Engine Control System: Workshop Manual

WORKSHOP MANUAL
727 (N SERIES)
ENGINE CONTROL SYSTEM

(4HL1 ENGINE)
SECTION 1A
International Service & Parts

Tokyo, Japan
NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the information
contained in Section - 0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on the latest product
information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Engine Control System 1A-1
ENGINE
Engine Control System
CONTENTS
Engine Control System . . . . . . . . . . . . . . . . . . . . 1A-2 DTC118 - Common Rail Pressure Fault
Precautions on Service . . . . . . . . . . . . . . . . . . 1A-2 (Control System) . . . . . . . . . . . . . . . . . . . . . 1A-177
Function and Operation . . . . . . . . . . . . . . . . . . 1A-3 DTC158 - Injector Power Supply System Short
Powertrain System Components . . . . . . . . . . . 1A-9 (Common 1) . . . . . . . . . . . . . . . . . . . . . . . . . 1A-182
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . 1A-20 DTC159 - Injector Power Supply System Short
Strategy-Based Diagnostics . . . . . . . . . . . . . . 1A-38 (Common 2) . . . . . . . . . . . . . . . . . . . . . . . . . 1A-186
Functional Check List . . . . . . . . . . . . . . . . . . . 1A-44 DTC211 - Fuel Temperature Sensor System
Hearing Diagnostic . . . . . . . . . . . . . . . . . . . . . 1A-44 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-190
On-Board Diagnostic (OBD) System Check . 1A-47 DTC217 - SCV Drive System Short . . . . . . . 1A-195
Inactive CHECK ENGINE Lamp Check . . . . . 1A-50 DTC227 - No Pump Pressure Feed (Fuel Leak)
Unblinking CHECK ENGINE Lamp Check . . . 1A-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-198
ECM Power Supply and Grounding System Circuit DTC241 - Idle Position Switch Circuit Open
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-56 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-203
Diagnosis with Tech 2 Scan Tool . . . . . . . . . . 1A-59 DTC242 - Idle Position Switch Circuit Short . 1A-206
Diagnostic Chart . . . . . . . . . . . . . . . . . . . . . . . 1A-88 DTC245 - Common Rail Pressure Sensor
DTC14 - CMP Sensor System Fault . . . . . . . 1A-93 System Fault . . . . . . . . . . . . . . . . . . . . . . . . 1A-209
DTC15 - CKP Sensor System Fault . . . . . . . . 1A-97 DTC247 - SCV Drive System Fault . . . . . . . 1A-215
DTC18 - Starter Degradation (For Only Vehicles DTC271 - Cylinder 1 (Injector Drive System)
Equipped with Idle Stop Function) . . . . . . . . 1A-101 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-219
DTC22 - IAT Sensor System Fault . . . . . . . . 1A-103 DTC272 - Cylinder 2 (Injector Drive System)
DTC23 - ECT Sensor System Fault . . . . . . . 1A-107 Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-223
DTC24 - Accelerator Sensor System Fault . 1A-112 DTC273 - Cylinder 3 (Injector Drive System)
DTC25 - Vehicle Speed Sensor System Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-227
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-116 DTC274 - Cylinder 4 (Injector Drive System)
DTC28 - PTO Accelerator Sensor System Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-231
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-120 DTC277 - Injector Power Supply System Open
DTC31 - Idle Up Volume System Fault . . . . 1A-123 Wiring Fault (Common 1) . . . . . . . . . . . . . . . 1A-235
DTC33 - VIM Internal Fault (EEPROM Write DTC278 - Injector Power Supply System Open
Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-127 Wiring Fault (Common 2) . . . . . . . . . . . . . . . 1A-239
DTC34 - ECM Internal Fault (Charge Circuit DTC416 - Main Relay System Fault . . . . . . . 1A-243
Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-129 DTC417 - Starter Switch System Fault . . . . 1A-246
DTC35 - VIM Internal Fault (A/D Conversion DTC543 - High Engine Speed Error . . . . . . . 1A-249
Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-132 Default Matrix Table . . . . . . . . . . . . . . . . . . . 1A-250
DTC43 - ITP Sensor System Fault . . . . . . . . 1A-134 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 1A-256
DTC44 - EGR Valve Position Sensor System Wiring Harness Repair: Shielded Cable . . . . . 1A-257
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-139 Removal Procedure . . . . . . . . . . . . . . . . . . . 1A-257
DTC45 - EGR Valve System Fault . . . . . . . . 1A-144 Installation Procedure . . . . . . . . . . . . . . . . . 1A-257
DTC46 - Exhaust Brake System Fault . . . . . 1A-147 Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . 1A-258
DTC51 - ECM Internal Fault (CPU Error / CPU Removal Procedure . . . . . . . . . . . . . . . . . . . 1A-258
History Error) . . . . . . . . . . . . . . . . . . . . . . . . 1A-150 Installation Procedure . . . . . . . . . . . . . . . . . 1A-258
DTC52 - ECM Internal Fault Weather-Pack Connector . . . . . . . . . . . . . . . . 1A-260
(Sub CPU Error) . . . . . . . . . . . . . . . . . . . . . . 1A-152 Removal Procedure . . . . . . . . . . . . . . . . . . . 1A-260
DTC61 - Intake Throttle Valve System Fault 1A-154 Installation Procedure . . . . . . . . . . . . . . . . . 1A-260
DTC71 - Barometric Pressure Sensor Fault 1A-157 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 1A-261
DTC81 - Clutch Switch System Fault . . . . . . 1A-159 Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-262
DTC82 - Neutral Switch System Fault . . . . . 1A-163 General Information . . . . . . . . . . . . . . . . . . . 1A-262
DTC84 - CAN Communication Fault Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-263
(CAN Bus Error) . . . . . . . . . . . . . . . . . . . . . . 1A-166 Removal Procedure . . . . . . . . . . . . . . . . . . . 1A-263
DTC86 - CAN Communication Fault Installation Procedure . . . . . . . . . . . . . . . . . 1A-263
(CAN Timeout Error) . . . . . . . . . . . . . . . . . . . 1A-169 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 1A-263
DTC115 - Common Rail Pressure Sensor Fixed
Output Fault . . . . . . . . . . . . . . . . . . . . . . . . . 1A-172
1A-2 Engine Control System

Precautions on Service polarity flow out and resultantly the person is
charged at high opposite polarity. Since static
Circuit test tools
electric charges cause damages, it is important
Unless otherwise specified in diagnostic procedures, when you handle or test electronic components.
do not use Test Light to diagnose the powertrain
electrical system. When diagnostic procedures need CAUTION:
probe connector, use Connector Test Adapter Kit 5- To prevent damages by electrostatic discharge,
8840-0385-0. follow the guidelines shown below.
• Do not touch ECM connector pins as well as
On-market electrical equipment and vacuum electronic components soldered to the ECM
devices circuit board.
On-market electrical equipment and vacuum devices • Do not unpack each replacement component
refer to those components that will be installed to until preparations are completed for the
vehicles after shipment from manufacturing plants. Be component.
careful that installation of these components is not • Before taking out a component from the
considered during the process of vehicle design. package, connect the package to the normal
grounding line of the vehicle.
CAUTION:
Do not install on-market vacuum devices to • When you intend to slide on the seat, change
vehicles. the posture from standing to sitting, or walk by
a certain distance to handle a component,
CAUTION: touch an appropriate grounding material.
Connect on-market electrical equipment, as well as
its power supplies and grounds, to the circuits Wire color
isolated from the electronic control system. All wiring harnesses are identified using colored jacket.
The wiring harness used for the main circuit in an
The on-market electrical equipment, even when
electrical system is identified with single color while the
installed to vehicles in normal manner, may bring
wiring harness used for the sub-circuit is identified with
functional troubles to the electronic control system.
color stripe. The following rule is used in each wiring
Affected devices include those not connected to the
diagram to indicate size and color of a wiring harness.
vehicle electrical equipment system, for example,
mobile phones or radios. Therefore, when you intend to
diagnose the powertrain, check such the on-market
electrical equipment has not been installed to the
vehicle and, if installed, remove it. If faults still occur
even after removal of on-market electrical equipment,
diagnose the vehicle according to normal procedures.
eg. : 0.5 GRN / RED
Damage by electrostatic discharge
1
Electronic components used in the electronic control
system are designed to work at very low voltages and, 2
for this reason, they are susceptible to damage by
electrostatic discharge and some types of electronic 3
components may be damaged even by the static
electricity of less than 100 V that is usually not sensed
by persons. Persons’ sensitivity level is 4,000 V.
Persons are electrostatically charged in various ways
and the most typical electrification sources are friction LNW21ASH000101-X
and induction. Shown below are examples.
• Electrification by friction occurs when a person
Legend
slides on the seat in the vehicle.
1. Red (stripe color)
• Electrification by induction occurs when a person 2. Green (base color)
with insulating shoes is standing near a highly 3. Harness size (0.5 mm2)
electrifiable substance and touches a ground
momentarily. Electric charges with the same
Symbol Color Symbol Color

B Black BR Brown
W White LG Light green
R Red GR Gray
G Green P Pink
Y Yellow LB Light blue
L Blue V Violet
O Orange
Function and Operation Voltages from ECM

Electronic Control System The ECM supplies reference voltages to various
switches and sensors. Resistances of the ECM are
The electronic control system processes the data,
very high and this allows the ECM to supply voltages to
which has been collected with various types of sensors,
these devices, and voltages actually applied to circuits
by means of the control program installed to ECM
are low and even connecting Test Light to individual
(engine control module) to totally control engine
circuits may fail turn-on. Since the voltmeter normally
parameters such as fuel injection quantity, injection
used in service factories has low input impedance,
timing, engine startup, altitude compensation, and
correct readings may not be obtained. To get accurate
EGR.
readings, a digital voltmeter whose input impedance is
10 MΩ (for example, 5-8840-0366-0) should be used.
ECM
Input/output devices of the ECM include analog-to-
ECM Description digital converter, signal buffer, counter, and special
The ECM is mounted in the inner part of the engine left driver. By using electronic switches, the ECM controls
side cover. The ECM monitors various data sent from most system components and turning off a switch
diversified sensors and controls systems in the closes the ground circuit. These switches are divided
powertrain. The ECM diagnoses these systems to into four-switch or seven-switch groups, and the former
detect faults with respect to system operations and group is called quad driver module (QDM) and controls
inform the driver of faulty condition via the CHECK up to four output pins respectively while the latter group
ENGINE lamp (MIL) and stores DTCs (diagnostic is called output driver module (ODM) and controls up to
trouble codes). DTC identifies the trouble generation seven outputs respectively. Note that all the outputs are
area to aid repairs by service operators. necessarily not used in the control.
Function of ECM Electrically Erasable Programmable ROM

(EEPROM)
ECM supplies 5 V and 12 V voltages to various sensors
and switches. Since powers are supplied via high EEPROM is a permanent memory chip and soldered to
resistances in ECM, Test Light, even when connected the board in the ECM. EEPROM stores program and
to the circuit, will not be lit. In a special case, a normal calibration data, both of which are necessary for the
voltmeter does not indicate correct values since the ECM to control the powertrain. Different from
resistance of the instrument is too low. To get accurate conventional ROMs, EEPROM cannot be replaced with
readings, you need a digital voltmeter whose input new component. If EEPROM fails, the complete ECM
impedance is at least 10 MΩ. The special tool 5-8840- assembly must be replaced with new one.
0366-0 is a proper choice for this measurement. In the
ECM, the output circuit is controlled by regulating the Precautions on ECM Service
grounding system or power circuit via transistor or The ECM is designed to withstand ordinary currents
either of the devices listed below. used in operations of a vehicle. Be careful that the
• Output driver module (ODM) circuits must not be overloaded. To test the ECM to
check open wiring or short, ECM circuits must be
• Quad drive module (QDM)
connected to the ground or voltages must not be
ECM and Components applied to the ECM. To test ECM circuits, the digital
voltmeter 5-8840-0366-0 should always be used.
The ECM is designed to offer excellent drivability and
fuel economy while achieving exhaust gas emission
control requirements. The ECM monitors engine and
vehicle functions via various electronic sensors such as
CKP (crank position) and VS (vehicle speed) sensors.
Accelerator
AP sensor
Idle position switch CAN Relay
ECO Relay,
Atomospheric Exhaust Brake
Starter pressure sensor
Switch
Ignition switch
A/C switch Starter switch Lamp
Exhaust Brake Lamp
Relay/Lamp
ECM Battery
Glow Lamp
Starter cut relay

(Engine Control Module) VIM Brake
Glow relay (Vehicle Interface Module) Stop Lamp Relay
Check engine lamp Exhaust Brake Lamp
Outer diagnostic unit
Common rail Transmission

pressure sensor Clutch Switch
Common rail Diagnostic switch Neutral Switch (MT)
Parking
SCV /Neutral (AT)
Switch
Supply Vehicle Speed Sensor
pump
FT sensor Power Take OFF (PTO)
Injector Vehicle functions PTO Switch (ACTIVE HIGH)
Main relay PTO Switch (ACTIVE LOW)
EGR cooler
Battery + PTO Accelerator Sensor
EGR valve drive Tachometer
EGR valve position sensor Quick Warm Up System
CMP sensor QWS Switch
ITP sensor TCM
Intake throttle drive
IAT sensor Idle
ABS/ASR ECU Idle Up Volume
Others
ISS ECU
Exhaust ECT Freezer Switch
pipe Clean Starting Memory
CKP
Exhaust brake
solenoid valve
LNW21ALF004601-X
The engine control system comprehends vehicle status

and driver’s intention based on the data acquired from
sensors and switches to adapt the engine to changing
situation so that the vehicle will achieve optimal running
condition. The heart of the engine control system is
ECM and this device provides direct control tasks for
the engine system, including fuel injection control,
intake throttle control, EGR control, and QWS control.
The ECM also governs vehicle system control
strategies such as exhaust brake control and idle stop
control via VIM. In addition, the ECM communicates
with other key systems, including ABS/ASR system
and clutch free system, via VIM.
Fuel Injection Control
ECM
DTC Detection Status
Battery Voltage
Compensation
Key Switch Position
Engine Speed
Injector Injector
Vehicle Speed Energize Time/ Control
Timing Determine
Engine Coolant Temp.
Compensation
Intake Air Temp.
Fuel Temp. Desired Injection

Status Judge Quantity
Common Rail Pressure Determine
Compensation
Accelerator Pedal Position
Idle Position Switch

SCV
SCV Position Control
Clutch Switch
Determine
Neutral Switch
PTO Switch
Idle Stop
LNW21AMF005601-X
The fuel injection control system manages the injection stopped, "split injection mode" where two (or more)
quantity, injection timing, and injection pressure injection shots are made for one cylinder at low engine
according to the status of vehicle. This system changes speeds and temperatures, "fixed injection mode" where
the injection quantity using injector operating period, only main injection is made at very low engine speeds
the injection timing using injector operation timing, and during startup, and "normal injection mode" where the
the injection pressure using SCV drive duty, fuel injection is made within normal engine speed
respectively. The fuel injection consists of two stages, range. The proper mode is selected according to such
pilot injection and main injection, and the control the parameters as engine speed, engine coolant
system changes the amount and timing in individual temperature, and DTC. The ECM uses the desired
stages according to the conditions encountered. injection quantity, intake air temperature, engine
The ECM uses the data acquired from associated coolant temperature, and other parameters to
sensors and switches to judge the current vehicle determine injector energize period (desired injection
status, i.e., startup, idling, PTO, or idle stop, and period) and injector energize timing (desired injection
calculate the desired injection quantity. Once the timing) and control injectors according to the injection
desired injection quantity is determined, ECM mode selected.
calibrates the value to determine injector energize time,
energize timing, and SCV opening and controls SCV Control (Pump Control)
injectors and the SCV accordingly. Pumps are controlled in six stages: "shutoff mode",
"start mode", "wait mode", "restart mode", "feedback
Calculation of Desired Injection Quantity mode", and "deflate mode". The proper mode is
The ECM calculates the basic injection quantity using selected according to such the parameters as key
engine speed, accelerator pedal position, engine switch position, common rail pressure, and engine
coolant temperature, and other necessary parameters speed. The ECM calculates desired injection pressure
and calibrates this value based on the atmospheric and pump flow rate for the selected mode based on
pressure or the like to determine the desired injection intake air temperature, engine coolant temperature,
quantity. engine speed, desired injection quantity, and other
necessary parameters. Then, the ECM determines the
Injector Control SCV opening (SCV drive duty) using these results and
The injector control consists of four stages: "control controls the SCV.
stop mode" where the fuel injection is completely
Intake Throttle Control
LNW21AMF005701
Legend
1. Intake throttle valve 3. Intake throttle DC motor
2. ITP (intake throttle position) sensor
The intake throttle control system changes (throttles) switch is turned off (within 0.5 to 3.0 seconds).
the air according to the vehicle status and reduces There is an opposing relationship between intake
suction noises generated from the working exhaust throttle control and EGR control. When the intake
brake and acceleration. This control is made by throttle valve is opened, the EGR valve is closed, and
opening and closing the intake throttle valve. The vice versa.
intake throttle valve is operated by the DC motor and Note 1: Duty (%) = Energize ratio
changing the drive voltage (duty: see Note 1) opens
and closes the valve. The intake throttle valve is fully
opened in the normal state (i.e., the DC motor is
inactive) and gradually reduces the opening as the
drive voltage is increased. The ECM uses the ITP
(intake throttle position) sensor to detect the working
condition of the intake throttle valve. When the valve
opening gets smaller (the drive voltage is increased),
the output voltage of the ITP sensor becomes lower.
The valve position is normally calculated using engine
coolant temperature, engine speed, and desired
injection quantity, and the DC motor drive voltage is
determined from this calculated value. However, the
ECM completely opens the throttle valve when the
vehicle is in idle stop, DTC is set for the intake throttle
system, AP sensor system, or EGR system, gear
shifting is performed (for manual transmission vehicle),
the engine coolant temperature is low (less than 70°C),
or the vehicle is in startup or engine stall status while it
completely closes the valve immediately after the key
EGR Control
LNW21AMF005801
Legend
1. EGR valve 3. EGR DC motor
2. EGR valve position sensor
The EGR control system recirculates a portion of Note 1: Duty (%) = T (*) / 5 (msec) × 100
exhaust gas to the intake to drop the combustion * T = Duty input time (see motor drive voltage
temperature and thus reduce NOx. This control is waveform)
made by opening and closing the EGR valve. The EGR
valve is operated by the DC motor and changing the
duty (see Note 1) opens and closes the valve. This
EGR valve is fully closed in the normal state (i.e., the
DC motor is inactive) and gradually enlarges the
1
opening as the duty is increased. The ECM uses the
EGR valve position sensor to comprehend the working
condition of the EGR valve. When the valve opening
gets larger (the duty is increased), the output voltage of
the EGR valve position sensor becomes higher. 2
The EGR control is initiated when parameters such as
engine speed, engine coolant temperature, accelerator
position, atmospheric pressure, and system voltage 3
meet the required conditions, and the EGR valve
opening is calculated from engine coolant temperature, 4
engine speed, and desired injection quantity. The ECM
determines the drive duty of the DC motor based on
this valve position and drives the motor. The EGR LNW21ASH009101
control is turned off when the exhaust brake is
operated, the PTO is working, the AP sensor fails, the Legend
ECT sensor fails, the EGR system fails, or the intake 1. 24V
throttle system fails. 2. 0V
There is an opposing relationship between EGR control 3. T (duty input time)
and intake throttle control. When the intake throttle 4. 5 msec
valve is opened, the EGR valve is closed, and vice
versa.
QWS Control • For a manual transmission vehicle, the clutch
The QWS (quick warm-up system) curtails the engine pedal is not pressed. For an automatic
warm-up time. The glow control covers the engine transmission vehicle, the exhaust brake command
warm-up during the period from pre-startup to is not sent from the automatic transmission.
immediate completion of startup. The QWS works • The system voltage stays between 20 V and 30 V.
when the vehicle meets the required conditions after
engine startup and the driver turns on the QWS switch, Idle Stop Control (for Vehicles Equipped with Idle
and lasts until the vehicle deviates from the QWS Stop Control System)
working conditions. The idle stop control system automatically cuts the
engine to prevent the black smoke emission from the
QWS working conditions vehicle that is not running for unloading or other works
• The engine coolant is less than 73°C. (to restart the engine, manual operation is needed).
• The engine is running at or above 400 rpm for at When all the idle stop conditions are met, the ECM
least 0.5 second. stops fuel injection and actuates energy-saving relays
• Both EGR and PTO controls are disabled. to turn off wipers, mirror defoggers, flashers, seat
heaters, and other electrical equipment.
• The vehicle is free from AP sensor fault, ECT
sensor fault, A/D conversion fault, idle position Idle Stop Control Working Conditions
switch fault, clutch switch fault, neutral switch fault,
and vehicle speed sensor fault. • The driver fails to apply the parking brake and the
signal is input from the alarm unit. (Note 1)
• The difference between actual and desired engine
speeds is less than 50 rpm. • The vehicle ran at or above 5 km/h.
• The desired engine speed is less than 1000 rpm. • The vehicle is idling.
• The vehicle is being off. • The vehicle speed is 0 km/h.
• The state where the starter switch is turned off and • The shift lever is in the neutral position.
the idle position switch is turned on lasts for at • The QWS switch is turned off.
least 0.5 seconds. • The engine coolant temperature is at least 10°C.
• The battery voltage is at least 22 V.
Exhaust Brake Control
• DTC has not been detected.
A valve is installed inside the exhaust pipe. Closing this Note 1: When all the following conditions are met, the
valve increases the resistance during the exhaust parking brake disengagement alarm unit outputs the
stroke to enhance the effect of engine brake. The drive idle stop permit signal to the VIM.
source of the exhaust brake valve is vacuum. A
• The idle stop main switch is turned on.
solenoid valve is installed to control the vacuum. The
exhaust brake is controlled by opening and closing this • The shift lever is in the neutral position.
solenoid electrically. When the engine is running at or • The parking brake is applied.
above 500 rpm, the exhaust cut command is not sent • The headlamps are turned off.
from the automatic transmission, and exhaust brake or
• Any of doors is opened.
QWS working conditions are completely met, the VIM
turns on the solenoid valve.
Exhaust Brake Working Conditions

• The vehicle is running at or above 5 km/h or faults
are not detected on the vehicle speed sensor.
• The exhaust brake switch is turned on.
• The engine is running at or above 500 rpm for at
least 1 second.
• The idle position switch is turned on and the gear
is engaged.
• The vehicle is not equipped with ABS/ASR or the
exhaust brake cut command is not sent from the
ASR.
• The vehicle is free from AP sensor fault, exhaust
brake circuit fault, clutch switch fault, neutral
switch fault, idle position switch fault, A/D
conversion fault (VIM), and CAN timeout (VIM).
Powertrain System Components
Component Layout - Vehicle Side
10
2
9
6 3
5 4
LNW21AMF005501
Legend
1. Engine 6. Accelerator pedal
2. Neutral switch 7. DLC (data link connector)
3. ECM (engine control module) 8. CHECK ENGINE lamp (MIL)
4. VIM (vehicle interface module) 9. Exhaust brake solenoid valve
5. Clutch pedal 10. VS (vehicle speed) sensor
Component Layout - Engine Side
1 2 3
7 6 5
LNW21AMF005301
Legend
1. ECT (engine coolant temperature) sensor 5. FT (fuel temperature) sensor
2. EGR valve 6. SCV (suction control valve)
3. Intake throttle valve 7. Common rail pressure sensor
4. CKP (crank position) sensor 8. CMP (cam position) sensor
Function and Operation The ECT (engine coolant temperature) sensor is

ECT Sensor installed to the thermostat housing and the thermistor
in the sensor alters the resistance in response to the
temperature change. The resistance is decreased
when the coolant temperature is high while increased
when the temperature is low. The ECM supplies 5 V to
the ECT sensor via pull-up resistance and calculates
the engine coolant temperature from the change in
voltage and uses it in fuel injection control, EGR
control, and other control tasks. This voltage is
decreased when the resistance is large (the
temperature is high) while increased when the
resistance is large (the temperature is low).
LNW21ASH007701
EGR Valve and EGR Valve Position Sensor The intake throttle valve is installed to the intake throttle
and operated by a DC motor. The DC motor operates
the intake throttle valve by changing the drive voltage.
The valve is closed when the drive voltage is increased
while opened when the voltage is decreased. The ECM
calculates the intake throttle valve opening based on
the vehicle running condition and controls the DC
motor accordingly.
The ITP (intake throttle position) sensor is installed to
the intake throttle valve and sends the voltage signal
that will change in response to the throttle valve
opening to the ECM. The ECM calculates the throttle
valve opening from the voltage signal and uses the
result in intake throttle control.
CMP Sensor
LNW21ASH008101
The EGR valve is installed at the top of the inlet cover

and operated by a DC motor. The DC motor operates
the EGR valve by changing the duty. The valve is
opened when the duty is increased while closed when
the duty is decreased. The ECM calculates the desired
EGR valve opening based on the vehicle running
condition and controls the DC motor accordingly.
The EGR valve position sensor is installed to the EGR
valve and sends the voltage signal that will change in
response to the EGR valve opening to the ECM. The
ECM calculates the desired EGR valve opening from
the voltage signal and uses the result in EGR control.
Intake Throttle Valve and ITP Sensor LNW21ASH007901
The CMP (cam position) sensor is installed to each

cylinder head and, when the hole on the camshaft gear
passes the sensor, a CMP signal is generated. The
ECM identifies the cylinder from the CMP signal as well
as CKP signal sent from the CKP sensor and
determines the crank angle, and uses this angle in fuel
injection control and engine speed calculation. These
tasks are usually performed based on the CKP signal
but if the CKP sensor fails, the CMP signal will
substitute for the CKP signal.
LNW21ASH008001
CKP Sensor SCV
LNW21ASH007601 LNW21ASH007501
The CKP (crank position) sensor is installed to the The SCV (suction control valve) is installed to the
flywheel housing and, when flywheel teeth pass the supply pump and controls the suction fuel quantity. The
sensor, a CKP signal is generated. The ECM identifies SCV is fully opened in normal state and larger drive
the cylinder from the CKP signal as well as the CMP voltage (duty) results in smaller opening. The ECM,
signal sent from the CMP sensor and determines the based on the data acquired from sensors, calculates
crank angle, and uses this angle in fuel injection control the desired common rail pressure and pump flow rate
and engine speed calculation. These tasks are usually and compares the calculated desired common rail
performed based on the CKP signal but if the CKP pressure to the actual value to determine the SCV
sensor fails, the CMP signal will substitute for the CKP opening. When the actual pressure is lower than the
signal. desired value, the SCV is opened to increase the pump
flow rate. When the actual pressure is higher than the
FT Sensor desired value, the SCV is closed to decrease the flow
rate.
Common Rail Pressure Sensor
LNW21ASH007401
The FT (fuel temperature) sensor is installed to the

supply pump and the thermistor in the sensor alters the LNW21ASH008201
resistance in response to the temperature change. The
resistance is decreased when the fuel temperature is The common rail pressure sensor is installed to the
high while increased when the temperature is low. The supply pump, and detects the fuel pressure in the
ECM supplies 5 V to the FT sensor via pull-up common rail, converts the pressure into a voltage
resistance and calculates the fuel temperature from the signal, and sends the signal to the ECM. Higher
change in voltage and uses it in supply pump control common rail pressure provides higher voltage while
and other control tasks. This voltage is decreased lower pressure provides lower voltage. The ECM
when the resistance is small (the temperature is high) calculates actual common rail pressure (fuel pressure)
while increased when the resistance is large (the from the voltage signal and uses the result in fuel
temperature is low). injection control and other control tasks.
IAT Sensor voltage signal for use in fuel injection control and other
diversified control tasks.
LNW21ASH008401
The IAT (intake air temperature) sensor is installed to LNW21ASH008801

the intake air duct and the thermistor in the sensor
alters the resistance in response to the temperature
change. Higher intake air temperature provides smaller The idle position switch is installed to the accelerator
resistance while lower intake air temperature provides pedal, and is turned off when the pedal is pressed and
larger resistance. The ECM supplies 5 V to the IAT turned on when the pedal is released. The ECM
sensor via pull-up resistance and calculates the intake receives the on/off signal from this idle position switch
air temperature from the change in voltage and uses it for use in exhaust brake control, warm-up control, and
in fuel injection control and other control tasks. The other control tasks.
voltage is decreased when the resistance is small (the
temperature is high) while increased when the Clutch Switch
AP Sensor
LNW21ASH008501
The clutch switch is installed to the clutch pedal, and is

LNW21ASH008901
turned on when the pedal is pressed and turned off
when the pedal is released. The VIM receives the on/
The AP (accelerator pedal position) sensor is installed off signal from this clutch switch for use in exhaust
to the top of the accelerator pedal and supplies the brake control and other control tasks.
voltage signal that will change in response to
accelerator pedal angle to the ECM. The ECM
calculates the accelerator pedal position from the
VS Sensor Exhaust Brake Solenoid Valve
The VS (vehicle speed) sensor is installed to the The exhaust brake solenoid valve is installed to the
transmission. The sensor is also equipped with a Hall rear of the right front wheel frame (some vehicle types
effect circuit. The magnet mounted to the transmission have different positions), and opens and closes the
output shaft is rotated together with the shaft to vacuum path connected to the exhaust brake valve.
generate a magnetic field. This Hall effect sensor When this solenoid valve is turned on, the path is
interacts with the magnetic field and generates and opened and the vacuum is applied to the exhaust brake
sends a signal to the VIM. The VS sensor is energized valve. When the solenoid valve is turned off, the path is
via meter fuse. The VIM uses VS signal pulses to judge closed and the atmospheric pressure is applied and
the vehicle speed. resultantly the exhaust brake valve is released. After
the exhaust brake switch is turned on and the vehicle
Neutral Switch meets all the necessary conditions, the ECM turns on
the exhaust brake solenoid valve.
Atmospheric Pressure Sensor

The atmospheric pressure sensor is installed inside the
VIM and converts the atmospheric pressure into a
voltage signal. The VIM calculates the atmospheric
pressure from the voltage signal and sends the result to
the ECM. The ECM uses this atmospheric pressure to
calibrate the fuel injection quantity (altitude
compensation).
ECM
LNW21ASH008601
The neutral switch (P/N switch in case of automatic

transmission) is installed to the transmission (shift lever
in case of automatic transmission), and is turned on
when the shift lever is moved to the neutral position.
The ECM receives the on/off signal from this neutral (or
P/N) switch to control the powertrain so that the driver
cannot start the engine as long as the shift lever is not
in the neutral (or parking) position.
LNW21ASH007001
The ECM is installed in the inner part of the engine left CHECK ENGINE Lamp (MIL)
side cover. The ECM uses signals sent from diversified
sensors to control those systems directly related to the
engine, for example, fuel injection control, intake
throttle control, EGR control, and QWS control.
VIM
LNW21ASH000201
The CHECK ENGINE lamp (MIL) is built in the meter

panel and informs the driver of faulty status of engine
or associated systems. When the ECM detects a fault
LNW21ASH008301
by means of its diagnostic function, this CHECK
ENGINE lamp is turned on. After the diagnostic switch
is turned on (DLC pins are shorted), the CHECK
The VIM is installed inside the center console in the ENGINE lamp blinks to inform the mechanic of
cab, and transmits signals sent from diversified detection of DTC.
switches and sensors and drives powertrain actuators
such as exhaust brake, relays, and warning lamps
according to the commands from the ECM.
DLC
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
LNW21ASH000301
DLC (data link connector) is installed to the dash side

pane of the driver’s seat and acts as a communication
interface between external diagnostic tool and on-
board controllers. The DLC can also function as a
diagnostic switch and when DLC pins are shorted, this
diagnostic switch is turned on.
Fuse Layout
[Fuse Box Label, In Glove Box]
22 19 16 13 10 7 4 1
25 23 20 17 14 11 8 5 2
26 24 21 18 15 12 9 6 3
[Fuse Box, Front Left of Radiator]
27 28
LNW21ALF000401-X
Legend
1. Spare fuse
No. Indication on label Capacity Devices connected

1 CONTROLLER 10A Control unit
HAZARD,HORN (12V) 15A
2 Hazard warning flashing lamp, horn
HAZARD,HORN (24V) 10A
3 — 10A —
AIR CON (12V) 10A Air conditioner
4
HEATER,AIR CON (24V) 15A Heater, air conditioner
5 FUEL, SEAT HEATER (24V) 10A Fuel, seat heater
6 ABS, HAB, RETARDER (24V) 15A ABS, HAB, retarder
7 ROOM LAMP 15A Room lamp
8 STOP LAMP 10A Stop lamp

9 POWER WINDOW (24V) 20A Power window
TAIL.ILLUMI (12V) 15A
10 Tail lamp
TAIL.ILUMI (24V) 10A
11 FOG.CORNER 10A Fog lamp, cornering lamp
12 ELEC.PTO (24V) 10A PTO switch (electric PTO)
13 WIPER,WASHER 15A Wiper, window washer
14 TURN 10A Turn signal lamp
GENERATOR (12V) 15A Generator
15
ELEC.PTO (24V) 20A PTO solenoid valve (electric PTO)
MIRROR HEAT (12V) 10A Heated side mirror
16
ENG.CONT (24V) 15A ECM
17 MIRROR 10A Electrically operated mirror
18 CIGAR,AUDIO 10A Cigarette lighter, audio
METER (12V) 10A
19 Meter
METER (24V) 15A
ENGINE STOP (12V) 10A Engine stop
20
HSA (24V) 10A HSA
21 AIR BAG 10A SRS airbag
22 STARTER 10A Starter
23 H/LAMP RH 10A Headlamp, RH
24 H/LAMP LH 10A Headlamp, LH
HEATER (12V) 30A Heater
25
ENG CONTROLLER (24V) 30A ECM (except for turbocharged vehicles)
26 POWER WINDOW (12V) 30A Power window
External Fuse Box

27 MARKER LAMP 10A Marker lamp
28 COND FAN 10A Condenser fan
Relay Layout
Relay Box No.1

13
14
15
16
18
Relay Box No.2
12
Bracket 11
10
9
Spare Power Circuit 8
67
5
Upper
Fuse & Front Right

Relay Box
20
19
Cooler Relay 4
3
2
1
17
LNW21ALF006101-X
No. Legend
12 V: On relay
1
24 V: Charge relay
2 Horn relay
12 V: ABS, VSV, FICD, EXH brake, valve (12 V)
3
24 V: Headlamp relay
4 Tail relay
12 V: Headlamp relay
5
24 V: 4WD relay
6 Dimmer relay
7 Power window relay
8 Fog lamp relay
No. Legend
9 Cornering lamp relay
10 Air conditioner thermo relay
12 V: Charge relay
11
24 V: Key on relay
12 Heater & air conditioner relay
24 V: PTO cut relay for electric PTO in fire engine (MT)
24 V: PTO solenoid relay for electric PTO (AT)
13 12 V: Exhaust brake cut relay (MT)
24 V: Idle on relay for fire engine (AT)
24 V: Idle stop, wiper relay (with CFS (clutch free system))
24 V: PTO solenoid relay for electric PTO (MT)
24 V: PTO buzzer relay for electric PTO (AT)
14 12 V: OD off relay (AT)
24 V: Idle keep relay for fire engine (AT)
24 V: Idle stop, radio relay (with CFS)
24 V: PTO main relay for electric PTO (MT)
24 V: Garbage relay for garbage collector (AT)
15
24 V: Indicator lamp relay for fire engine (AT)
24 V: Idle stop, engine control module relay (with CFS)
4WD relay
16
24 V: Idle stop, mirror relay (with CFS)
24 V: Full automatic air conditioner, high relay
17 24 V: Automatic air conditioner, high relay
24 V: Shift lock relay for fire engine (AT)
24 V: Shift relay for fire engine (AT)
18
24 V: PTO main relay for electric PTO (MT)
19 24 V: PTO solenoid relay for electric PTO (MT)
20 24 V: PTO cut relay for electric PTO (MT)
Circuit Diagram
ECM Circuit Diagram
Starter
Switch (ON)
0.75B/O 0.5L
109 90
#19 0.5L/W AP
CHECK ENGINE 84 Sensor
15A 0.5L/R
Lamp 94
0.5Y/B 0.5B/Y
99 108
A/C Condenser 0.5W/L
110
0.75W/R
13
Starter 0.5R/B
A/C Magnetic 49 ECT
Switch (ST) Clutch 0.5G/W
0.5B/W 46 Sensor
113
#22
Starter 0.5R/G
10A Starter 48 FT
Cut Relay
Relay 0.5B/R Sensor
102
To Starter 0.85L/B
91 IAT
0.85O Sensor
83
Glow 0.75W/R
Plug Glow 80
SBF SBF
60A 50A Relay 81
0.75W/R
SCV
SBF 0.5W/G
98
60A Main Relay
1.25W/R 0.75L
114 74
SBF SBF SBF 1.25W/R 75
115 0.75L
100A 50A 30A 1.25W/R
116
Battery 0.5L/Y 1.25W
117 1
0.5L/Y
118 2
1.25L/W
43 Cylinder 1 Injector
0.75G/W
0.75W/G 42 Cylinder 4 Injector
Intake M+ 16 ECM 0.75B
Throttle M
0.75R 1.25R
DC Motor M- 35 4
5
1.25L/R
ITP 0.5G/Y 0.75W/Y
69
Sensor
0.75L
0.75W/B 0.5SB Scan Tool Communication
M+ 59 88
EGR
M DLC
DC Motor 0.75L/Y 0.5GR/W Diagnostic Switch
M- 58 112
EGR Valve 0.5Y

Position 68
Sensor
0.5W 0.5R
63 89
0.5G 97 VIM
Common Rail 67 0.5W
Pressure 66
Sensor 0.5G 0.5B
0.5R
64
0.5B
87
0.85B
95
0.5W/R 1.25B
CKP 25 119
Sensor 0.5W/L 1.25B
6 120
1.25B
0.5L/R 121
8
CMP
Sensor 0.5L/W
27
0.5B
26
LNW21AXF002601-X
VIM Circuit Diagram
Starter SW (ON)
0.85B/O
36
#19
15A
Exhaust
Brake Lamp 0.5B/R
0.3BR/W 16
4 0.3B/G
53
0.3LG/B
0.5LG/B 56
2 0.5L/R
18 A/T ECU
Exhaust 0.5LG
Brake Solenoid 59
PTO Lamp Tachometer

PTO ECU
0.5BR
PTO SW 0.5V/W 17
7 0.5B/R
15 ABS/ASR
0.3B/L
19 ECU
0.5G/Y
57
Starter SW (ST)
0.5B/W 0.5G Sound Alarm
46 54
#22 (Simplified ISS)
SBF
50A 10A Main Relay
38
SBF SBF 1.25W/R
SBF 75
50A 30A
100A 1.25W/R
76
1.25W/R
CFS ECU
Battery
Glow Lamp
VIM
42
0.3O/L
0.5W
27
3 ECM
0.5G/Y 26 0.5R
ECO Relay 0.5B
CFS Vehicle Brake SW

CFS
Clutch SW CFS Non Vehicle
49 0.5G/W
0.5W/L 48 +B
Exhaust Brake SW
50
0.5LG/R Stop
Warm Up SW Lamp
12 Lamp Relay
0.5BR/R Fail Relay
M/T : N A/T : P or N
44
0.5B/G Other ECU
Freezer SW
47
0.5L/B
0.5Y/G Diagnostic SW
9
0.5SB DLC
24
Scan Tool Communication
0.5R/B
34 0.5B
PTO 0.5Y 73
31 0.85B
Accelerator 0.5Y/BR 60
Sensor 71 0.85B
39
0.85B
52
Idle Up 0.5Y/G 0.85B
30 66
Volume
VS Sensor 14
LNW21AXF002301-X
ECM/VIM Circuit Diagram (1/5)
SBF-1 80A/100A A
MAIN 5 W/B 1 5 W/B 3 W/B
H-6 C
OFF B
ACC
SBF-2 50A
KEY 3 W/L 1 3 W/L 2 ON 3
B 3B/Y
H-7 B-67 B-67
ST 4 F-16 15A
3B/W
B-67
ENG. CONT
SBF-3 60A
Starter Switch
GLOW PTO Cut Relay
0.5 B-216 (4)
0.5 B/O
SBF-5 50A 0.3
B/O B/O
ECM 0.5 0.5
3 W/G 2 3 W/G R/Y
H-7 1 B/O 2 1
Air Bleed Connector

B-89 B-89 B-89
Clutch Switch
1
3
CFS Control Unit

B-355
W/G
Clutch PTO Switch
B-354
B-258 (2)
1
B-89 B-89 B-89
F-25 30A
ENG.CONT 2 3 0.5 4
2L 0.5 G/O
2 0.3 B/O PTO Solenoid M/T Relay
W/G P 0.5
9 3 0.85 0.5 W/L B-64 (3)
H-4 B/L B/O LG/L 0.5
+ B/O
10 49 49 49
P-1 2
W/G B-352 B-352 B-352 B-352
3 1
P-2
X-18 X-18 VIM
Main Relay
B-349 B-349 B-349 B-349 B-352 B-350 B-350 B-350 B-350 B-352
+ 38 76 75 36 2 65 26 27 24 9
1.25 1.25 1.25 0.85 0.5 0.5
P-3 W/R W/R W/R B/O LG/B B
X-18 X-18
8 6 7 19
P-4 5 3 2 H-4 H-4 H-4 H-4 0.5
W/R LB
Solenoid Valve
Exhaust Brake
3 0.5
B/L 0.5
2 W/R 4 LG/B
0.5 0.5
16 15 14 13 12 11 10 9
X-22 X-22
8 7 6 5 4 3 2 1
R W 0.5 LB
Glow Relay
0.5 2
B 0.5 GR/W
Frame J-31 0.5 B
0.85 0.5 B
B/O
0.5
L/Y X-22 X-22
3 5 0.5 L
3
B/G 2 J-31
8 4 13 12 8 1
H-105 1 Diagnostic Connector
H-5 H-4 H-4 H-4 H-8 H-8
3 0.5 B-79
B/G W/G
Glow Plug E-3 1.25 1.25 1.25 0.75 0.5

W/R W/R W/R B/O B/O
0.5 0.5 0.5 0.85
R W GR/W B
0.75
0.5 0.5 B/O
L/Y L/Y
117 118 98 114 115 116 109 97 89 88 112
J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191
ECM
3
B
J-9
Left Side Frame

(Center) 8
3B 1.25 B 6
Right Frame (Front) B-274 B-274
Joint Connector
LNW21AXF002701-X
3B/Y
A
F-19 15A
3W/B 0.5W/R
C Charge Relay (4) Meter
X-1
3B/W
B D
1 2 1 TCM
X-12 X-12 B-172 B-47 12
Inhibitor Switch
2 Joint (JATCO) (AISIN)
Heater & A/C 31 Connector
Relay N P
B-172 H-5
J-69 J-69
X-12 X-12 Joint 0.85
Connector B/Y 5 6
3 5 4 0.3
0.5B 0.5B 7 6 1.25B 0.5 0.5
B/R 0.5 W/L
GND W/L W/R
B/Y 1
F-5 10A 8 B-274
20 22
0.5 FUEL, SEAT HEATER J-50 H-46 H-46

B/R 0.3
0.5 0.5 0.3 0.5 B Neutral 0.5 0.5
B/R 5 BR 6 B 2 B/R 3 5 Switch W/L W/R
7 8
(M/T)
B-69
Warm Up Switch
Warm Up Switch
B-319 B-319 B-31 B-31 X-33 X-33
Idling Stop &
Exhaust Brake
J-50
Switch
2
0.5
Diode
B/G 0.3
B-69 B-319 B-319 B-31 B-31 14 W/L
X-33
2 3 0.5 5 6 0.5 2 H-4 9
LG/R LG/R
0.5 0.5
0.5
LG/R B/G
Fuse F-10 (10A) Fuse F-10 (10A) B/G
50 12 12 44 44 44
TAIL,ILLUMI TAIL,ILLUMI
B-352 B-352 B-352 B-352 B-352 B-352
VIM
GND SIG 5V SIG
B-352 B-351 B-349 B-350 B-349 B-349 B-349 B-349 B-349 B-352
39 52 66 60 73 71 31 34 30 47
0.5
L/B
0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
B B B B B Y/BR Y R/B Y/BR Y/G R/B Y/BR Y R/B
1 1 3 1 2 3 5 5 7 3
B-282 B-325 B-282 B-281 B-281 B-281 H-8 H-4 H-8 H-8
0.5 0.5 0.5 0.85

PTO Accelerator Sensor Idle Control Switch Y/BR Y R/B L/B
1 2 3 1
J-7
J-166 J-166 J-166
PTO Accelerator Sensor
Compressor
Left Frame (Front) B-346
LNW21AXF002801-X
D
3B/W
0.5
0.5
0.3
0.3
B/W
B/W
B/L
B/L
H-8
J-177
B-351
B-352
7
46
12
19
0.5
0.5
LG/W
B/R
H-8
J-177
B-351
8
STARTER
11
15
F-22 10A
EHCU
0.5
L/R
0.5
0.5
G/Y
G/Y
CFS C/U B-259 6
H-8
J-177
B-351
19
18
57
BR
0.5
BR
0.5
0.3
G/B
H-8
J-177
B-351
20
17
17
TCM B-229 5 (AISIN)
B-351
18
TCM B-47 20 (JATCO)
0.5
Y/G
0.3
B/G
Meter B-52 17 Speed Meter TCM B-229 23 (AISIN)
B-351
B-351
53
14
Speed Sensor J-32 3 TCM B-47 13 (JATCO)
0.3
0.3
LG/B
VIM
BR/W
Meter B-51 6 EXH Brake W/L TCM B-230 7 (AISIN)
B-352
B-351
4
56
0.3
O/L
Meter B-52 15 Glow Indicator Lamp TCM B-47 8 (JATCO)
0.5B/W
B-352
42
LG
0.5
Meter B-52 8 (Tachometer)

B-351
0.5
59
W/O
CFS C/U B-259 19

B-352
11
LG
0.3
TCM B-229 1 (AISIN)

0.5
G/W
Stop Lamp Relay X-3 2

B-352
LG
0.5
48
TCM B-48 4 (JATCO)
Stop Lamp Switch B-66 2

LG
0.5
CFS B-259 1
0.5
V/W
PTO Switch (M/T) B-84 2

Parking Warning Unit
G
B-352
7
0.5
B-147 3 (Idling Stop)

B-351
54
Dump Control Switch B-77 1 Idling Stop ECM Relay

0.5
G/Y
X-15 3
B-352
3
E
LNW21AXF002901-X
0.5B/W
E F
(1)
E-5
Injector
Magnetic Clutch
No.2 No.3 No.4 No.1
E-115 E-115 E-115 E-115 E-115 E-115 E-115 E-115

6 7 2 3 8 5 1 4
0.75 0.75 1.25 1.25 0.75 0.75 1.25 1.25 0.75

L W/Y R L/R B G/W W L/W W/R
26 24 15 32 9 7 13 30 13
E-111 E-1114 E-111 E-111 E-111 E-111 E-111 E-111 E-111
ECM
E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111
22 54 19 16 33 34 17 12 29 46 45 39 1 56 36 37 52 18 35 2 21 38 4 55
0.5 0.5 0.5 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
R/B G/W R/G W/R W/R L L R W/G L/Y W/B W G/Y R W/R W/L B L/R L/W Y G W G
0.5 0.5 0.5 0.5

0.5 0.5 0.75 0.75 0.75 0.75
W R G R
G/W G/W W/R L R L/Y
1 2 2 1 1 2 4 2 1 1 2 3 2 1 3 2 3 2 1
E-90 E-90 E-93 E-93 E-116 E-116 E-114 E-114 E-114 E-98 E-98 E-112 E-112 E-94 E-94 E-94 E-113 E-113 E-113
Intake Throttle DC Motor
Fuel Suction Control 3 4 Intake Throttle Crank Position Cam Position EGR Position
Temperature Valve (SCV) Position (ITP) (CKP) Sensor (CMP) Sensor Sensor
(FT) Sensor E-114 E-94
Sensor
EGR DC Motor
E-90 Common Rail

Pressure Sensor
0.5 3
Y/B
E-114 E-94
Meter
6 6
0.75 0.75
B-52 (5) R L/Y
LNW21AXF003301-X
F
0.5
B/W
Accelerator Sensor
Meter B-51 5
(CHECK ENGINE Lamp)

B-280 B-280 B-280
3 2 1
0.5
Y/B
0.5 0.5 0.5
L L/W L/R IAT Sensor
30 10 1 3 2 4
H-5 H-4 H-4 H-4 H-4 J-190 J-190 H-8
2 1
0.5 0.5 0.5 0.5 0.85 0.5 0.5

B/W L L/W L/R O L/B Y/B
0.5
B/Y
113 108 90 84 94 83 91 99
J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191
5V SIG GND 5V SIG
ECM
J-191 J-191 J-191 J-191 J-191 J-191 J-191

102 110 95 121 120 119 87
0.5 0.5 0.75 1.25 1.25 1.25 0.5
B/R W/L 2 B B B B B
H-8
0.5
W/L 1
B-75
Accelerator
Pedal
Switch
B-75
2
0.5
Starter B 10
Cut Relay
B-172
X-26 3
6 Joint
1.25 Connector
B
3B
Right Frame (Front) B-274
Left Frame (Center) J-9
LNW21AXF003101-X
Component Layout
1
57
2,3
7
56
55
54
53
52
51
50 8
49
48 9
47
10
14
13 15
12
11
16
24
41,42,43,44,45,46
17
25
40 39
32 31
33,34,35,36,37,38
26,27,28,29,30
23
18
19
22
20
21
LNW21ALF006301
Legend
1 B-172 Joint connector
2 X-12 Heater and air conditioner relay (825/151)
3 X-33 Diode (810/002)
4 B-349, 350, 351, VIM (826/646)
352
5 J-31 Exhaust brake magnetic valve (156/086)
6 J-50 Neutral switch (230/171)
7 J-166 PTO accelerator sensor (101/867)
8 P-5 Frame ground
9 P-1 & P-2 Battery
10 P-3 & P-4 Battery (24 V)
11 E-3 Glow plug (011/010)
12 E-115 Injector (040/031)
13 E-113 Common rail pressure sensor (040/211)
14 E-94 EGR vacuum sensor (057/667)
14 E-94 EGR valve (057/001)
15 E-114 Intake throttle position sensor (025/373)
15 E-114 Intake throttle motor (025/373)

16 E-98 Crank position sensor (826/648)
17 E-112 Cam position sensor (040/001)
18 E-96 Timing control valve (040/001)
18 E-111 ECM (060/613)
19 H-105 Intermediate connector
20 J-190 IAT sensor (060/820)
21 E-116 Suction control valve (040/001)
22 E-93 Fuel temperature sensor (040/205)
23 E-90 Engine coolant temperature sensor (060/129)
24 J-69 Inhibitor switch (249/001)
25 J-9 Left frame (center) ground
26 F-5 Fuel seat heater fuse (810/005)
27 F-16 ENG.CONT fuse (810/005)
28 F-19 Meter fuse (810/005)
29 F-22 Starter fuse (810/005)
30 F-25 Engine controller (main) fuse (810/005)
31 B-346 Left frame (front) fuse
32 J-7 Compressor connector
33 SBF-1 Main slow blow fuse (810/174)
34 SBF-2 Key switch slow blow fuse (810/174)
35 SBF-3 Glow slow blow fuse (810/174)
36 SBF-5 ECM slow blow fuse (810/174)
37 X-18 Main relay (828/531)
38 X-22 Glow relay (060/046)
39 J-177 EHCU (350/089)
40 B-274 Right frame (front) ground
47 B-354 Air vent connector
47 B-355 Air vent connector
48 B-89 Clutch switch (825/021)
49 B-67 Starter switch (431/103)
50 B-69 Exhaust brake switch (825/001)
51 B-79 Diagnostic connector (DLC)
52 B-75 Accelerator switch (101/079)
53 B-280 Accelerator position sensor (101/243)
54 B-282 & B-325 PTO accelerator connector
55 B-281 Idle up position switch (101/262)
56 B-51 & 52 Meter warning (821/001)
57 B-31 Warm-up switch (825/423)
Connector List
No. Connector face No. Connector face
1 2 3 4 5 6 7 8
B-31 1
4
2
5
3
6
B-79 9 10 11 12 13 14 15 16
006-024 016-033
1
B-51 1 2 3 4 5 6 7 8 B-89
2
9 1011121314 1516 171819 20
020-024 002-011
1 2 3 4 5 6 7 8 9 10 11
3 2 1
B-52 5 4 B-172 12 13 14 15 16 17 18 19 20 21 22
005-025 022-005
2 1
B-67 4 3 B-274
004-035 000-012
1 2 3
B-67 1 2 B-280
3 4
004-015 003-098
4 3 2 1
B-69 8 7 6 5 B-281 1 2 3
008-028 003-064
1 2 3 4
B-69 5 6 7 8
B-282 1 2 3
008-021 003-015
2 1
B-75 1 2
B-325
002-022 002-015
1 2
B-346 E-90 3
000-037 003-095
38 37 28
36 35 34 33 32 31 30 29
B-349 76 75 74 73 72 71 70 69 68 67 66
E-93 1 2
022-025 002-208
1 2 3
27 26 25 24 23 22
B-350 E-94 4 5
65 64 63 62 61 60
012-054 005-034
21 20 19 18 17 16 15 14
B-351 59 58 57 56 55 54 53 52
E-98 1 2
016-067 002-178
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
5 4
13 12 3 2 1 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
11 10 9 8 7 6 5 4
B-352 51 50 49 48 47 46 45 44 43 42 41 40 39 E-111 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
3
2 1
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
026-013
081-001
1 2 3
B-354 1
E-112
001-003
003-097
1
B-355 E-113 1 2 3
001-034
003-111
1 1 2 3
E-3 E-114 4 5 6
001-029
006-084
1 2 3 4
E-115 J-31 1 2
5 6 7 8
008-046 002-008
E-116 1 2 J-50 1 2
002-178 002-210
9 8 7 6 5 4 3 2 1
3 4 5 6 7 8 9 10 11 12
1 2
H-4 20 19 18 17 16 15 14 13 12 11 10 J-177 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34
020-002 034-001
12 11 10 9 8 7 6 5 4 3
2 1
1 2 3 4 5 6 7 8 9
H-4
22 21 20 19 18 17 16 15 14 13
10 11 12 13 14 15 16 17 18 19 20 J-177 34 33 32 31 30 29 28 27 26 25 24
23
020-001 034-002
113 112 111 110 109 108 107 106

6 5 4 3 2 1
121 120 119
105 104 103 102 101 100 99 98
14 13 12 11 10 9 8 7
118 117
H-46 22 21 20 19 18 17 16 15
J-191 97 96 95 94 93 92 91 90
116 115 114
89 88 87 86 85 84 83 82
022-013 040-004
1 2 3 4 5 6
7 8 9 10 11 12 13 14
P-1
H-46
15 16 17 18 19 20 21 22
022-012
(24V)
000-028
1 2 P-2
H-105 3 4 5 6
(24V)
006-005 000-029
P-3
J-9
(24V)
000-012 000-029
No. Connector face H-5
P-4
(24V)
000-028
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
P-5 13
19
14
20
15
21
16
22
17
23
18
24
18
24
17
23
16
22
15
21
14
20
13
19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
(24V)
000-021
2 3 4
X-12 LNW21ASH010801
5
005-012
H-6
2
X-18
3 4 5
005-023
1 2 H-6 2 1
1 2 H-7 2 1
1 2 3 4 4 3 2 1
1 2 3 4 5 6
X-33 7 8 9 10 11 12 13 14
5 6 7 8 8 7 6 5
9 10 11 12 13 13 12 11 10 9
H-8
014-003
14 15 16 17 18 18 17 16 15 14
LNW21ASH010901
X-22 2 3
4 5
005-013
H-7 H-8
1 2 H-6 2 1
1 2 H-7 2 1
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
1 2 3 4 4 3 2 1 19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
5 6 7 8 8 7 6 5 31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
ECM Pinouts
LNW21ALF004501
4 5 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 106107108109110111112113 119 120 121

43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 98 99 100101102103104105
3 117 118
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 90 91 92 93 94 95 96 97
1 2 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 82 83 84 85 86 87 88 89 114 115 116
LNW21ASF002001
81-Way Connector (Engine side)
Pin No. Connected to Pin No. Connected to

1 Injectors #1 and #3 42 Injector #3 (cylinder 4)
2 Injectors #1 and #3 43 Injector #1 (cylinder 1)
3 — 44 —
4 Injectors #2 and #4 45 —
5 Injectors #2 and #4 46 Sensor ground (ECT, FT)
6 CKP sensor (–) 47 —
7 — 48 FT sensor signal
8 CMP sensor signal 49 ECT sensor signal
9 — 50 —
10 — 51 —
11 — 52 —
12 — 53 —
13 Air conditioner 54 —
14 — 55 —
15 — 56 —
16 Intake throttle DC motor (+) 57 —
17 — 58 EGR DC motor (–)
18 — 59 EGR DC motor (+)
19 — 60 —
20 — 61 —
21 — 62 —
22 — 63 5 V sensor power (ITP, common rail
pressure, EGR)
23 Injector #4 (cylinder 2) 64 5 V sensor ground 1 (ITP)
24 Injector #2 (cylinder 3) 65 —

25 CKP sensor (+) 66 Common rail pressure sensor signal
26 Shield ground (CMP, CKP, common rail 67 Common rail pressure sensor signal
pressure)
27 CMP sensor ground 68 EGR valve position sensor signal
28 — 69 ITP sensor signal
29 — 70 —
30 — 71 —
31 — 72 —
32 — 73 —
33 — 74 SCV (LO)
34 — 75 SCV (LO)
35 Intake throttle DC motor (–) 76 —
36 — 77 —
37 — 78 —
38 — 79 —
39 — 80 SCV (HI)
40 — 81 SCV (HI)
41 — — —
40-Way Connector (Vehicle side)

82 — 102 Starter cut relay
83 5 V sensor power 2 (IAT) 103 —
84 AP sensor signal 104 —
85 — 105 —
86 — 106 —
87 Casing ground 107 —
88 DLC (Tech 2 communications) 108 Shield ground (AP)
89 VIM (CAN communications) 109 Starter switch (ON)
90 5 V sensor power 2 (AP) 110 Idle position switch
91 IAT sensor signal 111 —
92 — 112 DLC (diagnostic switch)
93 — 113 Starter switch (ST)
94 5 V sensor ground 2 (AP) 114 ECM power
95 Signal ground 115 ECM power
96 — 116 ECM power
97 VIM (CAN communications) 117 Main relay
98 Glow relay 118 Main relay

99 CHECK ENGINE lamp 119 ECM power ground
100 — 120 ECM power ground
101 — 121 ECM power ground
VIM Pinouts
LNW21AMF005101
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 36 37 38
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
LNW21ASF001901
26-Way Connector
1 — 39 VIM power ground
2 Exhaust brake solenoid valve 40 —
3 ECO (power save) relay 41 —
4 Exhaust brake lamp 42 Glow lamp
5 — 43 —
6 — 44 Neutral (P/N) switch
7 PTO switch 45 —
8 — 46 Starter switch (ST)
9 DLC (diagnostic switch) 47 Freezer switch
10 — 48 Stop lamp switch
11 — 49 Clutch switch
12 Warm-up (QWS) switch 50 Exhaust brake switch
13 — 51 —
16-Way Connector
14 VS sensor signal 52 VIM power ground
15 ABS/ASR controller 53 AT controller
16 AT controller 54 Voice alarm unit (idle stop)
17 ABS/ASR controller 55 —
18 AT controller 56 AT controller
19 ABS/ASR controller 57 ABS/ASR controller
20 — 58 —
21 — 59 AT controller
12-Way Connector
22 — 60 Signal ground
23 — 61 —
24 DLC (Tech 2 communications) 62 —
25 — 63 —
26 ECM (CAN communications) 64 —
27 ECM (CAN communications) 65 Shield ground (CAN communications)
22-Way Connector
28 — 66 VIM power ground
29 — 67 —
30 Idle up volume 68 —
31 PTO accelerator sensor signal 69 —
32 — 70 —
33 — 71 5 V sensor ground 1 (PTO, IDL UP)
34 5 V sensor power 1 (PTO, IDL UP) 72 —
35 — 73 Casing ground
36 Starter switch (ON) 74 —
37 — 75 VIM power
38 VIM power 76 VIM power
Strategy-Based Diagnostics 3. Realistic fault:

Strategy-Based System Diagnostics • The fault occurs certainly and the customer
complaint is realistic and clear. You can
The system diagnostic is a uniform approach to repair reproduce the fault. However, there may exist
all electrical/electronic (E/E) systems. In the E/E two or more causes.
system, different from general vehicle problems, faults = Current fault
frequently occur along the steps shown as follows.
1. Initial stage: The diagnostic flow can always be used to resolve an
• A single fault occurs for a short while and, E/E system problem and is a starting point when
therefore, the customer may miss it. In this repairs are necessary. The following steps will instruct
stage, the customer complaint is unclear and the technician how to proceed with a diagnosis:
the fault cannot be reproduced. But, the ECM 1. Verify the customer complaint:
may have stored the fault. • To verify the customer complaint, the technician
= Past fault should know the normal operation of the
2. Middle stage: system.
• A single fault occurs for a short while but is 2. Perform preliminary checks:
observed intermittently. It always occurs under • Conduct a thorough visual inspection.
certain conditions. The customer complaint
• Review the service history.
(description of fault) is clear but fault
occurrence conditions are unidentified. If you • Detecting unusual sounds or odors.
comprehend these conditions, you can • Gather DTC (diagnostic trouble code)
reproduce the trouble. information using Tech 2
= Intermittent fault (intermittent) 3. Check bulletins and other service information.
4. Refer to “Symptom Diagnosis Chart” in this
manual.
• “Sympton Diagnosis Chart” contain information on 3. Use a check sheet or other method to identify the
a system that may not be suppored by one or more circuit or electrical system component.
DTCs. Sympton Diagnosis Chart verify proper
operation of the system. This will lead the No Trouble Found
technician in an organized approach to This condition exists when the vehicles is found to
diagnostics. operate normally. The condition described by the
5. Refer to related descriptions such as those for customer may be normal. Verify the customer
engine mechanicals. complaint against another vehicle that is operating
normally. The condition may be intermittent. Verify the
DTC Stored complaint under the conditions described by the
Follow the designated DTC chart exactly to make an customer before releasing the vehicle.
effective repair. 1. Reexamine the complaint.
When the complaint cannot be successfully found
No DTC or isolated, a re-evaluation is necessary. The
Select the symptom from the “Sympton Diagnosis complaint should be re-verified and could be
Chart”. Follow to the diagnostic paths or suggestions to intermittent as defined in Intermittents, or could be
complete the repair. You may refer to the applicable normal.
components/system check in the functional check. 2. Repair and verify.
After isolating the cause, the repairs should be
No Matching Symptom made. Validate for proper operation and verify that
the symptom has been corrected. This may involve
1. Analyze the complaint.
road testing or other methods to verify that the
2. Develop a plan for diagnostics. complaint has been resolved under the following
3. Utilize the wiring diagrams and the theory of conditions:
operation. • Conditions noted by the customer.
Call technical assistance for similar cases where repair
• If a DTC was diagnosed, verify a repair by
history may be available. Combine technician
duplicating conditions present when the DTC
knowledge with efficient use of the available service
was set as noted by Tech 2 data.
information.
Verifying Vehicle Repair
Intermittents
When the electronic control system has been repaired,
Conditions that are not always present are call
it is necessary to verify the repair is appropriate. If the
intermittents. To resolve intermittents, perform the
repair is incomplete, the CHECK ENGINE lamp (MIL)
following steps.
may be lit again while the vehicle is released, or the
1. Observe history DTCs, DTC modes, and engine drivability may be impaired. Particularly for the
data. intermittents, it is necessary to reproduce the trouble
2. Evaluate the symptoms and the condition under the same conditions described by the customer
described by the customer. and check the trouble is no longer found.
No. Item Objective Method

1 Verifying the To check the DTC is not set Clear the previous DTC. Sufficiently warm up the
DTC after the repair. engine under idling, and increase the engine
speed to 2200 rpm and provide racing to verify
the test conditions.
2 Verifying the idle To check the idle control is Upon completion of engine warm-up, verify the
speed after normally performed. idle speed is 575 rpm for a manual transmission
warm-up vehicle or 640 rpm for an automatic transmission
vehicle with the air conditioner turned off. If a fault
is detected, refer to "Instable idling" in "Sympton
Diagnosis Chart" to identify the cause.
3 Verifying Tech 2 To provide basic checking for Monitor Tech 2 data list and examine the data
data list engine control and using typical value sheet. Check typical values in
communication conditions. Tech 2 data list.
4 Verifying the To check the start control Upon completion of engine warm-up, verify the
restartability correctly works. cranking time is not more than 5 seconds and the
engine speed is stable after startup.
No. Item Objective Method

5 Verifying the To check electric wave Turn on and off the electric wave emission
electromagnetic emission equipment such as equipment, such as transceiver, to check whether
compatibility of transceiver, if added, does not idle speed will change. If a problem is found,
strong electric emit interfering waves. inform the customer that the electric wave
wave emission emission equipment must be dislocated or
equipment changing the power is needed.
Supplementary description about strong electric wave that were not previously monitored prior to OBD
emission equipment: If a problem is found in this diagnostics. Vehicle maintenance cannot be classified
checking, provide the following advices to the as "non-vehicle fault", but with the sensitivity of OBD
customer. diagnostics, vehicle maintenance schedules must be
• To install the antenna away from the vehicle more closely followed.
electronic system components such as control unit
and sensors as far as possible. Related system faults
• To install the antenna cord at least 20 cm away Many of OBD system diagnostics will not run if the
from the vehicle electronic system components ECM detects a fault on a related system or component.
such as control unit and sensors.
• Do not arrange the antenna cord together with Visual/Physical Engine Compartment Inspection
other cables. In addition, isolate the antenna cord Perform a careful visual/physical engine compartment
from other cables as far as possible. inspection when performing diagnostic procedure. This
• Install additional devices certainly according to can often lead repairing a problem without further
respective instruction manuals. steps. Use the following guidelines when performing a
visual/physical inspection.
• Do not install high-power mobile communication
equipment. • Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
CAUTION: • Inspect hoses that are difficult to see behind other
Follow the steps below when you verify repairs on components.
OBD systems. Failure to follow these steps could • Inspect all harnesses in the engine compartment
result in unnecessary repairs. for proper connections, burned or chafed spots,
1. Review and record Tech 2 data relative to the pinched harnesses, contact with sharp edges or
issued DTC. contact with hot exhaust manifolds or pipes.
2. Clear the DTC(s).
Basic Knowledge of Tools Required
3. Operate the vehicle while checking the associated
Tech 2 data. IMPORTANT:
Lack of basic knowledge of this powertrain when
Non-OEM parts performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain
All of the OBD diagnostics have been calibrated to run
components. Do not attempt to diagnose a
with OEM parts. Therefore, installation of general on-
powertrain problem without this basic knowledge.
market sensors or switches are will result in incorrect
A basic understanding of hand tools, including
OBD diagnostics and CHECK ENGINE lamp (MIL)
scan tool, is necessary to effectively use this
activation.
section of the Service Manual.
If on-market electronic devices such as mobile phones,
stereos, and theft deterrent system are improperly
On-Board Diagnostic Tests
installed, EMI (electromagnetic interference) radiation
occurs and affects the control system. As a result, The diagnostic test is a series of steps, the result of
incorrect data are sent from sensors to turn on the which is a pass or fail reported to the Diagnostic
CHECK ENGINE lamp (MIL). To diagnose the vehicle Executive. When a diagnostic test reports a pass
with the OBD system, turn off or remove all the on- result, the Diagnostic Executive records the following
market parts. data:
• The diagnostic test has been completed since the
Poor Vehicle Maintenance last ignition cycle.
The sensitivity of OBD diagnostics will cause the • The diagnostic test has passed during the current
CHECK ENGINE lamp (MIL) to turn on if the vehicle is ignition cycle.
not maintained properly. Restricted oil filters, fuel filters, • The fault identified by the diagnostic test is not
and crankcase deposits due to lack of oil changes or currently active.
improper oil viscosity can trigger actual vehicle faults
When a diagnostic test reports a fail result, the • Engine speed
Diagnostic Executive records the following data: • Vehicle speed
• The diagnostic test has been completed since the • ECT (engine coolant temperature)
last ignition cycle.
• IAT (intake air temperature)
• The fault identified by the diagnostic test is
• AP (accelerator position)
currently active.
• FT (fuel temperature)
• The fault has been active during this ignition cycle.
• Idle position switch
• The operating conditions at the time of the failure.
• Common rain pressure
Comprehensive Component Monitor Diagnostic
Operation Diagnostic Executive
Comprehensive component monitoring diagnostics are The Diagnostic Executive is a unique segment of
required to operate the engine properly. software that is designed to coordinate and prioritize
the diagnostic procedures as well as define the
Input Components protocol for recording and displaying their results. The
main responsibilities of the Diagnostic Executive are
Input components are monitored for circuit continuity
listed as following
and out-of-range values. This includes rationality
checking. Rationality checking refers to indicating a • Commanding CHECK ENGINE lamp (MIL) on and
fault when the signal from a sensor does not seem off
reasonable, i.e., accelerator position sensor (APS) that • DTC logging and clearing
indicates high throttle position at low engine loads or • Tech 2 data recording
low intake air pressure. Input components may include,
• Acquiring current status information on each
but are not limited to the following sensors:
diagnostic
• Intake air temperature (IAT) sensor
• Crank position (CKP) sensor Diagnostic Information
• Engine coolant temperature (ECT) sensor The diagnostic charts and functional checks are
• Cam position (CMP) sensor designed to locate a faulty circuit or component through
a process of logical decisions. The charts are prepared
• Accelerator position (AP) sensor
with the requirement that the vehicle functioned
• Common rail pressure sensor correctly at the time of assembly and there are not
• EGR valve position sensor multiple faults present.
• Intake throttle position (ITP) sensor There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented
• Fuel temperature (FT) sensor
by the diagnostic procedures contained in this manual.
• Vehicle speed (VS) sensor The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
Output Components
When a malfunction is detected by the control module,
Output components are diagnosed for proper response a diagnostic trouble code is set and the CHECK
to control module commands. Components where ENGINE lamp (MIL) is illuminated.
functional monitoring is not feasible will be monitored
for circuit continuity and out-of-range values if Malfunction Indicator Lamp (MIL)
applicable. Output components to be monitored
The malfunction indicator lamp (MIL) looks the same as
include, but are not limited to, the following circuits:
the MIL you are already familiar with ("Check Engine"
• EGR EVRV lamp).
• Intake throttle Basically, the MIL is turned on when the electronic
• SCV control system such as ECM (engine control module)
fails and a DTC is detected.
Terms Commonly Used in Diagnosis
Data Link Connector (DLC)
Diagnostic
The provision of communication with the control
When used as a noun, the word diagnostic refers to
module is the data link connector (DLC). The DLC is
any on-board test run by the vehicle’s Diagnostic
used to connect to Tech 2, or a scan tool. Some
Management System. A diagnostic is simply a test run
common uses of Tech 2 are listed below.
on a system or component to determine if the system
or component is operating according to specification. • Identifying stored diagnostic trouble codes (DTCs)
There are many diagnostics, shown in the following list. • Clearing DTCs
• EGR (exhaust gas recirculation) • Performing output control tests
• Reading serial data 1. Turn on the starter switch and check the CHECK
ENGINE lamp (MIL) is turned on. (Bulb check)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
LNW21ASH001801
LNW21ASH000201
Verifying Vehicle Repair 2. Keep the starter switch turned on and the engine
Verification of vehicle repair will be more turned off.
comprehensive for vehicles with on-board diagnostic 3. Short pins 6 and 4 on the DLC. The DLC is a black
(OBD) system diagnostic. Following a repair, the 16-way connector and located at the lower right
technician should perform the following steps: corner of the instrument panel.
1. Review and record DTC diagnosed or Tech 2 data
or both.
2. Clear DTC(s).
3. Operate the vehicle within the conditioned
described by Tech 2 data.
4. Monitor the DTC status information for the specific
DTC that has been diagnosed until the ECM
performs the diagnostic test associated with that
DTC.
Following these steps is very important in verifying
repairs OBD systems. Failure to follow these steps 1 2 3 4 5 6 7 8
could result in unnecessary repairs. 9 10 11 12 13 14 15 16
Diagnostic Trouble Code (DTC)

Whenever the starter switch is turned on, the ECM
executes self-testing for almost wirings and
components and, when detects a system fault, stores it LNW21ASH000301
and enables backup control according to the DTC set.
When a fault occurs that will affect the running, the
ECM turns on the CHECK ENGINE lamp (MIL) in the 4. On the CHECK ENGINE lamp (MIL), read the
meter panel or blinks the exhaust indicator lamp to number of blinks.
inform the driver of the fact. 5. Identify the DTC from the DTC Chart.
Reading Diagnostic Trouble Codes Diagnostic Trouble Codes Not Stored

Current and past DTCs stored to the ECM can be Code 12 that shows initiation of indication is repeatedly
visualized in the form of blinking CHECK ENGINE lamp displayed.
(MIL) when the DLC (data link connector) is shorted. To
this end, provide the following steps.
Diagnostic Trouble Codes Stored
Code 12 that is displayed three times and then stored
code is displayed three times. When multiple DTCs are
stored, each code is displayed three times, starting
from the lowest number. After all DTCs are displayed,
above sequence is repeated from code 12 as long as
DLC is being shorted.
eg.,) Display Start Cord "12"

Display Start 0.4 0.4
Turn On
Turn Off
3.2 1.2 3.2 Unit (sec)
eg.,) Trouble Cord "21"

Display Start 0.4 0.4
Turn On
urn Off
3.2 1.2 3.2 Unit (sec)
eg.,1 : Diagnostic Trouble Codes not Stored

12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 Endless Display
eg.,2 : Diagnostic Trouble Codes "21", "24" Stored

12 12 12 21 21 21 24 24 24 12 12 12 21 21 21 Endless Display
LNW21AMF000601-X
Clearing Diagnostic Trouble Codes 4. Turn on the idle position switch for not less than 1
When the system fails and the DTC is stored to the second but not more than 3 seconds. (Release the
ECM, even repairing the faulty portion will not clear the accelerator pedal.)
DTC from the memory. To clear the DTC, conduct the 5. Turn off the idle position switch for not less than 1
steps listed below. second but not more than 3 seconds. (Press the
• Keep the starter switch turned on and the engine accelerator pedal.)
turned off. 6. After the above operations are properly completed,
• Short the data link connector. the CHECK ENGINE lamp (MIL) illuminates for 3
Perform the following steps. seconds to report the memory is cleared.
1. Turn off the idle position switch for not less than 1 7. Turn off the starter switch. Wait for 5 seconds and
second but not more than 3 seconds. (Press the turn on the starter switch again.
accelerator pedal.) When Tech 2 has been connected to the vehicle, the
DTC can be cleared through the memory clear
2. Turn on the idle position switch for not less than 1
operation with Tech 2.
second but not more than 3 seconds. (Release the
accelerator pedal.)
3. Turn off the idle position switch for not less than 1
second but not more than 3 seconds. (Press the
accelerator pedal.)
ECM Voltage and Continuity Test/Measurement
To test and measure the ECM for voltage and
continuity, use a circuit breaker box and 4HL1 adapter
harness.
17
1 A
34
18
51
35
52 68 B
69 85
86 102
C
103 119
120 130
LNW21ASH010501
Functional Check List

Hearing The objective is to comprehend the symptom completely based on the
customer complaint and provide accurate diagnostic.
On-Board Diagnostic System The objective is to identify the faulty portion on the electronic engine control
Check system. (Checking procedure)
Inactive CHECK ENGINE Lamp The objective is to check the CHECK ENGINE lamp (MIL) when it is not
(MIL) Check turned on even after starter switch turn-on.
Active CHECK ENGINE Lamp The objective is to check the CHECK ENGINE lamp (MIL) when it does not
(MIL) Check blink (i.e., it keeps continuous lighting) even after diagnostic switch turn-on.
ECM Power Supply and The objective is to check ECM power supply and grounding system circuits
Grounding System Circuit Check when they seem to be faulty.
Hearing Diagnostic Key points on hearing

1. Using the Engine Control System Diagnostic
Chart, completely hear and comprehend the
• What • Faulty event
customer complaint.
Reference: • When • Date and time, generation
Proceed the process by focusing on the possible frequency
faulty system estimated from the fault (fact)
• Where • Situation of road
instead of random hearing.
2. Judge the failure information accurately. • State • Running condition, driving
Comprehend the situation concretely based on condition, weather conditions
5W1H principle. • Result • Feeling of fault
Example: Low temperature, startup stage,
permanent generation, vicinity of engine, metallic
sound, etc.
Engine Control System Diagnostic Chart
When receiving the vehicle from the customer in the
service factory, you must verify both the symptom and
failure data using the Engine Control System
Diagnostic Chart.
LNW21ASH001301
Legend
1. Symptom
2. Failure generation frequency and conditions
The reason why this sheet is needed is as follows.

1. The symptom may not be reproduced in the
service factory.
2. The customer complaint is always not represent
failure.
3. If failure conditions are not input to the responsible
technician correctly, unwanted repair man-hours
will be generated.
• The Engine Control System Diagnostic Chart helps
diagnostic, repair, and repair verification.
Engine Control System Diagnostic Chart Inspector:
Vehicle model and model

Customer year
Vehicle ID
Driver
Engine model
Vehicle acceptance
date Engine ID
Engine type
Registration No.
Odometer reading km
No engine start No cranking No initial combustion Incomplete initial combustion
Long cranking (6 seconds or more)

Poor startability
Others
Incorrect idle speed (idle speed enters into

typical range after warm-up) Unusual idle speed High ( rpm) Low ( rpm)
Instable idling
Rough idling (idle speed deviates from Others
the typical range after warm-up)
Symptom
Surging Knocking Extensive black/white smoke Engine vibration

Poor driveability
Unusual sound Others
Immediately after engine startup At release of accelerator pedal

Engine stall
At operation of A/C Immediately after engine oil replacement
At gear shifting Others
Vibration at idling Engine has transverse vibration and body has vertical vibration (engine’s vertical vibration is weaker than body’s
vibration)
Data observed at fault occurrence
Always Occasionally (cycles: times/month) Once

Fault generation frequency
Others
Weather Clear Cloudy Rainy Snowy Combined/

others
Temperature 30 C or above 20-30 C 10-15 C 0 C or below ( C)

Fault conditions
Highway Suburban area Urban area Uphill slope Downhill slope

Place
Rough road Others
Engine temperature Cold Warm-up After warm-up Coolant temperature C Oil temperature C
Startup Immediately after startup ( minutes) Idling Racing

Driving conditions Driving Steady-speed driving Acceleration Deceleration
A/C SW ON/OFF Others
Check Engine lamp ON Occasionally ON OFF
Past
DTC
Present
Date (year/month/day)
Fault history
Date (year/month/day)
LNW21AXF000701-X
On-Board Diagnostic (OBD) System Check
SBF SBF
100A 3W/L 50A
Battery
3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Relay
Main
DLC Relay CHECK
ENGINE
Lamp
0.5GR/W
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5Y/B
0.5L/Y
0.5L/Y
0.5SB
Glow
Relay
112 88 118 117 116 115 114 113 109 99 ECM
(Engine
Control
Module)
121 120 119 95 87
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF006001-X
Circuit Description
The on-board diagnostic (OBD) system check is a rubbed-through wire insulation or wire broken
starting point for any driveability complaint diagnosis. inside the insulator.
Before using this procedure, perform a visual/physical
check of the ECM (engine control module), VIM Test Description
(vehicle interface module), and engine grounds for Number(s) below refer to the step number(s) on the
cleanliness and tightness. Diagnostic Chart.
The OBD system check is an organized approach to 3: The CHECK ENGINE lamp (MIL) should be "ON"
identifying a problem created by an electronic engine steady with the starter switch "ON"/engine "OFF". If
control system malfunction. not, "Inactive CHECK ENGINE Lamp (MIL) Check"
should be used to isolate the malfunction.
Diagnostic Aids 4: Check the data communication circuit and ensures
An intermittent may be caused by a poor connection, a that both ECM and VIM are able to transmit serial data.
rubbed-through wire insulation, or a wire broken inside 5: When pins are jumpered and the voltage reads 0 V,
the insulator. Check for the following conditions and, if the cause is open wiring. When pins are not jumpered
a fault is found, perform repair or replacement. and the voltage reads 24 V, the cause is short.
• Poor connection at ECM: Inspect harness 10: This test ensures that the ECM is capable of
connectors for backed-out pins, improper mating, controlling the MIL and the MIL driver circuit is not
broken locks, improperly formed or damaged pins, shorted to ground. If a problem presents, the vehicle
and poor pin-to-wire connection. should be repaired using "Unblinking MIL Check".
• Damaged harness: Inspect the wiring harness for
13: A Tech 2 parameter that is not within the typical
range may help to isolate the area that is causing the
problem.
Step Action Value(s) Yes No

Check the main relay.
1. Remove the main relay.
1 2. Check the main relay for open wiring or —
short-circuit.
Is the main relay in normal condition? Go to Step 3 Go to Step 2

Replace the main relay
2 —
Is the action complete? Go to Step 3 —
Observe the CHECK ENGINE lamp for
operation.
1. Starter switch "ON", engine "OFF". Refer to "Inactive
3 2. Observe the CHECK ENGINE lamp. — CHECK ENGINE
Lamp (MIL)
Is the CHECK ENGINE lamp "ON" for 5 Check" and go to
seconds after starter switch "ON"? Go to Step 4 Step 4
Check the data communications are normally
established.
1. Starter switch "OFF".
4 2. Install Tech 2. —
3. Starter switch "ON".
4. Using Tech 2, display engine data.
Does Tech 2 display engine data? Go to Step 10 Go to Step 5

Check the data communication circuit for ECM pins
open wiring or short. 88-87
1. Starter switch "OFF", and disconnect the (jumpered:
ECM and VIM. pins 4-7): 0Ω
(not jumpered):
2. Jumper the data link connector (DLC)
∞Ω
5 pins, and measure resistances at ECM
VIM pins
and VIM connectors.
24-73
Was a problem found? (jumpered:
pins 4-7): 0Ω
(not jumpered):
∞Ω Go to Step 6 Go to Step 7
Repair or replace the faulty harness.
6 — Verify repair and
Is the action complete? go to Step 8 —
Check the operation of Tech 2 with another
7 vehicle. —
Is the Tech 2 in normal condition? Go to Step 9 Go to Step 8
Repair or replace Tech 2.
8 —

1. Replace the ECM.
IMPORTANT:
If necessary (for the vehicle equipped with
9 —
idle stop function), input the number of
startups to the replacing ECM.

Observe the CHECK ENGINE lamp for
operation.
1. Short DLC (Data Link Connector) pins 4
and 6 and turn on the diagnostic switch. Refer to
10 —
2. Starter switch "ON", and observe the "Unblinking
CHECK ENGINE lamp. CHECK ENGINE
Lamp Check" and
Does the CHECK ENGINE lamp blink? Go to Step 11 go to Step 11
Using Tech 2, check DTC. Go to the
11 — appropriate DTC
Is DTC detected? Chart. Go to Step 12
Start the engine. Refer to
“Symptom
12 Does the engine start and continue running? —
Diagnosis Chart”
Go to Step 13 and go to Step 13
1. Using Tech 2, display engine data.
2. Compare engine data to Tech 2 typical
13 values. —
The OBD system
Do engine data almost agree with typical is in normal Refer to "Test
values? condition Description"
Inactive CHECK ENGINE Lamp Check
SBF SBF
100A 3W/L 50A
Battery
3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Relay
Main
DLC Relay CHECK
ENGINE
Lamp
0.5GR/W
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5Y/B
0.5L/Y
0.5L/Y
0.5SB
Glow
Relay
112 88 118 117 116 115 114 113 109 99 ECM
(Engine
Control
Module)
121 120 119 95 87
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF006001-X
Circuit Description • Damaged harness: Inspect the wiring harness for

After the starter switch is turned on, the CHECK rubbed-through wire insulation or wire broken
ENGINE lamp (MIL) is lit for 5 seconds and then turned inside the insulator.
off. The power is supplied to this lamp from the battery
Test Description
via the starter switch.
The ECM recognizes the ON signal from the starter Number(s) below refer to the step number(s) on the
switch and turns on the CHECK ENGINE lamp. Diagnostic Chart.
2: When other lamps in the meter are turned on, the
Diagnostic Aids power circuit from the battery to the CHECK ENGINE
An intermittent may be caused by a poor connection, a lamp is sound.
rubbed-through wire insulation, or a wire broken inside
the insulator. Check for the following conditions and, if
a fault is found, perform repair or replacement.
• Poor connection at ECM: Inspect harness
connectors for backed-out pins, improper mating,
broken locks, improperly formed or damaged pins,
and poor pin-to-wire connection.

Perform the "On-Board Diagnostic (OBD)
System Check". Refer to OBD
1 — System Check
Was the OBD System Check performed? Go to Step 2 and go to Step 2
Check other lamps in the meter (such as
parking brake lamp and charge lamp) are
turned on. Refer to "ECM
1. Starter switch "ON". Power Supply and
2 —
2. Check the lamp power-on status in the Grounding
meter. System Circuit
Check" and go to
Are other lamps "ON"? Step 19 Go to Step 3
Check the SBF (key switch: 50 A) and fuse
3 (meter back: 15 A). —
Are SBF and fuse in normal condition? Go to Step 5 Go to Step 4
Replace the SBF or fuse.
Check the power is supplied to the SBF (key
switch: 50 A).
1. Remove the SBF.
5 2. Starter switch "ON". 16 ~ 32V
3. Measure the voltage at the SBF
connector.
Was the voltage within range? Go to Step 10 Go to Step 6

Check the battery voltage for correctness.
6 16 ~ 32V
Is the battery voltage is normal condition? Go to Step 8 Go to Step 7
Charge or replace the battery.
Check battery cables for poor connection or
8 open wiring. —
Are battery cables in normal condition? Go to Step 23 Go to Step 9
Repair or replace battery cables.
Check the power is supplied to the fuse
(meter back: 15 A).
1. Remove the fuse.
10 2. Starter switch "ON". 16 ~ 32V
3. Measure the voltage at the fuse
connector.

Repair or replace the harness between fuse
(meter back: 15 A) and CHECK ENGINE
11 lamp. —
Verify repair and

Check the CHECK ENGINE lamp bulb.
1. Remove the CHECK ENGINE lamp bulb.
12 —
2. Check the bulb is broken.
Is the bulb in normal condition? Go to Step 14 Go to Step 13
Replace the bulb.
Check the power is supplied to the starter
switch.
1. Disconnect the starter switch connector.
Pin 2-ground:
14 2. Measure the voltage between starter
16-32 V
switch connector pin (vehicle side) and
ground (e.g., frame or body).
Repair or replace the harness between SBF
15 (key switch: 50 A) and starter switch. — Verify repair and
Check the starter switch.
1. Remove the starter switch.
2. Starter switch "ON". Pins 2-3:
16
3. Check the continuity between starter Continued
switch pins.
Is the starter switch in normal condition? Go to Step 18 Go to Step 17

Replace the starter switch.
Repair or replace the harness between starter
18 switch and fuse (meter back: 15 A). — Verify repair and
Check the circuit between ECM and CHECK
ENGINE lamp for open wiring.
1. Disconnect the meter connector A. Pins A5-99:
2. Disconnect the ECM. Continued
19
(Meter) -
3. Check the continuity between meter and
(ECM).
ECM connectors pins.
Is the circuit in normal condition? Go to Step 21 Go to Step 20
Repair or replace the harness between ECM
20 and CHECK ENGINE lamp. — Verify repair and
Re-observe the CHECK ENGINE lamp for
operation.
1. Certainly install necessary components
21 such as connectors, fuses, and relays. —
2. Starter switch "ON”, and observe the
CHECK ENGINE lamp.
Refer to
Is the CHECK ENGINE lamp "ON"? "Diagnostic Aids" Go to Step 22

1. Replace the ECM.
Important:
22 —
startups to replacing the ECM.
Verify repair and
operation.
1. Certainly install necessary components
23 such as connectors, fuses, and relays. —
2. Starter switch "ON", and observe the
CHECK ENGINE lamp.
Repair is
Is the CHECK ENGINE lamp "ON"? complete Go to Step 1
Unblinking CHECK ENGINE Lamp Check
SBF SBF
100A 3W/L 50A
Battery
3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Relay
Main
DLC Relay CHECK
ENGINE
Lamp
0.5GR/W
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5Y/B
0.5L/Y
0.5L/Y
0.5SB
Glow
Relay
112 88 118 117 116 115 114 113 109 99 ECM
(Engine
Control
Module)
121 120 119 95 87
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF006001-X
Circuit Description • Damaged harness: Inspect the wiring harness for

After DLC pins are shorted (i.e., the diagnostic switch is rubbed-through wire insulation or wire broken
turned on), the CHECK ENGINE lamp starts blinking to inside the insulator.
indicate the engine and related systems are in faulty or
Test Description
normal condition.
The ECM recognizes the ON signal from the diagnostic Number(s) below refer to the step number(s) on the
switch and blinks the CHECK ENGINE lamp. Diagnostic Chart.
2: When even disconnecting the ECM does not turn off
Diagnostic Aids the CHECK ENGINE lamp, the ground circuit of the
An intermittent may be caused by a poor connection, a lamp is shorted.
rubbed-through wire insulation, or a wire broken inside

1 — System Check
Check the circuit between ECM and CHECK
ENGINE lamp for short to ground.
2 2. Disconnect the ECM. —
CHECK ENGINE lamp.
Is the CHECK ENGINE lamp "OFF"? Go to Step 4 Go to Step 3

3 and CHECK ENGINE lamp. — Verify repair and
Check the diagnostic switch circuit for open
wiring.
1. Disconnect the ECM.
2. Short DLC pins 4 and 6. ECM pin 112-
4 ground:
3. Check the continuity between ECM
Continued
connector pin and ground (e.g., frame or
body).

Check the DLC ground circuit for open wiring.
1. Check the continuity between DLC pin DLC 4/5 pin-
5 and ground (e.g., frame or body). ground:
Continued
Repair or replace the DLC ground circuit
6 harness. — Verify repair and
7 and DLC pin 6. — Verify repair and
operation.
1. Certainly connect connectors.
8 2. Short DLC pins 4 and 6. —
CHECK ENGINE lamp.
Refer to
Does the CHECK ENGINE lamp blink? "Diagnostic Aids" Go to Step 9
1. Replace the ECM.
Important:
9 —
Verify repair and

operation.
1. Certainly connect connectors.
10 2. Short DLC pins 4 and 6. —
CHECK ENGINE lamp.
The repair is
Does the CHECK ENGINE lamp blink? complete Go to Step 1
ECM Power Supply and Grounding System Circuit Check
SBF SBF
100A 3W/L 50A
Battery 3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Main Relay
Relay
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5L/Y
0.5L/Y
Glow
Relay
118 117 116 115 114 113 109
ECM
(Engine
Control
121 120 119 95 87 Module)
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF005001-X
Circuit Description
The power is supplied to the ECM from the battery via
the main relay. After the ECM recognizes the ON signal
from the starter switch and turns on the main relay, the
power is supplied to the ECM.
Diagnostic Aids • Damaged harness: Inspect the wiring harness for
An intermittent may be caused by a poor connection, a rubbed-through wire insulation or wire broken
rubbed-through wire insulation, or a wire broken inside inside the insulator.

1 — System Check
Check the SBF (ECU: 50 A, engine controller:
2 50 A) and fuse (engine controller: 10 A). —
Are the SBF and fuse in normal condition? Go to Step 4 Go to Step 3
Replace the SBF or fuse.
Check the ON signal is input to the ECM from
the starter switch.
2. Starter switch "ON". Pin 109-
4 ground:
3. Measure the voltage between ECM
16 ~ 24V
body)

Repair or replace the harness between starter
5 switch and ECM pin 109. — Verify repair and
Check the power supply voltage is applied to
the main relay.
6 16 ~ 32 V
3. Measure the voltage between main relay
connector (pin 1) and ground (e.g., frame
or body).

Check the power supply voltage is applied to
the SBF (engine controller: 30 A).
1. Remove the SBF.
7 2. Starter switch "ON". 16 ~ 32 V
3. Measure the voltage at the SBF
connector.
Verify repair and
Was the voltage within range? go to Step 9 Go to Step 8
8 (engine controller: 30 A) and main relay. — Verify repair and

9 (ECM: 50A) and SBF (engine controller: 30A). — Verify repair and
Check the main relay coil circuit for open
wiring. Pins 4-
117/118:
Continued
2. Disconnect the ECM. (Main relay) -
10
3. Check the continuity between main relay (ECM)
and ECM pin as well as main relay and Pin 3-ground:
ground (e.g., frame or body). Continued
(Main relay)
Check the circuit between main relay and
ECM for open wiring.
Pins 2-
114/115/116:
12 2. Disconnect the ECM. Continued
3. Check the continuity between main relay (Main relay) -
and ECM pin. (ECM)

Check the ECM power ground circuit for open
wiring.
1. Disconnect the ECM. Pin 119/120/
14 121-ground:
2. Check the continuity between ECM pin
Continued
and ground (e.g., frame or body).
Is the circuit in normal condition? Check is complete Go to Step 15

15 —
Is the action complete? Verify repair —
Diagnosis with Tech 2 Scan Tool
Tech 2 Scan Tool
Tech 2 is an effective tool for diagnosis of electrical
failures on the engine control system. This scan tool is
a small and lightweight handheld tester and, once
connected to the DLC on a vehicle, communicates with
the on-board ECM to perform various diagnostics and
tests.
4
3
LNW21ALF000201
Legend
1. PCMCIA card 3. DLC cable
2. Tech 2 4. SAE 16/19-pin adapter
Features of Tech 2 • Insert the PCMCIA card (1) into Tech 2. Then,
• Tech 2 (2) is operated at 12 V. Therefore, 24-V connect the DLC cable (3) and SAE 16/19-pin
power supply must not be used for this tool. If the adapter (4) to the VCI (vehicle communication
vehicle electrical system rating is 24 V, the adapter interface) of Tech 2 and connect Tech 2 to the DLC
must be connected to a 12 V battery. Tech 2 must on the vehicle.
not be powered by the cigarette lighter. • Insert or remove the PCMCIA card with the power
supply turned off.
• Tech 2 supports two snapshot capacities. Connect Tech 2 and 12 V battery with an adapter
• The PCMCIA card is susceptible to magnetism cable.
and static electricity and, therefore, complete care
should be taken in handling.
• Tech 2 can plot snapshot graphs.
• Hitting the Exit key allows you to return to the main
menu at any time.
• To clear DTC(s), you should open the application
menu and select "F1: Clear DTC Info" or "Clear
DTC".
Connection
1. Insert the ISUZU System PCMCIA card into Tech
2.
2. Install the SAE 16/19-pin adapter to the DLC
cable.
3. Connect the DLC cable to Tech 2.
4. Check the starter switch is turned off. LNW21ASH001401
5. Connect the Tech 2 SAE 16/19-pin adapter to the
DLC (data link connector = black) on the vehicle.
• If the voltage is not applied to Tech 2, check the
3 A fuse.
6. Turn on the starter switch and press the PWR key
on Tech 2.
7. Check the following screen appears on the Tech 2
display.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Press (ENTER) To Continue

LNW21ASH001801
RUW16ESH001501-X
CAUTION:
Before inserting or removing the PCMCIA card,
always check the power is not applied to Tech 2.
Operating Procedure
Vehicle Identification
Select one of the following
(N*) ELF, NPR, NQR, VFR
Press (ENTER) To Continue

(ELF, NPR, NQR, VFR ENTER)
(ENTER)
System Selection Menu
Main Menu (N*) ELF, NPR, NQR, VFR

F0 : Engine
F0 : Diagnostics F1 : Transmission
F1 : Service Programming System
(SPS) F2 : Chasis
F2 : View Capture Data F3 : Boody
F3 : Tool Options
(F0 ENTER)
F4 : Down load/Up load Help
(F0 ENTER) Vehicle Identification
Select one of the following
Eingine
Vehicle Identification
Select one of the following Denso 4H*
Model Year(s) 4JHI-TC Bosch
4HL1/4HJ1(COMMON RAIL)
(3) 2003 4HL1/4HJ1(Vehicle Interface Module)
(2) 2002 4HE1-TC (Diesel)
(1) 2001
(Y) 2000
(X) 1999 (4HL1/4HJ1(COMMON RAIL) or
(W) 1998 4HL1/4HJ1(Vehicle Interface
(2) 2002 Module) ENTER)
LNW21ALH000101-X
(2002 ENTER)
Menu List
RUW16ELH000101-X • The list below shows what function is currently
used by the Tech 2 software.
F0: Diagnostic Trouble Codes

F0: Read DTC Info As Stored By ECU
F1: Clear DTC Information
F1: Data Display
F0: Data Display
F1: Snapshot
F2: Programming
F0: Write Starting Counter
F1: Write Starting Replace Counter
F2: Snaphot Data Display

• Typical values are described in the Tech 2 data
F3: Actuator Test
list.
F0: Common Rail Pressure Control Test
F1: Injector Balance Test
Data Display
F2: Intake Throttle Test
System Voltage V
F3: EGR Control Test Vehicle Speed km/h
F4: Glow Time Relay Test Desired Idle Speed RPM
Engine Speed RPM
Menu Breakdown Accelerator Sensor V
Diagnostic Trouble Codes Final Accelerator Opening %

ECT Sensor (Engine Coolant Temparature) V
• When you find a DTC, go to the DTC Chart.
Coolant Temperature C
System Voltage
Diagnostic Trouble Codes Sel ect Quick

DTC Snapshot More
Items
F0 : Read DTC Info As Stored By ECU

LNW21ASH010601-X
F1 : Clear DTC Information

This menu displays the current data. The contents
synchronize with the vehicle status. For example, the
engine coolant temperature sensor is monitored and
displayed on the screen and, if the engine is idling, the
temperature on the screen will be changed accordingly.
• When you cannot select this data display menu:
A fault presents on the cable between ECM and
DLC.
• When an unusual value appears fixedly:
LNW21ASH001501-X Example - If the engine coolant temperature
displayed is fixed to –40°C or +140°C, the possible
The DTC is a language allowing you to communicate cause is faulty ECT sensor, open wiring, or short.
with the on-board ECM. The DTC is coarsely divided When moving connectors or wiring harnesses with
into two categories, past DTC and current DTC. hands changes the display, poor pin connection,
improper pin layout, broken harness wires, or short
• Current DTC: A fault (failure) is displayed that is is a cause and, therefore, repair is needed.
found in the current ignition cycle.
• When "✻" appears instead of value:
• Past DTC: A fault (failure) is displayed that was The Tech 2 software is faulty.
found in the last or past ignition cycle. If even one asterisk is observed instead of data on
• Multiple DTC is generated when several troubles the display, the PCMCIA card needs version up.
(failures) occur. When multiple sensors or switches
share a ground, or an open wiring or short occurs Snapshot
on the shared power supply or ground, DTCs with • The snapshot mode records menus on the data list
respect to related sensors or switches are and plots graphs.
displayed. If several DTCs are displayed, it is
• Using this mode, you can reproduce and record
necessary to inspect the shared power supply or
customer’s claimed conditions and find faulty
ground for open wiring or short. Using DTC clear
engine data.
mode erases the vehicle DTC information from the
ECM. • You can replay the recorded data with the
commercial power applied to home outlets.
• In the snapshot after determination of trigger type, Replaying recorded data graph
you can record the data obtained when the DTC is 1. Turn on Tech 2 and select "Snapshot data"
displayed. Reviewing this data can reveal the displayed thereafter.
cause of failure.
2. Check snapshot data titles appear on the screen.
3. Select the desired snapshot data title.
4. The data appears on the screen. To access the
Snapshot Plot
graph, select "Plot" at the bottom.
5. Menu select screen appears. Move to the desired
item and press the Enter key until three items are
selected. Then, select "Approve" at the bottom.
6. The graph is plotted on the screen.
1 2 3 4 5
ECT
Desired Idle Speed
Engine Speed
RUW16ESH001601
Snapshot after data indication

1. Select "Data Display" from the application menu.
2. After the vehicle data appears, select "Snapshot"
at the screen bottom.
3. After the elapse of some time, press the Exit key.
4. The screen changes. After "Continue" appears at
the bottom, select "Continue".
5. After "Plot" appears at the bottom, select "Plot".
6. The menu select screen appears. Move to the
desired item and press the Enter key until three
items are selected. Then, select "Approve" at the
bottom.
7. A graph is plotted on the screen.
Snapshot after determination of trigger type

1. Select "Data Display" from the application menu.
2. After items appears on the screen, select the
desired item.
3. After the snapshot option screen appears,
determine the trigger type and select "Record
Snapshot" at the bottom.
4. When "Standby" blinks at the upper right of the
screen, select "Trigger" at the bottom.
5. Verify the trigger type.
6. The screen changes. After "Continue" appears at
the bottom, select "Continue".
7. After "Plot" appears at the bottom, select "Plot".
8. The menu select screen appears. Move to the
desired item and press the Enter key until three
items are selected. Then, select "Approve" at the
bottom.
9. A graph is plotted on the screen.
Actuator test
F3: Actuator F0: Common This test aims at checking the common rail pressure is correctly controlled by the
Test Rail Pressure ECM and common rail pressure sensor.
Control Test Test procedure:
1. Select "Common Rail Pressure Control Test" from "Actuator Test".
2. Press "Decrease" or "Increase" soft key to check the data list.
3. When the data list changes as shown below, the common rail pressure control
is correctly performed.
Test result
Item Increase Decrease
instruction instruction
Desired Rail Pressure (MPa) Increase Decrease
Actual Rail Pressure (MPa) Increase Decrease
SCV Duty Ratio (%) Decrease Increase
Common Rail Pressure Sensor (V) Increase Decrease
SCV Current (mA) Decrease Increase
Difference Between Desired And Actual Values (MPa) within ±1
When a fault When a fault is found in this test, identify regular error, irregular error, or fixed
is found in indication.
"F0: Common Possible causes:
rail Pressure 1. The desired rail pressure is fixed:
Control Test" Tech 2 communication error occurs or the ECM is faulty.
2. The actual rail pressure does not follow the desired rail pressure:
• Following under regular error = The problem lies in accuracy of common rail
pressure sensor.
• Following under irregular error =The problem lies in collapsed fuel pipe, foreign
material mixing-in, poor fuel system vent, unstable battery voltage, SCV aging,
supply pump aging, or electrical or mechanical noise.
• Fixed indication of actual rail pressure = The problem lies in shorted common rail
pressure sensor system, faulty sensor, shorted SCV system, or faulty SCV.
F3: Actuator F1: Injector This test aims at checking the injector drive signals are correctly sent to injectors
Test Balance Test to operate the devices accordingly.
Test procedure:
1. Select "Injector Balance Test" from "Actuator Test".
2. Press "Next" soft key to select the injector number.
3. Press "Off" soft key to check the data list and vehicle condition.
4. When the vehicle condition changes as shown below, the injector control is
correctly performed.
Test result:
When the injector stops, the fuel injection to the relevant cylinder stops and
change in engine speeds is observed.
When a fault Possible causes:
is found in 1. The injector system is shorted.
"F1: Injector 2. The injector is aged. (Check the cylinder-to-cylinder calibration on the data list
Balance Test" and determine functions of the injector.)
3. The fuel pipe is collapsed. Foreign materials are mixed.
4. The fuel injection is restricted due to operation of flow damper. (After the engine
is left inoperative for about 8 hours, and the injector is retested and the fault does
not occur, the cause lies in operation of flow damper.)
F2: Intake This test aims at checking the working condition of the intake throttle valve and
Throttle Test ITP (intake throttle position) sensor.
Test procedure:
1. Select "Intake Throttle Test" from "Actuator Test".
3. When the data list changes as shown below, the intake throttle control is
correctly performed.
Test result:
Desired Intake Air Throttle Position (°C A) Decrease Increase
Actual Intake Throttle Position (°C A) Decrease Increase
Intake Throttle Duty Ratio (%) Increase Decrease
Intake Throttle Valve (V) Decrease Increase
Difference Between Desired And Actual Values (°C A) within ±1
"F2: Intake Possible causes:
Throttle Test" 1. The desired intake air throttle position is fixed (no change):
Tech 2 communication error occurs or the ECM is faulty.
2. The actual intake throttle position does not follow the desired intake throttle
position:
• Following under regular error = The problem lies in accuracy of ITP sensor.
• Following under irregular error = The problem lies in deformed intake throttle
valve, stain, foreign material mixing-in, unstable or aged motor power supply,
unstable battery voltage, aged motor functions, or electrical or mechanical noise.
• Fixed indication of actual intake throttle position = The problem lies in shorted
ITP sensor system, faulty sensor, stuck intake throttle valve, or faulty motor.
F3: Actuator F3: EGR This test aims at checking the working condition of the EGR valve and EGR valve
Test Control Test position sensor.
Test procedure:
1. Select "EGR Control Test" from "Actuator Test".
3. When the data list changes as shown below, the EGR control is correctly
executed.
Test result:
EGR Target Lift Position (mm) Increase Decrease
EGR Current Position (mm) Increase Decrease
EGR Duty Cycle (%) Increase Decrease
EGR Position Sensor (V) Increase Decrease
Difference Between Desired And Actual Values (mm) within ±1
"F3: EGR Possible causes:
Control Test" 1. The EGR Target Lift valve position is fixed (no change):
Tech 2 communication error occurs or the ECM is faulty.
2. The EGR Current valve position does not follow the EGR Target Lift valve
position:
• Following under regular error = The problem lies in accuracy of EGR valve
position sensor.
• Following under irregular error = The problem lies in deformed EGR valve,
contamination, foreign material mixing-in, unstable or aged motor power supply,
unstable battery voltage, aged motor functions, or electrical or mechanical noise.
• Fixed indication of actual intake throttle position = The problem lies in shorted
EGR valve position system, faulty sensor, stuck EGR valve, or faulty motor.
F4: Glow This test aims at checking the working condition of the glow relay and the integrity
Time Relay of the glow lamp bulb.
Test Test procedure:
1. Select "Glow Time Relay Test" from "Actuator Test".
2. Press "Run" or "Stop" soft key to check working sounds of the glow relay and
the operation of the glow lamp.
3. When the glow relay and glow lamp work as shown below, the warm-up control
is correctly performed.
Test result:
• Pressing "Run" soft key:
The glow relay generates sounds and the glow lamp is lit.
• Pressing "Stop" soft key:
The glow relay generates sounds and the glow lamp is turned off.
When a fault Possible causes:
is found in 1. No sound is generated: The glow relay system suffers from open wiring or
"F4: Glow short, or the relay is faulty.
Time Relay 2. The glow lamp is not turned on after "Run" soft key is hit: The glow lamp system
Test" suffers from open wiring or the lamp bulb filament is broken.
3. The glow lamp is not turned off after "Stop" soft key is hit: The glow lamp
system circuit is shorted to ground .
Tech 2 typical data values temporary or permanent deviation, so that you can
The data list is used to check the condition of the diagnose the vehicle (engine) and think out appropriate
vehicle (engine). The reference values (typical values) repair plan. (The menu in your Tech 2 may differ from
are compared to the data acquired from the actual that shown above due to software version. Also, the
vehicle to determine the current situation, for example, menu may be changed without prior notice.)
Tech 2 Engine Date
ECM Date
• Engine status: starter switch ON (room temperature: 20°C, all peripheral devices (air conditioner, freezer,
etc.): OFF)
Values at starter
Tech 2 Data Display Units displayed Fail-safe values
switch ON
System Voltage V 24 (DTC84 is detected) 16 ~ 38
Vehicle Speed km/h 0 (DTC84 is detected) 0
Manual transmission:
657, Automatic
transmission: 732
Desired Idle Speed RPM — (Values will change
depending on
temperatures around
the engine)
Engine Speed RPM 0 (DTC84 is detected) 0
Accelerator Sensor V — 0.3 ~ 0.6
Final Accelerator Opening % 0 (DTC84 is detected) 0
2.3 ~ 2.5
(The value will change
ECT Sensor (Engine Coolant
V — depending on
Temperature)
temperatures around
the engine)
Normal running phase: 20 ~ 23
55 (The value will change
Coolant Temperature °C Startup phase: –20 depending on
(DTC23 is detected) temperatures around
80 (DTC84 is detected) the engine)
2.6 ~ 2.9
IAT Sensor (Intake Air Temperature) V — depending on
temperatures around
the engine)
20 ~ 23
Normal running phase:
25
Intake Air Temperature °C depending on
Startup phase: –20
temperatures around
(DTC22 is detected)
the engine)
2.3 ~ 2.5
Fuel Temperature Sensor V — depending on
temperatures around
the engine)
Fuel Temperature °C Startup phase: –20 depending on
Barometric Pressure Sensor V — Approx. 3.6
Values at starter
switch ON
Approx. 100
100 (DTC61 or DTC84 is (The value will change
Barometric Pressure kPa
detected) depending on the
barometric pressure)
60 or less (DTC115,
DTC118, DTC227,
Desired Rail Pressure MPa —
DTC245, or DTC247 is
detected)
Actual Rail Pressure MPa — 0
Common Rail Pressure Sensor V — Approx. 0 ~ 0.9
SCV Duty Ratio % — —
SCV Current mA — —
EGR Duty Cycle % — 0
EGR Position Sensor V — Approx. 0.8
EGR Target Lift Position mm — 0
EGR Current Position mm — 0
Intake Throttle Valve V — Approx. 4.1
Actual Intake Throttle position °CA — Approx. 92.0 ~ 93.0
Desired Intake Air Throttle Position °CA — Approx. 83.0 ~ 84.5
Intake Throttle Duty Ratio % — 0
50 or less (DTC115,
DTC118, DTC227,
Desired Injection Quantity mm3 /st —
detected)
Desired Fuel Injection Timing °CA — 0
0 (DTC158 or DTC271 is
Cylinder 1 Compensation mm3/st 0
detected)
detected)
detected)
detected)
Main Injection Quantity mm3/st — —
3
Pilot Injection Quantity mm /st — —
Pilot Interval µsec — —
Main Injection Period µsec — 0
Pilot Injection Period µsec — 0
Idle Position Switch ON/OFF OFF(DTC84 is detected) ON
Idle Up Volume V 0 (DTC84 is detected) Approx. 0.4
PTO Accelerator Sensor V 0 (DTC84 is detected) 0.3 ~ 0.6
PTO Accelerator Opening % 0
detected)
Values at starter
switch ON
ASR Accelerator Opening % 100 (DTC84 is detected) 100
Starter Switch ON/OFF ON (DTC84 is detected) OFF
Ignition Switch ON/OFF ON (DTC84 is detected) ON
Clutch Switch ON/OFF OFF(DTC84 is detected) OFF
Neutral Switch ON/OFF ON (DTC84 is detected) ON
Stop Lamp Switch ON/OFF OFF(DTC84 is detected) OFF
Exhaust Brake Switch ON/OFF OFF(DTC84 is detected) OFF
Exhaust Brake Valve ON/OFF OFF(DTC84 is detected) OFF
Diagnostic Switch ON/OFF OFF(DTC84 is detected) OFF
Diagnostic Switch (VIM) ON/OFF OFF(DTC84 is detected) OFF
PTO Switch ON/OFF OFF(DTC84 is detected) OFF
A/C Switch (Air Conditioning) ON/OFF OFF(DTC84 is detected) OFF
Exhaust Brake (AT) Cutoff Switch ON/OFF OFF(DTC84 is detected) OFF
Exhaust Brake (ASR) Cutoff Switch ON/OFF OFF(DTC84 is detected) OFF
Glow Time Relay ON/OFF OFF(DTC84 is detected) OFF
Starter Relay ON/OFF OFF(DTC84 is detected) OFF
Glow Time Lamp ON/OFF OFF(DTC84 is detected) OFF
QWS Switch ON/OFF OFF(DTC84 is detected) OFF
ECO Relay ON/OFF OFF(DTC84 is detected) OFF
Freezer Switch ON/OFF OFF(DTC84 is detected) OFF
The value is
Transmission Coding MT/AT MT (DTC84 is detected) determined by the
transmission type.
• Engine status: idling (engine coolant temperature: 80°C, all peripheral devices (air conditioner, freezer,
etc.): OFF)
Tech 2 Data Display Units displayed Fail-safe values Values at idling
MT: 575
Desired Idle Speed RPM —
AT: 640
MT: 550 ~ 600
Engine Speed RPM 0 (DTC84 is detected)
AT: 615 ~ 665
Accelerator Sensor V — 0.3 ~ 0.6
Final Accelerator Opening % 0 (DTC84 is detected) 0
Approx. 0.6
V — depending on
Temperature)
temperatures around
the engine)

2.3 ~ 2.4
temperatures around
the engine)
29 ~ 30
25
temperatures around
(DTC22 is detected)
the engine)
1.2 ~ 1.3
temperatures around
the engine)
Approx. 3.6
Barometric Pressure Sensor V —
depending on the
100
60 or less (DTC115,
DTC118, DTC227,
Desired Rail Pressure MPa Approx. 31.4
detected)
Actual Rail Pressure MPa — Approx. 31.0 ~ 32.0
Common Rail Pressure Sensor V — Approx. 1.5
SCV Duty Ratio % — Approx. 50
SCV Current mA — Approx. 1015 ~ 1038
EGR Duty Cycle % — Approx. 13 ~ 17
EGR Target Lift Position mm — Approx. 9.5
EGR Current Position mm — Approx. 9.5
Actual Intake Throttle position °CA — Approx. 6.8
Desired Intake Air Throttle Position °CA — Approx. 6

Intake Throttle Duty Ratio % — Approx. 10 ~ 11
50 or less (DTC115,
DTC118, DTC227,
Desired Injection Quantity mm3/st Approx. 11.4 ~ 12.7
detected)
Desired Fuel Injection Timing °CA — 0
0 (DTC158 or DTC271 is –1.0 ~ 1.0
Cylinder 1 Compensation mm3/st
detected) (Limit: ±5)
0 (DTC159 or DTC272 is –1.0 ~ 1.0
0 (DTC159 or DTC273 is –1.0 ~ 1.0
0 (DTC158 or DTC274 is –1.0 ~ 1.0
Main Injection Quantity mm3/st — Approx. 8.4 ~ 9.7
Pilot Injection Quantity mm3/st — Approx. 3
Pilot Interval µsec — Approx. 3763 ~ 3776
Main Injection Period µsec — Approx. 896 ~ 950
Pilot Injection Period µsec — Approx. 638 ~ 642
Accelerator Switch ON/OFF OFF(DTC84 is detected) ON
detected)

The value is
transmission type.
• Engine status: running at around 1500 rpm (engine coolant temperature: 80°C, all peripheral devices
(air conditioner, freezer, etc.): OFF)
Values at around
1500 rpm
MT: 575
Desired Idle Speed RPM —
AT: 640
Engine Speed RPM 0 (DTC84 is detected) Approx. 1500
Accelerator Sensor V — 1.3
Final Accelerator Opening % 0 (DTC84 is detected) 19 ~ 21
Approx. 0.6
V — depending on
Temperature)
temperatures around
the engine)
80 (DTC84 is detected) the engine)j
2.3 ~ 2.4
temperatures around
the engine)
29 ~ 30
25
temperatures around
(DTC22 is detected)
the engine)
1.2 ~ 1.3
temperatures around
the engine)
Values at around
1500 rpm
Approx. 3.6
Barometric Pressure Sensor V —
depending on the
Approx. 100
60 or less ( DTC115,
DTC118, DTC227,
Desired Rail Pressure MPa Approx. 47.6 ~ 48.0
detected)
Actual Rail Pressure MPa — Approx. 47.6 ~ 48.0
Common Rail Pressure Sensor V — Approx. 1.7
SCV Duty Ratio % — Approx. 48
SCV Current mA — Approx. 979 ~ 1004
EGR Duty Cycle % — Approx. 13 ~ 17
EGR Target Lift Position mm — Approx. 9.5
EGR Current Position mm — Approx. 9.5
Actual Intake Throttle position °CA — Approx. 30.2
Desired Intake Air Throttle Position °CA — Approx. 30
Intake Throttle Duty Ratio % — Approx. 9 ~ 10
50 or less (DTC115,
DTC118, DTC227,
Desired Injection Quantity mm3/st Approx. 11.3 ~ 11.4
detected)
Desired Fuel Injection Timing °CA — Approx. 6.3 ~ 6.4
detected)
detected)
detected)
detected)
Main Injection Quantity mm3/st — Approx.11.3 ~ 11.4
Pilot Injection Quantity mm3/st — —
Pilot Interval µsec — —
Main Injection Period µsec — Approx. 800 ~ 810
Pilot Injection Period µsec — 0
Accelerator Switch ON/OFF OFF(DTC84 is detected) OFF
Values at around
1500 rpm
detected)
The value is
transmission type.
• Typical VIM data value (all peripheral devices (air conditioner, freezer, etc.): OFF)
Tech 2 Data Display Units displayed Fail-safe values Typical data values
3.6
Barometric Pressure Sensor V 0 (DTC84 is detected)
depending on the
100
Barometric Pressure kPa 100 (DTC84 is detected)
depending on the
Tech 2 Data Display Units displayed Fail-safe values Typical data values
detected)
Ignition Switch ON/OFF OFF(DTC84 is detected) ON
Idle Manual Switch ON/OFF OFF(DTC84 is detected) OFF
Neutral Switch ON/OFF OFF(DTC84 is detected) ON
Retarder Switch ON/OFF OFF(DTC84 is detected) OFF
Diagnostic Switch 1 ON/OFF OFF(DTC84 is detected) OFF
Diagnostic Switch 2 ON/OFF OFF(DTC84 is detected) OFF
PTO Idle Position Switch ON/OFF OFF(DTC84 is detected) OFF
Engine Stop Switch ON/OFF OFF(DTC84 is detected) OFF
Engine Start Counts Counts — Counts
Engine Start Counts (After Starter
Counts — Counts
Replace)
Installed/ Installed/
ASR Installation —
Not installed Not installed
ASR-PWM Output ON/OFF OFF(DTC84 is detected) OFF
Exhaust Brake (ASR) Cut Request ON/OFF OFF(DTC84 is detected) OFF
AT Accelerator Opening % 100 (DTC84 is detected) 100
AT-PWM Output ON/OFF OFF(DTC84 is detected) OFF
Tech 2 Engine Data Description
ECM Data
Tech 2 Data Units

Item Description How to use parameters
Display displayed
1/63 System Voltage V This parameter refers to the When the display substantially
power supply voltage applied to deviates from the actual battery
the ECM from the battery. voltage, a voltage drop may
occur due to accessories
installed to the circuit. If the value
deviates from the specified level,
the circuit, connector, connector
mating, or ECM may be faulty.
2/63 Vehicle Speed km/h This parameter refers to the When the display differs from the
value calculated by the ECM speedometer reading or is
using the signals from the VS unchanged, major cause may lie
sensor. in VS sensor, circuit, or ECM.
3/63 Desired Idle RPM This parameter refers to the When the required idle speed is
Speed value calculated by the ECM unstable, the cause may lie in
using ECT and vehicle condition improperly installed ECM or
(with respect to automatic sensors (such as improper
transmission, air conditioner, connector mating or deformed
QWS, freezer, idle up volume, connector pins), or ECM or
PTO, and neutral switch). sensor signal faults. When the
idle speed becomes unstable
after vibrations are applied to the
wiring harness, the cause may be
faulty harness or imperfect
connection of ground circuit.
4/63 Engine Speed RPM This parameter refers to the This parameter should be used
value calculated by the ECM by comparing to the desired idle
using the signals from CKP speed. Using the display needs
(crank position) and CMP (cam those conditions: the engine is
position) sensors. completely warmed up, all the
accessory systems, including air
conditioner, are turned off, and
the idle speed is stabilized. The
actual idle speed is stabilized
near the desired level. After the
load such as air conditioner is
added, the engine speed is
changed but finally stabilized.
5/63 Accelerator V This parameter refers to the When AP sensor’s signal voltage
Sensor signal voltage input to the ECM (accelerator pedal position)
from the AP (accelerator pedal deviates from the specified level
position) sensor.(Larger as the accelerator pedal press-
accelerator pedal stroke provides down stroke is changed, the
higher voltage.) sensor, circuit, or ECM may be
faulty.
6/63 Final Accelerator % This parameter refers to the When AP sensor’s signal voltage
Opening value calculated by the ECM (Final Accelerator Opening)
using the signals from the AP deviates from the specified level
sensor. as the accelerator pedal press-
down stroke is changed, the
sensor, circuit, or ECM may be
faulty.
Tech 2 Data Units

Display displayed
7/63 ECT Sensor V This parameter refers to the The engine coolant temperature
(Engine Coolant signal voltage input to the ECM is a proper criterion for various
Temperature) from the ECT (engine coolant control configurations (e.g.,
temperature) sensor. (Higher startup, cold, or post-warmup
engine coolant temperature condition). This parameter may
provides lower voltage.) be used as one of DTC detection
conditions.
8/63 Coolant °C This parameter refers to the When the display deviates from
Temperature value calculated by the ECM the specified level, the sensor,
using the signals from the ECT circuit, or ECM may be faulty.
sensor.
9/63 IAT Sensor V This parameter refers to the The intake air temperature is a
(Intake Air signal voltage input to the ECM proper criterion for various
Temperature) from the IAT (intake air control configurations (e.g.,
temperature) sensor. (Higher startup, cold, or post-warmup
intake air temperature provides condition). This parameter may
lower voltage.) be used as one of DTC detection
conditions.
10/63 Intake Air °C This parameter refers to the When the signal (temperature
Temperature value calculated by the ECM display) from the sensor deviates
using the signals from the IAT from the specified level, the
sensor. sensor, circuit, or ECM may be
faulty.
11/63 Fuel V This parameter refers to the The fuel temperature is a proper
Temperature signal voltage input to the ECM criterion for various control
Sensor from the FT (fuel temperature) configurations (e.g., startup, cold,
sensor. (Higher fuel temperature or post-warmup condition). This
provides lower voltage.) parameter may be used as one of
DTC detection conditions.
12/63 Fuel °C This parameter refers to the When the signal (temperature
Temperature value calculated by the ECM display) from the sensor deviates
using the signals from the FT from the specified level, the
sensor. sensor, circuit, or ECM may be
faulty.
13/63 Barometric V This parameter refers to the The barometric pressure sensor
Pressure Sensor signal voltage input to the VIM is a proper criterion for various
from the barometric pressure control configurations (e.g.,
sensor. (Higher barometric startup, cold, or post-warmup
pressure provides higher condition). This parameter may
voltage.) be used as one of DTC detection
conditions.
14/63 Barometric kPa This parameter refers to the When the display deviates from
Pressure value calculated by the VIM using the specified level, the sensor,
the signals from the barometric circuit, or ECM may be faulty.
pressure sensor.
15/63 Desired Rail MPa This parameter refers to the When the display is improper,
Pressure value calculated by the ECM fuel system components (such as
using engine speed, fuel common rail, pump, and fuel
temperature, engine coolant pipe), common rail pressure
temperature, and desired fuel sensor, circuit, or ECM may be
injection quantity. faulty.
Tech 2 Data Units

Display displayed
16/63 Actual Rail MPa This parameter refers to the This parameter should be used
Pressure value calculated by the ECM by comparing to the desired
using the signals from the common rail pressure. Using the
common rail pressure sensor. display needs those conditions:
the engine is completely warmed
up, all the accessory systems,
including air conditioner, are
turned off, and the idle speed is
stabilized. When the display
substantially deviates from the
desired value, fuel system
components (such as common
rail, pump, and fuel pipe),
common rail pressure sensor,
circuit, or ECM may be faulty.
17/63 Common Rail V This parameter refers to the When the signal from the sensor
Pressure Sensor signal voltage input to the ECM deviates from the specified level,
from the common rail pressure the sensor, circuit, or ECM may
sensor. be faulty.
18/63 SCV Duty Ratio % This parameter refers to the When the display is improper,
value calculated by the ECM fuel system components (such as
using desired fuel injection common rail, pump, and fuel
quantity, desired common rail pipe), common rail pressure
pressure, engine speed. (Larger sensor, circuit, or ECM may be
duty cycle provides small SCV faulty.
position.)
19/63 SCV Current mA This parameter refers to the When the display is improper,
value calculated by the ECM fuel system components (such as
based on the pump discharge common rail, pump, and fuel
determined from engine speed, pipe), common rail pressure
common rail pressure. (Larger sensor, circuit, or ECM may be
current provides smaller SCV faulty.
position.)
20/63 EGR Duty Cycle % This parameter refers to the DC When the display deviates from
motor drive duty calculated from the specified level, EGR valve
desired fuel injection quantity, sensors, circuit, or ECM may be
engine speed, engine coolant faulty.
temperature, barometric
pressure, accelerator position,
and intake throttle position.
21/63 EGR Position V This parameter refers to the When the display deviates from
Sensor voltage signal input to the ECM the specified level as the EGR
from the EGR valve position valve is operated, the sensor,
sensor. (Larger EGR valve circuit, EGR valve, or ECM may
position provides higher voltage.) be faulty.
22/63 EGR Target Lift mm This parameter refers to the When the display deviates from
Position value calculated by the ECM the specified level, EGR valve
using desired fuel injection sensors, circuit, or ECM may be
quantity, engine speed, and faulty.
engine coolant temperature.
Tech 2 Data Units

Display displayed
23/63 EGR Current mm This parameter refers to the When the display deviates from
Position value calculated by the ECM the specified level, the DC motor,
using the signals from the EGR EGR valve, sensor, circuit, or
position sensor. ECM may be faulty.
24/63 Intake Throttle V This parameter refers to the When the display deviates from
Valve voltage signal input to the ECM the specified level as the intake
from the ITP (intake throttle throttle valve is operated, the
position) sensor. (Larger intake sensor, circuit, intake throttle
throttle valve position provides valve, or ECM may be faulty.
higher voltage.)
25/63 Actual Intake °CA This parameter refers to the When the display deviates from
Throttle position value calculated by the ECM the specified level, the DC motor,
using the signals from the ITP intake throttle valve, sensor,
sensor. circuit, or ECM may be faulty.
26/63 Desired Intake °CA This parameter refers to the When the display deviates from
Air Throttle value calculated by the ECM the specified level, the intake
Position using engine speed, desired fuel throttle valve, sensors, circuit, or
injection amount, and engine ECM may be faulty.
coolant temperature, or the value
determined from the parameters
showing vehicle condition such
as exhaust brake and idling stop.
27/63 Intake Throttle % This parameter refers to the When the display deviates from
Duty Ratio value calculated by the ECM the specified level, the intake
using ITP sensor output voltage throttle valve, sensors, circuit, or
and battery voltage. ECM may be faulty.
28/63 Desired Injection mm3/st This parameter refers to the When the display deviates from
Quantity value calculated by the ECM the specified level, the fuel
using accelerator position, injection system, sensors, circuit,
engine speed, engine coolant or ECM may be faulty.
temperature, and barometric
pressure.
29/63 Desired Fuel °CA This parameter refers to the When the display deviates from
Injection Timing value calculated from intake air the specified level, the fuel
temperature, engine coolant injection system, sensors, circuit,
temperature, engine speed, and or ECM may be faulty.
desired fuel injection quantity.
30/63 Cylinder 1 mm3/st This parameter refers to the When the display deviates from
Compensation calibrated fuel injection quantity the specified level, the injector,
calculated using the signals from fuel injection system, sensors,
CKP and CMP sensors. circuit, or ECM may be faulty.
Tech 2 Data Units

Display displayed
34/63 Main Injection mm3/st This parameter refers to the When the display deviates from
using engine speed, desired fuel injection system, sensors, circuit,
injection quantity, calibrated or ECM may be faulty.
cylinder-to-cylinder injection
quantity, and fuel temperature.
35/63 Pilot Injection mm3/st This parameter refers to the When the display deviates from
using engine speed, desired fuel injection system, sensors, circuit,
injection quantity, engine coolant or ECM may be faulty.
temperature, intake air
temperature, and barometric
pressure.
36/63 Pilot Interval µsec This parameter refers to the When the display deviates from
value calculated by the ECM the specified level, the fuel
using estimated common rail injection system, sensors, circuit,
pressure and pilot fuel injection or ECM may be faulty.
quantity.
37/63 Main Injection µsec This parameter refers to the When the display deviates from
Period value calculated by the ECM the specified level, the fuel
using intake air temperature, injection system, sensors, circuit,
engine coolant temperature, or ECM may be faulty.
engine speed, and desired fuel
injection quantity.
38/63 Pilot Injection µsec This parameter refers to the When the display deviates from
Period value calculated by the ECM the specified level, the fuel
using intake air temperature, injection system, sensors, circuit,
engine coolant temperature, or ECM may be faulty.
engine speed, and desired fuel
injection quantity.
39/63 Accelerator ON/OFF This parameter refers to the When the display is fixed, the idle
Switch status of the signals input from position switch, circuit, or ECM
the idle position switch to the may be faulty.
ECM. This switch is turned on
when the accelerator pedal is not
pressed.
40/63 Idle Up Volume V This parameter refers to the When the display is improper, the
signal voltage input to the VIM idle up volume, circuit, VIM, or
from the idle up volume. (Higher ECM may be faulty.
idle speed provides higher
voltage.)
41/63 PTO Accelerator V This parameter refers to the When the display deviates from
Sensor voltage signal input to the VIM the specified level as the PTO
from the PTO accelerator sensor. accelerator position is changed,
(Larger PTO accelerator position the sensor, circuit, VIM, or ECM
provides higher voltage.) may be faulty.
Tech 2 Data Units

Display displayed
42/63 PTO Accelerator % This parameter refers to the When the display deviates from
Opening value calculated by the VIM using the specified level as the PTO
the signals from the PTO accelerator opening is changed,
accelerator sensor. the sensor, circuit, VIM, or ECM
may be faulty.
43/63 ASR Accelerator % When the ASR is working, the When the display is fixed,
Opening accelerator position is limited (the communications with ABS/ASR
position is normally reduced from control unit, ABS/ASR system,
100 %). This parameter refers to VIM, ECM, or ABS/ASR control
the percentage calculated by the unit may be faulty.
VIM using the signals input from
the ASR controller.
44/63 Starter Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from switch, circuit, or ECM may be
the key switch to the ECM. It faulty.
appears on the display after the
key switch is moved to the
position "ST".
45/63 Ignition Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from switch, circuit, or ECM may be
the key switch to the ECM. It faulty.
position "ON" or "ST".
46/63 Clutch Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from clutch switch, circuit, VIM, or
the clutch switch to the VIM. It ECM may be faulty.
clutch switch is pressed.
47/63 Neutral Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from neutral switch, circuit, VIM, or
the neutral switch to the VIM. It ECM may be faulty.
gear is in the neutral position.
48/63 Stop Lamp ON/OFF This parameter refers to the When the display is fixed, the
Switch status of the signals input from stop lamp switch, circuit, VIM, or
the stop lamp switch to the VIM. ECM may be faulty.
It appears on the display after the
brake pedal is pressed.
49/63 Exhaust Brake ON/OFF This parameter refers to the When the display is fixed, the
Switch status of the signals input from exhaust brake switch, circuit,
the exhaust brake switch to the VIM, or ECM may be faulty.
VIM. It appears on the display
after the exhaust brake switch in
the cab is pressed.
Tech 2 Data Units

Display displayed
Valve status of the signals output from exhaust brake valve, circuit, VIM,
the VIM to the exhaust brake or ECM may be faulty.
solenoid valve. After necessary
conditions such as engine speed,
QWS, automatic transmission,
ASR, and exhaust brake switch
are met, the ECM turns on the
solenoid valve.
51/63 Diagnostic ON/OFF This parameter refers to the When the display is fixed, the
Switch status of the signals input from DLC (data link connector), circuit,
the diagnostic switch to the ECM. or ECM may be faulty.
It appears on the display after
DLC (data link connector) pins
are jumpered.
Switch (VIM) status of the signals input from DLC (data link connector), circuit,
the diagnostic switch to the VIM. VIM, or ECM may be faulty.
are jumpered.
53/63 PTO Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from PTO switch, circuit, VIM, or ECM
the PTO switch to the VIM. It may be faulty.
PTO switch in the cab is pressed.
54/63 A/C Switch (Air ON/OFF This parameter refers to the When the display is fixed, the A/C
Conditioning) status of the signals input from switch, circuit, VIM, or ECM may
the A/C switch to the VIM. It be faulty.
A/C switch in the cab is pressed.
55/63 Exhaust Brake ON/OFF This parameter refers to the When the display is fixed,
(AT) Cutoff status of the exhaust bake cut communications with AT
Switch signals input from the AT controller, ATcontrol system,
controller to the VIM. It appears VIM, ECM, or ABS/ASR control
on the display after the signals unit may be faulty.
are input.
(ASR) Cutoff status of the exhaust bake cut communications with ABS/ASR
Switch signals input from the ABS/ASR control unit, ABS/ASR system,
are input.
57/63 Glow Time Relay ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from relay, circuit, or ECM may be
the ECM to the glow relay. It faulty.
appears on the display after
necessary conditions such as
engine coolant temperature,
engine speed, EGR, and QWS
switch are met.
Tech 2 Data Units

Display displayed
58/63 Starter Relay ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from relay, circuit, or ECM may be
the ECM to the starter cut relay. It faulty.
neutral, clutch, and starter
switches are met.
59/63 Glow Time Lamp ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from lamp, circuit, or ECM may be
the ECM to the glow lamp. It faulty.
engine speed, engine coolant
temperature, and starter are met.
60/63 QWS Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from QWS switch, circuit, VIM, or ECM
the QWS (quick warm-up may be faulty.
system) switch to the VIM. It
QWS switch in the cab is
pressed.
61/63 ECO Relay ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from relay, circuit, VIM, or ECM may
the VIM to the ECO relay. It be faulty.
battery voltage, engine coolant
temperature, vehicle speed,
QWS switch, neutral switch, and
clutch switch are met.
62/63 Freezer Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from freezer switch, circuit, VIM, or
the freezer switch to the VIM. It ECM may be faulty.
freezer controller outputs the
switch-on signal.
63/63 Transmission MT/AT This parameter refers to the
Coding transmission type, manual or —
automatic transmission.
VIM Data
Tech 2 Data Units

Display displayed
1/31 System Voltage V This parameter refers to the When the display substantially
power supply voltage applied to deviates from the actual battery
the VIM from the battery. voltage, a voltage drop may
occur due to accessories
installed to the circuit. If it
deviates from the specified level,
the circuit, connector, connector
mating, or VIM may be faulty.
2/31 Vehicle Speed km/h This parameter refers to the When the display differs from the
value calculated by the VIM using speedometer reading or is
the signals from the VS sensor. unchanged, major cause may lie
in VS sensor, circuit, VIM, or
ECM.
3/31 Barometric V This parameter refers to the The barometric pressure sensor
Pressure Sensor signal voltage input to the VIM is a proper criterion for various
from the barometric pressure control configurations (e.g.,
sensor. (Higher barometric startup, cold, or post-warmup
pressure provides higher condition). This parameter may
voltage.) be used as one of DTC detection
conditions.
4/31 Barometric kPa This parameter refers to the When the display deviates from
Pressure value calculated by the VIM using the specified level, the sensor,
the signals from the barometric circuit, or ECM may be faulty.
pressure sensor.
5/31 PTO Accelerator V This parameter refers to the When the display deviates from
Sensor voltage signal input to the VIM the specified level as the PTO
from the PTO accelerator sensor. accelerator position is changed,
(Larger PTO accelerator position the sensor, circuit, VIM, or ECM
provides higher voltage.) may be faulty.
6/31 PTO Accelerator % This parameter refers to the When the display deviates from
Opening value calculated by the VIM using the specified level as the PTO
the signals from the PTO accelerator position is changed,
accelerator sensor. the sensor, circuit, VIM, or ECM
may be faulty.
7/31 Ignition Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from switch, circuit, VIM,or ECM may
the key switch to the VIM. It be faulty.
position "ON" or "ST".
8/31 Idle Up Volume V This parameter refers to the When the display is improper, the
signal voltage input to the ECM idle up volume, circuit, VIM, or
from the idle up volume. (Higher ECM may be faulty.
idle speed provides higher
voltage.)
Tech 2 Data Units

Display displayed
9/31 Idle Manual ON/OFF This parameter refers to the When the display is fixed, the idle
Switch status whether the idle control is control change-over switch,
manual or automatic. It appears circuit, or ECM may be faulty.
on the display when the idle
control is in manual mode. (The
unit is always OFF.)
10/31 Clutch Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from clutch switch, circuit, VIM,or ECM
the clutch switch to the VIM. It may be faulty.
clutch switch is pressed.
11/31 Neutral Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from neutral switch, circuit, VIM, or
the neutral switch to the VIM. It ECM may be faulty.
gear is in the neutral position.
Switch status of the signals input from DLC (data link connector), circuit,
the diagnostic switch to the VIM. VIM, or ECM may be faulty.
jumpered.
Switch status of the signals input from exhaust brake switch, circuit,
the exhaust brake switch to the VIM, or ECM may be faulty.
VIM. It appears on the display
after the exhaust brake switch in
the cab is pressed.
Valve status of the signals output from exhaust brake valve, circuit, VIM,
the VIM to the exhaust brake or ECM may be faulty.
solenoid valve. After necessary
conditions such as engine speed,
QWS, AT, ASR, and exhaust
brake switch are met, the VIM
turns on the solenoid valve.
15/31 Retarder Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from retarder switch, circuit, VIM, or
the retarder switch to the VIM. ECM may be faulty.
(The unit is always OFF.)
Switch 1 status of the signals input from PTO switch, circuit, VIM, or ECM
Switch 2 status of the signals input from PTO switch, circuit, VIM, or ECM
Tech 2 Data Units

Display displayed
18/31 PTO Idle Position ON/OFF This parameter refers to the When the display is fixed, the
Switch working condition of the PTO PTO idle position switch, circuit,
accelerator. It appears on the VIM, or ECM may be faulty.
display when the PTO
accelerator is not working (the
PTO accelerator position is about
0 %).
19/31 QWS Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from QWS switch, circuit, VIM, or ECM
the QWS (quick warm-up may be faulty.
system) switch to the VIM. It
QWS switch in the cab is
pressed.
20/31 Glow Time Lamp ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from lamp, circuit, VIM,or ECM may be
the VIM to the glow lamp. It faulty.
engine speed, engine coolant
temperature, and starter are met.
21/31 ECO Relay ON/OFF This parameter refers to the When the display is fixed, the
status of the signals output from relay, circuit, VIM, or ECM may
the VIM to the ECO relay. It be faulty.
battery voltage, engine coolant
temperature, vehicle speed,
QWS switch, neutral switch, and
idle stop switch are met.
22/31 Engine Stop ON/OFF This parameter refers to the When the display is fixed, the
Switch status of the signals input from engine stop switch, circuit, VIM,
the engine stop switch to the or ECM may be faulty.
VIM. (The unit is always OFF.)
23/31 Engine Start Counts This parameter refers to the When the count number exceeds
Counts accumulated count of starter 150000, DTC18 is issued.
operations.
24/31 Engine Start Counts This parameter refers to the When the count number exceeds
Counts (After accumulated count of starter 150000, DTC18 is issued.
Starter Replace) operations after the starter is
replaced.
25/31 ASR Installation Installed/ This parameter refers to the When the display is fixed,
Not status whether the ASR is communications with ABS/ASR
installed installed to the vehicle. control unit, ABS/ASR system,
VIM, ECM, or ABS/ASR control
unit may be faulty.
26/31 ASR Accelerator % When the ASR is working, the When the display is fixed,
Opening accelerator position is limited (the communications with ABS/ASR
position is normally reduced from control unit, ABS/ASR system,
100 %). This parameter refers to VIM, ECM, or ABS/ASR control
the percentage calculated by the unit may be faulty.
VIM using the signals input from
the ASR controller.
Tech 2 Data Units

Display displayed
27/31 ASR-PWM ON/OFF This parameter refers to the When the display is fixed,
Output status whether accelerator communications with ABS/ASR
position signals are input to the control unit, ABS/ASR system,
VIM from the ASR controller. VIM, ECM, or ABS/ASR control
unit may be faulty.
(ASR) Cut status of the exhaust bake cut communications with ABS/ASR
Request signals input from the ABS/ASR control unit, ABS/ASR system,
are input.
29/31 AT Accelerator % On automatic transmission When the display is fixed,
Opening vehicles, the accelerator position communications with AT control
is limited (the position is normally unit, AT system, VIM, ECM, or
reduced from 100 %). This ABS/ASR control unit may be
parameter refers to the faulty.
percentage calculated by the VIM
using the signals input from the
AT controller.
30/31 AT-PWM Output ON/OFF This parameter refers to the When the display is fixed,
status whether accelerator communications with AT control
position signals are input to the unit, AT system, VIM, ECM, or
VIM from the AT controller. ABS/ASR control unit may be
faulty.
31/31 Freezer Switch ON/OFF This parameter refers to the When the display is fixed, the
status of the signals input from freezer switch, circuit, VIM, or
the freezer switch to the VIM. It ECM may be faulty.
freezer controller outputs the
switch-on signal.
Diagnostic Chart
CAUTION:
The values in "Judgment criteria" may vary
depending on measurement conditions.
Chart 1 (1/3)
CHECK
DTC Fault ENGINE Judgment start conditions Judgment criteria Fail-safe
lamp status
No CMP signal is input while the When the CKP sensor is sound, the
ON The battery voltage is at least 16 V
14 CMP Sensor System Fault CKP signal is input to the ECM 450 ECM will control the powertrain
(idling only) and the starter switch is turned on.
times. using the CKP signal.
No CKP signal is input while the When the CMP sensor is sound, the
ON The battery voltage is at least 16 V
15 CKP Sensor System Fault CMP signal is input to the ECM 40 ECM will control the powertrain
(idling only) and the starter switch is turned on.
times. using the CMP signal.
ON
The manual transmission vehicle is
18 Starter degradation (blinks 10
— in idle stop and the accumulated —
(VIM) (MT vehicles) times and
number of startups exceeds 150000.
turns off)
The ECM controls the powertrain
The IAT sensor output voltage
using the set intake air temperature
22 IAT Sensor System Fault ON — deviates from the range between 0.1
(normal running phase: 25°C,
V and 4.9 V for at least 2.9 seconds.
startup phase: –20°C).
The ECT sensor output voltage
using the set engine coolant
23 ECT Sensor System Fault ON — deviates from the range between 0.1
temperature (normal running phase:
V and 4.9 V for at least 1 second.
55°C, startup phase: –20°C).
The AP sensor output voltage The ECM controls the accelerator
Accelerator Sensor
24 ON — deviates from the range between 0.1 pedal position according to the
System Fault
V and 4.8 V for at least 1 second. signals from the idle position switch.
The state where clutch and neutral
switches are in normal condition, the
automatic transmission or clutch
25 Vehicle Speed Sensor switch is turned off, the engine is
ON — —
(VIM) System Fault running at 2200 rpm or more, the
neutral switch is turned off, and the
vehicle speed is 0 km/h lasts 5
seconds.
28 PTO Accelerator Sensor The PTO accelerator sensor output
— — using the set PTO accelerator
(VIM) System Fault signal exceeds 4.9 V for 1 second.
oposition (0 %).
The idle up volume output signal
31 Idle Up Volume System The idle up volume switch is
— — deviates from the range between 0.2
(VIM) Fault disabled.
V and 4.8 V for 1 second.
The stored count values do not
33 VIM Internal Fault agree each other when the starter Counted and stored values are
— —
(VIM) (EEPROM Write Error) switch position is changed from OFF reset.
to ON.
The battery voltage is at least 16 V,
ECM Internal Fault The charge circuit voltage in the
34 ON the starter switch is turned on, and All injectors are stopped.
(Charge Circuit Fault) ECM is excessively high or low.
the post injection is not performed.
Fault judgment is disabled on PTO
The A/D (analog-to-digital)
35 VIM Internal Fault accelerator sensor, atmospheric
ON — conversion is not complete in the
(VIM) (A/D Conversion Fault) pressure sensor, and idle up
VIM.
volume.
The ITP sensor output voltage
43 ITP Sensor System Fault ON — deviates from the range between 0.1 —
V and 4.9 V for at least 3 seconds.
The EGR valve position sensor
EGR Valve Position output voltage deviates from the
44 ON — —
Sensor System Fault range between 0.3 V and 4.6 V for at
least 3 seconds.
The starter switch is turned on for at
least 3 seconds, the EGR valve
position sensor is in normal
The valve drive voltage is
condition, neither #2 - 5 V Power
45 EGR Valve System Fault ON excessively high for at least 10 —
Supply Fault nor A/D Conversion
seconds.
Fault is detected, and the battery
voltage stays between 16 V and 32
V.
With the battery voltage at 20 V or
Exhaust Brake System more, the engine speed at 500 rpm
Fault or more, and the exhaust brake
(ON circuit open wiring) turned on, the solenoid valve is
46 turned off for 1 second. The exhaust brake system is
ON —
(VIM) With the battery voltage at 20 V or disabled.
Exhaust Brake System more, the engine speed at 500 rpm
Fault or more, and the exhaust brake
(OFF circuit open wiring) turned off, the solenoid valve is
turned on for 1 second.
Chart 1 (2/3)
CHECK
lamp status
ECM Internal Fault ON
The sub CPU judges the CPU fail. —
(CPU Error) (by sub CPU)
With the battery voltage 20 V or
51 — more and the starter switch turned
ECM Internal Fault
— off, the CPU working signals are not Injectors supply pump are stopped.
(CPU History Error)
detected even after the initial status
lasts for at least 0.4 second.
The post initial status lasts at least 2
seconds, the battery voltage is 22 V
ECM Internal Fault or more, the starter switch is turned
52 ON — Injectors supply pump are stopped.
(CPU Monitoring IC Fault) off for at least 0.5 second, and the
CPU working signals are faulty for
0.7 second or more.
The starter switch is turned on for at
least 3 seconds, the ITP sensor is in
normal condition, neither #3 - 5 V The valve drive voltage is
Intake Throttle Valve
61 ON Power Supply Fault nor A/D excessively high for at least 10
System Fault
Conversion Fault is detected, and seconds.
the battery voltage stays between —
16 V and 32 V.
The atmospheric pressure sensor
71 Atmospheric Pressure voltage deviates from the range
ON —
(VIM) Sensor Fault between 0.5 V and 4.5 V for 1
second.
On the manual transmission vehicle,
the engine is running for at least 180
81 Clutch Switch System seconds, the vehicle speed is at
ON — The exhaust brake is disabled.
(VIM) Fault least 80 km/h, and the clutch switch
is not toggled from off to on or on to
off.
The engine is running for at least
82 Neutral Switch System 180 seconds, the vehicle speed is at
ON — The exhaust brake is disabled.
(VIM) Fault least 80 km/h, and the neutral switch
is toggled from on to off.
Communications with VIM are
CAN Communication Fault Fault occurs on communications terminated and the control mode
84 ON —
(CAN Bus Error) with VIM. with predetermined values will be
dominant.
Communications with ECM are
CAN Communication Fault CAN signal is not input for 1 terminated and the control mode
86 ON —
(CAN Timeout Error) seconds. with predetermined values will be
dominant.
The state where the common rail
pressure sensor is in normal
condition, there is no change in
common rail pressure sensor output
voltage, the difference between The ECM controls the desired
Common Rail Pressure desired and actual common rail common rail pressure to 60 MPa or
115 ON —
Sensor Fixed Output Fault pressures is 10 MPa or more, the less and the desired fuel quantity to
actual common rail pressure is 10 50 mm3/st or less.
MPa or more, and the pump is under
feedback control is continuously
observed 255 times during A/D
conversion in the ECM.
pressure is in normal condition and
the actual common rail pressure is
Common Rail Pressure The ECM controls the desired
180 MPa or more is continuously
Fault common rail pressure to 60 MPa or
(First Stage in Control less and the desired fuel quantity to
conversion in the ECM. (The system
System) 50 mm3/st or less.
is restored when the common rail
pressure is at or below 130 MPa and
the idle position switch is turned on.)
118 ON —
pressure is in normal condition and
the actual common rail pressure is
Common Rail Pressure
200 MPa or more is continuously
Fault Injectors and supply pump are
(Second Stage in Control stopped.
conversion in the ECM. (The system
System)
is restored when the common rail
pressure is at or below 130 MPa and
the engine is stopped.)
The short to ground or the +B short
Injector Power Supply is detected on the common 1 drive
158 ON the starter switch is turned on, and The ECM stops injectors #1 and #3.
System Short (Common 1) circuits for injectors (injectors #1 and
#3).
The short to ground or the +B short
Injector Power Supply is detected on the common 2 drive
159 ON the starter switch is turned on, and The ECM stops injectors #2 and #4.
System Short (Common 2) circuits for injectors (injectors #2 and
#4).
The FT sensor output voltage
Fuel Temperature Sensor using the set fuel temperature
211 — — deviates from the range between 0.1
System Fault (normal running phase: 40°C,
V and 4.8 V for at least 1 second.
startup phase: –20°C).
Chart 1 (3/3)
CHECK
lamp status
Pump control and pump feedback
The SCV drive current is at least
are in normal mode, the SCV drive
1500 mA. (+B short is detected on
217 SCV Drive System Short — efficiency ranges between 30 % and —
the circuit between SCV+ and
50 %, and the battery voltage is at
ECM.)
least 16 V.
The low-temperature startup mode
is currently not active (i.e., the
engine coolant temperature is 60°C
or more), high-pressure pump
control and injector control are in
normal mode, the engine is running
No Pump Pressure Feed at or above 450 rpm, any of The fuel leak after the fuel filter The common rail pressure and fuel
227 ON
(Fuel Leak) Common Rail Pressure Sensor exceeds the threshold. injection quantity are limited.
System Fault (DTC115 or DTC245),
Injector Drive System Fault (DTC34,
DTC158, DTC159, DTC271,
DTC272, DTC273, or DTC274), or
Common Rail Pressure Fault
(DTC118) is not detected.
The state where the AP sensor is in
normal condition, the AP sensor
Idle Position Switch Circuit The ECM controls the accelerator
241 ON — output voltage is less than 0.6 V,
Open Wiring position to 80 % or less.
and the idle position switch is turned
off lasts at least 10 seconds.
The state where the AP sensor is in
normal condition, the AP sensor
Idle Position Switch Circuit
242 ON — output voltage is 1 V or more, and —
Short
the idle position switch is turned on
lasts at least 10 seconds.
pressure sensor output voltage The ECM controls the desired
Common Rail Pressure deviates from the range between 0.7 common rail pressure to 60 MPa or
245 ON —
Sensor System Fault V and 4.7 V is continuously less and the desired fuel quantity to
observed 3 times during A/D 50 mm3/st or less.
conversion in the ECM.
The SCV drive current is 1100 mA
Pump control and pump feedback or less. (Short to ground between The common rail pressure and fuel
are in normal mode, the SCV drive SCV+ and ECM, +B short between injection quantity are limited.
247 SCV Drive System Fault ON efficiency ranges between 30 % and SCV– and ECM, short to ground Fault judgment is disabled on pump
50 %, and the battery voltage is at between SCV– and ECM, or open overpressure and short pump
least 16 V. wiring between SCV and ECM is not pressure events 1 to 4.
detected.)
Open wiring is detected on the
The battery voltage is at least 16 V, circuit between injector #1 and ECM
Cylinder 1 (Injector Drive
271 ON the starter switch is turned on, and injector #1 pin, and Cylinder 4 Injector #1 is stopped.
System) Fault
the post injection is not performed. (Injector Drive System) Fault
System) Fault
System) Fault
System) Fault
Open wiring is detected between
Injector Power Supply The battery voltage is at least 16 V, injector #1/3 and ECM common 1
277 System Open Wiring ON the starter switch is turned on, and pin (both the drive circuits for Injectors #1 and #3 are stopped.
(Common 1) the post injection is not performed. injectors #1 and #3 have open
wiring).
Open wiring is detected between
Injector Power Supply The battery voltage is at least 16 V, injector #2/4 and ECM common 2
278 System Open Wiring ON the starter switch is turned on, and pin (both the drive circuits for Injectors #2 and #4 are stopped.
(Common 2) the post injection is not performed. injectors #2 and #4 have open
wiring).
The state where the starter switch is
ON
416 Main Relay System Fault — turned off and the main relay is —
(idling only)
turned on lasts at least 5 seconds.
The state where the starter switch is
Starter Switch System in "ST" position and the engine
417 — — —
Fault speed is more than 1000 rpm is
continuously observed 100 times.
The engine speed exceeds 4400 Injectors and supply pump are
543 High Engine Speed Error — —
rpm. stopped.
Chart 2 (1/2)
DTC Fault Major faulty event Parts to be inspected Applicable Tech 2 parameter
Wire harnesses and connectors (G sensor
14 CMP Sensor System Fault Poor startability Engine Speed
system), G sensor, ECM
Poor startability Wire harnesses and connectors (NE sensor
15 CKP Sensor System Fault Engine Speed
Poor driveability system), NE sensor, ECM
18 Starter degradation
Poor startability Starter Engine Start Counts
(VIM) (MT vehicles)
Wire harnesses and connectors (IAT sensor Intake Air Temperature, IAT
22 IAT Sensor System Fault Poor driveability
system), IAT sensor, ECM Sensor
Poor startability under cold
weather conditions Wire harnesses and connectors (ECT sensor Coolant Temperature, ECT
23 ECT Sensor System Fault
Poor driveability system), ECT sensor, ECM Sensor
Prolonged warm-up time
Short power
Wire harnesses and connectors (AP sensor Final Accelerator Opening,
24 Accelerator Sensor System Fault Poor pedal response
system), AP sensor, ECM Acceleraator Sensor
Poor driveability
25 Vehicle Speed Sensor System Improper speedometer indication Wire harnesses and connectors (VS sensor
Vehicle Speed
(VIM) Fault Poor driveability system), VS sensor, ECM
28 PTO Accelerator Sensor System Wire harnesses and connectors (PTO accelerator PTO Accelerator Opening, PTO
Poor driveability
(VIM) Fault sensor system), PTO accelerator sensor, ECM Accelerator Sensor
31 Wire harnesses and connectors (idle up volume
Idle Up Volume System Fault Poor driveability Engine Speed, Idle Up Volume
(VIM) system), idle up volume, ECM
33 VIM Internal Fault
— VIM Engine Start Counts
(VIM) (EEPROM Write Error)
Generation of black smoke
ECM Internal Fault
34 Short power ECM System Voltage
(Charge Circuit Fault)
Poor driveability
Generation of white/black smoke
35 VIM Internal Fault Inactive idle up volume system
VIM —
(VIM) (A/D Conversion Fault) Inactive PTO accelerator sensor
system
Actual Intake Throttle Position,
Short power
Wire harnesses and connectors (ITP sensor Desired Intake Throttle Position,
43 ITP Sensor System Fault Poor driveability
system), ITP accelerator sensor, ECM Intake Throttle Valve, Intake
Extensive suction noise during
Throttle Duty Ratio
acceleration or exhaust braking
Generation of black smoke Wire harnesses and connectors (EGR valve
EGR Valve Position Sensor EGR Valve Position Sensor, EGR
44 Short power position sensor system), EGR valve position
System Fault Duty Cycle
Poor driveability sensor, ECM
Generation of black smoke Wire harnesses and connectors (EGR valve and
EGR Valve Position Sensor, EGR
45 EGR Valve System Fault Short power EGR DC motor system), EGR valve, main relay,
Duty Cycle
Poor driveability EGR DC motor, ECM
Exhaust Brake System Fault
(ON circuit open wiring) Inactive exhaust brake system, Wire harnesses and connectors (exhaust brake
46
PTO and QWS solenoid valve system), exhaust brake solenoid Exhaust Brake Valve 1
(VIM) Exhaust Brake System Fault
Inactive ABS/ASR valve, ECM
(OFF circuit open wiring)
ECM Internal Fault (CPU Error)
51 ECM Internal Fault Engine stop ECM DTC
(CPU History Error)
ECM Internal Fault
52 Poor driveability ECM All data list
(Sub CPU Error)
Actual Intake Throttle Position,
Generation of black smoke Wire harnesses and connectors (intake throttle Desired Intake Throttle Position,
Intake Throttle Valve System
61 Short power valve system), intake throttle valve, main relay, Intake Throttle Valve, Intake
Fault
Poor driveability intake throttle DC motor, ECM Throttle Duty Ratio
71 Barometric Pressure Sensor Barometric Pressure, Barometric

Generation of black smoke VIM
(VIM) Fault Pressure Sensor
81 Inactive exhaust brake, QWS, and Wire harnesses and connectors (clutch switch
Clutch Switch System Fault Clutch Switch
(VIM) PTO system), clutch switch, ECM
82 Wire harnesses and connectors (neutral switch
Neutral Switch System Fault Poor driveability Neutral Switch
(VIM) system), neutral switch, ECM
Inactive exhaust brake and QWS
Poor driveability
CAN Communication Fault
84 Terminated VIM control ECM Vehicle Speed
(CAN Bus Error)
(e.g., tachometer or PTO)
Poor driveability
CAN Communication Fault
86 Terminated VIM control VIM Vehicle Speed
(CAN Timeout Error)
(e.g., tachometer or PTO)
Poor startability
Wire harnesses and connectors (common rail
Common Rail Pressure Sensor Generation of while/black smoke Actual Rail Pressure, Common
115 pressure sensor system), common rail pressure
Fixed Output Fault Short power Rail Pressure Sensor
sensor, ECM
Poor driveability
Common Rail Pressure Fault
(First Stage in Control System) Poor startability
Generation of while/black smoke Actual Rail Pressure, SCV Duty
118 Common Rail Pressure Fault pressure sensor system), common rail pressure
Short power Ratio, SCV Current
(Second Stage in Control sensor, SCV, flow damper, fuel pipe, ECM
Poor driveability
System)
Injector Power Supply System Short power Wire harnesses and connectors (injector #1/3 to
158 Cylinder 1/4 Compensation
Short (Common 1) Poor driveability ECM common 1 pin), injectors #1 and #3, ECM
Injector Power Supply System Short power Wire harnesses and connectors (injector #2/4 to
Short (Common 2) Poor driveability ECM common 2 pin), injectors #2 and #4, ECM
Chart 2 (2/2)
DTC Fault Major faulty event Parts to be inspected Applicable Tech 2 parameter
Fuel Temperature Sensor Wire harnesses and connectors (FT sensor
211 Poor driveability Fuel Temperature, FT Sensor
System Fault system), FT sensor, ECM
Poor startability
Generation of white/black smoke Wire harnesses and connectors (SCV+ to ECM), Actual Rail Pressure, SCV Duty
217 SCV Drive System Short
Short power SCV, ECM Cycle
Poor drivability
Generation of white/black smoke
No Pump Pressure Feed (Fuel Short power SCV, flow damper, common rail, supply pump, Actual Rail Pressure, SCV Duty
227
Leak) Poor driveability injector, fuel pipe, ECM Cycle
Engine stop
Short power
Idle Position Switch Circuit Open Poor driveability Wire harnesses and connectors (idle position
241 Idle Position Switch
Wiring (When the AP sensor is also switch system), idle position switch, ECM
faulty.)
Short power
Poor pedal response
Wire harnesses and connectors (idle position
242 Idle Position Switch Circuit Short Poor driveability Idle Position Switch
switch system), idle position switch, ECM
(When the AP sensor is also
faulty.)
Poor startability
Common Rail Pressure Sensor Generation of white/black smoke Actual Rail Pressure, Common
245 pressure sensor system), common rail pressure
System Fault Short power Rail Pressure Sensor
sensor, ECM
Poor driveability
Poor startability
Generation of white/black smoke Wire harnesses and connectors (SCV drive
247 SCV Drive System Fault SCV Duty Ratio, SCV Current
Short power system), SCV, ECM
Poor driveability
Cylinder 1 Short power Wire harnesses and connectors (injector #1 to
271 Cylinder 1 Compensation
(Injector Drive System) Fault Poor driveability ECM injector #1 pin), injector #1, ECM
Injector Power Supply System Engine stop Wire harnesses and connectors (injector #1/3 to
Open Wiring (Common 1) No startability ECM common 1 pin), injectors #1 and #3, ECM
Injector Power Supply System Engine stop Wire harnesses and connectors (injector #2/4 to
Open Wiring (Common 2) No startability ECM common 2 pin), injectors #2 and #4, ECM
Wire harnesses and connectors (main relay
416 Main Relay System Fault Battery over-discharge System Voltage
system), main relay, ECM
Wire harnesses and connectors (starter switch
417 Starter Switch System Fault Starter malfunction Starter Switch
system), starter switch, ECM
Shift position, transmission, NE and G sensor
543 High Engine Speed Error No pedal response Engine Speed
signals
DTC14 - CMP Sensor System Fault
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
CKP CMP ITP EGR Valve Common
Sensor Sensor Sensor Position Rail
Sensor Pressure
Sensor
LNW21AMF006901-X
Circuit Description Conditions for Clearing MIL/DTC

The CMP (cam position) sensor is installed to each When the system fails and the DTC is stored to the
cylinder head and, when the hole on the camshaft gear ECM, even repairing the faulty portion will not clear the
passes the sensor, a CMP signal is generated. Five DTC from the memory. To clear the DTC, conduct the
CMP pulses are generated per cycle (one rotation of following steps.
camshaft). The ECM identifies the cylinder from the 1. Turn off the idle position switch for not less than 1
CMP signal as well as the CKP signal sent from the second but not more than 3 seconds. (Press the
CKP sensor and determines the crank angle, and uses accelerator pedal.)
this angle in fuel injection control and engine speed
calculation. These tasks are usually performed based
on the CKP signal but if the CKP sensor fails, the CMP
accelerator pedal.)
signal will substitute for the CKP signal.
DTC14 will be set when the number of CMP signals 3. Turn off the idle position switch for not less than 1
received by the ECM is not correct. second but not more than 3 seconds. (Press the
accelerator pedal.)
Major Faulty Event 4. Turn on the idle position switch for not less than 1
• Poor startability second but not more than 3 seconds. (Release the
accelerator pedal.)
Conditions for Setting the DTC 5. Turn off the idle position switch for not less than 1
No CMP signal is input while the CKP signal is input to second but not more than 3 seconds. (Press the
the ECM 450 times. accelerator pedal.)
6. After the above operations are properly completed,
Action Taken When the DTC Sets the CHECK ENGINE lamp (MIL) illuminates for 3
• After the DTC is set and the engine runs at idle, seconds to report the memory is cleared.
the ECM will illuminate the CHECK ENGINE lamp 7. Turn off the starter switch. Wait for 5 seconds and
(MIL). turn on the starter switch again.
• When the CKP sensor is sound, the ECM will When Tech 2 has been connected to the vehicle, the
control the powertrain using the CKP signal. DTC can be cleared through the memory clear
Diagnostic Aids Test Description
Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the
intermittents. Check for the following conditions and, if Diagnostic Chart.
the fault is detected, repair or replace the faulty portion. 3. If the DTC is not detected, the possible cause is
• Poor connection at ECM: Inspect harness intermittent (intermittent fault).
connectors for backed-out pins, improper mating, 4. If the resistance is sound, the harness and sensor
broken locks, improperly formed or damaged pins, are not faulty.
and poor pin-to-wire connection. 7. If pins are jumpered and the resistance reads ∞ Ω,
the cause is open wiring. If pins are not jumpered and
the resistance reads 0Ω, the cause is short.
rubbed-through wire insulation or wire broken
inside the insulator. If the harness appears to be
OK, observe the display on Tech 2 while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate the
location of the fault.

1 — System Check
Check the CMP sensor and sensor connector
for installation and, if mounted improperly,
2 install these devices certainly. —

Review the DTC.
1. Using Tech 2, check and store the DTC.
3 2. Clear the DTC. —
3. Perform test run and review the DTC.
Refer to
Is DTC14 detected? Go to Step 4 Diagnostic Aids
Check the CMP sensor ground circuit for +B
short.
Pins 27-109/
4 2. Disconnect the ECM. 114/115/116:
3. At the ECM connector pins, measure the ∞Ω
resistance.
Was the resistance within range? Go to Step 6 Go to Step 8

Check the CMP sensor circuit for open wiring
or short. Pins 8-27:
1. Starter switch "OFF". 1850~2450 Ω
2. Disconnect the ECM. Pins 8/27-26:
6
∞Ω
3. At the ECM connector pins, measure the
Pins 8/27-
resistance.
ground: ∞Ω

Check the harness between ECM and CMP Pins 27-8
sensor for open wiring or short. (jumpered:
1. Disconnect the CMP sensor connector. pins 2-3): 0 Ω
(not jumpered):
2. Jumper the CMP sensor connector pins
∞Ω
and measure the resistance at the ECM
Pins 26-8
connector.
(jumpered:
Was the resistance within range? pins 1-3): 0 Ω
7 (not jumpered):
∞Ω
Pins 26-27
(jumpered:
pins 1-2): 0 Ω
(not jumpered):
∞Ω
Pins 26/27/8-
ground: ∞ Ω Go to Step 9 Go to Step 8
Check the CMP sensor. [Reference]
1. At the CMP sensor connector pins, Pins 1-2: ∞Ω
measure the resistance. Pins 2-3:
Approx.
9 Was the resistance within range? 120~130 Ω
Pins 1-3: ∞ Ω
Pin 1/2/3-
sensor body:
Replace the CMP sensor.
Review the DTC.
1. Certainly connect the CMP sensor and
ECM connectors.
11 2. Using Tech 2, clear the DTC. —
Refer to
1. Replace the ECM.
IMPORTANT:
12 —
Verify repair and
Check DTC14 will not be set again.
1. Using Tech 2, clear the DTC.
13 — Refer to
Diagnostic Aids Repair is
Is DTC14 detected? and go to Step 2 complete
Sensor Description
LNW21ASF003301
Legend
1. CMP sensor 3. Sensor ground
2. Shield ground 4. Sensor signal
DTC15 - CKP Sensor System Fault
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X

The CKP (crank position) sensor is installed to the When the system fails and the DTC is stored to the
flywheel housing and, when flywheel teeth pass the ECM, even repairing the faulty portion will not clear the
sensor, a CKP signal is generated. Ninety CKP pulses DTC from the memory. To clear the DTC, conduct the
are generated per cycle (one rotation of crankshaft). following steps.
The ECM identifies the cylinder from the CKP signal as 1. Turn off the idle position switch for not less than 1
well as the CMP signal sent from the CMP sensor and second but not more than 3 seconds. (Press the
determines the crank angle, and uses this angle in fuel accelerator pedal.)
injection control and engine speed calculation. These
tasks are usually performed utilizing the CKP signal but
if the CKP sensor fails, the CMP signal will substitute
accelerator pedal.)
for the CKP signal.
DTC15 will be set when the number of CKP signals 3. Turn off the idle position switch for not less than 1
received by the ECM is not correct. second but not more than 3 seconds. (Press the
accelerator pedal.)
• Poor startability second but not more than 3 seconds. (Release the
• Poor driveability accelerator pedal.)
Conditions for Setting the DTC second but not more than 3 seconds. (Press the
No CKP signal is input while the CMP signal is input to accelerator pedal.)
the ECM 40 times. 6. After the above operations are properly completed,
the CHECK ENGINE lamp (MIL) illuminates for 3
Action Taken When the DTC Sets seconds to report the memory is cleared.
• After the DTC is set and the engine runs at idle, 7. Turn off the starter switch. Wait for 5 seconds and
the ECM will illuminate the CHECK ENGINE lamp turn on the starter switch again.
(MIL). When Tech 2 has been connected to the vehicle, the
• When the CMP sensor is sound, the ECM will DTC can be cleared through the memory clear
control the powertrain using the CMP signal. operation with Tech 2.
connectors for backed-out pins, improper mating, 6. If the resistance is sound, the harness and sensor
broken locks, improperly formed or damaged pins, are not faulty.
the resistance reads 0Ω, the cause is short.

1 — System Check
Check the CKP sensor and sensor connector
2 install these devices certainly. —

Review the DTC.
Refer to
Check the CKP sensor ground circuit for +B
short. Pins 25-109/
1. Starter switch "OFF". 114/115/116
2. Disconnect the ECM. ∞Ω
4
Pins 6-109/
114/115/116
resistance.
∞Ω
Repair or replace the harness on which +B
5 short was found. —
Check the CKP sensor circuit for open wiring
or short. Pins 25-6:
1. Starter switch "OFF". 22~28 Ω
2. Disconnect the ECM. Pins 25/6-26:
6
∞Ω
Pins 25/6-
resistance.
ground: ∞ Ω

Check the harness between ECM and CKP Pins 25-6
1. Disconnect the CKP sensor connector. pins 1-2): 0 Ω
(not jumpered):
2. Jumper the CKP sensor connector pins
∞Ω
and measure the resistance at the ECM
Pins 25/6-
7 connector.
ground
Was the resistance within range? (jumpered:
pins 1/2-
ground): 0 Ω
(not jumpered):
Repair or replace the harness with open
8 wiring or short. — Verify repair and
Check the CKP sensor. [Reference]
1. At the CKP sensor connector pins, Approx.
measure the resistance. 20~250 Ω
9
Pin 1/2-
Was the resistance within range? sensor body:
Replace the CKP sensor.
Review the DTC.
1. Certainly connect the CKP sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
12 —
Verify repair and
13 2. Perform test run and review the DTC. — Refer to
Sensor Description
2
LNW21ASF003201
Legend
1. CKP sensor 3. Sensor signal (+)
2. Projections on flywheel 4. Sensor signal (–)
DTC18 - Starter Degradation (For Only Vehicles Equipped with Idle Stop Function)
Circuit Description 3. Turn off the idle position switch for not less than 1
The number of starter operations is stored to the VIM. second but not more than 3 seconds. (Press the
The VIM receives the signal from the starter switch accelerator pedal.)
and, whenever the starter is set to the position "ST", 4. Turn on the idle position switch for not less than 1
adds the count by one. When the accumulated number second but not more than 3 seconds. (Release the
of starter operations exceeds 150000, the VIM sends accelerator pedal.)
the signal to the ECM to illuminate the CHECK 5. Turn off the idle position switch for not less than 1
ENGINE lamp (the lamp blinks ten times and then goes second but not more than 3 seconds. (Press the
off) so that the driver is requested to replace the starter. accelerator pedal.)
DTC18 will be set when the accumulated number of 6. After the above operations are properly completed,
startups exceeds 150000 on the vehicle equipped with the CHECK ENGINE lamp (MIL) illuminates for 3
idle stop function and the idle stop function is enabled. seconds to report the memory is cleared.
Major Faulty Event 7. Turn off the starter switch. Wait for 5 seconds and
turn on the starter switch again.
• Poor startability
When Tech 2 has been connected to the vehicle, the
Conditions for Setting the DTC DTC can be cleared through the memory clear
The manual transmission vehicle is in idle stop and the
accumulated number of startups exceeds 150000. Diagnostic Aids
Action Taken When the DTC Sets Poor connection or damaged harness may cause
intermittents. Check for the following conditions and, if
After the DTC is set, the ECM will blink the CHECK the fault is detected, repair or replace the faulty portion.
ENGINE lamp (MIL) 10 times and the turn it off.
• Poor connection at VIM: Inspect harness
Conditions for Clearing MIL/DTC connectors for backed-out pins, improper mating,
When the system fails and the DTC is stored to the and poor pin-to-wire connection.
ECM, even repairing the faulty portion will not clear the
DTC from the memory. To clear the DTC, conduct the
following steps.
1. Turn off the idle position switch for not less than 1 OK, observe the display on Tech 2 while moving
second but not more than 3 seconds. (Press the connectors and wiring harnesses related to the
accelerator pedal.) sensor. A change in the display will indicate the
2. Turn on the idle position switch for not less than 1 location of the fault.
accelerator pedal.)

1 — System Check
Check the accumulated number of startups.
2. Install Tech 2.
2 —
3. Display "Engine Start Counts" and
observe the count.
Is the count over 150000? Go to Step 3 Go to Step 5
Replace the starter.
1. Check the engine runs.
2. Replace the starter.
3 —
3. Recheck the engine runs with the new
starter.

Reset the accumulated number of startups.
1. Engine "OFF", starter switch "ON".
2. Using Tech 2, reset the accumulated
4 number of startups. —
3. Start the engine.
4. Engine "OFF", starter switch "OFF".
Review the DTC.
5 —
Refer to
1. Replace the VIM.
IMPORTANT:
6 —
startups to the replacing VIM.
Verify repair and
7 — Refer to
DTC22 - IAT Sensor System Fault
ECM
(Engine
Control
Module)
91 83
0.5L/B
0.5O
0.85L/B
0.85O
IAT
Sensor
LNW21AMF007701-X

The IAT (intake air temperature) sensor consists of When the system fails and the DTC is stored to the
thermistor and alters the resistance in response to ECM, even repairing the faulty portion will not clear the
temperature change. Higher intake air temperature DTC from the memory. To clear the DTC, conduct the
provides smaller resistance while lower temperature following steps.
provides larger resistance. The ECM supplies 5 V to 1. Turn off the idle position switch for not less than 1
the IAT sensor via pull-up resistance and calculates the second but not more than 3 seconds. (Press the
intake air temperature from the change in voltage and accelerator pedal.)
uses it in fuel injection control and other control tasks.
The voltage is decreased when the resistance is small
(the temperature is high) while increased when the
accelerator pedal.)
DTC22 will be set when the signal voltage is 3. Turn off the idle position switch for not less than 1
excessively high or low. second but not more than 3 seconds. (Press the
accelerator pedal.)
• Poor driveability second but not more than 3 seconds. (Release the
• Generation of white smoke accelerator pedal.)
The IAT sensor output voltage deviates from the range accelerator pedal.)
between 0.1 V and 4.9 V for at least 3 seconds. 6. After the above operations are properly completed,
• After the DTC is set, the ECM will illuminate the 7. Turn off the starter switch. Wait for 5 seconds and
CHECK ENGINE lamp (MIL). turn on the starter switch again.
• The ECM controls the powertrain using the set When Tech 2 has been connected to the vehicle, the
intake air temperature (–10°C). DTC can be cleared through the memory clear
connectors for backed-out pins, improper mating, 5. If the output voltage is fixed to 5 V, the possible
broken locks, improperly formed or damaged pins, cause is open wiring in the circuit. If the output voltage
and poor pin-to-wire connection. is fixed to 0 V, the possible cause is short in the circuit.

1 — System Check
Check the IAT sensor connector for
installation and, if mounted improperly,
2 connect it certainly. —

Review the DTC.
Refer to
Check the IAT sensor output voltage.
1. Using Tech 2, displays the engine data.
2. Starter switch "ON", engine "OFF". Approx. 2.8 V
4
3. Observe the "IAT Sensor" display for (at 20°C)
output voltage. Refer to
Diagnostic Aids
Was the voltage within range? and go to Step 13 Go to Step 5
Check the IAT sensor output voltage.
5 —
Is the voltage fixed to 5 V? Go to Step 6 Go to Step 8
Check the IAT sensor circuit for open wiring.
2. Disconnect the ECM. Pins 91-83:
6 2.5 kΩ (ECT:
approx. 20°C)
resistance.


Check the harness between ECM and IAT
sensor for open wiring. Pins 91-83
1. Starter switch "OFF". (jumpered:
2. Disconnect the ECM. pins 1-2): 0 Ω
Pins 91-83-
7 3. Disconnect the IAT sensor connector.
ground
4. Jumper the IAT sensor connector pins (jumpered:
and measure the resistance at the ECM pins 1/2-
connector. ground): 0 Ω
Check the IAT sensor circuit for short.
1. Starter switch "OFF". Pins 91-83:
2. Disconnect the ECM. 2.5 kΩ (ECT:
8 approx. 20°C)
3. At the ECM connector, measure the
Pins 91/83-
resistance.
ground: ∞ Ω
Check the harness between ECM and IAT
sensor for short.
Pins 91-83:
2. Disconnect the ECM. ∞Ω
9
3. Disconnect the IAT sensor connector. Pins 91/83-
4. At the ECM connector, measure the ground: ∞ Ω
resistance.

Check the IAT sensor.
1. Disconnect the IAT sensor.
2. Provide temperature change on the
11 thermosensitive element of the IAT See graph
sensor and measure the resistance
between the sensor connector pins.

Replace the IAT sensor.
Review the DTC.
1. Certainly connect the IAT sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
14 —
Verify repair and

15 — Refer to
Characteristics of IAT Sensor (Reference)

100
Resistance Value (k )
10
1
0.1
-40 -30 -20 -10 0 10 20 30 40

Temperature ( C)
LNW21ASH010301-X
Sensor Description
LNW21ASF003501
Legend
1. IAT sensor 3. Sensor signal
2. Sensor ground
DTC23 - ECT Sensor System Fault
ECM
(Engine
Control
Module)
49 46 48
0.5R/B
0.5R/G
0.5G/W
0.5G/W
ECT FT
Sensor Sensor
LNW21AMF007101-X
Circuit Description • The ECM controls the powertrain using the set
The ECT (engine coolant temperature) sensor consists engine coolant temperature (normal running
of thermistor and alters the resistance in response to phase: 110°C, startup phase: –20°C).
temperature change. Higher engine coolant • EGR and warm-up systems are disabled.
temperature provides smaller resistance while lower
temperature provides larger resistance. The ECM Conditions for Clearing MIL/DTC
supplies 5 V to the ECT sensor via pull-up resistance When the system fails and the DTC is stored to the
and calculates the engine coolant temperature from the ECM, even repairing the faulty portion will not clear the
change in voltage and uses it in fuel injection control, DTC from the memory. To clear the DTC, conduct the
EGR control, and other control tasks. The voltage is following steps.
decreased when the resistance is small (the 1. Turn off the idle position switch for not less than 1
temperature is high) while increased when the second but not more than 3 seconds. (Press the
resistance is large (the temperature is low). accelerator pedal.)
DTC23 will be set when the signal voltage is
excessively high or low.
Major Faulty Event accelerator pedal.)
• Poor startability under cold weather conditions 3. Turn off the idle position switch for not less than 1
• Prolonged warm-up time
Conditions for Setting the DTC second but not more than 3 seconds. (Release the
accelerator pedal.)
The ECT sensor output voltage deviates from the
range between 0.1 V and 4.9 V for at least 3 seconds. 5. Turn off the idle position switch for not less than 1
Action Taken When the DTC Sets accelerator pedal.)
• After the DTC is set, the ECM will illuminate the 6. After the above operations are properly completed,
CHECK ENGINE lamp (MIL). the CHECK ENGINE lamp (MIL) illuminates for 3
seconds to report the memory is cleared.
7. Turn off the starter switch. Wait for 5 seconds and inside the insulator. If the harness appears to be
turn on the starter switch again. OK, observe the display on Tech 2 while moving
When Tech 2 has been connected to the vehicle, the connectors and wiring harnesses related to the
DTC can be cleared through the memory clear sensor. A change in the display will indicate the
operation with Tech 2. location of the fault.

connectors for backed-out pins, improper mating, 4. If DTC211 is also set, the possible cause is the
broken locks, improperly formed or damaged pins, ground circuit common to ECT and FT sensors.
and poor pin-to-wire connection. 10. If the output voltage is fixed to 5 V, the possible
cause is open wiring in the circuit. If the output voltage
is fixed to 0 V, the possible cause is short in the circuit.

1 — System Check
Check the ECT sensor connector for

Review the DTC.
Refer to
Check multiple DTCs are set.
4 Is DTC211 (Fuel Temperature Sensor System —
Fault) detected together with DTC23? Go to Step 5 Go to Step 10
Check the ground circuit common to ECT and
FT sensors for +B short.
Pins 46-109/
resistance.


Check the ground circuit common to ECT and Pins 49-46
FT sensors for open wiring or short. (not jumpered):
1. Starter switch "OFF". ∞Ω
2. Disconnect the ECM. Pins 46-
ground
7 3. Disconnect the ETC sensor connector.
(jumpered:
4. Jumper the ETC sensor connector pins pins 2-
and measure the resistance at the ECM ground): 0 Ω
connector. (not jumpered):
Was the resistance within range? ∞Ω Go to Step 9 Go to Step 8
Review the DTC.
1. Certainly connect the ECT sensor and
ECM connectors.
Refer to
Check the ECT sensor output voltage.
1. Using Tech 2, displays the engine data.
2. Starter switch "ON", engine "OFF". Approx. 0.6 V
10
3. Observe the "ECT Sensor" display for (ECT: 80°C)
output voltage.

Check the ECT sensor output voltage.
11 —
Is the voltage fixed to 5 V? Go to Step 12 Go to Step 14
Check the ECT sensor circuit for +B short.
2. Disconnect the ECM. Pins 49/46-
12 109/114/115/
116: ∞ Ω
resistance.

Check the ECT sensor circuit harness for Pins 49-
open wiring or short. ground
1. Starter switch "OFF". (jumpered:
pins 1-
ground): 0 Ω
3. Disconnect the ECT sensor connector. (not jumpered):
4. At the ECM connector, measure the ∞Ω
14
resistance. Pins 46-
ground
pins 2-
ground): 0 Ω
(not jumpered):

Check the ECT sensor.
1. Disconnect the ECT sensor.
16 thermosensitive element of the ECT See graph
sensor and measure the resistance
between the sensor connector pins.

Replace the ECT sensor.
Review the DTC.
1. Certainly connect the ECT sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
19 —
Verify repair and
20 — Refer to
Characteristics of ECT Sensor (reference)
[Thermistor Characteristics]
30
20
10
7.0
5.0
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100 120
Engine Coolant Temperature ( C)
LNW21ASH000901-X
Sensor Description
4 6
1 2 5
4 6 5
3
LNW21ASF003101
Legend
1. ECT sensor 4. Sensor ground
2. Thermistor for ECM 5. Sensor signal (on ECM)
3. Thermistor for meter 6. Sensor signal (on meter)
DTC24 - Accelerator Sensor System Fault
ECM
(Engine
110 Control
Module)
90 84 94 108
0.5W/L
0.5L
0.5L/W
0.5L/R
0.5B/Y
Idle
Switch
AP
Sensor
LNW21AMF007501-X
Circuit Description • ON/OFF fault judgment is disabled on idle position

The AP (accelerator pedal position) sensor sends the switch.
voltage signal that alters in response to the change in
Conditions for Clearing MIL/DTC
accelerator pedal angle to the ECM. The ECM
calculates the accelerator pedal position from this When the system fails and the DTC is stored to the
voltage signal and uses it in fuel injection control and ECM, even repairing the faulty portion will not clear the
other control tasks. DTC from the memory. To clear the DTC, conduct the
DTC24 will be set when the signal voltage is following steps.
excessively high or low. 1. Turn off the idle position switch for not less than 1
• Short power 2. Turn on the idle position switch for not less than 1
• Poor pedal response second but not more than 3 seconds. (Release the
The AP sensor output voltage deviates from the range accelerator pedal.)
between 0.1 V and 4.8 V for at least 1.5 seconds. 4. Turn on the idle position switch for not less than 1
• After the DTC is set, the ECM will illuminate the 5. Turn off the idle position switch for not less than 1
CHECK ENGINE lamp (MIL). second but not more than 3 seconds. (Press the
• The ECM controls the accelerator pedal position accelerator pedal.)
according to the signals from the idle position 6. After the above operations are properly completed,
switch. the CHECK ENGINE lamp (MIL) illuminates for 3
• EGR, warm-up, and intake throttle systems are seconds to report the memory is cleared.
disabled. 7. Turn off the starter switch. Wait for 5 seconds and
When Tech 2 has been connected to the vehicle, the connectors and wiring harnesses related to the
DTC can be cleared through the memory clear sensor. A change in the display will indicate the
operation with Tech 2. location of the fault.

connectors for backed-out pins, improper mating, 4. If the output voltage is fixed to 0 V, the possible
broken locks, improperly formed or damaged pins, cause is open wiring in the circuit. If the output voltage
and poor pin-to-wire connection. is fixed to 5 V, the possible cause is short in the circuit.
8. If pins are jumpered and the resistance reads ∞Ω,
the resistance reads 0 Ω, the cause is short.

1 — System Check
Check the AP sensor system for mechanical
fault.
1. Check the AP sensor connector for
install the device certainly.
2 2. Check the system components such as —
accelerator pedal link, bracket, and spring
for fault and, if troubles are found, repair
the faulty portion. (Refer to Section 1B
"Accelerator Pedal".)

Review the DTC.
Refer to
Check the AP sensor output voltage.
1. Install Tech 2.
2. Starter switch "ON", and display the Idling:
engine data. 0.43-0.73 V
4
3. Observe the "Accelerator Sensor" display WOT:
for output voltage while operating the 4.2-4.8 V
accelerator pedal.

Check the AP sensor output voltage.
5 —
Is the voltage 5 V or more? Go to Step 6 Go to Step 8

Check the AP sensor signal circuit for +B
short.
Pins 84-109/
resistance.
Check the harness between ECM and AP Pins 94-84
1. Starter switch "OFF". pins 1-2): 0 Ω
Pins 84-91
(jumpered:
3. Disconnect the AP sensor connector. pins 2-3): 0 Ω
4. Jumper the AP sensor connector pins Pins 94-90
and measure the resistance at the ECM (jumpered:
connector. pins 1-3): 0 Ω
(not jumpered):
8 Was the resistance within range? ∞Ω
Pins 94/84/
90-108
(not jumpered):
∞Ω
Pins 94/84/
90/108-
ground
(not jumpered):
Check the AP sensor.
1. At the AP sensor connector pins, Pins 1/2/3-
10 measure the resistance. ground: ∞ Ω
Replace the AP sensor.
Review the DTC.
1. Certainly connect the AP sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
13 —
Verify repair and

14 — Refer to
Switch Description
2 3
1
4
LNW21ASF003001
Legend
1. Idle position switch 4. Sensor signal
2. AP sensor 5. Sensor power
3. Sensor ground
DTC25 - Vehicle Speed Sensor System Fault
VIM
(Vehicle
Interface
Module)
34 31 71 30
0.5 0.5 0.5 0.5
R/B Y Y/BR Y/G
PTO Sensor Idling VS Sensor

Control
LNW21AMF007801-X

The VS (vehicle speed) sensor is equipped with a Hall When the system fails and the DTC is stored to the
effect circuit. The magnet installed to the transmission ECM, even repairing the faulty portion will not clear the
output shaft is rotated together with the shaft to DTC from the memory. To clear the DTC, conduct the
generate a magnetic field. This Hall effect sensor following steps.
interacts with the magnetic field and generates and 1. Turn off the idle position switch for not less than 1
sends a signal to the VIM. The VS sensor is energized second but not more than 3 seconds. (Press the
via meter fuse. The VIM uses the VS signal pulses to accelerator pedal.)
judge the vehicle speed.
DTC25 will be set when the VIM does not receive the
VS signal under the running conditions (clutch
accelerator pedal.)
engaged).
Major Faulty Event second but not more than 3 seconds. (Press the
accelerator pedal.)
• Improper speedometer indication
• Poor driveability
Conditions for Setting the DTC accelerator pedal.)
The state where clutch and neutral switches are in 5. Turn off the idle position switch for not less than 1
normal condition, the automatic transmission or clutch second but not more than 3 seconds. (Press the
switch is turned off, the engine is running at 2200 rpm accelerator pedal.)
or more, the neutral switch is turned off, and the vehicle 6. After the above operations are properly completed,
speed is 0 km/h lasts 5 seconds. the CHECK ENGINE lamp (MIL) illuminates for 3
Action Taken When the DTC Sets 7. Turn off the starter switch. Wait for 5 seconds and
• After the DTC is set, the ECM will illuminate the turn on the starter switch again.
CHECK ENGINE lamp (MIL). When Tech 2 has been connected to the vehicle, the
Diagnostic Aids OK, observe the display on Tech 2 while moving
Poor connection or damaged harness may cause connectors and wiring harnesses related to the
intermittents. Check for the following conditions and, if sensor. A change in the display will indicate the
the fault is detected, repair or replace the faulty portion. location of the fault.
• Poor connection at VIM: Inspect harness Test Description
broken locks, improperly formed or damaged pins, Number(s) below refer to the step number(s) on the
and poor pin-to-wire connection. Diagnostic Chart.
3. If the DTC is not detected, the possible cause is
• Damaged harness: Inspect the wiring harness for intermittent (intermittent fault).

1 — System Check
Check the VS sensor connector for installation
and, if mounted improperly, install the device
2 certainly. —

Review the DTC.
Refer to
Check the speedometer for operation.
1. Run the vehicle.
4 —
2. Check the speedometer.
Is the speedometer working correctly? Go to Step 5 Go to Step 6

Check the VS sensor signal circuit for open
wiring.
Pins 14-
1. Starter switch "OFF". ground
5 2. Jumper the VS sensor connector and (jumpered:
measure the resistance at the VIM pins 2-
Check the VS sensor power circuit for open
wiring.
2. Disconnect VIM and VS sensor
connectors. Pins 1-
6
ground: 24 V
4. At the VS sensor connector power pins,
measure the voltage.


Check the VS sensor ground circuit for open
wiring.
Pins 2-
7 2. Measure the resistance between VS
ground: 0 Ω
sensor connector ground pin and ground
(e.g., frame or body)
Check the VS sensor signal circuit for open
wiring.
Pins 14-
8 2. Jumper the VS sensor connector and (jumpered:
Check the VS sensor.
1. Remove the VS sensor.
2. Connect the VS sensor connector.
3. Starter switch "ON". 1.0 ~ 3.0 V /
10
4. While turning the VS sensor shaft slowly, 12.0 ~ 15.0 V
measure the voltage between connector
pins 2 and 3.
Did the voltage change within range? Go to Step 12 Go to Step 11

Replace the VS sensor.
Review the DTC.
12 —
Refer to
1. Replace the VIM.
IMPORTANT:
13 —
Verify repair and
14 — Refer to
Sensor Description
2 3 4
LNW21ASF002801
Legend
1. VS sensor 3. Sensor ground
2. Sensor signal 4. Sensor power
DTC28 - PTO Accelerator Sensor System Fault
VIM
(Vehicle
Interface
Module)
34 31 71 30
0.5 0.5 0.5 0.5
R/B Y Y/BR Y/G

Control
LNW21AMF007801-X
Circuit Description DTC from the memory. To clear the DTC, conduct the
The PTO accelerator sensor sends the voltage signal following steps.
that alters in response to the change in PTO control 1. Turn off the idle position switch for not less than 1
lever angle to the VIM. The VIM calculates the PTO second but not more than 3 seconds. (Press the
control lever angle from this voltage signal and sends it accelerator pedal.)
to the ECM through CAN communications. Then, the 2. Turn on the idle position switch for not less than 1
ECM uses the voltage signal in fuel injection control second but not more than 3 seconds. (Release the
during PTO. accelerator pedal.)
DTC28 will be set when the PTO accelerator sensor 3. Turn off the idle position switch for not less than 1
output signal is excessively high. second but not more than 3 seconds. (Press the
accelerator pedal.)
Major Faulty Event
The PTO accelerator sensor output signal exceeds 4.9
V for 1 second.
accelerator pedal.)
Action Taken When the DTC Sets 6. After the above operations are properly completed,
• Even after the DTC is set, the ECM will not
illuminate the CHECK ENGINE lamp (MIL).
7. Turn off the starter switch. Wait for 5 seconds and
• The ECM controls the powertrain using the set
PTO accelerator position (0 %).
Conditions for Clearing MIL/DTC DTC can be cleared through the memory clear
When the system fails and the DTC is stored to the
• Poor connection at VIM: Inspect harness Test Description

1 — System Check
Check the PTO accelerator sensor system for
mechanical fault.
1. Check the PTO accelerator sensor
connector for installation and, if mounted
improperly, install the device certainly.
2 —
2. Check the matching marks on the PTO
accelerator sensor and bolt for alignment
and, if misaligned, adjust positions of the
sensor and bolt.

Review the DTC.
Refer to
Check the PTO accelerator sensor output
voltage.
1. Install Tech 2.
2. Starter switch "ON", and display the Idling:
engine data. 0.3-0.6 V
4
WOT:
3. Observe the "PTO Accelerator Sensor"
4.07-4.67 V
display for output voltage while operating
the PTO control lever.

Check the PTO accelerator sensor circuit for
+B short.
Pins 31/34/
5 2. Disconnect the VIM. 71-38/75/76:
3. At the VIM connector pins, measure the ∞Ω
resistance.


Check the PTO accelerator sensor circuit for
short.
Pins 71-31:
1. Disconnect the VIM.
∞Ω
2. Disconnect the PTO accelerator sensor Pins 31-34:
7 connector. ∞Ω
3. At the VIM connector pins, measure the Pins 71-34:
resistance. ∞Ω

Check the PTO accelerator sensor.
1. Measure the resistance between each
9 sensor connector pin and ground (e.g., ∞Ω
frame or body)
Replace the PTO control lever (PTO
10 accelerator sensor). — Verify repair and
Review the DTC.
1. Certainly connect the PTO accelerator
sensor and VIM connectors.
Refer to
1. Replace the VIM.
IMPORTANT:
12 —
Verify repair and
13 — Refer to
DTC31 - Idle Up Volume System Fault
VIM
(Vehicle
Interface
Module)
34 31 71 30
0.5 0.5 0.5 0.5
R/B Y Y/BR Y/G

Control
LNW21AMF007801-X
Circuit Description DTC from the memory. To clear the DTC, conduct the
The idle up volume switch controls the idle speed following steps.
during warm-up and is installed in the driver’s side 1. Turn off the idle position switch for not less than 1
instrument panel. This switch is active only when the second but not more than 3 seconds. (Press the
gear is in the neutral position (parking or neutral accelerator pedal.)
position for automatic transmission vehicles). When the 2. Turn on the idle position switch for not less than 1
shift lever is moved to another position, the switch is second but not more than 3 seconds. (Release the
canceled. The ECM receives the idle up signal from accelerator pedal.)
this switch and controls the fuel injection quanti ty. 3. Turn off the idle position switch for not less than 1
DTC31 will be set when the output signal is excessively second but not more than 3 seconds. (Press the
high or low. accelerator pedal.)
accelerator pedal.)
The idle up volume output signal deviates from the
accelerator pedal.)
range between 0.2 V and 4.8 V for 1 second.
illuminate the CHECK ENGINE lamp (MIL). 7. Turn off the starter switch. Wait for 5 seconds and
• The idle up volume switch is disabled.
Conditions for Clearing MIL/DTC DTC can be cleared through the memory clear
• Poor connection at VIM: Inspect harness intermittent (intermittent fault).
connectors for backed-out pins, improper mating, 8. If pins are jumpered and the resistance reads ∞ Ω,
broken locks, improperly formed or damaged pins, the cause is open wiring. If pins are not jumpered and
and poor pin-to-wire connection. the resistance reads 0 Ω, the cause is short.

1 — System Check
Check the idle up volume switch connector for

Review the DTC.
Refer to
Check the idle up volume output voltage.
1. Install Tech 2.
2. Starter switch "ON", engine "OFF". approx. 0.4 V
(minimum) ~
4 3. Observe the "Idle Up Volume" display for
4.5 V
output voltage while operating the idle up
(maximum)
volume switch.

Check the idle up volume output voltage.
5 —
Check the idle up volume switch circuit for +B
short.
Pins 34/30/
6 2. Disconnect the VIM. 71-36/38/75/
3. At the VIM connector pins, measure the 76: ∞ Ω
resistance.


Check the idle up volume switch circuit Pins 71-34
harness for open wiring or short. (jumpered:
(not jumpered):
2. Disconnect the VIM.
∞Ω
3. Disconnect the idle up volume switch Pins 31-34
connector. (jumpered:
4. Jumper the idle up volume switch pins 2-3): 0 Ω
connector and measure the resistance at (not jumpered):
8 the VIM connector. ∞Ω
Pins 71-31
pins 1-3): 0 Ω
(not jumpered):
∞Ω
Pins 71/34/
31-ground
(not jumpered):
Check the idle up volume switch. Pins 1-2:
1. Remove the idle up volume switch. Discontinued
Pins 2-3:
10 2. Test the continuity between idle up
Discontinued
volume switch connector pins,
Pins 1-3:
Was the resistance within range? Continued Go to Step 12 Go to Step 11
Replace the idle up volume switch.
Review the DTC.
1. Certainly connect the idle up volume
switch and VIM connectors.
Refer to
1. Replace the VIM.
IMPORTANT:
13 —
Verify repair and
14 2. Perform test run and review the DTC. — Refer to
Idle Up Volume Switch Description
1 2 3
Circuit Diagram
1
300
0
3
LNW21ASF000701-X
Legend
1. Power supply 3. Signal
2. Ground
DTC33 - VIM Internal Fault (EEPROM Write Error)
Circuit Description 4. Turn on the idle position switch for not less than 1
The EEPROM is a memory device mounted inside the second but not more than 3 seconds. (Release the
VIM and counts the accumulated number of starter accelerator pedal.)
operation cycles. Multiple systems are used to record 5. Turn off the idle position switch for not less than 1
the number of starter operation cycles so that the second but not more than 3 seconds. (Press the
figures recorded can be compared each other. accelerator pedal.)
DTC33 will be set when the values recorded to the 6. After the above operations are properly completed,
EEPROM do not agree each other. the CHECK ENGINE lamp (MIL) illuminates for 3
Conditions for Setting the DTC
The stored count values do not agree each other when turn on the starter switch again.
the starter switch position is changed from OFF to ON. When Tech 2 has been connected to the vehicle, the
Action Taken When the DTC Sets operation with Tech 2.
illuminate the CHECK ENGINE lamp (MIL). Diagnostic Aids
• Counted and stored values are reset. Poor connection or damaged harness may cause
Conditions for Clearing MIL/DTC the fault is detected, repair or replace the faulty portion.
When the system fails and the DTC is stored to the • Poor connection at VIM: Inspect harness
ECM, even repairing the faulty portion will not clear the connectors for backed-out pins, improper mating,
DTC from the memory. To clear the DTC, conduct the broken locks, improperly formed or damaged pins,
following steps. and poor pin-to-wire connection.
1. Turn off the idle position switch for not less than 1 • Check the past service record for replacement of
second but not more than 3 seconds. (Press the VIM.
accelerator pedal.)
2. Turn on the idle position switch for not less than 1 Test Description
second but not more than 3 seconds. (Release the Number(s) below refer to the step number(s) on the
accelerator pedal.) Diagnostic Chart.
3. Turn off the idle position switch for not less than 1 3. If the DTC is not detected, the possible cause is
second but not more than 3 seconds. (Press the intermittent (intermittent fault).
accelerator pedal.)

1 — System Check
Check the VIM connector for installation and,
2 if mounted improperly, connect it certainly. —
Review the DTC.
Refer to

Check the VIM ground circuit for open wiring.
2. Disconnect the VIM. Pins 39/52/
4 3. Measure the resistance between VIM 60/66/73-
connector pin and ground (e.g., frame or ground: 0 Ω
body)
1. Replace the VIM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC34 - ECM Internal Fault (Charge Circuit Fault)
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 1
LNW21AMF007001-X
Circuit Description following steps.

The charge circuit in the ECM steps up the voltage for 1. Turn off the idle position switch for not less than 1
injectors and is divided into two banks, common 1 and second but not more than 3 seconds. (Press the
common 2. Common 1 covers injectors in cylinders 1 accelerator pedal.)
and 4 and common 2 covers injectors in cylinders 2 2. Turn on the idle position switch for not less than 1
and 3. second but not more than 3 seconds. (Release the
DTC34 will be set when the voltage on one of two accelerator pedal.)
charge circuits is excessively high or low. 3. Turn off the idle position switch for not less than 1
Major Faulty Event
accelerator pedal.)
• Short power
• Generation of black smoke accelerator pedal.)
The charge circuit voltage in the ECM is excessively accelerator pedal.)
high or low. 6. After the above operations are properly completed,
Action Taken When the DTC Sets
• Fault judgment is disabled on injector drive When Tech 2 has been connected to the vehicle, the
system. DTC can be cleared through the memory clear
• Poor connection at ECM: Inspect harness Test Description

1 — System Check
Check the ECM connector for installation and,
Review the DTC.
Refer to
Check the injector drive circuit for +B short.
2. Disconnect the ECM. Pins 1/2/4/5-
4 109/114/115/
116: ∞ Ω
resistance.

Check the ECM ground circuit for open wiring.
2. Disconnect the ECM. Pins 87/95/
5 3. Measure the resistance between ECM 119/120/121-
body)

1. 1. Replace the ECM.
IMPORTANT:
7 —
Verify repair and

8 — Refer to
DTC35 - VIM Internal Fault (A/D Conversion Fault)
The VIM converts analog signals (voltage signals) input second but not more than 3 seconds. (Press the
from various sensors into digital signals to perform accelerator pedal.)
diversified control tasks and arithmetic operations. 4. Turn on the idle position switch for not less than 1
DTC35 will be set when this A/D (analog-to-digital) second but not more than 3 seconds. (Release the
conversion is faulty. accelerator pedal.)
• Generation of white/black smoke accelerator pedal.)
• Inactive idle up volume system 6. After the above operations are properly completed,
• Inactive PTO accelerator sensor system the CHECK ENGINE lamp (MIL) illuminates for 3
Conditions for Setting the DTC 7. Turn off the starter switch. Wait for 5 seconds and
The A/D (analog-to-digital) conversion is not complete turn on the starter switch again.
in the VIM. When Tech 2 has been connected to the vehicle, the
Action Taken When the DTC Sets operation with Tech 2.
• After the DTC is set, the ECM will illuminate the
Diagnostic Aids
CHECK ENGINE lamp (MIL).
Poor connection or damaged harness may cause
• Fault judgment is disabled on PTO accelerator
sensor, atmospheric pressure sensor, and idle up
the fault is detected, repair or replace the faulty portion.
volume.
• Poor connection at VIM: Inspect harness
Conditions for Clearing MIL/DTC connectors for backed-out pins, improper mating,
When the system fails and the DTC is stored to the broken locks, improperly formed or damaged pins,
ECM, even repairing the faulty portion will not clear the and poor pin-to-wire connection.
DTC from the memory. To clear the DTC, conduct the • Check the past service record for replacement of
following steps. VIM.
Test Description
accelerator pedal.) Number(s) below refer to the step number(s) on the
Diagnostic Chart.
intermittent (intermittent fault).
accelerator pedal.)

1 — System Check
Check the VIM connector for installation and,
Review the DTC.
Refer to

Check the VIM ground circuit for open wiring.
2. Disconnect the VIM. Pins 39/52/
4 3. Measure the resistance between VIM 60/66/73-
body)
1. Replace the VIM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC43 - ITP Sensor System Fault
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X

The ITP (intake throttle position) sensor sends the When the system fails and the DTC is stored to the
voltage signal that alters in response to the change in ECM, even repairing the faulty portion will not clear the
throttle position to the ECM. The ECM calculates the DTC from the memory. To clear the DTC, conduct the
throttle position from this voltage signal and uses it in following steps.
intake throttle control and other control tasks. 1. Turn off the idle position switch for not less than 1
DTC43 will be set when the output voltage from the ITP second but not more than 3 seconds. (Press the
sensor is excessively high or low. accelerator pedal.)
• Short power 3. Turn off the idle position switch for not less than 1
• Poor driveability second but not more than 3 seconds. (Press the
• Extensive suction noise during acceleration or accelerator pedal.)
exhaust braking 4. Turn on the idle position switch for not less than 1
The ITP sensor output voltage deviates from the range 5. Turn off the idle position switch for not less than 1
between 0.1 V and 4.9 V for at least 1 second. second but not more than 3 seconds. (Press the
accelerator pedal.)
• After the DTC is set, the ECM will illuminate the the CHECK ENGINE lamp (MIL) illuminates for 3
CHECK ENGINE lamp (MIL). seconds to report the memory is cleared.
• Intake throttle and EGR systems are disabled. 7. Turn off the starter switch. Wait for 5 seconds and
• Fault judgment is disabled on intake throttle valve. turn on the starter switch again.
connectors for backed-out pins, improper mating, 4. If the DTC44 or DTC245 are also set, the possible
broken locks, improperly formed or damaged pins, cause is ground circuit common to ITP sensor and
and poor pin-to-wire connection. EGR position sensor or common rail pressure sensor.
10. If the output voltage is fixed to 0 V, the possible
14. If pins are jumpered and the resistance reads ∞ Ω,

1 — System Check
Check the intake throttle connector for

Review the DTC.
Refer to
4 Are DTC44 (EGR Position Sensor Fault)or —

DTC245 (Common Rail Pressure Sensor
Check the circuit ground common to ITP
sensor , EGR position sensor and common
rail pressure sensor for +B short.
1. Starter switch "OFF". Pins 64 -109/
∞Ω
resistance.


Check the circuit ground common or common Pins 64-63
power circuit to ITP, EGR position and (not jumpered):
common rail pressure sensors for open wiring ∞Ω
or short. Pins 64-
(jumpered):
Pins 1-
3. Disconnect the ITP sensor connector. ground: 0 Ω
7 4. Jumper the ITP sensor connector and (not jumpered):
measure the resistance at the ECM ∞Ω
connector. Pins 63-
ground
Was the resistance within range? (jumpered):
Pins 4-
ground: 0 Ω
(not jumpered):
Review the DTC.
1. Certainly connect the ITP sensor and
ECM connectors.
Refer to
Check the ITP sensor output voltage.
1. Install Tech 2.
2. Starter switch "ON", and display the
10 engine data. Approx. 4 V
3. Observe the "Intake Throttle Valve"
display for output voltage.

Check the ITP sensor output voltage.
11 —
Check the ITP sensor SIG circuit for +B short.
2. Disconnect the ECM. Pins 69-109/
12 114/115/116:
∞Ω
resistance.


Check the between ECM to ITP sensor Pins 69-64
1. Starter switch "OFF". 1-2): 0 Ω
(not jumpered):
∞Ω
3. Disconnect the Intake throttle connector. Pins 69-63
4. Jumper the Intake throttle connector and (jumpered:
measure the resistance at the ECM 2-4): 0 Ω
14
Pins 64-63
1-4): 0 Ω
(not jumpered):
∞Ω
Pins 64/69/
63-ground
(not jumpered):
Check the ITP sensor. Pins 1-2,
1. Test the continuity between ITP sensor Pins 2-4,
connector pins. Pins 1/2/4-
16 3/5:
Does the ITP sensor meet the requirements? Discontinued
Pins 1-4:
Continued Go to Step 18 Go to Step 15
Replace the Intake trottle (ITP sensor).
Review the DTC.
1. Certainly connect the ITP sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
19 —
Verify repair and
20 — Refer to
Intake Throttle Valve Description
5
8
6
9
7
4
LNW21ASF002101
Legend
1. Throttle valve 6. Sensor signal
2. ITP sensor 7. Motor (–)
3. Reduction gears 8. Sensor power
4. DC motor 9. Motor (+)
5. Sensor ground
DTC44 - EGR Valve Position Sensor System Fault
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X

The EGR valve position sensor sends the voltage When the system fails and the DTC is stored to the
signal that alters in response to the change in EGR ECM, even repairing the faulty portion will not clear the
valve position to the ECM. The ECM calculates the DTC from the memory. To clear the DTC, conduct the
EGR valve position from this voltage signal and uses it following steps.
in EGR control and other control tasks. 1. Turn off the idle position switch for not less than 1
DTC44 will be set when the output voltage from the second but not more than 3 seconds. (Press the
EGR valve position sensor is excessively high or low. accelerator pedal.)
• Short power 3. Turn off the idle position switch for not less than 1
accelerator pedal.)
The EGR valve position sensor voltage deviates from second but not more than 3 seconds. (Release the
the range between 0.3 V and 4.6 V for at least 3 accelerator pedal.)
seconds. 5. Turn off the idle position switch for not less than 1
accelerator pedal.)
• Intake throttle and EGR systems are disabled. seconds to report the memory is cleared.
• The EGR motor is deenergized. 7. Turn off the starter switch. Wait for 5 seconds and
• Fault judgment is disabled on EGR valve. turn on the starter switch again.
connectors for backed-out pins, improper mating, 4. If the DTC43 or DTC245 are also set, the possible
broken locks, improperly formed or damaged pins, cause is ground circuit common to ITP sensor and
and poor pin-to-wire connection. EGR position sensor or common rail pressure seosor.

1 — System Check
Check the EGR valve connector for

Review the DTC.
Refer to
4 Are DTC44 (EGR Position Sensor Fault)or —

DTC245 (Common Rail Pressure Sensor
sensor , EGR position sensor and common
rail pressure sensor for +B short.
1. Starter switch "OFF". Pins 64-109/
∞Ω
resistance.


power circuit to ITP sensor, EGR position (not jumpered):
sensor and common rail pressure sensors for ∞Ω
open wiring or short. Pin 64-
(jumpered:
2-ground):
3. Disconnect the EGR position sensor. 0Ω
7 4. Jumper the EGR sensor connector pin (not jumpered):
and measure the resistance at the ECM ∞Ω
connector. Pins 63-
ground
1-ground):
0Ω
(not jumpered):
Review the DTC.
1. Certainly connect the EGR position
sensor and ECM connectors.
Refer to
Check the EGR valve position sensor output
10 voltage. —
Check the EGR valve position sensor circuit
for +B short.
1. Starter switch "OFF". Pins 63/68/
2. Disconnect the ECM. 64-109/114/
11
115/116:
∞Ω
resistance.


Check the EGR valve position sensor circuit Pins 63-64
(not jumpered):
∞Ω
3. Disconnect the EGR valve connector. Pins 64-68
4. Jumper the EGR vale connector pin and (jumpered:
measure the resistance at the ECM pins 2-3): 0 Ω
13 ∞Ω
Was the resistance within range? Pins 63-68
(jumpered:
pins 1-3): 0 Ω
(not jumpered):
∞Ω
Pins 63/64/
68-ground
(not jumpered):
Check the EGR valve position sensor. [Reference]
1. At the EGR valve connector pins, Pins 1-2:
measure the resistance. Approx.
1.4~2 kΩ
Was the resistance within range? Pins 2-3:
Approx.
15
6~8 Ω
Pins 1-3:
Approx.
5~7 kΩ
Pins 1/2/3-4/
5: ∞ Ω Go to Step 17 Go to Step 16
Replace the EGR valve (EGR valve position
16 sensor). — Verify repair and
Review the DTC.
1. Certainly connect the EGR valve and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
18 —
Verify repair and

19 — Refer to
EGR Valve Description
1
5
6
LNW21ASF002201
Legend
1. Exhaust path 5. Sensor ground
2. Valve 6. Sensor power
3. Motor (–) 7. Motor (+)
4. Sensor signal 8. DC motor
DTC45 - EGR Valve System Fault
ECM
(Engine
Control
Module)
35 16 58 59
0.75W/G
0.75R
0.75L/Y
0.75W/B
M M
M- M+ M- M+
Intake EGR
Throttle DC Motor
DC Motor
LNW21AMF007301-X

The EGR valve is operated by the DC motor. The DC When the system fails and the DTC is stored to the
motor changes the drive duty to operate the valve, and ECM, even repairing the faulty portion will not clear the
increasing the duty opens the valve while decreasing DTC from the memory. To clear the DTC, conduct the
the duty closes the valve. The ECM calculates the following steps.
desired EGR valve position according to the current 1. Turn off the idle position switch for not less than 1
vehicle running condition and controls the DC motor. second but not more than 3 seconds. (Press the
DTC45 will be set when the difference between desired accelerator pedal.)
and actual EGR valve positions is excessively large or
the drive voltage is excessively high.
• Generation of black smoke
• Short power accelerator pedal.)
• Poor driveability 4. Turn on the idle position switch for not less than 1
accelerator pedal.)
The state where the EGR valve position sensor is in 5. Turn off the idle position switch for not less than 1
normal condition and the valve drive voltage is second but not more than 3 seconds. (Press the
excessively high lasts for at least 10 seconds. accelerator pedal.)
Action Taken When the DTC Sets 6. After the above operations are properly completed,
• EGR and intake throttle systems are disabled.
• The EGR motor is deenergized. When Tech 2 has been connected to the vehicle, the
Diagnostic Aids connectors and wiring harnesses related to the
Poor connection or damaged harness may cause sensor. A change in the display will indicate the
intermittents. Check for the following conditions and, if location of the fault.
Test Description
connectors for backed-out pins, improper mating, Number(s) below refer to the step number(s) on the
broken locks, improperly formed or damaged pins, Diagnostic Chart.
and poor pin-to-wire connection. 3. If the DTC is not detected, the possible cause is
• Damaged harness: Inspect the wiring harness for 4. If pins are jumpered and the resistance reads ∞ Ω,
rubbed-through wire insulation or wire broken the cause is open wiring. If pins are not jumper and the
inside the insulator. If the harness appears to be resistance reads 0 Ω, the cause is short.

1 — System Check
Check the EGR valve connector for

Review the DTC.
Refer to
Check the EGR DC motor drive circuit for Pins 59-58
open wiring or short. (jumpered:
(not jumpered):
∞Ω
3. Disconnect EGR valve connector. Pins 59-
4. Jumper the EGR vale connector and ground
measure the resistance at the ECM (jumpered:
connector. pins 4-
4 ground): 0 Ω
Was the resistance within range? (not jumpered):
∞Ω
Pins 58-
ground
(jumpered:
pins 5-
ground): 0 Ω
(not jumpered):
Check the EGR DC motor.
[Reference]
1. Measure the resistance between EGR Pins 4-5:
6 valve connector pins. Approx.
95~105 Ω

Replace the EGR valve (EGR DC motor).
Review the DTC.
1. Certainly connect the EGR valve position
sensor and ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
9 —
Verify repair and
10 — Refer to
EGR Valve Description
1
5
6
LNW21ASF002201
Legend
1. Exhaust path 5. Sensor ground
2. Valve 6. Sensor power
3. Motor (–) 7. Motor (+)
4. Sensor signal 8. DC motor
DTC46 - Exhaust Brake System Fault
SBF SBF
100A 50A
Battery
SBF Key SW Key SW

50A (START) (ON)
SBF
30A
# 22 # 19
10A 15A
Main Relay
0.5 L/Y
ECM 0.5 L/Y
Glow ECO Exhaust Exhaust

Lamp Relay Brake Brake
Lamp VSV
0.5 0.5 1.25 1.25 1.25 0.3 0.5 0.5 0.85 0.3 0.5
W 0.5R B W/R W/R W/R O/L G/Y B/W B/O BR/W LG/B
27 26 25 76 75 38 42 3 46 36 4 2
VIM
(Vehicle
Interface
Module)
LNW21ALF005801-X
Circuit Description Conditions for Setting the DTC

The exhaust brake is operated by the solenoid valve With the battery voltage at 20 V or more, the engine
on/off control and the resultant vacuum path open/ speed at 500 rpm or more, and the exhaust brake
close action. When the solenoid valve is turned on, the turned on, the solenoid valve is turned off or exhaust
vacuum path is opened and the exhaust brake valve brake turned off, the solenoid valve is turned on for 1
works. When the solenoid valve is turned off, the second.
vacuum path is closed and the atmospheric pressure is
applied to release the exhaust brake valve. After the Action Taken When the DTC Sets
exhaust brake switch is turned on and all the necessary • After the DTC is set, the ECM will illuminate the
vehicle conditions are met, the VIM energizes (turns CHECK ENGINE lamp (MIL).
on) the solenoid valve. • The exhaust brake system is disabled.
DTC46 will be set when the solenoid valve fails to
respond the on/off operation of the exhaust brake. Conditions for Clearing MIL/DTC
Major Faulty Event When the system fails and the DTC is stored to the
• Inactive exhaust brake system and QWS DTC from the memory. To clear the DTC, conduct the
• Inactive ABS/ASR following steps.
1. Turn off the idle position switch for not less than 1 Diagnostic Aids
second but not more than 3 seconds. (Press the Poor connection or damaged harness may cause
accelerator pedal.) intermittents. Check for the following conditions and, if
2. Turn on the idle position switch for not less than 1 the fault is detected, repair or replace the faulty portion.
second but not more than 3 seconds. (Release the • Poor connection at VIM: Inspect harness
accelerator pedal.) connectors for backed-out pins, improper mating,
3. Turn off the idle position switch for not less than 1 broken locks, improperly formed or damaged pins,
second but not more than 3 seconds. (Press the and poor pin-to-wire connection.
accelerator pedal.) • Damaged harness: Inspect the wiring harness for
4. Turn on the idle position switch for not less than 1 rubbed-through wire insulation or wire broken
second but not more than 3 seconds. (Release the inside the insulator. If the harness appears to be
accelerator pedal.) OK, observe the display on Tech 2 while moving
5. Turn off the idle position switch for not less than 1 connectors and wiring harnesses related to the
second but not more than 3 seconds. (Press the sensor. A change in the display will indicate the
accelerator pedal.) location of the fault.
Test Description
seconds to report the memory is cleared. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
4. If even this step fails to detect the DTC, the exhaust
brake solenoid valve is faulty.

1 — System Check
Check the exhaust brake solenoid valve
2 improperly, connect it certainly. —

Review the DTC.
Refer to
circuit.
2. Disconnect the exhaust brake solenoid
4 valve connector. —
3. Jumper the harness connector pins.
4. Use Step 3 and review the DTC
Is DTC46 detected? Go to Step 6 Go to Step 5

Replace the exhaust brake solenoid valve.

circuit. Pins 2-
2. Disconnect the VIM. (jumpered:
6 pins 2-
3. Jumper the solenoid valve connector and
ground): 0 Ω
measure the resistance at the VIM
(not jumpered):
connector.
∞Ω
circuit.
Pins 75-
ground
2. Disconnect the vehicle side connector (jumpered:
7 from ECM. pins 1-
3. Jumper the solenoid valve connector and ground): 0 Ω
measure the resistance at the ECM (not jumpered):
connector. ∞Ω

Review the DTC.
Refer to
1. Replace the VIM
IMPORTANT:
10 —
Verify repair and
11 — Refer to
2. Start the engine and review the DTC.
DTC51 - ECM Internal Fault (CPU Error / CPU History Error)
The CPU is a processor mounted in the ECM and second but not more than 3 seconds. (Press the
receives and processes signals from sensors and accelerator pedal.)
switches to control actuators. 4. Turn on the idle position switch for not less than 1
The sub CPU will set DTC51 when the CPU operation second but not more than 3 seconds. (Release the
signals are faulty. accelerator pedal.)
5. 5. Turn off the idle position switch for not less than
Major Faulty Event 1 second but not more than 3 seconds. (Press the
• Engine stop accelerator pedal.)
Conditions for Setting the DTC the CHECK ENGINE lamp (MIL) illuminates for 3
The sub CPU judges the CPU fail. Otherwise, with the seconds to report the memory is cleared.
battery voltage 20 V or more and the starter switch 7. Turn off the starter switch. Wait for 5 seconds and
turned off, the CPU working signals are not detected turn on the starter switch again.
even after the initial status lasts for at least 0.4 second. When Tech 2 has been connected to the vehicle, the
• After the DTC is set, the ECM (sub CPU) will
illuminate the CHECK ENGINE lamp (MIL). Diagnostic Aids
• Upon restoration of CPU, the accelerator position Poor connection or damaged harness may cause
is limited and then the limitation is relaxed intermittents. Check for the following conditions and, if
gradually. the fault is detected, repair or replace the faulty portion.
When the system fails and the DTC is stored to the broken locks, improperly formed or damaged pins,
ECM, even repairing the faulty portion will not clear the and poor pin-to-wire connection.
DTC from the memory. To clear the DTC, conduct the • Check the past service record for replacement of
following steps. ECM.
second but not more than 3 seconds. (Press the Test Description
accelerator pedal.) Number(s) below refer to the step number(s) on the
2. Turn on the idle position switch for not less than 1 Diagnostic Chart.
second but not more than 3 seconds. (Release the 3. If the DTC is not detected, the possible cause is
accelerator pedal.) intermittent (intermittent fault).

1 — System Check
Review the DTC.
Refer to

body)
1. Replace the ECM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC52 - ECM Internal Fault (Sub CPU Error)
The sub CPU monitors the CPU in the ECM and second but not more than 3 seconds. (Press the
detects fault(s) of the CPU. accelerator pedal.)
The CPU will set DTC52 when the sub CPU operation 4. Turn on the idle position switch for not less than 1
signals are faulty. second but not more than 3 seconds. (Release the
accelerator pedal.)
Major Faulty Event 5. Turn off the idle position switch for not less than 1
accelerator pedal.)
Conditions for Setting the DTC 6. After the above operations are properly completed,
The post initial status lasts at least 2 seconds, the the CHECK ENGINE lamp (MIL) illuminates for 3
battery voltage is 22 V or more, the starter switch is seconds to report the memory is cleared.
turned off for at least 0.5 second, and the CPU working 7. Turn off the starter switch. Wait for 5 seconds and
signals are faulty for 0.7 second or more. turn on the starter switch again.
• After the DTC is set, the ECM will illuminate the operation with Tech 2.
• The calibration of fuel injection quantity with Diagnostic Aids
common rail pressure and fuel temperature is Poor connection or damaged harness may cause
limited. intermittents. Check for the following conditions and, if
When the system fails and the DTC is stored to the connectors for backed-out pins, improper mating,
ECM, even repairing the faulty portion will not clear the broken locks, improperly formed or damaged pins,
DTC from the memory. To clear the DTC, conduct the and poor pin-to-wire connection.
following steps. • Check the past service record for replacement of
1. Turn off the idle position switch for not less than 1 ECM.
accelerator pedal.) Test Description
2. Turn on the idle position switch for not less than 1 Number(s) below refer to the step number(s) on the
second but not more than 3 seconds. (Release the Diagnostic Chart.
accelerator pedal.) 3. If the DTC is not detected, the possible cause is

1 — System Check
Review the DTC.
Refer to
Is DTC52 detected Go to Step 4 Diagnostic Aids

body)
1. Replace the ECM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC61 - Intake Throttle Valve System Fault
ECM
(Engine
Control
Module)
35 16 58 59
0.75W/G
0.75R
0.75L/Y
0.75W/B
M M
M- M+ M- M+
Intake EGR
Throttle DC Motor
DC Motor
LNW21AMF007301-X

The intake throttle valve is operated by the DC motor. When the system fails and the DTC is stored to the
The DC motor operates the intake throttle valve by ECM, even repairing the faulty portion will not clear the
changing the drive voltage (duty). The valve is closed DTC from the memory. To clear the DTC, conduct the
when the drive voltage is increased while opened when following steps.
the voltage is decreased. The ECM calculates the 1. Turn off the idle position switch for not less than 1
desired intake throttle valve position based on the second but not more than 3 seconds. (Press the
vehicle running condition and controls the DC motor accelerator pedal.)
accordingly.
DTC61 will be set when the difference between desired
and actual intake throttle valve positions is large or the
accelerator pedal.)
drive voltage is excessively high.
accelerator pedal.)
• Generation of black smoke
• Short power
The state where the ITP sensor is in normal condition accelerator pedal.)
and the valve drive voltage is excessively high lasts for
at least 10 seconds. 6. After the above operations are properly completed,
• Intake throttle and EGR systems are disabled.
• The intake throttle valve DC motor is deenergized. operation with Tech 2.
Test Description
rubbed-through wire insulation or wire broken the cause is open wiring. If pins are not jumpered and
inside the insulator. If the harness appears to be the resistance reads 0 Ω, the cause is short.

1 — System Check
Check the intake throttle connector for

Review the DTC.
Refer to
Check the intake throttle DC motor drive Pins 16-35
circuit for open wiring or short. (jumpered:
(not jumpered):
∞Ω
3. Disconnect the intake throttle connector. Pins 16-
4. Jumper the intake throttle connector and ground
measure the resistance at the ECM (jumpered:
connector. pins 3-
4 ground): 0 Ω
Was the resistance within range? (not jumpered):
∞Ω
Pins 35-
ground
(jumpered:
pins 5-
ground): 0 Ω
(not jumpered):
Check the intake throttle DC motor.
1. Measure the resistance between intake Pins 3-5:
6 throttle connector pins. 16 ~ 18 Ω

Replace the intake throttle (intake throttle DC
7 motor). — Verify repair and
Review the DTC.
1. Certainly connect the intake throttle and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
9 —
Verify repair and
10 — Refer to
Intake Throttle Valve Description
5
8
6
9
7
4
LNW21ASF002101
Legend
1. Throttle valve 6. Sensor signal
2. ITP sensor 7. Motor (–)
3. Reduction gears 8. Sensor power
4. DC motor 9. Motor (+)
5. Sensor ground
DTC71 - Barometric Pressure Sensor Fault
The atmospheric (barometric) pressure sensor is second but not more than 3 seconds. (Release the
installed inside the ECM and converts the atmospheric accelerator pedal.)
pressure into a voltage signal. The VIM calculates the 5. Turn off the idle position switch for not less than 1
atmospheric pressure from this voltage signal and second but not more than 3 seconds. (Press the
sends the result to the ECM. The ECM uses this accelerator pedal.)
atmospheric pressure to calibrate the fuel injection 6. After the above operations are properly completed,
quantity (altitude compensation). the CHECK ENGINE lamp (MIL) illuminates for 3
DTC71 will be set when the signal voltage is seconds to report the memory is cleared.
excessively high or low. 7. Turn off the starter switch. Wait for 5 seconds and
Major Faulty Event
• Generation of black smoke DTC can be cleared through the memory clear
The atmospheric pressure sensor voltage deviates Diagnostic Aids
from the range between 0.5 V and 4.5 V for 1 second. Poor connection or damaged harness may cause
Action Taken When the DTC Sets the fault is detected, repair or replace the faulty portion.
• After the DTC is set, the ECM will illuminate the • Poor connection at VIM: Inspect harness
CHECK ENGINE lamp (MIL). connectors for backed-out pins, improper mating,
• The ECM controls the powertrain based on the set broken locks, improperly formed or damaged pins,
atmospheric pressure (100 kPa). and poor pin-to-wire connection.
When the system fails and the DTC is stored to the inside the insulator. If the harness appears to be
ECM, even repairing the faulty portion will not clear the OK, observe the display on Tech 2 while moving
DTC from the memory. To clear the DTC, conduct the connectors and wiring harnesses related to the
following steps. sensor. A change in the display will indicate the
1. Turn off the idle position switch for not less than 1 location of the fault.
accelerator pedal.) Test Description
2. Turn on the idle position switch for not less than 1 Number(s) below refer to the step number(s) on the
second but not more than 3 seconds. (Release the Diagnostic Chart.
accelerator pedal.) 3. If the DTC is not detected, the possible cause is
accelerator pedal.)

1 — System Check
Check the atmospheric pressure sensor
output voltage.
1. Starter switch "OFF", and install Tech 2.
2. Starter switch "ON" and display the
2 engine data. 0.5 ~ 4.5 V
3. Check the atmospheric pressure sensor
output voltage.


Review the DTC.
2. Clear the DTC.
3 3. Start the engine. Run the engine at idle —
for 1 minute.
4. Review the DTC.
Refer to
1. Replace the VIM.
IMPORTANT:
4 —
Verify repair and
5 — Refer to
DTC81 - Clutch Switch System Fault
SBF SBF
100A 50A
Battery
Key Key SW
Main Relay SW (START)
(ON)
# 19 # 22
15A 10A
M/T : N Warm Exhaust Torque

Freezer Brake Cut Clutch
SW A/T : P Up SW
or N SW SW SW
CFS
0.85 L/B Non CFS CFS
Vehicle
Vehicle
0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5
L/B B/G BR/R LG/R W/O W/L 0.5 LG/L B/O B/W
47 44 12 50 11 49 36 46 VIM
(Vehicle
Interface
Module)
LNW21ALF005701-X
Circuit Description Action Taken When the DTC Sets

The clutch switch is installed to the clutch pedal, and is • After the DTC is set, the ECM will illuminate the
turned on when the pedal is pressed and turned off CHECK ENGINE lamp (MIL).
when the pedal is released. The ECM receives the on/ • The exhaust brake is disabled.
off signal from this clutch switch and uses it in exhaust
brake control and other control tasks. Conditions for Clearing MIL/DTC
DTC81 will be set when the clutch switch on/off signal When the system fails and the DTC is stored to the
is faulty. ECM, even repairing the faulty portion will not clear the
Major Faulty Event
following steps.
• Inactive exhaust brake
• Inactive QWS second but not more than 3 seconds. (Press the
• Inactive PTO accelerator pedal.)
Conditions for Setting the DTC second but not more than 3 seconds. (Release the
On the manual transmission vehicle, the engine is accelerator pedal.)
running for at least 180 seconds, the vehicle speed is 3. Turn off the idle position switch for not less than 1
at least 80 km/h, and the clutch switch is changed from second but not more than 3 seconds. (Press the
off to on or on to off. accelerator pedal.)
4. Turn on the idle position switch for not less than 1 the fault is detected, repair or replace the faulty portion.
second but not more than 3 seconds. (Release the • Poor connection at VIM: Inspect harness
5. Turn off the idle position switch for not less than 1 broken locks, improperly formed or damaged pins,
second but not more than 3 seconds. (Press the and poor pin-to-wire connection.
6. After the above operations are properly completed, rubbed-through wire insulation or wire broken
the CHECK ENGINE lamp (MIL) illuminates for 3 inside the insulator. If the harness appears to be
seconds to report the memory is cleared. OK, observe the display on Tech 2 while moving
7. Turn off the starter switch. Wait for 5 seconds and connectors and wiring harnesses related to the
turn on the starter switch again. sensor. A change in the display will indicate the
When Tech 2 has been connected to the vehicle, the location of the fault
operation with Tech 2. Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Aids Diagnostic Chart.
Poor connection or damaged harness may cause 3. If the DTC is not detected, the possible cause is
intermittents. Check for the following conditions and, if intermittent (intermittent fault).

1 — System Check
Check the clutch switch for mechanical fault.
1. Check the clutch switch connector for
2. Check the contact between clutch pedal
and switch and recondition the improper
2 contact, if any. —
3. Press the clutch switch with a finger to
check the sliding performance. In case of
unsmooth movement, blow air against the
switch to remove foreign materials.

Review the DTC.
Refer to
Check the clutch switch for operation.
1. Install Tech 2.
2. Starter switch "ON" and display the
4 engine data. —
3. Check the output voltage on "Clutch
Switch" screen.
Is the clutch switch turned on and off? Go to Step 13 Go to Step 5

Check the clutch switch for operation.
5 —
Is the clutch switch fixed to the off position? Go to Step 6 Go to Step 9

Check the clutch switch circuit for open wiring.
1. Starter switch "OFF", and disconnect the
VIM.
2. Disconnect the clutch switch connector
and jumper it. Pins 49-
6
3. Starter switch "ON". ground: 24 V
4. Measure the voltage between VIM
body)
Check the fuse side harness of the clutch
switch circuit for open wiring.
1. Remove the jumper wire from the clutch
switch.
2. Starter switch "ON". Pins 1-
7
ground: 24 V
3. Measure the voltage between clutch
switch connector pin and ground (e.g.,
frame or body)

Check the VIM side harness of the clutch
switch circuit for open wiring.
Pins 49-
8 2. Jumper the starter switch connector and (jumpered:
Check the clutch switch circuit for +B short.
2. Disconnect the VIM. Pins 49-36/
9
3. At the VIM connector pins, measure the 38/75/76: ∞ Ω
resistance.
Check the clutch switch circuit for short.
VIM.
2. Disconnect the clutch switch connector.
Pins 49-
10 3. Starter switch "ON".
ground: 0 V
connector pin and ground (such as frame
or body)

Replace the clutch switch.

Review the DTC.
1. Certainly connect the clutch switch and
VIM connectors.
Refer to
1. Replace the VIM.
IMPORTANT:
14 —
Verify repair and
15 — Refer to
DTC82 - Neutral Switch System Fault
SBF SBF
100A 50A
Battery
Key Key SW
Main Relay SW (START)
(ON)
# 19 # 22
15A 10A
M/T : N Warm Exhaust Torque

Freezer Brake Cut Clutch
SW A/T : P Up SW
or N SW SW SW
CFS
0.85 L/B Non CFS CFS
Vehicle
Vehicle
0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5
L/B B/G BR/R LG/R W/O W/L 0.5 LG/L B/O B/W
47 44 12 50 11 49 36 46 VIM
(Vehicle
Interface
Module)
LNW21ALF005701-X
Circuit Description Conditions for Setting the DTC

The neutral switch (P/N switch in case of automatic The engine is running for at least 180 seconds and the
transmission) is turned on when the shift lever is moved neutral switch is changed from on to off.
to the neutral position (parking or neutral position for
automatic transmission). The ECM receives the on/off Action Taken When the DTC Sets
signal from this neutral (or P/N) switch to control the • After the DTC is set, the ECM will illuminate the
powertrain so that the driver cannot start the engine as CHECK ENGINE lamp (MIL).
long as the shift lever is not in the neutral (or parking) • The exhaust brake is disabled.
position.
DTC82 will be set when the neutral (P/N) switch on/off Conditions for Clearing MIL/DTC
signal is faulty.
Major Faulty Event ECM, even repairing the faulty portion will not clear the
• Generation of black smoke following steps.
• Poor driveability 1. Turn off the idle position switch for not less than 1
• Inactive exhaust brake second but not more than 3 seconds. (Press the
• Inactive QWS accelerator pedal.)
2. Turn on the idle position switch for not less than 1 Diagnostic Aids
second but not more than 3 seconds. (Release the Poor connection or damaged harness may cause
accelerator pedal.) intermittents. Check for the following conditions and, if
3. Turn off the idle position switch for not less than 1 the fault is detected, repair or replace the faulty portion.
second but not more than 3 seconds. (Press the • Poor connection at VIM: Inspect harness
4. Turn on the idle position switch for not less than 1 broken locks, improperly formed or damaged pins,
second but not more than 3 seconds. (Release the and poor pin-to-wire connection.
5. Turn off the idle position switch for not less than 1 rubbed-through wire insulation or wire broken
second but not more than 3 seconds. (Press the inside the insulator. If the harness appears to be
accelerator pedal.) OK, observe the display on Tech 2 while moving
6. After the above operations are properly completed, connectors and wiring harnesses related to the
the CHECK ENGINE lamp (MIL) illuminates for 3 sensor. A change in the display will indicate the
seconds to report the memory is cleared. location of the fault.
Test Description
When Tech 2 has been connected to the vehicle, the Number(s) below refer to the step number(s) on the
DTC can be cleared through the memory clear Diagnostic Chart.
operation with Tech 2. 2. If the DTC is not detected, the possible cause is

1 — System Check
Review the DTC.
Refer to
Check the neutral (P/N) switch for operation.
1. Install Tech 2.
3 engine data. —
3. Observe the "Neutral Switch" display
while operating the shift lever.
Is the neutral switch turned on and off? Go to Step 8 Go to Step 4
Check the neutral (P/N) switch circuit for +B
short.
2. Disconnect the VIM. Pins 44-36/
4
38/75/76: ∞ Ω
3. At the VIM connector pins, measure the
resistance.


Check the neutral (P/N) switch circuit for
short.
VIM.
2. Disconnect the neutral switch connector. Pins 44-
5
3. Starter switch "ON". ground: 0 V
body)
Replace the neutral (P/N) switch.
Review the DTC.
1. Certainly connect the neutral (P/N) switch
and VIM connectors.
Refer to
1. Replace the VIM.
IMPORTANT:
9 —
Verify repair and
10 — Refer to
DTC84 - CAN Communication Fault (CAN Bus Error)
ECM
(Engine
Control
Module)
97 89
0.5R
0.5W
VIM
LNW21AMF007601-X
Mutual communications (CAN communications) are second but not more than 3 seconds. (Release the
established between ECM and VIM so that the data accelerator pedal.)
received by the ECM is sent to the VIM and vice versa. 3. Turn off the idle position switch for not less than 1
DTC84 will be set when the CAN signal is faulty. second but not more than 3 seconds. (Press the
accelerator pedal.)
• Terminated VIM control (e.g., tachometer or PTO) accelerator pedal.)
Fault occurs on communications with VIM. accelerator pedal.)
• After the DTC is set, the ECM will illuminate the seconds to report the memory is cleared.
CHECK ENGINE lamp (MIL). 7. Turn off the starter switch. Wait for 5 seconds and
• Communications between ECM and VIM are turn on the starter switch again.
terminated and the control mode with When Tech 2 has been connected to the vehicle, the
predetermined values will be dominant. DTC can be cleared through the memory clear
following steps.
accelerator pedal.)
Test Description

1 — System Check
if mounted improperly, install the device
2 certainly. —

Review the DTC.
Refer to
Check the CAN communication circuit. ECM pins 89-
1. Starter switch "OFF". 97 (jumpered:
VIM pins 26-
2. Disconnect ECM and VIM connectors.
27): 0 Ω
3. Jumper the VIM connector and measure (not jumpered):
the resistance at the ECM connector. ∞Ω
ECM pins 89-
Was the resistance within range?
ground
(jumpered:
VIM pins 27-
4
ground): 0 Ω
(not jumpered):
∞Ω
ECM pins 97-
ground
(jumpered:
VIM pins 26-
ground): 0 Ω
(not jumpered):

1. Replace the ECM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC86 - CAN Communication Fault (CAN Timeout Error)
ECM
(Engine
Control
Module)
97 89
0.5R
0.5W
VIM
LNW21AMF007601-X
Mutual communications (CAN communications) are second but not more than 3 seconds. (Release the
established between ECM and VIM so that the data accelerator pedal.)
received by the ECM is sent to the VIM and vice versa. 3. Turn off the idle position switch for not less than 1
DTC86 will be set when the CAN signal is not input. second but not more than 3 seconds. (Press the
accelerator pedal.)
• Terminated VIM control (e.g., tachometer or PTO) accelerator pedal.)
CAN signal is not input for 1 second. accelerator pedal.)
• After the DTC is set, the ECM will illuminate the seconds to report the memory is cleared.
CHECK ENGINE lamp (MIL). 7. Turn off the starter switch. Wait for 5 seconds and
• Communications between ECM and VIM are turn on the starter switch again.
terminated and the control mode with When Tech 2 has been connected to the vehicle, the
predetermined values will be dominant. DTC can be cleared through the memory clear
following steps.
accelerator pedal.)
Test Description

1 — System Check
2 certainly. —

Review the DTC.
Refer to
Check the CAN communication circuit. ECM pins 89-
1. Starter switch "OFF". 97 (jumpered:
VIM pins 26-
2. Disconnect ECM and VIM connectors.
27): 0 Ω
3. Jumper the VIM connector and measure (not jumpered):
the resistance at the ECM connector. ∞Ω
ECM pins 89-
ground
(jumpered:
VIM pins 27-
4
ground): 0 Ω
(not jumpered):
∞Ω
ECM pins 97-
ground
(jumpered:
VIM pins 26-
ground): 0 Ω
(not jumpered):

1. Replace the ECM.
IMPORTANT:
6 —
Verify repair and
7 — Refer to
DTC115 - Common Rail Pressure Sensor Fixed Output Fault
6 7 8
5
4 3
1
2
LNW21AMF005401
Legend
1. Fuel tank 6. Common rail
2. Fuel filter 7. Common rail pressure sensor
3. Supply pump 8. Injector
4. SCV (suction control valve) 9. ECM (engine control module)
5. FT (fuel temperature) sensor
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X

The common rail pressure sensor detects the fuel • After the DTC is set, the ECM will illuminate the
pressure in the common rail and outputs the voltage CHECK ENGINE lamp (MIL).
equivalent to the common rail pressure. Higher • The common rail pressure and fuel injection
pressure provides higher voltage while lower pressure quantity are limited.
provides lower voltage. The ECM calculates the actual
common rail pressure (fuel pressure) from the voltage Conditions for Clearing MIL/DTC
signal sent from the sensor and uses the result in fuel When the system fails and the DTC is stored to the
injection control and other control tasks. ECM, even repairing the faulty portion will not clear the
DTC115 will be set when the difference between DTC from the memory. To clear the DTC, conduct the
desired and actual common rail pressures is large and following steps.
the sensor output voltage is fixed to a certain value.
accelerator pedal.)
• Generation of while/black smoke
The state where the common rail pressure sensor is in 4. Turn on the idle position switch for not less than 1
normal condition, there is no change in common rail second but not more than 3 seconds. (Release the
pressure sensor output voltage, the difference between accelerator pedal.)
desired and actual common rail pressures is 10 MPa or
more, the actual common rail pressure is 10 MPa or
more, and the pump is under feedback control is
accelerator pedal.)
continuously observed 255 times during A/D
conversion in the ECM. 6. After the above operations are properly completed,
7. Turn off the starter switch. Wait for 5 seconds and Test Description
turn on the starter switch again. 5. When the common rail pressure sensor harness and
When Tech 2 has been connected to the vehicle, the other sensor harness are shorted, DTC245 may not be
DTC can be cleared through the memory clear set.
Diagnostic Aids
When the air mixes into the fuel system, the fuel
pressure (common rail pressure) may read incorrect
value. If air bleed resolves the fault, the possible cause
is the air mixing into fuel system.

1 — System Check
Review the DTC.
2. Clear the DTC.
2 —
3. Bleed the air from the fuel system.
Refer to
Check the common rail pressure. Engine off:
1. Install Tech 2. Desired
pressure -
0 MPa
3. Observe "Desired Rail Pressure" and Actual
"Actual Rail Pressure" displays . pressure -
4. Start and idle the engine for warm-up. 0 MPa
5. Observe "Desired Rail Pressure" and Idling:
3
"Actual Rail Pressure" displays again. Desired
pressure -
Does the actual common rail pressure Approx.
increase following the desired pressure? 40 MPa
Actual
pressure -
Approx.
40 MPa Go to Step 8 Go to Step 4
Check the ECM for fault.
1. Starter switch "ON", engine "OFF".
2. Disconnect the common rail pressure
sensor connector.
3. On Tech 2, observe the "Common Rail
Pressure Sensor" display for output
voltage.
4 Approx. 0 V
CAUTION:
After the common rail pressure sensor is
disconnected, DTC245 is set. Be sure to
clear this DTC245 upon completion of this
Step 4.


Check the common rail pressure sensor Pins 63-66/
circuit harness for open wiring or short. 67: ∞ Ω
1. Starter switch "OFF". Pins 66/67-
64: ∞ Ω
Pins 63-64:
3. Disconnect the common rail pressure ∞Ω
5 sensor connector. Pins 67-66:
4. Measure the resistance at the ECM 0Ω
connector. Pins 26-63/
67/66/64: ∞ Ω
Was the resistance within range? Pins 63/67/
66/64/26-
1. Replace the ECM.
IMPORTANT:
7 —
Verify repair and
Replace the common rail (common rail
8 pressure sensor). — Verify repair and
Review the DTC.
1. Restore the vehicle.
9 —
Repair is
Is DTC115 detected? Go to Step 10 complete
Inspect the fuel system according to the
following procedures.
1. Check the fuel filter for excessive
contamination and choke.
10 2. Check high- and low-pressure pipes for —
collapse, choke, and loose connection.
3. Check the feed pipe in the fuel tank for
foreign materials.
Is the fuel system sound? Go to Step 12 Go to Step 11

Repair or replace the faulty portion(s).
11 —
Inspect the common rail.
12 1. Check the pressure limiter for fuel leak. —
Is the common rail sound? Go to Step 14 Go to Step 13
Replace the common rail.
13 —

Replace the supply pump.
14 —
15 —
Repair is
DTC118 - Common Rail Pressure Fault (Control System)
6 7 8
5
4 3
1
2
LNW21AMF005401
Legend
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X

The common rail pressure is detected by the common When the system fails and the DTC is stored to the
rail pressure sensor and sent to the ECM. The ECM ECM, even repairing the faulty portion will not clear the
calculates the desired common rail pressure and pump DTC from the memory. To clear the DTC, conduct the
flow rate from the data sent from sensors and following steps.
compares these calculations with the actual common 1. Turn off the idle position switch for not less than 1
rail pressure to determine the SCV position. second but not more than 3 seconds. (Press the
DTC118 will be set when the common rail pressures is accelerator pedal.)
excessively high.
Major Faulty Event second but not more than 3 seconds. (Release the
accelerator pedal.)
• Generation of while/black smoke second but not more than 3 seconds. (Press the
• Poor driveability 4. Turn on the idle position switch for not less than 1
The state where the common rail pressure output 5. Turn off the idle position switch for not less than 1
voltage is in normal condition and the actual common second but not more than 3 seconds. (Press the
rail pressure is at least 180 MPa lasts 5 times accelerator pedal.)
continuously. 6. After the above operations are properly completed,
• The ECM prepares for engine shutdown. When Tech 2 has been connected to the vehicle, the
When the air mixes into the fuel system, the fuel 3. When the flow damper has been working, it will be
pressure (common rail pressure) may read incorrect returned to the ordinary condition only after left inactive
value. If air bleed resolves the fault, the possible cause overnight.
is the air mixing mixed into fuel system.

1 — System Check
Review the DTC.
2. Clear the DTC.
2 —
Refer to
1. The flow damper may have been
working. Leave the vehicle inactive
overnight.
3 —
Refer to Test
Is DTC118 detected? Go to Step 4 Description
foreign materials.
Is the fuel system sound? Go to Step 6 Go to Step 5

5 —
Check injectors.
1. Install Tech 2.
engine data.
6 3. Start the engine and observe the —
"Cylinder (1-4) Compensation" display for
individual cylinders.
Is there cylinder(s) whose calibrated quantity

is larger or less than other cylinders? Go to Step 7 Go to Step 8
Replace the faulty injector(s).
7 —

pressure -
0 MPa
"Actual Rail Pressure" displays. pressure -
4. Start the engine. Run the engine at idle 0 MPa
for warm-up. Idling:
8
5. Observe "Desired Rail Pressure" and Desired
"Actual Rail Pressure" displays again. pressure -
approx.
Does the actual common rail pressure 40 MPa
increase following the desired pressure? Actual
pressure -
approx.
sensor connector.
voltage.
9 Approx. 5 V
CAUTION:
Step 9.

circuit harness for open wiring or short. 67: ∞ Ω
1. Starter switch "OFF". Pins 66/67-
64: ∞ Ω
Pins 63-64:
10 sensor connector. Pins 67-66:
4. Measure the resistance at the ECM 0Ω
connector. Pins 26-63/
67/66/64: ∞ Ω
Was the resistance within range? Pins 63/67/
66/64/26-
1. Replace the ECM.
IMPORTANT:
12 —
Verify repair and

Review the DTC.
14 —
Repair is
Is the common rail sound? Go to Step 17 Go to Step 16
16 —
17 —
18 —
Repair is
DTC158 - Injector Power Supply System Short (Common 1)
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

The common 1 injector drive circuit is a high-voltage When the system fails and the DTC is stored to the
system and drives injectors installed to cylinders 1 and ECM, even repairing the faulty portion will not clear the
4. The ECM steps up the battery voltage and supplies DTC from the memory. To clear the DTC, conduct the
the resulted high voltage to the related injectors following steps.
continuously. 1. Turn off the idle position switch for not less than 1
DTC158 will be set when the common 1 injector drive second but not more than 3 seconds. (Press the
signal is faulty. accelerator pedal.)
accelerator pedal.)
The short to ground or the +B short is detected on the 4. Turn on the idle position switch for not less than 1
drive circuits for injectors located in common 1 second but not more than 3 seconds. (Release the
(injectors #1 and #3). accelerator pedal.)
Action Taken When the DTC Sets 5. Turn off the idle position switch for not less than 1
accelerator pedal.)
• Fault judgment is disabled on injector drive circuit
for cylinders 1 and 4 and supply pump system.
• Only main injection is enabled.
• The calibrated cylinder-to-cylinder injection turn on the starter switch again.
quantity becomes zero. When Tech 2 has been connected to the vehicle, the
• Fuel injection at cylinders 1 and 4 is terminated. DTC can be cleared through the memory clear
Test Description

1 — System Check
Check the injector connector for installation
and, if mounted improperly, connect it
2 certainly. —

Review the DTC.
Refer to
Check the common 1 injector drive circuit for
+B short.
Pins 1/2-109/
resistance.

Check the common 1 injector drive circuit Pins 1-
(ECM to intermediate connector) for short. ground
1. Disconnect the ECM. (jumpered:
pins 1/4-
2. Disconnect the injector connector.
ground): 0 Ω
3. Jumper the injector connector and (not jumpered):
connector. Pins 2-
6 ground
(jumpered:
pins 1/4-
ground): 0 Ω
(not jumpered):
∞Ω
Pins 1-2
(not jumpered):
0Ω Go to Step 7 Go to Step 10

Check the intermediate connector for fault. Pins 1-2/3/4
1. Disconnect ECM side and injector side (jumpered:
connectors from the intermediate pins 1-2/3/4):
connector. 0Ω
(not jumpered):
2. Remove the intermediate connector from
∞Ω
the engine block.
Pins 2-3/4
3. Jumper the intermediate connector that (jumpered:
7 was connected to the injectors and pins 2-3/4):
measure the resistance at the 0Ω
intermediate connector that was (not jumpered):
connected to the ECM. ∞Ω
(jumpered:
pins 3-4): 0 Ω
(not jumpered):
Replace the intermediate connector.
8 —
Check the common 1 injector drive circuit
(intermediate connector to injector) for open
wiring or short.
Cylinder 1
1. Disconnect the injector side connectors
-pins 1:
from the intermediate connector.
0Ω
9 2. Disconnect harnesses from injectors for Cylinder 4
cylinders 1 and 4. -pins 4:
3. Measure the resistance between injector 0Ω
terminal and connector pin as well as Pins 1-4: ∞ Ω
between connector pins.

Measure the resistance between injector
terminals (resistance of coil) for cylinders 1
11 and 4. 0.4 Ω

Repair or replace the faulty injector(s).
12 —
13 3. Bleed the air from the fuel system. —
4. Perform test run and review the DTC. Refer to

Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
Injector Description
2 3
LNW21ASH010701
Legend
1. Injector
2. Power supply harness
3. Drive harness
DTC159 - Injector Power Supply System Short (Common 2)
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

DTC159 will be set when the common 2 injector drive second but not more than 3 seconds. (Press the
signal is faulty. accelerator pedal.)
accelerator pedal.)
The short to ground or the +B short is detected on the 4. Turn on the idle position switch for not less than 1
drive circuits for injectors located in common 2 second but not more than 3 seconds. (Release the
(injectors #2 and #4). accelerator pedal.)
accelerator pedal.)
Test Description

1 — System Check
2 certainly. —

Review the DTC.
Refer to
Check the common 2 injector drive circuit for
+B short.
Pins 4/5-109/
resistance.

(ECM to intermediate connector) for open ground
wiring or short. (jumpered:
1. Disconnect the ECM. pins 2/3-
ground): 0 Ω
(not jumpered):
3. Jumper the injector connector and ∞Ω
measure the resistance at the ECM Pins 5-
6 connector. ground
(jumpered:
pins 2/3-
ground): 0 Ω
(not jumpered):
∞Ω
Pins 4-5
(not jumpered):

connector. 0Ω
(not jumpered):
∞Ω
the engine block.
Pins 2-3/4
connected to the ECM. ∞Ω
(jumpered:
pins 3-4): 0 Ω
(not jumpered):
8 —
wiring or short.
Cylinder 2
1. Disconnect the injector side connectors
-pins 2:
0Ω
9 2. Disconnect harnesses from injectors for Cylinder 3
cylinders 2 and 3. -pins 3:

11 and 3. 0.4 Ω

12 —

Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
DTC211 - Fuel Temperature Sensor System Fault
ECM
(Engine
Control
Module)
49 46 48
0.5R/B
0.5R/G
0.5G/W
0.5G/W
ECT FT
Sensor Sensor
LNW21AMF007101-X

The FT (fuel temperature) sensor consists of thermistor When the system fails and the DTC is stored to the
and alters the resistance in response to temperature ECM, even repairing the faulty portion will not clear the
change. Higher fuel temperature provides smaller DTC from the memory. To clear the DTC, conduct the
resistance while lower temperature provides larger following steps.
resistance. The ECM supplies 5 V to the FT sensor via 1. Turn off the idle position switch for not less than 1
pull-up resistance and calculates the fuel temperature second but not more than 3 seconds. (Press the
from the change in voltage and uses it in supply pump accelerator pedal.)
control and other control tasks. The voltage is
decreased when the resistance is small (the
temperature is high) while increased when the
accelerator pedal.)
DTC211 will be set when the signal voltage is 3. Turn off the idle position switch for not less than 1
excessively high or low. second but not more than 3 seconds. (Press the
accelerator pedal.)
accelerator pedal.)
The FT sensor output voltage deviates from the range second but not more than 3 seconds. (Press the
between 0.1 V and 4.8 V for at least 1 seconds. accelerator pedal.)
• Even after the DTC is set, the ECM will not seconds to report the memory is cleared.
illuminate the CHECK ENGINE lamp (MIL). 7. Turn off the starter switch. Wait for 5 seconds and
• The ECM controls the powertrain using the set fuel turn on the starter switch again.
temperature (normal running phase: 70°C, startup When Tech 2 has been connected to the vehicle, the
phase: –20°C). DTC can be cleared through the memory clear
connectors for backed-out pins, improper mating, 4. If DTC23 is also set, the possible cause is the
broken locks, improperly formed or damaged pins, ground circuit common to FT and ECT sensors.
and poor pin-to-wire connection. 7. If pins are jumpered and the resistance read ∞ Ω, the
cause is open wiring. If pins are not jumpered and the
resistance reads 0 Ω, the cause is short.

1 — System Check
Check the FT sensor connector for installation
and, if mounted improperly, install the device
2 certainly. —

Review the DTC.
Refer to
4 Is DTC23 (ECT Sensor System Fault) —
detected together with DTC211? Go to Step 5 Go to Step 10
Check the ground circuit common to FT and
ECT sensors for +B short.
Pins 46-109/
resistance.

Check the ground circuit common to FT and Pins 48-46
ECT sensors for open wiring or short. (not jumpered):
2. Disconnect the ECM. Pins 46-
ground
7 3. Disconnect the FT sensor connector.
(jumpered:
4. Jumper the FT sensor connector pin and pins 2-
measure the resistance at the ECM ground): 0 Ω

Review the DTC.
1. Certainly connect the FT sensor and
ECM connectors.
Refer to
Check the FT sensor output voltage.
1. Install Tech 2.
engine data. Approx. 1.5 V
10
(ECT: 80°C)
3. Observe the "Fuel Temperature Sensor"
display for output voltage.
Check the FT sensor output voltage.
11 —
Check the FT sensor circuit for +B short.
Pins 48/46-
2. Disconnect the ECM. 109/114/115/
12
3. At the ECM connector pins, measure the 116:
resistance. ∞Ω

Check the FT sensor circuit harness for open Pins 46-48
wiring or short. (jumpered:
(not jumpered):
∞Ω
3. Disconnect the FT sensor connector. Pins 46-
4. At the ECM connector, measure the ground
resistance. (jumpered:
pins 1-
14 Was the resistance within range? ground): 0 Ω
(not jumpered):
∞Ω
Pins 48-
ground
(jumpered:
pins 2-
ground): 0 Ω
(not jumpered):

Check the FT sensor.
1. Disconnect the FT sensor.
16 thermosensitive element of the FT sensor See graph
and measure the resistance between the
sensor connector pins.
Replace the supply pump (FT sensor).
18 —
Review the DTC.
1. Certainly connect the FT sensor and
ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
20 —
Verify repair and
21 — Refer to
Characteristics of FT Sensor (reference)
30
20
10
8
6
5
4
3
2
1
0.8
0.6
0.5
0.4
0.3
0.2
0.1
-20 0 20 40 60 80 100120
Temperature ( C)
LNW21ASH010401-X
Sensor Description
1 2
3
7 6 5
LNW21ASF002601
Legend
1. FT sensor signal 5. SCV
2. FT sensor ground 6. SCV (HI)
3. FT sensor 7. SCV (LO)
4. Camshaft
DTC217 - SCV Drive System Short
ECM
(Engine
Control
Module)
75 74 81 80
0.75L
0.75L
0.75W/R
0.75W/R
SCV
LNW21AMF007201-X

The SCV (suction control valve) is installed to the • After the DTC is set, the ECM will illuminate the
supply pump and controls the suction fuel quantity. The CHECK ENGINE lamp (MIL).
SCV is fully opened in normal state and larger drive • The common rail pressure and fuel injection
current (duty) results in smaller opening. The EMC, quantity are limited.
based on the data acquired from sensors, calculates
• Fault judgment is disabled on pump supply pump
desired common rail pressure and pump flow rate and
overpressure and short pump pressure events 1 to
compares the calculated desired common rail pressure
4.
to the actual value to determine the SCV position.
When the actual pressure is lower than the desired Conditions for Clearing MIL/DTC
value, the SCV is opened to increase the pump flow
rate. When the actual pressure is higher than the When the system fails and the DTC is stored to the
desired value, the SCV is closed to decrease the flow ECM, even repairing the faulty portion will not clear the
rate. DTC from the memory. To clear the DTC, conduct the
DTC217 will be set when the drive current is following steps.
excessively high. 1. Turn off the idle position switch for not less than 1
• Poor startability 2. Turn on the idle position switch for not less than 1
• Generation of white/black smoke second but not more than 3 seconds. (Release the
accelerator pedal.)
• Short power
The SCV drive current is at least 1500 mA. (+B short is
detected on the circuit between SCV+ and ECM.)
accelerator pedal.)
5. Turn off the idle position switch for not less than 1 intermittents. Check for the following conditions and, if
second but not more than 3 seconds. (Press the the fault is detected, repair or replace the faulty portion.
accelerator pedal.) • Poor connection at ECM: Inspect harness
6. After the above operations are properly completed, connectors for backed-out pins, improper mating,
the CHECK ENGINE lamp (MIL) illuminates for 3 broken locks, improperly formed or damaged pins,
seconds to report the memory is cleared. and poor pin-to-wire connection.
7. Turn off the starter switch. Wait for 5 seconds and • Damaged harness: Inspect the wiring harness for
turn on the starter switch again. rubbed-through wire insulation or wire broken
When Tech 2 has been connected to the vehicle, the inside the insulator. If the harness appears to be
DTC can be cleared through the memory clear OK, observe the display on Tech 2 while moving
operation with Tech 2. connectors and wiring harnesses related to the
Diagnostic Aids location of the fault.

1 — System Check
Check the SCV connector for installation and,
2 certainly. —

Review the DTC.
Refer to
Check the SCV drive circuit for +B short.
Pins 80/81/
2. Disconnect the ECM. 74/75-109/
4
3. At the ECM connector pins, measure the 114/115/116:
resistance. ∞Ω

Check the SCV.
1. At the SCV connector pins, measure the
6 resistance. 8Ω

Replace the supply pump (SCV).
8 3. Bleed the air from the fuel system —

Review the DTC.
1. Certainly connect the SCV and ECM
connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
10 —
Verify repair and
11 — Refer to
SCV Description
1 2
3
7 6 5
LNW21ASF002601
Legend
4. Camshaft
DTC227 - No Pump Pressure Feed (Fuel Leak)
6 7 8
5
4 3
1
2
LNW21AMF005401
Legend
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X
The pump pressure is controlled with the common rail second but not more than 3 seconds. (Press the
pressure. The common rail pressure is detected by the accelerator pedal.)
common rail pressure sensor and sent to the ECM. The 2. Turn on the idle position switch for not less than 1
ECM calculates desired common rail pressure and second but not more than 3 seconds. (Release the
pump flow rate from the data sent from sensors and accelerator pedal.)
compares these calculations with the actual common 3. Turn off the idle position switch for not less than 1
rail pressure to determine the SCV position. When the second but not more than 3 seconds. (Press the
actual pressure is lower than the desired pressure, the accelerator pedal.)
SCV is opened to increase the pump flow rate. When 4. Turn on the idle position switch for not less than 1
the actual pressure is higher than the desired pressure, second but not more than 3 seconds. (Release the
the SCV is closed to decrease the pump flow rate. accelerator pedal.)
DTC227 will be set when the common rail pressures is
excessively low. 5. Turn off the idle position switch for not less than 1
• Engine stall 6. After the above operations are properly completed,
Conditions for Setting the DTC seconds to report the memory is cleared.
The fuel leak after the fuel filter exceeds the threshold. 7. Turn off the starter switch. Wait for 5 seconds and
Action Taken When the DTC Sets When Tech 2 has been connected to the vehicle, the
• After the DTC is set, the ECM will illuminate the DTC can be cleared through the memory clear
CHECK ENGINE lamp (MIL). operation with Tech 2.
• The ECM prepares for engine shutdown. Diagnostic Aids
Conditions for Clearing MIL/DTC When the air mixes into the fuel system, the fuel
pressure (common rail pressure) may read incorrect
When the system fails and the DTC is stored to the value. If air bleed resolves the fault, the possible cause
ECM, even repairing the faulty portion will not clear the is the air mixing into fuel system.
following steps.
Test Description
3. When the flow damper has been working, it will be
returned to the ordinary condition only after left inactive
overnight.

1 — System Check
Review the DTC.
2. Clear the DTC.
2 —
Refer to
1. The flow damper may have been
working. Leave the vehicle inactive
overnight.
3 —
Refer to Test
Is DTC227 detected? Go to Step 4 Description
foreign materials.
Is the fuel system normal in condition? Go to Step 6 Go to Step 5

5 —
Check injectors.
1. Install Tech 2.
engine data.
6 3. Start the engine and observe the —
"Cylinder (1-4) Compensation" display for
individual cylinders.
Is there cylinder(s) whose calibrated quantity
is larger or less than other cylinders? Go to Step 7 Go to Step 8
7 —

pressure -
0 MPa
8
approx.
pressure -
approx.
sensor connector.
voltage.
9 Approx. 0 V
CAUTION:
Step 9.

circuit harness for open wiring or short. 67:
Pins 66/67-
64:
sensor connector. Pins 63-64:
10 4. Measure the resistance at the ECM ∞Ω
connector. Pins 67-66:
0Ω
Was the resistance within range? Pins 26-63/
67/66/64: ∞ Ω
Pins 63/67/
66/64/26-
1. Replace the ECM.
IMPORTANT:
12 —
Verify repair and

Review the DTC.
14 —
Repair is
Is the common rail normal in condition? Go to Step 17 Go to Step 16
16 —
17 —
18 —
Repair is
DTC241 - Idle Position Switch Circuit Open Wiring
ECM
(Engine
110 Control
Module)
90 84 94 108
0.5W/L
0.5L
0.5L/W
0.5L/R
0.5B/Y
Idle
Switch
AP
Sensor
LNW21AMF007501-X
Circuit Description • In case of AP sensor fault, the ECM controls the

The idle position switch is installed to the accelerator powertrain using the set accelerator position (20
pedal, and is turned off when the pedal is pressed and %).
turned on when the pedal is released. The ECM
receives the on/off signal from this idle position switch
and uses it in exhaust brake control, warm-up control, When the system fails and the DTC is stored to the
and other control tasks. ECM, even repairing the faulty portion will not clear the
DTC241 will be set when the accelerator pedal is in idle DTC from the memory. To clear the DTC, conduct the
position but the signal from the idle position switch is following steps.
being turned off. 1. Turn off the idle position switch for not less than 1
(When the AP sensor is also faulty.) 2. Turn on the idle position switch for not less than 1
• Short power second but not more than 3 seconds. (Release the
The state where the AP sensor is in normal condition, accelerator pedal.)
the AP sensor output voltage is less than 0.6 V, and the 4. Turn on the idle position switch for not less than 1
idle position switch is turned off lasts at least 10 second but not more than 3 seconds. (Release the
seconds.. accelerator pedal.)
Action Taken When the DTC Sets second but not more than 3 seconds. (Press the
• After the DTC is set, the ECM will illuminate the accelerator pedal.)
CHECK ENGINE lamp (MIL). 6. After the above operations are properly completed,
• Exhaust brake and warm-up systems are disabled. the CHECK ENGINE lamp (MIL) illuminates for 3
7. Turn off the starter switch. Wait for 5 seconds and turn on the starter switch again.
When Tech 2 has been connected to the vehicle, the • Damaged harness: Inspect the wiring harness for
DTC can be cleared through the memory clear rubbed-through wire insulation or wire broken
operation with Tech 2. inside the insulator. If the harness appears to be
Test Description

1 — System Check
Check the idle position switch for mechanical
fault.
1. Check the idle position switch connector
2. Check the contact between accelerator
2 pedal and switch and recondition the —
improper contact, if any.
3. Press the idle position switch with a finger
to check the sliding performance. In case
of unsmooth movement, blow air against
the switch to remove foreign materials.

Review the DTC.
Refer to
Check the display on Tech 2.
engine data.
4 2. Observe the "Idle Position Switch" display —
while operating the accelerator pedal.
Is the idle position switch turned on and off

according to the pedal operation? Go to Step 11 Go to Step 5
Check the idle position switch. Switch-on
1. Starter switch "OFF". (switch is
2. Measure the resistance between the idle released):
5 position switch connector pins while 50 Ω, max.
operating the switch with a finger. Switch-off
(switch is
Was the resistance within range? pressed): ∞ Ω Go to Step 7 Go to Step 6
Replace the idle position switch.
6 —

Check the idle position switch circuit (switch to
switch connector) for open wiring. Switch-on
1. Disconnect the idle position switch (switch is
connector. released):
7 50 Ω, max.
2. Measure the resistance between the idle
Switch-off
position switch connector pins while
(switch is
operating the switch with a finger.
pressed): ∞ Ω
Check the idle position switch circuit (ground
circuit) for open wiring.
1. Measure the resistance between idle
8 position switch connector (ECM side) pin 0Ω
2 and ground (e.g., frame or body).

Check the idle position switch circuit (ECM to
switch connector) for open wiring.
Pins 110-87:
9 2. Jumper the idle position switch connector
0Ω
pin and measure the resistance at the
ECM connector.

10 —
Review the DTC.
1. Certainly connect the idle position switch
and ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
12 —
Verify repair and
13 — Refer to
DTC242 - Idle Position Switch Circuit Short
ECM
(Engine
110 Control
Module)
90 84 94 108
0.5W/L
0.5L
0.5L/W
0.5L/R
0.5B/Y
Idle
Switch
AP
Sensor
LNW21AMF007501-X
Circuit Description • In case of AP sensor fault, the ECM controls the

The idle position switch is installed to the accelerator powertrain using the set accelerator position (20
pedal, and is turned off when the pedal is pressed and %).
turned on when the pedal is released. The ECM
receives the on/off signal from this idle position switch
and uses it in exhaust brake control, warm-up control, When the system fails and the DTC is stored to the
and other control tasks. ECM, even repairing the faulty portion will not clear the
DTC242 will be set when accelerator pedal is in idle DTC from the memory. To clear the DTC, conduct the
position but the signal from the idle position switch is following steps.
being turned on. 1. Turn off the idle position switch for not less than 1
(When the AP sensor is also faulty.) 2. Turn on the idle position switch for not less than 1
• Poor pedal response accelerator pedal.)
The state where the AP sensor is in normal condition, 4. Turn on the idle position switch for not less than 1
the AP sensor output voltage is 1 V or more, and the second but not more than 3 seconds. (Release the
idle position switch is turned on lasts at least 10 accelerator pedal.)
seconds. 5. Turn off the idle position switch for not less than 1
• After the DTC is set, the ECM will illuminate the 6. After the above operations are properly completed,
CHECK ENGINE lamp (MIL). the CHECK ENGINE lamp (MIL) illuminates for 3
• Exhaust brake and warm-up systems are disabled. seconds to report the memory is cleared.
7. Turn off the starter switch. Wait for 5 seconds and turn on the starter switch again.
Test Description

1 — System Check
Check the idle position switch for mechanical
fault.
1. Check the idle position switch connector
2. Check the contact between accelerator
2 pedal and switch and recondition the —
improper contact, if any.
3. Press the idle position switch with a finger
to check the sliding performance. In case
of unsmooth movement, blow air against
the switch to remove foreign materials.

Review the DTC.
Refer to
Check the display on Tech 2.
engine data.
4 2. Observe the "Idle Position Switch" display —
while operating the accelerator pedal.
Is the idle position switch turned on and off

according to the pedal operation? Go to Step 10 Go to Step 5
Check the idle position switch. Switch-on
1. Starter switch "OFF". (switch is
2. Measure the resistance between the idle released):
5 position switch connector pins while 50 Ω, max.
operating the switch with a finger. Switch-off
(switch is
Was the resistance within range? pressed): ∞ Ω Go to Step 7 Go to Step 6
Replace the idle position switch.
6 —

Check the idle position switch circuit (switch to
switch connector) for short. Switch-on
1. Disconnect the idle position switch (switch is
connector. released):
7 50 Ω, max.
2. Measure the resistance between the idle
Switch-off
position switch connector pins while
(switch is
operating the switch with a finger.
pressed): ∞ Ω
Check the idle position switch circuit (ECM to
switch connector) for short.
1. Disconnect the vehicle side connector Pins 110-87
from ECM. (jumpered):
8 0Ω
2. Jumper the idle position switch connector
(not jumpered):
pin and measure the resistance at the
∞Ω
ECM connector.
9 —
Review the DTC.
1. Certainly connect the idle position switch
and ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
11 —
Verify repair and
12 — Refer to
DTC245 - Common Rail Pressure Sensor System Fault
ECM
(Engine
Control
Module)
25 6 8 27 26 69 68 63 66 6764
0.5W/R
0.5W/L
0.5L/R
0.5L/W
0.5B
0.5G/Y
0.5Y
0.5W
0.5G
0.5G
0.5R
Sensor Pressure
Sensor
LNW21AMF006901-X
Circuit Description • The common rail pressure and fuel injection

The common rail pressure sensor detects the fuel quantity are limited.
pressure in the common rail, converts the pressure into • The ECM declares the common rail pressure
a voltage signal, and sends the signal to the ECM. sensor fault and stops the related control tasks and
Higher pressure provides higher voltage while lower fault judgment.
pressure provides lower voltage. The ECM calculates
the actual common rail pressure (fuel pressure) from Conditions for Clearing MIL/DTC
the voltage signal and uses the result in fuel injection When the system fails and the DTC is stored to the
control and other control tasks. ECM, even repairing the faulty portion will not clear the
DTC245 will be set when the sensor output voltage is DTC from the memory. To clear the DTC, conduct the
excessively high or low. following steps.
Major Faulty Event
• Poor startability accelerator pedal.)
• Generation of white/black smoke 2. Turn on the idle position switch for not less than 1
The state where the common rail pressure sensor accelerator pedal.)
output voltage deviates from the range between 0.7 V 4. Turn on the idle position switch for not less than 1
and 4.7 V is continuously observed 3 times during A/D second but not more than 3 seconds. (Release the
(analog/digital) conversion in the ECM. accelerator pedal.)
Action Taken When the DTC Sets second but not more than 3 seconds. (Press the
• After the DTC is set, the ECM will illuminate the accelerator pedal.)
6. After the above operations are properly completed, OK, observe the display on Tech 2 while moving
the CHECK ENGINE lamp (MIL) illuminates for 3 connectors and wiring harnesses related to the
seconds to report the memory is cleared. sensor. A change in the display will indicate the
7. Turn off the starter switch. Wait for 5 seconds and location of the fault.
When Tech 2 has been connected to the vehicle, the Test Description
DTC can be cleared through the memory clear Number(s) below refer to the step number(s) on the
operation with Tech 2. Diagnostic Chart.
Diagnostic Aids intermittent (intermittent fault).
Poor connection or damaged harness may cause 4. If the DTC43 or DTC44 are also set, the possible
intermittents. Check for the following conditions and, if cause is ground circuit common to ITP sensor and
the fault is detected, repair or replace the faulty portion. EGR position sensor or common rail pressure sensor.
• Damaged harness: Inspect the wiring harness for is fixed to 0 V, the possible cause is short in the circuit.

1 — System Check
Check the common rail pressure sensor
2 improperly, install the device certainly. —

Review the DTC.
Refer to
4 Are DTC43 (ITP Sensor Fault)or DTC44 —

(EGR Position Sensor Fault) detected
together with DTC245? Go to Step 5 Go to Step 10
sensor, EGR position sensor and common rail
pressure sensors for +B short.
1. Starter switch "OFF". Pins 64-109/
∞Ω
resistance.


power circuit harness to ITP sensor, EGR (not jumpered):
position sensor and common rail pressure ∞Ω
sensors for open wiring or short. Pins 64-
(jumpered):
Pins 1-
3. Disconnect the common rail pressure ground: 0 Ω
7 sensor connector. (not jumpered):
4. Jumper the common rail pressure sensor ∞Ω
connector pin and measure the Pins 63-
resistance at the ECM connector. ground
(jumpered):
Was the resistance within range? Pins 4-
ground: 0 Ω
(not jumpered):
Review the DTC.
1. Certainly connect the common rail
pressure sensor and ECM connectors.
Refer to
output voltage.
1. Install Tech 2.
engine data. Starter switch
3. Observe the "Common Rail Pressure ON:
10 Sensor" display for output voltage. Approx. 1 V
Idling:
4. Start the engine. Run the engine at idle
Approx. 1.6 V
for warm-up.
5. Observe the "Common Rail Pressure
Sensor" display for output voltage again.

circuit for +B short.
1. Starter switch "OFF". Pins 63/67/
11
114/115/116:
∞Ω
resistance.


Check the common rail pressure sensor Pins 64-66/67
circuit harness for open wiring or short. (jumpered:
(not jumpered):
∞Ω
3. Disconnect the common rail pressure Pins 66/67-63
sensor connector. (jumpered:
4. Jumper the common rail pressure sensor pins 2-3): 0 Ω
connector pin and measure the (not jumpered):
resistance at the ECM connector. ∞Ω
Pins 64-63
pins 1-3): 0 Ω
13
(not jumpered):
∞Ω
Pins 67-66
(not jumpered):
0Ω
Pins 26-64/
67/66/63
(not jumpered):
∞Ω
Pins 64/67/
66/63-ground
(not jumpered):
pressure -
0 MPa
15
approx.
pressure -
approx.
17 —

Review the DTC.
1. Certainly connect the common rail
pressure sensor and ECM connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
19 —
Verify repair and
20 — Refer to
Characteristics of Common Rail Pressure Sensor
Pressure Sensor Output Characteristic

V
Output Voltage
4.2
1.0
0 200 MPa
{0} {2039} {kg/cm2}
Pressure
LNW21ASH010201-X
Sensor Description
2
1
5 4 3
LNW21ASF002901
Legend
1. Pressure limiter 4. Sensor signal
2. Common rail pressure sensor 5. Sensor power
3. Sensor ground
DTC247 - SCV Drive System Fault
ECM
(Engine
Control
Module)
75 74 81 80
0.75L
0.75L
0.75W/R
0.75W/R
SCV
LNW21AMF007201-X
Circuit Description SCV– and ECM, short to ground between SCV– and
The SCV (suction control valve) is installed to the ECM, or open wiring between SCV and ECM is not
supply pump and controls the suction fuel quantity. The detected.)
SCV is fully opened in normal state and larger drive
current (duty) results in smaller opening. The ECM,
based on the data acquired from sensors, calculates • After the DTC is set, the ECM will illuminate the
desired common rail pressure and pump flow rate and CHECK ENGINE lamp (MIL).
compares the calculated desired common rail pressure • The common rail pressure and fuel injection
to the actual value to determine the SCV position. quantity are limited.
When the actual pressure is lower than the desired • Fault judgment is disabled on supply pump
value, the SCV is opened to increase the pump flow overpressure and short pump pressure events 1 to
rate. When the actual pressure is higher than the 4.
desired value, the SCV is closed to decrease the flow
rate. Conditions for Clearing MIL/DTC
DTC247 will be set when the drive current is
excessively high or low or the difference between
desired and actual drive currents is large.
Major Faulty Event following steps.
• Generation of white/black smoke accelerator pedal.)
• Short power 2. Turn on the idle position switch for not less than 1
accelerator pedal.)
The SCV drive current is 1100 mA or less. (Short to second but not more than 3 seconds. (Press the
ground between SCV+ and ECM, +B short between accelerator pedal.)
4. Turn on the idle position switch for not less than 1 • Poor connection at ECM: Inspect harness
second but not more than 3 seconds. (Release the connectors for backed-out pins, improper mating,
accelerator pedal.) broken locks, improperly formed or damaged pins,
5. Turn off the idle position switch for not less than 1 and poor pin-to-wire connection.
second but not more than 3 seconds. (Press the • Damaged harness: Inspect the wiring harness for
accelerator pedal.) rubbed-through wire insulation or wire broken
6. After the above operations are properly completed, inside the insulator. If the harness appears to be
the CHECK ENGINE lamp (MIL) illuminates for 3 OK, observe the display on Tech 2 while moving
seconds to report the memory is cleared. connectors and wiring harnesses related to the
When Tech 2 has been connected to the vehicle, the Test Description
operation with Tech 2. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
Diagnostic Aids 3. If the DTC is not detected, the possible cause is

1 — System Check
Check the SCV connector for installation and,
2 certainly. —

Review the DTC.
Refer to
Check the SCV drive circuit for +B short.
Pins 80/81/
4
3. At the ECM connector pins, measure the 114/115/116:
resistance. ∞Ω

Check the SCV drive circuit for open wiring or Pins 80/81-
short. 74/75
1. Starter switch "OFF". (jumpered):
2. Disconnect the ECM. 0Ω
(not jumpered):
5 3. Disconnect the SCV connector.
∞Ω
4. Jumper the SCV connector pins and Pins 80/81/
measure the resistance at the ECM 74/75-ground

Check the SCV.
1. At the SCV connector pins, measure the
7 resistance. 8Ω

Replace the supply pump (SCV).
9 —
Review the DTC.
1. Certainly connect the SCV and ECM
connectors.
Refer to
1. Replace the ECM.
IMPORTANT:
11 —
Verify repair and
12 — Refer to
SCV Description
1 2
3
7 6 5
LNW21ASF002601
Legend
4. Camshaft
DTC271 - Cylinder 1 (Injector Drive System) Fault
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X
Circuit Description • Fuel injection at cylinder 1 (injector #1) is

The injector drive circuit is a low-voltage system and terminated.
drives injectors. The ECM calculates the optimum fuel
injection timing using the data acquired from sensors
and energizes injector coils (TWV). The ECM also When the system fails and the DTC is stored to the
controls the fuel injection timing based on the injector ECM, even repairing the faulty portion will not clear the
drive timing and the fuel injection quantity based on the DTC from the memory. To clear the DTC, conduct the
coil energize time. following steps.
DTC271 will be set when fault(s) occur on the cylinder 1. Turn off the idle position switch for not less than 1
1 injector drive system. second but not more than 3 seconds. (Press the
accelerator pedal.)
Major Faulty Event
Open wiring is detected on the circuit between injector accelerator pedal.)
#1 and ECM injector #1 pin, and Cylinder 4 (Injector #3 4. Turn on the idle position switch for not less than 1
drive circuit) Fault (DTC274) is not detected. second but not more than 3 seconds. (Release the
accelerator pedal.)
• After the DTC is set, the ECM will illuminate the second but not more than 3 seconds. (Press the
CHECK ENGINE lamp (MIL). accelerator pedal.)
• Fault judgment is disabled on supply pump 6. After the above operations are properly completed,
system. the CHECK ENGINE lamp (MIL) illuminates for 3
• Only main injection is enabled. seconds to report the memory is cleared.
• The calibrated cylinder-to-cylinder injection 7. Turn off the starter switch. Wait for 5 seconds and
quantity becomes 0 mm3/st. turn on the starter switch again.
intermittents. Check for the following conditions and, if Test Description
the fault is detected, repair or replace the faulty portion. Number(s) below refer to the step number(s) on the
• Poor connection at ECM: Inspect harness Diagnostic Chart.
connectors for backed-out pins, improper mating, 3. If the DTC is not detected, the possible cause is
broken locks, improperly formed or damaged pins, intermittent (intermittent fault).

1 — System Check
2 certainly. —

Review the DTC.
Refer to
Check the cylinder 1 injector drive circuit for
+B short.
Pins 43-109/
resistance.

Check the cylinder 1 injector drive circuit
(ECM to intermediate connector) for open
wiring or short.
Pins 43-1
(jumpered:
6 2. Disconnect the injector connector. pins 5-1): 0 Ω
connector.


connector. 0Ω
(not jumpered):
∞Ω
the engine block.
Pins 6-7/8
connected to the ECM pins. ∞Ω
(jumpered:
pins 6-8): 0 Ω
(not jumpered):
8 —
wiring or short.
1. Disconnect the injector side connector
Cylinder 1-
9 2. Disconnect harnesses from the cylinder 1 Pins 5: 0 Ω
injector. Pins 1-5: ∞ Ω
3. Measure the resistance between injector
terminal and connector pin as well as

10 —
Check the injector coil for open wiring.
1. At cylinder 1 injector terminals, measure
11 the resistance. 0.4 Ω

Replace the injector.
12 —
Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

controls the feel injection timing based on the injector ECM, even repairing the faulty portion will not clear the
accelerator pedal.)
Major Faulty Event
accelerator pedal.)

1 — System Check
2 certainly. —

Review the DTC.
Refer to
+B short.
Pins 23-109/
resistance.

wiring or short.
Pins 23-5
(jumpered:
connector.


connector. 0Ω
(not jumpered):
∞Ω
the engine block.
Pins 6-7/8
(jumpered:
pins 6-8): 0 Ω
(not jumpered):
8 —
wiring or short.
Cylinder 4-

10 —

12 —
Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

accelerator pedal.)
Major Faulty Event
accelerator pedal.)

1 — System Check
2 certainly. —

Review the DTC.
Refer to
+B short.
Pins 24-109/
resistance.

wiring or short.
Pins 24-4
(jumpered:
connector.


connector. 0Ω
(not jumpered):
∞Ω
the engine block.
Pins 6-7/8
(jumpered:
pins 6-8): 0 Ω
(not jumpered):
8 —
wiring or short.
Cylinder 3-

10 —

12 —
Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

accelerator pedal.)
Major Faulty Event
accelerator pedal.)

1 — System Check
2 certainly. —

Review the DTC.
Refer to
+B short.
Pins 42-109/
resistance.

wiring or short.
Pins 42-2
(jumpered:
connector.


connector. 0Ω
(not jumpered):
∞Ω
the engine block.
Pins 6-7/8
(jumpered:
pins 6-8): 0 Ω
(not jumpered):
8 —
wiring or short.
Cylinder 4-

10 —

12 —
Review the DTC.
Refer to

1. Replace the ECM.
IMPORTANT:
15 —
Verify repair and
16 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
t
DTC277 - Injector Power Supply System Open Wiring Fault (Common 1)
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

DTC277 will be set when open wiring occurs on the second but not more than 3 seconds. (Press the
common 1 injector drive circuit. accelerator pedal.)
accelerator pedal.)
Open wiring is detected between injector #1/3 and 4. Turn on the idle position switch for not less than 1
ECM common 1 pin (both the drive circuits for injectors second but not more than 3 seconds. (Release the
#1 and #3 have open wiring). accelerator pedal.)
accelerator pedal.)
Poor connection or damaged harness may cause rubbed-through wire insulation or wire broken
intermittents. Check for the following conditions and, if inside the insulator. If the harness appears to be
the fault is detected, repair or replace the faulty portion. OK, observe the display on Tech 2 while moving

1 — System Check
2 certainly. —

Review the DTC.
Refer to
wiring. (jumpered:
1. Disconnect the ECM. 1/4-ground):
0Ω
(not jumpered):
4 connector. ground
(jumpered:
1/4-ground):
0Ω
(not jumpered):
∞Ω
Pins 1-2
(not jumpered):
connectors from the intermediate 1-2/3/4): 0 Ω
∞Ω
Pins 2-3/4
the engine block.
(jumpered:
5 3. Jumper the intermediate connector that 2-3/4): 0 Ω
was connected to the injectors and (not jumpered):
measure the resistance at the ∞Ω
intermediate connector that was Pins 3-4
connected to the ECM pins. (jumpered:
Was the resistance within range? 3-4): 0 Ω
(not jumpered):

6 —
wiring.
Cylinder 1-
pins 1:
0Ω
7 2. Disconnect harnesses from the cylinder 1 Cylinder 4-
or 4 injector. pins 4:
9 and 4. 0.4 Ω

10 —
11 —
Review the DTC.
Refer to
1. Replace the ECM.
IMPORTANT:
13 —
Verify repair and
14 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
DTC278 - Injector Power Supply System Open Wiring Fault (Common 2)
ECM
(Engine
Control
Module
23 24 5 4 42 43 2 1
0.75L
0.75W/Y
0.25L/R
1.25R
0.75B
0.75G/W
1.25L/W
1.25W
LNW21AMF007001-X

DTC278 will be set when open wiring occurs on the second but not more than 3 seconds. (Press the
common 2 injector drive circuit. accelerator pedal.)
accelerator pedal.)
Open wiring is detected between injector #2/4 and 4. Turn on the idle position switch for not less than 1
ECM common 2 pin (both the drive circuits for injectors second but not more than 3 seconds. (Release the
#2and #4 have open wiring). accelerator pedal.)
accelerator pedal.)
Poor connection or damaged harness may cause rubbed-through wire insulation or wire broken
intermittents. Check for the following conditions and, if inside the insulator. If the harness appears to be
the fault is detected, repair or replace the faulty portion. OK, observe the display on Tech 2 while moving

1 — System Check
2 certainly. —

Review the DTC.
Refer to
wiring. (jumpered:
1. Disconnect the ECM. 2/3-ground):
0Ω
(not jumpered):
4 connector. ground
(jumpered:
2/3-ground):
0Ω
(not jumpered):
∞Ω
Pins 4-5
(not jumpered):
connectors from the intermediate 1-2/3/4): 0 Ω
∞Ω
Pins 2-3/4
the engine block.
(jumpered:
5 3. Jumper the intermediate connector that 2-3/4): 0 Ω
was connected to the injectors and (not jumpered):
measure the resistance at the ∞Ω
intermediate connector that was Pins 3-4
connected to the ECM pins. (jumpered:
Was the resistance within range? 3-4): 0 Ω
(not jumpered):

6 —
Check the common 2 injector side connectors
drive circuit (intermediate connector to
injector) for open wiring or short.
Cylinder 2-
pins 2:
0Ω
7 2. Disconnect harnesses from the cylinder 2 Cylinder 3-
or 3 injector. pins 3:
9 and 3. 0.4 Ω

10 —
11 —
Review the DTC.
Refer to
1. Replace the ECM.
IMPORTANT:
13 —
Verify repair and
14 — Refer to
2 3
LNW21ASH010701
Legend
1. Injector
3. Drive harness
DTC416 - Main Relay System Fault
SBF SBF
100A 3W/L 50A
Battery
3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Main Relay
Relay
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5L/Y
0.5L/Y
Glow
Relay
118 117 116 115 114 113 109
ECM
(Engine
Control
121 120 119 95 87 Module)
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF005001-X

The main relay engages and disengages supplying the When the system fails and the DTC is stored to the
power supply voltage (24 V) to both the ECM and VIM, ECM, even repairing the faulty portion will not clear the
and is turned on when the signal is input from the ECM. DTC from the memory. To clear the DTC, conduct the
The ECM recognizes the starter switch ON signal and following steps.
outputs the relay ON signal to the main relay. 1. Turn off the idle position switch for not less than 1
DTC416 will be set when the main relay maintains the second but not more than 3 seconds. (Press the
ON status even after the main relay OFF command is accelerator pedal.)
issued.
accelerator pedal.)
• Battery over-discharge
accelerator pedal.)
With the starter switch in "OFF" position, the main relay
ON signal is output for at least 5 seconds. 4. Turn on the idle position switch for not less than 1
• After the DTC is set and the engine runs at idle, 5. Turn off the idle position switch for not less than 1
the ECM will illuminate the CHECK ENGINE lamp second but not more than 3 seconds. (Press the
(MIL). accelerator pedal.)
6. After the above operations are properly completed, the fault is detected, repair or replace the faulty portion.
the CHECK ENGINE lamp (MIL) illuminates for 3 • Poor connection at ECM: Inspect harness
seconds to report the memory is cleared. connectors for backed-out pins, improper mating,
7. Turn off the starter switch. Wait for 5 seconds and broken locks, improperly formed or damaged pins,
turn on the starter switch again. and poor pin-to-wire connection.

1 — System Check
Check the main relay.
1. Remove the main relay. Pins 1-2: ∞ Ω
2 2. At the main relay pins, measure the Pins 3-4:
resistance. 33.3-40.7 Ω
Replace the main relay.
Check the main relay system circuit for short.
1. Remove the main relay and measure the Pins 2-
4 voltage at the relay box. ground: 0 V
5 —
Review the DTC.
1. Certainly connect the relay and
connector.
Refer to
1. Replace the ECM.
IMPORTANT:
7 —
Verify repair and
8 — Refer to
Main Relay Description
4
2
1 2
3 5
5 4 3
LNW21ASF002701
Legend
1. Contact 1 (battery side) 4. Contact 3
2. Contact 2 (ECM side) 5. Coil 2 (ECM side)
3. Coil 1 (battery side)
DTC417 - Starter Switch System Fault
SBF SBF
100A 3W/L 50A
Battery
3W/G
IG IG
SBF (ST) (ON)
50A
SBF SBF
30A 60A #22 #19
10A 15A
2W/G
0.5B
Glow
Main Relay
Relay
1.25W/R
1.25W/R
1.25W/R
0.75B/O
0.5B/W
0.5L/Y
0.5L/Y
Glow
Relay
118 117 116 115 114 113 109
ECM
(Engine
Control
121 120 119 95 87 Module)
0.25B
1.25B
1.25B
0.75B
0.5B
LNW21ALF005001-X

The starter switch, after moved to the position "ST", is When the system fails and the DTC is stored to the
turned on and activates the starter. The ECM identifies ECM, even repairing the faulty portion will not clear the
the starter operation using the signal input from this DTC from the memory. To clear the DTC, conduct the
starter switch. When the starter switch is turned on for following steps.
a long period, the ECM activates the starter cut relay to 1. Turn off the idle position switch for not less than 1
stop the starter. second but not more than 3 seconds. (Press the
DTC417 will be set when the starter switch is still active accelerator pedal.)
even after the engine speed exceeds 1000 rpm.
accelerator pedal.)
• Starter malfunction
accelerator pedal.)
The state where the starter switch is in "ST" position
and the engine speed is more than 1000 rpm is 4. Turn on the idle position switch for not less than 1
continuously observed 100 times. second but not more than 3 seconds. (Release the
accelerator pedal.)
• Even after the DTC is set, the ECM will not second but not more than 3 seconds. (Press the
illuminate the CHECK ENGINE lamp (MIL). accelerator pedal.)
6. After the above operations are properly completed, the fault is detected, repair or replace the faulty portion.
the CHECK ENGINE lamp (MIL) illuminates for 3 • Poor connection at ECM: Inspect harness
seconds to report the memory is cleared. connectors for backed-out pins, improper mating,
7. Turn off the starter switch. Wait for 5 seconds and broken locks, improperly formed or damaged pins,
turn on the starter switch again. and poor pin-to-wire connection.

1 — System Check
Check the path between starter switch "ST"
and "ON" circuits for short.
2. Disconnect the ECM. Pins 109-113:
2
3. Starter switch "ON". ∞Ω
resistance.
Check the starter switch "ST" circuit harness
for short.
2. Disconnect the starter switch connector. Pins 109-113:
3
∞Ω
resistance.

Check the starter switch. Pins 3-4
1. Remove the starter switch. ("ON"
position):
2. Test the continuity between starter switch
4 Discontinued
connector pins.
("ST"
Does the starter switch meet the position):
requirements? Continued Go to Step 6 Go to Step 5
Replace the starter switch.
Check the starter switch "ST" circuit harness
for +B short.
1. Starter switch "OFF". Pins 113-
6
2. Measure the voltage between ECM ground: 0 V
connector pin and ground.


Review the DTC.
1. Certainly connect the relay and
connector.
Refer to
1. Replace the ECM.
IMPORTANT:
9 —
Verify repair and
10 — Refer to
DTC543 - High Engine Speed Error
The ECM calculates engine speeds using the signals second but not more than 3 seconds. (Release the
from CKP and CMP sensors. accelerator pedal.)
DTC543 will be set when the engine speed exceeds 5. Turn off the idle position switch for not less than 1
the specified limit due to some reason. second but not more than 3 seconds. (Press the
accelerator pedal.)
Major Faulty Event 6. After the above operations are properly completed,
• No pedal response the CHECK ENGINE lamp (MIL) illuminates for 3
Conditions for Setting the DTC 7. Turn off the starter switch. Wait for 5 seconds and
The engine speed exceeds 4400 rpm. turn on the starter switch again.
Action Taken When the DTC Sets DTC can be cleared through the memory clear
• Even after the DTC is set, the ECM will not operation with Tech 2.
illuminate the CHECK ENGINE lamp (MIL).
Diagnostic Aids
• The ECM stops fuel injection.
Conditions for Clearing MIL/DTC intermittents. Check for the following conditions and, if
When the system fails and the DTC is stored to the the fault is detected, repair or replace the faulty portion.
ECM, even repairing the faulty portion will not clear the • Poor connection at ECM: Inspect harness
DTC from the memory. To clear the DTC, conduct the connectors for backed-out pins, improper mating,
following steps. broken locks, improperly formed or damaged pins,
1. Turn off the idle position switch for not less than 1 and poor pin-to-wire connection.
second but not more than 3 seconds. (Press the • Damaged harness: Inspect the wiring harness for
accelerator pedal.) rubbed-through wire insulation or wire broken
2. Turn on the idle position switch for not less than 1 inside the insulator. If the harness appears to be
second but not more than 3 seconds. (Release the OK, observe the display on Tech 2 while moving
accelerator pedal.) connectors and wiring harnesses related to the
3. Turn off the idle position switch for not less than 1 location of the fault.
accelerator pedal.)

1 — System Check
Check the driving status (i.e., check whether
improper operation was performed due to
2 engine overrun). (Hear from the driver about —
past driving status.)
Was the operation inappropriate? Go to Step 2 Go to Step 5

Inform the driver of engine overrun due to
3 improper operation and give instructions. —
Check the vehicle for influence by engine
overrun (e.g., engine trouble) and, if fault(s)
4 are found, repair or replace the faulty —
portion(s).


1. Replace the ECM.
IMPORTANT:
5 —
Verify repair and
6 — Refer to
Default Matrix Table
Symptom Definitions
No cranking When the starter switch is moved to the position "ST", the starter is not
activated.
No initial combustion The engine provides cranking but does not run.
Poor startability at ordinary temperature The engine runs after long startup process.
Poor startability at low temperature The engine shows good startability at ordinary temperature but it takes
long time to start at low temperature.
Hunting / instable idling The idle speed is instable or varying. In the serious case, the engine or
vehicle may vibrate, resulting in occasional stall/stop.
High idle speed The idle speed is much higher than the specified level.
Low idle speed The idle speed is much lower than the specified level.
Engine stall before warm-up The engine frequently stalls before warm-up.
Engine stall after warm-up The engine frequently stalls after warm-up.
Short power / poor response / stumble The engine output is less than the desired level and even pressing the
accelerator pedal extensively will hardly or not increase the engine
speed.
Black smoke Lots of black smokes are generated on the road test.
White smoke Lots of white smokes are generated on the road test.
Large engine vibration The engine generates unusual vibrations as high as the driver feel them
in the cab.
Unusual sound Unusual sounds such as beep or rattling sounds are generated.
Symptom Diagnosis Chart

* Using Symptom Diagnosis Chart 1, cross-check the
symptom (column) and item number and diagnose the
current fault according to the procedure in Symptom
Diagnosis Chart 2.
Symptom Diagnosis Chart 1 (1/2)
Easy engine
Short power / poor response /

Poor startability Faulty idling
stall
Hunting / instable idling
Large engine vibration

Symptom
ordinary temperature
No initial combustion
Stall before warm-up
Stall after warm-up

Poor startability at
low temperature
High idle speed
Low idle speed
Unusual sound
White smoke
Black smoke
Check item
No cranking
stumble
ECM C-9
Control system
VIM C-9
System voltage /Battery C-1
Atmospheric pressure sensor C-7
SCV C-2
Pump assembly D-10
FT sensor A-2
Fuel system
Common rail pressure sensor A-1

Common rail / flow damper /
pressure limiter D-14
Injector C-3
Fuel filter / pipe / tank D-4
Fuel D-12
Valve clearance D-1
Valve timing D-11

Engine
Compression D-2
Ring gear D-6
Rotary parts D-10

Revolution control
CKP sensor D-8

system
CMP sensor D-8
Mechanical timing D-9
Pump mount condition D-9

Cooling
system
ECT sensor A-2

Intake system Warm-up
system
Glow relay B-7
Glow plug D-3
IAT sensor A-2
Intake throttle system C-4
Intake pipe, air cleaner D-5
LNW21AXF002401-X
PTO Vehicle speed control Exhaust system
system Switch and relay system Starter system
Starter
Catalyst
A/C relay
Main relay
VS sensor
AP sensor
A/C switch
Check item
PTO switch
QWS switch
Starter relay
EGR system
Starter switch
Exhaust brake
Freezer switch
Idle up volume
Starter cut relay
Idle position sensor
PTO accelerator sensor
Others/notes
Symptom Diagnosis Chart 1 (2/2)
Symptom
B-3
A-4
B-6
B-3
B-5
B-3
B-3
A-5
B-1
A-3
B-5
B-4
B-2
C-8
D-7
C-6
C-5
D-13
No cranking
No initial combustion
Inspect the clutch free system. ordinary temperature
Poor startability
low temperature
Hunting / instable idling
High idle speed

Faulty idling
Inspect the automatic transmission. Low idle speed
Note: Diagnose the system with the idle stop system Stall before warm-up
turned off.
stall
Note: Diagnose the system with the idle stop system Stall after warm-up
Easy engine
turned off. Inspect the clutch free system.

Inspect the system for ASR or AT accelerator cut
request. Short power / poor response /
Inspect the parking brake or retarder for working. stumble
Black smoke
Inspect the engine oil for proper amount. White smoke
Inspect the engine mount. Large engine vibration
Inspect the PCV for choke. Unusual sound
LNW21AXF002501-X
Symptom Diagnosis Chart 2
Inspection method
A: sensor system
1 Common rail pressure sensor 1. With the starter switch turned on and engine warmed up,
observe "Desired Rail Pressure" and "Actual Rail Pressure"
displays on Tech 2.
Reference value: Starter switch ON: 0 MPa
Engine warmed up: approx. 40 MPa
2 ECT sensor • Under the following conditions, observe "Coolant
IAT sensor Temperature", "ECT Sensor", "Intake Air Temperature",
FT sensor "Fuel Temperature", and "FT Sensor (Fuel Temperature)"
displays.
1. With the engine completely cooled down (the engine is
being shut down for at least 8 hours), check the voltages are
almost equivalent to the indicated temperatures for ECT,
IAT, and FT sensors, respectively.
2. With the engine completely warmed up (the engine coolant
temperature is about 80°C), measure the resistance of each
sensor and check the temperatures indicated on Tech 2 are
almost the same as the reference values. (For reference
values, refer to "DTC22 - IAT Sensor Fault", "DTC23 - ECT
Sensor Fault", and "DTC211 - Fuel Temperature Sensor
Fault".)
3 AP sensor 1. Check the accelerator pedal and surroundings for foreign
material and, if any, remove them.
2. Observe "Final Accelerator Opening" and "Accelerator
Pedal Position Sensor" displays while operating the
accelerator pedal.
Reference value: Idle position (0 %): approx. 0.6 V
WOT position (100 %): approx. 4.5 V
4 PTO accelerator sensor 1. Check the external accelerator is not active and, if working,
release the accelerator.
2. Observe "PTO Accelerator Opening" and "PTO Accelerator
Sensor" displays.
Reference value: approx. 0.6 V (0 %)
5 VS sensor 1. Install Tech 2 and run the vehicle, and compare the engine
control parameter “Vehicle Speed” displayed on Tech 2 to
the vehicle’s speedometer reading and also compare the
engine control parameter “Vehicle Speed” on Tech 2 to the
automatic transmission (if equipped) control parmeter
“Vehicle Speed” displayed on Tech 2.
2. Check above values are free from deviation each other.
B: Switch/relay system
1 Idle position switch (the switch is closed at 1. With the accelerator pedal completely released, observe the
idle and opened after the accelerator pedal is "Idle Position Switch" display.
pressed) 2. If even pressing the accelerator pedal does not turn on the
switch, check the switch for foreign materials and, if any,
remove them. Test the single switch for continuity.
2 Starter switch (N/O) 1. Move the starter switch to the "ST" position and observe the
"Starter Switch" display.
2. When the starter switch is not turned on, continuity-test the
circuit between starter switch and starter relay, as well as
single switch.
3 Refrigerator switch (N/C) 1. Move the starter switch to the "OFF" position and observe
QWS switch (N/O) the display for each switch.
A/C switch (N/O) 2. When any of the switches is not turned off, check the switch
PTO switch (N/O) circuit and the single switch for short.
4 Starter cut relay (N/C) 1. Check the relay and relay circuit for short.
5 Starter relay (N/O) 1. Check the relay and relay circuit for open wiring.
Main relay (N/O)
6 A/C relay (N/O) 1. Check the relay and relay circuit for short.
7 Glow relay (N/O) 1. Check the "Glow Time Relay" display appears within 18
seconds after turn-on of starter switch.
2. When the glow relay is not turned on, continuity-test the
glow relay system circuit (coil side) and glow relay.
C: Others
1 System voltage / battery 1. Observe the "System Voltage" display.
Reference value: 19-32 V
(In case of no cranking, directly measure the battery voltage
with tester instead of Tech 2.)
2 SCV 1. Start the engine and change the engine speed to observe
"SCV Duty Ratio" and "SCV Current" displays.
"SCV Duty Ratio" is decreased when the engine speed is
added.
"SCV Current" is decreased when the engine speed is
reduced.
3 Injector 1. Perform the injector balance test to check all the injectors
are working.
2. Observe the "Cylinder (1-4) Compensation" display for
individual cylinders to check all the cylinders acquire equal
calibrated fuel quantity.
3. If faulty cylinder(s) are identified, clean or replace it (them).
4 Intake throttle system 1. Perform the intake throttle test to check the "Actual Intake
Throttle Position" follows the "Desired Intake Air Throttle
Position".
2. If the actual value does not follow the desired value, check
the intake throttle valve for sticking and the motor for fault.
5 EGR system 1. Perform the EGR control test to check the "EGR Current
Position" follows the "EGR Target Lift Position".
2. If the actual value does not follow the desired value, check
the EGR valve for sticking and the motor for fault.
6 Exhaust brake 1. Operate the exhaust brake to check the "Exhaust Brake
Switch" display changes between "On" and "Off".
2. If the display does not follow the operation, check the
exhaust brake valve for sticking and the solenoid valve for
fault.
7 Atmospheric pressure sensor 1. Observe the "Barometric Pressure" display for abnormal
value.
8 Idle up volume 1. Set the idle up volume to the minimum and observe the "Idle
Up Volume" display.
Reference value: 0.55 V
2. Check the voltage for excessively high value or variation.
9 ECM 1. Install Tech 2 and display the data list.

VIM 2. If the data does not appear or the displayed data is
incorrect, perform the "On-Board Diagnostic (OBD) System
Check".
D: Engine mechanical system
1 Valve clearance 1. Using tools, measure and adjust the valve clearance. (Refer
to "Functional Check" in "Engine Mechanical".)
2 Compression 1. Using tools, measure the compression. (Refer to "Functional
Check" in "Engine Mechanical".)
2. If the measured value is incorrect, fact-find the compression
leak and repair or replace the faulty portion(s).
3 Glow plug 1. Using a tester, measure the resistance of the glow plug.
2. If the measured value is incorrect, check the circuit between
glow relay and glow plug, as well as glow plug.
4 Fuel filter / pipe / tank Perform the visual check according to the following
procedures.
• Check the fuel system for air bleed. (Bleed the air as
necessary. Refer to "Functional Check" in "Fuel System".)
• Check the fuel filter for excessive contamination and choke.
• Check the pipe for damage, collapse, and choke.
• Check the fuel tank for contamination with dust.
• Check the feed pipe in the fuel tank for foreign materials.
5 Air cleaner, intake pipe Perform the visual check according to the following
procedures.
• Check the air cleaner for excessive contamination and
choke.
• Check the pipe for damage, collapse, and poor assembling.
6 Ring gear Perform the visual check according to the following
procedures.
• Check the gear teeth for chipping.
• Check for cause(s) that prevent gear rotation.
• Check the gear for correct engagement.
7 Catalyst 1. Check the catalyst for internal damage sound.
8 CKP sensor 1. If non-OEM parts are installed, turn off all the powers and
CMP sensor reconfirm the symptom. If OEM parts resolve the symptom,
the cause lies in noises from the non-OEM parts. Report the
fact to the customer.
2. Check the sensors are firmly fixed.
9 Mechanical timing 1. Check the service history to identify the pump was removed
Pump mount condition in the past.
2. If a removal was recorded, check the pump has correctly
been installed. (Refer to "Supply Pump" in "Fuel System".)
10 Rotary parts in pump assembly 1. With the pump running, check the assembly for fuel leak
and unusual sounds.
11 Valve timing 1. Check the service history to identify the camshaft was
removed in the past.
2. If a removal was recorded, check the camshaft has correctly
been installed. (Refer to "Camshaft Assembly" in "Engine
Mechanical".)
12 Fuel 1. Drain the currently charged fuel completely.
2. Fill new (and appropriate) fuel.
13 Starter 1. Check the starter for motor rotation and pinion projection.
(Refer to "Starter" in "Electrical System".)
14 Common rail / flow damper / pressure limiter 1. Check the flow damper or pressure limiter is not working.
2. Check the pressure limiter for fuel leak.
* If the diagnosis with Tech 2 fails to identify faulty

parts, go to "Symptom Diagnosis" in engine mechanical
sections (Sections 1B to 1H).
Special Tools
Tool No.
Illustration
Tool name
5-8840-2691-0
Digital Multimeter
Tech 2 Scan Tool
5-8840-0632-0
Terminal Remover
5-8840-0388-0
Weather-Pack Terminal
Remover
Wiring Harness Repair: Shielded Cable

Removal Procedure 3. Wrap the splice with mylar and with the drain
(uninsulated) wire.
1. Remove the outer jacket.
2. Unwrap the aluminum/mylar tape. Do not remove
the mylar.
LNW21ASH004401
LNW21ASH004201 4. Tape over the whole bundle to secure.
3. Untwist the conductors.

4. Strip the insulator as necessary.
LNW21ASH004501
LNW21ASH004301
Installation Procedure
1. Splice the wires using splice clips and rosin core
solder.
2. Wrap each splice to insulate.
Twisted Leads
Removal Procedure 2. Cover the splice with tape in order to insulate it
from the other wires.
1. Locate the damaged wire.
2. Remove the insulation as required.
LNW21ASH004801
LNW21ASH004701
3. Twist the wires as they were before starting this
procedure.
1. Use splice clips and rosin core solder in order to
splice the two wires together.
LNW21ASH004901
LNW21ASH004601
4. Tape the wires with electrical tape. Hold in place.
LNW21ASH005101
Weather-Pack Connector
Removal Procedure 3. Cut the wire immediately behind the cable seal.
A Weather-Pack connector can be identified by a
rubber seal at the rear of the connector. This engine
room connector protects against moisture and dirt,
which could form oxidation and deposits on the pins.
This protection is important, because of the low voltage
and the low amperage found in the electronic systems.
1. Open the secondary lock hinge on the connector.
LNW21ASH005301
Make certain the connectors are properly seated and
all of the sealing rings are in place when you reconnect
the leads. The secondary lock hinge provides a backup
locking feature for the connector. The secondary lock
LNW21ASH005001 hinge is used for added reliability. This flap should
retain the pin even if the small pin lock tangs are not
2. Use terminal remover 5-8840-0388-0 or the positioned properly.
equivalent to remove the pin and sleeve pins. Push Do not replace the Weather-Pack connections with
on 5-8840-0388-0 to release. standard connections. Read the instructions provided
with the Weather-Pack connector and pin packages.
NOTE: 1. Replace the pin.
Do not use an ordinary pick or the pin may be bent 2. Slip the new seal onto the wire.
or deformed. Unlike standard blade pins, these
3. Strip about 5 mm of insulation from the wire.
pins cannot be straightened after they have been
improperly bent. 4. Crimp the pin over the wire and the seal.
5. Push the pin and the connector to engage the 6. Close the secondary locking hinge.
locking tangs.
LNW21ASH005401
Special Tools
Tool No.
Illustration
Tool name
5-8840-0388-0
Weather-Pack Terminal
Remover
Com-Pack III
General Information
The Com-Pack III pin looks similar to some Weather-
Pack pins. This pin is not sealed and is used where
resistance to the environment is not required. Use the
standard method when repairing a pin. Do not use the
Weather-Pack Terminal tool 5-8840-0388-0 or
equivalent. These will damage the pins.
Metri-Pack
Removal Procedure Installation Procedure
Some connectors use pins called Metri-Pack Series Metri-Pack pins are also referred to as "pull-to-seat"
150. These may be used at the engine coolant pins.
temperature (ECT) sensor. 1. In order to install a pin onto a wire, the wire must
1. Slide the seal (1) back on the wire. be inserted through the seal (2) and through the
2. Insert the tool 5-8840-0632-0 or equivalent (3) in connector (3).
order to release the pin locking tang (2). 2. The pin (1) is then crimped onto the wire.
1
3
2 2
3. Push the wire and the pin out through the 3. Then, the pin is pulled back into the connector to
connector. IF you reuse the pin, reshape the seat it in place.
locking tang.
Special Tools
Tool No.
Illustration
Tool name
5-8840-0632-0
Terminal Remover
LG4HL-WE-0229DOM
You are requested to order this manual using the

manual number that is shown above.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Nov., 2002

No.LG4HL-WE-0229DOM

Engine Control System: Workshop Manual

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WORKSHOP MANUAL

ENGINE CONTROL SYSTEM

International Service & Parts

Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended

that you carefully read and thoroughly understand the information

contained in Section - 0A under the headings “GENERAL REPAIR

INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product

information available at the time of publication.

Engine Control System

Symbol Color Symbol Color

Function and Operation Voltages from ECM

Function of ECM Electrically Erasable Programmable ROM

Starter cut relay

Common rail Transmission

The engine control system comprehends vehicle status

Fuel Temp. Desired Injection

Idle Position Switch

Exhaust Brake Working Conditions

Function and Operation The ECT (engine coolant temperature) sensor is

The EGR valve is installed at the top of the inlet cover

Intake Throttle Valve and ITP Sensor LNW21ASH007901

The CMP (cam position) sensor is installed to each

The FT (fuel temperature) sensor is installed to the

Idle Position Switch

The IAT (intake air temperature) sensor is installed to LNW21ASH008801

The clutch switch is installed to the clutch pedal, and is

Atmospheric Pressure Sensor

The neutral switch (P/N switch in case of automatic

The CHECK ENGINE lamp (MIL) is built in the meter

DLC (data link connector) is installed to the dash side

[Fuse Box Label, In Glove Box]

[Fuse Box, Front Left of Radiator]

No. Indication on label Capacity Devices connected

No. Indication on label Capacity Devices connected

External Fuse Box

Relay Box No.1

Relay Box No.2

Fuse & Front Right

EGR Valve 0.5Y

PTO Lamp Tachometer

CFS Vehicle Brake SW

Air Bleed Connector

CFS Control Unit

Glow Plug E-3 1.25 1.25 1.25 0.75 0.5

Left Side Frame

0.5 FUEL, SEAT HEATER J-50 H-46 H-46

0.5 0.5 0.5 0.85

PTO Accelerator Sensor

Left Frame (Front) B-346

TCM B-47 20 (JATCO)

Meter B-52 17 Speed Meter TCM B-229 23 (AISIN)

Meter B-52 8 (Tachometer)