 12.
OK
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
Note:
After diagnosis code was output and repair and replacement
work were performed, if defect is still not eliminated, go to
step 3.
A
1-271
3 'Engine Diagnostic Program' data reading (Saving data of during idling)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [Fuel Press], [Target
Common Rail Pressure], [Engine Speed].
Note:
diagnosis.
• Save the data list of during idling after warm-up.
Next
4 Exhaust gas inspection (White smoke)

2. Perform racing from idle to NMR and check if white smoke is
discharged.
Caution:
Note:
Whether the fuel is contaminated with oil or the fuel is unburnt
is determined by the smell of exhaust gas. When the fuel is
contaminated with oil, exhaust gas smells like burnt oil.
Result
Result Go to
White smoke is not discharged. A
White smoke is discharged. B
B Go to step 13.
SST 09111-36760-71 (09991-70201)

1. Check the injector compensation code (ID code). (See page 1-
installed.
NG Go to step 11.
OK
1-272
SST 09111-36760-71 (09991-70201)

Note:
cylinder.
for each cylinder to identify the defective cylinder.
Result
Result Go to
Note:
speed or idle vibration when a fuel cut (control the select
cylinder fuel cut) is performed during the engine idling.
idle.
B Go to step 14.
SST 09111-36760-71 (09991-70201)

Result
Result Go to
A
Note:
in compression.
B Go to step 13.
A
1-273

Caution:
failure.
leakage.
Next
1. Clean the fuel filter case sub ASSY and replace the fuel filter
element ASSY.
Note:
Next
Next

Next Go to step 24.

Next Go to step 24.
1-274
13 Engine ASSY inspection and replacement
1. Inspect the writing the injector compensation code.

(1) Check the compression of engine.
(2) Inspect the glow plug ASSY.
Next Go to step 24.
1. Read the data of [Fuel Press] and [Target Common Rail

Pressure] during idling, which was saved in step 3.
Result
Result Go to
[Fuel Press] exceeds ±5000 kPa of the [Target Common Rail Pressure]. A
B Go to step 21.

Note:
NG Go to step 19.
OK

Next
Next
1-275
SST 09111-36760-71 (09991-70201)

Note:
Next Go to step 24.

freezing).
Next

Next Go to step 24.
SST 09111-36760-71 (09991-70201)

Result
Result Go to
A Go to step 23.
B
1-276
Caution:
Note:
with cooler pipe S/A.
Next Go to step 24.
23 Engine mounting inspection (Cause of engine mounting system)
1. Visually inspect each engine mounting.

(1) Inspect the engine mounting for installation condition,
running-on interference, twist, and crack in rubber.
Note:
Repair or replace if defective.
Next
Next
End
1-277
TROUBLESHOOTING OF KNOCKING AND ABNORMAL NOISE
Caution:
1 Check of abnormal noise
1. Check the source of abnormal noise by using a sound scope.

Result
Result Go to
Combustion sound A
Other than the above (Engine mechanical abnormality, etc.) B
B Repairing defective parts
SST 09111-36760-71 (09991-70201)

procedure.)
Result
Result Go to
SST 09111-36760-71 (09991-70201)

screen, check the injector compensation code (ID code). (See
installed.
NG Go to step 16.
OK
1-278
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and select [injection Volume],
[MAP], [Atomosphere Pressure], [Fuel Press], [Target
Common Rail Pressure], [Engine Speed].
Note:
diagnosis.
Next
1. Read the data of [injection Volume] at NMR, which was saved

in step 4.
Result
Result Go to
[injection Volume] at NMR is less than 7.0 mm3/st. A
A Go to step 9.
1. Read the data of [Fuel Press] and [Target Common Rail

Pressure] during idling, which was saved in step 4.
Result
Result Go to
[Fuel Press] exceeds ±5000 kPa of the [Target Common Rail Pressure]. A
A Go to step 18.
7 Check of engine coolant temperature at knocking time
1. Check the condition of engine coolant temperature at the

knocking time.
Result
Result Go to
Knocking only when cool A
Knocking both when cool and after warm B
1-279
B Go to step 25.
8 Glow plug ASSY inspection
1. Inspect the glow plug ASSY.

OK Go to step 10.
NG
Glow plug ASSY replacement (See page 2-10 for the procedure)
9 Injector ASSY replacement
1. Replace the injector ASSY.

Caution:
the repair manual, tighten the injector to the specified
torque.
failure.
problems.
leak.
Next Go to step 14.
SST 09111-36760-71 (09991-70201)

Note:
cylinder.
for each cylinder to identify the defective cylinder.
1-280
Result
Result Go to
Note:
speed or idle vibration when a fuel cut (control the select
cylinder fuel cut) is performed during the engine idling.
idle.
B Go to step 25.
SST 09111-36760-71 (09991-70201)

Result
Result Go to
B
Note:
in compression.
B Go to step 13.

NG Engine unit inspection, repair
OK
1-281

Caution:
failure.
leakage.
Next
ASSY.
Note:
Next
Next

Next
Next
End
1-282

Note:
• At a low temperature, fuel filter element may become
NG Go to step 23.
OK

Next
Next
SST 09111-36760-71 (09991-70201)

Note:
Next
Next
End

freezing).
Next
1-283
Next
End
25 'Engine Diagnostic Program' data reading (manifold air pressure and atmosphere pressure)
SST 09111-36760-71 (09991-70201)

screen, press [Data monitor] and monitor [MAP],
[Atomosphere Pressure].
3. Compare the values of [MAP] and [Atomosphere Pressure] at
engine stop.
Reference Difference between [MAP] and [Atomosphere
Pressure] is less than 8 kPa.
Note:
• When the values of [MAP] and [Atomosphere Pressure] are
same, they are both normal. When the difference is 10 kPa
or more, compare them with the actual atmospheric
pressure. The sensor with the biggest difference is
defective.
Result
Result Go to
The values of [MAP] and [Atomosphere Pressure] are same. A
The value of [MAP] and the actual atmospheric pressure are different. B
The value of [Atomosphere Pressure] and the actual atmospheric pressure are different. C
B Diesel turbo pressure sensor replacement
C Engine control computer replacement
26 Basic inspection
1. Inspect the quality of fuel.

2. Inspect that fuel system is not clogged.
3. Inspect the air cleaner.
4. Inspect the engine oil.
5. Inspect the coolant.
6. Inspect the idle speed and the maximum engine speed.
7. Inspect the fuel pressure.
Next
End
1-284
VC POWER SUPPLY SYSTEM
Circuit description
Engine control computer always generates 5 V from the battery voltage applied to the +B (BATT) terminal to operate
CPU. The engine control computer also supplies this power to the sensor via VC output circuit.
BATT
From battery
Constant-voltage power
+B supply circuit
From MAIN relay
Fuel pressure sensor, VC

Micro
accelerator position sensor, etc.
Computer
Water temperature, intake

air flow meter S/A, etc. Resistance
When short-circuit occurs in VC circuit, power is not supplied from the VC circuit. Therefore, the CPU in the engine
control computer and the sensor which is power-supplied via VC circuit stop. In this state, the system does not start
up. Even when the system is defective, the engine check indicator does not light up.
Note:
Normally, when the ignition switch is turned on, the engine check indicator lights up. When the engine starts,
the engine check indicator turns off.
1-285
Circuit diagram
1 68
L VC A VCS1
Common rail ASSY 2 66
(Fuel pressure sensor) PR A PCR1
3 67
E2 A E2S1
3 94
V VNVC A VNVC
Turbo charger S/A 1 116
(Nozzle opening degree sensor) VNA A VNA
2 95
VNE2 A VNE2
S 3 75
VC A VCEG
Electric EGR 115
2
Control valve ASSY VTA A EGRA
1 92
E2 A EEGL
4 86
M+ A EGM+
5 85
M- A EGM-
3 93
R VC A VCPM
Diesel turbo pressure sensor 2 117
PIM A PIM
1 72
E A EPIM
T 4 55
VCPA B VCPA
Accelerator position sensor
1 57
(Potentiometer) VCP2 B VCP2
6 53
VPA B VPA
3 54
VPA2 B VPA2
5 56
EPA B EPA
2 58
EPA2 B EPA2
A B
Engine control
Computer
1-286
Caution:
1 Engine check indicator lighting inspection

2. Check that the engine check indicator in the combination
meter ASSY lights up.
Result
Result Go to
Engine check indicator does not light up. A
Engine check indicator lights up. B
B End
2 'Engine Diagnostic Program' data reading
SST 09111-36760-71 (09991-70201)

2. Check that the 'Engine Diagnostic Program' communicates
with the engine control computer.
Note:
ECU data monitor of ECD system can be checked.
Result
Result Go to
It does not communicate. A
It communicates. B
B Go to the engine check indicator circuit inspec-

tion (See page 1-203 for the procedure.)
A
1-287
Wire harness and connector inspection (Short circuit inspection between Engine control com-
3
puter - Accelerator position sensor (potentiometer))
1. Disconnect the connector of accelerator position sensor

(potentiometer).
3. Inspect the engine check indicator inside the combination
meter ASSY.
Result
Result Go to
Not lit A
Lit B
B Accelerator position sensor (potentiometer)

replacement

4
(Engine control computer - Common rail ASSY (fuel pressure sensor))
1. Disconnect the connector of common rail ASSY (fuel pressure

sensor).
meter ASSY.
Result
Result Go to
Not lit A
Lit B
B Common rail ASSY replacement


5
(Engine control computer - Turbo pressure sensor)
1. Disconnect the connector of turbo pressure sensor.

meter ASSY.
Result
Result Go to
Not lit A
Lit B
B Diesel turbo pressure sensor replacement
A
1-288

6
(Engine control computer - Electric EGR valve ASSY (EGR valve position sensor))
1. Disconnect the connector of electric EGR valve ASSY (EGR

valve position sensor).
meter ASSY.
Result
Result Go to
Not lit A
Lit B
B Electric EGR control valve ASSY

replacement (EGR valve position sensor)

7
(Engine control computer - Turbo charger S/A (Nozzle opening degree sensor))
1. Disconnect the connector of nozzle opening degree sensor of

turbo charger S/A.
meter ASSY.
Result
Result Go to
Not lit A
Lit B
B Turbo charger S/A replacement

A
1-289

8
(Engine control computer machine side connector - Each connector)
Note:
A 1. Disconnect the connector of common rail ASSY (fuel pressure
sensor).
2. Disconnect the connector of diesel turbo pressure sensor.
3. Disconnect the connector of electric EGR control valve ASSY
(EGR valve position sensor).
4. Disconnect the connector of accelerator position sensor
(potentiometer).
68(VCS1) 93(VCPM) 94(VNVC) 75(VCEG) 5. Disconnect the connector of turbo charger S/A (nozzle
opening degree).
Engine control computer 6. Disconnect the connectors A and B of engine control
computer.
B 7. Measure the resistance between terminals using a tester. (See
Resistance
Inspection
condition
A-75 (VCEG) -
55(VCPA) 57(VCP2) Other terminals Always 10 kΩ or more
and body ground
A-93 (VCPM) -
Other terminals Always 10 kΩ or more
and body ground
A-68 (VCS1) -
and body ground
A-94 (VNVC) -
and body ground
B-57 (VCP2) -
and body ground
B-55 (VCPA) -
and body ground
OK

1-290
ECU POWER SUPPLY SYSTEM
Circuit description
When ignition switch turns ON, current from the MREL terminal of engine control computer flows to the MAIN relay.
This closes the contact of MAIN replay and supplies current to +B and +B2 terminals of engine control computer.
Circuit diagram
25
1 2 2 4 1 2
B IGSW
AM1 AM1 IG1 ECU-IG
Ignition (starter)
switch ASSY
20
B +B2
1
1 2 5 3
B +B
EFI
45
MAIN 2 1
B MREL
EFI MAIN 109

A E1
Battery
A B
Engine control
Computer
Caution:
1 EFI MAIN relay individual inspection
1. Inspect the EFI MAIN relay.

NG EFI MAIN relay replacement
OK
2 Wire harness and connector inspection (EFI MAIN relay - Engine control computer)
1. Remove the EFI MAIN relay from the LH STEP relay block.
LH STEP relay block 2. Measure the voltage between terminals using a tester.
Voltage value
Inspection
condition
EFI MAIN relay holder
Always 11 to 14 V
5 terminal - Body ground
2 1
EFI MAIN 5
3
1-291

Resistance
Inspection
condition
2 terminal - Body ground
NG Wire harness or connector repair or

replacement (Battery - EFI MAIN relay, EFI MAIN
relay - Body ground)
OK
3 Wire harness and connector inspection (EFI MAIN relay - Engine control computer)
1. Remove the EFI relay from the LH STEP relay block.
Engine control computer 2. Disconnect the connectors A and B of the engine control
Connector on the machine side computer.
A 3. Measure the resistance between terminals with a circuit tester.
Resistance
Inspection
condition
3 terminal - B-20 (+B2)
109(E1)
3 terminal - B-1 (+B)
B
1 terminal - B-45 (MREL)
A-109 (E1) - Body ground Always Less than 1 Ω
Resistance
Inspection
45(MREL) Inspection terminal Standard
1(+B) 20(+B2) condition
LH STEP relay block 3 terminal and B-20 (+B2) - Always 10 kΩ or more
3 terminal and B-1 (+B) - Always 10 kΩ or more
1 terminal and B-45 (MREL) - Always 10 kΩ or more
2 1
EFI MAIN Other terminal and body ground
5
3
NG Wire harness and connector repair or replace-
ment (EFI MAIN relay - Engine control computer)
OK
1-292
4 Engine control computer inspection (IGSW voltage inspection)

Note:
A 1. Turn the ignition key switch ON.
2. Measure the voltage between the connector terminals of
engine control computer with a circuit tester. (See page 1-33
for the terminal layout.)
Voltage value
Inspection
condition
109(E1)
B-25 (IGSW) - Ignition key switch
11 to 14 V
A-109 (E1) ON
B
NG Go to step 5.
25(IGSW)
OK
5 Ignition (starter) switch ASSY inspection
1. Inspect the ignition (starter) switch ASSY.

NG Ignition (starter) switch ASSY replacement
OK
Wire harness or connector repair or replacement

(Battery - Ignition (starter) switch ASSY, Ignition (starter) switch ASSY - Engine control computer)
1-293
INDIVIDUAL INSPECTION
INLET AIR TEMPERATURE SENSOR
INSPECTION
2 1
Note:
See page 2-11 for the installation and removal procedure.
1. Resistance inspection
(1) Measure the resistance between terminals using a tester.
Resistance
Inspection
condition
1-2 20 °C (68 °F) 2.21 to 2.65 kΩ
30 1-2 60 °C (140 °F) 0.545 to 0.615 kΩ
20
10 Caution:
When immersing the sensor into water for inspection, be
5
careful not to let water enter the terminal. Also, wipe off water
Resistance 3
2 drops from the sensor after inspection.
kΩ
1
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
Temperature °C (°F)
CRANK POSITION SENSOR INSPECTION

G- G+
Note:
2 1 See page 2-41 for the installation and removal procedure.
Resistance
Inspection
condition
When cool
1 (G+) - 2 (G-) (-10 to 50 °C) 1630 to 2740 Ω
(14 to 122 °F)
When warm
1 (G+) - 2 (G-) (50 to 100 °C) 2065 to 3225 Ω
(122 to 212 °F)
1-294
CRANK POSITION SENSOR NO.2

NE- NE+ INSPECTION
Note:
2 1 See page 2-41 for the installation and removal procedure.
3 1. Resistance inspection
Resistance
Inspection
condition
When cool
1 (NE+) - 2 (NE-) (-10 to 50 °C) 1630 to 2740 Ω
(14 to 122 °F)
When warm
1 (NE+) - 2 (NE-) (50 to 100 °C) 2065 to 3225 Ω
(122 to 212 °F)
INTAKE AIR FLOW METER S/A INSPECTION

1. Intake air quantity inspection
Caution:
• With the engine stopped, keep the machine horizontal and inspect these functions indoors.
• Perform inspection with the intake air flow meter S/A mounted on the intake pipe (with the machine
installed).
• Do not suck air from the exhaust tail pipe in the exhaust duct.
SST 09111-36760-71 (09991-70201)
(1) Turn the ignition key switch ON and wait for 30 seconds. (Engine is in stop condition)
(2) According to the instruction of the 'Engine Diagnostic Program' screen, press [Data monitor] and monitor
[MAF] and read a numerical value.
Standard 1.2 g/sec. (0.0027 lb/sec.) or less
2. Sensor foreign matter adhesion inspection
Platinum filament (heater) Note:
(1) Visually check the platinum filament (heater) portion in
flow paths.
Standard No foreign matter that can be visually checked
Resistance
E2 THA Inspection terminal Inspection condition Reference
1 (THA) - 2 (E2) -20 °C (-4 °F) 13.6 to 18.4 kΩ
1 (THA) - 2 (E2) 20 °C (68 °F) 2.21 to 2.69 kΩ
54321
1 (THA) - 2 (E2) 60 °C (140 °F) 0.49 to 0.67 kΩ
1-295
WATER TEMPERATURE SENSOR

THW E2
INSPECTION
Note:
2 1
Resistance
Inspection
condition
1 (E2) - 2 (THW) 20 °C (68 °F) 2.32 to 2.59 kΩ
30 1 (E2) - 2 (THW) 60 °C (140 °F) 0.310 to 0.326 kΩ
20
10 Caution:
When immersing the sensor into water for inspection, be
5 careful not to let water enter the terminal. Also, wipe off water
Resistance 3 drops from the sensor after inspection.
2
kΩ
1
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100
Temperature °C (°F)
TURBO CHARGER S/A INSPECTION

M+ M-
Note:
2 1
1. DC motor resistance inspection
Resistance
Inspection
condition
2 (M+) - 1 (M-) 20 °C (68 °F) 1 to 100 Ω
1-296
SUPPLY PUMP ASSY INSPECTION

1. Suction control valve ASSY resistance inspection
2 1 (1) Measure the resistance between terminals using a tester.
Resistance
Inspection
Suction control condition
valve ASSY 1-2 20 °C (68 °F) 1.9 to 2.3 Ω
COMMON RAIL ASSY INSPECTION

Note:
1 2 3
1. Fuel pressure sensor resistance inspection
VC PR E2 (1) Measure the resistance between terminals using a tester.
Resistance
Inspection
condition
1 (VC) - 2 (PR) 25 °C (77 °F) 3 kΩ or less
2 (PR) - 3 (E2) 25 °C (77 °F) 16.4 kΩ or less
ELECTRIC EGR CONTROL VALVE

5 4 3 2 1 INSPECTION
M- M+ Note:
Resistance
Inspection
condition
5 (M-) - 4 (M+) 25 °C (77 °F) 0.3 to 100 Ω
2. Electric EGR control valve ASSY visual inspection

(1) Visually check the electric EGR control valve ASSY for carbon deposit, etc. If carbon deposit builds up,
clean the electric EGR control valve ASSY.
Caution:
• When cleaning the electric EGR control valve ASSY, keep the valve fully open.
• Do not force the control valve open. Otherwise, the electric EGR control valve ASSY is damaged or
deformed.
• When cleaning the electric EGR control valve ASSY, use cloth applied with brake cleaner, etc. Do not
spray brake cleaner directly on the control valve or immerse the control valve into solvent. This may
damage the control valve.
1-297
(2) Visually check that there is no clearance between the

valve and body. Hold the electric EGR control valve ASSY
against light from the direction shown in the illustration.
Standard If there is no valve clearance as shown in the
illustration of control valve, it is normal. If there
is clearance, replace the electric EGR control
valve ASSY.
Note:
Even when the valve is fully closed, light shines through
position A shown in the illustration. This is not abnormal.
Clearance
A
OK NG
Clearance
Maintenance
MA17-002
March 31, 2017
Repair Manual CE302-1 Update
SERVICE INFORMATION BULLETIN 8FD35U-8FD80U
Subject: Repair Manual CE302-1 Update (Engine Troubleshooting Specifications) Page 1 of 32
MODEL APPLICATION:
8FD35U-8FD80U
GENERAL INFORMATION:
Multiple specifications for engine troubleshooting have changed. This bulletin contains the updated
pages for the CE302-1 repair manual.
REPAIR INFORMATION:
Remove and discard the current pages and replace them with the pages supplied with this bulletin.
Pages with updated information:

Section 1
Pages:
1-3
1-35
1-40
1-41
1-42
1-44
1-50
1-51
1-68
1-73
1-80
1-88
1-128
1-253
1-263
Section 2
Pages:
2-82
Subject: Repair Manual CE302-1 Update (Engine Troubleshooting Specifications) Page 2 of 32
Page Left Blank on Purpose

1-3
3. Engine start inspection

(1) Inspect if the engine starts.
NOTICE:
• Engine should be cranked by two rotations at minimum when engine starting because ECD system
electrically detects the fuel injected cylinder.
• If it does not start, inspect relevant portions, referring to the LIST OF
SYMPTOMS (See page 1-8 for the procedure.)
4. Air filter inspection (See the machine repair manual for the procedure.)
5. Idle speed inspection
(1) Inspect idling.
Reference: Refer to repair manual of the vehicle (after warm-up, during idling)
6. Fuel pressure inspection
SST: 09240-36770-71
(1) According to the instruction of the screen, press [Data monitor] and monitor [Fuel Press] and measure fuel
pressure.
Reference: 30000 to 50000 kPa (after warm-up, during idling)
7. Fuel property
Inspect if a proper fuel is used as described in the Operator's Manual.
Diesel fuel
For 8FD35U to 8FD80U model
Use only ultra low-sulfur fuel defined by ASTM D0975 No.2-D S15.
Refer to the following table for details.
Detailed Requirement for ASTM D0975 No.2-D S15
Property Unit Value
Distillation Temperature °C 90 % 282 to 338
Kinematic Viscosity mm2/s at 40 °C 1.9 to 4.1
Sulfur ppm (μ g/g) max 15
Cetane index -, min 40
Aromaticity %vol, max 35
Lubricity, HFRR μm, max 520
NOTICE:
• Do not use bio-diesel fuel. Damage to engine will occur.
• In cold weather, use winter diesel fuel to prevent clogging of the fuel filter caused by paraffin precipitation.
In hot weather, do not use winter diesel fuel. Damage to engine will occur.
• Do not use deteriorated fuel which has been stored for a long period of time or impure fuel in which
foreign material, water and etc. is included.
• If fuel is frozen or becomes wax-like substance in winter season, engine may be hard starting, rough idle
after starting or engine rotation is impossible to increase. In that case, fuel for winter use should be used.
Melt the wax generated in the fuel filter by warming.
1-4
1-35
Engine stop
B1 - A109 [+B - E1] Input 11 to 14 V
Engine stop
B20 - A109 [+B2 - E1] Input 11 to 14 V
Engine stop
Engine stop
Engine stop
11 to 14 V
10 seconds or more elapsed after 0 to 1.5 V
ignition key switch turns off
Pulse Generation
(Waveform 1)
0 to 3 V
0 to 1.5 V
Engine stop
B7 - A109 [CANH - E1]
B6 - A109 [CANL - E1]
(32 to 176 °F)
Cooling water temperature 60 to 120 °C 0.2 to 1.0 V
A111 - A88 [THW - ETHW] Input
(140 to 248 °F)
Intake temperature 0 to 80 °C 0.5 to 3.4 V
A110 - A87 [THA - ETHA] Input
(32 to 176 °F)
Engine stop
A65 - A64 [VG - E2G] Input After warm-up, during idling Pulse Generation
Pulse Generation
(Waveform 4)
Pulse Generation
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
Pulse generation
(Waveform 5)
1-36
1-39
1-40
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display [Data monitor] to
inspect computer data.
NOTICE:
• To check the reference, unless otherwise specified, completely warm up the engine, disable all of outside
SST: 09240-36770-71
Description/
Item Name Reference Remarks
Display Range
Engine • Indicates engine speed • 50 to 400 rpm: During • It displays a value output from the
Speed • Display range: cranking crank position sensor No. 2.
0 to 6000 rpm • Refer to repair manual of • If the crank position sensor No. 2 does
the vehicle: After engine not operate properly, the engine
warm-up, during idling speed becomes about 0 rpm or is
remarkably different from the actual
engine speed.
Calculate • Indicates engine load. 10 to 30%: • It displays a value calculated by the
Load • Display range: After engine warm-up, during engine control computer.
0 to 100% idling (disable all of outside • Engine load value =
loads, N range) (Actual fuel injection
amount/Maximum fuel injection
amount in the current engine speed) x
100
MAF • Indicates intake air • 6 to 25 g/sec (0.79 to 3.17 • It displays a value output from the
quantity. lb/min): After engine warm- intake air flow meter S/A.
• Display range: 0 to up, during idling • Based on intake air quantity, the
655.35 g/sec (0 to • 30 to 80 g/sec (3.96 to 10.6 engine control computer controls fuel
86.69 lb/min) lb/min): For engine speed injection amount, injection timing,
NMR EGR, and others.
• When intake air quantity is always
NOTE: about 0 g/sec (0 lb/min):
It changes depending on -The power circuit of the intake air
the amount of EGR. flow meter S/A is disconnected.
-The VG circuit is disconnected or
short-circuited.
-The EVG circuit is disconnected.
-Rough Idling
Atmosphere • Atmospheric pressure Actual atmospheric pressure • With ignition key switch turned on,
Pressure value. when a difference between a value of
• Display range: 0 to 255 the atmospheric pressure sensor and
kPa that of the intake manifold pressure
sensor is 10kPa or more, either
sensor has an abnormality.
• With ignition key switch turned on,
when atmospheric pressure is 0kPa or
140 kPa, the sensor circuit is
abnormal.
• Standard atmospheric pressure: 101
kPa
• Atmospheric pressure decreases by 1
kPa with each lifting of 100 m (328 ft).
This changes depending on weather
(high or low atmospheric pressure).
• The atmospheric pressure sensor is
contained in the engine control
computer.
1-41
Description/
Display range
MAP • Indicates absolute • 90 to 110 kPa • With ignition key switch turned on or during idling,
pressure of the (depending on intake manifold pressure and atmospheric
internal intake atmospheric pressure are almost the same (standard
manifold. pressure): During atmospheric pressure = 101 kPa).
• Display range: idling • With the accelerator fully opened, when intake
0 to 255 kPa • 115 to 160 kPa: For manifold pressure is 20 kPa lower than target
engine speed NMR supercharging pressure for five seconds or more,
you may feel insufficient output.
• It displays a value output from the diesel turbo
pressure sensor.
Insufficient output
Coolant Temp • Indicates engine 70 to 90 °C • When engine cooling water temperature is -40 °C
cooling water tem- (158 to 194 °F): (-40 °F) or 140 °C (284 °F), the sensor circuit is
perature. After engine disconnected or short-circuited.
• Display range: warm-up • After it is left for a long time, engine cooling water
-40 to 140 °C temperature, intake air temperature, and ambient
(-40 to 284 °F) temperature become almost the same.
• It displays a value output from the water temper-
ature sensor.
starting the engine when cool, rough idling, black
smoke, insufficient output
Intake Air • Indicates intake air A value equal to tem- • After it is left for a long time, engine cooling water
temperature. perature in the posi- temperature, intake air temperature, and ambient
• Display range: tion where the intake temperature become almost the same.
-40 to 140 °C air flow meter S/A is • When intake air temperature is -40 °C
(-40 to 284 °F) mounted (-40 °F) or 140 °C (284 °F), the sensor circuit is
disconnected or short-circuited.
perature sensor contained in the intake air flow
meter S/A.
Engine Run • Indicates rotating Rotating time after the • Indicates elapsed time after the engine starts.
Time time after the engine starts
engine starts.
• Display range:
0 to 65535 sec
Starter Signal • Indicates starter ON: During cranking Ignition switch (STA) output:
signals. • ON: Indicates that the engine is cranking.
• Display range: ON/ • OFF: Indicates that the engine is not cranking
OFF Although STA is turned off, the starter continues to
operate.
The STA signal abnormality (P0617) is stored.
Injection • Indicates fuel injec- 5 to 15 mm3/st: • It displays fuel injection amount for each combus-
Volume tion amount. During idling (Disable tion.
• Display range: all of outside loads, N • For the injector ASSY clogging, low fuel quality,
0 to 1279.98 mm 3/ range) fuel filter element clogging, or increased engine
st friction, fuel injection amount will increase.
• For abnormalities such as low intake manifold
pressure or a small quantity of intake air, fuel
injection amount is limited, which causes insuffi-
cient output.
• It displays a value calculated by the engine con-
trol computer.
1-42
Item Name Description/Display Reference Remarks

Range
Injection injection period. (water temperature is less drivability, or white smoke, check pilot 1
Period  Display range: 0 than 60 °C (140 °F), disable injection period. (with or without pilot injection)
to 65535 µs all of outside loads, N range)  It displays a value calculated by the engine
control computer
Injection injection period. (complete warm-up, disable drivability, or white smoke, check pilot 2
Period  Display Range: 0 all of outside loads, N range) injection period. (with or without pilot injection)
control computer.
Main  Indicates main 300 to 600 µs: During idling  When fuel pressure becomes 15000 kPa or
Injection injection period. (complete warm-up, disable less, main injection period becomes 0 µs.
Period  Display range: 0 all of outside loads, N range)  For engine hard starting, check main injection
to 65535 µs period. (with or without injection)
 When P0093, P0627 or P062D is output, the
engine stop request is output. In this case,
main injection period becomes 0 µs.
NOTICE:
After the engine check indicator turns on, in
about one minute the engine stops.
Therefore, inspection cannot be performed
with freeze frame data.
 It displays a value calculated by the engine
control computer
After  Indicates after 0 to 400 µs: During idling  For symptoms such as black smoke and poor
Injection injection period. (complete warm-up, disable drivability, check after injection period. (with or
Period  Display range: 0 all of outside loads, N range) without after injection)
control computer.
Pilot 1  Indicates pilot 1 -14 to -5 °CA: Water  It displays a value calculated by the engine
Injection injection timing. temperature is less than 60 °C control computer.
Timing  Display range: -70 (140 °F), during idling, and the
to 20 °CA machine is in the range of
usual atmospheric pressure
Pilot 2  Indicates pilot 2 -10 to -2 °CA: After engine  It displays a value calculated by the engine
Injection injection timing. warm-up, during idling, and control computer.
Timing  Display range: -50 the machine is in the range of
to 20 °CA usual atmospheric pressure.
Main  Indicates main -3 to 1 °CA: After engine  For symptoms such as poor drivability, black
Injection injection timing. warm-up, during idling, and smoke, or white smoke, check main injection
Timing  Display range: -90 the machine is in the range of timing.
to 90 °CA usual atmospheric pressure.  It displays a value calculated by the engine
control computer.
After  Indicates after  It displays a value calculated by the engine
Injection injection timing. control computer.
Timing  Display range: -10
to 50 °CA
1-43
1-44
Item Name Description/ Reference Remarks
Display Range
Fuel Press  Indicates fuel 30000 to 50000kPa:  Fuel pressure means the actual common rail fuel
pressure during idling pressure.
 Display Range: (complete warm-up,  Inspect fuel pressure, comparing to common rail
0 to 655350 kpa disable all of outside target fuel pressure.
loads, N range)  In the stable condition (during idling after warm-
up) fuel pressure is within 5000 kPa of target
value.
 The engine control computer uses fuel pressure
to perform feedback control of common rail target
fuel pressure.
 Fuel injection amount is determined based on
injection timing and fuel pressure. Injection
patterns are also selected based on fuel pressure.
 Starting the engine requires a minimum of 25000
kPa fuel pressure. (note that when fuel pressure
is about to reach its target, a delay is introduced
even in the normal state)
 When fuel pressure is lower than 25000 kPa,
rough idling may occur.
 When fuel pressure decreases from common rail
target fuel pressure by 20000 kPa, output may be
insufficient.
 When the actual fuel pressure is 40000 kPa
higher than common rail target fuel pressure,
P1229 is output.
 When fuel pressure is lower than a target value,
insufficient output will occur without DTC output.
 When fuel pressure is higher than 250000 kPa,
DTC P0088 is output.
 It displays a value output from the fuel pressure
sensor (common rail assy)
Symptoms when outside the reference: Difficulty
starting the engine, poor drivability, insufficient
output, knocking.
Fuel  Indicates fuel Actual fuel temperature  When the engine is completely cooled, fuel
Temperature temperature temperature is equal to ambient temperature.
 Display range: -  It displays a value output from the fuel
40 to 215°C (-40 temperature sensor.
to 419°F)
Target Pump  Indicates a 1600 to 2000 mA:  It displays a calculated value by the engine
SCV Current target value of during idling (complete control computer for target current for driving the
final pump warm-up, disable all suction control valve assy and controls a target
current. outside loads, N range) value of solenoid current.
 Display range: 0  When high fuel pressure is required, a target
to 8192 mA value of solenoid current is higher.
 Typically, a target value of solenoid current is in
the range of 800 to 2500 mA.
 When the target value remains a 3000mA or
more, it indicates that the pump is defective.
(such as a defect due to deposit)
 If it is not in the standard, even when the pump
operates actively, the actual fuel pressure does
not match common rail fuel pressure.
starting the engine, insufficient output, or rough
idling.
1-49
1-50
Description/
Display range
Av Engine • Indicates the aver- - • It is output only when the engine speed is mea-
Speed of All age engine speed sured for each cylinder in the active test.
Cyl of all cylinders. • Indicates the average engine speed of all cylin-
• Display range: ders during cranking.
0 to 51199 rpm
Time after • Indicates elapsed Time after DTC is • It displays elapsed time after DTC is deleted (or
DTC Cleared time after DTC is deleted shipped from the factory).
deleted.
• Display range:
0 to 65535 min
Warm-up • Indicates warm-up - • It displays engine warm-up count after DTC is
Cycle Cleared count after DTC is deleted.
DTC deleted. • (Warm-up Cycle Cleared DTC of data list is
• Display range: deleted) - (Warm-up Cycle Cleared DTC of
0 to 255 freeze frame data is deleted) = Warm-up count
TC and TE1 • Indicates the con- - • When the TE1/TC terminals are turned on in the
nection condition active test, the system operates as if the TC ter-
between TC and minal and E terminal of the diagnostic connector
TE1 in the active are connected.
test.
OFF
Isochronous • Indicates the Isoch- Refer to repair manual
Control Tar- ronous Control Tar- • It displays a target engine speed with the re-
of the vehicle After quest of vehicle is taken.
get Speed get Speed.
engine warm-up,
• Display range:
0 to 12800 r/min during idling
Proportional Proportional Term.
Term • Display range:
-50 to 120 mm3/st
Integral Term Integral Term.
• Display range:
-80 to 79.997 mm3/
st
Total • Indicates the Total - • It displays a value calculated by the engine con-
Operation Operation Hours. trol computer.
Hours • Display range:
0 to 4500000000
sec
Total Number • Indicates the Total - • It displays a value calculated by the engine con-
of Rotations Number of Rota- trol computer.
tions.
• Display range:
0 to 4290000000
Rotations
Total Injection • Indicates the Total - • It displays a value calculated by the engine con-
Volume Injection Volume. trol computer.
• Display range:
0 to 33554432 L
(0 to 8864147 gal)
1-51
Description/
Display range
• Display range:
0 to 5.000 V
• Display range:
0 to 5.000 V
Pre Glow • Indicates the Pre - Pre Glow demand: ON
Glow.
• Display range:
ON/OFF
After Glow • Indicates the After - After Glow demand: ON
Glow.
• Display range:
ON/OFF
Target Idle • Indicates the Tar- • It displays a target value of the engine individual
Engine Speed get Idle Engine • Check "Isochronous Control Target Speed" because it
Speed. is not sometimes match with engine speed, while still
• Display range: installed on the vehicle.
0 to 10000 r/min
Fuel Return • Indicates the Fuel - • It displays a value calculated by the engine con-
Temp Return Temp. trol computer.
• Display range:
-40 to 215 °C
(-40 to 419 °F)
EGR Motor • Indicates the EGR 0 to 100% • It displays a value calculated by the engine con-
Duty #1 Motor Duty #1 trol computer.
• Display range:
0 to 127.5 %
2. Active test
(1) With 'Engine Diagnostic Program', according to the instruction of the screen, display the [Active test] screen
to perform the active test.
SST: 09240-36770-71
Item name Description Constraint condition

Control the Select Stop fuel injection of each cylinder #1/ With the machine stopped, during engine
Cylinder Fuel Cut #2/#3/#4 (Injection of multiple cylinders rotating
cannot be stopped.)
Check the Cylinder Stop fuel injection of all cylinders. With the machine stopped, when the crank
Compression Measure engine speed during cranking. position sensor and sensor No.2 are in the
normal state
Control the EGR Step Increase or decrease EGR opening With the machine stopped, Ignition key
Position degree. switch ON (Engine stop)
When the test is started, opening
degree shall be 0. It can be increased or
decreased in the range of 0 to 100% by
1%.
Activate the EGR Valve Forced closed of the EGR valve With the machine stopped, during engine
Close rotating after warm-up
1-52
1-67
1-68
NOTICE:
- Black smoke
- Poor drivability
Detection overview
turned OFF.
- The following illustration shows the relation between the engine speed and fuel pressure. When P0087
is stored, the fuel pressure does not rise with the increase of engine speed.
P0087:
Normal
Fuel pressure
Abnormal
Engine speed
Time

turned OFF.
1-73
Circuit description
P0088
3. Abnormal period
4. Others
After running at idle for 60 seconds, 1.Ignition key switch ON Common rail ASSY (fuel pressure
perform racing from idle to NMR for 2.Rail pressure is 250000 kPa or sensor)
30 seconds. more Suction control valve ASSY
3.- Fuel pressure sensor circuit discon-
4.1 trip nection
Disconnection or shorting of suction
control valve ASSY circuit
Related Data List

DTC No. Data list
• Fuel pressure
NOTICE:
Reference value
1-74
1-79
1-80
Circuit description
This diagnosis code indicates a fuel leakage in the high pressure area within the common rail system. After the engine
is started, the engine control computer monitors the fuel pressure within the common rail constantly. The engine
control computer stores this diagnosis code when the fuel pressure drops significantly at fuel injection.
P0093
3. Abnormal period
4. Others
Start up and warm up the engine. 1. Engine speed 650 r/min or more • Common rail ASSY
Keep the accelerator pedal fully 2. Fuel pressure drop before/after (fuel pressure sensor)
open for 5 seconds and then release fuel injection is larger than thresh- • Injector ASSY
the pedal. (*A) old • Fuel temperature sensor
Make the accelerator pedal fully 3. Specified number of times • Crank position sensor
open and release the pedal when 4. 1 trip • High pressure fuel pipe
NMR is reached. (*B) • Disconnection or shorting of injec-
Perform above (*A) and (*B) 5 times. tor driver wiring
tor circuit
• Injector driver
Related Data List

DTC No. Data list
• Fuel pressure
P0093
NOTICE:
Reference value
Circuit diagram
1-87
1-88

NOTICE:
failure.
injector and injection pipe, possibly resulting in fuel leakage.
OK
Next

Next Go to step 25.
SST 09111-36760-71
Result

Engine Speed
Idling (after warm-up) Refer to repair manual of the vehicle
NOTICE:
NG Go to step 19.
OK
1-127
1-128
SST 09111-36760-71
procedure.)
NOTICE:
Next

2 1 2. Measure the resistance between the terminals using a tester.
Resistance
Inspection Terminal Inspection Reference

Condition
1-2 Always Less than 5Ω
NG Go To Step 11
OK
7 Wire harness and connector inspection (Injector driver – Injector ASSY)

NOTICE:
See page 0-13 for the inspection procedure and notes of wire harness and
connectors.
1. Disconnect the connector F, G, H and I of injector ASSY (No.1), (No. 2), (No. 3) and
(No. 4)
1-253

NOTICE:
diagnosis.
Next
SST 09111-36760-71
in step 6.
Result
Result Go to
NOTICE:
A Go to step 10.
SST 09111-36760-71
Result
Result Go to
A Go to step 10.
B
1-254
1-263
in step 2.
Result
Result Go to
NOTICE:
B Go to step 11.
C Go to step 24.

Result
Result Go to
NOTICE:
B Go to step 18.
C Go to step 24.
A
1-264
2-81
2-82
3. Adjust the valve clearance.

(1) Remove the camshaft S/A and No. 2 camshaft S/A. (See
(2) Remove the valve lifter.
(3) Measure the thickness of removed valve lifter.
(4) Calculate the thickness of valve lifter so that the valve

lifter clearance becomes a standard value.
A Selection valve lifter
B Thickness of removed valve lifter
C Measured valve clearance
Valve Clearance
Intake: A = B + (C - 0.25 mm (0.0098 in.)) (When cold)
Exhaust: A = B + (C - 0.40 mm (0.0157 in.)) (When cold)
(5) Select the valve lifter.
NOTICE:
There are 55 types of supply for valve lifer in a range of 5.06 to 5.74 mm (0.1992 to 0.2260 in.)
(6) Install the selected valve lifter.
(7) Install the camshaft S/A and No. 2 camshaft S/A. (See page 2-41 for the procedure.)
IDLE SPEED INSPECTION

1. Measure the idle speed with the engine warmed up.
Engine speed
Inspection conditions Standard
N range Refer to repair manual of the vehicle
NO-LOAD MAXIMUM SPEED INSPECTION

1. Start the engine and measure the speed when the accelerator pedal is fully depressed.
No-load Maximum Speed
Inspection conditions Standard
Accelerator fully opened Refer to repair manual of the vehicle
COMPRESSION PRESSURE INSPECTION

1. Remove the glow plug ASSY. (See page 2-13 for the procedure.)
2. Disconnect the connector of each injector ASSY.
3. Connect the minus terminal of battery.
CAUTION:
To prevent short-circuiting, wrap a vinyl tape around the power supply system wiring.

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book 1 ページ ２０１３年９月２７日 金曜日 午後１２時４７分

ECD (ELECTRONIC CONTROL DIESEL)

ECD (ELECTRONIC CONTROL DIESEL) SYSTEM

3. Engine start inspection

PARTS LAYOUT DRAWING

Fuel pressure sensor

Intake air flow meter

Pressure limiter Diesel turbo

Glow plug ASSY

Suction control valve ASSY

Turbo charger S/A

DIAGNOSIS CODE LIST

Abnormal engine noise, or noisy engine

Excessive engine oil consumption

PROCEDURE FOR TROUBLESHOOTING

2 Checking diagnosis codes

1. Check the list of diagnosis codes

1. Check the list of symptoms

5 Basic inspection (See page 1-2 for the procedure.)

6 Inspecting with 'Engine Diagnostic Program'

1. Perform [Data monitor] and [Active test]

Inspecting ECU terminal voltage and circuits

8 INSPECTION OF IRREGULAR PROBLEMS (See page 1-15 for the procedure)

9 Repairing defective parts

10 Checking diagnosis codes (See page 1-5 for the procedure.)

INSPECTING/DELETING DIAGNOSIS CODE

5. Checking diagnosis results (using 'Engine Diagnostic Program')

FREEZE FRAME DATA/DIAGNOSIS DETAILED INFORMATION

Freeze frame data recording point

3. List of freeze frame data

INSPECTION OF IRREGULAR PROBLEMS

<Procedure 1/4> Cancel

(1) Turn the ignition key switch ON.

(3) <Procedure 2/4>

(4) <Procedure 3/4>

(5) <Procedure 4/4>

3. Reading and Saving the injector compensation code

Read Compensation Code

(In case of there is no (In case of there is

(1) Turn the ignition key switch ON.

(3) <Procedure 2/6>

(4) <Procedure 3/6>

(5) <Procedure 4/6>

(6) <Procedure 5/6>

If there is no previous saved data, and need to save new

(7) <Procedure 6/6>

4. Writing the injector compensation code

<Procedure 1/6> Cancel

Use saved Input manual

<Procedure 5-a/6> <Procedure 5-b/6>

(1) Turn the ignition key switch ON.

(4) <Procedure 2/6>

(5) <Procedure 3/6>

(6) <Procedure 4/6>

(7) <Procedure 5-a/6>

(8) <Procedure 5-b/6>

(9) <Procedure 6/6>

5. Fuel System inspection

book 1 ページ２０１３年９月２７日　金曜日　午後１２時４７分