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Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A1 ENGINE (6WF1-TC,6WG1-TC(Common Rail)) TABLE OF CONTENTS Engine Control System 1A2 Procautions for servicing 1A2 Explanation of Functions and Operations .....1A-4 Parts layout diagram : 1A31 Circuit Diagram 18-36 Connector List 458 Fault diagnosis process. 1A-69 Breakdown diayiwusio using ie sean foul... Function inspection List 1A-88 Oral consultation 10-89 On-Board Diagnosis (OBD) System Check. ..1A-91 Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON) 194 Checking the MIL (check engine lamp) flashing control system (MIL does not flashing) 197 Gnecking tne Scan 101 Gircuit System... 1A-1U0 Checking the starting system 4-103, Checking the fuel system. 1-108, Checking the intake air system 18-110 Checking the exhaust system 1Aet12 Checking the EGR : 1-116 Checking the engine control module (ECM) power supply and ground circuit 4A-119 Checking the PTO : A122 Table of diagnostics codes. 1126 DTC P0014 (Fash code 14)... 1-137 DTC P0015 (Flash code 15) A144 DTC P0022 (Fiash code 22) A145 DTC P0023 (Flash code 23) 1A-149 DTC P0024 (Flash code 24) 4A-153 DTC P0025 (Flash code 25) 1A157 DTC P0032 (Flash code 32) 4-162 DTC P0033 (Flash code 33) 1-166 DTC P0036 (Fiash code 35) ...... 1A-168 DTC P0042 (Fiash code 42) 1A-170 DTC P0051 (Flash code 51) 1173 DTC P0071 (Flash code 71) 1A175 DTC P0072 (Fiash code 72) 1AATT DTC P0115 (Flash code 115) 1A179 DTC P0118 (Flash code 118) 1183 DTC P0151 (Flash coda 151) 1A-180 DTC P0158 (Fash code 158) 1A-195 DTC P0150 (Flash code 159) 1A-100 DTC P0211 (Flash code 211)... 1-203 DTC P0217 (Flash code 217) 414-208 DTC P0218 (Flash code 218) 4-209 DTC P0226 (Flash code 226) ... 18-212 DTC P0227 (Flash code 227) 1A-217 DTC P0242 (Flash code 242) DTC P0245 (Flach code 245) DTC P0247 (Flash code 247) DTC P0248 (Flash code 248) DTC P0271 (Flash code 271) DTC P0272 (Flash code 272) DTC P0273 (Flash code 273) DIC FORTS (Flasin univ 274} DTC P0275 (Flash code 275) DTO P0276 (Flash code 276) DTC P0277 (Flash code 277) DTC P0278 (Flash code 278) DTC P0411 (Flash code 411) DTC Pos 12 (Flash code 412) DTC P0413 (Flash code 413) IG Pusat (riasn coae 478) DTC P0418 (Flash code 418) DTC P0421 (Flash code 421) DTC P0424 (Flash code 424) DIC P0441 (Flash code 441) DTC P0442 (Flash code 442) DTC P0446 (Flash code 446) DTC P0447 (Flash code 447) DTC P0448 (Flash code 448) DTC P0449 (Flash Code 449) DTC P0518(Flash Code 518). DTC P0543(Flash Code 543). Symptom List Engine Stall Engine hunting, rough idie Lack of power, slugginess or hesitation Excessive white smoke Excessive black smoke Idling revolutions cannot be adjusted. Idling revolutions cannot be adjusted down Special tool Programming Explanation of Functions and Operations Programming Special tool 1-222 1-226 414-230 14-233 14-236 4A-240 10-244 1A-252 1A-256 41-260 1A-263 1-266 1270 1A-274 qaAers 14-281 1-284 1-339 1A-342 1.343 1-343 1-344 1-354 1A-2 _ Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) Engine Control System Precautions for servicing If no specific instruction is made in the diagnostic procedure, test lights should not be used in the diagnosis of power train electrical equipment systems, It probe connectors are required tor diagnostic procedures, use connector test and adaptor kit 5-8840- 0385-0. Vendor Electrical Devices Vendor electrical devices are electrical devices that are purchased in the market and mounted in the vehicle aller it is shipped fram the factory Care is required because no specific consideration was given to such CAUTION: Vendor electrical devices must be connected to power supply and grounding circuits that are not involved with electronic control system circuits Even if they are connected normally, vendor electrical devices can cause malfunctions in electrical cantrol systems. Effects can even be caused by such devices that are not connected to vehicle electrical systems, such as cellular telephones and portable radio equipment Therefore, when diagnosing power train problems, first check that no vendor electrical devices are moiinted on the vehiela, and remove any that are After removing such devices, perform normal diagnostic procedures for any problems that persist. Table of abbre\ Damage Due to Static Electrical Discharge The electrical eampanents ised in slectronie control systems are designed to operate at very low voltages, so thay are vulnerable to damage to static electrical discharge. Even static electricity at 100V or less, which is usually imperceptible to humans, can damage some types of electrical components. For reference, a voltage of 4,000V is required to produce a human- perceptible current of static electrical discharge. There are several ways a person can accumulate static charge. The most common are through friction and induction. + For example, charging due to friction occurs when a person slides sideways across a car seat, + Charging through induction occurs when a person wearing insulating shoes stands near a highiy- charged body and momentarily touches a ‘grounded body. Charge of the same polarity flows ‘out, so the person becomes hichly charaed with the opposite polarity. Static electricity causes damane. so areat care is required when handlina ‘or testing electrical components. CAUTION: Follow the guidelines below to prevent damage by static electrical discharge: + Do not touch FCM eonnactor pins or electrinal components that are connected to an ECM circuit board. + Do not take a replacement component out of its packaging before you have completed all preparations for mounting i + Before removing a component from its packaging, connect that packaging to normal grounding in the vehicle. + While sliding across a seat while sitting fram a standing position, or after handling components while walking for some distance, touch a normally grounded object before attaching the components, [Abbraviati T on Name f Meaning. nates ‘ABS | Antvlock Brake System ‘A device to prevent brakes trom locking ‘AID | Analog/Digital ‘Analog/Digital ‘APP _| Accelerator Pedal Position The extent to which the accelerator pedal has been depressed. ‘ASR | Anli Slip Regulator ‘A device to restrict slipping of the driven wheels. ‘CAN | Anti Slip Regulator ‘Communications between control devices CKP | Crankshaft Position Indicates the position of the crankshaft (flywheel) Engine Control System (6WE1-1C,6WG1-TC(Common Rail) 1A- Abbreviat Name Meaning, notes DLC [Data Link Connector ‘A connector for connecting the scan tool DTC — | Diagnostic Trouble Code Self-diagnostic codes, trouble codes, diagnostic, codes EBS | Electronic Brake System ‘An electronically-controlled brake system. ECM _ | Engine Control Module ‘A computer for controling the engine ECT [Engine Goolant Temperature Temperature of he engine coolant, ECU | Electronic Control Unit ‘Compitters for various control fanctions EGR _ | Exhaust Gas Recirculation Recirculation of exhaust gas. EMI _ | Electronic Magnetic Interference Electromagnetic Interference. Exh | Exhaust Exhaust gas, GND | Grouna ‘Connection to ground/earth GVW __| Gross Vehicle Weight ‘The gross weight of the vehicle. TAT | Intake Air Temperature Temperature of air taken in (outside air temperature). MIL | Malfanction Indicator Lamp Warming lamp MIL (check engine lamp) OBD | On Board Diagnostic Diagnostic system on the vehicle (or vehicle- mounted maifunction diagnostic system) PCV | Pump Control Valve ‘A valve that controls the volume of fuel fiowing to tine fuel re PT | Power Tit Cab tiling mechanism PTO [Power Take OfF ‘System for taking motive power. PWM _ | Pulse Width Modulation Modulation of wave pulse width GOS | Quick On Start Engine warming system. RP | Rail Pressure Pressure in the rail ‘SBF _ | Slow Blow Fuse Slow blow fuse. SIG | Signal Signal TWV_| Two Way Vaive Valve within an injector. VES _ | Variable Goometry Turbo System Variable turbocharge oystom VSS _ | Vehicle Speed Sensor Vehicle speed sensor 1A-4 Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) Wiring colors ‘The wiring in all harnesses can be distinguished by the insulation colors, The harness that is the main circuit within a given electrical svstem is identified by single- colored wires, while sub-circults of that system are identified by striped colors. In wiring diagrams. sizes and colors are indicated by the following method: Example: 1B iL 1 red (Stripe color) Green (Base color) Wire size (0.5 me) ‘Symbols Colors ‘Symbols Colors B Black BR Brown Ww White us Light Green R Red GR Gray c Green P Peach ¥ Yellow SB Sky blue L Blue Vv Violet ° ‘Orange Explanation of Functions and Operations Electronic Control Systems The electronic control system takes the data detected by various lybes of sensors, aint performs calculations nit using the control programs of the electronic control luduie for uveraii Wonivut uF fue injection volume, injection timing, starting, high-altitude compensation and other factors. Electronic Control Fuel Injection System In the electronic control fuel injection system (fue! rail type), the electronic control module (ECM) obtains data such as the engine soeed and engine load through signals from many sensors. The ECM then sends electrical sianals to the suooly pump. injectors and elsewhere on the basis of that data, for optimum control Of fuel injection timing and volume for each cylinder, and other parameters. Injection Volume Control To achiove the optimum injection volume, the engine speed and accelerator depression are the main factors used to control the two-way valve (TWV) in each injector, controling the volume. Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A5 Injection Pressure Controt Fuel pressure inside the fuel rail is controlled to control the injection pressure. The optimum internal pressure for the fuel rail is calculated from oarameters such as engine speed and fuel injection volume, and the right volume of fuel is pumped out by controlling the supply pump (PCV: Pump Control Valve) to control fuel puurnping to the fuel rail ‘System Schematic Diagram Injection Timing Control In place of the timer function, the optimum fuel injection timing is calculated from parameters such as the engine speed and inlection volume. and controlled using the two way valve (TWV) inside each injector. Injection Rate Control To improve combustion in the cylinders, only a small quantity of fuel is injected at first (pre-injection) and ignited. Ignition ie fellowed by a second injection (main injection). Control of the injection timing and quantity is achieved using the two way valve (TWV) inside each Injector c *\ terete canene Engine control unit ko ‘a a ee (built in ECU) hai wee I > af Ex. = Fuel predsure sensor x -Flow dampor| a of» ) iran ea = Wa waced | oo Sree] | | weet ince Pett HewssaLroa1 IAL ‘System Control Schematic Diagram Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Basic fuel Injection rato neaton Engine coolant temperature sensor inptt, ‘accelerator podal postion sensor input ‘start switch input ‘Vehicle spoed sonsorinput, ‘luc ewich input Injector (THY) power supply tina, timing decision Conon al poss snes Common a (rormally igh pressure) Pov s ‘Supply “np AN Inipcor Howane oa Engine Control System (6WE1-1C,6WG1-TC(Common Rail))_1A-7 Exhaust Gas Recirculation (EGR) The EGR (Exhaust Gas Recirculation) system recirculates part of the exhaust gas within the intake manifold. mixing inert gases with intake air. This lowers the combustion temperature, reducing the generation of NOx. The EGR volume is controlled by the action (opening and closing) of the EGR valve, which is situated hetween the exhaust manifold and the intake manifold. The EGR volume is determined according to the engine speed and angina load rate (fuel injection volume). A vehicle equipped with an intercooler turbo has a caoler built into the EGR gas channel, sa that hot EGR gas is cooled by the cooler and mixed with fresh air. This achieves a greater reduction in combustion temperature than normal EGR, further reducing NOx generation (cooled EGR). Furthermore, the EGR system uses a one-way valve to restrict the backward volume can be increased ‘System Control Schematic Legend 1. EGR gas cooling device 9. Engine load 2. EGR valve 410. Accelerator pedal sensor 3. Air ine 41. EGR vaive 4. EGR magnetic valve 12. EGR gas cooling device 5. Air tank 48. Non retun valve 6. Engine contro! module (ECM) 14, Intake air 7. Grankstiall position (GKP) sensor 45. Non return valve 8. Engine speed 16. Engine 1A-8 _ Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 1/. exnaust gas Variable Geometry Turbo System (VGS) Air cylinder stroke (number of magnetic valve steps) is derived from the engine speed, with corrections for information received from various inputs to determine the final air cylinder stroke (number of magnetic valve steps) The VGS magnetic valve moves through the determined number of steps, moving the pneumatic cylinder with pneumatic pressure to control the nozzle vane angle inside the turbine housing. | Batecton Engine Speed —} +} "ofthe pers. VSS 07 GS sop T Various Switch — Magnet Valve canvl Crout Engine Contol Modula Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1-9 Pneumatic Cylinder (Ful Svoto Howasrerot ©: Pressurizes Air x : Atmospheric Open pa | 0 | 3] 6 | 9 | 2] 15] w] 2 Pott | x | O|] x] o|]x}lo|x]lo po |x| xlolo|x|xlolo pots | x |x |x] xlolololo Idling Control During warming operation, the idling control switch can be used to adjust the minimum idling speed. The switch can also be used to automatically set the minimum idling speed to the optimum value for the current engine coolant temperature. This function is disabled when PTO control (fuel injection characteristic switching) is used. Idling Control Switch The idling control switch can be used to switch the idling control function off and on. AUTO ... Auto mode The minimum idiing speed is set to the optimum value for the engine coolant temperature. When engine coolant temperature is low, the idling speed is high, but it is reduced as the engine coolant temperature rises. The idling contro! switch must be switched to Manual mode to adjust the idling speed. MANU ... Manual mode The idling control switch can be used to adjust the idling speed. The speed set in manual mode remains effective as the minimum idling speed when the switch is returned to Auto mode. 1A-10 Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) dling control swit The idling contro! switch can be used to adjust the idling speed. The maximum speed varies according to the engine type, vehicle specification and engine temperature. up While the switch is pressed to the Up side, the engine speed increases and the idling speed can be increased, Down While the switch is pressed to the Down side. the engine speed decreases and the idling speed can be decreased. However. it cannot be reduced below the minimum idling speed. HONBUASEENDOY PTO Control (fuel character switching) PTO control under the engine control system is called “fuel injection characteristic switching’. Fuel injection characteristic switching Switching driving characteristics and working characteristics, Fuvi injection charavieristic switching Hf, and oniy if, an external accelerator is connected, the fuel injection characteristics can be switched by the status of the PTO switch, which is input to the engine control. However, as before, fuel injection characteristic switchina is only possible when the vehicle is at rest. The switching conditions are as follows: Conditions in which it is possible to switch from driving characteristics to working characteristics (conditions in which working characteristics can be used) All the following conditions must be satisfied (these are AND eonditians) + PTO switch is tured on (PTO switch: ON) + Venioie is at rest. + Parking brake is engaged (parking brake switch’ On) + Extemal accalarator input is normal (PTO remote throttle sensor voltage 0. 1-4.8V) + Exteinal accelerator is in idling position (PTO remote throttle sensor <5%) + Drive accelerator is in idling position (accelerator sensor <5%) + PTO accelerator switch is not switched on (PTO accelerator switch: Off) NOTE: These are added setting (modified) switches for concrete pump vehicles. + No DTC has been issued to stop PTO control (tefer to DTCs) Conditions in which itis possible to switch from working characteristics to driving characteristics (conditions in ‘hich driving characteristics can be used). Al the following conditions must be satisfied (these are AND conditions) + PTO switch is not turned on (PTO switch: OFF) + Vehicle is at west. + Parking brake is engaged (parking brake switch: On) + Extemal accelerator inout is normal (PTO remote throttle sensor voltage 0.1-4.8V) + Extemal accelerator is in idling position (PTO remote throttle sensor <5%) + Drive accelerator is in idiing position (accelerator sensor <5%) + No DTC has been issued to stop PTO control (Teter to DTCs) Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A-11 Accelerator Switching Conditions “switching between driving accelerator and external accelerator Conditions in which the external accelerator can be used (driving accelerator and external accelerator can both be used) All the following conditions must be satisfied (these are AND rnnditions) + Vehicle is at rest. + Parking brake is engaged (parking brake switcn: On) + External accelerator is in idling position (PTO remote throttle sensor <5%) Conditions in which the external accelerator is disabled (only the driving accelerator can be used) When any of the conditions below is satisfied + The parking brake has been released. + The vehicle is in motion (vehicle speed has been Uvlwcted). pe ) a" Legend 1. PTO owiteh 2. Governor characteristic switching conditions 3. Accelerator open 0% 4. Drive characteristics t 6. PTO accelerator witch operation characteristics, ©. Operation characteristics IN" when using 1A-12_ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) ‘Speed Restriction Gontrot Speed restriction control is a function by which the engine control module (ECM) controls the fuel injection volume on the basis of the vehicle speed sianal and the engine speed, so that vehicle speed cannot exceed the set value (90kmih), The vehicle speed signal is received by the speed sensor ennirol unit from the vehicle spaed sensor The speed sensor control unit corrects the vehicle speed Signal according to the type of vehicle and forwards i to the ECM, meters and elsewhere. The ECM recognizes the engine speed from the signal provided by the CKP signal Equipment with speed restriction control (device) is mandatory under the Road Trucking Vehicle Law for vehicles with GVW of 8 or more, or with cargo load of st or more. Fuol Injection Control Ne Meter Other cu Ly Eom vss clu |CrankPosition(CKP)[~_] Vehicle Speed Sensor ‘Sensor Ly vss) Cruise Control This function can maintain speed at a set level (within the range 40-80km/h) without depression of the accelerator pedal. When the cruise main switch is tured On (the Cruise Main lamp lights) and the target speed is reached, the Cruise Set switch can be ‘operated (push - release) to put the vehicle into auto cruise mode (the Cruise Set lamp lights). Then, the target speed is maintained even if the accelerator pedal is released, ‘Temporary Acceleration Function During the cruise control, the accelerator pedal can be depressed for temporary acceleration. When the accelerator pedal is released, the vehicle decelerates and rotume to cruise control modo. Set Coast function (lower the cruise control set speed) If the Cruise Set switch is pressed during the cruise control, speed reduces for as long as the switch is pressed. Release the Cruise Set switch when speed has fallen to the desired level to change the set speed to the vehicle speed at that time. Tip Down function Thie function Inwere the sat speed during the eriice Control, It is used for fine tuning of the set speed, If the Set switch is briefly prassed and released during the cruise control, the set speed is reduced by tkm/h for each time it ie pressed. Fine adjustment of up to 10km/ h (press 10 times) is possible. However, It is not possible to adjust the cot spood below tho minimum cruise control set speed (40km/h), Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1-13 NOTE: If tip down operation is used repeatedly in a short penod, the gap between set speed and actual speed increased, so that the auxiliary brake linkage cruise control tunction may act to use auxllary braking (exhaust brake and retarder). Set Acceleration function (raise the cruise control set speed) During the cruise control. the Cruise Resume switch can be pressed to raise the speed for as long as it is pressed. Release the Cruise Resume switch when speed has increased to the desired level to change the set speed to the vehicle speed at that time. Tip Up function This function raises the set speed during the cruise Cruise Resume switch is briefly pressed and released during the cruise control, the sot speed is raised by ‘km/h for each time itis pressed. Fine adjustment of up to t0kmih (press 10 times) is possible. However, It is not possible to adjust the set speed above the maximum cruise control set speed (80km/h). The cruise control function is cancelled under any of the following conditions: + The Cruise Main switch is turned Off (Cruise Main switch: Off} + Vehicle speed falls down to 30km/h or loss, + The Cruise Set switch and the Cruise Resume switch are pressed at the same time (Cruise Set switch: On AND Cruise Resume switch: On). + A malfunction occurs in the engine control system (eter to DTCs). + The engine stops OR Brake switch-2: On), + The Exhaust Brake lever is operated (Exhaust Brake switch: On). + The Retarder lever is operated (Retarder switch: On). + The Ciuise Cancei switch is pressed (Ciuise Cancel switch: Off. + The Shitt lever is moved to neutral (Neutral switch: On), Resume function (revert to cruise control mode). If the cruise control function has been cancelled, the Cruise Resume switch can be operated (press - release) to revert to the cruise control state that aoolied before the cancellation (the Cruise Set lamp lights). However. if the cruise control was cancelled under any of the following conditions, itis not possible to revert to the eruise enntrol stata that applied hafore the cancellation The cruise control state must be sat again + The Cruise Main switch was tumed Off (Cruise Main ewiteh: Off. + The Cruise Set switch and the Cruise Resume switch are pressed at the same time (Cruise Set switch: On AND Cruise Resume switch: On) + A malfunction occurs in the engine control system (refer to DTCs). + The engine stops. NOTE: ‘The Rasime function is operable when vehicle speed is 40km/h or more. 1A-14 Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) ‘Auxillary Brake Linkage crulse control During the cruise control, auxliary braking (exhaust braking and retarder) are automatically linked, so that this function restricts acceleration on gentie downward slopes. The aim is to reduce diving strain on the driver (by reducing foot brake operations required to counter speed increases). When a vehiale diving under the entisa conten! enters a downhill slope and the vehicle speed exceeds the cniise set speed, the exhaust brake acts frst to restrict any increase in speed. If the vehicle speed increases while the exhaust brake is operating, the retarder acts in addition to the exhaust brake to restrict any increase in speed. (The stop lamps light during auxiliary braking). When vehicle speed has fallon to the cruise sot speed, auxliary braking ceases (the retarder is released first ces ee Cae Loo =— Downward slope Downward slope Flat way ‘Exhaust brake and retardor Exhaust brake operates operates. Engine Control System (6WF1-1C,6WG1-TC(Common Rail) _1A-15 ‘Auxiliary braking (exhaust brake and retarder) aunng the cruise control is performed through the exhaust brake and retarder control unit. The Engine Contro Module (ECM) sends an action signal to the exhaust brake and fetarder control unit. In response to the signal, the exhaust brake and retarder control unit engages and releases auxiliary braking (exhaust brake and retarder), Exhaust broke operato signal Engine contol unit Exhaust rake and retarder control unit Vehicle speed signal (pulse) Retardor Exhaust ‘Speed sensor control unit Mv brake MV Vehicle speed sensor Ll ewerasteount 1A-16 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail) ECM Communications The various control units are in communication and signals necessary for control functions (accelerator oveniing. vehicle speed. various switch signals. etc.) are sent and received The communications methods are Pulse Width Modulation (PWM) and Controller Area Network (CAN) (CAN (Controle Ara Network) Communications ‘ABSIASR 88 ee anor ECU (for Trucs) | | ECU (ort) | | ECU ecu wu eater | I | I Resisor a Smoother 4 Tes Fou eee hi | | owe uweoo201 Communications Methods + PWM (Pulse Width Modulation) frequency and amplitude are constant and the pulse width is varied according to the signal The proportion of On time in one cycle is varied to create the signal + CAN (Controller Area Network) CAN communication is implemented with two wires. (communication lines) to connect control Units to each other for communication. Each control unit is able to exchange multiple data items simultaneously at different transfer rates (high! medium/ low speed) and with the number of signals. Furthermore, signals are shared by each Control unit to use for various types of control Functions for communications with ABS/ASR, EBS control units and fuel reduction volume control NoTE: + ABSIASR control unit: Truck + EBS control unit: Tractor Functions for communications with ABS/ASR, EBS control units The Engine Control Module (ECM) uses CAN communications with the ABS/ASR and EBS control unite. + ECM — ABS/ASR and EBS control units (normal Wansinission) The ECM sends the current accelerator pedal depression distance, as the ASR accelerator opening signal, 0 the ABS/ASR. and EBS control units + ABS/ASR and EBS control units — ECM (transmission during ASR control oniy) The ABS/ ASR and EBS control units send the restricted accelerator pedal depression distance, as the fuel reduction volume signal, to the ECM. Engine Control System (6WF1-1C,6WG1-1C(Common Rail) 1A-17 Fuel Reduction volume control If the ABS/ASR and EBS control units detect slispaae of driven wheels, they send the fuel reduction volume signal. calculated from the ABS/ASR and EBS accelerator opening signal, to the ECM. The ECM uses this fuel volume reduction signal to choke the fuel injection volume, limiting the output of the engine to restrict slippage of driven wheels {Ehigine Conor modus (EC [Accelerator Pedal APP Detection] Commo Poston (APP) Sersor{ > “9 [m= ‘sins E65 cs Hewesaseto0r 1A-18 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Engine speed control and communications with the ‘Smoother-G control unit When ASR operates, or when there is a gear change request. in order to synchronize the transmission revolutions a signal is sent to the engine control module (ECM) (request to increase or decrease the fuel injection) to control the engine speed, Also, the following communications finetions are ised with the Smoother-G control unit. Accelerator Ped ration {APP} Senne Signals Control Medule (ecm) CAN Communicatons ‘APP ‘Seen sgnais - Viele Speed Stata of Cruiea Contr Fue! Cut Signa ADSIASR EBS ECU ‘Smoother. ‘Control Unt Engine Control System (6WF1-1C,6WG1-TC(Common Rail) _1A-19 Accolerotor Post Position (APP) Sensor 2 SS cums —o~o——_| = Sovtamsoucn Cruse Main Switch oe Cruse Sat Seiten ou (Cruse Reloaso Switch + Crise Resume Switch Cruse Release Switch 2 oe ‘smooiner-c Control Unit 6 2% as ame 21 (ECM) pth cANH caus 7 eons 2 nen s 5 aa) ia Cruise Operation Signal : see pen i ss Exhaust Brake: oases 97 eM SHEET ETETE E n | ramos ce cma Contra Unt ‘ante Un Vohicle Speed Sensor Exhaust Retardor Broke MV 1-20 _ Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) ‘Communications control with the meter ECU The meter ECU uses the Engine Control Module (ECM) CAN communications to send engine coolant temperature data, overheat signal and overheat warning buzzer action request signal to operate the engine coolant temperature meter, overheat warning lamp and overheat warning buzzer. ‘The ECM receives the parking switch signal from the ‘meter ECU using CAN communications. Engine Coolant | signal CAN Temperature — |) engine Contr [*——_——* (ECT) Sensor Module (ECM) | + ECT Signal + Baking Broke ‘Switch Signal ‘Thorme Motor Motor © Ecu ‘Over Host "| Warming Lamp Over Heat Warning Buzzer Parking Brake ‘witch Engine Speed Output to the Tachometer The Engine Control Module (ECM) outputs engine speed signal (4 pulses for one rotation of the engine) to the tachometer as tachometer output. The tachometer uses the engine speed signal received from the ECM to display the engine speed, Pe Legend 4. Crankshaft Position (CKP) Sensor 2, Engine Speed 3, Engine Contro! Module (ECM) 4. Tachometer output 5. Tachometer Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) 1A: Idle position signal output to the exhaust brake and retarder control unit Tire Enyine Cunivui Module vuipuis ihe “accelerator pedal depression state (depressed! not depressed)" to the brake cential control unit as an idle position signal output. ‘The exhaust brake and retarder control unit uses the “accelerator pedal depression state”, together with the Girectly detected control operation states (exaust brake lever, retarder lever, clutch pedal etc.) to engage and disengage the exhaust brake and retarder. ‘Accelerator Pedal] app Engine Control Postion wr) -—APB <=) Sau eon Module (ECM) lo Poston Signal Output Exhaust Brake Switch = rout ako He Retardor Switch ee Ba ina Sr and eae | meer comet Unk Rotardor WV (Clutch Switch Hi oo Q Adjustment Data When the vehicle is shipped, it has a label on the body to notify of Q adjustment data. Use it to compare against the content displayed on the scan tool (Tech2). Label Positions Hewesasreouot 1A-22 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail) Content of the label Legend 1. Q adjustment data numbers (Q1, Q2, Q3, from the lent) 2. Timing correction resistance value (not used) 3. Vehicle model 4. Factory management number (the number is different for each venicte) Engine Control Module (ECM) The ECM stn | Ihe EGM Is installed under tne center cluster inside the cab. The ECM constantly monitors data sent from vanous sensors, and controls the systems ot the power train. It performs diagnostic functions on systems, detects problems in their operation and uses the ML (Check Engine lamp) to warn the driver, as well as storing the DTC (diagnostic trouble code). The DTC identifies the area affected by the problem and assists the service engineer in making the repair. ECM Functions The ECM outputs 5V and other voltages to supply power to the sensors and switches, This power supply asses through the resistance of the ECM. so the resistance Is extremely high and even if a test light is eonnerted to the circuit. it will not light In special cases, the resistance of a normal multi meter may be tom low, so to ahtain an areirata caading it is necessary to use a digital multi meter with an input impedance of more than 10MO. Special tool 5-8840- 2691-0 is suitable. In the ECM, the ground or power supply circuits are controlled through transistors or another device to control the output circuits. ECM and Component Parts Ine ELM IS designes to maintain gas emissions at regulated levels while delivering superior driveabllty and fuel efficiency. The ECM monitors the functions of the engine and the vehicle through sensors such as the Crank Position (CKP) sensor and the Vehicle Speed (VS) sensor. Explanation of ECM Voltage The ECM applies standard voltage to various switches and sensors. The FCM is able to apply voltages in this way because its own resistance is very high, so that the voltage actually applied to the circuit is low. In some cases a test light connected to the circuit will not light in servicing workshops is tool low, 50 they may not give accurate readings in some cases. Use a digital multi meter with input impedance of 10MO (For example, 5- £9840-2601-0) to obtain accurate readings. ECM input/output devices include analog! digital converters, signal buffers, counters and special drivers. The ECM uses electronic switches to control most Erasable Electrically (EEPROM) Programmable ROM The EEPROM Is a permanent memory chip that is soldered to the circuit board inside the ECM. It contains the programs and calibration information the ECM needs to control the actions of the power train ‘The EEPROM cannot be replaced. Replace the ECM if any malfunction is found in the EEPROM. Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 10-23 Precautions on ECM Servicing The ECM is designed to withstand normal current consumption associated with driving, The circuits must not be overloaded. When testing for broken wires and short circuits, do not connect the ECM circuitry to a ground connect or apply voltage to it, unless specifically instructed to do so. Always use a digital multi meter 5-AR4N-2801-0 to perform such circuit tests Supply Pump ‘The supply pump uses the rotary force of the ending to highly pressurize fuel and pump it into the fue! rail, The. Pump Control Valve (PCV), Camshaft Position (CMP) Sensor and feed pump are attached to the supply pump, PCV (Pump Control Valve) SF The PCV (Pump Control Valve) Is attached to the supply pump and controls the supply of fuel (output Volume} to the tuel rail, The Engine Control Module (ECM) controls the time of communication to the PCV and so controls the uel output volume. 1A-24 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Fuel Rall Legend 1. Flow damper 3. Fuel pressure sensor 2. Pressure limiter ‘The fuel rail receives fuel from the supply pump, Flow Damper ‘maintains fuel rail fuel) pressure and distributes fuel to each cylinder. The fuel pressure sensor, Now damper and pressure limiter are attached to the fuel rail Engine Control System (6WE1-IC,6WG1-1C(Common Rail))_1A-25 Ine tlow damper resincts pressure pulsation inside the Engine Coolant Temperature (EG) Sensor {uel rail and prevents injection of excess fue! through the injectors. When tne tlow damper acts, tue! supply to the injectors is stopped Pressure Limiter oneesicor01 Legend 1. Signal 2. Meter output 3. GND ‘The pressure limiter acts when pressure inside the fuel rail becomes abnormally high, releasing the excess pressure. Fuel pressure sensor ‘Tho fucl pressure sensor is attached to the fuel rail and detects the fuel pressure inside it. The pressure is converted into a voltage signal and sent to the Engine Control Module (ECM). The voltage is higher with higher pressure, and vice versa. The EOM calculates the actual pressure in the fuel rail (the fuel pressure) from the voltage signal sent by the sensor, and uses it for fuel injection control and other purposes. ‘The engine coolant temperature (ECT) sensor is attached to the engine block thermostat housing. The resistance of its thermistor changes with temperature, The resistance value falls as the engine coolant temperature rises, and vice versa. The Engine Control Module (ECM) applies 5V to the ECT sensor through the pull-up resistance and calculates the engine coolant temperature from the change in that voltage. The result is used in fuel injection control and other control functions. The voltage is low when the resistance is low (18, when the temperature is high), and rises when the resistance is higher (when the temperature is lower) 1A-26 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Cam Shaft Position (CMP) sensor Crankshatt position (CKP) sensor 1 ee Patient venesieono emeesiones Legend Legend 1. Signal 1. Signal (High) 2. GND 2. Signal (Low) 3. Power supply ‘The cam shaft position (CMP) sensor is attached to the supply pump. A CMP signal is generated when the cam shaft inside the supply pump passes through the sensor. The Engine Control Module (ECM) identifies the cylinder from the crank shaft position (CKP) signal and the CKP signal input from the CKP sensor, determines the crank angle and uses it to calculate fuel injection control and engine speed. These control functions are usually based on the CKP signal, but if the CKP sensor malfunctions. they are based on the CMP signal The crank position (CKP) sensor is attached to the ‘flywheel housing. A CKP signal is generated when the hole in the flywheel passes the sensor. The Engine Control Module (ECM) identifies the cylinder from the CKP signal and the CMP signal input from the cam shaft position (CMP) sensor, determines the crank angle and uses it to calculate fuel injection control and engine speed. These control functions are usually based on the CKP signal, but if the CKP sensor malfunctions, they are based on the CMP signal, Engine Control System (6WF1-1C,6WG1-1C(Common Rail) 1A-27 Atmospheric Temperature Sensor Accelerator Pedal Position (APP) Sensor 3 7 Sy 2 ‘ Powasestontat Howaeeshonitot Legend Legend 1. Signal 1. GND 2. GND 2. Signal 3. Temperature sensor 3. Power supply ‘The atmospheric temperature sensor is attached to the inside of the front lid. The resistance of its thermistor changes with temperature. The resistance value falls as the intake air (external air) temperature rises, and vice versa. The Engine Control Module (ECM) applies 5V to the atmospheric temperature sensor through the pull-up resistance and calculates the intake air temperature from the change in that voltage. The result is used in fuel injection control and other control functions. The voltage is low when the resistance is low (i.e. when the temperature is high), and rises when the resistance is higher (when the temperature is lower) ‘The Accelerator Pedal Position (APP) sensor is attached to the top of the accelerator pedal and sends a voltage signal to the Engine Control Module (ECM) that corresponds to the angle of the accelerator pedal. ‘The ECM calculates the accelerator position from the voltage sianal and uses it for fuel injection control and many other control functions, Vehicle Speed Sensor (VSS) 1A-28 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Ine Vehicle Speed sensor (VSS) Is attached to the transmission, and the Hall effect circuit is attached to i. The magnet attacned to the output shatt ot tne transmission rotates with the shaft and interacts with the magnetic tield generated to send a signal to ne speed sensor control unit. The Engine Control Module (ECM) receives the vehicle speed signal from the speed sensor control unit. Boost Sensor oo Ct ‘Atmospheric Pressure Sensor romaosioao1 ch Legend 1. GND 2. Signat 3. Power supply ‘The boost sensor is connected to the intake duct of the engine. It detects the boost (intake pressure) inside the intake manifold, converts the pressure to a voltage signal and sends it to the Engine Control Module (FCM) The vaitage is higher with highar nrassiire, and vice versa. The ECM calculates the boost (the intake pressiite) fram the voltage signal sent hy the sensor, and uses it for fuel injection control and other purposes. The atmospheric pressure sensor is mounted inside the Engine Control Module (ECM) and converts atmospheric pressure into a voltage signal. The ECM calculates the atmospheric pressure from the voltage signal and carries out compensation etc. according to that pressure. Accelerator Pedal Position (APP) Switch Se, N&, ists ni ete] The Accelerator Pedal Position (APP) ewitch ie attached to the top of the accelerator pedal and supplies a switch signal to tho Engine Control Module (ECM) that corresponds to the position of the accolorator pedal, The CCM calculates the accelerator pedal position from the voltage signal and uses it for fuel injection control and many other control funetions. Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 10-29 PTO Remote Throttle Sensor 3 2 rowasestonint Legend 1. GND 2. Signal 3. Power supply ‘The PTO remote throttle sensor is attached outside the cab as an external accelerator voltage signal to the Engine Control Module (ECM) that changes according to the angle of the accelerator pedal. The ECM calculates the PTO accelerator opening from the voltage signal and uses it for fuel injection control and many other control functions. Injectors. ES gave TOIL 35DD 2157 0 ~) OO1F SAO 0000 BD Legend 1. Injector ID code plate 2. Injectors. Ihe injectors are mounted on the cylinder nead and inject fuel under the control of the Engine Control Module (ECM). The ECM raises the injector drive voltage intemally and applies it to the injectors. By controling tne duraton ot power supply to the injectors, it controls the volume, timing and other aspects of fuel injection, 1A-30__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) MIL (Check Engine Lamp) Display ‘The MIL (check enaine lamp) lights inside the meter. It lights to warn the driver of a matfunction in the engine or a related system. When the Engine Control Module (ECM) detects a malfunction using its self-diagnostic functions (vehicle-mounted malfunction diagnostic system), it lights the MIL (check engine lamp). If the diagnnstias switch (the connection with the diagnostics connector and the diagnostics common connector) is switched On, the MIL. (check angina lamp) flashes, and the DTC detection status can be checked. (Reference) The meter tor the 6WF1 Diagnostics Connector, Data Link Connector (DLC) Diagnostics Switch (diagnostics connector) The diagnostics switch (diagnostics connector) is attached to the inside of the inspection cover. When the dlagnastice connector and the diagnasties enmman connector are connected, the MIL (check engine lamp) inside the meter flashes and the DTC is displayed. DLC (Data Link Connector) ‘The DLC (data link connector) is attached to the inside of the inspection cover, Il is the connector for communications and connections with external diagnostic devices (scan tools) and controllers. Engine Control System (6WF1-1 Instrument Panel XN Legend Diagnostics connector (brown) Memory clear connector (white) Diagnostics common connector (green) Data link connector (DLC), 20 terminals Data link connector (DLC), 10 terminals Data link connector (DLC), 3 terminals Engine Component Layout Diagram Parts layout diagram 5,6WG1-TC(Common Rail)) _1A-31 ei “abide Howsuusrontor Legend 2 _ Engine Control System (6WF1-1C,6WG' TC(Common Rail)) 1. Boost Sensor 8. EGR valve 2. EGR valve 7. Crankshaft position (CKP) sensor 3. Engine coolant temperature (ECT) sensor 8. Fuel pressure sensor 4. EGR gas temperature sensor 9. PCV b. EGR gas temperature sensor 1U. CMP sensor Cab Interior Switch Layout Diagram at oo 1. PTO Switch 4, Idling Control AUTO/MANU Switch 2. ASR Cut Switeh 5. Idling Control UP/DOWN Switch 3. Cruise Main Switch Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) _1A-33 Cab Interior Control Unit Layout Diagram son te sewr tnt —— | [ivtnou Dig! Tachoarap [vineu Dig Tachonrn | ih | 8 y | ® | Lower Secon» [we Dita Tocnog] “ 10 Fad 18 | J Legend 14-34 Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) 1. ECM Main Relay 10. Glow Relay 2. Exhaust Brake and Retarder Control Unit 41. QOS Control Unit 3, Tachograph 12, Flasher Unt 4, Speed Sensor Control Unit 43. MIMAMORI Control Unit 5, SRS Control Unit 14. Flasher Unt 8. Digital Tachograph 15, EBS Control Unit 7. ABSIASR Control Unit 16. Cab Suspension Control Unit 8, Engine Contro! Module (ECM) 17. EBS Control Unit 9, Retractable Mirror Control Unit 18. Cab Suspension Control Unit Chassis Component Layout Diagram Chassis Section | 5 omaourooto1 Legend 1., Atmospheric temperature sensor (inside open It) 4, Transmission section (vehicle speed sensor, 2. Brake valve section neutral switch, reverse switch) 3, Cab rear member section (magnetic valve, PTO 9, Battery remote throttle sensor) 6. Air tank section Engine Control System (6WF1-1 Cab Rear Member Magnetic Valve ,6WG1-TC(Common Rail)) _1A-35 Legend 4. Cab back member 5. VGS magnetic valve 3 2. Exhaust brake magnetic valve 6. VGS turbocharger pneumatic cylinder 3. VGS magnetic valve 1 7. Exhaust brake air cyinder 4. VGS magnetic valve 2 TC(Common Rail)) 1A-36__ Engine Control System (6WF1-IC,6WG' Circuit Diagram ECM System Wiring Diagram Engine Control System (6WF1-1C,6WG1-1C(Common Rail))_1A-37 New Zealand Exgne con toaie Eom) (oon (ene (a ie ‘care Ree Aa MaMa MHRA (eee [Meese "gece Sn) ‘poor sions 316) Vos Fal sao Ray ca colonel cor i 8 (6 SH eens Fone Seo a # tor [_hesersi don" [7A toe | eersoncby | Treen ‘na {eosin een) * Fahy geass reer] Il 3-01 enna anol ee 1A-38__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Daca Sin le rretnie ny ii ensiccom tein Lovey cea sooiamount ley < steer ene D7 : ‘| seer eae, © oR Ft ly ac one Cat] “E \ Tiga San Ea 1:90 eo TE oncl me Engine Control System (6WF1-1C,6WG1-TC(Common Rail) _1A-39 GEXp Exgne con toaie Eom) (oon (ene Vos Fal sao Ray scales (cae EL CE eos, (gaya PMNS 7} Cans eee te [ mmemree to von [ ics sib tesco stones From] OE ects “ vo saeco a’ "[ ve ners eb Trem] woo [ tse” eh len << ey oe ‘Troe Sara a nt J Soe ™ at 22 ehet Eine 1A-40 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Daca Sin le ranaoniasnin |p ii ensiccom tein Lovey cea sooiamount ley < steer ene D7 : ‘| seer eae, © oR Ft ly ac one Cat] “E \ Tiga San Ea 1:90 eo TE oncl me Engine Control System (6WF1-1C,6WG1-1C(Common Rail)) 1A-41 com Pin Layout NOTE: Use the right control unit for the vehicle, as stated in the “Comment text and ‘oocable engine dentiir name stated inthe labels Use of the wrong control unit for the vehicle will cause breakdowns ie] | fe al 2 4 U a a Ld o @ q fl) | or ro | New Zealand Terminal Signal name Tornial Signal name i z 3 = 7 it 86 ct 3 i 87 Low air pressure switch signal [6WF 1] a = 38 | fling MANUIAUTO owch signal 3 | Power supply ain relay) 3 [PTO swich signa 6 | Power supply (Wain ay) %0 e 1A-42 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Aart Signal name Seta Signal name 7 [Power supply (Main relay) ‘91 | Exhaust brake magnetic valve (MV) action sighal input [SWS i] = 92__ | Cruise resume switch signal Tachometer 93 __ | Cruise release switch 7 signal 70 | Accelerator switch signal output (6WG1] ‘94 [Cruise release switch 2 (Exhaust Brake Switch) signal [6WG1] 11__ | Overheat lamp [6WF i] 95 | CAN-HIGH 72 | Overheat buzzer [6WF i] 96 | CAN-LOW 3 ‘97 _| Parking brake switch signal 7 8 15 5 99. [Idling Down switch signal 16 = 100 = 7 Ey 101 i 78 = 702 [OND 79 | Data ink connector (DLC) 703 _ | Iniector 1 (No. 1 evlinden 20 = 704 | Injector3 (No. 3 cylinder 21 | Accelerator pedal position (APP) sensor} 105 _| Injector 5 (No. 2 cylinder) signal 2 7 706 _ | Injector power supply (injector 1, 3, 5) 23 __ | PTO remote throttie sensor signal 107 _ [injector power supply (injector 1, 3, 6) 24 = 108 [EGRMV 1 25 . 70a [EGRMN2 Ea = 110 _ | EGR fail safe relay 27 | Vehicle speed sensor signal ti | VGSMIV 1 (6WGT] 2 = 112 |VGSMNV 2 [EwGT] 30 _ | EGR gas temperature sensor 2 signal 114 | VGS MN 3 [ewGt] 31 = 115 | VGSMNV3 [WGI] 32 = 116 = 33 | EGR gas temparature sonsor 1 signal "7 34 | PTO control resistance 118 = 35 . 119 . 36 = 720 _ | Camshaft position (CMP) sensor signal oF = 121 __| Fuel pressure sensor signal 38 = 122 = 39___| Crankshaft position (CKP) sensor shield 123 __ | Fuel pressure sensor power supply 40__ | CKP sensor (4) 124 = “41 [GRP sensor @) 125 = Engine Control System (6WF1-1C,6WG1-TC(Common Rail) 1A-43 Let Signal name a Signal name 42 | Exhaust brake drive signal output 426 [Boost and PTO remote throttle sensors power supbiy 3 = 127 = 44 | Starter cut relay 728 _ | Boost sensor signal 45 | Retarder drive signal output 129 = “46 | Starter switch “ON” signal (Battery relay) 130 = 47 |VGS fail safe relay [6WG1] 131 | CMP sensor GND 48 | Sarter switch “START” signal 732 | Fuel pressure sensor signal 49 | Exhaust brake switch signal (WF 1] 133 _ | CMP sensor power supply 50 | Engine stop switch signal 134 | Boost, PTO remote throttle sensors GND - © _| atmospheric temperature sensors GND 52 __| Clutch switch signal 736 | Fuel pressure sensor GND 53 | Stop lamp switch 1 signal 137 | Injector 2 (No. 5 cylinder) 54 [EGR aas temperature sensors and PTO| 138 | Injector 4 (No. 6 evlinder) control resistance GND 3S [APP seve GND 755 | inevion O (Nu. 4 uyiinden) 56 __ | Starter switch "ON" sianal (Battery relay) 740 [GND 57 = 747 [GND 58 __ | Accelerator switch signal 142 [injector power supply (injector 2, 4, 6) 59 | Retarder switch signal 143__| Injector power suppiy (injector 2, 4, 6) 60 __ | Gruise main switch signal 144 = 61 __ [Neutral switch signal 145 = 62 = 146 = 63 = 147 = 65 _ [APP sensor power supply 149 =~ 66 = 480 _ | Pomp control valve (PCV) 2 er = 751 |PCV2 68 | Diagnostics awitch 162 |PGVt 69 = 763 [PCVi 70 = 164 | Atmospheric temperature sensor signal 7 = 485 _ | ECT sensor signal 72 |ECMGND 150 = 73__ [ECM GND 187 = 74 [ECM main relay 158 = 75 [ECM main relay 159 = 76 = 160 = 1A-44 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) ie Signal name ieee Signal name 7 [Back lamp switch signal 761 = 78 7 162 = 79 | Cruise Set switch signal 163 = | Rtop lamp switch 9 signal 7a im 81 [Idling Up switch signal 765 = 82 | Check engine lamp 766 = 33 | Gruise setiamp Ter = 34 | Cruise main lamp = = GExp | oe | Signa Haine ] Terminal T Signa’ anne 7 = 85 [PTO control indicator lamp 2 = 3 = 3 7 7 | Lowair pressure switch signal 4 7 @8 [Idling MANUIAUTO switch signal 2 | Power suppiy (wan relay wo _ | P10 switen signar @ | Power supply (Main relay) 30 . 7__ [Power supply (Main relay) a e 3 = 2 | Cruise resume switch signal 9 | Tachometer 3 | Cruise release switch 1 signal 70 = 04 | Crise release ewitch 2 signal 11 | Overheat lamp % . 72 | Overheat buzzer 6 = 7% = ‘7 __| Parking brake switch signal 6 = 99___| idling Down switch signal 76 7 100 = 7 : tot = iG = 102 | GND 7@ | Data link connector (DLC) 70a _[Tnjector 1 (No.7 eylinder) 20 = 104 [Injector 3 (No. 3 cylinder) 21 [Accelerator pedal position (APP) sensor] 105 | Injector (No. 2 cylinder) signal 2 = 106 _ | injector power supply (injector 1, 3, 6) 23 | PTO remote throttle sensor signal 707 | Injector power supply (injector 1,3, 5) 24 : 708 [EGRMIVT 35 = 709 [EGRMV2 Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 10-45 Let Signal name a Signal name 26 = 110 _ | EGR fail safe relay 27 | Vehicle speed sensor signal m1 = 2B = 112 = 28 ay 114 = 30 | EGR gas temperature sensor 2 signal 114 = 3 = 115 = a2 = 116 = 33 | EGR gas temperature sensor 1 signal 117 = 34 [PTO control resistance 118 = 35 = 719 = 36 = 720 _ | Camshait position (CMP) sensor signal 37 721 __ | Fuel pressure sensor signal 38 = 122 = 39°__ | Crankshaft position (CKP) sensor shield 723 _ | Fuel pressure sensor power supply 40 | CKP sensor (+) 124 - 47 | ORF aenour 185 = 42 | Exhaust brake drive sianal output 726 [Boost and PTO remote throttle sensors power supply eB = 127 = d4__| Starter cat ralay 128 __ | Boost sensor signal 45 _| Retarder drive signal output 729 = 46 __ | Starter switch “ON signal (Battery relay) 130 = a7 = 731 __ | CMP sensor GND “48 | Starter switch “START” signal 732 __ | Fuel pressure sensor signal 49_ [Exhaust brake switch signal 133___ | CMP sensor power supply 50 [Engine stop switch signal 134 | Boost, PTO remote throttle sensors GND 5 = 735 [Engine coolant temperature (ECT) and atmospheric temperature sensors GND 52 __| Clutch switch signal 736 _ | Fuel pressure sensor GND 53 _ | Stop lamp switch 7 signal Ta7_| Injector 2 (No. 5 cylinder) © | contol resistance GNO i 55 | APP sensor GND 139 _ | Injector 6 (No. 4 cylinder) 5 | Slailer switch "ON" signal (Ballery relay) 140 | GND 57 = 741__ [GND 58 __ | Accelerator switch signal 142__ [Injector power supply (injector 2, 4, 6) 59 _ | Retarder switch signal 743 | Injector power supply (injector 2, 4, 6) 60 __| Cruise main switen signal 14 = 1A-46__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Aart Signal name Seta Signal name 61 [ Neutral switch signal 145 = 62 = 146 = 3 fe 147 = a = 7aR im @5 | APP sensor power supply 749 = 66 . 150 _ | Pomp control vaive (PCV) 2 oF = ier [POv2Z 68 | Diagnostics switch 762 [PCVt 69 163 [PCVT 70 = 164 | Almospheric temperature sensor signal 7 S 765 | ECT sensor signal 72 | ECM GND 166 73 |ECMGND 187 i 74 | ECM main relay 758 = 75 | ECM main relay 159 - 77___ [Back lamp switch sianal 761 = 78 7 162 iS 79 | Cruise Set switch signal 763 = 0 | Stop lamp switch 2 signal Te4 = &1 __| Idling Up switch signal 765 = 82 | Check engine lamp 166 = 83 | Cruise set lamp 167 i 84 | Cruise main lamp = = Engine Control System (6WF1-IC,6WG1-TC(Common Rail))_1A-47 ECM Circutt Diagram New Zealand 116 xl SEAN CePA rum) stom ir sue axis counnamion STH pocounnuon sere aK owaResaie gc ore a x LowaR esas gre ose a 1A-48 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) 216 us nacHomeren ac STARTER CUT RELAY a ry ‘ frro- a § i 3 4 fel fnel bel y fe anueren ¢— a ¢ 5 i - — | Eeomecron 2 3 4 F Gq) G2) Gel a f — ixalics Krai Ral Rea | coed Engine Control System (6WF1-IC,6WG1-TC(Common Rail) _1A-49 16 i ' ri ' ' areas euro. ' = Pr ' Be og \ Se fe Ay | i Bi Ei i ( ) eter conor venue ean a y eure short ra, secure ra 1A-5U__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) we ood ee ts fas a ens Pa) ‘AM SUBPENSION aU77ER ea enemw7ER) wnt a, 228 2280, 920 ig OO aap ONO oa, icon 0 im g2 20 ae ae SS. Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 516 10-51 page if 4 Ta isis 8 eS tte J J | J Sa eh F 3 | j pai ie tay ow i o4 eS zat dr : = 1A-52__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) 616 ( aay oe a aL ae a soe ca eae gi ai | ea) be || me dae LL _ wae =a) ‘Suny (evn on) ‘ HE Eat) Ph oh | bh! wae ete ated ete es ee ee ae IESE CYLNDER HEAD COVER GExp 415 Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) _1A-53 sey «tev, peer nnn ‘DLE SWITCes(ALITOIMANLAL) HL oom | “Opes, 2 2 , ee F ——— | : (tain rn a don pia 3 py ie i Hoe é iy Ne CoML MCOULE EH) me sa J J a i Haas oo | a ro mone ew g ronmyononnan vmior ¢ 282 088g ane 8 Hh memes «88 gts gy | — : ema LHL LEH 4 | sty momma «oe Fie amet sxsounreetseee! ane a eee ae smaounewenaeees «ame 1A-54 Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) 215 ne ad rr er egg rie eshte ee ee ee | ce ee rua prosnten «28 —) SB & & & & if 1g 3 i a \ pent oot vom 9 ys 4 : { a eal fal i ee 4 9 i fo By Ba ira i de Ge] Geel Bel § A ce [ a 3 fod Foe Fave = Fal fal ral Ral Rad fia ES Engine Control System (6WF1-IC,6WG1-TC(Common Rail))_1A-55 315 1A-56__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) 415 te few SE a) fi novmoenans $a [a+ sonore 5s) =| = La f a i eae (le ar fl fre Ee el] (al Del Fel {Ai tel bere sm — fod, sam en}; Fe Engine Control System (6WF1-1C,6WG1-TC(Common Rail))_1A-57 315 Ev CouTREL MODULE Eom) [giz eevee allt ali glia couse. iy 20] i FResun 3 i avons) ‘oa exe Tas fos Trea feaTecTe| Es eT fe eT 1A-58_Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) Connector List No. Cannector Face No, Connector Face B14 “[2[a E42 Bat E43 B43, E44 B44 E45 a B45 E46 Q(:02))> WS B54 E53 B55 E84 x20 0s. 536 E59 Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) _1A-59 No. ‘Connector Face No. ‘Connector Face E56 er x axa es7 er E-58 E-75 oor cal E50 a <6)) 76 E71 Fan leon eq =LKO) en Fetetslshofat os ea =O) E73 gono8o Ft ais] ova 1A-60__Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) No. ‘Connector Face No. sonnector Face F-70 FLA Fe-t0 =C—KO FL2 | Fest =cKO rus Ee] Fe-29 =O FLo FB-40 FL-10 Few Fun Tae wer anon] Fa-t4s FLat Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A Ro: ‘Connector Face No Connector Face FL21 FL-182 zon oxen FL49 FL96 PE Ey FL6s (alolalebaiaralsrolnt FL-385 Pek eere be ey FL-68 FL-397 F133 FL400 1A-62__Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) catco1 No. ‘Connector Face No. onnector Face = Lars L536 far mel wen rite Gi raw Ee pa2dslels lela] e]s so) FLSt Ha FL552 Fond FL 664 FL-522 FL555 rsa voor] etaletelat a Fs esse) ee ieelsicelete meses] [REESE vse) SRIETISIIan fl ie eee tt] | Engine Control System (6WF1-TC,6WG1-TC(Common Rail) 1A- No, Connector Face No. Connector Face Ty FL-560 elaletelelerelaai FLT16 Peiabebrieiy FL-s69 FLa31 FL-605 FU-5. xe ore — PEE Ey FLess Irlarwsharobebany Fu7 Taarshelefehors Hloebeere Sy FL-656 FU-8 FL697 rus ee _ ETE FL.658 elelelelelepelerai Fuad cats FL716 FU-18 1A-64 Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) No. Connecter Face Ne onnedtor Face FREES) br nlite FUL28 20 aouD inact cau soscos a= FU-35 H39 Fuse H29 7 aTeTa sero [soa ala FU-72 | Feshrelr7{1eltozolzs)zafzs|2e\25{26\27[29)70|30 Hea os Hae Peete Hea Has (elelevalis| fret aaier Hi nara Hae co ove Engine Control System (6WF1-TC,6WG1-TC(Common Rail) 1A-65 No. Connector Face No. Connector Face #158 helo HAT? Hets8 Siskel Marr bt cit H-162 Peet f H-179 He162 170 HA-75 oielr| H-180 Herre Hera A768 alta H-186 a2 H178 canta e186 1A-66__ Engine Control System (6WF1-T WG1-TC(Common Rail)) No. Connector Face No, sonnector Face fee) (Te He187 tfafate H.280 eee 7 a0 qf 1 #215 tetra H-282 (FORE Eer rt pace xeon ERIEEELEEEIELY H216 He2e82 H-256 H-290 Ge ZSOLT He286 ra H290 4.257 H-209 H-257, H-299 cred non Engine Control System (6WF1-1 5,6WG1-TC(Common Rail)) 18-67 We ‘Connector Face No. Connector Face #201 hl H-390 eon} cos. Glferfers| faqs [2] scot eae so a H-304 5 M vie] cxoon| H-316 -_ ‘J24 _ ss tee jl* +H-357, J48 1A-68 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) No. Connector Face Her Deh 1a we = | H6 Ty ce fo SE ute ms ral Bal jae pg as aucee| = |e Engine Control System (6WF1-1C,6WG1-TC(Common Rail) 1A-69 1.387 Baananeney 0 Pa Beeoeeeo) EE OasEHaq) Fault diagnosis process ‘System Diagnosis Method The system diagnosis method is a uniform procedure for the rapair af all electrical! electronic (E/E) systems E/E system breakdowns differ from general vehicle breakdowns and often involve the folowing steps: 1. Initial stage of the breakdown; + Breakdown occurrence is a single incident ot short duration, which is often overiooked by the customer, Customer compiaints at that stage are vague and the problem cannot be reproduced. However, there many be a record of the breakdown in the Engine Control Module (ECM) memory. = Past fault 2, Intermediate stage of the breakdown; short duration, but repeats at intervals, and will always occur under certain conditions, Customer complaint (nature of the breakdown) ig clear and the area of uncertainty is in the conditions under which the breakdown occurs. ‘Therefore, the vehicle diagnosis engineer can reproduce the breakdown by identifying the = Intermittent fault 3, Fault manifestation stage; + The breakdown occurrence is constant and fixed, with clear and concrete customer complaints. Therefore the diagnosis engineer _ can reproduce the breakdown. However. a single breakdown incident may have multiple causes. = Current fault The diagnostic procedure is always used to solve E/E system problems, and forms the starting point for any repairs that may be required. The progress of diagnosis will be described in the following steps: i. Coniirm customer compiaint + To confirm the content of the customer's complaint, the vehicle diagnosis engineer must know the normal operating state of the system. 2. Perform preliminary inspection. + Overal! visual inspection + Review service history. + Detect abnormal noises, odors ete, + Use a scan tool (Tech?) to gather DTCs, data ete. 3. Inspect the service information 4, Refer to “Diagnosis by symptoms" in the manual. + "Diagnosis by Symptoms” includes information about systems that is not displayed under the DTCs (Diagnostic Trouble Codes), Therefore “Diagnosis by Symptoms" can be used to confirm proper operation of the system and leam the appropriate diagnostic mathod 5. Refer to content related to engine mechanics etc. Hf there is a DTC ( memory Follow the specified DTC chart precisely to carry out the repair. gnostic Trouble Code) in If there is no DTC. Select the symptoms from Diagnosis by Symptom Follow the diagnostic procedure to complete the repair Inspections can be made with reference to functional diagnosis. 1A-70__ Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) It there are no applicable symptoms. 4. Investigate the complaint in detail 2. Draw up a diagnosis plan. 3. Use wiring diayraris and operating principe. ‘Ask for technical assistance with cases resembling repair histories Uhal you car oblain, Make effective use of technical knowledge and usable service information. If the fault is intermittent ‘A fault is said to be intermittent if it does not always appear. Take the following steps to solve an intermittent problem. 4. Check DTC information and engine data. 2. Evaluate signs and conditions described by the customer. 3. Use a check sheet or other method to check the circuits and electrical system components, If the trouble cannot be detected This state refers to cases where the vehicle is judged to be operating normally. The state described by the customer may actually be normal. Compare the customer's complaint against a different vehicle that is involve and intermittent problem. Before returning the vehicle, check the content of the complaint in the stato described by the customer. 1. Reunvestigate tne complaint It itis not possible to adequately detect or identify the problem, the diagnosis must be begun again, Recheck the complaint. As described in “If the fault Is intermittent’ above, tne complaint could reter to an intermittent fault, or the vehicle could actually be normal 2. Repair and check. Carry out the repair after identifying the cause. Check whether the vehicle operates normally. and check that the symptoms have been corrected. In the situations below, this check will include road driving tests and other methods to confirm solution of the problem. + Test in the state described by the customer to check + Ifa DTC has been diagnosed, check the scan tool data while reproducing’ the state that applied when the DTC was set, to confirm whether the fault has been repaired. Verify repair If an electrical cantral system has been repaired, it is necessary to check after repairing the vehicle whether the repair wae cntrect Hf thie check ie ant perinrmad thoroughly, the MIL (check engine lamp) could relight ‘whan the vehicle is being ratumed to the customer, or problems in drive performance could recur. With intermittent faults it ie particularly important to reproduce the conditions of the customer's complaint and Vorify ropair performance Ttem Tem Purpose Method 1 [DTG chook Check the DTC display afior|Delcte the provious DTC. Warm the engine the repair. thoroughly by idling, then raise the engine speed to more than 2,000rpm to race the engine, to establish test conditions. 2 [After warming | Check whether idling control | Check that the idling speed, after warming the the engine, | is normal. engine and with the air conditioning switched off, check the idling is constant and close to 475-525rpm. If a problem speed is observed. refer to “unstable idling” under Diagnosis by Symptom. 3 | heck the scan} Make @ basic check of the|Monitor the scan tool data ist and use the tool data list | state of engine control and | representative values sheet to check communications (Cneck the representative vaiues Tor the scan too! data list. 4 [Check re-starting | This is to check whether re- | After warming the engine, check that the cranking starting control is normal time for re-starting does not excead Ss and that the engine speed after starting is stable. Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A Item Item Purpose Method | Check that emit strong | electromagnetic waves Uevices | Ifa Uansceiver or olher strong [Check whether the idling engine speed varies emitter vivcirumaynetic | ailacied io tie veilicie, Lites | erie is iuined on and off. if any provien is that it is not emitting harmful | discovered at this stage, notify the customer that is| when the transceiver or other electromagnetic the mounting position and output of the electromagnetic emitter must be modified Assistance in checking strong electromagnetic emitter devices; If such a fault is discovered, notify the customer of the following check points, as necessary. + The antenna should be mounted as far as possible from the control units, sensors and other elements of the vehicle's electronic systems. + The antenna must be more than 20cm away from the control units, sensors and other elements of the vehicle's electronic systems. + The antenna cables and other wiring must not be placed together. The antenna cord and other wiring must be kept as far as possible apart + Devices mounted after the purchase of the vehicle must each be mounted exactly as described in the installation manuals, cannot be mounted. CAUTION: Follow the steps below to Verify repair using an On- Board Diagnostics (OBD) systems check. Failure to carry out these steps may result in needless repair work. + Review and record to scan lool dal for the DTCs: which were diagnosed. + Clear the DTCs. + Drive the vehicle while checking the related sean tool data Non-OEM parts All On-Board Diagnostics (OBD) systems checks are adjusted to run on official components. Therefore if ollier general-purpose sensurs, switches and ollier components from other vendors have been attached, mis-diagnosis will result, and the MIL. (check engine lamp) will light. Electronic devices trom otner vendors, suen as cellular telephones, audio and anti-theft devices can emit electronic magnetic interference (EMI) that affects the control systems. Incorrect sensor information can be generated as a result, causing the MIL (check engine lamp) to light. Before performing a breakdown diagnosis, turn the power off for all vendor components, (or remove them, Defective vehicle maintenance (On-Board Diagnostics (OBD) system checks are highly sensitive, so they can lead to the MIL (check engine lamp) lighting if vehicle maintenance is not carried out properly. Insufficient oil changing or oil of the wrong viscosity can cause oil iter or fuel fiter blockages or sediments sticking to the crank case. In such cases, vehicle matfunctions can occur that were not detected check Improper vehicle maintenance is not classified under *non-vehicular breakdowns", but as the On-Board Diagnostics (ODD) systems checks are so sensitive, the vehicle maintenance schedule must be observed even more strictly. Related System Sreakduwy In many On-Board Diagnostics (OBD) systems checks, the Engine Control Module (ECM) stops operating when a breakdown is detected in a related system or component. Visual inspection of the engine compartment Whon carrying out a diagnostic procedure, make a careful visual inspection of the engine compartment, Thie inspection ie often sufficient to colve the problem without starting any needless steps. Follow the guidelines below when performing a visual inspection + Check all compressed air hoses to make sure mere are no puncn noles, cuts, detacnea connections etc., and check that pipe connections are correct, + Inspect inconspicuous hoses that are positioned behind other components, + Check that all engine compartment are connected property, with no that are unbound, touching sharp edges, or touching hot components euch as the exhaust manifold or pipes. hamesees in the 1A-/2_ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Basic Knowledge of Necessary Tools IMPORTANT: When carrying out diagnostic procedures, a lack of basic knowledge of the oower train can lead to incorrect diagnosis and damage to elements of the power train. Do not attempt to diagnose power train- related problems without basic knowledge. A basic understanding af hand tools such as the scan tool is also required, in order to make effective use of the service manual On-Board Diagnostics Tests ‘The following aspects of fault diagnosis results must be checked + The diagnostic test for the previous ignition cycle was completed. + The diagnostin test for the currant ignition eynle was passed. + Faults identified by the diagnostic tests no longor exist. If a fault was revealed by the diagnostic tests, check the following points and record the data, + The diagnostic test tor the previous ignition cycle was completed. + Faults identified by the diagnostic tests stil exist. + The fault oxists in this ignition cycle. + Action status at the time of the breakdown, Ignition cycle The ignition cycle is defined as a ‘starter switch on, run, starter switch off" cycle performed by a method that salisfies diagnostic standards set for the vehicle. Comprehensive Diagnostic Component Monitors For the engine to run normally, a comprehensive Operation of Input Components: Check the input components by inspecting for broken wires in the circult and checking that all values are within their ranges. This process includes a rationality Inspection. The rationality inspection indicates a tault there are signals from sensors that appear inappropriate. Such as an APP (accelerator pedal position) sensor indicating a high throttle position when the engine load or intake pressure is low. In input components, there are the following sensors (not limited to only these sensors). + Atmospheric temperature sansor + Crankshatt position (CKP) sensor + Water Temperature (ECT) Sensor + Cam shaft position (CMP) sensor + Accelerator Pedal Position (APP) Sensor + Fuel Pressure Sensor + Vehicle Speed Sensor (VSS) Output components: For output components, diagnose whether the responses to control unit commands are appropriate. If itis not possible to perform function monitoring, check for broken connections in the circuits. and valies outside ranges, if such methods are applicable. In checked output components, there are the folowing Circuits (not limited to only these sensors). + Injectors + Pov + Lamps, relay controls Common terminology for self diagnostics if diag test performed in the vehicle according to the vehicle diagnosis method. Diagnosis consists of tests Performed on systems or components to ascertain whether they are acting according (© thelr specifications. There are many diagnoses, as listed below. + Engine speed + Engine coolant temperature (ECT) + Accelerator switch iS used a8 a noun, it refers te any desire Diagnostic executive Diagnostic executive refers to adjustment of diagnostic procedures and specification of priorities, and also to the recording and presentation of results, The main elements of diagnostic executive are as stated below. + MIL (check engine lamp) On/ Off commands + DTC recording and deletion + Scan tool data recording + Current status information diagnosis regarding each Diagnostic information This ic the detection of breakdowns in circuits or ‘components using diagnostic procedures. The chart is drawn up te chow that the vehicle functioned normally at the time of assembly and that multiple breakdowns diagnostic functions for certain control functions. These diagnostic functions are supplemented by the diagnostic procedures described in this manual. The DTC system is the language in which the cause of a functional failure is communicated, When a functional failure is detected by @ contiol unify the DTC is sel and the MIL (check engine lamp) lights. Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1-13 Multi-tunction Indicator Lamp (MIL) ‘The Multi-function Indicator Lamp shows warning lamps such as the MIL (check engine lamp). Basically, the MIL lichts when a breakdown occurs in the Engine Control Module (ECM) or other electronic control system. and a DTC (Diagnostic Trouble Code) has been detected, Data Link Connector (DLC) The Data Link Connector (DLC) is the equipnrent for ‘communication with the control units. The DLC is also provided (o enable connection with te scan tool. The general method for using the scan tool is shown below. + Identification of stored DTCs + DTC deletion + Implementation of an output control test + Reading serai cata Vehicle Repair Checking ‘The On-Board Diaanostics (OBD) systems check can be used effectively for checking vehicle repairs. When a repair is complete. the vehicle diagnosis engineer performs the following steps. diagnosed DTCs (Diagnostic Trouble Codes) which were diagnosed, or both 2. Delete the DTC. 3. Run the vehicle according to the scan tool data For DTC status information on the specific DTC that was diagnosed, check until the diagnostic test related to that DTC is performed by the control unit. The implementation of these steps is extremely important for checking repairs using an On-Board Diagnostics (OBD) systems check. Failure to implement these steps may necessitate repairs that Diagnostic Trouble Codes (DTCs) Every time the starter switch is turned on, the Engine Control Module (ECM) runs a self test of most wiring ‘and components. fa fault is detected in the system, it is recorded in the ECM memory and backup contro is performed, depending on the DTC. If a fault occurs ina system that affects driving, the MIL (check engine lamp) lights on the instrument pane! to notify the driver. Reading Flashing Diagnostic Trouble Codes Current and past trouble codes (DTCs) recorded in the ECM can be displayed, and the MIL (check engine lamp) made to fiash by connecting a diagnostics ‘witch ‘+ Tum the starter switch ON and check that tne MIL (check engine lamp) ights. (Bulb check) Atter staying lit tor 1 seconds, the lamp tlashes 3 times on a1 second cycle, then lights again. The light goes out wnen the engine starts. (However, the three flashes do not happen on fire car). + Tum the starter switch ON with the engine off + Connect the diagnostics switch + Read the number of times the MIL (check engine lamp) flashes. + The content of the DTC can be found from the wal Instrument Pane! saus* Legend Diagnostics connector (brown) Memory clear connector (white) Diagnostics common connector (green) Data link connector (DLC), 20 terminals. Data link connector (DLC), 10 terminals Data link connector (DLC), 3 terminals If a scan tool is connected, the DTC can be read by ‘operating the scan tool It the OTC is not stored ‘The code “1” indicating the start of code display is displayed repeatedly, 1A-74 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Itthe DIC Is stored The stored trouble code is shown three times. If multiple trouble codes are stored, each is displayed three times. starting from the one with the smallest number. After all the codes have been shown, the display starts repeating again from code 23. This display continues for as long as the diagnostics eannector is cannected ‘Check engine lamp (Incase of co00"25") 4 88 6 enero About 0:3 see ou ot {2 About 08 soo About 1.2 sec ‘About 24 88 OFF Tone nts digi, Chock gine amp (in case of ode ene nenen 6 on + orr | LU Tons L LU | Hundreds dat_| | dot | | units cit _| pefuncrede con TPO judo : DTCs from the MIL (check engine lamp) flashing 5. Push the accelerator pedal to the WOT position for display more than 1 second and lass than 3 seconds While the engine is stopped, both the current DTCs and 6. Release the accelerator pedal for more than 1 past DTCs are displayed. second and less than 3 seconds. While the engine is running, only currenty-occuring 7. After that, turn the starter switch Off again and DTCs are displayed back to On (Alternatively, disconnect the connector and then How to delete DTCs using accelerator pedal reconnect). operation If the deletion process was carried out correctly, the * Use of this operation deletes all electical system normal code is displayed. DTCs. other than those for some electrical systems (ABS, Smoother-G, SRS, etc.), so proceed with caution. + The starter switch is On with the engine stopped. + Connect the diagnostics connector and the diagnostics common connector. Under these conditions, perform the operations below to delete the trouble codes. 1. After the connector is connected, push the accelerator pedal to the wide open throttle (WOT) position for more than 1 second and less than 3 seconds, 2, Release the accelerator pedal for more than 1 second and less than 3 seconds 3. Push the accelerator pedal to the WOT position for more than 1 second and less than 3 seconds, 4, Release the accelerator pedal for more than 1 second and less than 3 seconds. Engine Control System (6WF1-1C,6WG1-TC(Common Rail) 1A-75 Breakdown diagnosis using the scan tool. ‘The Sean Tool (Tech?) and the Tech? Adapter This is an effective tool for diagnosing electrical breaksiowns in tine viveiruric conse: sysivins. an carrying out system checks. f the Tech2 adapter is used 10 connect to the DLC on the vehicle, various diagnoses and tests can be run on the ECM and ‘communicanons on the vehicle. Legend 1. PCMCIA card (specialized) 3. DLC cable 2. Tech2 (main unit) 1A-76 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail) Legend 1. Tech2 adapter 2. Adapter cabie (for connection to the vehicle Duc) 3. Adapter cable (for connection to the Tech2 DLC) Characteristics and precautions concerning the Tech2! Tech? adapter + Tech2 is a 12V power supply system. Do not connect it directly to a 24V power supply. The Fei puwes supply is supplied via Uwe Tevie adapter, (The Tech2 adapter has a built-in function to convert from 24V_ power supply to 12V) Therefore do not power the Tech? directly from the battery or cigarette lighter. + Turn off the power supply before inserting or removing the PCMCIA card. + Tech? has 2 lthe older varsian had 2) snapshots of capactty. + Tho POMCIA card is vulnerable to magnetism and static electricity, so It should be handled with care. + Tech2 can draw a graph ot a snapshot. + When selecting a menu item, used the selection or function keys to select an item, then press the Enter key. + Press the Exit key to go back to the Main Menu at any time. + To delete the diagnostic trouble code (DTC). open the Application menu and select “Clear DTC Info” ‘of DTC deletion + The Tech2 adapter has a built-in DC-DC converter manual for details. + The Tech2 adapter nas a selector to switch between signals (electronic control unit (ECU) signals) Select "3" for engine control + Set the PCMCIA card into the Tech2 and Attach the DLC cable to the VC (Vehicle Communication Interface) on the Tech2 body, Next. attach the adapter cable to the Tech2 adapter. The Tech2 and Tech2 adapter are linked, and the adapter cable is linked to the vehicle PC Engine Control System (6WF1-1C,6WG1-1C(Common Rail)) 1A-77 Parts of the Tech2 1 @ 2 © aoe tL || g0e |] Et Bee eee | Jf eee. 960 Pr 5 6 Legend *. Soft keypad 10. VCI module fastening bar 2. Selection keys (arow keys) 11. DLC cable connector 3. Action keys (Yes, No, Enter, Exit) 12. AC adapler connector 4. Function keys (FO -F9) 13. PCMCIA card slot (with cover) 5. Help key (7) 14, PCMCIA card release ballon 6. Control key (PWR/ Shift) 15. External communications connector (RS485 7. Wide sian port) 8. Display (LCD screen) 16. Extemal communications connector (RS232 9. Vehicle Communications interface (VI) module pon) ‘Soft keypad When Tech2 is operated, the selection instruction box appears in tne top of the screen, The soft keys correspond to the selection box. If there is no selection box on the screen, the instrument cannot be used, 2. Selection keys (arrow keys) These are used for menu selections and display switching on tne Tech2 screen, The highlighted portion of the screen display content is the selection 1A-78 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) 3. Action keys (Yes, No, Enter, Exit) These are used to confirm Tach2 operations, answer on-screen instructions and questions and switch’ move between menu screens. 4, Function keys (FO - F9) These confim menu functions within the screen display. Ifthe screen menu contains elements such as “FO the key corresponds to that display. 5. Help key (?) When this key is pressed, a cercon appears, explaining the Tech2 function currently in use. 6. Control key (PWR/ Shit) The PWR key turns the Tach2 power on and off ‘The shift key is used to adjust screen contrast. An LED lights (orange) when the shift key is enabled. At that time, all Keys and functions over tnan the selection keys are locked. An LED (green) lights when the power supply is turned on. 7. Wide stand This is used as a stand for the instrument. The stand can be moved through anales of 0-180? 8. Display (LCD screen) This is an LCD display with a contrast adjustment function. It displays ECM information, instruction 9. Vehicle Communications Interface (VCI) module The module that allows communications between the vehicle and Tech2 10. VCI module fastening bar Operate this bar to mount and fasten the VCI or remove It 14. DLC eable connector This is the connector for using (connecting) Tech2 on a vehicle. Connect the DLC cable. 12, AC adapter connector This is the connector for connecting the accessory AC adaptor. This is for using Tech2 outside a 13, POMCIA card slot (with cover) Open the cover to insert a PCMCIA card into Tech2, Insert the PCMCIA card with the cover open. Never insert or remove the PCMCIA card while Tech2 is switched on 14, PCMCIA card release button Lise thie button ta ramnve the POMCIA card foam Tech2. Press the button to take the PCMCIA card out. Never remove the PCMCIA card while Tach? is switched On. 15, External communications connector (RS485 port) This is a telephone line connector, but it is not curently used on Tech2. Do not conmect this connector to a telephone line etc. 16, External communications connector (RS232 port) This Is the connector to connect Tech2 to another computer. Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A-79 Parts of the Tech2 adapter Legend 1. Selector 2. Select switch (signal switching) 3. Adapter cable (for connection to the Tech2 DLC) connector 4. Adapter cable (for connection to the vehicle DLC) connector 6. Vehicle DLC connector 1 Selector The selector is provided so that Tech2 can recognize the ECM signals and can output signals to the ECM, The selector position varies according to the system concemed. 3: Engine Control 6: Cab suspension 7: Kick drive (single) Other: Free This is the switch to switch between signals when Tech2 reads cignals from the ECM and conde them to the ECM, Reading signals fram the COM: Switcht position (Reading DTCs, checking data, etc.) Sending signals from Tech2 to the EOM: Switch? position (OTC deletion command, various test instructions, etc.) 3. Adapter cable (for connection to the Tech2 DLC) connector Tech 2 Attach the cable to connect the DLC cable and the Tech? adapter. 4. Adapter cable (for connection ta the vehiele DLC) connector Attach the cable to connect the vehicle DLC and the Tech2 adapter. Vehicle DLC connector This Is the connector to connect to the vehicle the DLC differs from the device mounted on the vehicle, 20-pin: Cab suspension Spin: Engine, SKS, ABS/ASK, EBS, Smoother-G, alr suspension, HAS (with —Smoother-G), MIMAMORI System, Connection method 1, Check that the starter switch is in the OFF position, 1A-80__Engine Control System (6WF1-IC,6WG1-1C(Common Rail)) 2. Insert an ISUZU system PCMCIA card into the Tech2, Attach the DLC cable to the Tech2 unit. Attach an adapter cable to the Tach? adapter. Link the adaptor cable to the DLC cable. Link the adaptor cable to the DLC. Check the Tech? adapter selector position. 6: Cab suspension. Other: Free 8. Check that the Tech2 adapter select switch position is in tho “1” direction. 9. Turn the starter switch to the ON position, and press the Tech2 "PWR" key. 10. Check the Tech? display screen Operation procedure Select Diagnose from the main menu, then select the correct model year, model and system for this equipment ros) Press (ENTER) To Continue Press (ENTER) To Continue romaesronont 1 (ENTER) FO : Diagnostics T F14 : Service Programming System (SPS) ie ¢ | | F2: View Capture Data F3 : Tool Options Down load/Up load Help 1 (FO ENTER) Vehicle Identification Select one of the following Model Year(s) CAUTION: Always make sure that the power supply to the Tech? is off before inserting or removing the PCMCIA card. ’ (Model year ENTER) Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 10-81 Vehicle Identification s 2 of the Vehicle Type (s) (N*) ELF, NPR, NQR, VFR (off-Road) industrial Engine (C*E*L“F*) Heavy, Medium Duty| (CSE*L\F* ENTER) System Selection Menu (C*E‘L‘F*) Heavy, Medium Duty FO: Engine F1: Transmission F2 : Chassis F3 : Body Y (FO ENTER) = Vehicle Identification Select one of the following Engine @WF1-TC (Common Rail) 6WG1-TC (Common Rail) 6UZ1 (Common Rail) (Diagnostic Engine ENTER) The table below indicates which functions are Impiemented and displayed In the current Tech2 software, WF 1-TCIBWG1-TC (Common Rail) FO: Fault diagnosis code (DTC) F1: Fault history F2: DTC deletion F1: Data display 2: Snapshot F3: Actuator test FO: Common rail system FO: Rail pressure control F 1: Stop injection from each injector F1: Device contral FO: Turbocharger control Ft: EGR control F2: Exhaust brake relay FS: Retarder relay 4: Programming FO: Q adjustment compensation FO: Q adjustment compensation data upload (Tech2) Ft: adjustment download (ECM) F'1: Injector ID code FO: Injector ID code F1: ID code registration 2: ID code upload (lecn2) F3: ID code download (ECM) 4: History information compensation data Menu Items Select menu items to check DTCs and data, and for various tests and learning ete. 1A-82_ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Fault diagnosis code (DTC) Read, check and delete DTCs Put the Tech2 adapter select switch in the “1” position toread DTCs. Put the Tech2 adapter select switch in the “2” position to delete DTCs. oo Mee Data display The states recognized and controlled by the ECM are displayed in various items. Put the Tech2 adapter select switch in the to read data. The displayed numerical items are stated under representative values for the Tech2 data list Contant af the display items is stated under data * position Data Display System Votage v Engine Speed RPM Desired idle Spood RPM -APP{ecalartoe Pel) v ‘Accoloraior Opening -APP{Accelerator Pedal) ‘Accaluror Postion Le Soloct Quek ti || ove | otha | | moe DTCs are the language for the diagnosis engineer to ‘communicate with the vehicle ECM DTCs can be broadly divided into past and current DTCs. + Current DTCs: Indicate faults (breakdowns) in the curront ignition eyclo. + Past DTCs: Indicate faults (breakdowns) in the last or eariler ignition cycies. + Multiple DTCs: Several DTCs may be displayed at once. These are called multiple DTCs, This occurs when multiple faults (breakdowns) happen at once. In other cases, when multiple sensors or switches. share the same GND or power supply, a broken connection or short in that ground or power connection can cause the display of multiple DTCs for all related sensors and switches. If multiple DTCs are displayed. refer to the chart for DTCs that require inspection of broken connections and shorts in common pawer supply ar GND connections, and delete the vehicle DTC information Homenetacot This menu can be used to display current data. The display is synchronized with the state of the vehicle and any devices. + Ifthe mons for data display cannet be displayed: A breakdown has occurred in the wiring between the ECM and the DLC. The select switch on the Tech2 adapter is in the wrong position. + Ifthe display shows an abnormal fixed value’ Eg. It the data display values tor engine speed and various sensors are fixed and differ from the actual stalus. Move the connector or hamess by hand and see if the display stops being fixed. If so, the cause is a poorly fitting terminal, misaligned pins, a broken or shorted harness wire at the position moved by hand, ete., requiring repair. + Ifthe numerical display is marked with “> This Is a Tech2 software problem. Wpven ane item has an asterisk mark during data display, the PCMCIA card requires a version upgrade Snapshot A snapshot is taken so that data can be reviewed and sed in identifying the cause of a breakdown, + The snapshot can be stored in the data list menu and displayed graphically + Using this mode, the conditions of a customer complaint can be reproduced and recorded to identify data faults, Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 10-83 + It the metnod ot determining me tngger type is used, the data for the moment at which the DTC was displayed can be recorded. + Recorded data can be played back on a domestic, power supply. Programming When replacing the ECM, confirm history information prior to replacing. (Data confirmation), in addition upload data to Tach2. After replacing the ECM, download data to the new ECM Actuator test, Perform all applicable tests, operate components. inspect functions and confirm that they are either faulty (or normal When performing instructions (commands) for the ECM from the test screen, place the select switch of the Tech2 adapter in its second position. CAUTION: If conditions concerning the vehicle. operating conditions, coolant temperature, vehicle speed, switches, gear position are not satisfied or if a DTC is detected, there are cases where not all tests are performed. tem Description Magnetic | Exhaust brake valve | Confirm valve magnetic system operation valve when on/off|when tuned on, there may be an ‘commands are given. Method of use of theif the magnetic valve does not operate abnormality with the exhaust magnetic valve. hamess. or ECM. VGS valve Confirm operation of _the|if the magnetic valve does not operate magnetic vaive when onioft} when turned on, it means there is an commands are given. abnormality with the VGS magnetic valve, namess, or LUM. EGR valve Confirm operation of theif the magnetic valve dnas nat operate magnetic valve when onloff| when turned on, it means there is an ‘commands are given abnormality with the EGR valve, hamess, or ECM. control Engine |Rail pressure control | Perform a rail pressure increase | f the increase in rail pressure does not ‘command to check the condition | operate when performed, it means there is. of the rail pressure control. an abnormality with the PCV, PCV control harness or ECM etc. ‘Stoppage injection on a per Injector basis graph 2, Make the selection when items are displayed on the screen, 3, When the snapshot option is displayed on the screen, choose the trigger method, and select [record snapshot} at the bottom of the screen. 4, If (standby) at the bottom of the screen flashes, select [trigger] at the bottom of the screen. 5. Confirm the trigger type. ‘of | When @ command for stopping | there are no changes to engine rpm or in jection is performed for the|the way the engine vibrates when an injector for each cylinder, confirm | injector stop command is performed, this prior to the command being performed, This means that there is an abnormality in this injector, the harness, or ECM ete. 6. The screen will change and when (continue) is displayed at the bottom of the screen, select [oontinue} 7. When [plot] is displayed at the bottom of the screen, select [plot] 8. If the item selection screen is displayed, click on Ue desired iter and push the enter key, select up to 3 and select the “approval” button at the bottom of the screen. 9. Agraph is displayed on the screen. 1A-84 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) ‘Method tor playing back a graph of the recorded data 41, Select [snapshot data] from the screen after tuming the Tech2 oower on. Confirm that the snapshot data title is displayed. 3. Select the smmapshol data ile Data is displayed on the screen. If you would like to see a graph of the data, select on (plot} at the bottom of the screen, 5. Ifthe item selection screen is displayed, click on the desired item and push the enter key, select up to 3 and select the [approval] button at the bottom of the sereen 6. A graph is displayed on the screen Graph creation This enables creation of a graph of the snapshot data, Reviewing this graph enables investigation of the cause of a failure occurrence. Method for creating a graph after displaying data 1. After selenting [data display] in the application menu and vehicle data is displayed, select [ananshat] frm the hattam af tha seraan 2. After a certain amount of time passes, push the [Exit] button. 3. The screen will change and when [continue] is displayed at the bottom ot the screen, select {continue}. 4, When [plot] is displayed at the bottom of the screen, select (plotl 5. If the item selection screen is displayed, click on the desired item and push tho entor key, select up to 3 and select the [approval] button at the bottom of the screen. 6. Agraph is displayed on the screen Method for selecting trigger type and creating a graph 1. Select [data display] in the application menu. 2. Make tne selection when items are displayed on the screen. 3. When the snapshot option is displayed on the screen, choose the trigger method, and select [record snapshot] at the bottom of the screen, 4. If (standby) at the bottom of the screen flashes, select [trigger] at the bottom of the screen. Confiin Ue tigger type. ‘The screen will change and when [continue] is displayed at the bottom of the screen, select [continue]. 7. When [plot] is displayed at the bottom of the screen, select [plot] 8. If the item selection screen is displayed, click on the desired item and push the onter key, select up to 3 and select the [approval] button at the bottom 9. Agraph is displayed on the screen. Method for playing back a graph of the recorded data 1. Select [snapshot data] from the screen after turning the Tech2 power on. 2. Confirm that the enapchat data title is dieplayed 3, Select the snapshot data title 4, Data is displayed on the screen. It you would like to see a graph of the data, select on [plot] at the bottom of the screen. 5. If the item selection screen is displayed. click on the desired item and push the enter key, select up to 3 and select the [approval] button at the bottom of the screen 6. Agraph is displayed on the screen, Tech2 data reference values Data lists are for confirming the status of the vehicle and each piece of equipment Compares data from each vehicle to basic values and finds temporary deviations from reference values and cases where deviation is continuous. This is used for diagnostics. (This Tech2 display menu may be changed without notification.) caused by vehicle conditions) ‘System voltage more than 24 Engine RPM RPM Wilh respect to goals = Target idle speed RPM 475-525 ‘Acceleration sensor 0.25-0.75 ‘Accelerator amount open 0 ‘Accelerator pedal switch ‘ON/OFF ON, Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) _1A-85 Data display items Units Idle reference values (changes caused by vehicle conditions) ‘Amount accelerator is actually open % 0 Accelerator pedal position learning v 0.25-0.75 idle Fuel pressure (difference between MPa target ang actual) Fuel prassiira sensor Fuel pressure FIB control 0 PCV closed period 174-176 Intake air pressure ‘Aimoepherie tomperature eeneor Vv Engine coolant temperature Vv ‘Atmospheric pressure Vv Tntake air pressure Vv “Atmospheric tomporature e ‘Wher the same as extemal air temperature Engine coolant temperature °c 70-86 (when fully warmed up) EGA yao enwerature v EGR gas temperature 2 Vv ‘Atmospheric pressure KPa Boost (relative pressure) kPa ‘Approx. 2 Vehicie speed kmh 0 ‘Speed limit kenlh 0 Cruise set speed knlh 5 VGS control mode EGR control mode onoun 2 il ‘Second cylinder correction injection mmnvist 4 amount Third cylinder correction injection mamest 4 amount Fourth cylinder correction injection mmneist 4 amount Fifth cylinder correction injection mamnyst 4 amount Sixth cylinder correction injection mméist 44 ‘amount ‘Starter switch (ST) ON/OFF OFF ‘Starter switch ‘ON/OFF ON Neutral Switch ‘ONIOFF ‘On (while vehicle is stopped) 1A-86 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Data display items Units Idle reference values (changes caused by vehicle conditions) Cluteh switch ON/OFF ‘On (while vehicle is stopped) Brake switch 4 ON/OFF OFF Brake switch 2 ON/OFF OFF Parking switch ONIOFF ‘On (while vehicle is stopped) Reverse gear switch ‘ON/OFF ‘OFF Exhaust brake switch ‘ON/OFF OFF ‘Air pressure switch ‘ON/OFF OFF ‘Stop lamp switch ‘ON/OFF Retard switch ON/OFF OFF Cruise main switch ‘ON/OFF OFF Cruise set/down switch ON/OFF OFF ‘Cruise resume owiteh ‘ON/OFF OFF Cruise cancel switch ON/OFF OFF Exhaust brake actuator ON/OFF Starter cut operation ON/OFF COMP sensor isiallation vaniabilly “oR oS correction Acceleration open request (TCM) % "ASR accelerator opening % PTO aaneleratar apaning % PTO accelerator opening Vv PTO switch ON/OFF, OFF Tale control switch Manualfauto “Auto Idle up switch ‘On/O#f OFF Idle down switch ‘On/Off OFF Cruise release switch ‘On/O# OFF Cruise release switch 2 ‘OniOw OFF Cruise coast ‘OnIOH OFF Cruise cancel On/Off OFF Constant speed cruise ‘On/Off OFF ‘Overrun ‘Over heat CKP sianal actuator YesiNo CMP signal actuator YesiNo Q adjustment resistance data 1 Q adjustment resistance data 2 (Q adjustment resistance data 3 ROM code Engine Control System (6WF1-IC,6WG1-TC(Common Rail))_1A-87 Data display items Units Idle reference values (changes caused by vehicle conditions) Diagnosties switch OniOfF OFF Final amount injected aller mmst correction Injection amount control mode = = Injection control mode = = High pressure pump control mode = = Final injection amount mamlst TSC corrected injection amount mmvist 1A-88__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Function Inspection List (Oral consultation Point sequence based on customer's complaint for the purpose ot tully grasping fault symptoms and making accurate diagnosis, ‘On-Board Diagnosis (OBD) System Check Inspection for determining failure locations of the electronic engine control system (inspection procedure) ‘Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON) Inspection for when the MIL (check engine lamp) does rot turn on when the starter switch is tuned on, ‘Chocking the MIL (chook engine lamp) flashing control system (MIL does not flashing) Inepection when the MIL (check engine lamp) doos not flash (on constantly) when the diagnostic switch is tured on Checking the Sean Too! Circuit System Inspection if scan tool is not functioning ‘Checking the engine starting system Inspection if there is possibilty of abnormality in purlivits eiaied fy siarier UF engine sia up ‘Checking the fuel system Inspection if there is possibility of abnormality in portions related to fuel system ‘Checking the air intake system Inspection if here is possibilly of abnormality in portions related to alr intake system ‘Checking the exhaust system Inspection if there is possibility of abnormality in partions related to exhaust aystam Checking the EGR system Inspection if there is possibilty of abnormality in portions related to the EGR system Checking the engine control module (ECM) power supply and ground circuit Inspection if there is possibility of abnormality In power system circuit and GND system circuit of the ECM. ‘Checking the PTO Inspection if there is possibility of abnormality in PTO functioning (governor characteristics or accelerator switching) Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) _1A-89 Oral consultation Oral consultation 4, Adequately grasp the contents of customer cumpiainis by using tie engine vorivoi sysivm questionnaire The oral consultation should not be done at random but should narrow down on the target fault inferred fram the fault phenomena (fact) 2. Accurately interpret the fault data. Have a solid understanding based on SW1H, Example: Air temperature is low, at startup, regularly, near engine section, metallic sound, etc. Oral Consultation Points + What Failure symptoms + When Date, time, occurrence frequency + Where Road conditions + Under what conditions Driving conditions operating conditions weather were felt Engine control system questionnaire ‘At the time the vehicle is received at the service workshop from the customer, it is necessary to confirm the “fault symptoms” and “fault occurrence data” based (on the engine control system questionnaire with the customer. Legend 1. Fault symptoms 2. Fault frequency / fault conditions Because: The fault symptoms may not be reproducible at the service workshop. a fault When the tault conditions are not correctly communicated to the person in charge of repairs, man-hours are wasted The questionnaire is of assistance in the on-board diagnosis, repair, and repair verification at the service workshop, smpiaint may not neces: 1A-90 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) ENGINE CONTROL SYSTEM CHEGK SHEET Tiespectors Name Customers Name Model & Model Year Driver's Name Chassis No. (ote Vehicle Brought in Engine No. Liconse No. [Odometer Reading nimilos| © rgROPE Te engine aoe not ark 1 Nointelconbuston No completa combustion © Hard Stat | Eng canis domty © Otner( 0 ) : Tr Aomal Ging wood TB Fgh ang speed RP] owing apeod (RPA E | inooroctite | Roush ing i 5 Ober | sae 1 Hostaton, 9, sunbie Supe, cages 1D Cutout misses © | eer cumy | Lack of ower. sunashness, sooncinass| 5 T_Ober( ) 2 (Soon for saring 1D Air acclraor podal doprosod engno san] Gung operon G ‘nnoe sesotrat possi roeases Us ng rom nou 5 Omer 1 Or fac aka Whi sane Paar acanary © Obes | Fuel rock, combustion rsa G._Obwe( i Dates prob oocured Consent TH Tnarnitaniy( nes par dayimony Ooo ony rota raquo Problem feruoney | Shar, , Fro 0 Couey 0 Rang 0 row Wester 1 Varous/othr( 1 Sane Het appx) ET Warm oom a) i Temperature | Any tomporatur aa 1 Wohway 7 ime 7 Gaya apr é Down 1 Rough road 1D Ober( d A [Lcccconaeen |S Ove tno tow) No lead ©) Ober (approx tons) 5 [Eom Cols Warming op Tr Ateeweemingup Any temperate E |rotparawe (5 omer ) 5 Sting wat aor etna ( Min) Ding 2 | cngna oparten | Rate 0 rng 1 Conan sped 1 Aesalarton § [rere crestor 1 ecaoraton © AIC swten Onto 5 omer( 1 Fustanoant —[OFul Tr Row iz Tr Baiow i ear ony Fuol Band Conon of Crack Engine Lamp Remains On TD iternitaty tne On Does natu On Prosont Code 1D Nothing Dee A Symon Code ) Diagnostic Trouble ode (OFC) o Fen td tes Cato a Nob 1 0388 Symon cote ; ther Adonel Coneiton Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A-91 ‘On-Board Diagnosis (OBD) System Check Description The on-board diagnosis (OBD) system check is the siariiny point for aii venice Giving Condition diagnoses, Before using this procedure, carefully do a visual inspection to ensure there is no dirt or loose fittings in engine control module (ECM), connectors, and power supply and grounding, In addition, this is a method for confirming by each function the problems arising trom imperfect functioning of engine control system. Diagnostic Aids Intermittent fault (intermittent) may occur due to poor eonnection or harass damage Cheak far the following Conditions, and repair or replace if fault is detected, Connector, inspect to ensure there is no projecting terminal ‘end portion, inappropriate fit, lock damage, inappropriate shape or damage to nd wit oF poor connection of terminal + Damage to hamess: Inspect to ensure there is no abrasion of wire insulation, broken wire inside the insulation, and the like. Test Deser iption The following numbers show the step numbers of the laynosii¢ viva 2. The MIL (check engine lamp) is continually on while the starter switch is on but engine is not running and afterwards tums off. fit does not tum on, use a diagnostic chart to inspect functions in order to check the MIL circuit and repair it. 3, Make sure the ECM has the capability to control the MIL and that the MIL drive circuit is connected to ground. If there is an abnormality, use a diagnostic chart to inspect functions in order to check the MIL flash circuit and repair it confirm the ability of ECM to transmit serial data. 6. Ifthe specified DTC is detected, the engine may not start, In addition, inspect and repair since the engine control may nol be funetioning normally. ‘11. Reference an inspection method for each DTC and perform an inspection 14, Ifthe scan tool data differs from the representative value, this will be useful in checking the areas where an abnormality has occurred ‘Step ‘Action’ Value(s) Yes, No Perform oral consultation (confirmation of + | Vehicle conditions, etc.) by using check sheet. Go to “Oral Was oral consultation carried out? Goto Step 2 Consultation” ‘Make sure the ML (check engine lamp) tums on 4. Turn the starter switch ON. 2 After turing on for 18 seconds, flashes - three times with a 1 second period and then remains on until the engine is started, Go to “Checking the MIL lighting Did the MIL (check engine lamp) turn on? Goto Step 3 circuit system” Make sure the MIL (check engine lamp) iy 4, Turn the starter switch ON. (At this time, engine does not start up) Connect the diaanostic switch (diagnostic connector and diagnostic common connector. Did the MIL (check engine lamp) flash correctiy? Go to “Checking the MIL flashing Go to Step 4 circuit system’ 1A-92__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Step ‘Action Value(s) Yes No ‘Connect tho scan tool 4, Turn the starter switch OFF. 2. Connect scan tool to data link connector (0LC:3 pole}. 3. Turn the starter switch ON. 4 | 4. Tun ON the scan toot - 5. Communicate with the engine control module (ECM) using a scan too! Go to “Checking Was power supplied to scan tool, and was the scan tool connection with the ECM confirmed? GotoStep5 | circuit system” DTC is read and recorded using scan tool. 4 Tum the starter switch ON (At this time, engine does not start up) 5 la tumon oa 3. Read the DTC using scan tool Is the action complete? Go to Step 6 - ‘Check the content of the DTC and check ¢ | DTCs (P0033, P0035] have been detected _ Go to applicable Were DTCs [P0033, P0035] detected? DTC Goto Step 7 ‘Check to see ifthe engine starts. Goto “Checking 7 = the engine starting Did the engine start up? Go to Step 8 system” DTC is read and recorded using sean tool 4, Turn the starter switch ON, and start the engine 8 | 2. Turn ON the scan tool = 3. Read the DTC using scan tool Is the action complete? Go to Step 9 - Reconfirm the content of the DTC 9 | are current DTCs and previous DTCs oe Go to applicable recorded? prc Go to Step 10 ih DTC confirmation of stap ©, confirm that Repairthe previous DTCs are stil recorded. problem refer to the applicable 49 | Are the previous DTCs stil available? _ syria diagnostic table and the scan tool " Inspect the fuel system: View DTCs (P0014, PU015] (inspection of engine timing sensors), DTCs (P0271-P0276] (inspection related to injectors), DTC (P0115, P0118, P0151, P0245, P0226, P0227, P0245, P0247, P0248) (related to fuel pressure, inspection of supply pump), perform an inspection and if there is an abnormality, perform a repair or replacement, Is the action complete? Goto Step 12 Engine Control System (6WF1-1C,6WG1-TC(Common Rail) 1A-93 Step ‘Action Value(s) Yes No Porform inepostion of the ongine control status (ECM) scan tool, and. judge whetner the test performed’ normelly and whether the test results are normal 1. Rall pressure control When changing the set pressure of the fuel pressure inside the fuel rail, confirm that the actual pressure follows the set pressure and when pressure is increased Whether or not there are any leaks from 12 the fuel piping system - 2 Stapnage af injection an a per injector basis Stan tha injartor far ana eylindar at a time, to make sure fuel is being injected correctly. When normal, the sound of the engine will change when an injector is stopped; however, if there is an abnormality, the sound of the engine will not change. Were you able to complete the test correctv, land were the results normal? Goto Step 14 | Goto Step 13 1. Repairfreplace the portions judged to be abnormal by the inspection performed in Step 12, and related portions. In addition if the tests could not be performed making it so there is not any results one way or the other, replace the engine control module. 13 = IMPORTAN ‘Aer replacing the ECM, perform the following items of programming, + Qadjustment data + Injector ID code Is the action complete? Goto Stop 14 - Taspacticapair fault portions according to the phenomena considered to be faults by 14 | referring to oral consuitation (usar data) and = engine data Goto applicable symptom Is the action complete? Goto Step 15 | diagnostic table Erase DTCs from the ECM and restore the 45 | Vehicle to its inital state at Is the action complete? Verity repair a 1A-94 Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON) or. Circuit Deseri When the starter switch is tumed on, the MIL (check engine lamp) turns on and tums off based on the following conditions. + After turning on for 15 seconds, flashes three times with a 1 second period and then remains on unt the engine is started and then tums off once the engine starts. (However, the three flashes do not happen on fire car) When the engine control module (ECM) confirms the on signal from the starter, it performs MIL turn on/turn off control Diagnostic Aids conditions, and repair or replace if fault is detected, + Poor connection at ECM: At the hamess connector, inspect to ensure there is no projecting terminal end portion, inappropriate fit, lock damage, inappropriate shape or damage to terminal, or poor connection of terminal and wire, + Damage to hamess: Inspect to ensure there is no abrasion of wire insulation, broken wire inside the insulation, and the lke. 7288 darnage. Chi oy" 7 a Also check for abnormality such as of other ECM internal fault, meter, valve and the like, and repair or replace if fault is detected, Test Deseription The following numbers show the step numbers of the dlagnostic chart: 1. Ifother lamp in the meter is It, it can be judged that abnormality may exist in the power circuit from battery to MIL (check engine lamp). 4. As the ECM controle the MIL, make sure there is ‘no abnormality in the ECM power supply and ground circuits Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) _1A-95 Step ‘ation Value(s) Yes, No Make sure the other lights (parking brake light, charge ight, et.) inthe display turn on 4. Turn the starter switch on. 2. Make eure tho lights in the dieplay tum on Did the other lights turn on? Go to Step § Go to Step 2 Check the power supply system of meter 4. Turn the starter switch OFF. 2. Disconnect the meter. 3. Turn the starter switch ON, and measure the voltage between the display harness connector and GND. Is the voltage value normal? Between connector power terminal and GND: Battery voltage Go to Step 4 Goto Step 3 Tnspect the power supply circuit and ground circuit ofthe display. When fault is detected, replace if necessary. Is the action complete? Go to Step 5 Check the power supply and GND circuit fer the engine contro! module (ECM), Bu iv “Engine wnirul muduie (ECM) power supply and ground circut”. When fault is detected, replace if necessary. Is the action complete? Go to Step 5 ‘Make sure the MIL (check engine lamp) turns on again, 4. Connect all the harnesses. 2, Turn the starter switch ON (At this time, engine does not startup) After staying lt for 15s, the lamp flashes 3 times on a ts cycle, then lights again Did the MIL (check engine lamp) turn on? Verity repair and return to the OBD system check Goto Step 6 Check the MIL (check engine lamp) drive circuit 1, Tur the starter switch OFF. 2. Disconnect the hamess from the ECM, 2. Tum an the starter switch and confirm thatthe MIL (check engine lamp) turns on han a jumpar ie ised hatwaen the ECM harness connector and ground. Did the MIL (check engine lamp) turn on? Go to Step 8 Goto Step 7 Repair or replace the MIL (check engine lamp) drive circuit Is the action complete? Go to Step 9 1A-96 _ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Step ‘Action Value(s) Yes No Make sure the MIL (ehock engine lamp) tame on again 1. Connect ai me narnesses. | 2 Tum the starter switch ON. _ (At this time, engine does not start up) After staying it for 15s, the lamp flashes 3 times on a ts cycle, then lights again. Ventty repair and return to the OBD Did the MIL. (check engine lamp) turn on’? system check Go to Step 8 1. Replace the ECM. IMPORTANT: After replacing the ECM, perform the following items of programming, + Qadjustment data + injector iB code Is the action complete? return to the OBD systom check Engine Control System (6WE1-1C,6WG1-TC(Common Rail)) 1A97 ‘Checking the MIL (check engine lamp) flashing control system (MIL does not flashing) Circuit Deser When the starter switch is tumed on, the MIL (check engine lamp) turns on and turns off based on the following conditions. + After turning on for 15 seconds, flashes three times with a 1 second period and then remains on until the engine Is started. Turns on after engine is started. (Fire trucks do not flash three times) Diagnostic Aids Intermittent fault (intermittent) may occur due to poor connection or harness damage. Chock for the following conditions, and repair or replace if fault is detected + Poor connection at ECM: At the harness Connector, inspect to ensure there is no projecting terminal ‘end porton, appropriate tt, lock damage, inappropriate shape or damage to terminal, oF poor connection of terminal and wire, + Damaae to harness: Inspect to ensure there is no abrasion of wire insulation, broken wire inside the insulation, and the like. Also check for abnormality such as of other ECM internal fault. meter. diagnostic switch and the like. and repair or replace if fault is detected a308 The following numbers show the step numbers of the diagnostic chart 3. Ifthe circuit is shorted to ground, the MIL (check engine lamp) will not flash. Check the circuit for abnormalities 5. the dieplay le shorted to ground internally, the MIIL (check engine lamp) will not flash. Check the circuit for abnormalities 8 As the ECM controls the MIL (check engine lamp), make sure there is no abnormality in the ECM power supply and ground circuits. 1A-98__ Engine Control System (6WF1-IC,6WG1-TC(Common Rail)) Step ction value(s) Yes No ‘Check the diagnostic switch circutt 1. Turn the starter switch OFF. 2. Disconnect the hamess from the Engine Control Module (ECM). 4 | 3 Check that there are no short circuits or oroken wires in the namess detween the - ECM and the diagnostic switch 4. If fault is detected, repair or replace as necessary, Was an abnormality detected? Goto Step 2 - Check the diagnostic switch circuit 4. Turn the starter ewitch OFF, 2. Disconnect the hamess from the ECM. 3. Check that there are no short circuits or 2 broken wires in the hamess between the ae diagnostic switch and ground 4. If fault is detected, repair or replace as necessary, Was an abnormality detected? Goto Step 3 = ee 4, Tuin the starter switch OFF. 2. Disconnect the hamess from the display. 3. Disconnect the hamess from the ECM. 3 | 4. Chock that there aro no short circuits in the hamess between the display and the ECM 5. If fault is detected, repair or replace as necessary, Was an abnormality detected? Coto Step 4 Make sure the MIL (check engine lamp) flashes correcty again. 4. Connect all the harnesses. 2. Tur the starter switch ON. : {Atthis timo, engino doce not start up) 3. Connect the diagnostic switch (diagnostic, connector and diagnostic common connector). Did the MIL (check engine lamp) flash correctly? return to the OBD system check Go to Stop § ‘Step Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) _1A-99 ‘Action Value(s) Yes No Chook the display. 1. Turn the starter switch OFF. 2. Disconnect the hamess from the ECM. 3. Turn the starter switch ON 4, Make sure the MIL (check engine lamp) tuins on, Did the MIL (check engine lamp) turn off correctly? Goto Step 8 Goto Step 6 Replace the meter Is the action complete? Go to Step 7 Make sure the MIL (check engine lamp) tlashes correctly again, 4. Connect all the harnesses. 2. Turn the starter switch ON. (At this time, engine does not start up) 3. Connect the diagnostic switch (connector). Did the MIL (check engine lamp) flash correctly? Verify repair and return to the OBD. system check Goto Step 8 inspect ihe power Suppiy circuit and ground circult of the ECM ‘When fault s detected, replace if necessary. le the action complete? Go to Stop 9 Make sure the MIL (check engine lamp) rashes correctly again, 4. Connect all the harnesses. 2. Turn the starter switch ON. (At this time, engine does not start up) 3. Connect the diagnostic switch (connector). correctly? Verify repair and system check Go to Step 10 10 7, Replace the ECM, IMPORTANT: After replacing the ECM, perform the following items of programming. + Qadjustment data + Injector ID code Is the action complete? Verify repair and return to the OBD system check 1A-100 _ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Checking the Scan Tool Circuit System omecor ey The Tech2 can communicate with the engine contro! ‘module (ECM) through a connection using a data link ‘connector (DLC) and the power supply for the scan too! |s supplied through the DLC. Diagnostic Aids Intermittent fault (intermittent) may occur due to poor connection or hamess damage. Check for the following conditions, and repair or replace if fault is detected, + Poor connection at ECM: At the hamess connector, inapect to ensure there is no projecting terminal end portion, inappropriate fit, lock damage, inappropriate shape or damage to terminal, or poor connection of terminal and wire, sy owaurt fp ase | Coma ee. larestcs Comer = 12500, ecu + Damage to hamess: Inspect to ensure there is no abrasion of wire insulation, broken wire inside the insulation, and the like. Also check for abnormality such as of other ECM internal fault, scan tool and the like, and repair or replace if fault is detected. Test Description Ihe following numbers snow the step numbers ot the diagnostic chart: 7s the ECM conttols the MIL (check engine lamp), make sure there is no abnormality in the ECM power supply and ground circuits. Step ‘ction value(s) Yes No ‘Check the power circuit of scan tool 1. Turn tne starter switcn OFF. 2. Connect scan tool to data link connector 1 (Lc) 3. Turn the starter switch ON, 4. Turn ON the scan tool. Was the scan tool tumed ON? Go to Step 3 Go to Step 2 Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1-101 Step ‘Action Value(s) Yes No Chock to onaure that thore fe no broken wire ‘r short circuit in the power supply and GND 2 | if fault is detected, repair or replace as - necessary. Is the action enmplete? Gota Sep 3 - Check the communication circuit of scan tool. 1. Turn the starter switch OFF. 2. Disconnect the hamess from the Engine Control Module (ECM). 3. Check to eneure that there is no broken : wire or short circuit in the communication ia Girouit of the DLC. 4. If fault is detected, repair or replace as necessary, Is the action complete? Goto Stop 4 Connect the scan tool again. 4. Turn the starter switch OFF. 2. Connect the scan too! to the DLC. 3. Turn the starter switch ON. 4 | 4, Tum ON the scan tool - 5. Communicate with the ECM using a scan tool Verify repair and Was power supplied to scan tool, and was return to the OBD connection with the ECM confirmed? system check Goto Step 5 Inspect the scan tool 4. Reference the users manual and perform a auto diagnostics of the main unit, + Cable for connecting DLC 5 + PCMCIA card ul + Scan tool main unit 2. if fault is deiecied, repair or repiace as necessary, Is the action complete? Goto Step 6 - Connect the scan tool again. 4. Turn the starter switch OFF. 2. Connect the scan too! to the DLC. 6 | 4. Turn ON the scan tool - 5. Communicate with the ECM using a scan tool. Verity repair and Was power supplied to scan tool, and was return to the OBD connection with the ECM confirmed? system check Goto Step 7 Inspect the power supply circuit and ground circuit of the ECM. 7 | When fault is detected, replace if necessary. - Is the action complete? Goto Step 8 ay 1A-102 _ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) se] Action Value(s) Yes No ‘Connect the ecan tool again ‘Tur the starter switch OFF. Connect the scan tool to the DLC. ‘Turn the starter switch ON. Turn ON the sean tool ‘Communicate with the ECM using a scan tool Was power supplied to scan tool, and was connection with the ECM confirmed? 1. Replace the ECM. IMPORTANT: Ater replacing the ECM, perform the following items of programming + Qadjustment data + Injector ID code Is the action complate? Verify repair and return to the OBD system check Verify repair and return to the OBD system check Go to Step 9 Engine Control System (6WF1-1C,6WG1-1C(Common Rail) 1A-103 Checking the starting system AIT Smoot | onal unt a F [, a The starter circuit applies voltage to the starter relay when the starter switch is in the “start” position activating the relay and power is supplied to the starter main unit. In addition, the starter relay operating voltage is sent to the engine control module (ECM) as a starter operating signal and is used for controling start of the engine. For trucks with Smootner-, starting ot engine may be restricted using the neutral inhibitor function, Diagnostic Aids + Start system abnormalities (starter, starter relay, Starter ciruit, battery ate.) + Engine control system down (ECM, power supply, voarnality etc.) grou + Supply pump abnormality (main unit, PCV, feed pump) + Injector abnormality + Fuel rail abnormality + Fuel system abnormally + Intake air system abnormality + Exhaust system abnormality + Engine body abnormality Corel eon The following numbers show the step numbers of the diagnostic chart 2. Inspect the starter body, starter switch, starter relay, neutral relay. and circuit ate. and perform any necessary repairs andior replacements. In addin. inspect the flywheel (ring gear) and if there are any abnormalities, perform needed repairs and/or replacements. 3. _ Inspect for the amount of fuel, air removal, fuel piping ete. and if there are any abnormalitics, perform needed repairs and/or replacements. 4. Inspect the air intake pipe, and air cleaner and if there are any abnormalities perform any needed 5. Inspect the exhaust brake and exhaust brake magnetic valve etc, and if there are any abnormalities perform any needed repairs and) or replacements, 1A-104 _ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Step ction value(s) Yes No ‘Check battery voltage. Recharge or replace if there is battery voltage 1 | (specific gravity) abnormally. - Is the action complete? Goto Step 2 - Make sure the starter operates propery. 1, Make sure the starter operates when the Starter switch is turned to the “star” position and if it does not operate, perform needed repairs + For vehicles with Smoother-G check the DTCs for each system and if an 2 issue is found, perform inspections - and repair ((eference comesponding repair manual), + Reference engine mechanical repair manual section 1€ and perform needed inspections and repairs. Is the action compiate? Golo Stop 3 7 ‘Check the fuel system. 3 = Goto “Checking Is the action complete? Goto Step 4 | the fuel system™ ‘Check the air intake system. Go to “Checking 4 = the air intake Is the action complete? Goto Step 5 ‘ystem" ‘Cheok the exhaust aystom: Goto “Checking 5 - the exhaust Is the action complete? cle cise sere ‘Check the fuel injection timing 4. Inspect the mechanical timing at two locations of the supply pump and the crank pulley. + Supply pump (coupling) 6 Matching of inscribed line with the _ + Crank pulley: BTDC 0° 2. Make adjustments if there is an abnormality with the mechanical timing. Is the action complete? Goto Step 7 - Check whether DTC is detected. {DTCs that stoo engine based on backup control) 4. Connect the sean tool 7 | 2. Check whether or not the folowing DTCs are detected DTC: P0014, P0015, P0033, P0035, Pout, PUU/Z, PUTTS, PUIS8, PUTD=Y, P0227 Is DTC detected? Go to applicable pTc Go to Step 8 Engine Control System (6WE1-1 6WG1-TC(Common Rail)) 1A-105 ‘Step ‘Action Value(s) Yes No 7. Chock the mechanical aroas of tho engine and if there are any problems, + Valve system + Compression pressure + Timing gear + Piston and crankshaft Is the action complete? Go to Step 9 Restore the vehicle and Verily repair Is the action complete? Verify repair 1A-106 _ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Checking the fuel system Legend 1. Fuel fiter 2. Flow damper 3. Injector 4. Fuel pipe 5. Overflow valve 6. Fuel tank 7. PCV 8. Supply pump 9. Field pump 40. Pressure limiter 11. Fuel pressure sensor 12. Fuel ral Circuit Description ‘Tha fuel system is separated into the high pressure system and the low pressure system. The high pressure system describes the area between the supply pump, the fuel rail and the injectors. The low pressure side describes the area between the tank and the supply pump as well as the fuel retum. There are fuel system. In addition in order to prevent discharge of fuel, there is a flow damper and a proscure limiter installed in the fuel rail and an over flow valve installed in the supply pump to provent discharge of fuel. Diagnostic Aids + Air getting into the fuel piping + Pressure limiter, flow damper (operation, internal seal ability deterioration etc.) + Injector intemal malfunction + Supply pump internal failure (internal seal ability deterioration etc.) + Feed pump failure + Tuo! system pipe maifunetion (fue! leak, blockage, crushed pipe etc.) + Fuel titer abnormality (blockage, overtiow valve failure etc.) + Fuel tank matfunction (blockage, amount of fuel, additional tank ete.) + Fuel freezing + Amount and gualily of fuel Test Description The following numbers show the step numbers of the diagnostic chart: Engine Control System (6WF1-1C,6WG1-1C(Common Rail) Remove air from the fuel systam (law prassura side). Separation of air removal operation into low prassiire and high pressure areas makes it easier to determine areas with abnormalities. 4, 1A-107 Remove ait from the fuel system (high pressure side). As air removal from the high pressure side is performed through operation ofthe injectors, it can not be performed if there is an abnormality with engine control Step ‘Action Value(s) Yes No Tnepect the amount of fual Is there sufficient fuel? zt Filling with fuel, Goto Step2 | and goto Sten 2 Inspect the quality of the fuel. 1. _Liscnarge some tue! trom tne tue! tank. 2. Fill with fuel to the designated amount, 3. Remove air from the fuel piping. 4, Stail the engine. Did the engine start? Goto Step 7 Goto Step 3 Remove air from the fuel piping (work performed oniy wits he priming pump). (Air removal areas: between the fuel tank - feed pump - fuel ‘iter - supply pump). in addition, if fuel isnot supplied to the fuel fier, inspect the supply pump over tow vaive ana it there is an abnormality, replace the pump. It tnere is not an aonormality with te over flow valve, connect the fuel hoses on top the tue! tank (in and out) backward and remove air and if fuel is seen, reference step 7 and inspect the fuel tank Is the aotion complete? Golo Slep 4 7 Make sure the fuel filter is normal (Main fue! fiter) If the fiter is dirty or plugged, clean or replace the filter. Is the action complete? Goto Step 5 - Check the fuel piping and also inspect for fuel leaks. Inspect the fuel piping for crushina. breaks. cracking, looseness, and for abnormalities of the filter inside the pump section such as accumulation of filth and if there are any abnormalities perform any needed repairs and/or replacements, Is the action complete? Go to Stop 6 = 1A-108 _ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Step Action Value(s) Yes No 1 Chock the fuel tank + Are there any foreign materials inside ne tank? (Is the fuel suction opening blocked?) + Is the fuel suction pipe bent? + Are there cracks in the fuel suction pipe? 6 + Is the fuel tank deformed? a + Is the tuel tank mounted correctly? + Are the fuel tank cap and air removal hole plugged? + Is there water in the fuel tank? 2. If there are any abnormalities with the juei unk perionm any needed repairs and/or replacements, Is the action complete? Go to Step 7 = Restore the venice (0 IS inital state, remove 7 | alr from the fuel lines again and Verify repair _ Is the action complete? Verify repair = Air removal method Fuel filter 4. Tur the supply pump priming pump cap until it fips up, 2. Loosen the air removal plug on the fue! filter Operate the priming pump to discharge ait bubbles ‘rom the air removal plug. 4. In addition, operate the priming pump and when air bubbles are no longer discharged from the air removal plug, tighten the air removal plug. 5. Tighten the supply pump air removal olug 6. Operate the priming pump to discharge air bubbles 7. In addition, operate the priming pump and when air bubbles are no longer discharged trom the alr removal plug, tighten the air removal plug. 8. After tightening all of the plugs, push the priming ump over 150 times, 9. Return the priming pump cap to its original position and cecurely tighten the cap 40. Wipe up spilled fuel, start the engine and make sure there are not any fuel leaks. Here, if the engine does not start, repeat starting from step 8. Legend 1. Air removal piug Engine Control System (6WF1-1C,6WG1-TC(Common Rail)) 1A-109 ‘Supply Pump Legend 1. Priming pump 2, Air removal plug 3. Supply Pump 1A-110__ Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Checking the intake air system | (say Ale GA ° sh og mi L en bs | / [ie | / fie 5 5 : z Bo | Circuit Deseri The air intake system starts with air intake through the air cleaner and air is supplied through the turbo charger, the intake cooler and then to the engine. As air pressure Is increased using a turoo charger, alr leaks In the ducts will adversely affect engine performance. ‘An indicator 1s mounted on the air cleaner tnat detects air intake conditions (such as dirtiness of the fiter). If the air cleaner is detected as being dirty or plugged, the indicator signal area will turn red providing notification ‘The VGS magnetic vaive is used to supply air to the VGS air cylinder. Controlling the air supply to the air cylinder enables the air cylinder for the VGS to be appropriately controlled. Diagnostic Aids + Air fiter plugged + Abnormality with air damaged) + Abnormaity with the intake cooler duct (crushed, damaged, mounting failure) + Abnormaity with intake cooler body + VGS turbo abnormality (operation failure, air cylinder does not return) intake duct (crushed, The following numbers show the step numbers of the diagnostic chart: 1. Check to see if the air cleaner is dirty or plugged. If there is an abnormality, perform necessary cleaning and/or replacement. Also, the rnnalifion of the air cleaner can be inspected using the indicator. 7. An abnormality with the intercooler duct will cause problems with the boost pressure and adversely affect engine performance; therefore, carefully inspect clip position and direction and. how the duct ie mounted ete, Engine Control System (6WF1-C,6WG1-TC(Common Rail) 1A-111 Step ‘ation Value(s) Yes, No Check the condition of the air cleaner, (inspect the indicator and whether or not the filter is dirty) Is the air cleaner status normal? Go to Step 3 Go to Step 2 Clean or replace the air cleaner. Is the action complete? Go to Stop 3 Tnspect inside the air cleaner case to make sure there is not any water or fith. Is the inside of the case clean? Go to Step § Goto Step 4 Clean inside the air cleaner case or inspect the water removal valve. If there is an abnormality such as being plugged. nerfarm any necessary repair andlor replacements. Is the action complete? Go to Step 5 Inspect the intake air duct for crishing, looseness, or damage. Is the air intake duct normal? Go to Step 7 Goto Step 6 areas of the intake air duct Is the action complete? Go to Step 7 Inspect the intake cooler duct for being crushed, looseness, damage, and mounting failuro Is the intercooler duct normal? Go to Step 9 Goto Step 8 Repair or replace the crushed for damaged areas of the intercooler duct. Is the action enmplete? Gata Step 9 Inspect the VGS turbo. 1, Connect the scan tool (Tech2), inspect the VGS valve operating condition using the VGS M/V test. 2. If an issue is found, inspect the valve for deposits, air cylinder return, and for air leakage and perform repairs as needed Was an issue found? Go to Step 10 10 Restore the vehicle and Verily repair Is the action complete? Verify repair 1A-112 Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) ‘Checking the exhaust system om 8 Q@ * @ ® a ei Te 10 0 or ] Eraine ea Assumed factors Power is supplied to the exhaust brake operation circuit + Exhaust brake error (air cylinder not returning with by fuse No. 13, When the exhaust brake switch exhaust brake left closed, etc, (Combination switch) is ON, signals are sent to the «Exhaust brake magnetic valve error Intensive contro unit. Or, signal (exhaust brake switch * Brake intensive control unit error signal) is also sent to engine control module (ECM) at the same time. The brake intensive control unit that elisa ail lela receives the signal operates the exhaust brake magnetic valve, and that operation signal's also sent to the ECM al the same time. Step ‘Action Value(s) Yes No. ‘Check exhaust brake operating status. 1. Turn the starter switch ON. 2. Start engine and leave in an idling state. 3. Unnook connector (PAT-terminal, green) inside inspection cover, 4, Turn exhaust brake switch lever to ON. Did the engine start and exhaust brake operate? Goto Step 10 Go to Step 2 Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 14-113 Step ‘Action Value(s) Yes No Tropost oxhaust brake awitch 1. Connect scan tool (Tech2). 2. Set the gear position to neutral. 3. Turn the starter switch ON 4, Inspect switch input with scan tool. 2 | 5. Operate exhaust brake switch at 8. Confirm on scan tool screen data display whether exhaust switch (ON, OFF) changes according to operation of the switch Does display change according to operation of switch? Goto Step 4 Goto Step 3 Check conduction at exhaust brake switch cirewit, and repair ar raplaca places with errors, 4. Combination switch body 2. Fuse No. 13 to connection switch 3. Connection switch to base harness ‘connector 4, Base harness connector to engine control | 5 Combination switch to floor (let) harness ‘connector at 6. Instrument (lower) hamess connector to seat hamess connector 7 Floor (left) hamass connactar to brake intensive control unit connector (A) 8. After repairing or replacing, use the connector (PA ‘-terminal, green) inside the inspection cover again to check exhaust brake operation Does the exhaust brake operate? Go to Step 10 Go to Step 4 7, Measure resistance of exhaust brake magnetic valve with a digital muiti meter (om). 4 + Between multimedia terminals: 34 - ul 400 + Between terminal and body: nO Are the resistance values normal? Goto Step 6 Goto Step 5 Replace the exhaust brake magnetic valve. After repairing or replacing, use the connector 5 | (PA ‘-terminal, green) inside the inspection ii cover again to chock exhaust brake operation, Does the exhaust brake operate? Goto Step 10 Goto Sten 6 1A-114 Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) Step Action Value(s) Yes No ‘Chock conduction at exhaust brake magnatis valve circuit, and repair or replace places with 1. Brake intensive control unit connector (A) to floor (let) hammess connector 2, Seat harness connector to instrument (lower) harness connector 3. Floor (left) hamess connecter to frame (Ft) hamess connector 4, Floor (lef) harness connector to ECM 8 | 5. Instrument (lower) harness connector to ca member harness connector Frame (Fl) hamess connertor in exhaust brake magnetic valve 8, After repairing or replacing, use the connector {PA 1-terminal, green) inside the inspection cover again to check exaust brake operation Does the exhaust brake operate? Gotostep10 | Goto Step7 Inspect the functioning of the exhaust brake magnetic valve 1, Connect scan too 2, Set the gear position to neutral 3. tum me starter switch ON. 4, Inspect switch input with scan tool 7 | 5. Confirm on scan tool data display - whather exhaust brake switch (ON, OFF) changes by disconnecting/connecting connector (PA ‘-terminal, green) inside inspection cover. Did the display change by disconnecting’ connectina connector (PA 1-lerminal. ream)? Goto Sten 8 Goto Seo 9 Replace the exhaust brake valve. 8 a Is the measure complete? Goto Step 10 7 Replace the brake intensive control unit, or check the brake intensive control unit power 9 | supply and GND circuit, and repair or replace _ if there are abnormaities. Is the measure complete? Goto Step 10 a Restore the vehicle and check repair 10 a Inspection ts the measure complete? complete Engine Control System (6WF1-1 {6WG1-1C(Common Rail)) 1A-115 Magnetic valve appearance, connector name and ‘Magnetic valve connector name cane Connector Signal name Magnetic valve appearance number 7 ‘Magnetic valve (coll) 2 Magnetic valve (ceil) rowotasten0t Magnetic valve resistance> Check area Resistance ‘Comments Z-type 132 34-400 Between magnetic valve coils connector Terbod a Botwoon magnotic valve coil and bod) ray) 2- y a iy terminal 2erbody Q Between magnetic valve coll and body NOTE: Resistance values vary depending on the magnetic valve temperature, 1A-116 Engine Control System (6WF1-TC,6WG1-1C(Common Rail)) Checking the EGR | (rsa) 1 \ 8 2 \ ie ° sh og mi 5! hee | Jucs, | / hse je Ve | RR : : : ; a Description of circuit EGR magnetic valves 1 and 2 are used as valves to supply air to EGR vaive air cylinder. EGR valves are controlled appropriately by controlling air supply. EGR magnetic valve power Is supplied through EGR magnetic valve fail safe relay, and connected to the engine control module (ECM) through the EGR magnetic valve, ECM controls individual EGR magnetic valves. It abnormalities are detected, it controls the EGR magnetic valve fall safe relay to stop power supply to individual EGR magnetic valves and stop controls, Diagnostic aids Check the connector for poor connection, and check to make ctira that thare are na ahnormalitise