Documente Academic
Documente Profesional
Documente Cultură
F&G-SERIES
ENGINE EMISSION
6HK1-TC (COMMON RAIL)
SECTION 6E
SECTION 6E
CONTENTS
SUBJECT PAGE
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 3
How To Proceed With Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 3
Customer Problem Analysis Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 4
Symbols And Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 5
Parts For Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 7
Fuel System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E- 9
Construction And Operation of Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-13
Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-16
Strategy Based Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-16
General Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-16
On Board Diagnostic (OBD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-17
Reading Diagnostic Trouble Codes Using A Tech 2 or Other Scan Tool . . . . . . . . . . . . . . . . . .............. . . . . 6E-18
System Parts Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-32
ECM System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-37
Location Of Sensor And Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-42
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-45
Appearance Of ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-45
Detail Of 40 Pins Connector For Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-45
Detail Of 80 Pins Connector For Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-45
Chart Of ECM Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-46
Connector Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-46
Diagnostic Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-51
Contents Of Diagnostic Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-51
Diagnostic Lamp Patterns In User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-51
Diagnostic Code Outputting In Dealer Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-51
How To Read Flashing Of The Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-52
Clearing Method Of Diagnosis Trouble Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-53
Typical Scan Data Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-54
Engine Data Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-56
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-59
Engine Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-60
Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-61
Engine Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-62
Surging, Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-63
High Idle Engine Speed/Engine Starts But Will Not Accelerate . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-64
Excessive White Or Blue Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-65
Excessive Black Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-66
Lack Of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-67
Tachometer Output Error (Not Available DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-68
Exhaust Brake Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-70
PTO (Power Take Off) Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-72
Vehicle Speed Sensor Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-74
Common Rail System Diagnostic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-77
OBD System Check Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. . . . . 6E-78
6E – 2 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
No MIL Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-81
MIL Will Not Flash Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-84
Engine Will Not Start Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-86
Check Fuel Injection And Timing Relation (Engine OFF) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-88
Check Supply Pump (Engine OFF) Diagnosis Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-90
Check Injector (Engine OFF) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-93
Check Fuel Pressure In Common Rail (Engine OFF) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-95
System Operation Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-97
Check Fuel Injection And Timing Relation (Engine Running) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-99
Check Supply Pump (Engine Running) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-101
Check Fuel Pressure In Common Rail (Engine Running) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-103
Check Injector (Engine Running) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-105
Check Fuel System (Flow Damper Perform Check) Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-107
Multiple DTCs Stored Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-109
ECM Diagnosis Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-113
Diagnosis Trouble Code List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-113
DTC 14 Pump Position Sensor Error (CAM Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-117
DTC 15 Crank Position Sensor Error (CKP Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-121
DTC 22 Intake Air Temperature Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-125
DTC 23 Engine Coolant Temperature Sensor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-129
DTC 24 Accelerator Pedal Position (APP) Sensor Error 1 And 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-133
(Accelerator Pedal Position sensor circuit / circuit performernce)
Procedure Acceleration Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-135
DTC 25 Vehicle Speed (VS) Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-139
DTC 28 PTO Accelerator Position Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-142
DTC 32 Boost Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-145
DTC 33 CPU Monitoring IC Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-150
DTC 34 Fuel Rate Data Error (No History Recorded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-152
DTC 35 Analog Digital Conversion Error And Charging Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-153
DTC 42, 32 High Boost Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-155
DTC 65 Low Boost Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-159
DTC 71 BARO Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-163
DTC 115 Common Rail Pressure Sensor Output Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-165
DTC 118 Common Rail Pressure Abnormal (Control System) 1st And 2nd Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-170
DTC 151 Common Rail Pressure Abnormal (Pump Over Pressure Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-175
DTC 158 Injector Driving System Error (Common 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-180
DTC 159 Injector Driving System Error (Common 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-185
DTC 211 Fuel Temperature Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-190
DTC 217 PCV 1 (Coil Or Harness) B+ Shortage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-194
DTC 218 PCV 2 (Coil Or Harness) B+ Shortage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-197
DTC 226 Supply Pump Non Pressure Supply Or Pressure Limiter Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-200
DTC 227 Supply Pump Non Pressure Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-203
DTC 245 Abnormal Common Rail Pressure (PC Sensor System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-206
DTC 247 PCV 1 (Coil Or Harness) Disconnect Or GND Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-211
DTC 248 PCV 2 (Coil Or Harness) Disconnect Or GND Shorted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-215
DTC 261 (Cylinder No. 1) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-219
DTC 262 (Cylinder No. 2) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-221
DTC 263 (Cylinder No. 3) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-223
DTC 264 (Cylinder No. 4) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-225
DTC 265 (Cylinder No. 5) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-227
DTC 266 (Cylinder No. 6) Flow Damper Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-229
DTC 271 (Cylinder No. 1) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-231
DTC 272 (Cylinder No. 2) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-234
DTC 273 (Cylinder No. 3) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-237
DTC 274 (Cylinder No. 4) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-240
DTC 275 (Cylinder No. 5) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-243
DTC 276 (Cylinder No. 6) Injector Side Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-246
DTC 416 Main Relay System Error (Short Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-249
DTC 417 Starter Switch Abnormal (Short Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-251
DTC 421 PCV Relay (R/L) System Error (Short Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-254
DTC 543 Over Speed Condition (Not Turn On MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-257
Engine Control Module (ECM) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-258
On-Vehicle Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-259
Working On Electrical Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-265
Notes For Working On Electrical Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-265
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-270
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 3
GENERAL DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.
Title side numbers are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
Adjustment, Repair
No Good
Verify Repair
OK
End
6E – 4 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
km
License No. Odometer Reading miles
Engine does
not Start Engine does not crank No initial combustion No complete combustion
Others
Dates Problem
Occurred
Constant Sometimes ( times per day/month) Once only
Problem Frequency
Other
Outdoor
Problem Occurs
Condition When
Normal Mode
(Precheck) Normal Malfunction code(s) (code )
DTC Inspection
Check Mode Normal Malfunction code(s) (code )
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 5
Buzzer
Switch
Meter
Ground
Consent
Condenser
Battery
Resistor
Coil
Crossed portion
Diode
F07MT001
6E – 6 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Abbreviations
MAG MAGNETIC
ME/CONN MEMORY ERASER CONNECTOR
MIL MALFUNCTION INDICATOR LAMP
M/V MAGNETIC VALVE
Wire Color
All wires have color-coded insulation. Red (Stripe color)
Single color
Outside diameter
Base color
Colored stripe Stripe color
Cross sectional area
Wire Size
The size of wire, used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size Outside diameter
and load capacity, shown below, are specified by SAE.
Electronic Control
LFW36ESH000101
Sensor System
Computer Actuator
(Accel Pedal Angle)
Acceleration Sensor Injector
(Injection Quantity,
CKP Sensor (Engine RPM) Injection Timing Control)
(Crank Position Sensor)
ECM Common Rail
Pressure Sensor
CMP Sensor (Pump Position Signal)
(Pump Position Sensor)
060M200052
6E – 10 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
3. System Configuration [1]
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Starter Signal Common Rail
Pressure Sensor
Flow Damper
Air Supply Pump
Cleaner
LFW36ELF000601
ECM
Flow Damper
Fuel
injection
Common Rail Pressure sensor Injector
·Injection Quantity
Control
4. System Configuration [2]
·Injection Timimg
Control
·Injection Pressure Common Rail
Control
Crank Position Sensor
(Engine Speed Pressure Limiter
Number of Revolutions)
Engine · Vehicle
Vehicle Speed
Sensor
·A/T Control
·Exhaust Break Control Accelerator Pedal Position Sensor
·TECH 2 COMMUNICATION Boost Sensor
·Water Temperature Sensor
·Fuel Temperature Sensor
·Intake Air Temperature Pump Position Sensor
BARO Sensor Supply Pump
(inside ECM) Sensor Cylinder Recognition
Sensor
Communication
Injection Rate Control
LFW36EXF000101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 11
6E – 12 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
CONSTRUCTION AND OPERATION OF The injector controls injection amount and time by
switching on and off a TWV (Two Way Valve). When the TWV
THE SYSTEM is switched on (to carry current), the fuel circuit is changed
The COMMON RAIL SYSTEM consists of a supply pump,
over to such a status that the high pressure fuel in the control
common rail, injector, ECM and sensors.
chamber may flow out through and outlet orifice. Owing to
The supply pump generates the fuel pressure in the
nozzle valve opening force caused by the nozzle side of high
common rail. Fuel pressure is controlled depending on the
pressure fuel, the needle valve is lifted to start fuel injection.
fuel amount discharged from the supply pump. The fuel
When the TWV is switched off (to cut current), the fuel circuit
discharge amount is controlled by means of PCV provided in
is changed over to such a status that the high pressure fuel is
the supply pump which is opened/closed in response to
flowed back through the inlet orifice into the control chamber.
electric signals from ECM.
Therefore, the needle valve comes down to stop fuel
The common rail receives and distributes the fuel pressure
injection.
made by the supply pump to each cylinder. Fuel pressure is
Thus, fuel injection time can be electronically controlled by
detected by means of a common rail pressure sensor
TWV switching on and fuel injecting amount, by TWV
installed to the common rail and is feedback controlled so that
switching off.
the instructed pressure value set according to engine speed
and load can agree with an actual pressure value.
The fuel pressure in the common rail is applied through the
injection pipe of each cylinder to the nozzle side and control
chamber of the injector.
TWV
Pressure
Injection
Inlet
Control
Piston
056MY00002
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 13
CAM sensor
040MY00007-1
6E – 14 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
3. Operation the amount of fuel that corresponds with the lifting of
A The PCV remains open during the plunger’s the plunger after the PCV closes becomes the
downward stroke, allowing the low-pressure fuel to discharge volume, and varying the timing of the
be drawn into the plunger chamber by way of the closing of the PCV (plunger pre-stroke) causes the
PCV discharge volume to vary, thus regulating the
B Even after the plunger begins its upward stroke, if common rail pressure.
the valve remains open because current is not A’ After surpassing the cam’s maximum lift, the plunger
applied to the PCV, the fuel that was drawn in returns begins its downward stroke, causing the plunger
via the PCV, without becoming pressurized. chamber pressure to decrease. At this time, the
C When current is applied to the PCV in order to close delivery valve closes, thus stopping the pumping of
the valve at the timing that accommodates the the fuel. In addition, because the current to the PCV
required discharge volume, the return passage valve is stopped, the PCV opens, allowing the low-
closes, causing the pressure in the plunger chamber pressure fuel to be drawn into the plunger chamber.
to rise. Thus, the pump assumes the condition given in “A”.
Accordingly, the fuel passe through the delivery
valve (check valve) to the common rail. As a result,
Discharge
πd2(H-h)
volume Q=
Suction process Delivery process 4
H
Cam lift h
Pre-stroke
Valve open
PCV Valve
operation closed
Delivery valve
Plunger
φd
A B C A'
040MY00008
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 15
Speed Limiter (SLD)
The speed limiter (SLD) is control in the ECM which limits
vehicle speed not to exceed a setting value.
The limit of vehicle speed is performed by fuel rate control
in the ECM. Fuel rate is controlled based on vehicle speed
signal and engine speed signal.
Vehicle speed signal is inputted to the speed meter control
unit (VSS control unit). The VSS control unit rectifies vehicle
speed signal according to vehicles and outputs the signal to
ECM and meter.
Engine speed is computed by the ECM based on the crank
position (CKP) sensor.
Meter
Other C/U
LFW36ESF000401
6E – 16 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Diagnosis
Strategy-Based Diagnostics No Trouble Found
This condition exists when the vehicle is found to operate
Strategy-Based Diagnostics normally. The condition described by the customer may be
The strategy-based diagnostic is a uniform approach to normal. Verify the customer complaint against another
repair all Electrical/Electronic (E/E) systems. The diagnostic vehicle that is operating normally. The condition may be
flow can always be used to resolve an E/E system problem intermittent. Verify the complaint under the conditions
and is a starting point when repairs are necessary. The described by the customer before releasing the vehicle.
following steps will instruct the technician how to proceed 1. Re-examine the complaint
with a diagnosis: When the Complaint cannot be successfully found or
1. Verify the customer complaint. isolated, a re-evaluation is necessary. The complaint
• To verify the customer complaint, the technician should be re-verified and could be intermittent as
should know the normal operation of the system. defined in Intermittents, or could be normal.
2. Perform preliminary checks. 2. Repair and verify.
• Conduct a thorough visual inspection. After isolating the cause, the repairs should be made.
• Review the service history. Validate for proper operation and verify that the
• Detect unusual sounds or odors. symptom has been corrected. This may involve road
• Gather diagnostic trouble code information to testing or other methods to verify that the complaint has
achieve an effective repair. been resolved under the following conditions:
3. Check bulletins and other service information. • Conditions noted by the customer.
• This includes videos, newsletters, etc.
4. Refer to service information (manual) system check(s). General Service Information
• “System checks” contain information on a system
that may not be supported by one or more DTCs. OBD Serviceability Issues
System checks verify proper operation of the The list of non-vehicle faults that could affect the
system. This will lead the technician in an organized performance of the OBD system has been compiled. These
approach to diagnostics. non-vehicle faults vary from environmental conditions to the
5. Refer to service diagnostics. quality of fuel used.
The illumination of the MIL (“Service Engine Soon” lamp)
DTC Stored due to a non-vehicle fault could lead to misdiagnosis of the
Follow the designated DTC chart exactly to make an vehicle, increased warranty expense and customer
effective repair. dissatisfaction. The following list of non-vehicle faults does
not include every possible fault and may not apply equally to
No DTC all product lines.
Select the symptom from the symptom tables. Follow the
diagnostic paths or suggestions to complete the repair. You Poor Vehicle Maintenance
may refer to the applicable component/system check in the The sensitivity of OBD diagnostics will cause the MIL to
system checks. turn on if the vehicle is not maintained properly. Restricted air
filters, fuel filters, and crankcase deposits due to lack of oil
No Matching Symptom changes or improper oil viscosity can trigger actual vehicle
1. Analyze the complaint. faults that were not previously monitored prior to OBD. Poor
2. Develop a plan for diagnostics. vehicle maintenance can not be classified as a “non-vehicle
3. Utilize the wiring diagrams and the theory of operation. fault”, but with the sensitivity of OBD diagnostics, vehicle
Call technical assistance for similar cases where repair maintenance schedules must be more closely followed.
history may be available. Combine technician knowledge with
efficient use of the available service information. Maintenance Schedule
Refer to the Maintenance Schedule.
Intermittents
Conditions that are not always present are called Visual/Physical Engine Compartment
intermittents. To resolve intermittents, perform the following Inspection
steps: Perform a careful visual and physical engine compartment
1. Observe history DTCs, DTC modes. inspection when performing any diagnostic procedure or
2. Evaluate the symptoms and the conditions described by diagnosing the cause of an emission test failure. This can
the customer. often lead to repairing a problem without further steps. Use
3. Use a check sheet or other method to identify the circuit the following guidelines when performing a visual/physical
or electrical system component. inspection:
4. Follow the suggestions for intermittent diagnosis found • Inspection all vacuum hoses for punches, cuts,
in the service documentation. disconnects, and correct routing.
Most scan tool, such as the Tech II have data-capturing • Inspect hoses that are difficult to see behind other
capabilities that can assist in detecting intermittents. components.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 17
• Inspect all wires in e engine compartment for proper Diagnostic Information
connections, burned or chafed spots, pinched wires, The diagnostic charts and functional checks are designed
contact with sharp edges or contact with hot exhaust to locate a faulty circuit or component through a process of
manifolds or pipes. logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the time
Basic Knowledge of Tools Required of assembly and that there are not multiple faults present.
NOTE: Lack of basic knowledge of this powertrain There is a continuous self-diagnosis on certain control
when performing diagnostic procedures could functions. This diagnostic capability is complemented by the
result in an incorrect diagnosis or damage to diagnostic procedures contained in this manual. The
powertrain components. Do not attempt to language of communicating the source of the malfunction is a
diagnose a powertrain problem without this basic system of diagnostic trouble codes. When a malfunction is
knowledge. detected by the control module, a diagnostic trouble code is
A basic understanding of hand tools is necessary to set and the Malfunction Indicator Lamp (MIL) is illuminated.
effectively use this section of the Service Manual.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
On-Board Diagnostic (OBD) the MIL you are already familiar with (“Service Engine Soon”
lamp). However, OBD requires that the it illuminate under a
Passive and Active Diagnostic Tests strict set of guide lines.
A passive test is a diagnostic test which simply monitors a Basically, the MIL is turned on when the ECM detects a
vehicle system or component. Conversely, an active test, DTC that will impact the vehicle emissions and performance.
actually takes some sort of action when performing diagnostic
functions, often in response to a failed passive test. Extinguishing the MIL
Connect the memory clear switch (Blue) one to two
Intrusive Diagnostic Tests second then disconnect the memory clear switch (Blue).
This is any on-board test run by the Diagnostic
Management System which may have an effect on vehicle Data Link Connector (DLC)
performance or emission levels. The provision for communication with the control module is
the Data Link Connector (DLC). It is located under the inner
Warm-Up Cycle part of right side instrument (The left side of steering column)
A warm-up cycle means that engine at temperature must panel behind a small square cover.
reach a minimum of 70°C (160°F) and rise at least 22°C
(40°F) over the course of a trip.
Enable Criteria
The term “enable criteria” is engineering language for the
conditions necessary for a given diagnostic test to run. Each
diagnostic has a specific list of conditions which must be met 3 1
before the diagnostic will run. “Enable criteria” is another way
of saying “conditions required”.
LFW36ESH000201
Decimal/Binary/Hexadecimal Conversions
All scan tool manufacturer will display a variety of vehicle
information which will aid in repairing the vehicle. Some scan
tools will display encoded messages which will aid in
determining the nature of the concern. The method of
encoding involves the use of a two additional numbering
systems: Binary and Hexadecimal.
The binary number system has a base of two numbers.
Each digit is either a 0 or a 1. A binary number is an eight digit
number and is read from right to left. Each digit has a position 3 1
number with the farthest right being the 0 position and the
farthest left being the 7 position. The 0 position, when
displayed by a 1, indicates 1 in decimal. Each position to the 2
left is double the previous position and added to any other
position values marked as a 1. 060M200030
9
TE
CH
2
AD
AP
TE
R
8
2
6
1
7
PS
8
W
1
LFW36ELF001001
Tech 2 Features 7. The Tech 2 can plot a graph when replaying a snapshot.
1 Tech 2 is a 12 volt system. Do not apply 24 volt. 8. Always return to the Main Menu by pressing the EXIT
2. After connecting and/or installing, the Vehicle key several times before shutting down.
Communications Interface (VCI) module, PCMCIA card 9. To clear Diagnostic Trouble Codes (DTCs), open
and DLC connector to the Tech 2, connect the tool to the Application Menu and press “F1: Clear DTC Info”.
vehicle DLC.
3. Make sure the Tech 2 is powered OFF when removing or
installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the Tech 1
Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and static
electricity, so care should be taken in the handling of the
card.
6E – 20 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Getting Started 8. The vehicle starter switch turns on.
• Before operating the Isuzu PCMCIA card with the Tech 9. Verify the Tech 2 power up display.
2, the following steps must be performed:
1. The Isuzu PCMCIA card (1) inserts into the Tech 2 (2).
2. Connect the adapter cable (6) to the DLC cable (3)
and the Tech 2 adapter (4).
3. Connect the DLC cable (3) to the Tech 2 (2).
4. Make sure the vehicle starter key is off.
5. Connect the adapter DLC cable (8) to the vehicle
DLC.
060RW009
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
Press (ENTER) To Continue
6. Select “3” position of the selective switch (9).
7. Switch the signal selective switch (5).
1 side : Use when taking in data from ECM to Tech 2. (ENTER)
ex) Programming (Upload Fuel Rate Data),
Data Display, Read DTC
2 side : Use when commanding from Tech 2 to F0 : Diagnostics
ECM.
ex) Programming (Download Fuel Rate F1 : Service Programming
Data), Special Functions, Clear DTC
F2 : View Capture Data
F3 : Tool Options
TE
CH
2
AD
F4 : Getting Started
AP
TE
R
2
(F0)
1
7
PS
8
W
1
Vehicle Identification
Select one of the following
Model Year(S)
2
(Model year ENTER)
060HY00235 LFW36ELH000101-1
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 21
Menu
• The following table shows, which functions are used the
available equipment versions.
Vehicle Identification
Select one of the following F0: Diagnostic Trouble Codes
F0: Read DTC Info Ordered By Priority
Vehicle Type(S)
F1: Clear DTC Information
(UB) Trooper, Bighorn
F1: Data Display
(UE) Rodeo/Amigo,Wizard/MU
F2: Snap Shot
(C*,E*,L*,F*) Heavy,MediumDuty
F3: Programming
Heavy,MediumDuty
( ENTER
) F0: Upload Fuel Delivery Rate Data
F1: Download Fuel Delivery Rate Data
(F0 ENTER)
Vehicle Identification
Select one of the following
Powertrain
LFW36ELH000201
6E – 22 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
DTC Special Functions
On OBD has two options available in the Tech 2 DTC This special functions of three menus:
mode to display the enhanced information available. A
description of the new modes, DTC Info and Clear DTC
Information. After selecting DTC, the following menu appears:
• DTC Info
Special Functions
• Clear DTC Information
F0 : Engine Output Controls
DTC Information Mode
Use the DTC info mode to search for store DTC F1 : Fuel System
information. There are two choices. The service manual may
instruct the technician to test for DTCs in a certain manner.
Always follow published service procedures.
To get a complete description of any status, press the
“Enter” key before pressing the desired F-key. For example,
pressing “Enter” then an F-key will display a definition of the
abbreviated scan tool status.
Engine
This selection will display all DTCs that have failed during
the present ignition cycle.
History
This selection will display only DTCs that are stored in the LFW36ESH000401
Data Display
System Voltage V
Vehicle Speed km/h LFW36ESH000601
LFW36ESH000801
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 23
Fuel System Test
LFW36ESH000501
060MX010
6E – 24 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Cylinder Power Balance Test RPM Control System Test
Tech 2 must be used for this test. Tech 2 must be used for this test.
Test Procedure: Test Procedure:
1. Connect Tech 2 to the vehicle DLC. 1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle. 2. Run the Engine at idle.
3. Select F1: Fuel System in the Application Menu. 3. Select F1: Fuel System in the Application Menu.
LFW36ESH000701 LFW36ESH000701
4. Select F0: Cylinder Power Balance Test in the Fuel 4. Select F1: RPM Control Test in the Fuel System.
System.
Fuel System
Fuel System
F0 : Cylinder Power Balance
F0 : Cylinder Power Balance
F1 : RPM Control
F1 : RPM Control
F2 : Pilot Injector Stop
F2 : Pilot Injector Stop
F3 : Fuel Pressure Control
F3 : Fuel Pressure Control
F4 : Injection Timing
F4 : Injection Timing
F5 : Injection Stop
F5 : Injection Stop
060MX020
060MX019
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 25
Pilot Injector Stop Test 5. Push “Off” soft key.
This test is conducted to check Pilot Injector operation for
proper operation.
Tech 2 must be used for this test.
Test Procedure: Pilot Injector Stop
1. Connect Tech 2 to the vehicle DLC. System Voltage V
2. Run the Engine at idle. Vehicle Speed km/h
3. Select F1: Fuel System in the Application Menu. Desired Idle Speed RPM
Engine Speed RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
Special Functions APP Sensor Learned Minimum V
Final Accelerator Opening %
F0 : Engine Output Controls
F1 : Fuel System
Quit Off
LFW36ESH001001
F4 : Injection Timing
F5 : Injection Stop
060MX018
LFW36ESH000701
6E – 26 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
4. Select F3: Fuel Pressure Control Test in the Fuel Injection Timing
System. Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
Fuel System 3. Select F1: Fuel System in the Application Menu.
F5 : Injection Stop
060MX017
LFW36ESH000701
LFW36ESH001101
LFW36ESH001401 060MX015
6. Control Fuel Pressure and check data list. 5. Push the “Off” soft key.
7. If the data list changes, the Fuel Pressure Control
System is normal.
LFW36ESH001301
Programming
IMPORTANT; The replacement ECM must be stored the
capture fuel rate data by Tech 2.
LFW36ESH000701
ECM Replace procedure
1. Ignition “ON”, Engine “OFF”.
2. Tech2 “ON”.
3. Push “ENTER” key, when the “Tech2” appeared display
screen.
4. Operate “▲ ▲“ or “▼
▼“ key, put on the high-light bar to the
“F0: Diagnostic”.
5. Operate “▲ ▲“ or “▼
▼“ key, put on the high-light bar to the
“Model Year(s)”, and push “ENTER” key.
6. Select “Heavy, Medium Duty” by operating “▲ ▲“ or “▼▼“
key.
6E – 28 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
7. Select “F0: Engine” and push “ENTER” key. 13. The message will be appeared on the Display Screen,
8. Select “6HK1 (Common Rail)” by operating “▲ ▲“ or “▼
▼“ and push “Confirm” soft key.
key, and push “ENTER” key.
9. Select “F3: Programming by operating “▲ ▲“ or “▼
▼“ key,
and push “ENTER” key.
10. Switch the signal selective switch to 1 side. Upload Fuel Delivery Rate Data
11. Select “F0: Upload Fuel Delivery Rate Data”, and push
“ENTER” key.
Programming
Upload successful!
F0 : Upload Fuel Delivery Rate Data
F1 : Download Fuel Delivery Rate Data
Confirm
LFW36ESH001901
No Yes
LFW36ESH001801 LFW36ESH002001
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 29
21. The message will be appeared on the Display Screen, Plotting Snapshot Graph
and push “Yes” soft key. This test selects several necessary items from the data list
to plot graphs and makes data comparison on a long term
basis. It is an effective test particularly in emission related
evaluations.
Download Fuel Delivery Rate Data
Snapshot Plot
No Yes 1 2 3 4 5
ECT
Desired Idle Speed
Engine Speed
LFW36ESH002101
Download successful!
Confirm
LFW36ESH002201
After confirming FLOW “MAIN MENU After confirming FLOW “MAIN MENU
DIAGNOSIS” -ID, select “DATA DIAGNOSIS” -ID, select “SNAP
DISPLAY” from APPLICATION MENU. SHOT” from APPLICATION MENU.
If “CONTINUE” is displayed
under screen after the screen
is changed, select.
060RX085
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 31
Flow Chart for Snapshot Replay (Plotting Graph)
060RX040
6E – 32 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
056MV042
Feed Pump
The feed pump built in the supply pump to fuel pump up
and supply fuel through fuel filter into the supply pump unit.
Feed pump inside rotor is driven by supply pump camshaft.
When the inside rotor starts to rotate, outside rotor also rotate
together with inside rotor. The outside rotor has more one
teeth number than inside rotor, therefore, inside rotor tooth
sliding on the face of inside tooth in the outside rotor during
them rotating. The fuel hold clearance of between outside
rotor and inside rotor tooth then fuel is pressed to be pushed
040MX003 out of discharge port.
1 4
040MX002
Legend
(1) From fuel tank (3) Outside rotor
(2) To fuel filter (4) Inside rotor
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 33
Coupling Common Rail
The coupling is a laminated type, serving to transmit the The common rail is installed to intake manifold, equipped
driving torque from the engine side to the camshaft of the with flow damper, pressure limiter, and common rail pressure
supply pump. sensor.
The common rail unit has a common fuel passage, fuel
passage holes, and installing threaded holes. The common
fuel passage is a through hole made in the common rail unit.
The common rail pressure sensor is installed at the left end of
the hole.
Flow Damper
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball
moves further toward the injector until the ball comes into
contact with the seat surface of the flow damper unit, thereby
shutting the fuel passages.
040MV049
056MV043
6E – 34 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Pressure Limiter Injector
The pressure limiter opens when abnormally high pressure The injector comprises a two-way solenoid valve, hydraulic
is generated, releasing the pressure. When the common rail piston, and nozzle. The solenoid valve controls the injection
pressure reaches approx. 170 MPa (1,734 kg/cm2), the amount, injection timing, and injection rate of fuel by
pressure limiter is actuated (opens), and when the pressure controlling the pressure in the control chamber.
drops to approx. 30 MPa (310 kg/cm2) later, it works to The nozzle is a multihole type with a injection starting
maintain the pressure, thereby enabling continuous running. pressure (valve opening pressure) of 8.7 MPa (85 kg/cm2).
The injection body is clamped. The cylinder head injection
part is provided with an O-ring by which the entry of engine oil
into the injector hole of the cylinder head is prevented.
6
4 5
040MV051
060MX044
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 35
Crank Position (CKP) Sensor Fuel Temperature (FT) Sensor
This sensor comprises a permanent magnet, coil, and iron The FT sensor is a thermister type installed in the casing
core and is installed to the flywheel housing. With the engine provided in the fuel return (from the injector) circuit.
started, the signal holes made on the outer periphery of the Change in fuel temperature is changed into a resistance
flywheel cut off intermittently the magnetic field made by the change signal and sent to ECM for optimization of fuel
magnet, thereby generating AC in the coil. injection control.
The signal holes on the flywheel are provided every 7.5°,
but 3 point is holeless. 90 pulses are outputted per 2 rotations
of the engine. By this signal, engine speed and 7.5°-based
crank angle can be detected.
056MV045
101MX00016
056MV044
6E – 36 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Boost Sensor BARO Sensor
The boost sensor is fixed on the cab back frame and is BARO sensor is located in the ECM.
connected to rear portion of inlet manifold by vacuum hose. The BARO sensor signal send to the ECM for optimization
The boost sensor generates voltage according to air of fuel injection control under vehicle operation high.
aspiration pressure and generation voltage is input to ECM
for boost sensor signal.
Vehicle Speed Sensor (VSS)
Vehicle Speed Sensor (VSS) is located on the
transmission.
VSS signal is used for PTO control. (Fuel injection control:
All speed map control)
LFW36ESH001201
060MX046
060MX123
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 37
KEY SW R/L;
STARTER
B1 S G M1M2 B2 P2 P1
OFF
ACC
ON
HEAT STARTER
START
M/T
BR LE
A/T
GENERATOR BATTERY
SW;SUB
STARTER R/L; SW;
NEUTRAL NEUTRAL
R/L;
PCV
R/L;
MAIN
CYL. CYL. CYL. CYL. CYL. CYL.
PCV1 PCV2 1 5 3 6 2 4
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000201
6E – 38 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Data Link
Connector
TACHO
METER
SW; SW;
DIAGNOSIS MEMORY
CLEAR
BARO Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 39
A/T
ST
ON
KEY SW
M/T
SW;
SUB
STARTER
R/L;
SW;EXH.
EXH
BRAKE
BRAKE
R/L;
R/L;
NEUTRAL
STOP LAMP
METER
SW;IDLE
CONT
SW; SW;
(AUTO/ EXH
NEUTRAL BRAKE
MNL) BRAKE
SW;IDLE LAMP
CONT
(UP/
DOWN) STOP M/V:
UP DOWN LAMP EXH.
R/L; BRAKE
STARTER
27 10 29 33 26 8 2
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000301
6E – 40 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
PTO
INTAKE ENGINE ACCELE- CAM CKP ACCELERATOR
AIR FUEL COOLANT RATOR COMMON RAIL SENSOR SENSOR PEDAL
TEMP TEMP TEMP POSITION BOOST PRESSURE (PUMP (CRANK POSITION
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR POSITION) POSITION) SENSOR
SIG SIG GND VCC SIG GND VCC SIG GND VCC SIG – + – + GND VCC ACC GND VCC ACC
2 2 2 1 1 1
53 52 66 30 64 56 72 61 55 73 71 62 77 58 49 76 57 48 46 54 63 45 44 41
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000401
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 41
M/T
VEHICLE
SPEED SENSOR R/L;
(VSS) PTO
PARKING (CLUTCH)
DIAG
BRAKE
LAMP
LAMP
(MIL)
R/L;A/T
ECU
SW;
SW; SW;
PARKING
CLUTCH PTO
BRAKE
PTO LAMP
M/V;PTO
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000501
6E – 42 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
ECT
53751E
01/05/07
060M200028-1
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 43
Transmission Type: M/T
INJECTOR
CKP Sensor
Boost Sensor
Pressure hose
LFW36EMF000701
INJECTOR
Boost Sensor
CKP Sensor
3 1
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 45
90 81 50 41 10 1
100 91 60 51 20 11
110 101 70 61 30 21
120 111 80 71 40 31
LFW36EMF000901
2 4 6 7 8 10
0.5 0.5 0.5 0.5 0.5 0.5
LY B RL RG L PG 20
13 16 19
1.25 0.5 0.5
21 VW Lg LB
21 22 23 24 25 26 27 29 30
1.25 1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5
Br Br VW BW LoB G P PB YB
31 32 33
1.25 1.25 0.5
BrB BrB BG
40 LFW36ESH000101
41 81
41 44 45 46 48 49 81 82 85 86 87 88 89 90
0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
Y L GyG Gy W R 60 B B LR LW L GR GW G 100
52 53 54 55 56 57 58 59 91 100
0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25 1.25
61 LR LW R Gy B B G B 101 RW RL
61 62 63 64 66 101 102 105 108 109 110
0.5 0.5 0.5 0.5 0.5 1.25 1.25 0.5 0.5 0.5 1.25
R R W R LB 80 RW B BrW LW Y RY
71 72 73 75 76 77 111 112 113 114 118 119 120
0.5 0.5 0.5 0.5 / / 1.25 0.5 0.5 0.5 0.5 1.25 1.25
G W W PL S S B RB WR LR Y RL RL
120
LFW36ESF000301
6E – 46 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
90 89 88 87 86 85 84 83 82 81 50 49 48 47 46 45 44 43 42 41 10 9 8 7 6 5 4 3 2 1
100 99 98 97 96 95 94 93 92 91 60 59 58 57 56 55 54 53 52 51 20 19 18 17 16 15 14 13 12 11
110 109 108 107 106 105 104 103 102 101 70 69 68 67 66 65 64 63 62 61 30 29 28 27 26 25 24 23 22 21
120 119 118 117 116 115 114 113 112 111 80 79 78 77 76 75 74 73 72 71 40 39 38 37 36 35 34 33 32 31
LFW36ESF000201
Connector
Connector Pin Connector pin assignment
number
33 Neutral Switch
34 –
35 –
40 pin 36 –
connector 37 –
38 –
39 –
40 –
41 Accelerator Pedal Position Sensor 1 (SIG)
42 –
43 –
44 Accelerator Pedal Position Sensor 1 Power Source (VCC)
45 Accelerator Pedal Position Sensor 1 Ground (GND)
46 Accelerator Pedal Position Sensor 2 Ground (GND)
47 –
48 Crank Position Sensor Positive (+)
49 Pump Position Sensor Positive (+)
50 –
51 –
52 Fuel Temperature Sensor (SIG)
53 Intake Air Temperature Sensor (SIG)
54 Accelerator Pedal Position Sensor 2 Power Source (VCC)
55 Common Rail Pressure Sensor Ground (GND)
56 Sensor System Ground
80 pin 57 Crank Position Sensor Negative (–)
connector 58 Pump Position Sensor Negative (–)
59 Case Ground
60 –
61 Boost Sensor (SIG)
62 Common Rail Pressure Sensor (SIG)
63 Accelerator Pedal Position Sensor 2 (SIG)
64 PTO Accelerator Position Sensor (SIG)
65 –
66 Temperature Sensor Ground (GND)
67 –
68 –
69 –
70 –
71 Common Rail Pressure Sensor (SIG)
72 Sensor System Power Source
73 Common Rail Pressure Sensor Power Source (VCC)
74 –
6E – 48 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Connector
Connector Pin Connector pin assignment
number
75 Vehicle Speed Sensor (SIG)
76 Crank Position Sensor Sealed
77 Pump Position Sensor Sealed
78 –
79 –
80 –
81 Power Ground
82 Power Ground
83 –
84 –
85 Injector 6 (Cylinder #4)
86 Injector 5 (Cylinder #2)
87 Injector 4 (Cylinder #6)
88 Injector 3 (Cylinder #3)
89 Injector 2 (Cylinder #5)
90 Injector 1 (Cylinder #1)
91 Battery Positive (Main relay)
92 –
93 –
94 –
80 pin 95 –
connector 96 –
97 –
98 –
99 –
100 Common 1
101 Battery Positive (Main relay)
102 ECM Ground
103 –
104 –
105 Diagnostic Lamp
106 –
107 –
108 Automatic Transmission Relay
109 Main Relay
110 Common 1
111 ECM Ground
112 Tachometer Output
113 Serial Data (J1708B) Scan Tool
114 Serial Data (J1708A) Scan Tool
115 –
116 –
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 49
Connector
Connector Pin Connector pin assignment
number
117 –
80 pin 118 Main Relay
connector 119 Common 2
120 Common 2
6E – 50 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Method to confirm the self-diagnosis code
(dealer mode)
The self-diagnosis code can be read from the flashing of
the indicator lamp (service engine soon).
Operation:
When the diagnosis switch (White) mentioned below is
connected, the indicator lamp will start flashing. The self-
diagnosis code can be read from the flashing of the indicator
lamp.
As to the method to read the self-diagnosis code, please
refer to the ‘How to Read the flashing of the indicator lamp’ as
mentioned later.
3 1
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 51
Diagnostic Indication
Contents of diagnostic indication
In accordance with the conditions of Diagnostic switch, the diagnostic lamp indications are changed over as follows:
056MV023
• Mode changeover between User mode, Dealer mode 1 and Dealer mode 2 is made immediately.
• Mode changeover between Dealer mode 1 and Dealer mode 2 is made after a round of DTC output.
Priority of indications
Lamp control by user mode, Dealer mode 1 and 2 > Lamp check control.
Note: Tolerance of difference between light on and light out time is +0.3 to –0.1.
6E – 52 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
2.4 1.2 0.6 1.2 0.6 0.3 0.6 0.3 0.6 0.3 2.4
ON
OFF
Figure of ten Figure of one
F06MV045
2.4 0.3 0.6 0.3 0.6 0.3 0.6 1.2 0.6 0.3 0.6 0.3 2.4
ON
OFF
Figure of hundred Figure of ten Figure of one
F06MV046
ON
OFF
Figure of ten Figure of one
F06MV047
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 53
Condition 1
Condition 2
056MV028
Condition 1:
Check the memory clear switch (Blue) “OFF”
3 1
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
Condition 2:
EEPROM data does not match its mirror data.
6E – 54 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
NOTE:
(✽1) Make sure the desired idle speed and actual idle speed in the data list on the Tech2.
When the engine is at idle, the desired idle speed is applied lower creation by ECM, the result is displayed 615 rpm.
When the actual idle speed is displayed about 614 rpm, the result is normal at idle.
6E – 56 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
System Voltage This represents the system voltage measure by the ECM at ignition feed.
Vehicle Speed Vehicle speed is computed by the ECM from the Vehicle speed sensor.
Desired Idle Speed The desired idle speed that the ECM is commanding. The ECM will compensate
for various engine loads based on engine coolant temperature, to keep the engine
at the desired speed.
Engine Speed Engine speed is computed by the ECM from the CKP sensor. It should remain
closed to desired idle under various engine loads with engine idling.
APP (Accelerator Pedal Position) Sensor The voltage being monitored by the ECM on the APP sensor signal circuit.
APP (Accelerator Pedal Position) Angle APP angle is computed by the ECM from APP sensor voltages. This should display
0% at idle and 100% at wide open throttle.
APP Sensor Learned Minimum This is displayed voltage for APP sensor idle position signal.
Final Accelerator Opening Final Accelerator opening is computed by the ECM from APP sensor voltages. This
should display 0% at idle and 100% at wide open throttle.
Atmospheric Air Temperature The atmospheric air temperature is displayed intake air temperature. The ECM
applies 5 volts to the intake air temperature sensor circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
ECT (Engine Coolant Temperature) The ECT is displayed engine coolant temperature. The ECM applies 5 volts to the
ECT circuit. The sensor is a thermistor which changes internal resistance as
temperature changes. When the sensor is cold (high resistance), the ECM
monitors a high signal voltage and interprets that as a cold engine.
Fuel Temperature The fuel temperature is displayed fuel temperature. The ECM applies 5 volts to the
fuel temperature sensor circuit. The sensor is a thermistor which changes internal
resistance as temperature changes.
BARO (Barometric Pressure) The BARO is displayed barometric pressure. The barometric pressure is used to
compensate for altitude difference. The BARO is mounted in the ECM.
Relative Boost Pressure The relative boost pressure is computed by the ECM from the boost sensor. The
boost sensor measures the change in intake manifold pressure from the engine
load.
Desired Rail Pressure The desired rail pressure that the ECM is commanding. The ECM will compensate
for rail pressure on APP angle.
Actual Rail Pressure This is displayed current rail pressure. The ECM will compensate for rail pressure
to desired rail pressure.
Amount Of Goal Pilot Injection This is displayed fuel rate for the pilot injection at engine idling. The ECM will
compensate for the amount of goal pilot injection by various sensor signals.
Fuel Rate This is displayed current fuel rate that the ECM is commanding. The ECM will
compute for the fuel rate by various sensor signal.
Balancing Rate Cyl 1 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Balancing Rate Cyl 2 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Balancing Rate Cyl 3 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 57
Balancing Rate Cyl 4 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Balancing Rate Cyl 5 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Balancing Rate Cyl 6 This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Main Injection Timing The main injection timing that the ECM is commanding. The ECM will compensate
for main injection timing by APP angle and various sensor.
Basic Injection Timing The basic injection timing that the ECM is commanding. The ECM will compensate
for basic injection timing by various sensor signals.
PCV (Pump Control Valve) Close Interval This is displayed PCV operation interval. The ECM will compute for the PCV
operation by various sensor signals.
Rail Pressure Feedback Control Time This is displayed PCV control timing. The ECM will compute for rail pressure feed
back control timing by rail pressure and various sensor.
PTO Accelerator Opening PTO accelerator opening is computed by the ECM from PTO accelerator position
sensor voltage. This should display 0% at idle and 100% at full position.
PTO Accelerator Sensor The voltage being monitored by the ECM on the PTO accelerator position sensor
signal circuit.
Starter Switch This is displayed operating status for engine starter switch.
Clutch Switch This is displayed operating status for clutch switch. (Manual transmission only)
Parking Switch This is displayed operating status for parking brake switch.
Idle Control Switch This is displayed operating status for idling manual switch.
Idle Down Switch This is displayed operating status for idling down switch.
PTO Idle Switch This is displayed operating status for PTO idle switch.
Memory Clear Switch This is displayed operating status for memory clear switch.
AT Relay This is displayed operating status for AT relay. (Automatic transmission only)
Transmission Switch This is displayed operating status for transmission switch. (Automatic Transmission
only)
M/V Exhaust Brake This is displayed operating status for exhaust brake M/V.
Flow Damper 1 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
6E – 58 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Flow Damper 2 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 3 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 4 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 5 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 6 This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Fuel Del. Rate Data No. 1 This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
Fuel Del. Rate Data No. 2 This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
Fuel Del. Rate Data No. 3 This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
Engine Crank Signal (CKP) This is displayed input signal status by the CKP sensor.
Injection Pump Signal (CAM) This is displayed input signal status by the CAM sensor.
Overspeed Number Of Time This is displayed times for engine over speed.
Overheat Number Of Time This is displayed times for engine over heat.
G (Pump) Sensor Installation Error Correction This is displayed CAM sensor installation error correction.
Highest Fuel Temperature The ECM applies 5 volts to the fuel temperature sensor circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
The highest fuel temperature which immobirized is displayed.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 59
Symptom Diagnosis
PRELIMINARY CHECKS COMMON RAIL SYSTEM & SYMPTOM
Before using this section, perform the “On-Board
DIAGNOSIS MENU:
Diagnostic (OBD) System Check” and verify all of the
• Engine hard starting
following items:
• Engine cranks but does not start
• The engine control module (ECM) and malfunction
• Engine will not start and run
indicator lamp (MIL) (Check Engine lamp) are operating
• Rough engine idling
correctly.
• Engine hunting
• There are no DTC(s) stored.
• Surging, hesitation
• scan tool data is within normal operating range. Refer to
• High idle engine speed
Typical Scan Data Values.
• Excessive white or blue smoke
• Verify the customer complaint and locate the correct
• Excessive black smoke
symptom in the table of contents.Perform the procedure
• Lack of power
included in the symptom chart.
• Air bleed error
• Fuel leakage
VISUAL CHECK • Tachometer output error
Several of the symptom procedures call for a careful visual • Exhaust brake error
check. This can lead to correcting a problem without further • PTO (Power Take Off) error
checks and can save valuable time. This check should • Vehicle speed sensor error
include the following items: • SLD (Speed Limiter) error
• ECM grounds for cleanliness, tightness and proper
location.
The possibility DTCs with symptom diagnosis
• Vacuum hoses for splits, kinks, and proper connections,
as shown on the “Vehicle Emission Control Information”
Description DTC(s)
label. Check thoroughly for any type of leak or restriction.
• Air intake ducts for collapsed or damaged areas. Engine hard starting 14, 15, 118, 158, 159, 227,
• Ignition component for cracking, hardness, and carbon 23, 22, 245
tracking. Engine cranks but does 35, 227, 158, 159, 118
• Wiring for proper connections, pinches and cuts. not start
Engine will not start and 14, 15, 217, 218, 247, 248,
INTERMITTENTS run (Refer to common 271, 272, 273, 274, 275, 276,
An intermittent problem may or may not turn on the rail system check) 158, 159, 115
malfunction indicator lamp (MIL) or store a Diagnostic Trouble
Code. DO NOT use the Diagnostic Trouble Code (DTC) Rough engine idling 14, 15, 35, 115, 118, 151, 158,
charts for intermittent problems. The fault must be present to (Refer to common rail 159, 217, 218, 245, 247, 248,
locate the problem. system check) 261, 262, 263, 264, 265, 266,
Most intermittent problems are caused by faulty electrical 271, 272, 273, 274, 275, 276,
connections or wiring. Perform a careful visual/physical check 23, 22
for the following conditions: Engine hunting 25, 28, 115, 118, 151, 245, 15
• Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out). Surging, Hesitation 211, 23, 22, 14, 15
• Improperly formed or damaged terminal. High idle engine speed/ 24, 35, 217, 218, 226, 227,
• All connector terminals in the problem circuit should be Engine starts but will not 245, 247, 248
carefully checked for proper contact tension. accelerate
• Poor terminal-to-wire connection. This requires
removing the terminal from the connector body to check. Engine run steady 416, 421
Road test the vehicle with a 5-8840-0366-0 Digital (Refer to common rail
Multimeter connected to a suspected circuit. An abnormal system check)
voltage when the malfunction occurs is a good indication that Excessive White or 71, 22, 23, 35
there is a fault in the circuit being monitors. Blue Smoke
Use a scan tool to help detect intermittent conditions.
Excessive Black Smoke 34, 115, 217, 218, 226, 245,
247, 248
Lack of Power 24, 25, 28, 32, 33, 34, 35, 42,
65,115, 118, 158, 159,
217, 218, 226, 245, 247, 248,
261, 262, 263, 264, 265, 266,
271, 272, 273, 274, 275, 276
Tachometer 15
Output Error
SLD Error 25
6E – 60 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
6 Did you find to contamination of diesel with gasoline, etc? — Replace fuel Go to step 7
7 Did you find any leakage on the fuel pump, injection pipe etc.? — Repair problem
part Go to step 8
8 Had you bleed air from fuel line? — Bleed air from
Go to step 9 fuel line
Engine Hunting
STEP ACTION VALUE YES NO
1 Was the “On-Board Diagnostic (OBD) system check” — Go to OBD
performed? System
Go to step 2 Check
5 Did you find gasoline contaminated with fuel? — Replace fuel Go to step 6
6 Did you find any breakage on the fuel pump, injection pipe — Repair/replace
etc.? problem part. Go to step 7
7 Are fuel filters (prefilter, gauze filter and fuel main filter) —
normal condition? Clean/replace
(The gauze filter is fixed in suction eye bolt on the supply problem fuel
pump.) Go to step 8 filter
9 Did you done bleeding air from fuel line? — Bleed air
Refer to bleeding fuel system on section 6C2 in this manual. from fuel
Go to step 10 line
11 Was the “PTO (Power Take Off) system” check performed? Go to PTO
Go to step 12 error check
Surging, Hesitation
STEP ACTION VALUE YES NO
1 Was the “On-Board Diagnostic (OBD) system check” — Go to OBD
performed? System
Go to step 2 Check
6 Did you find any damage on the fuel pump, injection pipe — Repair/replace
etc.? problem part. Go to step 7
7 Are fuel filters (prefilter, gauze filter and fuel main filter) —
normal condition? Clean/replace
(The gauze filter is fixed in suction eye bolt on the supply problem fuel
pump) Go to step 8 filter
11 Was the “PTO (Power Take Off) system” check performed? Go to PTO
Go to step 12 error check
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 65
2 Was fuel used within recommended specification? See owner’s Replace fuel
manual with
NOTE: Low cetane number fuel is used, may caused recommend
white smoke. Go to step 3 specification
2 Was fuel used within recommended specification? See owner’s Replace fuel
manual with
recommend
Go to step 3 specification
Lack of Power
STEP ACTION VALUE YES NO
DEFINITION:
Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part-way.
9 Did you find any damage on the common rail system? — Repair or
replace
problem part Go to step 10
TACHO
– + – + OUT
77 58 49 76 57 48 112
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000501
Circuit Description
When CKP sensor and CAM sensor instable (DTC not
indicated), tachometer output becomes abnormal.
If vehicle running performance is adversely affected, repair
the abnormality first.
Unless CKP sensor and CAM sensor signal both normal,
tachometer output not produced.
• ECM delivers shortwave of 4 pulse (0 – 5V) per a
rotation to tachometer.
• Tachometer do not produce output at 230 rpm or less.
• If checking by voltage, digital multimeter reads around
2.5V under engine idling, and 5V or 0V for output
abnormality.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 69
2 Measure waveform between pin number 112 and pin number 184Hz
111 at ECM side. Replace
Did the pulse appear? tachometer Go to step 3
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 70 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
A/T
ST
ON
KEY SW
M/T
SW;
SUB
STARTER
R/L;
SW;EXH.
EXH
BRAKE
BRAKE
R/L;
R/L;
NEUTRAL
STOP LAMP
METER
SW;IDLE
CONT
SW; SW;
(AUTO/ EXH
NEUTRAL BRAKE
MNL) BRAKE
SW;IDLE LAMP
CONT
(UP/
DOWN) STOP M/V:
UP DOWN LAMP EXH.
R/L; BRAKE
STARTER
27 10 29 33 26 8 2
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000301
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 71
2 Measure the voltage between pin number 8 and pin number 24V
111 during key switch “ON”, exhaust brake switch “ON” at
ECM side connector.
Was voltage within value? Go to step 4 Go to step 3
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 72 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
M/T
VEHICLE
SPEED SENSOR R/L;
(VSS) PTO
PARKING (CLUTCH)
DIAG
BRAKE
LAMP
LAMP
(MIL)
R/L;A/T
ECU
SW;
SW; SW;
PARKING
CLUTCH PTO
BRAKE
PTO LAMP
M/V;PTO
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000501
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 73
2 Did you find DTCs 14, 15, 24, 25, 35, 115, 118, 151, 158, 159, — Repair
217, 218, 226, 227, 245, 247, 248, 271 to 276? DTCs table first Go to step 3
6 Measure voltage between pin number 16 and pin number 111 24V
during key switch “ON” and PTO switch pressed at ECM side Replace PTO
connector. switch or repair
Was voltage within value? Go to step 7 wire harness.
7 Measure voltage between pin number 19 and pin number 111 24V Replace
during key switch “ON” and Parking brake lever pulled at ECM parking brake
side connector. switch or repair
Was voltage within value? Go to step 8 wire harness.
10 Check the PTO magnetic valve and PTO relay. — Replace PTO
Was a problem found? magnetic valve
and/or PTO
Go step 11 relay
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 74 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
VEHICLE
SPEED SENSOR
(VSS)
VSS
CONTROL UNIT
SIG
75
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000601
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 75
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 77
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Starter Signal Common Rail
Pressure Sensor
Flow Damper
Air Supply Pump
Cleaner
LFW36ELF000601
6 1. Ignition "OFF". —
2. Connect the scan tool.
3. Ignition "ON".
Was the power supply "ON" and engine data indicated
on the Scan tool ? Go to step 7 Go to step 11
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 81
KEY SW
B1 S G M1 M2 B2 P2 P1
OFF
ACC
ON
HEAT
START R/L; R/L;
MAIN P.C.V.
Diag
Lamp
GENERATOR (MIL)
B
R
L
E START MAIN BP+ PUMP PUMP
R/L CONT. CONT.
VALVE1 VALVE2
R/L;
BATTERY STARTER Key
24 118 109 91 101 22 21 32 31 23 13 105
SW;SUB
STARTER
R/L; A/T
NEUTRAL
SW;
NEUTRAL
LFW36ELF000801
3 1. Ignition “OFF”. —
2. Disconnect following fuses.
(Main, PCV, Warning lamp, meter) Verify repair
3. Probe circuits for an open or short. Go to “OBD
If a problem was found, repair as necessary. system check”
Was a problem found ? Diagnosis chart Go to step 4
7 1. Ignition “OFF”. —
2. Disconnect main relay.
3. Disconnect following fuses.
• Main, PCV, Warning lamp, meter
4. Probe following point for an open to ground and short to
voltage.
• Between fuse and main relay Verify repair
• Between main relay and ECM Go to “OBD
If a problem was found, repair as necessary. system check”
Was a problem found? Diagnosis chart Go to step 8
11 1. Probe for an open or short between meter and fuse. — Verify repair
If a problem was found, replace ECM. Go to “OBD
Was a problem replace the ECM ? system check”
Diagnosis chart Go to step 12
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 84 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
KEY SW
B1 S G M1 M2 B2 P2 P1
OFF
ACC
ON
HEAT
START R/L; R/L;
MAIN P.C.V.
Diag
Lamp
GENERATOR (MIL)
B
R
L
E START MAIN BP+ PUMP PUMP
R/L CONT. CONT.
VALVE1 VALVE2
R/L;
BATTERY STARTER Key
24 118 109 91 101 22 21 32 31 23 13 105
SW;SUB
STARTER
R/L; A/T
NEUTRAL
SW;
NEUTRAL
LFW36ELF000801
2 1. Ignition “OFF”. —
2. Disconnect ECM.
3. Probe lamp circuit between lamp and ECM for an open or
short. Verify repair
If a problem was found, repair as necessary. Go to OBD
Was a problem found ? System check Go to step 3
3 1. Ignition “ON”. —
2. If NO lamp, check meter and fuse. Verify repair
If a problem was found, repair as necessary. Go to OBD
Was a problem found? System check Go to step 4
4 1. Ignition “OFF”. —
2. Connect ECM.
3. Ignition “ON”.
4. Diag switch “ON”.
5. Check to see if MIL lamp is flashing.
Is the MIL flashing? Go to step 7 Go to step 5
5 1. Ignition “OFF”. —
2. Check following circuit for open or short.
• Between ECM and diag switch
• Between diag switch and GND Verify repair
If a problem was found, repair diag switch circuit. Go to OBD
Was a problem found? System check Go to step 6
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 86 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Starter Signal Common Rail
Pressure Sensor
Flow Damper
Air Supply Pump
Cleaner
LFW36ELF000601
4 1. Perform air bleed. Bleed air from fuel system. — Verify repair
2. Ignition “ON”, engine “ON”. Go to OBD
Did the engine start and run? System check Go to step 5
5 Was the “Fuel injection and timing relation (engine off)” check — Go to “Fuel
performed? Injection and
Timing Relation
(engine off)”
Go to step 6 Diagnosis chart
6 Was the “Check supply pump (engine off)” check performed? — Go to “Check
supply pump
(engine off)”
Go to step 7 Diagnosis chart
8 Was the “Check the fuel pressure in common rail (engine off)” — Go to “Check
check performed? the fuel
pressure
(engine off)”
Go to step 9 Diagnosis chart
– + – +
77 58 49 76 57 48
En g i n e C o n t ro l Mo d u l e ( E C M)
060MY00035
Check Fuel Injection And Timing Relation (Engine OFF) Diagnosis Chart
STEP ACTION VALUE YES NO
1 Check fuel injection timing. —
Refer to the timing mark in 6A and 6B sections. Verify repair
If timing was in correct adjust as necessary. Go to OBD
Was a problem found? System check Go to step 2
3 Check the CKP sensor and CAM sensor performance. CKP sensor
Probe resistance between the terminal of the sensor and the 109 – 143Ω
other terminal. (about 20°C)
If a problem was found, repair as necessary. CAM sensor
Was a problem found? 1850 – 2450Ω Verify repair
NOTE:When CAM-Sensor is replaced, the supply pump (about 20°C) Go to OBD
assembly must be replaced. System check Go to step 4
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
En g i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
5 Probe a circuit between the pump relay and PCV for an open —
or short to ground and short to voltage. Verify repair
If a problem was found, repair as necessary. Go to OBD
Was a problem found ? System check Go to step 6
7 Probe resistance between the terminal of the PCV and the 0.9 – 1.3Ω
other terminal. Verify repair
If a problem was found, replace the supply pump ASM. Go to OBD
Was a problem found ? System check Go to step 8
10 1. Remove the pipe between the fuel filter and the supply —
pump.
2. Check the gauze filter Verify repair
If a problem was found, clean up the filter. Go to OBD
Was a problem found ? System check Go to step 11
6E – 92 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 95
PRESSURE SENSOR
COMMON RAIL
Eng i n e C o n t r o l M o d u l e ( E C M )
056MX022
7 Replace ECM.
Was the action complete ? Verify repair —
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 97
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Starter Signal Common Rail
Pressure Sensor
Flow Damper
Air Supply Pump
Cleaner
LFW36ELF000601
4 Check the manual idle control switch circuit for an open or — Repair or
short. Replace.
If a problem was found, repair or replace as necessary. Go to OBD
Was a problem found ? System check Go to step 5
– + – +
77 58 49 76 57 48
Engi n e C o n t ro l Mo d u l e ( E C M)
060MY00035
6 • CKP Sensor —
1. Check flywheel condition.
(Distortion, scratch, etc.)
2. Clean up
3. If a problem was found, repair or replace as necessary.
• CAM Sensor
1. Replace supply pump. Check the
CKP and CAM
Did you check the CKP and CAM sensors ? Go to step 7 sensors
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
PRESSURE SENSOR
COMMON RAIL
Engin e C o n t r o l M o d u l e ( E C M )
056MX022
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 1. Engine “OFF”. —
2. Replace a injector of a cylinder with no change in the
working noize and RPM drop.
3. Engine “ON”
Was the action completed? Go to step 1 Complete action
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 107
Fuel Filter
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
060MY00052
2 1. Ignition “OFF”. —
2. Check the fuel high pressure pipe with operated flow
damper.
3. Check for leak at injector piping.
If the pipe has a leak, repair as necessary. Repair or
Did you the problem repair? Go to step 3 Replace
3 Check the balancing fuel rate “Engine data” with the scan tool. –5 – 5 Verify repair
If a problem was found, repair as necessary. Go to OBD
Was a problem found? system check Go to step 4
1 2
Ball
060MY00039
R/L; PUMP
CONT.
VALVE
R/L; MAIN
E n g i n e C o n t ro l Mo d u l e ( E C M)
81 82 111 102 59
R P- ECM- ECM- CASE
GND GND GND GND GND
R/L;
STARTER
START
STARTER
HEAT
ACC
OFF
ON
B
R
E
L
GENERATOR BATTERY
LFW36ELF000901
6E – 110 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
B Group
PTO
INTAKE ENGINE ACCELE- CAM CKP ACCELERATOR
AIR FUEL COOLANT RATOR COMMON RAIL SENSOR SENSOR PEDAL
TEMP TEMP TEMP POSITION BOOST PRESSURE (PUMP (CRANK POSITION
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR POSITION) POSITION) SENSOR
SIG SIG GND VCC SIG GND VCC SIG GND VCC SIG – + – + GND VCC ACC GND VCC ACC
2 2 2 1 1 1
53 52 66 30 64 56 72 61 55 73 71 62 77 58 49 76 57 48 46 54 63 45 44 41
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000401
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 111
C Group
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
D Group
060MX113
6E – 112 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Circuit Description Test Description
The Engine Control module(ECM) monitors varlous Number below refer to the step number on the diagnosic
sensors to determines the engine operating conditions. chart.
The ECM provides a sensor ground to all of the 1 If the multiple DTCs set,check the common circuit for
sensors.The ECM applies varlous sensors for a power supply. sensors ground or power supply as necessary, set ,refer
Multiple DTCs will set when the ECM detects a problem on to the DTC Chart.
conmmon use for the sensors ground or power supply. A group: 217, 218, 247, 248, 416, 417, 421
If the multiple DTCs set,check the conmmon circuit for B group: 14, 15, 22, 23, 24, 25, 28, 32,42, 65, 115,
sensors ground or power supply as necessary. 118, 151, 211, 245
The following group to be set for circuit. C group: 158, 159, 271, 272, 273, 274, 275, 276
A group: Power Supply Circuit D group: 33, 34, 35, 71
B group: Varlous Sensors and Injectors
C group: Varlous Sensors and Injectors
D group: Internal Circuit for ECM, Signal Cicuit for
ECM
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed–through wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ECM Diagnosis Trouble Codes
The following table lists the diagnosis trouble codes supported by this vehicle may be faulty; notify the scan tool manufacture of any DTCs displayed that are not
application. If any DTCs not listed here are displayed by a scan tool, the scan tool data included in the following table.
ECM Diagnostic Trouble Codes
Illuminate
DTC Description Refer to Fail safe Remarks
MIL
14 Pump Position Sensor Error 2 Check Fuel Injection Timing • When Crank Position sensor is normal, Mechanical injection timing error,
(CAM sensor) Relations, DTC table backs up by Crank Position sensor Engine reverse rotation identification
• When both failure, injection stops. impossible,
Pump Control Valve (PCV) control position shift,
Engine hard starting
15 Crank Position Sensor Error 2 Check Fuel Injection Timing • When Pump Position sensor is normal, Mechanical injection timing error,
(CKP sensor) Relations, DTC table backs up by Pump Position sensor Engine reverse rotation identification
• When both failure, injection stops. impossible,
Pump Control Valve (PCV) control position shift,
Engine hard starting, Fuel consumption cylinder
balance (FCCB) impossible,
Pilot fuel injection impossible,
Taken in error of common rail pressure
22 Intake Air Temperature (IAT) 3 Multiple DTCs stored (Ground At starting: IAT = –20°C White smoke in cold weather
Sensor Error circuit), DTC table Other = 20°C Engine hard starting in cold weather
23 Engine Coolant Temperature 3 Multi trouble stored (Ground Starting: Based on –20°C Engine hard starting in cold weather
(ECT) Sensor Error circuit), DTC table Other: Based on 80°C Idle unstable in cold weather,
White smoke in cold weather
24 1. Accelerator Pedal Position 1 DTC table Item 1, 2, 3 and 4:When one sensor is Lack of power, PTO engage impossible,
(APP) Sensor Error 1 normal, backup by normal sensor. Accelerator position sensor output signal error,
When both sensor are faulty accel. is Idle speed error.
fixed at 20%, however using an injection
2. Accelerator Pedal Position map for PTO mode.
(APP) Sensor Error 2 If a brake pedal is “ON”, the degree of
accelerator value will became 0%.
3. Accelerator Pedal Position
(APP) Sensor 1 Intermediate
Voltage Hold Trouble
25 Vehcle Speed Sensor Error 1, 3 DTC table The ECM records only DTC. Lack of power.(with SLD)
(VSS) Operation prohibition of PTO accelerator. No operation exhaust brake.
No operation PTO
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 113
Illuminate
DTC Description Refer to Fail safe Remarks
MIL
28 PTO Accelerator Position Sensor 3 DTC table When the sensor is faulty, is substitute Lack of power.
Error accelerator pedal of PTO accelerator. Engine hunting.
32 Boost Sensor Error 3 Multiple DTCs stored (Ground Based on relative pressure of 0 kPa. Lack of power,
circuit), DTC table Injection amount map is used for a fail PTO abnormal (common used power source)
safe mode.
33 CPU Monitoring IC 1 System check, DTC table Injection amount limited to 80 mm3/st. Lack of power, Rough engine idling
Error (ECM inside trouble)
34 Fuel Rate Data Error (No History 1 DTC table, Scan tool operation Q (Fuel Rate Data) adjustment data Lack of power, Black smoke, Poor fuel
Recorded) No.8 selected economy
35 A/D Conversion Error (ECM 1 System check, DTC table Analog sensor abnormality decision Lack of power, Rough engine idling, Engine
inside trouble) stops and fail safe mode stall
42 High Boost Abnormal 3 DTC table Injection amount map is used as a fail Lack of power,
safe mode. PTO abnormal (common used power source)
65 Low Boost Abnormal 3 DTC table Injection amount map is used as a fail Lack of power,
safe mode. PTO abnormal (common used power source)
71 BARO Sensor Error 3 DTC table Based on the atmospheric pressure of Injection timing abnormal, White smoke,
100 kPa. Boost compensation don’t work
115 Common Rail Pressure Sensor 3 Check fuel pressure in a common Same as DTC P245 Lack of power, Black smoke, Both of fuel pressure
Output Fixed rail, DTC table and engine hunting
118 1. Abnormal Common Rail Pressure 1 Check fuel pressure in a common Same as DTC P245 Lack of power, White smoke,
(Control System 1st Stage) rail, DTC table Both of fuel pressure and engine hunting ,
PTO engage impossible,
2. Abnormal Common Rail Pressure Engine hard starting , Fuel leakage,
(Control System 2nd Stage) Engine stop (2nd stage)
151 Abnormal Common Rail Pressure 1 Check fuel pressure in a common Same as DTC P245 Lack of power, White smoke,
(Pump Over Pressure Supply) rail, DTC table Both of fuel pressure and engine hunting ,
158 Injector Driving System (common 1 Check Injector, DTC table • Constant current control by common 1 Rough engine idling, Lack of power, Engine
6E – 114 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
211 Fuel Temperature Sensor Error 3 Multi trouble stored (Ground Backup control by water temperature Common rail pressure guard impossible in high
circuit), DTC table sensor fuel temperature
Starting: Based on –20°C Black smoke (at Engine start)
Other: Based on 80°C
217 Coil or Harness for PCV1 are 1 Check supply pump, DTC table Abnormally high driving voltage Lack of power, Black smoke
Shorted generated PCV off, the target pressure
limited to 60 MPa or less.
218 Coil or Harness for PCV2 are 1 Check supply pump, DTC table Abnormally high driving voltage Lack of power, Black smoke
Shorted generated PCV off, the target pressure
limited to 60 MPa or less.
226 Supply pump does not Supply 1 System check, Check supply • Injection amount limit is 60 mm3/st. Lack of power, Black smoke
Pressure and/or Pressure Limiter pump, Check fuel system, DTC • Target common rail pressure is lower
Activated table than 25 MPa.
227 Supply pump does not Supply 1 System check, Check supply • Fuel injection value lower than 60 Engine stall, Engine hard starting
Pressure (Fuel Leakage) pump, Check fuel system, DTC mm3/st.
table • Common rail pressure lower than 25
MPa.
• Time required for running into backup
is varied with the difference common
rail pressure against target pressure.
245 Abnormal Common Rail Pressure 1 Check fuel pressure in a common Limits are set to common rail pressure Lack of power, Black smoke, Both of fuel
(PC Sensor System) rail, DTC table open loop control, common rail pressure pressure and engine hunting,
and injection amount. PTO engage impossible
Common rail pressure: 60 MPa
Injection amount: 50 mm3/st
247 PCV1 Coil or Harness Disconnect 1 Check supply pump, DTC table Common rail pressure is limited to 60 Lack of power, Black smoke
or Ground Shorted MPa or less.
248 PCV2 Coil or Harness Disconnect 1 Check supply pump, DTC table Common rail pressure is limited to 60 Lack of power, Black smoke
or Ground Shorted MPa or less.
261 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 1 Flow Damper Activated leakage
262 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 2 Flow Damper Activated leakage
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 115
Illuminate
DTC Description Refer to Fail safe Remarks
MIL
263 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 3 Flow Damper Activated leakage
264 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 4 Flow Damper Activated leakage
265 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 5 Flow Damper Activated leakage
266 Damper is Activated for Cylinder 3 System check, DTC table Cylinder injection stops Rough engine idling, Lack of power, Fuel
No. 6 Flow Damper Activated leakage
271 Open Circuit on Cylinder No. 1 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/stt. Rough engine idling, Lack of power
injector side Hard start
272 Open Circuit on Cylinder No. 2 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/st. Rough engine idling, Lack of power
injector side Hard start
273 Open Circuit on Cylinder No. 3 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/st. Rough engine idling, Lack of power
injector side Hard start
274 Open Circuit on Cylinder No. 4 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/st. Rough engine idling, Lack of power
injector side Hard start
275 Open Circuit on Cylinder No. 5 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/st. Rough engine idling, Lack of power
injector side Hard start
276 Open Circuit on Cylinder No. 6 at 1 Check Injector, DTC table Injection amount limited to 80 mm3/st. Rough engine idling, Lack of power
injector side Hard start
416 Main Relay System Error (No 2 Engine run steady, DTC table Only diagnostic lamp (Flashing lamp) Battery consume, The system will not turn off
History Record) can be lighted by key current.
417 Starter Switch Abnormal 3 Engine Not Run, DTC table — Startup additional fuel injection don’t work,
Engine reverse rotation identification
impossible, Air breathing impossible, Stator
motor erroneous functioning
421 PCV Relay System Error 1 Check supply pump, DTC table Only diagnostic code memory. Bad battery consume,
Pump control valve (PCV) relay burned out or
failed
6E – 116 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
543 Over Speed Condition 3 DTC table Fuel injection stop. Fuel pressure feed Stored DTC in ECM
stop. Scan Tool only (No flash)
Illuminate MIL
1 Turn on lamp is starter switch ON.
2 Turn on lamp after engine is running more than 20 second.(at idle)
3 Not turn on lamp.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 117
CAM SENSOR
(PUMP
POSITION)
- +
77 58 49
Engi n e C o n t r o l M o d u l e ( E C M )
060MY00028
Circuit Description Diagnostic Trouble Code 14 will set when the ECM detects
a no signal for open circuit or sensor damage on the CAM
CAM sensor is installed at the side of the supply pump,
sensor signal circuit.
serving to distinguish the cylinders of the engine and back up
the detection of engine speed (in case of CKP sensor
trouble). Conditions for Setting the DTC
This CAM sensor comprises the same parts as in CKP • CKP sensor pulse (Crank position, 450 times of pulse
sensor, but the number of turns of its coil is different from that input) is normal, there is no CAM sensor pulse input.
of CKP sensor and installed to the supply pump. • When CAM sensor pulse is inputted over specified cycles.
With the engine started, the pulser notches in the middle of
the supply pump camshaft cut off intermittently the magnetic
field made by the sensor magnet, thereby generating Action Taken When the DTC Sets
alternating current. • The ECM will illuminate the malfunction indicator lamp
The pulser notches are made every 60° of camshaft (every (MIL) the first time the fault is detected.
120° of crank angle) and there is a surplus tooth. • When CKP sensor (pump position) is normal, backs up by
Therefore, seven pulses are outputted per one rotation of CKP sensor.
camshaft (2 rotations of the engine). The pulse outputted by • When both fail, injection stops.
the surplus tooth is recognized as engine number 1 cylinder
reference pulse.
6E – 118 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
6 Measure shortage between CAM sensor terminal and CAM More than Replace CAM
sensor body. (Measuring method 4) 10MΩ sensor then
Is resistance within the value? Go to step 9 Go to step 9
Note:
• As compared with CAM sensor, CKP sensor is difficult
to detect trouble because its influence is smaller.
• An Intermittent condition can be caused by the
following
• Poor connections
• Rubbed through wire insulation
• There are two countermeasure for CAM sensor error,
one is CAM sensor replacement and the other is
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 120 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
49P
B 58P
A
View B 90 41
E
1 2 C
120 71
M
View A
Measuring method 5
Measurement
CAM SENSOR E
C
M
Harness
Measuring method 6
Measurement
CAM SENSOR E
C
M
Harness
ECM
CAM SENSOR 49
(PUMP POSITION)
58
77
LFW36EXF000201
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 121
CKP SENSOR
(CRANK
POSITION)
- +
76 57 48
Eng i n e C o n t r o l M o d u l e ( E C M )
060MY00029
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
NOTE: Air gap value is 0.9 to 1.2 mm between CKP sensor and flywheel. (Not adjustable)
6E – 124 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
48P
B 57P
A
View B 90 41
E
1 2 C
120 71
M
View A
Measuring method 5
Measurement
CKP SENSOR E
C
M
Harness
Measuring method 6
Measurement
CKP SENSOR E
C
M
Harness
ECM
CKP SENSOR 48
(CRANK POSITION)
57
76
FLW36EXF000301
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 125
SENSOR SENSOR
INTAKE ENGINE
AIR SENSOR COOLANT
TEMP FUEL TEMP TEMP
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
7 Measure resistance between pin number 53 and GND on the 10MΩ or more Repair/replace
IAT sensor harness. IAT sensor
Is resistance within value? harness.
Then go to
Go to step 8 step 10
9 1. Reconnect IAT sensor harness to ECM and IAT sensor. — Replace ECM
2. Clear DTC. assembly then
Is display DTC 22? Go to step 10 System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 128 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
66P
B View A 53P
A
View B 90 41
E
1 2 C
120 71
M
ECM
SENSOR
30
ENGINE COOLANT TEMP
66
SENSOR 5
FUEL TEMP
SENSOR 53
INTAKE AIR TEMP
FLW36EXF000401
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 129
SENSOR SENSOR
INTAKE ENGINE
AIR SENSOR COOLANT
TEMP FUEL TEMP TEMP
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
3 Measure the voltage between pin number 30 and pin number 0.1V to 4.8V
66 at ECM side while key switch “ON” and engine in
operation. (Measuring method 1)
Is voltage outside specified value?
(0.65V when water temp. about 80°C)
Note: When voltage abnormally high e.g. 24V, may be
short to voltage. Go to step 5 Go to step 4
7 Measure the resistance between pin number 30 and GND on 10MΩ or more Repair/replace
the ECT sensor harness. to ECT sensor
Is resistance within value? Go to step 8 harness
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 132 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
66P
B View A
A
View B 90 41
E
1 2 C
120 71
M
View A
30P 10 1
40 31
ECM
SENSOR
30
ENGINE COOLANT TEMP
66
SENSOR 52
FUEL TEMP
SENSOR 53
INTAKE AIR TEMP
FLW36EXF000501
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 133
ACCELERATOR SENSOR
46 54 63 45 44 41
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000201
Conditions for Setting the DTC Action Taken When the DTC Sets
Item 1. Accelerator • The ECM will illuminate the malfunction indicator lamp
Sensor Error 1 (MIL) the first time the fault is detected.
Item 2. Accelerator • Item 1, 2, 3 and 4: When one sensor is normal, backup by
Sensor Error 2 normal sensor.
Item 3. Accelerator • When both sensor are faulty accelerator is fixed at 20%,
Sensor 1 however using an injection map for ASC mode.
Intermediate throttle position voltage hold steady. If a brake pedal is “ON”, the degree of accelerator value
will became 0%.
6E – 134 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Damaged harness – Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
APP sensor display on the scan tool while moving
connectors and wiring harnesses related to the AP
sensor. A change in the APP sensor display will indicate
the location of the fault.
• Poor throttle response.
• No accelerator response.
• 1200 rpm fixed.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 135
056MV040
5
.)
EF
4
(R
5°
7.
∼
1°
VIEW A
2
056MV039
Legend
(1) Pedal Initial Position
(2) Sensor Set Position
(3) Sensor Travel (Deg.)
(4) Pedal Full Position
(5) Pedal Full Stroke Position
(6) Idling Side Sensor Set Position
6E – 136 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Note: After replacing the APP it is necessary to set voltage at idle position. (See page 6E-141 for procedure)
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 138 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
View A
View B A
1 2 3 90 46 45 44 41 41
54
E
63
4 5 6 120 71 C
M
ECM
41
44
ACCELERATOR 45
PEDAL POSITION
SENSOR 63
54
46
LFW36EXF000601
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 139
VEHICLE
SPEED SENSOR
(VSS)
VSS
CONTROL UNIT
SIG
75
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000601
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 141
View A
A
90 41
120 71 ECM
75P
View B
3P
Vehicle Speed
B
Sensor C/U
Measuring method 1 1 4
Measurement
5 12
VSS C/U
ECM 12P
Harness
10P
Measuring method 2
Measurement
VSS C/U VSS
ECM
Harness
ECM
Measuring method 3
VCC
Measurement
VEHICLE SIG VSS
VSS 75
SPEED C/U
VSS GND
SENSOR
C/U
Harness
LFW36EXF000701
6E – 142 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
PTO
ACCELERATOR
POSITION BOOST
SENSOR SENSOR
64 56 72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
6 Check the signal voltage of PTO accelerator position sensor. Sensor signal
1. Starter switch "OFF". position: 0.3 to
2. Reconnect the harness to PTO accelerator position 0.5V (Idle
sensor. Starter switch "ON". position)
3. Measure voltage between the signal wire and ground wire position: 4.2 to
at PTO accelerator position sensor side connector. 4.5V (WOT)
Was voltage within value? Go to step 7 Go to step 8
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 144 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
56P
64P
72P
B View A
A
View B 90 41
E
1 2 120 71 C
M
3 4
Measuring method 1
Measurement
PTO E
ACCELERATOR C
POSITION M
SENSOR Harness
Measuring method 2
Measurement
PTO E
ACCELERATOR C
POSITION M
SENSOR Harness
Measuring method 3
Measurement
E
PTO
C
ACCELERATOR
M
POSITION
Harness
SENSOR
ECM
PTO 64
ACCELERATOR
POSITION 72
SENSOR 56
LFW36EXF000801
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 145
PTO
ACCELERATOR
POSITION BOOST
SENSOR SENSOR
64 56 72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source voltage
of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 149
56P
72P
61P
B View A
A
View B 90 41
E
1 2 3 C
120 71
M
Measuring method 1
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 2
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR E
C
M
Harness
ECM
61
BOOST 72
SENSOR
56
LFW36EXF000901
6E – 150 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
060MX113
Circuit Description
The ECM supplies either 5 or 24 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low. The ECM
controls output circuits such as the injectors, ISC, etc.
The input/output devices in the ECM include analog-to-
digital converters, signal buffers, counters, and special
drivers. The ECM controls most components with electronic
switches which complete a ground circuit when turned “ON”.
Conditions for Setting the DTC
• Battery voltage higher than 16V after 0.5 sec. from
resetting, starter switch off continues for 300 ms, timer
pulse time abnormal continues over 50 times.
Action Taken When the DTC Sets
• The ECM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 151
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 152 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
060MX113
Compare to Fuel rate data (Q-data) chart on the cylinder Conditions for Clearing the MIL/DTC
head to the Fuel rate data (Q-data) on scan tool. DTC 34 can be cleared by using the “Clear Info” by scan
tool or using by the Diag Clear Switch.
Conditions for Setting the DTC
• EEPROM is not written to continues 0.2 sec. Refer to “Programming” of “Tech 2 Scan Tool” in this
manual.
Action Taken When the DTC Sets
• The ECM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
• Fuel rate data No. 8 selected (correction “0”).
2 Assume that fuel rate data may not be written to ECM after — Check scan
replaced ECM assembly. tool connection
Is the Fuel Rate data listed on the scan tool? and/or ECM
connection.
Then go to
step 4 Go to step 3
Note:
• When ECM assembly replaced, scan tool is required.
• Make sure that lamp is lighted when DTC 34 code is
set.
• When ECM replaced, down load fuel rate number from
the old ECM, and then input it into new ECM by scan
tool.
• If step 2 and/or 4 are intermittents, call ISUZU Tech
Line staff.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 153
060MX113
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 155
PTO
ACCELERATOR
POSITION BOOST
SENSOR SENSOR
64 56 72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source voltage
of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 158 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
56P
72P
61P
B View A
A
View B 90 41
E
1 2 3 C
120 71
M
Measuring method 1
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 2
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR E
C
M
Harness
ECM
61
BOOST 72
SENSOR
56
LFW36EXF000901
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 159
PTO
ACCELERATOR
POSITION BOOST
SENSOR SENSOR
64 56 72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source
voltage of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 162 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
56P
72P
61P
B View A
A
View B 90 41
E
1 2 3 C
120 71
M
Measuring method 1
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 2
Measurement
BOOST SENSOR E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR E
C
M
Harness
ECM
61
BOOST 72
SENSOR
56
LFW36EXF000901
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 163
060MX113
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 165
PRESSURE SENSOR
COMMON RAIL
Engine C o n t r o l M o d u l e ( E C M )
056MX022
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Damaged harness – Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
Rail pressure display on the scan tool while moving
connectors and wiring harnesses related to the Rail
pressure sensor. A change in the Rail pressure display
will indicate the location of the fault.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 167
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 169
55P
73P
62P
B View A 71P
A
View B 90 41
E
1 2 3 C
120 71
M
ECM
62
71
COMMON RAIL
PRESSURE 73
55
LFW36EXF001001
6E – 170 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
PRESSURE SENSOR
COMMON RAIL
Engin e C o n t r o l M o d u l e ( E C M )
056MX022
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Damaged harness – Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
display on the scan tool while moving connectors and
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault.
6E – 172 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
3 Measure the voltage following points. (Measuring method 2) Less than 0.1V Repair/replace
1. Disconnect common rail pressure sensor harness from common rail
both common rail pressure sensor and ECM. pressure
2. Check the harness for shorts to battery between pin sensor harness.
number 55 at ECM side. Then go to
Is voltage within value? Go to step 5 step 4
5 Measure the voltage while key switch “ON” as follow. 3.4V or more
(Measuring method 1) (at 125 MPa)
Between pin number 62 and 71 and pin number 55 at ECM
side. Go to step 9 Go to step 6
7 Is common rail pressure sensor voltage more than 3.4V when 3.4V or more Replace
key “ON”? common rail
pressure
sensor.
Then go to Go back to
step 8 step 6
10 Measure resistance between pin number 62 and 72 at ECM 10MΩ or more Replace Replace
side and GND on the common rail pressure sensor harness. common rail common rail
(Measuring method 3) pressure pressure
Is resistance within value? sensor. sensor harness
Then go to then
step 11 go to step 11
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 173
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 174 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
55P
73P
62P
B View A 71P
A
View B 90 41
E
1 2 3 C
120 71
M
ECM
62
71
COMMON RAIL
PRESSURE 73
55
LFW36EXF001001
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 175
DTC 151 Common Rail Pressure Abnormal (Pump over pressure supply)
PRESSURE SENSOR
COMMON RAIL
Eng i n e C o n t r o l M o d u l e ( E C M )
056MX022
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
• CKP sensor normal, pump normal mode, battery voltage
DTC 151 can be cleared by using the “Clear Info” by scan
more than 16V, engine revolution is 430 rpm or more.
tool or using by the Diag Clear Switch.
6E – 176 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
DTC 151 Common Rail Pressure Abnormal (Pump over pressure supply)
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Damaged harness – Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
Rail pressure display on the scan tool while moving
connectors and wiring harnesses related to the Rail
pressure sensor. A change in the Rail pressure display
will indicate the location of the fault.
• Poor condition - mechanical timing, Supply pump, Fuel
leak pipe, Fuel injection (High pressure) pipe
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 177
DTC 151 Common Rail Pressure Abnormal (Pump over pressure supply)
STEP ACTION VALUE YES NO
1 Was the “On-Board Diagnostic (OBD) System Check” — Go to OBD
performed? Go to step 2 System Check
2 Does the scan tool display DTC 151 while engine is running — Go to Fuel System
or when key switch “ON”? Check then
Go to step 3 Go to step 3
5 Check for an open circuit on the common rail pressure sensor — Reconnect or
harness connector. repair common
Is there a complete connection? rail pressure
sensor harness,
then
System OK Go to step 11
DTC 0151 Common Rail Pressure Abnormal (Pump over pressure supply)
STEP ACTION VALUE YES NO
10 Clear all DTCs then engine start. — Replace ECM
Is DTC 151 display? assembly.
Then go to
step 11 System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 179
DTC 151 Common Rail Pressure Abnormal (Pump over pressure supply)
55P
73P
62P
B View A 71P
A
View B 90 41
E
1 2 3 C
120 71
M
ECM
62
71
COMMON RAIL
PRESSURE 73
55
LFW36EXF001001
6E – 180 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display DTC 158 or DTC 159 while key — Go to
switch “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 184 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 185
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Poor condition of fuse, relay.
• No smooth rotation.
• Hard starting.
• Excessive smoke, etc.
• Lack of engine power.
• If Common 1 line and common 2 lines short-circuit, ECM
will set both of DTCs 158, 159.
• If harness (Injector to ECM) short-circuits between
Injectors circuit belonging to Common 1, DTC is not set
but engine may carry out hunching.
• If the harness between ECMs short-circuits from Injector
to GND, Engine may stop, DTC is set at this time.
• DTC is not set when the harness between ECMs short-
circuits on a battery line from Injector.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 187
2 Does the scan tool display DTC 158 or DTC 159 while key — Go to
switch “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 188 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 189
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
6E – 190 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
SENSOR SENSOR
INTAKE ENGINE
AIR SENSOR COOLANT
TEMP FUEL TEMP TEMP
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
2 Does the scan tool display DTC 211 while key switch “ON” or — Go to
engine running? Go to step 3 Diagnostic Aids
3 Measure the voltage between pin number 52 and pin number 0.1V
66 at the ECM while key switch “ON” and engine is running. to
(Measuring method 1) 4.8V
Is the voltage outside the specifical value?
(1.5V when fuel temp. about 60°C) Go to step 5 Go to step 4
7 Measure resistance between pin number 52 and GND. 10MΩ or more Repair/replace
(Measuring method 3) fuel
Is resistance within value? temperature
Go to step 8 sensor harness
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 193
66P
B View A 52P
A
View B 90 41
E
1 2 C
120 71
M
ECM
SENSOR
30
ENGINE COOLANT TEMP
66
SENSOR 52
FUEL TEMP
SENSOR 53
INTAKE AIR TEMP
LFW36EXF001201
6E – 194 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
En g i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
5 Repair the short to battery positive (B+) on the PCV input — Repair them.
circuit to ECM on the PCV harness Then go to
Did you repair them? Go to step 6 step 6
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 196 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
A 1
E B 4 2 3
C
M 5
View C
PCV1 View A View A 22P
82P 21P
View B 10 1
90 41
1 2
40 31
120 71
PCV2 32P
82P 31P
10 1
90 41
1 2
40 31
120 71
PCV E PCV E
C C
M M
Harness Harness
+B
ECM
PCV1 21
22
PCV2 31
32
82
LFW36EXF001301-1
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 197
KEY SW
BI S G MI M2 B2 P2 P1
OFF
ACC
ON
HEAT
START
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
5 Repair the short to battery positive (B+) on the PCV input — Repair them.
circuit to ECM on the PCV harness Then go to
Did you repair them? Go to step 6 step 6
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 199
A 1
E B 4 2 3
C
M 5
View C
PCV1 View A View A 22P
82P 21P
View B 10 1
90 41
1 2
40 31
120 71
PCV2 32P
82P 31P
10 1
90 41
1 2
40 31
120 71
PCV E PCV E
C C
M M
Harness Harness
+B
ECM
PCV1 21
22
PCV2 31
32
82
LFW36EXF001301-1
6E – 200 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
DTC 226 Supply Pump Non Pressure Supply or Pressure Limiter Activation
PRESSURE SENSOR
COMMON RAIL
Engi n e C o n t r o l M o d u l e ( E C M )
056MX022
DTC 226 Supply Pump Non Pressure Supply or Pressure Limiter Activation
Conditions for Clearing the MIL/DTC Diagnostic Aids
DTC 226 can be cleared by using the “Clear Info” by scan Check for the following conditions:
tool or using by the Diag Clear Switch. • Poor connection at ECM – Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Smoke, power shortage etc., due to lack of common rail
pressure (Pressure limiter activated)
• Check Fuel Filter.
2 Does the scan tool display DTC 226 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
4 Check the fuel lines from supply pump to common rail for — Repair or
broken, loose, or restriction. replace
Also check fuel filter for restriction. Go back to
Was a problem found? step 3 Go to step 5
5 Check the ECM and common rail fuel pressure sensor — Repair or
connectors, ECM ground, and wiring harness for looseness, replace
bent terminals, or chafed wires. Go back to
Was a problem found? step 3 Go to step 6
DTC 226 Supply Pump Non Pressure Supply or Pressure Limiter Activation
STEP ACTION VALUE YES NO
10 Using the scan tool, check the value for “PCV closed interval”. 120°CA to
1. Engine is idling. 180°CA
2. Disconnect the PCV1 harness.
3. Check the value for “PCV closed interval”.
4. Reconnect the PCV1 harness. Go to system
5. Disconnect the PCV2 harness. check
6. Check the value for “PCV closed interval”. (Common Rail
7. Reconnect the PCV2 harness. system check:
Is “PCV closed interval” within value? Go to step 11 Fuel system)
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
PRESSURE SENSOR
COMMON RAIL
Engi n e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description • PCV opening timing reaches the limit or feedback value
The common rail pressure sensor, installed at left end of –50CA.
the common rail, is used to detect fuel pressure. It is a • PCV closed interval is more than 98°CA.
semiconductor type pressure sensor utilizing silicon’s • When above condition continues 255 times.
property that the electric resistance of pressurized silicone is
varied. Action Taken When the DTC Sets
Further, a special gasket is used at the connection part • The ECM will illuminate the malfunction indicator lamp
with the common rail body so as to seal high pressure fuel. (MIL) the first time the fault is detected.
• Fuel injection value lower than 60 mm3/st.
Conditions for Setting the DTC • Common rail pressure lower than 25 MPa.
• ISC target speed, common rail pressure not controlled. • Time required for running into backup is varied with the
• DTC 245, 217, 218, 247 and 248 are not appear. difference in common rail pressure against target
• CKP sensor normal condition. pressure.
• Pump normal mode, battery voltage is higher than 16V. • Engine stop
• Pump speed higher than 450 rpm.
• ECT higher than 60°C. Conditions for Clearing the MIL/DTC
• DTC 226 detected, common rail pressure higher than DTC 227 can be cleared by using the “Clear Info” by scan
target pressure plus 5 MPa. tool or using by the Diag Clear Switch.
6E – 204 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
2 Does the scan tool display DTC 227 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
4 Check the fuel lines from supply pump to common rail for — Repair or
broken, loose, or restriction. replace
Also check fuel filter for restriction. Go back to
Was a problem found? step 3 Go to step 5
5 Check the ECM and common rail fuel pressure sensor — Repair or
connectors, ECM ground, and wiring harness for looseness, replace
bent terminals, or chafed wires. Go back to
Was a problem found? step 3 Go to step 6
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
PRESSURE SENSOR
COMMON RAIL
Engine C o n t r o l M o d u l e ( E C M )
056MX022
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 209
10 Measure the resistance between pin number 71 and GND. 10MΩ or more Repair or
Is resistance within value? replace
common rail
pressure
sensor harness
then
Go to step 11 Go to step 13
13 Check common rail pressure sensor harness connector for a — Make complete
poor connection? contact then
Was there a problem? Go to step 14 System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 210 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
55P
73P
62P
B View A 71P
A
View B 90 41
E
1 2 3 C
120 71
M
ECM
62
71
COMMON RAIL
PRESSURE 73
55
LFW36EXF001001
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 211
KEY SW
BI S G MI M2 B2 P2 P1
OFF
ACC
ON
HEAT
START
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
4 If DTC 421 is also present, inspect voltage before measuring 10MΩ or more
the resistance.
1. Key switch “OFF”.
2. Disconnect PCV connector.
3. Measure resistance at the following points. (Measuring
method 2). Repair PCV
• Between pin number 21, 22 and pin number 82. harness
Is resistance within value? Go to step 6 Go to step 5
11 Inspect for poor connection at the connector on PCV harness. — Repair it.
Was a problem found? Go to step 12 System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
NOTE: If PCV1 and PCV2 connectors are switched, engine will not start.
6E – 214 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
A 1
E B 4 2 3
C
M 5
View C
PCV1 View A View A 22P
82P 21P
View B 10 1
90 41
1 2
40 31
120 71
PCV2 32P
82P 31P
10 1
90 41
1 2
40 31
120 71
PCV E PCV E
C C
M M
Harness Harness
+B
ECM
PCV1 21
22
PCV2 31
32
82
LFW36EXF001301
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 215
R/L; PUMP
CONT. VALVE
PUMP PUMP
R/L; MAIN CONT. CONT.
VALVE1 VALVE2
MAIN MAIN
R/L +BP R/L KEY
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
4 If DTC 421 is also present, inspect voltage before measuring 10MΩ or more
the resistance.
1. Key switch “OFF”.
2. Disconnect PCV connector.
3. Measure resistance at the following points. (Measuring
method 2). Repair PCV
• Between pin number 31, 32 and pin number 82. harness
Is resistance within value? Go to step 6 Go to step 5
11 Inspect for poor connection at the connector on PCV harness. Repair it.
Was a problem found? — Go to step 11 System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
NOTE: If PCV1 and PCV2 connectors are switched, engine will not starts.
6E – 218 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
A 1
E B 4 2 3
C
M 5
View C
PCV1 View A View A 22P
82P 21P
View B 10 1
90 41
1 2
40 31
120 71
PCV2 32P
82P 31P
10 1
90 41
1 2
40 31
120 71
PCV E PCV E
C C
M M
Harness Harness
+B
ECM
PCV1 21
22
PCV2 31
32
82
LFW36EXF001301
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 219
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 261 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel — Repair or
injector. replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and — Repair or
injector. replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 261 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 221
Fuel Filter
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 262 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel — Repair or
injector. replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and — Repair or
injector. replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 262 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 223
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 263 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel Repair or
injector. — replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and Repair or
injector. — replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 263 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 225
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 264 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel — Repair or
injector. replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and — Repair or
injector. replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 264 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 227
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 265 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel — Repair or
injector. replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and — Repair or
injector. replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 265 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 229
PCV
Pressure Limiter
Over Flow Valve
Gauze Filter
Feed Pump
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
Common Rail Side Injector Side
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting 1 2
the fuel passages.
Ball
060MY00039
2 Does the scan tool display DTC 266 while Ignition “ON”, or — Go to
engine at idle? Go to step 3 Diagnostic Aids
6 Check for fuel leak in line between flow damper and fuel — Repair or
injector. replace
Was fuel leak found? Go back to
step 3 Go to step 7
8 Check for restriction in fuel line between flow damper and — Repair or
injector. replace
Was restriction found: Go back to
step 3 Go to step 9
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 266 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
• Clutch shudder
• Clutch shock Disengagement
• Air in Fuel Line
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 231
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 271 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 233
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
6E – 234 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 272 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 236 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 237
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 0273 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 239
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
6E – 240 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 274 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 242 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 243
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 275 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 245
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
6E – 246 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
2 Does the scan tool display any DTC from DTC 0276 while key — Go to
switch is “ON” or engine is running? Go to step 3 Diagnostic Aids
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
6E – 248 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
B
A
E
C
M
120 71 120 71
119P
110P 120P
INJECTOR 3(CYL3) INJECTOR 4(CYL6)
Connector1 100P Connector2 87P
88P
3 4 3 4
6 90 41 5 90 41
120 71 120 71
119P
110P 120P
INJECTOR 5(CYL2) INJECTOR 6(CYL4)
Connector1 100P Connector2 85P
86P
3 4 1 3 4
7 90 41 90 41
120 71 120 71
119P
110P 120P
Measuring method 1 Measurement Measuring method 2
INJECTOR E INJECTOR E
C C
M M
Harness
ECM
100
110
CYL1 90
CYL2
86
CYL3
88
119
120
CYL4
85
CYL5
89
CYL6
87
LFW36EXF001101
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 249
KEY SW
B1 S G M1 M2 B2 P2 P1
OFF
ACC
ON
HEAT
START R/L; R/L;
MAIN P.C.V.
Diag
Lamp
GENERATOR (MIL)
B
R
L
E START MAIN BP+ PUMP PUMP
R/L CONT. CONT.
VALVE1 VALVE2
R/L;
BATTERY STARTER Key
24 118 109 91 101 22 21 32 31 23 13 105
SW;SUB
STARTER
R/L; A/T
NEUTRAL
SW;
NEUTRAL
LFW36ELF000801
82P 13P
81P View A 23P
A
90 41 10 1
E
120 71 40 31 C
M
91P
101P
111P
102P
109P
118P
KEY SWITCH
OFF ECM
ACC
23
ON
ST 13
91
101
118
81
82
102
111
LFW36EXF001401
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 251
R/L; PUMP
CONT.
VALVE
R/L; MAIN
E n g i n e C o n t ro l Mo d u l e ( E C M)
81 82 111 102 59
R P- ECM- ECM- CASE
GND GND GND GND GND
R/L;
STARTER
START
STARTER
HEAT
ACC
OFF
ON
B
R
E
L
GENERATOR BATTERY
LFW36ELF000901
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
• Starter switch on and idle speed higher than 1000 rpm. DTC 417 can be cleared by using the “Clear Info” by scan
• When these conditions continue for 1.6 sec. tool or using by the Diag Clear Switch.
• Starter switch is abnormal condition. (Short circuited)
Diagnostic Aids
Action Taken When the DTC Sets Check for the following conditions:
• The ECM will not illuminate the malfunction indicator lamp • Poor connection at ECM – Inspect harness connectors
(MIL). for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
• Increase to remains applies on idling when cold start
engine.
6E – 252 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
2 Does DTC 417 display while key switch “ON” and engine is — Go to
running? Go to step 3 Diagnostic Aids
3 Measure voltage between pin number 24 and GND while key 24V always
switch “ON” and engine running. applied
Does voltage indicate 24V. Go to step 4 Go to step 5
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 253
82P 13P
81P View A 23P
A
90 41 10 1
E
120 71 40 31 C
M
91P
101P
111P
102P
109P
118P
KEY SWITCH
OFF ECM
ACC
23
ON
ST 13
91
101
118
81
82
102
111
LFW36EXF001401
6E – 254 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
R/L; PUMP
CONT.
VALVE
R/L; MAIN
E n g i n e C o n t ro l Mo d u l e ( E C M)
81 82 111 102 59
R P- ECM- ECM- CASE
GND GND GND GND GND
R/L;
STARTER
START
STARTER
HEAT
ACC
OFF
ON
B
R
E
L
GENERATOR BATTERY
LFW36ELF000901
5 Does DTC 421 display even if no change from LO (0V)? — Replace ECM. System OK
7 Possible cause that the cable (Battery → R/L → PCV) on the Less than 1V
side of PCV power supply short circuit to B+.
1. Key switch “OFF”.
2. Disconnect PCV harness from PCV, PCV relay and ECM.
3. Measure voltage between pin number 1 at PCV relay side Repair/replace
of PCV harness and pin number 82 at ECM side of PCV PCV harness.
harness. (Measuring method 5) Then go to
Is voltage within value? Go to step 8 step 8
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to “Programming” of “Tech 2 Scan Tool” in this manual.
5 1
4 2
4
3
2
5
060HY00471 060HY00472
6E – 256 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
A 1
E B 4 2 3
C
M 5
View C
PCV1 View A View A 22P
82P 21P
View B 10 1
90 41
1 2
40 31
120 71
PCV2 32P
82P 31P
10 1
90 41
1 2
40 31
120 71
PCV E PCV E
C C
M M
Harness Harness
+B
ECM
PCV1 21
22
PCV2 31
32
82
LFW36EXF001301-1
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 257
060MX113
2 Ask driver if over speed condition was caused by gear slip- — Misusage by
out, shift error, etc. owner or See Intermittent
operator. chart
6E – 258 ENGINE EMISSION AND ELECTRICAL DIAGNOSIS
ECM Function
The ECM supplies either 5 or 24 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low. Therefore,
a digital voltmeter with at least 10 megohms input impedance
is required to ensure accurate voltage readings. Tool 5-8840-
0366-0 meets this requirement. The ECM controls output
circuits such as the injectors, etc.
digital voltmeter (such as 5-8840-0366-0) to assure accurate There are several ways for a person to become statically
voltage readings. charged. The most common methods of charging are by
The input/output devices in the ECM include analog-to- friction and induction.
digital converters, signal buffers, counters, and special • An example of charging by friction is a person sliding
drivers. The ECM controls most components with electronic across a vehicle seat.
switches which complete a ground circuit when turned “ON”. • Charge by induction occurs when a person with well
insulated shoes stands near a highly charged object and
ECM Service Precautions momentary touches ground. Charges of the same
The ECM is designed to withstand normal current draws
polarity are drained off leaving the person highly charged
associated with vehicle operation. Avoid overloading any
with the opposite polarity. Static charges can cause
circuit. When testing for opens and shorts, do not ground or
damage, therefore it is important to use care when
apply voltage to any of the ECM’s circuits unless instructed to
handling and testing electronic components.
do so. These circuits should only be tested using digital
voltmeter 5-8840-0366-0. The ECM should remain connected NOTE: To prevent possible electrostatic discharge
to the ECM or to a recommended breakout box. damage, follow these guidelines:
• Do not touch the ECM connector pins or soldered
Aftermarket Electrical Equipment components on the ECM circuit board.
Aftermarket (add-on) electrical equipment is defined as • Do not open the replacement part package until the
any equipment which connects to the vehicle’s electrical part is ready to be installed.
systems that is installed on a vehicle after it leaves the factory. • Before removing the part from the package, ground
No allowances have been made in the vehicle design for this the package to a known good ground on the vehicle.
type of equipment. • If the part has been handled while sliding across the
NOTE: Add-on electrical equipment must only be seat, while sitting down from a standing position, or
connected to the vehicle’s electrical system at the battery while walking a distance, touch a known good
(power and ground). ground before installing the part.
Add-on electrical equipment, even when installed to these
guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not connected
to the vehicle electrical system such as portable telephones
and radios. Therefore, the first step in diagnosing any
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 259
ON-VEHICLE SERVICE
Fuel Temperature Sensor Installation Procedure
1. Install the Fuel Temp. sensor.
Removal Procedure 2. Install the Fuel Temp. sensor retaining bolt.
1. Disconnect the negative battery cable. Tighten
2. Remove the clip from resonator.
• Tighten the retaining bolt to 19.6 N·m (173 lb·in)
3. Remove the resonator.
4. Disconnect the electrical connector to the Fuel Temp. 3. Connect the electrical connector to the Fuel Temp.
Sensor. sensor.
060MX075 060MX075
CKP Sensor
060MX076
Installation Procedure
1. Install the ECT sensor. Transmission Type : A/T
2. Install the ECT sensor retaining bolt.
Tighten
CKP Sensor
ECT
Front
CKP Sensor
060M200032
Installation Procedure
1. Common Rail Pressure Sensor.
Common Rail Pressure Sensor only type
Install the New Common Rail Pressure Sensor.
Common Rail Pressure Sensor with Gasket type
Install the New Common Rail Pressure Sensor with new
gasket.
Front 2. Apply grease to the Common Rail Pressure Sensor.
LFW36ESH002301
Programming
Common Rail F0 : Upload Fuel Delivery Rate Data
F1 : Download Fuel Delivery Rate Data
Grease Point
LFW36ESH001701
LFW36ESH001501
12. The message will be appeared on the Display Screen,
Common Rail Pressure Sensor only type and push “Yes” soft key.
• Tighten the retaining bolt to 98 N·m (72lb·ft)
5. Operate “▲ ▲“ or “▼
▼“ key, put on the high-light bar to the
“Model Year(s)”, and push “ENTER” key.
6. Select “Heavy, Medium Duty” by operating “▲ ▲“ or “▼▼“
key.
7. Select “F0: Engine” and push “ENTER” key.
8. Select “6HK1 (Common Rail)” by operating “▲ ▲“ or “▼
▼“
key, and push “ENTER” key.
9. Select “F3: Programming by operating “▲ ▲“ or “▼ ▼“ key,
and push “ENTER” key.
10. Switch the signal selective switch to 1 side.
11. Select “F0: Upload Fuel Delivery Rate Data”, and push
“ENTER” key.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 263
13. The message will be appeared on the Display Screen, • Install the ECM panel the new ECM.
and push “Confirm” soft key. • Install the new ECM.
Down the cushion of the passenger seat.
17. Ignition “ON”. Tech2 “ON”.
18. Repeat from Item 3 to 9 (This procedure).
Upload Fuel Delivery Rate Data 19. Switch the signal selective switch to 2 side.
20. Select “F1: Download Fuel Delivery Rate Data” by
operating “▲ ▲“ or “▼
▼“ key, and push “ENTER” key.
Programming
Upload successful!
F0 : Upload Fuel Delivery Rate Data
F1 : Download Fuel Delivery Rate Data
Confirm
LFW36ESH001901
• Loosen the bracket retaining screws at the ECM. 21. The message will be appeared on the Display Screen,
• Remove the bracket from ECM. and push “Yes” soft key.
• Loosen the electrical connector retaining bolt.
• Disconnect the electrical connector from the ECM.
No Yes
LFW36ESH001601
Download successful!
Confirm
LFW36ESH002201
In this manual, such electrical device is classified by system. For major parts shown on the circuit based on the circuit diagram
for each system, inspection and removal and installation procedures are detailed.
NO
2
OK
Test probe
Test probe
Slender shaft
Tang lock
Pin
Parts Handling
Be careful when handling electrical parts. They should
not be dropped or thrown, because short circuit or other
Housing open pad damage may result.
Pin Wire
Slender shaft
Tang lock
Wire Cable Harness
When installing the parts, be careful not to pinch or
wedge the wiring harness.
All electrical connections must be kept clean and tight.
Splice clip
5. Solder
Apply 60/40 rosin core colder to the opening in the back
of the clip. Follow the manufacturer’s instructions for the
solder equipment you are using.
• Open the crimping tool to its full width and rest one
handle on a firm flat surface.
• Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the
back of the splice clip touches the wings of the clip.
• Make sure that the clip and wires are still in the
correct position. Then, apply steady pressure until
the crimping tool closes.
ENGINE EMISSION AND ELECTRICAL DIAGNOSIS 6E – 269
SPECIAL TOOLS
TOOL NO.
ILLUSTRATION
TOOL NAME
5-8840-0366-0
High Impedance Multimeter
(Digital Voltmeter – DVM)
TS22900
1
5
(1) PCMCIA Card
(2) RS232 Loop Back
2
Connector
3 4 (3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH-2
901RW181
6SD1-WE-0115HK
Issued by
Tokyo, Japan